Abstract:
A waste dust containment system includes a bag and a waste-dust fill chute. The bag is formed to include an interior region for storing dust. The waste dust fill chute conveys waste dust generated in a factory into the interior region of the bag. Once filled with wasted dust, the bag is delivered to a waste-dust disposal site away from the factory.

Description:
[0001]    This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/078,959 filed Jul. 8, 2008, which is expressly incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates to waste dust management, and particularly to a waste dust containment system. More particularly, the present disclosure relates to flexible intermediate bulk containers used in waste dust containment systems. 
         [0003]    Bulk containers are used to collect waste material such as waste dust and transport that material from a warehouse, manufacturing facility, or other industrial plant to a waste-dust disposal site. One example of a bulk container is a flexible intermediate bulk container (FIBC). This container is made of a flexible material and is used, for example, to collect waste dust generated in industrial plants associated with foundry, refractory, steel, and ceramics industries. 
       SUMMARY 
       [0004]    A waste dust containment system in accordance with the present disclosure includes a bag formed to include a dust-entry port opening into an interior region. The bag is configured to store waste dust discharged into the interior region through the dust-entry port from a waste delivery system 
         [0005]    In illustrative embodiments, the bag is formed to include a rake-access inlet that is separate from the dust-entry port. A rake-access inlet closure is coupled to the bag and configured to provide means for opening and closing the rake-access inlet while waste dust is being discharged into the interior region of the bag through the dust-entry port. 
         [0006]    In illustrative embodiments, the waste dust containment system further includes a dust rake extending into the interior region of the bag through the opened rake-access inlet while waste dust is being discharged into the interior region of the bag through the dust-entry port. The dust rake is arranged to be moved back and forth by a technician standing next to and outside of the bag to permit raking and flattening of a waste dust heap that has accumulated in the interior region of the bag under the dust-entry port. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The detailed description particularly refers to the accompanying figures in which: 
           [0008]      FIG. 1  is perspective view of a waste dust containment system in accordance with the present disclosure coupled to a waste delivery system, with portions of a bag included in the waste dust containment system broken away to show waste dust that has collected in an interior region of the bag; 
           [0009]      FIG. 2  is a perspective view similar to  FIG. 1  showing that a technician has opened a rake-access inlet formed in the bag and inserted a dust rake into the interior region of the bag while waste dust is being discharged into the interior region so that the dust can be raked and leveled as suggested in  FIGS. 5 ,  7 , and  9 ; 
           [0010]      FIG. 3  is an enlarged perspective view of a portion of the waste dust containment system showing a closure (e.g., zipper) coupled to the bag and arranged normally to close the rake-access inlet formed in the bag; 
           [0011]      FIG. 4  is a view similar to  FIG. 3  showing that a sliding piece included in the closure has been moved from right to left two separate two zipper tracks also included in the closure to open the rake-access inlet so that a technician can insert a dust rake into the interior region of the bag as suggested in  FIGS. 2 and 7 ; 
           [0012]      FIG. 5-9  illustrate use of a dust rake included in the waste dust containment system to rake dust in the bag while dust is being discharged by the waste delivery system into the interior region of the bag; 
           [0013]      FIG. 5  is a sectional view of the waste dust containment system taken along line  5 - 5  of  FIG. 1 ; 
           [0014]      FIG. 6  is a partial side elevation view taken along line  6 - 6  of  FIG. 5  showing the closure in a closed state; 
           [0015]      FIG. 7  is a sectional view similar to  FIG. 5  showing a handle of the dust rake extending through an opened rake-access inlet and suggesting back-and-forth motion of the rake under the control of a technician to level a heap of waste dust that has accumulated in the center of the interior region of the bag under a first waste-dust fill chute included in the waste dust containment system and coupled to the bag; 
           [0016]      FIG. 8  is a view similar to  FIG. 6  taken along line  8 - 8  of  FIG. 7  showing the closure in an opened state and showing the handle of the dust rake in the opened rake-access inlet; 
           [0017]      FIG. 9  is a sectional view similar to  FIGS. 5 and 7  showing a flattened or leveled pile of waste dust in the bag after the dust rake has been removed and the rake-access inlet has been closed; 
           [0018]      FIG. 10  is a partial side elevation view taken along line  10 - 10  of  FIG. 9  showing the closure now returned to a closed state; 
           [0019]      FIG. 11  is a partial perspective view of a waste dust container system in accordance with another embodiment of the present disclosure showing a rake-access inlet closure comprising a series of snaps mounted on a foldable narrow upper strip coupled to a bag and a series of companion snap receivers mounted on a narrow lower strip coupled to the bag; 
           [0020]      FIG. 12  is a partial perspective view of a waste dust container system in accordance with yet another embodiment of the present disclosure showing a rake-access inlet closure comprising a series of snaps mounted on a foldable wide strip coupled to a bag and a series of companion snap receivers mounted on a narrow lower strip coupled to the bag; and 
           [0021]      FIG. 13  is an exploded perspective view showing the waste dust container system of  FIG. 1  above a bag holder included in the waste dust containment system and sized to hold the bag. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    A waste dust containment system  10  in accordance with one embodiment of the present disclosure includes a bag  12  formed to include an interior region  14  and a rake-access inlet  16  opening into interior region  14 , a first waste-dust fill chute  18  coupled to bag  12  at a first waste-dust entry port  19  formed in bag  12 , and a rake-access inlet closure  20  coupled to bag  12  as suggested in  FIGS. 1 and 2 . Rake-access inlet closure  20  is configured to be operated by a technician  100  to open and close rake-access inlet  16  during discharge of waste dust  24  into interior region  14  of bag  12  through first waste-dust entry port  19  as suggested in  FIGS. 5-8 . An illustrative rake-access closure  20  is a zipper as suggested in  FIGS. 1-10  and other illustrative closures  120 ,  220  comprising snaps are suggested in  FIGS. 11 and 12 . 
         [0023]    A dust rake  26  also included in waste dust containment system  10  can be extended into interior region  14  of bag  12  through an opened rake-access inlet  16  by technician  100  while waste dust  24  is flowing into interior region  14  and then moved back and forth in directions  101 ,  102  as suggested in  FIGS. 7 and 8  to rake and flatten a heap of waste dust  24  that has accumulated in interior region  14  of bag  12  under first dust-entry port  19 . Use of dust rake  26  during flow of waste dust  24  into bag  12  to flatten and perhaps compact waste dust  24  accumulating in interior region  14  of bag  12  will maximize the fill capacity of bag  12 . 
         [0024]    In an illustrative embodiment, as suggested in  FIGS. 1 ,  2 ,  5 ,  7 , and  9 , a first waste-dust fill chute  18  is coupled to bag  12  at a first dust-entry port  19  formed in bag  12 . First waste-dust fill chute  18  is adapted to mate with a waste delivery system  11  to allow waste dust  24  discharged by waste delivery system  11  to flow into interior region  14  of bag  12  through first dust-entry port  19 . It is within the scope of the present disclosure to use any suitable means to admit waste dust  24  into interior region  24  of bag  12 . 
         [0025]    Bag  12  includes a basin  28  formed to include a waste-dust reservoir chamber  30  and a basin cover  32  coupled to basin  28  along a cover seam  34  to overlie waste-dust reservoir chamber  30 . Basin cover  32  cooperates with basin  28  to form interior region  14  therebetween as suggested in  FIGS. 1 ,  2 , and  5 . Basin cover  32  is formed to include first dust-entry port  19  as suggested in  FIG. 1 . Rake-access inlet  16  is formed in bag  12  to extend along a portion  341  of cover seam  34  in an illustrative embodiment shown in  FIGS. 2 and 4 . 
         [0026]    In an illustrative embodiment shown in  FIGS. 1 ,  2 , and  7 , a second waste-dust fill chute  38  is coupled to bag  12  at a second dust-entry port  39  formed in basin cover  32  of bag  12 . Second waste-dust fill chute  38  is adapted to mate with waste delivery system  11  to allow waste dust  24  discharged by waste delivery system  11  also to flow into interior region  14  of bag  12  through second dust-entry port  39 . Second dust-entry port  39  is located between first dust-entry port  19  and rake-access inlet  16  as suggested in  FIGS. 2 and 7 . 
         [0027]    Basin  28  includes a floor  280  and in series, first, second, third, and fourth side-wall panels  281 ,  282 ,  283 , and  284  that cooperate (in an illustrative embodiment) to form endless side wall  285 . Each of side-wall panels  281 - 284  is coupled to floor  280  along a floor seam  40  and to basin cover  32  along cover seam  34  to cause rake-access inlet  16  to lie above and in spaced-apart relation to floor  280  of basin  28  as suggested in  FIGS. 2 and 7 . Basin  28  is made of a flexible material in an illustrative embodiment. 
         [0028]    In an illustrative embodiment, first side-wall panel  281  is coupled to one edge of basin cover  32  along a first portion  341  of cover seam  34  and second side-wall panel  282  is coupled to a second edge of basin cover  32  along a second portion  342  of cover seam  34  as suggested in  FIG. 13 . Third side-wall panel  283  is coupled to a third edge of basin cover  32  along a third portion  343  of cover seam  34  and fourth side-wall panel  294  is coupled to a fourth edge of basin cover  32  along a fourth portion  344  of cover seam  34 . 
         [0029]    Endless side wall  285  is arranged to interconnect floor  280  and the basin cover  32  and coupled to basin cover  32  at cover seam  34  as suggested in  FIG. 1 . Fourth side-wall panel  284  is coupled to first side-wall panel  281  as suggested in  FIGS. 3 and 5 . Each of first and third side-wall panels  281 ,  283  has a short width W 1  as measured between adjacent second and fourth side-wall panels  282 ,  284  as suggested in  FIG. 13 . Each of second and fourth side-wall panels  282 ,  284  has a relatively longer long width W 2  as measured between adjacent first and third side-wall panels  281 ,  283  as suggested in  FIG. 13 . Rake-access inlet  16  is formed along portion  341  of cover seam  34  located between basin cover  32  and first side-wall panel  281 . 
         [0030]    Rake-access inlet closure  20  is coupled to bag  12  as suggested in  FIGS. 3 and 4 . Rake-access inlet  20  is configured to provide means for opening rake-access inlet  16  while waste dust  20  is flowing into interior region  14  of bag  12  through first dust-entry port  19  to receive a waste-dust rake  26  in rake-access inlet  16  to allow technician  100  to move waste-dust rake  26  relative to bag  12  to level a heap of waste dust  24  that has accumulated in interior region  14  of bag  12  under first dust-entry port  19  formed in bag  12  and for selectively closing rake-access inlet  16  after removal of dust rake  26  from interior region  14  formed in the bag  12  to limit discharge of waste dust  24  from bag  12 . 
         [0031]    Rake-access inlet closure  20  includes a first zipper track  21  coupled to first side-wall panel  281  and arranged to border rake-access inlet  16 , a second zipper track  22  coupled to basin cover  32  and arranged to border rake-access inlet  16 , and a sliding piece  23  in an illustrative embodiment as suggested in  FIGS. 1 and 2 . Sliding piece  23  is coupled to each of first and second zipper tracks  21 ,  22  for movement relative to bag  12  along portion  341  of cover seam  34  in one direction D 1  as suggested in  FIG. 4  to mate first and second zipper tracks  21 ,  22  to close rake-access inlet  16  and in an opposite second direction D 2  as suggested in  FIG. 3  to unmate first and second zipper tracks  21 ,  22  to open rake-access inlet  16 . 
         [0032]    Bag  12  is configured to minimize the amount of waste dust  24  that is released into the air surrounding bag  12 . Waste dust  24  enters interior region  14  of bag  12  through chutes  18 ,  38  (or any other suitable means). While in operation, the only access to waste dust  24  in interior region  14  is through an opened rake-access inlet  16 . Rake-access inlet closure  20  can be operated by technician  100  to allow limited access to waste dust  24  in interior region  14  so that waste dust  24  can be raked using a dust rake  26  extending into interior region of bag  12  through an opened rake-access inlet  16 . 
         [0033]    As suggested in  FIGS. 2 and 7 , dust rake  26  includes a rake head  261  and a handle  262  coupled to rake head  261 . Handle  262  is configured to provide means arranged to extend through rake-access inlet  16  for moving rake head  261  back and forth in interior region  14  to level a heap of waste dust  24  accumulated in interior region  14  while waste dust  24  is flowing into interior region  14  through (at least) first dust-entry port  19  and first and second zipper tracks  21 ,  22  are at least partly unmated to open rake-access inlet  16  as suggested in  FIGS. 2 ,  7 , and  8 . 
         [0034]    In use, on some occasions, a heap of waste dust  24  can form in interior region  14  of bag  12  under first dust-entry port  19  as suggested in  FIG. 5 . Technician  100  can use closure  20  to open rake-access inlet  16  as suggested in  FIGS. 4 ,  7 , and  8  while waste dust  24  is flowing from waste dust delivery system  11  into interior region  14  of bag  12 . Closure  20  provides access to bag  12  while bag  12  is being filled. This permits technician  100  to insert dust rake  26  into bag  12  and rake and flatten a heap of waste dust  24  while waste dust  24  continues to flow into interior region  14  of bag  12 . More capacity is created in bag  12  to allow interior region  14  to be filled to the top and thus maximize use of interior region  14  and fill capacity. Once bag  12  is full, chutes  18  and  38  are tied shut with durable polypropylene straps. Transport of a filled bag  12  to a remote bag-disposal site is facilitated by filling a bag  12  while it is located in a bag carrier  112  as suggested in  FIG. 13 . 
         [0035]    In other illustrative embodiments, a rake-access inlet closure  220  in accordance with the present disclosure comprises a series of snaps located along rake-access inlet  16  as shown, for example, in  FIGS. 11 and 12 . These snaps can be opened and closed by technician  100  to open and close rake-access inlet  16 . 
         [0036]    A bag  212  is formed to include a rake-access inlet  16  as suggested in  FIG. 11 . Bag  212  is coupled to a rake-access inlet closure  220  in accordance with another embodiment of the present disclosure. Rake-access inlet closure  220  includes a separable retainer snap  223  coupled to a basin cover  232  and to first side-wall panel  281  to close the rake-access inlet  16  as suggested in  FIG. 11 . It is within the scope of this disclosure to use one or retainer snaps or other suitable fasteners to close rake-access inlet  16  temporarily. 
         [0037]    Basin cover  232  includes a top wall  232 T formed to include first dust-entry port  19  and a foldable flap  232 F coupled to top wall  232 T. Top wall  237  of basin cover  232  is coupled to first, second, third, and fourth side-wall panels  281 ,  282 ,  283 , and  284  at cover seam  34 . Retainer snap  223  includes a first snap element  221  coupled to first side-wall panel  281  and a second snap element  222  coupled to foldable flap  232 F to move therewith relative to first side-wall panel  281  and configured to mate with first snap element  221  to retain foldable flap  232 F in a position closing rake-access inlet  16 . 
         [0038]    A bag  312  is formed to include a rake-access inlet  16  as suggested in  FIG. 12 . Bag  312  includes a basin cover  332  including top wall  232 T and a foldable flap  332 F coupled to top wall  232 T along portion  341  of cover seam  34 . Separable retainer snap  223  is coupled to first side-wall panel  281  and foldable flap  332 F. Foldable flap  332 F has a first length L 1  that is relatively greater than a second length L 2  of foldable flap  232 F as suggested in  FIGS. 11 and 12 . 
         [0039]    Each of bags  12 ,  212 , and  312  is made of a flexible material and is suitable for use in a flexible intermediate bulk container (FIBC) unit. Such units are configured to be collapsed and folded, when empty, to permit the volume of the unit to be reduced for easier handling and storage. 
         [0040]    An FIBC unit typically includes a single access that permits the unit to be filled with waste material. Often this access point is positioned in a manner that causes material to accumulate in the unit in a way that does not fill the entire volume of the unit effectively. Waste materials stored and transported in FIBC units include granular materials formed as by-products of industrial processes. FIBC units capture dust, debris, and other waste material formed during industrial and manufacturing processes, e.g., casting of metals and milling and machining of wood, steel, ceramics, and other refractory materials 
         [0041]    In illustrative embodiments, rake-access inlet  16 , when opened, permits a technician, e.g., a mill worker, to insert a dust rake  26  such as a rake, hoe, or other leveling device into interior region  14  of bag  12 ,  212 , or  312  while waste dust  14  is flowing into interior region  14 . The technician may smooth, level, flatten, and otherwise arrange waste dust  24  in interior region  14  to use fully the capacity of bag  12 ,  212 , or  312 . 
         [0042]    In illustrative embodiments, rake-access inlet  16  has a cross-sectional area that is sized to receive rake head  261  of dust rake  26  therein. Such area may be round-, oblong-, square-, or rectangle-shaped. 
         [0043]    In illustrative embodiments, closure  20  and  220  is configured to limit access to interior region  14  via rake-access inlet  16 . This, in turn, restricts flow of waste dust  24  that may be emitted from interior region  14  when interior region  14  is filled with waste dust  24 . 
         [0044]    In an illustrative embodiment, rake-access inlet closure  20  is configured to reduce the accessible portion of area of rake-access inlet  16  by at least about 50% when in its closed position. The closed position is the position where the least amount of material would be able to be emitted from container  100 . Illustratively, but not necessarily, closure  20  includes a sealable device. Examples of sealable devices that are suited for use in closure  20  include, but are not limited to, zippers, snaps, buttons, hook-and-loop fasteners, and frictional-fit type fasteners (e.g., ZIPLOC® fasteners), among others. These may be installed monolithically with rake-access inlet  16 , as illustrated in  FIG. 1 . In other illustrative embodiments, however, rake-access inlet closures in accordance with the present disclosure may be located remote from rake-access inlet  16 . Such remote-type sealable devices may include flaps and/or other pieces of material that can be positioned and secured to reduce the accessible area of rake-access inlet  16  by at least about 50%. In still other embodiments a closure may be removably secured to the bag so as to permit it to be detached from the bag in order to expose all of, or a portion of rake-access inlet  16 . These types of devices could then be secured to a bag with some type of fastener (e.g., snaps, buttons, hook-and-loop fasteners) in order to reduce the exposed portion of rake-access inlet  16  and restrict the number of particles emitted from the bag.