The present invention relates to a bulk bag discharging apparatus and to a method of discharging matter from a bulk bag using that apparatus.

Bulk bags are also known as builders’ bags, tonne bags or dumpy bags, and are typically used to store and transport free flowing dry materials such as rubble, sand, gravel, soil, or fertiliser. A bulk bag is typically made of flexible material, typically strands of polypropylene woven into fabric.

Conventionally, when delivering a bulk bag to a work site, the bulk bag is unloaded from a delivery vehicle via a crane arm, for example on a lorry loader, and then placed directly on the ground. Manual movement of the bulk bag is not possible and the bulk bag, due to its heavy weight, is confined to stay where it has been placed on the ground. The bagged material is then required to be manually transferred out of the bulk bag and to a desired location, and this can be extremely hard work. It is desired to provide improvements relating to discharging material from bulk bags.

Thus, according to an aspect of the present invention there is provided a bulk bag discharging apparatus comprising: a frame for supporting a bulk bag above the ground in use; and an outlet with a valve, wherein when the bulk bag is placed onto the frame in use, the matter contained therein is dispensable under gravity towards the outlet, and wherein the valve is configured selectively to control the discharge of the matter through the outlet. As will be appreciated, the apparatus of the present invention can support a bulk bag above ground level, and this can allow matter to be dispensed from the bulk bag in a convenient and controlled way via the outlet.

The frame may comprise a tray for supporting a bulk bag thereon. The frame and/or tray may be shaped and sized to accommodate a standard bulk bag thereon. In embodiments, the frame and/or tray may be substantially rectangular (including square). The frame and/or tray may have side lengths in the range 0.7- 1 5m, for example in the range 1 -1 2m. The tray may be sloped/funnelled towards the outlet to guide the matter that is dispensable from the bulk bag towards the outlet.

The outlet may comprise a conduit through which the matter is dispensable from the bag. The conduit may be in the form of a tube. The conduit may project substantially downwardly from the frame and/or tray. The conduit may be made of metal such as steel or aluminium, but other materials can be used. A sleeve may be provided to line at least a portion of the inside of the conduit. The sleeve may be removably attachable to the apparatus, for example via a removably attachable ring/collar provided on or adjacent to (e.g. the top of) the conduit. The sleeve may be substantially conformable to the conduit. The sleeve may be substantially flexible. The sleeve may be made of fabric or sheet material. The sleeve may be replaceable as and when necessary, for example when worn or damaged. The sleeve can help to protect the inside of the conduit and/or valve mechanism associated with the conduit.

The apparatus may further comprise a piercing structure configured to pierce the underside of the bulk bag when the bulk bag is placed onto the frame/tray. The piercing structure may comprise a plurality of cutters. The cutters may have first ends that are substantially co-located and second ends that are splayed to define spaces therebetween through which dispensed matter can pass. The cutters may be arranged to form a substantially pyramidal structure. The piercing structure can allow the matter to be dispensed through the spaces defined between the cutters and via the outlet. The piercing structure may be arranged substantially at the centre of the apparatus such that when a bulk bag is placed on the frame/tray, the bulk bag is pierced substantially at the centre of the base of the bulk bag. The outlet may be located under the piercing structure in use. The piercing structure may be removably attachable to the apparatus, for example to the frame/tray. Alternatively, the piercing structure may be permanently attached to and/or integral with the frame/tray.

The apparatus may comprise legs attached to the frame. The legs may be releasably attachable to the frame. The legs may be attachable to the frame by a releasable locking mechanism, such as a spring pin/latch mechanism. This can allow easy and quick assembly and disassembly whilst also allowing improved portability and storage. Thus, embodiments of the present invention can provide a portable and modular assemblable/disassemblable apparatus which can be efficiently stored on site or in the back of a vehicle and easily and quickly assembled and disassembled on site by an operator/user.

The legs may comprise tubular elements which are slidably mounted in or around first tubular structures. The first tubular structures (e.g., first box sections) may be attached to the frame, for example at or adjacent to each corner of the frame. In embodiments, the first tubular structures may be integral to the frame. ln embodiments, the legs may be splayed outwardly from the frame. The legs may be splayed by an angle in the range 10-30 degrees, for example approximately 15 degrees, outwardly from the vertical direction in use. The first tubular structures may be splayed so that the legs, when assembled in or around the first tubular structures, are also splayed. Thus, the first tubular structures may be splayed by an angle in the range 10-30 degrees, for example approximately 15 degrees, outwardly from the vertical direction in use so that the legs, when assembled in the first tubular structures, may also be splayed by the same angle. The direction in which each first tubular structure extends may have a horizontal (in use) component extending substantially along/in the direction of a radial line emanating from the centre of the frame. Where the frame is rectangular (including square), the direction in which each first tubular structure extends may have a horizontal (in use) component extending substantially along/in the direction of a diagonal line emanating from the centre of the frame. The legs may be splayed accordingly. Thus, load can be equally distributed between the legs. These embodiments can provide better stability and structural integrity whilst also creating more space underneath the frame, for example, to allow a wheelbarrow to fit thereunder.

In embodiments, one or more or all of the legs may each be supported on one or more wheels. The wheels may be fixed or may swivel and/or may have a brake. The wheels may be castors. These embodiments can allow the apparatus and the matter contained therein to be conveniently and manually manoeuvred by an operator/user to a desired location. The apparatus may comprise one or more side barriers extending substantially along the sides of the frame so as to form an enclosure within which a bulk bag is (e.g. horizontally) retained. The side barriers may be releasably attachable to the frame. The side barriers may be attachable by releasable locking means, such as by a spring pin/latch mechanism. This can allow easy and quick assembly/disassembly and improved portability and storage.

The side barriers may be configured to contain the bulk bag on the frame without the need to suspend a bulk bag above/on the frame, for example, without needing to attach the bag’s carrying loops to a structure that is arranged above the frame.

The side barriers may comprise a plurality of tubular elements (e.g., bars) that are slidably mounted in or around second tubular structures (e.g., second box sections). The second tubular structures may be attached to the frame, for example at or adjacent to each corner of the frame. In embodiments, a first pair of side barriers may be slidably mounted in or around the second tubular structures. In embodiments, the second tubular structures may be integral to the frame. The second tubular structures may extend substantially vertically upward in use so that the first pair of side barriers, when assembled in the second tubular structures, extend substantially vertically upward from the frame. The side barriers may be releasably attachable to each other. For example, a second pair of side barriers may be releasably attached to (e.g., between) the first pair of side barriers so as to extend above the frame and/or tray substantially along the other two opposing sides of the frame. The first and second pairs of barriers may therefore be arranged to form an enclosure that extends substantially about the periphery of the frame and/or tray to retain (e.g. horizontally) a bulk bag therein.

The side barriers may be fixed or extendable in height and/or width. The height and/or width of one or more of the side barriers may be adjustable to accommodate bulk bags of different sizes and shapes. For example, a telescopic or concertina arrangement may be used to expand or retract one or more of the side barriers.

The first and/or second tubular structures may have box/square or circular cross sections and/or may be made of metal, such as steel or aluminium, but other cross-sectional shapes and/or materials can be used.

As discussed above, the apparatus comprises a valve for controlling the discharge of the matter contained in the bulk bag. The valve may be designed to selectively and/or variably adjust the discharge flow rate. The valve may comprise a valve member (e.g., flap) which is configured to vary the open cross section of the outlet and/or conduit, thus adjusting the discharge flow rate. The valve member may be provided in or on the outlet and/or conduit. The valve member may be arranged under the frame and/or tray in use. The valve member may be pivotably and/or slidably mounted relative to the frame/outlet. In embodiments, the valve member may move rotationally or substantially laterally into and out of the outlet, thus varying the cross section of the outlet as desired. The valve member may be controlled by one or more arms pivotally mounted to the frame. The one or more arms may be controlled by one or more actuation bars. The one or more actuation bars may be attached to the one or more arms. The one or more actuation bars may be releasably attachable to the one or more arms by a releasable locking mechanism, such as by a spring pin/latch mechanism. This can allow easy and quick assembly and disassembly and improved storage and portability.

The valve member may be configured to move between a closed configuration in which the outlet is substantially blocked (and, e.g., the sleeve therein is constricted), and an open configuration in which the outlet is substantially unblocked (and, e.g., the sleeve therein is unconstricted). The valve member may be configured to return from the open configuration to the closed configuration by one or more return springs. The sleeve may be deformed (e.g., unconstricted/constricted) by the valve member during opening/closing operation of the valve. This arrangement not only allows selective variation of the cross section of the conduit, thus varying the flow rate of the dispensed matter, but can also prevent matter from jamming and potentially damaging the valve mechanism. In embodiments, the arms may be attached at or adjacent to respective opposed ends of the valve member. The actuation bar may be releasably attachable to the end of the respective arms, for example by a spring pin/latch mechanism. This symmetrical arrangement allows an even distribution of forces to be applied to the valve member via the actuation bar which improves the opening/closing operation of the valve.

It is believed that the valve arrangement described herein is advantageous in its own right, and not merely in combination with the other aspects and embodiments disclosed herein. Thus, according to another aspect of the present invention there is provided a valve for a bulk bag discharging apparatus, the valve being as disclosed herein in any aspect or embodiment.

This aspect of the present invention can include any one or more or all of the features of any other aspect or embodiment disclosed herein, as desired.

In any of the above aspects or embodiments, standard bulk bags of any type and size may be used. An empty bulk bag is typically formed by five walls (e.g., four vertical side walls and a base wall) which retain the matter within the bag and which are generally rectangular (including square) or quadrilateral. An upper opening allows the matter to be loaded into the bag. A bulk bag can generally define a cube or a cuboid space when empty, but may become substantially cylindrical or more generally an ovoid when filled. For a given weight of matter, the size of a bulk bag typically depends on the bulk density of the matter to be contained, but typically a one-tonne bulk bag when filled will have a height, a width, and a depth each in the range 0.8-1 m.

A bulk bag with a discharging spout incorporated on its underside may be used. Thus, the piercing structure may be removable from the frame to fit such a bulk bag and the discharging spout may be inserted into the outlet. A bulk bag with such a built-in discharging spout could be reusable, but is generally more expensive than a conventional bulk bag with a closed underside (no spout), the latter being typically disposable after use.

According to another aspect of the present invention there is provided a method of discharging matter from a bulk bag, the method comprising: providing an apparatus as described herein in any aspect or embodiment; supporting a bulk bag on the frame; dispensing the matter contained in the bulk bag through the outlet; and selectively controlling the discharge of the matter through the outlet by controlling the valve.

Controlling the valve may comprise moving the valve member, arms and/or actuation bar to open/close the valve. In embodiments, the valve may be opened by pushing down the actuation bar. The valve may be closed by releasing the actuation bar and/or by raising the actuation bar, e.g. with assistance from one or more return springs.

The method may further comprise piercing the underside of the bulk bag with the piercing structure when the bulk bag is placed onto the frame.

The method may further comprise (prior to placing the bulk bag onto the frame) assembling the apparatus by releasably attaching the legs and/or side barriers to the frame and/or by releasably attaching the actuation bar to the arms. The method may further comprise (after removing the (e.g., empty) bulk bag from the frame) disassembling the apparatus by detaching the legs and/or side barriers from the frame and/or by detaching the actuation bar from the arms.

Embodiments of the present invention accordingly can provide a portable and/or modular assemblable/disassemblable apparatus which can be efficiently stored on site or in the back of a vehicle and easily and quickly assembled and disassembled on site by an operator/user. Embodiments of the present application can also provide a mobile apparatus which can be conveniently moved and/or stored by a user/operator at a desired location. The apparatus may also be designed to allow a wheelbarrow to fit underneath the frame so that the contents discharged from the bulk bag are funnelled into the wheelbarrow. Moreover, embodiments of the present application can provide an improved method of discharging matter from a bulk bag.

By way of example only, embodiments of the invention will now be described in detail with reference being made to the accompanying drawings in which:

Figure 1 is a perspective exploded view of an apparatus according to an embodiment of the present invention;

Figure 2 is a front view of the apparatus of Figure 1 ;

Figure 3 is a side view of the apparatus of Figure 1 ; Figure 4 is a top plan view of the apparatus of Figure 1 ; and

Figure 5 is a perspective view showing part of the apparatus of Figure 1 in more detail.

Figures 1-5 show a bulk bag discharging apparatus 100 according to an embodiment of the present invention. The apparatus 100 comprises a frame 10 having a tray 15 onto which a bulk bag (not shown in the drawings) is positioned after being unloaded from a transportation/delivery vehicle.

The frame 10 and tray 15 are substantially square with a side length of approximately 1-1 2m to fit a standard one-tonne bulk bag. The tray 15 is tapered/funnelled to guide the matter that is discharged from the bulk bag towards an outlet 11.

The outlet 11 is located substantially at the centre of the tray 15. The outlet 11 comprises a conduit 21 that extends downwardly below the tray 15 to allow the discharged matter to be funnelled out of the bulk bag to a desired location. A sleeve (not shown) can be fastened at the top of the conduit 21 via a split collar bolted radially through the conduit (see apertures 51 in Figure 5) with the sleeve being retained between the split collar and the inner wall of the conduit 21 and with the sleeve extending downwards through the conduit 21 in order to line the inside of the conduit 21. A piercing structure 12 is arranged at the centre of the tray 15 and generally above the outlet 11. The piercing structure 12 is defined by three cutters 17 which are splayed to form a pyramidal structure. The piercing structure 12 is removably attached to the tray 15. In this embodiment, the piercing structure 12 is screwed or bolted to the tray 15, but other fixing means can be used. First tubular sections 14 (first box sections) extend downwardly and outwardly from each respective corner of the frame 10 below the tray 15 towards the ground. A pair of flanges 16, which are substantially L-shaped, are provided to reinforce the connection of each of the first tubular sections 14 to the frame 10. Legs 20 with wheels 25 in the form of castors are releasably attached to the first tubular sections 14 by a spring-biased pin mechanism. The legs 20 are tubular structures which are slidably mounted in the first tubular sections 14. The first tubular sections 14 are splayed approximately 15 degrees from the vertical direction in use, so that when the legs 20 are mounted in the first tubular sections 14 the legs 20 are splayed at the same angle. Figure 4 shows that the direction in which each first tubular structure/leg extends has a horizontal component extending substantially along/in the direction of a diagonal/radial line emanating from the centre of the frame/tray. This arrangement provides improved stability and structural rigidity whilst also allowing a wheelbarrow to fit under the frame for unloading purposes. This arrangement also provides improved mobility and portability.

Second tubular sections 13 (second box sections) extend upwardly and substantially vertically from each corner of the frame 10 above the tray 15 (substantially opposite to the first tubular sections 14). A first pair of opposed side barriers 30 are releasably mounted in the second tubular sections 13, so that when the side barriers 30 are mounted in the second tubular sections 13, the side barriers 30 extend upwardly and substantially vertical from the tray 15. A second pair of opposed side barriers 35 are releasably mounted to the side barriers 30 to define an enclosure to contain a bulk bag therein.

Figure 5 shows in more detail a valve arrangement 40 according to an embodiment of the present invention. The valve 40 is configured to vary the cross section of the conduit 21 by moving a valve member in the form of a flap 41 substantially laterally and at least partially in/out of the conduit 21 , thus selectively controlling the amount of matter dispensed. The flexible sleeve provided in the conduit 21 is deformed (unconstricted/constricted) by the flap 41 during the opening/closing operation of the valve 40. The sleeve is configured to protect the inside of the conduit 21 and/or the valve mechanism from being damaged and/or jammed by the dispensed matter. The sleeve is serviceable and/or replaceable to ensure longevity of the valve and the apparatus.

The flap 41 is supported and activated by a pair of arms 43. Each arm 43 is pivotally mounted to a flange 18 extending downwardly below the tray 15 on opposite sides of the frame 10. Each arm 43 is slidably received in an aperture that is defined at opposed ends of the flap 41. Bearings 46 are arranged in the flange 18 to constrain the arms 43 to rotate about a horizontal axis 49 whilst also reducing friction between moving parts. The arms 43 are manually operated via an actuation bar 45. The actuation bar 45 is releasably attached to the arms 43 by a spring-biased pin mechanism 42. An operator/user can variably open/close the valve and selectively adjust the discharge flow rate by moving the actuation bar 45 down/up. The arms 43 are configured to return to their initial/rest configuration (which corresponds to the valve being closed) by a return spring 44 that is arranged between the frame 10 and each of the arms 43 as is shown in Figure 5.