Pre-Stretched Coreless Film Roll Products
A coreless film roll product which may be used for both hand wrapping and machines wrapping with or without retrofitting stabilizing components.
This application claims priority to U.S. Provisional Application No. 61/478,239 filed Apr. 22, 2011.
FIELD OF INVENTIONThe present invention relates to palletizing material, and specifically to coreless and pre-stretched film rolls.
As used herein, the term “core” means any structure that is in contact with a substantial portion of the interior surface of a film roll.
As used herein, the term “coreless” means any film product which does not include a cardboard, plastic or metal core or any other core which cannot be disposed of or recycled using standard recycling procedures (e.g., because of adhesives, size, or any limitation of a recycling process which causes an added disposal or recycling cost). The term “coreless” may include a reusable, disposable or recyclable liner. “Coreless” may also include film products which use an interior structure adapted to use less material than a traditional core structure, such as rings, strips, bars and any other structure of device known in the art to form an interior structure. “Coreless” may also include any film roll which requires the use of stabilizing (e.g., retrofitting) structures on a wrapping machine to eliminate the need for a core.
As used herein, the term “film” includes flexible packaging material for any packaging use known in the art (e.g., industrial, medical, food and beverage, retail, shipping, pharmaceutical). Film may include organic and non-organic materials, biodegradable materials, carbon-based and non-carbon based materials, previously recycled materials, composite materials, laminate materials, metallic materials, cast films, blown films, metalized films, barrier films, heat treated materials, temperate materials, protective materials, light resistant materials, light sensitive materials, aerated materials, vacuum films, chemical resistant materials, chemical sensitive materials, reinforced materials, x-ray resistant materials, time-reactive materials, water and heat resistant materials, impact resistant materials, containment materials, multiple-layered materials, flattened materials, pre-stretched materials, biodegradable materials, films or other materials structurally integrated with other materials, combinations of materials and other film equivalent or film-related products known in the art.
As used herein, the term “pre-stretched” refers to a film which is stretched before being wound or provided as a product.
As used herein, the term “retrofitting stabilizing component” refers to any structure or device which may be used in conjunction with a coreless film roll in order to make the coreless film roll usable with existing wrapping machines.
BackgroundFilm which is wound, rolled or layered for use has an array of uses for industrial, medical, food and beverage, scientific and consumer uses.
For example, in order to stabilize and protect items stacked on a pallet, whether for storage or transport, a film is wrapped around the articles and pallet. Pallets may be wrapped by a machine or by hand. When wrapped by a machine, a roll of film is placed on an arm of the machine, and a pallet on a rotating platform. As the pallet spins, film is pulled from the roll and accumulates around the pallet and products. When wrapped by hand, a user may walk around a pallet carrying a roll of film and wrap the film around the pallet and products. Usually the film has a gripping texture and some stretch which allows the plastic film to grip the articles being wrapped and secure them. Whether a pallet is wrapped by machine or by hand, an amount of tension may or may not be required to stretch the film and allow it to more securely grip the items being wrapped.
Film known in the art is provided in rolls wound around a cardboard, plastic or metal tube known as a core. Cores must be of sufficient strength to withstand the pressures caused by the high-speed winding of film around the core and the total weight of the final rolled product to prevent the roll from collapsing. Cores, therefore, are usually made from a thick (up to 2 inches or more) tube made of cardboard or other structural materials and may contain an adhesive between layers of material to provide additional stability.
One problem with existing cores is the weight. Cores can weigh up to 5 pounds or more. When shipping film rolls, a significant portion of the fee is attributable to the weight of the core and freight. The weight can also cause workplace injuries when carrying film rolls, loading film rolls to a wrapping machine or even hand wrapping pallets. Women and smaller workers may not even be able to lift film rolls because of the weight.
A second problem known in the art with traditional cores is the inability to dispose of the cores. Cardboard cores may be recyclable if there is no adhesive in the core, but most recycling companies will not take cores unless they are already flattened. In order to flatten a core, it must be run over by a forklift or other industrial machine. Getting a core into condition for recycling takes time and labor, and therefore costs companies money. In addition, if recyclable cores are thrown in the trash, some waste management companies charge a fee for disposal of green products.
Due to the added cost and labor, the presence of glue within the cores, or core material, some companies may not recycle cores, but disposal may still be an issue. If cores are not flattened, they take up significant space in waste containers and dumpsters. Large companies may go through multiple rolls of film a day, resulting in many cores to be disposed of. Dumpster costs, including the number of dumpsters and the frequency of pick-up, are also expensive. Some waste companies even charge additional fees for collecting high-volume waste.
In addition to core waste, companies also end up using more film to wrap pallets than is necessary. Film may be stretched before it is used to wrap, but wrapping machines and individuals wrapping by hand are unable to fully stretch film before it is wrapped around a pallet. As a result, more film is used than necessary. Wrapping machines also experience additional stress when stretching film for use.
In order to overcome the problem of wasted film, machines are known in the art which pre-stretch and rewind the film. By pre-stretching the rolls, less force is needed to tighten wrap around a pallet and less wrap is used. Pre-stretching the film also helps lower the weight of the rolls. Pre-stretched film, however, is only used in the art to hand wrap pallets.
Technology exists in the art to make coreless film products; however coreless film cannot be used on existing wrapping machines. For example, NO.EL, a company operating out of Italy, manufactures and sells a machine capable of winding coreless film rolls. While the resulting rolls may be coreless, they cannot be used on current wrapping machines because the rolls will not be secured or stable on the machine arm. As a result, rolls unwind from the inside out and become tangled and unusable. Wrapping machines are expensive and last a long time, and the purchase of a wrapping machine is considered a large investment for companies. Manufacturers of film rolls are therefore not offering coreless film rolls or investing in the NO.EL machine because no clients would be able to use coreless film rolls.
SUMMARY OF THE INVENTIONThe present invention is a coreless pre-stretched film roll product which may be used with both hand wrapping devices and wrapping machines with or without stabilizing components. A thin reinforcing liner is provided in the center of a film roll to prevent the interior end from unraveling. Plugs may also be used on one or both ends of a coreless film roll to stabilize the roll for transport and storage. Coreless rolls to be used in a wrapping machine also include retrofitting stabilizing components which allow the coreless rolls to be used with current wrapping machines.
The present invention decreases the weight of and disposal and freight costs associated with film rolls by removing the traditional cardboard core. Thin, disposable liners and stabilizing plugs may be used with any rolled product, including, but not limited to, paper products, plastic products, fabric products or any other material which may be rolled, in order to decrease the weight and disposal, freight and manufacturing costs associated with cored products.
DETAILED DESCRIPTION OF INVENTIONFor the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of coreless and pre-stretched film rolls, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent structures and materials may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.
It should be understood that the drawings are not necessarily to scale; instead emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.
Moreover, the terms “substantially” or “approximately” as used herein may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.
In the exemplary embodiment shown, liner 20 is a thin plastic tube around which pre-stretched plastic film is wound. In further exemplary embodiments, pre-stretched film may be wound without a central core, and liner 20 inserted after the roll has formed. In still further exemplary embodiments, liner 20 may be cardboard, laminated paper, layer of adhesive or any other material known in the art which may provide a thin central liner to prevent the interior end of the roll from unraveling. Liner 20 must also be of sufficient strength to withstand forces generated during rewinding, if film is wound directly around liner 20, and the weight of the plastic film after it is rolled.
In the exemplary embodiments shown in
In further exemplary embodiments, plugs 40 may be configured to fit entirely within liner 20 so that grasping portion 45 does not protrude above the ends of roll 200.
In the exemplary embodiment shown in
As illustrated in
While in the exemplary embodiments shown in
In the exemplary embodiments shown, liners 20 are thin plastic rolls which prevent the interior end of film from unraveling. Because industrial stretch film dispensing apparatus 300 and 400 are to be used in a wrapping machine, liners 20, in addition to being able to withstand the weight of the film roll, need to be sufficiently durable to withstand the forces generated when plastic wrap is quickly pulled from industrial stretch film dispensing apparatus 300, 400 and industrial stretch film dispensing apparatus 300, 400 are quickly spun around a machine arm.
In some exemplary embodiments, machine industrial stretch film dispensing apparatus 300, 400 may contain an additional liner of a material with low friction to allow industrial stretch film dispensing apparatus 300, 400 to spin easily on a machine. In still further exemplary embodiments, liners 20 for rolls 300, 400 may be weighted or contain other design modifications which help stabilize industrial stretch film dispensing apparatus 300, 400 on a machine.
Also shown in
The exemplary industrial stretch film dispensing apparatus 300, 400 illustrated in
While in the exemplary embodiments shown in
In the exemplary embodiments described in
Retrofitting stabilizing component 50 is a flexible ring which is specifically designed to fit around the arm of existing machines and compensate for the difference in internal diameters between cored machine rolls and coreless machine rolls. In the exemplary embodiment shown in
In some exemplary embodiments, retrofitting stabilizing component 50 may be disposable or reusable. In further exemplary embodiments, retrofitting stabilizing component 50 may be a structure other than a flexible ring. For example, retrofitting stabilizing component 50 may be a wedge, clamp, bar, cap, contours, spring assembly, inflatable device, reusable core or any other device or structure known in the art which may be used to securely hold a coreless roll against a machine.
In still further exemplary embodiments, retrofitting stabilizing component 50 may include a mechanized component which works to secure industrial stretch film dispensing apparatus on a machine arm. For example, retrofitting stabilizing component 50 may be a structure which exerts a force on the interior surface of a cylindrical channel of an industrial stretch film dispensing apparatus, such as a spring mechanism. The force exerted must be enough to stabilize the industrial stretch film dispensing apparatus while not damaging any of the layers of industrial film product. In still further exemplary embodiments, retrofitting stabilizing component 50 may include an expansion component, such as a compressible or inflatable material, which expands to contact the interior surface of the uniform cylindrical channel of an industrial stretch film dispensing apparatus.
Retrofitting stabilizing component 50 may be any structure or device which increases the diameter of a wrapping machine arm and comes into contact with the inner surface of the uniform cylindrical channel or liner 20 of an industrial stretch film dispensing apparatus. As illustrated in
In still further exemplary embodiments, there may be more than one retrofitting stabilizing component 50, and retrofitting stabilizing components 50 may be of the same design or of differing designs. A single retrofitting stabilizing component 50 may also include multiple components. For example, a single retrofitting stabilizing component 50 may include multiple members which contact the inner surface of a uniform cylindrical channel.
Retrofitting stabilizing components 50 may also be used with industrial stretch film dispensing apparatus 100, 200 described above if industrial stretch film dispensing apparatus 100, 200 are used with hand wrapping devices known in the art which are designed to hold and secure rolls with traditional cores.
In some exemplary embodiments, liner 20, or the inner surface of a cylindrical channel itself, may be configured to interact with retrofitting stabilizing component 50. For example, liner 20 or cylindrical channel may include contours, surfaces, or other structures, such as a stabilizing strip, with which a retrofitting stabilizing component 50 interacts. Structures and surfaces integrally associated with a cylindrical channel may help retrofitting stabilizing component 50 secure industrial stretch film dispensing apparatus and may also protect the film product from damage by a retrofitting stabilizing component 50.
While in the exemplary embodiment shown in
In further exemplary embodiments, retrofitting stabilizing component 50 integrally associated with a wrapping machine arm may be any structure or device known in the art to allow an industrial stretch film dispensing apparatus to slide completely over the wrapping machine arm and exert a force on the inner surface of the cylindrical channel of industrial stretch film dispensing apparatus.
While in the exemplary embodiments illustrated in
Claims
1. An industrial stretch film dispensing apparatus comprised of:
- multiple layers of industrial stretch film arranged in a cylindrical fashion to form a coreless cylindrical film structure;
- said coreless cylindrical film structure having a uniform cylindrical channel at the center of said cylindrical film structure;
- said uniform cylindrical channel adapted to receive a wrapping machine arm; and
- said cylindrical film structure having one or more layers.
2. The apparatus of claim 1 which further includes a wrapping machine arm.
3. The apparatus of claim 2 wherein said wrapping machine arm has a diameter greater than 3 inches.
4. The apparatus of claim 2 wherein said wrapping machine arm has a diameter of less than the diameter of said uniform cylindrical channel.
5. The apparatus of claim 1 wherein said uniform channel has a diameter of 3.1 inches to 5 feet.
6. The apparatus of claim 1 wherein said uniform channel has a diameter of 5 feet to 10 feet.
7. The apparatus of claim 1 which further includes a retrofitted arm adapter component which extends the diameter said wrapping machine arm and comes in contact with the inner surface of said uniform cylindrical channel without affecting the rotational motion of said coreless cylindrical film structure.
8. The apparatus of claim 1 which further includes a retrofitted arm adapter component with at least one expansion component which expands to create a force upon the inner surface of said uniform cylindrical channel to stabilize said industrial stretch film while said coreless cylindrical film structure is rotating on said wrapping machine arm.
9. The apparatus of claim 8 wherein said at least one expansion component expands when said coreless cylindrical film structure is rotating and contracts for removal of said coreless cylindrical film structure from said wrapping machine arm.
10. The apparatus of claim 7 wherein said retrofitted arm adapter component is a singly molded component which partially encloses a wrapping machine arm to expand the diameter of said wrapping machine arm.
11. The apparatus of claim 10 which includes protuberance members radiating from the surface of said retrofitted arm adapter component which come in contact with the inner surface of said uniform cylindrical channel to secure said coreless cylindrical film structure.
12. The apparatus of claim 10 which includes structural protuberances which come in contact with the inner surface of said uniform cylindrical channel.
13. The apparatus of claim 1 wherein said coreless cylindrical film structure further includes a stabilizing strip.
14. The apparatus of claim 7 wherein said retrofitted arm adapter component engages a stabilizing strip.
15. The apparatus of claim 7 which wherein said retrofitted arm adapter component further includes contours to engage the inner surface of said coreless uniform cylindrical channel.
16. The apparatus of claim 7 wherein said retrofitted arm adapter component includes one or more removable expanding ring components.
17. The apparatus of claim 7 wherein said retrofitted arm adapter component is in contact with 10 to 100 percent of the interior of said uniform cylindrical channel.
18. The apparatus of claim 7 wherein said retrofitted arm adapter component is comprised of a rigid material.
19. The apparatus of claim 7 wherein said retrofitted arm adapter component is comprised of compressible material.
20. The apparatus of claim 7 wherein said retrofitted arm adapter component is comprised of both rigid and compressible material components to expand the diameter of said wrapping machine arm.
21. The apparatus of claim 7 wherein said retrofitted arm adapter component is comprised of one or more mechanized expansion components.
22. The apparatus of claim 1 which further includes an internal liner within said uniform cylindrical channel.
Type: Application
Filed: Jun 20, 2011
Publication Date: Oct 25, 2012
Inventors: Huong Nguyen (Menomonee Falls, WI), Hai Nguyen (New Berlin, WI)
Application Number: 13/164,389