WO2023150805A4 - An improved method of manufacturing a flexible container - Google Patents

Abstract

An improved method of manufacturing a flexible container is disclosed in which there is woven in selected areas of a length of fabric formed by a body of warp and weft yam threads where yarns in the weft are controlled in the intended load and pressure-bearing areas during weaving. Preferably, the area where tension is required of the yarns where product in the container is exerting pressure in the horizontal direction once filled being greater than the area where no or less load in the horizontal is exerted and during lifting where an area where no weft yarns are needed are reduced in weaving and therefore is greater in the tension of the body yarns in the horizontal load-bearing direction. Having increased weft yarns where a join or seam is needed. Having increased weft yarns where a lifting device or belt is attached to the fabric such needing a higher weft count for stitching or attaching and transferring load and reducing said weft where no lifting device is attached or where no tension is placed on the fabric by the join or attaching means force. Where such fabric is rotated 90 degrees and where the weft becomes the warp and the warp the weft and a lifting loop may be attached to the area of increased yarns or where a seam or join is made. A length of woven fabric being woven and cut and formed in such a manner as to reduce the amount of material used in a conventional method in production of such a flexible container bag. Summary and objective of the invention It is an object of the present invention therefore to overcome or substantially reduce these disadvantages, primarely the strengthening, increasing or reducing of the weft in the fabric where nessasary, which may be in various places and various lengths in a length of fabric used to make a flexible bulk container or any other type of bag with utility requiring such.

Claims

AMENDED CLAIMS received by the International Bureau on 07 November 2023 (07.11 .2023) *Primary Method Claim* Claim 1 : A Flexible intermediate Bulk Container FIBC(IO) comprising a unitary woven fabric(20) of functional zones(30) of components(40), Claim 2: A woven fabric (20)of claim 1, made of warp yams and weft yarns, said fabric(20) comprising of at least one zone(30) of a first zone type exhibiting a first selected functional property(50); Claim 3: A woven fabric(20) of claim 1, having at least one zone(30) of a second zone type representing a second selected functional property(50); And Claim 4: A woven fabric(20) of claim 1, having a third zone type representing a third selected functional property(50), Claim 5: Wherein a zone(30) may be made up of a plurality of sub zones(60); Claim 6: Where a zone(30) in Claim 5, having at least a set of instruction(70) for weft or warp yarns arranged to collectively provide a gradual and smooth transition(80) between sub zones(60) in a zone(30) made up of sub zones(60), And Claim 7: at least a set of instruct! ons(70) for weft or warp yarns arranged to provide a specific function(50) in at least one other zone(30) Claim 8: wherein each zone(30) and zones functional attribute(50) of Claim 2 - 7, is indicative of the set of instruct! ons(70) making up the construction of the warp and weft yams or the lack thereof and their particular properties without compromising the packing, containment, stacking and lifting capabilities of the container when used in Claim 1 Claim 9: in one zone(30) the warp and weft yarns in Claim 8, who's function(50) when woven is to optimize the containment strength. By 'Optimize' it is meant that the configuration is tailored to utilize precisely the necessary amount of material, ensuring just the right strength for effective containment during all phases of packing, storing and moving and where in Claim 5, where each sub zone(60) is optimized in containing the contents of each sub zone(60) and the contents above it while reducing either the warp or weft yarns or increasing yams with high amounts of recycled material when used in Claim 1 This optimization who's function(50) involves a careful balance of each sub zone(60) avoiding excess material usage or maximising the amount of recycled material while maintaining the required structural integrity, and or increasing the loom output. 10 AMENDED SHEET (ARTICLE 19) Claim 10: yet in another zone(30) the weft or warp yarns in Claim 8, are decreased, removed or altered and who's function(50) is to optimize the use of the loom, its output and materials or yarns and where such yarns are only used to lift the container are optimized for that function(50) By 'Optimize' it is meant that the configuration is tailored to utilize precisely the necessary amount of material, ensuring just the right strength for effective lifting while maintaining the required structural integrity and where that zone has no containment properties(l 10) when used in Claim 1 Claim 11 : yet in another zone(30) there are warp and weft ends in Claim 8, who's function(50) are when woven together such that they are optimized for bonding(lOO) or attaching(lOO) elements(90) together Claiml2: yet in another zone(30) the warp and or weft yarns in Claim 8, functionally(50) are optimized for folding or gathering a plurality of yarns being warp, weft or both warp and weft yarns Claim 13: yet in another zone(30) the warp and or weft yarns in Claim 8, functionally(50) are optimized for use of a high amount of recycled material from 10% up-to 100% without compromising the lifting capabilities of the container *Primary method claims* 11 AMENDED SHEET (ARTICLE 19) *Method 1* A method based on the claims of the primary method, Claim:

1.1 Wherein the first zone(30) has the attribute of a plurality of sub zones(60) and where there is provided a

1.2 set of instruct! ons(70) for arranging a collective set of warp or weft yarns to provide a

1.3 functionally(50) gradual and smooth transition(80) between sub zones(60)

1.3.1 Wherein the transition between the sub zones(60) in the fabric component being between 1% -100% an initial set of instructions(70) or composition of a defined first sub zone(60) area or length being at least 10mm up-to 100mm this can also be the number of yarns defined in this length or area so to provide functionally(50) a gradual, smooth transition(80) of the property;

And

1.4 Wherein the functional(50) attributes in Claim 1.1, are indicative of material differences being one or more of in

1.4.1 strength,

1.4.2 warp size,

1.4.3 warp type,

1.4.4 warp count,

1.4.5 weft count,

1.4.6 weft size,

1.4.7 weft type,

1.4.8 material type,

And

1.5 Where the first zone(30) having a defined length or area;

1.5.1 where such areas functional(50) component when formed into a FIBC container bag in the Base claim 1, will hold or carry product;

And

1.6 where a second zone(30) adjacent to or following a first zone(30) having a

1.6.1 set of instructions(70) arranging the warp or weft yarns such that the second zone(30) having a defined length or area has reduced, non or no warp or weft yarns

And

1.6.2 wherein the functional attributes(50) are indicative of a length or area of no strength in the direction having reduced yams or no yarns and ease of drawing the existing yarns together (120)

And

1.6.3

And

1.7 Where a third zone(30) adjacent to or following the second zone(30), such third zone(30) having a

1.7.1 set of instructions(70) arranging the weft or warp yarns such that the third zone(30) having a defined length and or area having a maximized strength of warp and weft yarns being at least equal in warp and weft yarn count in the defined length or area and

1.7.2 who's functional attribute(50) is to be joined(lOO) or bonded(100) together

12

AMENDED SHEET (ARTICLE 19) *Method 2*

A method based on the claims of the primary method,

Claim:

2.1 Wherein the first zone(30) has the attribute of a plurality of sub zones(60) and where there is provided a

2.2 set of instruct! ons(70) for arranging a collective set of warp or weft yarns to provide a

2.3 functionally(50) gradual and smooth transition(80) between sub zones (60)

2.3.1 Wherein the transition between the sub zones(60) in the fabric component being between 1% -100% an initial set of instructions (70)or composition of a defined first sub zone(60) area or length being at least

10mm up-to 100mm this can also be the number of yams defined in this length or area so to provide a gradual, smooth transition(80) of the property;

And

2.4 Wherein the functional attributes(50) in any zone are indicative of material differences being one or more of in,

2.4.1 strength,

2.4.2 warp size,

2.4.3 warp type,

2.4.4 warp count,

2.4.5 weft count,

2.4.6 weft size,

2.4.7 weft type,

2.4.8 material type,

And

2.5 Where the first zone(30) having a defined length or area;

2.5.1 where such areas functional component(50) when formed into a FIBC container bag in

The Primary method, will hold , contain or carry any said product;

And

2.6 where a second zone(30) adjacent to or following a first zone(30) having a

2.6.1 set of instructions(70) arranging the warp or weft yarns such that the second zone(30) having a defined length or area

And

2.6.2 Wherein the functional attributes(50) are indicative of material differences being one or more of in,

2.6.2.1 strength,

2.6.2.2 warp size,

2.6.2.3 warp type,

2.6.6.4 warp count,

2.6.6.5 weft count,

2.6.6.6 weft size,

2.6.6.7 weft type,

2.6.6.8 material type,

And

2.8 wherein the primary functional (50) attribute being an area used to attach(lOO) or bond(100) one or more of a separate or secondary functional element or elements(90)

13

AMENDED SHEET (ARTICLE 19) *Method 3 *

A method based on the claims of the primary method,

Claim:

3.1 Wherein the first zone(30) has the attribute of a plurality of sub zones(60) and where there is provided a

3.2 set of instruct! ons(70) for arranging a collective set of warp or weft yarns to provide a

3.3 functionally(50) gradual and smooth transit! on(80) between sub zones (60)

3.3.1 Wherein the transition between the sub zones(60) in the fabric component being between 1% -100% an initial set of instruct! ons(70) or composition of a defined first sub zone(60) area or length being at least

10mm up-to 100mm this can also be the number of yams defined in this length or area so to provide a gradual, smooth transition(80) of the property;

And

3.4 Wherein the functional attributes(50) in any zone are indicative of material differences being one or more of in,

3.4.1 strength,

3.4.2 warp size,

3.4.3 warp type,

3.4.4 warp count,

3.4.5 weft count,

3.4.6 weft size,

3.4.7 weft type,

3.4.8 material type,

And

3.5 Where the first zone(30) having a defined length or area;

3.5.1 where such areas functional component(50) when formed into a FIBC container bag in The Primary method, will hold, contain or carry any said product;

And

3.6 where a second zone(30) adjacent to or following a first zone(30) having a

3.6.1 set of instructions(70) arranging the warp or weft yarns such that the second zone(30) having a defined length or area

And

3.6.2 Wherein the functional attributes(50) are indicative of material differences being one or more of in,

3.6.2.1 strength,

3.6.2.2 warp size,

3.6.2.3 warp type,

3.6.6.4 warp count,

3.6.6.5 weft count,

3.6.6.6 weft size,

3.6.6.7 weft type,

3.6.6.8 material type,

And

3.8 wherein the area or zone(30) having multiple functional(50) attributes, which are indicative of the area or zone primarily being to ensure lifting capabilities remain unaffected by any variant claimed below.

14

AMENDED SHEET (ARTICLE 19)

3.8.1 where such area or zone(30) may have no yarns in one of the directions this being defined by a set of instructions(70) or pattern or

3.8.2where such area or zone (30)may have a controlled number of yarns being defined by a set of instructions(70) in one or both directions being less than those in the last sub-zone(60) in the first zone(30) or third zone(30) or

3.8.3 where such area or zone(30) may have yams in the non load-bearing direction, primarily consisting of recycled material with a recycled content ranging from 10% up to 100%,. or

3.8.4where such area or zone(30) may have a controlled number of yarns being defined by a set of instructions(70) in one or both directions being less than those in the last sub-zone(60) in the first zone(30) or third zone(30) and

3.8.5 where such area or zone(30) attribute is to lift and carry the container in the and

3.8.6where such area or zone(30) attribute is to gather the yarns(120) and

3.8.7where such yams form a lifting loop(130) or loops(130) used for lifting and

3.8.8where which area or zone has no containment properties(l 10) or means and

3.8.9which area and yarns grouped together (120) may have a collar or protecting cover when used in Claim 1

And

3.9 where a third zone(30) adjacent to or following a second zone(30) having a

3.9.1 set of instructions arranging the warp or weft yarns such that the third zone(30) having a defined length or area

And

4 Wherein the third zone(30) has the attribute of a plurality of sub zones(60) and where there is provided a

4.1 set of instructions(70) for arranging a collective set of warp or weft yarns to provide a

4.2 functionally(50) gradual and smooth transition(80) between sub zones (60)

4.2.1 Wherein the transition between the sub zones(60) in the fabric component being between 1% -100% an initial set of instructions or composition of a defined first sub zone(60) area or length being at least

10mm up-to 100mm this can also be the number of yarns defined in this length or area so to provide a gradual, smooth transition(80) of the property;

And

Claims claimed in 3.4

15

AMENDED SHEET (ARTICLE 19)