Abstract:
A package containing water-soluble bags filled with agricultural chemicals in gel or liquid form facilitates the transport of the bags in a manner which prevents the breakage thereof. The package includes compartments for holding the bags. The walls and base of these compartments contain raised and unraised portions in a pattern such that a baffling effect is created to damper transport shock waves in the gel or liquid bag. These and other features result in the transmission of dynamic shock loads in the package in a manner which prevents such shock loads from breaking the fragile water-soluble bags during transport.

Description:
This is a 371 of PCT/U.S. Ser. No. 93/05402, filed Jun. 11, 1993, which is a continuation-in-part of Ser. No. 07/913,960, filed Jul. 17, 1992, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the storage and transport of individual doses of chemicals. In particular, the present invention relates to a package containing individual portions of chemicals in the form of water-soluble bags containing agricultural chemicals in gel or liquid form. 
     2. Description of the Related Art 
     Water-soluble bags containing agricultural chemicals in gel or liquid form have just recently been developed and put into practical use. These water-soluble bags may be thrown into a water tank of a spray system whereupon the bags dissolve and the chemicals contained therein are dispersed into the water supply. Thus, there is no need to dispose of the packaging of the chemicals. U.S. Pat. No. 5,080,226 to Hodakowski et al. discloses a water-soluble bag of polyvinylalcohol containing agricultural chemicals in gel form. These bags are extremely susceptible to problems of leakage owing to the fact that small pin-holes may be formed in the polyvinylalcohol during its manufacture by a casting process. GB 2 244 258 teaches laminating layers of the polyvinylalcohol so as to reduce the chance that pin-holes in the individual layers of the laminate will allow leakage of the chemicals. 
     Nonetheless, these bags remain extremely fragile and susceptible to outright breakage during the transport thereof. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a package having a simple structure which facilitates the transport of bulk material, particularly agricultural chemicals, in a leak-free way. 
     Another object of the present invention is to provide a package which is particularly adapted to transport fragile water-soluble bags containing agriculture chemicals in gel or liquid form. To achieve this object, the packaged product has characteristics which transmit dynamic shock loads in order to prevent the breakage of the fragile water-soluble bags during transport. 
     Finally, another object of the present invention is to provide a package for use in the transport of chemicals which is very convenient for the end user. 
     To achieve this object, the package has &#34;waffling&#34; in the compartments holding the gel or liquid bags with raised portions along the sides and walls. The package also has features particular to each embodiment such as the dimensioning of the water-soluble bags relative to the receptacle openings in which they are fitted such that the length and width of the water-soluble bags are greater than those of the receptacle openings, the side and central sub-compartments of the second embodiment. and the particular design of the fourth embodiment such as the PVC material and the provision of the bottom walls of the receptacles in fixed contact with the underlying base sheet, are together responsible for the transmission of dynamic shock loads, commonly experienced during transport, in a manner which prevents breakage of the fragile water-soluble bags. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other objects, features and advantages of the present invention will become apparent to those of ordinary skill in the art from the following description of the preferred embodiments thereof made with reference to the accompanying drawings, in which: 
     FIG. 1 is a front, overhead perspective view of a gel bag transport package in accordance with the invention, the package being shown folded and in closed position; 
     FIG. 2 is a rear, underside perspective view thereof; 
     FIG. 3 is a front, overhead perspective view of the gel bag transport package illustrated in FIG. 1. further enclosed within a carrying sleeve; 
     FIG. 4 is a top plan view showing the interior of the gel bag transport package illustrated in FIG. 1, the package being shown open in flat position; 
     FIG. 5 is a broken away sectional view of the gel bag transport package in the open position of FIG. 4; 
     FIG. 6 is a perspective view of a gel bag; 
     FIG. 7 is a perspective view of the gel bag of FIG. 6 in a folded position; 
     FIG. 8 is perspective view of half of the gel bag transport package in the open position of FIG. 4 and the placement of gel bags therein; 
     FIG. 9 is a sectional view of the gel bag transport package containing two gel bags therein; 
     FIG. 10 is a sectional view of one half of a gel bag transport package in accordance with a second embodiment of the invention, with one gel bag contained therein; 
     FIG. 11 is a prespective view of a gel bag transport package in accordance with a third embodiment of the invention, the package being shown open; 
     FIG. 12 is a perspective view, partially broken-away, of constituent components constituting the package in accordance with a fourth embodiment of the invention; 
     FIG. 13 is a similar perspective view but showing water-soluble bags disposed in the receptacle openings of the package depicted in FIG. 12; 
     FIG. 14 is a similar perspective view but of the final packaged product depicted in FIG. 12 having removable lids covering the receptacle openings so as to retain the water-soluble bags therein; and 
     FIG. 15 is a perspective view of the packaged product depicted in FIG. 12 in its compact transport configuration. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference is first made to FIGS. 1 and 2 wherein a gel bag transport package, generally indicated at 20, is depicted. Gel bag transport package 20 contains two identical halves. specifically first half 21 and second half 22. shown in the closed position. First half 21 defines two compartments, 21a and 21b, which are bordered by first perimeter edge rim 23. Similarly, second half 22 defines two compartments. 22a and 22b, which are bordered by second perimeter edge rim 23. In the closed position, first and second halves 21 and 22 are joined at first and second perimeter edge rims 23 and 24 and interconnected at snap joints 25-28. 
     FIG. 4 shows gel bag transport package 20 in the open, unfolded position without gel bags. Snap joints 25 and 26 have been released into male members 25m and 26m on first half 21, and female members 25f and 26f on second half 22. When male members 25m and 26m are inserted respectively into female members 25f ad 26g, ridges 25r and 26r in male members 25m and 26m are caught by the edge of bars 25b and 26b of female members 25f and 26f to secure snaps joints 25 and 26 together until such time as they are released by the user. Similarly, snap joints 27 and 28 can be similarly separated such that identical halves 21 and 22 are completely separate, for instance as is later shown in FIG. 8. 
     FIG. 5 shows a cutaway sectional view of compartment 21a. In FIGS. 4 and 5, the interior surface of gel bag transport package 20 can be seen. The base portion of the interior surface of compartments 21a, 21b, 22a and 22b include a &#34;waffling&#34; design. Specifically, in each compartment, raised base frame 35 defines three unraised base surface portions 36. Additionally, each defined compartment has four raised side surfaces, specifically three raised side portions 38 and one central raised side portion 39. Each raised side portion 38 has three parts, the lower portion 38l, the middle portion 38m and the upper portion 38u. Lower portion 38l extends farthest into the compartment and upper portion 38u extends the shallowest, creating a pyrimidal effect. Central raised side portion 39 juts cylindrically into the compartment. 
     Gel bag transport package 20 can be made of any polymeric material such as polyvinylchloride or polypropylene, and preferably a lightweight plastic such as recycled polyethylene. Gel bag transport package 20 can be made according to any known manufacturing process, such as a deep drawing process, but one preferred technique is injection molding. Other materials and production techniques are exemplified in embodiments discussed below. 
     FIGS. 6 and 7 illustrate a typical gel bag 40. Gel bag 40 includes water-soluble polymeric film, such as polyvinylalcohol, surrounding a gel formulation. typically containing a chemical such as agricultural pesticides, herbicides, fertilizer, fungicides, insecticides and the like. The effectiveness of transport package 20 in reducing bag breakage is so great, it is to be understood that the gel in gel bag 40 may also have a viscosity low enough to be within the liquid range. Gel bag 40 has a vertical seam 42 and two side seams 43. For use in gel bag transport package 20, side seams 43 are turned underneath as shown in FIG. 7, and the side seam corners 43c are then also turned under. 
     As demonstrated in FIG. 8, gel bag 40 is then placed within one half section of gel bag transport package 20. in this case first half 21. Since side seams 43 have been tucked under gel bag 40, the side seams are not in direct contact with the side walls of compartments 21a or 21b. In order for gel bag 40 to maintain this shape, the length and width of gel bag 40 should be greater than the length and width of compartments 21a and 21b. Gel bags 40 will thus need to be tucked into compartments 21a and 21b. This placing of gel bags 40 will reduce stress on side seams 43 and thus reduce the chance for breakage of gel bags 40 during transport. 
     Once two gel bags 40 are placed in compartments 21a and 22b, a film cover layer 45 is placed thereon and heat sealed along first perimeter edge rim 23. Film cover layer may be formed of any lightweight polymeric film but clear polyester is particularly preferred. 
     Similarly, two more gel bags are also placed in the other half of gel bag transport package 20 and sealed therein, and then halves 21 and 22 are joined together and removably locked in place with snap joints 25-28. Gel bag transport package 20 and the four gel bags 40 contained therein are then ready for safe transport to the consumer destination. 
     An outer sleeve 30 shown in FIG. 3 may optionally be provided for convenience of the user. If so, gel bag transport package 20 is slideably placed within outer sleeve 30, and can similarly be easily removed. Outer sleeve 30 includes thumb and index finger grip holes 31 such that outer sleeve 30 and gel bag transport package 20 contained therein may be carried using the thumb and index finger of one hand. Outer sleeve 30 may be made of any lightweight material, preferably recyclable cardboard or corrugated board. 
     The benefits of gel bag transport package 20 for ensuring safe delivery. of gel bags 40 are as follows. As previously noted, the length and width of compartments 21a, 21b, 22a and 22b are such that side seams 43 of gel bags 40 are tucked underneath and subject to less stress from friction against the compartment side walls. However, the presence of the &#34;waffling&#34; designs on the base and side walls of the compartment is particularly important in deflecting shock waves generated in the gel during transport. As seen in FIG. 9, the present of raised base frame 35, unraised base surface portions 36, raised side portions 38 and central raised side portion 39 creates a pattern of baffles jutting into the gel bag which acts to damp the gel bag transport waves, just as baffles are used in so-called &#34;waveless&#34; waterbeds. The damping of the shock waves serves to reduce the stress placed on the fragile gel bag water-soluble outer film, and increase the chance that the gel bags will arrive intact to the consumer. 
     Moreover the effectiveness of gel bag transport package 20 in damping transport shock waves is so great that additional amounts of air may be introduced into gel bag 40. Such air might increase unstability in the transport of bags without the damping benefits of the raised portions in each compartment. Air is desirable in gel bags because such bags tend to float when introduced by the farmer user into the water tank system, and are thereby more likely to rapidly dissolve than bags without air which sink to the &#34;dead&#34; spot of the water tank. 
     A second embodiment of the invention is illustrated in FIG. 10. First half 121 is similar to its first embodiment counterpart, first half 21, in that it contains first perimeter edge rim 123, film cover layer 145 attached thereto, raised side portions 138, raised base frame 135 and unraised base surface portions 136. However, rather than each compartment having a length and width smaller than the length and width of gel bag 40 such that side seams 43 are tucked under gel bag 40, instead first half 12I includes side sub-compartments 151 and central sub-compartment 152. Side seams 43 are then placed in side sub-compartments 151 and central sub-compartment, again away from the friction of the compartment walls. 
     A third embodiment of the invention is illustrated in FIG. 11. Gel bag transport package 220 is similar to gel bag transport package 20, except each half 221 and 222 contains three compartments, 221a, 221b and 221c, and 222a, 222b and 222c, respectively. Also similar to the first embodiment, gel bag transport package 220 includes first and second perimeter edge rims 223 and 224, and snap joints 225 through 228 with their respective female and male members. The &#34;waffling&#34; design of the six compartments varies somewhat from the first embodiment. Raised base 235 defines only two unraised base surface portions 236 instead of three as in the first embodiment. Also, the sides of the compartments contain four raised side portions 238 and no central raised side portion equivalent to central side portion 39 in the first embodiment. Gel bag transport package 220 is particularly suited for transporting six smaller gel bags 40. 
     A fourth embodiment of the invention is illustrated in FIGS. 12-15. Referring to FIG. 12, gel bag transport package 320 includes a base sheet 301, preferably of PVC (polyvinylchloride), and two thermoformed sheets 302. 303, also preferably of PVC, which are discrete from the base sheet 301. These thermoformed sheets 302, 303 are disposed on the same major surface 301a of the base sheet in a juxtaposed relation. Each of the thermoformed sheets 302, 3033 is fixed to the base sheet 301, preferably by a thermal welding technique known per se. The thermoformed sheets 302, 303 each define at least one receptacle generally designated by reference numeral 304. In the illustrated embodiment, each of the thermoformed sheets 302, 303 define two receptacles 304. 
     The receptacles 304 are tray-like, meaning that they have a receptacle opening clearly shown in FIG. 12, a perimeter edge nm 323, a base defining the bottom of the receptacle opening including raised base frame 335 and unraised base surface portions 336, and side wall areas including raised side portions 338. As shown in FIG. 13, gel bags 40 are placed in the receptacle openings. Then, as shown in FIG. 14, a lid 350 is disposed over each of the receptacle openings so as to cover the same and retain the gel bags 40 therein. The lid 350 can be heat-sealed to the rim 223 of the receptacles. Although a single lid is shown in FIG. 14 as covering the receptacles of each respective thermoformed sheet 302 or 303, obviously individual lids may be provided for each of the receptacles 304, respectively. 
     Referring again to FIGS. 12-14, the thermoformed sheets 302, 303 are spaced from one another to sides of a central region of the base sheet 301. The central region is generally designated by reference numeral 310. The base sheet is scored at the central region 310 so as to allow the base sheet to be folded at the central region to allow the package to assume a compact configuration as shown in FIG. 15 and described in more detail below. 
     Specifically, the base sheet 301 has two parallel scores 311, 312 extending along the sides of the central region 310 of the base sheet 301, respectively. These scores 311, 312 are shown as grooves in the base sheet 301 of the present invention, but obviously the scores can take various other forms as long as they provide a hinge about which the package can be folded. 
     As best shown in FIG. 15, the receptacles 304 of the respective thermoformed sheets 302, 303 are brought face-to-face when the base sheet 301 is folded along the parallel scores 311, 312, whereby the package assumes a compact configuration. 
     The base sheet 301 also has a handle 333 at the central region 310 thereof. The handle 333 allows the package to be carried when in the compact configuration shown in FIG. 15. Specifically, the base sheet defines two spaced apart openings 333a, 333b through the central region 310 thereof. A portion of the base sheet extends between the openings 333a, 333b so as to constitute a handle which can be gripped by one&#39;s hand. 
     It should be noted that when the package is in its compact transport configuration shown in FIG. 15, the receptacles 304 do not prevent one&#39;s hand from being inserted through the openings 333a, 333b. This is because the receptacles 304, as shown in the figures, each have an outer configuration which tapers from the base sheet 301 to the rim 223 thereof. Thus, when the package is in the compact configuration shown in FIG. 15, a space 355 is left between the side walls of the receptacles 304 and the central region 310 of the base sheet. This space 355 can be reliably maintained by providing a rim 360 which will abut lower portions of the side wails of the receptacles 304 and prevent a collapsing of the central region into flush contact with the side walls of the receptacles 304. 
     As shown in the broken-away portion of FIG. 12, the bottom wall of each of the receptacles 304 is secured to the base sheet 301 by thermal welding, for example. The present inventors have found that for the lightweight PVC which is used as the material of the thermoformed sheets 302, 303, it is important that the bottom wall of the receptacle 304 contact the underlying base sheet 301 in order that dynamic shocks occurring during transport are transmitted throughout the package in a manner which will prevent the breakage of the water-soluble bags 40 which have been tucked into the receptacle openings. It would normally be expected that a shock-absorbing capability would be provided if the bottom wall of the receptacle were suspended above the underlying base sheet 301 of the package. However the present inventors have found that this is not the case at all and in fact breakage of the fragile water-soluble bags 40 of material, such as polyvinylalcohol, occurs more readily when the bottom wall of the receptacle in which the bag is tucked is spaced above the underlying base sheet 301. 
     Thus, it is seen that the features described above, particularly the &#34;waffling&#34; of the compartments with raised portions along the sides and walls, and also the particular features of each embodiments such as the dimensioning of the water-soluble bags relative to the receptacle openings in which they are fitted such that the length and width of the water-soluble bags are greater than those of the receptacle openings, the side and central sub-compartments of the second embodiment, and the particular design of the fourth embodiment such as the PVC material and the provision of the bottom walls of the receptacles in fixed contact with the underlying base sheet, are together responsible for the transmission of dynamic shock loads. commonly experienced during transport, in a manner which prevents breakage of the fragile water-soluble bags. 
     Although the present invention has been described above in connection with a preferred embodiment thereof, various changes and modifications will become apparent to those of ordinary skill in the art. Therefore, such changes and modifications are intended to be within the true spirit and scope of the present invention as defined by the appended claims.