Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
   Not applicable 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable 
   REFERENCE TO A “MICROFICHE APPENDIX” 
   Not applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The apparatus of the present invention relates to fabric bulk bags, also known as Flexible Intermediate Bulk Containers, and how these bags are handled. More particularly, the present invention relates to a bulk bag having a floor portion which includes a pair of spaced apart pockets for receiving a rigid member to define a channel through which tynes of a forklift may enter, and a portion of the floor extending between the pockets to define a support surface together with the rigid members. 
   2. General Background of the Invention 
   Bulk bags are for the most part bags constructed of a polypropylene material which would normally be of the type having four side walls, a bottom wall, a top wall and means such as loops for lifting the bag with a forklift after the bag has been loaded with bulk. The prior art bulk bags utilized the lifting loops at each corner in order to lift the loaded bag, which may weigh thousands of pounds, so that the filled bags may be stored in a warehouse or the like. Lifting loops are difficult to access by a forklift and usually takes a second person to assist. A second issue is the height needed to work with the bags when lifting from above. When filled, bulk bags may also be moved on pallets. Pallets, although easily accessible, are usually made of wood, and over time will be susceptible to splintering, mold, or insects. 
   The wood pallet solves those two problems but, as is often the case, created new problems to be overcome. The wooden pallet is heavy. This has caused many back and finger injuries. It also uses up valuable load limit during shipping. Pallets often weigh between 30 and 70 pounds each. A standard truckload of products will use 22 of these pallets which adds nearly three-quarters of a ton of weight to the total load. A reduction of this weight increases the amount of actual product that can be shipped each time. Another issue with the wooden pallet is the disposal issue. The pallet consists of wood and nails and any chemical residues that it picks up during the transport. This makes the disposal of these pallets quite expensive. The wood can contaminate the products it transports by shedding splinters which penetrate into the bags. In short, it is desirable to find an alternative to wooden pallets for the transportation of these bags. Plastic pallets may eliminate these problems, but are very expensive to produce. 
   One problem with transporting and storing bags of this type is that the bags, in order to conserve space, would typically be stacked upon one another to a height, so long as the bags did not risk of toppling over. However, because of the soft underside of the bags, when the bags, filled with dry, powdery bulk, are stacked upon one another, the bulk within the bag may shift, and in doing so, may cause the bag to lose its center of gravity and fall from its resting place, which could be both dangerous to persons working in the area, and cause the loss of thousands of pounds of what may be expensive bulk material. 
   There have been several attempts by past inventors to resolve these issues but each invention has fallen short of meeting the market&#39;s needs. U.S. Pat. No. 4,830,191 discusses the idea of using two tubular shaped objects to provide fork tine access under the bag. The patent further teaches that the bag should reach the floor rather than to ride above the fork tines. But, this patent left three important features unsolved. One, there is no connection of the bag to the pallet tubes. This allowed for independent movement which created the possibility for the bags to slip off during braking of the fork lifts. Second, the method for bringing the bag to the floor involved many layers of fabric. This made this invention very expensive and prevented the bag from having a bottom discharge. Bottom discharges are important to bulk bags as it provides for the easy emptying of the bags. In today&#39;s marketplace, cost plays a very important factor as well. Third, the invention could not travel down roller conveyors. This is due to the soft bottom of the invention. This soft bottom would form itself around the tops of the conveyor rollers and prevent movement along such conveyors. As many companies use such type of conveyor, this became a major problem for general acceptance. 
   A second notable attempt to provide bulk bags that could be handled from below without wooden pallets was made in U.S. Pat. No. 5,785,175 teaches how to shape a bag bottom so that no tubes are needed. It provided bag structure that provided a base to the floor for only a portion of the bag&#39;s total bottom. The other portion of the bottom then stood above the floor, providing a place for forklift tines to reach under those portions for lifting. In fact, a goal of this patent was to accomplish the transporting job without anything other than the bag. While the methods work mostly with the bottom portion of the bag that reaches the floor, in reality, it became necessary to use this only with a special type of bulk bag called a baffle bag. The patent also failed to meet general market needs due to three particular insufficiencies. One, the structure within the base portion of the bag, exists within the product storage area. This provides many opportunities for product contamination and prevents the use of a polyethylene liner. The liner is commonly used for any type of sensitive products such as food or pharmaceuticals. A second problem with this approach was the intended lack of support under the overhanging portions of the bag. While these do work as intended, meaning that the bag does not sag into the area and block forklift access, it added a new failing to the package. This lack of support in the outer 8 inches of the bag translated into very small bottom portions that the larger upper bag portions had to ‘balance’ on. This bag exhibited a reduced amount of stability when placed on the floor and a definite instability when double-stacked. The third insufficiency was, again, the inability to travel down roller conveyors due to the soft bottom. 
   A more recent attempt to improve the usability of alternatives to wood pallets is shown in U.S. Pat. No. 6,213,305. This patent attempts to resolve the problem of holding the tubes to the bag, or in reverse, to hold the bag to the tube. However, in this patent, the tube is still expected to carry the entire load again. Therefore the plastic must be of sufficient strength and thickness to manage that. 
   In another effort to attempt to solve the problem, reference is made to U.S. Pat. No. 6,213,305, entitled “Bulk Bag,” which disclosed the use of two rigid members placed within sleeves on the bottom of the bag, the rigid members formed to receive tynes of a forklift through the opening formed by the members. The members were secured within the sleeves with elastic bands. This attempt has fallen short of solving the problems in several reasons. First, the elastic bands need sufficient tension to hold the rigid members within the channel, which is difficult. Also, the rigid members, if not properly secured within the channels will tend to slide from the channels when the tynes of the forklift go into or out of the sleeves. Also, plastic inserts, which have been provided which are thick, extruded plastic, rectangular tubes. Such four-sided tubes cannot be nested when shipped or stored. Additionally, the rigid inserts do not provide any protection to the sleeves making direct contact with the floor where a bag may be slid along the floor, thus wearing or even tearing the sleeves on the bottom of the bag. 
   Therefore, there is a need for improving the art of inserts into channels on the floor of bulk bags which solves these aforesaid problems. What is needed is a straight forward solution that takes into account all parts of the application to provide a successful system that answers the usage shortfalls discussed above yet also answers the economic requirement for low cost replacements of the wooden pallet. Further this invention must work with low cost bags rather than only the expensive baffle types of bags. 
   Applicant is submitting herewith the prior art statement regarding patents which have been reviewed which may be pertinent to the subject matter of this invention. 
   SUMMARY OF THE PRESENT INVENTION 
   This inventor has done many tests to determine not only the solutions to the problems already known but to provide solutions to currently unstated problems that are anticipated with the introduction of new products. In all of the patents discussed above, it appears that each inventor has considered the needs of the bag or the needs of the pallet portions individually. It does not appear that anyone has considered combining the needs to eliminate overlapping costs and performances for the most economical and straightforward solutions. It is in this type of thinking that uncovered the proposed inventions. This invention proposes to solve the issues discussed above by considering the pallet and bag to be a single unit. This invention involves a bag design that brings the product to the floor in a manner that allows for an unencumbered product storage area and the use of a discharge spout. The portion of the bag that drops down to meet the floor is of sufficient size to support at least 40% of the entire bag&#39;s weight. This leaves only 30% of the total weight to be supported by each plastic tube. When this is taken into consideration, then the plastic tube can be drastically reduced in strength and cost. Since the tubes support the bag all the way to the edges, the stability of the bag is greatly increased over the Cholsaipant patent. 
   However, while testing of this idea proved that it can be accomplished, two new problems were encountered. The drop down portion of the bag that comes into contact with the floor is now in contact with contamination that can endanger the product during the discharging operation. Further, the drop down portion can be damaged if the bag is slid along the ground as often happens. This is solved with a unique cover flap that is very economical as it covers only the area between the plastic tubes. 
   Another problem that is encountered with this invention is the inability of the bag/pallet system as described to travel consistently down roller type conveyors. This problem is not inherently necessary for all situations as not all companies use roller conveyors. However, for those that do, the problem must be resolved as the lower portion of the bag tends to shape itself around the tops of each roll and prevent the bag from moving along the conveyor. 
   The present state of the art is to put the bag and pallet tubes onto another wooden pallet to accomplish this requirement. This defeats the whole purpose of this invention. In another form, the pallet tubes have been connected with a sheet of plastic at the top to form a traditional pallet. Again, this require full strength in the plastic which results in high cost. Recently, some companies have connected the pallet tubes with a sheet at floor level. This has not yet been done in conjunction with a bag designed to drop to floor level as we have suggested here, but even ignoring this combination, the connecting of the pallet tubes to the flat sheet has high cost due to the size of the mold and it eliminates any economical method of attaching the pallet tubes to the bag. 
   In the proposed invention, we teach a ‘floating sheet of hard material, preferably plastic, that will cover any area of contact between the bag and the floor level. This will perform several functions. It will protect the bag bottom from damage. It will protect the bag bottom from dirt. It will provide a platform that will allow the bag to travel down roller conveyors. It will provide for low cost as it can be produced in the lowest cost methods such as extrusion versus the high cost of large injection molding processes. 
   Another problem encountered in the use of pallet tubes is determining the length of such tubes. Naturally, the length relates to overall cost. The current standard in the market place seems to be 48 inches for this type of tube. This size has been promoted due to the potential for the bag to sag around the base. A 37 inch by 37 inch bag can round out into a circle of 47 inches. This sagging can then allow the bag fabric to cover part of the opening for the fork times and cause damage. To eliminate this, the market is currently using the 48 inch long tubes. 
   In this invention, the bottom of the bag is intentionally restricted to prevent the bag from sagging toward the open ends of the tubes. This is allowing for the safe use of tubes that are only 42 inches long. This has again, increased the economies of this design. 
   In summary, what is provided is an improved fabric bulk bag, of the type having wall portions, a top portion, and a floor portion, all defining a space for storing bulk therein, and in a first embodiment providing a pair of channels, substantially parallel in relation, secured along the outer surface of the floor portion, each channel having two open ends; a substantially elongated rigid support member insertable into each channel, the upper wall of the member contacting the outer surface of the bulk bag, and the two arms of the U-shaped member providing a travel space through the channel for receiving the tynes of a forklift, and allowing the tynes to contact the upper wall of the member when the bag is lifted; the two arms of the support member also providing a stable pallet-like foundation for the bag when the bag is positioned atop another filled bag. There is further provided a portion of the floor of the bag extending between the two support members when the bag has sufficient bulk, so that the portion filled with bulk defines a continuous support surface between the two support members and together define a continuous support across the floor of the bag. 
   In a second embodiment, the support members provide an undersurface therebetween, to define a pallet member, so that the bulk bag, with the additional bulk space, when set upon the pallet member, the bulk space fills the void between the support members of the pallet member, and together define a bulk bag/pallet combination upon which the bulk bag resides. 
   Therefore, it is a principal object of the present invention to provide an improved bulk bag which can be easily and safely transported by forklift and safely stacked on another filled bulk bag. 
   It is a further principal object of the present invention to provide an improved bulk bag which includes a pallet support structure incorporated therein. 
   It is a further object of the present invention to provide a bottom portion of the bag adapted with rigid members for defining a level, secure means to both transport the filled bag and allow the bag to be safely stacked on other such bulk filled bags. 
   It is a further object of the present invention to provide support members insertable into sleeves on the bottom of a bulk bag which allows the support members to contact the surface upon which the bag rests without contacting the sleeves. 
   It is a further object of the present invention to provide rigid inserts for bulk bags made of high density polyethylene which can be injection molded rather than extruded plastic, to allow for geometric shaping of the insert and to use a variety of plastic materials. 
   It is a further object of the present invention to provide plastic inserts for bulk bags which are inexpensive to mold, and can be nested when shipped or stored. 
   It is a further object of the present invention to provide removable inserts which are not permanently positioned within sleeves on bag bottoms allowing the inserts to be easily positioned into and removed from the bag, do not have to be shipped with the bags, and easily removed when refurbishing of the bag is necessary. 
   It is a further object of the present invention to provide a bulk bag having a modified floor portion between the two plastic inserts to define a continuous support surface along the bottom of the bag when the bag is filled with bulk material. 
   It is a further object of the present invention to provide a flat rigid member extending across the lower portions of the rigid members to define a pallet-like structure upon which the bag would rest, with the modified floor portion nestled between the two rigid members. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
       FIG. 1  illustrates an overall view of the preferred embodiment of the present invention; 
       FIG. 2  illustrates a view along lines  2 — 2  in FIG.  1  of the preferred embodiment of the present invention; 
       FIG. 3  illustrates an overall exploded view of the present invention; 
       FIG. 4  illustrates an underside view of the present invention with a protective cover tied and secured across the bag portion; 
       FIG. 5  illustrates an underside view of the present invention with a protective cover secured across the entire underside of the bulk bag; 
       FIG. 6  illustrates an underside view of the present invention in a bulk bag having an opening in its floor portion; 
       FIG. 7  illustrates an underside view of the present invention embodying a cover for the opening in the floor portion a bulk bag; 
       FIGS. 8 and 9  illustrate overall views of a prior art pallet portions which may be used with the present invention; 
       FIG. 10  illustrates a plurality of the bulk bags of the present invention stacked upon one another in rows in a rigid and secure manner; 
       FIG. 11  illustrates a partial cutaway view of an additional embodiment of the present invention; 
       FIG. 12  illustrates an isolated view of a pleat as illustrated in  FIG. 11 ; 
       FIGS. 13 and 14  illustrates a partial cutaway view of the modified drop down portion of the bulk bag; 
       FIG. 15  illustrates an additional embodiment of the drop down portion of the bulk bag; 
       FIG. 16  illustrates a top view of the pattern of the embodiment of the drop down portion illustrated in  FIG. 15 ; 
       FIG. 17  illustrates a side view of a bulk bag with no lifting loops with the modified drop down portion of the bulk bag filled with bulk material; 
       FIG. 18  illustrates the modified drop down portion of the bulk bag including the pleat features of  FIG. 11 ; 
       FIG. 19  illustrates a group of filled bulk bags of the type having a drop down portion set upon a roller conveyor; 
       FIG. 20  illustrates a modified bulk bag having a drop down portion protective member; 
       FIG. 21  illustrates a side view of the bulk bag illustrated in  FIG. 20 ; 
       FIG. 22  illustrates a side view of the bulk bag in  FIG. 21 , with the protective member released from the bag; and 
       FIG. 23  illustrates a box housing for enclosing the drop down portion as bulk is poured into the bag. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1 through 7  illustrate a first preferred embodiment of the container system  10 , which includes a bulk bag of the present invention incorporating a pallet feature therein.  FIGS. 8 and 9  illustrate views of a prior art pallet which may be utilized with the bulk bag of the present invention as illustrated in  FIGS. 1 through 7 .  FIGS. 11 through 23  illustrate additional preferred embodiments of the container system of the present invention. 
   Turning first to  FIGS. 1 through 7 , as illustrated in  FIGS. 1 and 2 , there is illustrated a fabric bulk bag  10 , of the type having a top wall  14 , side walls  16 , and a bottom wall  18 . In most cases the bulk bag  10  would have an opening in its top wall  14  through which bulk material is poured into the bag space  20 , and an opening  22  on its bottom wall  18  for allowing the bulk to flow from the bag space  20 , when the normally closed opening  22  is opened. The opening  22  would usually include a down spout for allowing the bulk material to flow into another vessel or the like. These features are quite common in most bulk bags. 
   Turning again to  FIGS. 1 and 2 , there is illustrated the underside or bottom wall  18  of bulk bag  10  of the present invention, which would include a pair of fabric sleeves  24  stitched, or secured in other ways, along the edges  25  so as to define an opening  26  between the sleeve  24  and the underside  18  of the bulk bag  10 . As illustrated the sleeves  24  are open at their two ends  28 ,  30 , which would allow a support member  32 , as illustrated, to be slidingly engaged through the opening  26 . Each support member would include an opening  35  throughout to accommodate a foklift tyne. The support members  32  may have ends  34 ,  36  extending beyond the ends  28 ,  30  of the sleeves, although this is not necessarily required. As is further illustrated the sleeves  24  are positioned substantially parallel to one another on the underside  12 , and spaced sufficiently apart so, after support members  32  are in place, will allow the tynes of a forklift to slide into each support member  32  when the filled bulk bag  10  is being lifted and moved, as will be discussed further. 
   In a related application, owned by Ameriglobe, there is provided a detailed explanation of various types of support members  32  which could be utilized with the bulk bag of the present invention. This related application, entitled “BULK BAG PALLET TUBE APPARATUS”, is incorporated herein in its entirety by reference thereto. 
   As seen particularly in  FIG. 2 , the underside  18  of bulk bag  10  is configured to define a bulk containing space  70  between the two sleeves  24 , so that when receiving sufficient bulk, the bulk  71  within the containing space  70  occupies the entire space between the two sleeves  24 , and further defines a continuous lower surface  72  upon which the bag rests, as defined by the two members  32  and the bulk bag space  70 . As illustrated, the bottom wall  18  of bulk bag  10  has been designed to provide sufficient fabric between the two sleeves  24 , so as to allow bulk within the bag to fill the entire void or space  70  between the entire length of the two sleeves  24  and perform the support function as seen in  FIG. 2 . 
   As illustrated in  FIG. 3 , the support members  32  are substantially rigid, four-sided rectangular members having a space  35  therethrough for accommodating the tynes of a forklift, as described earlier. After the members  32  are slidingly engaged within sleeves  24 , the two members  32  together with the bulk space  70  maintains a solid and flat support undersurface  72  extending across the entire bottom surface of the bag upon which the bulk bag rests. 
     FIGS. 4 and 5  illustrate additional features which may be included as part of the present invention to help maintain the bulk bag free from contamination and offer greater support. As seen first in  FIG. 4 , the bulk space  70  between support sleeves  24  has been provided with an underside  75 , which may be rigid or flexible, but, as seen, would be tied in place to bag  10  via ties  77 . This underside  75  would offer a barrier between the surface upon which the bag  10  rests and the underwall of the bulk space  70 . In this embodiment the two sleeves  24  are not covered by the underside  75 . 
   In  FIG. 5 , the underside  75  has been modified so that it extends across the entire underside  18  of the bag  10 , including the two sleeves  24 . In this embodiment the underside  75  may be secured to bag  10  in various ways, although the use of velcro to secure the undersurface  75  to the bag  10  would be preferred. In this embodiment there is no direct contact between any portion of the bulk bag underside  18  and the surface upon which the bag rests. Also, depending of the rigidity of the underside  75 , the bag would be more secure along its base with such an underside  75  in place across the entire underside  18  of the bag  10 . 
   Turning now to  FIGS. 6 and 7 , in these Figures, the bulk bag  10 , which incorporates the bulk space  70  along its underside  18  would be of the type having an opening  22  in its underside  18  for allowing bulk within the bag  10  to be released from the bag  10 . In  FIG. 6 , the underside  18  simply has the opening  22  exposed to the surface upon which it rests, between the two sleeves  24 . In  FIG. 7 , however, there is provided a cover  80  which can be attached along the two sleeves  24 , again through any means, although velcro is preferred, so that when in place the cover serves as a protective barrier between opening  22  and the surface. Of course when the product within the bag  10  is ready to be released, cover  80  is simply pulled away, as illustrated in  FIG. 7 , and the opening  22  is opened and bulk flows from the bag  10 . 
     FIGS. 8 and 9  illustrate two embodiments of a prior art pallet portion  90  which may be utilized with the present invention. As illustrated, the pallet  90  includes the two spaced apart support members  32 , with the undersurface  76  secured therebetween, on their lower ends, to define the pallet  90  to be used with the bulk bag of the present invention. Because the undersurface  76  is on the lower ends of the support members  32 , there is defined a void  94  therebetween which would be filled with the bulk space  70 , when that space is filled with bulk. Therefore, together, the two support members  32 , and the bulk space  70 , filling the void  100 , and resting on undersurface  76  would provide a bulkbag/pallet combination  96  which would be very stable. The only difference between the two embodiments of the pallet  90  shown in  FIGS. 8 and 9 , is that the embodiment in  FIG. 8  illustrates the pallet  90  with a central opening  92  which would be aligned with the opening  22  in the underside  18  in bulk bag  10  to allow bulk to flow therethrough when the downspout is released and bulk flows.  FIG. 9  illustrates an embodiment that would be utilized with a bulk bag having no opening in its bottom wall  18 , and therefore, eliminating the need for an opening in pallet undersurface  76 . 
   As seen in  FIG. 10 , there is represented a plurality of the bulk bags  10  of the present invention stacked upon one another. The pair of lower bags  10  represent the embodiment where the support members  32  secured within the sleeves  24 , and the bulk space  70  filled with bulk to define a continuous support underside  75  upon which the bags  10  rest. The pair of upper bags  10 , resting on lower bags  10 , represent the embodiment utilizing the integrated combination of bulk bag and pallet feature; that is, with the bulk bag  10  secured upon a, pallet  90 , which is not integrated as part of bag  10 , but which, when the bulk has filled bulk space  70 , allows the bag  10  to rest on pallet  90 , with the bulk space  70  nested between support members  32 , and undersurface  76  extending between the members  32 , to define a solid base upon which the upper bags  10  are supported. 
   For purposes of construction, the support members  32  would be injection molded high density polyethylene (HDPE), or be formed of some other suitable, equivalent material, but in each case sufficiently strong to support the weight of a filled bulk bag, yet geometrically shaped to strengthen the members  32  against deflection; and each side wall have a 10 degree angle to strengthen the walls against uneven floors. Also, the corners of each of the members  32  are rounded to allow the members  32  to easily inserted into sleeves  24  without snagging the fabric. The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims. 
     FIGS. 11 through 23  illustrate additional preferred embodiments of the container system of the present invention as illustrated by the numeral  110 . As illustrated in the figures, there is depicted a bulk bag  111  having a floor portion  112  of a bulk bag  111 , of the type as described in  FIGS. 1 through 10 , having a top portion  113  ( FIG. 17 ), plurality of sidewalls  115 . The floor portion  112  having a drop down portion  114  incorporated therein, positioned between to inserts  32  as was described earlier in  FIGS. 1 through 10 . It should be noted for purposes of construction, the drop down portion  114 , which as illustrated, has a pair of side walls  116 ,  118  and opposing end walls  120 ,  124 , which are stitched to form the rectangular drop down portion  114 . The upper edges  126  of the drop down portion would be stitched to the bottom portion  112  of the bulk bag to define the composite floor portion  112  with the drop down portion  114  incorporated therein, as illustrated. 
   It should be noted that when dry bulk material is delivered into the bulk bag during filling, usually from a spout on the upper wall, the bulk material, of course fills the lower end of the bulk bag, with the drop down portion  114  receiving the bulk initially. As more bulk is poured into the bag, the weight of the bulk tends to force the end walls  120 ,  124  and side walls  116 ,  118  outward, attempting to reform the drop down portion from the rectangular shape as illustrated to a circular shape. When this occurs, the expansion of the side walls  116 ,  118  begin to impinge on the inserts or support members  32 , and cause the members to disorient so that the members  32  are not lying flat. This presents difficulties in the tines of a forklift entering the spaces  35  within the members  32  to lift the bag. Furthermore, an even more difficult problem is that the shorter end walls  120 ,  124  will bulge outwards in the direction of arrows  130 , which causes high stress on the bag&#39;s fabric wall at the point above the stitch line to the drop down portion. This stress will result in a rupture of the bag wall, which, of course, is very undesirable. 
     FIGS. 11 and 12  illustrates one of the means for compensating for this bulging effect, and to reduce the outward bulging of end members  120 ,  124  which would also reduce the great stress on the fabric of the bag bottom  112  and the drop down portion  114 . This means comprises a pair of pleats  134 , which are formed along the sidewalls  116 ,  118  and the floor portion  112  of the drop down portion  114 . The pleats  134 , as formed, and illustrated ir isolated view in  FIG. 12 , take up fabric  135  along the length of the drop down portion  114 , tending to force the end walls  120 ,  124  inward, so that when bulk is poured into the bag  110 , and creates the stresses on the end walls  120 ,  124 , as referred to earlier, the end walls  120 ,  124  will not be forced outwardly to the extent as would occur without the pleats  134 , thus reducing the stress on the fabric of the bag. 
   In order to provide greater strength between the stitched connection between the bag floor portion  112  and the drop down portion  114 , reference is made to  FIG. 13  where there is illustrated a length of reinforced material, known in the industry as webbing  140 , which would be stitched along each end wall  120 ,  124  at the connection between the bag floor  112  and the drop down portion  114 . The ends  142  of the webbing  140  would wrap around to the side walls  116 ,  118  and would terminate along each side wall  116 ,  118 . In this embodiment the webbing  140  would cover only a portion of the end walls  120 ,  124  of the drop down portion  114 . An additional option to reinforce the side walls  116 ,  118  and end walls  120 ,  124  of the drop down portion  114  of the bag, is illustrated in  FIG. 14 . In this configuration, there would be provided a length of webbing  141 , which would be of the same width as the end walls  120 ,  124  of the drop down portion  114 , and would be sewn in place around the entire perimeter walls of the drop down portion  114 , as illustrated. Thus, when bulk material is placed therein, the reinforced webbing  141  would greatly assist in preventing the walls of the drop down portion  114  from bowing outward, and therefore minimizing the stress on the fabric of the bag. 
   Reference is now made to  FIGS. 15 through 17  for a discussion of yet an additional means for preventing or greatly reducing the bulging of the side walls  116 ,  118  of the drop down portion  114 . As illustrated first in  FIG. 15 , a top view of the drop down portion  114  is illustrated before it is sewn into the composite structure  114  that would be sewn to the bag. As illustrated, the two edges  121  of end walls  120 ,  124 , rather than forming a 90 degree angle to the edges  123  of side walls  116 ,  118 , the edges  121  are angulated inward, so that when the edges  121  are sewn to edges  123 , the composite structure, rather than being a rectangular box, as seen in  FIG. 11 , would have the two end walls  120 ,  124  formed in a trapezoid shape, with the two side walls  116 ,  118  brought inward as seen in  FIG. 16 . The result would be that when bulk is poured into the drop down portion  114 , as seen in  FIG. 17 , the side walls  116 ,  118 , forming the trapezoid configuration (seen in phantom view) rather than expand outward and impinge on the two inserts  32 , would move from the position inward (phantom view) to a postion either upright, or slightly bulging, to compensate for the stress caused by the bulk material. This would greatly reduce, if not totally eliminate any impingement of the side walls  116 ,  118  on the inserts, as was described earlier. 
   As seen in  FIG. 18 , there is illustrated a combination of the pleats  134  as described for reducing stress on the side walls  116 ,  118 , as described in  FIGS. 11 and 12 . In addition, there could be included the use of the reinforced webbing  140  along the end walls  120 ,  124 , as seen in  FIG. 13 , or the use of the wider webbing  141  around the entire perimeter of the drop down portion  114 , as seen in  FIG. 14 , when as used together with the trapezoid construction of the drop down portion  114 , as discussed, would define the most secure drop down portion  114 , which is resistant to bulging and deforming under the stress of the bulk within the bag. Of course all of the reinforcement features as discussed could be used in different combinations or independently depending on the requirements for a particular bag and its contents. 
   An additional means for reducing the bulging of the drop down portion  114  after being filled with bulk, is illustrated in  FIG. 23 . In this figure there is illustrated a rectangular box  150 , having sidewalls  152  and end walls  154  to define a space  156  therein. Box  150  would be substantially the same size as the dimensions of the drop down portion  114 . The box  150  would be set beneath the drop down portion  114  when the bag is yet filled. Upon being filled, the drop down portion  114  would expand to the configuration of the walls of the box  150 , but would be prevented from expanding further. When the bag is lifted from the box  150 , although there would be some expansion of the drop down portion  114 , it has been found through tests, that the expansion would be a great deal less than without the box  50 , when poured into a drop down portion  114  that has not been reinforced as described in relation to  FIGS. 11 through 18  above. 
   The final problem which must be addressed is the problem of the drop down portion  114  expanding downward beyond the floor portions of the two inserts  32 . This problem and its solution is discussed in  FIGS. 19 through 22 . In  FIG. 19 , bulk bags  111  are illustrated moving along a roller conveyor  160 . A common problem occurs when the filled bulk bag  111  would be lifted and set upon the conveyor rollers  162  to be moved from one place to the next. The bulge on the bottom of the drop down portion  114  would tend to encounter the rollers  162  and would cause the bag  111  to become lodged and unable to move along the rollers  162 . 
   The solution to this problem is provided in  FIGS. 20 through 22 . What is provided is a substanially rigid member  170 , constructed of hard plastic or the like, which would be of dimensions equal to the length and width of the drop down portion  114 . The member  170  would be secured to the sidewalls  115  of the bag, or walls  116 ,  118  of the drop down portion  114 , with a pair of fabric strands  172 ,  174 , sewn into the bag wall at a first end and threaded through openings  175  in the ends of the member  170  and tied in place. As illustrated, the length of the strands  172 ,  174 , would allow the member  170  to hang a distance below the filled drop down portion  114  when the bag is lifted. When the bag  110  is set in place on roller conveyor  160 , the member  170  would be resting on the conveyor surface, and the drop down portion  114  would rest on the inner face of the member  170 , making no contact with the conveyor surface. Therefore, together with the lower surfaces of the inserts  32  and the lower surface of the member  170 , the bag  111  would be resting on a flat, smooth surface and would move easily along the conveyor surface. Each bag would have such a member  170  attached; therefore, there would be no need to manually place such a member  170  beneath each bag, as each bag is set in place on the conveyor  160 . Furthermore, the member  170  would define a means to provide a barrier between the lower end of the bag and the surfaces upon which the bag would rest during transport and storage. This would prevent contamination of the bag contents, and would further provide a lower surface, defined by the two inserts and the member  170  upon which the bag rests. It has been shown that this under surface provides an almost “tripod” lower end which would more easily conform to an irregular surface, since each component; i.e., the two inserts  32  and the drop down portion  114  is acting apart from the other components and would allow greater stability of the bag when placed upon another bag. 
   As illustrated in  FIG. 22 , when the contents of the bag are ready to be removed via the downspout  177 , two of the strands  172 ,  174  would be untied from one end of the member  170 , and the member  170  would swing away from the bottom of the bag (arrow  179 ) to allow access to the downspout to release the bag contents  180 . When the bag is empty, the member  170  could returned to its full protective mode. 
   It is foreseen that the system as discussed in relation to  FIGS. 1 through 22  provide a complete system for supporting and transporting bulk bags. It should be noted that the bulk bag  110  as illustrated in  FIG. 17 , has no lifting loops as would a conventional bulk bag  110 . In the preferred system, there would be no use of lifting loops. The use of inserts  32  together with the drop down portion  114 , as illustrated, allows the bag to be moved easily and to be set upon a surface or upon other bags, as the case may be. The carrier system as described, including the pair of inserts  32 , and the manner in which the drop down portion is reinforced to maintain its rectangular configuration would define the single system of lifting and transporting the bulk bags in the system. 
   PARTS LIST 
   The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention. 
   
     
       
             
             
             
           
         
             
                 
                 
             
             
                 
               Part No. 
               Description 
             
             
                 
                 
             
           
           
             
                 
                10 
               Fabric bulk bag 
             
             
                 
                14 
               Top wall 
             
             
                 
                16 
               Side wall 
             
             
                 
                18 
               Bottom wall or underside 
             
             
                 
                20 
               Bag space 
             
             
                 
                22 
               Opening 
             
             
                 
                24 
               Fabric sleeves 
             
             
                 
                25 
               Edges 
             
             
                 
                26 
               Opening 
             
             
                 
                28, 30 
               Ends 
             
             
                 
                32 
               Support member 
             
             
                 
                34, 36 
               Ends 
             
             
                 
                35 
               Opening 
             
             
                 
                70 
               Bulk containing space 
             
             
                 
                71 
               Bulk 
             
             
                 
                72 
               Lower surface 
             
             
                 
                75 
               Underside 
             
             
                 
                76 
               Undersurface 
             
             
                 
                77 
               Ties 
             
             
                 
                80 
               Cover 
             
             
                 
                90 
               Pallet portion 
             
             
                 
                92 
               Central opening 
             
             
                 
                94 
               Void 
             
             
                 
                96 
               Bulk bag/pallet combination 
             
             
                 
               110 
               container system 
             
             
                 
               111 
               bulk bag 
             
             
                 
               112 
               floor portion 
             
             
                 
               113 
               top portion 
             
             
                 
               114 
               drop down portion 
             
             
                 
               115 
               side walls 
             
             
                 
               116, 118 
               side walls 
             
             
                 
               120, 124 
               end walls 
             
             
                 
               121, 123 
               edges 
             
             
                 
               126 
               upper edges 
             
             
                 
               130 
               arrows 
             
             
                 
               134 
               pleats 
             
             
                 
               135 
               fabric 
             
             
                 
               140 
               webbing 
             
             
                 
               141 
               webbing 
             
             
                 
               142 
               ends 
             
             
                 
               150 
               rectangular box 
             
             
                 
               152 
               side walls 
             
             
                 
               154 
               end walls 
             
             
                 
               156 
               space 
             
             
                 
               160 
               roller conveyor 
             
             
                 
               162 
               rollers 
             
             
                 
               170 
               rigid member 
             
             
                 
               172, 174 
               fabric strands 
             
             
                 
               175 
               openings 
             
             
                 
               177 
               down spout 
             
             
                 
               179 
               arrow

Technology Category: 7