Inflatable Container Liner for Bulk Material Loading
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Solution Overview
Problem
Existing methods for filling bulk containers, such as 20-foot containers with malt, result in high mechanical loads leading to dust and grain damage, creases in the lining, and inefficient use of space, causing tears and reduced loading capacity, which increases costs and complicates the loading and unloading process.
Innovation Solution
A method involving a vertical container with a loading nozzle in the middle of the front for efficient filling, creating a loading cone, and a separate nozzle for emptying, along with an inflatable lining to prevent creases and tears, allows for nearly full container utilization and quick loading and unloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the container is filled using a centrifugal belt, then the loading speed is improved, but the bulk material is subject to high mechanical loads leading to dust and grain damage
Solution Approach 1:
The patent replaces the mechanical centrifugal belt system with a pneumatic conveying system using air flow to transport bulk material into the container. This substitution eliminates the high mechanical loads and friction associated with belt conveyors, preventing dust generation and grain damage while maintaining efficient loading speeds.
Solution Approach 2:
The invention employs pneumatic principles by using pressurized air flow through a loading nozzle to convey bulk material into the container. The air stream carries the material gently, avoiding mechanical impact and reducing damage to the bulk material while achieving rapid loading.
2Ease of operation
If the container is loaded in a vertical position with a lining, then the loading process is simplified, but creases form in the container lining causing tears
Solution Approach 1:
The patent applies preliminary action by inflating the container lining with air before the loading process begins. This pre-inflation creates a taut, wrinkle-free surface that prevents crease formation during subsequent material loading, thereby maintaining lining integrity and preventing tears.
Solution Approach 2:
The invention changes the physical state of the lining from a loose, flexible membrane to a pressurized, taut structure by introducing air pressure. This parameter change eliminates the formation of creases and folds that would otherwise lead to tearing during the loading and unloading cycles.
3Ease of operation
If a loading opening is arranged at the front of the container, then the loading process is straightforward, but the loading quantity is reduced leaving unused space
Solution Approach 1:
The patent transitions from a two-dimensional front opening approach to a three-dimensional pneumatic injection method. The loading nozzle penetrates into the container interior, allowing material to be deposited directly into the core volume rather than only at the front surface, thereby maximizing space utilization and loading capacity.
Solution Approach 2:
The invention introduces air flow as an intermediary medium that carries bulk material through the loading nozzle and distributes it throughout the container volume. This intermediary enables efficient material placement in previously inaccessible areas, increasing overall loading quantity while maintaining operational simplicity.
4Device complexity
If the container is emptied through the loading nozzle, then the system is simplified, but the emptying process is inefficient and time-consuming
Solution Approach 1:
The patent segments the loading and emptying functions into separate dedicated nozzles: a loading nozzle for material input and an emptying nozzle for material discharge. This segmentation allows each nozzle to be optimized for its specific function, with the emptying nozzle positioned and sized for rapid, efficient material removal, thereby increasing productivity without excessive complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves a 10% higher loading capacity, reduces container handling costs, and prevents lining tears during filling and emptying, enabling faster and more efficient filling and unloading processes while maintaining the integrity of the lining.
Implementation Method 1
According to the invention, the container liner is inflated before filling. To inflate the container liner, all but one of the openings are closed first. Air is then preferably blown into the container lining. As a result, the container lining rests against the inner wall of the container and folds are largely avoided.
Implementation Method 2
Air is then preferably blown into the container lining. As a result, the container lining rests against the inner wall of the container
Implementation Method 3
By tilting the container using various tools such as chain hoists, hydraulic jacks, etc., loading can be simplified, since the bulk material falls to the lowest point due to gravity.
Data Source
AI summary
A liner (1) for a large-capacity container is essentially cuboid in shape and has a loading opening (3) on its end face (2) with a loading nozzle (4) located in the center of the end face (2). This allows the large-capacity container to be filled very completely with bulk material, especially when the container is placed in a vertical position for filling. It is advantageous if the container is inflated before filling so that the liner (1) fits as smoothly as possible against the inner surface of the large-capacity container.