Bulk Flux Bags Mixed Liner Bags

Abstract

A liner bag for use, for example, in a flexible intermediate bulk container (FIBC) is disclosed, the liner bag comprising a body portion formed from at least two sheets. The body portion has a first end and a second end defining a cavity between the first end and the second end. The first end has an opening for receiving a product. The liner bag also includes at least one seal (e.g., a vertical seal) connecting the two sheets. The liner bag further includes at least one polymer flange secured to the two sheets and extending outwardly from the vertical seal to provide at least one fastening location to secure the liner bag to the container.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is related to and claims priority to U.S. Provisional Patent Application Serial No. 62 / 888,170, filed on August 16, 2019, entitled “BULK FLUX BAG HYBRID LINER BAG,” the entire disclosure of which is incorporated herein by reference in its entirety; and U.S. Provisional Patent Application Serial No. 63 / 000,542, filed on March 27, 2020, entitled “BULK FLUX BAG HYBRID LINER BAG,” the entire disclosure of which is incorporated herein by reference in its entirety; and U.S. Provisional Patent Application Serial No. 16 / 909,108, filed on June 23, 2020, entitled “BULK FLUX BAG HYBRID LINER BAG,” the entire disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] Embodiments of the present invention are directed to bulk flux bags and liners for bulk flux bags for welding consumables. Background Art

[0004] Standard polyethylene or polypropylene film liner bags for flexible intermediate bulk containers (i.e. "FIBC") are often manufactured with extended flanges along the vertical heat-sealed seams for bonding with the sewn vertical seams of the FIBC. This is done to ensure that the liner bag remains securely connected to the bag throughout the discharge process of the product. Since foil laminated liner bags were introduced for moisture control, the characteristics of the foil laminate are such that the bag is very susceptible to tearing from any puncture holes in the laminate. Stitching through the extended vertical flange will cause a row of needle puncture holes, resulting in tearing of the foil laminated liner bag in use. To prevent tearing, current solutions include the careful application of bidirectional reinforcement tape, which is a very labor-intensive application. Summary of the invention

[0005] The following overview presents a simplified overview to provide a basic understanding of some aspects of the devices, systems and / or methods discussed herein. This overview is not an extensive review of the devices, systems and / or methods discussed herein. It is not intended to point out key elements or to delimit the scope of such devices, systems and / or methods. The only purpose is to present some concepts in a simplified form as a preface to a more detailed description presented later.

[0006] One embodiment is a liner bag for a container. The container may be, for example, a FIBC. The liner bag includes a body portion formed by at least two sheets. The body portion has a first end and a second end, defining a cavity between the first end and the second end. The first end has an opening for receiving a product. The second end may be closed. The liner bag also includes at least one seal (e.g., a vertical seal) connecting the two sheets. The liner bag further includes at least one polymer flange, which is fixed to the two sheets and extends outward from the vertical seal to provide at least one fastening position to secure the liner bag to the container. In one embodiment, the polymer flange is fixed between the two sheets. In at least one embodiment, the polymer flange is fixed above or below the two sheets. In one embodiment, the vertical seal extends from the first end to the second end to connect the two sheets. In one embodiment, the liner bag includes four sheets, and the shape of the liner bag is substantially rectangular. In another embodiment, the shape of the liner bag is substantially circular. In a further embodiment, the shape of the liner bag is substantially polygonal. In one embodiment, the liner bag is configured to be loaded into the interior of the container to line the container. In one embodiment, the polymer flange is made of polyethylene or polypropylene material, which is configured to resist tearing when fixed to the container. In one embodiment, the liner bag includes four sheets, wherein two sheets of the four sheets are each configured to be folded along the center line and fixed to the other two sheets of the four sheets to form a foldable liner bag. In one embodiment, the two sheets of the liner bag and the polymer flange are configured to be connected by adhesive or by heat sealing. In one embodiment, the polymer flange is integral with at least one sheet of the liner bag. In one embodiment, the sheet of the liner bag is a foil laminated sheet with a foil element and a polymer element. In one embodiment, the polymer element is applied to the foil element as a coating. In another embodiment, a part of the polymer element extends beyond the edge of the foil element to form the polymer flange.

[0007] One embodiment is a method for forming a liner bag and fixing the liner bag to a container. The container may be, for example, a FIBC. The method comprises joining at least two foil laminated sheets to form a liner bag for a container. Each of the two foil laminated sheets comprises a foil element and a polymer element. The two foil laminated sheets have at least one polymer flange extending outwardly from the two foil laminated sheets. The method also comprises sewing the liner bag to the container through the polymer flange. In one embodiment, the method comprises forming the polymer flange by making a part of the polymer element extend beyond the edge of the foil element. In another embodiment, the method comprises coating the polymer element on the foil element. In one embodiment, the method comprises joining the polymer flange to the two foil laminated sheets by at least one of heat sealing or applying an adhesive.

[0008] These and other aspects of embodiments of the present invention will be apparent when viewed in light of the drawings, detailed description and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The accompanying drawings that are incorporated into this specification and form a part of this specification have shown different embodiments of the present disclosure.It should be appreciated that the element boundaries (e.g., frame, frame group or other shapes) shown in the accompanying drawings represent an embodiment of the boundary.In certain embodiments, an element can be designed as a plurality of elements, or a plurality of elements can be designed as an element.In certain embodiments, another element shown as the internal components of an element can be implemented as an external component, and vice versa.In addition, the element may not be drawn to scale.

[0010] Figure 1 Exemplary, non-limiting embodiments of liner bags are presented.

[0011] Figure 2 An exploded view of an exemplary non-limiting embodiment of a liner bag is shown.

[0012] Figure 3 Exemplary, non-limiting embodiments of foil laminated sheets are presented.

[0013] Figure 4 Shown Figure 3 A close-up view of an exemplary non-limiting embodiment of a foil laminate sheet.

[0014] Figure 5 Exemplary, non-limiting embodiments of foil laminated sheets are presented.

[0015] Figure 6 Shown Figure 5 A close-up view of an exemplary non-limiting embodiment of a foil laminate sheet.

[0016] Figure 7 Exemplary, non-limiting embodiments of liner bags are presented.

[0017] Figure 8 Exemplary, non-limiting embodiments of liner bags are presented. DETAILED DESCRIPTION

[0018] Embodiments of systems and methods for preventing tearing of flexible intermediate bulk containers and liners of such containers are disclosed. In one embodiment, a strip of material (e.g., polyethylene, polypropylene, etc.) is inserted between two foil laminate sheets to serve as an extended flange when making a heat-sealed vertical seam. In another embodiment, the foil laminate sheet is manufactured to include an extended flange formed by extending the polymer portion of the foil laminate sheet beyond the foil portion of the foil laminate sheet. When the liner is attached to the FIBC, the flange becomes a suture anchor point. The tear resistance properties of the flange are well known and allow the elimination of strip reinforcement of the flange formed by the laminate material. This provides an advancement over current technology by allowing the use of optimal polyester film materials in the extended seam flange of the liner bag while improving product protection using foil laminate film in the liner bag body.

[0019] A number of different embodiments will now be described with reference to the accompanying drawings, wherein similar reference numerals are used throughout to refer to similar elements. In the following description, for the purpose of explanation, many specific details are set forth in order to provide a thorough understanding of the embodiments. However, it may be apparent that the features described herein may be practiced without these specific details. In addition, other embodiments are possible, and the features described herein may be practiced and implemented in a manner other than as described. The terms and phrases used herein are used for the purpose of promoting understanding of the present invention and should not be considered restrictive.

[0020] Go to Figure 1 , a liner bag 10 is shown. The liner bag 10 can be coupled to a FIBC (not shown) for packaging products (e.g., flux, etc.). The liner bag 10 can have a first end 12 and a second end 14. The first end 12 can include an opening 16 that extends into a hollow cavity 18 of the liner bag 10, in which the product can be stored. The second end 14 can be sealed or otherwise closed to keep the product within the liner bag 10. The liner bag 10 can include a flange 20 extending from a vertical seal 22 of the liner bag 10. The vertical seal 22 can extend from the first end 12 of the liner bag 10 to the second end 14 to connect one or more sheets 24, 26, 28, 30 of the liner bag 10.

[0021] In an embodiment, the liner bag 10 has four sheets and is substantially rectangular in shape. The liner bag 10 can be similar in size and shape to the FIBC so that the liner bag 10 fits inside the FIBC. In another embodiment, the liner bag 10 can be substantially circular in shape. In yet another embodiment, the liner bag 10 can be substantially polygonal in shape. It should be appreciated that the liner bag 10 can be any shape, any size, and can be formed using any number of sheets. The liner bag 10 of any embodiment described herein can correspond to the shape and size of a corresponding FIBC for storing products such as flux.

[0022] In an embodiment, the sheet of liner bag 10 is formed of a foil laminate to control moisture that may form within the FIBC. The foil laminate may include a foil element and a polymer element. The flange 20 may be formed of a polyethylene or polypropylene material that resists tearing when the liner bag 10 is secured to the FIBC.

[0023] Go to Figure 2 , showing an exploded view of the liner bag 10. In an embodiment, the liner bag 10 can be formed by a plurality of sheets 24, 26, 28, 30. According to an example, the plurality of sheets 24, 26, 28, 30 can be foil laminated sheets. Two sheets 26, 30 can be folded along their centers 32 and can be fixed to two unfolded sheets 24, 28 to form a foldable liner bag 10. A flange 20 (e.g., a polymer strip) can be placed between the sheet 24 and the sheet 30 at the location of the vertical seal 22. The vertical seal 22 can connect the sheet 24 and the sheet 30 to the polymer flange 20. The polymer flange 20 can extend from the vertical seal 22 in an outward direction to form an anchor point to connect the liner bag 10 to, for example, a FIBC. A plurality of sheets 24, 26, 28, 30 can be connected to the polymer flange 20 in any suitable manner (e.g., adhesive, heat seal, etc.).

[0024] In an embodiment, the polymer flange 20 can be fixed to the exterior of the plurality of sheets 24, 26, 28, 30 at a vertical seal (e.g., vertical seal 22). The polymer flange 20 can extend in an outward direction from the vertical seal to form an anchor point to attach the liner bag 10 to, for example, a FIBC. It should be understood that the polymer flange 20 can be fixed to the plurality of sheets 24, 26, 28, 30 in any suitable manner and at any suitable location to provide an anchor point for attaching the liner bag 10 to a FIBC. For example, the polymer flange 20 can be fixed between the plurality of sheets 24, 26, 28, 30, fixed above the plurality of sheets 24, 26, 28, 30, fixed below the plurality of sheets 24, 26, 28, 30, or any other combination of locations determined by reasonable engineering judgment.

[0025] Go to Figure 3 , shows another embodiment. In this embodiment, the foil laminate sheets 124, 126 may include a foil element 140 and a polymer element 150 (see Figure 4 ). The foil laminate sheets 124, 126 may be manufactured to include an integral flange 120 formed by a portion of the polymer element 150 extending beyond the edge of the foil element 140. The polymer flange 120 forms an anchor point to secure the liner bag 100 (formed by the foil laminate sheet) to the FIBC. For example, multiple foil laminate sheets 124, 126 may be secured to each other at a vertical seal 122. The vertical seal 122 may be formed at the edges 142, 144 of the foil element 140 of the foil laminate sheets 124, 126 for moisture protection.

[0026] Go to Figure 4 , showing Figure 3 122 of vertical seal portion 122. Foil laminated sheet 124,126 can be formed by foil element 140 and polymer element 150. Two elements (e.g., foil element 140 and polymer element 150) are connected so that polymer element 150 covers or coats foil element 140 to form foil laminate. Foil laminate can be manufactured to form foil laminated sheet 124,126. By making a part of polymer element 150 extend beyond the outer dimensions of foil element 140, flange 120 just can be formed integrally with foil laminated sheet 124,126. In other words, a part of polymer element 150 is exposed (e.g., extends beyond the size of foil element 140) to form polymer flange 120. For example, the size of foil element 140 can be less than the size of corresponding polymer element 150. Thus, when the foil element 140 is covered or coated by the polymer element 150 , the outer edges 142 , 144 of the foil element 140 do not extend to the outer edge 158 of the polymer element 150 .

[0027] Go to Figure 5 , shows another embodiment of a foil laminate. A polymer element 150 may cover or coat the foil element 140 (as shown) to form an integral polymer flange 120. Figure 6 A close-up view of the intersection of the polymer element 150 and the foil element 140 is shown.

[0028] Go to Figure 7, an assembled view of the liner bag 10, 100 is shown. The liner bag 10, 100 can be assembled using any of the embodiments described herein (e.g., vertical seams 22, 122). The polymer flange 20, 120 can extend from the vertical seams 22, 122 to form an anchor point along the vertical seams 22, 122, thereby attaching the liner bag 10, 100 to the FIBC. In an embodiment, the liner bag 10, 100 can be placed in the FIBC and secured to the FIBC by sewing the liner bag 10, 100 to the FIBC at the vertical seal 22, 122 of the liner bag. For example, the liner bag 10, 100 can be sewn to the corresponding seam of the FIBC at the polymer flange 20, 120, thereby securing the liner bag 10, 100 to the FIBC. Stitching through the polymeric flange 20, 120 may create a secure anchor point that resists tearing at the seam (ie, tearing at the seam securing the liner bag to the FIBC).

[0029] Current construction methods may cause seam tearing when the liner is punctured during sewing (e.g., caused by needle punctures during the sewing process). For example, a liner formed from a foil laminate film may easily tear at the location of the puncture caused by sewing the liner to the FIBC (e.g., zipper tearing). To address this problem, the expensive and time-consuming method of bidirectional reinforcement tape can be used to strengthen the liner at the seam. As described in the present application, the use of polymer flanges 20, 120 provides a solution that can prevent tearing at the seam. The method described in the present application can be cheaper and less time-consuming than current industry methods.

[0030] Go to Figure 8 , shows an embodiment of a liner bag 10, 100. The polymer flange 20, 120 can be secured to the foil laminate sheets 24, 26, 28, 30 to form the cavity 18 within the liner bag 10. Further, the polymer flange 120 can be integrally formed with the foil laminate sheets 124, 126 to form the cavity within the liner bag 100. The liner bag 10, 100 can be folded (e.g. Figure 8 as shown) to, for example, save storage space.

[0031] Various embodiments have been described herein. In one embodiment, a liner for a container includes: a body portion formed from at least two sheets, the body portion having a first end and a second end, defining a cavity between the first end and the second end, the first end having an opening for receiving a product; a vertical seal joining the at least two sheets; and a flange providing a securing position to secure the liner to the container. The sheet may be a foil laminate sheet including a foil element and a polymer element.

[0032] In one embodiment, the flange may be formed from a separate element placed between at least two sheets to provide a securing location for securing the liner to the container. In an example, the flange may be a polymeric strip.

[0033] In another embodiment, the sheet can be a foil laminate sheet including a foil element and a polymer element. A portion of the polymer element can extend beyond a portion of the foil element to form a polymer flange. The polymer flange can be integrally formed with the foil laminate sheet to provide a fastening location for securing the liner to the container.

[0034] In one embodiment, a method for securing a liner to a container includes: securing a polymer flange to at least two foil laminate sheets at a seal; joining the at least two foil laminate sheets at the seal to form a liner for the container, wherein the polymer flange extends outwardly from the liner to form a fastening location; and securing the liner to the container by sewing the liner to the container at the fastening location and a location of the container.

[0035] In another embodiment, a method for securing a liner to a container includes: forming a flange on a foil laminate sheet at a seal, the foil laminate sheet including a polymer element and a foil element; joining at least two foil laminate sheets at the seal to form a liner for a container, wherein the flange is formed by a portion of the polymer element extending beyond an edge of the foil element to create a fastening location; and securing the liner to the container by sewing the liner to the container at the fastening location and a location of the container.

[0036] The above examples are merely several possible embodiments of various aspects of the present invention, wherein equivalent changes and / or modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. Specifically, with respect to the various functions performed by the components (assemblies, devices, systems, circuits, etc.) described above, unless otherwise indicated, the terms used to describe such components (including references to "means") are intended to correspond to any component (such as hardware, software, or a combination thereof) that performs the specific functions of the described components (e.g., functionally equivalent components), even if the disclosed structures are not structurally equivalent to performing the functions in the implementations presented by the present invention. In addition, although a particular feature of the present invention may have been disclosed according to only one of several implementations, such features may be combined with one or more other features of other implementations as may be desired and advantageously for any given or particular application. Additionally, to the extent that the terms "including," "includes," "having," "has," "with," or variations thereof are used in the detailed description and / or claims, such terms are intended to be inclusive in a manner similar to the term "comprising."

[0037] This written description uses examples to disclose the invention, including the best mode, and also to enable a person skilled in the art to practice the invention, including making and using any device or system and performing any incorporated method. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0038] The best mode of carrying out the invention has been described at this time for the purpose of demonstrating the best mode known to the applicant. The examples are merely illustrative and are not meant to limit the invention as measured by the scope and value spirit of the claims. The invention has been described with reference to certain embodiments. Obviously, based on the reading and understanding of this specification, others will think of multiple modifications and changes. It is intended to include all such modifications and changes that fall within the scope of the attached claims or their equivalents.

[0039] Although the disclosed embodiments have been shown and described in considerable detail, it is not intended to constrain or in any way limit the scope of the appended claims to such details. Of course, for the purpose of describing various aspects of the subject matter, it is impossible to describe every conceivable combination of parts or methods. Therefore, the present disclosure is not limited to the specific details or illustrative examples shown and described. Therefore, the present disclosure is intended to include changes, modifications and variations that fall within the scope of the appended claims and meet the statutory subject requirements of 35 U.S.C. § 101. The above description of specific embodiments is given by way of example. According to the disclosure given, those skilled in the art will not only understand the overall innovative concept and the accompanying advantages, but will also find various obvious changes and modifications to the disclosed structures and methods. Therefore, what is sought is to cover all such changes and modifications that fall within the spirit and scope of the overall innovative concept as defined by the appended claims and their equivalents.

Claims

1. A liner bag for a container, comprising: a body portion formed from at least two sheets, the body portion having a first end and a second end defining a cavity therebetween, the first end having an opening for receiving a product; at least one vertical seal joining the at least two sheets; as well as at least one polymeric flange secured to the at least two sheets and extending outwardly from the at least one vertical seal to provide at least one fastening location to secure the liner bag to the container, wherein the at least one polymeric flange is integral with at least one of the at least two sheets, wherein each of the at least two sheets is a foil laminate sheet comprising a foil element and a polymer element, and Wherein a portion of the polymer element extends beyond an edge of the foil element to form the at least one polymer flange.

2. The liner bag according to claim 1, wherein: The at least one polymer flange is secured between the at least two sheets.

3. The liner bag according to claim 1, wherein: The at least one polymer flange is secured above or below the at least two sheets.

4. The liner bag according to claim 1, wherein: The at least one vertical seal extends from the first end to the second end to join the at least two sheets.

5. The liner bag according to claim 1, wherein: The second end is closed.

6. The liner bag according to claim 1, wherein: The at least two sheets include four sheets, and wherein the liner bag is substantially rectangular in shape.

7. The liner bag according to claim 1, wherein: The liner bag is configured to be loaded into the interior of the container to line the container.

8. The liner bag according to claim 1, wherein: The liner bag is substantially circular in shape.

9. The liner bag according to claim 1, wherein: The liner bag is substantially polygonal in shape.

10. The liner bag according to claim 1, wherein: The at least one polymeric flange is made of a polyethylene or polypropylene material configured to resist tearing when secured to the container.

11. The liner bag according to claim 1, wherein: The at least two sheets include four sheets, and wherein two sheets of the four sheets are each configured to be folded along a center line and secured to other two sheets of the four sheets to form a foldable liner bag.

12. The liner bag of claim 1, wherein: The at least two sheets and the at least one polymeric flange are configured to be joined by at least one of an adhesive or a heat seal.

13. The liner bag of claim 1, wherein: The at least two sheets are secured to each other at the vertical seal.

14. The liner bag of claim 1, wherein: The vertical seal is formed at the edge of the foil element of the foil laminate sheet for moisture protection.

15. The liner bag of claim 1, wherein: The polymer element comprises a coating on the foil element.

16. A method for forming a liner bag and securing the liner bag to a container, comprising: joining at least two foil laminated sheets to form a liner bag for a container, wherein each of the at least two foil laminated sheets comprises a foil element and a polymer element, the at least two foil laminated sheets having at least one polymer flange extending outwardly from the at least two foil laminated sheets, wherein the at least one polymer flange is integral with at least one of the at least two foil laminated sheets; forming the at least one polymer flange by extending a portion of the polymer element beyond an edge of the foil element; and The liner bag is sewn to the container through the at least one polymeric flange.

17. The method of claim 16, further comprising coating the polymer element on the foil element.

18. The method of claim 16, further comprising joining the at least one polymeric flange to the at least two foil laminate sheets via at least one of heat sealing or applying an adhesive.

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