CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application No. 62/897,725, filed on September 9, 2019, the entire disclosure of which is fully incorporated herein by reference.

FIELD

[0002] The general inventive concepts relate to wrapping materials and, more particularly, to a wrapping material with reinforced regions.

BACKGROUND

[0003] During shipping of lumber, the lumber is often wrapped in a material that protects the lumber from any environmental conditions (e.g., rain, dirt, snow, etc.). The wrapping material also protects lumber that is stored prior to use. The wrapping material is typically wrapped around the lumber and then stapled directly to the lumber to secure the wrapping material around the lumber. It is known for the wrapping material to be made entirely out of polypropylene. While polypropylene is an effective wrapping material, staples used to wrap the polypropylene around the lumber may break through the polypropylene wrapping material, thereby compromising the effectiveness of the wrapping material. It is also known for the wrapping material to be made entirely out of polyethylene. While polyethylene is less likely to have a staple break through, it is less effective overall as a wrapping material due to low abrasion resistance and tends to represent a higher cost.

[0004] In addition, it is also known to place polyester or polypropylene multifilament threads near an edge of the wrapping material to create a reinforcement area that prevents staples from breaking through the wrapping material during shipping or storage. The multifilament threads can be woven with the tapes of the wrapping material, or the multifilament threads can be laminated to the tapes. There are drawbacks, however, to using such threads, such as, for example, the creation of ridges that negatively impact rolling up of the wrapping material and distort any printing near the edges of the product. The ridges also do not cut easily, which can create processing problems. Furthermore, when the multifilament threads are made of polyester, the wrapping material is not recyclable. [0005] In view of the above, there is an unmet need for a wrapping material that overcomes any one or more of these drawbacks, that overcomes other drawbacks, and/or that exhibits improved performance.

SUMMARY

[0006] The general inventive concepts relate to a wrapping material having reinforced regions through which a fastener (e.g., staple, nail) can penetrate to secure the wrapping material directly to the objects being wrapped (e.g., lumber) or to a supporting member (e.g., pallet) holding the objects being wrapped.

[0007] In one preferred embodiment, the wrapping material fits over a stack or other arrangement of wood, wherein the wrapping material is secured to the wood by staples that penetrate through reinforced regions of the wrapping material. In some exemplary embodiments, the staples are metallic. In some exemplary embodiments, the staples are non- metallic. In some exemplary embodiments, the staples are plastic.

[0008] In one exemplary embodiment, the wrapping material comprises a sheet formed by weaving a plurality of polypropylene warp tapes and a plurality of polypropylene weft tapes, wherein the sheet has a reinforced region, and wherein the reinforced region is formed by weaving a plurality of polyethylene warp tapes and a plurality of polypropylene weft tapes.

[0009] In some exemplary embodiments, the sheet has a length S _L and a width Sw, wherein the wrapping material comprises a first reinforced region and a second reinforced region, wherein a length of the first reinforced region equals the length S _L , and wherein a length of the second reinforced region equals the length S _L .

[0010] In some exemplary embodiments, the first reinforced region has a first width and the second reinforced region has a second width, wherein the first width equals the second width.

[0011] In some exemplary embodiments, the first width is in the range of 1 inches to 6 inches. In some exemplary embodiments, the first width is in the range of 1 inches to 3 inches. In some exemplary embodiments, the second width is in the range of 1 inches to 6 inches. In some exemplary embodiments, the second width is in the range of 1 inches to 3 inches. [0012] In some exemplary embodiments, a sum of the first width and the second width is less than or equal to Sw/4.

[0013] In some exemplary embodiments, the width Sw is in the range of 48 inches to 152 inches.

[0014] In some exemplary embodiments, the length S _L is greater than the width Sw.

[0015] In some exemplary embodiments, the polyethylene warp tapes are made of high density polyethylene.

[0016] In some exemplary embodiments, the polyethylene warp tapes are visibly distinct from the polypropylene warp tapes.

[0017] In some exemplary embodiments, the wrapping material further comprises a coating applied to at least one side of the sheet. In some exemplary embodiments, the coating is applied to both sides of the sheet. In some exemplary embodiments, the coating is an extruded layer of polypropylene.

[0018] In one exemplary embodiment, a method of wrapping an object is disclosed. The method comprises placing a wrapping material according to any of the above-described embodiments over the object; and fixing the wrapping material relative to the object by placing one or more fasteners through the reinforced region(s) of the wrapping material.

[0019] In one exemplary embodiment, a system for wrapping an object is disclosed. The system comprises means for placing a wrapping material according to any of the above- described embodiments over the object; and means for applying one or more fasteners through the reinforced region(s) of the wrapping material to fix the wrapping material relative to the object.

[0020] Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

[0022] Figures 1A-1C illustrate a wrapping material with reinforced regions, according to one exemplary embodiment.

[0023] Figures 2A-2D illustrate exemplary arrangements of polypropylene warp tapes and polyethylene warp tapes in the reinforced regions shown in FIGS. 1 A-1C.

[0024] Figures 3A-3C illustrate an exemplary system for wrapping an object using the wrapping material shown in FIGS. 1A-1C.

DETAILED DESCRIPTION

[0025] Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

[0026] The general inventive concepts encompass a wrapping material having reinforced regions through which a fastener (e.g., staple, nail) can penetrate to secure the wrapping material directly to the objects being wrapped (e.g., lumber) or to a supporting member (e.g., pallet) holding the objects being wrapped.

[0027] In some exemplary embodiments, at least some of the fasteners are metallic. In some exemplary embodiments, at least some of the fasteners are non-metallic. In some exemplary embodiments, at least some of the fasteners are plastic. In some exemplary embodiments, all of the fasteners are metallic. In some exemplary embodiments, all of the fasteners are non-metallic. In some exemplary embodiments, all of the fasteners are plastic.

[0028] As shown in FIG. 1, a wrapping material 100 is formed as a sheet 102 having a sheet length S _L and a sheet width Sw. It will be appreciated that the sheet length S _L and/or the sheet width Sw can be readily varied without departing from the scope of the general inventive concepts.

[0029] For example, for those applications where the wrapping material 100 will be packaged on a roll for use downstream, the sheet length S _L and the sheet width Sw are selected to correspond to a desired package size. In this case, a user can install the roll of the wrapping material 100 in a manner whereby the wrapping material 100 can be unrolled and pieces cut off for use thereof (see FIG. 3). It will be appreciated that the roll could be used in a manual wrapping process or an automated wrapping process.

[0030] As another example, for those applications where the wrapping material 100 will be used to create a pre-sewn cover, the sheet length S _L and the sheet width Sw are selected to correspond to the desired dimensions of the cover. Again, it will be appreciated that the cover could be used in a manual wrapping process or an automated wrapping process.

[0031] The sheet 102 of the wrapping material 100 is generally composed of polypropylene (PP) tapes that are woven together to form the wrapping material 100 (see FIG. IB). More specifically, first PP tapes 110 that are fed in a machine direction indicated by arrow 160 are woven with second PP tapes 112 that are fed in a cross-machine (or transverse) direction indicated by arrow 162. The first PP tapes 110 are considered warp tapes, while the second PP tapes 112 are considered weft tapes. The machine direction 160 is parallel to the sheet length S _L and perpendicular to the sheet width Sw. The cross-machine direction 162 is parallel to the sheet width Sw and perpendicular to the sheet length S _L .

[0032] The first PP tapes 110 and the second PP tapes 112 can be woven in any conventional manner, such as by a standard loom. If a circular loom is used to increase throughput, the resulting cylindrical member can be slit to form a flat sheet (e.g., the sheet 102).

[0033] According to the general inventive concepts, one or more reinforced regions are provided. As shown in FIG. 1A, two portions of the sheet 102 are formed as reinforced regions, i.e., a first reinforced region 120 and a second reinforced region 122.

[0034] The first reinforced region 120 is offset from a first side 104 of the sheet 102 by a distance wi. The second reinforced region 122 is offset from a second side 106 of the sheet 102 by a distance W2. Typically, but not necessarily, the distance wi is equal to the distance W2. In some exemplary embodiments, the distance wi is in the range of 0 to 6 inches. In some exemplary embodiments, the distance W2 is in the range of 0 to 6 inches.

[0035] The first reinforced region 120 has a width W ₃ and the second reinforced region 122 has a width W ₄ . Typically, but not necessarily, the width W ₃ is equal to the width W ₄ . In some exemplary embodiments, the width W ₃ is in the range of 1 to 6 inches. In some exemplary embodiments, the width W ₃ is in the range of 1 to 3 inches. In some exemplary embodiments, the width W ₄ is in the range of 1 to 6 inches. In some exemplary embodiments, the width W ₄ is in the range of 1 to 3 inches. Thus, the width of each reinforced region 120, 122 is considerably less than the total width of the sheet 102 of the wrapping material 100 (i.e., the width Sw). For example, in some exemplary embodiments, the width Sw is in the range of 48 to 152 inches.

[0036] Each of the reinforced regions 120, 122 is formed by replacing one or more of the first PP tapes 110 being fed in the machine direction with a polyethylene (PE) tape 114. For example, as shown in FIG. 1C, three of the PP tapes 110 have been replaced with the PE tapes 114 in the reinforced region 122. Addition of the PE tapes 114 creates the reinforced regions 120, 122 and provides the sheet 102 of the wrapping material 100 with enhanced properties, as described herein.

[0037] While the illustrative embodiment shown in FIG. 1C presents an arrangement wherein each of the PE tapes 114 is abutted by a PP tape (i.e., one of the first PP tapes 110) on both sides thereof, any other suitable arrangement of the PE tapes 114 and the PP tapes 110 is encompassed by the general inventive concepts. Various other exemplary arrangements 200 of the warp tapes are shown in FIGS. 2A-2D.

[0038] Introduction of the PE tapes 114 involves replacing select corresponding feedstocks of the first PP tapes 110 being fed into the aforementioned weaving process. As with the PP tapes 110, the PE tapes 114 are fed in the machine direction 160 and get woven with the second PP tapes 112 that are fed in the cross-machine direction 162. Thus, the PE tapes 114 (like the first PP tapes 110) are considered warp tapes. The PE tapes 114 used in the present invention are generally selected/produced to be heavier and stronger than the PP tapes 110, 112

[0039] In some exemplary embodiments, the PE tapes 114 are formed to be considerably darker than the PP tapes 110, 112. For example, as noted above, the PE tapes 114 can be formulated to be black (e.g., by addition of colorants). Conversely, the PP tapes 110, 112 can be formulated to be white (e.g., by addition of fillers). This contrast in colors allows the reinforced regions 120, 122 of the sheet 102 of the wrapping material 100 to be readily visible to the human eye. This facilitates a user (or a machine in the case of an automated wrapping process) to readily discern the reinforced regions 120, 122 on the sheet 102 for placement of suitable fasteners (e.g., staples) therein. The use of black and white tapes constitutes but one example and, so long as the contrast between the colors of the PE and PP tapes are visibly distinguishable in the final product (i.e., the sheet 102), such other color variations are encompassed by the general inventive concepts.

[0040] Each of the first PP tapes 110, the second PP tapes 112, and the PE tapes 114 can have any suitable width. These widths can vary from 2 mm to 8 mm. The tapes 110, 112, 114 can have different widths relative to each other in different embodiments.

[0041] For example, in one exemplary embodiment, the sheet 102 is formed with a ratio of 2: 1 warp tapes to weft tapes. Put another way, in this embodiment, there are roughly 10 warp tapes per inch and roughly 5 weft tapes per inch. Since 1 inch equals 25.4 mm, the tape widths are selected to approximate these dimensions. More specifically, in this embodiment, the first PP tapes 110 have a width of 2.5 mm and a weight of 888 dTex; the second PP tapes 112 have a width of 5.1 mm and a weight of 1,260 dTex; and the PE tapes 114 have a width of 3.1 mm and a weight of 1,665 dTex.

[0042] Production of the sheet 102 is completed by application of a polypropylene coating thereon. The polypropylene coating can be applied in any suitable manner, such as by extrusion coating. The coating can be applied to either side or both sides of the sheet 102. The coating is intended to close the interstices between the tapes 110, 112, 114 to form a weather (e.g., moisture) barrier. The contrast in colors between the PP tapes 110, 112 and the PE tapes 114, as described above, can be observed through the coating.

[0043] No reinforcing filaments are included in the completed sheet 102. The completed sheet 102 can be packaged on a roll for downstream use or can be subject to further processing (e.g., being formed into a pre-sewn cover).

[0044] For example, an exemplary system 300 for wrapping a package 302 (e.g., lumber on a pallet) will be described with reference to FIGS. 3A-3C. The system 300 includes a roll 304 of wrapping material 306 (e.g., the wrapping material 100 described above). The package 302 rests on a surface 308. In some exemplary embodiments, the surface 308 is a conveyor (manual or automated) that moves in a direction indicated by the arrow 320. In the case of a conveyor, the package 302 can be moved into a desired position for wrapping.

[0045] As an initial step, a quantity of the wrapping material 306 is unrolled from the roll 304 and cut or otherwise separated therefrom to create a piece 310 of the wrapping material 306, as shown in FIG. 3 A. The piece 310 of the wrapping material 306 is allowed to fall (in a controlled or uncontrolled manner) onto the package 302, as shown by the arrows 322.

[0046] As the piece 310 of the wrapping material 306 drapes around the package 302, the piece 310 effectively covers a top surface of the package 302, as well as a substantial portion (if not all) of each of the four sides of the package 302 (see FIG. 3B). In this manner, reinforced regions 312 of the piece 310 of the wrapping material 306 approach positions where the piece 310 can be attached to the package 302.

[0047] As the piece 310 of the wrapping material 306 is fully positioned on the package 302, one or more fasteners 314 are applied within the reinforced regions 312 to secure the wrapping material 306 to the package 302 (see FIG. 3C). In some exemplary embodiments, at least some of the fasteners are metallic. In some exemplary embodiments, at least some of the fasteners are non-metallic. In some exemplary embodiments, at least some of the fasteners are plastic. In some exemplary embodiments, all of the fasteners are metallic. In some exemplary embodiments, all of the fasteners are non-metallic. In some exemplary embodiments, all of the fasteners are plastic. Thereafter, the wrapped package can be moved, such as along the surface 308, and another package 302 positioned on the surface 308 for wrapping with the wrapping material 306.

[0048] As shown in FIG. 3B, the wrapping material 306 can have information 330 (e.g., text, graphics) printed on an outer surface of the wrapping material 306. The information 330 can include branding information (e.g., names, logos), information on the contents of the package 302 being wrapped, shipping information, regulatory information, etc. In some exemplary embodiments, the information 330 includes instructions to apply the fasteners 314 in the visibly observable reinforced regions 312.

[0049] In view of the above, an improved wrapping material (e.g., the wrapping material 100) is disclosed. The improved wrapping material is a polypropylene wrapping material that includes a reinforcement area, wherein the reinforcement area has polypropylene tapes and polyethylene tapes such that the reinforcement area can better secure the wrap to the package via fasteners (e.g., staples), as compared to the rest of the wrapping material. The polyethylene tapes of the reinforcement area can be woven with or laminated to the polypropylene tapes. In some embodiments, the polyethylene tapes are stronger and/or heavier than the polypropylene tapes, such as, for example, by using high density polyethylene (HDPE) tapes and/or tapes of a higher decitex/denier. In certain embodiments, the width of the polyethylene tapes is different than the width of the polypropylene tapes. The polyethylene tapes can also be made of a different color than the polypropylene tapes such that the reinforcement area is visible.

[0050] The improved wrapping material is advantageous over conventional wrapping materials because it includes the advantages of both polypropylene and polyethylene tapes. That is, the polypropylene tapes are superior to the polyethylene tapes for the majority of the wrapping material because of, for example, their abrasion resistance and their tensile and bursting strength. However, the polyethylene tapes are superior to the polypropylene tapes for holding staples because of their elongation, impact resistance, and cold temperature performance. For example, the inventive wrapping material exhibits an improved fastener (e.g., staple) holding strength in the reinforced regions versus a comparable wrapping material lacking the reinforced regions. The use of polyethylene tapes in the reinforcement area also provides various advantages over using multifilament threads. For example, the polyethylene tapes are recyclable. As a result, a majority (e.g., more than half, more than 80%, all) of the wrapping material is recyclable. Moreover, the polyethylene tapes are relatively flat, and thus do not have the roll profile or distorted printing problems. Furthermore, the polyethylene tapes cut easier than the multifilament threads, thus preventing potential processing problems due to cutting.

[0051] In some embodiments, it may be possible to utilize the various aspects of the general inventive concepts introduced herein in combination with one another. Additionally, any particular element recited as relating to a particularly disclosed embodiment should be interpreted as available for use with all other disclosed or suggested embodiments, unless incorporation of the particular element would be contradictory to the express terms of the embodiment. Furthermore, all combinations of method or process steps as used herein can be performed in any order, unless otherwise specified or clearly implied to the contrary by logic or the context in which the referenced combination is made. [0052] The scope of the general inventive concepts pressented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.