IES20060194A2 - Wrapped loads and methods for wrapping loads - Google Patents

Abstract

A first aspect of the invention relates to a wrapped load (1) comprising a load (2) having at least tow fork engaging projections (3) in a substantially parallel arrangement on opposing vertical surfaces (4) of the load. The wrapped load (1) further comprises wrapping material (5) wrapped around the load such that it at least partially envelops the fork engaging projections (3). The at least partially enveloped fork engaging projections are adapted to receive the forks (6) of a lifting device for transporting the wrapped load without the use of a pallet platform. A second aspect of the invention relates to a wrapped load (1) comprising a strip (7) of wrapping material (5) wrapped around a load such that it at least partially envolops the load. The wrapped load (1) further comprises a rope (8) of wrapping material (5) formed from the strip (7) of wrapping material as it is applied to the load. The rope of wrapping material encircles the load such that it reinforces the wrapping material. The invention also relates to methods for wrapping loads. <Figure 1>

Description

Wrapped loads and methods for wrapping loads Field of the Invention The invention relates to wrapped loads and methods for wrapping loads of goods and materials in a wrapping material including an integral support means to assist in transporting the loads. The invention provides an alternative to a conventional pallet but serves the same purpose of supporting and transporting loads.

Background to the Invention Pallets are commonly used for transporting and storing good and materials. Pallets typically comprise a portable wooden platform on which the load is carried. The platform usually comprises two parallel planar surfaces spaced apart by transverse wooden battens to form channels intended to receive the forks of a forklift truck.

Typically the load is built up on the wooden platform and the whole load may then be cling wrapped or shrink wrapped in a suitable plastics wrapping material.

The use of conventional wooden pallets represents a high element in the cost of transport and storage, and there is a further significant hidden cost in the logistics of pallet management. Firstly, there is the production cost of conventional wooden pallets which each utilise a large number of wooden elements that are joined together to form the pallet, usually using steel nails. There is a significant cost in the transport of the empty pallets; firstly they have to be shipped to the supplier, who uses the pallets for the transport of goods to a customer. In many case, after use they have to be shipped back to the supplier as a return. It has been found that in the case of hired pallets, for example, they spend more time being trans-shipped than actually in use.

Conventional pallets utilise a lot of storage space at each destination, and in the event of the pallets being used for perishable goods, they must be stored under cover. It has been found that in many cases the cost associated with the use of conventional pallets represents up to 50% of total packaging costs. Also, conventional pallets usually have wrapping material applied in one plane only, which can easily rupture.

IE ο 6 ο 1 9 4 '{'he constant shipment of empty pallets results in a high level of pallet fatigue, resulting in damage to loads, and a high risk of injury to users due to hazardous pallet loads. The use of steel nails in the manufacture of conventional pallets is also a problem. There are significant breakages of pallets through handling causing the nails to protrude from the pallets. These frequently are a cause of motor vehicle tyre punctures and of injury to workers.

European Patent No. 1 214 245 issued to the same applicant discloses a method and apparatus for wrapping loads of goods and materials in a wrapping material including an internal support means to assist in transporting the goods, thereby negating the need for conventional pallets. In one embodiment ofthe invention, the method includes creating at least two fork entry openings in a spaced substantially parallel orientation on one surface of the load without use of a pallet platform and then wrapping the load such that the fork entry openings are at least partially enveloped in the wrapping material. Due to the absence of a supporting pallet platform, loads wrapped in this way have been found be prone to instability in certain circumstances due to the presence of fork-entry opening or voids within the load itself, especially when the plastic wrapping around the load is cut to allow the contents to be used.

Object of the Invention It is an object of the present invention to provide a method for wrapping a load which will eliminate the need for conventional pallets. It is also an object to provide a stable wrapped load, even when the wrapping is cut or tom to allow the contents to be used. It is another object of the present invention to provide a wrapped load which will provide the support and ease of transport associated with conventional pallets.

Summary of the Invention According to a first aspect of the present invention, there is provided a wrapped load comprising a load having at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load; and wrapping material wrapped around the load such that it at least partially envelops the fork engaging projections; wherein the at least partially enveloped fork engaging projections are ΙΕ ο 6 Ο 1 9 4 adapted to receive the forks of a lifting device for transporting the wrapped load without the use of a pallet platform.

The present invention also relates to a method for wrapping a load in a wrapping material comprising the steps of creating at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load without the use of a pallet platform; and at least partially wrapping the load in a wrapping material such that the fork engaging projections are at least partially enveloped in the wrapping material by establishing relative rotational motion between the load and a dispensing means for the wrapping material.

The wrapped load of the present invention is self-supporting and stable due to the solid nature of the base of the load. The need for a conventional pallet is eliminated by presence of the fork engaging projections, which are adapted to receive the forks of a lifting device. The lifting device may be, for example, a forklift truck, or any other device suitable for lifting a palletised load. The wrapped load thus provides the ease of transport normally associated with conventional pallets.

Preferably, the load comprises a plurality of stackable elements arranged in substantially horizontal layers. The present invention is particularly suitable for use with loads of bricks, blocks, boxes, cartons or other stackable elements. According to a preferred embodiment, the stackable elements in at least one of the layers are arranged such that their ends project from opposing vertical surfaces of the load to form fork engaging projections.

In a preferred embodiment of the invention, each layer has a length L greater than its width W, and at least one substantially horizontal layer is oriented substantially orthogonal to the other layers, such that the stackable elements in said at least one layer are arranged so that their ends extend beyond opposing vertical surfaces of the load to create two fork engaging projections in substantially parallel arrangement on opposing vertical surfaces of the load. ΙΕΟ 6 ο 1 ¢4 In one embodiment, the method for wrapping the load further comprises the steps of creating a partial load comprising a first plurality of substantially identical layers of length L and width W arranged in a first orientation to form a partial load of length L and width W; adding at least one layer of length L and width W to the top of the partial load in an second orientation orthogonal to the first orientation, such that the stackable elements in the at least one layer are arranged so that their ends extend beyond opposing vertical surfaces of the partial load to create a pair of fork engaging projections in substantially parallel orientation on opposing vertical surfaces of the load; and adding further layers to the partial load in the first orientation to complete the load.

In the preferred embodiment, the fork engaging projections are integrally formed with the load. This allows the wrapped load to be formed without the use of any additional parts or components, thereby eliminating the costs associated with conventional pallets.

According to a second aspect of the present invention, there is provided a wrapped load comprising a strip (or web or sheet) of wrapping material wrapped around a load such that it at least partially envelops the load; and a rope of wrapping material formed from the strip of wrapping material as it is applied to the load; wherein the rope of wrapping material encircles the load such that it reinforces the wrapping material.

There is also provided a method for wrapping a load in a wrapping material comprising the steps of at least partially wrapping a load in a strip (or web, or sheet) of wrapping material such that the load is at least partially enveloped in the wrapping material by establishing relative rotational motion between the load and a dispensing means for the wrapping material; before or after the partial wrapping step, forming a rope of wrapping material from the strip of wrapping material as it is applied to the load; and reinforcing the wrapping of the load by encircling the load with the rope of wrapping material by establishing relative rotational motion between the partially wrapped load and means for forming the rope of wrapping material.

Preferably, the rope of wrapping material is formed by reducing the width of the strip of wrapping material, for example by gathering the sheet together, as it is applied to the load, to provide a relatively nanow rope of wrapping material.

It 0 6 ο 1 94 The rope of wrapping material provides the wrapped load with added stability, even when the wrapping material is cut or tom to allow the contents to be used. In use, the wrapped load or pack is generally cut around its circumference in a plane parallel to the ground to allow the top layers of contents, e.g. bricks to be used. With prior art loads, this often resulted in the entire wrapped load collapsing under its own weight, as the cut or tom wrapping material was no longer strong enough to support the load. In the present invention, the rope of wrapping material reinforces the strip of wrapping material and supports the load, thereby allowing the load to retain its shape and structural integrity even when the wrapping has been cut. Preferably, the rope is applied to the load at a number of positions to provide maximum reinforcement to the load and to allow the contents of the load to be used as required.

The rope of wrapping material may be formed by twisting the strip of wrapping material about itself; or crimping the strip of wrapping material; or tucking the strip of wrapping material.

In a preferred embodiment, the wrapping material comprises a plastics film and the method further comprises the steps of: pre-stretching the strip of plastics film by between 50% and 100% of its length before application to the load; forming the rope of plastics film from the pre-stretched strip of plastics film as it is applied to the load; and post-stretching the rope of plastics film by between 10% and 200% of its length, wherein the post-stretching step is earned out after or simultaneously with the forming step.

Ideally, the steps of forming the rope of plastics film and post-stretching the rope of plastics film are earned out simultaneously by means of a pair of moveably mounted spools which are moved together towards the centre of the strip of plastics film, such that a rope of film is formed as the strip of plastics film passes between the spools and wherein the spools are geared such that the forward spool is moving more quickly than the rear spool to impart a secondary stretch to the rope of plastics film as it is drawn through a film-stretching zone between the two spools.

IE Ο 6 ο 1 9 4 Plastic film roped in this way is very strong and relatively inelastic, and thus imparts additional strength to the wrapped load and provides additional support to the load when the wrapping material is cut.

According to an optional feature of the present invention, at least one strip of high impact plastic sheeting is arranged on a lower surface of the load after wrapping the load, such that puncturing of the underside of the wrapped load is prevented. The high impact plastic sheet may be attached to the underside of the wrapped load by adhesive; or by heat shrinking; or by applying localised heat to fuse it the film or by any other l o method by which plastics may be joined. Ideally, the at least one strip of plastic sheeting is arranged on the lower end of the load to cover a portion of the load which contacts the forks of a lifting device during transportation.

The sheet of high impact plastic protects the wrapping material on the lower surfaces of the load from being punctured by forks of fork lift trucks and from being tom or damaged when the load is placed on rough ground. This further improves the stability of the load by ensuring that the integrity of the plastic wrapping is maintained.

The present invention also provides a method for wrapping a load in wrapping material, which comprises creating at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load without the use of a pallet platform; moving the load onto a wrapping platform at a first wrapping station; rotating the wrapping platform to rotate the load relative to dispensing means for wrapping material and/or rotating the dispensing means around the load on the wrapping platform to partially wrap the load in wrapping material; effecting linear motion of the wrapping platform towards a second wrapping station; rotating dispensing means for wrapping material around the load about a substantially horizontal axis to further wrap the load in wrapping material; pivoting a wrapping table at a third wrapping station from a substantially horizontal position to a substantially vertical position; before, after or simultaneously with the effecting step, moving the wrapping platform with the load horizontally and/or vertically to position the load in a desired alignment with the wrapping table; returning the wrapping table back from the substantially vertical position to the substantially horizontal, and simultaneously turning the wrapping IE 0 6 ο 1 9 4 platform from the horizontal position towards a substantially vertical position such that the load is transferred from the wrapping platform onto the wrapping table; and rotating the load about a substantially horizontal axis on the wrapping table and simultaneously effecting a relative rotational movement, about a substantially vertical axis, between the load and at least one dispensing means for wrapping material to completely wrap the load in wrapping material.

According to another aspect of the invention, there is provided a load comprising a plurality of stackable elements arranged in a plurality of substantially horizontal layers; wherein the surface area of at least one lowermost layer of the load is smaller than that of the remaining plurality of layers, such that two fork entry openings are created in a spaced substantially parallel orientation on one surface of the load without the use of a pallet platform; and further comprising a pair of support elements interposed between the at least one lowermost layer and the remaining plurality of layers.

According to a further aspect of the invention, there is provided a load comprising a plurality of stackable elements arranged in a plurality of substantially horizontal layers; wherein both the width and the length of at least one lowermost layer of the load are smaller than the width and length, respectively, of the remaining plurality of layers, such that two pairs of fork entry openings are created on a lower surface of the load without the use of a pallet platform; thereby allowing the forks of a lifting device to be inserted into either pair of fork entry openings for transporting the load.

Several embodiments of the wrapped loads and methods of the present invention will now be described with reference to and/or as illustrated in the accompanying drawings.

Brief Description of the Drawings Figure I is a perspective view of a wrapped load according to a first aspect of the present invention; Figure 2a is front elevation view of the wrapped load of Figure 1; Figure 2b is an end elevation view of the wrapped load of Figure 1; Figure 3 is a front elevation view of the wrapped load of Figure 1, raised by a lifting device; IE ο 6 ο 1 9 4 Figure 4 is a top plan view of a partial load created by the method of the present invention; Figure 5 is a perspective view of a portion of a wrapping machine suitable for carrying out the method according to a second aspect of the present invention; Figure 6 is a top plan view of a mechanism suitable for carrying out the roping step of the method according to the second aspect of the present invention; Figure 7 is a perspective view of the mechanism of Figure 6; Figure 8 is a front elevation of the mechanism of Figure 6; Figure 9 is a front elevation view of a wrapped load according to the present invention; Figure 10 is a perspective view of the wrapped load of Figure 9; Figure 11 is a perspective view of an alternative embodiment of a wrapped load according to the present invention; Figure 12 is a front elevation view of the wrapped load of Figure 11; Figure 13 is a front elevation view of a further embodiment of a wrapped load according to the present invention; and Figure 14 is a perspective view of the wrapped load of Figure 13; Figures 15, 16, 17 and 18 are perspective views of a partial load according to the first aspect of the present invention and a stacking machine suitable for performing at least part of the method according to the first aspect of the invention; Figure 19 is a perspective view of an apparatus suitable for attaching a strip of high impact plastic sheeting to the underside of a wrapped load according to the first or second aspect of the present invention; Figure 20 is a front elevation of a load according to a further aspect of the present invention; Figure 21 is a perspective view of a wrapped load according to a further aspect of the present invention; Figure 22 is a perspective view of the load of Figure 21; Figure 23 is a perspective view of a combined stacking and wrapping apparatus, suitable for carrying out the methods of the present invention.

Detailed Description of the Drawings As shown in Figures 1 to 3 of the drawings, the first aspect of the present invention provides a wrapped load 1 comprising a load 2 having at least two fork engaging ΙΕ ο 6 Ο 19 4 projections 3 in a substantially parallel arrangement on opposing vertical surfaces 4 of the load 2 and wrapping material 5 wrapped around the load 1 such that it at least partially envelops the fork engaging projections 3; wherein the at least partially enveloped fork engaging projections 3 are adapted to receive the forks 6 of a lifting device for transporting the wrapped load 1 without the use of a pallet platform. The fork engaging portions 3 are arranged so that the forks (or tines) of a lifting device, for example a forklift truck, may be positioned on either side of the wrapped load 1 so that they are located beneath the fork engaging portions 3. When the forks 6 of the lifting device are raised, each fork will engage the underside 11 of the corresponding fork engaging projection 3 as shown in Figure 3, thereby raising the wrapped load 1 off the ground 12 (or any other surface).

In the embodiments shown, the load 2 comprises a plurality of stackable elements 14 arranged in substantially horizontal layers 15. The stackable elements 14 shown in Figures 1 to 3 are bricks, but the invention is equally suitable for use with blocks, boxes, cartons or any other stackable objects. In the embodiment shown in Figures 1 to 3, the stackable elements 14 in at least one of the layers 15 are arranged such that their ends 16 project from opposing vertical surfaces 4 of the load to form fork engaging projections 3.

As shown in Figures 15 to 18, a stacking apparatus 18, for example a plate stacker or slide palletiser, may be used to form a load or stack comprising layers of a predetermined length L and width W. This is done by arranging a predetermined number of stackable elements 14 to form a first layer of the required dimensions L and W on the plate 17 of the stacker 18. The plate may then be dropped a distance equal to the thickness of a layer 15 of stackable elements. A next layer of length L and width W may then be added on top of the first layer. This may be repeated to form a partial load or stack 19 of the desired height as shown in Figure 15.

In alternative embodiments, the stacking apparatus 18 may be a cuber, in which case each layer is picked up by the cuber and placed on top of the preceding layer. The stack or load 2 may be formed by any suitable stacking apparatus known in the art.

IE c 5 ο 1 9 4 The plate of the plate stacker may then be rotated through 90 degrees as shown in Figure 16. A layer of length L and width W is then added to the top of the partially formed load or stack. Because the plate has been rotated through 90 degrees, this layer is added to the stack such that it is orientated orthogonal to the previous layers. As the length L of each layer is greater than the width W, the stackable elements in the new layer are arranged so that their ends 16 extend beyond opposing vertical surfaces 4 of the partially formed load, as shown in Figure 4. The stackable elements 14 in the new layer thus form two fork-engaging projections 3 in substantially parallel arrangement on opposing vertical surfaces 4 of the partial load 19. If required, further layers 15 may be added in this orientation. This may be necessary where the thickness of the stackable elements is small relative to the height of the load. The plate may then be rotated back through 90 degrees to its original position as shown in Figure 17. Referring to Figure 18, further layers may be added to the partially formed stack 19 in the original orientation to form a complete load 2.

In the embodiment shown in Figures 1 to 3, the fork engaging projections 3 are integrally formed with the load 2. The wrapping material 5 is wrapped around the load by establishing relative rotational motion between the load and a dispensing means for the wrapping material 5. As shown in the drawings, especially Figure 1, the wrapping material comprises a strip 7 of plastics film 5, which is wrapped around the load in overlapping turns.

Referring now to Figure 5 of the drawings, the present invention also relates to a wrapped load 1 comprising a strip 7 of wrapping material 5 wrapped around a load 2 such that it at least partially envelops the load; and a rope 8 of wrapping material 5 formed from the strip 7 of wrapping material 5 as it is applied to the load 2, wherein the rope 8 of wrapping material 5 encircles the load 2 such that it reinforces the wrapping material.. In the embodiment shown in Figure 5, the load 2 is formed as described above with reference to Figures 1 to 4. This aspect of the invention may also be used with differently shaped loads, for example, as described below with reference to Figures 13 and 14, Figure 20, Figures 21 and 22, or with conventional palletised loads for additional support.

IE c 6 ο 1 9 4 As shown in Figure 5, the rope 8 of wrapping material is formed by reducing the width of the strip 7 of wrapping material to provide a relatively narrow rope 8 of wrapping material. In the embodiment shown in Figure 5, the wrapping material 5 is a plastics film. The rope is integrally formed with the strip or web of plastics film, that is, the strip of plastics film remains continuous while the rope is formed and while the load is wrapped. The width of the strip of film is reduced over a portion of its length as it is applied to the load, as will be described in more detail below. Wrapping of the load may continue after the roping step is complete. The strip of wrapping material is allowed to return to its original width for the remainder of the wrapping process. No break in the strip of film is required.

The rope 8 of wrapping material 5 may be formed in a number of ways for example, by twisting, crimping or tucking the wrapping material. The strip of wrapping material may be twisted by rotating the dispensing means 30 for the wrapping material through an angle of approximately 90 degrees, so that the edge of the strip of wrapping material is applied to the load (rather than the full width of the strip). This results in the entire width of the strip 7 of wrapping material being applied in one localised area around the load. Alternatively, the strip of wrapping material may be twisted about itself by one or more arms mounted on the dispensing means 30. The strip of wrapping material may be crimped by passing it through an annular ring with a diameter significantly smaller than the width of the strip of wrapping material. The annular ring may be formed in two halves. When the strip of wrapping material is to be roped, the two halves may be brought together from either side of the dispensing means 30 for the wrapping material, thereby pinching the wrapping material into a rope. The wrapping material may be tucked by providing one or more arms moveably mounted on the dispensing means for the wrapping material. When the strip of material is to be formed into a rope 8, the arms may be brought together, thereby causing the strip to accumulate in one area.

The wrapping of the load is reinforced by encircling the partially wrapped load 2 with the rope 8 of wrapping material by establishing relative rotational motion between the partially wrapped load 2 and means 10 for forming a rope of wrapping material. ΙΕ ο 6 ο 1 9 4 When wrapping loads in plastics film, it is desirable that the film fits tightly around the load and adheres closely to the contours of the load to be wrapped. Film dispensers of the type used for wrapping loads in this way usually include a film pre-stretching device so that when the pre-stretched web of film is applied to the load, it remains under tension to provide an air-tight and water-tight covering. Pre-stretching may be achieved in a number of ways, for example, as shown in Figures 6 to 8 by providing a holder 20 on which a reel 21 of film 5 is rotatably mounted, and a pair of rollers 22, 23 adjacent the film reel between which the strip 7 or web of film 5 may be drawn by a load wrapping apparatus. The pair of rollers 22, 23 may be geared such that the first roller 23 (that is, the roller nearer to the load 2 to be wrapped) is driven at a higher speed than the second roller 22. Thus, as the strip 7 of wrapping material 5 is drawn through a film-stretching zone 24 between the two rollers, the different peripheral speeds ofthe rollers 22, 23 cause pre-stretching of the film. The plastic film may be manufactured from, for example, polytnide, polypropylene, PVC, polybutene, polyethylene, or co15 polymers or mixtures of such materials. Using such film, the pre-stretch unit may be designed to pre-stretch the film by between 50% and 300% of its length. The usual stretch ratio is between 50% and 100% of length, and more preferably about 70%. Different stretch ratios may be used depending on the type of film being used. The load 2 is then wrapped in the pre-stretched film 5.

According to a preferred embodiment of the present invention, a secondary stretching step is carried out after the strip 7 of wrapping material 5 has been formed into a rope 8, or simultaneously with the roping step. When the wrapping material has been roped as described above, it becomes much stronger than the strip 7 of wrapping material and may be stretched further without risk of breaking. The secondary stretching step stretches the rope of wrapping material by a further 10% to 200%. The actual degree of stretching carried out will depend on the type of film used.

The step of forming the rope 8 of wrapping material from the strip of wrapping material and the step of post-stretching (secondary stretching) the rope 8 of wrapping material may be combined in a single operation. This may be done for example by using spools 25, 26 located at either side of the dispensing means for wrapping material, wherein one spool 26 is located in front of the other 25 (that is, closer to the load to be wrapped).

IE n 6 o 1 9 4 When the wrapping material is to be roped, the pair of rollers or spools may be moved together towards the centre of the strip 7 of wrapping material such that the strip 7 of film passes over spool 25 and under spool 26, as shown in Figures 6, 7 and 8. This reduces the width of the strip, in a similar manner to that described above with reference to tucking or crimping of the strip. The spools 25, 26 may be mounted on moveable arms on either side of the dispensing means 30. As described above with reference to the pre-stretching step, the spools 25, 26 may also be geared such that the forward spool 26 is moving more quickly than the spool behind 25. This results in a secondary stretch being imparted to the rope 8 of wrapping material as it is formed and simultaneously drawn through the film-stretching zone 27 between the two spools. The apparatus may further include a pair of slave rollers 28, 29. These ensure that the strip 7 of film 5 is correctly aligned with the spools as they are engaged with the film.

Because the film has been stretched twice, in the pre-stretch and post-stretch steps, the rope 8 applied to the load has substantially no further capacity for stretching and there is no “give” left in the roped film. After secondary stretching, the plastic film has lost its plastic memory and has become relatively inelastic. Plastic film roped in this way is therefore very strong and thus imparts additional strength to the wrapped load and provides additional support to the load when the wrapping material is cut. According to the present invention, the rope 8 of wrapping material reinforces the strip 7 of wrapping material and supports the wrapped load 1, thereby allowing the load 2 to retain its shape even when the wrapping has been cut.

Figures 9 to 12 show another embodiment of a wrapped load according to the present invention. The load is shaped as described above with reference to Figures 1 to 3. In addition, the wrapped load shown in Figures 9 to 12 further comprises at least one sheet 9 of high impact plastic arranged on a lower end of the load after wrapping the load, such that puncturing of the underside of the wrapped load is prevented. The sheet 9 of plastic sheeting may be for example, HIPS (High Impact Polystyrene) or APET (Amorphous Polyethylene Terephthlat).

As shown in Figures 9 and 10, the sheet may be applied to the entire lower surface of the wrapped load I, including the fork engaging projections 3, and may optionally be IE 0 6 0 1 9 4 shaped to cover several surfaces of the load. The sheet of high impact plastic is thus arranged on the lower end of the load to cover a portion of the load which contacts the forks of a lifting device during transportation.

Alternatively, and as shown in Figures 11 and 12, two strips 9 of plastic sheeting may be applied to the bottom comers of the wrapped load 1 to protect the integrity of the film where it may come in contact with the forks 6 of a lifting device during lifting and manoeuvring. Again, the strips 9 may optionally be shaped to cover several surfaces of the load. The strips 9 of plastic sheeting are arranged on the lower end of the load to cover a portion of the load which contacts the forks of a lifting device during transportation. The strips may be attached by, for example, gluing, heat shrinking or by applying localised heat to fuse it the film.

Figures 13 and 14 show an alternative embodiment of a wrapped load according to the second aspect of the present invention. In this case, the load 2 comprises two fork-entry openings 13 in a spaced substantially parallel orientation on one surface 34 of the load 2, and does not require use of a pallet platform. The load 2 is wrapped in a strip 7 of plastics film wrapping material 5 such that the load 2 and the fork entry openings 13 are at least partially enveloped in the wrapping material. This may be done by establishing relative rotational motion between the load 2 and a dispensing means 30 for the wrapping material. The wrapping 5 of the load 2 may be reinforced by forming a rope 8 of wrapping material from the strip of wrapping material as it is applied to the load and encircling the partially wrapped load 2 with the rope 8 of wrapping material by establishing relative rotational motion between the partially wrapped load and a means 10 for forming a rope of wrapping material. In addition, the wrapped load shown in Figures 13 and 14 further comprises a sheet 9 of high impact plastic arranged on a lower end of the load after wrapping the load, such that puncturing of the underside of the wrapped load is prevented. The high impact plastic may be attached to the wrapped load as described above with reference to Figures 9 to 12.

The strips or sheets 9 of high impact plastic sheeting may be either flat or pre-formed to a desired shape. Apparatus suitable for attaching the strips/sheets 9 to the wrapped load 1 is shown in Figure 19. The strips are placed in a magazine 31. An applicator arm 32 picks up a strip 9 from the magazine 31 using, for example, suction cups. Where the strip is to be attached by gluing, the applicator arm 32 will then move to another position where glue may be applied to the surface of the strip that will come in contact with the wrapped load. The arm 32 will then place the strip 9 against the stack 1 along the fork entry opening 13 (or fork-engaging projection 3) and apply the necessary pressure and/or heat to stick the plastic to the wrapped load. Localised heat may be applied to the strip 9 to cause it to shrink around the wrapped load 1 or cause it to fuse with the wrapping material 5 already applied to the stack.

Figure 20 illustrates a load 2 according to a further aspect of the present invention. The load 2 comprises a plurality of stackable elements 14 arranged in layers 15. The load 2 further comprises two fork entry openings 13 in a spaced substantially parallel orientation on one surface 34 of the load 2, and does not require use of a pallet platform. The lowermost layers 15 of the load 2 are of width w and are narrower than the higher layers, which are of width W. This difference in width provides the fork entry openings 13. A pair of support elements 36 are interposed between the lowermost layers of width w and the higher layers of width W. The support elements 36 are of substantially the same length L as the layers 15. The support elements may be formed from metal, wood, or rigid plastic, or from any other suitable material. The load 2 may be wrapped as described above with reference to any of Figures 1 to 19, the support elements thereby being incorporated into the wrapped load. The support elements 36 provide additional stability to the resulting wrapped load especially when the wrapping is tom or cut to allow the contents to be used.

Figures 21 and 22 illustrate a load 2 according to a further aspect of the present invention. The load 2 may comprise a plurality of stackable elements arranged in layers. The load 2 further comprises a plurality of fork entry openings 13 on one surface 34 of the load 2, and does not require use of a pallet platform. The lowermost layers 15 of the load 2 are of width w and length 1, and the higher layers are of width W and length L. The lowermost layers are therefore smaller than the higher layers in two dimensions. This difference in size provides the fork entry openings 13. The load illustrated in Figure 21 is therefore a multi-directional load and can be lifted by a lifting device such as a forklift truck from any of four directions. This allows the load to be ΙΕ ο 6 ο 1 9 4 approached from any side and easily lifted by the lifting device, without any need for additional manoeuvring. As shown in Figure 21, the load may be wrapped as previously described. In Figure 21, the wrapped load is shown mounted on the forks of a lifting device in one possible orientation. It will be appreciated that the load may also be lifted by the lifting device from any of its other three sides.

Referring now to Figure 23 of the drawings, there is illustrated a combined stacking and wrapping apparatus, suitable for carrying out the methods of the present invention The wrapping of the load is carried out substantially as described in European Patent No. 1 io 214 245.

The apparatus comprises a stacking station 18, including stacking means for forming the load 2 as described above with reference to Figures 15 to 18. The apparatus also includes means for transferring the completed load from the stacking station 18 to a first wrapping station 37.

The apparatus further comprises a first wrapping station 37 including a wrapping platform 39 to receive the load 2 to be wrapped, wrapping material dispensing means 30 at the first wrapping station 37, means for rotating the platform 39 relative to dispensing means 30 and/or means for rotating the dispenser relative to the platform 39 to partially wrap the load 2 with the wrapping material 5, and means for transferring the load to a second wrapping station 38. The wrapping apparatus at the first wrapping station wraps the load substantially as described in European Patent No. 1 214 245.

In the first wrapping step, the wrapping platform 39 is rotated, which in turn causes the load 2 to rotate about a vertical axis. A film dispenser 30 is mounted on rotatable wrapping arm 43 on one side of the wrapping station. The film dispenser is also moveable along the wrap arm in a vertical direction. The film dispenser 30 is of a well known construction and may include a pre-tensioning unit through which the plastics wrapping material is fed and stretched. Preferably, the wrapping material dispensing means 30 at the first wrapping station 37 further includes means 10 for forming a rope of wrapping material as described above with reference to Figures 5 to 8. A cut and ΙΕΟ 60 1J 4 start device for severing the film at the end of wrapping may be mounted on the platform 39.

At the start of the wrapping cycle, the free end of the strip 7 of film 5 is attached to the 5 cut and start device on the wrapping platform 39 and the platform 39 is caused to rotate by a motor. The dispensing means 30 mounted on arm 43 may also be rotated (in an opposite direction) around the load by a motor. The relative rotational motion between the load and the dispensing means unwinds the film 5 from the dispenser 30 and causes the film 5 to wrap the load 2. Where a rope of wrapping material is to be applied to the load 2, the rope 8 of wrapping material 5 may be formed from the strip 7 of wrapping material and applied to the load at this stage. The roping process is described in detail above with reference to Figures 5 to 8. When the roping step is complete and the strip of wrapping material has been returned to its original width, the cut and start mechanism catches the film 5.

At the end of the first wrapping step, the wrapping platform 39 (and thus the load) is advanced towards the second wrapping station 38. The second wrapping station 38 includes means for further wrapping the load 2. Preferably, the wrapping means at the second wrapping station 38 includes wrapping material dispensing means 42 for rotation about a substantially horizontal axis to apply wrapping material 5 to the load as it is moved towards the second wrapping station. The film dispenser 42 at the second wrapping station is mounted on a ring 44 and is rotated around the partially wrapped load 2 in a circular path as the load is advanced towards the second wrapping station. The load 2 is wrapped as it is moved from the first wrapping station to the second wrapping station, such that the top and bottom surfaces of the load are fully wrapped in the wrapping material 5.

At the end of the second wrapping process, the load is transferred to the third wrapping station. Preferably, the wrapping means at the third wrapping station 40 includes a belt table 41 for rotating the load 2 about a substantially horizontal axis. Alternatively, the belt table is additionally rotatable about a vertical axis relative to the film dispensing means. Preferably, the belt table 41 at the second wrapping station 40 is pivotable from a normally horizontal position, through approximately 90 degrees, to a position in which IE Ο 6 Ο 1 ο 4 engagement means on the belt table engage with means on the wrapping platform 39, and the wrapping platform 39 is pivotably mounted, such that when the belt table 41 is retuned to its original horizontal position it causes the wrapping platform to swing from a normally horizontal position, through approximately 90 degrees, to deposit the partially wrapped load onto the belt table at the third wrapping station 40. The load is transferred substantially as described in European Patent No. 1214 245.

The third wrapping station 40 includes means for completing wrapping of the load 2, including wrapping material dispensing means for rotation about a substantially vertical axis to apply wrapping material 5 to the load as it is rotated about a horizontal axis. The wrapping of the load is completed substantially as described in European Patent No. 1 214 245 (with reference to the second wrapping station). The rotation of the load 2 about a horizontal axis, while wrapping around a vertical axis ensures a complete wrapping of the load 2 in wrapping material 5.

The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Claims (22)

Claims

1. A wrapped load comprising: a load having at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load; and wrapping material wrapped around the load such that it at least partially envelops the fork engaging projections; wherein the at least partially enveloped fork engaging projections are adapted to receive the forks of a lifting device for transporting the wrapped load without the use of a pallet platform.

2. A wrapped load as claimed in claim 1, wherein the load comprises a plurality of stackable elements arranged in substantially horizontal layers.

3. A wrapped load as claimed in claim 2, wherein the stackable elements in at least one of the layers are arranged such that their ends project from opposing vertical surfaces of the load to form fork engaging projections.

4. A wrapped load as claimed in claim 2 or claim 3, wherein each layer has a length L greater than its width W, and wherein at least one substantially horizontal layer is oriented substantially orthogonal to the other layers, such that the stackable elements in said at least one layer are arranged so that their ends extend beyond opposing vertical surfaces of the load to create two fork engaging projections in substantially the same horizontal plane on opposing vertical surfaces of the load.

5. A wrapped load comprising: a strip of wrapping material wrapped around a load such that it at least partially envelops the load; and a rope of wrapping material formed from the strip of wrapping material as it is applied to the load; wherein the rope of wrapping material encircles the load such that it reinforces the wrapping material. ΙΕ ο 6 ο ιβ<

6. A wrapped load as claimed in any preceding claim, further comprising at least one strip of high impact plastic sheeting arranged on a lower end of the load after wrapping the load, such that puncturing of the underside of the wrapped load is prevented.

7. A wrapped load as claimed in claim 9, wherein the at least one strip of plastic sheeting is arranged on the lower end of the load to cover a portion of the load which contacts the forks of a lifting device during transportation.

8. A method for wrapping a load in a wrapping material comprising the steps of: creating at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load without the use of a pallet platform; at least partially wrapping the load in a wrapping material such that the fork engaging projections are at least partially enveloped in the wrapping material by establishing relative rotational motion between the load and a dispensing means for the wrapping material.

9. A method as claimed in claim 11, wherein the load comprises a plurality of stackable elements arranged in substantially horizontal layers.

10. A method as claimed in claim 12, wherein the stackable elements in at least one of the layers are arranged such that their ends project from opposing vertical surfaces of the load to form fork engaging projections. 1 l.A method as claimed in claim 12 or claim 13, further comprising the steps of: creating a partial load comprising a first plurality of substantially identical layers of length L and width W arranged in a first orientation to form a partial load of length L and width W; adding at least one layer of length L and width W to the partial load in an second orientation orthogonal to the first orientation, such that the stackable elements in the at least one layer are arranged so that their ends extend beyond opposing vertical surfaces IE o s Q t p 4 of the partial load to create a pair of fork engaging projections in the same horizontal plane on opposing vertical surfaces of the load; adding further layers to the partial load in the first orientation to complete the load.

11. 12. A method for wrapping a load in a wrapping material comprising the steps of: at least partially wrapping a load in a strip of wrapping material such that the load is at least partially enveloped in the wrapping material by establishing relative rotational motion between the load and a dispensing means for the wrapping material; 10 before or after the partial wrapping step, forming a rope of wrapping material from the strip of wrapping material as it is applied to the load; and reinforcing the wrapping of the load by encircling the load with the rope of wrapping material by establishing relative rotational motion between the partially wrapped load and a means for forming the rope of wrapping material,

12. 13. A method as claimed in claim 15, wherein the rope of wrapping material is formed by: twisting the strip of wrapping material about itself; or crimping the strip of wrapping material; or 20 tucking the strip of wrapping material.

13. 14. A method as claimed in claim 15, wherein the wrapping material comprises a plastics film and further comprising the steps of: pre-stretching the strip of plastics film by between 50% and 100% of its length 25 before application to the load; forming the rope of plastics film from the pre-stretched strip of plastics film as it is applied to the load; and post-stretching the rope of plastics film by between 10% and 200% of its length, wherein the post-stretching step is carried out after or simultaneously with the forming 30 step.

14. 15. A method as claimed in claim 17, wherein the steps of forming the rope of plastics film and post-stretching the rope of plastics film are carried out simultaneously by 22 ΙΕθ6θ1®4 means of a pair of moveably mounted spools which are moved together towards the centre of the strip of plastics film, such that a rope of film is formed as the strip of plastics film passes between the spools and wherein the spools are geared such that the forward spool is moving more quickly than the rear spool to impart a secondary stretch to the rope of plastics film as it is drawn through a film-stretching zone between the two spools.

15. 16. A method for wrapping a load in a wrapping material as claimed in any of claims 11 to 18, further comprising the step of providing at least one strip of high impact plastic sheeting on a lower end of the load after wrapping the load, such that puncturing of the underside of the wrapped load is prevented.

16. 17. A method as claimed in claim 19, wherein the at least one strip of plastic sheeting is arranged on the lower end of the load to cover a portion of the load which contacts the forks of a lifting device during transportation.

17. 18. A method for wrapping a load in wrapping material, which comprises: creating at least two fork engaging projections in a substantially parallel arrangement on opposing vertical surfaces of the load without the use of a pallet platform; moving the load onto a wrapping platform at a first wrapping station; rotating the wrapping platform to rotate the load relative to dispensing means for wrapping material and/or rotating the dispensing means around the load on the wrapping platform to partially wrap the load in wrapping material; effecting linear motion of the wrapping platform towards a second wrapping station; rotating dispensing means for wrapping material around the load about a substantially horizontal axis to further wrap the load in wrapping material; pivoting a wrapping table at a third wrapping station from a substantially horizontal position to a substantially vertical position; before, after or simultaneously with the effecting step, moving the wrapping platform with the load horizontally and/or vertically to position the load in a desired alignment with the wrapping table; IE 0 6 0 1 9 4 returning the wrapping table back from the substantially vertical position to the substantially horizontal, and simultaneously turning the wrapping platform from the horizontal position towards a substantially vertical position such that the load is transferred from the wrapping platform onto the wrapping table; and rotating the load about a substantially horizontal axis on the wrapping table and simultaneously effecting a relative rotational movement, about a substantially vertical axis, between the load and at least one dispensing means for wrapping material to completely wrap the load in wrapping material.

18. 19. A load comprising: a plurality of stackable elements arranged in a plurality of substantially horizontal layers; wherein the surface area of at least one lowermost layer of the load is smaller than that of the remaining plurality of layers, such that two fork entry openings are created in a spaced substantially parallel orientation on one surface of the load without the use of a pallet platform; and further comprising a pair of support elements interposed between the at least one lowermost layer and the remaining plurality of layers.

19. 20. A load comprising: a plurality of stackable elements arranged in a plurality of substantially horizontal layers; wherein both the width and the length of at least one lowermost layer of the load are smaller than the width and length, respectively, of the remaining plurality of layers, such that two pairs of fork entry openings are created on a lower surface of the load without the use of a pallet platform; thereby allowing the forks of a lifting device to be inserted into either pair of fork entry openings for transporting the load.

20. 21 .A load substantially as hereinbefore described with reference to, and as illustrated in Figure 20 of the accompanying drawings. IE 0 S ο 1 β 4

21. 22.Α load substantially as hereinbefore described with reference to, and as illustrated in Figures 21 and 22 of the accompanying drawings.

22. 23.A wrapped load substantially as hereinbefore described with reference to, and as 5 illustrated in, Figures 1 to 3 of the accompanying drawings.