REINFORCED STRETCH FILM AND ITS METHOD OF PRODUCTION
A method of producing a reinforced stretch film includes the steps of: providing an elongated base sheet of plastic stretch film having a longitudinal axis; forming a plurality of cord-like, elongated reinforcement members; positioning the plurality of reinforcement members to the base sheet where the reinforcement members extend along the longitudinal axis of the base sheet; positioning a plurality of plastic film strip overlay over each of the reinforcement members where the overlays being parallel and spaced from one another; and attaching the overlays to the reinforcement members and to the base sheet to fixedly sandwich the reinforcement members between the base sheet and the overlays. Whereby, the reinforcement members comprising parallel, elongated reinforcement strips defining elongated spaces therebetween.
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The instant invention relates to a method for producing plastic film, more particularly reinforced stretch film or plastic films used for stretch wrapping, and even more particularly, reinforced stretch film employed in pallet wrapping and other applications. The invention also encompasses the reinforced stretch film.
BACKGROUND OF THE INVENTIONStretch films are well known and such films are commonly employed, for example, to wrap goods and products of various types positioned on a pallet, the film wholly or partially covering the goods or products and also typically applied to the pallet itself to secure the pallet to the items positioned thereon. The films themselves are typically made of polyethylene, although other stretch film sheet materials can be employed as well.
To reduce packaging costs, it may be desired to use as little stretch film as possible. In addition, to reduce shipping costs by keeping the shipping weight as low as possible and minimizing the space required for shipping, it may be desired for the film to be as light weight and as thin as possible. However, for obvious safety concerns of both the product being shipped and the humans and equipment used in shipping, stretch films need to have high strength. These problems are all interrelated as typically the less film you use, or the lighter and thinner the stretch film is, the less strength it will have. This is especially true for heavier loads (like bricks, cement blocks, bags, drums, steel tubes, pipes etc.) where stretch films are being continuously wrapped around the pallets to achieve load retention. Currently, the safety concerns are strong enough that the stretch film has to be wrapped with heavier gauge material, like straps, bags or stretch hoods, or an immense amount of film with low pre-stretch is used to keep the heavy product secure. However, both of these options clearly increase packaging and/or shipping costs.
Thus, there is clearly a need to create a light weight thin stretch film that has high strength and can create a high force to load. The instant invention is designed to provide a reinforced stretch film that addresses at least some of the above mentioned problems.
SUMMARY OF THE INVENTIONThe instant invention is directed toward a reinforced stretch film and its method of production. The method of producing the reinforced stretch film includes the steps of: providing an elongated base sheet of plastic stretch film having a longitudinal axis; forming a plurality of cord-like, elongated reinforcement members; positioning the plurality of cord-like, elongated reinforcement members to the elongated base sheet where the cord-like, elongated reinforcement members extend along the longitudinal axis of the elongated base sheet; positioning a plurality of plastic film strip overlay over each of the cord-like, elongated reinforcement members where the plastic film strip overlays being parallel and spaced from one another; and attaching the plastic film strip overlays to the cord-like, elongated reinforcement members and to the elongated base sheet to fixedly sandwich the cord-like, elongated reinforcement members between the elongated base sheet and the narrow plastic film strip overlays. Whereby, the narrow plastic film strip overlays and the cord-like, elongated reinforcement members comprising parallel, elongated reinforcement strips defining elongated spaces therebetween.
The reinforced stretch film includes the elongated base sheet and the plurality of elongated reinforcement strips. The elongated base sheet is made of plastic stretch film and has a longitudinal axis. The plurality of elongated reinforcement strips extend along the longitudinal axis of the elongated base sheet, are disposed substantially parallel to one another, and define elongated spaces therebetween. Each elongated reinforcement strip includes: a cord-like, elongated reinforcement member and a narrow plastic film strip overlay. The reinforcement members are attached to the elongated base sheet and extend along the longitudinal axis of the base sheet. Each of the narrow plastic film strip overlays are positioned over the cord-like, elongated reinforcement members thereof. The narrow plastic film strip overlay may be attached to the cord-like, elongated reinforcement member and to the elongated base sheet at opposed sides of the cordlike, elongated reinforcement member to fixedly sandwich the cord-like, elongated reinforcement member between the elongated base sheet and the narrow plastic film strip overlay.
For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
Referring to the drawings, wherein like numerals, indicate like elements, there is shown in the Figures an embodiment of a reinforced stretch film 1 (see
The elongated base sheet 10 may have a longitudinal axis and be made of any suitable material for a stretch film, including any suitable plastic stretch films. See
Each of the elongated reinforcement strips 30 may be made from a reinforcement member 22 and an overlay 26. See
The reinforcement strips 30 may be attached to the base sheet 10 by any means. See
Referring to
The method of producing reinforced stretch film 1 may include a step of forming a plurality of cord-like, elongated reinforcement members 22. See
Referring specifically to
Referring back to
A step of positioning the plurality of cord-like, elongated reinforcement members 22 to the elongated base sheet 10 may be included in the method of producing the reinforced stretch film 10. The step of positioning the reinforcement members 22 may include any steps for positioning the reinforcement members on base sheet 10. In one embodiment, this step may include attaching the plurality of cord-like, elongated reinforcement members 22 to the elongated base sheet 10, where the cord-like, elongated reinforcement members 22 may be spaced from one another and disposed substantially parallel to one another. In another embodiment, the step of positioning the plurality of cord-like, elongated reinforcement members 22 on the elongated base sheet 10 may include attaching the plurality of cordlike, elongated reinforcement members 22 to the elongated base sheet 10 via a line of adhesive beads and/or a static charge.
A step of attaching the plastic film strip overlays 26 to the cord-like reinforcement members 22 and base sheet 10 may be included in the method of producing the reinforced stretch film 10. This step of attaching the overlays 26 to the reinforcement members 22 and base sheet 10 may include any steps for attaching the overlays 26. In one embodiment, this step may include: a step of holding the plastic film strip overlays onto the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10 via static electricity; a step of laminating the plastic film strip overlays 26 to the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10; a step of sealing the plastic film strip overlays 26 to the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10 via a sonic welder; or combinations thereof. In one embodiment, the step of attaching the overlays 26 to the reinforcement members 22 and base sheet 10 may include a combination of: a step of holding the plastic film strip overlays onto the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10 via static electricity; a step of laminating the plastic film strip overlays 26 to the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10; and a step of sealing the plastic film strip overlays 26 to the cord-like, elongated reinforcement members 22 and to the elongated base sheet 10 via a sonic welder.
Immediately thereafter, plastic film strip overlays 26, which also may be polyethylene or other like material, may be applied to the base sheet 10. Plastic film strip overlays 26 may be flat and narrow. In one embodiment, the plastic film strip overlays 26 may be made from linear low-density polyethylene, also known as LLDP. In one embodiment, plastic film strip overlays 26 may be similar to base plastic film strips 16, including, being cut from the same master material 32. The plastic film strip overlays 26 may be laid over to thereby cover the cord-like reinforcement members 22. The film strip overlays 26 may be on and in engagement with the elongated base sheet 10 on opposed sides of the reinforcement members 22. In one embodiment, a second idler roll 28 may be employed for such purpose and may also establish a firm interconnection between the base sheet 10, the reinforcement members 22, and the narrow film strip overlays 26.
The reinforcement members 22 and the film strip overlays 26 may form any number of elongated reinforcement strips 30 on base sheet 10. In one embodiment, the reinforcement members 22 and the film strip overlays 26 may form three elongated reinforcement strips 30, as shown in the arrangement illustrated in
The reinforced stretch film 1 may provide an increase in the stretch percent over the stretch percent of just providing elongated base sheet of plastic stretch film. In one embodiment, the reinforced stretch film may provide an increase in the stretch percent over the stretch percent of just providing elongated base sheet of plastic stretch film by up to 400 percent. In another embodiment of the present invention, the reinforced stretch film may provide an increase in the stretch percent over the stretch percent of just providing elongated base sheet of plastic stretch film by between 150 and 400 percent. In still another embodiment of the present invention, the reinforced stretch film may provide an increase in the stretch percent over the stretch percent of just providing elongated base sheet of plastic stretch film by between 250 and 400 percent. In yet another embodiment of the present invention, the reinforced stretch film may provide an increase in the stretch percent over the stretch percent of just providing elongated base sheet of plastic stretch film by between 300 and 400 percent.
The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention. The invention illustratively discloses herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.
Claims
1. A method of producing a reinforced stretch film comprising the steps of:
- providing an elongated base sheet of plastic stretch film having a longitudinal axis;
- forming a plurality of cord-like, elongated reinforcement members;
- positioning said plurality of cord-like, elongated reinforcement members on said elongated base sheet where said cord-like, elongated reinforcement members extending along the longitudinal axis of said elongated base sheet;
- positioning a plurality of plastic film strip overlay over each of said cord-like, elongated reinforcement members where said plastic film strip overlays being parallel and spaced from one another; and
- attaching said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet to fixedly sandwich said cord-like, elongated reinforcement members between said elongated base sheet and said narrow plastic film strip overlays;
- whereby, said narrow plastic film strip overlays and said cord-like, elongated reinforcement members comprising parallel, elongated reinforcement strips defining elongated spaces therebetween.
2. The method of producing a reinforced stretch film of claim 1 wherein said step of forming a plurality of cord-like, elongated reinforcement members including randomly compressing a plurality of flat and narrow base plastic film strips by randomly compressing each of said flat and narrow, base plastic film strips by rotating a collector roll.
3. The method of producing a reinforced stretch film of claim 1 wherein said plurality of cord-like, elongated reinforcement members and said plurality of plastic film strip overlays are formed from a master material.
4. The method of producing a reinforced stretch film of claim 3 wherein said master material being slit by a slitter unit to provide said base film strips of said plurality of cord-like, elongated reinforcement members, and said plurality of plastic film strip overlays.
5. The method of producing a reinforced stretch film of claim 3 wherein said master material being slit by a slitter unit at evenly spaced distances to provide said base film strips of said plurality of cord-like, elongated reinforcement members and said plurality of plastic film strip overlays of equal widths.
6. The method of producing a reinforced stretch film of claim 1 wherein said step of positioning said plurality of cord-like, elongated reinforcement members to said elongated base sheet including attaching said plurality of cord-like, elongated reinforcement members to said elongated base sheet, where said cord-like, elongated reinforcement members being spaced from one another and disposed substantially parallel to one another.
7. The method of producing a reinforced stretch film of claim 6 wherein said step of positioning said plurality of cord-like, elongated reinforcement members to said elongated base sheet including attaching said plurality of cord-like, elongated reinforcement members to said elongated base sheet via a line of adhesive beads.
8. The method of producing a reinforced stretch film of claim 1 wherein said step of attaching said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet to fixedly sandwich said cord-like, elongated reinforcement members between said elongated base sheet and said narrow plastic film strip overlays including the steps of:
- holding said plastic film strip overlays onto said cord-like, elongated reinforcement members and to said elongated base sheet via static electricity;
- laminating said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet;
- sealing said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet via a sonic welder; or combinations thereof.
9. The method of producing a reinforced stretch film of claim 8 wherein said step of attaching said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet to fixedly sandwich said cord-like, elongated reinforcement members between said elongated base sheet and said narrow plastic film strip overlays including the steps of:
- holding said plastic film strip overlays onto said cord-like, elongated reinforcement members and to said elongated base sheet via static electricity;
- laminating said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet; and then sealing said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet via a sonic welder.
10. The method of producing a reinforced stretch film of claim 1 wherein said base sheet being uncovered in said elongated spaces therebetween said parallel, elongated reinforcement strips defined by said narrow plastic film strip overlays and said cord-like, elongated reinforcement members.
11. The method of producing a reinforced stretch of claim 1 further comprising:
- transporting the elongated base sheet in a direction of movement corresponding to the longitudinal axis of said elongated base sheet;
- said step of forming a plurality of cord-like, elongated reinforcement members being completed simultaneously with the transport of said elongated base sheet;
- where each of said cord-like, elongated reinforcement members is made by simultaneously randomly compressing said plurality of transported flat, narrow plastic film strips by randomly compressing each of said flat, narrow plastic film strip by simultaneously rotating said collector roll and employing a compressor nozzle during transport thereof;
- said step of positioning said plurality of cord-like, elongated reinforcement members to said elongated base sheet being during transport of said elongated base sheet;
- transporting said elongated base sheet and said cord-like, elongated reinforcement members attached thereto in the direction of movement to the longitudinal axis of said elongated base sheet; and
- said step of attaching said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet being during transport of said elongated base sheet and said cord-like, elongated reinforcement members attached thereto.
12. The reinforced stretch film obtained by the method of claim 1.
13. The reinforced stretch film of claim 12 wherein the stretch percent of said reinforced film being increased over the stretch percent of said elongated base sheet of plastic stretch film.
14. Reinforced stretch film comprising:
- an elongated base sheet of plastic stretch film having a longitudinal axis; and
- a plurality of elongated reinforcement strips extending along the longitudinal axis of said elongated base sheet, disposed substantially parallel to one another, and defining elongated spaces therebetween;
- each elongated reinforcement strip comprising: a cord-like, elongated reinforcement member attached to said elongated base sheet and extending along the longitudinal axis of said elongated base sheet; and a narrow plastic film strip overlay positioned over the cord-like, elongated reinforcement member thereof; where, said narrow plastic film strip overlay being attached to the cord-like, elongated reinforcement member and to the elongated base sheet at opposed sides of said cord-like, elongated reinforcement member to fixedly sandwich the cord-like, elongated reinforcement member between the elongated base sheet and narrow plastic film strip overlay.
15. The reinforced stretch material of claim 14 wherein said plurality of cord-like, elongated reinforcement members being:
- a randomly compressed flat, narrow plastic film strip; and
- spaced from one another and parallel.
16. The reinforced stretch material of claim 14 wherein said base sheet being uncovered in said elongated spaces therebetween said parallel, elongated reinforcement strips defined by said narrow plastic film strip overlays and said cord-like, elongated reinforcement members.
17. The reinforced stretch material of claim 14 further comprising a plurality of glue bead lines for attaching said cord-like, reinforcement members to said base sheet.
18. The reinforced stretch material of claim 14 wherein said narrow plastic film strip overlay being attached to the cord-like, elongated reinforcement member and to the elongated base sheet by a bond being:
- a lamination bond of said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet; and
- a static electric seal of said plastic film strip overlays to said cord-like, elongated reinforcement members and to said elongated base sheet.
19. The reinforced stretch film of claim 14 wherein the stretch percent of said reinforced film being increased over the stretch percent of said elongated base sheet of plastic stretch film.
20. The reinforced stretch film of claim 19 wherein the stretch percent of said reinforced film being increased over the stretch percent of said elongated base sheet of plastic stretch film by up to 400 percent.
Type: Application
Filed: Apr 25, 2014
Publication Date: Oct 29, 2015
Applicant: Alliance Plastics, LLC (Rock Hill, SC)
Inventor: Luis Arturo LOPEZ (Mountain View, CA)
Application Number: 14/261,500