Mulch film punching machine

Abstract

The present invention relates to a mulch film punching machine designed to pre-punch holes in mulch film, optimizing its use for agricultural applications This machine addresses challenges in traditional manual punching methods, providing 5 precise, efficient, and consistent hole spacing that enhances planting accuracy, irrigation efficiency, weed control, and crop protection. Key components include an online machine body structure, front and back dancing units for maintaining film tension, an indexing roller assembly for precise film advancement, a pneumatic punching station for high-speed operation, and an electric control panel for customizable settings. The punching tools are interchangeable, allowing adaptability to various crop spacing needs and film types. This machine enables rapid production of pre-holed mulch film, significantly reducing labor requirements while delivering uniformity, durability, and adaptability for different agricultural uses. The result is improved crop growth and yield potential with reduced water usage and effective weed suppression.

Description

[0001] MULCH FILM PUNCHING MACHINE

[0002] Field of the Invention:

[0003] The present invention relates to agricultural machinery and, more specifically, to a mulch film punching machine designed for creating perforations or punch holes in agricultural mulch films. Mulch films are commonly used in farming practices to cover soil, regulate temperature, conserve moisture, and control weed growth, which promotes better crop yields. The invention is intended to facilitate efficient, uniform punching of holes in mulch films, enabling precise planting and growth of crops by allowing the appropriate amount of soil exposure and aeration beneath the film. The mulch film punching machine offers a solution for high-speed, accurate punching operations, which can be customized to meet varying agricultural requirements, and is suitable for large-scale farming applications.

[0004] Background of the Invention:

[0005] In modern agriculture, mulch films are widely used to enhance crop growth by controlling soil temperature, conserving moisture, and suppressing weeds. These thin, plastic films are laid over the soil, forming a barrier that improves soil and plant health, leading to higher crop yields and reduced dependency on herbicides. While mulch films provide several agronomic advantages, one of the critical challenges faced by farmers is creating uniform, precise holes in the film to facilitate planting, water delivery, and plant growth. Traditionally, farmers have used manual methods, such as puncturing the film with a pipe or similar tool, to make holes in mulch films. However, these native methods are time-consuming, labor-intensive, and prone to damaging the film, resulting in tears and uneven hole sizes that diminish the film's effectiveness.The limitations of manual punching methods highlight the need for an automated, reliable solution to create precise holes in mulch films, ensuring consistency and uniformity. The present invention addresses this need by introducing a mulch film punching machine, which offers key benefits over manual and native methods. This machine allows for automated, controlled punching of holes at predetermined intervals and sizes, delivering an advanced solution for modern agricultural practices.

[0006] To overcome above limitation, the present invention provide a sophisticated, efficient solution for preparing mulch films with prepunched holes, enabling farmers to adopt advanced agricultural practices that are both labor-saving and yield-enhancing. By addressing the limitations of traditional methods, this mulch film punching machine stands to make a significant impact on crop production, resource conservation, and sustainability in agriculture.

[0007] Object of the Invention:

[0008] The primary object of the invention is to provide an efficient and reliable mulch film punching machine that enables farmers to create precise, uniformly spaced holes in mulch films for planting, irrigation, and weed control. This machine overcomes the challenges associated with traditional manual punching methods, which are time-consuming, labor-intensive, and often lead to film damage, thereby enhancing the efficiency of agricultural practices that use mulch films.

[0009] Specific objectives of the invention include:

[0010] 1. To Enable Precise and Uniform Hole Punching: The machine is designed to punch holes at consistent, pre-determined intervals and sizes. This ensures that each plant can bepositioned accurately within the planting bed, facilitating optimal plant spacing and promoting uniform growth. The precision in hole placement reduces competition between plants and enhances overall crop yield by allowing each plant access to adequate nutrients, sunlight, and space.

[0011] 2. To Improve Irrigation Efficiency through Targeted Water Delivery:

[0012] The invention aims to align punched holes with drip irrigation systems, directing water precisely to each plant’s root zone. This targeted irrigation approach minimizes water wastage due to runoff or evaporation, thus promoting efficient water usage. By ensuring water is directly absorbed by the plant roots, the machine supports sustainable farming practices and reduces irrigation costs.

[0013] 3. To Facilitate Weed Control and Minimize Herbicide Usage:

[0014] One of the objectives of this invention is to assist in weed management by ensuring that the mulch film acts as a complete barrier except where the holes are punched. This barrier prevents sunlight from reaching the soil surface beneath the mulch, thereby inhibiting weed germination and growth. The punched holes allow plant seedlings to emerge without compromising the film’s weed control properties, reducing reliance on chemical herbicides and labor for manual weeding.

[0015] 4. To Provide Soil Temperature Regulation for Enhanced Plant Growth:

[0016] The mulch film punching machine is designed to maintain the thermal properties of the mulch film, creating a controlled soil environment beneath it. The punched holes allow for optimalair circulation while maintaining a consistent soil temperature, which is critical for healthy root development and rapid plant growth. By stabilizing soil temperatures, this invention promotes better crop health and faster maturity.

[0017] 5. To Reduce Labor and Time Requirements in Crop Preparation:

[0018] This invention aims to reduce the labor-intensive process of manually creating holes in mulch films. By automating the punching process, the machine significantly cuts down the time and labor required to prepare mulch films for planting. This results in a streamlined field preparation process, allowing farmers to prepare larger areas for planting more efficiently and at a lower cost.

[0019] 6. To Enhance Crop Protection and Reduce Pest Exposure:

[0020] The invention is designed to create a barrier against soilborne pests and diseases. By limiting soil exposure through precisely placed holes, the machine helps to protect seedlings from pathogens and pests that may be present in the soil. This protection reduces the need for pesticide applications, promoting healthier crop growth and a reduced risk of crop loss due to disease.

[0021] 7. To Accommodate Diverse Crop Types through Customizable Settings:

[0022] Another objective of the invention is to offer versatility in hole size and spacing to meet the requirements of various crops. The machine is capable of adjusting hole configurations to match the specific planting and spacing needs of different crops, making it adaptable for a wide range of agricultural applications, from vegetables to high-value crops. Thiscustomization provides farmers with flexibility in crop planning and maximizes the machine's utility across different planting seasons.

[0023] 8. To Provide a Durable and User-Friendly Agricultural Tool:

[0024] The invention is intended to be a durable, easy-to-operate machine that can withstand agricultural environments. The design focuses on providing ease of use, minimal maintenance, and high durability, ensuring that farmers of all skill levels can operate it effectively. The robust build and simplicity in operation make it a reliable tool for both small- scale and large-scale farming applications.

[0025] Through these objectives, the invention seeks to provide an advanced solution for improving the efficiency, precision, and effectiveness of agricultural practices involving mulch films. By addressing the limitations of manual methods and offering significant benefits for crop growth and resource management, this mulch film punching machine aligns with sustainable agricultural goals, supporting farmers in achieving higher yields, reducing costs, and enhancing overall crop quality.

[0026] Statement of the Invention:

[0027] The present invention, titled "Mulch Film Punching Machine," is a specialized agricultural device designed for the efficient, precise punching of holes in mulch films. This machine is intended primarily for use by mulch film manufacturers, allowing them to create prepunched holes as per the specific requirements of farmers. The machine significantly improves on traditional manual methods, where farmers previously created holes using a pipe — a process that was not only time-consuming but also often led to film damage. Bydelivering accurately punched, consistently spaced holes, the Mulch Film Punching Machine ensures enhanced planting accuracy, optimized irrigation, effective weed control, and labor savings, among other agronomic benefits.

[0028] Distinguishing Features and Advantages of the Invention:

[0029] • Enhanced Speed and Accuracy: The machine performs punching operations faster and more accurately than other existing machines, improving production rates and hole quality.

[0030] • Minimized Downtime: This invention allows for the adjustment of machine size and settings even during operation, reducing downtime. Unlike competitor machines, which may require full shutdowns for size changes or adjustments, this machine is designed to be adaptable with minimal interruptions, reducing production loss.

[0031] • Customizable Hole Sizes and Patterns: The punching mechanism and adjustable components allow manufacturers to meet the specific hole size and spacing requirements for various crop types, providing a versatile solution for farmers’ diverse planting needs.

[0032] The Mulch Film Punching Machine, with its advanced design and operational efficiency, offers a transformative solution for mulch film production. By automating and enhancing the precision of the holepunching process, this invention supports farmers in achieving higher productivity, efficient irrigation, effective weed control, and improved crop health, thereby aligning with the goals of sustainable agriculture.

[0033] BRIEF DESCRIPTION OF THE DRAWINGSThe structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments.

[0034] Detailed description of the inventions

[0035] Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

[0036] Fig.1 represents the line diagram of the present invention MULCH FILM PUNCHING MACHINE

[0037] DETAILED DESCRIPTION OF THE INVENTION:

[0038] The present invention, titled "Mulch Film Punching Machine," provides an advanced and efficient means for punching precise, uniform holes in mulch films. This machine is primarily designed for use by mulch film manufacturers, enabling them to produce prepunched mulch films according to the specific requirements of farmers. This document provides a detailed description of each key component and its function in the operational flow of the machine. As shown in Fig.1 , in the Mulch Film Punching Machine, the machine body structure (1) forms the primary support framework, housing all essential components and mechanisms. Designed fordurability, this modular structure provides a stable base for continuous operation and facilitates easy adjustment for handling mulch films of various sizes and thicknesses. The structure’s robust design minimizes vibration and enhances punching accuracy and stability, ensuring smooth operation under heavy-duty use. Positioned at the entry of the machine, the front linear dancing unit (2) guides the mulch film as it is fed into the system. This component maintains proper film tension, ensuring that the film remains flat and aligned as it advances through the machine. By controlling the initial tension, this unit prevents film sagging or misalignment, which are critical for achieving precise hole placement. The indexing roller assembly (3) is responsible for controlling the stepwise movement of the mulch film through the machine. By advancing the film at specific intervals, it ensures that each section aligns perfectly with the punching mechanism. The assembly is synchronized with the punching station, so each movement positions the film exactly for the next punch, achieving consistent hole spacing. This precise indexing minimizes errors and ensures uniformity across the entire length of the film. Serving as the central control hub, the electric controlling panel box (4) houses the electronic interface for managing various machine settings. Operators can set punching speed, adjust hole spacing, regulate film tension, and control the pressure settings of the pneumatic system. This panel is equipped with user-friendly controls, allowing easy customization to suit different agricultural needs and crop types. Additionally, the panel includes safety features and diagnostic indicators for monitoring machine performance and troubleshooting. Located at the exit of the machine, the back dancing assembly (5) controls the tension of the film as it moves out of the punching area. This assembly prevents wrinkles orfolds from forming in the film, maintaining a smooth and even surface as it exits the machine. Consistent tension at this stage ensures that the punched holes remain uniform and prevents damage to the film. The punching station (6) is the core functional area where the actual hole-punching takes place. This station is designed for high-speed punching and equipped with advanced mechanisms that deliver clean and accurate cuts without damaging the film. The punching station’s alignment with the indexing roller assembly ensures that each punch is precisely positioned on the film. The station’s design allows for rapid punching rates, making it suitable for large-scale mulch film production. The punching set (7) comprises interchangeable tools that create holes of varying sizes and patterns. These tools are adjustable, allowing the machine to meet specific crop planting requirements. By modifying the punch sizes and patterns, the machine can cater to different plant spacing needs, making it versatile for various agricultural applications. The modular design of the punching set enables quick and easy tool changes, reducing downtime and enhancing production flexibility. The guide roller set (8) assists in maintaining proper alignment and smooth passage of the film as it progresses through each station of the machine. These rollers help to direct the film accurately, reducing lateral movement or misalignment that could affect punching precision. The rollers are positioned strategically to support the film without causing tension imbalances, ensuring that each segment remains in line for precise punching. This adjustable set of pressure rollers (9) applies controlled pressure on the film as it moves through the punching station. The sliding mechanism allows these rollers to adapt to varying film thicknesses, applying consistent pressure for stable punching operations. The pressure roller sliding set enhancesthe film’s stability, preventing slippage or misalignment, which contributes to accurate, consistent punching results. The pneumatic pressure regulator (10) controls the air pressure applied to the punching tools, ensuring consistent punching force across varying film thicknesses. This setup allows for precise, controlled punching operations, avoiding excessive pressure that could tear or distort the film. The pneumatic system is essential for maintaining consistent punch quality, regardless of variations in film density. The nip roller assembly (11) provides a steady grip on the mulch film, pulling it through the machine in coordination with the indexing roller. This assembly ensures a continuous, stable forward movement of the film, critical for aligning each segment accurately for the punching operation. The nip rollers work in tandem with the indexing roller assembly, maintaining film tension and ensuring that each punch occurs exactly where intended. The punching tool (12) is the component that directly interacts with the film to create the holes. Designed for durability and precision, the tool is sharp enough to produce clean cuts without leaving jagged edges, preserving the integrity of the film. The punching tool is easily interchangeable, allowing operators to adjust hole size and shape as per specific crop requirements. This flexibility in design ensures that the machine can cater to a wide range of agricultural needs.

[0039] In the present invention Operational Flow as follow:

[0040] 1. Film Infeed and Tension Control:

[0041] The mulch film enters the machine through the front linear dancing unit, where it is initially aligned and tensioned. Thisinitial tensioning ensures that the film remains flat and smooth as it moves into the indexing roller assembly.

[0042] Precise Indexing and Alignment for Punching:

[0043] The indexing roller assembly advances the film at precise intervals, bringing each section into alignment with the punching station. The electric controlling panel allows operators to set the desired spacing and speed, ensuring each punch is executed accurately.

[0044] Punching Process:

[0045] Once the film section is aligned, the punching station activates, with the punching tool creating holes at designated points. The pneumatic pressure regulator ensures that the punching force is consistent, preventing film tearing or distortion.

[0046] Film Exit and Final Tension Control:

[0047] After the holes are punched, the film exits the punching station and moves through the back dancing assembly, which maintains final tension. This stage smooths out any residual slack or wrinkles, preserving the film’s quality as it exits the machine.

[0048] Output Collection:

[0049] The punched mulch film is collected and rolled for storage or packaging, ready for dispatch to agricultural users.This invention significantly improves the efficiency and accuracy of the mulch film punching process, providing an essential tool for mulch film manufacturers to meet farmers’ specific requirements. The machine’s modular design, precision components, and control systems enable high-quality production with reduced labor and time, benefiting both manufacturers and end-users in agricultural applications.

[0050] 13

Claims

1. Claims1. A mulch film punching machine, comprising:o An online machine body structure configured to provide structural support and house the primary components of the machine;o A front linear dancing unit positioned at the film entry point, configured to maintain tension and alignment of the mulch film during its advancement through the machine;o An indexing roller assembly for controlling the stepwise movement of the mulch film, advancing the film in precisely calibrated intervals to align with a punching station;o An electric controlling panel box equipped to manage operational settings, including punching speed, hole spacing, and pressure adjustments;o A back dancing assembly for regulating the tension of the film as it exits, preventing wrinkles and folds; o A punching station configured for high-speed, accurate punching, designed to deliver uniform hole placement across the film without damaging the surrounding material;o A punching set comprising interchangeable tools adjustable to create holes of varying sizes and patterns, catering to different agricultural requirements; o A guide roller set configured to align and direct the mulch film through each stage of the machine, maintaining tension and alignment;o A pressure roller sliding set with adjustable rollers, designed to apply controlled pressure on the film, maintaining stability during punching;o A pneumatic pressure regulator set to control the air pressure applied to the punching tools, adaptable to various mulch film thicknesses;o A nip roller assembly that grips and pulls the mulch film through the machine, coordinating with the indexing roller assembly to ensure each punch is executed at precise intervals;o A punching tool designed for sharp, durable performance to achieve clean, accurate cuts, with interchangeable configurations for varying hole sizes and shapes.

2. The mulch film punching machine of claim 1, wherein the online machine body structure is modular, allowing easy adjustments for different mulch film sizes and thicknesses.

3. The mulch film punching machine of claim 1, wherein the front linear dancing unit maintains tension to prevent film sagging and misalignment, ensuring precise hole placement.

4. The mulch film punching machine of claim 1, wherein the indexing roller assembly is synchronized with the punching station to provide consistent, repeatable punching at designated positions on the film.

5. The mulch film punching machine of claim 1, wherein the electric controlling panel box further includes safety features and diagnostic indicators for real-time monitoring and troubleshooting of machine performance.

6. The mulch film punching machine of claim 1, wherein the back dancing assembly ensures uniform film tension at the exit, preventing wrinkles or folds that could affect hole placement quality.

7. The mulch film punching machine of claim 1, wherein the punching station is engineered for high-speed operation, providing clean cuts with minimal risk of film damage or deformation.

8. The mulch film punching machine of claim 1, wherein the punching set is modular and adjustable, allowing the creation of varied hole configurations to accommodate specific crop spacing requirements.

9. The mulch film punching machine of claim 1, wherein the guide roller set aligns and directs the mulch film with high precision, reducing lateral movement that could impact punching accuracy.

10. The mulch film punching machine of claim 1, wherein the pressure roller sliding set applies controlled pressure on the film, adapting to variations in film thickness to maintain optimal punching conditions.

11. The mulch film punching machine of claim 1, wherein the pneumatic pressure regulator set provides adjustable pressure control, ensuring consistent punching force across various film thicknesses without tearing or overcompression.

12. The mulch film punching machine of claim 1, wherein the nip roller assembly coordinates with the indexing roller assembly to advance the film steadily, ensuring each punch occurs at the exact designated position.

13. The mulch film punching machine of claim 1, wherein the punching tool is interchangeable and configurable, allowing rapid adaptation to different hole sizes and patterns to meet diverse agricultural needs.

14. A method for operating the mulch film punching machine of claim 1 , comprising the steps of:• Feeding the mulch film into the machine through the front linear dancing unit to establish initial tension and alignment; • Advancing the film stepwise via the indexing roller assembly, aligning each film segment with the punching station;• Configuring the electric controlling panel box to set the desired hole spacing, punching speed, and pneumatic pressure;• Executing the punching operation at the punching station, wherein holes are created uniformly across the film according to preset spacing;• Regulating the film tension as it exits the machine through the back dancing assembly, ensuring smooth, wrinkle-free output;• Collecting the punched mulch film for subsequent processing or storage.Dated 25thDecember 2024PARMAR NILESHKUMAR RAMESHBHAI APPLICANT AND INVENTORTo,The Controller of PatentsThe Patent Office, at Mumbai17

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