EP3464121B1 - Coreless flexible film packaging system, containment package therefor and method for packaging - Google Patents
Coreless flexible film packaging system, containment package therefor and method for packaging Download PDFInfo
- Publication number
- EP3464121B1 EP3464121B1 EP17725030.5A EP17725030A EP3464121B1 EP 3464121 B1 EP3464121 B1 EP 3464121B1 EP 17725030 A EP17725030 A EP 17725030A EP 3464121 B1 EP3464121 B1 EP 3464121B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- film
- flexible film
- containment
- cylinder
- coreless
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
- 238000004806 packaging method and process Methods 0.000 title claims description 25
- 238000000034 method Methods 0.000 title claims description 20
- 238000004804 winding Methods 0.000 claims description 32
- 238000003825 pressing Methods 0.000 claims 1
- 239000010408 film Substances 0.000 description 126
- 239000000463 material Substances 0.000 description 12
- 238000004519 manufacturing process Methods 0.000 description 10
- 239000004033 plastic Substances 0.000 description 7
- 229920003023 plastic Polymers 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 5
- 239000000123 paper Substances 0.000 description 5
- 239000004743 Polypropylene Substances 0.000 description 3
- 238000001746 injection moulding Methods 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 235000015895 biscuits Nutrition 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 229920005570 flexible polymer Polymers 0.000 description 2
- 238000009474 hot melt extrusion Methods 0.000 description 2
- 239000005022 packaging material Substances 0.000 description 2
- 239000010816 packaging waste Substances 0.000 description 2
- 239000006120 scratch resistant coating Substances 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000004043 dyeing Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000010339 medical test Methods 0.000 description 1
- 239000011104 metalized film Substances 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000012858 packaging process Methods 0.000 description 1
- 235000021485 packed food Nutrition 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000011112 process operation Methods 0.000 description 1
- 230000003678 scratch resistant effect Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B63/00—Auxiliary devices, not otherwise provided for, for operating on articles or materials to be packaged
- B65B63/04—Auxiliary devices, not otherwise provided for, for operating on articles or materials to be packaged for folding or winding articles, e.g. gloves or stockings
-
- 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
- B65D83/00—Containers or packages with special means for dispensing contents
- B65D83/08—Containers or packages with special means for dispensing contents for dispensing thin flat articles in succession
- B65D83/0805—Containers or packages with special means for dispensing contents for dispensing thin flat articles in succession through an aperture in a wall
- B65D83/0811—Containers or packages with special means for dispensing contents for dispensing thin flat articles in succession through an aperture in a wall with means for assisting dispensing
- B65D83/0835—Containers or packages with special means for dispensing contents for dispensing thin flat articles in succession through an aperture in a wall with means for assisting dispensing the articles being pulled out of the container
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B31/00—Packaging articles or materials under special atmospheric or gaseous conditions; Adding propellants to aerosol containers
-
- 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
- B65D41/00—Caps, e.g. crown caps or crown seals, i.e. members having parts arranged for engagement with the external periphery of a neck or wall defining a pouring opening or discharge aperture; Protective cap-like covers for closure members, e.g. decorative covers of metal foil or paper
- B65D41/02—Caps or cap-like covers without lines of weakness, tearing strips, tags, or like opening or removal devices
-
- 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
- B65D59/00—Plugs, sleeves, caps, or like rigid or semi-rigid elements for protecting parts of articles or for bundling articles, e.g. protectors for screw-threads, end caps for tubes or for bundling rod-shaped articles
- B65D59/06—Caps
-
- 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
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H18/00—Winding webs
- B65H18/28—Wound package of webs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H19/00—Changing the web roll
- B65H19/22—Changing the web roll in winding mechanisms or in connection with winding operations
- B65H19/2292—Removing cores or mandrels from web roll after winding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
- B65H75/04—Kinds or types
- B65H75/16—Cans or receptacles, e.g. sliver cans
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H2701/00—Handled material; Storage means
- B65H2701/10—Handled articles or webs
- B65H2701/17—Nature of material
- B65H2701/175—Plastic
- B65H2701/1752—Polymer film
Definitions
- the present invention relates to packaged flexible polymer films and packaging systems for flexible polymer films.
- flexible films formed from polymeric materials and/or plastics are typically packaged at the manufacturing site as rolls, with the film wound onto a cylindrical supporting carrier formed from rigid, non-compressible plastic, cardboard or the like (called a core).
- the roll is then enclosed and contained in a box, bag or other packaging to protect the film during transport and provide an aesthetically pleasing appearance to customers.
- the flexible films are often packaged during manufacture in large and heavy "bulk” rolls; however, product distribution channel requirements demand that film wound on such bulk rolls be unwound and then rewound into smaller "commercial” rolls for shipping and eventual sale.
- window films are often wound on bulk rolls of around 3000 meters at manufacture and then repackaged for sale to customers in relatively short rolls wherein 30.5 meters or less of material is wound on a 76.5mm diameter plastic core.
- Highly specialized flexible films such as metallized films for use in medical testing devices, electronic devices, displays and the like, are also packaged as rolls of material wound on a core.
- the leading end of the film nearest the core is typically adhered to the core using a double-sided self-adhesive strip that runs transversely along the full width of the film at the leading end.
- a double-sided self-adhesive strip that runs transversely along the full width of the film at the leading end.
- One prior art attempt to overcome the embossment problem included chamfering the leading end of the film so that the cut end of the film is angled or gradually reduced in thickness rather than presenting a sharp vertical end. It is difficult with such thin materials, however, to achieve any uniform angled cut of this kind, particularly at such a shallow angle as would be necessary to materially reduce the impact of the leading end on the imprint problem.
- embossments remain a significant source of waste and inefficiency for the flexible films industry.
- the films industry is in lock step with industry in general as it seeks out improved, sustainable packaging systems and for its products that reduce excess packaging material and waste.
- the prior art document DE 93 00 693 U1 describes a container for receiving a pack of bags tearably connected to each other and which can be carried in a handbag.
- the container is formed by a piece of pipe at whose end faces one end wall is detachably connected to the pipe section for filling the container.
- the pipe section having a withdrawal slot running along a circumferential line for pulling out the pipe section.
- the GB 2 472 436 A describes portable bag dispenser comprising a roll of bags contained in a cartridge inside the container.
- the container is formed from two sections that can be joined together and separated. When the container is joined together it encloses the cartridge and when it is separated the cartridge can be removed.
- the EP 1 352 602 A2 describes a package for dispensing a paper roll, comprising a rotatable paper roll and a housing in which the paper roll is contained.
- the housing forms a dispenser for the paper roll having an opening provided in the housing and a fastener for attaching the package to a wall.
- the US 4 771 889 A describes a packaged food casing article having a rotatable support to support e.g. paper rol.
- the GB 934 550 A describes forming a package of biscuits which comprises applying wrapping material about an end of a continuous column of biscuits.
- the EP 2 017 2015 A1 describes a method of manufacturing a roll that unwinds from the centre by forming a protrusion along a length axis of one of side of the roll.
- the present invention relates to a coreless flexible film packaging system.
- the system includes (i) a containment cylinder including a cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) a film feed slot in the cylindrical wall extending longitudinally along the containment cylinder; and (iii) a supply of flexible film wound about itself to form a film roll having a central cylindrical cavity, with the roll comprising a leading end and a terminal end and contained within said interior film containment area, and wherein said flexible film is self-winding.
- the present invention relates to a method for packaging a flexible film including: (i) providing a containment cylinder, the cylinder including a cylindrical wall and a film feed slot extending longitudinally along the containment cylinder, with the cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) feeding the flexible film into the interior film containment area through the film feed slot; and (iii) winding said flexible film about itself to form a film roll having a central cylindrical cavity lined by the film, with roll contained within the interior film containment area, wherein said film is self-winding.
- Containment cylinder 30 may be formed from materials well known to one of ordinary skill, for example cardboard or plastics such as polypropylene or polystyrene, using well-known manufacturing techniques selected depending in part on the material chosen, such as for example injection molding or hot melt extrusion when the core is formed from plastic.
- coreless is utilized herein to denote that the film is wound about itself to form a film roll which includes a central cylindrical cavity lined by film as opposed to packaging in which the film roll is wound onto a cylindrical supporting carrier or core.
- the coreless flexible film packaging system 75 includes: (i) a containment cylinder 30 that includes cylindrical wall 35 having an outer surface 40, with cylindrical wall 35 defining first and second cylinder end apertures 45 and 50 and an interior film containment area 52; (ii) a film feed slot 55 in said cylindrical wall 35 extending longitudinally along said containment cylinder 30; and (iii) a supply of flexible film 15 wound about itself to form a film roll 20 having a central cylindrical cavity 25 lined by film 15. Film 15 further includes a leading end 18 and terminal end 19 and is contained within said interior film containment area 52.
- Containment cylinder 30 may be formed from materials well known to one of ordinary skill, for example cardboard or plastics such as polypropylene and made using well-known manufacturing techniques selected depending in part on the material chosen, such as for example injection molding or hot melt extrusion when the core is formed from plastic.
- the system 75 preferably further includes seal strip 57 affixed to said containment cylinder 30 at said outer surface 40.
- seal strip 57 is located adjacent to film feed slot 55 and most preferably is also affixed to the terminal end 19 of the supply of said flexible film 15.
- Seal strip 57 may be applied to the core and formed in situ from materials well known to one of ordinary skill, for example a pressure sensitive, hot melt or curable adhesive composition. Seal strip 57 may also be a separately formed adhesive tape adhered to the core.
- the system 75 further includes caps 60 at each of said first and second end apertures 45 and 50.
- Caps 60 may be formed from materials well known to one of ordinary skill, for example thermoplastic polymers, using well-known manufacturing techniques such as for example injection molding and extrusion.
- the outer surface 40 of the cylindrical wall 35 of the cylinder constitutes the exposed surface 80 of the coreless flexible film packaging system.
- the system 75 provides an advantageous, environmentally friendly and cost-saving alternative that uses significantly less packaging material and accordingly reduces the amount of packaging waste.
- the film feed slot of the system is also a dispensing port for the contained flexible film in this embodiment.
- At least one of the caps 60 is substantially transparent so as to facilitate visual inspection of the film.
- Exposed surface 80 may also optionally include at least one of printing or graphics so as to provide information and/or an aesthetically pleasing appearance to customers.
- the flexible film for use with the present invention may be any flexible film, web or the like typically packaged concurrent with or after manufacturing as a roll.
- Non-limiting examples include PET, polypropylene, PVC, polyurethane and the like.
- the flexible film is "self-winding", defined herein to encompass films that exhibit a natural tendency to wind or curl about themselves without application of external force.
- MD machine direction
- a tendency of the film to curl in the direction in which the film travels during process operations such as dyeing, coating, laminating and slitting.
- This tendency can be particularly relevant in flexible films with multiple laminated layers or applied coatings and is created as tension that is applied during the processing steps elongates the film and creates strain in the layers that varies for example by layer type and thickness. For example, MD curl in commercial window film constructions generally towards the scratch-resistant coating.
- the present invention relates to a method for packaging a flexible film.
- the method of the present invention includes: (i) providing a containment cylinder that includes a cylindrical wall with an outer surface and a longitudinally extending film feed slot, with the cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) feeding the flexible film into the interior film containment area through the film feed slot; and (iii) winding said flexible film about itself to form a roll having a central cylindrical cavity lined by said film, with the roll contained within the interior film containment area, wherein said fil 15 is self-winding.
- film may be fed into the film containment area of the containment cylinder by means of a feed device such as a driven nip roller 65 in relatively close proximity to the film feed slot 55.
- the containment cylinder is preferably held stationary in position during the feeding step. It will be understood by one of ordinary skill that a number of variables, such as for example the feed velocity and feed angle of the film on entry into the containment cylinder, through the feed slot and the distance between the nip and the feed slot may be adjusted to optimize winding performance. It is anticipated that film angled towards the top inside surface of the core and the shortest distance from the nip to core entrance slot will provide better winding.
- the flexible film is a self-winding film which winds about itself to form the roll without externally applied force and the winding step therefore includes self-winding of the flexible film.
- winding includes self-winding of the flexible film toward the scratch resistant side. In typical window film constructions, this will leave a release liner side, a more slippery surface, to slide against the inside surface of the cylinder during winding.
- the winding step may include applying external winding force to the film.
- the optional winding force is applied by a rotatable axle 85 such that the winding step of the method present invention includes (a) removably inserting a rotating axle 85 into the interior film containment area 52 and (b) removably attaching said leading end 18 of flexible film 15 to the axle 85.
- the method of the present invention most preferably includes the further step (c) of releasing the leading end of the film from the axle at the conclusion of said winding step and removing the rotating axle from interior film containment area.
- rotating axle 85 is a perforated axle connected to a vacuum/pressure source such that the removably attaching step (b) above preferably includes applying vacuum to the flexible film during winding and the releasing step (c) preferably includes releasing the vacuum when winding is complete.
- the releasing step (c) may optionally also include applying positive pressure to the flexible film to facilitate release of the leading end of the flexible film 15 at the conclusion of the winding step when winding is complete.
- Axle 85 and the nip roller speed should be controlled and adjusted so that the flexible film 15 does not wind up around the axle 85 but is simply held by it at and close to the leading end18.
- the method of the present invention preferably includes electrically grounding the flexible film and the containment cylinder.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Storage Of Web-Like Or Filamentary Materials (AREA)
- Packaging Of Machine Parts And Wound Products (AREA)
- Wrappers (AREA)
- Packages (AREA)
Description
- The present invention relates to packaged flexible polymer films and packaging systems for flexible polymer films.
- In the prior art, flexible films formed from polymeric materials and/or plastics are typically packaged at the manufacturing site as rolls, with the film wound onto a cylindrical supporting carrier formed from rigid, non-compressible plastic, cardboard or the like (called a core). The roll is then enclosed and contained in a box, bag or other packaging to protect the film during transport and provide an aesthetically pleasing appearance to customers. For some products, for example films for application to windows installed in automobiles and buildings, the flexible films are often packaged during manufacture in large and heavy "bulk" rolls; however, product distribution channel requirements demand that film wound on such bulk rolls be unwound and then rewound into smaller "commercial" rolls for shipping and eventual sale. By way of example, such window films are often wound on bulk rolls of around 3000 meters at manufacture and then repackaged for sale to customers in relatively short rolls wherein 30.5 meters or less of material is wound on a 76.5mm diameter plastic core. Highly specialized flexible films, such as metallized films for use in medical testing devices, electronic devices, displays and the like, are also packaged as rolls of material wound on a core.
- So that the film can be wound onto the core properly for commercial rolls, the leading end of the film nearest the core is typically adhered to the core using a double-sided self-adhesive strip that runs transversely along the full width of the film at the leading end. When the film is unwound from the commercial roll for use, the 1-3 meters of the film packaged nearest the core when originally wound thereon, is often found to be unusable as a result of a repeating imprint, sometimes referred to as an "embossment", created in the initial wraps of the film around the core. Because the flexible film is relatively thin, in the order of 60 - 400µ, this imprint effect is replicated in several of the innermost layers of wound film close to the core. These imprints are caused by one or more factors typically present in the packaging process and system. There are several reasons why film suffers from imprints. These include:
- Film tension. Mechanical requirements demand that tension is applied during winding in order to be able to process film through the winding machine.
- Film Edge. The leading end of the film runs across the width of the wound film and is cut with a relatively sharp vertical edge that forms a ridge at the interface of the film's leading end with surface of the core.
- Adhesive Strip. The double sided adhesive strip has a minimized (typically 25-50µ) but nonetheless potentially impactful thickness and can create an even more severe imprint than the end of the film. It presents two ends rather than one and the general evenness of the thickness of adhesive strip over the entire area of adhesive, particularly hand-applied aerosol pressure sensitive adhesives, can be very poor.
- Core surface. The core surface itself may have defects or minute contaminants that impact its uniformity and smoothness.
- These imprints are typically permanent such that, if use of the film is attempted, defects in the final product's functionality and/or aesthetic appearance are highly likely. With respect to window films, installation of this portion of the film from the roll on a vehicle or building window is often the source for consumer complaints and warranty claims.
- One prior art attempt to overcome the embossment problem included chamfering the leading end of the film so that the cut end of the film is angled or gradually reduced in thickness rather than presenting a sharp vertical end. It is difficult with such thin materials, however, to achieve any uniform angled cut of this kind, particularly at such a shallow angle as would be necessary to materially reduce the impact of the leading end on the imprint problem. Other prior art methods to reduce imprinting involve changing aspects of the core, for example (i) milling an angled depression into the length of the core such that the leading end of the film seats in the depression in the core so as to present a smooth surface over which subsequent layers of film wrap during winding onto the core or (ii) modifying the core to include a slit or other feature to "trap" and/or hold the leading end of the film within the core cavity. Such solutions are, however, typically not cost effective as they add expensive machining, molding, slitting or other high-precision steps to the core manufacturing process and create the need for cores that are highly customized to match individual film types and thicknesses. Further, they also present challenges in properly adhering the leading end of the film to the core so that the roll can be properly wound.
- Despite these prior art efforts, embossments remain a significant source of waste and inefficiency for the flexible films industry. Aside and apart from the embossment problem, the films industry is in lock step with industry in general as it seeks out improved, sustainable packaging systems and for its products that reduce excess packaging material and waste.
- The prior art document
DE 93 00 693 U1 describes a container for receiving a pack of bags tearably connected to each other and which can be carried in a handbag. The container is formed by a piece of pipe at whose end faces one end wall is detachably connected to the pipe section for filling the container. The pipe section having a withdrawal slot running along a circumferential line for pulling out the pipe section. - The
GB 2 472 436 A - The
EP 1 352 602 A2 describes a package for dispensing a paper roll, comprising a rotatable paper roll and a housing in which the paper roll is contained. The housing forms a dispenser for the paper roll having an opening provided in the housing and a fastener for attaching the package to a wall. - The
US 4 771 889 A describes a packaged food casing article having a rotatable support to support e.g. paper rol. - The
GB 934 550 A - The
EP 2 017 2015 A1 - In a first aspect, the present invention relates to a coreless flexible film packaging system. The system includes (i) a containment cylinder including a cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) a film feed slot in the cylindrical wall extending longitudinally along the containment cylinder; and (iii) a supply of flexible film wound about itself to form a film roll having a central cylindrical cavity, with the roll comprising a leading end and a terminal end and contained within said interior film containment area, and wherein said flexible film is self-winding.
- In yet another aspect, the present invention relates to a method for packaging a flexible film including: (i) providing a containment cylinder, the cylinder including a cylindrical wall and a film feed slot extending longitudinally along the containment cylinder, with the cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) feeding the flexible film into the interior film containment area through the film feed slot; and (iii) winding said flexible film about itself to form a film roll having a central cylindrical cavity lined by the film, with roll contained within the interior film containment area, wherein said film is self-winding.
- Further aspects of the invention are as disclosed and claimed herein.
-
-
Figure 1 is a side elevational view of an embodiment of the coreless flexible film packaging system of the present invention, with the packaged flexible film shown partially outside the containment cylinder for illustration purposes only. -
Figure 2 is partial side elevational view of an embodiment of the coreless flexible film packaging system of the present invention, with the packaged flexible film shown partially outside the containment cylinder for illustration purposes only. -
Figure 3 is a partial side elevational view of an embodiment of the coreless containment package of the present invention. -
Figure 4 is a side elevational view of an embodiment of the coreless containment package of the present invention that includes caps. -
Figure 5 is a partial side elevational view illustrating suitable equipment for practicing the method of the present invention for packaging a flexible film. -
Containment cylinder 30 may be formed from materials well known to one of ordinary skill, for example cardboard or plastics such as polypropylene or polystyrene, using well-known manufacturing techniques selected depending in part on the material chosen, such as for example injection molding or hot melt extrusion when the core is formed from plastic. The term "coreless" is utilized herein to denote that the film is wound about itself to form a film roll which includes a central cylindrical cavity lined by film as opposed to packaging in which the film roll is wound onto a cylindrical supporting carrier or core. - The present invention relates to a coreless flexible film packaging system. In its most general sense and as shown in
Figures 1-4 . Accordingly, the coreless flexiblefilm packaging system 75 includes: (i) acontainment cylinder 30 that includescylindrical wall 35 having anouter surface 40, withcylindrical wall 35 defining first and secondcylinder end apertures film containment area 52; (ii) afilm feed slot 55 in saidcylindrical wall 35 extending longitudinally along saidcontainment cylinder 30; and (iii) a supply offlexible film 15 wound about itself to form afilm roll 20 having a centralcylindrical cavity 25 lined byfilm 15.Film 15 further includes aleading end 18 andterminal end 19 and is contained within said interiorfilm containment area 52.Containment cylinder 30 may be formed from materials well known to one of ordinary skill, for example cardboard or plastics such as polypropylene and made using well-known manufacturing techniques selected depending in part on the material chosen, such as for example injection molding or hot melt extrusion when the core is formed from plastic. - The
system 75 preferably further includesseal strip 57 affixed to saidcontainment cylinder 30 at saidouter surface 40. Preferably theseal strip 57 is located adjacent tofilm feed slot 55 and most preferably is also affixed to theterminal end 19 of the supply of saidflexible film 15.Seal strip 57 may be applied to the core and formed in situ from materials well known to one of ordinary skill, for example a pressure sensitive, hot melt or curable adhesive composition.Seal strip 57 may also be a separately formed adhesive tape adhered to the core. - In a particularly preferred embodiment, the
system 75 further includescaps 60 at each of said first andsecond end apertures Caps 60 may be formed from materials well known to one of ordinary skill, for example thermoplastic polymers, using well-known manufacturing techniques such as for example injection molding and extrusion. In this embodiment, theouter surface 40 of thecylindrical wall 35 of the cylinder constitutes the exposedsurface 80 of the coreless flexible film packaging system. In comparison to the prior art flexible film packaging systems wherein film is wound on a core which is then enclosed in a box, bag or other packaging to protect the film, thesystem 75 provides an advantageous, environmentally friendly and cost-saving alternative that uses significantly less packaging material and accordingly reduces the amount of packaging waste. Further, it will be readily appreciated that the film feed slot of the system is also a dispensing port for the contained flexible film in this embodiment. - In this embodiment, at least one of the
caps 60 is substantially transparent so as to facilitate visual inspection of the film. Exposedsurface 80 may also optionally include at least one of printing or graphics so as to provide information and/or an aesthetically pleasing appearance to customers. - The flexible film for use with the present invention may be any flexible film, web or the like typically packaged concurrent with or after manufacturing as a roll. Non-limiting examples include PET, polypropylene, PVC, polyurethane and the like. The flexible film is "self-winding", defined herein to encompass films that exhibit a natural tendency to wind or curl about themselves without application of external force. For example, many films utilized in the window films industry develop during manufacture what is known in the art as "MD (machine direction) curl", a tendency of the film to curl in the direction in which the film travels during process operations such as dyeing, coating, laminating and slitting. This tendency can be particularly relevant in flexible films with multiple laminated layers or applied coatings and is created as tension that is applied during the processing steps elongates the film and creates strain in the layers that varies for example by layer type and thickness. For example, MD curl in commercial window film constructions generally towards the scratch-resistant coating.
- In a third aspect, the present invention relates to a method for packaging a flexible film. The method of the present invention includes: (i) providing a containment cylinder that includes a cylindrical wall with an outer surface and a longitudinally extending film feed slot, with the cylindrical wall defining first and second cylinder end apertures and an interior film containment area; (ii) feeding the flexible film into the interior film containment area through the film feed slot; and (iii) winding said flexible film about itself to form a roll having a central cylindrical cavity lined by said film, with the roll contained within the interior film containment area, wherein said
fil 15 is self-winding. - Suitable equipment for operation of the method of the present invention is shown in
Figure 5 . With regard to the in-feed step, film may be fed into the film containment area of the containment cylinder by means of a feed device such as a drivennip roller 65 in relatively close proximity to thefilm feed slot 55. The containment cylinder is preferably held stationary in position during the feeding step. It will be understood by one of ordinary skill that a number of variables, such as for example the feed velocity and feed angle of the film on entry into the containment cylinder, through the feed slot and the distance between the nip and the feed slot may be adjusted to optimize winding performance. It is anticipated that film angled towards the top inside surface of the core and the shortest distance from the nip to core entrance slot will provide better winding. - The flexible film is a self-winding film which winds about itself to form the roll without externally applied force and the winding step therefore includes self-winding of the flexible film. For example, in the embodiment where the flexible film is a window film that includes a scratch-resistant coating, winding includes self-winding of the flexible film toward the scratch resistant side. In typical window film constructions, this will leave a release liner side, a more slippery surface, to slide against the inside surface of the cylinder during winding.
- Optionally, the winding step may include applying external winding force to the film. In one particular embodiment, the optional winding force is applied by a
rotatable axle 85 such that the winding step of the method present invention includes (a) removably inserting arotating axle 85 into the interiorfilm containment area 52 and (b) removably attaching said leadingend 18 offlexible film 15 to theaxle 85. In this embodiment, the method of the present invention most preferably includes the further step (c) of releasing the leading end of the film from the axle at the conclusion of said winding step and removing the rotating axle from interior film containment area. In a particularly preferred embodiment, rotatingaxle 85 is a perforated axle connected to a vacuum/pressure source such that the removably attaching step (b) above preferably includes applying vacuum to the flexible film during winding and the releasing step (c) preferably includes releasing the vacuum when winding is complete. The releasing step (c) may optionally also include applying positive pressure to the flexible film to facilitate release of the leading end of theflexible film 15 at the conclusion of the winding step when winding is complete.Axle 85 and the nip roller speed should be controlled and adjusted so that theflexible film 15 does not wind up around theaxle 85 but is simply held by it at and close to the leading end18. - As movement of materials such as flexible films can cause static build up, it will be understood that the method of the present invention preferably includes electrically grounding the flexible film and the containment cylinder.
- The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims.
Claims (12)
- A coreless flexible film packaging system (75), said system comprising:(i) a containment cylinder (30) comprising a cylindrical wall (35) with an outer surface (40), said cylindrical wall (35) defining first and second cylinder end apertures (45, 50) and an interior film containment area (52);(ii) a film feed slot (55) in said cylindrical wall (35) extending longitudinally along said containment cylinder (30); and(iii) a supply of flexible film (15) wound about itself to form a film roll (20) having a central cylindrical cavity (25), said film roll (20) comprising a leading end and a terminal end and contained within said interior film containment area (52),characterized in that,
said flexible film (15) is self-winding. - The coreless flexible film packaging system of claim 1 wherein said central cylindrical cavity (25) is lined by said film (15).
- The coreless flexible film packaging system of claim 1 further comprising a seal strip (57) affixed to said containment cylinder (30) at said outer surface (40).
- The coreless flexible film packaging system of claim 3 wherein said seal strip (57) is adjacent to said film feed slot (55).
- The coreless flexible film packaging system of claim 3 wherein said terminal end of said supply of said flexible film (15) is affixed to said seal strip (57).
- The coreless flexible film packaging system of claim 1 further comprising caps (60) at each of said first and second end apertures (45, 50).
- The coreless flexible film packaging system of claim 6 wherein at least one if said caps (60) is substantially transparent.
- A method for packaging a flexible film, said method comprising:(i) providing a containment cylinder (30), said cylinder (30) comprising a cylindrical wall (35) with an outer surface (40) and a film feed slot (55) in said cylindrical wall (35) extending longitudinally along said containment cylinder(30), said cylindrical wall (35) defining first and second cylinder end apertures (45, 50) and an interior film containment area (52);(ii) feeding said flexible film (15) into said interior film containment area (52) through said film feed slot (55); and(iii) winding said flexible film (15) about itself to form a roll having a central cylindrical cavity (25) lined by said film (15), said roll contained within said interior film containment area (52), wherein said film (15) is self-winding.
- The method of claim 8 wherein said winding step includes(a) removably inserting a rotating perforated axle (85) into said interior film containment area (52); and(b) removably attaching said leading end of said flexible film (15) to said axle (85).
- The method of claim 9 wherein said removably attaching step (b) includes applying vacuum to said flexible film (15).
- The method of claim 9 further comprising releasing said vacuum and optionally applying pressure to said flexible film (15) at the conclusion of said winding step.
- The method of claim 9 further comprising removing said perforated axle (85) from said interior film containment area (52) at the conclusion of said winding step.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/164,014 US20170341798A1 (en) | 2016-05-25 | 2016-05-25 | Coreless flexible film packaging system and coreless containment package therefor |
PCT/US2017/031876 WO2017205053A1 (en) | 2016-05-25 | 2017-05-10 | Coreless flexible film packaging system, containment package therefor and method for packaging |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3464121A1 EP3464121A1 (en) | 2019-04-10 |
EP3464121B1 true EP3464121B1 (en) | 2020-08-26 |
Family
ID=58745413
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP17725030.5A Active EP3464121B1 (en) | 2016-05-25 | 2017-05-10 | Coreless flexible film packaging system, containment package therefor and method for packaging |
Country Status (4)
Country | Link |
---|---|
US (1) | US20170341798A1 (en) |
EP (1) | EP3464121B1 (en) |
TW (1) | TW201742791A (en) |
WO (1) | WO2017205053A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA3135999A1 (en) | 2019-04-04 | 2020-10-08 | Reynolds Consumer Products LLC | Assembly system and method for packaging web material in a roll |
CN114249022A (en) * | 2020-09-24 | 2022-03-29 | 长春石油化学股份有限公司 | Film roll packaging structure and film roll packaging method |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1285382B (en) * | 1960-06-07 | 1968-12-12 | Nat Bisquit Company | Process for packing solid objects such as food |
US4771889A (en) * | 1987-06-17 | 1988-09-20 | Viskase Corporation | Packaged food casing article with attached splice tape |
DE9300693U1 (en) * | 1993-01-20 | 1993-06-17 | Meblo-Vertriebsgesellschaft mbH, 7064 Remshalden | Container for holding a roll of bags formed from tear-off bags |
GB2387377A (en) * | 2002-04-12 | 2003-10-15 | Sca Hygiene Prod Gmbh | A package for dispensing a paper roll |
ES2433382T3 (en) * | 2003-06-12 | 2013-12-10 | Sca Tissue France | Manufacturing procedure of a roll with central winding |
GB2472436B (en) * | 2009-08-06 | 2013-10-30 | Rita Masango | Small bag dispenser |
-
2016
- 2016-05-25 US US15/164,014 patent/US20170341798A1/en not_active Abandoned
-
2017
- 2017-04-14 TW TW106112487A patent/TW201742791A/en unknown
- 2017-05-10 EP EP17725030.5A patent/EP3464121B1/en active Active
- 2017-05-10 WO PCT/US2017/031876 patent/WO2017205053A1/en unknown
Non-Patent Citations (1)
Title |
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None * |
Also Published As
Publication number | Publication date |
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WO2017205053A1 (en) | 2017-11-30 |
US20170341798A1 (en) | 2017-11-30 |
TW201742791A (en) | 2017-12-16 |
EP3464121A1 (en) | 2019-04-10 |
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