Welded Seam Flexible Container for Bulk Materials

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Solution Overview

Problem

Flexible large containers used for bulk materials face issues with leaky seams due to stitching, particularly under heavy loading conditions, and the manual sewing process is inefficient, leading to potential leaks and structural weaknesses.

Innovation Solution

The use of welded seams made from polyethylene (PE) fabric sheets instead of stitched seams, allowing for automated production and enhanced durability, with additional reinforcement such as intermediate PE layers and laminated films for improved leak-proofing and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If stitched seams are used to join fabric sheets, then the container can be manufactured with simple materials and processes, but the seams become leaky and structurally weak under heavy loading

Engineering Contradiction:

Improveleak-proofingVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical stitching system with a thermal welding system. Instead of using needles and threads to join fabric sheets, the invention uses heat to fuse the sheets together, eliminating stitch holes and creating leak-proof seams that maintain structural integrity under heavy loading conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the joining method from mechanical (stitching) to thermal (welding). This parameter change in the joining process transforms the seam characteristics from leaky and weak to leak-proof and structurally sound, while enabling automated manufacturing through welding equipment.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If manual sewing is used to join fabric sheets, then the process can be performed with simple equipment, but the production efficiency is low and stitching errors increase leak risk

Engineering Contradiction:

Improveproduction efficiencyVSAvoidseam quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces manual mechanical sewing with automated thermal welding. This substitution enables continuous automated production, eliminates human error in stitching, and creates consistent, high-quality leak-proof seams that maintain reliability while dramatically improving production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If polypropylene fabric is used for the container, then the material is inexpensive with good mechanical properties, but it welds poorly and requires stitching

Engineering Contradiction:

ImproveweldabilityVSAvoidmaterial cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent changes the material parameter from polypropylene to polyethylene. This material substitution enables effective thermal welding of the fabric sheets, allowing automated production of leak-proof seams. The slight increase in material cost is offset by the elimination of stitching requirements and improved manufacturing efficiency.

Inventive Principle:

Principle #35Parameter changes

4Strength

If lift loops are attached with stitching, then the attachment can be made with simple processes, but the heavy loading pulls on stitch holes and increases leak risk

Engineering Contradiction:

Improveattachment strengthVSAvoidleak resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the mechanical stitching attachment method with thermal welding for attaching lift loops. This substitution creates strong, leak-proof attachments that can withstand heavy loading forces without creating vulnerable stitch holes, thereby maintaining both attachment strength and leak resistance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The welded seams provide a leak-proof and structurally robust container capable of withstanding heavy loads, reducing the risk of leaks and improving the efficiency of filling and emptying operations, while also being recyclable and resistant to environmental factors.

Implementation Method 1

to weld the edges of the fabric sheets together

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The inliner can be made of a plastic film, for example, and not only prevent leaks, but also prevent the ingress of gas or moisture into the usable space

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS11292664B2Flexible large container with a seam-free useful space

Publication Date: 2022.04.05 ALSAN PLASTIK TEKSTIL VE METAL SAN VE TIC LTD STI

AI summary

A flexible large container for transporting and storing a filling product. The container has a usable space formed by top, bottom, and side walls that are constructed from a plurality of fabric sheets. The portions of the fabric sheets that enclose the usable space are welded together to provide a stitchless usable space. Upper portions of the sidewalls extend upward beyond the usable space to form a hem. Lift loops that enable the large container to be lifted by mechanical means are sewn onto the hem. Thus, the usable space remains stitchless, i.e., without stitch holes, yet the lift loops are stitched to the hem.