EP4613670A1

EP4613670A1 - A package and a method for forming a package

Info

Publication number: EP4613670A1
Application number: EP24161562.4A
Authority: EP
Inventors: Rikhard Storbacka; Frank Timmerbacka; Sami Viitasalo
Original assignee: Rani Plast Oy AB
Current assignee: Rani Plast Oy AB
Priority date: 2024-03-05
Filing date: 2024-03-05
Publication date: 2025-09-10

Abstract

A package (1) has a longitudinal direction (L), a cross direction (C) and a vertical direction (H). The package (1) comprises a supporting structure (2) and film reels (3) packed on the supporting structure (2). Each film reel (3) comprises a central axis (4) and layers of a film (5) wound on the central axis (4) where the outer film layer forms the outer circumference (6) of the film reel (3). The film reels (3) stand on the supporting structure (2) in such a manner that the central axis (4) is in the vertical direction (H). The films reels (3) form a matrix comprising rows (7) in the longitudinal direction and rows (8) in the cross direction. The package (1) also comprises a protective sheet (9) that is a continuous sheet that winds partially around the outer circumferences (6) of the film reels (3) alternately clockwise and counterclockwise through the whole matrix. A method for forming a package is also disclosed.

Description

FIELD OF THE INVENTION

The present invention relates to a package and a method for forming a package. The package contains film reels, especially stretch film reels.

BACKGROUND OF THE INVENTION

Film reels are packed usually on a pallet in such a manner that they stand side by side on a pallet. One of the disadvantages associated with the packages is that the adjacent film reels rub each other and may get damaged.

BRIEF DESCRIPTION OF THE INVENTION

An object of the present invention is to provide a package and a method so as to overcome the above problem. The object of the invention is achieved by a package and a method which are characterized by what is stated in the independent claims. The preferred embodiments of the invention are disclosed in the dependent claims.
An advantage of the package and the method is that the film reels do not get damaged during handling and transportation. The package and the method are extremely advantageous in connection with stretch film reels because they cling to each other due to sticky surfaces of the rolls.
The package has a longitudinal direction, a cross direction and a vertical direction. The package comprises a supporting structure, film reels packed on the supporting structure and a protective sheet. The supporting structure may be a pallet, or any other suitable plane. Each film reel comprises a central longitudinal axis and layers of a film wound around the central longitudinal axis. The outer film layer forms the outer circumference of the film reel. The film reels stand erect on the supporting structure, i.e. the central longitudinal axis is in the vertical direction. There may be an elongated core that is concentric with the central longitudinal axis and the film is wound on the core. The films reels form a matrix comprising rows in the longitudinal direction and rows in the cross direction. The matrix is usually rectangular. The protective sheet may be a continuous sheet that winds partially around the outer circumferences of the film reels alternately clockwise and counterclockwise through the whole matrix.
The continuous protective sheet has a first surface, a second surface, a longitudinal direction and a width direction. The continuous protective sheet is on a roll wherefrom it is taken in use. The continuous protective sheet is usually a plastic film but other materials may also be applicable. The plastic material is the preferred choice.
The continuous protective sheet separates the film reels so that their outer circumferences do not touch each other during transport and handling when the package shakes. In other words, the film reels may be in contact with each other through the continuous protective sheet, or they may have a short gap between each other in stable conditions but the continuous protective sheet prevents a direct contact in unstable conditions.
The continuous protective sheet may be e.g. a one-layer film, a tubular film, a one-layer film that is folded double, or two separate films attached face to face against each other. Each of the choices that has a double structure may be constructed so that the surfaces that are in contact with the film reels, i.e. the first surface and the second surface, are tacky and the inner surface that is in contact with the opposite inner surface is slippery. The static coefficient of friction (COF) of the slippery surface may be less than 0.35 (film against film friction, measured according to ISO 8295).
A method for forming the package may comprise pulling at least once the continuous protective sheet diagonally over the supporting structure with the width direction of the continuous protective sheet upwards, and placing alternately in the following order or in the reverse order one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet until the matrix is complete. Thus, the continuous protective sheet is pulled diagonally over the supporting structure at least once but it may be pulled diagonally over the supporting structure once in the beginning, or after every complete row, or after two complete rows.
A method for forming the package may comprise repeating the following sequence until the matrix is complete: Pulling the continuous protective sheet diagonally over the supporting structure with the width direction of the continuous protective sheet upwards, i.e. the width direction of the continuous protective sheet is erect but not necessarily perpendicular to the supporting structure, and placing alternately in the following order or in the reverse order one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet until one row is complete.
A method for forming the package may comprise pulling from a roll the continuous protective sheet diagonally over the supporting structure with the width direction of the continuous protective sheet upwards, i.e. the width direction of the continuous protective sheet is erect but not necessarily perpendicular to the supporting structure and repeating the following sequence until the matrix is complete: Placing alternately in the following order or in the reverse order one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet until two rows are complete and transferring the roll further away from the supporting structure. The roll is usually transferred in respect of the the supporting structure in the cross-direction of the supporting structure or in the cross-direction and longitudinal direction of the supporting structure.
A method for forming the package may comprise pulling the continuous protective sheet diagonally over the supporting structure with the width direction of the continuous protective sheet upwards, i.e. the width direction of the continuous protective sheet is erect but not necessarily perpendicular to the supporting structure and repeating the following sequence until the matrix is complete: Placing alternately in the following order or in the reverse order one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet until the package is complete.
The film reels may be conveyed to the proximity of the supporting surface by a conveyor belt. A packaging robot may grab a reel having a core from the inside of the core with its expansion shaft tool and transfer the reel on the supporting structure one by one. The same packaging robot may be used to transfer the roll comprising the continuous protective sheet. However, it is also possible that more than one robot is used, or some phases are accomplished manually.
The continuous protective sheet that is wound on the roll is unwound from a holder or alike provided with a brake that keeps the sheet tensioned. Depending on a case the continuous protective sheet may have a width that is equal, less or greater than the width of the film on the film reel. The preferred width is the width that is greater than the width of the film on the film reel.
If the continuous protective sheet advances in one row from right to left it advances in the next row from left to right, or vice versa. When there is an odd number of the film reels in one row and if one row begins with placing one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet then the next row begins with placing one film reel on the supporting structure on the side of the second surface of the continuous protective sheet and another film reel on the side of the first surface of the continuous protective sheet.
When there is an even number of the film reels in one row and if one row begins with placing one film reel on the supporting structure on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet then the next row begins in the same manner.
It is clear that the matrix may comprise any number of the longitudinal rows and any number of the cross-directional rows. It is also clear that the continuous protective sheet may advance along the cross-directional rows.
The film reels may be wrapped with the continuous protective sheet after the supporting structure is fully packed in order to protect the film reels, i.e. the continuous protective sheet surrounds the outer circumference of the package.
The package may be covered with a stretch film, or a stretch hood when the package is fully packed.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawings, in which

Figure 1 shows a package with two matrices one upon the other in a perspective view;
Figure 2 shows a package from above;
Figures 3a and 3b show a partial side view of the package;
Figures 4 - 24 show packaging schemes from above.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 shows a package 1 in a perspective view. The package 1 has a longitudinal direction L, a cross direction C and a vertical direction H. The package 1 comprises a supporting structure 2, film reels 3 packed on the supporting structure 2 and a protective sheet 9. The supporting structure 2 may be a pallet. The film reels 3 may be for industrial or agricultural purposes.
Each film reel 3 comprises an elongated core 4 around a central longitudinal axis RL and layers of a film 5 wound on the elongated core 4. Preferably the film 5 is a tacky film, such as a stretch film. The outer film layer forms the outer circumference 6 of the film reel 3.
The film reels 3 stand on the supporting structure 2 in the vertical direction H. The films reels 3 form a matrix comprising rows 7 in the longitudinal direction L and rows 8 in the cross-direction C. Fig. 1 shows 5x3 matrix comprising film reels 3A - 3O on the supporting structure 2. The adjacent film reels 3 may contact each other in the matrix, or they may be close to each other without contacting. The protective sheet 9 is a continuous sheet that winds partially around the outer circumferences 6 of the film reels 3 alternately clockwise and counterclockwise through the whole matrix. For example, the protective sheet 9 winds on the circumference 6 of film reel 3A clockwise, on the circumference 6 of film reel 3B counterclockwise, on the circumference 6 of film reel 3E clockwise and on the circumference 6 of film reel 3F counterclockwise if the winding direction is considered from film reel 3A on. If the winding direction is considered from film reel 3O on the winding directions around the film reels 3 are naturally the other way around.
The package 1 may have only one matrix, i.e. only one layer of film reels 3 stand on the surface of the supporting structure 2, or the package 1 may comprise more than one matrix on top of each other. Fig. 1 shows two matrices 10, 11 and a planar sheet 12 between the matrices. However, also more than two matrices on top of each other are possible. The planar sheet 12 is not always necessary between the matrices.
The protective sheet 9 may be a one-layer sheet that contains only one material layer. Such sheets may be e.g. paper or plastic sheets. The one-layer sheet may also comprise different material layers attached to each other. One example of the one-layer sheet containing different material layers is a plastic film having a multilayer structure.
The protective sheet 9 may be a tubular film. The tubular film may be continuous through the matrix, or it may be continuous through one row of the matrix. The tubular film may have a one-layer sheet that contains only one material layer in a tubular form or the tubular film may contain different material layers. The tubular film is usually made of plastic material. The tubular film may be e.g. a polyethylene film whose thickness is 15 - 100 µm.
The protective sheet 9 in a tubular form has an inner surface and an outer surface. The inner surface may have lower friction than the outer surface. The static coefficient of friction of the inner surface may be less than 0.6, preferably less than 0.35 and more preferably less than 0.25 (film against film friction, measured according to ISO 8295). The outer surface is in contact with the outer circumferences 6 of the adjacent film reels 3 and clings substantially well to the film reels 3. The inner surface of the tubular film contacts itself and the inner surfaces slide in respect of each other. When one of film reels 3 shifts, the inner surface of the protective sheet 9 that is on the side that makes a contact with the film reel 3, slides in respect with the inner surface of the protective sheet that is on the opposite side of the side that makes the contact with the film reel 3. In that manner damages to the films on the film reels 3 can be effectively prevented.
The tubular film is the preferred choice. However, there are a few ways to get towards to achieve the same effect as with the tubular film, i.e. have a tacky outer surface and a slippery inner surface. A one-layer film having one tacky side and another slippery side may be folded double so that the slippery side is inside. Two separate films may be attached face to face so that slippery sides are against each other. Two separate films may be attached to each other here and there according to a predetermined pattern so that slippery sides are against each other. The pattern may comprise points and/or lines. The films may be attached by a suitable technique, for example micro-perforation.
Fig. 2 shows a package from above. The film reels 3 stand on the supporting structure 2. The films reels 3 form a matrix comprising rows 7 in the longitudinal direction L and rows 8 in the cross-direction C. Fig. 2 shows 4x3 matrix comprising film reels 3A1- 3L1 on the supporting structure 2. The film reels 3 may contact each other in the matrix, or they may be close to each other without contacting. The protective sheet 9 is a continuous sheet that winds partially around the outer circumferences 6 of the film reels 3 alternately clockwise and counterclockwise through the whole matrix. When the winding direction is considered from film reel 3A1 to film reel 3L1 the protective sheet 9 winds partially around the circumferences 6 of film reels 3A1, 3C1, 3E1, 3G1, 311 and 3K1 clockwise and the protective sheet 9 winds partially around the circumferences 6 of the film reels 3B1, 3D1, 3F1, 3H1, 3J1 and 3L1 counterclockwise.
Figs. 3a and 3b show what happens when one film reel 3 shifts in respect with another film reel 3. The film reels 3 stand erect in Fig. 3a and there is a two-fold protective sheet 9 between the film reels 3. The two-fold protective sheet 9 may be a tubular film. The two-fold protective sheet has an outer surface 9a and an inner surface 9b. Point T shows a point where the film has been folded. When one of the film reels 3 starts to move upwards U as shown in Fig. 3b the slippery inner surfaces slide against each other and the point T moves to another position. As the protective sheet 9 yields between the film reels 3, the film reels 3 are prevented to damage each other by causing ruptures or holes.
Figures 4 - 16 show a packaging scheme from above. A package is formed on a supporting structure 2, such as a pallet. A continuous protective sheet 9 has a first surface F, a second surface S, a longitudinal direction LP and a width direction WP (shown in Fig. 1). The continuous protective sheet is wound on a roll 10 that stands at one corner of the supporting structure 2. The continuous protective sheet 9 is pulled diagonally over the supporting structure 2 from the roll 10 in such a manner that the width direction WP is upwards from the supporting structure 2. The protective sheet 9 may be a tubular film. The tubular film may be such as described in connection with Fig. 1 and it may behave as described in connection with Figs. 3a and 3b.
Film reels 3, which are numbered R1 - R5 in figures 4 - 16, are placed alternately on the side of the first surface F and on the side of the second surface S starting from a corner of the supporting structure 2 that is furthest away from the roll 10 (Figs. 4 - 6).
When the first row is ready the roll 10 is transferred parallel to the longitudinal direction L of the supporting structure 2 in such a manner that the continuous protective sheet 9 extends diagonally over the supporting structure 2. Film reels 3, which are numbered R6 - R10 in figures 4 - 16, are placed alternately on the side of the second surface S and on the side of the first surface F starting from a location that is aligned with the film reel R5 (Figs. 7 - 9).
When the second row is ready the roll 10 is transferred parallel to the longitudinal direction L of the supporting structure 2 in such a manner that the continuous protective sheet 9 extends diagonally over the supporting structure 2. Film reels 3, which are numbered R11- R15 in figures 4 - 16, are placed alternately on the side of the first surface F and on the side of the second surface S starting from a location that is aligned with the film reel R10 (Figs. 10 - 12).
When the third row is ready the roll 10 is transferred parallel to the longitudinal direction L of the supporting structure 2 in such a manner that the continuous protective sheet 9 extends diagonally over the supporting structure 2. Film reels 3, which are numbered R16 - R20 in figures 4 - 16, are placed alternately on the side of the second surface S and on the side of the first surface F starting from a location that is aligned with the film reel R15 (Figs. 13 - 16).
When the fourth row is ready the whole package is complete. The roll 10 may be transferred parallel to the longitudinal direction L of the supporting structure 2 to the location where it was before starting to form the package.
The package comprises 5x4 matrix comprising film reels R1 - R20 on the supporting structure 2. Adjacent film reels 3 may contact each other in the matrix in such a manner that only the continuous protective sheet separates them, or they may be close to each other without contacting as shown in Figs. 4 - 16. The protective sheet 9 is a continuous sheet that winds partially around the outer circumferences 6 of the film reels 3 alternately clockwise and counterclockwise through the whole matrix. When the winding direction is considered from film reel R1 to film reel R16 the protective sheet 9 winds partially around the circumferences 6 of film reels R2, R4, R6, R8, R10, R12, R14 and R16 clockwise and the protective sheet 9 winds partially around the circumferences 6 of the film reels R1, R3, R5, R7, R9, R11, R13 and R15 counterclockwise.
The method that is shown in figures 4-14 may be accomplished by one or more robots. The film reels R1 - R16 and the roll 10 may be transferred to desired locations by robotics.
Figures 17 - 20 another packaging scheme from above. It differs from that shown in figures 4 - 16 in that the roll 10 containing the continuous protective sheet 9 has been placed differently and thus, more than one row can be formed without changing the position of the roll 10. The continuous protective sheet 9 is pulled diagonally over the supporting structure 2 from the roll 10 in such a manner that the width direction WP is upwards from the supporting structure 2 but the angle between the longitudinal direction L and the continuous protective sheet 9 is different. Two rows 7 of the film reels 3 are packed without changing the position of the roll 10. After the two rows 7 have been formed the roll 10 is transferred further away from the supporting structure 2. The roll is usually transferred in respect of the supporting structure in the cross-direction C of the supporting structure or in the cross-direction C and longitudinal direction L of the supporting structure. After the roll 10 has been transferred the next two rows 7 are packed.
Figures 21 - 24 show still another packaging scheme from above. It differs from that shown in figures 17 - 20 in that the roll 10 containing the continuous protective sheet 9 has been provided with guides 13, 14 so that the roll can be placed substantially freely. The continuous protective sheet 9 is pulled diagonally over the supporting structure 2 from the roll 10 in such a manner that the width direction WP is upwards from the supporting structure 2. The rows 7 of the film reels 3 are packed without changing the position of the roll 10.
It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.

Claims

A package (1) having a longitudinal direction (L), a cross direction (C) and a vertical direction (H), the package (1) comprising
- a supporting structure (2),

- film reels (3) packed on the supporting structure (2), each film reel (3) comprising a central axis (4) and layers of a film (5) wound on the central axis (4) where the outer film layer forms the outer circumference (6) of the film reel (3), the film reels (3) standing on the supporting structure (2) in such a manner that the central axis (4) is in the vertical direction (H), the films reels (3) forming a matrix comprising rows (7) in the longitudinal direction and rows (8) in the cross direction, and

- a protective sheet (9),
characterized in that the protective sheet (9) is a continuous sheet that winds partially around the outer circumferences (6) of the film reels (3) alternately clockwise and counterclockwise through the whole matrix.
The package according to claim 1, characterized in that the protective sheet (9) is a two-fold plastic film having an outer surface (9a) and an inner surface (9b).
The package according to claim 1 or 2, characterized in that the protective sheet (9) is a tubular film.
The package according to claim 2 or 3, characterized in that friction on the inner surface is less than friction on the outer surface.
The package according to claim 1, characterized in that the protective sheet is a planar film or web.
The package according to any preceding claim, characterized in that the package comprises matrices on top of each other.
The package according to any preceding claim, characterized in that the film reels (3) are stretch film reels.
A method for forming a package having a longitudinal direction (L), a cross direction (C) and a vertical direction (H), the package comprising
- a supporting structure (2),

- film reels (3) packed on the supporting structure (2), each film reel (3) comprising a central axis (4) and layers of a film (5) wound on the central axis (4) where the outer film layer forms the outer circumference (6) of the film reel (3), the film reels (3) standing on the supporting structure (2) in such a manner that the central axis (4) is in the vertical direction (H), the films reels (3) forming a matrix comprising rows (7) in the longitudinal direction and rows (8) in the cross direction, and

- a protective sheet (9),
characterized in that the protective sheet (9) is a continuous protective sheet that is wound on a roll (10) and having a first surface (F), a second surface (S), a longitudinal direction (LP) and a width direction (WP), and the method comprises
- pulling at least once the continuous protective sheet (9) diagonally over the supporting structure (2) with the width direction (WP) of the continuous protective sheet (2) upwards, and

- placing alternately in the following order or in the reverse order one film reel on the supporting structure (2) on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet (9) until the matrix is complete.
The method according to claim 8, characterized in that the method comprises repeating the following sequence until the matrix is complete:
- pulling the continuous protective sheet diagonally over the supporting structure (2), and

- placing alternately in the following order or in the reverse order one film reel on the supporting structure (2) on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet (9) until one row is complete.
The method according to claim 8, characterized in that the method comprises
- pulling the continuous protective sheet (9) diagonally over the supporting structure (2), and

- repeating the following sequence until the matrix is complete: Placing alternately in the following order or in the reverse order one film reel on the supporting structure (2) on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet (9) until two rows are complete, and transferring the roll (10) further from the supporting structure (2).
The method according to claim 8, characterized in that the method comprises
- pulling the continuous protective sheet (9) diagonally over the supporting structure (2), and

- repeating the following sequence until the matrix is complete: Placing alternately in the following order or in the reverse order one film reel on the supporting structure (2) on the side of the first surface of the continuous protective sheet and another film reel on the side of the second surface of the continuous protective sheet (9) until the matrix is complete.
The method according to any preceding claim 8 - 11, characterized in that the method comprises transferring the film reels to the proximity of the supporting structure by a conveyor belt.
The method according to claim 12, characterized in that the method comprises transferring the film reels on the supporting structure (2) by a packaging robot.