Load wrapping apparatus and method for wrapping a load with paper-based packaging material

Abstract

An apparatus and method for wrapping a load with paper-based packaging material include one or more of a paper-based packaging material holder, a paper-based packaging material roping mechanism and a paper-based packaging material pressing mechanism.

1 . An apparatus for wrapping a load, comprising:
 a paper-based packaging material dispenser configured to dispense a web of paper-based packaging material to the load;   a rotational drive configured to generate relative rotation between the paper-based packaging material dispenser and the load about an axis of rotation during a wrap cycle; and   a paper-based packaging material holder, the paper-based packaging material holder including:
 a clamp including a downwardly-facing opening configured to receive a leading end of the web of paper-based packaging material and hold the leading end of the web of paper-based packaging material during at least a portion of the wrap cycle; and 
 an arm supporting the clamp, the arm being biased to a first position that is separated from a side of the load, and the arm being movable to a second position that positions the clamp against the side of the load in response to tension in the web of paper-based packaging material during the relative rotation when the leading end of the web of paper-based packaging material is held by the clamp. 
   
     
     
         2 . The apparatus of  claim 1 , wherein the paper-based packaging material holder further includes an arm support configured to support the arm, the arm support configured to maintain a substantially constant rotational position about the axis of rotation relative to the load during wrapping. 
     
     
         3 . The apparatus of  claim 2 , further comprising:
 a platen configured to rotate about the axis of rotation; and   a platen support configured to move the platen in the direction of the axis of rotation to engage with a top of the load during wrapping;   wherein the arm support is mounted to the platen.   
     
     
         4 . The apparatus of  claim 2 , wherein the arm support is configured to support the arm for rotation about a pivot axis, wherein the pivot axis is substantially parallel to the axis of rotation. 
     
     
         5 . The apparatus of  claim 1 , wherein the clamp is a first clamp, and wherein the apparatus further comprises a second clamp that is movable in a direction along the axis of rotation and configured to support the leading end of the web of paper-based packaging material prior to the wrap cycle. 
     
     
         6 . The apparatus of  claim 5 , wherein the second clamp is configured to hold a trailing end of the web of paper-based packaging material at an end of the wrap cycle. 
     
     
         7 . The apparatus of  claim 5 , wherein the second clamp is configured to move in the direction along the axis of rotation with the paper-based packaging material dispenser. 
     
     
         8 . The apparatus of  claim 5 , further comprising a controller, wherein the controller is configured to control the apparatus to, proximate a start of the wrap cycle:
 move the leading end of the web of paper-based packaging material in the direction along the axis of rotation while being held by the second clamp such that the leading end of the web of paper-based packaging material is received within the opening of the first clamp;   actuate the first clamp to hold the leading end of the web of paper-based packaging material after the leading end of the web of paper-based packaging material is received in the opening of the first clamp; and   release the second clamp after actuating the first clamp.   
     
     
         9 . The apparatus of  claim 1 , wherein at least one layer of the web of paper-based packaging material overwraps the clamp during the wrap cycle, and wherein the arm is movable in a direction along the axis of rotation to withdraw the clamp from the leading end of the web of paper-based packaging material proximate an end of the wrap cycle. 
     
     
         10 . The apparatus of  claim 1 , wherein the clamp includes first and second jaws, wherein the first jaw has at least one longitudinal groove and the second jaw includes at least one longitudinal rib that is received within the at least one longitudinal groove when the clamp is actuated to provide greater holding resistance in a first direction transverse to the axis of rotation than in a second direction parallel to the axis of rotation. 
     
     
         11 . An apparatus for wrapping a load, comprising:
 a paper-based packaging material dispenser configured to dispense a web of paper-based packaging material to the load;   a rotational drive configured to generate relative rotation between the paper-based packaging material dispenser and the load about an axis of rotation during a wrap cycle; and   a paper-based packaging material pressing mechanism configured to adhere a trailing end of the web of paper-based packaging material to the load on each of upstream and downstream sides relative to a corner of the load proximate an end of the wrap cycle, the paper-based packaging material pressing mechanism including:
 an upstream pressing member configured to press the trailing end of the web of paper-based packaging material against the upstream side of the load; and 
 a downstream pressing member configured to press the trailing end of the web of paper-based packaging material against the downstream side of the load. 
   
     
     
         12 . The apparatus of  claim 11 , wherein the upstream pressing member is configured to press the trailing end of the web of paper-based packaging material against the upstream side of the load while adhesive is disposed between the trailing end of the web of paper-based packaging material and the upstream side of the load, and the downstream pressing member is configured to press the trailing end of the web of paper-based packaging material against the downstream side of the load while adhesive is disposed between the trailing end of the web of paper-based packaging material and the downstream side of the load. 
     
     
         13 . The apparatus of  claim 12 , further comprising an adhesive applicator configured to apply adhesive to the upstream and downstream sides of the load prior to pressing the trailing end of the web of paper-based packaging material against the upstream and downstream sides of the load. 
     
     
         14 . The apparatus of  claim 13 , further comprising a controller, wherein the controller is configured to control the apparatus to:
 prior to completing a last wrap around the load, actuate the adhesive applicator to apply the adhesive to first and second portions of the web of paper-based packaging material that respectively overlay the upstream and downstream sides of the load; and   thereafter complete the last wrap around the load such that the trailing end of the web of paper-based packaging material overlays at least the first portion of the web of paper-based packaging material.   
     
     
         15 . The apparatus of  claim 13 , further comprising an arm configured to support the adhesive applicator and controllably move the adhesive applicator into a position to apply adhesive to the web of paper-based packaging material. 
     
     
         16 . The apparatus of  claim 11 , wherein the upstream and downstream pressing members are separately actuatable. 
     
     
         17 . The apparatus of  claim 11 , wherein the paper-based packaging material pressing mechanism further includes a cutter configured to sever the trailing end of the web of paper-based packaging material. 
     
     
         18 . The apparatus of  claim 17 , wherein the paper-based packaging material pressing mechanism is configured to press the trailing end of the web of paper-based packaging material against the upstream side of the load with the upstream pressing member prior to severing the trailing end of the web of paper-based packaging material, and to press the trailing end of the web of paper-based packaging material against the downstream side of the load with the downstream pressing member after severing the trailing end of the web of paper-based packaging material. 
     
     
         19 . The apparatus of  claim 11 , wherein the paper-based packaging material pressing mechanism further includes an arm configured to support the upstream and downstream pressing members, the arm being movable between a first position separated from the load and a second position proximate the load. 
     
     
         20 . The apparatus of  claim 19 , wherein the paper-based packaging material pressing mechanism is configured to press the upstream pressing member against the upstream side of the load through movement of the arm, and to press the downstream pressing member against the downstream side of the load through actuation of a downstream pressing member actuator after movement of the arm to the second position. 
     
     
         21 . An apparatus for wrapping a load, comprising:
 a paper-based packaging material dispenser configured to dispense a web of paper-based packaging material to the load;   a rotational drive configured to generate relative rotation between the paper-based packaging material dispenser and the load about an axis of rotation during a wrap cycle; and   a paper-based packaging material roping mechanism configured to form a rope along a bottom edge of the web of paper-based packaging material, the paper-based packaging material roping mechanism including:
 a substantially horizontal surface; and 
 first and second substantially vertical rollers positioned proximate the substantially horizontal surface and separated from one another by a gap; 
 wherein when the bottom edge of the web of paper-based packaging material is received in the gap between the first and second substantially vertical rollers, the first and second substantially vertical rollers gather and crease the bottom edge of the web of paper-based packaging material against the substantially horizontal surface and into a rope. 
   
     
     
         22 . The apparatus of  claim 21 , wherein the first and second substantially vertical rollers are horizontally movable to track the web of paper-based packaging material during at least a portion of the relative rotation. 
     
     
         23 . The apparatus of  claim 21 , further comprising first and second guides positioned upstream of the first and second substantially vertical rollers. 
     
     
         24 . The apparatus of  claim 23 , wherein the first and second guides define an upwardly-facing opening. 
     
     
         25 . The apparatus of  claim 24 , wherein the first and second guides are horizontally movable to track the web of paper-based packaging material during at least a portion of the relative rotation. 
     
     
         26 . The apparatus of  claim 21 , wherein the substantially horizontal surface is defined on a substantially horizontal roller. 
     
     
         27 . The apparatus of  claim 21 , wherein the first and second substantially vertical rollers are cone shaped. 
     
     
         28 . (canceled) 
     
     
         29 . A method of wrapping a load with a load wrapping apparatus that includes a paper-based packaging material dispenser configured to dispense a web of paper-based packaging material to the load and a rotational drive configured to generate relative rotation between the paper-based packaging material dispenser and the load about an axis of rotation during a wrap cycle, the method comprising:
 moving a platen downwardly along the axis of rotation to engage with a top of the load and to position a leading end of the web of paper-based packaging material within an opening of a first clamp supported on an arm that is rotatably mounted to the platen;   actuating the first clamp to hold the leading end of the web of paper-based packaging material;   initiating relative rotation between the paper-based packaging material and the load to wrap the web of paper-based packaging material around the load, including rotating the arm in response to tension in the web of paper-based packaging material during the relative rotation to move the clamp against a side of the load and wrap paper-based packaging material around the clamp;   prior to completing a final rotation around the load, applying adhesive to first and second portions of the web of paper-based packaging material that overlay upstream and downstream sides of the load relative to a corner of the load;   performing the final rotation around the load;   pressing a trailing end of the web of paper-based packaging material against the upstream side of the load with an upstream pressing member to adhere the trailing end of the web of paper-based packaging material to the upstream side of the load;   severing the trailing end of the web of paper-based packaging material;   pressing the trailing end of the web of paper-based packaging material against the downstream side of the load with a downstream pressing member to adhere the trailing end of the web of paper-based packaging material to the downstream side of the load; and   prior to completing the final rotation around the load, performing at least a portion of one rotation around the load while a bottom edge of the web of packaging material is received by a paper-based packaging material roping mechanism that includes a substantially horizontal surface and first and second substantially vertical rollers positioned proximate the substantially horizontal surface and separated from one another by a gap such that the bottom edge of the web of paper-based packaging material is received in the gap between the first and second substantially vertical rollers and the first and second substantially vertical rollers gather and crease the bottom edge of the web of paper-based packaging material against the substantially horizontal surface and into a rope.