Abstract:
Pre-stretched films may be used to increase the rate at which loads can be wrapped and to minimize the exertion required when using traditional handheld film. However, the edges of pre-stretched films are easily damaged, which may result in tearing or failure of the film during use. The present disclosure describes devices, systems, and methods for folding the edges of the film, resulting in a film that is less susceptible to damage and easier to use.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application is a divisional application of U.S. patent application Ser. No. 12/470,238, filed May 21, 2009, which claims the benefit of U.S. Provisional Patent Application, Ser. No. 61/082,398, filed on Jul. 21, 2008, the contents of which are hereby incorporated by reference in their entirety. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present disclosure generally relates to devices, systems, and methods for producing film in-process for use in the stretch film market. In particular, the present disclosure relates to devices, systems, and methods for folding the edges of the film, resulting in a film that is less susceptible to damage and easier to use. 
       BACKGROUND OF THE DISCLOSURE 
       [0003]    Stretch films are widely used in a variety of bundling and packaging applications. For example, stretch films have become a common method of securing bulky loads such as boxes, merchandise, produce, equipment, parts, and other similar items on pallets. Such films are typically made from various polyethylene resins and may be single or multilayer products. An additive known as a cling agent is frequently used to ensure that adjacent layers of film will cling to each other. 
         [0004]    An issue with conventional stretch films is that the edges of the film can be easily damaged, which may result in tearing or failure of the film during use. Typically, the edges of the film are prepared by transversely slitting individual roll widths of film from a wider width of film by means of a conventional sharp edge slitter assembly. Any defects that are introduced into the edges of the film during the slitting process can result in film failure during the application process. Dropping the film roll or any other abuse during handling may also create zones of weakness or tears in the edges of the film. 
         [0005]    One method of reinforcing the edges of the film is to fold the edges of the material to form a hem. For example, U.S. Pa. No. 5,565,222 discloses an apparatus for hemming the edges of stretch film. The apparatus consists of a first hemming roller with a width less than the width of the film, guide bars located adjacent to the film&#39;s path of travel, and a second hemming roller. As another example, U.S. Pat. No. 5,531,393 discloses a film with folded edges. Folding occurs before the film is stretched and is achieved by means of folding fingers that project inwardly from the side plates of the apparatus. 
         [0006]    As can be seen, edge folds make the film easier to use and reduce waste by making the film less susceptible to failure due to tears, rough handling, or excessive stretching. However, current methods provide for edge folding in a separate and secondary process after the film has been produced, which increases the time and costs of film production. Thus, there is a need for methods, systems, and devices which can efficiently fold the edges of the film in-process. There is also a need for methods, systems, and devices that can simultaneously fold each edge of multiple widths of film that have been cut from a wider width of film. Finally, there is also a need for methods, systems, and devices that can re-introduce a fold without operator intervention if the fold is lost due to defects in the film. 
       SUMMARY OF THE DISCLOSURE 
       [0007]    An apparatus for folding the edges of a film during the production process is provided. The apparatus comprises a first idler roll, a second idler roll, and a plurality of folding guide assemblies located between the first idler roll and the second idler roll. The apparatus may include a nip roll assembly to produce edge folds that are flat. 
         [0008]    A method for folding the edges of a film during the production process is further provided. The method comprises the steps of providing a film with edges created by longitudinal slits, a first idler roll, a second idler roll, and a plurality of folding guide assemblies. The folding guide assemblies are placed between the first idler roll and the second idler roll. The film moves over the first idler roll, through the folding guide assemblies, and over the second idler roll. The method may include passing the film through a nip roll assembly to produce edge folds that are flat. 
         [0009]    A film with folded edges produced by the apparatus and method described above is further provided. 
         [0010]    These and other features, aspects, and advantages of the present disclosure will become better understood with reference to the following drawings, description, and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The disclosure will be better understood from the following description and the accompanying drawings given as non-limiting examples, and in which: 
           [0012]      FIG. 1  illustrates the steps for producing film in-process according to an embodiment disclosed herein; 
           [0013]      FIG. 2  illustrates the edge folding apparatus and folding guide assembly, with the folding guide assembly comprised of folding rods, according to an embodiment disclosed herein; 
           [0014]      FIG. 3  illustrates the folding guide assembly, with the folding guide assembly comprised of folding rods and re-folders, according to an embodiment disclosed herein; 
           [0015]      FIG. 4  illustrates an edge fold wherein the film is passed through the edge folding apparatus and a nip roll assembly, according to an embodiment disclosed herein; and 
           [0016]      FIG. 5  illustrates an edge fold wherein the film is passed through the edge folding apparatus without the nip roll assembly, according to an embodiment disclosed herein. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    The following detailed description is of the best currently contemplated modes of carrying out the disclosure. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the disclosure, since the scope of the present disclosure is best defined by the appended claims. 
         [0018]    Broadly, the current disclosure includes systems, devices, and methods for producing film in-process for use in the stretch film market. More specifically, according to an embodiment of the disclosure, an apparatus and method are provided for folding the edges of a film in-process. The apparatus and method may allow for edge folds on each side of a single width of film. Alternatively, the apparatus and method may allow for edge folds on each side of multiple widths of film that have been cut from a wider width of film, thus allowing multiple film rolls to be simultaneously formed from a single wider sheet of film during production. Edge folds may increase the ease of use and reduce waste by making the film less susceptible to failure due to tears, rough handling, or excessive stretching. 
         [0019]    Referring generally to  FIG. 1 , the steps  100  for producing cast film in-process, according to an embodiment of the present disclosure, are illustrated. Specifically, the steps comprise producing a film from molten resins  110 , gauging the film  120 , longitudinally slitting the film into multiple sections  130 , folding the edges of the film  140 , oscillating the film  150 , and winding the film onto a film roll  160  in a manner that prevents stacking of the edge folds and entraps air between the layers of film. All of the steps may be performed in-process along a single production line. The steps may be performed in a different order, and one or more steps may be eliminated without departing from the scope of the present disclosure. 
         [0020]    Slitting assemblies are well-known in the field, and the present disclosure may use any conventional slitting assembly to slit the film into multiple sections. An interior slit may be defined as a slit made somewhere within the original width of film, resulting in multiple sections of lesser width. Each interior slit may require only one folding guide assembly to accommodate both adjacent film edges. An exterior slit may be defined as a slit made along one of the edges of the original width of film. Each exterior edge may require a separate folding guide assembly. 
         [0021]    As shown in  FIG. 1 , the edges of the film may be folded immediately after the film is longitudinally slit into multiple sections. The edge folds may make the film less susceptible to failure due to tears, rough handling, dropping, or excessive stretching. Thus, the ability to introduce and maintain edge folds is a key component of film performance. 
         [0022]    As shown in  FIG. 2 , the means for folding the edges of the film  210  comprises a first idler roll  220 , a second idler roll  230 , and a plurality of folding guide assemblies  235  also known as folding guides, placed between the first idler roll  220  and the second idler roll  230 . Each folding guide assembly  235  may be comprised of steel, aluminum, nylon, or any other material of sufficient modulus to be able to maintain rigidity with no one material demonstrating an advantage. Each folding guide assembly may also have a coefficient of friction that allows the edge of the film to turn back on itself, thus introducing a fold. The diameter and placement of the folding guide assemblies  235  may be key factors in achieving and maintaining edge folds  250  without roping or wrinkling of the film  210 . 
         [0023]    The folding guide assemblies  235  may be comprised of a plurality of folding rods  240 - 245 , which may be placed in the slits  270  between sections of film  210  to separate the sections of film  210 . After the sections of film  210  are separated, the cling agent and the tension of the film  210  may cause the edge folds  250  to form spontaneously. Each interior folding rod  240  may produce two edge folds  250 , while each exterior folding rod  245  may produce one edge fold  250 . 
         [0024]    The folding rods  240 - 245  may vary from ⅜ inch to 1 inch in diameter, with a preferred diameter of approximately 11/16 inch. The folding rods  240 - 245  may have uniform diameter throughout their length. As an alternative, the portions of the folding rods  240 - 245  that contact the film  210  may have a smaller diameter or narrow to a point to further aid in separating the sections of film  210 . 
         [0025]    The folding rods  240 - 245  may be placed in the slits  270  between sections of the film  210  at a guide distance  280  and a guide angle  290 . The guide distance  280  may be approximately ⅔ of the distance between the first idler roll  220  and the second idler roll  230 , as measured from the point where the film  210  leaves the first idler roll  220  to the point where the film  210  first contacts the folding rods  240 - 245 . The guide angle  290  between the film  210  and the folding rods  240 - 245 , measured with the folding rods  240 - 245  leaning toward the first idler roll  220 , may vary from 20° to 90°, with a preferred angle of approximately 45°. 
         [0026]    As shown in  FIG. 3 , the folding guide assemblies  235  may also be comprised of a plurality of folding rods  240 - 245  and a plurality of re-folders  248 . Each folding rod  240 - 245  and each re-folder  248  may be separate units that can be positioned independently. Alternatively, each folding rod  240 - 245  and each re-folder  248  may be combined into a single unit. If the folding rod  240 - 245  and re-folder  248  are combined into a single unit, their positions may be fixed or adjustable relative to each other. 
         [0027]    The re-folders  248  may be placed in the slits  270  between sections of the film  210  after the folding rods  240 - 245  and before the second idler roll  230 . The re-folders  248  may function to further separate the sections of film  210  and to direct the film  210  back onto itself at an angle that aids in re-establishing folds  250  that are lost during the production process. Causes of lost folds  250  include, but are not limited to, holes, gels, contaminated resins, flaws in the film, and other production problems. 
         [0028]    The composition and diameter of the re-folders  248  may be comparable to that of the folding rods  240 - 245 . The re-folders  248  may have uniform diameter throughout their length. However, as shown in  FIG. 3 , the portions  249  of the re-folders  248  that contact the film  210  may be wider than the other portions of the re-folders  248  in order to increase the amount of separation between adjacent sections of the film  210 . For example, the portions  249  of the re-folders  248  that contact the film  210  may be capped by an inverted cone or sphere. 
         [0029]    As shown in  FIG. 2 , the means for folding the edges of the film  210  may also comprise a nip roll assembly  260 . The nip roll assembly  260  may consist of two rollers  265  pressed together, and may be primarily intended to control the tension of the film  210  as it passes through the slitting assembly and the edge folding apparatus. The nip roll assembly  260  may also aid in pressing the folds  250  into the film  210 , resulting in flat edge folds as shown in  FIG. 4 . If the nip roll assembly  260  is not employed, air entrapment may occur within the edge folds as shown in  FIG. 5 . Air entrapment within the edge folds may result in a film roll with a different appearance and functionality, much like having bubble wrap on the ends of the roll. 
         [0030]    As shown in  FIG. 1 , the film may be oscillated and wound onto film rolls once the film&#39;s edges are folded. Oscillation may efficiently distribute the edge folds onto the film roll. In addition, air may be entrapped between the layers of film as the film is wound onto a film roll, making the film easier to unwind and less susceptible to damage. 
         [0031]    From the foregoing, it will be understood by persons skilled in the art that devices, systems, and methods for folding the edges of the film have been provided, resulting in a film that is less susceptible to damage and easier to use. While the description contains many specifics, these should not be construed as limitations on the scope of the present disclosure, but rather as an exemplification of the preferred embodiments thereof. The foregoing is considered as illustrative only of the principles of the present disclosure. Further, because numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the present disclosure to the exact methodology shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the present disclosure. Although this disclosure has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of the method may be resorted to without departing from the spirit and scope of the present disclosure.