Multilayer Bale Wrap with Selective Melt Layer

Solution Overview

Problem

Existing bale wrapping materials, particularly tacky films, face issues with maintaining bale integrity due to insufficient tackiness, uniformity of tackiness, and self-adhesion to agricultural products, leading to premature unwrapping and contamination.

Innovation Solution

A bale wrap comprising a solid layer and a melt layer, where the melt layer is selectively melted using electromagnetic radiation to create a strong bond, eliminating the need for a tacky film and reducing self-adhesion, with the solid layer being transparent to the radiation and the melt layer containing an additive that absorbs energy to melt and seal the wrap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a tacky film is used to wrap the bale, then the film can be easily applied and adheres to itself, but the tackiness is insufficient to keep the tail fastened and the film adheres to the agricultural product causing loss of crop

Engineering Contradiction:

Improveease of applicationVSAvoidbale integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent changes the bonding mechanism from chemical tackiness to physical melting by introducing a melt layer with different thermal properties. The melt layer contains an additive that lowers its melting point relative to the solid layer, enabling it to melt and bond layers together when exposed to electromagnetic radiation, while the solid layer maintains its structural integrity and does not adhere to the crop.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure with two distinct layers: a solid layer that provides structural support and transparency to electromagnetic radiation, and a melt layer containing an additive that absorbs the radiation and melts to create bonds. This composite approach allows each layer to perform its specific function without the drawbacks of using a uniformly tacky film.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the entire area of the film is made tacky to ensure bonding, then bonding coverage is improved, but the level of tackiness is limited and the film adheres to the agricultural product

Engineering Contradiction:

Improvebonding strengthVSAvoidcrop loss due to adhesion

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies the local quality principle by confining the melting and bonding action to specific localized areas where electromagnetic radiation is applied, rather than making the entire film surface tacky. The melt layer only bonds where irradiated, leaving the rest of the film surface non-tacky and non-adhesive to the crop.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the bonding mechanism from chemical tackiness to physical melting by introducing a melt layer with different thermal properties. The melt layer contains an additive that lowers its melting point relative to the solid layer, enabling it to melt and bond layers together when exposed to electromagnetic radiation, while the solid layer maintains its structural integrity and does not adhere to the crop.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If electromagnetic radiation is used to melt the melt layer, then strong bonds are created between layers, but energy is required to operate the emitter

Engineering Contradiction:

Improvebond strengthVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the bonding mechanism from chemical tackiness to physical melting by introducing a melt layer with different thermal properties. The melt layer contains an additive that lowers its melting point relative to the solid layer, enabling it to melt and bond layers together when exposed to electromagnetic radiation, while the solid layer maintains its structural integrity and does not adhere to the crop.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition (melting) of the melt layer as the bonding mechanism. The additive in the melt layer causes it to melt at a lower temperature than the solid layer when exposed to electromagnetic radiation, creating a liquid state that bonds the layers together upon cooling, while the solid layer remains in solid state throughout the process.

Inventive Principle:

Principle #36Phase transitions

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

The solution provides a strong, non-tacky bale wrap that maintains bale integrity, minimizes contamination, and allows for easy removal without adhering to the product, enhancing safety and efficiency in wrapping and unwrapping processes.

Implementation Method 1

The additive within the melt layer may absorb the radiation and convert the radiation to heat

Methodology Applied

Scientific EffectAbsorption of electromagnetic radiation: Absorption (EM radiation)

Implementation Method 2

thereby melting the melt layer to join two adjacent solid layers

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

the solid layer may be free or substantially free of the additive, the EM radiation passes through the solid layer with minimal effect on the solid layer

Methodology Applied

Scientific EffectTransparency to electromagnetic radiation:

Data Source

PatentUS20230126009A1Multilayer Bale Wrap

Publication Date: 2023.04.27 TAMA GRP

AI summary

A bale wrapping system includes an emitter configured to generate electromagnetic radiation within an emitted spectrum and a wrap. The wrap includes a melt layer containing an additive absorbent to at least some electromagnetic radiation within the emitted spectrum and a solid layer substantially free of the additive.