Patent Publication Number: US-2012031045-A1

Title: Film Applicator

Description:
RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Application No. 61/401,133, filed Aug. 9, 2010, the disclosure of which is incorporated herein by reference. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Many aspects of the embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
    
    
     
         FIG. 1  is a view of an embodiment of a film applicator having a roll of film thereon. 
         FIG. 2  is a view of an embodiment of a film applicator showing the film extending off the roll of film and over the adjustable tensioning roll and the roll. 
         FIG. 3  is a view of an embodiment of a film applicator having a roll of film thereon. 
         FIG. 4  is a view of an embodiment of a film applicator. 
         FIG. 5  is an exploded view of an embodiment of a film applicator. 
         FIG. 6  is a view of an embodiment of a film applicator. 
         FIG. 7  is a cross section view of the grip and frame taken along the line  7  in  FIG. 6 . 
         FIG. 8  is a view of an embodiment of a film applicator. 
         FIG. 9  is a cross section view of the roller taken along the line  9  in  FIG. 8 . 
         FIG. 10  is an exploded view of one embodiment the roller. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one. 
     Referring to  FIG. 1 , an embodiment of the film applicator comprises a stand  1 , a frame  2 , brackets  3 , roller  4 , an adjustable tensioning roller  5 , film cutter  6 , tension knob  7 , abutments  8 , magnets  9 , plugs  10 , rod  11 , and a grip  14 . A film roll core is located on the plugs  10 . 
     The frame  2  is generally U-shaped. The frame  2  can be made of metal, ceramics, plastics and composites. In one embodiment the frame  2  comprises of tubular aluminum. The frame  2  may include magnets  9  located on one or both ends of the frame  2 . These magnets  9  enable the user to attach the film applicator to any metallic surface that is able to have a magnet attached thereto, such as a pallet lifter or metal shelves. In some embodiments, the frame  2  is tubular and the magnets  9  are situated so that a portion of the magnets  9  reside within the frame  2  and a portion will serve as an end cap of the frame  2 . It is understood that the magnets  9  need not be of the same size. The magnets  9  can correspond to the shape of their respective end of the frame  2 . 
     The stand  1  is attached to the frame  2 . In some embodiments, the stand  1  is made of the same material as the frame  2  and is permanently attached (e.g. welded, adhered). In other embodiments, the stand  1  is made of material different than that of the frame  2 . It is understood that the stand  1  can be attached to the frame  2  by fasteners such as screws or by a coupling means that enable the stand  1  to be disconnected. Additionally in some embodiments, the stand  1  is planar, without bend ends. In some instances, the user must apply the film  13  to the very bottom of the pallet. In those environments, the less height the stand  1  adds, the better. 
     Referring to  FIG. 5 , in one embodiment, the frame  2  comprises the top frame  202  and the bottom frame  201 . The stand  1  is attached to the bottom frame  201 . Additionally, a rod  11  is firmly secured to the to the bottom frame  201  between the abutments  8 . When assembled, the abutments  8  serve to prevent the bracket  3  from rotating. The bottom frame  201  has a diameter that is less than that of the top frame  202  such that the top frame  202  is able to side over the bottom frame  201 . In some embodiments the top frame  202  comprises ⅞ OD X 0.58 6063 T832 aluminum tubing, and the bottom frame 201 comprises ¾ OD X 0.58 6063 T832. 
     The top frame  202  comprises abutments  8  and a through hole. When fully assembled, a treaded portion  12  of the rod  11  extends through the through hole such that the tension knob  7  is able to engage the treaded portion  12 . In some embodiments, a grip  14  is located on a portion of the top frame  202 . The grip  14  can be made of a soft material that will allow for a comfortable gripping surface  401 . In some embodiments, the grip  14  comprises neoprene. Both the bottom frame  201  and the top frame  202  have the plugs  10  attached to them. The plugs  10  can be attached so that they are able to rotate or not. In some embodiments, the material of the plugs  10  is such that the core of the film is able to rotate about the plug  10 . The magnets  9  are located on the ends of the bottom frame  201  and the top frame  202 . 
     The adjustable tensioning roller  5  is located over the rod  11 . A bracket  3  is located on each end of the rod  11  and positioned between the abutments  8  on each of the bottom frame  201  and top frame  202 . The tension knob  7 , when tightened, is able to increase the force required to turn the adjustable tensioning roller  5 . Alternatively, when the tension knob  7  is loosened, the force required to rotate the adjustable tensioning roller  5  is lessened. The other end of the brackets  3  is secured to the roller  4 . The outer circumference of the roller  4  is free to rotate. On one of the brackets  3 , a film cutter  6  is located near the roller  4 . The film cutter  6  can be located on the upper or lower bracket  3 . In one embodiment the brackets  3  extend substantially perpendicular to the frame  2 . In other embodiments, the brackets  3  extend at an angle with respect to the frame  2 . The angle is in the range from 0-90 degrees. 
     It some embodiments, the tension knob  7  has a treaded projection that extends through the through hole and is accepted in the rod  11 . In some embodiments, the rod  11  is approximately 5/16 inch (approximately 0.7937 centimeter) in diameter. 
     Referring to  FIG. 2 , an embodiment of the film applicator having film  13  extending out from the roll, around the adjustable tensioning roller  5 , and around the roller  4 . Some films  13  have different properties on each side of the film  13 . When the film&#39;s interior is designed to the applied side, the film  13  is arranged such that the interior of the film  13  contacts the adjustable tensioning roller  5  and the roller  4 . The user is able to adjust the tension of the film  13  as it is applied to the item by adjusting the tension knob  7 . When tightening the tension knob  7 , the force required to pull the film  13  from the roller  4  is increased. 
     The film cutter  6  only needs to start the cut or harm the integrity of the film  13 . The nature of most films will easily allow for the completion of the cut once a slit has started. The film cutter  6  can be a device such that when the film cutter  6  is actuated, the film  13  is caught between two arms that will cut, crimp, and/or pierce the film  13 . In other embodiments, the film cutter  6  can have one arm that is actuated so that it moves through the film  13 . It is understood that the blades may or may not be sharp. In some embodiments, the film cutter  6  is a toggle wing nut. 
     Referring to  FIGS. 9 and 10 , an embodiment of roller  4  is shown. The roller  4  comprises an axle  403 , a rotating member  402 , and a gripping surface  401 . The gripping surface  401  is such that the film will be gripped by the gripping surface  401 . In some embodiments, the gripping surface  401  is a coating on the rotating member  402 . The rotating member  402  is able to rotate about the axle  403 . In some embodiments, the axle  403  is an aluminum tube that is secured to the brackets  3  via a fastener, the rotating member  402  comprises phenolic tubing, and the gripping member comprises rubber tubing. In one embodiment the rotating member  402  comprises phenolic garolite grade CE ½ inch (1.27 centimeters) OD (outer diameter) by 5/16 inch (0.7937 centimeter) ID (inner diameter). In other embodiments the gripping surface  401  comprises plastic, and the rotating member  402  comprises plastic, metal, ceramics, and/or composite. In one embodiment the gripping member comprises natural rubber. One of the benefits of using natural rubber is that it helps eliminate the creation of static electricity that has been known to shock users during the application of film. The thickness of the gripping surface  401  can be in the range of about ½ inches (about 1.27 centimeters) OD to about 3/32 inches (about 0.2381 centimeter). In some embodiments only two of the axle  403 , the rotating member  402  and the gripping surface  401  are present. In some embodiments, the fasteners can serve as an axle  403 . 
     The adjustable tensioning roller  5  can be similar to the roller  4 ; however, the rod  11  will serve the same purpose as the axle  403 . The tension knob  7  is able to increase the resistance of the adjustable tensioning roller  5  by applying pressure to the frame  2 , which in turn applies pressure to the brackets  3  to clamp the adjustable tensioning roller  5 . 
     In some embodiments, the plugs  10  are circular with a stepped configuration. The larger diameter section  102  is designed to abut the roll of film core. The smaller diameter section  101  is designed to reside in the roll of film core. The roll of film core is able to rotate with/or about the smaller diameter section  101  while the larger diameter section  102  helps keep the roll of film secured on the film applicator. In some embodiments, as can be seen in  FIG. 5 , there may be a plug base  15  between the plug  10  and the frame  2 . The interaction between the plug base  15  and the plug  10  will act like a clutch to help determine the amount of force required to rotate the plug  10 . This can be achieved by choices of materials and/or texture of the adjoining surfaces. The plug base  15  can be a circular disk that is secured to the frame  2 . The plugs  10  can be made of metal, plastic, ceramics, composites, and combinations thereof. In one embodiment, the plugs  10  comprises of UHMW (Ultra High Molecular Weight) plastics. In some embodiments the plugs  10  are approximately ⅝ inch (approximately 1.587 centimeters) thick. 
     In order to insert a film roll onto the film applicator; the tension knob  7  is loosened or removed. When the tension knob  7  is loosened, the user is able to slide the top frame  202  up so that a roll of film is able to slide in between the plugs  10  such that the inner diameter section  101  of the lower plug  10  is located in the film roll core. The users is then slides the top frame  202  down so that the upper plug&#39;s  10  inner diameter section  101  is located in the film roll core. The user is then able to tighten the tension knob  7  to prevent relative movement between the bottom frame  201  and top frame  202 . The user will then run the film around the adjustable tensioning roller  5  and the roller  4 . If there is a side of the film that is designed to be applied, that side will be in contact with the adjustable tensioning roller  5  and the roller  4 . The film  13  is ready to be applied. 
     There are times when a user will like to vary the direction of application of the film  13  (e.g. clockwise to counterclockwise). In some embodiments, the user is able to remove the tension knob  7 , slide the top frame  202  from the bottom frame  201 , slide the adjustable tensioning roller  5  off the rod  11 , flip the adjustable tensioning roller  5  (with the roller  4  secured by the brackets  3 ) over, slide back over the rod  11 , and reassemble. This ability allows the user to determine what direction they would like to apply the film  13 . 
     When applying stretch film to pallets, it is beneficial to pretension the film before it is secured in place and in contact with itself. Thus when the film  13  is put in place, the film  13  wants to contract do to its elasticity. The shape of the wrapped item goes 360 degrees around the items on the pallet. This serves to tightly compress the items and better secure the items located on the pallet. This helps the items and the pallet act as a single unit. 
     When using the film applicator, the user is able to adjust the pretension of the film  13  before it is put in place. The user is able to adjust the tension knob  7  to adjust the force required to rotate the adjustable tensioning roller  5 . The more force required to rotate the adjustable tensioning roller  5 , the increase in the pretension of the film before it is secured in place. 
     The adjustable tensioning roller  5  and the roller  4 , in addition to generating pretension, allow for smooth film delivery. The adjustable tensioning roller  5  and the roller  4  create a greater surface area to pull against the film applied on the object. This greater surface area and a convenient holding means, allows the user to even apply more tension to the film  13  before the film  13  is put in place, than would be easily applicable without the film applicator. This tension also enables the user to provide a counter force (e.g. lean away) to the tension, as the film  13  is being applied, such that makes it makes it easier for the user to maintain the weight of the film applicator. 
     Most pallets are prepared on and to ground level. Thus the wraps must be applied at ground level as well. This can be inconvenient, awkward, and injurious for the user. When using the film applicator, the user is able to hold the curved portion of the top frame  202  while applying film  13  at this lower level. In some embodiments, the user is able to hold on to a section of the top frame  202  that is between the curve and the tension knob  7 . 
     In many environments that have a need for film  13 , there are metallic items nearby. These metallic items include manual pallet movers, forklifts, and shelves. The magnets  9  are able to secure the film applicator to these items. This helps not only to conveniently store the film applicator, and keep it out of the way, but keep the film  13  located thereon, on hand for use. Thus, a user is able to always have film  13  handy and ready to use. 
     It is also understood that the film applicator is lightweight. In some embodiments, the film applicator weights less 4.5 lbs (2.041 kilograms). In other embodiments, it is less than 2.125 lbs (0.9639 kilogram). In some embodiments, the film applicator is designed to accept rolls of film that are about 15.4 inches (39.12 centimeters) in height. 
     It is to be understood, however, that even though numerous characteristics and advantages have been set forth in the foregoing description of embodiments, together with details of the structures and functions of the embodiments, the disclosure is illustrative only and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. And while the invention has been described above with respect to several embodiments, any element described in reference to any particular embodiment is hereby disclosed to be associated with any other embodiment of the invention.