Note: Descriptions are shown in the official language in which they were submitted.
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SYSTEMS AND METHODS FOR PACKAGING AND
TRANSPORTING BULK MATERIALS
Cross-Reference to Related Application
[1001] This application is a continuation-in-part of U.S. Patent
Application No.
13/367,911, entitled "Systems and Methods for Packaging and Transporting Bulk
Materials,"
filed February 7, 2012, which claims priority to U.K. Patent Application No.
1115601.5,
entitled "Transport of Granular Materials," filed September 9, 2011 and U.S.
Provisional
Patent Application No. 61/440,202, entitled "Containerized Coal," filed
February 7, 2011, the
disclosure of each of which is incorporated herein by reference in its
entirety. This
application also claims priority to U.S. Provisional Patent Application No.
61/644,166,
entitled "Systems and Methods for Packaging and Transporting Bulk Materials,"
filed May 8,
2012, the disclosure of which is incorporated herein by reference in its
entirety.
Background
[1002] The embodiments described herein relate to systems and methods for
packaging
and transporting a bulk material. More particularly, the embodiments described
herein relate
to systems and methods for packaging and transporting coal within a flexible
container.
[1003] Recent reports indicate that the United States has about 263,781
billion tons of
recoverable coal. Yet, surprisingly, the U.S. exports only approximately 90
million tons per
year. In contrast, Russia exports 116 million tons per year out of its
estimated 173,074
billion tons of recoverable coal, and Australia exports 259 million tons per
year even though
it is estimated to have only one-third of the recoverable tons of the United
States (84,437
billion tons).
[1004] One reason why the U.S. exports so little coal is because known
transportation
facilities and methods limit the ability to ship coal. According to known
methods, coal is
transported in its raw form via bulk carrier vessels (for intercontinental
transport), and via
open rail cars, barges, slurry pipelines and trucks (for intra-continental
transport).
Numerous factors limit the capacity of such transport means, including the
lack of suitable
deep draught ports and limited availability of coal handling facilities that
can handle
hazardous materials.
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[1005] Known bulk transport processes utilized in the United States and
other coal
producing countries are also inefficient and environmentally unsound. In
particular, after
extraction, coal is typically loaded onto open trucks using construction
equipment and
conveyor systems, and then transported to a railhead. At the railhead, the
coal is unloaded
and stored outdoors in large open piles until further transport is arranged at
a later point in
time. When further transport is scheduled, the coal is reloaded onto available
trains,
typically in open, bulk rail cars.
[1006] When coal is destined for overseas locations, such as Asia, it is
conveyed by rail
car to ports that can handle bulk materials. According to known methods, at
these ports,
coal is unloaded and stored outdoors in large open piles until it is scheduled
for loading on a
vessel. Once a vessel arrives for transporting the coal, the coal is loaded
onto one or more
bulk holds of the vessel. Once the vessel arrives at its destination port, the
coal is unloaded,
stored and reloaded for further transport by land or rail to the generating
plant or another
end user. At the generating plant, the coal is again unloaded and stored
outdoors in a large
open pile, where it remains until it is needed. Thus, at multiple stages
during known
methods of transportation, coal is loaded, unloaded, stored, and reloaded.
This repetitive
loading, unloading, storage and re-loading of bulk material is highly
inefficient.
[1007] Further, at each stage in the transportation process, coal is
exposed to air and
earth. Such practices are environmentally unsound, as coal dust is
environmentally
hazardous. Moreover, highly acidic materials can leach from storage piles into
nearby
aquifers. In addition, product is lost to the effects of wind and rain, having
a negative
economic impact.
[1008] The lack of deep-water ports can also be a limiting factor in the
export of coal
using known methods. For example, there are a limited number of deep-water
ports
throughout the U.S., particularly the west coast. Although most all U.S. ports
can typically
accommodate bulk vessels of the Handy class, which typically have a capacity
in the range
of 35-40,000 tons, most U.S. ports cannot accommodate larger bulk transport
ships vessels.
For example, most U.S. ports cannot accommodate large draught vessels, such as
Panamax
vessels (with a capacity in the range of 60-80,000 tons) and Cape vessels
(with a capacity of
100-150,000 or more tons). While many west coast ports are seeking to expand
their ability
to accommodate larger bulk ships, these efforts have been delayed or prevented
by cost,
environmental laws and regulations, and community-based concerns. As a result,
coal
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suppliers and exporters have had no choice but to incur the high costs
associated with
transport via Handy sized vessels through busy ports, shipping via Canadian
ports or
topping off in Canadian and other country's ports.
[1009] Until recently, Asian countries have been supplied with the majority
of their coal
requirements from China, Australia, Indonesia, South Africa and Russia.
Because China
has now become a net importer of coal, however, there is increased demand for
large bulk
carrier capabilities, and several port initiatives have been undertaken to
address these
deficiencies. Unfortunately, these initiatives, which are often related to
changes in the
infrastructure related to shipping, are costly, long-term projects that are
facing increasing
local and national concerns over the environmental impact of current handling
and transport
methods for coal.
[1010] Known bulk transport methods are also limited in their ability to
deliver different
grades of material, including value-added forms of coal, such as processed
coal.
Specifically, when transported by bulk carrier according to known methods, it
is difficult to
segregate materials, and to maintain their quality. While bulk transport
methods may be
acceptable for transport of raw coal, they are often not adequate for
transport of a variety of
forms of processed coal to multiple end users, except by inclusion in
fluidized beds or
pipelines. However, fluidized beds and pipelines are expensive to construct,
maintain and/or
utilize.
[1011] Although intermodal containerization of goods has made
transportation of
goods significantly more efficient than other transportation methods, bulk
commodities,
such as coal, have not been able to benefit from the intermodal containerized
transport
systems for a variety of reasons. For example, one such reason is that coal is
subject to
spontaneous combustion when exposed to air and pressure. Thus, shipping coal
by
container according to known systems and methods can increase the likelihood
of
spontaneous combustion.
[1012] Thus a need exists for improved systems and methods packaging and
transporting
a bulk material.
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Summary
[1013] Apparatus, systems, and methods for housing a bulk material within a
flexible
container are described herein. In some embodiments, a method includes
maintaining a
flexible container in an expanded configuration to define an interior volume.
A bulk material
is conveyed into the interior volume of the expanded flexible container. The
flexible
container is then moved from the expanded configuration to a collapsed
configuration, such
that movement of the bulk material within the interior volume is limited.
Brief Description of the Drawings
[1014] FIG. 1 is a schematic illustration of a flexible container,
according to an
embodiment in an expanded configuration while being filled with a bulk
material.
[1015] FIG. 2 is a schematic illustration of the flexible container of FIG.
1, in the
expanded configuration.
[1016] FIG. 3 is a schematic illustration of the flexible container of FIG.
1, in a collapsed
configuration.
[1017] FIGS. 4 and 5 are schematic illustrations of a flexible container
according to an
embodiment, in first configuration and a second configuration, respectively.
[1018] FIGS. 6A-6C are perspective views of flexible containers, according
to various
embodiments.
[1019] FIG. 7 is a front view of a portion of the flexible container of
FIG. 6A.
[1020] FIG. 8 is a front view of a bulkhead included in the flexible
container of FIG. 6A.
[1021] FIG. 9 is an illustration of a label included in the bulkhead of
FIG. 8.
[1022] FIG. 10 is a rear view of the flexible container of FIG. 6A.
[1023] FIG. 11 is a side view of the flexible container of FIG. 6A.
[1024] FIG. 12 is a front view of a portion of the flexible container of
FIG. 6A.
[1025] FIG. 13 is a bottom view of the flexible container of FIG. 6A.
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[1026] FIG. 14 is a schematic illustration of a device for packaging and/or
shaping a
flexible container, according to an embodiment.
[1027] FIG. 15 is a perspective view of a container, according to an
embodiment.
[1028] FIG. 16 is a top perspective view of a container, according to an
embodiment.
[1029] FIG. 17 is a bottom perspective view of a container, according to an
embodiment.
[1030] FIG. 18 is a bottom perspective view of a container, according to an
embodiment.
[1031] FIG. 19 is a perspective view of a container, according to an
embodiment.
[1032] FIG. 20 is a schematic illustration of a valve assembly included in
a flexible
container, according to an embodiment.
[1033] FIG. 21 is a perspective view of a sliding hatch and release
mechanism included
in a container, according to an embodiment.
[1034] FIG. 22 is a perspective view of a loading and unloading device
included in the
container of FIG. 21.
[1035] FIGS. 23A-23C are flow charts illustrating methods for storing and
transporting a
bulk material, according to various embodiments.
[1036] FIG. 24 is a flowchart illustrating a method for transporting a bulk
material,
according to an embodiment.
[1037] FIG. 25 is a perspective view of a flexible container, according to
an embodiment.
[1038] FIGS. 26 ¨ 28 are schematic illustrations of flexible containers
with buffer ribs,
according to various embodiments.
Detailed Description
[1039] Apparatus, systems, and methods for housing a bulk material within a
flexible
container are described herein. In some embodiments, a flexible container
includes a
container body and a flexible cover. The container body defines an interior
volume and
includes a side wall that defines an opening. The opening is configured to
receive a bulk
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material therethrough such that the bulk material can be disposed within an
interior volume of
the container body. In some embodiments, for example, the opening can have a
non-circular
shape to accommodate a delivery member, such as a coal conveyer. The flexible
cover can
be coupled to the side wall about the opening. The cover is configured to
fluidically isolate
the interior volume from a volume substantially outside of the flexible
container.
[1040] In some embodiments, a method includes maintaining a flexible
container in an
expanded configuration to define an interior volume. A bulk material is
conveyed into the
interior volume of the expanded flexible container. The flexible container is
then moved
from the expanded configuration to a collapsed configuration, such that
movement of the
bulk material within the interior volume is limited. For example, moving the
flexible
container into the collapsed configuration can include reducing the head space
of the
container such that movement of a first portion of the bulk material relative
to a second
portion of the bulk material is impeded.
[1041] In some embodiments, a flexible container includes a first portion,
constructed
from a first material, and a second portion, constructed from a second
material. The flexible
container defines an interior volume and is placed in an expanded
configuration when the
interior volume receives a bulk material, such as, for example raw or
processed coal. The
flexible container is configured to be moved from the expanded configuration
to a collapsed
configuration when the bulk material is disposed within the interior volume
via a reduction in
pressure within the interior volume. The first portion is configured to deform
a first amount
when the flexible container is moved from the expanded configuration to the
collapsed
configuration. The second portion is configured to deform a second amount,
substantially
different than the first amount.
[1042] In some embodiments, a system includes a rigid shipping container
and a flexible
container configured to be coupled within the rigid shipping container. The
flexible container
defines an interior volume and can be placed in an expanded configuration when
the interior
volume receives a bulk material. The flexible container is configured to be
moved from the
expanded configuration to a collapsed configuration when the bulk material is
disposed
within the interior volume via a reduction in pressure within the interior
volume. The system
further includes at least one flexible tether configured to anchor the
flexible container within
the rigid shipping container to form the system. The system is devoid of a
dunnage bag
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and/or a bulwark. Similarly stated, the bulk material can be coupled within
the rigid shipping
container solely via the at least one flexible tether.
[1043] In some embodiments, a method includes disposing a flexible
container within a
rigid container. The flexible container is magnetically coupled to the rigid
container, such
that an interior volume is defined within the flexible container. A bulk
material is conveyed
into the expanded interior volume of the flexible container. The pressure
within the interior
volume can be reduced, such that a pressure differential between the interior
volume and a
volume outside the interior volume overcomes the magnetic coupling. In some
embodiments,
when the flexible container is decoupled from the rigid container, the
interior volume of the
flexible container can define a collapsed interior volume. In some
embodiments, the pressure
within the interior volume can be reduced to eliminate substantially all head
space between
the bulk material and the flexible container, such that the volume of the
flexible container is
approximately equal to the volume of the bulk material.
[1044] In some embodiments, a flexible container having a magnetic portion
can be
magnetically coupled to a side wall of a rigid shipping container, to define
an interior volume
within the flexible container. The interior of the flexible container can, for
example, have a
volume and/or shape approximately equal to the interior volume of the rigid
shipping
container when the flexible container is magnetically coupled thereto. A bulk
material can be
conveyed into the interior volume of the flexible container. The flexible
container can be
moved from an expanded configuration to a collapsed configuration by
decoupling the
magnetic portion of the flexible container from the rigid shipping container.
When
decoupled, the magnetic portion of the flexible container can be spaced apart
from the side
wall of the rigid shipping container.
[1045] In some embodiments, a system includes a rigid shipping container
and a flexible
container configured to be coupled within the rigid shipping container. The
flexible container
defines an interior volume and can be placed in an expanded configuration when
the interior
volume receives a bulk material. The flexible container is configured to be
moved from the
expanded configuration to a collapsed configuration when the bulk material is
disposed
within the interior volume via a reduction in pressure within the interior
volume. The system
further includes at least one tether including a first portion and a second
portion. The first
portion is configured to be coupled to the flexible container. The second
portion is
configured to be coupled to the rigid shipping container. The tether defines a
length
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configured to change when the flexible container is moved between the expanded
configuration and the collapsed configuration.
[1046] In some embodiments, a method includes conveying a bulk material
into an
interior volume of a flexible container via an opening defined by the flexible
container. The
method further includes coupling a cover about the opening to fluidically
isolate the interior
volume from a volume outside the flexible container. The method further
includes reducing
the pressure within the interior volume after the cover is coupled to the
flexible material to
move the flexible container into a collapsed configuration. In this manner,
the bulk material
and the flexible container can collectively form a substantially solid body
that can be handled
and/or shipped.
[1047] As used herein, the term "flexible" and/or "flexibility" relates to
an object's
tendency towards deflection, deformation, and/or displacement under an applied
force. For
example, a material with a greater flexibility is more likely to deflect,
deform and/or be
displaced when exposed to a force than a material having a lower flexibility.
Similarly
stated, a material having a higher degree of flexibility can be characterized
as being less rigid
than a material having a lower degree of flexibility. Flexibility can be
characterized in terms
of the amount of force applied to the object and the resulting distance
through which a first
portion of the object deflects, deforms, and/or displaces with respect to a
second portion of
the object. In certain situations, this can be depicted graphically as a
stress-strain curve.
When characterizing the flexibility of an object, the deflected distance may
be measured as
the deflection of a portion of the object different than the portion of the
object to which the
force is directly applied. Said another way, in some objects, the point of
deflection is distinct
from the point where force is applied.
[1048] Flexibility is an extensive property of the object being described,
and thus is
dependent upon the material from which the object is formed and certain
physical
characteristics of the object (e.g., shape of the object, number of plies of
material used to
construct the object, and boundary conditions). For example, the flexibility
of an object can
be increased or decreased by selectively including in the object a material
having a desired
modulus of elasticity, flexural modulus and/or hardness. The modulus of
elasticity is an
intensive property of (i.e., is intrinsic to) the constituent material and
describes an object's
tendency to elastically (i.e., non-permanently) deform in response to an
applied force. A
material having a high modulus of elasticity will not deflect as much as a
material having a
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low modulus of elasticity in the presence of an equally applied force. Thus,
the flexibility of
the object can be increased, for example, by introducing into the object
and/or constructing
the object of a material having a relatively low modulus of elasticity.
[1049] Similarly, the flexural modulus is used to describe the ratio of an
applied stress on
an object in flexure to the corresponding strain in the outermost portions of
the object. The
flexural modulus, rather than the modulus of elasticity, is used to
characterize certain
materials, for example plastics, that do not have material properties that are
substantially
linear over a range of conditions. An object with a first flexural modulus is
more elastic and
has a lower strain on the outermost portions of the object than an object with
a second
flexural modulus greater than the first flexural modulus. Thus, the
flexibility of an object can
be increased by including in the object a material having a relatively low
flexural modulus.
[1050] The flexibility of an object constructed from a polymer can be
influenced, for
example, by the chemical constituents and/or arrangement of the monomers
within the
polymer. For example, the flexibility of an object can be increased by
decreasing a chain
length and/or the number of branches within the polymer. The flexibility of an
object can
also be increased by including plasticizers within the polymer, which produces
gaps between
the polymer chains.
[1051] As used herein, the terms "expandable," "expanded configuration,"
"collapsible"
and/or "collapsed configuration" relate to a flexible container defining a
first cross-sectional
area (or volume) and a second cross-sectional area (or volume). For example, a
flexible
container of the types described herein, can define a larger cross-sectional
area (or volume)
when in an expanded configuration than the cross-sectional area (or volume) of
the flexible
container in the collapsed configuration. Expandable components described
herein can be
constructed from any material having any suitable properties. Such material
properties can
include, for example, a flexible material having a high tensile strength, high
tear resistance,
high puncture resistance, a suitable level of compliance (e.g., the expandable
components
ability to expand appreciably beyond its nominal size) and/or a suitable
modulus of elasticity
(e.g., as described above).
[1052] In some embodiments, for example, an expandable component (e.g., a
flexible
container) can include at least a portion constructed from a high-compliant
material
configured to significantly elastically deform when expanded. In other
embodiments, an
expandable component (e.g., the flexible container) can include at least a
portion constructed
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from a low-compliant material (e.g., a material configured to expand without
significant
elastic deformation). The compliance of an expandable component defining, for
example, an
interior volume, is the degree to which a size of the expandable component (in
an expanded
state) changes as a function of the pressure within the interior volume. For
example, in some
embodiments, the compliance of a flexible container can be used to
characterize the change
in the diameter or perimeter length of the expanded flexible container as a
function of the
pressure within the interior volume defined by the flexible component. In some
embodiments, the diameter or perimeter length of an expanded component
characterized as a
low-compliant component can change by zero to ten percent over the range of
pressure
applied to the interior volume thereof (e.g., either a positive pressure or a
vacuum). In other
embodiments, the diameter or perimeter length of an expanded component
characterized as a
high-compliant component can change as much as 30 percent, 50 percent, 100
percent or
greater.
[1053] Because the overall characteristics of a flexible container, including
the compliance,
can be a function of both the material from which the flexible container is
constructed and the
structural characteristics of the flexible container, the material from which
the flexible
container is constructed can be selected in conjunction with the desired
structural
characteristics of the flexible container. For example, in some embodiments, a
flexible
container can include a first portion defining a first compliance and/or
flexibility and a
second portion defining a second compliance and/or flexibility. In such
embodiments, it can
be desirable that the first portion (e.g., a bottom portion) include a lower
compliance and/or
greater stiffness than the second portion (e.g., a top portion). Thus, the
first portion of the
flexible container can be configured to deform less under increased or
decreased pressure
within an interior volume than the second portion. For example, in some
embodiments, a
force exerted by a bulk material (e.g., the weight of the bulk material) may
be such that
substantial deformation of the first portion could result in tearing of the
material.
[1054] As used herein, the term "bulk material" relates to a cargo that is
transported in
large quantities in the absence of individual packaging. Bulk material and/or
bulk cargo can
be very dense, corrosive, or abrasive. For example, a bulk material can be
bauxite, sand,
gravel, copper, limestone, salt, cement, fertilizers, plastic granular, resin
powders, coal (e.g.,
lignite, bituminous and/or anthracite, etc.), grains, iron (e.g., iron ore,
direct reduced iron, pig
iron, etc.), gasoline, liquefied natural gas, petroleum, and/or the like. Some
bulk materials,
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for example, coal, can define a low flowability, can be abrasive, can define
an uneven weight
distribution, and can spontaneously combust. Direct reduced iron can be
extremely reactive,
corrosive, flammable, susceptible to re-oxidation, overheating, and the
generation of highly
combustible hydrogen if left unprotected. Exposure of direct reduced iron to
seawater can be
particularly dangerous. In contrast, a slurry or flowable material can be less
abrasive and can
be easily distributed. Therefore, handling, packaging and/or shipping of a
bulk material can
pose different challenges than the handling, packaging and/or shipping of a
slurry or flowable
material.
[1055] Some embodiments described herein include flexible containers
operable to
substantially hermetically seal the bulk material from the outside atmosphere.
The
atmosphere of the interior volume of the flexible container can be evacuated
and/or replaced
with an inert substance, such as, for example, nitrogen, carbon dioxide,
argon, etc.
[1056] FIG. 1 is a schematic illustration of a flexible container 100,
according to an
embodiment. The flexible container 100 includes a container body 110 and a
cover 160 and
is configured to move between an expanded configuration (e.g., FIGS. 1 and 2)
and a
collapsed configuration (e.g., FIG. 3). The flexible container 100 includes a
side wall 112
and defines an interior volume 111 within the container body 110. The flexible
container 100
can be any suitable shape, size, or configuration. For example, in some
embodiments, the
flexible container 100 can define an irregular shape as shown in FIG. 1. In
other
embodiments, a flexible container 100 can have a rectangular prism shape, a
cylindrical
shape or the like.
[1057] The flexible container 100 can be formed from any suitable material
or material
combination. For example, in some embodiments, the flexible container 100 can
be formed
from polyethylene, ethylene vinyl acetate (EVOH), amorphous polyethylene
terephthalate
(APET), polypropylene (PP), high-density polyethylene (HDPE),
polyvinylchloride (PVC),
polystyrene (PS), polyethylmethacrylate (EMA), metallocene polyethylene
(plastomer
metallocene), low-density polyethylene (LDPE), high-melt strength (LDPE),
ultra-low-
density linear polyethylene (ULLDPE), linear low-density polyethylene (LLDPE),
K-resin,
polybutadiene, and/or mixtures, copolymers, and/or any combination thereof. As
used herein
the term "copolymer" includes not only those polymers having two different
monomers
reacted to form the polymer, but two or more monomers reacted to form the
polymer.
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[1058] In some embodiments, the container body 110 can be constructed from
multiple
layers of material. For example, in some embodiments, the flexible container
100 can
include an inner layer and an outer layer. In such embodiments, the inner
and/or outer layer
can be formed from any suitable material or material combination such as, for
example, those
described above. In other embodiments, the flexible container 100 can include
three or more
layers. Furthermore, the layers from which the container body 110 is
constructed can be
formed from a similar or dissimilar material. For example, in some
embodiments, a first
layer can be formed from a first material, a second layer can be formed from a
second
material, and a third layer can be formed from a third material. In other
embodiments, one or
more layers can be constructed from similar materials.
[1059] As shown, the side wall 112 defines an opening 113 having a
substantially non-
circular shape. The opening 113 is configured to receive a portion of a
delivery member C,
such as, for example, a conveyer, a chute, a pipe, or the like. In this
manner, the delivery
member can convey a bulk material (not shown) into the interior volume 111
defined by the
container body 110 according to the methods described herein. In some
embodiments, the
delivery mechanism is a conveyer C configured to transfer coal to the interior
volume 111 via
the opening 113. In other embodiments, the bulk material can be any suitable
material of the
types described herein. For example, the bulk material can be phosphate, coal,
iron ore,
direct reduced iron, mined ore, grain, and/or the like. In some embodiments,
when the bulk
material is being conveyed into the interior volume 111, the container body
110 can be
maintained in an expanded (or partially expanded) configuration by conveying
an inflation
fluid (e.g., air, nitrogen or any other suitable gas) into the interior
volume. The inflation fluid
can be conveyed into the interior volume 111 via the opening 113. Similarly
stated the
inflation fluid can be conveyed into the interior volume 111 via the same
opening through
which the bulk material is conveyed. In other embodiments, the container body
110 can be
maintained in the expanded (or partially expanded) configuration by any
suitable mechanism,
such as by attaching the corners of the container body 110 to a rigid
structure via tethers
and/or cords.
[1060] In some embodiments, the conveyer C can be configured to telescope
(i.e., change
lengths) within the container body 110. For example, in some embodiments, the
conveyer C
can be disposed through the opening 113 and within the interior volume 111 of
the container
body 110 such that the conveyer C can transfer the bulk material to a
particular location the
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interior volume 111. In this manner, the container body 110 can be loaded from
back to
front. Similarly stated, according to this method, when the conveyer C
transfers the bulk
material to the interior volume 111, the conveyer C can be configured to
retract (move from
the back portion towards the front portion) with respect to the side wall 112.
In this manner,
the bulk material can be loaded into the container body 110 evenly (i.e., with
a suitable
weight distribution) thus reducing load shifting during transport.
[1061] As shown in FIG. 2, after the desired quantity of the bulk material
disposed within
the interior volume 111 of the container body 110, the conveyer C can be
removed from the
interior volume 111 via the opening 113. The cover 160 can then be disposed
about the
opening 113 to fluidically isolate the interior volume 111 from a volume
substantially outside
the container body 110. Similarly stated, the cover 160 is configured to
fluidically and/or
hermetically seal the container body 110.
[1062] The cover 160 can be constructed from any suitable material and can
be coupled
to the container body 110 by any suitable means. For example, in some
embodiments, the
cover 160 can be formed from a similar material as at least a portion of the
container body
110 (e.g., the cover 160 can be formed from a flexible material). The cover
160 can be
coupled to the side wall 112, for example, via an adhesive, adhesive strip, a
chemical weld or
the like. In other embodiments, the cover 160 can be coupled to the side wall
112 via a
zipper style fit. In some embodiments, the cover 160 and the side wall 112 can
define a
substantially planar surface when the flexible container 100 is in the
expanded configuration.
In this manner, the container body 110 and the cover 160 can form a
substantially continuous
surface after the cover 160 is coupled to the container body 110. By avoiding
a protruding
cover, this arrangement can result in ease of packaging, handling and/or
shipping of the
flexible container 100.
[1063] As shown in FIG. 3, the flexible container 100 can be placed in the
collapsed
configuration. More specifically, container body 110 and the cover 160 can be
placed in the
collapsed configuration by evacuating at least a portion of a gas within the
interior volume
111 via a port (not shown). In some embodiments, the cover 160 defines the
port. In other
embodiments, the container body 110 (e.g., the side wall 112) can define the
port. In this
manner, the port can be engaged by, for example, a vacuum source such that the
pressure
within the interior volume 111 of the container body 110 is reduced. The
reduction of the
pressure within the interior volume 111 can be such that container body 110
deforms.
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Similarly stated, the vacuum source can exert a suction force on the interior
volume 111
thereby urging at least a portion of the container body 110 to deform under
the vacuum force.
Furthermore, the vacuum source can be configured to expose interior volume 111
to the
suction force such that the interior volume 111 is substantially devoid of a
gas (e.g., air).
Said another way, the interior volume 111 is exposed to a negative pressure
and thereby urges
the container body 110 to substantially conform to a contour of the bulk
material disposed
therein.
[1064] In some embodiments, the flexible container 100 can collapse (e.g.,
conform to
the bulk material) such that the bulk material disposed within the container
body 110 can act
as a substantially solid mass. For example, in some embodiments, the flexible
container 100
can collapse such that a distance between adjacent parts of a bulk material is
reduced. In this
manner, the movement of specific parts (e.g., particles, pellets, grains,
chunks, portions,
and/or the like) of the bulk material is reduced relative to adjacent parts of
the bulk material.
Thus, the potential of load shifting within the flexible container 100 is
reduced. In some
embodiments, the substantial evacuation of the gas (e.g., air) within the
flexible container 100
can reduce the risk of spontaneous combustion of the bulk material (e.g.,
coal).
[1065] In some embodiments, the flexible container 100 can be placed into
and/or
secured within a rigid shipping container. In such embodiments, the flexible
container 100
can include a set of tethers (not shown in FIGS. 1-3) configured to couple the
flexible
container 100 to an inner surface of the rigid container. For example, in some
embodiments,
the tethers can include a first portion that can be coupled to the flexible
container 100 and a
second portion that can be coupled to the rigid container. In some
embodiments, the tethers
can be formed of a flexible material such that with the tether coupled to the
flexible container
100 and the rigid container, a length of the tether can extend when the
flexible container 100
is moved from the expanded configuration to the collapsed configuration.
Similarly stated,
the flexible container 100 can be disposed within the rigid container such
that the flexible
container 100 moves relative to the rigid container (e.g., away from a set of
walls of the rigid
container) thereby urging the length of the tethers to extend. In some
embodiments, the
flexible container 100 can further include a bumper portion configured to
engage a surface of
the rigid container and absorb a portion of a force from any load shifting
within the rigid
container. The bumper portions can be any suitable portion. For example, in
some
embodiments, the bumper portions include one or more sleeves configured to
receive a shock
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absorbing member. In other embodiments, the bumper portions can be inflated
with a gas
(e.g., air). Similarly stated, in some embodiments, the flexible container 100
can include an
integrated dunnage system to minimize the transfer of load to (or deformation
of) the rigid
container within which the flexible container 100 is disposed.
[1066] In some embodiments, a flexible container can include portions
formed from
different materials. In this manner, the rate of deformation of the flexible
container when
moved to the collapsed configuration can vary spatially. For example, FIGS. 4
and 5 show a
flexible container 200 that includes a container body 210 and defines an
interior volume 211
therein. The flexible container 200 is configured to move between an expanded
configuration
(e.g., FIG. 4) and a collapsed configuration (e.g., FIG. 5). Although the
flexible container
200 is shown as defining a volume when in the collapsed configuration, in
other
embodiments, the flexible container 200 can be configured to be moved to a
collapsed
configuration in which the container defines substantially no volume therein
(e.g., a container
storage configuration). The flexible container 200 can be any suitable shape
or size. For
example, in some embodiments, the flexible container 200 can define a
cylindrical shape.
The flexible container 200 can be formed from any suitable material, such as
any suitable
materials of the type described herein or any combination thereof
[1067] As shown in FIG. 4, the container body 210 includes a first portion
220 and a
second portion 240. The first portion 220 and the second portion 240 can be
formed from a
similar or dissimilar material, and can be characterized by a similar or
dissimilar stiffness
and/or flexibility. The first portion 220 is formed from a first material that
has a first stiffness
and the second portion 240 is formed from a second material, different than
the first material,
and which has a second stiffness, different from the first stiffness. In some
embodiments, the
first material of the first portion 220 is substantially stiffer than the
second material of the
second portion 240.
[1068] In some embodiments, the first portion 220 and the second portion
240 can be
coupled together to form the container body 210. In such embodiments, the
first portion 220
and the second portion 240 can be coupled in any suitable manner. For example,
in some
embodiments, the first portion 220 and the second portion 240 can be coupled
via adhesive,
chemical weld or bond, sewn, insertion into a flange or coupling device,
and/or the like. In
this manner, the first portion 220 and the second portion 240 define a
substantially fluidic
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and/or hermetic seal. Similarly stated, the first portion 220 is coupled to
the second portion
240 to define a non-permeable coupling (e.g., air tight).
[1069] In some embodiments, the flexible container 200 includes multiple
layers (not
shown). For example, in some embodiments, the first portion 220 and the second
portion 240
can each be constructed from multiple layers. In such embodiments, the
multiple layers of
the first portion 220 and/or the second portion 240 can be formed from any
suitable material
such as those described herein. Furthermore, the multiple layers of the first
portion 220
and/or the second portion 240 can be formed from similar or dissimilar
materials. For
example, a first layer can be formed from a first material and a second layer
can be formed
from a second material. In some embodiments, one or more of the multiple
layers included in
the second portion 240 can be similar to one or more of the multiple layers of
the first portion
220. The multiple layers of the first portion 220 and the multiple layers of
the second portion
240 can be coupled together to define the fluidic and/or hermetic seal (e.g.,
as described
above).
[1070] When in the expanded configuration (e.g., FIG. 4), the flexible
container 200 can
receive a bulk material (not shown) such that the bulk material is disposed
within the interior
volume 211. With the desired amount of bulk material disposed within the
interior volume
211, the flexible container 200 can be moved from the expanded configuration
to the
collapsed configuration, as shown in FIG. 5. More specifically, a pressure
within the interior
volume 211 can be reduced such that the flexible container 200 collapses in
response to the
reduced pressure. In some embodiments, the flexible container 200 can include
a port (not
shown in FIGS. 4 and 5) that can be engaged by, for example, a vacuum source
configured to
reduce the pressure within the interior volume 211 of the container body 210.
Similarly
stated, the vacuum source can exert a suction force on the interior volume 211
thereby urging
at least a portion of the container body 210 to deform under the force.
Furthermore, the
vacuum source can be configured to expose the interior volume 211 to the
suction force such
that the interior volume 211 can be substantially evacuated (i.e.,
substantially devoid of a
gas). Said another way, the interior volume 211 is exposed to a negative
pressure and thereby
urges the container body 210 to substantially conform to a contour of the bulk
material
disposed therein.
[1071] As described above, the first portion 220 can be formed from the
first material and
define the first stiffness and the second portion 240 can be formed from the
second material
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and define the second stiffness. In this manner, with the suction force
applied to the interior
volume 211 of the container body 210, the first stiffness of the first portion
220 is such that
the first portion 220 deforms a first amount, as shown by the arrows A1 in
FIG. 5. Similarly,
the second stiffness of the second portion 240 is such that the second portion
240 deforms a
second (different) amount, as shown by the arrows A2 in FIG. 5. Furthermore,
with the
stiffness of the second portion 240 being substantially less than the first
portion 220, the
second portion 240 deflects (e.g., deform) substantially more than the first
portion 220.
[1072] In some embodiments, the flexible container 200 can collapse (e.g.,
conform to
the bulk material) such that the bulk material disposed within the container
body 210 can act
as a substantially solid mass. For example, in some embodiments, the flexible
container 200
can collapse such that a distance between adjacent portions and/or components
of the bulk
material is reduced. In this manner, the movement of specific parts (e.g.,
particles, pellets,
grains, chunks, portions, and/or the like) of the bulk material is reduced
relative to adjacent
parts of the bulk material. Similarly stated, when the flexible container 200
is moved from
the expanded configuration to the collapsed configuration, the bulk material
therein can be
moved from a flowable (or partially flowable) state to a substantially non-
flowable state.
Thus, the potential of load shifting of the bulk material within the flexible
container 200 is
reduced. Accordingly, the flexible container 200 can be strapped and/or
anchored to and/or
within a shipping platform or container using tethers and/or straps. In some
embodiments,
for example, the flexible container 200 can be coupled within any of the rigid
shipping
containers described herein (e.g. the rigid shipping container 465) without
the need for
dunnage bags, bulkheads and/or bulwarks to absorb load from the shifting of
the bulk
material therein.
[1073] In some embodiments, the substantial evacuation of the gas (e.g.,
air) within the
flexible container 200 can reduce the risk of spontaneous combustion of the
bulk material
(e.g., coal, direct reduced iron, etc.). In some embodiments (e.g., when the
bulk material is a
food product), the substantial evacuation of the gas (e.g., air) within the
flexible container
200 can reduce the risk contamination, reaction and/or the like.
[1074] In some embodiments, the flexible container 200 can include one or
more layers
that are monolithically formed and are disposed within the first portion 220
and the second
portion 240 to act as a liner (not shown in FIGS. 4 and 5). The inner layer
(or liner) can be
formed from any suitable material and can include any suitable material
characteristic such
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as, for example, flexibility, durometer, compliance, abrasion resistance,
and/or the like. For
example, in some embodiments, the flexible container 200 can include the inner
layer and the
first portion 220 and the second portion 240. The first portion 220 and the
second portion
240 can be coupled together such that the inner layer is disposed within the
interior volume
211 defined by the first portion 220 and the second portion 240 of the
container body 210. In
some embodiments, the inner layer abrasion resistant and fluidically
permeable. In this
manner, the inner layer can protect the first portion 220 and the second
portion 240 from
sharp portions and/or points included in the bulk material. Moreover, when the
flexible
container 200 is moved to the collapsed configuration, the suction force
(e.g., the vacuum)
can pass through the inner layer and exert at least a portion of the suction
force of the first
portion 220 and the second portion 240. Therefore, the first portion 220 and
the second
portion 240 can collapse to place the flexible container 200 in the collapsed
configuration.
[1075] While shown in FIGS. 1-3 as defining an irregular shape, in some
embodiments a
flexible container can define a substantially rectangular shape. For example,
as shown in
FIGS. 6A and 7-13, a flexible container 300 includes a container body 310, a
side wall 312, a
bulkhead 325, and a cover 360. FIGS. 6B and 6C show a flexible container 364
that differs
from the flexible container 300 in that, among other things, the flexible
container 364
includes a series of magnets 365. Many aspects of the flexible container 364
are similar to
those of the flexible container 300, and thus the details of the flexible
container 364 are note
discussed in detail below. The flexible container 300 and the flexible
container 364 can be
any suitable size, for example, a size configured to fit within a commercially-
available
shipping container, or any of the rigid containers shown and described herein.
For example,
the flexible container 300 defines a length L, a height H, and a width W. In
some
embodiments, the length L can be approximately 20 feet, the height H can be
approximately
8 feet, and the width can be approximately 7.5 feet. In other embodiments, the
length L can
be approximately 40 feet, the height can be approximately 8 feet, and the
width can be
approximately 7.5 feet.
[1076] The container body 310 includes a first portion 320 and a second
portion 340 and
defines an interior volume 311. The first portion 320 and the second portion
340 can be
formed from any suitable material. In some embodiments, the first portion 320
and/or the
second portion 340 can be formed from a similar or dissimilar material and can
define a
similar or dissimilar stiffness (e.g., flexibility). For example, the first
portion 320 is formed
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from a first material that has a first stiffness, and the second portion 340
is formed from a
second material, different than the first material, that has a second
stiffness, different from the
first stiffness. In some embodiments, at least a portion of the first portion
320 is formed from
polyethylene woven fabric (e.g., 120 g/sqm) and at least a portion of the
second portion 340
is formed from polyethylene film (e.g., 140 microns thick). Polyethylene is
flexible, inert,
and creates a lower static charge than, for example, polypropylene. Thus,
polyethylene is a
suitable material for the transportation of certain bulk materials such as,
for example, coal.
Furthermore, with the first portion 320 formed from polyethylene woven fabric,
the first
portion 320 is substantially stiffer than the second portion 340 formed from
polyethylene
film. As described herein, this arrangement can result in different rates of
deformation when
the container 300 is moved from an expanded configuration to a collapsed
configuration.
[1077] As shown in FIGS. 6A-C, the first portion 320 and the second portion
340 are
coupled together to form the container body 310. The first portion 320 and the
second
portion 340 can be coupled in any suitable manner. For example, in some
embodiments, the
first portion 320 and the second portion 340 can be coupled via adhesive,
chemical weld or
bond, sewn, insertion into a flange or coupling device, and/or the like. In
this manner, the
first portion 320 and the second portion 340 define a substantially fluidic
and/or hermetic
seal. Similarly stated, the first portion 320 is coupled to the second portion
340 such as to
define a non-permeable coupling (e.g., air tight). In other embodiments, the
first portion 320
and the second portion 340 form a monolithically constructed container body
310.
[1078] The flexible container 300 includes multiple layers (not shown). In
some
embodiments, the first portion 320 and/or the second portion 340 include
multiple layers. In
some embodiments, the flexible container 300 can include one or more layers
substantially
independent of the first portion 320 and/or the second portion 340 (e.g., a
liner). In such
embodiments, the multiple layers of the first portion 320 can be formed from
any suitable
material such as those described above. Furthermore, the multiple layers of
the first portion
320 can be formed from similar or dissimilar materials. For example, an inner
layer can be
formed from polyethylene woven fabric a first material and a second layer can
be formed
from a second material. Similarly, the multiple layers of the second portion
340 can be
formed from any suitable material. In some embodiments, the multiple layers of
the second
portion 340 are formed from a similar or dissimilar material. In some
embodiments, one or
more of the multiple layers included in the second portion 340 can be similar
to one or more
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of the multiple layers of the first portion 320. The multiple layers of the
first portion 320 and
the multiple layers of the second portion 340 can be coupled together to
define the fluidic
and/or hermetic seal (e.g., as described above).
[1079] As shown in FIG. 7, the side wall 312 defines a substantially
rectangular-shaped
opening 313. The opening 313 can receive a portion of a delivery member (not
shown)
configured to convey a bulk material (not shown) to be disposed within the
interior volume
311 defined by the container body 310. For example, in some embodiments, the
delivery
member can be a conveyer configured to transfer raw coal to the interior
volume 311 via the
opening 313. In other embodiments, the delivery mechanism can be a hose
configured to be
coupled to the side wall 312 such that the hose delivers processed coal to the
interior volume
311 via the opening 313.
[1080] In some embodiments, the delivery mechanism is configured to
telescope (i.e.,
change lengths) within the container body 311, as described above. For
example, in some
embodiments, a conveyer can be disposed through the opening 313 and within the
interior
volume 311 of the container body 313 such that the conveyer can transfer the
bulk material to
the interior volume 311 such that the container body 310 is loaded from back
to front.
Similarly stated, as the conveyer transfers the bulk material to the interior
volume 311, the
conveyer can be configured to retract with respect to the side wall 312. In
this manner, the
bulk material can be loaded with a suitable weight distribution thus reducing
load shifting
during transport. In some embodiments, the flexible container 300 can include
an internal
telescoping member (not shown) configured to selectively convey a bulk
material from a
delivery member (e.g., distribute the bulk material within the interior
volume).
[1081] The cover 360 includes a port 361 and is configured to be coupled to
the side wall
312 about the opening 313. More particularly, the cover 360 is coupled to the
side wall 312
and about the opening 313 such that the cover 360 fluidically isolated the
interior volume 311
from a volume substantially outside the container body 310. Similarly stated,
the cover 360
is configured to fluidically and/or hermetically seal the container body 310.
The cover 360
can be formed from any suitable material, such as a similar material as at
least a portion of
the container body 310. For example, in some embodiments, the cover 360 is
formed from
polyethylene film with a 140 micron thickness. In other embodiments, the cover
360 can be
any suitable thickness.
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[1082] The cover 360 can be coupled to the side wall 312 in any suitable
manner. For
example, as shown in FIG. 7, cover 360 is coupled to the side wall 312 via an
adhesive strip
342. The adhesive strip 342 can be any suitable adhesive such as, for example,
a glass fiber
glue tape. In this manner, the cover 360 and the side wall 312 can define a
substantially
planar surface when the flexible container 300 is in the expanded
configuration. As another
example, as shown in FIGS. 6B and 6C, cover 360 is operable to be coupled to
the side wall
312 via a magnet portion 366. Similarly stated, the cover 360 is configured to
engage a
substantially flat surface of the side wall 312 such that the cover 360 and
the side wall 312
are substantially co-planar. Said another way, the cover 360 couples to a
portion of the side
wall 312 defining the opening 313 that is substantially flat (e.g., does not
include a mounting
flange, ring, protrusion, and/or the like). The use of the adhesive strip 342
and/or the
magnetic portion 366 is such that when the cover 360 is coupled to the side
wall 312 the
cover 360 fluidic and/or hermetic seal isolates the interior volume 311
defined by the
container body 310. In other embodiments, the cover 360 can be coupled to the
side wall 312
using any suitable method, such as, for example, a chemical weld.
[1083] The side wall 312 further includes a portion configured to which the
bulkhead 325
is coupled (see e.g., FIG. 8). The bulkhead 325 is configured to provide
mechanisms for
absorbing load, handling and/or manipulating the container 300. The bulkhead
325 can be
any suitable shape, size, or configuration. For example, the bulkhead 325 is
substantially
similar in height and width as the first portion 320 of the container body
310. In this manner,
when coupled to the side wall 312 the bulkhead 325 transfers a portion of a
force (e.g., a load
shift during transport) to the relatively stiff first portion 320 and not the
relatively flexible
second portion 340. The bulkhead 325 can be formed from any suitable material
that
includes any suitable weight. For example, in some embodiments, the bulkhead
325 is
formed from polypropylene woven fabric with a weight of 210 g/sqm. In this
manner, the
use of polypropylene woven fabric is such that the bulkhead is substantially
stiffer than the
first portion 320 and/or the second portion 340. Thus, in use the bulkhead 325
is less likely
to deform when the flexible container 300 is placed in the collapsed
configuration.
[1084] The bulkhead 325 includes a sleeve 321, a set of webbing strips 326,
and a
material label 335. As shown in FIG. 9, the material label 335 can include
information
associated with the flexible container 300. The sleeve 321 is configured to
extend from a
surface of the bulkhead 325 to define a void. In some embodiments, the sleeve
321 can be
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coupled to the bulkhead 325 in any suitable manner such as, for example, those
described
above. In other embodiments, the sleeve 321 can be monolithically formed with
the bulkhead
325. The sleeve 321 is configured to receive a shock absorbing member (not
shown) within
the void defined between the sleeve 321 and the bulkhead 325, as described in
further detail
herein. The webbing strips 326 can be coupled to the bulkhead 325 in any
suitable manner.
For example, in some embodiments, the webbing strips 326 can be sewn to the
bulkhead 325.
In other embodiments, the webbing strips 326 can be chemically welded and/or
coupled via
adhesives. The webbing strips 326 include a set of loops 327, a set of ratchet
straps 328, and
a set of tethers 355. In use, the flexible container 300 is configured to be
disposed within a
rigid container (not shown) and the loops 327, the ratchet straps 328, and/or
the tethers 355
can engage an interior portion of the rigid container to couple the flexible
container 300 to the
interior portion of the rigid container.
[1085] Similarly, the second portion 320 and a rear portion of the flexible
container 300
can include members configured to engage the interior portion of the rigid
container. For
example, as shown in FIG. 10, the rear portion can include an elastic band 314
configured to
engage the interior portion of the rigid container. The rear portion can
further include corner
caps 315 configured to protect the corners of the flexible container 300. In
some
embodiments, the corner caps 315 can include tethers and/or straps configured
to engage the
rigid container.
[1086] As shown in FIGS. 11 and 12, the second portion 340 includes a set
of attachment
members 345 configured to receive a portion of the tethers 355. The attachment
members
can be disposed on or within the second portion 340 at any suitable position.
For example, in
some embodiments, the attachment members 345 can be disposed along a top
surface of the
second portion 340 at a distance D1 from adjacent attachment members 345.
While shown in
FIG. 11 as being substantially uniformly spaced, in some embodiments, the
attachment
members 345 can be spaced at any given distance from adjacent attachment
members 345.
[1087] As shown in FIG. 12, the attachment members 345 include a loop
portion 346 and
a base 347. The base 347 is coupled to the second portion 340 of the container
body 310.
For example, in some embodiments, the base 347 is coupled to the second
portion 340 via
adhesive strips. In some embodiments, the second portion 340 defines a channel
configured
to receive the base 347 of the attachment member 345. The loop portion 346 is
configured to
receive a portion of the tether 355. More specifically, the tether 355
includes a first portion
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356 configured to couple to the loop portion 346 and a second portion 357
configured to
couple to the rigid container.
[1088] Although the flexible container 300 is described as being coupleable
to a rigid
container via the tethers 355, in other embodiments, the flexible container
300 or any of the
flexible containers shown and described herein can be coupled to and/or within
a rigid
container via any suitable mechanism. Moreover, in some embodiments, the
flexible
container 300 or any of the flexible containers shown and described herein can
be removably
coupled to and/or within a rigid container. For example, in some embodiments,
magnets 365
can be attached to a flexible container 364 (which can be similar to the
flexible container 300,
as discussed above; see FIGS. 6B and 6C) to keep the bag in its inflated or
expanded
configuration during loading. The magnets 365 can be coupled to the side
and/or top of the
container body 310. The coupling of the magnets 365 to the container body 310
may be in
the form of pockets or battens, in which magnets 365 can be removably coupled
to the
container body. In other embodiments, the magnets 365 can be permanently
attached to the
flexible container 364 during the manufacturing process such that the magnets
365 become
an integral part of the flexible container 364. In some embodiments, multiple
pockets can be
provided on the flexible container 364 and the magnets 365 can be reconfigured
depending
on the configuration of the rigid structure into which the container body is
placed. In some
embodiments, the container body 310 or a portion thereof is formed from a
magnetic
material.
[1089] As described below, in use, when the air is withdrawn from the
flexible container
364 when a vacuum is applied (e.g., to move the flexible container 364 to a
collapsed
configuration), the magnets 365 detach from the rigid structure and the
flexible container
364, and the contents therein achieve a solid or semi-solid form as described
herein. The
magnets 365 can be designed to have a magnetic field of sufficient force such
that the
container body 310 is coupled to the rigid structure until the flexible
container 364 is
sufficiently filled, at which time, the force of the magnets 365 is overcome
by the weight of
the filler material and/or the applied vacuum, allowing the flexible container
364 to pull away
from the rigid structure.
[1090] In some embodiments, the magnets 365 can detach simultaneously. In
other
embodiments, the magnets 365 are configured to detach in a defined manner
(i.e., the
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magnets 365 furthest from the opening of the container detaching first, and
the magnets 365
closest to the opening of the flexible container 364 detaching last.
[1091] In use, the flexible container 300 (and/or the flexible container
364) is coupled to
the rigid container (e.g., any of the rigid containers shown herein) and
receives the bulk
material via the opening 313. In some embodiments, when the bulk material is
being
conveyed into the interior volume 311, the container body 310 can be
maintained in an
expanded (or partially expanded) configuration by conveying an inflation fluid
(e.g., air,
nitrogen or any other suitable gas) into the interior volume 311. The
inflation fluid can be
conveyed into the interior volume 311 via the opening 313. Similarly stated
the inflation
fluid can be conveyed into the interior volume 311 via the same opening
through which the
bulk material is conveyed. This arrangement eliminates the need for multiple
openings
within the container body 310. Additionally, this mechanism for loading the
container body
310 does not require a fluid-tight coupling between the delivery member and
the container
body 310. In other embodiments, the container body 310 can be maintained in
the expanded
(or partially expanded) configuration by any suitable mechanism, such as by
attaching the
corners of the container body 310 to a rigid structure via the tethers 355.
[1092] With the desired amount received within the internal volume, the
cover 360 is
coupled to the side wall 312 and the flexible container 300 is then moved to
the collapsed
configuration. Expanding further, the port 361 included in the cover 360 can
be configured
to act as an ingress or egress for a gas to be disposed within or expelled
from the interior
volume 311. For example, the port 361 can be engaged by a vacuum source such
that the
pressure within the interior volume 311 of the container body 310 is reduced.
The reduction
of the pressure within the interior volume 311 can be such that all or
portions of the container
body 310 deform. Similarly stated, the vacuum source can exert a suction force
on the
interior volume 311 thereby urging at least a portion of the container body
310 to deform
under the force. Furthermore, the vacuum source can be configured to expose
interior
volume 311 to the suction force such that the interior volume 311 is
substantially devoid of a
gas (e.g., air). Said another way, the interior volume 311 is exposed to a
negative pressure
and thereby urges the container body 310 to substantially conform to a contour
of the bulk
material disposed therein. In some embodiments (e.g., embodiments that include
a magnetic
coupling, as described above with the flexible container 364), the negative
pressure can be
sufficient to overcome the magnetic coupling between the flexible container
and the rigid
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container. Similarly stated, a pressure differential between the interior
volume of the flexible
container (e.g., container 364) and a volume outside of the interior volume is
sufficient to
overcome the magnetic coupling. In some embodiments, the cover 360 is hingedly
coupled
to the container 300.
[1093] As described above, the first portion 320 can be formed from the
first material
(e.g., polyethylene woven fabric) and define the first stiffness and the
second portion 340 can
be formed from the second material (e.g., polyethylene film) and define the
second stiffness.
In this manner, with the suction force applied to the interior volume 311 of
the container
body 310, the first stiffness of the first portion 320 is such that the first
portion 320 deforms a
first amount. Similarly, the second stiffness of the second portion 340 is
such that the second
portion 340 deforms a second amount. Furthermore, with the stiffness of the
second portion
340 being substantially less than the first portion 320, the second portion
340 deflects (e.g.,
deform) substantially more than the first portion 320.
[1094] In some embodiments, the tethers 355 (FIGS. 11 and 12) are formed
from an
elastomeric material such that with the tethers coupled 355 to the flexible
container 300 and a
rigid container, a length of the tether 355 extends when the flexible
container 300 is moved
from the expanded configuration to the collapsed configuration. This
arrangement allows the
flexible container 300 to be disposed and/or coupled within a rigid container
such that the
flexible container 300 moves relative to the rigid container (e.g., away from
a set of walls of
the rigid container) thereby urging the length of the tethers 355 to extend
when the flexible
container 300 is moved from the expanded configuration to the collapsed
configuration.
[1095] In some embodiments, the flexible container 364 (FIGS. 6B, 6C) can
be coupled
to the rigid container via magnets 365 such that when the flexible container
is moved from
the expanded configuration to the collapsed configuration, the magnets 365
decouple from
the rigid container. The magnets 365 can be decoupled by a force resulting
from decreasing
the pressure within the flexible container. Alternatively, the magnets 365 can
be manually
decoupled from the rigid container. In some embodiments, the magnets 365 can
be
electromagnets which can be decoupled from the rigid container via de-
energization.
[1096] In some embodiments, the flexible container 300 (or the flexible
container 364)
can be moved to a collapsed configuration (e.g., can conform to the bulk
material) such that
the bulk material disposed within the container body 310 can act as a
substantially solid mass.
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For example, in some embodiments, the flexible container 300 can collapse such
that a
distance between adjacent portions and/or components of the bulk material is
reduced. As
shown in FIG. 6C, the flexible container 364 in the collapsed configuration
can have a height
H' less than the height H of the flexible container 364 in the expanded
configuration. In
other embodiments any dimension of the flexible container 364 (e.g., the width
W and/or the
length L) can be decreased when the flexible container 364 moves from the
expanded
configuration to the collapsed configuration. In this manner, the movement of
specific
portions (e.g., particles, pellets, grains, chunks, portions, and/or the like)
of the bulk material
is reduced relative to adjacent portions of the bulk material. Similarly
stated, when the
flexible container 300, 364 is moved from the expanded configuration to the
collapsed
configuration, the bulk material therein can be moved from a flowable (or
partially flowable)
state to a substantially non-flowable state. Thus, the potential of load
shifting of the bulk
material within the flexible container 300, 364 is reduced and/or eliminated.
Accordingly,
the flexible container 300, 364 can be strapped and/or anchored within a
shipping container
using tethers, magnets and/or straps. Furthermore, as described above with
reference to FIG.
8, the bulkhead 325 includes the sleeve 321 and the shock absorbing member. In
this manner
the sleeve 321 and the shock absorbing member (e.g., a steel member, series of
members or
bumper) can be configured to absorb a portion of a force (e.g., load shifting
of the
substantially solid mass within the rigid container) to reduce damage done to
the rigid
container, the flexible container 300 and/or the bulk material. Similarly, as
shown in FIG. 13,
a bottom surface of the flexible container 300 includes a sleeve 321.
Furthermore, while
shown in FIGS. 8 and 13 as being disposed in specific locations, in some
embodiments, a
flexible container can include any number of sleeves 321 that can be disposed
at any suitable
location on or about the flexible container.
[1097] Any of the flexible containers described herein can be disposed
and/or coupled
within a commercially-available, rigid shipping container. In this manner,
processed or raw
coal or other granular or powdered material may be transported in a sealed
container of a size
and weight that is within the capabilities of existing shipping and transfer
equipment utilized
in connection with containerized transport. Currently, this is in the range of
25-30 tons per
one twenty-foot equivalent (TEU) container, which measures 20 feet by 10 feet
by 8 feet, and
approximately the same tonnage per two TEU containers, which measures 40 feet
by 10 feet
by 8 feet. Using containerized transport, a 5,000 TEU vessel can transport
100,000 tons of
raw coal per voyage, which is substantially larger than the amount of raw coal
per voyage
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that can be transported using the Handy or Panamax class. If greater
quantities are desired, a
10,000 TEU vessel can be utilized, which can transport approximately 240,000
tons of coal,
or a 15,000 TEU vessel can be used to transport in excess of 300,000 tons of
coal.
[1098] In some embodiments, the flexible containers can be pre-loaded into
rigid
containers that are configured/dimensioned to be loaded into standard shipping
containers. In
some embodiments, the flexible containers can be arranged into pre-loaded
stacks that are
configured to be placed into TEU containers.
[1099] In some embodiments, any of the flexible containers described herein
(e.g. the
flexible container 300) can be loaded and/or processed by a device configured
to compress,
shape and/or prepare the flexible container for disposition within a rigid
container (e.g., any
of the containers of the types shown herein). For example, FIG. 14 is a
schematic diagram of
a form or device 1300 for shaping flexible containers prior to placement
within a rigid
shipping container. The form 1300 can have one or more moveable members. As
shown, the
form 1300 has two pairs of moveable members 1340, 1350. The form 1300 can be
operable
to control the size and/or shape of a flexible container while the flexible
container is moving
from an expanded configuration (indicated by the dashed lines identified as
1310) to a
collapsed configuration (indicated by the solid lines identified as 1320). In
some
embodiments, moving the flexible container from the expanded configuration
1310 to a
collapsed configuration 1320 without the form 1300 can result in the collapsed
configuration
1320 having an irregular shape, such as bowed sides, that can be difficult to
stack and/or
position within a rigid container for shipping. The form 1300 can apply force
to the flexible
container, such that gas is purged from the flexible container, the flexible
container assumes a
regular shape, and the like when the flexible container in the collapsed
configuration 1320.
The moveable members 1340, 1350 can be driven by a hydraulic pump, electric
motor,
internal combustion engine, and/or any other suitable means to apply a force
to the flexible
container. In other embodiments, the moveable members 1340, 1350 can be
inflatable.
[1100] In some embodiments, the form 1300 can include a vibratory shaker
which can aid
the moveable members 1340, 1350 in shaping the flexible container while it is
moving from
the expanded configuration 1310 to the collapsed configuration 1320. A
vibratory shaker can
act to fluidize the bulk material to increase its flowability and/or
deformability while the
moveable members 1340, 1350 apply a force to transition the flexible container
from an
expanded configuration to a collapsed configuration.
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[1101] The pressure inside the flexible container can be reduced while the
moveable
members 1340, 1350 compact the flexible container. In some embodiments, the
flexible
container in the collapsed configuration 1320 can assume a relatively rigid
form with
relatively flat side walls. For example, in embodiments where the internal
volume of the
flexible container includes a bulk flowable granular material, the collapsed
configuration
1310 can include approximately no headspace to allow a portion of bulk
material to move
relative to another portion of the bulk material. The form 1300 can be
operable to urge the
flexible container to assume a collapsed configuration with a flat bottom,
top, and/or sides,
which can be conducive to stacking and/or loading the flexible container
within a rigid
shipping container.
[1102] The moveable members 1340, 1350 can retract once the flexible
container is in the
collapsed configuration 1320, which can allow the flexible container to be
removed from the
form. The flexible container in the collapsed configuration 1320 can retain
the shape of the
form 1300 after being removed. Thus, in some embodiments, flexible containers
can be
filled and moved into a collapsed configuration 1320, and then stacked and/or
staged for later
shipment. In such an embodiment, the flexible containers in the collapsed
configuration 1320
can be loaded into a rigid shipping container.
[1103] Although two pairs of moveable members 1340, 1350 operable to
compact the
length and width of the flexible container are shown in FIG. 14, in other
embodiments the
form 1300 can include any number of moveable members. For example, a single
moveable
member can be operable to compact the flexible container by applying a force
to one side of
the flexible container while, for example, the bottom and three other sides
are stationary. In
another embodiment, the form 1300 can include six movable members, operable to
compact
the flexible container in three orthogonal dimensions.
[1104] The most common sizes for rigid shipping containers are 20 feet or
40 feet in
length. In some embodiments, for example, in use with a flexible container, a
20-foot
container can have the capacity of holding approximately 25-30 tons of raw
granular coal or
powdered coal. In some embodiments, to accommodate larger quantities of
processed
materials (such as 40-45 tons of pulverized material) a rigid container can be
reinforced
and/or specially designed to maximize the efficiency of transporting coal.
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[1105] As shown in FIG. 15, a typical rigid container 465 includes four
corner posts 466,
467, 468, 469. The rigid container 465 also includes long rails 470, 471, 472,
473 along of
the top and bottom of the rigid container 465, which are connected to the
corner posts. The
rigid container 465 also includes short rails 474, 475, 476, 477 along the top
and bottom of
the rigid container 465, which are also connected to the corner posts 466,
467, 468, 469. The
corner posts, long rails and short rails provide structural support for the
rigid container 465,
and enable it to be secured to a crane, or a truck or rail car. The rigid
container 465 also
includes side panels 478, 479, 480, 481, bottom panel 482 and top panel 483,
which are
secured to the corner posts, long rails and short rails. In some embodiments,
for example as
seen in FIG. 15, the rigid container 465 includes a hinged or sliding door 484
in the top panel
483. The door permits loading and unloading of the material to be transported.
[1106] After processing, the granulated or powdered coal is loaded into the
rigid
container 465. In some embodiments, system can include a flexible container
(such as the
flexible container 300) disposed within the rigid container 465, and the coal
can be loaded in
via a front opening (e.g., opening 313), as described above. The coal can be
loaded into the
rigid container 465 and/or a flexible container therein with a conventional-
type conveyor
loading system, or feeding through an enclosed piping system, such as a forced-
air fluid bed
system or a screw-based system. In other embodiments, the coal can be loaded
into the rigid
container 465 and/or a flexible container by conventional mechanical means,
such as via a
construction payloader. In yet other embodiments, the coal can be loaded into
the rigid
container 465 and/or a flexible container by an air-driven system. As shown in
FIG. 16, in
some embodiments, a rigid container 565 can include a flexible pipe 586
coupled thereto to
facilitate a method using an air driven system.
[1107] During loading, the rigid container 465 may also be positioned above
the ground,
at ground level or below ground. It could also be positioned on an automated
track system
such that multiple rigid containers can be filled in a continuous manner.
Filling can be
completed until the rigid container 465 capacity is reached, as determined by
volume or by
weight. In other embodiments, as described herein, the rigid container 465
and/or the flexible
container therein (e.g., flexible container 300) can be filled to a capacity
that is less than the
interior volume when the flexible container is in the expanded configuration.
[1108] As shown in FIG. 15, in one embodiment, coal is loaded through a
sealable
opening in the top of the rigid container. This can include one or more chutes
positioned to
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receive the bulk material (e.g., raw coal and/or pulverized coal). The hinged
or sliding door
484, or another type of portal, on the top of the rigid container 465 permits
access to interior
for loading. In such embodiments, a system can also include a flexible
container, similar to
the flexible container 300, having an opening in the top portion, rather than
in the front
portion (as shown in FIGS. 6A and 7). In the alternative, the entire top wall,
or a portion of
the top wall 483 of the rigid container 465 could be hinged to a side of the
rigid container
465. Likewise, loading may be accomplished through a sliding or hinged door
484, or
another portal, positioned in the side of the rigid container 465. An entire
side-wall, or a
portion of a side-wall, could also be hinged to another side-wall, or to the
remaining portion
of the side-wall that provides access. After the coal is loaded, the rigid
container may be
closed, locked and sealed from the outside air.
[1109] The rigid container 465 design can be such that the interior can be
sealed from
outside air after the powder or granulated material is loaded therein. This
may be
accomplished by use of a permanent or extractable flexible container, such as
the flexible
container 300, a permanent or extractable hard liner, a single use throwaway
recyclable liner
or a purpose-built rigid container.
[1110] The liner and/or flexible container, whether permanent or single
use, extractable,
flexible or hard, can be manufactured of a puncture resistant, sealable
material that does not
interact chemically with the processed coal. The liner and/or flexible
container disposed
and/or coupled within the rigid container 465 can be constructed from any of
the materials
described herein. An extractable liner will enable reuse of general purpose
shipping rigid
containers in the transport of other products (avoiding rigid container dead-
heading). If the
material is durable enough, an extractable liner would also permit efficient
reuse of the liner
for additional coal transport.
[1111] In some embodiments, a system can include a flexible container, of
the types
shown and described herein, disposed within a rigid container. For example, a
flexible
polymer-based bag with a thickness in the range of 0.5 inches to 0.75 inches
would be well-
suited for use in lining the rigid containers. The bag (or flexible container,
such as the
container 300) can be made of a non-reactive material, such as plastic, vinyl
or silicon. The
bag (or flexible container, such as the container 300 or the container 364)
could also be made
of an environmentally friendly material, or any material that is non-reactive,
can be sealed,
and will maintain a vacuum. The purpose of the liner is to aid sealing the
contents of the
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rigid container, and to permit the rigid container to be reused for shipping
of other goods after
the coal is removed.
[1112] As shown in FIG. 15, the system includes a flexible container 400
disposed within
the rigid container 465. The flexible container 400, which can be similar to
the flexible
container 300, may be temporarily held in position within the rigid container
465 prior to
filing through the use of hook and loop fasteners 485 positioned along the
edges and corners
of the interior of the rigid container and the exterior of the liner. In some
embodiments, the
weight of the rigid container coal acts as a pressure seal when the bottom of
the bag employs
a flap for evacuating the coal.
[1113] As an alternative to a reusable flexible bag, in some embodiments, a
liner may
include a single-use sealable bag that may be discarded after use and
recycled.
[1114] As an alternative to a flexible container, liner or bag, the rigid
container can be
lined with a non-reactive coating, such as a ceramic material. The coating
might be
permanent, in which case it could be cleaned after use, such that the rigid
container can be re-
used for shipment of other goods and services. In the alternative, the coating
might be
applied to a temporary sheath that could be removed from the rigid container
and reused,
permitting the rigid container to be used for other purposes.
[1115] Another approach is to have collapsible boxes (box within a box),
with sealed
hinges allowing for size to be minimized. The hinged box would be inserted
into the outer
rigid container by means of a sliding track or other method. The walls would
be opened from
their collapsed state and locked, creating a sealable box. Another alternative
approach would
be a purpose built rigid container, with the interiors being ceramic or
polymer coated. Such
coatings would permit efficient cleaning after coal transport. A purpose-built
rigid container
could also be designed so that it is collapsible in order to minimize cost of
transport back to
its point of origin.
[1116] Once sealed, air can be removed from the rigid container to reduce
the risk of
combustion, to minimize shifting of the bulk material therein or the like. For
example as
shown in FIGS. 19 and 20 a rigid container 865 can include a flexible
container 800, a hose
assembly 892, and a valve assembly 895. In some embodiments, air can be
removed from
the flexible container 800 with the valve assembly 895 positioned through one
or more of the
side-walls or the top of the rigid container. The valve assembly 895 can be
positioned inside
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the rigid container such that the port is flush with the surface of the rigid
container 896, so
that it is not damaged during loading, transport or unloading of the rigid
container. The valve
assembly can include a portal 897 that can be attached to a negative pressure
(vacuum)
source, and a valve mechanism 898 for opening and sealing the portal. Suitable
value
mechanisms can include a ball valve, a butterfly valve, a gate valve or a
globe valve.
Alternative valve mechanisms, including mechanisms that are automatically
actuated when a
suitable negative pressure is achieved, may be utilized. The valve mechanism
may also
include a screen or filtration mechanism to prevent the rigid container
contents from being
drawn into the vacuum system. The vacuum could also be applied through
multiple openings
and seal assemblies on the upper and lower surfaces of the rigid container, or
through the
flexible pipe 586 (see e.g., FIG. 16) that is used to fill the rigid
container. In some
embodiments, the valve assembly 895 can be fluidically coupled to the vacuum
port (e.g.,
port 361) of a flexible container (e.g., container 300) disposed within the
rigid container.
[1117] Although shown as being coupled to the hose assembly 892, in other
embodiments, the valve assembly 895 or any other suitable valve for the
ingress (e.g., of the
bulk material) and/or egress (e.g., of air) can be coupled directly to the
flexible container.
For example, in some embodiments, any suitable valve can be chemically welded
to a side
wall of a flexible container.
[1118] Regardless of the means for applying a vacuum, there can be
corresponding
openings in the liner or coating. With a permanent coating, this could be
accomplished by
sealing the coating around the vacuum port. With a flexible or hard liner, a
portion of the
liner could be fitted around the portal in a configuration that seals the
liner to the surface
adjacent the portal, such that when loaded with coal, air cannot leak into the
liner. The liner
could also include a region that is permeable to gasses but not solid
materials, such that air
can be withdrawn without coal powder and other solid materials being removed
from the
rigid container. After the vacuum is applied, to the portal, the portal
opening is sealed to
maintain negative pressure.
[1119] Vacuum sealing will minimize loss of volatiles from the coal.
Further, the
absence of oxygen will inhibit the combustibility of the processed coal inside
the rigid
container. A vacuum pump system would be present at loading and unloading
sites. In one
embodiment, a mobile vacuum pump can be utilized to extract the air from rigid
containers
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are they are filled in an automated process. In the alternative, the mobile
vacuum pump can
be equipped to seal multiple rigid containers at the same time.
[1120] If further protection from combustion is required, an inert or non-
combustible gas
or mixture of gases may be injected into the rigid container after it is
filled with coal. The
gas can be injected into the rigid container through the vacuum port, or
through a second port
specifically designed for injection of the gas.
[1121] Preferred gases include helium, neon, argon, krypton, xenon, and
radon. Other
gases and mixtures of gases can be used, as long as they displace oxygen and
provide a
means of controlling the combustibility of the material in the rigid
container. For example,
nitrogen or carbon dioxide could be used when transporting coal.
[1122] For unloading, the rigid container may include an outlet port that
can be attached
to a hose and vacuum system at the end user location. In another embodiment,
the rigid
container can include a hinged or sliding door on the bottom panel as depicted
in FIG. 17. In
this configuration, the bottom door 687 is designed to withstand the weight of
coal in the
loaded rigid container. It is also designed to be opened via a handle or latch
688 positioned
along a side wall at the bottom of the rigid container.
[1123] FIG. 21 is a view of a rigid container 965 showing a sliding hatch
with a releasing
mechanism controlled by an electrically activated sensor. The rigid container
965 can
include, for example, tracks for sliding hatches. In some embodiments, a rigid
container can
include an automatic trip switch sensor to release or lock a sliding hatch. In
some
embodiments, a container can include a tracking sensor to identify whether the
container is
fully loaded/ fully unloaded.
[1124] FIG. 22 is a view of a rigid container 965 showing a top or bottom
(or side)
loading and unloading device by means of a flexible tube 992 (allowing even
distribution of
materials during the loading process). The loading and unloading mechanism
includes a
locking collar that can be coupled to the loading and unloading chute. The
loading and
unloading mechanism includes a sealing valve for either the exhaust of air or
the introduction
of inert gas.
[1125] In some embodiments, any of the containers shown and described
herein can
include a grounding mechanism for electrically grounding the container during
the loading
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and/or unloading process, as well as during transportation. For example, in
some
embodiments, the flexible tube 992 can include a ground wire or rod coupled
thereto. The
ground wire can, for example, extend from an area outside of the rigid
container 965 into an
interior volume defined by the rigid container 965, an inner liner and/or a
flexible container
disposed therein. In this manner, the static charge that can develop from the
contact between
particles during loading (or unloading) can be dissipated. More particularly,
such static
buildup can become hazardous when the materials contain, or are composed of,
dust or
powders (as are common with coal, ores, grain, aggregates and other bulk
materials to be
handled by the systems and methods described herein). In addition the ground
wire or rod, in
those embodiments in which the flexible container is evacuated, the evacuation
reduces
friction during transport and thus minimizes the formation of static charges
during transport.
[1126] In some embodiments, the innermost layer of any of the containers
shown and
described herein is constructed of an anti static material, such as high
density polyethylene,
Acetal and Ester based Thermoplastic Polyurethane, amongst others. The
material used on
the inner layer of the liner bag can be any suitable material, generally
composed of modified
conductive thermoplastic compounds that allow for the rapid dissipation of
static charge so
that a significant electrostatic discharge event does not take place during,
loading, unloading
and/or transportation.
[1127] As shown in FIG. 18, the interior of the rigid container can include
a hopper
shaped bottom 790, 791 which directs material be removed from the rigid
container towards a
portal positioned in the middle of the bottom. In this embodiment, the
contents will flow
from the rigid container opening. Content removal can also be assisted with a
pump and hose
assembly 792 or other device designed to disgorge the contents under pressure.
[1128] Unloading can also be accomplished via a portal or door on a side
panel. If
necessary, for unloading, one side of the rigid container could be lifted or
tipped up, or the
rigid container could be positioned above an unloading chute so that coal or
other materials
can be extracted directly into a feeding or storage mechanism utilized by the
end user. A
design including a side portal or door is preferred, as the same portal or
door could be used
for loading and unloading of the coal or other volatile material.
[1129] The liner also includes a release mechanism associated with the
outlet port or
door. For example, the liner can include a breakaway region, a folded flap
that may be
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unfolded for discharge of the contents, or a release cord that opens the liner
in a specific
region. In such embodiments, the liner mechanism can be positioned to align
with the rigid
container discharge opening or mechanism.
[1130] In some embodiments, a collapsible bag, such as the flexible
container 300 or the
flexible container 364, is utilized as the liner. In such embodiments a
sealable flap or a
puncturable area can be opened when the rigid container is opened, such as
with a sliding or
hinged door. In the alternative, the bag could have a portal or series of
portals aligned with
the rigid container openings. These portals could also be attached to an
external hose, such
that, when connected to the hose, the contents of the bag could be removed.
[1131] An alternative embodiment entails a connection between the bag and
the interior
or exterior of the rigid container, which could assist in removal of the
contents.
[1132] In some embodiments, the rigid containerization of powdered,
granulated or other
processed coal, or raw coal, is such that large-scale rigid containerized
transport ships can
efficiently and safely transport the material to multiple end-users in
multiple destinations.
This allows for "on demand" transport of commodities to higher value markets
and/or
flexible distribution decision strategies for trading companies. Some
embodiments can also
be used for transport of other volatile and non-volatile materials in
powdered, granular and/or
other solid forms.
[1133] Although certain embodiments are shown and described as being used
to contain
raw coal, any of the embodiments herein can be used to contain processed coal
and/or other
bulk materials. For example, in some embodiments, a method includes processing
coal or
other products into value added material at the location where it is mined, or
another location,
before being loaded onto ships for transport to end users. The processed coal
can then be
loaded into a sealed, non-combustible rigid container, for environmentally
safe transport by
land or sea. The sealed rigid containers can also store the coal (or other
processed materials)
such that the contents are not exposed to wind and rain, preventing product
deterioration,
product loss, and dispersion of potentially harmful dust and other materials
into the air or
land through leaching or exposure to the elements. By processing coal before
shipping, and
transporting processed coal in sealed shipping containers, different coal
products can be
distributed to multiple users in different locations with relative ease. Thus,
coal can be
marketed and supplied in a much wider variety of formats than are currently
available.
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[1134] In this manner, the methods and systems described herein allow for
the trade in
Lingnite Coal. Lignite coal has a very high moisture content causing its
energy content (BTU
per pound) to be relatively low when compared with other types of coal (e.g.,
Bituminous,
Sub-Bituminous and Anthracite). Thus, it is not practical to transport Lignite
coal (either
nationally or internationally) using known methods. As a result, sites
containing Lignite
deposits generally have electrical generating or concrete manufacturing plants
constructed
thereon. According to the methods described herein, Lignite coal can be
processed at the
mine to remove the moisture and pulverize the coal, thereby producing a
processed coal
having a higher energy content than some known forms of coal. Using the
systems and
methods described herein, the processed Lignite coal can be economically
packaged, handled
and shipped.
[1135] Refined bulk materials such as Direct Reduced Iron (DRI) are
extremely reactive,
corrosive and flammable. These products must be transported in specially
constructed rail
cars, trucks and bulk ships. DRI is highly susceptible to re-oxidation,
overheating, and the
generation of highly combustible/explosive hydrogen if left unprotected. DRI
reacts easily
with water, particularly seawater and produces heat if exposed to seawater or
moisture laden
sea air.
[1136] The flexible containers described herein are configured to eliminate
or
significantly reduce exposure to water and air thus eliminating or
significantly reducing the
possibility of combustion. An additional protection against combustion would
be to insert an
inert gas into the bag after sealing. Bulk ships generally avoid shipping DRI
when possible
owing to the extremely corrosive nature of the material. The systems and
methods described
herein eliminate the corrosive impact of DRI and other materials on the
interior and exterior
of bulk ships.
[1137] Although certain embodiments are shown and described as being used
to contain
coal, any of the embodiments herein can be used to contain and/or transport
any suitable bulk
materials. Such bulk materials can include, for example, the following ores:
Argentite,
Azurite, Barite, Bauxite, Bornite, Calcite, Cassiterite, Chalcocite,
Chalcopyrite, Chromite,
Cinnabar, Cobaltite, Columbite-Tantalite or Coltan, Cuprite, Dolomite,
Feldspar, Galena,
Gold, Gypsum, Hematite, Ilmenite, Magnetite, Malachite, Molybdenite,
Pentlandite,
Pyrolusite, Scheelite, Sphalerite, Talc, Uraninite, Wolframite. In other
embodiments, such
bulk materials can include grains (either raw or processed). Grains that can
be packaged and
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transported according to the methods described herein include corn, wheat,
soybean, oats or
the like. Moreover, processed grain products, such as flour, can also be
packaged and
transported according to the methods described herein.
[1138] Any of the systems and containers described herein can be loaded and
unloaded
onto containerized ships, using conventional container loading and
transportation equipment.
The loading and unloading of bulk materials according to the systems and
methods described
herein avoids the cost and/or hazards associated with bulk shipping and
storage of volatile
materials, and reduces the amount of product lost in the environment. Shipment
of materials
according to the systems and methods described herein also permits the
transport of materials
through larger vessels, capable of transporting larger quantities of coal than
bulk carriers.
Thus, containerized shipping can decrease transportation costs associated with
known
methods of coal shipment.
[1139] Furthermore, some embodiments provide for control over the weight
and/or
density of the coal pile. By limiting the weight and/or density of the coal
pile, and by
providing a non-reactive surface and a controlled atmosphere, the risk of
spontaneous
combustion can be minimized. Further, the risk of a chemical reaction between
the coal and
the containment vessel is minimized.
[1140] Transport of containerized coal according to the systems and methods
described
herein is environmentally safe when compared to known bulk transport methods,
since the
coal is not repeatedly exposed to the air and weather, and the creation and
release of coal dust
is minimized. In addition, embodiments described herein also serve to reduce
inefficiency in
the trade imbalance. The imbalance in trade between various countries and
regions, more
particularly between Asia and the United States, and most particularly between
China and the
Unites States has for many years resulted in a surplus of containers in the
United States. In
particular, there remains significant unused container ship capacity from the
economic crises
of 2008 crash. Moreover, slowing manufacturing and exports from the U.S. have
created an
excess of shipping containers in the U.S. By streamlining the transportation
process, and
using retrofit systems for sealing existing used cargo containers, embodiments
described
herein will provide a means of returning cargo containers to Asia, including
China, reducing
the number of unused containers in the U.S. Some embodiments also provide a
means for re-
using containers in the transport of other goods to the United States. Thus,
rather than using
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containers one time, or shipping empty containers back to Asia for re-use,
some embodiments
enable reuse of containers back and forth between the U.S. and Asia.
[1141] FIG. 23A is a flowchart illustrating a method 1000 for storing
and/or transporting
a bulk material, according to an embodiment. In some embodiments, the bulk
material is
stored and/or transported in a flexible container such as, for example, any of
the flexible
containers described herein. In such embodiments, the flexible container can
include a
container body and a cover and can be configured to move between an expanded
configuration and a collapsed configuration. The flexible container further
includes a side
wall and defines an interior volume within the container body. In some
embodiments, the
side wall can include a substantially non-circular opening configured to
receive a bulk
material. In some embodiments, the flexible container is substantially similar
to the flexible
container 300 described herein with reference to FIGS. 6A and 7-13 or the
flexible container
364 described herein with reference to FIGS. 6B and 6C. While not explicitly
described, the
flexible container can include any features included in the flexible container
300 and or any
other embodiment described herein.
[1142] In some embodiments, the method 1000 optionally includes aligning a
delivery
member with the opening defined by the side wall of the flexible container, at
1002. The
delivery member can be any suitable member. For example, in some embodiments,
the
delivery member is a conveyer. In some embodiments, a portion of the delivery
member is
disposed through the opening defined by the side wall and is disposed within
the interior
volume of the container body, at 1004. In some embodiments, the method 1000
can include
conveying a gas from a volume outside the flexible container to maintain the
container in the
expanded configuration. In some embodiments, the gas can be an inert gas. In
other
embodiments, the gas can be air. In some embodiments, the inflation fluid can
be conveyed
into the flexible container via the same opening through which the bulk
material is conveyed.
[1143] The method includes conveying the bulk material into the flexible
container via an
opening therein, at 1006. In some embodiments, the delivery member can be
disposed within
the interior volume such that at least a portion of the delivery member is
disposed at a rear
portion of the interior volume. In this manner, the delivery member can
transfer the bulk
material through the opening and into the rear portion of the interior volume
of the container
body. While transferring the bulk material into the interior volume of the
container body, in
some embodiments, the delivery member can be configured to telescope such that
a length of
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the delivery member disposed within the interior volume is reduced. Similarly
stated, the
delivery member can retract at a given rate through the opening. Thus, the
bulk material
(e.g., processed coal) can be loaded in a rear to front manner. Said another
way, the
telescopic motion of the delivery member toward the opening is configured to
even distribute
the bulk material within the interior volume. In some embodiments, the method
1000
includes filling the interior volume with the bulk material to a predetermined
volume and/or
weight. For example, in some embodiments, the method 1000 includes filling the
flexible
container until the flexible container is approximately 60 percent full (by
volume when
compared to the volume of the flexible container in the expanded
configuration). In other
embodiments, the flexible container can be filled to any suitable level. For
example, in some
embodiments, the flexible container can be filled to a volume ratio of
approximately 50
percent, 55 percent, 65 percent, 75 percent, 85 percent, or more.
[1144] With the desired amount of bulk material transferred to the interior
volume of the
flexible container, the delivery member can be retracted through the opening
defined by the
side wall. With the delivery member retracted, the cover included in the
flexible container
can be disposed about the opening and coupled to the side wall, at 1008. For
example, in
some embodiments the cover can be coupled to the side wall via an adhesive
strip. In other
embodiments, the cover can be coupled to the flexible container in any
suitable manner. In
some embodiments, the coupling of the cover to the side wall places the
interior volume in
fluidic isolation with a volume outside the flexible container. Similarly
stated, the cover can
be coupled to the side wall to define a hermetic seal.
[1145] With the cover coupled to the side wall and disposed about the
opening the
pressure within the interior volume can be reduced, thereby moving the
flexible container
from the expanded configuration to the collapsed configuration, at 1010. More
specifically,
container body and the cover can be placed in the collapsed configuration by
evacuating a gas
within the interior volume via a port. In some embodiments, the cover defines
the port. In
other embodiments, the container body or the side wall can define the port. In
this manner,
the port can be engaged by, for example, a vacuum source such that the
pressure within the
interior volume of the container body is reduced. The reduction of the
pressure within the
interior volume can be such that container body deforms. Similarly stated, the
vacuum
source can exert a suction force on the interior volume thereby urging at
least a portion of the
container body to deform under the force. Furthermore, the vacuum source can
be configured
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to expose interior volume to the suction force such that the interior volume
is substantially
devoid of a gas (e.g., air). Said another way, the interior volume is exposed
to a negative
pressure and thereby urges the container body to substantially conform to a
contour of the
bulk material disposed therein.
[1146] In some embodiments, the flexible container can collapse (e.g.,
conform to the
bulk material) such that the bulk material disposed within the container body
can act as a
substantially solid mass. For example, in some embodiments, the flexible
container can
collapse such that a distance between adjacent portions and/or constituents of
a bulk material
is reduced. In this manner, the movement of specific parts (e.g., particles,
pellets, grains,
chunks, portions, and/or the like) of the bulk material is reduced relative to
adjacent parts of
the bulk material. Thus, the potential of load shifting within the flexible
container is reduced.
In some embodiments, the substantial evacuation of the gas (e.g., air) within
the flexible
container can reduce the risk of spontaneous combustion of the bulk material
(e.g., coal).
[1147] FIG. 23B is a flowchart illustrating a method 3000 for storing
and/or transporting
a bulk material, according to an embodiment. In some embodiments, the flexible
container is
substantially similar to the flexible containers 300, 364 described herein
with reference to
FIGS. 6A-6C and 7-13. While not explicitly described in the context of the
method below,
the flexible container can include any features included in the flexible
container 300, 364 and
or any other embodiment described herein.
[1148] The flexible container can be magnetically coupled to a rigid
container to define
an interior volume within the flexible container, at 3002. For example, as
shown in FIG. 6B,
the flexible container can include magnets operable to magnetically attach to
a rigid shipping
container of the types shown and described herein. Thus, the flexible
container can be
magnetically coupled to a rigid structure outside of the interior volume of
the flexible
container. The magnets can be operable to couple a top, a side wall, a font, a
rear, and/or any
other portion of the flexible container to the rigid container. In some
embodiments, the
magnetic coupling between the flexible container and the rigid container can
be operable to
maintain the flexible container in an expanded configuration, at 3004. In
addition or
alternatively, a gas can optionally be conveyed into the interior volume to
maintain the
flexible container in the expanded configuration.
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[1149] A bulk material is conveyed into the flexible container, at 3006.
Conveying the
bulk material, at 3006, can be similar to conveying the bulk material, at
1006, as shown and
described with reference to FIG. 23A. The pressure is reduced inside the
flexible container
such that a pressure differential between the interior volume and a volume
outside of the
interior volume is sufficient to overcome the magnetic coupling, at 3010
Similarly stated,
reducing the pressure can result in the application of a force to the flexible
container operable
to overcome the magnetic coupling force, such that the flexible container
pulls away from the
rigid container. In this manner, the flexible container can move from the
expanded
configuration towards the collapsed configuration as the magnets can become
spaced apart
from the rigid container.
[1150] Reducing the pressure inside the flexible container can move the
flexible
container from an expanded configuration to a collapsed configuration. When in
the
collapsed configuration, flowability of the bulk material can be impeded.
Similarly stated,
when in the collapsed configuration, the flexible container can be operable to
impede the
movement of a first portion of the bulk material with respect to a second
portion of the bulk
material. The bulk material can form a substantially solid block when the
flexible container
is in the collapsed configuration.
[1151] In some embodiments, the magnets can be decoupled from the rigid
container
before the pressure is reduced inside the flexible container. In such an
embodiment, the
magnets can be manually separated from the rigid container. For example,
tethers can be
coupled to the flexible container which can be used to pull the flexible
container and the
magnets away from the rigid container. In embodiments, the magnets can be
electromagnets,
which can be de-energized prior to reducing the pressure inside the flexible
container.
[1152] FIG. 23C is a flowchart illustrating a method 4000 for storing
and/or transporting
a bulk material, according to an embodiment. In some embodiments, the flexible
container is
substantially similar to the flexible container 300 and/or the flexible
container 364 described
herein with reference to FIGS. 6A-6C and 7-13. While not explicitly described,
the flexible
container can include any features included in the flexible container 300 and
or any other
embodiment described herein.
[1153] The method includes maintaining the flexible container in an
expanded
configuration to define an interior volume, at 4004. Maintaining the flexible
container in the
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expanded configuration, at 4004, can be similar to maintaining the flexible
container in the
expanded configuration, at 1004, and/or 3004, as shown and described with
reference to
FIGS. 23A and 23B. For example, in some embodiments, the flexible container
can be
maintained in an expanded configuration by magnetically coupling the bag to a
frame or
structure, by conveying a gas into the flexible container, or the like. Bulk
material can be
conveyed into the flexible container, at 4006. The conveying the bulk
material, at 4006, can
be performed via any suitable method, such as those described herein (e.g.,
similar to
conveying the bulk material, at 1006, and/or 3006, as described above).
[1154] The flexible container can be shaped via a form into a desired size
and/or shape, at
4009. The form can be similar to the form 1300, shown and described with
reference to FIG.
14. In some embodiments, the form can be coupled to the flexible container to
maintain the
flexible container in the expanded configuration, as described above.
Moreover, as described
above, the form can exert a force on the flexible container to urge it to
assume a particular
shape.
[1155] The pressure can be reduced inside the flexible container, at 4010,
which can be
similar to reducing the pressure at 1010 and/or 3010. In some embodiments, the
actuation of
the form can reduce the pressure by compressing the flexible container. The
flexible
container, having been shaped, at 4009, and moved into a collapsed
configuration, at 4010,
can become substantially rigid. The flexible containers can take and maintain
a shape
amenable to stacking, storage and/or loading, such as a cylinder and/or a
rectangular prism
with substantially flat surfaces. In this way, the flexible containers can be
stored on site
where the bulk material is generated and/or prepared in anticipation of
receiving shipping
containers. Preparing bulk containers in advance of transport means (trains,
trucks, barges,
etc.) can advantageously decrease loading time as compared to filling shipping
containers as
they arrive.
[1156] Thus, in some embodiments, the flexible container can be optionally
removed
from the form and can be staged and/or stored for loading into a shipping
container, at 4011.
The flexible containers can be loaded into a rigid shipping container, at
4012. In some
embodiments, air bumpers can be inflated, at 4014, and/or other dunnage
systems can be
deployed to prevent the flexible container from shifting within the rigid
container.
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[1157] FIG. 24 is a flowchart illustrating a method 1100 for processing
coal at the mine
or railhead, at 1101. At either location, the coal can be processed into
crushed, granulated or
powder form, and graded by a variety of factors, such as quantity, type, size,
moisture
content, and ash content. Processing can also entail mixing of different
grades of coal (BTU
content), in order to achieve specialized coal products for particular end
users.
[1158] Additionally, the processing can include coal washing and drying to
meet
enhanced end user specifications. At the time of processing, the coal can be
loaded into
sealed containers 1102. The containers can be loaded according to any of the
methods
described herein. Moreover, the container can be any of the containers
described herein.
After loading, the containers can be purged of air, and, if desired, filled
with an inert or other
gas that reduces the risk of combustion 1103. The filled, sealed, and oxygen
purged
containers can be stored for later transport, at 1104. Loaded, sealed
containers may also be
placed on trucks 1105, for delivery to a railhead 1107, where the containers
are loaded
directly onto railcars designed for transport of cargo containers. In the
alternative, the
containers may be loaded onto railcars 1105 for direct transport to ports that
handle
containerized cargo 1110. At the port, the sealed containers can be stored
1115 until
scheduled for sea transport, when they may be loaded onto mid- to large-sized
container ships
1120.
[1159] After loading on a ship 1120, the containerized material is
transported via sea
1125 to a destination port 1130, where the containers are unloaded 1135. Once
unloaded, the
containers can be stored for future transport 1140, or immediately loaded onto
railcars or
trucks 1145 for transport to the end user 1150. Once the containers arrive at
the end user
location they are unloaded form the transport means 1155, and may be stored
until needed
1160, or opened such that the contents are made available for immediate use
1165.
[1160] In some embodiments, a shipping container for the transportation of
granular
materials includes a load- carrying space which is sealable to prevent ingress
and egress of
gas. In some embodiments, the load-carrying space is provided by a liner
positioned within
the shipping container. In some embodiments, the liner is removable from the
container. In
some embodiments, the liner can be formed of a polymer material. In some
embodiments,
the liner is a flexible bag. In other embodiments, the liner is a collapsible
box. In still other
embodiments, the liner is coated on the interior of the shipping container. In
such
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embodiments, the liner is formed of a material that is non-reactive with coal.
In some
embodiments, the liner has a thickness in the range 1.27 cm to 1.91 cm (0.5 to
0.75 inches).
[1161] In some embodiments, a shipping container includes a sealable
loading port for
loading granular materials into the load-carrying space. In some embodiments,
the shipping
container includes a port for extracting gasses from the load-carrying space,
or injecting
gasses into the load-carrying space. The port can be configured for connection
to a vacuum
source for evacuation of gasses from the load-carrying space. The port can be
configured for
connection to a source of inert gas for injecting inert gas into the load-
carrying space. In
some embodiments, the shipping container is a twenty-foot equivalent
container.
[1162] In some embodiments, a method of transporting granular material
includes
loading the granular material into a container. The method can further include
sealing the
load-carrying space and extracting gas from the load carrying space to reduce
the pressure in
the load-carrying space to substantially below atmospheric pressure. In some
embodiments,
the method includes injecting an inert gas into the load-carrying space to
purge air from the
load-carrying space.
[1163] While embodiments herein have been described with reference to the
transportation of coal, other materials may be transported utilizing the same
systems and
methods to obtain comparable advantages. For example the system and method may
be
suitable for transporting Potash. Potash is a mined and processed mineral used
primarily as
fertilizer. Unlike coal, potash is not combustible yet has specific chemical
characteristics that
have significant transport and storage challenges. Embodiments described
herein effectively
meets those issues and do so in a more efficient manner than current methods
and/or
technologies.
[1164] Potash is commonly transported in crystalline form. These crystals
are extremely
sensitive to humidity and moisture, forming clumps and "pan caking" when
exposed to
humidity and moisture. Current transport requires specialized rail cars and
truck bodies that
keep the potash from coming into contact with water. These specialized
vehicles are
expensive and require considerable maintenance. Current storage facilities, at
the processing
plant, at both sending and receiving ports and distribution centers are
specialized and
expensive to construct. Current handling methods and facilities at all the
above steps are
costly to build and maintain. By applying the technology described herein to
potash,
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transport becomes more efficient, storage will not require expensive
facilities, handling at
ports and distribution centers will be more efficient and cheaper and ocean
transport will be
scalable, more flexible, cheaper and much more efficient.
[1165] In some embodiments, the bulk material can be processed at or near
the mine. For
example, processing may include milling to produce granular or powdered coal
of a specific
size desired by an end user. Processing may also entail washing or chemical
processing to
remove undesirable materials and gases, or drying to produce material with
specified, known
water content. Examples of pulverizing equipment that may be utilized include
mills such as
the ball and tube mill or the bowl mill. By processing the coal at the mine,
at the rail-head or
elsewhere in the supply chain, the coal may be supplied in the exact form
specified by the end
user, such that the coal need not be processed by the end user before it is
consumed. For a
power plant, this means that the supplied coal can be fed directly into the
power generation
furnace or boiler, avoiding the need for complex milling and drying equipment.
Thus, the
plant operator need not install, maintain or operate such equipment,
significantly reducing
operating costs and plant size. The plant operator may also reduce
environmental risks and
issues, as coal may be stored in containers until needed, rather than in open
piles. As
contemplated herein, coal may be supplied in the following forms: raw lump,
granulate, or
powder, or mixed with higher or lower BTU coal to end user specifications.
[1166] While various embodiments have been described above, it should be
understood
that they have been presented by way of example only, and not limitation.
Where methods
described above indicate certain events occurring in certain order, the
ordering of certain
events may be modified. Additionally, certain of the events may be performed
concurrently
in a parallel process when possible, as well as performed sequentially as
described above
[1167] For example, in reference to FIGS. 1-3, while the flexible container
100 is shown
as receiving the conveyer C, in other embodiments, a flexible container can
receive any
suitable delivery member. In other embodiments, a container can include a
portion of a
delivery member therein. For example, as shown in FIG. 25, a flexible
container 2000
includes a container body 2010 and a side wall 2012. The container body 2010
defines an
interior volume 2011 and is configured to house, at least partially, an
internal chute 2017.
The side wall 2012 defines an opening 2013 configured to be aligned with the
internal chute
2017. Furthermore, a delivery hose 2016 can be configured to couple to the
side wall 2012
such that the delivery hose 2016 and the internal chute 2017 are in fluid
communication. In
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this manner, the delivery hose 2016 can be configured to transfer, for
example, a pulverized
(e.g., processed) coal. In addition, the internal chute 2017 can be configured
to telescope in
the direction of the arrow AA (e.g., mechanically and/or electrically) such
that the processed
coal is loaded into the flexible container 2000 from the rear forward. Thus,
the weight
distribution of the processed coal can be controlled.
[1168] Where schematics and/or embodiments described above indicate certain
components arranged in certain orientations /or positions, the arrangement of
components
may be modified. Similarly, where methods and/or events described above
indicate certain
events and/or procedures occurring in certain order, the ordering of certain
events and/or
procedures may be modified. While the embodiments have been particularly shown
and
described, it will be understood that various changes in form and details may
be made.
[1169] For example, although the flexible container 300 is shown and
described as
including a bulkhead 325 that includes a sleeve 321 that receives a shock
absorbing member,
in other embodiments, the flexible container 300 need not include a bulkhead
300. For
example, in some embodiments, the flexible container 300 can be disposed
and/or coupled
within a rigid shipping container to form a shipping system that is devoid of
a dunnage bag,
bulwark, bulkhead and/or any other mechanism for absorbing a load produced by
the
movement of the bulk material within the flexible container 300. In
particular, as described
above, when the flexible container 300 is moved from the expanded
configuration to the
collapsed configuration, the bulk material therein can be moved from a
flowable (or partially
flowable) state to a substantially non-flowable state. Thus, the potential of
load shifting of
the bulk material within the flexible container 300 is reduced and/or
eliminated.
Accordingly, the flexible container 300 can be coupled within a rigid
container solely with a
tether or strap (i.e., without the need for a bulwark, dunnage bag or the
like).
[1170] Conversely, although the flexible container 300 is shown and
described as
including a bulkhead 325 that is constructed separately from and later
attached to a container
body, in other embodiments, a flexible container can include an integrated
bulkhead, dunnage
system or the like. For example, in some embodiments, a flexible container can
include an
inflatable portion (e.g., towards the rear or front thereof) configured to be
inflated in
conjunction with loading the flexible container with the bulk material. In
this manner, the
flexible container can provide additional protection to the rigid container
within which it is
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disposed. Similarly stated, this arrangement can obviate the need for external
dunnage bags,
bulwark systems or the like.
[1171] FIGS. 26 ¨ 29 depict flexible containers (which can be similar to
the flexible
container 300) with various configurations of buffer ribs. FIG. 26 is a front
view of a flexible
container 4300 having buffer ribs 4382 extending circumferentially around the
flexible
container. The buffer ribs 4382 can be operable to resist movement of the
flexible container
4300 when it is disposed within a shipping container. For example, the buffer
ribs, 4382 can
be inflated to take up excess space between the flexible container 4300 and
the shipping
container. FIG. 27 is similarly a front view of a flexible container 5300 with
buffer ribs 5382
disposed on the edges of the flexible container, and FIG. 28 is a front view
of a flexible
container 6300 having buffer ribs 6382 disposed on the bottom of the flexible
container. In
other embodiments, buffer ribs can be disposed on any surface, edge, corner,
etc. of a flexible
container.
[1172] Although various embodiments have been described as having
particular features
and/or combinations of components, other embodiments are possible having a
combination of
any features and/or components from any of embodiments as discussed above. For
example,
any of the rigid containers described herein can include any of the flexible
containers
described herein.
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