Segmented Film Wrap Profile for Palletized Rolled Paper Load Stability
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Solution Overview
Problem
Rolled paper products packaged in underhung or partially underhung configurations on pallets are unstable during shipping, leading to potential damage and increased costs due to the need for thicker films and higher tensions, which can result in film tears and compression issues.
Innovation Solution
A method of securing rolled products on pallets using a specific wrap profile of plastic film that reduces the quantity of film needed while enhancing load stability, involving multiple layers of film with varying tensions and locations to connect the load with the pallet and neighboring layers, thereby creating a more stable footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If thicker films and higher tensions are used to secure underhung loads, then load stability is improved, but film tears and compression issues occur
Solution Approach 1:
The wrap profile is segmented into multiple distinct layers (first layer, second layer, third layer) with different functions. The first layer provides base securing, the second layer adds reinforcement, and the third layer provides final stabilization. This segmentation allows each layer to be optimized for its specific function rather than relying on a single thick film layer, thereby achieving load stability without excessive tension that causes film tears and compression.
Solution Approach 2:
Different layers of the wrap profile apply different tensions and provide different levels of containment at different locations and heights. The first layer wraps around the entire load-pallet assembly, the second layer wraps around specific portions, and the third layer provides additional containment. This local differentiation of film properties and application locations enables effective stabilization without the need for uniformly high tension throughout, preventing film tears and compression issues.
2Stability of the object's composition
If more film is used to secure underhung loads, then load stability is improved, but cost and waste increase
Solution Approach 1:
The wrap profile divides the film application into three distinct layers, each serving a specific stabilization function. This segmentation allows for efficient use of film by applying it only where needed for stability, rather than using excessive amounts uniformly. The first layer provides base securing with moderate film quantity, the second layer adds targeted reinforcement, and the third layer provides final stabilization, collectively achieving load stability with optimized film usage that reduces waste and cost.
Solution Approach 2:
The wrap profile applies film in a controlled, partial manner rather than excessive coverage. Each layer is applied to specific portions of the load where stabilization is needed, rather than uniformly covering the entire load with excessive film. This partial action approach achieves the necessary load stability while minimizing film consumption, thereby reducing cost and waste.
3Stability of the object's composition
If higher film tension is applied to stabilize underhung loads, then load stability is improved, but film tears occur
Solution Approach 1:
The wrap profile segments the tension application across three separate layers. The first layer applies moderate tension for base securing, the second layer applies controlled tension for reinforcement, and the third layer applies final stabilization tension. This segmentation distributes the stabilizing force across multiple applications rather than requiring one high-tension wrap, thereby achieving load stability while maintaining film integrity and preventing tears.
Solution Approach 2:
Different layers of the wrap profile apply different levels of tension at different locations and stages. The first layer applies lower tension around the entire assembly, the second layer applies controlled tension to specific portions, and the third layer provides final stabilization with appropriate tension. This local differentiation of tension levels enables effective load stabilization without applying excessive tension that would cause film tears, thereby preserving film integrity.
Data Source
AI summary
Aspects of the present disclosure relate to cargo assemblages that may include containers of rolled products stacked on pallets secured thereto with film and methods of producing such cargo assemblages. The load may include containers of absorbent paper product arranged in stacked layers from a bottom layer of containers to a top layer of containers. A film may be applied to connect the load with the pallet and to connect neighboring stacked layers together. The film may be wrapped around the pallet and/or layers of containers with a wrap profile having different characteristics, such as for example, containment forces; tensions; numbers of layers, and/or locations of layers with respect to the load, the pallet, and/or each other.