Moisture prevention packaging system and methods

A packaged article is composed of a bulk bag having a top end and a bottom end. Further included is a pallet having a first side and a second side. Also included are an outer bag having a first closed end and a first open end and a heatshrink bag having a second closed end and a second open end. The first closed end of the outer bag is between the bottom end of the bulk bag and the first side of the pallet. The first open end of the outer bag is gathered over the top end of the bulk bag to enclose the bulk bag within the outer bag. The second closed end of the heatshrink bag is proximate to the top end of the bulk bag and the second open end contacts the second side of the pallet.

BACKGROUND

The disclosure relates generally to packaging and more particularly to a packaged article and to a packaging method that substantially prevents moisture penetration.

SUMMARY

According to one aspect, embodiments of a packaged article are provided. The packaged article is composed of a bulk bag having a top end and a bottom end and containing a material. The packaged article also includes a pallet having a first side and a second side in which the second side is opposite the first side. Further, the packaged article includes an outer bag having a first closed end and a first open end and a heatshrink bag having a second closed end and a second open end. The bulk bag is positioned in the outer bag such that the first closed end of the outer bag is between the bottom end of the bulk bag and the first side of the pallet. Further, the first open end of the outer bag is gathered over the top end of the bulk bag to enclose the bulk bag within the outer bag. Additionally, the heatshrink bag is positioned such that the second closed end is proximate to the top end of the bulk bag and such that the second open end contacts at least a portion of the second side of the pallet.

In another aspect, embodiments of a packaged article are provided. The packaged article includes a bulk bag having a top end and a bottom end. The bulk bag contains a dry mix of bed ash and cement in which the weight ratio of bed ash to cement is from 3:1 to 5:1. The packaged article also includes a pallet having a first side and a second side in which the second side being opposite the first side. Also included are an outer bag having a first closed end and a first open end and a heatshrink bag having a second closed end and a second open end. The bulk bag is positioned in the outer bag such that the first closed end of the outer bag is between the bottom end of the bulk bag and the first side of the pallet. The first open end of the outer bag is gathered over the top end of the bulk bag to enclose the bulk bag within the outer bag. Additionally, the heatshrink bag is positioned such that the second closed end is proximate to the top end of the bulk bag and such that the second open end contacts at least a portion of the second side of the pallet.

In still another aspect, embodiments of a method of packaging a bulk bag containing a material are provided. In the method, the bulk bag is inserted inside an outer bag. The bulk bag inside the outer bag is positioned on a pallet. The bulk bag is enclosed inside the outer bag. The pallet on which the bulk bag and the outer bag are positioned is placed on an elevated surface. The bulk bag, the outer bag, and at least a portion of the pallet are covered with a heatshrink bag, and heat is applied to the heatshrink bag so as to cause shrinkage of the heatshrink bag around the bulk bag, the outer bag, and at least a portion of the pallet.

While the invention will be described in connection with certain embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

Generally, in this disclosure, various embodiments of a packaged article and method of packaging are provided. The packaging of the packaged article is configured to substantially prevent moisture from reaching the contents on the interior of the packaging. In particular, the packaging is especially suitable for protecting moisture from being absorbed by hydratable or water-reactive materials, such as cements, ashes, and/or other pozzolanic materials. In general, the method of packaging involves placing a bulk bag of such materials into an outer bag, securing the top of the outer bag, and applying a heatshrink bag over the top of the outer bag. Applicant has determined that packaging constructed in accordance with the method disclosed herein is resistant to penetration of ambient water (e.g., humidity, precipitation, and the like) for extended periods of time. In this way, the packaging prevents the contents of the bulk bag from prematurely reacting with or absorbing water during periods of storage. The following exemplary embodiments of the system and method are provided for the purpose of illustration and should not be viewed as limiting.

As used herein, a “bulk bag” refers to a large bag designed to carry bulk materials, especially dry bulk materials. In embodiments, the bulk bag may be made from a woven material. Further, in embodiment, the bulk bag may be made from one or more materials, such as polyester and/or nylon. Bulk bags typically range in size from 28″×28″×12″ to 51″×51″×71″ and can hold loads of up to 4000 lbs. Often, bulk bags have one or more loops or sleeves that can be attached to the forks of a forklift or to a crane hoist line so that the bulk bag may be lifted and transported. A bulk bag may also be referred to as a flexible intermediate bulk container (FIBC).

As used herein, “heatshrink” refers to the property of a material that causes it to shrink when heat is applied. Heatshrink materials generally are formed from a polymeric film that has been stretched while warm to orient the polymeric macromolecules. Cooling the film sets the orientation of the macromolecules until it is reheated, causing the film to shrink back to the film's original dimensions. When a heatshrink material is placed over an object, the heatshrink material will shrink tightly over or around that object. A “heatshrink bag,” thus, refers to a bag having the property of shrinking when exposed to heat (e.g., heat sufficient to raise the temperature of the heatshrink material to a temperature range of about 225° F. to about 375° F.) so as to tightly engage the object around which the heatshrink bag is placed.

FIG. 1provides a flow-diagram of an embodiment of a packaging method100. Briefly, the method involves a first step101of placing a bulk bag in an outer bag. Then, in a second step102, the bulk bag inside the outer bag is placed on a pallet, and in a third step103, the outer bag is cinched or otherwise secured around the bulk bag so that the outer bag completely encloses the bulk bag. In a fourth step104, the pallet is placed on an elevated surface so that, in a fifth step105, a heatshrink bag can be placed around the bulk bag, the outer bag, and at least a portion of the pallet. A sixth step106involves applying heat to the heatshrink bag to constrict the heatshrink bag around the bulk bag, the outer bag, and at least a portion of the pallet.

Packaging an object in this fashion prevents moisture from penetrating to the contents of the bulk bag. Indeed, in practice, such bulk bags may be stored outdoor or in sheds that are not sealed from ambient moisture. As such, the risk of exposure of the contents to ambient moisture is high, and absorption of moisture by the bulk material may degrade the performance of the bulk material when later used, especially where that bulk material's performance depends on its ability to absorb water, such as cements, ashes, and other pozzolanics.

Having briefly described the packaging method, each step of the method will be described in greater detail with respect toFIGS. 2-9. Turning first toFIG. 2, a pallet200and an outer bag205are depicted. The pallet200has a first side200aand a second side200bthat is opposite the first side200a. In the embodiment depicted, a cardboard sheet210is provided on the first side200aof the pallet200to provide a flat surface on which the bulk bag215(shown inFIG. 3) is supported. Additionally, in embodiments, the cardboard sheet210provides a layer between the pallet200and the outer bag205and bulk bag215to protect the outer bag205and bulk bag215from punctures resulting from splinters, which may be present on the pallet200, especially wooden pallets200. As pictured inFIG. 3, the bulk bag215is full of a bulk material and is being lifted by the forks220of a forklift225. To facilitate lifting and transporting of the bulk bag215, a loop230is provided at each corner235of the bulk bag215.

As shown inFIG. 4, the bulk bag215has been placed inside the outer bag205, and the bulk bag215has been positioned on the pallet200. As can be seen inFIG. 4, the outer bag205has a first open end205aand a first closed end205b, and the bulk bag215has a top end215aand a bottom end215b. The bottom end215bof the bulk bag215is inserted into the outer bag205through the first open end205a. When supported by the pallet200, the first closed end205aof the outer bag205is located between bottom end215bof the bulk bag215and the first side200aof the pallet200. The first open end205ais brought up past the top end215aof the bulk bag215. The excess portion of the first open end205athat extends past the top end215aof the bulk bag215is gathered together at gather point237to enclose the outer bag205around the entirety of the bulk bag215. The gathered portion of the outer bag205is then twisted, cinched, or otherwise secured together as shown inFIG. 5. Further, as shown inFIG. 6, the excess portion of the outer bag205may be secured in place around the bulk bag215using packing tape240.

By providing the outer bag205around the bulk bag215, a first layer of protection against moisture is provided. As discussed, the outer bag205entirely encloses the bulk bag215. The outer bag205can be made from a variety of suitable materials. In embodiments, the outer bag205is made from at least one polyolefin, such as low density polyethylene, linear low density polyethylene, and high density polyethylene, among others. Additionally, in embodiments, the outer bag205can have a thickness of from 0.2 mil to 10 mil. In other embodiments, the outer bag205has a thickness of from 1 mil to 6 mil, and in still other embodiments, the outer bag205has a thickness of from 2 mil to 4 mil.

After enclosing the bulk bag215in the outer bag205, the pallet200is placed on an elevated surface, which, as will be discussed more fully below, allows for the heatshrink bag to be shrunk around at least a portion of the bottom of the pallet. As can be seen inFIG. 7, the pallet200has been elevated on a tire245. In embodiments, the elevated surface is selected such that at least a portion of the pallet200extends past the outer perimeter of the elevated surface. InFIG. 7, the elevated surface provided by the tire245is in the shape of a circle having a diameter that is less than at least a side length of the rectangular-shaped pallet200. In this way, at least the corners250of the pallet200extend past the outer perimeter of the tire245. In other embodiments, the elevated surface may be a lifting device, such as the forks220of a forklift225(as shown inFIG. 3), for example. That is, the forks220lift the pallet200to an elevated position.

As shown inFIG. 8, a heatshrink bag255is then placed over the bulk bag215, the outer bag205, and the pallet200. The heatshrink bag255has a second open end255aand a second closed end255b. In relation to the bulk bag215, the heatshrink bag255is positioned around the bulk bag215such that the second closed end255bis proximate to the top end215aof the bulk bag215. The second open end255aof the bulk bag255extends past the second side200bof the pallet200. As can be seen, using a tire245having a diameter smaller than a side length of the pallet200allows the heatshrink bag255to extend unimpeded below the second side200bof the pallet200.

After positioning the heatshrink bag255over the bulk bag215, the outer bag205, and the pallet200, heat is applied to the heatshrink bag255to cause the heatshrink bag255to shrink and constrict around the bulk bag215, the outer bag205, and at least a portion of the pallet200. Heat can be applied to the heatshrink bag255in a variety of ways, include an electric or gas powered heat gun. The fully packaged bulk bag215is depicted inFIG. 9. As can be seen, the heatshrink bag255tightly engages the bulk bag215, the outer bag205, and at least a corner250of the pallet200. In particular, the second open end255aof the heatshrink bag255engages the second side200bof the pallet, which ensures tight engagement between the heatshrink bag255, the bulk bag, the first outer bag205, and the pallet200. In particular, tension is maintained in the heatshrink bag255such that the second closed end255bpulls against the top end215aof the bulk bag215and the second open end255apulls against the second side200bof the pallet200. In this way, excess material between the second open end255aand the second closed end255bdoes not bunch, fold, and/or gather, which might lead to water accumulation that could penetrate through the heatshrink bag255given the right conditions and enough time. By preventing bunching, folding, and/or gathering, water, such as rain water, will run off the surface without pooling.

The heatshrink bag255can be made from variety of materials that can be configured to exhibit the heatshrink property as discussed above. In embodiments, the heatshrink bag255is made from at least one polyolefin, such as polyethylene (low density, linear low density, or high density) or polypropylene, or from polyvinyl chloride (PVC). Further, in embodiments, the heatshrink bag255is a laminate material made from two or more layers of these materials. In embodiments, the heatshrink bag255has a thickness of from 0.25 mil to 12 mil. In other embodiments, the heatshrink bag255has a thickness of from 0.45 mil to 5 mil, and in still other embodiments, the heatshrink bag255has a thickness of from 1 mil to 4 mil.

An exemplary material that can be protected from moisture using the packaging system is a dry mix that includes cement and bed ash (and optionally, an aggregate). Such materials are described in U.S. Provisional Application Nos. 62/561,556, filed on Sep. 21, 2017, and 62/641,838, filed on Mar. 12, 2018, and U.S. Non-Provisional application Ser. No. 16/137,163, filed on Sep. 20, 2018, the contents of these three applications are incorporated in their entireties herein by reference. As described therein, the bed ash is produced via coal combustion in a fluidized bed reactor, particularly high sulfur coal that, in embodiments, has been post-treated with quicklime. The cement can be, e.g., a calcium sulfoaluminate (CSA) cement and/or an ASTM C150 type I, type II, type III portland cement. In embodiments, the bed ash and cement are mixed in a weight ratio of bed ash to cement of 3:1 to 5:1. In a particular embodiment, the cement makes up from 18 wt % to 20 wt % of the bed ash and cement mixture. Where provided, the aggregate may be a rock of the size 1.5″×3″, i.e., the rock passes through a 3″ mesh and is caught by a 1.5″ mesh. In embodiments, the amount of bed ash and cement and the amount of aggregate are each about 50 wt %. Embodiments of the dry mix are usable for repairing roadways, especially in underground mines, and for repairing soil slips. In such contexts, the dry mix may be stored at a worksite until needed for repair of a roadway or of a soil slip, and keeping moisture out of the dry mix is desirable so that the dry mix is available for use as needed.