DISPERSED GAS-FILLED PODS AND METHODS FOR RELEASING AND DETECTING GAS IN BULK MATERIALS

Abstract

A monitoring system for cargo detects the presence of a gas released from a gas-filled pods mixed in the cargo to alert a user to a changed state or condition of the cargo, such as an elevated temperature or pressure.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This utility patent application claims benefit of U.S. Provisional Patent Application Ser. No. 63/418,157, filed in the United States Patent and Trademark Office on Oct. 21, 2022, which is incorporated by reference thereto in its entirety.

BACKGROUND OF THE DISCLOSURE

Extreme changes in temperature or the state of cargo can be dangerous. Bauxite, for instance, which is a primary source of aluminum, can liquefy if it becomes too moist. Liquefaction can cause a rapid shift of cargo inside a hold of a ship thereby destabilizing it, and potentially sinking the ship.

Various systems and methods are used to convey information about bulk cargo or material, such as radioactivity levels, a physical state, or hazardous characteristics using, for example, placards with symbols, injected taggants, and the like. Many information systems use electromagnetic sensors and wiring to communicate cargo conditions via radiofrequency.

At least one drawback to conventional cargo monitoring arrangements occurs at ports of entry when hundreds of cargo containers are off-loaded and are separated from electronic monitoring systems. Once a particular parcel or payload is no longer connected to an electromagnetic monitoring system, unless the cargo is opened, which may be prohibited, impracticable, or dangerous, it may be nearly impossible to ascertain an internal condition of the cargo. Further, there can be a significant lag time in ascertaining internal cargo conditions with conventional external monitoring equipment since the internal data is not being delivered in real time.

What is needed in the industry is a method of identifying internal conditions or characteristics about bulk cargo without the need for conventional monitoring systems, wiring or cables, radiofrequency communications, and the like.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure is directed in general to gas-containing carriers, such as pods, which are dispersed into bulk material or cargo, including but not limited to hazardous or volatile cargo, for identifying data or characteristics, e.g., temperature, about the bulk material without using wiring and radiofrequency communications. The inventions described herein are simple to introduce or infuse into cargo, easy to utilize, and are cost-effective.

In an exemplary embodiment according to the disclosure, a monitoring system for a cargo container may include one or more gas-filled carriers or pods disposed or dispersed in bulk material being carried in a container, the gas-filled carrier fitted with a release mechanism, and the bulk material being in a first state; and a gas monitoring and detection system in communication with the container; wherein, upon the bulk material transitioning from the first state to a second state, gas is released from the release mechanism of the carrier and detected by the gas monitoring and detection system to alert a user of the second state of the bulk material.

In this embodiment, the gas may be an inert gas or noble gas such as helium, nitrogen, argon, neon, krypton, xenon, and combinations thereof, and the release mechanism may be a valve or a plug. However, any gas that is suitable for the material and conditions being monitored may be used, even propane.

Also in this embodiment, the first state of the cargo may be a gas, a liquid, or a solid when at normal or ambient temperature and pressure, or under a refrigerated temperature. The second state of the cargo may be an elevated temperature, an elevated pressure, or a change in first state from a solid to a liquid and the like.

In another embodiment, a method of monitoring a cargo state or condition may include dispersing gas-filled pods in bulk material in a container, the gas-filled pods being fitted with respective release mechanisms with the bulk material being in a first state; providing a gas monitoring and detection system in communication with the container; opening the release mechanism when the bulk material transitions from the first state to a second state and releasing gas into the carrier; and detecting the released gas by the gas monitoring and detection system to alert a user of the second state of the bulk material. Here, the gas may be a noble gas, and the release mechanism may be a valve or a plug. Further, the second state may consist of an elevated temperature, an elevated pressure, a change in first state, and combinations thereof. By way of example, if humidity was being monitored, the setpoint of a pod or first state might be less than 50% humidity while the second state might be greater than 50% humidity, or if temperature was being monitored, the setpoint or first state might be less than 130° F. while the second state might be greater than 130° F.

Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referenced, and discussed features, processes, and elements hereof may be practiced in various embodiments and uses of the disclosure without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like. Those of ordinary skill in the art will better appreciate the features and aspects of the various embodiments, and others, upon review of the remainder of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which refers to the appended FIGURES, wherein

FIG. 1 is a schematic of an embodiment of the disclosure, particularly showing an exemplary gas-filled pod in an inset view, with multiple such pods in an intended use environment.

DETAILED DESCRIPTION OF THE DISCLOSURE

As required, detailed embodiments are disclosed herein; however, the disclosed embodiments are merely exemplary and may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the exemplary embodiments of the present disclosure, as well as their equivalents.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. In the event that there is a plurality of definitions for a term or acronym herein, those in this section prevail unless stated otherwise.

Wherever the phrase “for example,” “such as,” “including,” and the like are used herein, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise. Similarly, “an example,” “exemplary” and the like are understood to be non-limiting.

The term “substantially” allows for deviations from the descriptor that do not negatively impact the intended purpose. Descriptive terms are understood to be modified by the term “substantially” even if the word “substantially” is not explicitly recited.

The term “about” when used in connection with a numerical value refers to the actual given value, and to the approximation to such given value that would reasonably be inferred by one of ordinary skill in the art, including approximations due to the experimental and or measurement conditions for such given value.

The terms “comprising” and “including” and “having” and “involving” (and similarly “comprises,” “includes,” “has,” and “involves”) and the like are used interchangeably and have the same meaning. Specifically, each of the terms is defined consistent with the common United States patent law definition of “comprising” and is therefore interpreted to be an open term meaning “at least the following,” and is also interpreted not to exclude additional features, limitations, aspects, et cetera. Thus, for example, “a device having components a, b, and c” means that the device includes at least components a, b, and c. Similarly, the phrase “a method involving steps a, b, and c” means that the method includes at least steps a, b, and c.

Where a list of alternative component terms is used, e.g., “a structure such as ‘a,’ ‘b,’ ‘c,’ ‘d’ or the like,” or ‘a’ or ‘b’,” such lists and alternative terms provide meaning and context unless indicated otherwise.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, in the sense of “including, but not limited to.”

The various embodiments of the disclosure and/or equivalents falling within the scope of present disclosure overcome or ameliorate at least one of the disadvantages of the prior art or provide a useful alternative.

The drawings show examples embodying the present subject matter. Any detailed description using numerical and letter designations refer to features of the drawings. The drawings and detailed description provide a full and written description of the present subject matter, and of the manner and process of making and using various exemplary embodiments, so as to enable one skilled in the pertinent art to make and use them, as well as the best mode of carrying out the exemplary embodiments. The drawings are not necessarily to scale, and some features may be exaggerated to show details of particular components. Thus, the examples set forth in the drawings and detailed descriptions are provided by way of explanation only and are not meant as limitations of the disclosure. The present subject matter thus includes any modifications and variations of the following examples as come within the scope of the appended claims and their equivalents.

Turning now to FIG. 1, a gas monitoring system is broadly indicated by element number 10. The system may include gas-filled carriers, detectors, or pods 12 fitted with respective release valves 14, which may be solenoid valves, thermal or melt plugs, and the like, and may be or include microcontrollers for directed gas-release. The pods 12 are injected or dispersed into bulk material 16 in a bulk container or storage unit 18. Continuous gas monitoring equipment 20 that may be connected to the container 18 by a line 22 will detect the presence of a gas 24 released from one or more of the pods 12 following a gas release event, such as a sufficiently high temperature to melt a pod plug 14. The presence of the gas 24—typically in significantly greater amounts than trace or ambient amounts—will signify a changed condition of the cargo 16 without the need to open the container 18 and physically inspect the cargo 16.

By way of exemplary operation, the pods 12 are filled with the gas 24, which may be an inert gas or aerogen, such as helium or argon, to be used as a marker or indicator for certain cargo conditions whereby the gas 24 is released from the plugs 14 at a certain pressure or temperature or other condition or state within or around the material 16. More particularly, the pods 12 are fitted with preset valves or plugs 14 based on an event of concern, such as high temperature or moisture. As noted above, the plugs 14 may be a solenoid or pressure relief valve, or a melt plug for a temperature-related release, but also may include a microcontroller to permit a supervised gas release based on any connected sensor condition. The material changes, events, and conditions that may be indicated by the released gas 24 include, but are not limited to, the examples in the following Table:

	Cargo or Material	Changed Condition	Released Gas
	Grain or seed	Elevated Moisture	Helium
	Iron Ore	Elevated Temperature	Nitrogen
	Bauxite	Elevated Moisture	Argon

The gas-filled pods 12 may be any shape, including but not limited to cylindrical, spherical, or cube-shaped. As shown in FIG. 1, the pods 12 are placed on or around and/or are dispersed into the bulk material 16 during loading of the carrier 18 to allow detection of potential changed properties in or around the material 16. Once released or mixed into the material 16, the continuous gas monitoring equipment 20 will detect the gas 24 after a gas release event, such as high temperature, and communicate the condition detected within the bulk material 16 to provide early warning of possible unsafe or undesired material conditions. This communicated condition will remain with the carrier 18 even when it is separated from an original ship, load, or control systems, which may occur at a port of entry, on a busy dock, during cross-country shipment, or in a warehouse. For example, at bulk transport loading points if loose material 16 is craned or clawed out and poured into another container 18, the detectors 12 are craned/clawed out with the material 16, too. Thus, the detectors 12 remain with the loose material 16. For ease of transport another detection system 10 would ideally be installed in the receiving container 18, such as a barge to speed loading/unloading while maintaining monitoring. Also, since the detectors 12 remain inside the bulk material 16 during all phases of loading, unloading, transfer, shipping, et cetera, detectors 12 are constantly gathering data and providing real-time internal conditions of the material 16 without a lag time.

By way of example and not of limitation, potential claims in a utility patent application that may claim benefit of the present application could include but are not limited to.

EMBODIMENT 1: A monitoring system for a cargo container, comprising a gas-filled carrier disposed in bulk material being carried in a container, the gas-filled carrier fitted with a release mechanism, and the bulk material being in a first state; and a gas monitoring and detection system in communication with the container; wherein, upon the bulk material transitioning from the first state to a second state, gas is released from the release mechanism of the carrier and detected by the gas monitoring and detection system to alert a user of the second state of the bulk material.

EMBODIMENT 2: The monitoring system as in Embodiment 1, wherein the gas-filled carrier is a plurality of gas-filled carriers dispersed in the bulk material.

EMBODIMENT 3: The monitoring system as in Embodiments 1 or 2, wherein the gas is an inert or a noble gas.

EMBODIMENT 4: The monitoring system as in Embodiments 1 through 3, wherein the gas is selected from the group consisting of helium, nitrogen, argon, neon, krypton, xenon, and combinations thereof.

EMBODIMENT 5: The monitoring system as in any of the foregoing embodiments, wherein the release mechanism is a valve or a plug.

EMBODIMENT 6: The monitoring system as in any of the foregoing embodiments, wherein the first state is a gas, a liquid, or a solid at ambient temperature and pressure.

EMBODIMENT 7: The monitoring system as in any of the foregoing embodiments, wherein the second state is selected from the group consisting of an elevated temperature, an elevated pressure, a change in first state, and combinations thereof.

EMBODIMENT 8: A method of monitoring a cargo state or condition, comprising dispersing gas-filled pods in bulk material in a container, the gas-filled pods being fitted with respective release mechanisms with the bulk material being in a first state; providing a gas monitoring and detection system in communication with the container; opening the release mechanism when the bulk material transitions from the first state to a second state and releasing gas into the carrier; and detecting the released gas by the gas monitoring and detection system to alert a user of the second state of the bulk material.

EMBODIMENT 9: The method of monitoring a cargo state or condition as in Embodiment 8, wherein the gas is a noble gas.

EMBODIMENT 10: The method of monitoring a cargo state or condition as in Embodiments 8 or 9, wherein the release mechanism is a valve or a plug.

EMBODIMENT 11: The method of monitoring a cargo state or condition as in Embodiments 8 through 10, wherein the second state is selected from the group consisting of an elevated temperature, an elevated pressure, a change in first state, and combinations thereof.

While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.

Claims

1. A monitoring system for a cargo container, comprising:

a gas-filled carrier disposed in bulk material being carried in a container, the gas-filled carrier fitted with a release mechanism, and the bulk material being in a first state; and

a gas monitoring and detection system in communication with the container;

wherein, upon the bulk material transitioning from the first state to a second state, gas is released from the release mechanism of the carrier and detected by the gas monitoring and detection system to alert a user of the second state of the bulk material.

2. The monitoring system as in claim 1, wherein the gas-filled carrier is a plurality of gas-filled carriers dispersed in the bulk material.

3. The monitoring system as in claim 1, wherein the gas is an inert gas.

4. The monitoring system as in claim 1, wherein the gas is a noble gas.

5. The monitoring system as in claim 1, wherein the gas is selected from the group consisting of helium, nitrogen, argon, neon, krypton, xenon, and combinations thereof.

6. The monitoring system as in claim 1, wherein the release mechanism is a valve.

7. The monitoring system as in claim 1, wherein the release mechanism is a plug.

8. The monitoring system as claim 1, wherein the first state is a gas at ambient temperature and pressure.

9. The monitoring system as claim 1, wherein the first state is a liquid at ambient temperature and pressure.

10. The monitoring system as claim 1, wherein the first state is a solid at ambient temperature and pressure.

11. The monitoring system claim 1, wherein the second state is selected from the group consisting of an elevated temperature, an elevated pressure, a change in first state, and combinations thereof.

12. A method of monitoring a cargo state or condition, comprising:

dispersing gas-filled pods in bulk material in a container, the gas-filled pods being fitted with respective release mechanisms with the bulk material being in a first state;

providing a gas monitoring and detection system in communication with the container;

opening the release mechanism when the bulk material transitions from the first state to a second state and releasing gas into the carrier; and

detecting the released gas by the gas monitoring and detection system to alert a user of the second state of the bulk material.

13. The method of monitoring a cargo state or condition as in claim 12, wherein the gas is a noble gas.

14. The method of monitoring a cargo state or condition as in claim 12, wherein the release mechanism is a valve.

15. The method of monitoring a cargo state or condition as in claim 12, wherein the release mechanism is a plug.

16. The method of monitoring a cargo state or condition as in claim 12, wherein the second state is selected from the group consisting of an elevated temperature, an elevated pressure, a change in first state, and combinations thereof.