Collapsible bulk containers and spreader bar

Abstract

A bulk container or bag capable of being filled with material, with features configured to facilitate being lifted and emptied, comprising a body having a bottom wall connected to one or more outer sidewalls to define an interior space, wherein the bottom wall includes an opening to a chute in fluid communication with the interior space, and a plurality of straps secured to the one or more outer sidewalls and the bottom wall, wherein the first end portion and the second end portion of each strap includes engagement members for connecting with a forklift or other apparatus.

Description

BACKGROUND OF THE INVENTION

[0001] The invention generally relates to flood barrier systems, and in particular, to improved flexible bulk containers that may advantageously be used to form a flood barrier, and a support frame that facilitates the lifting and transportation of bulk containers.

[0002] Floods can have a devastating effect, both in economic loses and in lives disrupted or lost. The most common solution for water control problems involves the use of earthen embankments or levees made of soil. While earthen levees are economical to install, the motion of the water causes rapid deterioration, as the levee has no structure or armor to protect it.

[0003] Accordingly, for the above reasons and others, there is a need for an effective, sturdy, long-lasting flood barrier system.SUMMARY OF THE INVENTION

[0004] The invention is generally directed to systems, methods and apparatus which addresses the issues cited above as well as other issues.

[0005] Some embodiments of the invention are directed to a bulk container comprising a body having a bottom wall connected to one or more outer sidewalls, the one or more outer sidewalls having an upper rim defining an opening to an interior space formed by the bottom wall and the one or more sidewalls, wherein the bottom wall includes a chute opening; an intermediate wall dividing the interior space into a first cell and a second cell, the intermediate wall having an upper edge and a lower edge, wherein the lower edge is adjacent to the chute opening and the upper edge is adjacent to the upper rim; a chute having a proximal open end and a distal open end, the proximal open end being connected to the chute opening whereby the chute in fluid communication with the first cell and the second cell through the chute opening; a plurality of straps having a first end portion, a second end portion and a middle portion, the middle portion of each strap of the plurality of straps being secured to the one or more outer sidewalls and the bottom wall, wherein the first end portion and the second end portion of each strap of the plurality of straps protrude from the upper rim of the one or more outer sidewalls, the first end portion and the second end portion including engagement members.

[0006] In some embodiments of the aforementioned bulk container, the one or more outer sidewalls are perpendicular to the bottom wall.

[0007] In some embodiments of the aforementioned bulk container, the one or more outer sidewalls comprise a front wall, a back wall, a first side wall and a second side wall.

[0008] In some embodiments of the aforementioned bulk container, the front wall and the back wall are parallel with respect to one another, the first side wall and the second side wall are parallel with respect to one another, and the front wall, back wall, first side wall and second side wall are perpendicular with respect to the bottom wall.

[0009] In some embodiments of the aforementioned bulk container, the plurality of straps comprise at least one strap having the first end portion protruding from the first side wall and the second end portion protruding from the second side wall.

[0010] In some embodiments of the aforementioned bulk container, the plurality of straps comprise at least one strap having the first end portion protruding from the front wall and the second end portion protruding from the back wall.

[0011] In some embodiments of the aforementioned bulk container, the engagement members comprise loops, hoops, hooks or other non-permanent fasteners.

[0012] In some embodiments of the aforementioned bulk container, the chute comprises a tube, which may be made of a flexible material that is capable of being folded against the bottom wall.

[0013] In some embodiments, the aforementioned bulk container further comprises a cross-webbing member positioned in at least one of the first cell and or second cell, wherein the cross-webbing member is connected with the one or more of the sidewalls and the intermediate wall.

[0014] In some embodiments of the aforementioned bulk container, the one or more outer sidewalls further comprise at least two sidewall openings.

[0015] In some embodiments, the aforementioned bulk container further comprises at least two lateral tubular members, each lateral tubular member having an proximal open lateral end and an distal open lateral end, wherein the proximal open lateral end of each lateral tubular member is connected with one sidewall opening of the at least two sidewall openings whereby each lateral tubular member is in fluid communication with the interior space.

[0016] Some embodiments of the invention are directed to a bulk container comprising a body having a bottom wall having four sides, the four sides being connected to a front wall, a back wall, a first side wall and a second side wall, respectively, to define an interior space, an upper rim connecting the front wall, the back wall, the first side wall and the second wall at opposing ends thereof relative to the bottom wall, the upper rim defining an opening to the interior space, wherein the bottom wall includes a chute opening; an intermediate wall dividing the interior space into a first cell and a second cell on opposing sides of the intermediate wall, the intermediate wall having an upper edge and a lower edge, wherein the lower edge is adjacent to the chute opening and the upper edge is planar with the upper rim; a tubular member having a proximal open end and a distal open end, the proximal open end being connected to the chute opening whereby the tubular member is in fluid communication with the first cell and the second cell through the chute opening; a plurality of straps having a first end portion, a second end portion and a middle portion, the first end portion and the second end portion including engagement members, the plurality of straps including one or more lateral straps having the middle portion secured to the bottom wall, the front wall and the back wall, wherein the first end portion of the one or more lateral straps protrudes from the upper rim adjacent to the front wall and the second end portion of the one or more lateral straps protrudes from the upper rim adjacent to the back wall, and one or more longitudinal straps having the middle portion secured to the bottom wall, the front wall and the back wall, wherein the first end portion of the one or more longitudinal straps protrudes from the upper rim adjacent to the front wall and the second end portion of the one or more longitudinal straps protrudes from the upper rim adjacent to the back wall.

[0017] In some embodiments of the aforementioned bulk container, the front wall and the back wall are parallel with respect to one another, the first side wall and the second side wall are parallel with respect to one another, and the front wall, back wall, first side wall and second side wall are perpendicular with respect to the bottom wall.

[0018] In some embodiments of the aforementioned bulk container, the engagement members comprise loops, hoops, hooks or other non-permanent fasteners.

[0019] In some embodiments, the aforementioned bulk container further comprises a cross-webbing member positioned in at least one of the first cell and the second cell, wherein the cross-webbing member is connected to at least the intermediate wall, the front wall and the back wall;

[0020] In some embodiments of the aforementioned bulk container, the front wall includes a front wall opening to the first cell and the back wall includes a back wall opening to the first cell, the front wall opening and the back wall opening being in opposing positions relative to one another.

[0021] In some embodiments, the aforementioned bulk container further comprises a front wall lateral tubular member having an proximal open lateral end and a distal open lateral end, wherein the proximal open lateral end of the front wall lateral tubular member is connected with the front wall opening; and a back wall lateral tubular member having an proximal open lateral end and a distal open lateral end, wherein the proximal open lateral end of the back wall lateral tubular member is connected with the back wall opening, whereby the front wall lateral tubular member and the back wall lateral tubular member are in fluid communication with the first cell.

[0022] Other embodiments, features and advantages of the invention will be readily appreciated and apparent from the following detailed description when considered in connection with the accompanying images.BRIEF DESCRIPTION OF DRAWINGS

[0023] While the disclosure concludes with claims particularly pointing out and distinctly claiming specific embodiments, various features and advantages of embodiments within the scope of this disclosure may be more readily ascertained from the following description when read in conjunction with the accompanying drawings, in which:

[0024] FIG. 1 is a perspective view of a bulk material container constructed according to some embodiments of the invention;

[0025] FIG. 2 is a front elevated view of the bulk material container shown in FIG. 1;

[0026] FIG. 3 is a side elevated view of the bulk material container shown in FIG. 1;

[0027] FIG. 4 is a top view of the bulk material container shown in FIG. 1;

[0028] FIG. 5 is a bottom view of the bulk material container shown in FIG. 1;

[0029] FIG. 6 is a front elevated view of a bulk material container constructed according to other embodiments of the invention;

[0030] FIG. 7 is a side elevated view of a bulk material container constructed according to yet other embodiments of the invention;

[0031] FIG. 8 is a top view of a bulk material container constructed according to yet other embodiments of the invention;

[0032] FIG. 9 is a perspective view of a spreader bar constructed according to some embodiments of the invention which may be used to transport a bulk material container, such as those disclosed herein;

[0033] FIG. 10 is a first side elevated view of the spreader bar shown in FIG. 9;

[0034] FIG. 11 is a second side elevated view of the spreader bar shown in FIG. 9; and

[0035] FIG. 12 is a bottom view of the spreader bar shown in FIG. 9.DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THE INVENTION

[0036] The following description of the invention is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by this application.

[0037] It must also be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Furthermore, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. The terms “comprising”, “including”, “having” and “constructed from” can also be used interchangeably and the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,”“comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, terms such as “mounted,”“connected,”“supported,”“seated”, “secured” and “positioned”, and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, seating and couplings. Further, these terms are not restricted to physical or mechanical features. Unless otherwise apparent, or stated, directional references, such as “front,”“back,”“upper,”“lower,”“side,”“bottom”, “top”, “opposing,” and “lateral”, and variations thereof, are intended to be relative to the parts described or orientation of a particular embodiment of the disclosure as shown, and are not limiting of the invention. Reference is now made to the figures wherein like parts are referred to by like numerals throughout.

[0038] Some embodiments of the invention relate to a bulk container or bag 10 that is adapted to be filled with a filling material. The filling material may include any suitable material, such as stones, crushed rock, concrete, cement, sand, etc., and / or liquids, such as water, or combinations thereof. Other suitable fill materials may be used as well depending on the needs of the specific application. The filling material may be used to give weight to the bag so that it can withstand the forces of the floodwaters and remain in place when being used. A filled bulk container of the invention may be transported and used by itself, or with other filled bulk containers and / or structures to build a retaining wall or other protective formation.

[0039] Bag 10 includes a body 12 formed by a back wall 14, a front wall 16, a first sidewall 18, a second side wall 20, and a bottom wall 22, which together define and partially enclose an interior space 24 in body 12.

[0040] In this embodiment, body 12 forms a generally rectangular box-like shape with an opening 23 that opposes bottom wall 22. A rim 25 defines the periphery of opening 23 into the interior space 24 in body 12.

[0041] Interior space 24 is divided by an intermediate wall 26 into two partially enclosed spaces, a cell 28 and a cell 30. In some embodiments, bulk container 10 includes only one interior space, whereas in other embodiments the interior cavity is separated by one or more intermediate panels into two or more cells.

[0042] While bulk container 10 has a body 12 formed as a three-dimensional rectilinear shape, such as a form approximating a cube, it should be understood that body 12 may be formed of other shapes according to principles of the invention, such as tubular shape having one or more arcuate sidewalls.

[0043] In this embodiment, body 12 may be formed of resilient and durable yet flexible or semi-flexible materials. In some embodiments, a flexible bulk container formed according to principles of the invention, such as bag 10, has a body, such as body 12, made from a woven synthetic fabric. The woven synthetic fabric may be a polymeric-based material. In some embodiments, body 12 is made from woven polypropylene fabric which may be of a multi-ply or layered construction for added strength.

[0044] A bulk container of the invention, such as bag 10, may be made of other synthetic or natural materials or a combination of natural and synthetic materials may also be used. Vertical seams may be provided between adjoining sidewalls and the bottom. In some embodiments are formed by stitching or welding sections of fabric together.

[0045] Bag 10 further includes features that facilitate lifting body 12 when filled and emptying the contents of interior space 24, from either one or both cell 28 and / or cell 30.

[0046] Bottom wall 22 of bag 10 includes an opening 32 which is connected with a chute 34 that provides communication, that is, ingress and egress of material, into and out of interior space 24. For example, chute 34 may be used to empty the contents of interior space 24. In this embodiment, chute 34 is positioned generally centrally on bottom wall 22 and / or adjacent to intermediate wall 26.

[0047] The position of chute 34 and communication with opening 32 at a first end enables ingress and egress of material from both cell 28 and cell 30 at substantially the same time. In other embodiments, chute 34 may be connected with one cell 28 or 30, or more one than chute 34 may be used, such as a chute for each cell 28 and cell 30 as shown by bag 110 having a body 112 with chutes 134a and 134b, with each chute 134a and 134b being in fluid communication independently with cell 128 and cell 130, respectively.

[0048] In the embodiment shown herein, chute 34 is an elongated tubular member having a first or proximal end connected with opening 32 and a second or distal end 35 protruding from bottom wall 22. In some embodiments, chute 34 is non-permanently closable by being inserted or tucked into a pocket formed by a flap of material secured on the exterior of bottom wall 22. In other embodiments, chute 34 or distal end 35 thereof may be closed off temporarily by any conventional means, such as drawstrings for example.

[0049] Bag 10 includes a plurality of straps 36 connected with body 12. In this embodiment, each end 38 of a strap 36 is formed as a loop or hoop, or otherwise which is adapted and shaped to be engaged by a spreader bar, forklift, backhoe, crane or similar motorized construction.

[0050] Straps 36 are secured to body 12 by bands 40. In this embodiment, there are two straps 36a,36b which extend along back wall 14, bottom wall 22 and front wall 16, with both ends 38 of these straps 36a,36b protruding above opening 23 and rim 25, and two straps 36c,36d which extend along first side wall 18, bottom wall 22 and second side wall 20, over straps 36a,36b adjacent bottom wall 22, with both ends 38 of straps 36c,36d protruding above opening 23 and rim 25. In this embodiment, strap 36a is adjacent cell 28 and strap 36b is adjacent cell 30.

[0051] In some embodiments, bulk container 10 includes openable / closeable top panel rather than open top 23.

[0052] In some embodiments, any or all of walls 14, 16, 18 and / or 20 and / or bottom wall 22 further include a sleeve defined adjacent to rim 25 which is configured to receive material therein, such as a rigid planar substrate.

[0053] In some embodiments, the bulk container is configured to be collapsible, whereby the walls 14, 16, 18 and 20 may be folded against one another and bottom wall 22.

[0054] A bulk container 210 in another embodiment of the invention includes elongated tubular members 242a and 242b having protruding laterally from opposing walls of body 212, such as back wall 214 and front wall 216. Tubular members 242a and 242b each have proximal ends with openings enabling communication with interior space 224 and openings at distal ends 244a, 244b, respectively. In some embodiments, tubular members 242a and 242b are elongated and in axial alignment with one another. In some embodiments, tubular members 242a and 242b may be in communication with one or more cells formed in interior space 224, but less than the entire interior space 224. Tubular members 242a and 242b may also be configured and dimensioned to enable a bar, pole or pipe to be inserted through the tubular members 242a, 242b and interior space 224.

[0055] A bulk container 310 in another embodiment of the invention includes cross-webbing members 346, with a first cross-webbing member 346 extending within cell 328 having ends 348 connected to back wall 314, first side wall 318, front wall 316 and intermediate wall 326, and a second cross-webbing member 346 extending within cell 330 having ends 348 connected to back wall 314, second side wall 320, front wall 316 and intermediate wall 326. In some embodiments, cell 328 and / or cell 330 may include one or more cross-webbing members 346 positioned between upper rim 325 and bottom 322, with such cross-webbing members 346 being positioned at various depths or planes within cells 328 and / or cell 330 relative to the upper rim 325. Cross-webbing members 346 may be formed of one unitary member or two beams or web members which cross over one another. Cross-webbing members 346 may be constructed of a rigid material or a flexible but resilient material. In some embodiments, cross-webbing members 346 are removable or foldable with body 312. In some embodiments, cross-webbing members 346 are fabricated to resist outward movement or bulging of the walls of body 312, including any or all of back wall 314, first side wall 318, second side wall 320, and front wall 316.

[0056] The invention is further directed to a support frame structure or spreader bar 50 which may advantageously be used in connection with the overhead lifting and transport of bulk containers of the invention, such as bags 10, 110, 210 or 310. In the embodiment shown, the spreader bar 50 includes a rectangular frame 52 defined by two sets of elongated support beams, lateral beams 54 and connecting beams 56 connected thereto. Frame 52 further includes conduits 58 supported by crossbeams 64 connecting to lateral beams 54. Conduits 58 extend between lateral beams 54 and a plurality of connecting points 60 along beams 54 and connecting beams 56. Conduits 58 are spaced, configured and dimensioned with openings 62 therein which are configured to receive a set of forks from a forklift. Each connecting point 60 defines a location, which for example, may comprise a loop, hoop or ear configured to receive and secure a rope, chain, hook or strap, such as straps with ends 38, 138 or 238, 338 of bags 10, 110, 210 and 310. In some embodiments, connecting points 60 correspond in position and / or amount with strap ends. In some embodiments, frame 52 is dimensioned to substantially correspond with opening of the bulk container of the invention and, among other things, facilitates balanced weight distribution when lifting the bulk container. The spreader bar may be constructed of any suitable material, such as metal.

[0057] The bulk containers or bags of the invention may be used to store and / or transport a variety of materials, such as manufactured goods, powders, agricultural products, construction materials, and excavation debris, and come in sizes suited to the type and quantity of material to be stored.

[0058] While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope of the present invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. Therefore, the described embodiments should not be considered as limiting of the scope of the invention in any way. Accordingly, the invention embraces alternatives, modifications and variations which fall within the spirit and scope of the invention as set forth herein, in the claims and any equivalents thereto.

Claims

1. A bulk container, comprising:a body having a bottom wall connected to one or more outer sidewalls, the one or more outer sidewalls having an upper rim defining an opening to an interior space formed by the bottom wall and the one or more sidewalls, wherein the bottom wall includes a chute opening;an intermediate wall dividing the interior space into a first cell and a second cell, the intermediate wall having an upper edge and a lower edge, wherein the lower edge is adjacent to the chute opening and the upper edge is adjacent to the upper rim;a chute having a proximal open end and a distal open end, the proximal open end being connected to the chute opening whereby the chute is in fluid communication with the first cell and the second cell through the chute opening;a plurality of straps having a first end portion, a second end portion and a middle portion, the middle portion of each strap of the plurality of straps being secured to the one or more outer sidewalls and the bottom wall, wherein the first end portion and the second end portion of each strap of the plurality of straps protrude from the upper rim of the one or more outer sidewalls, the first end portion and the second end portion including engagement members.

2. The bulk container of claim 1, wherein the one or more outer sidewalls are perpendicular to the bottom wall.

3. The bulk container of claim 1, wherein the one or more outer sidewalls comprise a front wall, a back wall, a first side wall and a second side wall.

4. The bulk container of claim 2, wherein the front wall and the back wall are parallel with respect to one another, the first side wall and the second side wall are parallel with respect to one another, and the front wall, back wall, first side wall and second side wall are perpendicular with respect to the bottom wall.

5. The bulk container of claim 4, wherein the plurality of straps comprise at least one strap having the first end portion protruding from the first side wall and the second end portion protruding from the second side wall.

6. The bulk container of claim 4, wherein the plurality of straps comprise at least one strap having the first end portion protruding from the front wall and the second end portion protruding from the back wall.

7. The bulk container of claim 1, wherein the engagement members comprise loops.

8. The bulk container of claim 1, wherein the chute comprises a tube made of a flexible material.

9. The bulk container of claim 1, further comprising a cross-webbing member positioned in at least one of the first cell and or second cell, wherein the cross-webbing member is connected with the one or more of the sidewalls and the intermediate wall.

10. The bulk container of claim 1, wherein the one or more outer sidewalls further comprise at least two sidewall openings.

11. The bulk container of claim 10, further comprising at least two lateral tubular members, each lateral tubular member having an proximal open lateral end and an distal open lateral end, wherein the proximal open lateral end of each lateral tubular member is connected with one sidewall opening of the at least two sidewall openings whereby each lateral tubular member is in fluid communication with the interior space.

12. A bulk container, comprising:a body having a bottom wall having four sides, the four sides being connected to a front wall, a back wall, a first side wall and a second side wall, respectively, to define an interior space;an upper rim connecting the front wall, the back wall, the first side wall and the second wall at opposing ends thereof relative to the bottom wall, the upper rim defining an opening to the interior space, wherein the bottom wall includes a chute opening;an intermediate wall dividing the interior space into a first cell and a second cell on opposing sides of the intermediate wall, the intermediate wall having an upper edge and a lower edge, wherein the lower edge is adjacent to the chute opening and the upper edge is planar with the upper rim;a cross-webbing member positioned in at least one of the first cell and the second cell, wherein the cross-webbing member is connected to at least the intermediate wall, the front wall and the back wall;a tubular member having a proximal open end and a distal open end, the proximal open end being connected to the chute opening whereby the tubular member is in fluid communication with the first cell and the second cell through the chute opening;a plurality of straps having a first end portion, a second end portion and a middle portion, the first end portion and the second end portion including engagement members, the plurality of straps including: (i) one or more lateral straps having the middle portion secured to the bottom wall, the front wall and the back wall, wherein the first end portion of the one or more lateral straps protrudes from the upper rim adjacent to the front wall and the second end portion of the one or more lateral straps protrudes from the upper rim adjacent to the back wall; and (ii) one or more longitudinal straps having the middle portion secured to the bottom wall, the front wall and the back wall, wherein the first end portion of the one or more longitudinal straps protrudes from the upper rim adjacent to the front wall and the second end portion of the one or more longitudinal straps protrudes from the upper rim adjacent to the back wall.

13. The bulk container of claim 12, wherein the front wall and the back wall are parallel with respect to one another, the first side wall and the second side wall are parallel with respect to one another, and the front wall, back wall, first side wall and second side wall are perpendicular with respect to the bottom wall.

14. The bulk container of claim 12, wherein the engagement members comprise loops.

15. The bulk container of claim 12, wherein the front wall includes a front wall opening to the first cell and the back wall includes a back wall opening to the first cell, the front wall opening and the back wall opening being in opposing positions relative to one another.

16. The bulk container of claim 15, further comprising: (i) a front wall lateral tubular member having an proximal open lateral end and a distal open lateral end, wherein the proximal open lateral end of the front wall lateral tubular member is connected with the front wall opening; and (ii) a back wall lateral tubular member having an proximal open lateral end and a distal open lateral end, wherein the proximal open lateral end of the back wall lateral tubular member is connected with the back wall opening, whereby the front wall lateral tubular member and the back wall lateral tubular member are in fluid communication with the first cell.

Images