Method of Packaging a Continuous Length of Product on a Spool using Indexed Layers

Abstract

A method is provided for packaging a continuous thread of a woven material or finished product, such as an absorbent food pad, onto a spool, spindle, or other large roll in indexed layers forming rows, for efficient loading and unloading of the product from the spool. A finished spool formed by rows of indexed layers of a continuous thread of the product is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/601,554, filed Feb. 21, 2012, and the benefit of U.S. Provisional Application No. 61/644,374, filed May 8, 2012.

BACKGROUND OF THE DISCLOSURE

1. Field of Disclosure

The present disclosure relates to a method of packaging a continuous length of a product on a spool by indexing the layers as wrapped around the spool to be slightly offset from (and partially overlap) the previous layer. The product, such as an absorbent food pad, is wound around the circumference of the spool to form rows of indexed layers along the axial extent of the spool.

2. Description of Related Art

Continuous lengths of a woven material or of a finished product can be packaged by winding the material or product on to a large roll for storage, shipping, and use by an end-user.

However, conventional packaging techniques for a continuous thread of material or of a finished product often produces a package that is space-consuming, inconvenient to ship, and difficult to dispense by the end-user. Also, conventional packaging of a continuous thread of a product often must be dispensed at low production speeds to avoid damaging the product that does not easily separate from the underlying layer.

SUMMARY OF THE DISCLOSURE

A method is provided for efficiently packaging a continuous thread of a woven material or a finished product onto a spool, spindle, or other large roll by using “indexed” layers. This method also provides a finished spool that permits an end-user to dispense the continuous thread of material or product as a feeder source for a machine or production line.

The “indexed” layers and rows are formed by wrapping each layer of product onto the spool so that the layer is offset (i.e., shifted a small distance) in relation to the previous wrapped layer, so that each layer partially, but not completely, overlaps the previous, adjacent layer, in a direction along the axial extent of the spool.

When the leading edge of the material or product being wrapped around the spool reaches an edge of the spool to form an entire row of indexed layers, the direction is reversed so that the wrapping proceeds in the opposite direction along the axial extent of the spool to form a second row of indexed (wrapped) layers, until the leading edge reaches the opposite edge of the spool, at which time the wrapping of indexing layers reverses again and proceeds in the direction of the first row. The process repeats, back-and-forth, forming rows of indexed layers until the desired amount of material or finished product is loaded onto the spool.

The indexed layers provide more air pockets between layers of material or product for easy release during dispensing as compared with conventional packaging. Offsetting the layers as they are wrapped on the spool reduces material-on-material friction, and makes the product more compressible on the spool, so that the product is easily wrapped onto the spool, and easily dispensed (released) from the finished spool, since each of the indexed layers form a natural plane of separation from the layer immediately below.

The present disclosure also includes a finished spool that has been prepared with indexed layers of the material or finished product.

A guide can be used to help direct the material or product onto the spool in offsetting layers, so that each layer partially, but not completely, overlaps the previous layer. The extent of the overlap between adjacent layers (the index distance) can be selected based on the type of product that is being wound onto the spool, its thickness/stiffness, and the total amount of product that needs to be loaded. The index distance can be identical for all layers and rows, or can vary, as long as there is partial overlap of adjacent layers.

The method permits the amount of a continuous thread of a product to be tailored to specific run lengths that are customized for the end-user's needs. As an example, the total number of absorbent food pads that are wound onto a spool as a continuous thread can be tailored to accommodate the production machinery of a given customer/end-user. As a further benefit to the end-user, the duration of continuous feed can be extended by splicing the tail of the product on one spool to the head of the product on the next spool, to reduce the set-up time and minimize interruption of the production line.

Another advantage of the present method is that large amounts of a continuous thread of material or finished product can be packaged for storage and transport without a using a box or other large container. A box or other container is space-consuming on a production floor, and can be susceptible to collapse of the stacks of product within because of uneven weight distribution when a portion of product has been loaded or dispensed.

The present method also maximizes the amount of the woven material or finished product that can be wound about the circumference of the spool.

Another advantage is that shipping of the finished spool is easy and low-cost, since little packing material is needed to safely move the product.

Also provided is a floor-mounted, roll-away floor fixture on which to mount a spool of the present disclosure, to mitigate the weight problem, particularly if the spool were mounted away from the machine. The use of a floor-mounted, roll-away floor fixture can be integrated into the method, and/or is a separate product.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic that illustrates an exemplary embodiment of the method of the present disclosure whereby a continuous thread of product is wound around a spool in indexed layers to form a finished spool.

FIG. 2 is a schematic that illustrates the exemplary embodiment of FIG. 1, in which material is guided onto a spool (core) by an indexing head that moves side-to-side as the method lays down rows of indexed layers across the axial extent of the spool, to produce a finished spool.

FIG. 3 is a photograph of the start of an exemplary embodiment of FIG. 1, showing the first wrap (layer) of the first row of absorbent food pads around a spool.

FIG. 4 is a photograph of the continuing process in FIG. 3 showing the fourth wrap (layer) of the first row of absorbent food pads is wound onto the spool, showing the partial overlap of each wrapped layer on the previous layer.

FIG. 5 is a photograph of the process in FIG. 4, further continuing after multiple wraps (layers) of absorbent food pads are wound onto the spool in indexed layers to complete a first row of indexed layers of the product.

FIG. 6 is a photograph of the process in FIG. 1, after completion of the first row of indexed layers of absorbent food pads, further continuing in the reverse direction for wrapping the second row of absorbent food pads along an axial extent on top of the first row of material, in the opposite direction.

DETAILED DESCRIPTION OF THE DISCLOSURE

Referring to the figures, and in particular, FIGS. 1 to 6, there is provided a method for packaging a continuous thread of a material or a finished product onto a spool using rows of “indexed” layers of the material or finished product (herein referenced collectively as the “product”). Each layer of the product that is wrapped around the spool is slightly offset or shifted (i.e., “indexed”) a certain distance in relation to the previous layer of product, so as to partially, but not completely, overlap the previous layer. The indexed layer continues across an axial extent of the spool until it reaches one end of the spool to complete a first row of indexed layers, after which the direction of winding is reversed. The process continues in the opposite direction, until the other end is reached to complete a second row of indexed layers of the product. The direction of winding is reversed again, to wrap a third row of indexed layers across an axial extent of the spool in the same direction as the first row, and so on, until the desired amount of the product in indexed layers/rows is loaded onto the spool, thereby forming a “finished spool” or “loaded spool.” The finished spool is then removed for storage and shipping to an end-user/customer, who can dispense the product off of the finished spool as a feeder source for a continuous production line.

This present “spooling” method using indexed layers and rows that are wrapped around a spool provides efficient loading of a continuous length of a product, and also provides efficient continuous dispensing of the product by the end-user for a machine or production line.

The present disclosure also provides a finished spool that is wrapped with a continuous thread of a product or material in indexed layers that form one or more indexed rows that each extend across an axial extent of the spool. The finished spool can be a desired height, weight, diameter, and/or number of individual products in the continuous thread that is wrapped around the spool.

As used herein, a “spool” is a hollow cylindrical structure around which a product can be wound. The ends of the spool are typically unflanged, but can be low-flanged, or even high-flanged, at one or both ends to help prevent the product from slipping off the spool. As used herein, “spool,” “core,” “tube,” “cylinder,” “spindle,” and “reel” are used interchangeably.

FIGS. 1 and 2 illustrate an exemplary embodiment of the present method of packaging a continuous length of a product onto a spool 10. In this embodiment, the product is a continuous thread of absorbent food pads 30 being fed from a feeder roll 40, also called an infeed roll or source roll, onto spool 10 by a dispensing device (not shown), also called a dispensing machine or dispensing apparatus. The absorbent food pads are passed over a guide 20, also called an indexing head or linear actuator, which uses movement from side-to-side to direct absorbent food pads 30 onto spool 10 in indexed (offset) layers that are each indexed a preset distance from the immediately previous layer. In this exemplary embodiment, absorbent food pads 30 are wrapped around spool 10 in a first row of indexed layers moving from left to right, each layer being slightly offset from, and partially overlapping, the previous (adjacent) layer.

When the leading edge of a layer approaches or reaches the right end of spool 10, guide 20 reverses the direction of dispensing the product, so that the product is wrapped in layers that are indexed along a row extending along the axial extent of the spool from right-to-left, to form a second row on top of the first row, until the left end of the spool is reached. Guide 20 then reverses the direction that the product is wrapped in indexed layers to go back in the original direction (in this instance, left-to-right), to form a third row on top of the second row. As this process is repeated, the indexed layers of product build on top of each other to form a spool with a plurality of rows of indexed layers that gradually enlarges in diameter, with a single, continuous thread of product. This process continues until the desired total amount of the product is wound onto the spool in indexed layers and horizontal rows, thereby forming a “finished spool.”

In FIG. 2, the position of guide 20 (indexing head or linear actuator) is shown at three different positions in time—guiding the product onto spool 10 (1) near the left end of the spool, (2) approximately the middle of spool 10, and (3) near the right end of spool 10. This further illustrates loading the product by movement of the guide that directs the wrapping of layers back-and-forth across the spool.

The index distance, which is the distance that one layer is offset from the previous layer, can be the same between each layer, but does not need to be the same, as long as the two adjacent layers partially overlap, but do not completely overlap. The index distance can be created by moving “infeed” (source) roll 40, by moving guide 20, or by moving spool 10, and/or by any combinations thereof.

As shown in FIG. 3 to FIG. 6, a removable hollow spool is slid over a spinnable shaft, so that the product is wrapped around the removable spool. In this exemplary embodiment in FIGS. 3 to 6, the removable spool is a cardboard spool. Once the spool is wrapped with rows of indexed layers of the product, the spool is “finished” and removed from the axial shaft and is the “core” of the shippable product. The spool is analogous to the inner cardboard tube in the center of a roll of paper towels, but has a larger diameter and circumference so that the core can hold a large, continuous thread of the product. Alternatively, the removable spool can be made of plastic or any other material that can be shaped into a hollow cylindrical structure around which the product can be wrapped. When the finished spool is shipped and then received by the end-user, the process can be reversed to dispense the product to use to feed a production line. For example, the spool is mounted on an axial shaft by the end user, who draws off the product in a continuous thread to feed the material to the production line. In some instances, the continuous thread of product will be cut by the end user to separate the individual products (such as individual absorbent food pads) to be inserted into individual food trays.

Several stages of the wrapping process are illustrated in FIGS. 3 to 6. In FIG. 3, the first and second wraps of an absorbent food pad around a cardboard spool (core) is shown. The process continues in FIG. 4, where four offsetting (indexed) layers of the absorbent food pads are wrapped around the spool. Each of the layers partially, but does not completely, overlap the previous, adjacent layer. As shown in FIG. 4, the index distance does not need to be identical for every pair of indexed layers in order for the method to operate efficiently. The process continues in FIG. 5, which shows multiple indexed layers that are wrapped around the circumference of the spool to form a complete first row of the product. At this point, after completion of the first row, the direction is reversed, and the indexing proceeds in the opposite (reciprocal) direction along the axial extent of the spool, as shown in FIG. 6, to form a second row of indexed layers of product. Each layer of product in the second row is indexed on the opposite side in relation to the layers in the first row. Continuing the process, a third row (not shown) of indexed layers of product can be wound around the circumference of the spool on top of the second row, such that the indexed layers of the third row are offset in the opposite direction in relation to the second row, but are in the same direction as the first row.

This process can be repeated for a fourth row, fifth row, sixth row, and so on, so that there is a plurality of rows of indexed layers of the product wrapped around the finished spool. In this way, the finished spool can hold a single, continuous length of the finished product, which is stored and/or shipped to an end-user.

The indexed layers that form horizontal on the spool provide stability and safety while the product is being loaded onto the spool, as well as later, when the product is dispensed from the spool by the end-user. Because the loading and dispensing of the present method proceeds preferably evenly, back-and-forth, across the axial extent of the spool, the overall weight distribution of the product remaining on the spool is more balanced and stable as compared to a spool that loaded by conventional (non-indexed) techniques, where a partially loaded (or partially unloaded) spool would be unbalanced.

Although the aforementioned illustrations show a spool that is loaded by machine, the product could also be loaded onto the spool, and/or dispensed from the spool, by hand.

Further steps may be used to increase the amounts of the material or finished product wound around the spool. To help anchor first layer of product to the spool, a portion of the first layer can be fastened or adhered to the spool with a fastener such as, but not limited to, glue, tape, and hook-and-eye devices such as VELCRO®.

As shown in FIGS. 1 to 6, and particularly in FIGS. 3 to 6, each layer of material is offset or displaced in relation to the previous layer by an index distance. The index distance can also be selected based on the dimensions and physical characteristics of the product (see below) that is being wound onto the spool. In an exemplary embodiment, index distance is about one inch (1″); however, the index distance can be any amount or distance that is less than an extent (usually width) of the product, so there is a partial, but not total, overlap of product in two adjacent layers. Typically, the index distance can be from about five-hundredths of an inch (0.05″) to about 10 inches (10″). Preferably, the index distance is from about one-tenth of an inch (0.10″) to about five inches (5″), and more preferably from about one-fifth of an inch (0.20″) to about 2 inches (2″). The index distance can be identical between adjacent layers, or can vary between successive layers. When not a uniform amount, index distance can vary according to a fixed ratio among layers, or can vary randomly. The physical characteristics of the material or product, such as its thickness, stiffness, and coefficient of friction can affect the selection of the index distance between layers.

The diameter of the continuous thread of the product that is loaded onto the finished spool can be tailored to a particular end-user's production requirements. Large-diameter spools (i.e., with a large amount of product) reduce the number of set-ups for the end-user. However, these additional amounts have to balanced against the increased weight of the finished spool. A non-limiting example is an end-user who is a food tray assembler. The food tray assembler uses the continuous thread of absorbent food pads that are fed from a finished spool of the present disclosure to cut into individual pads, and then to load an individual absorbent food pad into each food tray.

An exemplary embodiment of a spool used in the present method is a spool that is about 4 to 6 times as wide across its axial extent as the individual product is wide. For instance, if the product being loaded onto the spool is an absorbent food pad that is about 4 inches across and in an uncut continuous thread, the spool could be about 16″ across its axial extent. However, depending on the product and strength of the core, and how tightly-indexed the layers of product (i.e., a small index distance between each layer wrapped around the spool), a spool that is 2 to 20 times as wide across its axial extent as the individual product is wide can be used with this method.

The dispensing device is a machine or apparatus that can transfer a continuous thread of a product from an external storage source, such as a feeder roll, onto the spool. An example of a dispensing device includes, but is not limited to, a gantry. The guide disclosed above may be integral to, or may be separate from, the dispensing device. The dispensing device can move lengthwise along the lengthwise extent of the spool to dispense the product onto the spool. When the product reaches one end of the spool, completing a horizontal row, the dispensing device can reverse direction to start dispensing the next horizontal row of the product onto the spool in indexed layers.

The index distance between adjacent layers can be formed by moving the dispensing device, or by moving the guide, or by moving the spool, or by any combination thereof. An advantage of creating the index distance (offset) among layers by moving the dispensing device and/or guide is that the dispensing device and the guide may be lighter (or at least are a consistent weight) and more maneuverable than the spool, which can vary considerably in weight as the spool fills. However, the combination of movements of the dispensing device, guide, and/or spool can be selected by the machine operator based on the physical characteristics of the continuous thread of product that is being loaded onto the spool, such as the product's thickness or elasticity.

Examples of the “guide” that direct the product onto the spool so that each layer is indexed, and partially overlaps the previous layer, include, but are not limited to, a mechanical guide, a loop, a bar, and any combinations thereof. An exemplary embodiment of a guide is a one-sided funnel that is mounted between the product roll and the spool, so that each layer of the product is offset a preset distance from the previous layer, and so that direction of wrapping the indexed layers can be reversed when the end of the spool is reached. A guide may also be used by the end user between the spool and the production line to dispense the product.

Another benefit of using indexed layers is that the method provides more air pockets between layers of the product for easy release during dispensing. The partial, yet not complete, overlap of the indexed layers in each row provides a natural separation plane between adjacent layers that reduces material-on-material friction, increasing the ease and rapidity of loading the product onto, and dispensing the product off of, the spool. The method also makes the layers of the product more compressible on the spool. The present method eliminates the need in some conventional product packaging methods to place physical dividers between columns and rows of the product. The present method also eliminates the need for splices of the product within an individual spool, as required in some conventional packaging methods. The method also reduces the amount of stretching and/or tearing of the product that can be caused when one layer of product “sticks to” the adjacent layer below it, particularly when the layered materials are fibrous, and/or the layers completely overlap and are compressed on each other by wrapping

The present method can be tailored to specific run lengths of the material or finished product that are customized for the end-user's needs. For example, using the exemplary embodiment in FIGS. 1 to 6, the number of absorbent pads that are wound onto the finished spool can be tailored to accommodate the production machinery of any given end-user (customer).

Another advantage of the present method is that dispensing the product by the end-user does not require a guide, since the material or product can be drawn from the finished spool rapidly and easily, and the spool can function as a pivot point.

Because of the benefits of indexing each layer of material, the method maximizes the amount of the product that can be wound about the circumference of the spool.

Also, if the end-user wishes to have a continuous feed of stock that is more than a single finished spool, the “tail” of the product on one spool can be spliced to the “head” of the product on the next finished spool, to provide greater continuity and longer duration of the thread of product supplied to the end-user's production line without interruption.

Another advantage of finished spools produced by the present method is the saving of floor space, both during transport and at or near the production lines of the end-user. The finished spools of the present disclosure eliminate the need for a large box or other container of products that can take up a large amount of floor space during transport or the end-user's floor space. For end-users who have only a small area or space between production lines, the finished spool produced by the present method can be mounted on the line itself, thus avoiding the problem of conventional methods that require large amounts of space between lines to position large source containers of the product. Shipping is easier as well, since little packing material is needed to safely move the finished spools produced by the present method.

Because of the simplicity of the indexing used, the product can be wound onto the spool at high speeds. The method even permits a “wind-and-forget” process, such that “forget” means an almost automatic process that does not require constant monitoring.

The method can also include a floor-mounted, roll-away floor fixture on which to mount a spool. The spool would be fed over the current machine spindle to guide the thread of product into the machine. The floor fixture could mitigate the problem of the weight of the loaded spool, particularly if the spool were mounted away from the machine. This floor fixture can be integrated as a component in the present method, or can be a separate component apart from the present method.

As used in this application, the word “about” for dimensions, weights, and other measures means a range that is ±10% of the stated value, more preferably ±5% of the stated value, and most preferably ±1% of the stated value, including all subranges therebetween.

It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the disclosure.

Claims

1. A method for packaging a continuous length of a product onto a spool comprising:

dispensing the product onto the spool with a dispensing device to form a first layer of the product that is wrapped around the spool;

indexing the product by an index distance that is shifted in relation to the first layer;

dispensing a second layer of the product onto the spool with the dispensing device to form an indexed layer that partly overlaps the first layer, wherein the second layer is offset in relation to the first layer by the index distance;

dispensing one or more additional indexed layers of the product onto the spool, wherein each of the one or more additional indexed layers is offset from the immediate previous layer by the index distance,

wherein the first layer, the second layer, and the one or more additional indexed layers of the product form a first horizontal row of the product along an axial extent of the spool.

2. The method according to claim 1, further comprising:

reversing the direction of the dispensing device when the first horizontal row of the product reaches a first end of the spool; and

dispensing one or more indexed layers of the product onto the spool in an opposite direction from the first horizontal row, to form a second horizontal row of product along the axial extent of the spool.

3. The method according to claim 2, further comprising:

reversing the direction of the dispensing device when the second horizontal row of the product reaches a second end of the spool opposite the first end of the spool; and

dispensing one or more indexed layers of the product onto the spool in an opposite direction from the second horizontal row, to form a third horizontal row of the product along the axial extent of the spool.

4. The method according to claim 3, further comprising:

repeating the reversing and the dispensing steps until the spool is loaded with a continuous length of the product to form a finished spool having indexed layers and horizontal rows of the product.

5. The method according to claim 1, wherein the dispensing device further comprises a guide that directs the product onto the spool, wherein the guide is selected from the group consisting of: loop, bar, funnel, and any combinations thereof.

6. The method according to claim 5, wherein the indexed layers are formed by movement of the dispensing device, guide, and/or spool.

7. The method according to claim 5, wherein the size of the index distance is established by the size of the movement of the dispensing device, guide, and/or spool.

8. The method according to claim 1, wherein the size of the index distance is from one-fifth of an inch (0.20″) to about two inches (2″).

9. The method according to claim 1, wherein the axial extent of the spool is about 4 to about 6 times as wide across as compared with the width of the product dispensed onto the spool.

10. The method according to claim 1, wherein the indexed layers of the product are dispensed onto the spool at high production speeds.

11. The method according to claim 1, wherein the product is an absorbent food pad.

12. The method according to claim 1, further comprising a spindle on which the spool is mounted during dispensing of the product.

13. The method according to claim 1, further comprising a floor fixture on which the spool is mounted, wherein the floor fixture mitigates the weight of the spool and provides stability while dispensing the product onto the spool.

14. A spool for packaging a continuous length of a product, comprising:

a removable hollow spool; and

a continuous length of the product that is wound around the spool in indexed layers that form one or more horizontal rows of the product along an axial extent of the spool.