Patent ID: 12225856

DETAILED DESCRIPTION

When referring to specific orientations, dimensions, or compositions of elements in the following disclosure, it should be understood that both the precise quantity or example given and functionally equivalent values are contemplated. For example, if a compound is stated to be 90% of a given element or composition, near equal compositions being, for example, 88% to 92% that same compound are contemplated. The range of such approximations should be considered to encompass all nearby values that a skilled person would understand to perform in a substantially equivalent manner to the specific value stated.

FIGS.1A and1Billustrate an example wrapping material100for wrapping around an agricultural product, such as cotton, in order to form a bale. In the examples ofFIGS.1A and1B, an unrolled portion of the wrapping material100is shown. The unrolled portion extends in a longitudinal or X direction and has a uniform width in a lateral or Y direction. The wrapping material may be stored in a rolled configuration, such as on a roll, and may be unrolled at a time when the agricultural material is to be wrapped. In the example ofFIGS.1A and1B, the wrapping material may be unrolled in the X direction (from left to right).

The wrapping material100may be formed as a continuous web of material. The continuous web of material may be made of polyolefins, such as polyethylene, or other suitable polymeric material that is approximately 40 to 120 microns thick. The continuous web may include a plurality of individual wrapping units110, whereby each wrapping unit may be designed as a discrete unit for wrapping a respective bale. For example, a roll of wrapping material may include 24 individual wrapping units and may have a diameter of between about 20-30 centimeters.

The wrapping material may also have a first surface112and an opposing second surface114separated by the thickness of the material used.FIG.1Ashows the first surface112, andFIG.1Bshows the second surface114. As can be seen fromFIGS.1A and1B, properties of the wrapping unit110may be different between the first and second surfaces. In the examples of the present disclosure, the first surface112may be designed to face towards the agricultural product, and the second surface may be designed to face away from the agricultural product, when wrapped to form a bale.

The wrapping units may be formed adjacent to one another longitudinally along the X direction, such that a leading end of one wrapping unit begins where the tail end of an adjacent wrapping unit ends.FIGS.1A and1Bshow an example wrapping unit110, which is representative of the other wrapping units of the wrapping material100. The wrapping unit110may include a leading end116that meets at a tail end of a previously unrolled wrapping unit (to the right of wrapping unit110) and a tail end118that terminates at a leading end of a next wrapping unit to be unrolled (to the left of wrapping unit110). Adjacent wrapping units may be fully connected to one another. Alternatively, adjacent wrapping units may be connected by a weak seam such as a perforation, to improve each of separating the wrapping units from one another. Alternatively, adjacent wrapping units may be connected by adhesives, by folding the leading and tail ends over one another, or any combination thereof. Some exemplary mechanisms for connecting the wrapping units are shown in commonly owned U.S. Pat. Nos. 6,787,209 and 7,541,080, the disclosures of which are incorporated herein by reference.

The first surface112of the wrapping unit110may include each of a nontacky portion120extending lengthwise in the −X direction from the leading end116until border125which is at a predetermined distance from the leading end116, and a tacky portion130extending lengthwise in the −X direction from the border125until the tail end118. The tacky portion130may be designed to be sufficiently tacky so that the second surface114of the wrapping unit adheres to the tacky portion130of the first surface112. For example, the tacky portion may have a tackiness property of more than 0.05 Newtons (N), using the standard peel test method ASTM D1876-01. Conversely, the nontacky portion120may be designed to be sufficiently nontacky so that the agricultural product does not adhere to the first surface112of the nontacky portion120of the first surface112. For example, the tacky portion may have a tackiness property of less than or equal to about 0.05 N, using ASTM D1876-01.

In the example ofFIGS.1A and1B, the entire first surface112of the tacky portion130is shown as being covered with tacky material. However, in other examples, the tacky portion of the first surface112may be intermittently tacky in any pattern desired, including but not limited to a vertical stripe pattern, a horizontal stripe pattern, a diagonal stripe pattern, a combination of patterns, and so on. In those examples of tacky portions having intermittent tackiness, the spaces between the tacky material may have a tackiness property the same or similar to that of the nontacky portion.

In the example ofFIGS.1A and1B, the tacky portion130is tacky on the first surface112and nontacky on the second surface114. However, in other examples, the tacky portion130may be tacky on both surfaces112,114. Also, in the example ofFIGS.1A and1B, the nontacky portion120may be nontacky on both the first and second surfaces112,114. However, in other examples, the nontacky portion may be nontacky on the first surface112and tacky on the second surface114. In any of these examples, the surfaces of the wrapping unit that are tacky may be entirely tacky or intermittently tacky as described herein.

Dimensions of the wrapping unit110and each of the nontacky portion120and tacky portion130may be selected so as to provide a secure wrap around the bale of agricultural product, while at the same time improving ease of removal of the wrapping material from the agricultural product, such as upon unloading the bale at a processing station. The example wrapping material ofFIGS.1A and1Bis designed for wrapping a bale having a width of approximately 2.5 meters and a circumference of about 6 meters. In this particular example, the width of the wrapping unit110in the Y direction is about 2.5 meters, approximately equal to that of the bale width. The length of the wrapping unit110in the X direction is about 21 meters, and more particularly more than triple that of the bale circumference. The length of the non-tacky portion120in the X direction is about 7 meters, and more particularly it is greater than the circumference of the bale. The length of the tacky portion130in the X direction is about 14 meters, and more particularly it is greater than twice the circumference of the bale.

Also shown inFIG.1Bis a visual indicator140positioned along a width of the wrapping unit110on the second surface114of the tacky portion130. The visual indicator140is provided to identify a predetermined location along the circumference of the bale at which the wrapping unit should be cut when unwrapped. As described in greater detail herein, the predetermined location may be chosen to avoid creating loose or separated fragments of wrapping material as the wrapping material is being separated from the agricultural product.

FIG.2illustrates an example wrapped bale200including a cylindrical bale of agricultural product201and a wrapping unit210wrapped around the bale. In the example ofFIG.2, the bale is round or cylindrical. A diameter of the bale is shown, and a width of the bale is in a direction pointing into or out of the figure. In other example arrangements, the bale may be another shape such as square, prism, or the like without departing from the underlying principles of the disclosure. In some examples, the bale may have a width of between about 2.5 to 3 meters, and a circumference of between about 6 to 7 meters. However, it should be understood that the underlying principles of this disclosure may be applicable to bales of any width and circumference. For example, comparable wrapping materials may be designed to wrap a bale may having a width of about 1.5 meters, a diameter of about 2.4 meters, and a circumference of about 5.7 meters. In such an example, the wrapping material may be slightly wider than the bale's width, such as about 1.8 meters, slightly longer than double or triple the bale's circumference, such as about 12 meters or 17.5 meters

A leading end216of the wrapping unit210is shown inFIG.2as abutting a surface of the bale agricultural product201. A tail end218of the wrapping unit210is shown as resting on an outer surface of the wrapped bale including the wrapping unit. The leading end216and tail end218may extend into or out of the figure so as to run along an entire or about an entire width of the bale.

In the example ofFIG.2, a nontacky portion220constitutes an inner portion of the wrapping unit210, such that its first surface is in contact with the bale of agricultural product201when wrapped around the bale. Also, in the example ofFIG.2, the nontacky portion220has a length that is greater than 100% of the circumference of the bale, so as to overlap the leading end216of the wrapping unit210. The overlap250between overlapping portions of the nontacky portion220may be provided to ensure that the entire circumference of the bale201is in contact with the nontacky portion220, as opposed to a portion of the bale201being in contact with the tacky portion230. This, in turn, may ensure that none of the agricultural product adheres to the wrapping unit210, and particularly to the tacky portion230of the wrapping unit210, which would impede with separation of the agricultural product from the wrapping unit during an unwrapping procedure. The length that the overlap250extends around the circumference of the bale may be a limited distance. In some examples, the length of the overlap may be limited to about 1 meter. which in the case of a bale having a 6 meter circumference, may be about 15% of the circumference of the bale, whereby the length of the nontacky portion220is about 115% of that of the circumference of the bale. In some examples, the length of overlap may be limited to approximately 0.4 meters or less, which in the case of a bale having a 6 meter circumference may be about 6-7% of the circumference of the bale, whereby the length of the nontacky portion220is about 106%-107% of that of the circumference of the bale. The presence of overlap250results in a portion of the nontacky portion220not being in contact with any part of the tacky portion230. Specifically, in the example ofFIG.2, a length of nontacky portion220from the leading end216to a part of the nontacky portion220underlying a boundary225between the nontacky portion220and the tacky portion230, is not in contact with the tacky portion230. This length of the nontacky portion220forms an appendage which, if cut, could become separated from the rest of the wrapping unit. Limiting the length of the overlap250may avoid an excess length of wrapping material forming an unwieldy appendage which may become separated when the wrapping unit is ultimately unwrapped from the agricultural product. For instance, with reference toFIG.2, if the wrap210is cut at a circumferential location between leading end216and border225, a piece of the wrapping unit210would be detached from the rest of the wrapping unit210and could become a loose or separated piece of plastic. Minimizing this circumferential length of overlap250, or at least decreasing the length of overlap250, can decrease a risk of a loose or separated piece of plastic separating from the wrapping unit and getting mixed in with and contaminating the agricultural product during processing.

Also in the example ofFIG.2, a tacky portion230constitutes an outer portion of the wrapping unit210, such that its first surface avoids contact with and adhering to the bale of agricultural product201when wrapped around the bale. Instead, the first surface of a first sub-portion232of the tacky portion230is in direct contact with and adhered to the second surface of the nontacky portion220, the first surface of a second sub-portion234of the tacky portion230is in direct contact with and adhered to the second surface of the first sub-portion232of the tacky portion230. Also, in the example ofFIG.2, the nontacky portion220has a length that is greater than 200% of the circumference of the bale, so as to twice overlap the boundary225between the nontacky portion220and the tacky portion230of the wrapping unit210. The double overlap may be provided to ensure a sufficient thickness or rigidity of the wrapping unit around the circumference of the bale201. Stated another way, the second sub-portion234of the tacky portion230may be thought of as a reinforcement for the first sub-portion232of the tacky portion230. This may ensure that the agricultural product retains its structure during formation, transportation, unloading and unwrapping, which in turn may ensure clean separation of the wrapping unit from the bale. It should be understood that the reinforcement sub-portion234may be partially omitted without departing from the underlying principles of the present disclosure.

Also shown in the example arrangement ofFIG.2. is a visual indicator240. The visual indicator may extend along a width of the wrapping unit210at a given distance from the tail end218. The given distance from the tail end218may be predetermined to not lie at a same circumferential position as the overlap250of the nontacky portion220, such that it does not overlay the overlap250when wrapped around the bale. Circumferentially separating the overlap250from the visual indicator240may minimize the risk of cutting within the overlap250and separating the aforementioned appendage from the remainder of the wrapping unit during unwrapping. Thus, the visual indicator can decrease the likelihood of a portion of the nontacky portion220that is not adhered to the first surface of the tacky portion230being physically separated from the rest of the wrapping unit210when the bale is unwrapped. As a result, it is easier for the wrapping unit to be separated from the bale of agricultural product in a single piece, leaving no pieces of plastic to get mixed in with and contaminate the agricultural product during processing.

FIG.3is an exploded diagram illustrating an example wrapping unit300after it has been cut and separated from a bale of agricultural product. In the example ofFIG.3, the wrapping unit is cut along a cut line310that extends across a width of the wrapping unit. In some examples, the cut line may be defined by a visual indicator (not shown).

InFIG.3, a first surface312of the wrapping unit is shown. The first surface is the surface that previously faced inward towards the bale of agricultural product when the wrapping unit was wrapped around the bale. Although the exploded diagram ofFIG.3shows three portions320,330,340of the wrapping unit300as separate from one another, it should be understood that these portions actually remain adhered to one another during the unwrapping process, as the tacky first surface of the second portion330causes it to adhere to the second surface of the first portion320, and the tacky first surface of the third portion340causes it to adhere to the second surface of the second portion330.

It should be understood that each of the portions320,330and340shown inFIG.3has a length equal to a circumference of the bale, as the cut line310for each portion is aligned circumferentially on the bale.

It can be seen inFIG.3that the nontacky portion of the wrapping material is longer than a circumference of the bale. In other words, the nontacky portion covers the entire first portion320of the wrapping unit, but an additional length of an appendage350. The appendage is shown as free inFIG.3because it is not adhered to a first surface of the tacky second portion330. By design, the wrapping unit300is designed such that the appendage350is located circumferentially away from the cut line310, so that cutting the wrapping unit300at the cut line310does not cut through the appendage350. Thus, while the appendage350is free on one end in the exploded diagram ofFIG.3, it remains connected at its other end, and thus remains a connected part of portion320. Since, as noted above, portion320is connected to portion330, which in turn is connected to portion340, the appendage350remains attached to all of the portions320,330,340upon removal of wrapping unit300from the bale by cutting along cut line310. It should be understood that the wrapping unit may also be cut at any other circumferential location except through appendage350, and the appendage would remain connected to the entire wrapping unit300when the wrapping unit300is removed from the bale in a single piece.

It can also be seen from the example ofFIG.3that the tacky portion of the wrapping material is exactly twice as long as the circumference of the bale. In other words, the tacky portion covers the entire second portion330and entire third portion330of the wrapping unit300. In other examples, the tacky portion may be longer, extending to a fourth portion that may adhere to a second surface of part of the third portion. In other examples, the tacky portion may be shorter, such as having a third portion that adheres to the second surface of the second portion and extends only part of the length of the circumference of the bale.

In the above example wrapping materials, each wrapping units includes a visual indicator indicating a circumferential location at which the wrapped bale may be cut. The goal of this visual indicator is to avoid cutting over the free portion or appendage of the nontacky portion of the wrapping unit, since cutting through that appendage may form an appendage which can separate from the rest of the wrapping material and cause it to become mixed in with the agricultural product. However, in other examples, a visual indicator may directly indicate a location that the wrapped bale should not be cut, such that avoiding cutting the wrapping material at the circumferential location of the visual indicator in turn avoids cutting the loose portion of the nontacky portion.FIG.4illustrates a wrapping unit410of an example wrapping material400like in the example ofFIGS.1A and1B, having each of a nontacky portion420and a tacky portion430. A second surface of the wrapping material400is shown inFIG.4. The tacky portion430includes a visual indicator440positioned at a location along the length of the wrapping unit that is expected to overlap with the tail of the nontacky portion420, such as the appendage350shown inFIG.3. For instance, if the wrapping material is designed to wrap a bale having a circumference of about 6 meters and the nontacky portion has a length of about 6.4 meters, then the visual indicator may be positioned at a distance of between about 18.4 to 18.8 meters from the leading end, which is about 12 to 12.4 meters from the boundary450between the nontacky portion420and tacky portion430. This distancing ensures that when the wrapping unit is wrapped over the bale, the overlapping portions of the nontacky portion420and the visual indicator440all overlap one another, and thus, during removal of the wrapping unit, an operator sees the visual indicator and knows not to cut along that circumferential location.

In the example ofFIG.4, the visual indicator is shown as having a measurable width in the lengthwise direction −X of the wrapping material. However, in other examples, this visual indicator may be thinner and instead provide notice to an operator to avoid cutting anywhere in the vicinity of the visual indicator in order to avoid cutting over the overlapping portions of the nontacky portion.

In the above example wrapping materials, the wrapping units are of uniform length. However, in some instances, either or both of the leading and tail ends of the wrapping unit may be designed to have narrower widths than the middle of the wrapping unit. This may be done at the edge of the leading end in order to improve feeding of the wrapping material into a baler machine, and at the edge of the tail end in order to avoid forming loose corners of the wrapping materials on an outer perimeter of the wrapped bale.FIG.5illustrates a wrapping unit510of an example wrapping material500like in the example ofFIGS.1A and1B. A second surface of the wrapping material500is shown inFIG.5. The nontacky portion520includes a first tapered portion542that widens from a first width to a second width in a lengthwise direction −X of the wrapping material. Similarly, the tacky portion530includes a second tapered portion544that narrows from the second width to the first width.

In the example of a wrapping material made for wrapping bales that are about 2.7 meters in width, the first width may be about 2.3 meters, and the second width may be about 2.7 meters. Thus, the first width may be between 85-90% of the second width. In other examples, different first and second widths may be provided, for instance depending on the width of the bale intended to be wrapped with the wrapping material and the amount of desired exposure at either edge of the wrapped bale of the second width relative to the first width.

Also, in the example ofFIG.5, the tapered portions542,544are spaced apart from the edges of the leading and tail ends. However, in other examples, a tapered portion may be positioned directly at the edge of the leading end, the edge of the tail end, or both.

FIG.6is a flow diagram illustrating an example routine600for using the example wrapping materials described herein. It should be understood that the routine600is provided merely by way of example, and that in other examples, certain steps may be added, omitted, or reordered without departing from the underlying principles of the present disclosure. For example, the routine600is divided into two separate phases: wrapping a bale; and unwrapping the bale. However, either one of these phase may be performed on its own. Additionally or alternatively, a routine of using the wrapping material may involve such steps as harvesting an agricultural product and organizing it into a mass for baling inside a baler, loading the wrapping material into a baler, operating the baler, storing a wrapped bale, transporting a wrapped bale, unloading a wrapped bale, processing the agricultural product from an unwrapped bale, and so on.

At block610, the width of the wrapping material is aligned with a width of the bale. The alignment may be performed manually, or automatically such as with a baling device. Generally, the wrapping material may be formed on a roll, and the width of the roll of wrapping material may be about equal to the width of the bale.

At block620, a wrapping unit of the wrapping material is wound around a circumference of the bale. The wrapping unit has each of a first surface facing towards the bale, and an opposing second surface facing away from the bale. For example, portions of the first surface may be nontacky and portions of the first surface may be tacky, as described herein.

Winding the wrapping unit around the bale may involve, at block622, winding a nontacky portion of the wrapping unit around the bale, and at block624, winding a tacky portion of the wrapping unit around the bale and over the nontacky portion. The nontacky portion may be wrapped for a length greater than a circumference of the bale, and the tacky portion may be wound for a length greater than the circumference of the bale. In some examples, the nontacky portion of the wrapping unit may be wound for a length that is more than 100% but less than 115% of the circumference of the bale, or more than 100% but less than 106% or 107% of the circumference of the bale. Also in some examples, the tacky portion of the wrapping unit may be wound for a length that is about twice the circumference of the bale, or in some instances longer than twice the circumference of the bale, or in other instances less than twice the circumference of the bale or even only about one circumference of the bale. Increasing the length of the tacky portion may improve stability of the wrapped bale, while decreasing the length of the tacky portion provides for less use of wrapping materials. After block624, the wrapping unit may be separated from the rest of the roll of wrapping material, thus leaving a single wrapped bale of agricultural product.

In some examples, winding the wrapping unit around the bale may further involve securing the tail end of the wrapping unit to the rest of the wrapping material. Securing the tail end of the wrapping unit may be necessary to avoid the tail end peeling away from the bale during storage or transport. In some instances, a tackiness property of the tail end may be the same as the remainder of the tacky portion, and may be sufficient for securing the tail end so that it does not peel away from the bale. In other examples, the first surface of the tail end may have an adhesive material applied thereto. The adhesive material may have a greater adhesion property than the tacky material, and thus may improve reinforcement of the tail end and protect against the tail end peeling away from the bale during storage or transport. Example adhesive materials are described in commonly owned U.S. Pat. No. 7,541,080, the disclosure of which are incorporated herein by reference.

At block630, the wrapping material may be cut along an entire width of the wrapping unit. The cut may be lined up based on the position of a visual indicator made on an outer surface of the bale, particularly on a second surface of the tacky portion of the wrapping unit. In some examples the visual indicator may be positioned circumferentially away from overlapping portions of the nontacky material, such that cutting along an entire width of the wrapping unit may involve cutting along the visual indicator to avoid cutting the overlapping portions of the nontacky portion. Alternatively, the visual indicator may be a “DO NOT CUT” indicator that overlaps with the overlapping portions of the nontacky material, and cutting along an entire width of the wrapping unit may involve avoiding cutting along the visual indicator in order to avoid cutting the overlapping portions of the nontacky portion.

At block640, the wrapping material may be separated from the agricultural product. The outer layers of tacky wrapping material may adhere or cling to the inner layer of non-tacky material. Additionally, the inner layer of nontacky material may avoid adhering to the agricultural product. Thus, the wrapping unit may be separated from the agricultural product in a single piece, leaving the entire bale agricultural product for processing.

The above example wrapping materials, and example wrapping and unwrapping methods may be useful for safely and cleanly unloading bales of cotton at a processing facility, such as a ginning facility. Generally, a ginning facility will include an unloading dock onto which the cotton bale may be unloaded from a vehicle. Unloading the bale from the vehicle may involve lowering the bale from the vehicle while also tipping the bale from a resting position on its side in the vehicle to an upright position on the dock, and subsequently unwrapping the wrapping material from the bale. In some examples, the dock may be a stationary platform. In other examples, the dock may be a conveyor belt, which may or may not be moving at the time of unloading.

In order to unload the cotton bale safely without damaging the bale, it is necessary for the wrapping material to be sturdy enough to support the bale as it is lowered from the vehicle and tilted upright. Additionally, in order to unwrap the bale cleanly without fragments of the wrapping material mixing in with the cotton, it is necessary for the wrapping material to pull away from the bale in as few pieces as possible. The above example wrapping materials and wrapping and unwrapping methods provide for a wrapping material that gives sufficient support for unloading the bale while also allowing for the wrapping material to be separated from the bale in a single piece. As a result, a risk of failure during the bale unwrapping process is lowered, which leads to less wrapping material becoming mixed in with the cotton. Thus, the cotton processed at the ginning station may have lower overall amounts of contamination.

Cotton bales wrapped with a wrapping unit in accordance with the above-described design were tested against cotton bales wrapped with two alternative wrapping materials, TamaWrap+™ and TamaWrap™ blue to confirm that the design of the present disclosure mitigates the risk of failure during the bale unwrapping process. The tests were conducted to determine a failure rate for unloading and unwrapping the cotton bales, whereby failure was measured by pieces of the wrapping material being found in the ginning equipment. The ginning equipment was inspected using a camera set up at the beginning of the feeding process, and an apparatus was set up for automated residue removal at the ginning stand. Testing was conducted for each bale under similar location, season and weather conditions.

Results of the test are shown in the Table below. The results exclude test bales that arrived at the unloading dock with one or more tears in the wrapping material, and test bales that arrived with a smaller-than-usual diameter, such as a diameter less than 2 meters, and tipped over during unloading as a result of its dimensions.

UnloadUnwrapOverallWrapFailureFailureFailureTypeRateRateRateCurrent design0.51%0.26%0.97%TamaWrap+ ™0.81%0.40%1.23%TamaWrap ™ blue0.98%0.87%1.84%

As can be seen from the Table, the wrapping material of the present disclosure performed better than the known alternatives. The failure rate for unloading the cotton that was baled in the wrapping material of the present disclosure was about 59% lower than for the TamaWrap+™ wrapping material, and about 92% lower than for the TamaWrap™ blue wrapping material. The failure rate for unwrapping cotton that was baled in the wrapping material of the present disclosure was about 54% lower than for the TamaWrap+™ wrapping material, and about 235% lower than for the TamaWrap™ blue wrapping material. The overall failure rate for processing the cotton that was baled in the wrapping material of the present disclosure was about 27% lower than for the TamaWrap+™ wrapping material, and about 90% lower for the TamaWrap™ blue wrapping material, which means that 27% and 90% fewer bales, respectively, were found to be contaminated. These figures suggest significant mitigation of the risk of failure during the unwrapping process, which in turn reduces the overall level of contamination in the unwrapped cotton after being processed at the ginning facilities.

The reduction in failure rate caused by use of the wrapping material of the present application can lead to fewer batches of contaminated cotton being processed, on average. This in turn can preserve the overall value of the processed cotton, since fewer batches are contaminated and thus fewer batches suffer a reduction in value. Furthermore, producing fewer batches of contaminated cotton can improve or preserve the grower's or supplier's reputation, enabling the grower or supplier to sell even non-contaminated cotton for higher values.

The above example test results generally describe that the wrapping materials and wrapping/unwrapping methods of the present disclosure are advantageous for baling cotton. However, it will be readily appreciated that same or similar principles may be applied to wrapping materials and wrapping/unwrapping methods for other agricultural products, including but not limited to hay, flax straw, or silage.

Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.