Stitchless bulk bag with heat fused seams and method of production

A heat sealing system for heat sealing a flexible plastic fabric bulk bag, the system comprising:

• a) a first heat sealing station that is adapted to enable assembly of overlapped bag parts and formation of one or more heat sealed joints;
• b) wherein the first heat sealing station enables forming said one or more heat sealed joints in a containment area of the bag in 10 minutes or less;
• c) wherein the first heat sealing station comprises a machine having a seal bar coupled to the machine with a first connection and a second connection;
• d) wherein the first connection is adapted to maintain the seal bar at an at least relatively fixed location during heat sealing;
• e) wherein the second connection is adapted to allow a rocking motion of the seal bar wherein the seal bar pivots along a seal bar longitudinal axis while the seal bar is maintained at the at least relatively fixed location during heat sealing;
• f) wherein the rocking motion enables an equal pressure, or at least a substantially equal pressure, to be applied by the seal bar to the bag parts being heat sealed together even where the bag parts being heat sealed together have an uneven surface or an uneven density;
• g) a second heat sealing station operable to heat seal other bag parts together;
• h) wherein the first heat sealing station is adapted to enable forming a top and body heat sealed joint and a body and bottom heat sealed joint;
• and
• i) wherein the second heat sealing station is adapted to enable forming one or more lift loop assembly to body heat sealed joints.

A flexible plastic fabric bulk bag automated production system comprising:

• a) a first heat sealing station;
• b) a carrier plate for assembling bulk bag parts thereon and for moving the bulk bag parts through the first heat sealing station for forming one or more heat sealed bag joints;
• c) wherein the carrier plate includes (i) first guides for guiding positioning of the bulk bag parts and (ii) second guides that facilitate alignment of the carrier plate in a first machine of the first heat sealing station;
• and
• d) wherein the carrier performs functions as (i) a quality check for bag part assembly, (ii) a machine tooling set-up function to aid in alignment of the carrier in the first machine, and (iii) an inspection tool for quality checking the bag parts during assembly.