Coreless Flexible Film Packaging System
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Solution Overview
Problem
Flexible films packaged on cores often suffer from permanent imprints or embossments due to film tension, sharp film edges, adhesive strips, and core surface defects, leading to waste and inefficiency, and existing solutions are costly and inefficient.
Innovation Solution
A coreless flexible film packaging system where the film is wound about itself within a containment cylinder with a film feed slot, allowing self-winding without external force, using a containment cylinder made from materials like cardboard or plastics, and optionally with caps and a seal strip for packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If film is wound onto a rigid core using adhesive strips, then the film can be properly contained and wound, but permanent imprints or embossments are created on the film surface
Solution Approach 1:
The invention removes the rigid core from the packaging system entirely, extracting the source of imprinting pressure. The film is wound onto itself without requiring a rigid supporting carrier, thereby eliminating the mechanical contact that causes embossments while maintaining proper film containment through the containment bag structure.
Solution Approach 2:
The invention replaces the reusable rigid core with a disposable containment bag that is discarded after use. This single-use containment structure prevents imprinting while avoiding the need for expensive core manufacturing and customization, aligning with the principle of using inexpensive, disposable objects to solve a problem.
2Manufacturing precision
If chamfering is applied to the leading end of the film, then the imprint severity is reduced, but achieving uniform angled cut is difficult and costly
Solution Approach 1:
Instead of modifying the film edge through chamfering, the invention extracts the problematic interaction between the film leading end and the rigid core by eliminating the core entirely. This avoids the need for complex chamfering operations while still preventing imprinting at the film edge.
3Reliability
If cores are customized with milled depressions or slits, then film adhesion and winding are improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The invention removes the core entirely, eliminating the need for costly customization operations such as milling depressions or creating slits. Film adhesion is achieved differently through the containment bag structure rather than through core modifications.
Solution Approach 2:
The reusable, customized core is replaced with an inexpensive, disposable containment bag that requires no complex manufacturing. This single-use structure provides the necessary containment and adhesion functions without the high costs associated with precision core manufacturing.
4Strength
If rigid cores are used for film packaging, then film tension and containment are maintained, but packaging waste and material usage increase
Solution Approach 1:
The invention extracts the rigid core from the system, eliminating the source of packaging waste. The film is contained and tension is maintained through the flexible containment bag structure, which uses significantly less material than traditional rigid core packaging.
Solution Approach 2:
The rigid core is replaced with a flexible containment bag made from thin film material. This flexible structure maintains the necessary containment and tension while using minimal material, thereby reducing packaging waste and environmental impact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces packaging waste and material usage, eliminates embossments, and provides a cost-effective, environmentally friendly solution for packaging flexible films, enhancing the aesthetic and functional quality of the final product.
Implementation Method 1
a supply of flexible film wound about itself to form a film roll having a central cylindrical cavity... wherein said flexible film is self-winding
Data Source
Figure 1~5
AI summary
A coreless flexible film packaging system is disclosed. The system includes: (i) a containment cylinder (30) including a cylindrical wall (35) defining first and second cylinder end apertures (45, 50) and an interior film containment area (52); (ii) a film feed slot (55) in the cylindrical wall (35) extending longitudinally along the containment cylinder (30); and (iii) a supply of flexible film (15) wound about itself to form a film roll having a central cylindrical cavity (25), said roll including a leading end (18) and a terminal end (19) and contained within the interior film containment area (52). A coreless containment package (10) and a method for packaging a flexible film are also described.