Packaged, Wrapped, Cylindrically Rolled Moisture-Sensitive Film and Method of Making the Same

A method for packaging a wrapped, moisture-sensitive, cylindrically rolled film by positioning along an alignment axis, a wrapped, rolled moisture-sensitive film, a funneling guide, a tube, and an extendible rod that includes a support head. The method comprises the steps of extending the rod through the tube while simultaneously and while maintaining the alignment of the wrapped film, funneling guide, tube and rod, tilting the alignment axis from a first position to a second position such that the wrapped film enters and moves through the funneling guide, and the wrapped film contacts the support head of the rod, retracting the rod such that the wrapped film enters the tube through the funneling guide, and while maintaining the alignment of the wrapped film, funneling guide, tube and rod the alignment axis, tilting from the second position to the first position and retracting the rod from the tube.

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Description
CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. patent application No. 61/357,240 filed on Jun. 22, 2010, the entire content of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

The present invention relates generally to packaging a wrapped, cylindrically rolled, moisture-sensitive film. In one aspect, the invention relates to a packaged, wrapped, cylindrically rolled moisture-sensitive film while in another aspect, the invention relates a method of packaging such a film.

Photovoltaic (PV) cells generate electricity from solar energy. The cells require protection from the environment, and are packaged in glass and/or plastics and are typically sealed within a water-impervious polymeric film. Typically one or more polymers that comprise the film will crosslink upon exposure to moisture, e.g., the water vapor in air, thus rendering the film impervious to water or at least improving its imperviousness to water. While this is a desired result, typically and preferably the crosslinking of the film is delayed until after the film has been applied to the PV cell so that maximum adhesion can be obtained during lamination of the components.

Since typically the film is manufactured at a site separate and apart from the site of PV cell manufacture, the film is usually shipped and stored prior to use. Since these films are moisture-sensitive, e.g., the polymers from which they are made are prone to crosslink upon exposure to moisture, the film is packaged in a wrap that comprises a moisture barrier, i.e., a wrap through which water in liquid or vapor form cannot pass (or at least pass only in an amount that is of little, if any, consequence to the integrity of the film over a designated period of time, e.g., nine months and under ambient conditions. Typically, as the film is manufactured, it is collected onto rolls, wrapped in a flexible bag, sealed and the wrapped rolls stacked in storage and/or shipping bins for ultimate transport to a customer. As just noted, because the film is sensitive to moisture, the bag comprises a moisture barrier and is hermetically sealed, e.g., vacated of air and/or heat or otherwise sealed from the environment. Typically a means is employed to maintain a low humidity environment within the bag, such as a desiccant.

While this packaging protects the film from moisture, it does not provide protection against crushing or injury from rough handling and shipping forces. The weight of the rolls can vary greatly, e.g., from a tens of pounds to hundreds of pounds, which means that not only can the rolls be difficult to maneuver manually (and thus require the use of mechanical assists, e.g., robotic arms, forklifts, etc., which can damage the wrap and/or enclosed film) but when stacked one upon the other they can experience damage, e.g., crease, tear, block, flatten, etc., particularly those rolls on the bottom of the stack.

BRIEF SUMMARY OF THE INVENTION

In one embodiment the invention is a packaged, moisture-sensitive, cylindrically rolled film comprising:

    • A. A moisture-sensitive film in a cylindrically rolled configuration,
    • B. A flexible, moisture-barrier wrap having an exterior surface, the rolled film hermetically enclosed within the wrap, and
    • C. A tube comprising (1) an elongated sidewall with an interior surface, and (2) first and second ends, the rolled film hermetically enclosed in the wrap situated within the sidewall and between the first and second ends.

In one embodiment the film is wound around a core, typically hollow and cylindrical. In one embodiment a desiccant is placed inside the barrier wrap before the wrap is sealed. In one embodiment one or more spacers are situated within the tube for receiving and holding the wrapped, rolled film such that the exterior surface of the wrap is not in contact with the interior surface of the tube. In one embodiment the spacers are situated on the core. In one embodiment the tube comprises one or more end caps and the spacers are situated on the end caps.

In another embodiment the invention is a packaged moisture-sensitive, cylindrically rolled film comprising:

    • A. A moisture-sensitive film in a cylindrically rolled configuration and having an exterior surface and first and second ends, and
    • B. A tube comprising (1) a moisture barrier, (2) an elongated sidewall with an interior surface, and (3) first and second end caps, the rolled film hermetically enclosed within the tube.

In one embodiment the film is wound around a core, typically hollow and cylindrical. In one embodiment a desiccant is placed inside the tube before the tube is hermetically sealed. In one embodiment one or more spacers are situated within the tube for receiving and holding the rolled film such that the exterior surface of the rolled film is not in contact with the interior surface of the tube. In one embodiment the spacers are situated on the core. In one embodiment the spacers are situated on the end caps.

In another embodiment the invention is a method of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:

    • A. Positioning along an alignment axis in a first position:
      • 1. The hermetically wrapped, moisture-sensitive cylindrically rolled film,
      • 2. A funneling guide having first and second ends,
      • 3. A tube having first and second ends connected by an elongated sidewall, and
      • 4. An extendible rod comprising a support head,
      • such that
        • a. The second end of the wrapped film is opposite the first end of the funneling guide,
        • b. The first end of the tube is opposite the second end of the funneling guide, and
        • c. The support head of the rod is opposite the second end of the tube,
    • B. Extending the rod through the tube such that the support head is at or near the second end of the funneling guide,
    • C. Simultaneously and while maintaining the alignment of the wrapped film, funneling guide, tube and rod,
      • 1. Tilting the alignment axis from the first position to a second position such that:
        • a. The wrapped film enters and moves through the funneling guide, and
        • b. The second end of the wrapped film contacts the support head of the rod, and
      • 2. Retracting the rod such that the wrapped film enters the tube through the funneling guide to a position within the tube such that both ends of the wrapped film are within the sidewall of the tube,
    • D. Returning while maintaining the alignment of the wrapped film, funneling guide, tube and rod the alignment axis from the second position to the first position, and
    • E. Retracting the rod from the tube such that the support head of the rod is outside the sidewall of the tube and opposite the second end of the tube.

In one embodiment the wrapped film slides into the tube due to gravity. In one embodiment the alignment of the wrapped film and tube is maintained by positioning the wrapped film and tube on a cradle. In one embodiment the wrapped film and tube are positioned on separate but aligned cradles. In one embodiment the wrapped film includes packaging ears that are folded back by the funneling guide as the wrapped film enters the tube.

In one embodiment the invention is storage and/or shipping containers comprising stacked tubes containing packaged, hermetically wrapped, moisture-sensitive, cylindrically rolled film.

In one embodiment the invention is an apparatus for packaging hermetically wrapped, moisture-sensitive, cylindrically rolled, film into a tube open on both ends, the apparatus comprising:

    • A. A first cradle to receive and hold a hermetically wrapped, moisture-sensitive, cylindrically rolled film, the first cradle having first and second ends,
    • B. A funneling guide having first and second ends with the first end positioned opposite the second end of the first cradle,
    • C. A second cradle to receive and hold a tube open on both ends, the second cradle having first and second ends with the first end of the second cradle opposite the second end of the funneling guide,
    • D. An extendible rod comprising first and second ends, the first end of which
      • 1. Comprises a support head, and
      • 2. Is positioned opposite the second end of the second cradle,
    • E. An actuator for extending the rod in a longitudinal direction, the actuator connected to the second end of the rod, and
    • F. A tilting mechanism for moving the first cradle, funneling guide, second cradle, rod and actuator between first and second positions,
      with the provisos that
    • 1. The first cradle, funneling guide, second cradle, rod and actuator are longitudinally aligned along a central axis, and
    • 2. The tilting mechanism is attached to each of the first cradle, funneling guide, second cradle, rod and actuator such that their longitudinal alignment along the central axis is maintained during movement between the first and second positions.

In one embodiment, the invention is an automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:

    • A. Positioning along a vertical alignment axis:
      • 1. The hermetically wrapped, moisture-sensitive, cylindrically rolled film, and
      • 2. A tube having first and second ends connected by an elongated sidewall, and
    • B. While maintaining the alignment of the wrapped film and tube, at least one of
      • 1. Lowering the tube over the wrapped film, and
      • 2. Raising the wrapped film into the tube,
        such that the wrapped film is positioned substantially inside the tube.

In one embodiment, the invention is an automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:

    • A. Positioning along a vertical alignment axis:
      • 1. The hermetically wrapped, moisture-sensitive, cylindrically roiled film, and
      • 2. A tube having first and second ends connected by an elongated sidewall, and
    • B. While maintaining the alignment of the wrapped film and tube, at least one of,
      • 1. Lowering the wrapped film into the tube, and/or
      • 2. Raising the tube to insert the wrapped film,
        such that the wrapped film is positioned substantially inside the tube.

In one embodiment, the invention is an automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:

    • A. Positioning along an alignment axis:
      • 1. The hermetically wrapped, moisture-sensitive, cylindrically rolled film,
      • 2. A funneling guide having first and second ends,
      • 3. A tube having first and second ends connected by an elongated sidewall, and
      • 4. An extendible support head,
      • such that
        • a. The second end of the wrapped film is opposite the first end of the funneling guide,
        • b. The first end of the tube is opposite the second end of the funneling guide, and
        • c. The support head is in a first position opposite the first end of the film,
    • B. While maintaining the alignment of the wrapped film, funneling guide, tube and support head, extending the ram head along the alignment axis from the first position to a second position such that the support head contacts the first end of the wrapped film and moves the wrapped film through the funneling guide, through the first end of the tube, and into the tube such that both ends of the wrapped film are within the sidewall of the tube, and
    • C. Retracting the support head to the first position.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described generally with reference to the drawings for the purpose of illustrating certain embodiments only, and not for the purpose of limiting the scope of the invention. In the drawings like numerals are used to designate like parts throughout the same.

FIG. 1A is an exploded perspective view of an exemplary packaged, wrapped, cylindrically rolled moisture-sensitive film comprising, a tube, wrap, moisture-sensitive film cylindrically rolled about a core, and desiccant.

FIG. 1B is a cross-sectional view of the packaged rolled film of FIG. 1A at 1-1.

FIG. 2 is a side view of the rolled film inside the sealed flexible barrier having wrapping ears.

FIG. 3 is a flow chart describing an exemplary automated process of packaging the wrapped rolled film of FIG. 1A.

FIG. 4 is a schematic of an exemplary packaging station for the automated process of packaging wrapped rolled film, with the station shown in a first position.

FIG. 5 is the station of FIG. 4 shown in a second position.

FIG. 6 is the station of FIG. 4 shown in a third position.

FIG. 7 is the station of FIG. 4 shown in a fourth position.

FIG. 8 is the station of FIG. 4 shown in a fifth position.

FIG. 9A is a perspective view of an exemplary packaged cylindrically rolled, moisture-sensitive film comprising a tube and a cylindrically rolled, moisture-sensitive film.

FIG. 9B is a cross-sectional view of the packaged rolled film of FIG. 9A at 9-9.

FIG. 10 is a side view of the packaged rolled film of FIG. 9A further comprising, first and second end caps.

FIG. 11 is a perspective view of the packaged rolled film of FIG. 9A in which the first and second end caps each include a support.

FIG. 12A is a schematic of another exemplary packaging station for the automated process of packaging wrapped or unwrapped rolled film, with the station shown in a first position

FIG. 12B is the station of FIG. 12A shown in a second position.

FIG. 13A is a schematic of another exemplary packaging station for the automated process of packaging wrapped or unwrapped rolled film, with the station shown in a first position.

FIG. 13B is the station of FIG. 13A shown in a second position.

FIG. 13C is the station of FIG. 13A shown in a third position.

FIG. 14 is a schematic of an exemplary storage container with a plurality of packaged, wrapped rolled films situated inside for transportation and/or storage.

 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Definitions

For purposes of United States patent practice, the contents of any referenced patent, patent application or publication are incorporated by reference in their entirety (or its equivalent US version is so incorporated by reference) especially with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art.

The numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if a compositional, physical or other property, such as, for example, equipment dimensions, rolled film size, tube size, etc., is from 100 to 1,000, then all individual values, such as 100, 101, 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated. For ranges containing values which are less than one or containing fractional numbers greater than one (e.g., 1.1, 1.5, etc.), one unit is considered to be 0.0001, 0.001, 0.01 or 0.1, as appropriate. For ranges containing single digit numbers less than ten (e.g., 1 to 5), one unit is typically considered to be 0.1. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated, are to be considered to be expressly stated in this disclosure. Numerical ranges are provided within this disclosure for, among other things, the angle of tilt α, the size of the tubes and size of the rolled films.

“Moisture-sensitive film” and like terms mean a film that experiences change upon exposure to moisture either in the form of liquid water or water vapor. This change can take any form, e.g., crosslinking, color, adhesion, tensile strength and/or elongation, etc., and can occur at different rates under different conditions.

“Rolled film” and like terms mean a moisture-sensitive film rolled into a cylindrical configuration. The film may be wound around a core or upon itself, i.e., without a core.

“Tube” and like terms mean a hollow, generally cylindrical construction comprising an elongated sidewall connecting two ends. The tube ends may be open or closed. If a tube end is closed, the end can be closed either by an end cap or the closed end can be integral to the sidewall, i.e., a continuous extension of one into the other. The tube may be constructed of any solid material, such as cardboard, plastic, wood, or metal.

“Desiccant” and like terms mean a drying agent, e.g., a material that can absorb moisture from the air.

“Moisture-barrier wrap” and like terms mean a wrap, e.g., film, bag, etc., generally impervious to the passage of moisture. When the wrap is configured into a container and closed so as to seal the inside of the container from the environment, moisture in liquid and/or vapor form cannot pass, or pass only in an amount and at a rate as to have minimal, if any, detectable effect on the film, from outside the container into the inside of the container and vice versa.

“Hermetically sealed” and like terms as applied to packaged, moisture-sensitive, cylindrically rolled film mean that the film is protected against moisture from outside the package.

“Core” and like terms as applied to moisture-sensitive, cylindrically rolled film mean a generally cylindrical article about which the film is wound. The core can be constructed of any material, e.g., cardboard, plastic, wood, metal, etc., hollow or solid, and is generally of the same length as the width of the film.

“Automated” and like terms as applied to the method of packaging a moisture-sensitive, cylindrically rolled, film mean the performance of the majority, if not all, of the steps without manual intervention. The steps are typically performed through the use of machine sequenced functions, such as programmed robotics.

Rolled, Moisture-Sensitive Film

In one embodiment, the rolled moisture-sensitive film comprises a cylindrically wound length of moisture-sensitive film having a width extending between a film first end and a film second end. In one embodiment, the film is wound about a core, although in other embodiments the rolled film is coreless (either because a core was not used in the winding process or if a core was used in the winding process, it was subsequently removed). The cross-section of the core can take any shape, e.g., circular, elliptical, polygonal (e.g., octagonal), and it can comprise one or more sections that are hollow and/or solid. Typically, a core is present, and it is a one piece, tube of cardboard that is generally as long as the Film is wide.

The film can vary in size (length, width and thickness) and shape, and the rolled film can vary in size (diameter and weight) although in at least one embodiment the rolled film has an outside diameter of six inches to twenty inches and a width of twenty-three inches to forty-eight inches. The rolled film typically varies in weight from a few tens of pounds to several hundred pounds or more.

Representative of moisture-sensitive film are those comprising one or more polyolefins having silane functionality such as the silane-grafted ethylene/α-olefins and others described in US 2008/0115825 and US 2008/0078445.

Barrier Wrap

In one embodiment the barrier wrap comprises a waterproof material, such as a plastic (e.g., polyethylene, polyvinylidene chloride, polypropylene, PET, etc.), silicon oxide coating, or metal foil, e.g., aluminum. In one embodiment the barrier wrap further comprises an oxygen barrier such as polyvinylidene chloride, ethylene vinyl alcohol (EVOH) or certain nylons. The wrap is typically a composite construction comprising multiple layers of various plastics, and/or papers, and/or coatings, and/or foil.

The barrier wrap is typically in the form of a bag that can be hermetically sealed after the rolled film is placed inside of it. In one embodiment the wrap is a sheet or film in which the rolled film is enclosed. The wrap is sealed by any conventional means, typically by heat sealing. The bag can be evacuated of air prior to sealing. Upon sealing the wrap typically comprises “ears” which comprise area of the wrap in excess of that needed to hermetically seal the moisture-sensitive film. These ears are typically located near the seal of the wrap about the rolled film, and typically constitute a small amount, e.g., less than 5-10 percent, of the total area of the wrap about the rolled film.

Tube

In one embodiment the tube comprises an elongated cylindrical sidewall extending between first and second open ends, the sidewall including a tube exterior surface and a tube interior surface. The tube is sized to accommodate the size of the rolled film and the storage and shipping constraints. Typically the tube is longer than the width of the rolled film that it will package by at least one inch, more typically by at least two inches based on the width of the film. Typically the tube is constructed of a heavy cardboard such that the weight of multiple, e.g., 1 to 4 or more, similar tubes containing the rolled film stacked upon it will not crush or otherwise compromise the integrity of the packaging, in one embodiment the tube has an outside diameter of seven inches to twenty-four inches, and a length of fifty inches.

In those embodiments in which the tube is used to package a wrapped, rolled moisture-sensitive film, at least one end, preferably both ends, of the tube are open. In those embodiments in which the tube is used to package an unwrapped, rolled film, the tube comprises a moisture barrier, optionally an oxygen barrier, and is closed on both ends either by one end of the tube having an integrally closed end and one capped end, or both ends capped. The end caps also typically comprise a moisture barrier. In those embodiments in which the rolled film is unwrapped, the tube is typically evacuated of air, e.g., either by pulling a vacuum or flushing with a moisture-free gas, after the film as been placed inside the tube and before or after sealing the tube ends.

Wrapped, Rolled Film in Open-Ended Tube

In general, the cylindrically rolled, moisture-sensitive film is enclosed within a barrier wrap to form a wrapped rolled film. The wrapped rolled film is conveyed to a packaging station for insertion into an open-ended tube. The wrap protects the rolled film from moisture and contaminants, while the tube protects the rolled film and the wrap from mechanical damage caused by manual or automated packaging operations and allows for the safe transportation and storage of the rolled film.

Referring to FIGS. 1A and 1B, one embodiment of a packaged wrapped rolled film 2 is depicted. Packaged wrapped rolled film 2 comprises a cylindrically rolled film 4, flexible barrier wrap 6, and tube 8. Rolled film 4 is hermetically sealed inside wrap 6 to form wrapped rolled film 10, which is automatically inserted into tube 8 to prepare the wrapped rolled film for storage and/or transit. FIG. 2 is provided to particularly illustrate one embodiment of the wrapped rolled film prior to insertion into the tube. More particularly, FIG. 2 depicts a side view of wrap 6 in a sealed bag configuration enclosed about the rolled film, the wrap having a heat-sealed closed end 14. Generally, when a wrap in a bag configuration is sealed, extraneous nonconforming wrap portions, i.e., ears, are formed that result in at least one wrap protrusion extending in a direction opposite the rolled film. These wrap protrusions are situated typically about the seal of the wrap and may be formed in numerous shapes and sizes. In one embodiment, as shown in FIG. 2, wrap protrusions 16 extend from both sides of the closed end of the wrap. These protrusions present packaging problems as discussed below. In addition, packaged wrapped rolled film 2 can further include a desiccant 11 (FIG. 1A) that is inserted inside the wrap prior to sealing. Further, concurrent with sealing the wrap, the wrap can be evacuated of air or chemically purged to remove moisture in the air between the rolled film and the wrap. Once the rolled film is sealed in the wrap, wrapped rolled film 10 is ready to be inserted inside tube 8.

One method of inserting wrapped rolled film 10 into tube 8 is described in flowchart 100 provided in FIG. 3. The steps provided in flowchart 100 are described with reference to an exemplary packaging station 30, shown in FIG. 4, configured for the automated method of packaging the wrapped rolled film. Station 30 is comprised of wrapped film positioner 32, tube positioner 34, funneling guide 36, and rod 40 that includes a support head 50. These elements are positioned along alignment axis 42, which provides for a substantially in-line packaging path for the wrapped rolled film from the film positioner into the tube.

Referring further to FIG. 4, in one embodiment film positioner 32 is positioned to receive wrapped rolled film 10. Film positioner 32 includes a cradling surface 35 that is provided to position the wrapped rolled film along alignment axis 42 for insertion into funneling guide 36. In one embodiment the film positioner is dynamic cradle, such as a cradling conveyor. In one embodiment the film positioner stabilizes and/or guides the wrapped rolled film through the funnel guide, such as a robotic arm.

As discussed above, often when sealing wrap 6, protrusions 16 are created. These protrusions can result in difficulties with loading wrapped rolled film 10 into tube 8, as the protrusions can snag on equipment or the tube. To address this, funneling guide 36 is provided to guide the protrusions into the tube. The funneling guide is situated between the film positioner and the tube. In one embodiment funneling guide 36 is comprised of a tapered ring having a guide first end 43 and a guide second end 44, where the circumference of the guide first end is greater than the circumference of the guide second end. The tapered configuration of the funneling guide provides a means to guide the protrusions 16 into the tube 8 by folding them downwards to conform to the circumference of the tube, thus eliminating binding of the protrusions that can result in damage to the wrap 6 and the prevention of proper insertion into the tube. In one embodiment funneling guide 36 can be comprised of another tapered entry guide, such as a plurality of flat extensions positioned about the entry to tube 8. The funneling guide 36 can be shaped and sized to accommodate the dimensions of the wrapped rolled film, the protrusions, and the tube. In addition, funneling guide 36 can be comprised of one or more of various materials, such as metal, plastic, and fiberglass.

Referring still to FIG. 4, rod 40 is depicted positioned along the alignment axis. The rod serves to provide a mechanism for lowering wrapped rolled film 10 into tube 8 when a downward gravitational force is imparted on the wrapped rolled film, such as when the alignment axis is tilted from a first position to a second position (discussed below). In one embodiment, rod 40 is comprised of a shaft 48 having a terminus support head 50. The rod is extensible via, an actuator 46 configured to extend the support head through the tube. The shaft and the support head can vary in size and shape, although they are intended to be sized to pass through the tube without damaging the tube. Support head 50 is configured to provide a suitable surface for contacting and supporting the wrapped rolled film without incurring any damage, such as a padded surface. In one embodiment the center of support head 50 is centered in-line with shaft 48 along alignment axis 42. In one embodiment the center of support head 50 is offset from the alignment axis.

Station 30 further comprises tube positioner 34. The tube positioner is situated between funneling guide 36 and rod 40 and serves to support tube 8 in a position along alignment axis 42 for receiving wrapped rolled film 10 from the guide second end 44 of the funneling guide. In particular, the tube positioner supports a tube first end 56 adjacent to the guide second end and a tube second end 58 adjacent to support head 50. Further, the tube positioner can include one of numerous positioning mechanisms, such as, one or more cradles, which are sized and shaped to receive and position tube 8. Alternatively, a robotic arm (not shown) can be used to hold tube 8 in the proper position during insertion of the wrapped rolled film. Additionally, such a robotic arm can be used to convey tube 8 to or from the tube positioner, prior to and/or subsequent to, the loading of the wrapped rolled film. Station 30 can further comprise a mounting platform 52 for supporting and/or securing packaging elements, such as film positioner 32, tube positioner 34, funneling guide 36, and rod 40. In this manner, the packaging elements can be held in sufficient alignment along alignment axis 42 during tilting of the alignment axis, as discussed below. In some embodiments, platform 52 can be omitted and one or more of these packaging elements can be separately supported and tilted.

Referring back to FIG. 3, flow chart 100 is provided that describes the exemplary steps 104-116 for the automated method of packaging wrapped rolled film 10. Although the process is described with reference to the packaged wrapped rolled film 2 depicted in FIG. 1A, which includes wrapped rolled film 10 and tube 8, the method can be modified to accommodate various deviations from the packaged wrapped rolled film 2.

Generally, flow chart 100 provides numerous steps that comprise loading wrapped rolled film 10 into tube 8. More particularly, guiding the wrapped rolled film through funneling guide 36, actuating support head 50 through tube 8 to receive the wrapped rolled film, tilting these aforementioned elements to facilitate the insertion of the wrapped rolled film into the tube, then returning the elements to their original position and retracting the support head from the tube. To further illustrate these steps, FIGS. 5, 6, 7, and 8 have been provided, which depict the station 30 in various stages of packaging the wrapped rolled film.

Flow chart 100 begins at step 104 in which wrapped rolled film 10, funneling guide 36, tube 8, and support head 50 are positioned along an alignment axis in a first position. More particularly, the wrapped rolled film is positioned by film positioner 32 along the alignment axis with film second end 54 situated opposite guide first end 43 of the funneling guide. Additionally, tube 8 is conveyed to the tube positioner with tube first end 56 situated opposite guide second end 44. Further, support head 50 is situated in a starting position opposite tube second end 58.

Turning to FIG. 5, in step 106 support head 50 is actuated from a starting position (as shown in FIG. 4), through tube 8 such that the support head is situated adjacent to at least one of film second end 54 and guide first end 43. Referring to FIG. 6, simultaneously and while maintaining alignment of wrapped rolled film 10, funneling guide 36, tube 8, and support head 50, alignment axis 42 is tilted in step 108 from a first position to a second position, such that gravity moves the film second end to enter the guide first end and move through the funneling guide and into the tube. Prior to or immediately subsequent to the movement of the wrapped rolled film, the film second end is situated in contact with the support head.

The tilting of alignment axis 42 (i.e., packaging station 30) includes raising the wrapped rolled film to a point that is located higher than tube 8. For example, raising station first end 70 above station second end 72, as shown in FIG. 6, such that the first position 74 of the alignment axis is at an angle α with respect to raised, second position 76 of the alignment axis. This positioning exerts gravitational force on the rolled film to move the rolled film into the tube. In one embodiment first position 74 of the alignment axis is along a horizontal plane and the second position of the alignment axis is at an angle α that is 45 degrees to 60 degrees. In one embodiment angle α is 5 degrees to 90 degrees. In one embodiment the first position is off the horizontal plane and angle α is 5 degrees to 90 degrees. Further, various tilt sensors (not shown) can be provided to monitor the positions of one or more elements of station 30.

The abutment of film second end 54 and support head 50 is utilized in step 110, in which the support head is retracted while gravity moves the wrapped rolled film 10 downwards into tube 8. The support head is retracted until film first end 55 and the film second end are situated within the tube, as shown in FIG. 7. By utilizing the support head, the wrapped rolled film can be moved at a controlled rate into the tube to prevent damage to the wrapped rolled film. In one embodiment threes other than gravity can be applied to coerce movement of the wrapped rolled film into the tube, although in at least one embodiment, gravity alone can provide the necessary force to move the wrapped rolled film into the tube. Upon completion or substantial completion of the insertion of the wrapped rolled film inside the tube, in step 112, while maintaining alignment of wrapped rolled film 10, funneling guide 36, tube 8, and support head 50, alignment axis 42 is tilted from the second position to the first position. In step 114 the support head is retracted to a start position outside the tube. Subsequent to retraction of the support head from the tube, in step 116 the packaged wrapped rolled film 2 is removed from tube positioner 34 in preparation for storage or transit. Although not provided in the flow chart 100, in one embodiment tube first and second ends may be closed using a tube closing flap (not shown) or separate first and second tube end caps. Closing the tube first and second ends can secure the wrapped rolled film inside the tube and/or provide additional structural rigidity for the tube. In addition, one or more spacers (not shown) can be provided to support the wrapped roiled film inside the tube, such that a gap along their lengths is provided in the range of about one-half inch to about three-quarters of an inch. A greater or lesser gap can be provided to accommodate the size of the wrapped film roll and the tube, as well as to facilitate effective loading of the wrapped film roll into the tube. The spacers can be installed in the tube prior to, concurrent with, or subsequent to, the insertion of the wrapped rolled film into the tube.

Numerous sensor inputs can be utilized throughout the packaging method to facilitate the method steps. For example, various sensors such as pressure and proximity sensors can be utilized to verify that wrapped rolled film 10 is situated in contact with the support head 50 prior to retracting the support head 50. Additionally, the sensors can be used to provide the necessary feedback to stop retraction of the support head if the wrapped rolled film fails to continue maintaining contact with the support head, thus signaling a possible malfunction. Although not identified in the drawings, numerous sensors can be located as needed to provide the desired feedback to facilitate the method of packaging as described.

Unwrapped, Moisture-Sensitive, Cylindrically Rolled Film in a Closed Tube

As described with reference to FIGS. 1A and 1B, enclosing moisture-sensitive rolled film with a barrier wrap can protect the film during storage and transit. If desired, another form of moisture protection can be provided to ensure that the rolled film is not degraded. In one embodiment tube 8 can include a barrier layer, as described above, which serves to protect the rolled film provided that the tube is sealed. As shown in FIGS. 9A and 9B, in one embodiment packaged rolled film 60 is depicted comprising rolled film 4 and tube 8. The packaged rolled film can further include first end cap 62 and second end cap 64, as shown in FIG. 10. The end caps provide a means for sealing the tube and can also improve the structural rigidity of the tube. Further, the tube and/or end caps can include a moisture barrier layer (not shown) that is integral with or situated on the interior or exterior surface of the tube and the caps to provide moisture protection similar to wrap 6. The barrier layer and/or end caps can comprise a water blocking material, such as plastic (e.g., polyethylene, polyvinylidene chloride, polypropylene, PET, etc) or metal foil, e.g., aluminum. Further, the tube and/or end caps can comprise solely a water blocking material, such as aluminum or plastic, thus avoiding the need for any additional water blocking material. Further, an adhesive water blocking seal can be used at the interface between the end cap and tube to hold the cap in place and to prevent moisture from entering the tube.

Utilizing a moisture barrier layer and sealing the tube with end caps can provide moisture protection without the use of a wrap. In addition to or in place of the using waterproofing material, moisture can be diminished in the tube, by evacuation and/or purging, and/or the use of a desiccant, and/or the replacement of paper liners and/or cores with metal or plastic liners and/or cores. In addition, when sealing of the tube is not desired, one or both of the end caps can be omitted. Likewise, one or both of such end caps can also be utilized on packaged rolled film 60 to provide additional sealing or structural rigidity. Further, in one embodiment tube $ can include one or more closed ends and therefore require only one end cap or no end caps.

To further provide protection of rolled film 4, supports can be provided to suspend the rolled film from the tube. In this manner, damage to the rolled film can be minimized, such as preventing flat spots in the rolled film due to disproportionate pressure about the rolled film. In addition, by stabilizing and supporting the rolled film, jostling is minimized during transit and a space buffer is provided between the rolled film and the tube that further protects the rolled film from mechanical damage. FIG. 11 depicts first and second end caps that include supports, namely, core plugs 66 secured to or formed integral with the first and second end caps. In one embodiment the core plugs are configured to fit inside a central portion 28 of rolled film 4, or where applicable, along the interior surface of core 12. Alternatively, other types of supports may be provided, such as cradling type spacers (not shown) which are positioned along tube interior surface 17. These spacers and core plugs may be used with either packaged wrapped rolled film 2 or packaged rolled film 60, as described above. In addition, spacers and core plugs can be used in one or more other embodiments as described above or below.

Horizontal Push for Open and Closed End Tubes

Referring to FIGS. 12A and 12B, a packaging station 30 is depicted that includes rod 40 for loading film 10 into tube 8, without the assistance of gravitational forces. The ram includes an actuator 46, a shaft 48, and a support head 50. The center of the support head is offset from alignment axis 42, and support head 50 is configured to push the film into the tube without damaging the film. In one embodiment, the center of the support head is positioned along alignment axis 42. As shown in FIG. 12A, the film is positioned on film positioner 32 and support head 50 is positioned about the first end of the film 55, opposite funneling guide 36. The rod 40 is then actuated, pushing the film through the funneling guide and into tube 8, as shown in FIG. 12B. Although the above insertion has been discussed with regard to wrapped rolled film 10, rolled film 4 can be inserted in the same manner, with or without the use of funneling guide 36. Further, tube 8 can include a closed end when inserting the film in this manner.

Pull Insertion/Open End Tube

In one embodiment not shown, support head 50 is configured to pull rolled film 4 into tube 8 from an actuated position as shown in FIG. 4, in this manner, support head 50 is configured to pass through the tube, grasp the second end of the wrapped film, pull the wrapped film into the tube, release the wrapped film, and then fully retracting from the tube.

Tube Drop

Referring to FIGS. 13A, 13B, and 13C, in one embodiment tube 8 is manipulated as opposed to the film. In this embodiment the film has a high diameter to width ratio so that the packaging is accomplished with minimal effort. More particularly, film 4 or 10 is positioned along vertical alignment axis 77 on platform 81, with the tube positioned above the film along the vertical alignment axis, as shown in FIG. 13A. Additionally, spacer 83 can be positioned under the tube to provide an offset. A tube lowering mechanism 79 is provided to lower the tube along the vertical alignment axis and over the film, as shown in FIG. 13B. Mechanism 79 can include an automated mechanism or a manual one. The offset provided by the spacer allows for the film to be situated a distance from the end of the tube. Also, the tube end adjacent the platform can be a closed end thus avoiding a need for spacer 83. The platform can be configured to rotate (as shown in FIG. 13C) from a vertical axis to a horizontal axis to facilitate removal from platform 81. In one embodiment (not shown) tube 8 is vertically positioned on platform 81 and film 4 or 10 is lowered into it in a manner similar to the tube drop although, of course, mechanism 79 manipulates the film from one of its ends as opposed to its sidewall. In a preferred embodiment, the distance between tube interior surface 17 and the outermost surface of the film 4 or 10 is about three-quarters of an inch about the circumference, although in another embodiment the distance is about one-half inch. The distance can be sized to accommodate various tubes, films, and shipping requirements.

With regard to the removal of packaged wrapped rolled film 10 from station 30, this can be wholly or in part automated. For example, in one embodiment one or more robotic arms can be employed to remove the packaged rolled film 2 and convey an empty tube 8 into tube positioner 34. This is particularly beneficial when the packaged rolled film 2 is of significant size and/or weight, or when the process is operated at a rapid pace. After removal from tube positioner 34, packaged wrapped rolled film 2 or packaged rolled film 60 is conveyed to a storage device for storage and/or transportation. The storage device can be one of numerous devices, such as a pallet or storage container 80 (as shown in FIG. 12). In one embodiment storage container 80 is a four-sided box with a lid, where a plurality of packaged wrapped rolled films 2 is stacked for efficient storage and shipping. Tubes 8 provide the necessary structural rigidity to enable packaged rolled film 2 to be stacked in this manner without damaging wrapped rolled film 10. In some embodiments, support cradles (not shown) are provided in storage container 80 and these may be situated between the packaged wrapped rolled film and the tube to serve and provide further support to minimize shifting of the packaged wrapped rolled film.

Although the invention has been described in considerable detail by the preceding examples and references to the drawings, this detail is for the purpose of illustration and is not to be construed as a limitation upon the spirit and scope of the invention as it is described in the appended claims.

Claims

1. A packaged, moisture-sensitive, cylindrically rolled film comprising:

A. A moisture-sensitive film in a cylindrically rolled configuration,
B. A flexible, moisture-barrier wrap having an exterior surface, the rolled film hermetically enclosed within the wrap, and
C. A tube comprising (1) an elongated sidewall with an interior surface, and (2) first and second ends, the rolled film hermetically enclosed in the wrap situated within the sidewall and between the first and second ends.

2. The packaged rolled film of claim 1 further comprising:

D. A core having an exterior surface with the film wound around the exterior surface of the core.

3. The packaged rolled film of claim 2 in which the core is hollow and cylindrical.

4. The packaged rolled film of claim 1 further comprising:

D. A desiccant situated inside the barrier wrap.

5. The packaged rolled film of claim 1 in which the barrier wrap is a heat-sealed bag that is at least one of (1) evacuated of air, or (2) purged of moisture.

6. The packaged rolled film of claim 2 further comprising,

E. One or more spacers situated within the tube for receiving the rolled film such that the exterior surface of the wrap is not in contact with the interior surface of the tube.

7. The packaged rolled film of claim 6 in which the spacers are situated on the core.

8. An automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically roiled film having first and second ends, the process comprising the steps of:

A. Positioning along an alignment axis in a first position: 1. The hermetically wrapped, moisture-sensitive, cylindrically rolled film, 2. A funneling guide having first and second ends, 3. A tube having first and second ends connected by an elongated sidewall, and 4. An extendible rod comprising a support head, such that a. The second end of the wrapped film is opposite the first end of the funneling guide, b. The first end of the tube is opposite the second end of the funneling guide, and c. The support head of the rod is opposite the second end of the tube,
B. Extending the rod through the tube such that the support head is at or near the second end of the funneling guide.
C. Simultaneously and while maintaining the alignment of the wrapped film, funneling guide, tube and rod, 1. Tilting the alignment axis from the first position to a second position such that: a. The wrapped film enters and moves through the funneling guide, and b. The second end of the wrapped film contacts the support head of the rod, and 2. Retracting the rod such that the wrapped film enters the tube through the funneling guide to a position within the tube such that both ends of the wrapped film are within the sidewall of the tube,
D. Returning while maintaining the alignment of the wrapped film, funneling guide, tube and rod the alignment axis from the second position to the first position, and
E. Retracting the rod from the tube such that the support head of the rod is outside the sidewall of the tube and opposite the second end of the tube.

9. The process of claim 8 comprising the further step of removing the tube containing the wrapped film to a receiving container.

10. The process of claim 8 in which the wrapped film slides into the tube due to gravity.

11. The process of claim 8 in which the alignment of the wrapped film and tube are maintained by positioning the wrapped film and tube on at least one cradle.

12. The process of claim 11 in which the wrapped film and tube are positioned on the same cradle.

13. The process of claim 11 in which the wrapped film and tube are positioned on separate but aligned cradles.

14. The process of claim 8 in which the wrapped film comprises packaging ears that are folded downwards to confirm to the circumference of the tube as the wrapped film enters the tube.

15. An apparatus for packaging hermetically wrapped, moisture-sensitive, cylindrically rolled film into a tube open on both ends, the apparatus comprising: with the provisos that

A. A first cradle to receive and hold a hermetically wrapped, moisture-sensitive, cylindrically rolled film, the first cradle having first and second ends,
B. A funneling guide having first and second ends with the first end positioned opposite the second end of the first cradle,
C. A second cradle to receive and hold a tube open on both ends, the second cradle having first and second ends with the first end of the second cradle opposite the second end of the funneling guide,
D. An extendible rod comprising first and second ends, the first end of which 1. Comprises a support head, and 2. positioned opposite the second end of the second cradle,
E. An actuator for extending the rod in a longitudinal direction, the actuator connected to the second end of the rod, and
F. A tilting mechanism for moving the first cradle, funneling guide, second cradle, rod and actuator between first and second positions,
1. The first cradle, funneling guide, second cradle, rod and actuator are longitudinally aligned along a central axis, and
2. The tilting mechanism is attached to each of the first cradle, funneling guide, second cradle, rod and actuator such that their longitudinal alignment along the central axis is maintained during movement between the first and second positions.

16. The packaged rolled film of claim 1 in which the film is a polymeric film used in the preparation of a photovoltaic cell.

17. The packaged rolled film of claim 16 in which the film comprises a polyolefin having silane functionality.

18. The packaged rolled film of claim 17 in which the film comprises an ethylene/α-olefin copolymer having silane functionality.

Patent History
Publication number: 20110308974
Type: Application
Filed: Jun 6, 2011
Publication Date: Dec 22, 2011
Inventors: Paul M. Curtin (Pickerington, OH), Derek R. Kurtzman (Findlay, OH), Jay A. Stoker (Newark, OH)
Application Number: 13/153,509
Classifications
Current U.S. Class: With Moisture Absorbent (206/204); For Roll Or Reel (206/389); Evacuated (206/524.8); Vacuum Or Gas Treating (53/432); Plural Covers (53/449); Vacuum Or Inert Atmosphere (53/510); Wrapping And Subsequent Filling Of Preformed Receptacle (53/174)
International Classification: B65D 81/26 (20060101); B65B 19/00 (20060101); B65B 31/02 (20060101); B65B 11/00 (20060101); B65D 85/00 (20060101); B65D 81/20 (20060101);