FLEXIBLE BULK CONTAINERS CONSTRUCTED TO BE LIFTABLE FROM BELOW BY A FORKLIFT

Abstract

Flexible bulk containers are configured to be liftable without the necessity of a pallet. A base of a bulk bag has a pair of tine-receiving members secured thereto. The tine-receiving members have a cross-section for creating a pair of tine-receiving channels that can receive the tines of a forklift for lifting the filled container. The tine-receiving members advantageously are substantially water-resistant. The tine-receiving members can be formed of paperboard that is treated to increase its water-resistance. For example, the tine-receiving members can each be a portion of a round or non-round paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube. The paperboard of which the tube is constructed can comprise paperboard that is sized to increase its water-resistance.

Description

BACKGROUND OF THE INVENTION

The present disclosure relates to flexible intermediate bulk containers (FIBCs), also referred to herein as flexible bulk containers, or bulk bags. The present disclosure particularly relates to bulk bags that features integrated into the base of the bag permitting the bag to be lifted from below by a forklift or the like.

Various types of flowable bulk materials are contained and transported using bulk bags. A typical bulk bag comprises a large bag constructed principally of woven fabric and having a generally cuboid or cylindrical shape when filled. Bulk bags include both single-use and reusable bulk bags. Many bulk bags have some kind of bottom closure that allows the bag to be emptied by releasing the closure, while the bag is supported above the container or vessel into which the contents are to be emptied. Some bulk bags have a bottom wall defining an opening connected to a discharge spout or funnel through which the bag is emptied, and a bottom closure such as a petal or star closure, pajama or bonnet closure, or the like, is used to keep the discharge spout closed until it is time to empty the bag. In other bulk bags, particularly for materials that tend to bridge or that otherwise do not flow well, the bag has a bottom closure that opens up to the full cross-sectional size of the bag, and the bag includes a bottom flap (sometimes called a “diaper”, dust flap, or hygiene flap) that covers the bottom closure and that is releasable to allow the bottom closure to open up so the bag can be emptied. Bags having discharge spouts can also include such a bottom flap.

It is conventional to employ wood pallets for transporting bulk bags from place to place. It would be desirable, however, to eliminate the requirement for pallets, in view of the many well-known drawbacks associated with wood pallets.

BRIEF SUMMARY OF THE DISCLOSURE

Described herein are various configurations of flexible bulk containers that are constructed to be liftable from below by a forklift or the like, such that the containers do not have to be supported atop a pallet.

In a first aspect of the present disclosure, a flexible bulk container comprises a bag formed of a flexible fabric material and having a base. The base optionally can define a discharge opening, and the bag can further comprise a bottom closure movable between a closed position in which the discharge opening is closed and an open position in which the discharge opening is open for emptying the bag therethrough. The bag is made to be “palletless” (i.e., to have its own means for receiving the tines of a forklift or the like, so that the bag does not have to be supported atop a conventional pallet) by incorporating into the base of the bag a pair of substantially rigid tine-receiving members that define channels into which the tines of a forklift can be inserted for lifting and transporting the bag. Each of the tine-receiving members comprises a portion of a paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube. For example, the tube can be cut in half longitudinally to produce two substantially identical tine-receiving members. The tube can be round or non-round in cross-section; in the case of non-round tubes, the cross-section can be generally oval or elliptical, for example. The paperboard tube can be formed of paperboard that is sized (or otherwise treated) to increase the paperboard's water-resistance. The tine-receiving members can be secured to the base of the bag in any suitable way, and the first aspect of the invention is not limited in that respect.

In a second aspect of the disclosure, the tine-receiving members can be formed from paperboard tubes as described above, or can comprise other types of tine-receiving members. For instance, the tine-receiving members can have a configuration other than half of a tube, and/or can be made from materials other than paper, such as virgin plastic, recycled plastic, plastic mixed with fibrous material (e.g., fiber-reinforced plastic, wood-plastic composite, or the like), metal, etc. The second aspect concerns various ways of securing the tine-receiving members to the bag. In one embodiment according to the second aspect, the flexible bulk container comprises a bag that includes a bottom closure, and a bottom flap having opposite ends affixed to a lower end of the bag at opposite sides thereof. The bottom flap in a closed position extends beneath and covers the bottom closure of the bag. The bottom flap is narrower than the bottom wall of the bag, such that two portions of the bottom wall on opposite sides of the bottom flap are not covered by the bottom flap. At least one of the ends of the bottom flap is releasably affixed to the bag by a fastening arrangement so as to permit the bottom flap to be moved to an open position in which the bottom closure is exposed.

The container includes a pair of substantially rigid tine-receiving members respectively secured to the two portions of the bottom wall not covered by the bottom flap. The tine-receiving members can have any cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the flexible bulk container. Accordingly, a pallet is not required for supporting and lifting the bulk container.

In accordance with one variation of this embodiment, the tine-receiving members can be secured to the bag by using a pair of sleeves that are respectively affixed to the two portions of the bottom wall not covered by the bottom flap, the sleeves being disposed beneath a lower surface of the bottom wall and extending parallel to each other. The tine-receiving members are inserted into the sleeves, which secure the tine-receiving members to the bag and position the tine-receiving members parallel to each other and spaced apart at the proper spacing corresponding to the spacing of the forklift tines.

In accordance with other variations, the tine-receiving members can be secured to the bag in other ways. For example, the walls of the tine-receiving members can have holes therethrough, and the bag can have straps fastened to the bottom wall of the bag and extending downwardly therefrom and terminating at free ends of the straps. The free ends of the straps are inserted through the holes in the walls of the tine-receiving members and are secured to the bag (e.g., by buckles, hook-and-loop fasteners such as VELCRO®, or other fastening devices) so as to secure the tine-receiving members to the bottom wall of the bag. As another example, small loops can be affixed to the bottom wall of the bag (e.g., at least two loops per tine-receiving member, aligned with one another along the lengthwise direction of each tine-receiving member), and straps or ties can be passed around each tine-receiving member (or through holes in the walls of the tine-receiving member) and secured to the bag using the loops as anchor points for the straps or ties.

A flexible bulk container in accordance with the above-described embodiment is particularly suitable for configurations of bulk containers that are emptied through a central opening in the bottom wall (e.g., bulk bags having a discharge spout). The bottom flap can be released to expose the opening or discharge spout, while the tine-receiving members can be kept in place. If the bag has a discharge spout, it can extend down between the two tine-receiving members. Accordingly, if desired, the container can be emptied while the container is supported above the ground by a forklift. This is advantageous, compared to bulk bags that must be suspended from upper lifting loops, because the forklift does not have to lift its forks as high in order to raise the bottom end of the bag to the height necessary for positioning the bag above the container or vessel into which the bag contents are to be emptied. This may also provide a safety advantage for the person who must release the bottom closure to empty the bag.

In accordance with another embodiment described herein, a flexible bulk container comprises a bag formed of a flexible fabric material and having a base that defines a discharge opening, the bag further comprising a bottom closure movable between a closed position in which the discharge opening is closed and an open position in which the discharge opening is open for emptying the bag therethrough. The container includes a bottom flap comprising a flexible sheet and having opposite ends affixed to the bag at opposite sides thereof proximate the base. The bottom flap in a closed position extends beneath and covers the bottom closure, at least one of the ends of the bottom flap being releasably affixed to the bag by a fastening arrangement so as to permit the bottom flap to be moved to an open position in which the bottom closure is exposed.

A pair of substantially rigid tine-receiving members are secured to the bottom flap, the tine-receiving members being disposed beneath a lower surface of the bottom flap and extending parallel to each other. The tine-receiving members have any suitable cross-section for creating a pair of tine-receiving channels that can receive the tines of a forklift for lifting the flexible bulk container. In this embodiment, the assembly comprising the bottom flap and tine-receiving members is released and moved away from the base of the bag to allow the bag to be emptied.

The tine-receiving members can be secured to the bottom flap in any of the ways previously described (e.g., using sleeves, straps, ties, etc.).

In accordance with yet another embodiment described herein, a flexible bulk container comprises a bag having a bottom flap to which tine-receiving members are secured, as in the previously described embodiment. The container further includes a pair of fastening lines respectively extending through the channels of the pair of tine-receiving members and each having opposite end portions of sufficient length to be releasably fastened to the bag so as to secure the bottom flap in the closed position. The bottom flap, upon disconnecting the fastening lines from the bag, is movable into an open position to expose the bottom closure. Alternatively, the fastening lines can be affixed to the bottom flap rather than extending through the channels of the tine-receiving members.

The present disclosure also includes a third aspect directed to a support system for supporting and facilitating the lifting and transportation of an item. The item, for example, can be a stack of small bags each containing a bulk material, wherein the stack is wrapped with a plastic film such as stretch film. Alternatively, the item can be a bale of non-bulk goods, or a large bulk bag. The support system includes a flexible sheet for underlying the item, and securing members affixed to the flexible sheet, extending upwardly therefrom, and configured for being secured to the item.

A pair of substantially rigid tine-receiving members are secured to the flexible sheet (in any of the various ways previously described, e.g., using sleeves, straps, ties, etc.) and are disposed beneath a lower surface of the flexible sheet. The tine-receiving members have a cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the support system with the item thereon.

The securing members can be configured so that their ends are fastened to each other to secure the members about the item. Alternatively, fastening lines can be affixed to the securing members and can be configured for being releasably connected to each other to secure the securing members about the item.

In the various embodiments as noted above, the tine-receiving members advantageously are substantially water-resistant. In some embodiments, the tine-receiving members comprise paperboard treated to increase the paperboard's water-resistance. For example, each of the tine-receiving members can comprise a portion of a round or non-round paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube. The paperboard tube can be formed of paperboard that is sized (or otherwise treated) to increase the paperboard's water-resistance.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1A is a diagrammatic illustration of a flexible bulk container in accordance with one embodiment of the invention, showing the bottom flap in the closed position, and showing one tine-receiving member slid out slightly from its sleeve;

FIG. 1B depicts the flexible bulk container of FIG. 1A with the bottom flap released;

FIG. 1C shows the bulk container of FIG. 1B, with the discharge spout released for emptying the bag;

FIG. 1D is a fragmentary perspective view of a base of a bag, showing an alternative way to secure the tine-receiving members to the bottom wall of the bag;

FIG. 1E is a fragmentary perspective view of a base of a bag, showing a further alternative way to secure the tine-receiving members to the bottom wall of the bag;

FIG. 2A is a diagrammatic illustration of a flexible bulk container in accordance with another embodiment of the invention, showing the bottom flap in the closed position;

FIG. 2B depicts the flexible bulk container of FIG. 2A with the bottom flap released;

FIG. 3A is a diagrammatic illustration of a flexible bulk container in accordance with yet another embodiment of the invention, showing the bottom flap in the closed position;

FIG. 3B depicts the flexible bulk container of FIG. 3A with the bottom flap released;

FIG. 4A shows a stack of small bags of bulk material or the like;

FIG. 4B shows a support system for the stack in FIG. 4A, in accordance with still another embodiment of the invention;

FIG. 4C is a side view of the support system of FIG. 4B engaged about the stack of FIG. 4A;

FIG. 4D is a top view of the support system of FIG. 4B engaged about the stack of FIG. 4A;

FIG. 5A is an exploded view of a bale of non-bulk goods and a support system for the bale, in accordance with a still further embodiment of the invention; and

FIG. 5B shows the support system of FIG. 5A secured about the bale.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention now will be described more fully hereinafter with reference to the accompanying drawings in which some but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

FIGS. 1A through 1C show a flexible bulk container 100 in accordance with one embodiment of the invention. The container comprises a bag 110 constructed of flexible material such as woven fabric. A woven polyester material such as polyethylene terephthalate (PET) is a typical fabric material used for such bags. The bag can include an inner waterproof liner or coating (not shown) for applications in which the bulk material must be protected from moisture, or in which the bulk material is wet and leakage of liquid must be prevented. The bag includes a side wall assembly 112 that encircles a vertical central axis of the bag. The side wall assembly can comprise a plurality of discrete side walls (there typically being four such side walls, only two of which, 114 and 116, are visible in the figures) that are serially attached together (typically by sewing) along their opposite vertical edges so as to form a generally tubular structure; alternatively, the side wall assembly can comprise a continuous (seamless) circular fabric forming the tubular structure. The bag also includes a base comprising a bottom wall 122 affixed to the lower end of the side wall assembly 112. The bottom wall defines a discharge opening 124 (FIG. 1C) located substantially at the center of the bottom wall, and a bottom closure is provided for closing the discharge opening. The bottom closure can comprise, for example, a discharge spout 126 (FIG. 1C) having a petal or star closure, a pajama or bonnet closure, or the like. The particular type of bottom closure is not important for purposes of the present invention.

The illustrated bag 110 also includes a top wall 128 that defines a fill opening, and a fill spout 130 connected to the top wall for filling the bag through the spout and fill opening. However, the present invention is equally applicable to flexible bulk containers of the open-top type in which there is no top wall. The container optionally can include lifting loops 132 secured to a top end of the bag for facilitating lifting and supporting the bag during filling and emptying.

The flexible bulk container 100 also includes a bottom flap 140 having opposite ends affixed to a lower end of the bag 112 at opposite sides thereof. The bottom flap in a closed position extends beneath and covers the bottom closure 126. The bottom flap is narrower than the bottom wall 122 such that two portions of the bottom wall on opposite sides of the bottom flap are not covered by the bottom flap. The bottom flap can comprise any of various materials, non-limiting examples of which include fabric (e.g., woven fabric made from synthetic yarns such as multifilament polypropylene yarns or the like), heavy-gauge polymer film, water-resistant cardboard, or combinations thereof. At least one of the ends of the bottom flap is releasably affixed to the bag by a fastening arrangement 142 so as to permit the bottom flap to be moved to an open position in which the bottom closure 126 is exposed. The fastening arrangement generally includes one or more first fastening elements mounted on the end of the bottom flap 140 and a corresponding number of cooperating second fastening elements mounted on the bag adjacent its base and engageable with the first fastening elements. In the illustrated embodiment, the fastening arrangement 142 comprises ties affixed to the end of the flap 140 and to the bag, but any other suitable releasable fastening arrangement could be used.

The container 100 further comprises a pair of sleeves 150 respectively affixed to the two portions of the bottom wall 122 not covered by the bottom flap 140. The sleeves are disposed beneath a lower surface of the bottom wall 122, and extend parallel to each other. The sleeves can be formed of fabric (similar or identical to the fabric described above for the bottom flap) or other flexible material.

The container 100 also includes a pair of substantially rigid tine-receiving members 160 respectively inserted into the pair of sleeves 150. The right-hand tine-receiving member 160 in FIG. 1A is shown slightly slid out from its normal position in the sleeve 150, for illustrative clarity. The location and orientation of the sleeves 150 relative to each other is important, because the sleeves must keep the tine-receiving members parallel to each other and spaced at the correct spacing as dictated by the spacing between the forklift tines. It must also be recognized that because of the flexibility of the bulk bag and its contents, the spacing between the sleeves can be somewhat variable as the bag deforms as a result of shifting of the flowable contents of the bag. For example, the bottom wall of the bulk bag, in the region between the tine-receiving members, can tend to sag down in between the tine-receiving members, and this deformation of the bottom wall can change the spacing of the sleeves and hence of the tine-receiving members. Thus, it is important to secure the sleeves 150 to the bottom wall 122 in a manner that minimizes as much as possible the ability of the sleeves to be moved toward from or away from each other. This can be done, for example, by sewing the sleeves to the bottom wall using a stitching technique designed to immobilize the sleeves as much as possible.

The tine-receiving members 160 have a cross-section suitable for creating a pair of tine-receiving channels that can receive the tines of a forklift for lifting the filled container. The members can be open-sided (e.g., generally U-shaped in cross-section) or can be tubular or lumen-shaped members. The tine-receiving members advantageously are substantially water-resistant. In some embodiments of the invention, the tine-receiving members can be formed of paperboard that is treated to increase its water-resistance. For example, the tine-receiving members can each be a portion of a cylindrical paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube. The paperboard of which the tube is constructed can comprise paperboard that is sized to increase its water-resistance. The paperboard can be sized with any of various sizing compositions, including alkenyl succinic anhydride (ASA), alkyl ketene dimer (AKD), alum, rosin, or the like. Alternatively, the paperboard tine-receiving members can be made water-resistant in other ways, such as by coating or impregnating the members with a water-resistant material (e.g., wax-based, polyolefin-based, phenolic resin-based, etc.).

The tine-receiving members 160 can be secured to the bottom wall 122 of the bag in other ways that do not require sleeves 150. For example, as shown in FIG. 1D, the walls of the tine-receiving members 160 can have holes 162 therethrough, and the bag can have straps 164 fastened to the bottom wall 122 of the bag and extending downwardly therefrom and terminating at free ends of the straps. The free ends of the straps 164 are inserted through the holes 162 in the walls of the tine-receiving members 160 and are secured to the bag (e.g., by buckles, hook-and-loop fasteners such as VELCRO®, or other fastening devices) so as to secure the tine-receiving members 160 to the bottom wall 122 of the bag.

In another example as shown in FIG. 1E, small loops 166 can be affixed to the bottom wall 122 of the bag (e.g., at least two loops per tine-receiving member, aligned with one another along the lengthwise direction of each tine-receiving member), and separate straps or ties (not shown) can be passed around each tine-receiving member (or through holes in the walls of the tine-receiving member) and secured to the bag using the loops 166 as anchor points for the straps or ties.

In operation, the flexible bulk container 100 is filled with a quantity of bulk material through the fill spout 130, which is then closed by a suitable closure. The container 100 can then be lifted and transported using a forklift or the like, by inserting the tines of the forklift into the channels defined by the tine-receiving members 160. To empty the container, the container is lifted and supported and the fastening arrangement 142 is released and the bottom flap 140 is swung down to its open position, thereby exposing the discharge spout 126 (FIG. 1C). The closure for the discharge spout is opened to allow the bulk material to flow out through the discharge spout. The bag can then be reclosed for later reuse. One advantage of the container 100 is that it can be lifted and supported from below by a forklift during the emptying process, by virtue of the bottom flap 140 being confined to the area between the two tine-receiving members 160. This means that the forklift does not have to lift its tines nearly as high as would be necessary if the tines lifted the container by the lifting loops 132, which in turn means that emptying can be accomplished in a facility with less overhead clearance than would be necessary when lifting via the lifting loops.

Another embodiment of the invention is illustrated in FIGS. 2A and 2B, which depict a flexible bulk container 200 having similarities to the previously described container. The container includes a bag 210 having a side wall assembly 212 (which may include discrete side walls 214, 216, etc., or a seamless circular side wall, not shown), a top wall 228 with a fill spout 230, and lifting loops 232 generally as in the prior embodiment. The container 200 differs from the prior embodiment firstly in that there is a bottom flap 240 that can have substantially the same width as the base of the bag, rather than being narrower than the base as in the prior embodiment. The base of the bag has a flat bottom and can incorporate any suitable type of bottom closure operable for emptying the bag. As non-limiting examples, the bag 210 can have any of the following bottom types: full-open dump; discharge spout with petal/star closure; discharge spout with pajama/bonnet closure; remote-open discharge; and the like. The bottom flap 240 in its closed position (FIG. 2A) extends beneath and covers the bottom closure. One end of the flap 240 is releasably affixed to the bag near its base by any suitable fastening arrangement 242 (e.g., as illustrated, ties). The opposite end of the flap 240 can be non-releasably affixed to the bag, such as by sewing or any other suitable technique.

The container 200 further differs from the prior embodiment in that the sleeves 250 for the tine-receiving members 260 are affixed to the flap 240 rather than to the bottom wall of the bag. As in the prior embodiment, it is important to secure the sleeves 250 to the flap 240 in a manner that minimizes as much as possible the ability of the sleeves to be moved toward from or away from each other. This can be done, for example, by sewing the sleeves to the flap using a stitching technique designed to immobilize the sleeves as much as possible. Additionally, the fastening arrangement 242 advantageously puts the flap 240 in tension so as to further help immobilize the sleeves, and hence the tine-receiving members.

In operation, the flexible bulk container 200 is filled with a quantity of bulk material through the fill spout 230, which is then closed by a suitable closure. The container 200 can then be lifted and transported using a forklift or the like, by inserting the tines of the forklift into the channels defined by the tine-receiving members 260. To empty the container, the container is lifted and supported (e.g., by the lifting loops 232) and the fastening arrangement 242 is released and the bottom flap 240 is swung down to its open position (FIG. 2B), thereby exposing the bottom closure of the bag. The closure is opened to allow the bulk material to flow out. The bag can then be reclosed for later reuse.

The tine-receiving members 260 can be secured to the flap 240 in ways other than using sleeves 250. For example, the tine-receiving members can be secured to the flap using straps, ties, and/or loops generally as described above in connection with FIGS. 1D and 1E.

A flexible bulk container in accordance with a further (unillustrated) embodiment of the invention is substantially similar to the container 200 described above, the chief difference being that the bottom flap has both of its ends releasably affixed to the bag by respective fastening arrangements such as the fastening arrangement 242 of the container 200. Any suitable fastening arrangements can be used as previously noted, including but not limited to the illustrated ties.

A flexible bulk container 300 in accordance with yet another embodiment of the invention is illustrated in FIGS. 3A and 3B. The container 300 is generally similar to the container 200, having a bag 310 comprising a side wall assembly 312 (which may include discrete side walls 314, 316, etc., or a seamless circular side wall, not shown), a top wall 328 with a fill spout 330, and lifting loops 332 generally as in the prior embodiments. Sleeves 350 are affixed to the bottom flap 340 for receiving tine-receiving members 360. The chief difference from the previous embodiment is that the bottom flap 340 is releasably affixed to the bag by a pair of fastening lines 370 respectively extending through the channels of the pair of tine-receiving members 360 and each having at least one of its ends releasably fastened to the bag so as to secure the bottom flap 340 in the closed position. Advantageously both ends of each fastening line 370 are releasably affixed to the bag. The ends of the fastening lines 370 can be releasably fastened to the bag in various ways, such as by tying each end to one of the straps or lifting loops 332, by securing one part of a hook-and-loop fastening system affixed to the end of the fastening line 370 to the other part of the hook-and-loop fastening system affixed to the bag, or by any other suitable technique. Upon disconnecting the end portions of the fastening lines 370 from the bag, the bottom flap 340 is movable into an open position exposing the bottom closure of the bag, as shown in FIG. 3B.

The fastening lines 370 alternatively can be affixed to the bottom flap 340 rather than extending through the channels of the tine-receiving members 360.

As in the prior embodiments, it is important to secure the sleeves 350 to the flap 340 in a manner that minimizes as much as possible the ability of the sleeves to be moved toward from or away from each other. This can be done, for example, by sewing the sleeves to the flap using a stitching technique designed to immobilize the sleeves as much as possible. Additionally, the fastening lines 370 advantageously put the flap in tension so as to further help immobilize the sleeves, and hence the tine-receiving members.

A further aspect of the invention is now explained with reference to FIGS. 4A through 4D, which depict a support system 400 for supporting and facilitating the lifting and transportation of an item I. For example, the item I can be a stack or pile of small bags of bulk material, the stack being wrapped by a plastic wrap such as stretch film in order to consolidate it. Alternatively, the item can be a large bulk bag. Typically when transporting a pile of small bags on a conventional pallet, the bags are stacked in layers wherein each layer has from 3 to 5 bags and the orientations of the bags in adjacent layers are different so as to ensure that the gaps between the bags in one layer are not aligned with the gaps between the bags in the adjacent layers. The support system 400 comprises a flexible sheet 440 for underlying the item I, and securing members 470 affixed to the flexible sheet 440, extending upwardly therefrom, and configured for being secured to the item. The securing members 470 advantageously are formed as loops that can be used as lifting loops for lifting the support system 400 with the item I thereon. A pair of spaced-apart sleeves 450 are affixed to the flexible sheet 440, the sleeves being disposed beneath a lower surface of the flexible sheet and extending parallel to each other. A pair of substantially rigid tine-receiving members 460 are respectively inserted into the pair of sleeves. Fastening lines 480 are affixed to the securing members 470 and are configured for being releasably connected to each other to secure the support system about the item. For example, a fastening line defining a loop can be affixed to one of the securing members 470 generally diagonally opposite from another fastening line without a loop secured to the other securing strap, and a second pair of loop and non-loop fastening lines can be respectively affixed to the securing members 470 along a second diagonal, such that securing each pair of loop/non-loop fastening lines to each other results in the fastening lines crossing each other at the top of the item I as shown in FIG. 4D.

As in the prior embodiments, it is important to secure the sleeves 450 to the sheet 440 in a manner that minimizes as much as possible the ability of the sleeves to be moved toward from or away from each other. This can be done, for example, by sewing the sleeves to the sheet using a stitching technique designed to immobilize the sleeves as much as possible. Additionally, the securing members 470 advantageously put the sheet 440 in tension so as to further help immobilize the sleeves, and hence the tine-receiving members.

The tine-receiving members 460 can be secured to the flexible sheet 440 in ways other than using sleeves 450. For example, the tine-receiving members can be secured to the sheet using straps, ties, and/or loops generally as described above in connection with FIGS. 1D and 1E.

The tine-receiving members 460 can have any suitable cross-sectional shape that creates channels for receiving the tines of a forklift. Advantageously, the tine-receiving members have a cross-sectional shape that gives the members a load-bearing capacity adequate to support the weight of the bags stacked on the flexible sheet 440. Thus, at least the upper sides of the tine-receiving members 460 advantageously can be generally arch-shaped, since arches are good load-bearing structures. The members can be open-sided (e.g., generally U-shaped in cross-section) or can be tubular or lumen-shaped members of any suitable cross-section.

The flexibility of the sheet 440 allows the sheet to assume non-planar configurations, which is advantageous. In particular, the sheet allows the small bags to be stacked such that a lowermost layer of the stack fits completely within the space between the tine-receiving members 460 as shown in FIG. 4C. The height of the tine-receiving members 460 advantageously is approximately the same as the height of this lowermost layer of bags, such that the upper sides of the lowermost layer of bags and the upper sides of the tine-receiving members are at about the same vertical level, thus forming a good surface upon which to stack the next layer of bags. Accordingly, the lowermost bags rest upon the floor, but are separated from the floor by the sheet 440. In this regard, it may be advantageous in certain usage environments for the sheet 440 to have barrier properties to protect the bags from exposure to the floor, and particularly to any moisture on the floor. Thus, it may be advantageous for the sheet 440 to provide a moisture-barrier function. As an example, the sheet can be woven synthetic fabric (e.g., polypropylene fabric) that is coated with a moisture-barrier coating of any suitable type.

A support system 500 for supporting and facilitating the lifting and transportation of an item I in accordance with a further embodiment of the invention is illustrated in FIGS. 5A and 5B. In this case, the item is shown as a bale of non-bulk goods, but the support system is useful with items of various types. The support system 500 is similar to the support system 400, the chief difference being that the securing members 570 themselves secure the support system about the item. Thus, for example, each securing member 570 can have opposite ends formed as loop and non-loop ends releasably engageable with each other for securing the support system about the item. Sleeves 550 are affixed to the sheet 540, and tine-receiving members 560 are inserted into the sleeves.

The tine-receiving members 560 can be secured to the sheet 540 in ways other than using sleeves 550. For example, the tine-receiving members can be secured to the sheet using straps, ties, and/or loops generally as described above in connection with FIGS. 1D and 1E.

In the various embodiments described herein, the tine-receiving members 160, 260, 360, 460, and 560 have any suitable cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the filled flexible bulk container or the support system and item. The tine-receiving members advantageously are substantially water-resistant. In the present description and claims, “substantially water-resistant” means that the tine-receiving members can be exposed to liquid water or other aqueous liquids to the same extent that conventional wood pallets are so exposed during normal use in environments in which palleted flexible bulk containers are typically used, without losing their ability to maintain the channels open for receiving the tines of a forklift.

In some embodiments of the invention, the tine-receiving members can be formed of paperboard that is treated to increase its water-resistance. For example, the tine-receiving members can each be a portion of a cylindrical paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube. The paperboard of which the tube is constructed can comprise paperboard that is sized to increase its water-resistance.

As noted, the tine-receiving members in some embodiments can be secured to the bag by being inserted into sleeves that are affixed to the bag. In such embodiments, the length of the sleeves can be different from the length of the tine-receiving members. For instance, the sleeves can be shorter than the tine-receiving members, and in some cases can be very short (e.g., half or even one-third the length of the tine-receiving members). The use of such short sleeves allows the bulk bag to be lifted and transported using a hand-operated pallet jack.

In the various embodiments described above, the bulk bag or items being supported is separated from the floor by the underlying bottom flap or flexible sheet. Often, the floor is an unsealed concrete floor, which can harbor moisture and/or contaminants that should not be allowed to contact or affect the contents of the bulk bag or items being supported. In this regard, it may be advantageous in certain usage environments for the bottom flap or sheet to have barrier properties to protect the bag or items from exposure to the floor, and particularly to any moisture on the floor. Thus, it may be advantageous for the bottom flap or sheet to provide a moisture-barrier function. As an example, the bottom flap or sheet can be woven synthetic fabric (e.g., polypropylene fabric) that is coated with a moisture-barrier coating of any suitable type.

In embodiments in which the tine-receiving members are constructed from paperboard, certain advantages are realized over prior-art palletless bulk bags that employ plastic members. For example, the paperboard members are formed from a recycled and renewable material (recycled paper fibers), and this material is also recyclable and/or disposable in existing recycling or waste streams. Additionally, the manufacture of the paperboard members entails a lower amount of carbon emissions than for plastic members. Furthermore, in the case of paperboard half-tube members, the members are nestable with one another for efficient use of space during storage and transportation of the members prior to their being integrated into bulk bags, whereas many existing palletless bulk bags employ tubular or lumen-shaped members that are not nestable.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A flexible bulk container for containing a flowable bulk material, comprising:

a bag formed of a flexible fabric material and having a base; and

a pair of tine-receiving members secured to the base of the bag, the tine-receiving members defining channels into which the tines of a forklift can be inserted for lifting and transporting the bag, each of the tine-receiving members comprising a portion of a paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube.

2. The flexible bulk container of claim 1, wherein the tine-receiving members comprise paperboard treated to increase the paperboard's water-resistance.

3. A flexible bulk container for containing a flowable bulk material, comprising:

a bag formed of a flexible fabric material and comprising at least a side wall assembly, a bottom wall affixed to a lower end of the side wall assembly, the bottom wall defining a discharge opening, and a bottom closure operable for closing the discharge opening, the bottom closure being openable for emptying the bag through the discharge opening;

a bottom flap having opposite ends affixed to a lower end of the bag at opposite sides thereof, the bottom flap in a closed position extending beneath the bottom closure so as to cover the bottom closure, the bottom flap being narrower than the bottom wall such that two portions of the bottom wall on opposite sides of the bottom flap are not covered by the bottom flap, at least one of the ends of the bottom flap being releasably affixed to the bag by a fastening arrangement so as to permit the bottom flap to be moved to an open position in which the bottom closure is exposed; and

a pair of substantially rigid tine-receiving members respectively secured to the two portions of the bottom wall not covered by the bottom flap, the tine-receiving members being disposed beneath a lower surface of the bottom wall and extending parallel to each other;

the tine-receiving members having a cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the flexible bulk container.

4. The flexible bulk container of claim 3, wherein the tine-receiving members are substantially water-resistant.

5. The flexible bulk container of claim 4, wherein the tine-receiving members comprise paperboard treated to increase the paperboard's water-resistance.

6. The flexible bulk container of claim 5, wherein each of the tine-receiving members comprises a portion of a paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube.

7. The flexible bulk container of claim 6, wherein the paperboard tube comprises paperboard that is sized to increase the paperboard's water-resistance.

8. The flexible bulk container of claim 3, further comprising a pair of sleeves respectively affixed to the two portions of the bottom wall not covered by the bottom flap, the sleeves being disposed beneath the lower surface of the bottom wall, the tine-receiving members being inserted through the sleeves so as to secure the tine-receiving members to the bag and position the tine-receiving members parallel to each other and spaced apart.

9. A flexible bulk container for containing a flowable bulk material, comprising:

a bag formed of a flexible fabric material and having a base that defines a discharge opening, the bag further comprising a bottom closure movable between a closed position in which the discharge opening is closed and an open position in which the discharge opening is open for emptying the bag therethrough;

a bottom flap comprising a flexible sheet and having opposite ends affixed to the bag at opposite sides thereof proximate the base, the bottom flap in a closed position extending beneath and covering the bottom closure, at least one of the ends of the bottom flap being releasably affixed to the bag by a fastening arrangement so as to permit the bottom flap to be moved to an open position in which the bottom closure is exposed; and

a pair of substantially rigid tine-receiving members secured to the bottom flap and disposed beneath a lower surface of the bottom flap, the tine-receiving members being parallel and spaced apart, and having a cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the flexible bulk container.

10. The flexible bulk container of claim 9, wherein the bag includes a pair of spaced-apart sleeves affixed to the bottom flap, the sleeves being disposed beneath the lower surface of the bottom flap, the tine-receiving members being inserted into the sleeves and thereby being secured to the bottom flap.

11. The flexible bulk container of claim 9, wherein the tine-receiving members comprise paperboard treated to increase the paperboard's water-resistance.

12. The flexible bulk container of claim 11, wherein each of the tine-receiving members comprises a portion of a paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube.

13. The flexible bulk container of claim 12, wherein the paperboard tube comprises paperboard that is sized to increase the paperboard's water-resistance.

14. The flexible bulk container of claim 9, wherein each of the ends of the bottom flap is releasably affixed to the bag by a fastening arrangement.

15. The flexible bulk container of claim 10, further comprising:

a pair of fastening lines respectively extending through the channels of the pair of tine-receiving members and each having opposite end portions projecting out from the channels and fastened to the bag so as to releasably secure the bottom flap in the closed position, at least one end portion of each fastening line being releasably fastened to the bag;

the bottom flap, upon disconnecting the end portions of the fastening lines from the bag, being movable into an open position exposing the bottom closure.

16. A support system for supporting and facilitating the lifting and transportation of an item, comprising:

an assembly comprising a flexible sheet for underlying the item and a pair of substantially rigid tine-receiving members secured to the flexible sheet and disposed beneath a lower surface of the flexible sheet, the tine-receiving members having a cross-section that creates a pair of tine-receiving channels that can receive the tines of a forklift for lifting the support system with the item thereon;

securing members attached to the assembly, extending upwardly therefrom, and configured for being secured to the item.

17. The support system of claim 16, further comprising fastening lines affixed to the securing members and configured for being releasably connected to each other to secure the support system about the item.

18. The support system of claim 16, wherein the securing members are configured to be releasably connected to one another to secure the support system about the item.

19. The support system of claim 16, wherein the tine-receiving members are substantially water-resistant.

20. The support system of claim 19, wherein the tine-receiving members comprise paperboard treated to increase the paperboard's water-resistance.

21. The support system of claim 20, wherein each of the tine-receiving members comprises a portion of a paperboard tube divided along a plane containing or parallel to a central longitudinal axis of the tube.

22. The support system of claim 21, wherein the paperboard tube comprises paperboard that is sized to increase the paperboard's water-resistance.

23. The support system of claim 16, further comprising:

a pair of spaced-apart sleeves affixed to the flexible sheet, the sleeves being disposed beneath the lower surface of the flexible sheet and extending parallel to each other;

wherein the tine-receiving members are inserted into the sleeves, thereby being secured to the flexible sheet.