Pallet Wrapping System With Overlapping Banded Film Plies
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Solution Overview
Problem
Existing pallet wrapping systems require excessive amounts of stretch film and time to wrap pallets, and often necessitate additional packaging materials like corner boards and strapping, while compromising load containment.
Innovation Solution
A pallet wrapping system featuring a support bar with parallel channels, guides that narrow the stretch film to form banded edges, and rollers to facilitate film passage, allowing for the creation of composite stretch films with layered banded plies that can be pre-stretched and wrapped efficiently around palletized loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional pallet wrapping systems are used, then load containment is achieved, but excessive amounts of stretch film and time are required
Solution Approach 1:
The stretch film is divided into multiple banded plies (first banded ply, second banded ply, third banded ply) with different widths and functions. The guides segment the film into distinct bands that are layered and overlapped to create a composite wrapping structure, allowing each band to serve specific containment purposes and reduce overall film consumption.
Solution Approach 2:
The patent creates a composite stretch film structure by layering multiple banded plies with different widths and properties. The first banded ply has a first width, the second banded ply has a second width, and the third banded ply has a third width, forming a composite material that optimizes both containment strength and film efficiency.
2Reliability
If additional packaging materials like corner boards and strapping are used, then load containment is improved, but device complexity and cost increase
Solution Approach 1:
The stretch film system performs multiple functions that were previously required separate packaging materials. The banded plies provide corner protection, load containment, and structural support simultaneously, eliminating the need for corner boards and strapping while maintaining or improving containment reliability.
Solution Approach 2:
The guides create localized banded edges with specific properties at critical locations. The first set of guides creates a first banded ply with specific width and strength characteristics, while the second set of guides creates a second banded ply with different characteristics, providing targeted reinforcement where needed without adding overall system complexity.
3Loss of substance
If higher pre-stretch levels are applied to reduce film usage, then film efficiency improves, but film tearing occurs
Solution Approach 1:
The layered composite structure of multiple banded plies distributes the stress and strain during pre-stretching. The overlapping bands and different ply widths create a reinforcement effect that prevents film tearing while allowing higher pre-stretch levels to be applied, improving film efficiency without sacrificing integrity.
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 system significantly reduces the amount of stretch film used and the time required for wrapping, while enhancing load containment and allowing for higher pre-stretch levels without film tearing, thus improving operational efficiency and cost-effectiveness.
Implementation Method 1
a plurality of guides configured to narrow the width of stretch film as the stretch film passes through the plurality of guides and form a banded edge on the stretch film
Implementation Method 2
a plurality of rollers extending parallel to the support bar, each roller of the plurality of rollers positioned adjacent to the plurality of guides and configured to facilitate passing the stretch film through the plurality of guides
Implementation Method 3
layer the banded stretch film onto unbanded stretch film to form an unbanded composite stretch film, and then pass the unbanded composite stretch film to the second set of guides to form a banded composite stretch film
Data Source
AI summary
A pallet wrapping system with at least two guides sets configured to narrow the width of stretch film to form a banded edge on the stretch film. A plurality of rollers is positioned adjacent to the plurality of guides to facilitate passing the stretch film through the plurality of guides. A first roll of stretch film positioned to pass stretch film to the first set of guides, and a second roll of stretch film positioned to receive banded stretch film from the first set of guides, layer the banded stretch film onto unbanded stretch film to form an unbanded composite stretch film, and then pass the unbanded composite stretch film to the second set of guides to form a banded composite stretch film having a banded first ply with a width equal to the first width and a banded second ply with a width equal to the second width.