Packaged, Wrapped, Cylindrically Rolled Moisture-Sensitive Film and Method of Making the Same

Abstract

A method for packaging a wrapped, moisture-sensitive, cylindrically rolled film by positioning along an alignment axis, a wrapped, rolled moisture-sensitive film, a funneling guide, a tube, and an extendible rod that includes a support head. The method comprises the steps of extending the rod through the tube while simultaneously and while maintaining the alignment of the wrapped film, funneling guide, tube and rod, tilting the alignment axis from a first position to a second position such that the wrapped film enters and moves through the funneling guide, and the wrapped film contacts the support head of the rod, retracting the rod such that the wrapped film enters the tube through the funneling guide, and while maintaining the alignment of the wrapped film, funneling guide, tube and rod the alignment axis, tilting from the second position to the first position and retracting the rod from the tube.

1 . A packaged, moisture-sensitive, cylindrically rolled film comprising:
 A. A moisture-sensitive film in a cylindrically rolled configuration,   B. A flexible, moisture-barrier wrap having an exterior surface, the rolled film hermetically enclosed within the wrap, and   C. A tube comprising (1) an elongated sidewall with an interior surface, and (2) first and second ends, the rolled film hermetically enclosed in the wrap situated within the sidewall and between the first and second ends.   
     
     
         2 . The packaged rolled film of  claim 1  further comprising:
 D. A core having an exterior surface with the film wound around the exterior surface of the core. 
 
     
     
         3 . The packaged rolled film of  claim 2  in which the core is hollow and cylindrical. 
     
     
         4 . The packaged rolled film of  claim 1  further comprising:
 D. A desiccant situated inside the barrier wrap. 
 
     
     
         5 . The packaged rolled film of  claim 1  in which the barrier wrap is a heat-sealed bag that is at least one of (1) evacuated of air, or (2) purged of moisture. 
     
     
         6 . The packaged rolled film of  claim 2  further comprising,
 E. One or more spacers situated within the tube for receiving the rolled film such that the exterior surface of the wrap is not in contact with the interior surface of the tube. 
 
     
     
         7 . The packaged rolled film of  claim 6  in which the spacers are situated on the core. 
     
     
         8 . An automated process of packaging a hermetically wrapped, moisture-sensitive, cylindrically roiled film having first and second ends, the process comprising the steps of:
 A. Positioning along an alignment axis in a first position:
 1. The hermetically wrapped, moisture-sensitive, cylindrically rolled film, 
 2. A funneling guide having first and second ends, 
 3. A tube having first and second ends connected by an elongated sidewall, and 
 4. An extendible rod comprising a support head, 
 such that
 a. The second end of the wrapped film is opposite the first end of the funneling guide, 
 b. The first end of the tube is opposite the second end of the funneling guide, and 
 c. The support head of the rod is opposite the second end of the tube, 
 
   B. Extending the rod through the tube such that the support head is at or near the second end of the funneling guide.   C. Simultaneously and while maintaining the alignment of the wrapped film, funneling guide, tube and rod,
 1. Tilting the alignment axis from the first position to a second position such that:
 a. The wrapped film enters and moves through the funneling guide, and 
 b. The second end of the wrapped film contacts the support head of the rod, and 
 
 2. Retracting the rod such that the wrapped film enters the tube through the funneling guide to a position within the tube such that both ends of the wrapped film are within the sidewall of the tube, 
   D. Returning while maintaining the alignment of the wrapped film, funneling guide, tube and rod the alignment axis from the second position to the first position, and   E. Retracting the rod from the tube such that the support head of the rod is outside the sidewall of the tube and opposite the second end of the tube.   
     
     
         9 . The process of  claim 8  comprising the further step of removing the tube containing the wrapped film to a receiving container. 
     
     
         10 . The process of  claim 8  in which the wrapped film slides into the tube due to gravity. 
     
     
         11 . The process of  claim 8  in which the alignment of the wrapped film and tube are maintained by positioning the wrapped film and tube on at least one cradle. 
     
     
         12 . The process of  claim 11  in which the wrapped film and tube are positioned on the same cradle. 
     
     
         13 . The process of  claim 11  in which the wrapped film and tube are positioned on separate but aligned cradles. 
     
     
         14 . The process of  claim 8  in which the wrapped film comprises packaging ears that are folded downwards to confirm to the circumference of the tube as the wrapped film enters the tube. 
     
     
         15 . An apparatus for packaging hermetically wrapped, moisture-sensitive, cylindrically rolled film into a tube open on both ends, the apparatus comprising:
 A. A first cradle to receive and hold a hermetically wrapped, moisture-sensitive, cylindrically rolled film, the first cradle having first and second ends,   B. A funneling guide having first and second ends with the first end positioned opposite the second end of the first cradle,   C. A second cradle to receive and hold a tube open on both ends, the second cradle having first and second ends with the first end of the second cradle opposite the second end of the funneling guide,   D. An extendible rod comprising first and second ends, the first end of which
 1. Comprises a support head, and 
 2. positioned opposite the second end of the second cradle, 
   E. An actuator for extending the rod in a longitudinal direction, the actuator connected to the second end of the rod, and   F. A tilting mechanism for moving the first cradle, funneling guide, second cradle, rod and actuator between first and second positions,   
       with the provisos that
 1. The first cradle, funneling guide, second cradle, rod and actuator are longitudinally aligned along a central axis, and 
 2. The tilting mechanism is attached to each of the first cradle, funneling guide, second cradle, rod and actuator such that their longitudinal alignment along the central axis is maintained during movement between the first and second positions. 
 
     
     
         16 . The packaged rolled film of  claim 1  in which the film is a polymeric film used in the preparation of a photovoltaic cell. 
     
     
         17 . The packaged rolled film of  claim 16  in which the film comprises a polyolefin having silane functionality. 
     
     
         18 . The packaged rolled film of  claim 17  in which the film comprises an ethylene/α-olefin copolymer having silane functionality.