Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
  • B65D81/24—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants
  • B65D81/26—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators
  • B65D81/266—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators for absorbing gases, e.g. oxygen absorbers or desiccants
  • B65D81/268—Adaptations for preventing deterioration or decay of contents; Applications to the container or packaging material of food preservatives, fungicides, pesticides or animal repellants with provision for draining away, or absorbing, or removing by ventilation, fluids, e.g. exuded by contents; Applications of corrosion inhibitors or desiccators for absorbing gases, e.g. oxygen absorbers or desiccants the absorber being enclosed in a small pack, e.g. bag, included in the package
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
  • B65D85/67—Containers, packaging elements or packages, specially adapted for particular articles or materials for web or tape-like material
  • B65D85/671—Containers, packaging elements or packages, specially adapted for particular articles or materials for web or tape-like material wound in flat spiral form
  • B65D85/672—Containers, packaging elements or packages, specially adapted for particular articles or materials for web or tape-like material wound in flat spiral form on cores

Definitions

• the present invention relates generally to packaging a wrapped, cylindrically rolled, moisture-sensitive film.
• the invention relates to a packaged, wrapped, cylindrically rolled moisture-sensitive film while in another aspect, the invention relates a method of packaging such a film.
• PV ceils generate electricity from solar energy.
• the cells require protection from the environment, and are packaged in glass and/or plastics and are typically sealed within a water-impervious polymeric film.
• one or more polymers that comprise the film will crosslink upon exposure to moisture, e.g.. the water vapor in air, thus rendering the film impervious to water or at least improving its imperviousness to water, While this is a desired result, typically and preferably the crosslinking of the film is delayed until after the film has been applied to the PV ceil so thai maximum, adhesion can be obtained during lamination of the components.
• the film Since typically the film is manufactured at a site separate and apart from the site of PV cell manufacture, the film is usually shipped and stored prior to use. Since these films are moisture-sensitive, e.g., the polymers from which they are made are prone to crosslink upon exposure to moisture, the film is packaged in a wrap that comprises a moisture barrier, i.e., a wrap through which water in liquid or vapor form cannot pass (or at least pass only in an amount that is of little, if any, consequence to the integrity of the film over a designated period of time, e.g., nine months and under ambient conditions.
• a moisture barrier i.e., a wrap through which water in liquid or vapor form cannot pass (or at least pass only in an amount that is of little, if any, consequence to the integrity of the film over a designated period of time, e.g., nine months and under ambient conditions.
• the film is collected onto rolls, wrapped in a flexible bag, sealed and the wrapped rolls stacked in storage and/or shipping bins for ultimate transport to a customer.
• the bag comprises a moisture barrier and is hermetically sealed, e.g., vacated of air and/or heat or otherwise sealed from the environment.
• a means is employed to maintain a low humidity environment within the bag, such as a desiecant.
• the weight of the rolls can vary greatly, e.g., from a tens of pounds to hundreds of pounds, which means that not only can the roils be difficult to maneuver manually (and thus require the use of mechanical assists, e.g., robotic arms, forklifts, etc., which can damage the wrap and/or enclosed film) but when stacked one upon the other they can experience damage, e.g., crease, tear, block, flatten, etc., particularly those rolls on the bottom of the stack.
• the invention is a packaged, moisture-sensitive, cylindricaUy rolled film comprising:
• a flexible, moisture-barrier wrap having an exterior surface, the rolled film hermetically enclosed within the wrap, and
• a tube comprising (1) an elongated sidewall with an interior surface, and (2) first and second ends, the rolled film hermetically enclosed in the wrap situated within the sidewall and between the first and second ends,
• the film is wound around a core, typically hollow and cylindrical
• a desiccant is placed inside the barrier wrap before the wrap is sealed.
• one or more spacers are situated within the tube for receiving and holding the wrapped, rolled film such that the exterior surface of the wrap is not in contact with the interior surface of the tube.
• the spacers are situated on the core.
• the tube comprises one or more end caps and the spacers are situated on the end caps,
• the invention is a packaged moisture-sensitive, cylindricaUy rolled film comprising:
• a tube comprising (1) a moisture barrier, (2) an elongated sidewall with an interior surface, and (3) first and second end caps, the rolled film hermetically enclosed within the tube.
• the film is wound around a core, typically hollow and cylindrical.
• a desiccani is placed inside the tube before the tube is hermetically sealed,
• one or more spacers are situated within the tube for receiving and holding the rolled film such that the exterior surface of the rolled film is not in contact with the interior surface of the tube.
• the spacers are situated on the core, in one embodiment the spacers are situated on the end caps.
• the invention is a method of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:
• a funneling guide having first and second ends
• a tube having first and second ends connected by an elongated sidewal!
• An extendible rod comprising a support head
• the second end of the wrapped film is opposite the first end of the funneling guide
• the first end of the tube is opposite the second end of the funneling guide
• the support head of the rod is opposite the second end of the tube
• the wrapped film enters and moves through the funneling guide, and b, The second end of the wrapped film contacts the support head of the rod, and
• the wrapped film slides into the tube due to gravity.
• the alignment of the wrapped film and tube is maintained by positioning the wrapped film and tube on a cradle.
• the wrapped film and tube are positioned on separate but aligned cradles, in one embodiment the wrapped film includes packaging ears that are folded back by the tunneling guide as the wrapped film enters the tube.
• the invention is storage and/or shipping containers comprising stacked tubes containing packaged, hermetically mapped, moisture-sensitive, cylindrically rolled film.
• the invention is an apparatus for packaging hermetically wrapped, moisture-sensitive, cylindrically rolled, film into a tube open on both ends, the apparatus comprising:
• a first cradle to receive and hold a hermetically wrapped, moisture-sensitive, cylindrically rolled film, the first cradle having first and second ends,
• a funneling guide having first and second ends with the first end positioned opposite the second end of the first cradle
• Ail extendible rod comprising first and second ends, the first end of which 1.
• the first cradle, funneling guide, second cradle, rod and actuator are longitudinally aligned along a central axis, and
• the tilting mechanism is attached to each of the first cradle, funneling guide, second cradle, rod and actuator such that their longitudinal alignment along the central axis is maintained during movement between the first and second positions.
• the invention is an automated process of packaging a hermetically wrapped, moisture-sensitive, cylindricaliy rolled film having first and second ends, the process comprising the steps of:
• a tube having first and second ends connected by an elongated sidewall
• the invention is art automated process of packaging a hermetically wrapped, moisture-sensitive, cylindricaliy rolled film having first and second ends, the process comprising the steps of:
• the hermetically wrapped, moisture-sensitive, cylindricaliy rolled film and 2.
• a tube having first, and second ends connected by an elongated sidewall, and
• the invention is an automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically rolled film having first and second ends, the process comprising the steps of:
• a funneling guide having first and second ends
• a tube having first and second ends connected by an elongated sidewall
• the second end of the wrapped film is opposite the first end of the funneling guide
• the first end of the tube is opposite the second end of the funneling guide
• the support head is in a first position opposite the first end of the film
• Figure, 1 A is an exploded perspective view of an exemplary packaged, wrapped, cylindrically roiled moisture-sensitive film comprising, a tube, wrap, moisture-sensitive film cylindrically rolled about a core, and desk: cant,
• Figure. IB is a cross-sectional view of the packaged rolled film of Figure 1A at 1-1.
• Figure 2 is a side view of the rolled film inside the sealed flexible barrier having wrapping ears.
• Figure 3 is a flow chart describing an exemplary automated process of packaging the wrapped rolled film of Figure 1A.
• Figure 4 is a schematic of an exemplary packaging station for the automated process of packaging wrapped roiled film, with the station shown in a first position.
• Figure 5 is the station of Figure 4 shown in a second position
• Figure 6 is the station of Figure 4 shown in a third position.
• Figure 7 is the station of Figure 4 shown in a fourth position.
• Figure 8 is the station of Figure 4 shown in a fifth position.
• Figure 9A is a perspective view of an exemplary packaged cylindrically rolled, moisture-sensitive film comprising a tube and a cylindrically rolled, moisture-sensitive fiim.
• Figure 9B is a cross-sectional view of the packaged rolled film of Figure 9 A at 9-9.
• Figure 10 is a side view of the packaged rolled film of Figure 9A further comprising, first and second end caps.
• Figure 11 is a perspecti ve view of the packaged rolled film of Figure 9A in which the first and second end caps each include a support.
• Figure 12A is a schematic of another exemplary packaging station for the automated process of packaging wrapped or unwrapped rolled film, with the station shown in a first position
• Figure 12B is the station of Figure 12 A shown in a second position.
• Figure 13 A is a schematic of another exemplary packaging station for the automated process of packaging wrapped or unwrapped rolled film, with the station shown in a first position.
• Figure 13B is the station of Figure 13 A shown in a second position.
• Figure 13C is the station of Figure 13A shown in a third position.
• Figure 14 is a schematic of an exemplary storage container with a plurality of packaged, wrapped rolled films situated inside for transportation and/or storage.
• the numerical ranges in this disclosure are approximate, and thus may include values outside of the range unless otherwise indicated. Numerical ranges include all values from and including the lower and the upper values, in increments of one unit, provided that there is a separation of at least two units between any lower value and any higher value. As an example, if a compositional, physical or other property, such as, for example, equipment dimensions, rolled film size, tube size, etc., is from 100 to 1,000, then all individual values, such as 100, 101 , 102, etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly enumerated.
• ''Moisture-sensitive film and like terms mean a film that experiences change upon exposure to moisture either in the form of liquid water or water vapor, This change can take any form, e.g., crosslinking, color, adhesion, tensile strength and/or elongation, etc., and can occur at different rates under different conditions.
• Rolled film and like terms mean a moisture-sensitive film rolled into a cylindrical configuration.
• the film may be wound around a core or upon itself, i.e., without a core.
• Tube and like terras mean a hollow, generally cylindrical construction comprising an elongated sidewall connecting two ends.
• the tube ends may be open or closed. If a tube end is closed, the end can be closed either by an end cap or the closed end can be integral to the sidewali, i.e., a continuous extension of one into the other.
• the tube may be constructed of any solid material, such as cardboard, plastic, wood, or metal.
• Desiccant and like terms mean a drying agent, e.g., a material that can absorb moisture from the air.
• “Moisture-barrier wrap” and like terms mean a wrap, e.g., film, bag, etc., generally impervious to the passage of moisture.
• moisture in liquid and/or vapor form cannot pass, or pass only in an amount and at a rate as to have minimal, if any, detectable effect on the film, from outside the container into the inside of the container and vice versa.
• Core and like terms as applied to moisture-sensitive, cyiindrically rolled film mean a generally cylindrical article about which the film is wound.
• the core can be constructed of any material, e.g., cardboard, plastic, wood, metal, etc., hollow or solid, and is generally of the same length as the width of the film.
• the roiled moisture-sensitive film comprises a eyiindricaily wound length of moisture-sensitive film having a width extending between a film first end and a film second end.
• the film is wound about a core, although in other embodiments the roiled film is careless (either because a core was not used in the winding process or if a core was used in the winding process, it was subsequently removed).
• the cross-section of the core can take any shape, e.g., circular, elliptical, polygonal (e.g., octagonal), and it can comprise one or more sections that are hollow and/or solid.
• a core is present, and it is a one piece, tube of cardboard that is generally as long as the Film is wide.
• the film can vary in size (length, width and thickness) and shape, and the roiled film can vary in size (diameter and weight) although in at least one embodiment the rolled film has an outside diameter of six inches to twenty inches and a width of twenty-three inches to forty-eight inches.
• the rolled film typically varies in weight from a few tens of pounds to several hundred pounds or more.
• moisture-sensitive film are those comprising one or more polyolefins having silane functionality such as the silane-grafted ethylene/a-olefms and others described in US 2008/01 15825 and US 2008/0078445.
• the barrier wrap comprises a waterproof material, such as a plastic (e.g., polyethylene, polyvinylidene chloride, polypropylene, PET, etc), silicon oxide coating, or metal foil, e.g., aluminum, in one embodiment the barrier wrap further comprises an oxygen barrier such as polyvinylidene chloride, ethylene vinyl alcohol (EVOH) or certain nylons.
• a plastic e.g., polyethylene, polyvinylidene chloride, polypropylene, PET, etc
• silicon oxide coating e.g., aluminum
• metal foil e.g., aluminum
• the barrier wrap further comprises an oxygen barrier such as polyvinylidene chloride, ethylene vinyl alcohol (EVOH) or certain nylons.
• EVOH ethylene vinyl alcohol
• the wrap is typically a composite construction comprising multiple layers of various plastics, and/or papers, and/or coatings, and/or foil.
• the barrier wrap is typically in the form of a bag that, can be hermetically sealed after the rolled film is placed inside of it.
• the wrap is a sheet or film in which the rolled film is enclosed.
• the wrap is sealed by any conventional means, typically by heat sealing.
• the bag can be evacuated of air prior to sealing, Upon sealing the wrap typically comprises "ears" which comprise area of the wrap in excess of that, needed to hermetically seal the moisture-sensitive film. These ears are typically located near the seal of the wrap about the rolled film, and typically constitute a small amount, e.g., less than 5-10 percent, of the total area of the wrap about the rolled film.
• the tube comprises an elongated cylindrical sidewall extending between first and second open ends, the sidewall including a tube exterior surface and a tube interior surface.
• the tube is sized to accommodate the size of the rolled film and the storage and shipping constraints.
• the tube is longer than the width of the rolled film that it will package by at least one inch, more typically by at least two inches based on the width of the film.
• the tube is constructed of a heavy cardboard such that the weight of multiple, e.g., i to 4 or more, similar tubes containing the roiled film stacked upon it will not crush or otherwise compromise the integrity of the packaging.
• the tube has an outside diameter of seven inches to twenty-four inches, and a length of fifty inches.
• the tube is used to package a wrapped, rolled moisture-sensitive film
• at least one end, preferably both ends, of the tube are open.
• the tube comprises a moisture barrier, optionally an oxygen barrier, and is closed on both ends either by one end of the tube having an integrally closed end and one capped end, or both ends capped.
• the end caps also typically comprise a moisture barrier.
• the tube is typically evacuated of air, e.g., either by pulling a vacuum or flushing with a moisture-free gas, after the film as been placed inside the tube and before or after sealing the tube ends.
• the cylindricaliy rolled, moisture-sensitive film is enclosed within a barrier wrap to form a wrapped rolled film
• the wrapped rolled film is conveyed to a packaging station for insertion into an open-ended tube.
• the wrap protects the rolled film from moisture and contaminants, while the tube protects the rolled film and the wrap from mechanical damage caused by manual or automated packaging operations and allows for the safe transportation and storage of the rolled film,
• FIG. 1A and I B one embodiment of a packaged wrapped rolled film 2 is depicted.
• Packaged wrapped roiled film 2 comprises a cylindricaliy rolled film 4, flexible barrier wrap 6, and tube 8,
• Rolld film 4 is hermetically sealed inside wrap 6 to form wrapped rolled film 10, which is automatically inserted into tube 8 to prepare the wrapped rolled film for storage and/or transit.
• Figure 2 is provided to particularly illustrate one embodiment of the wrapped rolled film prior to insertion into the tube. More particularly, Figure 2 depicts a side view of wrap 6 in a sealed bag configuration enclosed about the rolled film, the wrap having a heat-sealed closed end 14.
• wrap protrusions 16 extend from both sides of the closed end of the wrap. These protrusions present packaging problems as discussed below.
• packaged wrapped rolled film 2 can further include a desiccant 1 1 ( Figure 1 A) that is inserted inside the wrap prior to sealing.
• the wrap can be evacuated of air or chemically purged to remove moisture in the air between the rolled film and the wrap. Once the rolled film is sealed in the wrap, wrapped roiled film 10 is ready to be inserted inside tube 8.
• FIG. 3 One method of inserting wrapped rolled film 10 into tube 8 is described in flowchart 100 provided in Figure 3.
• the steps provided in flowchart 100 are described with reference to an exemplary packaging station 30, shown in Figure 4, configured for the automated method of packaging the wrapped roiled film.
• Station 30 is comprised of wrapped fiim positioner 32, tube positioner 34, funneling guide 36. and rod 40 that includes a support head 50. These elements are positioned along alignment axis 42, which provides for a substantially in-line packaging path for the wrapped rolled film from the film positioner into the tube.
• film positioner 32 is positioned to receive wrapped rolled film 10.
• Film positioner 32 includes a cradling surface 35 thai is provided to position the wrapped roiled film along alignment axis 42 for insertion into funneling guide 36.
• the film positioner is dynamic cradle, such as a cradling conveyor.
• the film positioner stabilizes and/or guides the wrapped rolled film through the funnel guide, such as a robotic arm.
• protrusions 16 are created. These protrusions can result in difficulties with loading wrapped rolled film 10 into tube 8, as the protrusions can snag on equipment or the tube.
• tunneling guide 36 is provided to guide the protrusions into the tube.
• the funneling guide is situated between the film positioner and the tube, in one embodiment funneling guide 36 is comprised of a tapered ring having a guide first end 43 and a guide second end 44, where the circumference of the guide first end is greater than the circumference of the guide second end,
• the tapered configuration of the funneling guide provides a means to guide the protrusions 16 into the tube 8 by folding them downwards to conform to the circumference of the tube, thus eliminating binding of the protrusions that can result in damage to the wrap 6 and the prevention of proper insertion into the tube.
• funneling guide 36 can be comprised of another tapered entry guide, such as a plurality of flat extensions positioned, about the entry to tube 8,
• the tunneling guide 36 can be shaped and sized to accommodate the dimensions of the wrapped rolled film, the protrusions, and the tube, in addition, funneling guide 36 can be comprised of one or more of various materials, such as metal, plastic, and fiberglass,
• rod 40 is depicted positioned along the alignment axis.
• the rod serves to provide a mechanism for lowering wrapped rolled film 10 into tube 8 when a downward gravitational force is imparted on the wrapped rolled film, such as when the alignment axis is tilted from a first position to a second position (discussed below).
• rod 40 is comprised of a shaft 48 having a terminus support head 50.
• the rod is extensible via an actuator 46 configured to extend the support head through the tube.
• the shaft and the support head can vary in size and shape, although they are intended to be sized to pass through the tube without damaging the tube.
• Support head 50 is configured to provide a suitable surface for contacting and supporting the wrapped rolled film without incurring any damage, such as a padded surface.
• the center of support head 50 is centered in-line with shaft 48 along alignment axis 42, In one embodiment the center of support head 50 is offset from the alignment axis.
• Station 30 further comprises tube positioner 34.
• the tube positioner is situated between funneling guide 36 and rod 40 and serves to support tube 8 in a position along alignment axis 42 for receiving wrapped rolled film 10 from the guide second end 44 of the funneling guide,
• the tube positioner supports a tube first end 56 adjacent to the guide second end and a tube second end 58 adjacent to support head 50.
• the tube positioner can include one of numerous positioning mechanisms, such as, one or more cradles, which are sized and shaped to receive and position tube 8.
• a robotic arm (not shown) can be used to hold tube 8 in the proper positiori during insertion of the wrapped rolled film.
• Station 30 can further comprise a mounting platform 52 for supporting and/or securing packaging elements, such as film positioner 32, tube positioner 34, funneling guide 36, and rod 40. in this manner, the packaging elements can be held in sufficient alignment along alignment axis 42 during tilting of the alignment axis, as discussed below, in some embodiments, platform 52 can be omitted and one or more of these packaging elements can be separately supported and tilted.
• packaging elements such as film positioner 32, tube positioner 34, funneling guide 36, and rod 40.
• flow chart 100 is provided that describes the exemplary steps 104-116 for the automated method of packaging wrapped rolled film 10, Although the process is described with reference to the packaged wrapped roiled film 2 depicted in Figure 1A, which includes wrapped rolled film 10 and tube 8, the method can be modified to accommodate various deviations from the packaged mapped rolled film 2,
• flow chart 100 provides numerous steps that comprise loading wrapped rolled film 10 into tube 8, More particularly, guiding the wrapped rolled film through funneling guide 36, actuating support head 50 through tube 8 to receive the wrapped rolled film, iiiting these aforementioned elements to facilitate the insertion of the wrapped rolled film into the tube, then returning the elements to their original position and retracting the support head from the tube.
• Figures 5. 6, 7, and 8 have been provided, which depict the station 30 in various stages of packaging the wrapped rolled film,
• Flow chart 100 begins at step 104 in w r hich wrapped rolled film 10, funneling guide 36, tube 8. and support head 50 are positioned along an alignment axis in a first position, More particularly, the wrapped roiled film is positioned by film positioner 32 along the alignment axis with film second end 54 situated opposite guide first end 43 of the funneling guide. Additionally, tube 8 is conveyed to the tube positioner with tube first end 56 situated opposite guide second end. 44. Further, support head 50 is situated in a starting position opposite tube second end 58.
• step 106 support head 50 is actuated from a starting position (as shown in Figure 4), through tube 8 such that the support head is situated adjacent to at least one of film second end 54 and guide first end 43.
• alignment axis 42 is tilted in step 108 from a first position to a second position, such that gravity moves the film second end to enter the guide first end and move through the tunneling guide and into the tube.
• the film second end Prior to or immediately subsequent to the movement of the wrapped rolled film, the film second end is situated in contact with the support head.
• the tilting of alignment axis 42 includes raising the wrapped rolled film to a point that is located higher than tube 8. For example, raising station first end 70 above station second end 72, as shown in Figure 6, such that the first position 74 of the alignment, axis is at an angle a with respect to raised, second position 76 of the alignment axis.
• This positioning exerts gravitational force on the rolled film to move the roiled film into the tube, in one embodiment first position 74 of the alignment axis is along a horizontal plane and the second position of the alignment axis is at an angle a that is 45 degrees to 60 degrees.
• angle a is 5 degrees to 90 degrees
• the first position is off the horizontal plane and angle a is 5 degrees to 90 degrees
• various tilt sensors can be provided to monitor the positions of one or more elements of station 30,
• step 1 10 The abutment of film second end 54 and support head 50 is utilized in step 1 10, in which the support head is retracted while gravity moves the wrapped rolled film 10 downwards into tube 8, The support head is retracted until film first end 55 and the film second end are situated within the tube, as shown in Figure 7.
• the wrapped rolled film can be moved at a controlled rate into the tube to prevent damage to the wrapped rolled film.
• forces other than gravity can be applied to coerce movement of the wrapped rolled film into the tube, although in at least one embodiment, gravity alone can provide the necessary force to move the wrapped, roiled film into the tube.
• step 1 12 Upon completion or substantial completion of the insertion of the wrapped rolled film inside the tube, in step 1 12, while maintaining alignment of wrapped rolled film 10, fumieling guide 36, tube 8, and support head 50, alignment axis 42 is tilted from the second position to the first position.
• step 114 the support head is retracted to a start position outside the tube.
• step 1 16 the packaged wrapped rolled film 2 is removed from tube positioner 34 in preparation for storage or transit,
• tube first and second ends may be closed using a tube closing flap (not shown) or separate first and second tube end caps.
• Closing the tube first and second ends can secure the wrapped rolled film inside the tube and/or provide additional structural rigidity for the tube,
• one or more spacers can be provided to support the wrapped rolled film inside the tube, such that a gap along their lengths is provided in the range of about one-half inch to about three-quarters of an inch. A greater or lesser gap can be provided to accommodate the size of the wrapped film roll and the tube, as well as to facilitate effective loading of the wrapped film roll into the tube, The spacers can be installed in the tube prior to, concurrent with, or subsequent to, the insertion of the wrapped rolled film into the tube,
• Numerous sensor inputs can be utilized throughout the packaging method to facilitate the method steps. For example, various sensors such as pressure and proximity sensors can be utilized to verify that wrapped rolled film 10 is situated in contact with the support head 50 prior to retracting the support head 50. Additionally, the sensors can be used to provide the necessary feedback to stop retraction of the support head if the wrapped rolled film fails to continue maintaining contact with the support head, thus signaling a possible malfunction. Although not identified in the drawings, numerous sensors can be located as needed to provide the desired feedback to facilitate the method of packaging as described. Unwrapped, Moisture-Sensitive, Cylindrically Rolled Film in a Closed Tube
• tube 8 can include a barrier layer, as described above, which serves to protect the rolled film provided that the tube is sealed.
• packaged rolled film 60 is depicted comprising rolled film 4 and tube 8.
• the packaged rolled film can further include first end cap 62 and second end cap 64, as shown in Figure 10, The end caps provide a means for sealing the tube and can also improve the structural rigidity of the tube.
• the tube and/or end caps can include a moisture barrier layer (not shown) that is integral with or situated on the interior or exterior surface of the tube and the caps to provide moisture protection similar to wrap 6.
• the barrier layer and/or end caps can comprise a water blocking material, such as plastic (e.g., polyethylene, polyvinylidene chloride, polypropylene, PET, etc) or metal foil, e.g., aluminum.
• the tube and/or end caps can comprise solely a water blocking material, such as aluminum or plastic, thus avoiding the need for any additional water blocking material.
• an adhesive water blocking seal can be used at the interface between the end cap and tube to hold the cap in place and to prevent moisture from entering the tube.
• Utilizing a moisture barrier layer and sealing the tube with end caps can provide moisture protection without the use of a wrap.
• moisture can be diminished in the tube, by evacuation and/or purging, and/or the use of a desiccant, and/or the replacement of paper liners and/or cores with metal or plastic liners and/or cores.
• one or both of the end caps can be omitted.
• one or both of such end caps can also be utilized on packaged rolled film 60 to provide additional sealing or structural rigidity
• tube 8 can include one or more closed ends and therefore require only one end cap or no end caps.
• FIG. 1 1 depicts first and second end caps that include supports, namely, core plugs 66 secured to or formed integral with the first and second end caps.
• the core plugs are configured to fit inside a central portion 28 of roiled film 4, or where applicable, along the interior surface of core 12, Alternatively, other types of supports may be provided, such as cradling type spacers (not shown) which are positioned along tube interior surface 17, These spacers and core plugs may be used with either packaged wrapped rolled film 2 or packaged rolled film 60, as described above. In addition, spacers and core plugs can be used in one or more other embodiments as described above or below,
• a packaging station 30 that includes rod 40 for loading film 10 into tube 8, without the assistance of gravitational forces.
• the ram includes an actuator 46, a shaft 48, and a support head 50.
• the center of the support head is offset from alignment axis 42, and support head 50 is configured to push the film into the tube without damaging the film, in one embodiment, the center of the support head is positioned along alignment axis 42.
• the film is positioned on film positioner 32 and support head 50 is positioned about the first end of the film 55, opposite tunneling guide 36.
• rolled film 4 can be inserted in the same manner, with or without the use of funneling guide 36.
• tube 8 can include a closed end when inserting the film in this manner,
• support head 50 is configured to pull roiled film 4 into tube 8 from an actuated position as shown in Figure 4. In this manner, support head 50 is configured to pass through the tube, grasp the second end of the wrapped film, pull the wrapped film into the tube, release the wrapped film, and then fully retracting from the tube. Tube drop
• tube 8 is manipulated as opposed to the film, in this embodiment the film has a high diameter to width ratio so thai the packaging is accomplished with minimal effort. More particularly, film 4 or 10 is positioned along vertical alignnient axis 77 on platform 81, with the tube positioned above the film along the vertical alignment axis, as shown in Figure 13 A, Additionally, spacer 83 can be positioned under the tube to provide an offset.
• a tube lowering mechanism 79 is provided to lower the tube along the vertical alignment axis and over the film, as shown in Figure 13B, Mechanism 79 can include an automated mechanism or a manual one.
• the offset provided by the spacer allows for the film to be situated a distance from the end of the tube, Also, the tube end adjacent the platform can be a closed end thus avoiding a need for spacer 83.
• the platform can be configured to rotate (as shown in Figure 13C) from a vertical axis to a horizontal axis to facilitate removal from platform 81.
• tube 8 is vertically positioned on platform 81 and film 4 or 10 is lowered into it in a manner similar to the tube drop although, of course, mechanism 79 manipulates the film from one of its ends as opposed to its sidewalL
• the distance between tube interior surface 17 and the outermost surface of the film 4 or 10 is about three-quarters of an inch about the circumference, although in another embodiment the distance is about one-half inch, The distance can be sized to accommodate various tubes, films, and shipping requirements.
• packaged wrapped rolled film 10 With regard to the removal of packaged wrapped rolled film 10 from station 30, this can be wholly or in part automated. For example, in one embodiment one or more robotic arms can be employed to remove the packaged rolled film 2 and convey an empty tube 8 into tube positioner 34. This is particularly beneficial when the packaged rolled film 2 is of significant size and/or weight, or when the process is operated at a rapid pace.
• packaged wrapped rolled film 2 or packaged rolled film 60 is conveyed to a storage device for storage and/or transportation.
• the storage device can be one of numerous devices, such as a pallet or storage container 80 (as shown in Figure 12).
• storage container 80 is a four-sided box with a iid, where a plurality of packaged wrapped roiled films 2 is stacked for efficient storage and shipping.
• Tubes 8 provide the necessary structural rigidity to enable packaged roiled film 2 to be stacked in this manner without damaging wrapped rolled film 10.
• support cradles (not shown) are provided in storage container 80 and these may be situated between the packaged wrapped roiled film and the tube to serve and provide further support to minimize shifting of the packaged wrapped rolled film.

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• 2011
  • 2011-06-06 US US13/153,509 patent/US20110308974A1/en not_active Abandoned
  • 2011-06-06 WO PCT/US2011/039213 patent/WO2011162935A1/en active Application Filing
  • 2011-06-06 JP JP2013516589A patent/JP2013529582A/ja not_active Withdrawn
  • 2011-06-06 EP EP11727047.0A patent/EP2585384A1/de not_active Withdrawn
  • 2011-06-06 CN CN2011800310144A patent/CN102958815A/zh active Pending
  • 2011-06-06 BR BR112012032471A patent/BR112012032471A2/pt not_active IP Right Cessation

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