FIELD OF THE INVENTION

The present invention relates to a method for producing a packing material arrangement and more particularly to a method for producing a packing material arrangement as described in the preamble of the independent claim 1.

The present invention further relates to an apparatus for producing a packing material arrangement and more particularly to an apparatus for producing a packing material arrangement as described in the preamble of the independent claim 8.

The present invention further relates to an apparatus for a packing material arrangement and more particularly to a packing material arrangement as described in the preamble of the independent claim 12.

BACKGROUND OF THE INVENTION

The circular packing material elements are typically used to protect ends of different kind of coils such as paper coils, board coils and steel coils. In the prior art circular packing material elements are manufactured by punching individual sheets by punching machine. There is a demand of circular packing material elements which have different diameters. There is also a demand of increasing the diameter of circular packing material elements.

The circular packing material elements are arranged to a packing material arrangement which comprises circular packing material elements and a packing which protects the circular packing material elements during storage and transportation. Circular packing material elements are usually packed on pallets. Typically, horizontal dimensions of a pallet are less than 1200 mm x 1200 mm and horizontal dimensions of a larger pallet are less than 1500 mm x 1500mm.

One of the problems associated with the prior art is that it is inefficient to adjust a punching machine every time when there is need to change a diameter of the circular packing material element.

Another of the problems associated with the prior art is that circular packing material element arrangements produced by known methods and apparatuses are complicate to pack for storage and transportation. BRIEF DESCRIPTION OF THE INVENTION

An object of the present invention is to provide a method, an apparatus and an arrangement so as to overcome or at least alleviate the prior art disadvantages.

The objects of the invention are achieved by a method which is characterized by what is stated in the independent claim 1. The objects of the invention are achieved by an apparatus which is characterized by what is stated in the independent claim 8. The objects of the invention are achieved by an arrangement which is characterized by what is stated in the independent claim 12. The preferred embodiments of the invention are disclosed in the dependent claims.

The invention is based on the idea of providing a method for producing a packing material arrangement. The method comprises: c) providing a plurality of packing material sheets such that the plurality of packing material sheets forms a stack of packing material sheets d) holding the plurality of packing material sheets together in the stack e) cutting the packing material sheets in the stack to circular packing material elements.

In one embodiment, the step d) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets. This improves efficiency of the process.

In another embodiment, the step c) further comprises aligning edges of the packing material sheets in the stack by positioning the edges of the packing material sheets against a stopper. This improves alignment of the circular packing material elements.

In a further embodiment, the step c) further comprises aligning edges of the of packing material sheets in the stack by inclining the stack. In an alternative embodiment the step c) further comprises aligning edges of the of packing material sheets in the stack by vibrating the stack. In an alternative embodiment the step c) further comprises aligning edges of the of packing material sheets in the stack by blowing air to the stack. In an alternative embodiment the step c) further comprises aligning edges of the of packing material sheets in the stack by inclining the stack and by vibrating the stack. In an alternative embodiment the step c) further comprises aligning edges of the of packing material sheets in the stack by inclining the stack and by blowing air to the stack. In an alternative embodiment the step c) further comprises aligning edges of the of packing material sheets in the stack by vibrating the stack and by blowing air to the stack. In an alternative embodiment, the step c) further comprises aligning edges of the of packing material sheets in the stack by inclining the stack and by vibrating the stack and by blowing air to the stack. This improves alignment of the circular packing material elements.

In one embodiment, the method further comprises after the step e) a step f) wrapping a wrapping material around the stack of circular packing material elements such that wrapping material covers at least partly the first base of first circular packing material element, at least partly the second base of last circular packing material element and at least partly the cylindrical surfaces of all circular packing material elements. This reduced weight of the circular packing material arrangement.

In one embodiment, the step e) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets, rotating the stack of packing material sheets around an axis in a direction perpendicular to the surfaces of the packing material; and moving the cutting device in a direction parallel to said axis such that the cutting device is positioned at a distance from said axis. This improves alignment of the circular packing material elements in a stack.

In another embodiment, the method comprises after the step e) a step g):

- simultaneously sharpening a blade of a cutting device and replacing produced circular packing material elements in a cutting device with an uncut stack of packing material sheets. This improves efficiency of the method.

In one embodiment the method further comprises following steps before the step c): a) producing a packing material strip b) cutting the packing material strip to packing material sheets. This improves efficiency of the method.

In one preferred embodiment, the step c) a plurality of packing material sheets comprises 400 - 5 000 packing material sheets. This improves efficiency of the method.

The invention is also based on the idea of providing an apparatus for producing a packing material arrangement. The apparatus comprises:

- a base part arranged to provide a support for a stack of packing material, - a holding device arranged to hold the stack of packing material on the base part in a defined position,

- a cutting device arranged to cut the stack of packing material supported on the base part in a defined position,

- a rotating device arranged to rotate the cutting device and the base part relative to each other.

In other words the rotating device is arranged to rotate the cutting device or the base part.

In one embodiment, the apparatus further comprises a wrapping device arranged to wrap wrapping material around the stack of circular packing material and an aligning device arranged to align edges of the of packing material sheets. In an alternative embodiment the apparatus further comprises a wrapping device arranged to wrap wrapping material around the stack of circular packing material. In an alternative embodiment the apparatus further comprises an aligning device arranged to align edges of the of packing material sheets. This improves an efficiency of the apparatus.

In another embodiment, the apparatus further comprises:

- one or two rotating device arranged to rotate the base part and the holding device such that the base part and the holding device rotate relative to the cutting device around an axis in a direction perpendicular to the surfaces of the packing material; and

- the apparatus comprises a moving device arranged to move the cutting device in a direction parallel to said axis at a distance from said axis. This further improves an efficiency of the apparatus.

In one another further embodiment, the apparatus further comprises a sharpening device for sharpening a blade of the cutting device. This further improves efficiency of the apparatus.

In one embodiment, the cutting device is arranged to cut a stack of 400 - 5 000 circular packing material elements. This further improves efficiency of the apparatus.

The invention is also based on the idea of providing a packing material arrangement. The packing material arrangement comprises:

- 400 - 5 000 circular packing material elements

- each circular packing material element having a first base, a second base and a cylindrical surface between the first base and the second base

- each circular packing material element having the same diameter between 850- 3000mm.

- the circular packing material elements are arranged to form a stack comprising superposed circular packing material elements such that there are a plurality of circular packing material elements between the first circular packing material element and the last circular packing material element, and the first bases of each circular packing material element are facing in the same direction such that the first base of the first circular packing material element and the second base of last circular packing material element are facing away from the stack.

- a wrapping material such that the wrapping material covers at least partly the first base of first circular packing material element, at least partly the second base of last circular packing material element and at least partly the cylindrical surfaces of all circular packing material elements.

In one preferred embodiment each circular packing material element having the same diameter between 1250- 3000mm. This size packing material elements are not possible to support with a typically used pallet having the horizontal dimensions less than 1200 mm xl200 mm. In one preferred embodiment each circular packing material element having the same diameter between 1550- 3000mm. This size packing material elements are not possible to support with a typically used pallet having the horizontal dimensions less than 1500 mm x 1500 mm.

Surprisingly 400 - 5 000 circular packing material elements provide required stiffness to a self-supporting stack of circular packing material elements.

In one embodiment, the wrapping material is a stretchable film, and the wrapping material comprises one or more enforcement portion comprising multiple layers of the wrapping material; and a plurality of rounds of the wrapping material extends on the cylindrical surfaces of the circular packing material elements from the first base of the first circular packing material element to the second base of the last circular packing material element, across the second base of the last circular packing material element, on the cylindrical surfaces of the circular packing material element from the second base of the last circular packing material element to the first base of the first circular packing material element and across the first base of the first circular packing material element. This improves strength of the packing material arrangement. The one or more enforcement portion comprising multiple layers of the wrapping material improve maintaining the circular packing material elements together in order. In one embodiment, the circular packing material element is produced from corrugated board. This decreases weight of the packing material elements.

In one embodiment, the packing material arrangement is produced by any previously mentioned method.

An advantage of the invention is that it provides an efficient method and an efficient apparatus to produce an arrangement comprising a plurality of circular packing material elements. Additionally, an advantage of the present invention is that it provides an efficient method and an efficient apparatus to produce circular packing material element arrangements which have different diameters. Additionally, an advantage of the present invention is that it provides a supporting arrangement for such packing material elements which are not possible to support with a typical pallet. Additionally, an advantage of the present invention is that it provides a self-supporting arrangement of a plurality of surprising large circular packing material elements. Additionally, an advantage is that the self-supporting arrangements according to the present invention require less space in a logistic phase compared to the packing material elements on pallets.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is described in detail by means of specific embodiments with reference to the enclosed drawings, in which

Figure 1 shows schematically a packing material arrangement according to present invention as seen from one side ; and

Figure 2 shows schematically a packing material arrangement according to present invention in different position.

Figure 3 shows schematically a packing material arrangement according to present invention as seen from one side; and

Figure 4 shows schematically a base part of the apparatus in different position;

Figure 5 shows flow chart of method for producing a packing material arrangement according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 shows a packing material arrangement 100 according to the present invention. The packing material arrangement 100 comprises: - 400 - 5 000 circular packing material elements 102,107,108

- each circular packing material element 102,107,108 having a first base 104, a second base 105 and a cylindrical surface 106 between the first base 104 and the second base 105.

- each circular packing material element 102,107,108 having the same diameter between 850- 3000mm.

- the circular packing material elements 102 are arranged to form a stack comprising superposed circular packing material elements 102,107,108 such that there are a plurality of circular packing material elements 102 between the first circular packing material element 107 and the last circular packing material element 108, and the first bases 104 of each circular packing material element 102,107,108 are facing in the same direction such that the first base 104 of the first circular packing material element 107and the second base 105 of last circular packing material element 108 are facing away from the stack.

- a wrapping material 109 such that the wrapping material 109 covers at least partly the first base 104 of first circular packing material element 107, at least partly the second base 105 of last circular packing material element 108 and at least partly the cylindrical surfaces 106 of all circular packing material elements 102, 107, 108.

In other words, the circular packing material elements 102,107,108 are arranged such that successive circular packing material elements 102,107,108 beginning from first circular packing material element 107 and ending to last circular packing material element 108 form a right circular cylindrical; and the first base 104 of the second circular packing material element 110 is in contact with the second base 105 of the first circular packing material element 107 and the first base 104 of last circular packing material element 108 is in contact with the second base 105 of next to last circular packing material element 111. The wrapping material 109 is around the circular packing material elements 102,107,108.

In one preferred embodiment, each circular packing material element 102,107,108 having the same diameter between 1250- 3000mm.

In one preferred embodiment each circular packing material element 102,107,108 having the same diameter between 1550 - 3000 mm.

In one embodiment, the wrapping material 109 comprises a polymer material.

In one embodiment, the wrapping material 109 is plastic. In one embodiment the plastic is shrinkable plastic. In one preferred embodiment, the wrapping material 109 is a stretchable plastic film.

In one embodiment, the wrapping material 109 is a stretchable film comprising one or more enforcement portion 103. The enforcement portion comprises multiple layers of the wrapping material 109. A plurality of rounds of the wrapping material 109 extends on the cylindrical surfaces 106 of the circular packing material elements 102,107,108 from the first base 104 of the first circular packing material element 107 to the second base 105 of the last circular packing material element 108, across the second base 105 of the last circular packing material element 108, on the cylindrical surfaces 106 of the circular packing material elements 102,107,108 from the second base 105 of the last circular packing material element 108 to the first base 104 of the first circular packing material element 107 and across the first base 104 of the first circular packing material element 107.

In one embodiment, the wrapping material 109 covers the first base 104 of first circular packing material element 107, the second base 105 of last circular packing material element 108 and the cylindrical surfaces 106 of all circular packing material elements 102, 107, 108.

In one embodiment the circular packing material elements 102,107,108 are produced from corrugated board. In one embodiment the circular packing material elements 102, 107, 108 are produced from corrugated board consists of two kraft liner board outer surfaces with a corrugated interior that is bonded together with adhesive or glue.

Figure 2 shows schematically a packing material arrangement according to present invention in different position. In one embodiment the a plurality of an enforcement portion 103 of wrapping material 109 extends across the second base 105 of the last circular packing material element 108 such that a distance z between adjacent enforcement portions is 100-500 mm.

Typically, the stretchable plastic film is linear low-density polyethylene or LLDPE, which is produced by copolymerization of ethylene with alpha-olefins, the most common of which are butene, hexene and octene. The use of higher alpha- olefins (hexene or octene) gives rise to enhanced stretch film characteristics, particularly in respect of elongation at break and puncture resistance. Other types of polyethylene and PVC can also be used.

In one embodiment, the plastic wrapping material 109 is made from recycled high-density polyethylene or polypropylene materials. This type of material allows for greater non-tear strength and an increased number of uses in cold and humid environments.

In one embodiment, the wrapping material 109 has about 500% stretch at break but are only stretched to about 100 - 300% in use. Once stretched, the elastic recovery is used to keep the load tight.

Figure 3 shows schematically one embodiment of an apparatus 1 for producing a packing material arrangement 100 according to the present invention. The apparatus 1 comprises:

- a base part 2 arranged to provide a support for a stack of packing material;

- a holding device arranged 3 to hold the stack of packing material on the base part 2 in a defined position;

- a cutting device 4 arranged to cut the stack of packing material supported on the base part 2 in a defined position;

- a rotating device 5c arranged to rotate the cutting device 4 or a rotating device 5a, 5b arranged to rotate the base part 2 and the holding device 3 such that the cutting device 4 and the base part 2 rotate relative to each other.

In other words, a part of the holding device 3 comprises a part arranged to move towards the base part 2 and thus create a pressing force between the holding device 3 and the base part 2; or the holding device 3 comprises stoppers which hold the stack of packing material on the base part 2. The blade 10 of cutting device 4 is arranged to penetrate each packing material sheets in a distance from rotating axis and to cut packing material sheet to circular form.

In one embodiment the blade 10 of the cutting device 4 is a laser beam. In one preferred the blade 10 of the cutting device 4 is a steel blade.

In one embodiment a width of the blade 10 is 5 - 200 mm.

In one embodiment, the apparatus 1 comprises:

- a wrapping device 6 arranged to wrap wrapping material 109 around the stack of circular packing material elements 102,107,108 and an aligning device 7 arranged to align edges of the of packing material sheets; or

- a wrapping device 6 arranged to wrap wrapping material 109 around the stack of circular packing material elements 102,107,108; or

- an aligning device 7 arranged to align edges of the of packing material sheets.

In one embodiment the aligning device 7 comprises a stopper for aligning the packing material sheets against the stopper.

In one embodiment, the apparatus 1 comprises:

- one or two rotating device 5a, 5b arranged to rotate the base part 2 and the holding device 3 such that the base part 2 and the holding device 3 rotate relative to the cutting device 4 around an axis x in a direction perpendicular to the surfaces of the packing material; and

- a moving device 15 arranged to move the cutting device 4 in a direction parallel to said axis x at a distance y from said axis.

In one embodiment, the apparatus 1 comprises a sharpening device 11 for sharpening the blade 10 of the cutting device 4.

In one embodiment, the sharpening device 11 comprises two circular elements. The blade 10 of the cutting device 4 is arranged to be in contact with the circular elements of the sharpening device 11 such that movement of the circular elements of the sharpening device 11 against the blade 10 sharpens the blade 10.

In one embodiment, a position of the blade 10 of the cutting device 4 is arranged to be adjustable in a direction parallel to the surfaces of packing material sheets. In other words by this enables changing a diameter of circular packing material element.

Figure 4 shows schematically a base part of the apparatus in different position.

In one embodiment, the base part 2 comprises one or more openings 12 in a surface which is arranged to provide a support for a stack of packing material.

In one embodiment, the base part 2 comprises one or more support element 13 which is arranged into the openings 12.

In other words, the opening 12 provides a space for a conveying device such as a lifting fork and the support element 13 provides a support for the packing material sheets during cutting the packing material sheets. Preferably the support element 13 is flexible in a direction perpendicular to the axis x

In one embodiment, the base part 2 comprises a flexible layer in a surface which is arranged to provide a support for a stack of packing material.

In one embodiment, the apparatus 1 is arranged to cut a stack of 400 - 5 000 packing material sheets.

Figure 5 shows a flow chart of method for producing a packing material arrangement according to the present invention.

The method according to figure 1 comprises following processing steps carried out successively: c) providing a plurality of packing material sheets such that the plurality of packing material sheets forms a stack of packing material sheets d) holding the plurality of packing material sheets together in the stack e) cutting the packing material sheets in the stack to circular packing material elements.

In one embodiment, the step d) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets. The pressing causes a friction between packing material sheets and thus packing material sheets hold their position relate to each other.

In one embodiment, the step c) further comprises aligning edges of the packing material sheets in the stack by positioning the edges of the packing material sheets against a stopper.

In one embodiment, the step c) further comprises aligning edges of the of packing material sheets in the stack:

- by inclining the stack, or by vibrating the stack; or

- by blowing air to the stack, or by inclining the stack and by vibrating the stack; or

- by inclining the stack and by blowing air to the stack, or by vibrating the stack and by blowing air to the stack, or by inclining the stack and by vibrating the stack and by blowing air to the stack.

Preferably, the step c) further comprises aligning edges of the of packing material sheets in the stack by inclining the stack and by vibrating the stack and by blowing air to the stack. This embodiment enables an alignment of large packing material sheets.

In one embodiment the edges of the packing material sheets are aligned with a tolerance range from 0 to 1 mm. This reduces material lose.

In one embodiment, the method further comprises after the step e) a step f) wrapping a wrapping material around the stack of circular packing material elements such that wrapping material covers at least partly the first base of first circular packing material element, at least partly the second base of last circular packing material element and at least partly the cylindrical surfaces of all circular packing material elements.

In one embodiment, step f) wrapping a wrapping material around the stack of circular packing material elements is carried out by a rotary ring wrapper. The film is housed in a carriage on a ring in which the stack of circular packing material elements remains static while the ring is rotating around the stack.

In one embodiment, the step e) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets, rotating the stack of packing material sheets around an axis x which is in a direction perpendicular to the surfaces of the packing material; and moving the cutting device in a direction parallel to said axis such that the cutting device is positioned at a distance y from said axis. In other words pressing causes a friction between the packing material sheets. The packing material sheets keep their position due to the friction when the stack rotates. The pressed stack of packing material sheets remains aligned even when a blade 10 of a cutting machine 4 cuts the sheets. The blade 10 cuts the packing material sheets to a circular form by penetration through the surfaces of the sheets. The movement is perpendicular to the surfaces of packing material sheets and the blade 10 is at a distance y from rotating axis x of the stack.

In one embodiment, the step e) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets, rotating the cutting device around an axis which is in a direction perpendicular to the surfaces of the packing material sheets; and moving the cutting device in a direction parallel to said axis such that the cutting device is positioned at a distance y from said axis. In other words the packing material sheets keep their position due to the friction between the packing material sheets. Pressing the stack causes the friction. The pressed stack of packing material sheets remaining aligned even when a blade of a cutting device cuts the sheets. The blade cuts the sheets in a circular form by penetrating movement through the surfaces of the packing material sheets. The movement is perpendicular to the surfaces of packing material sheets and the blade is at a distance y from rotating axis of the stack.

In one embodiment, the step e) further comprises pressing the stack in a direction perpendicular to the surfaces of the packing material sheets for forming a pressed stack of packing material sheets, rotating the cutting device around an axis x which is in a direction perpendicular to the surfaces of the packing material sheets; and moving the pressed stack in a direction parallel to said axis such that the cutting device is positioned at a distance y from said axis. In other words the packing material sheets keep their position due to the friction between the packing material sheets. Pressing the stack causes the friction. The pressed stack of packing material sheets remaining aligned even when a blade of a cutting device cuts the sheets. The blade cuts the sheets in a circular form by penetrating through the surfaces of the packing material sheets. The blade is at a distance y from rotating axis of the stack.

In one embodiment, the method comprises after the step c) a step z) conveying a stack of packing material sheets from step c) to step d).

In one embodiment the method comprises after the step e) a step w) conveying the circular of packing material elements 102,107,108 from step e) to step f).

In one embodiment, the method comprises after the step e) the method a step g) simultaneously sharpening a blade 10 of a cutting device 4 and replacing circular packing material elements 102,107,108 with an uncut stack of packing material sheets. In other words, step w and step z are carried out in same time with sharpening a blade 10 of a cutting device 4.

In one embodiment, the step e) cutting the packing material sheets comprises a small backward movement of the blade 10.

In one embodiment, the method comprises before the step d) a step j) positioning the stack of packing material sheets concentric to a base part 2. Preferably position in the step j) is defined by an optical device.

In one embodiment, the method comprises before the step e) a step k) adjusting a position of the blade 10 in a direction parallel to the surfaces of packing material sheets. This enables changing the diameter of circular packing material elements.

In one embodiment, the packing material strip is corrugated fiberboard consists of one kraft liner board with a corrugated board that is bonded together with adhesive or glue. This bonded material provides the necessary strength. The advantages associated with this material are low cost.

In one embodiment, the packing material strip is corrugated fiberboard consists of two kraft liner board outer surfaces with a corrugated interior that is bonded together with adhesive or glue. The advantages associated with this material is its strength when to be moved by a conveyor or lift truck.

In one embodiment, the packing material strip is fiberboard (thick paperboard) slip sheet consists of several layers of solid kraft paperboard sheets laminated together. The bonding of layers of several flat solid kraftboard sheets increases the slip sheet’s non-tear strength. In addition, some fiberboard slip sheets are protected by a plastic coating to improve its use in humid environments. The advantages with this material are its ability to withstand humid and cold environments.

In one embodiment, the method according to the invention comprises after step a) an optional step b) cutting the packing material strip to packing material sheets. This improves efficiency of the method. In one embodiment, the step b) comprises cutting a plurality of packing material sheets and transporting the sheets.

In one embodiment, a packing material arrangement 100 according to present invention is produced by any of previously disclosed method.

The invention has been described above with reference to the examples shown in the figures. However, the invention is in no way restricted to the above examples but may vary within the scope of the claims.