Stretch wrapping machine with film sealing assembly

Abstract

Various embodiments provide a stretch wrapping machine with a sealing and cutting device that applies stitching to seal the film after the load is wrapped.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and benefit of U.S. Provisional Patent Application No. 63 / 367,511, filed July 1, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to stretch wrapping machines, and more particularly to stretch wrapping machines that include a film sealing assembly. [Background technology]

[0003] Several types of known stretch wrappers use stretch film to secure loads of goods on pallets. These stretch wrappers include a film carriage to which replaceable rolls of stretch film are attached. Depending on the type of stretch wrapper, either the film carriage rotates relative to the palletized load, or the palletized load rotates relative to the film carriage, while the film carriage moves vertically relative to the load to spirally wrap the load with stretch film. For example, turntable wrappers rotate a turntable carrying the palletized load while moving the film carriage vertically to wrap the load with stretch film. Ring wrappers rotate the film carriage vertically and rotate it around a circular ring circumscribing the palletized load to wrap the load with stretch film. Rotating arm wrappers rotate a cantilever arm carrying the film carriage around the palletized load to wrap the load with stretch film while moving the film carriage vertically.

[0004] Once the wrapping process is substantially complete, the film web extending between the load and the film roll on the film carriage is severed, creating a film tail extending from the load. This film tail must be secured to the film already wrapped around the load to prevent the film from unwinding from the load. This securing process can occur before or after the film web is cut to form the film tail. While some existing stretch wrapping machines include various mechanisms for securing the film tail, there is a continuing need to simplify and speed this process to increase throughput. Summary of the Invention [Means for solving the problem]

[0005] Various embodiments of the present disclosure provide a packaging machine including a packaging machine frame, a guide attached to the packaging machine frame, a guide actuator operatively connected to the guide and configured to move the guide vertically relative to the packaging machine frame, a packaging assembly attached to the guide and including a film carriage, a packaging assembly actuator operatively connected to the packaging assembly and configured to move the packaging assembly relative to the guide, and a sealing and cutting device attached to the guide, the sealing and cutting device including a heating element support, a heating element guard, a heating element disposed between the heating element support and the heating element guard and movable between a sealing position and a home position to seal two layers of film together, and a clamp facing inward toward the heating element and positionable on an opposite side of the two layers of film from the heating element.

[0006] Various embodiments of the present disclosure provide a method for packaging a load with a packaging machine, the method including the steps of: positioning the load in a packaging area of the packaging machine; positioning the load with a packaging assembly attached to a guide; positioning a sealing and cutting device including a heating element assembly near the packaged load; wrapping the load and heating element assembly with an inner film seal layer; overlapping the outer film seal layer with at least a portion of the inner film seal layer; positioning a clamp against the outer film seal layer so that the clamp faces inward toward the load; operating the sealing and cutting device to seal the inner film seal layer to the outer film seal layer; and cutting the outer film seal layer. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view of one exemplary embodiment of a stretch wrapping machine of the present disclosure. [Figure 2] FIG. 2 is a block diagram illustrating certain components of the stretch wrapping machine of FIG. 1. [Figure 3A] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 3B] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 3C] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 3D] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 3E] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 3F] 2 is a cross-sectional view of the load, film, and film sealing assembly of the packaging machine of FIG. 1 undergoing a sealing process. [Figure 4] 10 is a flowchart showing steps of a packaging process including a film sealing process. DETAILED DESCRIPTION OF THE INVENTION

[0008] While the systems, devices, and methods described herein may be embodied in various forms, the drawings show certain exemplary and non-limiting embodiments and illustrate the present specification. Not all of the components shown in the drawings and described in the specification are required, and particular implementations may include additional, different, or fewer components. Changes in the arrangement and type of components, the shape, size, and materials of components, and the manner of connection of components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to herein reflect the orientation of the components shown in the corresponding drawing and do not limit the scope of the present disclosure. Furthermore, terms referring to methods of attachment, such as attaching, connecting, and the like, are not limited to direct attachment methods but should be interpreted broadly to include indirectly and operably attaching, connecting, and similar methods of attachment. This specification is intended to be interpreted as a whole and in accordance with the principles of the present disclosure, as understood by those skilled in the art.

[0009] Various embodiments of the present disclosure provide a stretch wrapping machine with a heating element assembly configured to seal a sealing layer of a film to complete a strap wrap of a load.

[0010] 1, 2, and 3A-3F illustrate one exemplary embodiment of a stretch wrapping machine 1 (sometimes referred to herein for brevity as a "wrapping machine") of the present disclosure. The wrapping machine 1 includes a wrapping machine frame 10, a circular guide 20, a guide actuator 30, a wrapping assembly 40, a sealing and cutting device 100 (not shown in FIGS. 1 and 2), an operator interface 500, and a control device 600.

[0011] The packaging machine frame 10 is formed from a plurality of tubular and / or solid members (not individually labeled) and is configured to support the other components of the packaging machine 1. The packaging machine frame 10 defines a packaging area therein, having an infeed area 10a where palletized loads (such as load L on pallet P) are transported (e.g., via conveyor C) to the packaging area for packaging, and an outfeed area 10b where palletized loads are transported (e.g., via conveyor C) from the packaging area after packaging. The illustrated packaging machine frame 10 is merely one example configuration, and any suitable configuration may be employed.

[0012] The circular guide 20 serves as a mounting point for the packaging assembly 40 and is movably mounted to the packaging machine frame 10 (such as to one or more vertical members of the packaging machine frame 10) so that the circular guide 20 is vertically movable relative to the packaging machine frame 10 between an upper position and a lower position.

[0013] The guide actuator 30 is operably connected to the circular guide 20 to move the circular guide 20 between an upper position and a lower position relative to the packaging machine frame 10. In certain embodiments, the guide actuator 30 includes one or more motors operably connected to the circular guide 20 via one or more belt and pulley assemblies to move the circular guide 20 between the upper and lower positions. In other embodiments, the guide actuator 30 includes one or more pneumatic or hydraulic cylinders operably connected to the circular guide 20 to move the circular guide 20 between the upper and lower positions. These are merely examples, and the guide actuator 30 may include any suitable actuator configured to move the circular guide 20 between the upper and lower positions.

[0014] The packaging assembly 40 is movably mounted to the circular guide 20 such that the packaging assembly 40 is rotatable relative to the circular guide 20. The packaging assembly 40 includes a ring-shaped support (not shown), a film carriage (not numbered), and a packaging assembly actuator 400 (FIG. 2).

[0015] The ring-shaped support serves as a mount for the film carriage and is movably mounted to the circular guide 20 so that the support (and other components connected to the carriage and support) can rotate relative to the circular guide 20. In this embodiment, the support is movably mounted to the circular guide 20 via a plurality of spaced rollers (not shown) that are connected to the support and disposed on tracks (not shown) on the circular guide 20.

[0016] The film carriage is fixedly connected to the support and moves with the support (i.e., rotates relative to the circular guide 20 and moves perpendicularly relative to the packaging machine frame 10). The film carriage is configured to rotatably support a roll of film (such as plastic stretch film). The film carriage can include various components such as, but not limited to, a film carriage frame, a film reel support, one or more idler rollers, one or more pinch rollers, one or more pre-stretch rollers, and a pre-stretch drive assembly.

[0017] The packaging assembly actuator 400 is operably connected to the packaging assembly 40 to rotate the packaging assembly 40 relative to the circular guide 20 and the load L. In certain embodiments, the packaging assembly actuator 400 includes one or more motors operably connected to the packaging assembly 40 via one or more belt and pulley assemblies to rotate the packaging assembly 40 relative to the circular guide 20 and the load L. This is merely one example, and the packaging assembly actuator 400 may include any suitable actuator configured to rotate the packaging assembly 40 relative to the circular guide 20 and the load L.

[0018] The sealing and cutting device 100 is supported by the packaging machine frame 10 and is configured to seal two layers of film F together and cut film F from the film roll after a package L has been packaged to complete the packaging process. Cutting film F creates a leading edge of film F for the film roll to be used in the next packaging process. The sealing and cutting device 100 can also be configured to retain the leading edge of film F after cutting it and connect it to the next package as it is wrapped.

[0019] As best shown in FIGS. 3A-3F , the sealing and cutting apparatus 100 includes a film sealing assembly 200 and a cutter (not shown). The film sealing assembly 200 includes a heating element assembly 205 and a clamp 240. The heating element assembly 205 includes a heating element 210, a heating element support 220, and a heating element guard 230. The heating element assembly 205 is vertically movable (relative to the load L) between a home position (an upper position in this exemplary embodiment) and a sealing position (a lower position in this exemplary embodiment). In the home position, the film sealing assembly is positioned away from the film and the load so that it can encase the load L without interference from the film sealing assembly 200. In the sealing position, the heating element assembly 205 is positioned as shown in FIG. 3B to perform the film sealing process, as described in detail below. The film sealing assembly 200 can be coupled to the circular guide 20 and / or the packaging assembly 40 and can be moved between the upper and lower positions by a sealing and cutting actuator 300. In certain embodiments, the sealing and cutting actuator 300 may be configured to move the film sealing assembly 200, the heating element assembly 205, the clamp 240, and / or one or more components of these assemblies.

[0020] Heating element 210 includes suitable components configured to melt two overlapping layers of film F together via thermal conduction, convection, or radiation, depending on the embodiment. In this exemplary embodiment, heating element 210 includes a rotatable roller configured to heat to a temperature higher than the melting temperature of film F via electrical heating (such as, but not limited to, resistive heating or induction heating). Heating element 210 is disposed between heating element support arm 220 and heating element guard 230 in this embodiment and is rotatable relative to heating element support arm 220 and heating element guard 230. Heating element guard 230 is capable of moving independently relative to heating element support arm 220 and heating element 210. 3B and 3C, heating element guard 230 is movable relative to heating element support arm 220 and heating element 210 between a shielding position in which heating element guard 230 shields heating element 210 from heating and melting inner and outer film seal layers FS1 and FS2 (e.g., FIG. 3B) and a heating position in which heating element guard 230 exposes heating element 210 to inner film seal layer FS1 (e.g., FIG. 3C), such that heating element 210 can heat and melt inner and outer film seal layers FS1 and FS2. As best shown in FIGS. 3C-3E, heating element support arm 220 is positioned on the inner (or load side) of heating element 210, and heating element guard 230 is positioned on the outer (or seal side) of heating element 210. In various other embodiments, the heating element guard is connected to the heating element support and movable with the heating element support. In such an embodiment, the bottom of the heating element guard is above the heating element, and thus the heating element guard protects the film above, except at the location or level of the heating element.

[0021] Clamp 240 is movable between a release position and a clamped position. In the release position, clamp 240 is positioned so that packaging assembly 40 can wrap film F around load L and / or heating element support arm 220 and heating element guard 230 without interference from clamp 240. In the clamped position, clamp 240 moves toward and engages the outermost film layer (e.g., outer film seal layer FS2). Clamp 240 can be moved between the release and clamped positions via any suitable form of movement, such as sliding, pivoting, rotating, or translating, under the control of sealing and cutting actuator 300.

[0022] The operator interface 500 is configured to receive input from an operator and, in certain embodiments, output information to the operator. The operator interface includes one or more input devices configured to receive input from the operator. In various embodiments, the one or more input devices include one or more buttons (e.g., hard or soft keys), one or more switches, and / or a touch panel. In various embodiments, the operator interface 500 includes a display device configured to display information to the operator, such as information about the pallet load, the status of the packaging operation, or parameters of the packaging machine 1. The operator interface may include other output devices, such as one or more speakers and / or one or more lights, instead of or in addition to a display device. In certain embodiments, the operator interface 500 is formed as part of the packaging machine 1, for example, attached to the packaging machine frame 10. In other embodiments, the operator interface is separate from the packaging machine 1.

[0023] The controller 600 includes a processing device communicatively coupled to a memory device. The processing device may include any suitable processing device, such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital signal processor, one or more microprocessors, one or more microprocessors associated with a digital signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and / or state machines. The memory device may include any suitable memory device, such as, but not limited to, read-only memory, random access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and / or removable memory, magneto-optical media, and / or optical media. The memory device stores instructions executable by the processing device to control the operation of the packaging machine 1 (to perform packaging operations, as described below).

[0024] The controller 600 is communicatively and operably connected to the guide actuator 30, the sealing and cutting device 100, the sealing and cutting actuator 300, and the packaging assembly actuator 400, and controls the operation of these components in conjunction with the packaging operation. The controller 600 is communicatively connected to the operator interface 500 and (1) receives signals from the operator interface 500 representing inputs received by the operator interface 500, and (2) sends signals to the operator interface 500 to cause the operator interface 500 to output (e.g., display) information.

[0025] The packaging process, including the film sealing step of sealing the film after packaging, is shown in Figures 3A to 3F and will be described with reference to the flowchart shown in Figure 4. Furthermore, Figures 3A to 3F show partial cross-sectional views of the right side of the package, so the left side of the package and the film layer wrapped on the left side of the package are not shown.

[0026] As shown in block 410, the packaging process includes positioning the load L in the packaging area, with the circular guide 20 positioned in its upper position and the sealing and cutting device 100 holding the leading edge of the film F on the roll R. The control device 600 controls the conveyor C to move the load L on the pallet P through the infeed area 10a and into the packaging area of the packaging machine 1.

[0027] As shown in block 420, the wrapping process includes wrapping the load L substantially as shown in FIG. 3A. After the load L on the pallet P reaches the wrapping area, the control device 600 controls the guide actuator 30 to lower the circular guide 20 so that the packaging assembly 40 is at least partially vertically aligned with a portion of the load L. The control device 600 controls the sealing and cutting device 100 to hold the leading edge of the film F against the load L, while controlling the packaging assembly actuator 400 to rotate the packaging assembly 40 relative to the circular guide 20 and the load L. Rotating the packaging assembly 40 relative to the load L associated with the sealing and cutting device 100 causes the film F to be pulled through rollers of the film carriage and wrapped around the load L.

[0028] Once the film F is wrapped around the leading edge, the control device 600 controls the sealing and cutting device 100 to release the leading edge and move it away from the load L. Controller 600 continues to control packaging assembly actuator 400 to rotate packaging assembly 40, while controlling guide actuator 30 to move circular guide 20 vertically so that package L is wrapped with film F in a spiral pattern. During wrapping, controller 600 controls one or more pre-stretch actuators to rotate one or more pre-stretch rollers to pre-stretch film F as it is drawn through the rollers.

[0029] 3A shows a package L wrapped with one layer of film, labeled F1. Although the illustrated embodiment shows package L wrapped with a single layer F1, package L can be wrapped once, twice, or more times by packaging assembly 40, using any suitable pattern, such as a spiral pattern.

[0030] As shown in block 430, the film sealing step of the packaging process includes positioning a film sealing assembly near the package. Figure 3B illustrates the film sealing assembly 200 positioned near the package L after the package L has been wrapped with a layer of film F1. The film sealing assembly 200 may be positioned to engage with the film layer F1 or may be positioned adjacent to the film layer F1 without contacting it. The heating element guard 230 is in a shielded or lowered position, preventing exposure of any film to the heating element 210.

[0031] As shown in block 440, the film sealing step of the packaging process includes packaging the package L and film sealing assembly 200 with an inner film seal layer and an outer film seal layer. The inner film seal layer is illustrated in FIG. 3B as first film seal layer FS1. FIG. 3C shows the second film seal layer FS2 positioned by the packaging assembly so as to at least partially overlap the first film seal layer FS1. The second film seal layer FS2 need not extend completely around the package L; instead, it may extend only partially around the package to create an overlap with the first film seal layer FS1. The overlapping portions of the first and second film seal layers FS1 and FS2 may be positioned to be aligned with the film seal assembly 200. The first and second film seal layers FS1 and FS2 can be wrapped around the package so as to be perpendicularly aligned with each other, as shown in FIG. 3C.

[0032] As shown in block 450, the film sealing step of the packaging process includes positioning clamp 240 against outer film seal layer FS2. FIG. 3C shows clamp 240 moved to the clamping position and pressed against outer film seal layer FS2. Alternatively, clamp 240 can be positioned next to or near second film seal layer FS2 without contacting it. Next, heating element guard 230 is moved from the shielding position to the heating position to expose heating element 210 to first film seal layer FS1, as shown in FIG. 3C.

[0033] As shown in block 460, the film sealing step of the packaging process includes activating the heating element assembly 205 to seal the inner film seal layer FS1 to the outer film seal layer FS2. Figures 3D and 3E show the heating element assembly 205 moving from the sealing position toward the home position, where the heating element 210 seals the inner film seal layer FS1 to the outer film seal layer FS2, creating sealed layers FS1 / FS2. To seal the layers together, the heating element 210 presses the first and second film seal layers FS1 and FS2 into the clamp 240 and applies heat as the heating element 210 moves upward. As the heating element assembly 205 moves upward, the combined and sealed film layers FS1 / FS2 spring back into contact with the layer of film F1 wrapped around the load L, due in part to the pre-stretch applied to those portions of film F. As shown in the figure, the heating element 210 extends beyond the heating element guard 230 (i.e., to the right) when the guard 230 is in the heating position. This can be caused by the guard 230 moving up and to the left when moved to the heating position (i.e., to expose the heating element), or by moving the heating element 210 to the right (i.e., beyond the guard 230) when the guard 230 is moved to the heating position. Alternatively, the heating element guard 230 may not be movable and may always be positioned in the heating position so that the heating element 210 is always exposed.

[0034] 3F shows heating element assembly 205 after movement to the home position is complete, with film seal layers FS1 and FS2 sealed together and springing onto film layer F2. At this stage, clamp 240 can be moved to the release position to allow wrapped and sealed load L to be removed from the packaging area.

[0035] As shown in block 470, the packaging process includes cutting the outer film seal layer FS2. Although not shown in Figures 3A-3F, the cutter of the sealing and cutting apparatus 100 can cut the film either during or after the sealing process. For example, as the heating element assembly 205 moves from the sealing position to the home position and seals layers FS1 and FS2 together, the cutter simultaneously moves to cut film layer FS2 (i.e., the outermost layer of the film). The cutter can also include a leading edge film holder to hold the cut end of the film in preparation for wrapping the next load.

Claims

1. A packaging machine, A packaging machine frame; a guide attached to the packaging machine frame; a guide actuator operatively connected to the guide for moving the guide vertically relative to the packaging machine frame; a packaging assembly attached to the guide and including a film carriage; a packaging assembly actuator operatively connected to the packaging assembly to move the packaging assembly relative to the guide; a sealing and cutting device attached to the guide, the sealing and cutting device comprising: a heating element support; a heating element guard; a heating element disposed between the heating element support and the heating element guard, the heating element being movable between a sealing position and a home position to seal the two layers of film together; a clamp facing inwardly toward the heating element and positionable on an opposite side of the two layers of film from the heating element.

2. 2. The packaging machine of claim 1, wherein the heating element support is located on a first side of the heating element and the heating element guard is located on an opposite second side of the heating element.

3. 3. The packaging machine of claim 2, wherein the heating element guard is movable between a shielding position and a heating position, wherein in the shielding position the heating element guard prevents the heating element from engaging the first layer of film and wherein in the heating position the heating element guard allows the heating element to engage the first layer of film.

4. The packaging machine of claim 1 , wherein the clamp is movable between a release position and a clamped position.

5. A method for packaging a package using a packaging machine, comprising: positioning the package in a packaging area of a packaging machine; wrapping a package using a packaging assembly attached to a guide; positioning a sealing and cutting device comprising a heating element assembly adjacent the packaged package; packaging the load and heating element assembly with an inner film sealing layer; overlapping at least a portion of the inner film seal layer with the outer film seal layer; positioning the clamp relative to the outer film sealing layer so that the clamp faces inward toward the load; activating a sealing and cutting device to seal the inner film seal layer to the outer film seal layer; The method includes the step of cutting the outer film sealing layer.

6. The method of claim 5 , wherein the heating element assembly includes a heating element positioned facing away from the load, a heating element support, and a heating element guard.

7. 7. The method of claim 6, wherein the heating element guard is movable between a shielding position and a heating position, further comprising the step of moving the heating element guard to the heating position to expose the inner film sealing layer to the heating element.

8. Furthermore, moving the heating element assembly from the sealing position to a home position while the inner film sealing layer is exposed to the heating element; 8. The method of claim 7, further comprising pressing a heating element against the inner film seal layer and against a clamp to seal the inner film seal layer to the outer film seal layer.

9. 7. The method of claim 6, further comprising the step of positioning the heating element assembly so that the heating element support engages an outer layer of film wrapped around the load and the heating element guard engages an inner film sealing layer.

10. The method of claim 5 , wherein the inner film seal layer and the outer film seal layer are vertically aligned.

11. The method of claim 5 , wherein the clamp is positioned against an outer surface of the outer film seal layer.

12. 6. The method of claim 5, wherein the step of cutting the outer film seal layer occurs simultaneously as the sealing and cutting device seals the inner film seal layer to the outer film seal layer.

13. activating the sealing and cutting device to seal the inner film seal layer to the outer film seal layer; exposing the inner film seal layer to a heating element of a heating element assembly so that the heating element contacts the inner film seal layer and faces away from the load; 6. The method of claim 5, including the step of moving the heating element assembly from the sealing position to the home position while maintaining contact between the heating element and the inner film sealing layer.

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