Patent Publication Number: US-7908831-B1

Title: Stretch wrap rope converter and wrapping system

Description:
BACKGROUND OF INVENTION 
     a. Field of Invention 
     The invention relates generally to stretch wrapping loads, such as stacked boxes and the like. More specifically, it relates to a converter and wrapping system wherein the film is converted from sheet to rope before engaging loads to be wrapped. 
     b. Description of Related Art 
     The following patents are representative of wrapping devices and systems: 
     U.S. Pat. No. 6,874,297 B2 to Solis et al. describes an apparatus and method for wrapping a load under tension with a web of stretch wrap flexible material and then binding the wrapping material to the load by compressing the end of the flexible material into a rope-like configuration. The rope formed is wound around the load at least one turn. A second turn of the rope around the load is then bound to the first rope with a mechanical twisting tie around the two ropes to prevent unwrapping of the load during transit and storage. A hot wire cutting mechanism cuts the rope and the bound two ropes snap back into position against the wrapped load from the force of the stretch wrap tension. 
     U.S. Pat. No. 6,729,106 B2 to Wiley describes a stretch-wrapping machine which consists of a revolving ring with a packaging material dispenser mounted to it. The ring revolves about a horizontal axis to dispense the stretch wrap material around a load that is supported by a forklift. The revolving ring is mounted on a track that allows the ring to travel back and forth in a direction perpendicular to the ring. This allows the machine to wrap any load that fits within the ring. This allows the machine to wrap any load that fits within the ring. Thus the length and the weight of the load do not limit the wrapping capability of the machine. 
     U.S. Pat. No. 6,594,970 B1 to Hyne et al. describes a method and apparatus for wrapping a loop of film about a pallet, which supports a layer of products, and a guide, through which said layer passes, to prevent crushing and/or displacement of the product layer. Subsequent product layers are similarly protected by looping film about a previous loop of film and said guide. The guide is designed to facilitate removal of the film looped thereabout as the product layers are lowered. 
     U.S. Pat. No. 6,550,222 B2 to DeGrasse describes a top platen device used to maintain stability in loads while the load is wrapped for shipping. The top platen device applies a compressive force to the load to stabilize the load while it is being wrapped. The top platen includes a shaft supporting platen pad which is placed on top of the load. The shaft and platen pad are configured to rotate eccentrically with respect to the geometric center of the top platen in order to rotate with the load about the load&#39;s center of rotation. 
     U.S. Pat. No. 6,293,074 to Lancaster, III et al. describes a leading end of packaging material which is attached to a retainer to hold the leading end of the packaging material as the retainer moves toward the load. The retainer is positioned adjacent the load and packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material is released from the retainer in response to force applied to the retainer to withdraw it from the wrapped load. 
     U.S. Pat. No. 6,189,291 to Martin et al. describes a leading end of packaging material grasped in a packaging material holder while a load is wrapped. Packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material holder is positioned on the rotating surface of a turntable but is isolated from any electrical or fluid power source of a rotatable surface of the turntable. During the wrapping cycle, a spring builds and stores energy as the packaging material holder moves downstream along the turntable, automatically releasing the leading end of the packaging material and automatically grasping a trailing end of the packaging material. At least a portion of the packaging material is cut between the packaging material holder and the load, and the spring releases the stored energy to move the packaging material holder upstream toward the dispenser. 
     U.S. Pat. No. 6,185,914 B1 to Mackie describes a pre-stretch wrapping device consisting of a base, a pre-stretch station, a vertical drive, and a rotatable load causes a pre-stretched web to become wrapped around the load under controlled tension. The pre-stretch station comprises a pair of pre-stretch rollers located on a pivotal frame, a spring which opposes the pivotal movement of the frame relative to the base, a roller motor, and a sensor located between the frame and the base. The sensor monitors relative movement of the frame from the base and a controller in response to signals from the sensor controls the operation of the roller motor. 
     U.S. Pat. No. 6,185,900 B1 to Martin et al. describes a leading end of packaging material grasped in a packaging material holder while a load is wrapped. Packaging material is dispensed from a packaging material dispenser, and relative rotation is provided between the dispenser and a load to wrap packaging material around the load. The packaging material holder is positioned on the rotating surface of a turntable but is isolated from any electrical or fluid power source of a rotatable surface of the turntable. During the wrapping cycle, a spring builds and stores energy as the packaging material moves downstream along the turntable, automatically releasing the leading end of the packaging material and automatically grasping a trailing end of the packaging material. At least a portion of the packaging material is cut between the packaging material holder and the load, and the spring releases the stored energy to move the packaging material holder upstream toward the dispenser. 
     U.S. Pat. No. 5,515,973 to Sharp describes a system of wrapping and securing together the components of a bulk package including a bottom tray element and a top cap element with an integral web of plastic material. The plastic material, while in a rope-like configuration, is looped about only a single pair of diagonally opposed corners of each of the top cap element and bottom tray element. The tail or terminal end of the web is secured in place by being positioned between a wrap convolution and the bulk package. 
     U.S. Pat. No. 5,031,771 to Lancaster describes a wrapping apparatus having a frame, a reciprocally driven carriage moveably mounted on the frame, the carriage being adapted to hold a rotatable roll of stretchable film material and a film width varying mechanism. A driven rotatable turntable adapted to support a load is positioned adjacent to the frame, and the leading edge of the film material is held adjacent to the load. A brake is connected to the film roll to restrict movement of the web of material from the roll and the film width varying mechanism is mounted in the material path so that the film web travels through a pivotable “C” shaped assembly of the film width varying mechanism to collapse the film web width so that the web edges are formed into rope configurations connected by a membrane of film. The carriage is driven along the frame in one direction to provide a wrap, stops when the sensing mechanism on the carriage indicates that a junction between units on the load is present to deposit the stretched collapsed film web so that each roped edge is placed on an adjoining vertically positioned unit with the membrane connecting the two units. The carriage carries the film roll to the next or subsequent junctions where the wrap cycle is repeated until the package wrap is complete, at which time the material web is severed from the material roll dispenser. 
     U.S. Pat. No. 4,845,920 to Lancaster describes a wrapping apparatus having a frame, a reciprocally driven carriage moveably mounted on the frame, the carriage being adapted to hold a rotatable roll of stretchable film material and a film width varying mechanism. A driven rotatable turntable adapted to support a load is positioned adjacent to the frame, and the leading edge of the film material is held adjacent the load. A brake is connected to the film roll to restrict movement of the web of material from the roll and the film width varying mechanism is mounted in the material path so that the film web travels through a pivotable “C” shaped assembly of the film width varying mechanism to collapse the film web width so that the web edges are formed into rope configurations connected by a membrane of film. The carriage is driven along the frame in one direction to provide a wrap, stops when the sensing mechanism on the carriage indicates that a junction between units on the load is present to deposit the stretched collapsed film web so that each roped edge is placed on an adjoining vertically positioned unit with the membrane connecting the two units. The carriage carries the film roll to the next or subsequent junctions where the wrap cycle is repeated until the package wrap is complete, at which time the material web is severed from the material roll dispenser. 
     U.S. Pat. No. 4,754,594 to Lancaster describes a wrapping apparatus having a frame, a reciprocally driven carriage moveably mounted on the frame, the carriage being adapted to hold a rotatable roll of stretchable film material and a film width varying mechanism. A driven rotatable turntable adapted to support a load is positioned adjacent to the frame, and the leading edge of the film material is held adjacent the load. A brake is connected to the film roll to restrict movement of the web of material from the roll and the film width varying mechanism is mounted in the material path so that the film web travels though a pivotable “C” shaped assembly of the film width varying mechanism to collapse the film web width so that the web edges are formed into rope configurations connected by a membrane of film. The carriage is driven along the frame in one direction to provide a wrap, stops when the sensing mechanism on the carriage indicates that a junction between units on the load is present to deposit the stretched collapsed film web so that each roped edge is placed on an adjoining vertically positioned unit with the membrane connecting the two units. The carriage carries the film roll to the next or subsequent junctions where the wrap cycle is repeated until the package wrap is complete, at which time the material web is severed from the material roll dispenser. 
     U.S. Pat. No. 4,255,918 to Lancaster et al. describes a wrapping apparatus having a frame, a reciprocally driven carriage moveably mounted on the frame, the carriage being adapted to hold a rotatable roll of stretchable film material and a film width varying mechanism. A driven rotatable turntable adapted to support a load is positioned adjacent to the frame, and the leading edge of the film material is held adjacent the load. A brake is connected to the film roll to restrict movement of the web of material from the roll and the film width varying mechanism is mounted in the material path so that the film web travels through a pivotable “C” shaped assembly of the film width varying mechanism which when pivoted by spring action reduces the film web width, so that the film material is stretched and reduced in width as it leaves the roll. The carriage is driven along the frame in one direction to provide a wrap for a load and returns in an opposite direction while continuing to wrap the load, at which time the material web is severed from the material roll dispenser. 
     U.S. Pat. No. 4,235,062 to Lancaster, III et al. describes a process for automatically making a spiral wrapped unitary package with a single web of stretchable material to form a netting overwrap. A series of loads, each containing a plurality of units are fed one at a time onto a turntable adjacent a film dispenser with the leading edge of the film from the film dispenser being collapsed in width and held by a clamp mechanism mounted on the turntable. The collapsed film web is spirally wrapped around the load to one end of the load and spirally wrapped around the load to the other end to complete a first cycle defining an overwrap netting configuration with a plurality of symmetrical angular spaces. The turntable is then rotated at least 90° to offset the collapsed film web and a second cycle is repeated with the film web being spirally wrapped to overlie part of the originally spirally wrapped film web and reduce the angularly shaped spaces formed by the first cycle. On the return of the collapsed film web is tucked under a portion of the collapsed film wrapped around the load. 
     U.S. Pat. No. 4,204,377 to Lancaster et al. describes an apparatus and process for automatically making spiral wrapped unitary package having a netting overwrap. In the apparatus a series of loads, each containing a plurality of units are fed one at a time onto a turntable adjacent a netting dispenser with the leading edge of the netting from the netting dispenser being held by a clamp mechanism mounted on the turntable. The netting is spirally wrapped around the load and is then formed into a rope-like configuration by a roper mechanism, with the roped netting being wrapped around the turntable clamp mechanism, at which time the roped netting is clamped by a clamping, tucking and cutting mechanism. The clamping, tucking and cutting mechanism tucks the portion of the roped wrap between the load and the roped netting wrapped around the clamp mechanism and severs the roped netting as the turntable clamp mechanism is retracted below the edge of the turntable causing the roped overwrap to attempt to return to its memory position, holding the severed end of the roped netting in a fixed position as the clamping, tucking and cutting mechanism is raised out of the contracting roped wrap. The new leading edge of the netting is held by the clamping, tucking and cutting mechanism which carries the leading edge back towards the turntable clamp mechanism allowing the netting to be clamped by the turntable clamp for the next operation, at which time the clamping, tucking and cutting mechanism releases the new leading edge of the netting and is removed from the netting dispensing path. 
     Notwithstanding the prior art, the present invention is neither taught nor rendered obvious thereby. 
     SUMMARY OF INVENTION 
     The present invention is a stretch wrap rope converter and wrapping system wherein the film is converted from sheet to rope before engaging loads to be wrapped. The present invention includes: a.) a wrapping apparatus, the wrapping apparatus having: (i) a frame with a vertical vector for movement of a carriage thereon; (ii) the carriage moveably mounted to the frame for reciprocal movement along the vertical vector; (iii) drive means connected to the carriage for the movement of the carriage, the carriage adapted to hold at least one rotatable roll of stretchable film material thereon and being adapted to generate two separate streams of film therefrom, being a first stream of film and a second stream of film; (iv) a stretch wrap rope converter functionally connected to the carriage so as to receive the first stream of film and the second stream of film, the converter having a first orifice for receiving the first stream of film and for diminishing the width of the first stream of film to create a first rope, and having a second orifice for receiving the second stream of film and for diminishing its width to create a second rope, the converter further including rope rotation means so as to rotate the first orifice and the second orifice through an arc in at least one of a reciprocal fashion and a circular fashion to cause the first rope and the second rope to move toward and then away from one another; and b.) wrapping target rotation means adapted to rotate at least one of the wrapping apparatus and a wrapping target so that the first rope and the second rope engage the wrapping target during rotation. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system has an arc that is greater than 90 degrees so as to cause the first rope and the second rope to cross over one another during rotation of the wrapping target rotation means. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system first orifice and the second orifice have a fixed orifice size. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system first orifice and the second orifice have adjustable orifice sizes. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system has rope rotation means that has a fixed speed of rotation. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system has rope rotation means that has an adjustable speed of rotation. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system wrapping target rotation means is a frame rotation means adapted to move the frame around a wrapping target. 
     In some preferred embodiments of the present invention, the wrapping target rotation means is a target rotation means that includes a base that rotates a target in the base relative to the frame. 
     In some preferred embodiments of the present invention, the rope rotation means is adapted to rotate reciprocally through the arc on a rope rotation means controller that is adapted to create rotation selected from the group consisting of continuous, intermittent and combinations affording a choice of each. 
     In some preferred embodiments of the present invention, the stretch wrap rope converter and wrapping system carriage is adapted to hold one notable roll of stretchable film material and includes a slitting mechanism to slit stretchable film material into the two streams of film. 
     In other embodiments of the present invention stretch wrap rope converter and wrapping system, the system includes: a.) a wrapping apparatus, the wrapping apparatus having: (i) a frame with a vertical vector for movement of a carriage thereon; (ii) the carriage moveably mounted to the frame for reciprocal movement along the vertical vector; (iii) drive means connected to the carriage for the movement of the carriage, the carriage adapted to hold at least one rotatable roll of stretchable film material thereon and being adapted to generate two separate streams of film therefrom, being a first stream of film and a second stream of film; (iv) a stretch wrap rope converter functionally connected to the carriage so as to receive the first stream of film and the second stream of film, the converter having a first orifice for receiving the first stream of film and for diminishing the width of the first stream of film to create a first rope, and having a second orifice for receiving the second stream of film and for diminishing its width to create a second rope, the converter further including rope rotation means so as to rotate the first orifice and the second orifice through an arc in at least one of a reciprocal fashion and a circular fashion to cause the first rope and the second rope to move toward and then away from one another; b.) wrapping target rotation means adapted to rotate at least one of the wrapping apparatus and a wrapping target so that the first rope and the second rope engage the wrapping target during rotation; c.) a computer control subsystem connected to the carriage, the stretch wrap rope converter and the wrapping target rotation means so as to coordinate simultaneous movement of the carriage reciprocally on the frame, movement of the first film and second film through the orifices, rotation of the converter reciprocally about the arc and movement of the wrapping target rotation means. Further all of the other features and preferences described above in this section apply to these embodiments as well. 
     Additional features, advantages, and embodiments of the invention may be set forth or apparent from consideration of the following detailed description, drawings, and claims. Moreover, it is to be understood that both the foregoing summary of the invention and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the detail description serve to explain the principles of the invention. In the drawings: 
         FIG. 1  is a top view of a diagrammatic representation of one embodiment of the present invention; 
         FIG. 2  is a top view of a diagrammatic representation of another embodiment of the present invention; 
         FIG. 3  is a side view of one preferred embodiment of a stretch wrap rope converter and wrapping system according to the present invention; 
         FIG. 4  is a side view of another preferred embodiment of a stretch wrap rope converter and wrapping system according to the present invention; 
         FIG. 5  is a partial side view of another preferred embodiment of a stretch wrap rope converter and wrapping system according to the present invention; and, 
         FIG. 6  is a side view of another preferred embodiment of a stretch wrap rope converter and wrapping system according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     The present invention stretch wrap rope converter and wrapping system permits the use of stretch wrap sheets to be converted to rope and presents the user with opportunities to wrap loads in criss-cross fashion with the converted ropes, wherein the degree of separation between crossing ropes can be altered and the heights between complete circles of rope can also be adjusted. 
       FIG. 1  and  FIG. 2  are top views of diagrammatic representations of two different embodiments of the present invention a stretch wrap rope converter and wrapping system, simply illustrating the two different manners in which the stretch wrap rope converter and the load being wrapped may move relative to one another. 
     In  FIG. 1 , system  1  is shown wherein the present invention wrapping device  3  provides two interacting stretch wrap ropes  7  and  9  being wrapped around load  5 . Wrapping device  3  is stationary on support carriage  12 , and, from this top view, it can be seen that the target load  5  is rotated to achieve the wrapping. This is accomplished by a rotating base or turntable upon which the target load  5  is set. The raising and lowering of the rope to move up and down the load to wrap may be achieved by raising and lowering device  3 , raising and lowering target load  5 , or a combination thereof. 
     In  FIG. 2 , the opposite arrangement from  FIG. 1  is shown and may be preferred for large or heavy target loads. Thus, in  FIG. 2 , system  11  is shown wherein the present invention wrapping device  13  provides two interacting stretch wrap ropes  17  and  19  being wrapped around load  15 , the details of which are illustrated in the Figures below. Here, target load  15  is stationary and, from this top view, it can be seen that the present invention wrapping device  13  is supported for vertical and horizontal movement on support carriage  14 , which is rotated to achieve the wrapping. This is accomplished by rotating the present invention wrapping device base around a track or path that circumvents the target load  15 . The raising and lowering of the rope to move up and down the load to wrap may be achieved by raising and lowering device  13 , raising and lowering target load  15 , or a combination thereof. 
       FIG. 3  is a side view of one preferred embodiment of a stretch wrap rope converter and wrapping system  31  according to the present invention. A single roll  33  of stretch wrap feeds to a guide bar with top guide  37  and bottom guide  39 . About midpoint therebetween is sheet slitter  35  that cuts the sheet into two separate sheets  41  and  43 . Sheet  41  feeds through a first orifice  47  on rope converter  45 , and sheet  43  feeds through second orifice  47  on rope converter  45 . The sheet  41  is converted to rope  51  and sheet  43  is converted to rope  53  as each passes through rope converter  45 . Rope converter  45  moves reciprocally through an arc and thus the ropes  51  and  53  are repeatedly crossing one another such as at intersection  61 , to bind load  55 . Corner inserts  57  and  59  are provided to protect the corners of load  55  while being wrapped and while in transit. The length of the arc may be adjusted to make wider or narrower distances between each of the ropes and its speed may be adjusted as well. Spacing between each wrap around the load  55  may be adjusted by the rise rate of the supporting carriage of the device and the speed of the turntable  65  upon which load  55  is rotated. (In this Figure, a supporting carriage is not shown, to simplify the illustration of the functionality of the rope converter  45 , but the carriages permit the present invention wrapping devices to be controllably moved through a vertical vector, and one is shown in conjunction with  FIG. 6 , below). 
       FIG. 4  is a side view of another preferred embodiment of a stretch wrap rope converter and wrapping system  71  according to the present invention. In this embodiment, the wrapping device travels around the load. Two separate rolls  73  and  75  of stretch wrap feed to separate guide bars  77  and  79 . Because two separate rolls are used here, there is no need for a sheet slitter. Sheet  81  feeds through a first orifice  87  on rope converter  85 , and separate sheet  83  feeds through second orifice  87  on rope converter  85 . The sheet  81  is converted to rope  91  and sheet  83  is converted to rope  93  as each passes through rope converter  85 . Rope converter  85  moves reciprocally through an arc and thus the ropes  91  and  93  are repeatedly crossing one another such as at intersection  103 , to bind the load made up of stacked boxes, such as boxes  95  and  97 , on pal let  105 . Corner inserts, such as inserts  99  and  101  are provided to protect the corners of the target load while being wrapped and while in transit. The length of the arc may be adjusted to make wider or narrower distances between each of the ropes and its speed may be adjusted as well. Spacing between each wrap around the load may be adjusted by the rise rate of the supporting carriage (not shown) of the device and the speed of the carriage upon which the wrapping device with the converter  85  and rolls  73  and  75  are rotated around the load. 
       FIG. 5  is a partial side view of another preferred embodiment of a stretch wrap rope converter and wrapping system  110  illustrating one type of mechanical drive system for the converter. Other types of drive systems are within the skill of the artisan now that the present invention has been shown. Thus, the present invention should not be seen as limited to the  FIG. 5  mechanical drive system. ( FIG. 6 , below, illustrates another type of drive system. Others could be electronic drive systems.) 
       FIG. 5  shows two separate stretch wrap rolls  111  and  115 , but it could alternatively be a single roll with one or more slitters. These rolls have sheets  115  and  117  respectively fed (pulled) through converter orifices  121  and  123  on converter  119  to become ropes  125  and  127 . Converter  119  is attached to a drive wheel  129 , that is moved through an arc via drive rod  143 . Because drive rod  143  is rotatably attached to wheel  129  and is slideably attached to drive wheel  141 , it will move only through an arc and not a full circle at converter  129 , thus creating the type of rope wrapping shown in the last two Figures. 
       FIG. 6  is a side perspective view of another preferred embodiment of a stretch wrap rope converter and wrapping system  200  according to the present invention. Carriage base  245  raises and lowers carriage  243  along a vertical vector as it revolves around the load, the load rotates on a turntable, or both. Drive motor  241  may be programmed, or remotely controlled with wireless controller  247 , to rotate drive axle  207  or to reciprocally move drive axle  207  through an arc to simultaneously rotate or move through the arc, the rolls and converter to the right thereof. That is, stretch wrap roll  203  on axle  273  and stretch wrap roll  205  on its axle (not shown), along with guides  277  and  279 , and converter  211  follow the path of drive axle  207 . The sheets  233  and  231  respectively pass through converter  211  at orifices  215  and  220  respectively. They are converted to rope, and the tightness or rough rope diameter can be adjusted by adjusting the orifice size or offering different size orifices on the converter or different converter plates with different orifice sizes. Likewise, the spacing of the orifices will, in part, determine the spacing of the ropes on the load. Hence, on this converter  211 , orifices such as orifices  213 ,  215 ,  217 ,  219 ,  220  and  221  are presented. The resulting ropes  235  and  237  are crossed and wrap load  225 , as shown. 
     Although particular embodiments of the invention have been described in detail herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those particular embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.