Pallet Wrapping With Composite Stretch Films

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Solution Overview

Problem

Current pallet wrapping systems require excessive stretch film and time to secure loads, often using ancillary materials like corner boards and strapping, which increases costs and inefficiencies.

Innovation Solution

A method involving the formation of composite stretch films by narrowing and pre-stretching film through guides to create banded films with filaments, overlaying them to form stronger composite films, and wrapping these around pallets with gaps to reduce film usage and wrapping time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If traditional pallet wrapping methods are used with continuous stretch film, then load containment is achieved, but the amount of stretch film consumed is excessive and wrapping time is increased

Engineering Contradiction:

Improvestretch film consumptionVSAvoidload containment

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The stretch film is divided into multiple discrete bands instead of using continuous film. Each band is pre-stretched to high elongation (at least 275%) and applied as a separate segment around the palletized load. The bands are positioned with gaps between them, creating a segmented wrapping pattern that reduces overall film consumption while maintaining load containment through the cumulative effect of multiple tensioned bands.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical parameters of the stretch film by pre-stretching it to at least 275% elongation before application. This high pre-stretch transforms the film into a high-tension band that can contain load with less material. The film is also narrowed in width and overlaid to create composite bands with enhanced strength properties, changing the mechanical parameters of the wrapping material.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional pallet wrapping methods are used with continuous stretch film, then load containment is achieved, but the time required to wrap each pallet is increased

Engineering Contradiction:

Improvewrapping speedVSAvoidload containment

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The stretch film bands are pre-stretched to high elongation (at least 275%) and prepared in advance before the wrapping process. This preliminary action of pre-stretching and positioning the bands allows for faster application during the actual wrapping operation, as the bands are already prepared and can be quickly applied to the palletized load without requiring continuous film feeding and stretching during the wrapping process.

Inventive Principle:

Principle #10Preliminary action

3Loss of substance

If stretch film width is reduced to decrease film consumption, then material usage is optimized, but the strength and containment capability of the wrapping is compromised

Engineering Contradiction:

Improvestretch film usageVSAvoidfilm strength

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The patent creates composite stretch film bands by overlaying multiple layers of stretched film. The second stretched film is positioned over the first stretched film with their filaments interleaved, creating a composite structure with enhanced strength properties. This composite construction allows the use of narrower individual bands while maintaining or increasing overall wrapping strength through the combined effect of multiple layered films.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes the curvature and three-dimensional geometry of the wrapped load by applying bands at different orientations and positions. The bands are wrapped around the palletized load in a pattern that conforms to its shape, with gaps positioned to allow air circulation while maintaining containment. This geometric approach distributes the containment force efficiently across the load surface.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

This method significantly reduces the amount of stretch film needed and time required to wrap pallets while maintaining load containment, enhancing film strength and air circulation.

Implementation Method 1

pre-stretching each of the at least two composite stretch films by at least 275%

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11801953B2Pallet wrapping system with overlapping bands

Publication Date: 2023.10.31 ALLIED PACKAGING CORP

AI summary

A method of wrapping a palletized load includes forming at least two composite stretch films, wrapping each of the composite stretch films around the palletized load, and leaving a gap between the first composite stretch film and the second composite stretch film as the composite stretch films are wrapped around the palletized load. Forming the composite stretch films includes narrowing stretch film from a first spool to create a first banded stretch film with a first width, narrowing stretch film from a second spool to create a second banded stretch film with a second width smaller than the first width, and overlaying the second banded stretch film on the first banded stretch film, with the second banded stretch film positioned between the top edge and bottom edges of the first banded stretch film. The gap may have a width that is equal to or larger than the first width.