Claims:1. A method of manufacturing a Flexible Intermediate Bulk Container with baffles, characterized in that, the baffles are associated with the Flexible Intermediate Bulk Container without any sewing holes, said association of baffles with the Flexible Intermediate Bulk Container being achieved through:

producing a high density polyethylene fabric from high density polyethylene tape, with the denier ranging from 800 to 1,000;
laminating said fabric on both sides with low density polyethylene to provide a uniform surface on the fabric, with the thickness of said low density polyethylene being 20 microns to 40 microns;
marking of each sealing area (28);
making cut piece holes (27) in the high density polyethylene reinforced fabric, said holes (27) bring of oval shape or square shape or rectangle shape;
marking the cut pieces at both ends;
fixing appropriate ends of the cut pieces at appropriately marked sealing area (28) positions;
completing the sealing using heat bar sealing or impulse sealing or ultrasonic sealing, with the sealing being uniform on both sides of the fabric;
marking the different panels of the bag with reinforced sewing lines; and
attaching the liner sealed reinforced panels with the bag,

said method being configured to: allow the Flexible Intermediate Bulk Container to retain a perfect square shape after filling; make the Flexible Intermediate Bulk Container moisture proof, and provide required protection to the filled material.
2. The method of manufacturing a Flexible Intermediate Bulk Container with baffles as claimed in claim 1, wherein the barrier liner comprises ethylene vinyl alcohol or nylon.

3. The method of manufacturing a Flexible Intermediate Bulk Container with baffles as claimed in claim 1, wherein the dimensions of the liner (26) are 50 cm to 70 cm greater than the full circumference of the bag.

4. The method of manufacturing a Flexible Intermediate Bulk Container with baffles as claimed in claim 1, wherein 8 cm to 10 cm are kept in excess to accommodate the sealing of the high density polyethylene fabric.

5. A Flexible Intermediate Bulk Container with baffles manufactured through the method as claimed in claim 1, said Flexible Intermediate Bulk Container with baffles being configured to: allow the Flexible Intermediate Bulk Container to retain a perfect square shape after filling; make the Flexible Intermediate Bulk Container moisture proof, and provide required protection to the filled material. , Description:TILE OF THE INVENTION: A FLEXIBLE INTERMEDIATE BULK CONTAINER WITH BAFFLES AND METHOD OF MANUFACTURING THEREOF
FILED OF THE INVENTION
The present disclosure is generally related to flexible intermediate bulk containers with baffles.
BACKGROUND OF THE INVENTION
Present Flexible Intermediate Bulk Containers (FIBC) with baffles available in the market, which are also known as baffle bags, Q bags, etc., suffer from several drawbacks.
First, they are not completely moisture proof. Even though the fabric is laminated, the sewing holes are directly exposed to the atmosphere; so, moisture can enter through the sewing holes. Second, they do not have the properties to retain aroma of the filled material. Third, they cannot be used to fill fine free flowing powders; this is due to the leakage of materials through the sewing holes.
The baffle liner is made of complete LLDP/LDPE including reinforcement in the FIBC with baffles which are available in the market. Since the baffle reinforcements have an elongation greater than 200 %, the bag does not retain its dimensions. Also, since the liners are not secured with outer liners, the bulging of the outside layer cannot be controlled.
There is, therefore, a need in the art for a FIBC with baffles, which overcomes the aforementioned drawbacks and shortcomings.
SUMMARY OF THE INVENTION
A method of manufacturing a Flexible Intermediate Bulk Container with baffles is disclosed. The method is characterized in that the baffles are associated with the Flexible Intermediate Bulk Container without any sewing holes, said association of baffles with the Flexible Intermediate Bulk Container being achieved through: producing a high density polyethylene fabric from high density polyethylene tape, with the denier ranging from 800 to 1,000; laminating said fabric on both sides with low density polyethylene to provide a uniform surface on the fabric, with the thickness of said low density polyethylene being 20 microns to 40 microns; marking of each sealing area; making cut piece holes in the high density polyethylene reinforced fabric, said holes bring of oval shape or square shape; marking the cut pieces at both ends; fixing appropriate ends of the cut pieces at appropriately marked sealing area positions; completing the sealing using heat bar sealing or impulse sealing or ultrasonic sealing, with the sealing being uniform on both sides of the fabric; marking the different panels of the bag with reinforced sewing lines; and attaching the liner sealed reinforced panels with the bag. The method is configured to: allow the Flexible Intermediate Bulk Container to retain a perfect square shape after filling; make the Flexible Intermediate Bulk Container moisture proof, and provide required protection to the filled material.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates an embodiment of a HDPE reinforced hole punched cut piece sealed with a liner, in accordance with the present disclosure;
Figure 2 is a schematic diagram for the installation of a HDPE reinforced hole punched cut piece sealed with a liner in a Flexible Intermediate Bulk Container, in accordance with the present disclosure; and
Figure 3 illustrates an embodiment of a Flexible Intermediate Bulk Container with baffles, in accordance with the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Throughout this specification, the use of the word "comprise" and variations such as "comprises" and "comprising" may imply the inclusion of an element or elements not specifically recited.
Throughout this specification, the disclosure of any range is to be construed as being inclusive of the lower limit of the range and the upper limit of the range.
A Flexible Intermediate Bulk Container (FIBC) with baffles is disclosed. The FIBC with baffles is characterized in that the baffles are associated with the FIBC without any sewing holes, and is configured to: allow the FIBC to retain a perfect square shape after filling; make the FIBC moisture proof, and provide required protection to the filled material. Further, the liner is inserted into the FIBC without any sewing holes.
Fabrication:
This disclosure is based on sealing of high density polyethylene (HDPE), along with low density polyethylene (LDPE) liner, to avoid any sewing holes.
The HDPE fabric is produced from HDPE tape, with the denier ranging from 800 to 1,000, depending on the bag design and its capacity to retain its square shape. The tape is converted to fabric through circular/flat loom machine. At most care is taken, while making the fabric, to avoid any tape folding during weaving (to improve the lamination adhesion of LDPE).
The fabric is laminated on both sides with LDPE to give a uniform surface on the fabric. Each side is laminated with 20 – 40 micron thickness, which has been found by the inventors to be suitable for sealing.
The LDPE/LLDPE (linear low density polyethylene)/barrier (inner layer with LDPE) liner is produced by mono or multilayer liner plant, and the liner is converted to the bag size, with top and bottom spout in a single piece, by firm fit liner machine. The barrier liner may comprise ethylene vinyl alcohol, nylon, or any other barrier liner to improve the WTR, OTR, and/or other requirements.
The barrier liners are made by co-extruder blown film or cast film, having LDPE on the outer surface of both layers, to ensure good sealing.
In an embodiment of the present disclosure, the dimensions of the LDPE/LLDPE/barrier liner are 50 cm to 70 cm greater than the full circumference of the bag.
In each corner of the bag, 8 cm to 10 cm are kept in excess to accommodate the sealing of the HDPE fabric. As illustrated in Figure 1, each sealing area (28) is marked, which includes folding of each side for sealing. As illustrated in Figure 2, in another embodiment of the present disclosure, the reinforced area numbers are marked as follows:
1 and 2 marked as A; 3 and 4 marked as B; 5 and 6 marked as C; and 7 and 8 marked as D; 9 and 10 marked as E; 11 and 12 marked as F; and 13 and 14 marked as G.
The distance of each marking is dependent on the bag size. For example, the distance between 1 and 2 may be 8 cm to 10 cm, depending on the sealing requirement.
The HDPE fabric is cut to size based on the bag height and width. In the fabric, cut piece holes (27) are made through a blade; the holes (27) can be of any shape such as, oval or square or rectangle, based on the material flow requirement.
In another embodiment of the present disclosure, a total of four HDPE reinforced hole punched cut pieces (25) are marked: the first cut piece is marked with the number “1” at one end and the number “2” at another end, with the next cut piece being marked with the number “3” at one end and the number “4” at another end. Likewise, the third cut piece is marked with the numbers 5 and 6, while the fourth cut piece is marked with the numbers 7 and 8.
First, the HDPE cut piece with the “1” marking is fixed at position A, in between “1” and “2”, to cover both sides of the liner (26) in the marked area, with a clip securing the position of the liner (26). Likewise, the other end of the HDPE cut piece, marked “2”, is fixed at B in between “3” and “4.”
In the same way:
The HDPE cut piece with the “3” marking is fixed at position C, in between “5” and “6”, to cover both sides of the liner (26) in the marked area, with a clip securing the position of the liner (26). Likewise, the other end of the HDPE cut piece, marked “4”, is fixed at D in between “7” and “8.”
The HDPE cut piece with the “5” marking is fixed at position E, in between “9” and “10”, to cover both sides of the liner (26) in the marked area, with a clip securing the position of the liner (26). Likewise, the other end of the HDPE cut piece, marked “6”, is fixed at F in between “11” and “12.”
The HDPE cut piece with the “7” marking is fixed at position G, in between “13” and “14”, to cover both sides of the liner (26) in the marked area, with a clip securing the position of the liner (26). Likewise, the other end of the HDPE cut piece, marked “8”, is fixed at G in between “15” and “16.”
In yet another embodiment of the present disclosure, the reinforced piece has an elongation of less than 25% to retain the square shape of the bag.
The sealing processes are carried out by using heat bar sealing/ impulse sealing/ultrasonic sealing, through a special attachment of double stroke arrangement. The sealing machine is specially configured for this application. During the sealing processes, it is ensured that the sealing is uniform on both sides of the fabric. The sealing strengths are checked frequently for assessing the quality of sealing. After completing the all sealing, the liner (26) is closed by sealing using impulse sealing.
Inserting or Fixing the Liner in the Bag:
In yet another embodiment of the present disclosure, as illustrated in Figure 3, the different panels of the bag are marked with reinforced sewing lines, and the liner sealed reinforced panels are attached based on the following sequences:
The end “A” is attached through sewing (without obstructing liner) along the “A1” marked line on the fabric, while the other end “B” is attached with the “A2 marked line.”
The end “C” is attached through sewing along the “B1” marked line on the fabric, while the other end “D” is attached with the “B2” marked line.
The end “E” is attached through sewing along the “C1” marked line on the fabric, while the other end F is attached with the “C2” marked line
The end “G” is attached through sewing along the “D1” marked line on the fabric, while the other end H is attached with the “D2” marked line.
All the panels are attached together to form the bag, and top and bottom are also fixed. The bags are tested by using high pressure blower to test the leakage test for air, and leakage of water by filling with water to confirm whether they are 100% moisture proof.
Accordingly, the disclosure provides for a method of manufacturing a FIBC with baffles, characterized in that, the baffles are associated with the FIBC without any sewing holes, said association of baffles with the FIBC being achieved through:
producing a high density polyethylene fabric from high density polyethylene tape, with the denier ranging from 800 to 1,000;
laminating said fabric on both sides with low density polyethylene to provide a uniform surface on the fabric, with the thickness of said low density polyethylene being 20 microns to 40 microns;
marking of each sealing area (28);
making cut piece holes in the high density polyethylene reinforced fabric, said holes bring of oval shape or square shape;
marking the cut pieces at both ends;
fixing appropriate ends of the cut pieces at appropriately marked sealing area (28) positions;
completing the sealing using heat bar sealing or impulse sealing or ultrasonic sealing, with the sealing being uniform on both sides of the fabric;
marking the different panels of the bag with reinforced sewing lines; and
attaching the liner sealed reinforced panels with the bag,
said method being configured to: allow the FIBC to retain a perfect square shape after filling; make the FIBC moisture proof, and provide required protection to the filled material.
Accordingly, the present disclosure also provides for a FIBC with baffles manufactured through the above method, said FIBC with baffles being configured to: allow the FIBC to retain a perfect square shape after filling; make FIBC moisture proof, and provide required protection to the filled material.
It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations and improvements without deviating from the spirit and the scope of the disclosure may be made by a person skilled in the art. Such modifications, additions, alterations and improvements should be construed as being within the scope of this disclosure.
LIST OF REFERENCE NUMERALS
25 – Double Side Laminated HDPE Reinforced Hole Punched Cut Pieces
26 – Liner
27 – Hole on the Double Side Laminated HDPE Reinforced Cut Pieces
28 – Sealing Area