BULK MATERIAL HANDLING SYSTEM AND APPARATUS Applicant hereby claims priority benefits under 35 U.S. C. § 119(e) of U.S. Provisional Patent Application No. 60/782,800 filed March 16, 2006, the disclosure of which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Technical Field

[0001] The present invention relates to bulk material handling systems in general, and to bulk material handling systems that utilize collapsible containers in particular.

2. Background Information

[0002] Bulk material handling systems that can be used in an outdoor environment and carted by road have historically included a rigid bulk container such as a truck body, a dumpster, or the like. Dumpsters are often delivered to a construction site by truck and subsequently retrieved by truck when filled with debris. In some instances, raw materials such as sand and stone are delivered by dumpster. In all cases, the cost of using the dumpster necessarily includes the cost of trucking the dumpster to and from the job site. Water can also be delivered in bulk, but requires a bulk container for storage at the destination.

[0003] Rigid bulk containers must be stored before and after use by the service provider and during use by the end-user. Because of the size and weight of the container, the end-user must accept the location of the bulk container after it has been delivered, or incur the cost and inconvenience of having heavy equipment move the container. In addition, the area where a bulk container can be used is limited because the container must be truck accessible for loading and unloading, or the ground surface adjacent the container must be such that the container can be rolled or dragged to the truck. [0004] Some local governments and residential associations (e.g., condominium associations, neighborhood associations, etc.) either prohibit the use of rigid bulk containers, or restrict the size of the rigid bulk container that can be used. [0005] What is needed is a bulk material handling system that does not require a truck to both deliver and remove the bulk material container, a bulk material container

that is easy to handle and move, one that does not require close access by truck, and one that can be used in place of existing rigid bulk material containers.

DISCLOSURE OF THE INVENTION

[0006] According to the present invention, a system for handling bulk material is provided that includes one or more collapsible bags and a vehicle operable to lift and transport the collapsible bags. The bags have a side wall with a height extending between a first end and a second end, a bottom panel attached to the first end of the side wall, an opening formed by the second end of the side wall, and at least one handling member attached to the side wall adjacent the opening.

[0007] According further to the present invention, a method for handling bulk material between a first site and a second site, which sites are physically remote from one another, is provided that includes the steps of: a) providing a collapsible bag having at least one handling member attached to the side wall adjacent the opening; b) filling the collapsible bag with a bulk material; c) providing a vehicle operable to transport and lift the collapsible bag using the handling member; and d) transporting the collapsible bag containing the bulk material from the first to the second site.

[0008] An advantage of the present invention is that it eliminates the need for a rigid bulk container and the disadvantages associated therewith. Rigid bulk containers must be trucked to and from the site where they are used, thereby incurring significant cost to and from. Rigid bulk containers also must be stored on site during use. Many sites are limited in space and cannot accept, or do not permit the use of rigid bulk containers. If it is feasible to use a bulk container, many times the available size containers do not coincide with the need of the end-user. The collapsible bag used with the present system and method avoids these problems by not requiring trucking to and from, limiting the storage space necessary, and offering a variety of sizes that will undoubtedly fit a large number of applications.

[0009] Another advantage of the present invention is that it provides a system and method that can be used to expeditiously deliver materials that are not typically delivered in bulk form, but can be as the need arises (e.g., disaster relief materials). The present system and method can be used to deliver water in bulk, for example, and at the same

time provide a portable storage container that can be used where fixed size storage containers are unavailable.

[0010] These and other objects, features and advantages of the present invention will become apparent in light of the detailed description of the invention provided below, and as illustrated in the accompanying drawings.

BRIEF DESCRIP TION OF THE DRAWINGS

[0011] FIG. 1 is a diagrammatic view of a collapsible bag embodiment.

[0012] FIG. 2 is a diagrammatic view of a collapsible bag embodiment.

[0013] FIG. 3 is a diagrammatic sectioned view of a collapsible bag embodiment.

[0014] FIG. 4 is a diagrammatic view of a vehicle that can be used to lift and transport collapsible bags within the present system and method.

[0015] FIG. 5 is a diagrammatic view of a vehicle that can be used to lift and transport collapsible bags within the present system and method.

[0016] FIG. 6 is a diagrammatic view of a vehicle that can be used to lift and transport collapsible bags within the present system and method.

DETAILED DESCRIPTION OF THE INVENTION

[0017] Referring to FIGS. 1-6, a system and method for handling bulk material is provided that includes an ordering system, a collapsible bag 10 and an over-the-road vehicle 34 operable to lift and transport the collapsible bag 10 containing bulk material between a first site and a second site remote from one another.

[0018] Referring to FIGS. 1-3, the collapsible bag 10 includes a side wall 12, a plurality of support members 14, and a bottom wall 16. The bottom wall 16 is directly or indirectly attached to the side wall 12, and possesses sufficient mechanical strength so that the collapsible bag 10 is not intended to be used with a structural member (e.g., pallet) adjacent the bottom wall 16 to enable lifting. An interior volume, which is defined by the side wall 12 and bottom wall 16, is created when the collapsible bag 10 is disposed in an open configuration. The collapsible bag 10 can be made from a variety of different materials that are sufficiently flexible to permit the bag 10 to be collapsed from

the open configuration to a closed configuration. In the closed configuration, the interior volume of the bag 10 is substantially zero.

[0019] The side wall 12 has a height 18 that extends between a bottom end 20 and an open end 22, and a plurality of support member stations 24. The side wall 12 can assume numerous configurations (e.g., a continuously extending panel, or a side wall including a plurality of panels).

[0020] Referring to FIG.3, in some embodiments, the collapsible bag 10 has a funnel geometry wherein the cross-sectional area of the bottom end 20 of the bag 10 is less than the cross-sectional area of the open end 22 of the bag 10. The funnel geometry can be created, for example, by skewing at least a pair of opposing side walls 12 (or portions of side wall 12, opposing support member stations 24, etc.) outwardly from a plane 26 extending substantially perpendicular to the bottom wall 16 (e.g., the side walls 12 are skewed by an angle (e.g., "α") from the plane 26 perpendicular to the bottom wall 16, so that the side wall 12 portions extend away from one another when traveling in a direction toward the open end 22). The angle(s) at which the side wall 12 portions extend away from the perpendicular plane 26 and away from each other is preferably sufficient to cause weight of the side wall 12 portions to maintain the open configuration. The funnel geometry helps to keep the collapsible bag 10 in the open configuration when empty and when not completely full of material.

[0021] In some embodiments, the collapsible bag 10 may include one or more support straps 28 attached to the side wall 12, extending around the side wall 12, and/or attached to the bottom wall 16 for support. The straps 28 may be fixed to the side wall 12 or bottom wall 16, or may be attachable to the side wall 12 or bottom wall 16. In those embodiments having reinforcement in the bottom wall 16, the support strap 28 may be stitched to the bottom wall 16 in the form of an "X". Other support strap configurations can be used alternatively. In some embodiments, the stitching itself may be sufficient to create a support strap feature.

[0022] In some embodiments, the collapsible bag 10 side wall 12 has a height 18 that is specifically chosen to give the bag 10 a low profile that provides added stability to the bag 10. The increased stability of bag 10 decreases the chance that a filled collapsible container will tip over during transit. At present, most bulk materials bags (e.g., those

disclosed in U.S. patent Nos. 6,415,927; 6,394,277; and 6,328,470) have a high profile in which the vertical height of the bag is greater than the width of the bag. A filled bulk bag with a high profile has a center of gravity that is greater than one of similar size with a low profile. Hence, the low profile collapsible bag 10 possesses greater stability relative to the high profile bag. In the low profile embodiments, the collapsible bag 10 has a height 18 that is approximately equal to or less than the width 30 of the bag 10. [0023] The bag 10 embodiments having greater stability also facilitate loading.

Existing bulk material bags are typically designed to be filled by an automated process that utilizes a relatively narrow, constant sized inlet into the bulk material bag (e.g., existing bulk material bags typically have a side wall height greater than width of the bag). The embodiments of the present invention bag 10 that have a side wall height 18 that is equal to or less than the width 30 of the bag 10 provide a greater opening through which the bag 10 can be filled. The larger size opening also enables the collapsible bag 10 to receive larger sized elements (e.g., construction debris, etc.). [0024] Each support member station 24 includes a mechanism that is operable to attach at least one support member 14 to the side wall 12. The term "attach" is used here to indicate that the support member 14 is joined with the side wall 12 in any manner that enables the support member 14 to provide support to the side wall 12. In some embodiments, a support member station 24 is pocket sized to receive a support member 14. In another embodiment, a support member station 24 is a side wall section or independent panel that includes fasteners (e.g., straps, ties, Velcro® brand hook and loop fasteners, snaps, etc.) for attaching a support member 14. Depending on the type of fastener used, the support member 14 may have a first fastener portion that mates with a second fastener portion connected to the side wall 12. The manner in which the support member 14 is attached to the support member station 24 can vary depending upon the application at hand (e.g., a collapsible bag 10 with support members 14 attached to the inner surface of the bag 10 side wall protects the side wall of the collapsible bag 10). [0025] The support members 14 are substantially rigid members that are attachable to the support member stations 24. Each support member 14 may be a one- piece unit, or alternatively it may include several pieces that collectively form the support member 14. The support members 14 can be configured to have a length that is

substantially equal to the height 18 of the side wall 12. The support members 14 can be made from a variety of different materials, and are therefore not limited to any particular material. Corrugated plastic is an example of an acceptable material for the support members 14.

[0026] The collapsible bag 10 can be offered in a variety of different geometries.

In a preferred embodiment, the support members 14 are provided having uniform geometries so that the same support members 14 can be used for all or nearly all of the different size collapsible bags 10. The various size bags 10 use multiple numbers of the same type of support member 14. Using the same support members 14 for all, or nearly all, of the different size bags 10 facilitates bag design and use, and decreases cost. [0027] Preferred embodiments of the collapsible bag 10 include at least one handling member 32 disposed adjacent the open end 22 of the collapsible bag 10. The handling member 32 permits the collapsible bag 10 to be connected to a mechanism for lifting or otherwise moving the collapsible bag 10. The collapsible bag 10 embodiment shown in FIGS. 1 and 2, includes multiple handling members 32 in the form of lift loops attached to the side wall 12. The lift loops form an orifice large enough to receive a strap or hook that is, for example, attached to a lifting mechanism. The lift loops may be fabricated from a variety of different materials (e.g., bag material loops, metal rings, polymer rings, etc.).

[0028] The collapsible bag 10 may also include one or more handling members

32 attached to the side wall 12 or bottom wall 16, adjacent the intersection of the bottom wall 16 and side wall 12. The collapsible bag 10 embodiment shown in FIGS. 1 and 2, includes multiple handling members 32 in the form of lift loops attached to the side wall 12, adjacent the bottom wall 16. As will be discussed below, the handling members 32 disposed adjacent the bottom wall 16 facilitate emptying the collapsible bag 10. [0029] The collapsible bag 10 is not limited to having any particular interior volume. Indeed, one of the advantages of the present system is that it can be used with a variety of different size collapsible bags 10. Preferably, the collapsible bag 10 has a number of different embodiments each with a different interior volume (e.g., 1, 2, 3, 4, 5, 6, etc. cubic yards). A variety of different size bags 10 enables the end-user to select the bag 10 best suited to the job at hand.

[0030] The collapsible bag 10 may be used with any type of over-the-road vehicle

34 or trailer capable of carrying the full collapsible bag 10. In one embodiment, a truck having a bed and a boom crane (e.g., an articulated boom, knuckle boom, etc.) is used to pick up filled collapsible bags 10. In another embodiment, the "bed" of the truck may be a roll-off box (e.g., a dumpster). In still another embodiment, a trailer can be used. The trailer itself may have a crane, or it may be used with a truck that has a crane. A cable drawn from the crane is attached directly or indirectly to the handling members 32. The collapsible bag 10 is lifted, placed on the bed of the truck (or trailer), and carted away. Preferably, the vehicle 34 can carry multiple filled collapsible bags 10. The invention is not limited to any particular type of vehicle 34. Once the filled collapsible bags 10 are brought to their destination, the bags 10 are off-loaded from the truck (and/or trailer). Each bag 10 can be emptied by attaching the cable to one or more of the handling members 32 disposed adjacent the bottom wall 16 and subsequently tipping the bag 10 upside down.

[0031] The ordering system includes bag delivery, customer communications, and bag retrieval. Regarding bag delivery, the collapsible bag 10 may be "delivered" to the end-user in a variety of different ways. For example, the collapsible bag 10 may be offered at public facilities (e.g., hardware store, lumber yard, refuse collection facility, etc.) where the end-user may select the collapsible bag 10 most appropriate for the job at hand. Alternatively, the end-user may order a bag 10 by contacting the provider via mail, telephone, e-mail, internet website, etc. Once the order is placed, the provider can send the collapsible bag(s) 10 to the end-user via mail or other carrier or the end-user can pick up the bag 10 at a predetermined destination. In applications where the end-user regularly utilizes collapsible bags 10, the provider may ship bags 10 to the end-user on a routine basis.

[0032] The collapsible bag 10 is typically delivered in a folded configuration with at least some of the support members 14 not attached to the bag 10. The support members 14 are provided with the bag 10 for later attachment.

[0033] When the collapsible bag 10 is needed, the end-user takes the folded bag

10 to the location desired, unfolds the bag 10 and attaches the support members 14 in the appropriate support member stations 24. In those embodiments that have multiple

support member 14 configurations, the different support members 14 may be labeled regarding the support member station 24 where they should be attached, hi those embodiments where the support members 14 have uniform geometries, it is not necessary to label the specific location where each particular support member 14 must be attached. Once the collapsible bag 10 is set up, the bulk materials can be deposited within the bag 10. Preferably, the bag 10 is located where it can be accessed by the vehicle 34. If not, the bag 10 can be moved where it can be accessed.

[0034] The customer communications portion of the ordering system provides one or more mechanisms by which the end-user can request pick-up of the filled collapsible bags 10. For example, the end-user may telephone or e-mail the provider and request a pick-up. Alternatively, the provider may have an interactive internet website that allows the end-user to submit a pick-up request and/or a request for additional collapsible bags 10. In each of these alternatives, the provider may solicit information from the end-user regarding the contents of the collapsible bags 10. For example, for those applications where the end-user is using the bags 10 to dispose of waste or environmental materials, the provider may solicit information regarding the nature of the waste material (e.g., mixed debris, concrete, metal, brush, etc.) or the environmental material (contaminated soil, spilled chemicals, etc.) Content information will enable the provider to more efficiently handle the materials, and may also have a bearing on the cost of disposing of the bulk materials.

[0035] Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and the scope of the invention. For example, the invention has been described above in terms of a system for handling bulk material that includes an ordering system, a collapsible bag 10 and a vehicle 34 operable to lift and transport the collapsible bag containing bulk material between a first site and a second site remote from one another. In alternative embodiments, the present invention system can be utilized by bulk material businesses to deliver bulk material. A company that sells exterior products such as gravel, sand, landscaping materials, etc., for example, can use the present invention system to deliver products in manner that is advantageous for the end-user. For those jobs that require a

certain amount of one exterior product and a certain amount of another exterior product separate from one another (e.g., stone and mulch), the company can provide each material in a collapsible bag 10. Delivery of the materials in this manner keeps the materials separate and eliminates having the materials dumped onto the property and the mess and contamination associated therewith.

[0036] In addition, the present bulk material handling system can also be used to efficiently deliver materials that are not typically delivered in bulk form, but can be as the need arises. For example, the present system can be used to deliver bulk quantities of water and relief goods as part of a disaster relief program. Large volumes of water can be loaded into sealable collapsible bags 10. The bags 10 can then be delivered and accessed upon demand. If the entire volume of water is not used immediately, the bag 10 can be resealed and stored for later use. The present system advantageously allows the water to be delivered to places not typically accessed by traditional water sources, and stored where there is no large volume liquid container available. Likewise, relief goods can be distributed in areas of need in a collapsible bag 10 that facilitates handling such goods. In both instances, the collapsible bags 10 can be folded when the materials are removed from the bag 10 and either disposed of properly or reused. [0037] What is claimed is: