Reusable film core for coreless film rolls

Abstract

Reusable film core (200) for a coreless film roll (CLR), the reusable film core (200) including an elongated tube (300), having a first end section (340) and a second end section (350), the tube (300) insertable into a central bore of a coreless film roll (CLR); a first end plug (400) removably insertable into the first end section (340) of the tube (300) and configured to cause the first end section (340) to expand radially outwardly when inserted in the first end section (340); and a second end plug (500) removably insertable into the second end section (350) of the tube (300) and configured to cause the second end section (350) to expand radially outwardly when inserted in the second end section (350).

Description

REUSABLE FILM CORE FOR CORELESS FILM ROLLSPriority

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 505,474, filed June 1, 2023, the entire contents of which is incorporated herein by reference.Field

[0002] The present disclosure relates to reusable film cores for coreless film rolls.Background

[0003] Several types of stretch-wrapping machines use stretch film to secure loads of goods on pallets. Each of these str etch- wrapping machines includes a film roll carriage configured to support a removable stretch film roll. Each stretch-wrapping machine is configured to rotate the film roll carriage relative to the load while vertically moving the film roll carriage relative to the load to wrap the load in a spiral pattern with the stretch film taken from the film roll.

[0004] Film rolls with corrugated cores have been widely employed, and many types of stretch-wrapping machines are configured to support film rolls with such corrugated cores. Figure 1 A shows an example film roll R including film F wound and mounted on a core C. After the film F of the film roll R has been used up, the core C is discarded or recycled. To reduce waste, film rolls without cores have been developed and commercially employed. Figure IB shows an example coreless film roll CLR that includes film F but no core. Such a coreless film roll CLR cannot by itself be supported by the film roll carriages of certain stretch-wrapping machines. Thus, such a coreless film roll CLR needs to be mounted on a core before use with these stretch-wrapping machines.Summary

[0005] Various embodiments of the present disclosure provide a reusable film cores for coreless film rolls. In various embodiments, the reusable film core includes an elongated tube, a first end plug, and a second end plug. The tube is configured to be inserted into a central bore of a coreless film roll, the first end plug is configured to be inserted and locked in a first end of the tube after the tube is inserted in the central bore of the coreless film roll, and the second end plug is configured to be inserted and locked in an opposite second end of the tube after the tube is inserted in the central bore of the coreless film roll. The reusable film core is configured such after the coreless film roll is mounted on the reusable film core, the reusable film core and the coreless film roll mounted thereon can be attached to a stretch wrapping machine. The reusable film core is also configured such after the film of the coreless film roll is used up, the reusable film core can be disassembled and then used again for another coreless film roll. The reusable film core is also configured such that it can be removed from a coreless film roll before the film is used up, and then used again for another coreless film roll.Brief Description of the Figures

[0006] Figure 1 A is a perspective view of an example film roll having a core.

[0007] Figure IB is a perspective view of an example coreless film roll.

[0008] Figure 2A is a perspective view of an example stretch-wrapping machine.

[0009] Figures 2B and 2C are opposite perspective views of a film carriage of a wrapping assembly of the stretch- wrapping machine of Figure 2A.

[0010] Figure 3A is a perspective view of an assembled reusable film core of one example embodiment of the present disclosure.

[0011] Figure 3B is a cross-sectional view of the assembled reusable film core of Figure 3A taken alone line 3B-3B of Figure 3A.

[0012] Figure 4A is an exploded perspective view of the un-assembled reusable film core of Figure 3 A showing the tube thereof in a resting configuration and the end plugs thereof removed from the tube.

[0013] Figure 4B is a perspective view of the tube in a compressed configuration.

[0014] Figure 4C is a perspective view of the tube in an expanded configuration.

[0015] Figure 5 is a perspective view of one of the end plugs.

[0016] Figure 6 is an outer end view of the end plug of Figure 5.

[0017] Figure 7 is an inner end view of the end plug of Figure 5.

[0018] Figure 8 is a side view of the end plug of Figure 5.

[0019] Figure 9 is a perspective view of a coreless film roll mounted on the reusable film core of Figure 3 A.Detailed Description

[0020] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show, and the specification describes certain exemplary and nonlimiting embodiments. Not all of the components shown in the drawings and described in the specification may be required, and certain implementations may include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

[0021] Reusable film cores of various embodiments of the present disclosure are usable with coreless stretch film rolls that are usable by stretch-wrapping machines. Thus, for a better understanding of the reusable film cores of the present disclosure, an example stretchwrapping machine is first generally described.

[0022] Figures 2A, 2B, and 2C show certain parts of an example stretch-wrapping machine 1 (sometimes referred to herein as the “wrapping machine” for brevity). The wrapping machine 1 includes a wrapping-machine frame 10, a circular guide 20, a guide actuator (notshown), a wrapping assembly 40, a cutting-and-fixing device (not shown), an operator interface (not shown), and a controller (not shown). The wrapping-machine frame 10 is formed from multiple tubular and / or solid members (not individually labeled) and configured to support the other components of the wrapping machine 1. The wrapping-machine frame 10 defines a wrapping area within its interior and has an infeed area 10a at which a palletized load (such as a load CB on a pallet P) is conveyed (such as via a conveyor C) into the wrapping area for wrapping and an outfeed area 10b at which the palletized load is conveyed (such as via the conveyor C) from the wrapping area after wrapping.

[0023] The circular guide 20 serves as the mount for the wrapping assembly 40 and is movably mounted to the wrapping-machine frame 10 (such as to one or more vertical members of the wrapping-machine frame 10) such that the circular guide 20 is vertically movable relative to the wrapping-machine frame 10 between an upper position and a lower position.

[0024] The guide actuator is operably connected to the circular guide 20 to move the circular guide 20 relative to the wrapping-machine frame 10 between the upper and lower positions. The guide actuator includes one or more motors (not shown) operably connected to the circular guide 20 via one or more belt-and-pulley assemblies (not shown) to move the circular guide 20 between the upper and lower positions. The guide actuator could alternatively include one or more pneumatic or hydraulic cylinders (not shown) operably connected to the circular guide 20 to move the circular guide 20 between the upper and lower positions.

[0025] The wrapping assembly 40 is movably mounted to the circular guide 20 such that the wrapping assembly 40 is rotatable relative to the circular guide 20. The wrapping assembly 40 includes a ring-shaped support (not shown), a film carriage 100, and a wrappingassembly actuator (not shown).

[0026] The ring-shaped support serves as the mount for the film carriage 100 and is movably mounted to the circular guide 20 such that the support (and the carriage and other components connected to the support) is rotatable relative to the circular guide 20. The support is movably mounted to the circular guide 20 via multiple spaced-apart rollers (not shown) that are connected to the support and positioned on a track (not shown) on the circular guide 20.

[0027] The film carriage 100 is fixedly connected to the support to move with the support (i.e., rotate relative to the circular guide 20 and move vertically relative to the wrapping-machine frame 10). The film roll carriage 100 is configured to rotatably support a film roll (such as the plastic stretch wrap film rolls described above). The film carriage 100 includes a filmcarriage frame 105, spaced apart film-reel supports 110a and 110b connected to the frame 105, and various other components not described here for brevity. The film supports 110a and 110b are configured to hold a film roll.

[0028] As shown in Figure IB, the example coreless film roll CLR is tubular and includes a plurality of layers of a film F (such as a plastic stretch film). The coreless film roll CLR does not include any core (such as any plastic or corrugated core) that supports the film F and that can be used to mount the coreless film roll CLR to the film supports 110a and 110b of the stretch wrapping machine 1.

[0029] Figures 3A-9 show one example embodiment of the reusable film core of the present disclosure that is sometimes referred to herein as the “film core” for brevity. The reusable film core 200 includes an elongated tube 300, a first end plug 400, and a second end plug 500. The tube 300 is sized, shaped, and otherwise configured to be inserted into a central bore CB of coreless film roll CLR. The first end plug 400 is sized, shaped, and otherwise configured to be inserted and locked in a first end of the tube 300 (as shown in Figures 3A and 3B) after the tube 200 is inserted in the central bore CB of coreless film roll CLR. The second end plug 500 is sized, shaped, and otherwise configured to be inserted and locked in an opposite second end of the tube 300 (as shown in Figures 3A and 3B) after the tube 200 is inserted in the central bore CB of the coreless film roll CLR. The first end plug 400 and the second end plug 500 are also sized, shaped, and otherwise configured to expand the tube 300 and cause the tube 300 to frictionally engage the inner layer of film of the coreless film roll as further described below. The reusable film core 200 is sized, shaped, and otherwise configured such after the coreless film roll CLR is mounted on the reusable film core 200, the reusable film core 200 and the coreless film roll CLR mounted thereon can be attached to a stretch wrapping machine such as but not limited to the stretch wrapping machine 1 and particularly the film supports 110a and 110b thereof. The reusable film core 200 is also configured such after the film F of the coreless film roll CLR is used up, the reusable film core 200 can be disassembled and then used again for another coreless film roll. The reusable film core 200 is also configured such that it can be removed from a coreless film roll CLR before the film F is used up, and then used again for another coreless film roll.

[0030] More specifically, the tube 300 has an elongated longitudinally extending tubular body 310 having a longitudinally extending central section 320, a longitudinally extending first end section 340 connected to and extending from a first end 324 of the central section 320, and a longitudinally extending second end section 350 connected to and extending from a second end 325 of the central section 320. The body 310 includes elongated longitudinally extending inner edges 370 and 380 that define an elongated longitudinally extending space 375 therebetween. The body 310 of the tube 300 also defines a longitudinally extending cylindrical central bore 315 having a first opening (not labeled), a second opening (not labeled), and a central axis A.

[0031] In the illustrated example embodiment, the tube 300 has a resting configuration (which in this example is shown in Figures 3A and 4A), a compressed configuration (which in this example is shown in Figure 4B), and an expanded configuration (which in this example is shown in Figure 4C). In other embodiments, the resting configuration can be the configuration shown in Figure 4B, the compressed configuration can include the edges 370 and 380 closer together such as engaging each other (not shown), and the expanded configuration can be either of the configurations shown in Figures 4A or 4C. Thus, the respective widths of the space 375 can vary based on the different configurations in accordance with the present disclosure.

[0032] In the resting configuration, the elongated space 375 has a first width W and the central section 320 of the body 310 of the tube 300 has a first outer diameter D as shown in Figure 4 A.

[0033] In the compressed configuration, the elongated space 375 has a second width that is smaller than the first width, and the central section 320 of the body 310 of the tube 300 has a second outer diameter that is smaller than the first outer diameter. As shown in Figure 4B, in the compressed configuration, the edges 370 and 380 are closer together than they are in the resting configuration. In the compressed configuration, the edges 370 and 380 can but do not have to be in contact with each other. The tube 300 can be put in the compressed configuration to insert the tube 300 into the central bore CB of the coreless film roll CLR, as further described below.

[0034] In the expanded configuration, the elongated space 375 has a third width that is larger than first and second widths, and the central section 320 of the body 310 of the tube 300has a third outer diameter that is larger than the first and second outer diameters. As shown in Figure 4C, in the expanded configuration, the edges 370 and 380 are further apart from each other than they are in the resting configuration (and in the compressed configuration). The tube 300 can be put in the expanded configuration by inserting the end plugs 400 and 500 in the tube 300 to cause the tube 300 to fictionally engage the inner film of the coreless film roll.

[0035] The first end section 340 of the tube 300 includes a base 342 and a plurality of radially outwardly extending circumferentially spaced-apart first film engaging ridges 344 (not individually labeled). Each of the first film-engaging ridges 344 extends longitudinally along the entire length of the first end section 340 and is configured to engage the innermost layer of film F of the coreless film roll CLR (that is adjacent to and that defines the central bore CB of the coreless film roll CLR) to prevent rotation of the film F relative to the film core 200. The first end section 340 of the tube 300 also includes a first end-plug-engagement member 346. The first end-plug-engagement member 346 is conical and inwardly tapers from an internal area to an external area. The first end section 340 and particularly the first end-plug-engagement member 346 also defines a first locking notch 348. The first locking notch 348 includes a first angled surface (not labeled) and a second angled surface (not labeled). The first locking notch 348 is configured to removably receive first locking members of the first end plug 400 to lock the first end plug 400 in the first end section 340 of the tube 300 as further described below.

[0036] Likewise, the second end section 350 of the tube 300 includes a base 352 and a plurality of radially outwardly extending circumferentially spaced-apart second film engaging ridges 354 (not individually labeled). Each of the second film-engaging ridges 354 extends longitudinally along the entire length of the second end section 350 and is configured to engage the innermost layer of the film F of the coreless film roll CLR (that is adjacent to and that defines the central bore CB of the coreless film roll CLR) to prevent rotation of the film F relative to the film core 200. The second end section 350 of the tube 300 also includes a second end-plug- engagement member 356. The second end-plug-engagement member 356 is conical and inwardly tapers from an internal area to an external area. The second end section 350 and particularly the second end-plug-engagement member 356 also defines a second locking notch 358. The second locking notch 358 includes a first angled surface (not labeled) and a second angled surface (not labeled). The second locking notch 358 is configured to removably receive second lockingmembers of the second end plug 500 to lock the second end plug 500 in the second end section 350 of the tube 300 as also further described below.

[0037] As best seen in Figures 5, 6, 7, and 8, the first end plug 400 includes a head 410, a neck 430 connected to the head 410, and a body 450 connected to and extending from the neck 430 in a direction opposite the head 410.

[0038] The head 410 of the first end plug 400 includes an annular flange having an outer annular surface 412, an inner annular surface 414, an outer cylindrical side surface 416, and inner cylindrical side surface 418. The outer side surface 416 has an outer diameter that is larger than the first outer diameter of the tube 300. The head 410 includes inner surfaces (not labeled) that define a pair of opposing spaced apart notches 422 and 424. These notches 422 and 424 are configured to receive a suitable tool (such as a screwdriver) such that the tool can be used to remove the first end plug 400 from the tube 300.

[0039] The neck 430 of the first end plug 400 is conical, is connected to and extends from the head 410. The neck 430 includes an outer surface 432, an inner surface (not labeled), an inner side connected to the head 410, and an outer side connected to the body 450. The outer diameter of the neck 430 just below the head 410 is greater than the inner diameter of the first end section 340 of the tube 300 when the tube 300 is in the resting configuration.

[0040] The body 450 of the first end plug 400 includes a plurality of elongated longitudinally extending spaced apart inwardly tapered fingers (not all individually labeled). The quantity of fingers can vary in accordance with the present disclosure. Each finger in the example embodiment is identical so only finger 452a will be described herein for brevity.

[0041] Finger 452a includes a first section 454a, a second section 456a, and a third section 458. The first section 454a has an inner end (not labeled) connected to and extending from the neck 430 and an outer end (not labeled) connected to the second section 456a. The third section 458a has an inner end (not labeled) connected to the second section 456a and an outer free end (not labeled). The second section 456a includes an inner end (not labeled) connected to the first section 454a, an outer end (not labeled) connected to the third section 458a, and an outwardly extending locking member 457a. The outwardly extending locking member 457a includes a first surface (not labeled) and a second surface (not labeled) that are respectively configured to engage and mate with the locking notch 348 of the tube 300, and particularly the first angled surface and the second angled surface of the locking notch 348. These engagementsof the locking members of all of the fingers in the locking notch 348 co-act to secure the end plug 400 in the first end of the tube 300.

[0042] In this example embodiment, the finger 452a is inwardly tapered such that the first section 454a has a greater thickness than the second section 456a, and the second section 456a has a greater thickness than the third section 458. This facilitates the radial inward and outward movements of the fingers.

[0043] The fingers are also each sized, shaped and otherwise configured such that there is a longitudinally extending space such as space 451a between each respective pair of adjacent fingers. This also enables the fingers to each be individually flexible in the radial directions (i.e., inwardly and outwardly). Thus, the fingers can move inwardly when being inserted in the end of the tube 300.

[0044] The end plug 400 is thus configured such that the insertion of the fingers of the end plug 400 into the first end section of the tube 300 causes the expansion of the first end section 400 of the tube 300 to lock the tube in the coreless film roll CLR.

[0045] The end plug 400 is also configured such that it can receive a mounting member of one of the film supports of the stretch wrapping machine (such as one of the mounting member of the film supports 110a and 110b of the stretch wrapping machine 10).

[0046] The end plug 500 is identical to the end plug 400 and is thus not described herein for brevity.

[0047] A film core attachment operation is now described.

[0048] The tube 300 is placed into its compressed configuration as shown in Figure 4B. This can be done manually (such as by squeezing the tube 300) or via a suitable compression device. This can be done for just one end section of the tube 300 that will be first inserted into the coreless film roll CLR or the entire tube 300. The compressed respective end section 340 or 350 of the tube 300 is then inserted into the central bore CB of the coreless film roll CLR such that the tube 300 extends longitudinally through the central bore CB of the coreless film roll from side to side of the coreless film roll CLR. After being inserted, the tube 300 will expand back toward its resting configuration as much as allowed by the coreless film roll CLR (i.e., based on the relative outer diameter of the tube 300 and the inner diameter of the coreless film roll CLR). The first and second film engaging ridges 344 and 354 of the first and second end sections 340 and 350 of the tube 300 can engage the innermost layer of the film F of the corelessfilm roll CLR depending on the relative outer diameter of the tube 300 and the inner diameter of the coreless film roll CLR.

[0049] The first end plug 400 is then inserted (fingers first) into the first end section 340 of the tube 300. This insertion can cause the fingers of the first end plug 400 to be moved radially inwardly and then aligned such that the locking members of the fingers extend into and engage the first locking notch of the first end section 340 of the tube 300 such as shown in Figure 3B and such that the head of the first end plug 400 is adjacent to the end of the first end section 340 of the tube 300 as shown in Figure 3A. The insertion of the neck and fingers of the first end plug 400 into the first end section 340 of the tube 300 causes the expansion of the first end section 340 of the tube 300 in the coreless film roll CLR. Specifically, as mentioned above, the outer diameter of the end plug 400 at the neck 430 just below the head 410 is greater than the inner diameter of the first end section 340 of the tube 300 when the tube 300 is in the resting configuration. Inserting this larger neck 430 into the tube 300 forces the tube 300 to expand. The insertion of the neck and fingers of the first end plug 400 into the first end section 340 of the tube 300 also causes the first film-engaging ridges 344 to engage the inner layer of film of the coreless film roll CLR. The engagement of the locking members in the locking notch also locks the first end plug 400 in the first end section 340 of the tube 300. As also best shown in Figure 3B, the respective mating of the opposing tapered first end-plug-engagement member 346 and tapered fingers of the first end plug 400 also assist in this secured engagement. Figure 9 shows a coreless film roll CLR with the tube 300 and the first end plug 400 inserted in the coreless film roll CLR.

[0050] The second end plug 500 is then inserted (fingers first) into the second end section 350 of the tube 300. This insertion can cause the fingers of the second end plug 500 to be moved radially inwardly and then aligned such that the locking members of the fingers extend into and engage the first locking notch of the second end section 350 of the tube 300 such as shown in Figure 3B and such that the head of the second end plug 500 is adjacent to the end of the second end section 350 of the tube 300 as shown in Figure 3A. The insertion of the neck and fingers of the second end plug 500 into the second end section 350 of the tube 300 causes the expansion of the second end section 350 of the tube 300 in the coreless film roll CLR. Specifically, the outer diameter of the end plug 500 at the neck just below the head is greater than the inner diameter of the second end section 350 of the tube 300 when the tube 300 is in theresting configuration. Inserting this larger neck into the tube 300 forces the tube 300 to expand. The insertion of the neck and fingers of the second end plug 500 into the second end section 350 of the tube 300 also causes the second film-engaging ridges 354 to engage the inner layer of film of the coreless film roll CLR. The engagement of the locking members in the locking notch locks the second end plug 500 in the second end section 350 of the tube 300. As also best shown in Figure 3B, the respective mating of the opposing tapered second end-plug-engagement member 356 and tapered fingers of the second end plug 500 also assist in this secured engagement.

[0051] These insertions of the end plugs 400 and 500 can be done in any order or at the same time.

[0052] The coreless film roll CLR with the reusable film core 200 inserted therein can then be mounted on the film supports of the stretch wrapping machine (such as film supports 110a and 110b of the stretch wrapping machine 10).

[0053] After the film on the coreless film roll CLR has been used up, the reusable film core 200 can be removed from the spaced apart film-reel supports 110a and 110b, and disassembled. The disassembly can include putting the tube 300 in the expansion configuration (such as shown in Figure 4C) manually or by using an expansion device, and removing each of the end plugs 400 and 500 from the tube 300. A suitable tool (such as a screwdriver) can be inserted in the notches of the end plugs 400 and 500 (such as notches 422 or 424 in end plug 400) to remove the first end plugs 400 and 500 from the tube 300.

Claims

Claims1. A reusable film core comprising: a tube having a first end section and a second end section, the tube insertable into a central bore of a coreless film roll; a first end plug removably insertable into the first end section of the tube and configured to cause the first end section to expand radially outwardly when inserted in the first end section; and a second end plug removably insertable into the second end section of the tube and configured to cause the second end section to expand radially outwardly when inserted in the second end section.

2. The reusable film core of claim 1, wherein the tube has a resting configuration, a compressed configuration, and an expanded configuration.

3. The reusable film core of claim 2, wherein the tube comprises longitudinally extending inner edges that define a longitudinally extending space therebetween.

4. The reusable film core of claim 3, wherein when the tube is in the compressed configuration, the inner edges are closer together than they are when the tube is in the resting configuration, and when the tube is in the expanded configuration, the inner edges are further apart from each other than they are when the tube is in the resting configuration.

5. The reusable film core of claim 3, wherein tube comprises a longitudinally extending central section between the first end section the second end section.

6. The reusable film core of claim 5, wherein the tube defines a longitudinally extending central bore having a first opening in the first end section of the tube and a second opening in the second end section of the tube.

7. The reusable film core of claim 5, wherein when the tube is in the resting configuration, the elongated space has a first width and the central section of the tube has an firstouter diameter, wherein when the tube is in the compressed configuration, the elongated space has a second width that is smaller than the first width and the central section of the tube has a second outer diameter that is smaller than the first outer diameter, and wherein when the tube is in the expanded configuration, the elongated space has a third width that is larger than first width and the central section of the tube has a third outer diameter that is larger than first outer diameter.

8. The reusable film core of claim 5, wherein the first end section of the tube includes a base and a plurality of radially outwardly extending circumferentially spaced apart first film engaging ridges, and wherein the second end section of the tube includes a base and a plurality of radially outwardly extending circumferentially spaced apart second film engaging ridges.

9. The reusable film core of claim 5, wherein in the first end section of the tube includes a first end-plug-engagement member.

10. The reusable film core of claim 9, wherein the first end-plug-engagement member is conical and inwardly tapers from an internal area to an external area.

11. The reusable film core of claim 9, wherein the first end-plug-engagement member defines a first locking notch configured to removably receive first locking members of the first end plug to lock the first end plug in the first end section of the tube.

12. The reusable film core of claim 1, wherein the first end plug includes a head, a neck connected to the head, and a body connected to and extending from the neck.

13. The reusable film core of claim 12, wherein the body of the first end plug comprises a plurality of longitudinally extending spaced apart fingers.

14. The reusable film core of claim 13, wherein each finger comprises an outwardly extending locking member configured to engage and mate with a locking notch of the first end section of the tube.

Images