WRAPPING APPARATUS HAVING TOP LOADING AND THREADING DISPENSER

Abstract

A packaging material dispenser may include a roll carriage having an upper portion and a lower portion, and a base plate separating the upper portion from the lower portion. The packaging material dispenser may also include a packaging material dispensing assembly mounted on an upper surface of the base plate and defining at least a portion of a packaging material path. A first portion of the packaging material path may extend behind the packaging material dispensing assembly. The upper portion of the roll carriage may include an opening defining a packaging material path access area positioned to provide access to a top of the packaging material path. The packaging material dispenser may also include a packaging material dispensing assembly drive mechanism extending below the base plate.

Description

TECHNICAL FIELD

The present disclosure relates to a wrapping apparatus for wrapping a load with packaging material, and more particularly, to a wrapping apparatus having a top loading and threading packaging material dispenser.

BACKGROUND

Various packaging techniques have been used to build a load of unit products and subsequently wrap them for transportation, storage, containment and stabilization, protection, and waterproofing. Products may be stacked as a load on a pallet to simplify handling of the products. The load is commonly wrapped with packaging material. One system uses a stretch wrapping machin to stretch, dispense, and wrap stretch packaging material around a load. Stretch wrapping can be performed as an inline, automated packaging technique that dispenses and wraps packaging material in a stretch condition around a load to cover and contain the load. Stretch wrapping, whether accomplished by a turntable, rotating arm, or vertical rotating ring, typically covers the four vertical sides of the load with a stretchable packaging material, such as polyethylene packaging material. In each of these arrangements, relative rotation is provided between the load and the packaging material dispenser to wrap packaging material about the sides of the load.

Conventional stretch wrapping apparatuses employ a packaging material dispenser having two closely spaced rollers to stretch between them a web of thermoplastic stretch packaging material. Such a stretch wrapping apparatus performs admirably in accomplishing its intended goal of wrapping a load with a stretched web of packaging material. However, the procedure of loading and threading the packaging material through the series of rollers in the packaging material dispenser prior to operation of the stretch wrapping apparatus has been found to be time consuming and difficult.

It is preferable that a stretch wrapping apparatus with pre-stretch rollers have the following features. The upstream and downstream pre-stretch rollers should be closely spaced during operation to prevent neckdown of the packaging material as it is being substantially stretched in the dispensing direction. Since the forces exerted on a web of packaging material between the pre-stretch rollers is very significant, for example in the order of 50 pounds of force, the frame and the mounting of the pre-stretch rollers should be required to be very sturdy. The surface of the pre-stretch rollers should be covered by the packaging material over a sufficient extent such that the packaging material does not slip on the pre-stretch rollers. The rotational inertia of the pre-stretch rollers should not be so high as to require excessively high power to vary their velocity. To accommodate these requirements, a series of idle rollers are used to support the packaging material proximate to the pre-stretch rollers. As a result, the packaging material follows a tortuous path around the closely-spaced pre-stretch and idle rollers. The downstream pre-stretch roller has a faster surface speed than the upstream pre-stretch roller. This stretches the packaging material between the upstream and downstream pre-stretch rollers in the dispensing direction.

Before operating a stretch wrapping apparatus having pre-stretch rollers, it is necessary to load and thread the packaging material along the tortuous path. The increased numbers of rollers in the packaging material dispenser for pre-stretch, and the close spacing of such rollers with their effective interconnection for pre-stretching the packaging material prior to dispensing the packaging material on the load, makes it very difficult to thread the packaging material through the pre-stretch portion of the packaging material dispenser. This loading and threading is difficult and time consuming since, due to the close spacing of the rollers, an operator cannot manually carry the packaging material between the rollers. Rather, the operator must feed the packaging material from one side of each roller nip with one hand and pull the packaging material from the other side of the roller nip with the other hand. This procedure is rendered considerably more difficult because of the large widths of the webs of packaging material that are used commercially. Such webs generally have a width in the range of 10 to 30 inches. Other problems in loading and threading resulted from the fact that the operator is required to place his fingers proximate to the nip of the rollers and blindly feed the packaging material from the rear of the frame which carried the rollers, which makes the threading operation difficult and more time consuming.

The present disclosure is directed to overcoming one or more of the problems set forth above, as well as other problems associated with loading and threading a packaging material dispensers.

SUMMARY

In accordance with this disclosure, embodiments of a packaging material dispenser including one or more packaging material dispensing rollers for dispensing packaging material is provided. Embodiments of an apparatus for wrapping a load including a packaging material dispenser having one or more dispensing rollers for dispensing packaging material also are provided.

In accordance with one aspect of this disclosure, a packaging material dispenser may include a roll carriage having an upper portion and a lower portion, and a base plate separating the upper portion from the lower portion. The packaging material dispenser may also include a packaging material dispensing assembly mounted on an upper surface of the base plate and defining at least a portion of a packaging material path. A first portion of the packaging material path may extend behind the packaging material dispensing assembly. The upper portion of the roll carriage may include an opening defining a packaging material path access area positioned to provide access to a top of the packaging material path. The packaging material dispenser may also include a packaging material dispensing assembly drive mechanism extending below the base plate.

In accordance with another aspect of this disclosure, a packaging material dispenser may include a roll carriage having an upper portion and a lower portion, and a base plate separating the upper portion from the lower portion. The packaging material dispenser may also include a packaging material dispensing assembly mounted on an upper surface of the base plate and defining at least a portion of a packaging material path. An upstream portion of the packaging material path may extend behind the packaging material dispensing assembly, and a downstream portion of the packaging material path may extend in front of the packaging material dispensing assembly. At least one of the upstream portion and the downstream portion may be accessible via one or more passageways at the top of the roll carriage. The packaging material dispenser may also include a drive assembly for the packaging material dispensing assembly, the drive assembly extending below the base plate.

In accordance with yet another aspect of this disclosure a packaging material dispenser may include a roll carriage having a base plate on which a packaging material dispensing assembly is mounted. The packaging material dispenser may also include a packaging material path for packaging material being dispensed by the packaging material dispensing assembly. The packaging material path may include a substantially U-shaped configuration including a first leg through which packaging material is drawn in a first direction. The packaging material path may also include a second leg through which packaging material is drawn in a second direction different than the first direction, and a connecting portion connecting the first leg to the second leg. At least one of the first leg and the second leg may be accessible via one or more passageways at a top of the roll carriage. The packaging material dispenser may also include a drive assembly for the packaging material dispensing assembly, the drive assembly extending below the base plate.

In accordance with yet another aspect of this disclosure, a wrapping apparatus for wrapping a load may include a packaging material dispenser. The packaging material dispenser may include a roll carriage having a base plate on which a packaging material dispensing assembly may be mounted. The packaging material dispenser may also include a packaging material path for packaging material being dispensed by the packaging material dispensing assembly. The packaging material path may have a substantially U-shaped configuration. The wrapping apparatus may also include a column on which the packaging material dispenser is movably mounted. The base plate may be cantilevered to provide a gap between the packaging material dispensing assembly and a surface of the column, providing access to at least a portion of the packaging material path. The wrapping apparatus may also include means for providing relative rotation between the packaging material dispenser and the load.

In accordance with yet another aspect of this disclosure, a wrapping apparatus for wrapping a load may include a packaging material dispenser. The packaging material dispenser may include a packaging material dispensing assembly. The packaging material dispenser may also include a roll carriage having a base plate on which the packaging material dispensing assembly is mounted, and a packaging material dispensing assembly drive mechanism mounted below the base plate. The wrapping apparatus may also include a load support surface configured to support the load during wrapping. The load support surface may include an opening configured to allow the at least a portion of the packaging material dispensing assembly drive mechanism to pass below the load support surface.

In accordance with yet another aspect of this disclosure, a packaging material dispenser may include a packaging material dispensing assembly, and a roll carriage having a base plate on which the packaging material dispensing assembly is mounted. The packaging material dispenser may also include a cover assembly including a door with a hinged end rotatably coupled to the roll carriage and a free end opposite the hinged end. The free end may be configured to selectively engage a top portion of the roll carriage. The door may be configured to move between at least one open position and a closed position to position packaging material against the packaging material dispensing assembly.

In accordance with yet another aspect of this disclosure, a method for wrapping a load may include inserting packaging material downward into a first portion of a packaging material path. The first portion may extend behind one or more packaging material dispensing rollers of a packaging material dispensing assembly mounted on a base plate. The method may also include providing relative rotation between the packaging material dispensing assembly and the load. The method may also include driving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

In accordance with yet another aspect of this disclosure, a method for wrapping a load may include inserting packaging material downward into a packaging material path of a packaging material dispensing assembly mounted on a base plate of a roll carriage. Inserting may include inserting a first portion of packaging material downward into an upstream portion of the packaging material path behind the packaging material dispensing assembly. Inserting may also include inserting a second portion of packaging material downward into a downstream portion of the packaging material path in front of the packaging material dispensing assembly. The method may also include providing relative rotation between the packaging material dispensing assembly and the load. The method may also include driving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

In accordance with yet another aspect of this disclosure, a method for wrapping a load may include inserting packaging material downward into a substantially U-shaped packaging material path of a packaging material dispensing assembly mounted on a base plate of a roll carriage. Inserting may include inserting a first portion of packaging material downward into a first leg of the packaging material path, through which packaging material is drawn in a first direction. Inserting may also include inserting a second portion of packaging material downward into a second leg of the packaging material path, through which packaging material is drawn in a second direction different than the first direction. The method may also include providing relative rotation between the packaging material dispensing assembly and the load. The method may also include driving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

In accordance with yet another aspect of this disclosure, a method for wrapping a load may include dispensing packaging material with a packaging material dispensing assembly mounted on a base plate of a roll carriage. The method may also include driving the packaging material dispensing assembly to dispense packaging material with a packaging material dispensing assembly drive mechanism mounted below the base plate. The method may also include providing relative rotation between the packaging material dispensing assembly and the load, and moving at least a portion of the packaging material dispensing assembly drive mechanism into an opening in a load support surface supporting the load such that the at least a portion of the packaging material dispensing assembly drive mechanism moves below the load support surface.

In accordance with yet another aspect of this disclosure, a method for wrapping a load may include opening a door having a hinged bottom end rotatably coupled to a base plate to provide an opening between the door and a packaging material dispensing assembly mounted on the base plate. The method may also include inserting a length of packaging material into the opening. The method may also include moving the door to close the opening and thereby position the length of packaging material on the packaging material dispensing assembly. The method may also include dispensing packaging material with the packaging material dispensing assembly, and providing relative rotation between the packaging material dispensing assembly and the load.

Additional objects and advantages of the disclosed embodiments will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the embodiments. The objects and advantages of the embodiments may be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features claimed.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the description, serve to explain the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a wrapping apparatus, including a packaging material dispenser, according to an aspect of the present disclosure.

FIG. 2 shows an isometric view of a portion of the packaging material dispenser of FIG. 1, according to an aspect of the present disclosure.

FIG. 3 shows an isometric view similar to that of FIG. 2, with a cover assembly of the packaging material dispenser in an open position, according to an aspect of the present disclosure.

FIG. 4 shows a close-up perspective view of a portion of the wrapping apparatus of FIG. 1, with the cover assembly of the packaging material dispenser in an open position, according to an aspect of the present disclosure.

FIG. 5 shows a close-up perspective view of a portion of the wrapping apparatus of FIG. 1, according to an aspect of the present disclosure.

FIG. 6 shows a close-up perspective view of a hinge assembly of the packaging material dispenser of FIG. 1, with the cover assembly in a first open position, according to an aspect of the present disclosure.

FIG. 7 shows a close-up perspective view of the hinge assembly of the packaging material dispenser of FIG. 1, with the cover assembly in a second open position, according to an aspect of the present disclosure.

FIG. 8 shows a close-up perspective view of a bottom portion of the packaging material dispenser of FIG. 1, including a drive housing, according to an aspect of the present disclosure.

FIG. 9 shows a close-up perspective view of a bottom portion of the stretch wrapping apparatus of FIG. 1, with the drive housing removed, according to an aspect of the present disclosure.

FIG. 10 shows a schematic top view of portions of the wrapping apparatus of FIG. 1, with the cover assembly in an open position, according to an aspect of the present disclosure.

FIG. 11 shows a schematic top view of portions of the wrapping apparatus of FIG. 1, with the cover assembly in a closed position, according to an aspect of the present disclosure.

FIG. 12 shows a schematic top view of portions of another wrapping apparatus, according to an aspect of the present disclosure.

FIG. 13 shows a schematic top view of portions of yet another wrapping apparatus, according to an aspect of the present disclosure.

FIG. 14 shows a top view of the packaging material dispenser of FIG. 1 with a cap removed, according to an aspect of the present disclosure.

FIG. 15 shows a bottom view of the packaging material dispenser of FIG. 1 with the drive housing removed, according to an aspect of the present disclosure.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made to the present exemplary embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

In accordance with the present disclosure, embodiments of a wrapping apparatus are provided, the wrapping apparatus being provided for wrapping a load with packaging material. In an exemplary embodiment, stretch wrap packaging material is used, however, various other packaging materials such as netting, strapping, banding, or tape can be used as well. As used herein, the terms “packaging material,” “packaging material,” “web,” and “packaging material web” are interchangeable.

As shown in FIG. 1, an apparatus 100 may include a packaging material dispenser 102 for dispensing packaging material 104, and means for providing relative rotation between a load 101 and the packaging material dispenser 102 so that packaging material 104 can be wrapped around load 101. The means may include a rotatable turntable assembly, a horizontal rotatable ring assembly, a vertical rotatable ring assembly, or a rotatable arm assembly. Apparatus 100 includes a rotatable turntable 188 on which load 101 is supported during the wrapping process. Rotatable turntable 188 may be a low-profile turntable. As used herein and generally understood in the art, a low profile turntable is a rotatable turntable having a load support surface that is less than or equal to 3 inches above a floor surface supporting the turntable. Apparatus 100 may also include a column 156, on which packaging material dispenser 102 is mounted for vertical travel along column 156. While packaging material 104 is being dispensed by packaging material dispenser 102, relative rotation between packaging material dispenser 102 and load 101, which may be provided by rotatable turntable 188, may wrap packaging material 104 around load 101. Combining that relative rotation with vertical travel of packaging material dispenser 102 along column 156 may provide for wrapping of load 101 with packaging material 104 in a spiral-like fashion.

Before wrapping of load 101 may begin, packaging material 104 must be loaded into and threaded through packaging material dispenser 102. Loading packaging material dispenser 102 includes placing a roll 118 of packaging material 104 onto a roll support 120, as shown, for example, in FIG. 5. Roll support 120 may be similar to the roll support shown in U.S. Patent Application Publication No. 2009/0235617, filed as application Ser. No. 12/409,407, entitled “WRAPPING APPARATUS HAVING TOP LOADING AND THREADING PACKAGING MATERIAL DISPENSER,” filed Mar. 23, 2009, the entire disclosure of which is incorporated by reference. A door 108 that is part of a cover assembly 106 of packaging material dispenser 102 may be opened, as shown in FIGS. 3, 4, 6, and 7. An operator may open door 108 by pulling on a handle 173. Pulling on handle 173 may release a latch assembly 172 by, for example, releasing a bolt 171 from a catch 176. Door 108 may rotate about a pivot 117. A hinge assembly 114 may include a groove 192 for guiding door 108 from its closed position to first and second open positions. Door 108 may include a protrusion 113 configured to be received in groove 192. As door 108 swings open by pivoting about pivot 117, protrusion 113 may slide upward along a first portion 194 of groove 192. When protrusion 113 reaches an upper end of first portion 194, door 108 is in a first open position (FIGS. 3, 4, and 6), creating a space 166 between door 108 and a packaging material dispensing assembly, such as a prestretch assembly 122, into which packaging material 104 can be loaded. If the operator continues to pull handle 173, hinge assembly 114 may rotate about pivot 119 in a clockwise direction toward column 156, aligning protrusion 113 with a lower end of a second portion 196 of groove 192. As door 108 swings wider open by pivoting about pivot 117, protrusion 113 may slide upward along second portion 196 of groove 192. When protrusion 113 reaches an upper end of second portion 196, door 108 is held in a second open position (FIG. 7), thus increasing accessibility into space 166, and allowing greater access to internal components of packaging material dispenser 102.

As shown in FIG. 5, a portion of leading portion 190 of packaging material 104 may be pulled off of roll 118, and may be inserted downward into a gap 144. Gap 144 may open downward into a first portion 160 of a packaging material path 159 that extends behind prestretch assembly 122 and in front of at least a portion of column 156. For example, gap 144 may extend between prestretch assembly 122 and a plane formed by a surface of column 156. First portion 160 of packaging material path 159 is easily accessible via the top of packaging material dispenser 122. Packaging material 104 may travel in a first direction 125 (FIGS. 10 and 11), relative to packaging material dispenser 102, when moving through first portion 160.

With door 108 opened to either of the first and second open positions, another portion of leading portion 190 of packaging material 104 may be wrapped around a side of prestretch assembly 122 and inserted in a space 166 between open door 108 and a front of prestretch assembly 122. As door 108 is closed (FIGS. 1, 2, and 11), idle rollers 150, 151, and 152, rotatably mounted on door 108, may press packaging material 104 against an idle roller 153 and one or more packaging material dispensing rollers. The one or more packaging material dispensing rollers may include an upstream prestretch roller 124 and a downstream prestretch roller 126. The pressing provides traction between packaging material 104 and upstream and downstream prestretch rollers 124 and 126. Surfaces of idle roller 150, idle roller 151, idle roller 152, idle roller 153, upstream prestretch roller 124, and downstream prestretch roller 126 may form a second portion 168 of packaging material path 159 that may have a serpentine form, (e.g., S-shaped or W-shaped), as shown, for example, in FIG. 11, and similar to that which can be found in U.S. Patent Application Publication No. 2009/0235617. Packaging material 104 may travel in a second direction 127 (FIGS. 10 and 11), relative to packaging material dispenser 102, when moving through second portion 168 of packaging material path 159. A third portion 170 of packaging material path 159, extending along a side of prestretch assembly 122, connects first portion 160 and second portion 168 of packaging material path 159, such that first portion 160, second portion 168, and third portion 170 of packaging material path 159 together form a substantially U-shaped path for packaging material 104.

An operator may close door 108 by pushing door 108 toward prestretch assembly 122. If door 108 is in its second open position, the force on door 108 may rotate door 108 about pivot 117, causing protrusion 113 to travel downward along second portion 196 of groove 192. Protrusion 113 may press against a lower edge of groove 192, causing hinge assembly 114 to rotate in a counterclockwise direction away from column 156, bringing protrusion 113 against a lower end of second portion 196 (and a top end of first portion 194), and into alignment with first portion 194 of groove 192, thus placing door 108 in its first open position. As the operator continues to push door 108 toward prestretch assembly 122, door 108 may continue to rotate about pivot 117, and protrusion 113 may travel downward along first portion 194 of groove 192. Eventually, as protrusion 113 reaches a lower end of groove 192, latch assembly 172 may latch onto door 108, holding door 108 in its closed position. A stop 115 is provided on hinge assembly 114 to absorb some of the force associated with the closing of door 108. It is also contemplated that door 108 may include a window 198 allowing an operator to view internal components of packaging material dispenser 102 with door 108 in its closed position.

As shown in FIG. 1, downstream from packaging material dispenser 102, leading portion 190 of packaging material 104 may be attached to load 101, a location near load 101, or a clamp 186 on rotatable turntable 188, in preparation for wrapping. Clamp 186 may be similar to the packaging material holder described in U.S. Pat. No. 6,269,610, filed as application Ser. No. 09/137,119, entitled “METHOD AND APPARATUS FOR STRETCH WRAPPING A LOAD,” filed Aug. 20, 1998, the entire disclosure of which is incorporated by reference.

As packaging material 104 is dispensed from roll 118, it may travel in first direction 125 along first portion 160 of packaging material path 159, reverse direction along third portion 170 of packaging material path 159, and travel in second direction 127, relative to dispenser 102, along second portion 168 of packaging material path 159, before reaching load 101.

Packaging material dispenser 102 may include a roll carriage 112. Roll carriage 112 may include a top plate 116, a base plate 110, a roll support 120 mounted on base plate 110, and a vertical support member 164 extending between top plate 116 and base plate 110, as shown in FIGS. 5, 6-8, 14, and 15. It is also contemplated that at least a portion 111 of roll carriage 112 having one or more rollers thereon may movably engage a track or frame within a space (not shown) in column 156. Top plate 116 and base plate 110 may rotatably support upstream prestretch roller 124, downstream prestretch roller 126, and idle roller 153. “Upstream” and “downstream,” as used herein, are intended to define the direction of movement relative to the flow of packaging material 104 through packaging material dispenser 102. Movement in a direction that is against the flow of packaging material 104 is defined as “upstream,” and movement in a direction that is with the flow of packaging material 104 is defined as “downstream.” “Upstream” and “downstream,” as used herein, do not (necessarily) describe the positions of the rollers relative to roll support 120 for roll 118 of packaging material 104. Upstream prestretch roller 124 and/or downstream prestretch roller 126 may be connected to a power source, such as a drive motor 132 shown in FIGS. 2 and 3; however, they do not need to be, and upstream prestretch roller 124 and/or downstream prestretch roller 126 therefore may be powered or unpowered.

As shown in FIGS. 10, 11, and 14, upstream prestretch roller 124 and downstream prestretch roller 126 may be mounted on shafts 128 and 130, respectively. A first end of each of shafts 128 and 130 may be supported by base plate 110 of roll carriage 112, while a second end of each of shafts 128 and 130 may be supported by top plate 116 of roll carriage 112. A sprocket 134 is mounted on/attached to shaft 128 of upstream prestretch roller 124 above top plate 116, and similarly, a sprocket 136 is mounted on/attached to shaft 130 of downstream prestretch roller 126 above top plate 116. The sprockets may be connected by a chain, belt, or any other suitable connection 137, such that upstream prestretch roller 124 may be rotatably driven by the rotation of downstream prestretch roller 126.

As shown in FIGS. 9 and 15, a sprocket 141 may be mounted on or otherwise attached to shaft 130 of downstream prestretch roller 126 below base plate 110. Sprocket 141 may be connected to a sprocket 142 on drive motor 132 by a drive belt 145. Drive belt 145 may include, for example, a belt, a chain, a cable, one or more gears, and/or any other suitable connection. Sprocket 141, sprocket 142, and/or drive belt 145, may be housed in a drive housing 182 below base plate 110 of roll carriage 112, as shown in FIG. 8. Positioning roll carriage 112 above drive housing 182 allows roll carriage 112 to be used to prevent debris from entering into drive housing 182 from above.

Drive housing 182, and the components housed therein, may have a relatively small vertical thickness as compared to conventional drive components. This creates a low-profile drive design, which allows packaging material dispenser 102 to move through a wide range of vertical positions. Attempting to use conventional drive components, instead of the low-profile drive components, may not be feasible, or may be problematic, for at least a few reasons.

Impacts between bottom-mounted drive components and an object, such as, for example, the ground, a conveyor, or a machine part, may cause damage, resulting in machine downtime. Thus, a clearance must be maintained between the drive components and the object, so that impacts can be avoided. Providing that clearance requires moving the drive components vertically higher relative to a load wrapping surface to provide a clearance distance between the drive components and the object. The packaging material dispensing components on the roll carriage, being positioned above the drive components, must also be moved vertically higher by at least the sum of the clearance distance and the thickness of the drive components. The thicker the drive components, the farther away the packaging material dispensing components are from the load wrapping surface.

If the packaging material dispensing components are too high relative to the load wrapping surface, they may have difficulty wrapping the bottom surfaces of a load on the load wrapping surface. Even greater difficulties arise if roping assemblies are used to rope up the packaging material before it reaches the load, since roping assemblies may move the packaging material even higher, and thus, farther away from the load wrapping surface. While the use of drive down rollers may help drive the packaging material downward, its capacity to drive down packaging material to a lower height has a limit. When that limit is exceeded, it may not be able to drive the packaging material down any further, or may fail to operate in a desired manner.

One way to avoid such problems associated with bottom-mounted drive components is by eliminating mechanical drive components, so that packaging material dispensing rollers mounted on the roll carriage are driven by separate motors controlled by a microprocessor unit. Such an arrangement, however, would increase the complexity and cost of a system.

The overall vertical thickness of the low-profile drive system including “low-profile” drive components, such as drive housing 182, sprocket 141, sprocket 142, and drive belt 145, helps avoid the above-described drawbacks. This is because the vertical thicknesses of the low-profile drive components are less than that of conventional components. Thus, packaging material 104 can be dispensed at a height closer to the bottom surfaces of load 101 than would be possible with conventional components. In addition, offsetting the height of roll support 120 relative to roll carriage 112 by, for example, lowering roll support 120 relative to roll carriage 112, helps to compensate for the vertical thicknesses of drive housing 182, the bottom sprocket of downstream prestretch roller 126, sprocket 142, and drive belt 145. The offsetting of roll support 120 may be similar to that which is shown in U.S. Patent Application Publication No. 2009/0235617. Furthermore, providing an opening 146 in a support surface 148 of wrapping apparatus 100, as shown in FIG. 9, may allow drive housing 142 (removed in FIG. 9 for clarity) and the components housed therein to move even further downward, further compensating for the vertical thickness of those components. It is contemplated that support surface 148 may include a surface on which rotatable turntable 188 is rotatably mounted. Additionally or alternatively, in the case where packaging material dispenser 102 is mounted on a rotatable arm, support surface 148 may include a conveyor on which a load rests during wrapping.

Packaging material dispenser 102 may also include a roping and drive down assembly 184. Roping and drive down assembly 184 may include at least one drive down roller assembly 185 and a roping assembly 187 similar to those described in U.S. Patent Application Publication No. 2009/0235617, as well as U.S. Patent Application Publication No. 2007/0209324 A1, filed as application Ser. No. 11/709,879, entitled “METHOD AND APPARATUS FOR SECURING A LOAD TO A PALLET WITH A ROPED PACKAGING MATERIAL WEB,” filed Feb. 23, 2007, the entire disclosures of which are incorporated herein by reference. For example, roping and drive down assembly 184 may include one or more components similar to those shown in FIGS. 5-8 of U.S. Patent Application Publication No. 2007/0209324 A1.

As embodied herein and shown in FIG. 12, a wrapping apparatus 200 is contemplated having a packaging material dispenser 202 for dispensing packaging material 204. Packaging material dispenser 202 may be similar to packaging material dispenser 102 in some respects, and similar in other respects to the packaging material dispenser shown in FIGS. 1-7 of U.S. Patent Application Publication No. 2009/0235617.

For example, packaging material dispenser 202 may include a roll carriage 212 including a base plate 210 and a top plate 216. Base plate 210 may support a prestretch assembly 222 including an upstream prestretch roller 224 (mounted for rotation on a shaft 228) and a downstream prestretch roller 226 (mounted for rotation on a shaft 230). Upstream prestretch roller 224 and downstream prestretch roller 226 may be cantilevered from base plate 210, and supported by support members 274 and 276, similar to the arrangement shown in FIGS. 1-7 of U.S. Patent Application Publication No. 2009/0235617. Packaging material dispenser 202 may also include idle rollers 250 and 254 for guiding packaging material 204 along a packaging material path 259.

Packaging material path 259 has a general U-shape and is illustrated in FIG. 12. Packaging material 204 may be dispensed from a roll 218 of packaging material 204 supported on a roll support 220. To initiate packaging material movement through packaging material dispenser 202 in packaging material path 259, packaging material 204 may be inserted downwardly through a gap 244, similar to gap 144 of packaging material dispenser 102, between prestretch assembly 222 and column 256, such that packaging material 204 lies in a first portion 260 of U-shaped packaging material path 259 behind prestretch assembly 222, through which packaging material 204 will be drawn in a first direction 225, relative to dispenser 202, during wrapping. Packaging material 204 also may be inserted downwardly through one or more passages at the top of roll carriage 212 such that packaging material lies in a second portion 268 of packaging material path 259 in front of prestretch assembly 222, through which packaging material 204 will be drawn in a second direction 227 relative to dispenser 202 during wrapping. Packaging material 204 also may lie in a third portion 270 of packaging material path 259 extending between first portion 260 and second portion 268. The one or more passages at the top of roll carriage 212 may be similar to that which is shown in FIGS. 1-7 of U.S. Patent Application Publication No. 2009/0235617.

It is also contemplated that packaging material dispenser 202 may include low-profile drive components similar to those that are shown in FIGS. 1-7 of U.S. Patent Application Publication No. 2009/0235617. Means for providing relative rotation between packaging material dispenser 202 and the load may include, for example, a rotatable turntable (not shown). Alternatively, packaging material dispenser 202 may be vertically driven on a rotatable arm (not shown) or a wrapping ring (not shown). Exemplary embodiments of a rotatable turntable, a rotatable arm, and a wrapping ring that may form a part of this disclosure are described in U.S. Patent Application Publication No. 2009/0235617.

As embodied herein and shown in FIG. 13, a stretch wrapping apparatus 300 is contemplated having a packaging material dispenser 302 for dispensing packaging material 304. Packaging material dispenser 302 may be similar to packaging material dispenser 102 in some respects, and similar in other respects to the packaging material dispenser shown in FIGS. 8-11 of U.S. Patent Application Publication No. 2009/0235617.

For example, packaging material dispenser 302 may include a roll carriage 312 including a base plate 310 and a top plate 316. Base plate 310 may support a prestretch assembly 322 including an upstream prestretch roller 324 (mounted for rotation on a shaft 328) and a downstream prestretch roller 326 (mounted for rotation on a shaft 330). Upstream prestretch roller 324 and downstream prestretch roller 326 may be cantilevered from base plate 310, and supported by support members 374 and 376, similar to the arrangement shown in FIGS. 8-11 of U.S. Patent Application Publication No. 2009/0235617. Packaging material dispenser 302 may also include idle rollers 350, 352, and 354 for guiding packaging material 304 along a packaging material path 359.

Packaging material path 359 has a general U-shape and is illustrated in FIG. 13. Packaging material 304 may be dispensed from a roll 318 of packaging material 304 supported on a roll support 320. To initiate packaging material movement through packaging material dispenser 302 in packaging material path 359, packaging material 304 may be inserted downwardly through a gap 344, similar to gap 144 of packaging material dispenser 102, between prestretch assembly 322 and column 356, such that packaging material 304 lies in a first portion 360 of U-shaped packaging material path 259 behind prestretch assembly 322, through which packaging material 304 will be drawn in a first direction 325 relative to dispenser 302 during wrapping. Packaging material 304 also may be inserted downwardly through one or more passages at the top of roll carriage 312 such that packaging material lies in a second portion 368 of packaging material path 359 in front of prestretch assembly 322, through which packaging material 304 will be drawn in a second direction 327 relative to dispenser 302 during wrapping. Packaging material 304 also may lie in a third portion 370 of packaging material path 359 extending between first portion 360 and second portion 368. The one or more passages at the top of roll carriage may be similar to that which is shown in FIGS. 8-11 of U.S. Patent Application Publication No. 2009/0235617. It is also contemplated that packaging material dispenser 302 may include low-profile drive components similar to those that are shown in FIGS. 8-11 of U.S. Patent Application Publication No. 2009/0235617.

Means for providing relative rotation between packaging material dispenser 302 and the load may include, for example, a rotatable turntable (not shown) similar to rotatable turntable 188. Alternatively, packaging material dispenser 302 may be vertically driven on a rotatable arm (not shown) or a wrapping ring (not shown). Exemplary embodiments of a rotatable turntable, a rotatable arm, and a wrapping ring that may form a part of this disclosure are described in U.S. Patent Application Publication No. 2009/0235617.

A method for loading and threading packaging material 104 in packaging material dispenser 102 will now be described. With packaging material 102 in a vertically low position, such as that occupied at the end of a previous wrapping cycle (see FIG. 1), an operator begins loading packaging material dispenser 102 by sliding roll 118 onto roll support 120. The operator then grasps a leading end of packaging material 104 from roll 118. The operator may pull the leading end to produce leading portion 190. It is also contemplated that the operator may form at least a portion of leading portion 190 into a rope. The operator inserts a portion of leading portion 190 downward through gap 144 into first portion 160 of packaging material path 159. The operator opens door 108 to create space 166 between prestretch assembly 122 and door 108. At third portion 170 of packaging material path 159, the operator wraps a portion of leading portion 190 around upstream prestretch roller 124. At second portion 168 of packaging material path 159, the operator inserts a portion of the length of packaging material into space 166. The operator then attaches the leading end of packaging material 104 to load 101, a point near load 101, or clamp 186. Either before or after attaching the leading end, the operator closes door 108 to pin leading portion 190 against upstream prestretch roller 124, downstream prestretch roller 126, and idle roller 153, using idle rollers 150, 151, and 152.

With the leading end being clamped or otherwise held, relative rotation may be provided between load 101 and packaging material dispenser 102, causing packaging material 104 to be wrapped about load 101. Packaging material dispenser 102 may travel vertically along column 156 from a bottom portion of load 101 to a top portion of load 101, and then back down to the bottom portion, while the relative rotation is being provided, to spirally wrap packaging material 104 about load 101.

The method for loading packaging material in packaging material dispensers 202 and 302 may be similar to the method described above with respect to packaging material dispenser 102. There are, however, differences between the methods.

With packaging material dispenser 202, once a portion of the length of packaging material has been inserted downward through gap 244 into first portion 260 of packaging material path 259, the operator wraps a portion of the length of packaging material around idle roller 250 at third portion 270 of packaging material path 259. At second portion 268 of packaging material path 259, the operator inserts a portion of the length of packaging material downward through one or more passageways at the top of roll carriage 212, as described in U.S. Patent Application Publication No. 2009/0235617. Then the operator may attach the leading end of packaging material 204 to the load to be wrapped, a point near the load, or a clamping device. With the leading end being clamped or otherwise held, relative rotation may be provided between the load being wrapped and packaging material dispenser 202, causing packaging material 204 to be wrapped about the load. Packaging material dispenser 202 may travel vertically along column 256 from a bottom portion of the load to a top portion of the load, and then back down to the bottom portion, while the relative rotation is being provided, to spirally wrap packaging material 204 about the load.

With packaging material dispenser 302, once a portion of the length of packaging material has been inserted downward through gap 344 into first portion 360 of packaging material path 359, the operator will wrap a portion of the length of packaging material around idle roller 350 at third portion 370 of packaging material path 359. At second portion 368 of packaging material path 359, the operator may insert a portion of the length of packaging material downward through one or more passageways at the top of roll carriage 312, as described in U.S. Patent Application Publication No. 2009/0235617. Then the operator may attach the leading end of packaging material 304 to the load to be wrapped, a point near the load, or a clamping device. With the leading end being clamped or otherwise held, relative rotation may be provided between the load being wrapped and packaging material dispenser 302, causing packaging material 304 to be wrapped about the load. Packaging material dispenser 302 may travel vertically along column 356 from a bottom portion of the load to a top portion of the load, and then back down to the bottom portion, while the relative rotation is being provided, to spirally wrap packaging material 304 about the load.

Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. A packaging material dispenser comprising: a roll carriage having an upper portion and a lower portion, and a base plate separating the upper portion from the lower portion;a packaging material dispensing assembly mounted on an upper surface of the base plate and defining at least a portion of a packaging material path, a first portion of the packaging material path extending behind the packaging material dispensing assembly;the upper portion of the roll carriage including an opening defining a packaging material path access area positioned to provide access to a top of the packaging material path for insertion of packaging material into the packaging material path; anda packaging material dispensing assembly drive mechanism extending below the base plate.

2. The packaging material dispenser of claim 1, wherein packaging material in the first portion of the packaging material path extends behind one or more packaging material dispensing rollers of the packaging material dispensing assembly.

3. The packaging material dispenser of claim 2, wherein the packaging material path includes a second portion extending in front of the one or more packaging material dispensing rollers of the packaging material dispensing assembly.

4. The packaging material dispenser of claim 1, wherein the opening extends between the packaging material dispensing assembly and a column on which the packaging material dispenser is movably mounted.

5. The packaging material dispenser of claim 4, wherein the base plate is cantilevered.

6. The packaging material dispenser of claim 1, wherein the packaging material dispensing assembly drive mechanism includes a low profile housing.

7. The packaging material dispenser of claim 6, wherein the packaging material dispensing assembly drive mechanism includes a sprocket coupled to a first packaging material dispensing roller of the packaging material dispenser assembly.

8. The packaging material dispenser of claim 7, wherein the packaging material dispensing assembly drive mechanism includes a drive belt coupling the sprocket to a packaging material dispensing assembly drive.

9. A packaging material dispenser comprising: a roll carriage having an upper portion and a lower portion, and a base plate separating the upper portion from the lower portion;a packaging material dispensing assembly mounted on an upper surface of the base plate and defining at least a portion of a packaging material path, an upstream portion of the packaging material path extending behind the packaging material dispensing assembly, and a downstream portion of the packaging material path extending in front of the packaging material dispensing assembly;at least one of the upstream portion and the downstream portion being accessible for receiving packaging material via one or more passageways at the top of the roll carriage; anda drive assembly for the packaging material dispensing assembly, the drive assembly extending below the base plate.

10. The packaging material dispenser of claim 9, wherein the upstream portion extends through a gap along a side of the packaging material dispensing assembly facing a surface of a column to which the packaging material dispenser is movable mounted.

11. The packaging material dispenser of claim 10, wherein the downstream portion includes a space extending along a side of the packaging material dispensing assembly facing away from the column.

12. The packaging material dispenser of claim 9, wherein at least a portion of the downstream portion has a serpentine shape.

13. A packaging material dispenser comprising: a roll carriage having a base plate on which a packaging material dispensing assembly is mounted;a packaging material path for packaging material being dispensed by the packaging material dispensing assembly, the packaging material path including a substantially U-shaped configuration including a first leg through which packaging material is drawn in a first direction,a second leg through which packaging material is drawn in a second direction different than the first direction, anda connecting portion connecting the first leg to the second leg,wherein at least one of the first leg and the second leg is accessible for receiving packaging material via one or more passageways at a top of the roll carriage; anda drive assembly for the packaging material dispensing assembly, the drive assembly extending below the base plate.

14. The packaging material dispenser of claim 13, wherein the first direction is upstream.

15. The packaging material dispenser of claim 13, wherein the second direction is downstream.

16. The packaging material dispenser of claim 13, wherein at least a portion of the second leg has a serpentine shape.

17. A wrapping apparatus for wrapping a load, comprising: a packaging material dispenser including a roll carriage having a base plate on which a packaging material dispensing assembly is mounted, anda packaging material path for packaging material being dispensed by the packaging material dispensing assembly, the packaging material path having a substantially U-shaped configuration;a column on which the packaging material dispenser is movably mounted, wherein the base plate is cantilevered to provide a gap between the packaging material dispensing assembly and a surface of the column, providing access to at least a portion of the packaging material path for insertion of packaging material into the packaging material path; andmeans for providing relative rotation between the packaging material dispenser and the load.

18. The wrapping apparatus of claim 17, wherein at least a portion of the gap extends between a top portion of the roll carriage and the surface of the column.

19. A wrapping apparatus for wrapping a load, comprising: a packaging material dispenser including a packaging material dispensing assembly;a roll carriage having a base plate on which the packaging material dispensing assembly is mounted, anda packaging material dispensing assembly drive mechanism mounted below the base plate; anda load support surface configured to support the load during wrapping, wherein the load support surface includes an opening configured to allow the at least a portion of the packaging material dispensing assembly drive mechanism to pass below the load support surface.

20. The wrapping apparatus of claim 19, wherein the load support surface includes a rotatable turntable.

21. The wrapping apparatus of claim 20, wherein the load support surface includes a based configured to rotatably support the rotatably turntable.

22. A packaging material dispenser comprising: a packaging material dispensing assembly;a roll carriage having a base plate on which the packaging material dispensing assembly is mounted; anda cover assembly including a door with a hinged end rotatably coupled to the roll carriage and a free end opposite the hinged end, the free end being configured to selectively engage a top portion of the roll carriage, wherein the door is configured to move between at least one open position and a closed position to position packaging material against the packaging material dispensing assembly.

23. The packaging material dispenser of claim 22, wherein the free end includes a first portion of a latch assembly.

24. The packaging material dispenser of claim 23, wherein the top portion of the roll carriage includes a second portion of the latch assembly configured to receive the first portion of the latch assembly.

25. The packaging material dispenser of claim 22, further including at least one idle roller rotatably mounted on the door.

26. The packaging material dispenser of claim 24, wherein with the door in the closed position, the at least one idle roller is configured to press the packaging material against at least one packaging material dispensing roller of the packaging material dispensing assembly.

27. A method for wrapping a load, comprising: inserting packaging material downward into a first portion of a packaging material path, the first portion extending behind one or more packaging material dispensing rollers of a packaging material dispensing assembly mounted on a base plate;providing relative rotation between the packaging material dispensing assembly and the load; anddriving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

28. The method of claim 27, wherein inserting packaging material downward into a first portion includes inserting packaging material behind prestretch rollers of the packaging material dispensing assembly.

29. The method of claim 27, further including opening a door covering at least a portion of the packaging material dispensing assembly and inserting packaging material into a space between the open door and the one or more packaging material dispensing rollers.

30. The method of claim 29, further including closing the door to bring one or more idle rollers rotatably mounted on the door into engagement with the packaging material inserted into the space.

31. The method of claim 30, further including clamping the inserted packaging material between the one or more idle rollers and the one or more packaging material dispensing rollers.

32. A method for wrapping a load, comprising: inserting packaging material downward into a packaging material path of a packaging material dispensing assembly mounted on a base plate of a roll carriage, wherein inserting includes inserting a first portion of packaging material downward into an upstream portion of the packaging material path behind the packaging material dispensing assembly, andinserting a second portion of packaging material downward into a downstream portion of the packaging material path in front of the packaging material dispensing assembly;providing relative rotation between the packaging material dispensing assembly and the load; anddriving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

33. The method of claim 32, wherein inserting a first portion of packaging material includes inserting the first portion into a gap between the packaging material dispensing assembly and a column on which the roll carriage is movable mounted.

34. The method of claim 32, wherein inserting a second portion of packaging material includes opening a door covering a side of the packaging material dispensing assembly to create a space, and inserting the second portion into the space.

35. The method of claim 34, further including closing the door to clamp the second portion of packaging material between one or more idle rollers rotatably mounted on the door and the packaging material dispensing assembly.

36. A method for wrapping a load, comprising: inserting packaging material downward into a substantially U-shaped packaging material path of a packaging material dispensing assembly mounted on a base plate of a roll carriage, wherein inserting includes inserting a first portion of packaging material downward into a first leg of the packaging material path, through which packaging material is drawn in a first direction, andinserting a second portion of packaging material downward into a second leg of the packaging material path, through which packaging material is drawn in a second direction different than the first direction;providing relative rotation between the packaging material dispensing assembly and the load; anddriving the packaging material dispensing assembly to dispense packaging material for wrapping the load using a drive assembly mounted below the base plate.

37. The method of claim 36, wherein inserting a first portion of packaging material downward into a first leg includes inserting the first portion into a gap between the packaging material dispensing assembly and a column on which the packaging material dispensing assembly is movably mounted for vertical travel.

38. The method of claim 36, wherein inserting a second portion of packaging material downward into a second leg includes opening a door covering a side of the packaging material dispensing assembly to create a space between the door and the packaging material dispensing assembly, and inserting the second portion into the space.

39. The method of claim 38, further including closing the door to clamp the second portion of packaging material between one or more idle rollers rotatably mounted on the door and the packaging material dispensing assembly.

40. A method for wrapping a load, comprising: dispensing packaging material with a packaging material dispensing assembly mounted on a base plate of a roll carriage;driving the packaging material dispensing assembly to dispense packaging material with a packaging material dispensing assembly drive mechanism mounted below the base plate;providing relative rotation between the packaging material dispensing assembly and the load; andmoving at least a portion of the packaging material dispensing assembly drive mechanism into an opening in a load support surface supporting the load such that the at least a portion of the packaging material dispensing assembly drive mechanism moves below the load support surface.