Abstract:
The present invention discloses an apparatus and method for packaging, cooling and transporting asphalt at ambient temperature. The packaging of the asphalt can be melted and integrated with the asphalt by the end user providing a beneficial additive to improve the characteristics of the asphalt.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to asphalt, and more particularly, to a method and apparatus for the transport of asphalt at ambient temperature with the added value of having the option to use the packaging itself as a valuable additive to enhance the asphalt&#39;s characteristics. 
         [0003]    2. Description of the Related Art 
         [0004]    Several designs for bulk containers have been designed in the past. None of them, however, include a method for receiving, cooling and transporting asphalt and then being able to use the packaging itself to supply an additive to enhance the characteristics of the asphalt upon re-heating by the end-user. 
         [0005]    Applicant believes that the closest reference corresponds to U.S. Pat. No. 4,207,937 issued to Allan M. Sandeman, Et. Al. The Sandeman patent discloses generally a woven fabric bulk container. However, it differs from the present invention because the present invention includes, inter alia, a liner, structural support enhancements, a method for receiving and cooling liquid asphalt and a method for integrating the bulk container into the asphalt upon reheating the asphalt. 
         [0006]    Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention. 
       SUMMARY OF THE INVENTION 
       [0007]    About 70 billion pounds of asphalt are used annually in the United States alone, and asphalt usage is in particularly high demand in developing areas of the world. 
         [0008]    Almost all asphalt used today is derived from the bottom of the barrel—that is, the last cut in the petroleum refinery after naphtha, gasoline, kerosene, and other fractions have been removed from crude oil. 
         [0009]    Once the asphalt is produced at the refinery, it is stored in specially heated and insulated storage tanks that sit alongside the refinery docks for subsequent pumping into heated asphalt ships. In order to pump the asphalt from the storage tanks into the ships, it is heated to about 300° F. (roughly 150° C.) prior to loading to decrease its viscosity and make it more manageable. 
         [0010]    The storage of asphalt at the refineries or inland terminals is an expensive, energy consuming and dangerous operation. It is particularly expensive because of the fuel that must be burned to keep the asphalt at a temperature of 300° F. (roughly 150° C.) to be able to pump it into the specialized, heated asphalt ships. 
         [0011]    Presently the transportation and storage of asphalt requires substantial infrastructure in the refineries along the coast where the ships can load and unload their cargo. Because of the economies of scale asphalt shipping requires large ships and deep water ports. In the case of the Caribbean and the Western Mediterranean markets, small ships are required in order to access the limited depth of the harbors which in turn causes the local prices to rise. This problem is particularly acute in the Caribbean Market which does not require large quantities of asphalt to be delivered at any given time and have limited infrastructure and storage facilities and therefore the prices are particularly high. 
         [0012]    This situation causes prices of asphalt to remain high and limits the development of some of the third world country roads and infrastructure. This is more pronounced in land-locked countries in Africa, South East Asia, Eastern Europe, the Caribbean and Mediterranean markets. 
         [0013]    Once the asphalt arrives at its terminal destination, in order to get into the market it must still be stored hot in storage tanks for several days before it is loaded unto heated tanker trucks and delivered to the customers. 
         [0014]    The whole process of asphalt transportation, storage and distribution is cumbersome and expensive, because under present conditions the asphalt must be heated several times along the process and remain hot until it is delivered to the customers. Subsequently the customer must also re-heat it to use for its particular applications. 
         [0015]    This invention solves many problems associated with the shipping and distribution of asphalt on a world wide basis. 
         [0016]    The invention consists of having developed a packing method and apparatus that permits the asphalt to be packed, cooled, transported at ambient temperature in ocean going containers and conventional dry cargo ships, and trucked in unheated semi-trailer trucks. Furthermore it allows for the asphalt to be stored very economically in any given storage yard at ambient temperature without the need for expensive infrastructure and heated storage tanks. 
         [0017]    This invention substantially reduces the cost of heating, the cost of transportation in specialized ships, the cost of storing in heated terminals upon arrival at destination, and the cost of transporting in heated trucks for final distribution to customers. It permits transportation in ocean going containers and conventional cargo ships which are more abundant than asphalt ships. In addition it permits relatively easy access to land-locked countries and small markets like the Caribbean and Western Mediterranean Markets. It reduces energy consumption, carbon dioxide emissions and potential danger and liability of dealing with a very hot product in the process shipping and delivery to end-users. 
         [0018]    Since the price fluctuation for asphalt on a world wide basis is seasonal (generally, higher prices in summer and lower prices in winter) it allows for asphalt to be purchased when market is low and storing it very economically for later use. 
         [0019]    It is one of the main objects of the present invention to provide a method and apparatus to transport asphalt at ambient temperature. 
         [0020]    It is another main object of this invention to provide a transport container for asphalt that also acts as an additive to enhance the characteristics of the asphalt when re-heated by the end user. 
         [0021]    It is another object of this invention to provide a method and apparatus to transport asphalt that does not require heating during the transport process. 
         [0022]    It is still another object of the present invention to provide a method and apparatus to reduce the necessity of specialized asphalt handling and transportation facilities and equipment. 
         [0023]    It is another object of this invention to provide a method and apparatus to transport asphalt to locations where currently it is not feasible. 
         [0024]    It is another object of this invention to provide a method and apparatus to transport asphalt in a manner safe to handlers and to the environment. 
         [0025]    It is another object of this invention to provide a method and apparatus to transport asphalt in small batches. 
         [0026]    It is another object of this invention to provide a method and apparatus to transport asphalt that can also act as a long term storage solution for asphalt. 
         [0027]    It is yet another object of this invention to provide such an apparatus and method that is inexpensive to manufacture and maintain while retaining its effectiveness. 
         [0028]    It is another object of this invention to provide a container for asphalt transportation that can be used as an asphalt additive by melting the container into the asphalt by the end-user thereby improving the characteristics of the asphalt. 
         [0029]    Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]    With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which: 
           [0031]      FIG. 1  represents a perspective view of a liner assembly nested inside a bag assembly. 
           [0032]      FIG. 2  shows a perspective view of a liner assembly. 
           [0033]      FIG. 3  illustrates a perspective view of an alternate embodiment of a liner assembly. 
           [0034]      FIG. 4  is a perspective view of a rack assembly. 
           [0035]      FIG. 5  is a perspective view of an alternate embodiment of a bag assembly. 
           [0036]      FIG. 6  is a perspective view of an alternate embodiment of a bag assembly. 
           [0037]      FIG. 7  is a perspective view of an alternate embodiment of a bag assembly. 
           [0038]      FIG. 8  is a perspective view of an alternate embodiment of a bag assembly. 
           [0039]      FIG. 9  is a perspective view of an alternate embodiment of a liner assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0040]    Referring now to the drawings, where the present invention is generally referred to with numeral  10 , it can be observed that it basically includes a bag assembly  100  and a liner assembly  200 . 
         [0041]    Said bag assembly is essentially a variation of a commonly available bulk bag, also known as a flexible intermediate bulk container (FIBC), used in the transportation industry. Said bag assembly comprises, inter alia, a top panel  102 , side panel  104 , loops  108 , band  110 , side panel  114  and porthole  116 . In the preferred embodiment said bag assembly has six sides comprised of a top panel  102 , a bottom panel (opposite top panel  102  but not seen in this view) side panels  104 ,  114  and two other side panels (opposite side panels  104  and  114 , respectively, but not seen in this view.) Said four side panels  114 ,  104  (and the two panels opposite these side panels), top panel  102  and bottom panel (opposite top panel  102  but not shown in this view) can be individual pieces attached to each other by seams or they may a unitary piece. 
         [0042]    Said top panel  102  has a porthole  116  where said liner assembly  200  penetrates the top panel  102  to provide access to the liner assembly  200 . An optional band  110  encircles the bag assembly  100  and is positioned generally in the middle three-quarters of the height of each side panel  114 ,  104  (and the two panels opposite these side panels). In the preferred embodiment said band  110  is sewn onto each side panel to fix its position. Said band  110  provides additional support to the bag assembly  100  especially when the temperature of the contents of the bag assembly  100  is high enough to cause the side panel material to soften and/or stretch. At four equally spaced positions along the seam between the top panel  102  are loops  108 . Said loops  108  serve the purpose of aiding in securing the bag assembly  100  while filling and providing a lifting point to transport a filled bag assembly  100 . To improve the lifting capacity that the loops  108  can support the lower end of the loops can be sewn along the height of the seams between the side panels. 
         [0043]    Now referring to  FIG. 2  where a liner assembly  200  is shown to comprise, inter alias, a cap  202 , fitment  204  and panel  208 . Said liner assembly  200  in a preferred embodiment is formed of a unitary, flexible and impermeable material. A fitment  204  is welded or otherwise affixed to upper side of the liner assembly  200  at a seam  206 . The fitment  204  provides access to the interior of the liner assembly  200  and can be sealed with a threaded cap  202 . When in use said liner assembly  200  is employed to line the interior of a bag assembly such as bag assembly  100  shown in  FIG. 1  or any of the other bag assemblies described throughout this description. 
         [0044]    Referring to  FIG. 3  where an alternate embodiment of a liner assembly  300  is demonstrated comprised of, inter alia, a panel  308 , neck  304 , rim  306  and top panel  302 . Said liner assembly  300  in preferred embodiment is formed of a unitary, flexible and impermeable material. In this embodiment a distinguishing feature is the neck  304  as an alternative to the fitment  204  (shown in  FIG. 2 ). The neck  304  provides access to the interior of the liner assembly  300  through the rim  306 . After the liner assembly is filled with asphalt the neck can be heat sealed, welded, tied, banded or otherwise closed. When in use said liner assembly  300  is employed to line the interior of a bag assembly such as the bag assembly  100  in  FIG. 1 . 
         [0045]    Now referring to  FIG. 4  where a rack assembly  400  is shown. Said rack assembly  400  is comprised of, inter alia, panel  402 , panel  404 , panel  406 , panel  408 , hinges  410 , casters  412 , latch  414 , handle  416 , grille  418  and hooks  420 . Said rack assembly  400  is formed from five panels with an open top. Said casters  412 , panel  402  and panel  404  are affixed to a bottom panel (not shown in this figure). Said panels  408  and  406  are supported by hinges  410  affixed to panel  402  and panel  404 , respectively. Arranged near the upper edge of each of said panels is affixed a hook  420 . These hooks  420  are utilized to support a bag assembly such as the bag assembly  100  shown in  FIG. 1  when filling the bag assembly  100  by securing the loops  108  over the hooks  420 . Said panels  402 ,  404 ,  406  and  408  are each constructed of a unitary frame that supports one or more grilles  418 . Said grilles  418  provide airflow to aid cooling the heated asphalt contained in, for example, the bag assembly  100  and liner assembly  200 . Said casters  412  facilitate easy movement of the rack assembly  400 . 
         [0046]    In typical use a bag assembly such as the bag assembly  100  shown in  FIG. 1  is fit inside the rack assembly  400  and secured by the hooks  420  fit into the loops  108  on the bag assembly  100 . Inside the bag assembly  100  is a liner assembly  200 . Heated, viscous asphalt is dispensed into the liner assembly  200 . When the liner assembly  200  is filled the rack assembly is rolled to an area where the asphalt can cool to a solid. Once cool, said latch  414  is opened and the handle  416  is pulled and panels  406  and  408  are opened on the hinges  410  to permit removal of the bag assembly  100  with the then cooled and solidified asphalt. 
         [0047]    Referring to  FIG. 5  where an alternate embodiment of a bag assembly  500  is demonstrated and comprises side panels  504 ,  510 ,  502  and  514 , and loops  508 . Said bag assembly  500  also has a bottom panel that is not visible in this view. Said bag assembly  500  is dimensioned to fit around a liner assembly such as the liner assembly  200  as shown in  FIG. 2  or the liner assembly  300  in  FIG. 3 . Although not shown in  FIG. 5  the bag assembly  500  optionally may include a band analogous to band  110  shown in  FIG. 1 . 
         [0048]    Referring to  FIG. 6  where an alternate embodiment of a bag assembly  550  is shown comprising, inter alia, a top panel  562 , side panel  560 , side panel  558 , sleeves  552 , neck  554 , drawstrings  556  and bands  564 . Not visible in this view, but also present are a bottom panel and side panels opposite side panels  560  and  558 , respectively. Extending from the top panel  562  is a neck  554  that provides access to the interior of the bag assembly  550  and any of the liner assemblies, for example the liner assemblies shown in either  FIG. 2  or  3 . Bands  564  are optional and may be present singly or in pairs and wrapping around the bag assembly  550  horizontally and spaced apart to contribute to the strength of the bag assembly  550 . Sleeves  552  provide a lifting point when transporting the bag assembly  550 . 
         [0049]      FIG. 7  shows an alternate embodiment of a bag assembly  600  comprised of, inter alia, side panel  604 , side panel  606 , loops  608 , skirt  602  and a drawstring  610 . Not visible in this view, but also present are a bottom panel and side panels opposite side panels  604  and  606 , respectively. Any of the liner assemblies, for example the liner assemblies shown in either  FIG. 2  or  3 , are suitable to be placed inside the bag assembly  600 . After filling, the liner assembly may be protected on top by closing the drawstrings  610  thereby cinching the top of the skirt  602 . Loops  608  provide a lift point to aid in moving the bag assembly and to hold the bag assembly up in the rack assembly  400  as shown in  FIG. 4  by placing the loops  608  over said hooks  420 . 
         [0050]      FIG. 8  shows an alternate embodiment of a bag assembly  650  comprised of, inter alia, side panels  660 ,  658 ,  664  and  662 , loops  652 , loops  654  and straps  656 . Like the other embodiments of bag assemblies described above, this bag assembly  650  is dimensioned to have a liner assembly, such as the liner assemblies shown in  FIG. 2  or  3 , fit inside. Although not visible in this view, the top of this bag assembly could have an open top similar to the embodiment shown in  FIG. 5 , a neck and drawstring similar to the embodiment shown in  FIG. 6 , a top panel and porthole similar to the embodiment shown in  FIG. 1  or a skirt and drawstring similar to the embodiment shown in  FIG. 7 . The distinguishing feature of this embodiment is the straps  656  and the loops  654  that interact to close the bottom of the bag assembly  650 . Said straps  656  are fastened to said loops  654  to create a bottom panel. Said straps  656  are released from said loops  654  to open the bottom of the bag assembly  650  and release the contents with the aid of gravity. Loops  652  are positioned in the upper corners and aid in transporting the bag assembly  650  and holding the bag assembly  650  up into a rack similar to the rack assembly  400  shown in  FIG. 4  with hooks  420 . 
         [0051]      FIG. 9  shows a liner assembly  700  compatible with any of the bag assemblies described above and comprising, inter alia, side panels  702 ,  704 ,  706  and  708 . A bottom panel is present but not visible in this view. Said liner assembly  700  in a preferred embodiment is formed of a unitary, flexible and impermeable material. 
         [0052]    In their preferred embodiment all of the above described liner assemblies and bag assemblies are made of a polymer material with a melting point below 300° F. and can be selected from the group of polyester, polyethylene, polystyrene, polyvinyl, polypropylene or any combination or mixture thereof. 
         [0053]    The preferred embodiment of any of the liner assemblies described above are constructed of an impermeable solid film of any of the above listed polymers. The preferred embodiment of any of the bag assemblies described above are constructed of a fabric made of any of the polymers described above to provide structural strength. In yet another preferred embodiment the interior surface of any of the above described bag assemblies is coated with a film of any of the above described polymers to become an integrated unit. 
         [0054]    Any of the bag assemblies described above may also be filled with asphalt without any liner at all if the fabric is woven tight enough to prevent any viscous asphalt from leaking through the fabric. 
         [0055]    Each of the liner assemblies can be melted with the asphalt with or without the bag assemblies to be incorporated into a unitary viscous mix of asphalt and polymer resulting in superior characteristics demonstrated by the asphalt. 
         [0056]    The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.