Abstract:
A bucket loader apparatus for scooping, filling, transporting and placing a plurality of bags used in constructing barriers. The bucket loader includes a universal mounting attachment for attachment to a loading vehicle whereby the loading vehicle manipulates the bucket loader between a range of dispositions. In a scooping disposition, the loading vehicle directs the bucket loader to scoop a flowable, granular material. In a loading disposition, the flowable granular material is directed through a plurality of integral funnels and into a plurality of bags, each funnel having a bag retained proximally to the funnel. After filling the bags, the bucket loader is transported to a point of use whereby the loading vehicle manipulates the loader bucket to an unloading disposition allowing placement of the filled bags. The bucket loader further includes a bag attachment assembly for selectively retaining empty bags and releasing filled bags.

Description:
PRIORITY CLAIM 
   The present invention claims priority to U.S. Provisional Application No. 60/443,514, entitled “BUCKET LOADER,” filed Jan. 29, 2003, and hereby incorporated by reference in its entirety. 

   FIELD OF THE INVENTION 
   The subject of this invention is an apparatus for filling bags with pourable, granular material such as sand. In particular, this invention relates to a loader bucket that can be operably coupled to a host vehicle whereby the host vehicle can manipulate the loader bucket through a range of dispositions such that the loader buck can scoop a granular material, fill a plurality of bags with the granular material, transport the filled bags to a point of use and place the filled bags to form a barrier. 
   BACKGROUND OF THE INVENTION 
   In areas where flooding is a frequent occurrence, both temporary or permanent barriers such as levees created from bags filled with sand have been found to be effective in containing flood waters. Barriers created by using sandbags are also used in other situations such as environmental spills and drainage control. However, it is to be appreciated that in creating such a barrier, a large number of sandbags are typically needed in a short span of time. 
   Typically, sandbags are manually filled at the site by volunteers. This is a time consuming and backbreaking endeavor. When manually filling sandbags, each bag must be held open while sand is poured in by the shovelful. When filled, the sandbags are either hand carried to the barrier or are lifted into a transport mechanism such as a wheelbarrow or truck bed. 
   In an attempt to simplify this manual procedure, various sandbag filling devices have been proposed in the art. For example, U.S. Pat. Nos. 5,564,886; 5,829,949; 5,873,396; 5,894,871; 5,947,347 and 4,184,522 all disclose various attachments for filling one or more sandbags by way of an auger or gravity feed. However, these examples are expensive and inefficient solutions to the problem. Furthermore, they fail to address the issue of transporting and placing sandbags at the barrier. 
   There is a need then for a device that can fill multiple sandbags simultaneously and preferably place them in the desired location. The device should be able to perform equally well with wet or dry filler material. Furthermore, the device should be simple in design for greater reliability in that failure may result in unacceptable property damage. Therefore, there is a need for a reliable, efficient and low cost sandbag filling machine. 
   SUMMARY OF THE INVENTION 
   The present invention is a bucket loader, which addresses the needs outlined above. The invention relates to an apparatus capable of being mounted on a vehicle, such as a front-end loader, and used to scoop up and dispense granular, flowable material such as sand into a plurality of bags. The apparatus can then hold the bags while the loader is properly positioned for bag deployment at the barrier. 
   The apparatus comprises a bucket mounted on the arms of a front-end loader. The bucket includes a universal mounting plate for attachment to the loader. The bucket may be rotated as well as raised to a suitable height using the hydraulic arms of the loader. A portion of the bucket is shaped so that by suitably moving the loader and/or the arms of the loader, the bucket can be oriented to scoop and raise material into a cavity of the bucket. The bucket is further partitioned into a plurality of funnel shaped channels. One end of each funnel shaped channel communicates with the scooping cavity of the bucket while a dispensing end functions like a spout. The bucket contains a selectively rotatable bag attachment mechanism to retain a plurality of fillable bags, one bag for each of the funnel shaped channels, in an open position whereby each bag is proximally positioned to receive material from the dispensing end of the funnel shaped channels. 
   In operation, the cavity of the bucket is first loaded with sand in a manner set forth above, and then progressively tilted, using a hydraulic means on the loader, so as to cause the sand to flow toward the rear of the bucket and through the dispensing funnels into the bags thereby filling the bags with the sand. In one particular orientation of the bucket, the spouts of the channels are accessible for conveniently attaching the empty bags or unmounting the bags after they have been filled with sand. Once the bags have been filled, the bags maintain their relative position within the bucket while the loader is directed to a point of use. The bucket is then oriented such that the weight of the loaded bags causes a spring-loaded chute to open, thereby allowing the plurality of filled bags to slide down the chute to form the barrier. 
   One objective of the present invention is to provide a bucket attachment for loaders, which allows the user to load a quantity of flowable material into the bucket and dispense the flowable material simultaneously into a plurality of bags. 
   Another objective of the present invention is to provide a bucket attachment for loaders, which is substantially more reliable, less labor intensive and efficient than any flowable material dispenser of the prior art. 
   Another objective of the present invention is to provide a bucket attachment for loaders, which serves the dual function of simultaneously loading a plurality of bags and placing the loaded bags at a point of use to construct a barrier. 
   Yet another objective of the present invention is to provide a bucket attachment for loaders, which can be universally attached, detached and oriented with a variety of alternative loader configurations. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a front, perspective view of a bucket loader of the present invention. 
       FIG. 2  is a front, perspective view of the bucket loader of  FIG. 1 . 
       FIG. 3  is a front, perspective view of the bucket loader of  FIG. 1 . 
       FIG. 4  is a rear, perspective view of the bucket loader of  FIG. 1 . 
       FIG. 5  is a bottom, perspective view of the bucket loader of  FIG. 1 . 
       FIG. 6  is a perspective view of a pair of second flappers. 
       FIG. 7  is a loader vehicle including the bucket loader of  FIG. 1  in a scooping disposition. 
       FIG. 8  is the loader vehicle of  FIG. 7  with the bucket loader in a filling disposition. 
       FIG. 9  is the loader vehicle of  FIG. 7  with the bucket loader in an unloading disposition. 
       FIG. 10  is the loader vehicle of  FIG. 7  preparing to scoop a flowable, granular material. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   A bag-filling bucket loader  100  of the present invention is depicted in  FIGS. 1 ,  2 ,  3 ,  4 , and  5 . Bucket loader  100  has a generally box-like construction including a scoop portion  102 , a bagging portion  104 , a mounting portion  106  and an unloading portion  108 . Generally, bucket loader  100  is a weldment assembly. Bucket loader  100  is preferably constructed of heavy-duty metal plate, for example, load bearing surfaces can comprise 5/16 inch metal plate while non-load bearing surfaces can comprise 3/16 inch metal plate to reduce the overall weight of bucket loader  100 . Bucket loader  100  is defined by a pair of sidewalls  110   a ,  110   b , a scoop floor  112 , a mounting wall  114 , a rear support wall  116  and chute wall  118 . 
   At the front of scoop portion  102  as shown in  FIGS. 1 ,  2  and  3 , the scoop floor  112  includes a tapered or angled scoop surface  120  having a leading edge  122 . Scoop portion  102  includes a pair of funnel walls  124   a ,  124   b  separated by a center support wall  126 . Funnel walls  124   a ,  124   b  are angled with respect to the scoop floor  112  such that the spacing between funnel walls  124   a ,  124   b  and the scoop floor  112  is at a maximum toward leading edge  122 . Mounted between funnel walls  124   a ,  124   b  and the scoop floor  112  is a plurality of funnel dividing walls  128 . The combination of funnel walls  124   a ,  124   b , scoop surface  120  and funnel dividing walls  128  define a plurality of individual funnels  130 . As depicted, bucket loader  100  includes twelve funnels  130 . In alternative configurations, bucket loader  100  can comprise varying numbers of funnels  130 , most typically dependent on an overall lifting capacity of a loading vehicle. 
   As depicted in  FIGS. 1 ,  2 , and  3 , bagging portion  104  defines a pair of bag retaining areas  132   a ,  132   b . Mounted within bagging portion  104  is a retaining assembly  134 . Retaining assembly  134  comprises a rotation rod  136 , a mounting rod  137 , a rotation assembly  138  and a plurality of flapper assemblies  140 . Rotation rod  136  and mounting rod  137  can be constructed of suitable rod or pipe. Rotation rod  136  is rotatably mounted between the sidewalls  110   a ,  110   b  and through center support wall  126 . Mounting rod  137  is attached, by welding or suitably fastening means, in position between the sidewalls  110   a ,  110   b  and through the center support wall  126  in parallel alignment with the rotation rod  136  but on an opposed side of the funnels  130 . The rotation assembly  138  is operably mounted between the retaining rod  136  and the mounting wall  114 . 
   The rotation assembly  138  shown in  FIGS. 1 ,  2 ,  3  and  4  comprises a rotation arm  142 , a mounting arm  144 , a hinge bracket  146 , a piston assembly  148  and a piston mounting bracket  150 . The piston assembly  148  includes a connector for operably connecting the piston assembly  148  with a suitable, external drive source, for example a pneumatic, hydraulic, or electrical source. A first end  152  of the rotation arm  142  is welded to the retaining rod  136  while a second end  154  includes a throughbore for coupling the rotation arm  142  to the hinge bracket  144  with a hinge pin  155 . The hinge bracket  144  can be integral with or welded to a movable piston of the piston assembly  148 . The piston assembly  148  can be attached to the piston mounting bracket  150  by welding or with a suitable fastener. Piston mounting bracket  150  is preferably welded to the mounting wall  114 . 
   Each flapper assembly  140  comprises a first flapper  160  fixedly attached to the rotation rod  136  and a second flapper  162  rotatably mounted to the mounting rod  137  as shown in  FIG. 6 . First flapper  160  and second flapper  162  are constructed substantially the same as each include a pair of angled projecting arms  164   a ,  164   b  and a connecting arm  166 . The first flapper  160  and second flapper  162  may comprise, for example, hot rolled ½ inch steel rods formed into the desired shape. In addition, each of the second flappers  162  includes a flapper plate  168  with a flapper mounting throughbore  169 . In general, first flapper  160  and second flapper  162  have a generally triangular appearance such that the distance between the arms  164   a ,  164   b  increases from either the rotation rod  136  or the mounting rod  137  to the connecting arm  164 . The first flappers  160  are preferably welded to the rotation rod  136  such that all of the first flappers  160  reside within a common plane. Each of the second flappers  162  is individually, slidably mounted about the mounting rod  137  using the flapper mounting throughbore  169 . Both the first flappers  160  and the second flappers  162  are spaced such that each flapper assembly  140  corresponds to a funnel box  172  on a dispensing end  174  of each funnel  130 . When assembled, each funnel box  172  has on opposing sides, a first flapper  160  and a second flapper  162 . In addition, each funnel box  172 , as depicted in  FIG. 6 , includes a biasing spring  176  oriented to engage the flapper plate  168  on each of the second flappers  162 . 
   As depicted in  FIG. 4 , mounting portion  106  comprises a universal mounting plate  178 , for example a quick-tach type mounting plate, welded to the mounting wall  114 . Generally, the universal mounting plate  178  allows the bucket loader  100  to be used interchangeably with any suitable loading vehicle, for example an excavator, a skid-steer loader, a backhoe, a track loader, a front-end loader or other suitable loading vehicle, having a pair of arms adapted to interface with the universal mounting plate  178 . 
   Unloading portion  108  as depicted in  FIG. 5 , allows the bucket loader  100  to be unloaded of filled bags by manipulating the orientation of the bucket loader  100  with the loader. Unloading portion  108  includes the chute wall  118 , a pair of chute springs  180   a ,  180   b  and a pair of spring covers  182   a ,  182   b . Chute wall  118  includes a chute member  184  rotatably mounted between the sidewalls  110   a ,  110   b . Chute member  184  can include a pair of mounting pins  185   a ,  185  projecting into opposed throughbores on the sidewalls  110   a ,  110   b . Chute wall  118  can further includes a chute rod  188  retained within a formed chute retaining surface  190 . 
   Preferably, chute retaining surface  190  is formed about the chute rod  188  such that the retaining surface  190  can be tacked to the chute wall  118  to permanently retain the chute rod  188 . Both a first chute rod end  192   a  and a second chute rod end  192   b  are adapted for attachment to one of the chute springs  180   a ,  180   b . The first chute rod end  192   a  and the second chute rod end  192   b  can be threaded such that the chute springs  180   a ,  180   b  are physically retained by a threaded nut  194 . The opposing ends of the chute springs  180   a ,  180   b  can then be coupled to a projection or bore present between the sidewalls  110   a ,  110   b  and the corresponding spring covers  182   a ,  182   b . The chute springs  180   a ,  180   b  are covered by the spring covers  182   a ,  182   b  to protect bystanders should the chute springs  180   a ,  180   b  break or become detached. Preferably, chute springs  180   a ,  180   b  have a combined spring tension of at least  100  pounds such that the chute wall  118  is biased shut as shown in  FIG. 5 . 
   Use of the bucket loader  100  is described with respect to  FIGS. 7 ,  8 ,  9  and  10 . As depicted, a conventional front-end loader  200  includes a pair of loader arms  202   a ,  202   b  adapted for coupling to the universal mounting plate  178 . Front-end loader  200  is equipped such that loader arms  202   a ,  202   b  can raise and lower the bucket loader  100  while a pair of piston-cylinder devices  204   a ,  204   b  allow tilting of the bucket loader  100  to a variety of orientations. Front-end loader  200  further includes a hydraulic, pneumatic or electrical source for connection with the piston assembly  148 . 
   Once the bucket loader  100  is physically and operably coupled to the loader  200 , the loader  200  manipulates the bucket loader  100  to a filling disposition  207  as shown in  FIG. 8 . Using the hydraulic or pneumatic drive source, an operator directs the piston assembly  148  such that the mounting arm  144 , and consequently the rotation rod  136 , are caused to rotate such that the connecting arms  164  on the first flappers  160  approach the funnel box  172 . An operator then attaches a bag  208  to each flapper assembly  140 . The bag  208  includes a single bag opening and preferably has a bag length slightly exceeding the distance between the funnel box  172  and the rear support wall  116 . The bag  208  is positioned such that the bag opening is placed around the second flapper  162 . The bag opening is then directed over the funnel box  172  and around the first flapper  160 . As the operator wraps the bag  208  over the first flapper  160 , the biasing spring  176  is compressed between the funnel box  172  and the flapper plate  168 . Once the bag  208  is placed over the first flapper  160 , the operator releases the bag  208  whereby the compressed biasing spring  176  directs the second flapper  162  away from the funnel box  172  such that the bag  208  is retained by the flapper assembly  140  with the funnel box  172  positioned within the bag opening. The operator similarly attaches one bag  208  to each flapper assembly  140 . 
   Once a bag  208  is attached to each flapper assembly  140 , the operator manipulates the hydraulic, pneumatic or electronic drive source to actuate the piston assembly  148  resulting in the mounting arm  144 , and consequently the rotation rod  136 , rotating such that the connecting arms  164  on the first flappers  160  move away from the funnel boxes  172 . This stretches the opening of the bags  208  such that each bag  208  is tightly retained by the flapper assemblies  140 . 
   Following attachment of the bags  208 , the loader arms  202   a ,  202   b  and piston-cylinder devices  204   a ,  204   b  are manipulated on the loader  200  such that the bucket loader  100  is oriented in a scooping disposition  209  as shown in  FIGS. 7 and 10 . In the scooping disposition  209 , the loader  200  directs the bucket loader  100  into a pile of granular material  210  such that the leading edge  122  cuts into the granular material  210 . The bucket loader  100  is directed forward by the loader  200  such that the scoop portion  102  is filled with granular material  210 . Typically, the granular material  210  is sand, either wet or dry, or similar materials available at the site. 
   Once scoop portion  102  has been filled with granular material  210 , the loader arms  202   a ,  202   b  and piston-cylinder devices  204   a ,  204   b  are manipulated with the loader  200  such that the bucket loader  100  is again oriented in the filling disposition  207  shown in  FIG. 8 . In the filling disposition  207 , the granular material  210  is directed between the funnel walls  124   a ,  124   b  and the scoop floor  112 . The granular material  210  is evenly distributed by the funnel dividing walls  128  whereby the granular material  210  flows into and through the funnels  130 . The granular material  210  exits out of the dispensing end  174  of each funnel  130  and flows into the bags  208 . As the bags  208  receive the granular material  210 , the individual flapper assemblies  140  continue to retain the bags  208  due to the tension supplied through the rotation assembly  138 . 
   Once filled, each bag  208  weighs on average fifty five to sixty pounds, though this will vary based on the dimensions of bag  208  and the make-up of granular material  210 . The operator can then manipulate the drive source such that the piston assembly  148  rotates the mounting arm  144 , and consequently the rotation rod  136 , such that the connecting arms  164  of the first flappers  160  approach the funnel boxes  172 . At this point, each flapper assembly  140  is no longer stretching the bag opening such that the bags  208  are supported by the rear support wall  116 . The operator then drives the loader  200 , with the bucket loader  100  in the filling disposition  207 , to a point of use. 
   Once the loader  200  is positioned at the point of use, the operator manipulates the loader arms  202   a ,  202   b  and piston-cylinder devices  204   a ,  204   b  such that the bucket loader  100  is in an unloading disposition  214  as shown in  FIG. 9 . As the bucket loader  100  is rotated from the filling disposition  207  to the unloading disposition  214 , the weight of the granular material  210  within the bags  208  becomes increasingly supported by the chute wall  118 . Once the bucket loader  100  is in the unloading disposition  214 , the combined weight within the filled bags  208 , approximately 660–720 pounds in the preferred embodiment, is supported by chute wall  118 . As the combined weight of the bags  208  exceeds the combined spring tension of the chute springs  180   a ,  180   b , the chute wall  118  rotates about the chute member  184  to an open chute disposition  216  shown in  FIG. 9  with respect to the sidewalls  110   a ,  110   b . As the chute wall  118  rotates to the open disposition  216 , the bags  208  begin to slide out of the mounting portion  106  whereby they are deposited at the point of use in an upright disposition. Once all of the bags  208  are positioned, the operator can repeat the process by attaching another set of bags  208  to the flapper assemblies  140  as discussed above. 
   It is understood that this invention is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only.