Flowable material container

Abstract

A flowable material container comprises an outer container, including a circumferentially extending, flexible fabric sidewall with stiffeners mounted within pockets in the sidewall, and an inner bag. The stiffeners may be removable to permit the support container to be placed in a collapsed, shipping state. A vertical lifting element may be associated with at least one of the inner bag and the outer container. The sidewall may be circumferentially expandable to provide access to the inner bag. The sidewall may also include a door to provide lateral access to the entire interior of the outer container when opened.

Description

CROSS-REFERENCE TO OTHER APPLICATIONS

None.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

BACKGROUND OF THE INVENTION

Equipment used to hold, carry and dispense concrete at a building site, including concrete trucks and concrete pumps, may be washed or cleaned out soon after use. This washout procedure typically takes place at or close to the job site. In addition, tools and equipment used for a drywall finishing, stucco application and other similar work are typically washed at the worksite. In the last several years the construction industry, and in particular the concrete industry, has seen many changes in the ecological regulations covering the washout procedure to protect groundwater from contamination from waste concrete as well as other groundwater-contaminating materials. New regulations have created additional restrictions and requirements relating to the treatment and disposal of excess material and wastewater. One of the main concerns is the relatively high pH level in concrete waste. The prevention of spilled concrete from contaminating the ground during the operation of a concrete pump or during the discharge of concrete from a concrete truck is also important. Also, contamination from washing groundwater-contaminating materials, such as concrete, from tools and equipment must also be eliminated.

One method of dealing with this problem is to build small plastic-lined impoundments on site. It was believed that once the water settled and was clear, the water was no longer problem. However, it has become recognized that the wastewater, after settling, may still have an unacceptably high pH. In addition, such impoundments are typically constructed using straw bales; the walls of such impoundments are typically too tall for concrete pumps to be washed out into.

BRIEF SUMMARY OF THE INVENTION

A first aspect of the invention is directed to a flowable material container comprising an outer container and an inner bag. The outer container comprises a circumferentially extending, flexible fabric sidewall, the sidewall defining an interior and comprising pockets, and stiffeners mounted within the pockets. The stiffeners are preferably removable to permit the support container to be placed in an open, use state and a collapsed, shipping state. A vertical lifting element may be associated with at least one of the inner bag and the outer container. The sidewall may include a door movable between a closed state and an open state to provide lateral access to the entire interior when in the open state.

A second aspect of the invention is directed to a method for containing a material, the material being at least initially flowable. A flowable material container is placed on a support surface at a chosen location, the flowable material container comprising an inner bag and an outer container, the outer container comprising a circumferentially extending, flexible fabric sidewall and the inner bag comprising an inner, flexible, conformable bag within the outer container. An at least initially flowable material is discharged into the inner bag. At least portions of the inner bag, with the material therein, and the outer container are separated from one another to facilitate removing the inner bag and material therein from the outer container. The settable material may be allowed to set before opening the door in the sidewall.

A third aspect of the invention is directed to a method for preparing an area for concrete discharge. An outer container, comprising a circumferentially extending, flexible fabric sidewall with pockets, is selected. Stiffeners are placed within at least some of the pockets so to permit the outer container to be placed in an open, use state from a collapsed, shipping state. An inner, flexible, conformable bag is arranged within the interior to create a flowable material container. The flowable material container is positioned at a concrete discharge area for receipt of discharged flowable concrete. The method may further comprise discharging flowable concrete into the inner bag, allowing the flowable concrete to set, lifting the flowable material container together with the material in the inner bag, separating at least portions of the inner bag, with the set concrete therein, and the outer container from one another to facilitate the removing step, and removing the inner bag and set concrete therein from the outer container.

Various features and advantages of the invention will appear from the following description in which the preferred embodiments have been set forth in detail in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded isometric view of a flowable material container made according to the invention;

FIG. 2 illustrates the container of FIG. 1 in an assembled state;

FIG. 3 is an enlarged partial cross-sectional view taken along line 3-3 of FIG. 1;

FIG. 4 is an enlarged partial cross-sectional view of a corner of the outer container of FIG. 1;

FIG. 5 is an enlarged partial cross-sectional view taken along line 5-5 of FIG. 1;

FIG. 6 shows the outer container of FIG. 1 with the sidewall doors opened;

FIG. 7 is an isometric view of an alternative embodiment of the outer container of the flowable material container of FIG. 1;

FIG. 8 is a view of a further alternative embodiment of the outer container of FIG. 1 including a releasable bottom portion, similar to the structure of FIG. 7, releasably secured to a circumferential sidewall;

FIGS. 9 and 10 show a still further alternative embodiment of the outer container of FIG. 1 having a drop-down door shown in an upright, closed state in FIG. 9 and shown in a down, open state in FIG. 10;

FIG. 11 shows the assembly of FIG. 2 after the inner bag has been at least partially filled with a material and the upper edge of the inner bag has been gathered together and tied off, such as for disposal;

FIG. 12 is an overall view of a concrete-embeddable anchor;

FIG. 13 is an isometric view of a hinged top or lid for use with a flowable material container shown in an open state to permit access to the interior of the container; and

FIGS. 14 and 15 illustrate the sidewall with a circumferentially expandable portion to permit portions of the inner bag and the outer container to be separated from one another.

DETAILED DESCRIPTION OF THE INVENTION

The invention is disclosed with reference to various embodiments with like reference numerals referring to like elements.

FIG. 1 is an exploded isometric view of a flowable material container 10 including an outer container 12 and an inner bag 14. Inner bag 14 is typically in a flexible, conformable bag made of, for example, 4 mm thick plastic. Inner bag 14 is preferably waterproof to prevent concrete wastewater from leaking therethrough. FIG. 2 illustrates container 10 in an assembled state. Container 10 includes a circumferentially extending, flexible fabric sidewall 16 and an integral bottom 17, shown in FIG. 6. Sidewall 16 includes inner and outer layers 18, 20, both layers being made of flexible fabric, typically woven polypropylene. Layers 18, 20 define pockets 22 therebetween within which stiffeners 24 are housed. Stiffeners 24 help to reduce the deformation of outer container 12 from concrete waste are material. In one embodiment stiffeners 24 are made of a stiff corrugated plastic about 13 mm thick. Inner and outer layers 18, 20 are secured to one another along their upper edges 26 using, for example, hook and loop fastener material 28 sold under the trademark Velcro®. Fastener material 28 creates stiffener access regions 30 to permit user access to pockets 22. This allows the user to insert or remove stiffeners 24. Removal of one or more stiffeners 24 is often useful or necessary to permit outer container 12 to be folded to a compact, shipping configuration. Stiffeners 24 are preferably solid members occupying entire pockets 22. Although some rigidity may be lost, flexible stiffeners, hinged stiffeners or multiple stiffeners within a single pocket may be used for some or all of pockets 22 to facilitate folding into the compact shipping configuration. Stiffeners 24 may also be used within pockets 22 formed in bottom 17.

Outer container 12 also includes first and second doors 32, 34 which are secured to another using hook and loop fastener material 26 at their overlapping vertical edges 36, 38. Door attachment elements 40, 42 are secured to appropriate positions along outer layer 20 to retain doors 32, 34 in their fully open state shown in FIG. 6.

Outer container 12 also includes four vertical lifting elements 44 sewn or otherwise secured to sidewall 16. Each vertical lifting element 44 is typically made of nylon strapping 46. The size and strength of strapping 46 is chosen to accommodate the load intended for container 10. Strapping 46 extends down each corner 48 of outer container 12 and then beneath bottom 17. The pattern for strapping 46 beneath bottom 17 may be, for example, the X shaped pattern shown in FIG. 7 or the straight across pattern shown in FIG. 10. Each vertical lifting element 44 also includes a lifting loop 50 to permit lifting of container 10 using a crane, back hoe, forklift or other suitable lifting equipment.

One or more of corners 48 may be constructed as shown in FIG. 3 in which inner and outer layers 18, 20 extend continuously from one side to another side at the corner. Alternatively, one or more of corners 48 may be created as shown in FIG. 4 by sewing together inner and outer layers 18, 20. Some or all of hook and loop fastener material 28 may be replaced by other fastener elements, such as snaps, hooks, buckles, etc. Strapping 46 may be secured to sidewall 16 and bottom 17 by one or more of sewing, using an adhesive, heating to weld the material together, using rivets, etc.

FIG. 7 illustrates an alternative, pan-like embodiment of the outer container 12 of FIG. 1. Pan-like outer container 52 has a relatively short sidewall 16. Doors are not needed on this embodiment because the inner bag, not shown, used with this embodiment may be separated from outer container 52 without the need for such doors. Pan-like outer container 52 may be used in a manner of a drip pan to catch a relatively small amount of concrete or other waste. In this embodiment stiffeners are typically positioned horizontally and inserted through stiffener access regions 30 created along corners 48.

FIG. 8 is a partial cross-sectional view of a corner of a further alternative embodiment of the outer container of FIG. 1. In this embodiment outer container 54 includes a sidewall 16 removably secured to a releasable bottom 56. Releasable bottom 56 is similar to the structure of FIG. 7 and is releasably secured to circumferential sidewall 16 using, for example, buckle assemblies 58. Other types of attachment structures may also be used.

FIGS. 9 and 10 show an outer container 60 similar to that of FIG. 1 but having a drop-down door 62. Door 62 is shown secured in a closed, upright state in FIG. 9. Door 62 is maintained in the closed state using fastener material 28 secured to sidewall 16 and the exposed outer ends 64 of strapping 66. Releasing fastener material 28 permits door 62 to drop down to the down, open state of FIG. 10.

FIG. 11 shows flowable material container 10 of FIG. 2 after inner bag 14 has been at least partially filled with a material and the upper edge 68 of the inner bag has been gathered together and tied off for disposal. Container 10 may be lifted at lifting loops 50 and transported to, for example, a disposal site. One of the advantages of the invention is that outer container 12 is typically reusable. To permit reuse of outer container 12, side doors 32, 34 are opened to provide access to inner bag 14. One way to remove inner bag 14 and its contents from outer container 12 is to lift the lifting loops 50 opposite doors 32, 34 causing inner bag 14 and its contents to be discharged from outer container 12. One or more of stiffeners 24 can then be removed from pockets 22 to facilitate folding outer container 12 down to a collapsed, shipping configuration.

Vertical lifting elements 44 have been shown secured to an extending from outer container 12. However, vertical lifting elements may be provided by, for example, strapping positioned between outer container 12 and inner bag 14. In addition, a concrete-embeddable anchor 70, one embodiment being shown in FIG. 12, may be placed within inner bag 14. Inner bag 14 would then be filled with a settable material, such as concrete, to a depth permitting the upper end 72 of anchor 70 to extend above the material. After the concrete, or other settable material, has set, the user can lift the material, and typically inner bag 14 therewith, by simply engaging upper and 72 and lifting. It will typically be advisable, if not necessary, to open side doors 32, 34 to permit removal of the hardened concrete, or other settable material, because flowable material such as concrete will tend to cause sidewall 16 to bow outwardly when placed within container 10. The design of anchor 70 may be changed so long as a portion extends out of the set concrete, or other settable material. While anchor 70 preferably has some type of exposed loop or hook to facilitate lifting, it may not be necessary to have one.

Concrete test cylinders are often made during construction. It is important that these concrete test cylinders be properly cured. One way to help ensure that the concrete test cylinders are properly cured is to ensure that they are not subjected to inappropriately high or low temperatures. To provide such an environment, container 10 may be used with a top or lid 76 shown in FIG. 13. Lid 76 includes a hinged region 78 to permit user access to the interior of container 10 without the need to completely remove the lid. Lid 76 includes a pair of stiffeners 24 within pockets on each side of hinged region 78. To enhance the thermal insulation properties of container 10 with lid 76, stiffeners 24 may be made of honeycomb, structural foam, composite or other materials having good thermal insulation properties. Lid 76 may be loosely placed on container 10 or secured to container using appropriate fasteners, such as hook and loop fastener material, buckles, or latches. Container 10 with lid 76 would be strong enough to allow the concrete test cylinders to be stored, lifted and transported without removal from the container.

Doors 32, 34 and 62, as discussed above, can be opened to provide access to inner bag 14. Access to inner bag 14 can also be provided by providing sidewall 16 with a circumferentially expandable portion 82 as shown in FIGS. 14 and 15. FIG. 14 illustrates portion 82 in a first, reduced circumference state through the use of a releasable strap 84. In FIG. 15, strapping 84 has been released to permit sidewall 16 to assume a second, expanded circumference state thereby providing access to inner bag 14. Expandable portion 82 would be particularly useful when lifting the set concrete from outer container 12 using anchor 70 or strapping between inner bag 14 and outer container 12. The use of doors 32, 34 and 62 and expandable portion 82 are particularly useful for separating at least a portion of outer container 12 and inner bag 14 from one another when the concrete or other material has set to a solid state. Other structure could be used to provide this separation, which facilitates removal of inner bag 14 from outer container 12, when the material has not or does not set up. Such a structure could include sack-like netting between outer container 12 and inner bag 14 which upon lifting would squeeze the inner bag to facilitate removal.

The various embodiments of the present intention have been described using hook and loop fastener material 28 to secure various components together. However, in many cases hook and loop fastener material 28 can be replaced by other fasteners, such as cam buckles, similar to those used on aircraft seat belts, to help lower the cost of container 10.

Other modification and variation can be made to the disclosed embodiments without departing from the subject of the invention as defined in following claims. For example, the invention can be used as a washout basin for washing tools and equipment used in applying stucco, wallboard mud, and other groundwater-contaminating materials.

Any and all patents, patent applications and printed publications referred to above are incorporated by reference.

Claims

1. A flowable material container comprising:

an outer container comprising: a circumferentially extending, flexible fabric sidewall, the sidewall defining an interior and comprising pockets; and stiffeners mounted within the pockets; and

an inner bag located within the interior for receipt of a flowable material.

2. The container according to claim 1 wherein at least some of the stiffeners are removably mounted within the pockets to permit the support container to be placed in an open, use state and a collapsed, shipping state.

3. The container according to claim 1 further comprising a vertical lifting element associated with at least one of the inner bag and the outer container, whereby the flowable material container, with a flowable material within the inner bag, may be lifted vertically using the vertical lifting elements.

4. The container according to claim 3 wherein the vertical lifting element comprises a plurality lifting elements extending from the outer container.

5. The container according to claim 3 wherein the vertical lifting element comprises a concrete-embeddable anchor at least partially housed within the inner bag.

6. The container according to claim 3 wherein the vertical lifting element comprises strapping positioned between the outer container and the inner bag.

7. The container according to claim 1 wherein the sidewall is a generally rectangular sidewall.

8. The container according to claim 1 wherein the outer container comprises a bottom and the bottom is an integral extension of the sidewall.

9. The container according to claim 1 wherein the outer container comprises a bottom and the bottom is releasably secured to the sidewall.

10. The container according to claim 1 further comprising means for separating at least portions of the outer container and inner bag from one another to facilitate the removal of the inner bag with a flowable material therein from the outer container and permit the reuse of the outer container.

11. The container according to claim 10 wherein the sidewall has a height, the separating means comprising a door in the sidewall movable between a closed state and an open state to provide lateral access to the entire interior when in the open state.

12. The container according to claim 11 wherein the door extends over the entire height.

13. The container according to claim 11 wherein the door is a side-opening door movable about an axis generally parallel to the height.

14. The container according to claim 11 wherein the door comprises first and second side-opening doors movable about first and second axes, the axes oriented generally parallel to the height.

15. The container according to claim 11 wherein the door is a drop-down door movable about an axis generally perpendicular to the height.

16. The container according to claim 15 wherein the sidewall is a generally rectangular sidewall comprising a first side and the door constitutes said first side.

17. The container according to claim 11 further comprising means for at least temporarily maintaining the door in the open state.

18. The container according to claim 10 wherein the separating means comprises a selectively circumferentially expandable portion of the sidewall placeable in a second, expanded circumference state from a first, reduced circumference state thereby providing access to the inner bag when in the second, expanded circumference state.

19. The container according to claim 1 wherein the sidewall comprises:

inner and outer layers, said inner and outer layers defining said pockets; and

stiffeners access regions permitting user access to said at least some of the stiffeners.

20. The container according to claim 1 wherein the inner bag is a liquid impervious inner bag so to prevent water from leaking therethrough.

21. A flowable material container comprising:

an outer container comprising: a circumferentially extending, flexible fabric sidewall, the sidewall having a height and defining an interior and comprising pockets; stiffeners mounted within the pockets to permit the support container to be placed in an open, use state and a collapsed, shipping state; and stiffener access regions permitting user access to said at least some of the stiffeners so that said stiffeners may be removed from and placed into the pockets;

a vertical lifting element associated with at least one of the inner bag and the outer container;

an inner, flexible, conformable bag located within the interior for receipt of a flowable material, whereby the flowable material container, with a flowable material within the inner bag, may be lifted vertically using the vertical lifting elements;

the inner bag being removably housed within the outer container; and

means for separating at least portions of the outer container and inner bag from one another to facilitate the removal of the inner bag with a flowable material therein from the outer container and permit the reuse of the outer container.

22. A method for containing a material, the material being at least initially flowable, comprising:

placing a flowable material container on a support surface at a chosen location, the flowable material container comprising an inner bag and an outer container, the outer container comprising: a circumferentially extending, flexible fabric sidewall, the sidewall defining an interior, the sidewall having a height; and the inner bag comprising an inner, flexible, conformable bag located within the interior for receipt of a flowable material;

discharging an at least initially flowable material into the inner bag;

separating at least portions of the inner bag, with the material therein, and the outer container from one another to facilitate the removing step; and

removing the inner bag and material therein from the outer container.

23. The method according to claim 22 further comprising lifting the flowable material container with the material within the inner bag.

24. The method according to claim 22 wherein the discharging step comprises discharging a settable material into the inner bag, and further comprising allowing the settable material to set before the separating step.

25. The method according to claim 22 wherein the placing step is carried out with the inner bag having an upper portion folded back over an outside surface of the sidewall, and further comprising securing the material within the inner bag, said securing step comprising pulling the upper portion of the inner bag up over the sidewall.

26. The method according to claim 22 wherein the separating step comprises moving a door between a closed state and an open state to provide lateral access to the inner bag within the interior when in the open state.

27. The method according to claim 22 wherein the separating step comprises placing a selectively circumferentially expandable portion of the sidewall in a second, expanded circumference state from a first, reduced circumference state thereby providing access to the inner bag when in the second, expanded circumference state.

28. A method for preparing an area for concrete discharge, comprising:

selecting an outer container comprising a circumferentially extending, flexible fabric sidewall, the sidewall defining an interior and comprising pockets;

placing stiffeners within at least some of the pockets so to permit the outer container to be placed in an open, use state from a collapsed, shipping state;

arranging an inner, flexible, conformable bag within the interior to create a flowable material container; and

positioning the flowable material container at a concrete discharge area for receipt of discharged flowable concrete.

29. The method according to claim 28 further comprising:

discharging flowable concrete into the inner bag;

allowing the flowable concrete to set;

lifting the flowable material container together with the material in the inner bag;

separating at least portions of the inner bag, with the set concrete therein, and the outer container from one another to facilitate the removing step; and

removing the inner bag and set concrete therein from the outer container.

30. The method according to claim 29 wherein the discharging step is carried out using flowable concrete having excess water, and further comprising removing excess water from the set concrete after the allowing step.