Helical Stretch Film Packaging for Variable Bundle Sizes
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Solution Overview
Problem
Existing packaging methods for stretch film bundles are limited in variability, requiring machine conversion for different container sizes and lacking flexibility in forming larger packaging units and pallet layers.
Innovation Solution
A method for multi-layer helical wrapping of articles or piece goods using stretchable film applied under tension, with optional spiral application and perforations to allow for variable bundle sizes, enabling continuous production of different pack formations without machine changes, and allowing for mixed container sizes in pallet layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If shrink film is used to hold containers together, then mechanical stability for handling and stacking is achieved, but high energy input is required for heat treatment
Solution Approach 1:
The patent transitions from thermal processing (shrink film requiring heat treatment) to mechanical processing (stretch film applied under tension). This parameter change eliminates the need for heat treatment while maintaining package stability through elastic tension of the stretched film.
2Loss of substance
If stretch film packages are made with very thin films, then film consumption is significantly reduced, but package stability may be compromised
Solution Approach 1:
The patent applies stretch film under controlled tension to achieve the desired package stability. By controlling the application parameters (tension, stretch ratio, layer configuration), thin films can provide sufficient stability without requiring thick or excessive amounts of material.
3Manufacturing precision
If packaging machines are set up for defined bundle sizes, then consistent package dimensions are achieved, but flexibility to produce different package sizes is limited
Solution Approach 1:
The patent introduces variable control parameters into the packaging process, allowing the machine to dynamically adjust between different package sizes. This includes variable stretch ratios, adjustable film application patterns, and flexible bundle configuration options that enable production of multiple package sizes without retooling.
Solution Approach 2:
The packaging machine is designed with universal capabilities to handle multiple package configurations. By implementing adjustable parameters and flexible film application mechanisms, a single machine can produce various bundle sizes and arrangements, eliminating the need for dedicated setups for each package type.
4Manufacturing precision
If hot wire cutting is used to separate bundles, then clean cuts between containers are achieved, but interference with the packaging process and reduced productivity occur
Solution Approach 1:
The patent replaces the hot wire cutting mechanism with an alternative separation method that does not interfere with the continuous packaging process. This could include mechanical separation at pre-defined weak points in the film, perforation followed by manual separation, or design of the film application pattern that naturally creates separable sections without requiring cutting intervention.
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
Enables flexible production of various pack sizes and mixed container arrangements, reducing film consumption by up to 50%, eliminating the need for heat treatment, and enhancing pallet stability and packing density.
Implementation Method 1
stretchable film applied under tension
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
The invention relates to a method for packaging articles, piece goods or containers (12) and/or for grouping the articles, piece goods or containers (12) to form packages (32) via the multi-layered helical wrapping of the articles, piece goods or containers (12) transported in a conveying direction (18) in an article or piece goods flow (14) and/or of the groupings about a longitudinal axis running through the article or piece goods flow (14) by means of flexible film applied under tension. In this way, a film package (30) of the articles, piece goods or containers (12) continuously moving in the conveying direction (18) is formed, which is provided with perforations in planes perpendicular to the longitudinal axis and/or which is cut between successive articles, piece goods, containers (12) or article, piece goods or container pairs or groups of multiple articles, piece goods or containers (12) conveyed next to one another, forming packages (32) conveyed behind one another. The packages (32) that are separated from one another are sorted in downstream transport and/or handling stations (34), and assembled, palletised and/or stacked in layers, wherein the film packaging (30) is cut at respective defined and/or variable distances to preceding cutting points in order to separate packages (32) of variable sizes or packages (32) having a variable number of articles, piece goods or containers (12) assembled with film.