Abstract:
The present invention is directed to a method of wrapping a rounded bale, and more specifically, to a method of wrapping that fully envelopes the rounded bale and ties at either end so as to maintain the integrity of the bale during, pick-up, transport, and storage. In one embodiment, the wrap ties at either end. In other embodiments, the integrity of the bale is enhanced in that the wrap clings to the surface as well as the ends of the bales. The wrap may comprise elastomeric material to facilitate clinging and conformance to the bales.

Description:
TECHNICAL FIELD  
       [0001]     The present invention generally relates to a method of wrapping a rounded bale, and more specifically to a method of wrapping that fully envelopes the rounded bale so as to maintain the integrity of the bale during, pick-up, transport, and storage.  
       BACKGROUND OF THE INVENTION  
       [0002]     Netting is often prepared either by knitting, weaving, or extrusion. Knitted netting typically comprises a plurality of threads oriented in a first direction and being essentially equal spaced from one another, and having wefts oriented in a second direction which is perpendicular to the first direction, the threads and wefts being interlocked and secured. Nets may be prepared by a Racshel knitting method, a process in which the threads are attached to knitting elements that comprise two needles and knock-over comb bars positioned opposite to one another, and comprising ground guide bars, pattern guide bars and stitch comb bars. An example of such a knitted net is described in European Patent No. 0 723 606, to Fryszer, et al., incorporated herein by reference.  
         [0003]     Knitted netting has a variety of end use applications, including but not limited to hay bale wrap, cargo wrap, netted bags, and drainage nets. Racshel knitted nets have been used for round hay bale wrapping as disclosed in U.S. Pat. No. 4,569,439 and No. 4,570,789, both incorporated herein by reference. Twines and films have also been used to tie up hay bales; however the twine usually cuts in the bale and doesn&#39;t provide ample support to keep the bale tidy and neat. Further, the twining of the rolled bales with the binding yarn is relatively time-consuming and requires substantial manual labor. Film covers don&#39;t allow the rolled bale enough air circulation, which lead to the growth of mold and eventually rotting. The Racshel knitted net doesn&#39;t cut into the hay bale and allow ample amount of air to circulate through the bale. Although Racshel knitted netting has several advantages over twine and plastic film, the netting tends to shrink in overall width when pulled lengthwise. Due to the shrinkage in the width, the outer most edges of the hay bale are left exposed, which can cause the bale to become disheveled during pick-up and transport. Further, the wrapping process usually involves wrapping the bale three to four times around to ensure the bale material, whether it be hay or straw, is properly covered, as well as to ensure that the wrap is properly secured around the bale.  
         [0004]     There is an unmet need for a net that will provide maximum coverage with one wrap to a rounded bale maintaining the rolled bale&#39;s compact shape during pick-up and transport, as well as during storage.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention is directed to a method of wrapping a rounded bale, and more specifically, to a method of wrapping that fully envelopes the rounded bale and ties at either end so as to maintain the integrity of the bale during, pick-up, transport, and storage. In one embodiment, the wrap ties at either end. In other embodiments, the integrity of the bale is enhanced in that the wrap clings to the surface as well as the ends of the bales. The wrap may comprise elastomeric material to facilitate clinging and conformance to the bales.  
         [0006]     In accordance with the present invention, the method of wrapping a rounded bale entails inserting the bale into an apparatus that receives a wrap material. U.S. Pat. No. 4,697,402 and No. 5,129,208, incorporated herein by reference, are representative of such apparatuses. In one embodiment, the apparatus receives the bale length-wise. A wrap material that is greater than the length of the bale to be wrapped is fed into the apparatus. The wrap is positioned about the bale in a single rotation and cut from the remainder of the wrap material. Subsequently, the excess wrap that extends over either side, so as to completely cover the bale.  
         [0007]     In a second embodiment, the apparatus receives the bale width-wise. A wrap material that is greater than the width of the bale to be wrapped is fed into the apparatus. The wrap is positioned about the bale in a single rotation and cut from the remainder of the wrap material. Subsequently, the excess wrap that extends over either side of the bale&#39;s width, so as to completely cover the bale.  
         [0008]     In one form of the invention, the excess bale wrap is tied off or fastened by some other means. In another form, the wrap clings to the surface as well as the end of the bale.  
         [0009]     In another embodiment, a device fastens the wrap at one end prior to positioning the wrap about the bale, completely covering the bale, In this embodiment, the wrap acts like a sock that fits over the bale, wherein the wrap is first arranged in a tubular fashion. The wrap can them be stretched over the bale clinging to the surface of the bale, as well as covering the sides of the bale.  
         [0010]     The bale wrap material may be a Raschel knit. The knitted net may comprise a specific performance, such as differential elongation, wherein a plurality of chain yarns orientated in a first direction have dissimilar elongation performances. The net may further comprise fill yarns having an elastomeric performance.  
         [0011]     The bale wrap material of the present invention may also be laminated material. For instance, a knitted net may be mechanically or chemically bonded to a nonwoven fabric to provide improved coverage to the rounded bale. Optionally, the nonwoven fabric and/or net may be mechanically and/or chemically treated so as to impart as specific performance into the bale wrap material.  
         [0012]     The yarns of the knitted net may comprise flat filaments, such as tapes, mono-filaments, or a combination thereof. The filaments of the net and/or the nonwoven fabric may be of similar or dissimilar polymeric compositions. Suitable filaments, which may be blended in whole or part with natural or synthetic polymeric compositions, include polyamides, polyesters, polyolefins, polyvinyls, polyacrylics, and the blends or coextrusion products thereof. The synthetic polymers may be further selected from homopolymers; copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  illustrates a view of a portion of a Racshel machine;  
         [0014]      FIG. 2  is diagrammatic view of the wrapping method of the present invention;  
         [0015]      FIG. 3  is diagrammatic view of the wrapping method of the present invention; and  
         [0016]      FIGS. 4 and 5  are diagrammatic views of further wrapping methods of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0017]     While the present invention is susceptible of embodiment in various forms, there will hereinafter be described, presently preferred embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments disclosed herein.  
         [0018]     In accordance with the present invention, the method of wrapping a rounded bale entails inserting the bale into an apparatus that receives a wrap material. The aforementioned U.S. Pat. Nos. 4,697,402 and No. 5,129,208, both incorporated herein by reference, are representative of such apparatuses. In one embodiment, the apparatus receives the bale length-wise. A wrap material that is greater than the length of the bale to be wrapped is fed into the apparatus. The wrap is positioned about the bale in a single rotation and cut from the remainder of the wrap material. Subsequently, the excess wrap that extends over either side of the bale&#39;s length so as to completely cover the bale. The excess wrap is tied off or fastened, or clings to the bale.  
         [0019]     In a further embodiment, the apparatus receives the bale width-wise. A wrap material that is greater than the width of the bale to be wrapped is fed into the apparatus. The wrap is positioned about the bale in a single rotation and cut from the remainder of the wrap material. Subsequently, the excess wrap that extends over either side of the bale&#39;s width is tied off or fastened by some other means, or clings to the bale, so as to completely cover the bale.  
         [0020]     In a third embodiment, a device fastens the wrap at one end prior to positioning the wrap about the bale, completely covering the bale. In this embodiment, the wrap can act like a sock that fits over the bale, wherein the wrap is first arranged in a tubular fashion. The wrap can then be stretched over the bale clinging to the surface of the bale, asd well as covering the sides of the bale.  
         [0021]     The bale wrap of the present invention may be a Racshel knitted net.  FIG. 1 , is representative of a Racshel machine, whereby it is provided with a comb plate  1  in which a plurality of latch needles  3  are mounted for reciprocating motion along their axes  2  in a vertical plane, as viewed. As shown, the needles  3  are disposed on a bar  4  which is movable up and down.  
         [0022]     In addition, the machine includes a plurality of lapping belts or guide bars  5  spaced from the needles  3  on one side, i.e., the downstream side, of the plane of the needles  3  for guiding pattern yarns to the needles  3 . A yarn laying-in comb  6  is also mounted on the same side of the plane  2  of the latch needles  3  in order to carry out an orbital motion perpendicularly of the plane  2  while penetrating between the pattern yarns. As indicated in chain-dotted line  7 , the orbital motion is a combined stroke and oscillating motion. The comb  6  is provided with a plurality of parallel sinkers  8  each of which carries a guide rod  9  and which has a deflecting edge  10  at the forward end extending towards the plane  2 . In addition, each sinker  8  has a yarn catch  11  at a lower region of the deflecting edge  10  below the guide rod  9 . A trace comb  12  is also mounted over the comb plate  1  in known manner.  
         [0023]     The machine also has a plurality of guide bars  13  which have needle guides thereon for directing stitch yarns to the latch needles  3 . As shown, the guide bars  13  are mounted on the side of the plane  2  of the latch needles  3  opposite the lapping belts  5 , i.e., on the upstream side. Suitable means are also provided for oscillating the guide bars  13  at an angle to the pattern yarns.  
         [0024]     As shown in  FIG. 1 , the lapping belts  5  are positioned at an acute angle downstream of the plane  2 . A yarn guide  14  is also disposed between the belts  5  and the guide bars  13  for deflecting the pattern yarns upon laying-in of the stitch yarns. This yarn guide  14  is used for laying the pattern yarns in the needle lanes (not shown). The yarn guide  14  may be coupled to the guide bars  13  so as to move therewith or may be provided with an independent drive (not shown).  
         [0025]     The knitted wrap may optionally comprise a plurality of chain yarns orientated in a first direction, wherein the yarns have dissimilar elongation performances. The dissimilar elongation performances of the yarns provide for optimal coverage of the bale upon stretching of the netting. In order to achieve the desired necking performance when stretching the netting, the yarns located proximal to either edge have a higher elongation performance than those located distal to the outer edges. Upon stretching, those yarns located proximal the outer edges stretch further than those located distal to the outer edge. This causes the outer edge of the net to flair, allowing the net to fold over the edges of the hay bale, maintaining the compact nature of the rolled bale.  
         [0026]     The bale wrap material of the present invention may have specific zones. A zone is defined as an area within the wrap that has a similar performance. For instance, when the bale wrap material is a knitted net, the net may comprise at least three zones, wherein the zones located proximal to the outer edges have a first performance and the zones located distal to the outer edge have a second performance.  
         [0027]     The bale wrap may optionally comprise a net with fill yarns having an elastomeric performance to provide optimal coverage of the bale upon stretching of the netting. When stretched in the cross-direction, the netting easily conforms about the shape of a bale, hugging the surface, which may include the sides, so as to maintain the compact nature of the rolled bale.  
         [0028]     The bale wrap of the present invention may be a knitted net and nonwoven laminate. Preferably, the nonwoven fabric is a continuous filament fabric. In general, continuous filament nonwoven fabric formation involves the practice of the spunbond process. A spunbond process involves supplying a molten polymer, which is then extruded under pressure through a large number of orifices in a plate known as a spinneret or die. Optionally, the molten polymer may incorporate a filament modifying melt additive. The resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls. The continuous filaments are collected as a loose web upon a moving foraminous surface, such as a wire mesh conveyor belt. When more than one spinneret is used in line for the purpose of forming a multi-layered fabric, the subsequent webs are collected upon the uppermost surface of the previously formed web. The web is then at least temporarily consolidated, usually by means involving heat and pressure, such as by thermal point bonding. Using this means, the web or layers of webs are passed between two hot metal rolls, one of which has an embossed pattern to impart and achieve the desired degree of point bonding, usually on the order of 10 to 40 percent of the overall surface area being so bonded.  
         [0029]     The spunbond fabric of the laminate may have elastomeric properties in addition to the knitted net having elastomeric properties. In this embodiment, the wrap can act like a sock that fits over the bale, wherein the wrap is first arranged in a tubular fashion. The wrap can then be stretched over the bale clinging to the surface of the bale, as well as covering the sides of the bale.  
         [0030]     From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.