Abstract:
A soft container and handling system for transporting, handling, and dispensing flowable dry goods, the container having a resealable discharge chute extending from a bottom wall portion and arranged to allow gravity induced discharge of goods when raised above a surface and to be closed against an upper portion of the container to prevent flow with the container supported on the surface.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a container and system for handling, storing, and discharging flowable dry materials. 
     BACKGROUND OF THE INVENTION 
     It has recently become common to handle, store and dispense flowable dry goods, such as agricultural feed, plastic molding resins, dry chemicals, and many dry food products, in large soft containers. A typical container of this type has a capacity of approximately one ton, and dimensions of approximately four feet by four feet by four feet. These dimensions allow the containers to be transported and stored on standard pallets. 
     The ease, convenience, and flexibility of using such containers make them most practical and desirable to medium sized processors, for whom small fifty-pound bags of goods are burdensome and not economical. For such users, the purchase of goods in truckloads and the storage in silos is also not feasible, but such containers as are the subject herein still allow the processor to purchase goods “by the ton” as opposed to “by the pound”, so that a significant bulk discount can be realized. The ability to store many of these containers in a relatively small area allows the processor to inventory many types of goods simultaneously and access each on short notice. 
     Additionally, these reinforced fabric bag-like containers are reusable many times, offering the processor a significant savings over disposable paper bags or Gaylord boxes, which are generally only reusable once or twice. 
     These containers are filled through the top, and goods are generally dispensed through openings in a side or in the bottom through a variety of methods and means. They are these methods and means of dispensing which to date have been the most troublesome aspects of prior art soft storage containers. 
     Some materials just do not flow as well as others and are inherently more suitable to bottom discharge containers while other materials are very fluid or hazardous and more suitable to side discharge containers. 
     During transporting from the vendor to the customer, and over time, some dry goods can become compacted. As a result, they cake and clump and become not readily flowable. Vibrators are sometimes employed to reduce clumping and improve flow, but this is quite burdensome and complicated and adds an additional expense. 
     Precise and simple control of the flow rate of materials of varying viscosities is not provided and automatic control of flow rate and the termination of discharge is not provided in present systems. 
     Precise control and measurement of the amount of material which has been dispensed, such as by weight, is not provided in present systems. 
     To date, there are no known re-usable soft containers or dispensing systems which provide a means for an individual operator to conveniently handle bulk quantities of dry goods, to move the goods freely about a warehouse, to position the goods precisely where and as needed, to dispense the goods precisely and with minimal loss, and to reseal and restore the containers. 
     SUMMARY OF THE INVENTION 
     The present invention is a soft dry goods container and dispenser and a handling system therefor. 
     The container comprises a substantially planar top, front, back, left side, right side, and bottom panels, arranged in an orthogonal hexahedron. The panels are constructed of a durable and flexible fabric and, therefore, the containers are inherently collapsible when empty. The top panel has an inlet opening through which the container is filled with the flowable dry goods. The container is adapted to contain the dry goods and to dispense the same through a resealable discharge chute that is provided along the edge formed by the bottom and front panels. The system comprises means for transporting and supporting the container, means for lifting and lowering the container to allow the goods to automatically flow from the open chute in a precisely controllable manner and by only the force of gravity, means for pinching the chute closed as the container is lowered, means for distorting the container to force all of the goods therefrom, and means for precisely maneuvering and locating the container and system. 
     Both the container and the system are adapted to allow an individual to conveniently and effectively handle and dispense dry goods without assistance. 
     OBJECTS OF THE INVENTION 
     It is the primary object of the present invention to provide a dry goods container, and a handling and dispensing system therefor, that are more efficient and effective than existing containers and systems. 
     It is another object of the invention to provide a container and system that can be operated by an individual user. 
     It is still another object of the invention to provide a container and system that allow a more efficient material discharge. It is still another object of the invention to provide a container and system that allow a more controllable discharge of the goods. 
     It is still another object of the invention to provide a container and system that reduce the problems created by the compacting and caking of the goods before or during discharge without the use of vibrators or such. 
     It is a further object to provide an edge-discharge soft container and a handling system. 
     It is another object of the invention to provide a container with an edge-discharge spout that can be accessed from the front. 
     It is another object of the invention to provide an edge-discharge container including an adjustable flap that maintains the shape and integrity of the container before initial discharge and after partial discharge. 
     These and other objects will be apparent from the description and claims that follow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1A is a side view of a container and system according to the preferred embodiment of the invention in the pre-dispensing condition; 
     FIG. 1B is a front view of the container and system of FIG. 1A invention in the pre-dispensing condition; 
     FIG. 1C is a perspective view of the container and system of FIG. 1A in the pre-dispensing condition; 
     FIG. 1D is a sectional side view of the container of FIG. 1A in the pre-dispensing condition; 
     FIG. 1E is a bottom view of the container of FIG. 1A in the pre-dispening condition; 
     FIG. 2A is a side view of the container and system of FIG. 1A with the resealing flap opened and the chute still folded; 
     FIG. 2B is a front view of the container and system of FIG. 1A with the resealing flap opened and the chute still folded; 
     FIG. 2C is a perspective view of the container and system of FIG. 1A with the resealing flap opened and the chute still folded; 
     FIG. 3A is a side view of the container and system of FIG. 1A with the dispensing chute unfolded and extended and the container unlifted; 
     FIG. 3B is a perspective view of the container and system of FIG. 1A with the dispensing chute unfolded and extended and the container unlifted; 
     FIG. 4A is a side view of the container and system of FIG. 1A with the container lifted and the dispensing chute opened for dispensing therefrom; 
     FIG. 4B is a perspective view of the container and system of FIG. 1A with the container lifted and the dispensing chute opened for dispensing therefrom; 
     FIG. 4C is a sectional side view of the container of FIG. 1A with the container lifted and the dispensing chute opened for dispensing therefrom; 
     FIG. 4D is a sectional front view of the container of FIG. 1A with the container lifted and the dispensing chute opened for dispensing therefrom; 
     FIG. 5A is a side view of the container and system of FIG. 1A with the winching line retracted to empty the container; 
     FIG. 5B is a perspective view of the container and system of FIG. 1A with the winching line retracted to empty the container; 
     FIG. 5C is a sectional side view of the container of FIG. 1A with the winching line retracted to empty the container; 
     FIG. 6A is a side view of the container and system of FIG. 1A with the container lowered and the dispensing chute pinched by the flow restriction barrier; 
     FIG. 6B is a perspective view of the container and system of FIG. 1A with the container lowered and the dispensing chute pinched by the flow restriction barrier; 
     FIG. 7A is a side view of the container and system of FIG. 1A with the chute refolded; 
     FIG. 7B is a perspective view of the container and system of FIG. 1A with the chute refolded; 
     FIG. 8A is a side view of the container and system of FIG. 1A with the resealing flap resealed to the lower “velcro” strip; 
     FIG. 8B is a perspective view of the container and system of FIG. 1A with the resealing flap resealed to the lower “velcro” strip; 
     FIG. 9 is a perspective view of the container and system of FIG. 1A with the front-moving push/pull arm extended; and 
     FIG. 10 is a perspective view of the container and system of FIG. 1A with the side-moving push/pull arm extended. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In accordance with the preferred embodiment of the present invention, a soft container  101  for storing and handling flowable dry goods and a system  102  for handling and discharging the goods therefrom is described and depicted in FIGS. 1A through 10. 
     The container is preferably constructed of a durable nylon reinforced polyethylene fabric, although any similarly durable, strong, and flexible sheet material may be substituted. The container comprises six panels; top panel  104 , front panel  105 , right side panel  106 , left side panel  107 , back panel  108 , and bottom panel  109 . The top, side and front and back panels are preferably all sewn together at their edges for their entire lengths, although gluing or hot-sealing might be satisfactory, so long as the seams  110  are at least as strong as the fabric itself. The bottom panel is fully sewn along its edges with the side and back panels, but is not attached to the front panel at the front-bottom edge  111 . This is a key element of the invention. The container further comprises a funnel-shaped discharge chute  113  and a rectangular resealing flap  114 , both made of the same fabric material. The chute includes a top wall  115  and a bottom wall  116 , with the top wall being an extension of fabric from the front panel and the bottom panel. The top and bottom walls are sewn together at their side edges  117 , but not at the front edge  111 , which thereby forms the discharge opening when the container is lifted as depicted in FIGS. 4A through 5C. Initially though, the chute is folded as can best be seen in FIGS. 2A through 2C. 
     Shown in FIG. 1E, the resealing flap is sewn from side to side at its rear edge  119  to the bottom panel  109 . At its front edge  120 , the flap includes a female “velcro” strip  122 . The front panel of the container includes an upper male “velcro” strip  123  and a lower male “velcro” strip  124  affixed horizontally there-across. The flap is thus adapted to extend from the bottom panel, across the container&#39;s front-bottom edge  111 , over the folded chute, and to be attached to the upper male “velcro” strip before the container is filled with the dry goods. This maintains the container in the shape of a near-perfect orthogonal hexahedron, which is most efficient for transportation and storage. It can be readily appreciated that the flap covers and secures the chute in its closed position. and that the chute can be repeatedly resecured in the closed position by the flap in combination with the upper male “velcro” strip. 
     The container  101  of the Figures is shown in FIGS. 1A through 1E already filled with flowable dry goods  125 . The top panel has an inlet opening  126  through which the goods have previously been deposited. This filled container may be placed on a pallet for normal handling, or can be lifted and transported by means of the loading loops  127  at the upper corners of the container. It is desirable to lift the filled container at these loops when moving the container from a truck or a pallet and onto the bed  128  of the dispensing system  102 . 
     The dispensing system  102  comprises the afore-mentioned bed  128 , two lift support members  130  standing on opposite sides of the bed, a flow restriction barrier  131 , and an electro-hydraulic controller  132 . The underside of the bed includes two slots  133  that mimic the size and location of standard pallet slots to allow a standard fork-lift or pallet jack to be used in transporting the system. 
     Each lift support member includes an upright post  134 , a horizontal lift arm  135 , and an emptying winch  136 . The support members are positioned so as to straddle the container when it is properly positioned on the bed, with each front distal end  137  and rear distal end  138  of each horizontal lift arm being adjacent a lifting loop  139 , four of which are affixed to and positioned midway up the side edges of the container. After so positioning the container on the bed, with its front-bottom edge  111  up against the flow restriction barrier  131  which extends across the forward edge  140  of the bed, the lifting loops are fitted over the distal ends. 
     The emptying winch  136  of each support arm is affixed toward the front distal end  137  of each horizontal lift arm, and has a retractable winch line  141  extending therefrom. The container has two winching loops  142 ; each affixed at the rear-bottom corner  143  of each side panel. Hooks  144  at the ends of the winch lines  141  are attached to the winching loops such that the winch lines lie diagonally across each side panel from the rear-bottom corner toward the front-upper corner  145 . The filled container may be stored and handled as is now attached to the dispensing system, or moved to various locations about a warehouse for remote discharge. The bed is also equipped with retractable wheels  147 , and has a side-moving push/pull arm  148  and a forward-moving push/pull arm  149 , which each can be moved against a stationary object and extended or retracted horizontally to push or pull the dispensing system and thereby locate it more accurately than may be done with a fork-lift. This is best shown in FIGS. 9 and 10. 
     With the filled container in position for discharging goods as shown in FIGS. 1A through 1D, the resealing flap  114  is peeled from the upper “velcro” strip  123  as shown in FIGS. 2A through 2C, and the discharge chute  113  is extended as shown in FIGS. 3A and 3B. The flow restriction barrier  131  pinches the chute to maintain it in a closed confriguration and no goods can escape. 
     The controller  132  is then triggered to begin hydraulically raising the horizontal lift arms  135  up and away from the bed  128  to thereby lift the container by the lifting loops  139 . As the front-bottom edge  111  of the container is moved from the flow restriction barrier  131 , the chute opens as shown in FIGS. 4A through 4D, and goods begin to flow through the chute at a rate which varies proportionally with the height to which the container is lifted from the bed. 
     To best appreciate the mechanism by which the chute is opened and by which its opening size is controlled, one should look at FIGS. 4C and 4D. It will be noted that the unsewn front-bottom edge  111  allows the front panel  105  to bow forwardly at that edge and the bottom panel  109  to bow downwardly, opening the chute as the side walls collapse inward. As the container is incrementally lifted from the bed, the bowing incrementally increases and the chute opening expands. This effect additionally allows the side and bottom panels to slope downwardly toward the chute, improving flow and breaking up any goods which might have caked and clumped. Once the container is totally lifted from the bed, the chute achieves its maximum opening size and the rate of flow is maintained at its maximum rate until the bag is near empty or is re-lowered. As the goods are being discharged, an electronic scale within the controller  132  monitors and displays the dispensed and remaining weight of the goods. The controller may be programmed to terminate the discharge at a pre-selected weight by lowering the container as that weight is approached. 
     If the flow rate from the chute is more than desired or if the full contents of the container are not to be discharged, the container is simply lowered against the bed to reduce the chute opening size and reduce the flow rate or further lowered against the flow restriction barrier  131 , which pinches the chute shut to terminate flow as shown in FIGS. 6A and 6B. The container may now be resealed and restored for later use of the remaining contents. It should be appreciated though, that the bowing of the front and bottom panels will not be completely removed by the lowering of the container, and the partially discharged container will no longer have a near perfect orthogonal hexahedral shape. So with the chute  113  refolded as shown in FIGS. 7A and 7B, and the resealing flap  114  pulled upwards and over the chute, the flap can no longer reach the upper “velcro” strip  123 . However, the resealing flap can now be attached to the front panel  105  at the lower “velcro” strip  124  as shown in FIGS. 8A and 8B. 
     Should discharge of the container&#39;s entire contents be desired, the container will be maintained in the lifted position of FIGS. 4A through 4C until flow ceases. This will occur before the contents are entirely discharged, because the slope of the bottom panel is not sufficient to cause all of the goods towards the back panel to flow to the chute. The controller can now be activated, either manually or by automatically sensing the remaining weight, to retract the winch lines  141  into the winches  136  and thereby pull the back bottom edge  150  of the container upward and forward, increasing the slope of the bottom panel towards the chute, and causing the remaining goods to discharge. 
     Once the container is completely emptied, it can be washed, resealed as originally, and reused indefinitely. 
     It should be appreciated by those skilled in the art that the disclosed is simply the preferred of many possible embodiments of the invention, and therefore, the scope of the invention should only be limited by the following claims.