Hybrid Liner Bags for Bulk Flux Bags

Abstract

To provide a hybrid liner bag for a bulk flux bag.SOLUTION: For example, a liner bag for a flexible intermediate bulk container (FIBC) includes a main body part formed of at least two sheets. The main body part has a first end part and a second end part defining a cavity therebetween. The first end part has an opening for receiving a product. The liner back includes at least one seal (for example, a longitudinal seal) for joining the two sheets together. The liner bag further includes at least one polymer flange which is fixed to the two sheets and extend outward from the longitudinal seal so as to provide at least one fastening position for fixing the liner bag to a container.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 888,170, entitled "BULK FLUX BAG HYBRID LINER BAG," filed August 16, 2019, which is incorporated by reference in its entirety, U.S. Provisional Patent Application No. 63 / 000,542, entitled "BULK FLUX BAG HYBRID LINER BAG," filed March 27, 2020, which is incorporated by reference in its entirety, and U.S. Nonprovisional Patent Application No. 16 / 909,108, entitled "BULK FLUX BAG HYBRID LINER BAG," filed June 23, 2020, which is incorporated by reference in its entirety.

[0002] SUMMARY OF THE DISCLOSURE Embodiments of the present invention relate to bulk flux bags and bulk flux bag liners for consolidating consumables. [Background technology]

[0003] Standard polyethylene or polypropylene film liner bags for flexible intermediate bulk containers (i.e., "FIBCs") are often manufactured with flanges extending along the vertical heat-sealed seams for incorporation into the sewn vertical seams of the FIBC. This is done to ensure that the liner bag remains securely attached to the bag throughout all releases of product. Because foil laminated liner bags are deployed for moisture control, the properties of the foil laminate make the bag highly susceptible to tearing from any holes in the laminate. Stitching through the extended vertical flanges creates rows of pinholes that result in tearing of the foil laminated liner bag during use. To prevent tearing, current solutions include the elaborate application of bidirectional reinforcing tape, which is very labor intensive to apply. Summary of the Invention [Means for solving the problem]

[0004] The following summary presents a simplified overview to provide a basic understanding of some aspects of the devices, systems, and / or methods discussed herein. This summary is not an extensive overview of the devices, systems, and / or methods discussed herein. It is not intended to identify key elements or to delineate the scope of such devices, systems, and / or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0005] One embodiment is a liner bag for a container. For example, the container may be 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 therebetween. 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) joining the two sheets. The liner bag further includes at least one polymeric flange secured to the two sheets and extending outwardly from the vertical seal to provide at least one fastening location for securing the liner bag to a container. In one embodiment, the polymeric flange is secured between the two sheets. In at least one embodiment, the polymeric flange is secured at the top of the two sheets or at the bottom of the two sheets. In one embodiment, the vertical seal extends from the first end to the second end to join the two sheets. In one embodiment, the liner bag includes four sheets, and the liner bag is generally rectangular in shape. In another embodiment, the liner bag is generally circular in shape. In a further embodiment, the liner bag is generally polygonal in shape. In one embodiment, the liner bag is configured to fit inside the container to line the container. In one embodiment, the polymer flange is made from a polyethylene or polypropylene material configured to resist tearing when secured to the container. In one embodiment, the liner bag includes four sheets, and two of the four sheets are each configured to be folded along a centerline and secured to two other of the four sheets to create a collapsible liner bag. In one embodiment, the two sheets of the liner bag and the polymer flange are configured to be joined by an adhesive or by heat sealing. In one embodiment, the polymer flange is integral to at least one of the sheets of the liner bag. In one embodiment, the sheets of the liner bag are foil laminated sheets having a foil element and a polymer element.In one embodiment, the polymer element is applied as a coating onto the foil element, hi another embodiment, a portion of the polymer element extends beyond the edge of the foil element to create a polymer flange.

[0006] One embodiment is a method for making and securing a liner bag to a container. For example, the container may be a FIBC. The method includes joining at least two foil laminates to form a liner bag for the container. Each of the two foil laminates comprises a foil element and a polymer element. The two foil laminates have at least one polymer flange extending outwardly from the two foil laminates. The method also includes sewing the liner bag to the container through the polymer flange. In one embodiment, the method includes forming a polymer flange by having a portion of the polymer element extend beyond an edge of the foil element. In another embodiment, the method includes coating the polymer element onto the foil element. In one embodiment, the method includes joining the polymer flange to the two foil laminates by at least one of heat sealing or applying an adhesive.

[0007] These and other aspects of embodiments of the invention will become apparent when viewed in consideration of the drawings, detailed description, and appended claims.

[0008] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the present disclosure. It will be understood that the element boundaries shown in the figures (e.g., boxes, groups of boxes, or other shapes) represent one embodiment of the boundaries. In some embodiments, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some embodiments, an element shown as an internal component of another element may be implemented as an external element, and vice versa. Furthermore, the elements may not be drawn to scale. [Brief description of the drawings]

[0009] [Figure 1] 1 illustrates an exemplary, non-limiting embodiment of a liner bag. [Diagram 2] 1 illustrates an exploded view of an exemplary non-limiting embodiment of a liner bag. [Diagram 3] 1 illustrates an exemplary, non-limiting embodiment of a foil laminate sheet. [Figure 4] 4 illustrates an enlarged view of an exemplary, non-limiting embodiment of the foil laminate sheet of FIG. 3. [Diagram 5] 1 illustrates an exemplary, non-limiting embodiment of a foil laminate sheet. [Figure 6] 6 shows an enlarged view of an exemplary, non-limiting embodiment of the foil laminate sheet of FIG. 5. [Figure 7] 1 illustrates an exemplary, non-limiting embodiment of a liner bag. [Figure 8] 1 illustrates an exemplary, non-limiting embodiment of a liner bag. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Disclosed are embodiments of systems and methods for preventing tearing of flexible intermediate bulk containers and tearing of liners of such containers. In one embodiment, a strip of material (e.g., polyethylene, polypropylene, etc.) is inserted between two foil laminate sheets to act as an extended flange when making a heat sealed longitudinal seam. In another embodiment, the foil laminate sheet is manufactured to include an extended flange formed by a polymer portion of the foil laminate sheet that extends beyond the foil portion of the foil laminate sheet. The flange becomes a sewn anchor point when attaching the liner to the FIBC. The tear resistance characteristics of the flange are well understood, allowing for the elimination of tape reinforcement of the flange formed by the laminate material. This provides an advancement over current technology by allowing the use of an optimal poly film material for the extended sewn flange of the liner bag while still using a foil laminate film in the liner bag body for improved product protection.

[0011] Various embodiments are now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a detailed understanding of the embodiments. However, it may be apparent that the features described herein can be practiced without these specific details. Furthermore, other embodiments are possible, and the features described herein can be implemented and performed in ways other than as described. The terms and expressions used in this specification are adopted for the purpose of facilitating understanding of the present invention and should not be taken as limiting.

[0012] Referring to FIG. 1, a liner bag 10 is shown. The liner bag 10 may be incorporated into a FIBC (not shown) that is used to package a product (e.g., flax, etc.). The liner bag 10 may have a first end 12 and a second end 14. The first end 12 may include an opening 16 that extends into a hollow cavity 18 of the liner bag 10 in which a product may be stored. The second end 14 may be sealed or otherwise closed to retain the product within the liner bag 10. The liner bag 10 may include a flange 20 extending from a vertical seal 22 of the liner bag 10. The vertical seal 22 may extend from the first end 12 to the second end 14 of the liner bag 10 to join one or more sheets 24, 26, 28, 30 of the liner bag 10.

[0013] In one embodiment, the liner bag 10 has four sheets and is generally rectangular in shape. The liner bag 10 may be approximately the same size and shape as the FIBC such that the liner bag 10 fits inside the FIBC. In another embodiment, the liner bag 10 may be generally circular. In yet another embodiment, the liner bag 10 may be generally polygonal. It will be appreciated that the liner bag 10 may be any shape, size, and may be formed using any number of sheets. The liner bag 10 of any of the embodiments described herein may correspond to the shape and size of a respective FIBC for containing a product such as flax.

[0014] In one embodiment, the sheets of the liner bag 10 are formed from a foil laminate to control moisture that may form in the FIBC. The foil laminate may include a foil element and a polymer element. The flanges 20 may be formed from a polyethylene or polypropylene material that resists tearing when the liner bag 10 is secured to the FIBC.

[0015] Referring to FIG. 2, an exploded view of the liner bag 10 is shown. In an embodiment, the liner bag 10 may be formed from a plurality of sheets 24, 26, 28, 30. By way of example, the plurality of sheets 24, 26, 28, 30 may be foil laminated sheets. To create the collapsible liner bag 10, the two sheets 26, 30 may be folded along their centers 32 and secured to the two unfolded sheets 24, 28. A flange 20 (e.g., a strip of polymer) may be placed between the sheets 24 and 30 at the vertical seal 22. The vertical seal 22 may join the sheets 24 and 30 to the polymer flange 20. The polymer flange 20 may extend outwardly from the vertical seal 22 to create an anchor point for joining the liner bag 10 to a FIBC, for example. The multiple sheets 24, 26, 28, 30 may be joined to the polymer flange 20 in any suitable manner (eg, adhesive, heat sealing, or the like).

[0016] In certain embodiments, the polymeric flange 20 may be secured to the exterior of the plurality of sheets 24, 26, 28, 30 at a vertical seal (e.g., vertical seal 22). The polymeric flange 20 may extend outwardly from the vertical seal to, for example, create an anchor point for joining the liner bag 10 to a FIBC. It should be appreciated that the polymeric flange 20 may be secured to the plurality of sheets 24, 26, 28, 30 in any suitable manner and at any suitable location to provide an anchor point for joining the liner bag 10 to a FIBC. For example, the polymeric flange 20 may be secured between the plurality of sheets 24, 26, 28, 30, secured at the top of the plurality of sheets 24, 26, 28, 30, secured at the bottom of the plurality of sheets 24, 26, 28, 30, or secured at any other combination of locations as determined by sound engineering judgment.

[0017] Referring to Figure 3, another embodiment is shown. In this embodiment, the foil laminated sheets 124, 126 may include a foil element 140 and a polymer element 150 (see Figure 4). The foil laminated sheets 124, 126 may be manufactured to include an integral flange 120 formed by a portion of the polymer element 150 that extends beyond the edge of the foil element 140. The polymer flange 120 forms an anchor point that secures the liner bag 100 (formed from the foil laminated sheets) to the FIBC. For example, multiple foil laminated sheets 124, 126 may be secured together with a vertical seal 122. The vertical seal 122 may be formed at the edges 142, 144 of the foil elements 140 of the foil laminated sheets 124, 126 for moisture protection.

[0018] Referring to FIG. 4, an enlarged view of the vertical seal 122 of FIG. 3 is shown. The foil laminated sheets 124, 126 may be formed from a foil element 140 and a polymer element 150. Two elements (e.g., foil element 140 and polymer element 150) are joined such that the polymer element 150 covers or envelops the foil element 140 to create a foil laminate. The foil laminate may be manufactured to form the foil laminated sheets 124, 126. The flange 120 may be integrally formed by the foil laminated sheets 124, 126 by extending a portion of the polymer element 150 beyond the outer dimensions of the foil element 140. In other words, a portion of the polymer element 150 is exposed (e.g., extends beyond the size of the foil element 140) to create the polymer flange 120. For example, the size of the foil element 140 may be smaller than the corresponding size of the polymer element 150. Thus, when the foil element 140 is covered or enveloped 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 .

[0019] 5, another embodiment of a foil laminate sheet is shown. As shown, a polymer element 150 may cover or envelope a foil element 140 to form an integral polymer flange 120. An enlarged view of the intersection of the polymer element 150 and the foil element 140 is shown in FIG.

[0020] Referring to FIG. 7, an assembly diagram of the liner bag 10, 100 is shown. The liner bag 10, 100 is assembled using any of the embodiments described herein (e.g., vertical seams 22, 122). The polymer flanges 20, 120 may extend from the vertical seams 22, 122 to create anchor points along the vertical seams 22, 122 for joining the liner bag 10, 100 to the FIBC. In an embodiment, the liner bag 10, 100 may be secured to the FIBC by placing the liner bag 10, 100 in the FIBC and sewing the liner bag 10, 100 to the FIBC at the vertical seals 22, 122 of the FIBC. For example, the liner bag 10, 100 may be sewn at the polymer flanges 20, 120 to corresponding seams of the FIBC to secure the liner bag 10, 100 to the FIBC. Stitching through the polymer flanges 20, 120 can create a strong anchor point that is resistant to tearing at the seam (ie, tearing at the seam that secures the liner bag to the FIBC).

[0021] Current construction methods can result in tears at the seams when the liner is punctured during sewing (e.g., caused by a needle hole in the sewing process). For example, liners formed from foil laminated film can be susceptible to tears (e.g., zipper tears) at the location of the holes caused by sewing the liner to the FIBC. To solve this problem, expensive and time-consuming methods of bi-directional reinforcing tape can be used to reinforce the liner at the seams. The use of polymer flanges 20, 120 described in this application provides a solution that can prevent tears at the seams. The methods described in this application can be less expensive and less time-consuming than current industry methods.

[0022] Referring to Figure 8, an embodiment of the liner bag 10, 100 is shown. The polymer flanges 20, 120 may be secured to the foil laminate sheets 24, 26, 28, 30 creating the cavity 18 in the liner bag 10. Additionally, the polymer flanges 120 may be integrally formed with the foil laminate sheets 124, 126 to create the cavity in the liner bag 100. The liner bags 10, 100 may be folded as shown in Figure 8, for example, to save space for storage.

[0023] Various embodiments are described herein. In one embodiment, a liner for a container comprises a body portion formed by 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, a longitudinal seal joining the at least two sheets, and a flange providing a fastening location for securing the liner to the container. The sheet may be a foil laminate sheet comprising a foil element and a polymer element.

[0024] In one embodiment, the flanges may be formed from separate elements that are placed between at least two sheets to provide fastening locations to secure the liner to the container. In one example, the flanges may be strips of polymer.

[0025] In another embodiment, the sheet may be a foil laminated sheet comprising a foil element and a polymer element. A portion of the polymer element may extend beyond a portion of the foil element to form a polymer flange. The polymer flange may be integrally formed with the foil laminated sheet to provide a fastening location for securing the liner to a container.

[0026] In one embodiment, a method for securing a liner to a container includes securing a polymer flange to at least two foil laminates at a seal, joining the at least two foil laminates at the seal to create a liner for the container, where the polymer flanges extend outwardly from the liner to create fastening locations, and securing the liner to the container by sewing the liner to the container at the fastening locations and at a location on the container.

[0027] 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 comprising a polymer element and a foil element, joining at least two foil laminates at the seal to create a liner for the container, the flange being 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 at a location on the container.

[0028] The above examples are merely intended to illustrate some possible embodiments of the various aspects of the present invention, and equivalent changes and / or modifications will occur to those skilled in the art upon reading and understanding this specification and the accompanying drawings. In particular, with respect to the various functions performed by the above-described components (assemblies, devices, systems, circuits, etc.), the terms used to describe such components (including references to "means") are intended, unless otherwise indicated, to correspond to any components, such as hardware, software, or combinations thereof, that perform the particular functions of the described components, even if they are not structurally equivalent to the disclosed structures that perform the functions in the described implementations of the present invention. In addition, although certain features of the present invention have been disclosed in connection with only one of several implementations, such features may be combined with one or more other features of other implementations, as may be desirable or advantageous for a given or specific application. Also, when the terms "including, includes," "having, has," "with," or variations thereof are used in the detailed description and / or claims, these terms are intended to be inclusive, as well as "comprising."

[0029] This specification uses examples to disclose the invention, including the best mode, and also enables one of ordinary skill in the art to practice the invention, including making and using any devices or systems, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those of ordinary skill 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 those literally recited in the claims, or if they include equivalent structural elements that differ only insignificantly from those literally recited in the claims.

[0030] The best mode has been described for the purpose of illustrating the best mode for carrying out the invention known to the applicant at the time of filing this application. The examples are illustrative only and are not intended to limit the invention, which is measured by the claims and their merits. The invention has been described with reference to specific embodiments. Obviously, changes and modifications will occur to others upon reading and understanding this specification. All such changes and modifications are intended to be included in this application, insofar as they come within the scope of the appended claims or the equivalents thereof.

[0031] Although the disclosed embodiments have been illustrated and described in considerable detail, it is not intended to limit or in any way restrict the scope of the appended claims to such details. It is, of course, not possible to describe every conceivable combination of components or methodologies for describing various aspects of the subject matter. Thus, the disclosure is not limited to the specific details or illustrative examples shown and described. Thus, the disclosure is intended to embrace modifications, changes, and variations that are within the scope of the appended claims, which satisfy the statutory subject matter requirements of 35 U.S.C. § 101. The above description of the specific embodiments is given by way of example. From the present disclosure provided, those skilled in the art will not only understand the general inventive concept and its attendant advantages, but will also find apparent various changes and modifications in the disclosed structures and methods. It is, therefore, desired to embrace all such changes and modifications within the spirit and scope of the general inventive concept as defined by the appended claims, and equivalents thereof. [Explanation of symbols]

[0032] 10 Liner Bag 12 First end 14 Second end 16 Aperture 18 Cavity 20 Polymer flange 22 Vertical seal 24, 26, 28, 30 sheets 32 center 100 Liner Bag 120 Polymer flange 122 Vertical sticker 124, 126 Foil laminated sheet 140 Foil Elements 142, 144 Edge 150 Polymer Elements 158 Outer Edge

Claims

1. In a liner bag for a container, a body portion formed by at least two sheets, said body portion having a first end and a second end defining a cavity therebetween, said first end having an opening for receiving a product and said second end being closed; at least one vertical seal joining the at least two sheets; 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 for securing the liner bag to the container, each of the at least two sheets being a foil laminated sheet including a foil element and a polymer element, the at least one polymeric flange being formed by a portion of the polymer element, and at least one foil laminated sheet being secured to at least a second foil laminated sheet by a vertical seal, the vertical seal being formed by an edge of the foil element; Equipped with Liner bag.

2. the at least one polymer flange is secured between the at least two sheets; The liner bag of claim 1.

3. the at least one polymer flange is secured to the top of the at least two sheets or to the bottom of the at least two sheets; The liner bag of claim 1.

4. the at least one longitudinal seal extends from the first end to the second end to join the at least two sheets; The liner bag of claim 1.

5. the at least two sheets include four sheets; The liner bag has a generally rectangular shape. The liner bag of claim 1.

6. the liner bag is configured to fit inside the container to line the container; The liner bag of claim 1.

7. The liner bag of claim 1 , wherein the liner bag is generally circular in shape.

8. The liner bag of claim 1 , wherein the liner bag is generally polygonal in shape.

9. the at least one polymer flange is made from a polyethylene or polypropylene material configured to resist tearing when secured to the container; The liner bag of claim 1.

10. the at least two sheets include four sheets; two of the four sheets are each configured to be folded along a centerline and secured to two other of the four sheets to create a foldable liner bag; The liner bag of claim 1.

11. the at least two sheets and the at least one polymer flange are configured to be joined by at least one of an adhesive or heat sealing; The liner bag of claim 1.

12. the at least one polymer flange is secured to at least one of the at least two sheets; The liner bag of claim 1.

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

14. a portion of the polymer element extends beyond an edge of the foil element to create a polymer flange of the at least one polymer flange; The liner bag of claim 1.

15. 1. A method for making a liner bag having an open first end and a closed second end and securing the liner bag to a container, comprising: joining at least two foil laminates to form the liner bag for the container, each of the at least two foil laminates comprising a foil element and a polymer element, the at least two foil laminates having at least one polymer flange extending outwardly from the at least two foil laminates, the at least one polymer flange being integral with at least one foil laminate of the at least two foil laminates, at least one foil laminate sheet being secured to at least a second foil laminate sheet by a vertical seal, the vertical seal being formed by at least one edge of the foil element; forming the at least one polymer flange by extending a portion of the polymer element beyond an edge of the foil element; sewing the liner bag to the container through the at least one polymer flange; A method comprising:

16. forming said at least one polymer flange by extending a portion of said polymer element beyond an edge of said foil element; Further comprising: The method of claim 15.

17. Coating said polymer element onto said foil element. Further comprising: The method of claim 15.

18. joining said at least one polymer flange to said at least two foil laminates by at least one of heat sealing or applying an adhesive. The method of claim 15 further comprising:

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