Bundle wrapping apparatus and associated methods

Abstract

Various embodiments of the present invention provide devices and processes for packaging elongate items in shippable bundles using a corrugated slip sheet and wrapping material. The elongate items may then be stacked within a frame. The frame with the stacked elongate items may then be wrapped with a wrapping material. Next, the stack of elongate items with the wrapping material may be removed from the frame as a single unitized bundle for storage and subsequent shipment.

1 . A bundle of elongate items comprising:
 a slip sheet having a planar base portion and at least one flap extending from the base portion;   a plurality of elongate items disposed in a plurality of rows atop the slip sheet, wherein a first row is disposed adjacent to the base portion with a longitudinal axis of the elongate items substantially parallel with the plane formed by the base portion; and   a wrapping material disposed around the plurality of rows wherein the wrapping material engages both ends of the elongate items and at least a portion of the slip sheet.   
     
     
         2 . The bundle of  claim 1 , wherein the flap is disposed between a portion of the wrapping material and at least one of the elongate items. 
     
     
         3 . The bundle of  claim 1 , wherein the base portion is substantially rectangular with the flap extending from one side of the base portion and the slip sheet further comprising a back wall portion extending substantially perpendicularly from an edge of the base portion opposite the flap and two side walls extending perpendicularly from edges adjacent the flap, wherein the two side walls are attached to the back wall. 
     
     
         4 . The bundle of  claim 3 , wherein the wrapping material engages at least a portion of the back and two side walls but does not engage the flap. 
     
     
         5 . The bundle of  claim 1 , wherein the flap that extends beyond the elongate length of the elongate items. 
     
     
         6 . The bundle of  claim 1 , wherein the slip sheet is constructed from cardboard, plastic or metal. 
     
     
         7 . The bundle of  claim 1 , wherein the elongate items are rolls of textile material. 
     
     
         8 . The bundle of  claim 7 , wherein the plurality of items is greater than 50. 
     
     
         9 . The bundle of  claim 1 , wherein the wrapping material is an elastic film. 
     
     
         10 . The bundle of  claim 1 , wherein the wrapping material is an inelastic film, a fabric or paper. 
     
     
         11 . A bundling system for packaging a plurality of elongate items comprising:
 a stacking frame configured to align the elongate items, wherein the stacking frame comprises:
 a substantially planar platform; 
 a plurality of posts attached to the platform, wherein the posts position the platform at a position spaced apart from a supporting surface; and 
 a plurality of support blocks attached to the frame; and 
   an undocking station comprising a plurality of rails configured to slideably engage the support blocks to restrict movement of the stacking frame in a direction substantially perpendicular to the platform.   
     
     
         12 . The bundling system of  claim 11 , wherein the support blocks are attached to respective posts. 
     
     
         13 . The bundling system of  claim 11  further comprising a bar attached to the platform proximate one edge wherein the bar is configured to cooperate with the platform to align items on an inclined relative to the support surface when placed thereon. 
     
     
         14 . The bundling system of  claim 11 , wherein the platform is inclined relative to the support surface. 
     
     
         15 . The bundling system of  claim 11  further comprising a wrapping station configured to apply a wrapping material around the plurality of elongate items disposed in the stacking frame and a portion of the posts. 
     
     
         16 . A method of bundling a plurality of elongate items comprising the steps of:
 stacking a plurality of elongate items into a plurality of rows atop a slip sheet; and   applying wrapping material around the stack of elongate items wherein the wrapping material is engages the ends of the plurality of elongate items and at least a portion of the slip sheet.   
     
     
         17 . The method of  claim 16  further comprising the steps of:
 placing the slip sheet onto a frame between a plurality of posts, wherein the posts are configured to provide lateral support for the elongate items; and the step of applying wrapping material comprises applying the wrapping material around the elongate items and a portion of the plurality of posts. 
 
     
     
         18 . The method of  claim 17  further comprising the steps of:
 engaging at least one of the posts and removing the stack of elongate items and wrapping material from the frame after applying the wrapping material.