Method for filling and forming a transportable container for bulk goods

p00001Procedure for filling and forming a transportable container for bulk goods.

BACKGROUND OF THE INVENTION

<dl><dt>1.</dt><dd> Field of the Invention </dd></dl>

The present invention relates to a process for filling a transportable bulk container, particularly a method using a soft handling hopper and a crumpled bag to reduce the amount of breakage in bulk goods arranged in the transportable container.

<dl><dt>2.</dt><dd> Description of the prior art </dd></dl>

p00002Systems are known in the art for packaging a plurality of bulk goods in transportable containers. Typical transportable containers used for the transport of bulk goods are inefficient, do not have a very large volume, and often require a large amount of manual labor to be used in filling and handling the transportable container. Typically, the filling of these containers requires that bulk goods be dropped large distances, which may result in the breaking of bulk goods.

p00003An example of such a system is described in US Patent No. 6,176,276 to Maunder et al. The '276 patent describes a device for introducing a granular material from an upstream source, such as a conveyor belt, to a water container down. The hopper has a gradually narrowed section downward that narrows inward to a supply ramp that has a widened lower end that ends in a radial flange. An adjustable ring is defined between a frustoconical member and the latch wall near the narrowed section into the hopper to control the flow from the narrowed section down to the supply ramp. An adjustable radial outlet is defined between the flange of the ramp and elanillo. A jet of compressed air is supplied to the supply ramp by means of an air pipe to generate an air jet to drag the material that falls through the ring, and throw the material from the ramp.

p00004Another similar system known in the art is described in U.S. Patent No. 5,697,408 of Reves. The '408 patent describes a telescopic tube that extends down into a container to fill the container. The volume of the telescopic tube varies based on the position of the end of the tube. A cylindrical valve member and valve seat move vertically in the storage container, so that the particles do not have to fall as much distance from the telescopic tube to the storage container.

p00005Another similar system known in the art is described in U.S. Patent No. 4,546,598 to Karpisek. The '598 patent describes a wrapping apparatus that has an expandable carrier or frame that is supported on a conveyor. The carrier comprises a rectangular tubular member that is telescopic. A support or arm extends from each corner of the tubular member to the wrap that will be applied. The wrap is a bag that has a closed base and an open end. The carrier is placed in a gathering device or charger where the bag of wrap material is loaded into the carrier. Each of the brackets is coupled to a belt that drives the envelope over the carrier. After the envelope has been loaded onto the carrier, the carrier expands telescopically to a diameter greater than that of the cargo of previously stacked goods on which it will be placed. The loaded carrier is then transferred and positioned on a pallet with the load of stacked goods. The carrier is lowered so that the open end descends on the stacked goods. The closed base is coupled with the upper part of the load as it is lowered to the carrier, causing the envelope to detach from the carrier as it descends downward, thereby depositing the envelope on the cargo of goods. Once released from the stretching forces applied by the wearer, the stretched bag will begin to contract to reach its prestressed state.

p00006Another known system of the state of the art is a transportable container for bulk goods and a method for forming the container such as that described in WO 0144051, in which a transportable container is formed from a bag having a closed base and an open top. The open upper part is in a retracted position and a lower support is located adjacent to the closed base. A particulate material is loaded into the bag and an outer wrap spirals around the lower support and the bag, so that the outer wrap fixes the bag to the lower support and fixes the open top in the folded position. The procedure for forming the transportable container includes the steps of fixing the upper part of the bag in an open position and supporting a base of the bag. The bag is filled to a predetermined level with a particulate material and, while it is being filled, the level of filling of the particulate material in the bag is monitored. Simultaneously with the filling of the bag, an outer wrap is spirally wrapped around the bag in an upward direction to a predetermined filling level. Once the bag is completely full, the open top of the bag is released and moved to a folded position, whereby the outer wrap coiled around the bag in a downward direction to fix the open top in the retracted position thus forming the transportable container.

SUMMARY OF THE INVENTION

p00007The present invention relates to a method of forming a transportable container of agrarian goods from a soft handling hopper and a wrinkled or puckered bag. A bag that has an open upper part and a closed base is gathered on an intermediate carrier. The intermediate carrier is fixed to a packaging system, with the upper part open of the bag being arranged adjacent to the distribution end of a hopper and the closed base of the bag being positioned vertically below the open top. The distribution end of the hopper is placed over the bag to create a vertical space between the distribution end and the closed base. Bulk goods are distributed inside the hopper opening of the hopper to establish a level of filling of the hopper. Bulk goods are dispensed from the distribution end of the hopper through the open top of the bag into the closed base of the bag to establish a level of bulk goods in the bag. The hopper moves vertically during the dispensing of the bulk goods to maintain the vertical space between the hopper distribution end and the level of bulk goods in the bag. A level of filling of the hopper is maintained in the hopper during the dispensing of bulk goods from the hopper and concurrent with the movement of the hopper in response to the level of bulk goods in the bag. The intermediate carrier moves relative to the closed base of the bag to distribute the bag from the intermediate carrier as the level of bulk goods in the bag increases. An outer wrap spirals around the bag while the bag is filled to form the transportable container. The outer wrap stays close to the level of bulk goods in the bag.

BRIEF DESCRIPTION OF THE DRAWINGS

p00008Other advantages of the present invention will be readily appreciated, as it is understood to improve reference to the following detailed description when considered in connection with the accompanying drawings, in which:

p00009Figure 1 is a perspective view of a packaging system according to the present invention with a flexible bag of the present invention in an open position before filling and wrapping;

p00010Figure 2 is a perspective view of the system of Figure 1 during the carrying and wrapping phases;

p00011Figure 3 is a perspective view of the transportable container in a completely wrapped phase;

p00012Figure 4 is a perspective view of an exemplary intermediate carrier according to the present invention;

p00013Figure 5 is a perspective view of an exemplary intermediate carrier according to the present invention;

p00014Figure 6 is a perspective view of a soft handling hopper according to the present invention;

p00015Figure 7 is a cross-sectional view of the soft handling hopper along line 7-7 of Figure 6;

p00016Figure 8 is a flowchart showing an exemplary method of forming a transportable container according to the present invention; and

p00017Figure 9 is a flow chart showing another exemplary method of forming a transportable container according to the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

p00018Throughout the present specification and the claims the phrase "bulk goods" is used as a shorthand version of the wide range of products that can be packaged using the present invention. The present invention is useful in the packaging of any material that can be packaged in bulk. These items can cover large pieces packed in bulk as well as very small pieces packed in bulk. Examples of smaller bulk goods include, but are not limited to, the following: agricultural products such as seeds, rice, grains, vegetables, fruits, chemicals such as pure chemicals, pharmaceuticals, raw chemicals, fertilizers, plastics such as microspheres of plastic resin, plastic parts, discarded plastic parts, machined plastic parts, cereals and cereal products such as compotrigo, various machined parts of all types, wood products such as wood shavings, material for gardening, peat, earth, sand, gravel, rocks and cement The present invention is also useful in bulk packaging of larger bulk goods including, but not limited to: prepared foods, partially processed foods such as frozen fish, frozen chicken, other frozen meat and meat products, manufactured items such as textiles, clothing, footwear, toys such as plastic toys, plastic halves, metal parts, soft toys, stuffed animals and other toys and toy products. It is intended that all these types of materials and similar bulk packaged materials be encompassed herein and claims by this phrase.

p00019Referring to the figures, in which similar numbers indicate similar or corresponding parts in the different views, a soft handling hopper 20 and a wrinkled bag system 22 are generally shown to fill and form a transportable container 24 of bulk goods 26.

p00020Although the soft handling hopper 20 and the wrinkled bag system 22 can be adapted to operate with any number of packaging systems 28, the exemplary embodiment of the present invention will be explained in reference to the exemplary packaging system 28 described below.

p00021As shown in Figures 1 and 2, the exemplary packaging system 28 includes a frame having a top bracket 30 separated from a frame base 32. At least one support column 34 extends between the frame base 32 and the support upper 30. The base of the frame 32 includes a pair of legs of the base 36. The upper support30, the base of the frame 32 or both can be movable vertically along the support column 34. The upper support 30 includes an opening of the support 38 through which the agrarian goods 26 can be introduced from a power source 40 into the bag 42 to form the transportable container 24 as shown in Figure 3. A rotating plate 44 It is mounted on the upper support 30 of the packaging system 28. A lower turntable 46 is mounted on the base of the frame 32 of the packaging system 28. Both the lower turntable 46 and the turntable 44 are rotatable, and the rotation of the lower turntable 46 and the turntable 44 can be synchronized so that they turn in unison. The synchronized rotation of the upper and lower rotating plates 44, 46 allows the uniform distribution of bulk goods 26 in the transportable container 24.

p00022The packaging system 28 may include a filling sensor 48 for monitoring and measuring the level of bulk goods 26 in the bag 42. The measured level of bulk goods 26 in the bag 42 can be used in conjunction with the various features and functions of the delivery system. packaging 28. For example, the level of bulk goods 26 in the bag 42 can be used to determine the flow of bulk goods into the bag 42 from the power source 40, the movement of the upper support 30 or the base of the frame 32 to accommodate more agrarian goods 26, and the rotation of the upper and lower turntables 44, 46 to distribute the bulk goods 26 uniformly deform within the bag 42 forming the transportable container 24. The filling sensor 48 may be an ultrasonic transmitter and receiver, or any other sensor known in the art.

p00023The packaging system 28 may comprise a conventional chiller device 50 such as, for example, a semi-automatic Lantech Q series packer. The chiller device 50 further includes a wrapping head that includes an outer wrap roll 52 fixed on a base of the wrap head The outer wrap 52 is preferably a stretch wrap that has a high adhesion factor, but the outer wrap 52 can be any of several stretch wrap films known in the art. The wrapping head is movable vertically along a guide bar that runs parallel to the support column 34. The movement of the wrapping head can be controlled by a motor or any other movement control mechanism known in the art.

p00024Initially, the bulk goods 26 are arranged inside a flexible bag 42 from the feed source 40. The filling sensor 48 is used to detect the height or level of the bulk goods 26 within the flexible bag 42. As the flexible bag 42 is filled with bulk goods 26, the rotating plate 44 and the lower turntable 46 rotate at a speed and the wrapping head moves vertically upward, so that the outer wrap 52 is always kept at a level slightly below or near the level of bulk goods 26 in the bag 42. In an alternative embodiment, the outer wrap 52 may be rotated around a stationary bag 42. As the bag 42 fills, the filling sensor 48 will slowly remove from the flexible bag 42. The system can be adjusted to provide overlapping outer shell layers 52 separated from 0.5 to 15 inches (1.27 to 38.1 cm).

p00025The outer shell 52 generates tangential forces that apply a gentle squeeze to the bulk goods 26, helping to stabilize the bulk goods 26. The tangential forces stabilize the bulk goods 26 by promoting controllable contact between the elements of the bulk goods 26 which they are being loaded into bag 42 of transportable container 24, thereby promoting bridging between components of bulk goods 26. For example, when the bulk goods 26 that are being loaded are a bulk cereal in the form of inflated flakes or flakes, the tangential forces promote bridging between the cereal pieces, thereby reducing the relative movement between the pieces and immobilizing the cereal in the bag 42. By adjusting the extent to which the outer envelope 52 is applied to the bag 42, the tangential forces can be tailored to the type of bulk goods 26 that are being inserted into the transportable container 24. The tangential forces allow a very compact and rigid transportable container 24, which does not allow bulk goods 26 to move or be crushed in the transportable container 24.

p00026The exemplary embodiment includes a wrinkled bag system 22 having an intermediate carrier 54 for keeping a flexible bag 42 in an open and wrinkled or pursed position. The flexible bag 42 includes a super-open part 56 and a closed base 58 to form the transportable container 24 of bulk goods 26. The flexible bag 42 is of circular or square cross-section to define an open circular or square upper part

p0002756. The closed base 58 may be formed in the bag 42 or the bag 42 may be a continuous tubular roll in which the closed base 58 is formed by folding the tube, pursing the tube or twisting and attaching a length of the tube that could later be used as a spill nozzle during subsequent unloading of agranel goods 26. The bag 42 is preferably a bellows bag 42 and can be formed from any material suitable for bulk goods 26 arranged in the bag 42 of the transportable container 24, such as, for example, low density polyethylene, high density polyethylene, a Polymer suitable for food or Nylon.

p00028The intermediate carrier 54 has a carrier base 60 and a plurality of carrier arms 62 extending from the base of the carrier 60 to one end of the arm 64. In the exemplary embodiment, the carrier base 60 is circular and defines a carrier opening. 66. Although the base of the carrier 60 is circular in exemplary embodiment, the base of the carrier 60 may be of any form known in the art, including but not limited to, square and rectangular. In the exemplary embodiment, the intermediate carrier 54 has four arms of the carrier 62, but the intermediate carrier 54 may have any necessary number of carrier arms 62. As shown in Figure 4, the arms of the carrier 62 have a first arm portion 68 extending perpendicularly from the base of the intermediate carrier 54 and a second arm part 70 that are angled radially outward with respect to the end of the arm 64. Each of the ends of the arm 64 may include a lid portion 72 to help guide the bag 42 to the intermediate carrier 54. The lid portion 72 pushes out against the inner surface of the flexible bag 42 creating a force on the bag 42 to fix the bag 42 on the intermediate carrier 54. In the exemplary embodiment, the lid portion 72 is a spherical cap, but may be of any form known in the art. In an alternate embodiment , as shown in Figure 5, each of the arms of the carrier 62 may extend at an angle from the base to the end of the arm 64 which is arranged radially outwardly from the base of the intermediate carrier 54.

p00029The intermediate carrier 54 may include a plurality of support arms 74 that extend radially from the base. The support arms 74 are used to engage the packaging system 28 and secure the intermediate carrier54 to the packaging system 28.

p00030The bag 42 used to create the transportable container 24 is introduced into the intermediate carrier 54 with a feeder. The feeder is independent of the packaging system 28. Prior to placement on the packaging system 28, the intermediate carrier 54 is placed on the feeder. The open upper part 56 of the bag42 is placed around the plurality of arms of the carrier 62 and is fixed to the intermediate carrier 54 by using at least one support clip 78. In the exemplary embodiment, the support clip 78 is disposed on the carrier base 60 adjacent at least one of the arms of the carrier 62. The feeder controls the flow of the bag 42 on the intermediate carrier 54. The feeder has a plurality of rollers and / or tapes for uniformly controlling the introduction of the bag 42 on the intermediate carrier 54. The uniform introduction of the bag 42 onto the intermediate carriers 54 allows the bag 42 to spread evenly from the carrier when it forms the transportable container 24. The uniform disbursement of the bag 42 from the intermediate carrier 54 is useful for maintaining a desired shape for the transportable container 24.

p00031Once the bag 42 is placed on the intermediate carrier 54, the intermediate carrier 54 is transported to the packaging system 28. This can be done by a human operator, a robot or other mechanical means. In the exemplary embodiment, the intermediate carrier 54 is placed on a cylindrical piece 80 extending from the rotating plate 44 of the upper support 30. The cylindrical part 80 is fixed to the turntable 44 so that, when the turntable 44 rotates, the cylindrical part 80 can rotate with it. In the alternative embodiment, the cylindrical part 80 may be fixed to the upper support 30 and remains stationary. The cylindrical piece 80 includes a plurality of cylindrical arms 82 extending upwardly from the swivel plate 44, with each of the cylindrical arms 82 defining a support notch 84 adjacent to each end of the cylindrical arm. Each of the support notches 84 supports a support arm 74 of the intermediate carrier 54 to fix the intermediate carrier 54 to the turntable 44 of the packaging system 28. The arms of the carrier 62 extend downwardly from the cylindrical part and through the opening of the support 38, so that the bag 42 will be disposed from the intermediate carrier 54 through the opening of the support 38 as the bulk goods 26 are inserted from the power supply 40 into the bag 42. In an alternative embodiment, the cylindrical arms 82 can extend downward from the upper support 30 or the turntable

p0003244.

p00033In the exemplary embodiment, the intermediate carrier 54 is fixed to the packaging system 28 so that the wrinkled bag 42 disposed on the intermediate carrier 54 is placed through the opening of the support 38 of the upper support 30 of the packaging system 28. The open upper part 56 is disposed adjacent to the power supply 40, and the closed base 58 of the bag 42 is placed in an initial shaper 88 or slide sheet resting on a support of the transportable container 86 or pallet. The initial shaper 88 and the support of the transportable container 86 may be independent of each other or a single unit. In the exemplary embodiment, the support of the transportable container 86 is a pallet that is used in the transport of the transportable container 24, but can be any other support of the transportable container 86 known in the art. In the exemplary embodiment, the initial shaper 88 is a slide sheet that is placed on the carrier of the transportable container 86, but the initial shaper 88 may be any other initial shaper 88 known in the art.

p00034The support of the transportable container 86 is placed on and movable with the lower swivel plate 46 and the frame base 32. The base of the frame 32 can be moved vertically and the lower swivel plate 46 can be rotatable in the base of the frame 32. Although the upper and lower rotating plates 44, 46 may be stationary, in the exemplary embodiment, the upper and lower rotating plates 44, 46 are rotatable, preferably with synchronized rotation to provide a uniform distribution of bulk goods 26 in the transportable container 24.

p00035In the exemplary embodiment, the bulk goods 26 are introduced into the open upper part 56 of the bag 42 through the opening of the carrier 66 by the power source 40. The power source 40 can be a conveyor belt, a hopper 20 or any other source for introducing bulk goods 26 in a transportable container 24.

p00036In the exemplary embodiment, as the bulk goods 26 are introduced into the bag 42 to increase the level of bulk goods 26 in the bag 42, the upper support 30, the cylindrical piece 80, and the fixed intermediate carrier 54 move towards top in response to the level of bulk goods 26 in bag 42. The weight of the bulk goods 26 in the bag 42 will keep the closed base 58 of the bag 42 fixed in the initial shaper 88 and the support of the transportable container 86 arranged on the base of the frame 32 while the bag 42 is distributed from the intermediate carrier 54 . Since the bag 42 has been uniformly distributed in the carrier, the bag 42 will be distributed evenly from the arms of the carrier 62 as the bag 42 is dragged away from the intermediate carrier 54. As described above, the part The lid 72 of the intermediate carrier 54 pushes outward against the inner surface of the flexible bag 42 to create a force on the bag 42 that secures the bag 42 to the intermediate carrier 54. The weight of the bulk goods in the bag 42 will cause the bag 42 to be dragged away from the cover portion 72 of the intermediate carrier 54 to create the transportable container

p0003724. The uniform distribution of the bag 42 from the intermediate carrier 54 will allow the transportable container 24 to retain its shape. The transportable container 24 may have any form known in the art, including, but not limited to, round and square.

p00038As shown in Figure 1, the outer wrap 52 is initially wound in a spiral around the support, the initial shaper 88 and a part of the bag 42 into which the bulk goods 26 have been introduced. As shown in Figure 2, as the level of bulk goods 26 increases in the bag 42, the outer wrap 52 is spirally wound by the chiller device 50 at a predetermined level below the level of bulk goods 26 to form the transportable container 24. The bulk goods 26 will initially adapt to the shape of the initial shaper 88 and the shape of the bag 42 that is being introduced to the intermediate carrier 54. As the bag 42 is filled with bulk goods 26, the closed base 58 of the bag 42 moves vertically with respect to the open top 56 in response to the level of filling of the bulk goods 26 in the bag 42. In a an exemplary embodiment, the open upper part 56 moves upwards with respect to the stationary closed base 58 in response to the level of filling of the bulk goods 26 in the bag 42. In another embodiment, the closed base 58 moves downwardly with respect to the upper open stationary part 56 in response to the level of filling of the bulk goods 26 in the bag 42. As the bag42 is filled with bulk goods 26, additional parts of the stretch wrap are arranged around the bag

p0003942 The stretch wrap is maintained at a level below the level of filling of the bulk goods 26 to maintain the shape of the transportable container 24 and to tighten the bag 42 and immobilize together the bulk goods 26 arranged in the bag 42. In the exemplary embodiment, the stretch wrap is an outer wrap 52 of a roll of stretch wrap that spirals around the base of the conveyor and the bag 42, but any stretch wrap known in the art can be used, including, but not limited to a, a stretchable bag 42 and a heat shrink film.

p00040The use of a crumpled bag 42 will limit the distance that bulk goods 26 should fall and, therefore, length, from the power supply 40 into the transportable container 24. The wrinkled bag 42 allows the power supply 40 to be keep at a constant distance from the level of filling of the bulk goods 26 in the transportable container 24.

p00041In another exemplary embodiment, the base of frame 32 is vertically movable. During the initial phases of filling the bag 42, the lower swivel plate 46 is placed in a position adjacent to the upper support 30. The closed base58 of the bag 42 rests on the support of the transportable container 86 and the initial shaper 88 which is placed on and mobile with the bottom turntable 46 and the base of the frame 32. As the bag 42 fills, the base of the frame 32 together with the closed base 58 of the bag 42 moves in a downward direction to accommodate additional bulk goods 26.

p00042The weight of the bulk goods 26 will keep the closed base 58 of the bag 42 on the support of the transportable container 86 while the bag 42 is distributed from the intermediate carrier 54. Since the bag 42 has been evenly distributed on the carrier, the Bag 42 will be distributed evenly from the arms of the carrier 62 as the bag 42 is dragged away from the carrier. As described above, the cover portion 72 of the intermediate carrier 54 pushes outward against the inner surface of the flexible bag 42 to create a force on the bag 42 that secures the bag 42 to the intermediate carrier 54. The weight of the merchandise in bulk in the bag 42 will cause the bag 42 to be dragged away from the lid portion 72 of the intermediate carrier 54 to create the transportable container 24. The uniform distribution of the bag 42 from the intermediate carrier 54 will allow the transportable container 24 to retain its shape. The transportable container 24 may have any shape known in the art, including, but not limited to, round and square.

p00043The movement of the lower turntable 46 can be achieved by any of several mechanisms including scissor platform legs, hydraulic pistons, pneumatic pistons or a gear mechanism. As the level of bulk goods 26 increases in the bag 42 and the frame base 32 moves vertically down to accommodate additional bulk goods 26, The outer envelope 52 is spirally wound by the chiller device 50 at a predetermined level below the level of bulk goods 26 to form the transportable container 24.

p00044As shown in Figures 1 and 2, and particularly Figures 5 and 6, the power supply 40 can be a soft handling hopper 20 to fill the bag 42 and create the transportable container 24. The soft handling hopper 20 can be used with a bag 42 disposed on an intermediate carrier 54 as described above, with only one bag 42, or any other system known in the art. In an exemplary embodiment, the soft handling hopper 20 is disposed at the end of a conveyor belt and has a fixed volume. In an alternative embodiment, the hopper 20 may have a telescopic tube to modify the volume of the hopper 20. The hopper 20 minimizes the vertical drop from the conveyor belt to the bag 42 to minimize the length of the bulk goods 26. The hopper 20 is movable vertically so that the hopper 20 is positioned continuously deformed on the open upper part 56 of the bag 42. Based on the level of bulk goods 26 in the transportable container 24, the hopper 20 will introduce bulk goods 26 from a power source 40, such as a conveyor belt in the transportable container 24.

p00045Hopper 20 can be stationary or mobile. The hopper 20 can move up in response to the bulk goods level 26 in the bag 42 as determined by the filling sensor 48. As the bulk goods level 26 rises, the hopper 20 will move upwards with the support upper 30. In the preferred embodiment, the movement of the hopper 20 and the upper support 30 will be synchronized, so that the hopper 20 will remain at a constant distance from the bulk level of bulk goods 26 in the bag 42. The conveyor belt is mobile to along a path both horizontally and vertically to maintain the position of latch 20 over the open top 56 of the bag 42. Preferably, the hopper 20 is held in a position on the center of the open upper part 56, which allows a more uniform distribution of bulk goods 26 in the bag 42.

p00046In another exemplary embodiment, the hopper 20 remains stationary as the base of the frame 32 moves down in response to the level of the bulk goods 26 in the transportable container 24. In this embodiment, during the initial phases of filling the bag 42, the base of the frame 32 is placed in a position adjacent to the rotating plate 44. The closed base 58 of the bag 42 rests on the support of the transportable container 86 and the initial shaper 88 that is placed on and movable with the lower swivel plate 46 and the base of the frame 32. As the bag 42 becomes full, the base of the frame 32 together with the closed base 58 of the bag 42 moves in a downward direction to accommodate additional bulk goods 26 from the stationary hopper 20. The weight of the bulk goods 26 will keep the closed base 58 of the bag 42 on the support pallet while the bag 42 moves down.

p00047The hopper 20 includes an opening of the hopper 90 for receiving the bulk goods 26 from the feed source 40. In the exemplary embodiment, the power supply 40 is a conveyor belt and the bulk goods 26 are introduced from the end of the belt conveyor inside the hopper opening 90. The cross section of the hopper opening 90 is generally rectangular but can be in any way known in the art. In a first part of the hopper 20, the cross-section of the hopper 20 sews down gradually to a second part of the hopper 20. The second part of the hopper 20 is generally rectangular transverse desiccation, but it can be of any known shape in the technique, and extends vertically up to a third of the hopper 20. The third part of the hopper 20 passes from the second part of generally rectangular cross-section to a fourth part of the hopper 20 which has a generally circular cross-section but can be of any form known in the art. The fourth part of the hopper 20 extends vertically downward from the third part of the hopper 20 to a distribution end 92 of the hopper 20. The distribution end 92 is positioned on the open upper part 56 of the bag 42 at a predetermined distance above the level of bulk goods 26.

p00048The hopper 20 is handled by keeping the bulk goods 26 at a relatively high level in the hopper 20. The bulk goods 26 do not have to fall far from the end of the conveyor belt in the opening of the hopper 90.The movement of the goods to Bulk 26 through the hopper 20 is controlled so that the bulk goods 26 that fall from the distribution end 92 of the hopper 20 into the bag 42 of the transportable container 24 have to fall a smaller distance. The hopper 20 divides the fall of the bulk goods 26 from the end of the conveyor belt to the bag 42 into two short falls as opposed to a larger fall. The two more short falls minimize the breakage of bulk goods 26.

p00049The hopper 20 includes a modulation valve 94 arranged at the distribution end 92 to adjust the flow of the bulk goods 26 from the hopper 20 into the bag 42. A cone, plate or screw can also be used to adjust the flow of the bulk goods 26 from the hopper 20. The modulation valve 94 is moving closer and away from a valve seat 96 to maintain the level of the bulk goods 26 at a desired level in the hopper 20. The modulation valve 94 can also be rotatable based on the agranel goods 26 that are being distributed from the distribution end 92 of the hopper 20. If the level of bulk goods 26 in the hopper 20 is above the desired level, the cylindrical valve will move away from the valve seat 96 to distribute the bulk goods 26 in the bag 42 at a higher speed thereby lowering the level of the goods to bulk 26 in hopper 20, so that bulk goods 26 will not spill out of the opening of hopper 90. If the level of bulk goods 26 in the hopper 20 is below the desired level the cylindrical valve will move towards the valve seat 96 to distribute the bulk goods 26 in the bag 42 at a lower speed thereby raising the level of the bulk goods 26 in hopper 20 to minimize the bulk that bulk goods 26 must fall from the power supply 40. As a result, bulk goods 26 fall a smaller distance from the power source 40 into the interior of the hopper 20 and travel smoothly and gradually to the distribution end 92 of the hopper 20 to be distributed inside the bag 42 to form the container transportable 24. Additionally, the valve 94 helps to distribute the bulk goods 26 in the bag 42 to maintain a uniform filling and part have a flat top portion, thereby increasing the amount of bulk goods 26 in the transportable container 24.

p00050The modulation valve 94 may also include a bulk merchandise distributor. In the exemplary embodiment, the bulk merchandise distributor is at least one ramp that aids in the preferential distribution or flow of the bulk goods 26 from the distribution end 92 of the hopper 20, but the bulk merchandise distributor can be any mechanism known in the art of preferential flow of goods agranel 26. The bulk merchandise distributor may be flat, may include side walls, be rounded or any other configuration based on the desired flow and the type of bulk merchandise 26 being distributed. The bulk merchandise distributor may be incorporated into the design of the modulation valve 94 or it can be a separate and distinct unit that can be fixed to the modulation valve 94. The bulk merchandise distributor allows the distribution of bulk goods to desired locations of the transportable container 24, which helps to clog transportable containers in a square or rectangular form 24. The bulk merchandise distributor allows more flow of bulk goods 26 to the corners of the square or rectangular transportable container 24 to improve the stability and consistency of the shape of the square or rectangular holes. The bulk merchandise distributor allows the flow of bulk goods 26 from the distribution end 92 of the hopper 20 to be controlled and directed to desired parts of the transportable container 24 to aid in the conformation of the transportable container 24.

p00051The hopper 20 includes a hopper sensor 98 to measure the level of filling of the bulk goods hopper 26 in latch 20. The hopper sensor 98 is in communication with the modulation valve 94 to control the distribution speed of the bulk goods 26 and the level of hopper filling in hopper 20. The hopper sensor 98 monitors the quantity of bulk goods 26 in the hopper 20 and regulates the modulation valve 94, cone, screw plate to maintain the height of the bulk goods 26 or the filling level of the hopper in the hopper. hopper 20.

p00052The packaging system 28 preferably includes a control panel to allow an operator to control various functions such as stop, start, rotation speed and movement speed of the wrapping head. Such controls are known in the art. The packaging system 28 also includes conventional controls to maintain the appropriate filling level, external wrapping force 52 and sequencing.The ratio of these parameters is constantly monitored and automatically adjusted by means known in the art. The hopper 20 and the power supply 40 may be in communication with the filling sensor 48 of the packaging system 28 which monitors the level of bulk goods 26 in the bag 42 of the transportable container 24 via the control panel. For example, the filling sensor 48 can communicate with the hopper 20 to control, by turning off or on, the flow of bulk goods 26 from the distribution end 92 of the hopper 20. In addition, the filling sensor 48 can communicate with the power supply 40 to control, by turning off or on, the flow of bulk goods 26 from the power supply 40 into the hopper 20.

p00053The hopper 20 improves the quality of the bulk goods 26 by reducing the breakage that occurs. Hopper 20 will reduce the vertical drop that bulk goods 26 will experience. Bulk goods 26 have a shorter fall from conveyor belt to hopper 20. Bulk goods 26 have a more soft landing on hopper 20 when landing on other goods in bulk 26 that are already in hopper 20. The bulk goods 26 then flow gradually through the hopper 20 and there is a small drop from the distribution end 92 of the hopper 20 to the bag 42 that is being filled to form the transportable container 24. Latolva 20 is easier to Clean due to limited moving parts within the food stream and easy to switch between products.

p00054The outer wrap 52 is initially spirally wound around the support, the initial shaper 88 and a part of the bag 42 into which the bulk goods 26 have been introduced. As the level of bulk goods 26 increases in the bag 42, The outer envelope 52 is spirally wound by the chiller device 50 at a predetermined level below the level of bulk goods 26 to form the transportable container 24. As the bag 42 is filled with bulk merchandise 26, additional stretchable wrap parts are arranged around the bag 42. The stretch wrap is maintained at a level below the level of bulk merchandise 26 to maintain the shape of the container. transportable 24 and to tighten the bag 42 and immobilize together the bulk goods 26 arranged in the bag 42. In the exemplary embodiment, the stretch wrap is an outer wrap 52 from a roll of stretch wrap that is spirally arranged around the conveyor base and the bag 42, but any stretch wrap known in the art can be used, including, but not limited to , a stretchable bag 42 and heat shrink film.

p00055The outer shell 52 generates tangential forces that apply a gentle squeeze to the bulk goods 26, helping to support and affirm them. The tangential forces stabilize the bulk goods 26 by promoting a controllable contact between the elements of the bulk goods 26 that are being loaded inside the bag 42 of the transportable container 24, thereby promoting bridging between the components of the goods to bulk 26. For example, when bulk goods 26 that are being loaded are uncereal in bulk in the form of inflated flakes or flakes, they are tangentially promoted by bridging between pieces of cereal, thereby reducing the relative movement between the pieces and immobilizing the cereal in the bag 42. By adjusting the extent to which the outer envelope 52 is applied to the bag 42, the tangential forces can be tailored to the type of bulk goods 26 that are being inserted into the transportable container 24. The tangential forces allow a very compact transportable container and rigid 24, which does not allow bulk goods 26 to move or be crushed in the transportable container 24.

p00056The transportable container 24 may be closed or left open depending on the bulk goods 26. For example, some bulk goods 26 such as wood chips, sand, gravel and other bulk goods26, may not require that the transportable container 24 be closed. In such cases, the outer wrap 52 would be applied around the bulk goods 26 in an upward direction to fix the bulk goods 26 and create the transportable container 24. Alternatively, the transportable container 24 can be closed in any of various ways known in the art including, but not limited to: sonic or heat welding of the upper part of the transportable container 24, closing the upper part of the transportable container 24 by refolding the bag 42 and fixing it with at least one additional outer shell 52, closing the upper part of the transportable container 24 with a knot plastic slide, closure of the upper part of the transportable container 24 with wire or rope, closure of the upper part of the transportable container 24 with a clamp, and other closure means known in the art.

p00057The transportable container 24 can also be closed by placing a base of the conveyor, a sliding sheet, or a flat sheet of cardboard or plastic on top of the transportable container 24. After placement of the conveyor base, the slide sheet or flat sheet on top of the transportable container 24, the transportable container 24 is wrapped with additional outer wrap 52 to secure the conveyor base, the slide sheet or flat sheet on the top of the transportable container

p0005824.

p00059In summary, a transportable bulk container 24 of bulk goods 26 is formed from a soft handling hopper 20 and a wrinkled or pursed bag 42. A bag 42 having an open top 56 and a closed base 58 is gathered on a carrier intermediate 54. To secure the bag 42 to the intermediate carrier 54, the rigid intermediate carrier 54 is placed in a feeder. The open end of the bag 42 is disposed between the plurality of arms of the feeder and the plurality of arms of the carrier 62 and each of the ends of the arm 64 of the plurality of arms of the carrier 62 are coupled with one of the plurality of arms of the feeder for uniformly distributing the bag 42 on each of the ends of the arm 64 on each of the arms of the carrier 62 and fixing the bag 42 on the intermediate carrier 54.

p00060The intermediate carrier 54 is fixed to the packaging system 28, with the upper part open 56 of the bag 42 being adjacent adjacent to the distribution end 92 of a hopper 20 and the closed base 58 of the bag 42 being positioned vertically below the part upper open 56. The distribution end 92 of the hopper 20 secolocates over the bag 42 to create a vertical space between the distribution end 92 and the closed base 58. The intermediate carrier 54 is fixed to the rotating plate 44 of the packaging system 28 and the closed base 58 of the bag 42 is arranged in the initial shaper 88, which is placed on the support of the transportable container 86, which is disposed on the base of the frame 32 of the packaging system 28. The upper and lower rotating plates 44, 46 turn, preferably in synchronized rotation, to distribute the bulk goods 26 in the bag 42.

p00061The bulk goods 26 are distributed in the opening of the hopper 90 of the hopper 20 to establish a filled level of the hopper. The bulk goods 26 are distributed from a power source 40 into the hopper opening 90 of the hopper 20 to establish the fill level of the hopper 20. The bulk goods 26 are dispensed from the distribution end 92 of the hopper 20 through the open top 56 of the bag 42 into the closed base 58 of the bag 42 to establish a level of bulk goods 26 in the bag 42. A valve operatively disposed at the distribution end 92 of the hopper 20 is opened in a variable manner to dispense the bulk goods 26 through the open upper part 56 of the bag 42 into the base closed 58 of the bag 42 to establish the level of bulk goods 26 in the bag 42. The speed of dispensing of the bulk goods from the distribution end 92 of the hopper 20 in response to the level of filling of the hopper is adjustable in based on the level of bulk goods 26 in hopper 20 or in the transportable container 24.

p00062The hopper 20 moves vertically during the dispensing stage to maintain the vertical space between the distribution end 92 of the hopper 20 and the level of bulk goods 26 in the bag 42. The level of filling of the hopper is maintained in the hopper 20 during the dispensing of bulk goods 26 from the hopper 20 and concurrent with the movement of the hopper 20 in response to the level of bulk goods 26 in the bag 42.

p00063The intermediate carrier 54 moves relative to the closed base of the bag 42 to distribute the bag 42 from the intermediate carrier 54 as the level of bulk goods 26 in the bag 42 increases. In the exemplary embodiment, the intermediate carrier 54 moves upwardly relative to the stationary closed base 58 in response to the level of the bulk goods 26 in the bag 42 to distribute the bag 42 from the intermediate carrier 54 as the level of goods to Bulk 26 in bag 42 increases. The outer envelope 52 is then spirally wound around the bag 42 in an upward direction while the bag 42 is filled to form the transportable container 24.

p00064In an alternative exemplary embodiment, the closed base is moved down with respect to the stationary intermediate carrier 54 in response to the level of the bulk goods 26 in the bag 42 to distribute the bag 42 from the intermediate carrier 54 as the level of goods to Bulk 26 in bag 42 increases. The outer wrap 52 is kept close to the level of bulk goods 26 in the bag 42.

p00065The foregoing invention has been described in accordance with the relevant legal standards, therefore the description is exemplary rather than limiting in nature. Variations and modifications of the described embodiment may be apparent to those skilled in the art and fall within the scope of the invention. Therefore, the scope of legal protection provided by this invention can only be determined by studying the following claims.