PALLET WRAPPING FILM PERFORATION SYSTEM AND METHOD

Information

  • Patent Application
  • 20250206482
  • Publication Number
    20250206482
  • Date Filed
    November 13, 2024
    a year ago
  • Date Published
    June 26, 2025
    5 months ago
Abstract
A pallet wrapping system with at least one spindle, a support bar, a perforation roller, and a pre-stretch machine. The support bar has a plurality of arms that are configured to receive stretch film from the at least one spindle and create banded edges on the stretch film as it passes through the plurality of arms. The pallet wrapping system is configured to form a reinforced stretch film using the plurality of arms and the stretch film from the at least one spindle. The perforation roller is configured to form a plurality of holes through the reinforced stretch film as the reinforced stretch film passes over the perforation roller. The pre-stretch machine is configured to receive the reinforced stretch film and stretch the reinforced stretch film prior to wrapping a palletized load with the reinforced stretch film.
Description
TECHNICAL FIELD

This document relates to a pallet wrapping system that provides secure loads using perforated film layers.


BACKGROUND

Goods to be transported in containers on, for example, ships, trucks, trains or the like frequently are packed on pallets. Such palletized goods or material may be wrapped in stretch film to protect the material from damage caused by, for example, shifting on a pallet or being bumped by goods on adjacent pallets. Additionally, many goods types need perforation to allow for adequate ventilation. Many perforated films, in addition to being much more expensive than conventional film, cannot provide adequate load containment due to the perforations. Use of such perforated films often results in damaged products and loads which burst their containment.


SUMMARY

Aspects of this document are related to a pallet wrapping system, comprising a first spindle configured to receive at least a first roll of stretch film and a second roll of stretch film and allow stretch film from the first roll of stretch film and from the second roll of stretch film to unwind by rotating about the first spindle, wherein a stretch film path through the pallet wrapping system begins at the first spindle, a support bar positioned along the stretch film path after the first spindle, the support bar having a plurality of arms coupled to the support bar and configured to receive stretch film from the first roll of stretch film and the second roll of stretch film and create a banded edge on the stretch film as the stretch film passes through the plurality of arms to form a first banded stretch film and a second banded stretch film, a second spindle positioned along the stretch film path after the support bar, the second spindle configured to receive a third roll of stretch film and allow stretch film from the third roll of stretch film to unwind by rotating about the second spindle, wherein the pallet wrapping system is configured to layer the first banded stretch film and the second banded stretch film onto the third roll of stretch film of the second spindle to form a reinforced stretch film, wherein a gap separates the first banded stretch film from the second banded stretch film on the reinforced stretch film, a perforation roller positioned along the stretch film path after the second spindle, the perforation roller comprising a plurality of perforation blades spaced along a length of the perforation roller and configured to form a plurality of holes through the reinforced stretch film in the gap between the first banded stretch film and the second banded stretch film as the reinforced stretch film passes over the perforation roller, wherein each of the plurality of perforation blades is removably coupled to the perforation roller, each of the plurality of perforation blades comprises a curved blade edge and a blade guard that is curved to match a curve of the perforation roller, and each blade guard is configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, and a pre-stretch machine configured to receive the reinforced stretch film from the perforation roller and stretch the reinforced stretch film before the reinforced stretch film is wrapped around a palletized load.


Particular embodiments may comprise one or more of the following features. The perforation roller and the pre-stretch machine may be positioned such that a path of the reinforced stretch film over the perforation roller changes direction by at least 90 degrees.


Aspects of this document are related to a pallet wrapping system, comprising at least one spindle configured to receive at least one roll of stretch film and allow stretch film from the at least one roll of stretch film to unwind when the at least one roll of stretch film rotates about the at least one spindle a support bar having a plurality of arms coupled to the support bar and configured to receive a first stretch film and a second stretch film from the at least one spindle and create banded edges on the first stretch film and the second stretch film as the first stretch film and the second stretch film pass through the plurality of arms to form a first banded stretch film and a second banded stretch film, wherein the pallet wrapping system is configured to layer the first banded stretch film and the second banded stretch film onto a third stretch film from the at least one spindle to form a reinforced stretch film, a perforation roller configured to form a plurality of holes through the reinforced stretch film as the reinforced stretch film passes over the perforation roller, and a pre-stretch machine configured to receive the reinforced stretch film and stretch the reinforced stretch film prior to wrapping a palletized load with the reinforced stretch film.


Particular embodiments may comprise one or more of the following features. A gap may separate the first banded stretch film from the second banded stretch film on the reinforced stretch film and the plurality of holes may be configured to extend through the stretch film in the gap between the first banded stretch film and the second banded stretch film. The perforation roller may comprise a plurality of perforation pins spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. The perforation roller may comprise a plurality of perforation blades spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. Each of the plurality of perforation blades may comprise a curved blade edge. Each of the plurality of perforation blades may be removably coupled to the perforation roller. Each of the plurality of perforation blades may comprise a blade guard configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, wherein each blade guard is curved to match a curve of the perforation roller. A path of the reinforced stretch film over the perforation roller may change direction by at least 90 degrees.


Aspects of this document are related to a pallet wrapping system, comprising at least one spindle configured to receive at least one roll of stretch film and allow stretch film from the at least one roll of stretch film to unwind when the at least one roll of stretch film rotates about the at least one spindle, a support bar having a plurality of arms coupled to the support bar and configured to receive stretch film from the at least one spindle and create banded edges on the stretch film as the stretch film passes through the plurality of arms, wherein the pallet wrapping system is configured to form a reinforced stretch film using the plurality of arms and the stretch film from the at least one spindle, a perforation roller configured to form a plurality of holes through the reinforced stretch film as the reinforced stretch film passes over the perforation roller a perforation roller configured to form a plurality of holes through the reinforced stretch film as the reinforced stretch film passes over the perforation roller, and a pre-stretch machine configured to receive the reinforced stretch film and stretch the reinforced stretch film prior to wrapping a palletized load with the reinforced stretch film.


Particular embodiments may comprise one or more of the following features. The reinforced stretch film may comprise a first banded stretch film and a second banded stretch film. A gap may separate the first banded stretch film from the second banded stretch film on the reinforced stretch film. The plurality of holes may be configured to extend through the stretch film between a banded edge of the first banded stretch film and a banded edge of the second banded stretch film. The perforation roller may comprise a plurality of perforation pins spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. The perforation roller may comprise a plurality of perforation blades spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. Each of the plurality of perforation blades may comprise a curved blade edge. Each of the plurality of perforation blades may be removably coupled to the perforation roller. Each of the plurality of perforation blades may comprise a blade guard configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, wherein each blade guard is curved to match a curve of the perforation roller. A path of the reinforced stretch film over the perforation roller may change direction by at least 90 degrees.


Aspects of this document are related to a method of wrapping a palletized load with a pallet wrapping system, the method comprising receiving a first stretch film, a second stretch film, and a third stretch film into the pallet wrapping system, creating a banded edge on the first stretch film and the second stretch film to form a first banded stretch film and a second banded stretch film, layering the first banded stretch film and the second banded stretch film onto the third stretch film to form a reinforced stretch film, wherein a gap separates the first banded stretch film from the second banded stretch film on the reinforced stretch film, forming a plurality of holes through the third stretch film, stretching the reinforced stretch film, and wrapping a palletized load using the reinforced stretch film.


Particular embodiments may comprise one or more of the following features. Stretching the reinforced stretch film may comprise expanding the plurality of holes to a larger size. The plurality of holes may be formed through the third stretch film with a perforation roller of the pallet wrapping system. Forming the plurality of holes through the third stretch film may occur after layering the first banded stretch film and the second banded stretch film onto the third stretch film to form the reinforced stretch film. The method may comprise changing direction of a path of the reinforced stretch film by at least 90 degrees as the reinforced stretch film passes over the perforation roller. The perforation roller may comprise a plurality of perforation blades spaced along a length of the perforation roller, wherein forming the plurality of holes through the reinforced stretch film comprises cutting the plurality of holes through the reinforced stretch film with the plurality of perforation blades. Each of the plurality of perforation blades may be removably coupled to the perforation roller. The perforation roller may comprise a plurality of perforation pins spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. The perforation roller may comprise a plurality of perforation blades spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film. Each of the plurality of perforation blades may comprise a curved blade edge. Each of the plurality of perforation blades may be removably coupled to the perforation roller. Each of the plurality of perforation blades comprises a blade guard configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, wherein each blade guard is curved to match a curve of the perforation roller.


The foregoing and other aspects, features, and advantages will be apparent from the DESCRIPTION and DRAWINGS, and from the CLAIMS if any are included.





BRIEF DESCRIPTION OF THE DRAWINGS

Implementations will hereinafter be described in conjunction with the appended and/or included DRAWINGS, where like designations denote like elements, and:



FIG. 1 is a front perspective view of a pallet wrapping system according to some embodiments;



FIG. 2 is a rear perspective view of a pallet wrapping system according to some embodiments;



FIG. 3 is a rear perspective view of a pallet wrapping system according to some embodiments;



FIG. 4 is a top view of a pallet wrapping system according to some embodiments;



FIG. 5 is a perspective view of a perforation blade of a perforation roller according to some embodiments;



FIG. 6 is a perspective view of a perforation blade of a perforation roller according to some embodiments;



FIG. 7 is a front view of a perforation blade of a perforation roller according to some embodiments;



FIG. 8 is a right-side view of a perforation blade of a perforation roller according to some embodiments;



FIG. 9 is a left-side view of a perforation blade of a perforation roller according to some embodiments;



FIG. 10 is a top view of a perforation blade of a perforation roller according to some embodiments;



FIG. 11 is a perspective view of a perforation roller according to some embodiments;



FIG. 12 is a perspective view of a perforation ring of a perforation roller according to some embodiments;



FIG. 13 is an exploded view of a perforation ring of a perforation roller according to some embodiments;



FIG. 14 is a front view of a perforation ring of a perforation roller according to some embodiments;



FIG. 15 is a right-side view of a perforation ring of a perforation roller according to some embodiments;



FIG. 16 is a rear view of a perforation ring of a perforation roller according to some embodiments;



FIG. 17 is a top view of a perforation ring of a perforation roller according to some embodiments; and



FIG. 18 is a perspective view of a perforation pin of a perforation roller according to some embodiments.





DETAILED DESCRIPTION

Detailed aspects and applications of the disclosure are described below in the following drawings and detailed description of the technology. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts.


In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the disclosure. It will be understood, however, by those skilled in the relevant arts, that embodiments of the technology disclosed herein may be practiced without these specific details. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed technologies may be applied. The full scope of the technology disclosed herein is not limited to the examples that are described below.


The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a step” includes reference to one or more of such steps.


The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.


When a range of values is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. All ranges are inclusive and combinable.


Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, mean “including but not limited to”, and are not intended to (and do not) exclude other components.


As required, detailed embodiments of the present disclosure are included herein. It is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limits, but merely as a basis for teaching one skilled in the art to employ the present invention. The specific examples below will enable the disclosure to be better understood. However, they are given merely by way of guidance and do not imply any limitation.


The present disclosure may be understood more readily by reference to the following detailed description taken in connection with the accompanying figures and examples, which form a part of this disclosure. It is to be understood that this disclosure is not limited to the specific materials, devices, methods, applications, conditions, or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed inventions. The term “plurality”, as used herein, means more than one. When a range of values is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. All ranges are inclusive and combinable.


More specifically, this disclosure, its aspects and embodiments, are not limited to the specific material types, components, methods, or other examples disclosed herein. Many additional material types, components, methods, and procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.


Conventional methods of wrapping a palletized load require that the benefits of security of the load and breathability of the load be balanced, as increasing security tends to decrease breathability and vice versa. To address this issue, the present disclosure provides a pallet wrapping system allows for the combination of the benefits that stretch film provides with the ability of perforations to enhance air circulation and facilitate easier handling. The concept of incorporating perforations into stretch film is designed to offer a more efficient and versatile wrapping solution.


The present disclosure also addresses several technical challenges that arise from perforating stretch film. These include ensuring the integrity and strength of the film despite the presence of perforations, maintaining the desired stretchability and cling properties, and effectively integrating the formation of holes for ventilation with the load-wrapping process without compromising production efficiency. The present disclosure enhances the functionality of stretch film in palletizing applications, ultimately contributing to better protection of goods and more streamlined packaging processes


The present disclosure is related to a pallet wrapping system 100 that is configured to wrap a palletized load with stretch film 102, shown in FIGS. 1-4. The pallet wrapping system 100 may comprise at least one spindle 104 that is configured to receive one or more rolls 106 of the stretch film 102. The at least one spindle 104 may include a first spindle 108 and a second spindle 110. In some embodiments, the pallet wrapping system 100 may have a stretch film path 112 through the pallet wrapping system 100 that begins at the first spindle 108, as shown in FIG. 4. Each of the at least one spindle 104 may be configured to receive more than one roll 106 of the stretch film 102. Each of the at least one spindle 104 is also configured to allow the stretch film 102 to unwind from the roll 106 by rotating the roll 106 about the at least one spindle 104.


The pallet wrapping system 100 may also comprise a support bar 114 and a plurality of adjustment arms 116 as described and shown in more detail in U.S. Pat. No. 11,958,642, issued on Apr. 16, 2024 to Darrel Bison, the entirety of the disclosure of which is hereby incorporated herein by this reference. The support bar 114 may be positioned along the stretch film path 112 after the first spindle 108. The adjustment arms 116 are configured to narrow the width of stretch film 102 for wrapping the palletized load and band the edges of the stretch film 102 to provide additional strength to the stretch film 102. For example, as the stretch film 102 passes between a pair of adjustment arms 116, the adjustment arms 116 force the stretch film 102 into a smaller width because the adjustment arms 116 are closer together than the original width of the stretch film 102. This bunches or bands the edges of the stretch film 102 together to form banded stretch film 120. Depending on the number of rolls 106 of stretch film 102 on the first spindle 108, the plurality of adjustment arms 116 may be configured to create a first banded stretch film 122, a second banded stretch film 124, or more. In some embodiments, the banded stretch film 120 may have a width of two inches or less. Depending on the embodiment, the top edge, the bottom edge, or both may be banded in the banded stretch film 120. The pallet wrapping system 100 may also comprise guide rollers 118, also described in the '642 patent. The guide rollers 118 are configured to guide the stretch film 102 to pass between the adjustment arms 116, and/or to guide the stretch film 102 away from the adjustment arms 116, as shown in FIGS. 3-4.


The second spindle 110 may be positioned along the stretch film path 112 after the support bar 114. Thus, the banded stretch film 120 may exit the adjustment arms 116 and be layered directly onto the stretch film 102 on the second spindle 110. In some embodiments, the second spindle 110 is separated from the stretch film path 112 and the stretch film 102 on the second spindle 110 is inserted into the stretch film path 112 after the stretch film 102 is unwound from the second spindle 110. In some embodiments, the pallet wrapping system 100 is configured to layer the first banded stretch film 122 and the second banded stretch film 124 onto the stretch film 102 on the second spindle 110 to form a reinforced stretch film 126. In some embodiments, a gap 128 separates the first banded stretch film 122 from the second banded stretch film 124 on the reinforced stretch film 126.


The pallet wrapping system 100 may also comprise a perforation roller 130 configured to form a plurality of holes 132 through the stretch film 102 and a pre-stretch machine 134 configured to receive the reinforced stretch film 126 and stretch the reinforced stretch film 126 before the reinforced stretch film 126 is wrapped around a palletized load. The perforation roller 130 may be positioned along the stretch film path 112 after the second spindle 110. In some embodiments, the perforation roller 130 comprises a plurality of perforation blades 136, shown in FIGS. 5-10. The plurality of perforation blades 136 may be spaced along a length of the perforation roller 130 and may be configured to form the plurality of holes 132 through the stretch film 102 by cutting the stretch film 102. The plurality of perforation blades 136 may be configured to cut the stretch film 102 in the gap 128 between the first banded stretch film 122 and the second banded stretch film 124 as the stretch film 102 passes over the perforation roller 130. In some embodiments, the perforation roller 130 may have multiple perforation blades 136 at any given length of the perforation roller 130. For example, the perforation roller 130 may have two perforation blades 136 at a particular length, separated by 180 degrees. Other embodiments may have more or fewer perforation blades 136.


In some embodiments, each of the plurality of perforation blades 136 is removably coupled to the perforation roller 130, such as through the use of a screw. As shown in FIG. 6, each of the plurality of perforation blades 136 may have a threaded end to receive the screw. Each of the plurality of perforation blades 136 may comprise a curved blade edge 138 and a blade guard 140. The curved blade edge 138 may be configured to facilitate cutting the stretch film 102 as the stretch film 102 passes over the perforation roller 130. The blade guard 140 may be curved to match a curve of an outer surface 142 of the perforation roller 130. Thus, in some embodiments, the blade guard 140 is configured to sit against the outer surface 142 of the perforation roller 130 when the perforation blade 136 is installed in the perforation roller 130. This helps to stabilize the perforation blade 136 against the perforation roller 130 and prevent the curved blade edge 138 from becoming misaligned with the direction of travel of the stretch film 102.


In some embodiments, the perforation roller 130 and the pre-stretch machine 134 are positioned such that the stretch film path 112 over the perforation roller 130 changes direction by at least 90 degrees. This helps to ensure that the plurality of perforation blades 136 have sufficient contact with the stretch film 102 to cut through the stretch film 102. This in turn increases the reliability of the formation of the plurality of holes 132. In some embodiments, the direction of the stretch film path 112 changes by at least 150 degrees or by at least 180 degrees. In some embodiments, the plurality of holes 132 are formed as slits through the stretch film 102.


In some embodiments, the perforation roller 130 may be moved to different locations in the pallet wrapping system 100. For example, the perforation roller 130 may be configured to create the plurality of holes 132 before the banded stretch film 120 is layered onto the banded stretch film 120 on the second spindle 110. Similarly, the perforation roller 130 may be configured to create the plurality of holes 132 after the reinforced stretch film 126 has passed through the pre-stretch machine 134. Other modifications may also be made to the pallet wrapping system 100 without departing outside the scope of this disclosure. For example, a single sheet of the stretch film 102 may be used, where the adjustment arms 116 are used to the band the edges of the single sheet of the stretch film 102 and the perforation roller 130 is used to create the plurality of holes 132 through the single sheet of the stretch film 102 before stretching the stretch film 102 and wrapping it around the palletized load. Thus, the specific configurations shown in the figures and described are meant to be illustrative and not restrictive or limiting in any way.


In some embodiments, the perforation roller 130 may be replaced with a perforation roller 144, shown in FIGS. 11-18. The perforation roller 144 may comprise a center axle 146 and a plurality of perforation rings 148, as illustrated by the embodiment shown in FIG. 11. Each of the perforation rings 148 is positioned on and is axially aligned with the center axle 146. This allows the perforation rings 148 to rotate about the center axle 146 as the stretch film 102 passes over the perforation roller 144. Each of the perforation rings 148 is configured to perforate the stretch film 102 when the stretch film 102 passes over the perforation rings 148.


In some embodiments, each of the perforation rings 148 comprises an outer ring 150, an inner ring 152, and a plurality of perforation pins 154, as illustrated in the embodiment shown in FIGS. 12-17. The outer ring 150 may comprise a plurality of pinholes 156 extending through the outer ring 150. The plurality of pinholes 156 may be spaced apart around a circumference of the outer ring 150. The plurality of perforation pins 154 are configured to be positioned in and/or extend through the plurality of pinholes 156. Thus, the plurality of perforation pins 154 may be spaced along a length of the perforation roller 130 and may be configured to form the plurality of holes 132 through the stretch film 102. In some embodiments, each of the plurality of perforation pins 154 has a stem 158 and a tapered end 160 opposite the stem 158, as illustrated by the embodiment shown in FIG. 18. The stem 158 may be configured to be positioned within the outer ring 150, while the tapered end 160 may be configured to extend outward from the outer ring 150. In some embodiments, the tapered end 160 of each of the plurality of perforation pins 154 has a length of at least ⅛ inch. However, it will be apparent to one of skill in the art that the length of the tapered end 160 of each of the plurality of perforation pins 154 may be longer or shorter than 0.125 inches. In some embodiments, the tapered end 160 of each of the plurality of perforation pins 154 has a length between 1/16 inch and ¼ inch.


A variety of methods may be implemented to maintain the plurality of perforation pins 154 within the plurality of pinholes 156. In some embodiments, the stem 158 of each of the plurality of perforation pins 154 has a maximum diameter that is larger than a minimum diameter of each of the plurality of pinholes 156. In such embodiments, the plurality of perforation pins 154 may be inserted into the plurality of pinholes 156 from an inside surface 162 of the outer ring 150. This allows the plurality of perforation pins 154 to be inserted into the plurality of pinholes 156 but prevents the plurality of perforation pins 154 from passing completely through the plurality of pinholes 156 because the minimum diameter of each of the plurality of pinholes 156 is smaller than a maximum diameter of each of the plurality of perforation pins 154. In some embodiments, the plurality of holes 132 created by the plurality of perforation pins 154 have a diameter less than or equal to ½ inch. In some embodiments, the diameter of each of the plurality of holes 132 is less than or equal to ¼ inch. In some embodiments, the maximum diameter of each of the plurality of perforation pins 154 is less than or equal to 0.1 inches. This leads to the plurality of perforation pins 154 creating relatively small perforations or holes in the stretch film 102 when the stretch film 102 passes over the perforation roller 144. These smaller holes can later be expanded to the desired size when the stretch film 102 is wrapped around a palletized load, allowing for the improved ventilation discussed above. As will be apparent to one of skill in the art, the plurality of perforation pins 154 may have a maximum diameter that is smaller or larger than 0.1 inches.


In some embodiments, each of the perforation rings 148 may also comprise a plurality of tighteners 164. The plurality of tighteners 164 may be threadedly coupled to the outer ring 150 and may be configured to tighten up against the plurality of perforation pins 154 within the outer ring 150. This allows the plurality of perforation pins 154 to be positioned at the desired depth within the plurality of pinholes 156 and then locked into place with the plurality of tighteners 164 because the plurality of tighteners 164 push against the plurality of perforation pins 154, using friction to prevent further movement of the plurality of perforation pins 154 within the plurality of pinholes 156. In some embodiments, multiple methods of maintaining the plurality of perforation pins 154 within the plurality of pinholes 156 may be implemented.


The inner ring 152 is configured to at least partially insert into the outer ring 150 and sit inside of the outer ring 150. This allows the inner ring 152 to cover the inside surface 162 of the outer ring 150, and therefore help to hold the plurality of perforation pins 154 in an extended position with the tapered end 160 of each of the plurality of perforation pins 154 extending through the plurality of pinholes 156. The inner ring 152 may also comprise a spacer 166 which is configured to separate the outer ring 150 of each perforation ring 148 from the outer ring 150 of adjacent perforation rings 148. The inner ring 152 may be attached to the outer ring 150 with one or more fasteners 168. Each of the perforation rings 148 may also have one or more tighteners 170 that are configured to insert radially into the outer ring 150 or the inner ring 152 toward the center axle 146. The one or more tighteners 170 can thus be used to fix each perforation ring 148 in place on the center axle 146 such that the perforation ring 148 is rotationally fixed with respect to the center axle 146 and also fixed in place along the length of the center axle 146.


The plurality of perforation pins 154 are configured to extend out from the outer ring 150 and are configured to perforate the stretch film 102 when the stretch film 102 passes over the perforation rings 148 as described above. As the stretch film 102 passes over the perforation rings 148, the plurality of perforation pins 154 moves with the stretch film 102, allowing the plurality of perforation pins 154 to puncture the stretch film 102 at specific points where the plurality of perforation pins 154 make contact with the stretch film 102, rather than tearing the stretch film 102 as would occur if the plurality of perforation pins 154 did not move with the stretch film 102. The plurality of perforation pins 154 may comprise any number of pins. The perforation rings 148 may be adaptable, allowing the user to select a desired number of pins for the plurality of perforation pins 154. In addition, because the plurality of perforation pins 154 are detachable from the perforation rings 148, pins that break or otherwise need to be replaced or sharpened can be easily detached and replaced with new pins. The plurality of perforation pins 154 may be spaced apart such that the perforations created by the plurality of perforation pins 154 in the stretch film 102 are spaced between one and four inches apart. Depending on the embodiment, the perforations may be spaced one inch apart, two inches apart, three inches apart, or four inches apart. As will be apparent to a person of skill in the art, any other spacing for the perforations may be implemented, including placing the perforations closer together or further apart.


The present disclosure is also related to a method of wrapping a palletized load with the pallet wrapping system 100. The method may comprise receiving stretch film 102, including a first stretch film, a second stretch film, and/or a third stretch film into the pallet wrapping system 100. The first stretch film and the second stretch film may be stretch film 102 taken from the first spindle 108. Similarly, the third stretch film may be stretch film 102 taken from the second spindle 110. A banded edge may be created on the first stretch film and the second stretch film to form the first banded stretch film 122 and the second banded stretch film 124. The first banded stretch film 122 and the second banded stretch film 124 may then be layered onto the third stretch film to form the reinforced stretch film 126. The plurality of holes 132 may be formed through the third stretch film. Forming the plurality of holes 132 through the third stretch film may occur before or after layering the first banded stretch film 122 and the second banded stretch film 124 onto the third stretch film. The reinforced stretch film 126 may be stretched and then wrapped around the palletized load. In embodiments where the plurality of holes 132 are formed before stretching the reinforced stretch film 126, stretching the reinforced stretch film 126 may comprise expanding the plurality of holes 132 to a larger size to provide improved ventilation to the palletized load. The method may also comprise changing the direction of the stretch film path 112 as the stretch film 102 passes over the perforation roller 130 by at least 90 degrees. In some embodiments, the direction of the stretch film path 112 changes by at least 150 degrees or by at least 180 degrees.


The plurality of holes 132 are prevented from expanding beyond the bounds of the stretch film 102 and tearing the stretch film 102 completely by the banded edges of the banded stretch film 120. In this way, the pallet wrapping system 100 is able to wrap the palletized load with stretch film 102 that provides ventilation and still provides secure containment of sufficient strength without tearing. The system and method disclosed herein also uses less stretch film 102 than traditional systems because of the tearing problems inherent in prior art systems that required more wraps and layers.


Many additional implementations are possible. Further implementations are within the CLAIMS.


It will be understood that implementations of the pallet wrapping system include but are not limited to the specific components disclosed herein, as virtually any components consistent with the intended operation of various pallet wrapping systems may be utilized. Accordingly, for example, it should be understood that, while the drawings and accompanying text show and describe particular pallet wrapping system implementations, any such implementation may comprise any shape, size, style, type, model, version, class, grade, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of pallet wrapping systems.


The concepts disclosed herein are not limited to the specific pallet wrapping system shown herein. For example, it is specifically contemplated that the components included in particular pallet wrapping systems may be formed of any of many different types of materials or combinations that can readily be formed into shaped objects and that are consistent with the intended operation of the pallet wrapping system. For example, the components may be formed of: rubbers (synthetic and/or natural) and/or other like materials; glasses (such as fiberglass), carbon-fiber, aramid-fiber, any combination therefore, and/or other like materials; elastomers and/or other like materials; polymers such as thermoplastics (such as ABS, fluoropolymers, polyacetal, polyamide, polycarbonate, polyethylene, polysulfone, and/or the like, thermosets (such as epoxy, phenolic resin, polyimide, polyurethane, and/or the like), and/or other like materials; plastics and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, spring steel, aluminum, and/or other like materials; and/or any combination of the foregoing.


Furthermore, pallet wrapping systems may be manufactured separately and then assembled together, or any or all of the components may be manufactured simultaneously and integrally joined with one another. Manufacture of these components separately or simultaneously, as understood by those of ordinary skill in the art, may involve 3-D printing, extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled or removably coupled with one another in any manner, such as with adhesive, a weld, a fastener, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material(s) forming the components.


In places where the description above refers to particular pallet wrapping system implementations, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other implementations disclosed or undisclosed. The presently disclosed pallet wrapping systems are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims
  • 1. A pallet wrapping system, comprising: a first spindle configured to receive at least a first roll of stretch film and a second roll of stretch film and allow stretch film from the first roll of stretch film and from the second roll of stretch film to unwind by rotating about the first spindle, wherein a stretch film path through the pallet wrapping system begins at the first spindle;a support bar positioned along the stretch film path after the first spindle, the support bar having a plurality of arms coupled to the support bar and configured to receive stretch film from the first roll of stretch film and the second roll of stretch film and create a banded edge on the stretch film as the stretch film passes through the plurality of arms to form a first banded stretch film and a second banded stretch film;a second spindle positioned along the stretch film path after the support bar, the second spindle configured to receive a third roll of stretch film and allow stretch film from the third roll of stretch film to unwind by rotating about the second spindle, wherein the pallet wrapping system is configured to layer the first banded stretch film and the second banded stretch film onto the third roll of stretch film of the second spindle to form a reinforced stretch film, wherein a gap separates the first banded stretch film from the second banded stretch film on the reinforced stretch film;a perforation roller positioned along the stretch film path after the second spindle, the perforation roller comprising a plurality of perforation blades spaced along a length of the perforation roller and configured to form a plurality of holes through the reinforced stretch film in the gap between the first banded stretch film and the second banded stretch film as the reinforced stretch film passes over the perforation roller, wherein: each of the plurality of perforation blades is removably coupled to the perforation roller;each of the plurality of perforation blades comprises a curved blade edge and a blade guard that is curved to match a curve of the perforation roller; andeach blade guard is configured to sit against the perforation roller when the perforation blade is installed in the perforation roller; anda pre-stretch machine configured to receive the reinforced stretch film from the perforation roller and stretch the reinforced stretch film before the reinforced stretch film is wrapped around a palletized load.
  • 2. The pallet wrapping system of claim 1, wherein the perforation roller and the pre-stretch machine are positioned such that a path of the reinforced stretch film over the perforation roller changes direction by at least 90 degrees.
  • 3. A pallet wrapping system, comprising: at least one spindle configured to receive at least one roll of stretch film and allow stretch film from the at least one roll of stretch film to unwind when the at least one roll of stretch film rotates about the at least one spindle;a support bar having a plurality of arms coupled to the support bar and configured to receive a first stretch film and a second stretch film from the at least one spindle and create banded edges on the first stretch film and the second stretch film as the first stretch film and the second stretch film pass through the plurality of arms to form a first banded stretch film and a second banded stretch film, wherein the pallet wrapping system is configured to layer the first banded stretch film and the second banded stretch film onto a third stretch film from the at least one spindle to form a reinforced stretch film;a perforation roller configured to form a plurality of holes through the reinforced stretch film as the reinforced stretch film passes over the perforation roller; anda pre-stretch machine configured to receive the reinforced stretch film and stretch the reinforced stretch film prior to wrapping a palletized load with the reinforced stretch film.
  • 4. The pallet wrapping system of claim 3, wherein a gap separates the first banded stretch film from the second banded stretch film on the reinforced stretch film and the plurality of holes are configured to extend through the stretch film in the gap between the first banded stretch film and the second banded stretch film.
  • 5. The pallet wrapping system of claim 3, the perforation roller comprising a plurality of perforation pins spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film.
  • 6. The pallet wrapping system of claim 3, the perforation roller comprising a plurality of perforation blades spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film.
  • 7. The pallet wrapping system of claim 6, wherein each of the plurality of perforation blades comprises a curved blade edge.
  • 8. The pallet wrapping system of claim 6, wherein each of the plurality of perforation blades is removably coupled to the perforation roller.
  • 9. The pallet wrapping system of claim 6, wherein each of the plurality of perforation blades comprises a blade guard configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, wherein each blade guard is curved to match a curve of the perforation roller.
  • 10. The pallet wrapping system of claim 3, wherein a path of the reinforced stretch film over the perforation roller changes direction by at least 90 degrees.
  • 11. A method of wrapping a palletized load with a pallet wrapping system, the method comprising: receiving a first stretch film, a second stretch film, and a third stretch film into the pallet wrapping system;creating a banded edge on the first stretch film and the second stretch film to form a first banded stretch film and a second banded stretch film;layering the first banded stretch film and the second banded stretch film onto the third stretch film to form a reinforced stretch film, wherein a gap separates the first banded stretch film from the second banded stretch film on the reinforced stretch film;forming a plurality of holes through the third stretch film;stretching the reinforced stretch film; andwrapping a palletized load using the reinforced stretch film.
  • 12. The method of claim 11, wherein stretching the reinforced stretch film comprises expanding the plurality of holes to a larger size.
  • 13. The method of claim 11, wherein the plurality of holes are formed through the third stretch film with a perforation roller of the pallet wrapping system.
  • 14. The method of claim 13, wherein forming the plurality of holes through the third stretch film occurs after layering the first banded stretch film and the second banded stretch film onto the third stretch film to form the reinforced stretch film.
  • 15. The method of claim 14, further comprising changing direction of a path of the reinforced stretch film by at least 90 degrees as the reinforced stretch film passes over the perforation roller.
  • 16. The method of claim 14, the perforation roller comprising a plurality of perforation blades spaced along a length of the perforation roller, wherein forming the plurality of holes through the reinforced stretch film comprises cutting the plurality of holes through the reinforced stretch film with the plurality of perforation blades.
  • 17. The method of claim 16, wherein each of the plurality of perforation blades is removably coupled to the perforation roller.
  • 18. The method of claim 16, wherein each of the plurality of perforation blades comprises a curved blade edge.
  • 19. The method of claim 16, wherein each of the plurality of perforation blades comprises a blade guard configured to sit against the perforation roller when the perforation blade is installed in the perforation roller, wherein each blade guard is curved to match a curve of the perforation roller.
  • 20. The method of claim 14, the perforation roller comprising a plurality of perforation pins spaced along a length of the perforation roller and configured to form the plurality of holes through the reinforced stretch film.
RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patent application 63/614,326, filed Dec. 22, 2023 to Bison, et al., titled “Pallet Wrapping Film Perforation System and Method,” the entirety of the disclosure of which is hereby incorporated by this reference.

Provisional Applications (1)
Number Date Country
63614326 Dec 2023 US