OCTAGON SHAPED STACKABLE FLEXIBLE INTERMEDIATE BULK CONTAINER AND METHOD OF MANUFACTURE

Abstract: A bulk bag (20) comprises eight substantially identical side wall portions (28, 30, 32, 34, 36, 38, 40, 42) each containing a stiffening panel (80). A bottom wall (26) is connected to the bottom edges of the side wall portions and may be provided with a discharge port. Alternatively, a discharge port may be provided in one of the side wall portions. The bulk bag may be provided with a top wall (24) which may be either openable or secured in place. A pallet and/or lift loops (98, 142) may be provided for transporting the bulk bag and the contents thereof.

Description: OCTAGON SHAPED STACKABLE FLEXIBLE INTERMEDIATE BULK CONTAINER AND METHOD OF MANUFACTURE TECHNICAL FIELD The present invention relates generally to flexible intermediate bulk containers, also known as bulk bags, and more particularly to octagon shaped bulk bags which are adapted for stacking one on top of another. BACKGROUND AND SUMMARY OF THE INVENTION Over the past thirty years flexible intermediate bulk containers, commonly known as bulk bags, have come into widespread use for receiving, storing, transporting, and discharging flowable materials of all types. Although circular bulk bags are known, bulk bags are typically constructed from rectangular panels which are sewn together along their adjacent edges to define a bulk bag which is initially square or rectangular m horizontal cross section. Nevertheless, all bulk bags, whether initially square, rectangular, or circular m cross section tend to assume a circular configuration when filled due to the uniform pressure imposed by the contents of the bulk bag against the flexible fabric side walls thereof. U.S. patent number 4,903,859 discloses a bulk bag comprising four double layer side walls. Stiffeners formed from cardboard are inserted between the layers of the side walls thereby imparting sufficient rigidity to the container for permit its use with liquids. Although the bulk bag of the '859 patent has been generally well received, its utilization has been somewhat limited by the fact that it cannot be stacked. Co-pending application serial number 09/390,403 assigned to the assignee hereof (doing business as Composite Container Corp.) discloses an improvement over the bulk bag of the λ 859 patent. In application serial number 09/390,403 there is disclosed a bulk bag having double layer side walls and vertically extending corner pockets. Plywood sheets are received between the layers of the side walls and wooden posts are received in the corner pockets to provide a bulk bag suitable for use with liquids which is stackable. U.S. patent number 5,076,710 discloses a baffle-type bulk bag wherein bridge panels or baffles are sewn across the four corners of a nominally rectangular bulk bag. The baffles prevent the side walls of the bulk bags from bulging outwardly when the bulk bag is filled, thereby retaining the filled bulk bag in a more or less rectangular cross-sectional configuration. The baffles may be provided with apertures which allow material to flow into and out of the corners of the bulk bag during filling and discharging operations . Co-pending application serial number 09/458,362 also assigned to the assignee hereof discloses a baffle-type bulk bag which is stackable. In the bulk bag of application serial number 09/458 , 362 , triangular stiffeners are provided in the triangular corners of baffle-type bulk bags. The stiffeners may be formed from various materials including plastic panels, panels formed from corrugated paperboard and similar materials etc. The stiffeners may be provided with apertures aligned with the apertures of the baffles thereby permitting the flow of material into and out of the bulk bag during filling and discharging operations . The present invention comprises an improvement over the bulk bags disclosed in the v 859 and λ 710 patents and in the v 403 and λ 362 patent applications which provides an octagon shaped bulk bag which is stackable. The use of the octagon shape in the construction of the bulk bag is advantageous in that it provides maximum stackability while eliminating the need for baffles and triangular stiffeners contained within the baffles. In accordance with the broader aspects of the invention, there is provided a bulk bag comprising eight double layer side wall portions. Each double layer side wall portion receives a stiffening panel which extends substantially the entire length and width of the side wall portion. The stiffening panels used in the side wall portions of the bulk bag of the present invention may comprise corrugated plastic panels or similar panels made from other materials which are sufficiently resistant to bending. The octagon shaped bulk bags of the present invention are adapted for mounting on pallets. The bulk bag may also be provided with lift loops. The bulk bags of the present invention have bottom walls which may include a discharge port. Alternatively, one of the side wall panels may be provided with a discharge port located at the lower end thereof. The bulk bags of the present invention may have an open top, or a suitable top closure may be provided. Suitable top closures useful in the practice of the invention include openable flexible panels, openable rigid panels, and permanently mounted panels including fill spouts . In accordance with another aspect of the invention, there is provided an eight piece bulk bag side wall construction. The eight pieces are arranged in four sets each comprising an inner layer and an outer layer. The inner and outer layers are joined together by vertically extending seams which are spaced apart by a distance equal to approximately 1/8 of the circumference of the bulk bag, thereby forming four of the side wall portions. The opposite edges of the inner and outer layers comprising the four side wall assemblies are joined edge to edge to form the remaining four side wall portions of the bulk bag. A stiffening panel is positioned between the inner and outer layers of each side wall portion and at least the bottom edges of the side wall sections are sewn together to secure the stiffening panels therein. BRIEF DESCRIPTION OF THE DRAWINGS A more complete understanding of the invention may be had by reference to the following Detailed Description, when taken in conjunction with the accompanying Drawings, wherein: FIGURE 1 is a perspective view of an octagon shaped bulk bag incorporating in the present invention; FIGURE 2 is a perspective view of a side wall assembly useful in the practice of the invention; FIGURE 3 is an enlarged partial top view of the octagon shaped bulk bag of FIGURE 1 illustrating the joinder of adjacent side wall assemblies; FIGURE 4 is a top view of the octagon shaped bulk bag of FIGURE 1; FIGURE 5 is a perspective view illustrating a first variation of the octagon shaped bulk bag of FIGURE 1; FIGURE 6 is a view similar to FIGURE 5 in which certain component parts are shown in section more clearly to illustrate certain features of the invention; FIGURE 7 is a top perspective view illustrating a second variation of the bulk bag of FIGURE 1; FIGURE 8 is a bottom perspective view of the bulk bag of FIGURE 7; FIGURE 9 is a sectional view of the bulk bag of FIGURE 7 illustrating the use of liners in conjunction with bulk bags incorporating the invention; FIGURE 10 is a perspective view illustrating the stacking of octagon shaped bulk bags comprising the present invention; FIGURE 11 is a perspective view illustrating the folding of octagon shaped bulk bags of the present invention for return shipment; and FIGURE 12 is perspective view illustrating the positioning of several small size versions of the octagon shaped bulk bag of the present invention on a single pallet, and the stacking of pallets having several small size bulk bags positioned thereon. DETAILED DESCRIPTION Referring now to the Drawings, and particularly to FIGURE 1 thereof, there is shown an octagon shaped bulk bag 20 comprising in the present invention. The octagon shaped bulk bag 20 is characterized by an octagonal side wall 22 having a top or upper edge 24 and a bottom or lower edge 26. The octagonal side wall 22 comprises eight substantially identical side wall portions 28, 30, 32, 34, 36, 38, 40, and 42. The side wall portions 28-42, inclusive, are connected edge to edge to form the octagonal side wall 22. As is best shown in FIGURE 2, the octagonal side wall 22 of the bulk bag 20 comprises four substantially identical side wall assemblies 50. Each side wall assembly 50 comprises an outer layer 52 having a top or upper edge 54, a bottom or lower edge 56, and opposed side edges 58 and 60. The side wall assembly 50 further comprises an inner layer 62 having a top or upper edge 64, a bottom or lower edge 66, and opposed side edges 68 and 70. Each side wall assembly 50 comprising the bulk bag 20 is further characterized by a predetermined length, which is the vertical dimension, and a predetermined width, which is the horizontal dimension. The layers 52 and 62 are preferably formed from woven polypropylene fabric; however, other materials may also be used in the practice of the invention. The outer layer 52 and the inner layer 62 comprising the side wall assembly 50 are joined by spaced apart vertically disposed seams 72 and 74. The seams 72 and 74 of the side wall assemblies 50 define the side wall portions comprising the side wall 22 of the bulk bag 20. The seams 72 and 74 also define stiffening panel receiving pockets 76. Each stiffening panel receiving pocket 76 eventually receives a stiffening panel 80 therein. In the construction of the bulk bag 20, the stiffening panel receiving pockets 76 are closed at the bottom or lower ends thereof by a bottom seam 82. The stiffening panels 80 of the present invention may be manufacturing from plastic panels of the type sold by Coroplast of Dallas, Texas, under the trademark COREX(TM) . Other types of plastic panels may also be used, depending upon the requirements of particular applications of the invention. The stiffening panels 80 may also be formed from various types of paperboard; fiberboard, including medium density fiberboard (MDF) ; cardboard; plywood; and other materials depending upon the ability of stiffening panels formed from such materials to resist bending. Referring simultaneously to FIGURES 1 and 2, the top or upper end of each stiffening panel receiving pocket 76 and the top or upper edges of the outer and inner layers 52 and 62 may be permanently joined by a seam 84. Alternatively, the top or upper ends of the stiffening panel receiving pockets 76 may be releaseably closed by fastening mechanisms 86 which may comprise hook-and-loop fasteners of the type sold under the trademark VELCRO®, buttons, or snaps. The use of the releaseable fasteners 86 allows the stiffening panels 80 to be removed from the stiffening panel receiving pockets 76 to facilitate folding of the bulk bag 20 for transportation and storage. In the construction of the bulk bag 20 the four side wall assemblies 50 are connected edge to edge to form the side wall 22. As is best shown in FIGURE 3, the side edges 58 and 60 of adjacent side wall assemblies 50 are joined by seams 90. Likewise, the adjacent edges 68 and 70 of the inner layers 62 are joined by seams 92. As will be appreciated by those skilled in the art, the circumference defined by the joinder of the four inner layers 62 comprising the four side wall assemblies 50 must be somewhat less than the circumference defined by the four outer layers 52 in order to provide sufficient space between the outer layers 52 and the inner layers 62 to received the stiffening panels 80. For this reason, the seams 92 which join the inner layers 62 consume somewhat more fabric when compared with the seams 90 which join the outer layers 52. When the seams 90 and 92 are completed, the outwardly extending portions of the outer and inner layers 52 and 62 comprising the side wall assemblies 50 form stiffening panel receiving pockets 76. Thus, the completed side wall 22 includes eight stiffening panel receiving pockets 76, including the stiffening panel receiving pockets defined by the seams 72 and 74 of each side wall assembly 50 and the stiffening panel receiving pockets 76 which are formed when the seams 90 and 92 are completed. Referring simultaneously to FIGURES 1 and 4, the bulk bag 20 includes an octagon shaped bottom wall 96 which is secured to the outer and inner panels 52 and 62 of the side wall assemblies 50 by the bottom seam 82. L ke the other components of the bulk bag 20, the bottom wall 96 is preferably formed from polypropylene fabric. Other materials may be utilized m the construction of the bottom wall 96 and the other components of the bulk bag 20 depending upon the requirements of particular applications of the invention. A pallet 98 may be employed to facilitate transportation and positioning of the bulk bag 20 and the contents thereof. In such instances, the bulk bag 20 is preferably provided with retaining members 100 which are extended around component parts of the pallet 98 to retain the bulk bag 20 m engagement therewith. Other mechanisms for securing the bulk bag 20 to the pallet 98 may be utilized m lieu of the retaining members 100 depending upon the requirements of particular applications of the invention. The bulk bag 20 may be provided with a top or cover 102. If used, the top or cover 102 is preferably formed from woven polypropylene fabric, it being understood that other materials can be utilized in the construction of the top 102, if desired. The top 102 may be completely removable from the side wall 22 of the bulk bag 20. Alternatively, the top 102 may hingedly secured to the side wall 22 by means of the top seam 84 situated at the top of the side wall 22. The top 102 may comprise a cover panel 104 and a skirt 106 extending downwardly from the panel 104. The top 102 can be flexible or rigid, in which event a stiffening panel 108 is used. Conventional retaining apparatus may be utilized to secure the top 102 to the side wall 22 of the bulk bag 20, if desired. In FIGURE 5, there is shown a bulk bag 120 comprising a first variation of the bulk bag 20 illustrated in FIGURES 1-4, inclusive, and described hereandabove in conjunction therewith. Many of the component parts of the bulk bag 120 are identical in construction and function to component parts of the bulk bag 20. Such identical component parts are designated in FIGURE 5 with the same reference numerals utilized above in the description of the bulk bag 20. Bulk bags constructed in accordance with the present invention may be provided with conventional gland-type liners which facilitate the use of the bulk bag to receive, transport, discharge, and store liquids. The liner extends around the entire interior of the bulk bag 120 including the interior of the side wall 22, the bottom wall 96, and the top wall 102. Bulk bags constructed in accordance with the present invention are adapted for use with a variety of discharge apparatus. The bulk bag 120 includes a discharge port 130 formed in one of the side wall portions comprising the side wall 22, it being understood that the discharge port 130 can also be positioned in the bottom wall of the bulk bag 120. The discharge port 130 extends through the side wall 22 and through the liner, thereby connecting the interior of the bulk bag 120 to the exterior thereof. Discharge ports of the type shown in FIGURE 5 are particularly adapted for use in bulk bags designed to received, transport, store, and discharge liquids. FIGURE 6 comprises a horizontal sectional view taken through the upper portion of the bulk bag 120 of FIGURE 5, it being understood that a similar horizontal section view taken through the upper portion of the bulk bag 20 of FIGURE 1 would be, in all practical respects, identical. In FIGURE 6 the eight stiffener panel receiving pockets 76 and the eight stiffener panels 80 received therein are illustrated. FIGURES 7, 8, and 9 illustrated a bulk bag 140 comprising a second alternative version of the bulk bag 20 of FIGURE 1. Many of the component parts of the bulk bag 140 are identical in construction and function to component parts of the bulk bag 20 illustrated in FIGURE 1 and to component parts of the bulk bag 120 illustrated in FIGURE 5. Such identical component parts are designated in FIGURES 7, 8, and 9 with the same reference numerals utilized in the foregoing description of the bulk bags 20 and 120. The bulk bag 140 differs from the bulk bags 20 and 120 in that the bulk bag 140 is not mounted on a pallet. Rather, the bulk bag 140 is provided with lift loops 142 which are utilized in the transportation and positioning of the bulk bag 140. The lift loops 142 are preferably formed from nylon webbing and are conventional in design and function. The bulk bag 120 differs from the bulk bag 20 in that it is provided with a permanently installed top 122 which is secured to the side wall 22 by a seam 124. As is conventional in bulk bag construction, the top 122 is provided with a fill spout 126. The bulk bag 140 further differs from the bulk bags 20 and 120 in that the bulk bag 140 is provided with a discharge port 144 formed in the bottom wall 96. The discharge port 144 comprises four closure flaps 146 formed from the material of the bottom wall 96 and interconnected by a drawstring 148. A liner 128 extends through the discharge port 144 and may be provided with closure apparatus such as a tie-tie 150. Those skilled m the art will realize that the discharge port 144 is conventional m design and construction. Referring to FIGURE 10, one of the primary advantages deriving from the use of the present invention comprises the fact that octagon shaped bulk bags constructed m accordance with the invention are readily adapted for stacking. FIGURE 10 illustrates the bulk bag 120 of FIGURE 5, however, it will be understood that the bulk bag 20 of FIGURE 1, the bulk bag 140 of FIGURE 7, and m fact all bulk bags incorporated m the present invention are readily adapted for stacking. FIGURE 10 illustrates three bulk bags comprising the present invention stacked one on top of another but m actual fact up to s x bulk bags comprising the present invention can be stacked one on top of another depending on the density of the material contained m the bulk bags . As is best shown m FIGURE 11, bulk bags comprising the present invention are readily foldable for return shipment. FIGURE 11 illustrates a bulk bag 20 of the type shown m FIGURE 1 folded and position on the pallet 98 for return shipment, it being understood that the bulk bag 120 of FIGURE 5, the bulk bag 140 of FIGURE 7, and m fact all bulk bags incorporating the invention are adapted for folding m the manner illustrated m FIGURE 11. Bulk bags comprising the present invention can be manufacturing in a variety of sizes. FIGURE 12 illustrates a plurality of small size bulk bags 160 incorporating the present invention. The bulk bags 160 are octagon in shape and are otherwise substantially identical to the bulk bags of FIGURES 1-9, inclusive. As is clearly shown in FIGURE 12, a plurality of small size bulk bags 160 may be received on a single pallet 162 and secured by a strap 164. The bulk bags 160 thus positioned and secured are adapted for stacking one on top of another. Up to six layers of bulk bags 160 may be stacked one on top of another depending upon the density of the material contained in the bulk bags . The present invention further comprises a method of manufacturing octagon shaped bulk bags. In accordance with the method, there is provided eight substantially identical fabric sheets. The fabric sheets are preferably formed from woven polypropylene fabric, however, other fabric materials can be utilized in the practice of the invention. Each of the sheets is characterized by an upper edge, a lower edge, and opposed side edges. The fabric sheets are arranged in four pairs, each pair comprising an inner layer and an outer layer. The upper, lower, and side edges of each pair are respectively aligned. The inner and outer layers comprising each pair are joined by seams extending parallel to the side edges which are spaced apart to define a side wall portion comprising a stiffening panel receiving pocket. The inner and outer layers comprising the four pairs are joined edge to edge to form four additional side wall portions, each comprising a stiffening panel receiving pocket. The method further comprises the step of providing an octagonal shaped bottom wall. The bottom wall is preferably formed from woven polypropylene fabric, however, other materials can be used in the practice of the invention. The bottom wall is secured to the lower edges of the inner and outer layers of the side wall portions by a bottom seam which also closes the lower ends of the stiffening panel receiving pockets. A stiffening panel is received in each stiffening panel receiving pocket. The stiffening panels preferably comprise corrugated plastic panels, however, other materials can be used in the manufacture of the stiffening panels. After the stiffening panels are installed, the upper ends of the stiffening panel receiving pockets are closed, either permanently or releaseably. Transportation and positioning of the bulk bag and the contents thereof is facilitated either by mounting the bulk bag on a pallet or by providing the bulk bag with lift loops. The bulk bag may be provided with a top closure which may be either flexible or rigid and which may be either permanently or releaseably secured. Discharge ports ay be provided either in the bottom wall or in one of the side wall portions of the bulk bag. Although preferred embodiments of the invention have been illustrated in the accompanying drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.

Claims: THE CLAIMS What is claimed is: 1. An octagon shaped bulk bag comprising: eight double layer side wall portions disposed in an octagonal array and each comprising a stiffening panel receiving pocket; eight stiffening panels each received in the stiffening panel receiving pocket comprising one of the side wall portions; means for retaining the stiffening panels in the stiffening panel receiving pockets; and a bottom wall extending between and connected to the bottom of each of the side wall portions. 2. The bulk bag according to Claim 1 wherein each of the side wall portions is further characterized by: spaced apart vertically extending seams defining the width of the side wall portion; a bottom seam connecting the bottom wall to the side wall portion; and a top seam; the four seams defining the length and width of the side wall portion and comprising the means for securing the stiffening panel in the stiffening panel receiving pocket of the side wall portion. 3. The bulk bag according to Claim 2 wherein the eight side wall portions comprising the bulk bag are substantially equal m length and width and wherein the eight stiffening panels which are received m the stiffening panel receiving pockets of the side portions are substantially equal m length and width. 4. The bulk bag according to Claim 3 wherein the stiffening panels each comprise a panel formed from corrugated plastic material. 5. The bulk bag according to Claim 1 wherein each of the side wall portions is further characterized by: spaced apart vertically extending seams defining the width of the side wall portion; a bottom seam connecting the bottom wall to the side wall portion; and a releaseable closure mechanism located at the top of the side wall portion; the three seams and the releaseable closure mechanism defining the length and width of the side wall portion and comprising the means for retaining the stiffening panel m the stiffening panel receiving pocket of the side wall portion. 6. The bulk bag according to Claim 5 wherein the eight side wall portions comprising the bulk bag are substantially equal in length and width and wherein the eight stiffening panels which are received in the stiffening panel receiving pockets of the side portions are substantially equal in length and width. 7. The bulk bag according to Claim 6 wherein the stiffening panels each comprise a panel formed from corrugated plastic material. 8. The bulk bag according to Claim 1 wherein the bottom wall has a discharge port formed therein. 9. The bulk bag according to Claim 8 further including a liner contained within the bulk bag and wherein the liner extends through the discharge port formed in the bottom wall of the bulk bag. 10. The bulk bag according to Claim 1 further including a discharge port formed in one of the side wall portions of the bulk bag. 11. The bulk bag according to Claim 10 further including a liner positioned within the bulk bag and wherein the discharge port provides fluid communication from outside the bulk bag through the side wall portion and through the liner to the interior of the bulk bag. 12. The bulk bag according to Claim 1 further including a pallet secured to the bottom of the bulk bag for facilitating transportation of the bulk bag and its contents . 13. The bulk bag according to Claim 12 further including a plurality of fasteners secured to the bottom of the bulk bag for releaseably securing the bulk bag to the pallet . 14. The bulk bag according to Claim 1 further including four lift loops secured to the alternating side wall portions of the bulk bag to facilitate transportation of the bulk bag and the contents thereof. 15. The bulk bag according to Claim 1 further including a top panel for closing the upper end of the bulk bag. 16. The bulk bag according to Claim 15 wherein the top panel is releaseably secured to facilitate opening and closing of the upper end of the bulk bag. 17. The bulk bag according to Claim 16 wherein the top panel comprises a double layer top panel and further including a stiffening panel received between the double layers of the top panel. 18. The bulk bag according to Claim 15 wherein the top panel is permanently secured to the upper ends of the side wall portions and further including a fill spout formed in the top panel . 19. The bulk bag according to Claim 1 wherein the bulk bag comprises four side wall assemblies each comprising an inner fabric layer, an outer fabric layer, and spaced apart, vertically extending seams defining one of the side wall portions, the four side wall assemblies being sewn together end to end to define the remaining four side wall portions . 20. The bulk bag according to Claim 19 further characterized by a bottom seam extending along the bottoms of each of the four side wall assemblies for closing the lower ends of the stiffening panel receiving pockets thereof and for joining the bottom wall to the side wall assemblies; and a top seam extending along the tops of all four side wall assemblies for closing the tops of the stiffening panel receiving pockets thereof. 21. An octagon shaped bulk bag comprising: eight side wall portions each having spaced apart substantially parallel top and bottom edges and spaced apart substantially parallel side edges; the eight side wall portions being characterized by substantially identical length and width dimensions; the eight side wall portions being disposed in an octagonal array; each of the side wall portions comprising a stiffening panel receiving pocket which is closed along at least the side wall edges and the bottom edge of the side wall portion; eight substantially identical stiffening panels each received in the stiffening panel receiving pocket of one of the side wall portions; and a bottom wall extending between and connected to the bottom edges of each of the side wall portions. 22. The bulk bag according to Claim 21 wherein each of the side wall portions is further characterized by: spaced apart vertically extending seams defining the width of the side wall portion; a bottom seam connecting the bottom wall to the side wall portion; and a top wall seam; the four seams defining the length and width of the side wall portion. 23. The bulk bag according to Claim 22 wherein the eight stiffening panels substantially fill the stiffening panel receiving pockets of the side portions. 24. The bulk bag according to Claim 23 wherein the stiffener panels each comprise a panel formed from corrugated plastic material. 25. The bulk bag according to Claim 21 wherein each of the side wall portions is further characterized by spaced apart vertically extending seams defining the width of the side wall portion; a bottom seam connecting the bottom wall to the side wall portion; a releaseable closure mechanism located at the top of the side wall portion; the three sew lines and the releaseable closure mechanism defining the length and width of the side wall portion. 26. The bulk bag according to Claim 25 wherein the eight stiffener panels substantially fill the stiffener panel receiving pockets of the side portions. 27. The bulk bag according to Claim 26 wherein the stiffener panels each comprise a panel formed from corrugated plastic material. 28. The bulk bag according to Claim 21 wherein the bottom wall has a discharge port formed therein. 29. The bulk bag according to Claim 28 further including a liner contained within the bulk bag and wherein the liner extends through the discharge port formed in the bottom wall of the bulk bag. 30. The bulk bag according to Claim 21 further including a discharge port formed in one of the side wall portions of the bulk bag. 31. The bulk bag according to Claim 30 further including a liner positioned within the bulk bag and wherein the discharge port provides fluid communication from outside the bulk bag through the side wall portion and through the liner to the interior of the bulk bag. 32. The bulk bag according to Claim 21 further including a pallet secured to the bottom of the bulk bag for facilitating transportation of the bulk bag and its contents . 33. The bulk bag according to Claim 32 further including a plurality of fasteners secured to the bottom of the bulk bag for releaseably securing the bulk bag to the pallet. 34. The bulk bag according to Claim 21 further including four lift loops secured to the alternating side wall portions of the bulk bag to facilitate transportation of the bulk bag and the contents thereof. 35. The bulk bag according to Claim 21 further including a top panel for closing the upper end of the bulk bag. 36. The bulk bag according to Claim 35 wherein the top panel is releaseably secured to facilitate opening and closing of the upper end of the bulk bag. 37. The bulk bag according to Claim 36 wherein the top panel comprises a double layer top panel and further including a stiffening panel received between the double layers of the top panel. 38. The bulk bag according to Claim 37 wherein the top panel is permanently secured to the upper ends of the side wall portions and further including a fill spout formed in the top panel . 39. The bulk bag according to Claim 21 wherein the bulk bag comprises four side wall assemblies each comprising an inner fabric layer, an outer fabric layer, and spaced apart, vertically extending seams defining one of the side wall portions, the four side wall assemblies being sewn together edge to edge to define the remaining four side wall portions. 40. The bulk bag according to Claim 39 further characterized by a bottom seam extending along the bottoms of each of the four side wall assemblies for closing the lower ends of the stiffening panel receiving pockets thereof and for joining the bottom wall to the side wall assemblies; and a top seam extending along the tops of all four side wall assemblies for closing the tops of the stiffening panel receiving pockets thereof . 41. For use in constructing an octagon shaped bulk bag, a side wall assembly comprising: an inner side wall layer having top and bottom edges ; an outer side wall layer having top and bottom edges aligned with the top and bottom edges of the inner side wall layer; spaced apart vertically extending seams interconnecting the inner and outer side wall layers and defining a side wall portion therebetween; and the side wall portion comprising a stiffening panel receiving pocket; a bottom seam extending along the bottom edges of the inner and outer side wall layers to close the bottom of the stiffening receiving pocket. 42. The side wall assembly according to Claim 41 further including a stiffening panel received in the stiffening panel receiving pocket comprising the side wall assembly. 43. The side wall assembly of Claim 42 further characterized by a seam extending along the top edges of the inner and outer layers for retaining the stiffening panel in the stiffening panel receiving pocket. 44. The side wall assembly according to Claim 42 further characterized by a releaseable closure mechanism for connecting the top edge of the inner layer to the top edge of the outer layer thereby retaining the stiffening panel in the stiffening panel receiving pocket of the side wall assembly. 45. The side assembly according to Claim 42 wherein the stiffener panel comprises a corrugated plastic stiffener panel. 46. A method of manufacturing octagon shaped bulk bags including the steps of: providing eight substantially identical fabric sheets each having upper, lower, and side edges; arranging the eight fabric sheets in four pairs each comprising an inner layer and an outer layer with the upper, lower, and side edges of each pair respectively aligned; joining the inner and outer layers comprising each pair by seams extending parallel to the side edges and spaced apart to define a side wall portion comprising a stiffening panel receiving pocket; joining the inner and outer layers comprising the four pairs edge to edge to form four additional side wall portions each comprising a stiffening panel receiving pocket ; providing an octagon shaped bottom wall; securing the bottom wall to the lower edges of the inner and outer layer comprising the side wall portion; providing eight substantially identical stiffening panels; and positioning a stiffening panel in each of the stiffening panel receiving pockets. 47. The method according to Claim 46 wherein the steps of providing eight identical fabric sheets is carried out by providing eight identical fabric sheets formed from woven polypropylene fabric. 48. The method according to Claim 46 wherein the step of providing a bottom wall is carried out by providing a bottom wall formed from woven polypropylene fabric and wherein the step of securing the bottom wall to the lower edges of the inner and outer layers comprising the side wall portions is carried out by forming a seam which connects the bottom wall to the lower edges of the inner and outer layers comprising in the side wall portions. 49. The method according to Claim 46 wherein the step of providing eight identical stiffening panels is carried out by providing stiffening panels formed from corrugated plastic material. 50. The method according to Claim 46 including the additional step of at least releaseably securing the upper edges of the inner and outer panels comprising the side wall portions one to another and thereby securing the stiffening panels in the stiffening panel receiving pockets . AMENDED CLAIMS [received by the International Bureau on 9 November 2000 (09 1 1 00), original claims 2- 18 and 21 -40 cancelled, original claims 1 , 19, 41 and 46 amended, remaining claims unchanged (5 pages)] 1. An octagon shaped bulk bag comprising: eight double layer side wall portions disposed in an octagonal array and each comprising a stiffening panel receiving pocket; eight stiffening panels each received in the stiffening panel receiving pocket comprising one of the side wall portions; means for retaining the stiffening panels in the stiffening panel receiving pockets; a bottom wall extending between and connected to the bottom of each of the side wall portions; each of the side wall portions being characterized by: spaced apart vertically extending seams defining the width of the side wall portion; a bottom seam connecting the bottom wall to the side wall portion; and a top seam; the four seams defining the length and width of the side wall portion and comprising the means for securing the stiffening panel m the stiffening panel receiving pocket of the side wall portion; the eight side wall portions comprising the bulk bag being substantially equal in length and width; the eight stiffening panels which are received in the stiffening panel receiving pockets of the side portions being substantially equal in length and width; the eight stiffening panels each comprising a panel formed from corrugated plastic material. 19. An octagon shaped bulk bag comprising: eight double layer side wall portions disposed in an octagonal array and each comprising a stiffening panel receiving pocket; eight stiffening panels each received in the stiffening panel receiving pocket comprising one of the side wall portions; means for retaining the stiffening panels in the stiffening panel receiving pockets; a bottom wall extending between and connected to the bottom of each of the side wall portions; the bulk bag further comprising four side wall assemblies each comprising an inner fabric layer, an outer fabric layer, and space apart, vertically extending seams defining one of the side wall portions and two half side wall portions each extending outwardly from one of the vertically extending seams, the four side wall assemblies being sewn together end to end thereby connecting the half side wall portions to define the remaining four side wall portions . 41. For use in constructing an octagon shaped bulk bag, a side wall assembly comprising: an inner side wall layer having top and bottom edges; an outer side wall layer having top and bottom edges aligned with the top and bottom edges of the inner side wall layer; spaced apart vertically extending seams interconnecting the inner and outer side wall layers and defining a side wall portion therebetween; the side wall portion comprising a stiffening panel receiving pocket extending between the vertically extending seams and two half side wall receiving pockets each extending outwardly from one of the vertically extending seams; a bottom seam extending along the bottom edges of the inner and outer side wall layers to close the bottoms of the stiffening panel receiving pocket and the two half stiffening panel receiving pockets. 46. A method of manufacturing octagon shaped bulk bags including the steps of: providing eight substantially identical fabric sheets each having upper, lower, and side edges; arranging the eight fabric sheets in four pairs each comprising an inner layer and an outer layer with the upper, lower, and side edges of each pair respectively aligned; joining the inner and outer layers comprising each pair by seams extending parallel tot he side edges and space apart to define a side wall assembly comprising a stiffening panel receiving pocket extending between the parallel seams and two half stiffening panel receiving pockets each extending outwardly from one of the parallel seams; joining the inner and outer layers comprising the four pairs side edge to side edge to form four additional stiffening panel receiving pockets each comprising two half stiffening panel receiving pockets joined edge to edge; providing an octagon shaped bottom wall; securing the bottom wall to the lower edges of the inner and outer layers comprising each side wall portion; providing eight substantially identical stiffening panels; and positioning a stiffening panel in each of the stiffening panel receiving pockets.

Inventors: BROWN BOBBY GLENN, EISENBARTH BRADLEY MATTHEW, NICKELL CRAIG ALAN, BROWN, BOBBY, GLENN, EISENBARTH, BRADLEY, MATTHEW, NICKELL, CRAIG, ALAN
Applicants: BAG CORP, B.A.G. CORP.
Application year: 2000
Main classification: B65D19
IPC codes: B65D19, B65D77, B65D88