Ballast bag

A ballast bag that is durable and prevents exposure to FOD is provided. The ballast bag includes a bag body with a first end and a second end, a first side and a second side, and a front side and a rear side. A first strap is connected to the front side forming a loop defined by two parallel lines along the front side of the bag and a handle extending past each end of the bag. A second strap is connected to the rear side forming a loop defined by two parallel lines along the rear side of the bag and a handle extending past each end of the bag. The handles of the straps are the same size to form a double handle on each end of the bag. The first and second strap each have an inner and outer band of embedded non-slip material.

BACKGROUND

The disclosed embodiments relate to weight ballasts. More specifically, the disclosed embodiments relate to weight ballast bags for aircraft balancing.

Ballast is used in an aircraft to attain a desired center of gravity balance when the center of gravity is not within limits or is not at the location desired by the operator. Any ballast required is usually placed as far aft or as far forward as possible to bring the center of gravity within limits while using a minimum amount of weight. Ballast that is installed to compensate for the removal or installation of equipment items and that is to remain in the aircraft for long periods is called permanent ballast. Permanent ballast is generally in the form of lead bars or plates bolted to the aircraft structure. The installation of permanent ballast results in an increase in the aircraft empty weight, and it reduces the useful load.

Temporary ballast, or removable ballast, is used to meet certain loading conditions that may vary from time to time. It generally takes the form of lead shot bags, sand bags, or other weight items that are not permanently installed. The baggage compartment of an aircraft is an example of a convenient location for temporary ballast.

Whenever permanent or temporary ballast is installed, it must be placed in an approved location and secured in an appropriate manner. If permanent ballast is being bolted to the structure of the aircraft, the location must be one that was previously approved and designed for the installation, or it must be approved by the FAA as a major alteration before the aircraft is returned to service. When temporary ballast is placed in a baggage compartment, it must be secured in a way that prevents it from becoming a projectile if the aircraft encounters turbulence or an unusual flight attitude.

Other uses for ballast bags may include structural testing for aircraft components. Ballast bags are often stacked to achieve a target pounds-per-square-foot of downward force during structural testing on a given aircraft component. For example, in some instances maintenance personnel may need to simulate full fuel tanks within a wing before inspecting for structural cracks. Ballast bags may be used and stacked on the wing in order to simulate the weight of the full fuel tank.

Typical ballast bags such as shot bags or sand bags have several drawbacks. For example, such bags may be difficult to handle and to secure to provide temporary ballast to an aircraft. In testing application, the bags may not stack securely, or may be in risk of falling on maintenance personnel, such as when stacked on a curved wing surface. Further, as the bags wear out, there is a risk that the contents of the bags will be released. The shot or sand from the bag creates a mess for operators and in some implementations is a source of foreign objects and debris (FOD) that could potentially damage aircraft components, resulting in cost and safety hazards.

Thus there is a need for a ballast bag that is easily handled, is durable, and that prevents FOD issues during use.

SUMMARY

Accordingly, a durable, easily handled ballast bag is provided that effectively prevents FOD exposure to a surrounding area. In one embodiment, a ballast bag includes a bag body having a first end and a second end, a first side and a second side, and a front side and a rear side. The bag body may be formed from a single piece of material that is folded along the first side and is connected together along the second side and the first and second ends to form the bag body. The bag body may also have at least one internal layer formed from a contrasting color from an external layer of the bag body. Thus, when then external layer experiences wear, the internal layer is easily noticed by personnel, and the worn ballast bag can be removed from service prior to releasing any material within the ballast bag.

The ballast bag may include a first strap connected to the front side of the bag body. The first strap may be formed from a single strap with ends of the first strap overlapping one another on the front side of the bag body. The strap extends from the overlapping ends in both directions in a first line parallel to the first and second sides. The strap continues past the first and second ends of the bag body and returns to extend along the front side of the bag body in a second line parallel to the first line. The first strap thus forms a handle on each of the first and second ends of the bag body with the portion of the strap that extends past the first and second ends of the bag body.

Similarly, the ballast bag may include a second strap connected to the rear side of the bag body. The second strap may be formed from a single strap with ends of the second strap overlapping one another on the rear side of the bag body. The strap extends from the overlapping ends in both directions in a first line parallel to the first and second sides. The strap continues past the first and second ends of the bag body and returns to extend along the rear side of the bag body in a second line parallel to the first line. The second strap thus forms a handle on each of the first and second ends of the bag body with the portion of the strap that extends past the first and second ends of the bag body. The handles of the second strap and the handles of the first strap are formed to be the same size to form a double handle on each of the first and second ends of the bag body.

In some embodiments, each of the first and second strap have one or more bands of embedded non-slip material extending along the length of the first and second strap. The one or more bands of embedded non-slip material may include an inner band and an outer band extending along the length of the first and second strap.

The strap may be formed from a polypropylene material and the inner and outer bands may be made of rubber. In some embodiments, the first and second strap each have dimensions of 1.5 inches wide and 47.5 inches long. The first and second strap may be connected to the front and rear sides via stitching that is disposed on an outer side of each of the inner and outer band of embedded non-slip material. The first strap and the second strap may be sewn together at the first and second ends of the ballast bag.

The ballast bag may further include reinforcing seams connecting the first and second straps to the front and rear sides of the ballast bag. The reinforcing seams may be disposed perpendicular to the inner and outer bands and parallel to the first and second ends. The reinforcing seams are located on the straps adjacent to the first and second ends. The filler material may be inserted in the first end of the ballast bag, and a double seam may be provided along the first end to close the first end.

In another exemplary embodiment, a ballast bag includes a bag body that has a first end and a second end, a first side and a second side, and a front side and a rear side. A first strap may be connected to the front side of the bag body. The first strap forms a loop in two parallel lines along the front side of the bag and a handle extending past each of the first end and the second end of the bag connecting to the two parallel lines.

A second strap may be connected to the rear side of the bag body. The second strap may form a loop in two parallel lines along the rear side of the bag and a handle extending past each of the first end and the second end of the bag connecting the two parallel lines. The handles of the second strap and the handles of the first strap may be the same size to form a double handle on each of the first and second ends of the bag body. Filler material is disposed within the bag body.

The first and second strap may each include an inner band and an outer band of embedded non-slip material extending along the length of the first and second strap. The first and second strap may be connected to the front and rear sides of the bag body via stitching that is disposed on an outer side of each of the inner and outer bands of embedded non-slip material. In some cases, the first strap and the second strap are sewn together at the first and second ends of the bag body.

Reinforcing seams may connect the first and second straps to the front and rear sides of the ballast bag. The reinforcing seams are disposed perpendicular to the inner and outer bands and parallel to the first and second ends adjacent to the first and second ends.

The ballast bag may be formed from a single piece of material that is folded along the first side and is connected along the second side and the first and second ends. The ballast bag may include at least one internal layer formed from a contrasting color from an external layer of the bag body.

The first and second straps may each be formed from a single strap with ends of the first and second strap overlapping one another on the front side and rear side of the bag body, respectively. The first and second straps may be formed from a polypropylene material and the inner and outer bands of embedded non-slip material may be comprised of rubber. The first and second strap may each have dimensions of 1.5 inches wide and 47.5 inches long.

In some embodiments, the filler material may be inserted in the first end, and a double seam is provided along the first end to close the first end. The ballast bag may be a square shape where the first and second sides and the first and second ends have a length of twelve inches. The parallel lines of the loops formed by the first and second straps may be spaced two and a half inches from the first and second sides, respectively.

The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1is a front view of a ballast bag according to an exemplary embodiment. InFIG. 1, a ballast bag10is formed having a square shape. In this embodiment, the ballast bag is a twelve-inch by twelve-inch bag. Other shapes of course, may also be used, and the square shaped ballast bag10is exemplary.

The ballast bag10may be formed from any suitable material with sufficient strength and durability. In this embodiment, the ballast bag is formed from a durable nylon material. For example, a 1000 denier nylon or nylon blend material is used to form the ballast bag10. This material may be more commonly known under the trade name CORDURA® (e.g. 1000D CORDURA material). Other materials having sufficient durability and strength may also be used.

The ballast bag10includes a first end12and a second end14opposite the first end12, a first side16and a second side18opposite the first side16, and a rear side20and a front side22opposite the rear side20. The ballast bag10may be formed from a single piece of material that is folded over and connected at the edges. For example, the material may be folded along the first side16and connected along the second end14and the second side18by sewing along the second end14and the second side18. Once filling material40(FIG. 5) is put into the ballast bag10, the first end12may also be sewn together to close the ballast bag10.

In the example twelve-inch by twelve-inch bag, the blank material may have dimensions of 13.5 inches by 25.5 inches. The material is folded over at the seams in order to create a clean look and provide a strong seam, resulting in the 12-inch by 12-inch ballast bag10. Of course, as mentioned above, the ballast bag may take on other sizes and shapes. In some embodiments, the ballast bag10may be formed from two pieces of materials forming the rear side20and the front side22, with seams at each of the first and second ends12,14and the first and second sides16,18.

To provide for stability during use and to facilitate transportation of the ballast bag10, straps50are provided on the ballast bag10. The straps50are formed from any suitable material with sufficient strength and durability. In this embodiment, the straps are formed from a polypropylene material. The straps50are connected to both the rear side20and the front side22of the ballast bag10and extend beyond the first and second ends12,14to form handles54,56at each end12,14.

The straps50on each of the rear and front sides20,22may be formed from a single strap. In this exemplary embodiment, the strap used is 47.5 inches long and 1.5 inches wide. On the front side22shown inFIG. 1, the ends of the strap50are connected and sewn to the front side22via seam52. The strap50extends in both directions from seam52forming a handle54,56at each end12,14, and then running parallel to itself along the front side22. Thus, the strap50forms a loop with two parallel lines on the ballast bag10and the handles54,56extending past each end12,14. In this embodiment, the straps50along the rear and front sides20,22are spaced about 2.5 inches from first and second sides16,18. However, other arrangements and spacings may also be used.

To create a slip resistant surface, the straps50are embedded with a friction enhancing material. Here, the straps50include an outer non-slip band58and an inner non-slip band60. The non-slip bands58,60may be formed from a rubber or silicone material that increases the coefficient of friction between the ballast bag10and a surface on which the ballast bag10rests, or with adjacent ballast bags1. Here, the outer and inner non-slip bands58,60are embedded in the strap material of the straps50.

FIG. 2is an enlarged back view of the ballast bag ofFIG. 1. InFIG. 2, the back side20is shown including a strap50attached to the back side. The strap50along the back side20is similar to that shown inFIG. 1along the front side. The strap50along the rear side20and the strap50along the front side22form two handles56, or a double handle, on each end of the bag10(end14shown inFIG. 2).

FIG. 3is an enlarged view of a top end of the ballast bag ofFIG. 1. As shown inFIG. 3, the strap50is attached to the ballast bag10via seams30,32. More specifically, and outer seam32is disposed outside the outer non-slip band58and an inner seam30is disposed inside the inner non-slip band60. The seams30,32provide a secure connection between the strap50and the ballast bag10.

After filler material40(FIG. 5) is inserted into the bag10, the bag10is closed via seams24,26. The double seams24,26provide extra protection against any leakage from the bag10. Due to the use of ballast bags in aerospace application, it is important for the top end12to be securely closed by the seams24,26to prevent exposure of aircraft or aircraft components to FOD from the filler material40. The double seams24,26are formed with the straps50already in place. Thus, the double seams24,26also provide another connection point for the straps50with the ballast bag10. The straps50on each of the rear and front sides20,22are connected together at the double seams24,26providing stability to the handles54,56.

A reinforcing seam28is provided along the strap50parallel to the end12and seams24,26. The reinforcing seam28provides added strength to the bag10for when the bag10is lifted via the handles54,56.

FIG. 4is an enlarged view of a bottom end of the ballast bag ofFIG. 1. As shown inFIG. 4a first reinforcing seam34is provided on the strap50parallel to the bottom end14, similar to the reinforcing seam28near the top end12shown inFIG. 3. A second reinforcing seam36is provided adjacent to the end14to connect the straps50on the rear and front sides20,22together. The reinforcing seams34,34provide added strength to the bag10for when the bag10is lifted via the handles54,56.

FIG. 5is a cut-away view of the ballast bag ofFIG. 1. As mentioned above, it is critical that personnel utilizing the ballast bag10do not unintentionally introduce FOD into an area proximate to aircraft or aircraft components. Accordingly, the ballast bag10is provided with at least one internal layer38. The internal layer38is preferably formed with a contrasting color as compared to the exterior of the ballast bag10. The contrasting color of the at least one internal layer38allows personnel utilizing the ballast bag10to easily observe wear in the exterior of the ballast bag10. When the contrasting color of the at least one internal layer38can be seen through the exterior layer, personnel utilizing the ballast bag10can take the bag out of service before the ballast bag10is at risk of introducing FOD to an area where there are aircraft or aircraft components.

As shown inFIG. 5, the ballast bag10comprises a filler material40. The filler material provides weight to the ballast bag10so that, for example, the ballast bag10may act as a portable ballast for an aircraft. The filler material40may include one or a combination of material such as shot, such as steel shot, sand, fine gravel, etc.