Pallet Roping and Wrapping Apparatus with Segmented Film Guides
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Solution Overview
Problem
Existing pallet wrapping technologies fail to provide adequate air circulation and tamper-deterrent features for perishable goods and struggle with tear resistance, especially when using stretch film, which is not suitable for all types of palletized materials.
Innovation Solution
A pallet roping and wrapping apparatus utilizing multiple rolls of stretch film and guides to form overlapping ropes that secure the load without cutting the film, ensuring air circulation and tamper-deterrent properties by using differently colored secondary rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stretch film is used to wrap palletized loads, then load-holding strength is improved, but air circulation is blocked and tamper-deterrent properties are reduced
Solution Approach 1:
The continuous stretch film web is segmented into multiple parallel ropes by the guide system. This segmentation creates gaps between the ropes that allow air circulation while maintaining the load-holding strength through the distributed rope structure. The film is divided into discrete functional elements (ropes) rather than a continuous sheet, resolving the contradiction between strength and air flow.
Solution Approach 2:
The rope configuration creates a porous wrapping structure with inherent gaps between parallel ropes. This porous arrangement allows air to circulate through the wrapped load while the combined tension of multiple ropes maintains sufficient load-holding strength. The structure transforms from a solid continuous film to a porous rope array.
2Strength
If stretch film is used to wrap palletized loads, then load-holding strength is improved, but tamper-deterrent properties are reduced
Solution Approach 1:
Different colored stretch film rolls are used to create visually distinct parallel ropes in the wrapping. This color differentiation provides tamper-deterrent properties by making it obvious when the wrapping has been tampered with, as any disruption to the multi-color pattern would be immediately visible. The aesthetic property of color serves as a security feature while maintaining the mechanical strength function.
Solution Approach 2:
The use of multiple separate colored ropes instead of a single continuous film creates a segmented visual pattern that enhances tamper detection. If any rope is cut or moved, the disruption in the segmented color pattern is easily noticeable, providing inherent tamper-deterrent capability while maintaining load-holding strength through the distributed rope structure.
3Strength
If multiple secondary rolls and guides are added to form overlapping ropes, then tear resistance and tamper-deterrent capabilities are improved, but device complexity increases
Solution Approach 1:
The guide system performs multiple functions: it narrows the stretch film into ropes, positions multiple parallel ropes, and enables overlapping configurations. This single guiding mechanism accomplishes what would otherwise require multiple separate components, reducing overall device complexity while achieving enhanced tear resistance through the overlapping rope structure.
Solution Approach 2:
Multiple secondary rolls of stretch film are combined with the primary roll and guided through a unified guiding system to create an integrated overlapping rope structure. This merging of multiple film sources into a single coordinated wrapping operation enhances tear resistance through redundancy while using a compact guide assembly that minimizes added complexity.
4Strength
If multiple secondary rolls and guides are added to form overlapping ropes, then tear resistance is improved, but wrapping time increases
Solution Approach 1:
The multiple secondary rolls are fed simultaneously and continuously through the guides to form overlapping ropes in a single uninterrupted wrapping operation. This continuous multi-stream feeding process achieves enhanced tear resistance through overlapping ropes without requiring multiple sequential wrapping passes, thereby minimizing additional wrapping time.
Solution Approach 2:
The stretch film is pre-positioned on multiple rolls and fed through guides that pre-arrange the parallel ropes in the correct overlapping configuration before application to the load. This preliminary arrangement of the ropes ensures that the enhanced tear-resistant overlapping structure is achieved in one wrapping operation rather than requiring multiple adjustments or passes.
Data Source
AI summary
Pallet roping and wrapping machines having a plurality of spools of stretch film supported on one or more spools and guides that form ropes of stretch film without cutting. Specific implementations of guides include guides formed or rings and rollers. Positions of guides may be adjustable. A primary roll of stretch film may be positionally coupled to a primary spool core, and a plurality of secondary rolls of stretch film may be positionally coupled to one or more secondary spool cores. The wrapping machines may include a plurality of guides positioned to narrow the stretch film from the plurality of secondary rolls to form a plurality of ropes fully overlapping a web of the primary roll of stretch film when wrapped around a palletized load.