Note: Descriptions are shown in the official language in which they were submitted.
CA 02844303 2014-02-28
FESTOONING DEVICE AND METHOD FOR PACKAGING A CONTINUOUS
LENGTH OF MATERIAL INTO A CONTAINER
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
[0001] The present disclosure provides a festooning device and a method for
using the festooning device for packaging a continuous length of a material or
a
product into a container. In particular, the present disclosure provides a
festooning
device that fills the container with fan folded, indexed layers at high
operating
speeds, resulting in a container that has more of the product, and is more
stable
than those filled by conventional dispensing devices.
2. Description of Related Art
[0002] Conventional devices that dispense a continuous web of material or a
product into a container have several disadvantages that limit its
practicality.
Conventional devices that operate by moving a dispensing arm back-and-forth to
form vertical fan folded layers into individual stacks or "lanes" that are cut
and
spliced together to fill the container.
[0003] Conventional devices use a single movement, namely, moving the
dispensing shuttle back-and-forth over the top of the open container, to form
several adjacent "lanes" of the product inside the container. However, a
single
back-and-forth dispensing movement produces lanes of the product that do not
completely reach from edge to edge near the bottom of the container, and then
"overthrows" the product over the outer edge of the container as the material
nears
the top of the container for each lane. This results in containers that are
CA 02844303 2014-02-28
=
incompletely filled or require frequent operator adjustments during filling.
These
effects are exacerbated when the product is too soft, or too stiff, and
generally
require the dispensing speed to be considerably slowed. But even at low
operating
speeds, a single dispensing movement by the dispensing shuttle generally
cannot
completely fill the interior space of the container or provide a level, stable
fill of
product therein.
SUMMARY OF THE DISCLOSURE
[0004] The present disclosure provides a festooning device for packaging a
continuous web of a material or a product into a container at high operating
speeds.
[0005] The festooning device can include an articulated paddle that pushes
the material farther toward and into each edge of the container to achieve a
complete fill, and prevents "overthrows" of the material as the level of the
material
nears the top of the container.
[0006] The festooning device of the present disclosure may further include
a
sensor that detects the level of the material in the container, which can be
used to
adjust the travel distance of the dispensing shuttle and/or the oscillation of
the
articulated knuckle, so that the product reaches the container edges and
continues
to be level for maximal fill, and avoids "overthrowing" the web of material as
the fill
level approaches the top of the container.
[0007] The festooning device of the present disclosure can dispense a
material or a product of varied thickness and/or stiffness into a container
without
operator adjustments, even at high operating speeds.
2
CA 02844303 2014-02-28
[00081 The festooning device of the present disclosure can synchronize the
movements of the dispensing shuttle, the container, and/or the articulated
paddles
to provide optimal filling even at high operating speeds. Two synchronized
movements reduce the travel distance of the individual moving components and
provide more-complete, more-level filling of the product in the container at
high
operating speeds. Three synchronized movements provide still further
reductions
in the movements of the individual moving components and even more optimal
filling of the container, In addition to saving production time, reducing the
travel
distances of the individual parts increases the longevity and reduces the need
to
re-index the festooning device and the conveyor on which the container moves.
[0009] The festooning device of the present disclosure dispenses the
material
or product into the container in "indexed" rows that form successive
horizontal
layers until the container is completely filled. The indexed rows and
successive
horizontal layers create a natural separation plane between adjacent rows and
layers of the material, permitting the end-user to dispense the material
quickly and
cleanly.
(0010] The festooning device of the present disclosure fills the entire
container with a single, unbroken, continuous web of a material or product
without
cuts or splices between adjacent lanes or stacks, as in conventional
dispensing
devices. The indexed rows and horizontal layers of material make the filled
container more stable, and safer to handle, and eliminate the need to separate
individual stacks with physical dividers to prevent the stacks from tipping
when the
end user removes the material from the container.
[OM The present disclosure further provides a method of packaging a
single, continuous web of a product, such as an absorbent food pad, from a
large-
diameter source roll into a rectangular container by fan folding, using a
festooning
3
CA 02844303 2014-02-28
method that forms indexed rows of the product in the container at commercial
production speeds.
[0012] Still further, the present disclosure provides a method that employs
a
production line that includes a pivoting "dancer assembly" to permit packaging
continuous webs of different thicknesses, without having to adjust production
line
settings. A sensor on the dancer assembly can be used to automatically
regulate
the speed of the motor driving the source (feeder) roll to prevent "snatching"
and
"snapping" of the continuous web, which improves web control and eliminates
web
breaks.
[0013] The present disclosure yet further provides that the subject
container
can have an adjustable deflector positioned along the upper edges that reduce
or
eliminate overhangs of the product over the top edge of the container when fan
folding at commercial production speeds.
[0014] The present disclosure provides a method of packaging a continuous
web in a container to form indexed rows or layers of the continuous web in the
container, where each row or layer of the continuous web that is dispensed
into the
container is slightly offset or shifted (i.e., indexed) in relation to the
previous row or
layer, to partially overlap the previous layer. As additional rows of a
product or
material continue to be dispensed into the container, the indexed rows form
horizontal layers that completely fill the container.
[0015] The method further provides festooning the fan folded rows of
material
in indexed layers to provide increased stability and safety while the
container is
being filled, and when dispensed by the end-user. The indexed rows and
successive horizontal layers formed by the festooning method of the present
disclosure create a natural separation plane between adjacent rows of the
product,
4
CA 02844303 2014-02-28
. .
permitting the end-user to dispense the product quickly and cleanly. The
present
method also eliminates the need to separate individual stacks of fan folded
products with physical dividers (that prevent the rows from shifting or
falling down
inside the container after some portion of the product is removed by an end-
user)
and splices between adjacent rows.
[0016] Still further, the present method permits a very large amount
of the
continuous web to be packaged in the container, with little "crowning" (or
other
wasted space) in the container. A rectangular container filled with a fan-
folded
continuous web of product by the present festooning method permits the end-
user
to dispense the entire contents of the container with a single set-up,
reducing down
time and inconvenience.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a front view of an exemplary embodiment of a
festooning
device of the present disclosure.
10018] FIG. 2 is a right side view of the festooning device of FIG. 1.
[0019] FIG. 3 is a top view of the festooning device of FIG. 1.
[0020] FIG, 4 is a front view of the frame assembly portion of the
festooning
device of FIG, 1.
[0021] FIG. 5 is a right side view of the frame assembly portion of
the
festooning device of FIG. 1, and of one of the foot pads.
[0022] FIG. 6 is a top view of the frame assembly portion of the
festooning
CA 02844303 2014-02-28
device of FIG. 1.
[0023] FIG. 7 is a detail view of the drive motor mount, nipped roll drive,
articulating arm fixed pivot support, and idler roll support components of the
festooning device of FIG. 1.
[0024] FIG. 8A, FIG. 8B and FIG. 8C are detail views of further components
of the portion of the festooning device shown in FIG. 7.
[0025] FIG. 9A and FIG. 9B are detail views of the tending side idler roll
support for the frame assembly shown in FIG. 7.
[0026] FIG. 10 is a detail view of an idler roll in the frame assembly
portion of
the festooning device of FIG. 1.
[0027] FIG. Ills a front detail view of the drive motor mount, nipped roll
drive, articulating arm fixed pivot support, and idler roll support components
of the
frame assembly portion of the festooning device of FIG. 1.
[0028] FIG. 12 is a right side view of the frame assembly further
illustrating
the tending side idler roll support components of FIG. 9A and FIG. 9B, and the
idler
roll component of FIG. 10.
[0029] FIG. 13 is a top side view of the frame assembly further
illustrating the
tending side idler roll support components of FIG. 9A and FIG. 9B, and the
idler roll
component of FIG. 10.
[0030] FIG. 14 is detail view of the articulating nipped roll drive
assembly
component of the festooning unit of FIG. 1.
6
CA 02844303 2014-02-28
[0031] FIG. 15 is another detail view of the articulating nipped roll drive
assembly component of the festooning unit of FIG. 1.
[0032] FIG. 16 is yet another detail view of the articulating nipped roll
drive
assembly component of the festooning unit of FIG. 1.
[0033] FIG. 17 is still another detail view of the articulating nipped roll
drive
assembly component of the festooning unit of FIG. 1.
[0034] FIG, 18A through FIG. 18C are detail views of the articulating
nipped
roil drive component of the festooning device of FIG. 1. FIG. 18A is a detail
view of
the articulating nipped roll drive showing the drive shaft from the gearbox.
FIG.
18B is a detail view of the articulating nipped roll drive showing the knuckle
shaft.
FIG. 18C is a detail view of the articulating nipped roil drive showing the
drive shaft
to nipped roll.
[0035] FIG. 19 is a detail view of the shuttle plate component of the
festooning device of FIG. 1.
[0036] FIG. 20 is another detail view of the shuttle plate component of the
festooning device of FIG. 1.
[0037] FIG. 21 is a detail view of the shuttle plate of FIG. 19.
[0038] FIG. 22 is another detail view of the shuttle plate of FIG. 19.
[0039] FIG. 23A is a front view of a nipped roll idler of the festooning
device
of FIG. 1. FIG. 23B is a right side view of the nipped roll idler of FIG, 23A.
7
CA 02844303 2014-02-28
[0040] FIG. 24 is a front view of the shaft used for the nipped roll idler
of FIG.
23A.
[0041] FIG. 25A is a front view of the slide mount for the nipped roll
idler of
FIG. 23A. FIG. 25B is a right side view of the slide mount of FIG. 25A,
[0042] FIG. 26A is a front view of the driven nipped roll with shaft of the
festooning device of FIG. 1. FIG. 268 is a right side view of the driven
nipped roll
and shaft of FIG. 26A.
[0043] FIG. 27 is a front view of the rod end attachment of the festooning
device of FIG. 1.
[0044] FIG. 28A is a front view of the mounting spacer of the festooning
device of FIG. 1. FIG. 28B is a right side view of the mounting spacer of FIG.
28A.
[0045] FIG. 29 is front view of an exemplary embodiment of the festooning
device of FIG. 1 having an articulating paddle, and indicating its attachment
on the
actuating arm, and pivot point. The movement of the articulating paddle is
marked
as a center (neutral) position, "extreme south position" and "extreme north
position." For clarity, the festooning device of FIG. 1 is shown without much
of its
support structure and assembly components.
[0046] FIG. 30 illustrates the range of movement of the articulating paddle
of
FIG. 29 at its attachment point on the actuating arm and at its tip.
[0047] FIG. 31 is a top view of the articulating paddle(s) of FIG. 29, and
their
position relative to the drive belts of the festooning device of FIG. 1.
8
CA 02844303 2014-02-28
[0048] FIG. 32 is a right side view of another embodiment of the
articulating
paddles of FIG. 29 that are slotted for weight reduction,
[0049] FIG. 33 illustrates the range of movement (travel) of each of the
articulating paddles of FIG, 29 at its attachment point on the actuating arm
and at
its tip (in relation to the shuttle travel) at its center position, "extreme
north
position," and "extreme south position."
[0050] FIG, 34 illustrates another embodiment of the festooning device of
FIG. I having articulating paddles that pivot using a cam follower in a cam
track,
and indicating the range of movement of the articulating paddles (in relation
to the
shuttle) from "extreme south position" to "extreme north position."
[0051] FIG. 35 is a schematic of an exemplary embodiment of a portion of a
production line to package a continuous web of absorbent pads into a container
according to the present disclosure.
[0052] FIG. 36A illustrates a cross-section of the side of a large
container to
clearly show the dispensing of layers of the absorbent web into a container by
the
method of the present disclosure.
[0053] FIG. 36B illustrates the problem of overhang, when a portion of the
continuous web is thrown over the upper edge of the container at high
operating
speeds.
[0054] FIG. 36C illustrates the use of a pair of "deflector plates" along
the
upper edges of the container to prevent the overhang of the continuous web
shown
in FIG. 36B.
9
CA 02844303 2014-02-28
[0055] FIG. 37A is a perspective view of an exemplary embodiment of the
present disclosure illustrating a rectangular container being filled with a
continuous
web in an exemplary embodiment of the present method.
[0056] FIG. 37B is a magnified section of a portion of the continuous web
being placed in the rectangular container in FIG. 37A. A second row of the
continuous web that is indexed a certain distance in relation to a first row
of the
product is also shown.
[0057] FIG. 38A, FIG. 38B, and FIG. 38C illustrate a sequence of steps for
placing indexed rows of a product or material in a container by the method of
the
present disclosure.
[0058] FIG. 38A illustrates the first step, in which a first row of a
product or
material is laid on the bottom of a container.
[0059] FIG. 38B illustrates the next step, in which a second row of the
same
material is laid in the container in an opposite direction from the first row,
and which
is indexed a certain distance in relation to the first row, so that the first
row and
second row partly, but do not completely, overlap.
[0060] FIG. 38C illustrates the next step, in which a third row of the same
product or material is laid in the container in an opposite direction of the
second
row. The third row is indexed in relation to the second row. The process would
continue (not shown) until a single horizontal layer of a fan folded product
is
formed.
DETAILED DESCRIPTION OF THE DISCLOSURE
CA 02844303 2014-02-28
[0061] Referring to the drawings, and in particular, FIGS, 1 through 3,
there is
provided an exemplary embodiment of a festooning device of the present
disclosure for packaging a continuous web of a material or a product in
indexed
rows to form horizontal layers in a container (container not shown).
[0062] FIG, 4 through FIG. 28B provide detail views of specific components
of the festooning device of FIG. 1, and are described more fully below.
[0063] FIG. 29 through FIG. 34 illustrate an embodiment of the festooning
device of FIG. 1 having an articulating paddle (also called an articulating
knuckle
herein) that improves the performance of the festooning device and fill of the
container, as described more fully below.
[0064] FIG, 1 shows an exemplary embodiment of a festooning device of the
present disclosure. The festooning device includes a frame assembly (detailed
in
FIG. 4 through FIG. 6) having gussets and foot pads, a drive motor and a drive
motor mount, a nipped roll drive, an articulating arm fixed pivot support, and
an
idler roll support (detailed in FIG. 8A, FIG. 8, FIG. 8C, FIG. 11 and FIG.
12). The
frame assembly portion of the festooning device further includes a tending
side
idler roll support (detailed in FIG. 9A, FIG. 9B, FIG. 11, FIG. 12 and FIG.
13) and
one or more idler rolls (detailed in FIG. 10, FIG. 12 and FIG. 13). The
festooning
device further includes an articulating nipped roll drive assembly (detailed
in FIG.
14, FIG. 15, FIG. 16, FIG. 17, FIG. 18A, FIG. 18B, and FIG. 18C), The
festooning
device still further includes a shuttle plate assembly (detailed in FIG. 19,
FIG. 20,
FIG. 21, and FIG. 22). The festooning device further includes a nipped roll
idler
(detailed in FIG. 23A and 23B), nipped roll idler shaft (detailed in FIG. 24),
and a
nipped roll idler slide mount (detailed in FIG. 25A and FIG. 25B), The
festooning
device can include a driven nipped roll and shaft (detailed in FIG. 26A and
FIG.
11
CA 02844303 2014-02-28
. .
26B), a rod end attachment (detailed in FIG. 27), and a mounting spacer
(detailed
in FIG. 28A and 28B).
[0065] The festooning device of the present disclosure includes a
linear
actuator. In the embodiment shown in FIGS. 1 through 3, the linear actuator
may
be fully-enclosed. The movement of the linear actuator and the articulating
nipped
roll drive assembly at its starting position, and at four other positions, are
shown in
FIG. 1.
[0066] As shown in FIG. 29, the festooning device may further include
an
articulating paddle, also called an articulating knuckle herein. The
articulating
paddle preferably is a matched pair of paddles that are opposite each other
and
slightly oriented toward each other to come together at a tip at one end. An
exemplary embodiment of the articulating paddles and their movements are
illustrated in FIG. 30, FIG. 31, FIG. 32, and FIG. 33. The articulating paddle
is
attached to an actuating arm. The articulating paddles each have a pivot point
(shown in FIG, 29 and FIG. 30). Generally, the articulating paddles move in a
swinging motion from a center (neutral) position to oscillate between an
"extreme
south position" and an "extreme north position," as shown in FIG. 29, FIG. 30,
and
FIG. 33.
[0067] The articulated paddle moves back-and-forth as the shuttle
moves
back and forth. This movement of the articulated paddle helps to push the
continuous web of the material or product into the edge of the container. This
provides a better fill, and a level fill of the container, as compared with
conventional
techniques.
[0068] The movement (swing) of the articulated paddle is
programmable. The
movement (i.e., the swing or "whip") of the articulated paddles may be
controlled by
12
CA 02844303 2014-02-28
a programmable controller and a motor-driven servo.
[0069] Alternatively, the movement of the articulated paddles can be
controlled by the addition of weights at (or near) the bottom of the
articulated
paddles, so that the amount of movement of the articulated paddles is
partially
momentum-driven. Depending on the amount of movement (whip) generated by
the travel of the dispensing shuttle, the movement of the articulated paddles
can be
adjusted by using different amounts of weights, and/or moving the weights
nearer
or farther from the paddle tips. The weights may be added manually by the
operator. In this way, movement of the articulated paddles can be controlled
without motors or electronic controllers.
[0070] One or more sensor positioned on the framework and/or on the
shuttle, measures the fill level of the material inside the container. This
sensor can
be, but is not limited to, an ultrasonic sensor. In a preferred embodiment,
the
sensor is an ultrasonic sensor that is fixed to the framework.
[0071] The distance that the shuttle travels (i.e., how close the thread of
material comes to the edge of the container) has a significant effect on the
neatness of the product as it is dispensed into the container, and the
distance is
not a constant. For example, when the box is nearly empty, the stroke distance
must be greater to lay down the product neatly in the container. The stroke
distance should decrease as the fill level of the product increases in the
container.
By the time the fill level is nearly to the top of the container, the stroke
distance
must be considerably shorter than when filling began, so that the material is
not
"thrown" out over the top edge of the container by the shuttle motion at high
operating speeds.
[0072] The measurements of the fill level in the container detected by the
one
13
CA 02844303 2014-02-28
or more sensors will automatically adjust the travel of the shuttle based on
that
level. As noted above, as the sensor measures that the fill level in the
container is
rising, the signal will be sent to a controller that decreases the travel of
the shuttle
in relation to that fill level. In an exemplary embodiment, the electronic
power
required to achieve this can come from a touch screen controller on the
festooning
device. These controllers can have a user-friendly display that improves the
operator-machine interface, and also provide a capability to store
programmable
data that are specific to different materials or products that can be
dispensed into
the container by the festooning device.
[0073] For example, when the shuttle moves 18" from its center position to
its
extreme north position, the associated 18" of belt travel causes the 36T
sprocket to
rotate 1.588 revolutions. The 32T sprocket also rotates 1.588 revolutions,
which
causes its belt travel (and the movement of the actuating arm) to be 16".
Movement of the end of the actuating arm by 16" while the pivot point is also
moving 18" (i.e., 2" relative movement) results in 24" of movement at the tip
of the
articulating paddle, as shown in FIG. 30. These same relative motions of the
carriage to the tip of the articulating paddle exist for the entire range of
motion of
the components as they cycle from the extreme north to extreme south.
[0074] For reference in the calculations above, a 36T sprocket pitch
diameter
is 3.609". 361 sprocket pitch circumference is 3.609 x 3.14159, which equals
11.338". 18" of belt travel results in 18" /11338" per revolution, which
equals
1.588 revolutions. 32T sprocket pitch diameter is 3.208". A 32T sprocket pitch
circumference therefore is 3.208 x 3.14169, which equals 10.078". The belt
travel
for a belt on a 32T sprocket is 1.588 revolutions x 10.078" per revolution,
which
equals 16".
[0075] In an alternative embodiment, an articulating chute between nipped
14
CA 02844303 2014-02-28
rolls and the deposit point in the container may be used. This would permit
control
of the continuous web of material and position that material precisely near
the edge
of the container without allowing the material to free-fall more than a few
inches, so
that the new row or layer can nestle on the product layer immediately below.
[0076] The nipped roll speed and resultant web speed can be held constant
during the filling operation. As the container fills, the speed of the
carriage needs
to change as the drop distance of the continuous web of material decreases.
For
instance, if the carriage speed does not increase as the container fills, too
much of
the product is deposited at the edge of the container before the carriage
changes
direction, This can be avoided by programming the controller to adjust
carriage
speed.
[0077] FIG. 32 shows that the articulated paddles can be slotted for weight
reduction.
[0078] As shown in FIG, 29 through FIG. 33, the articulating paddles are
straight members. This accomplishes having the continuous web of material
reach
each of the opposite sides of a large container, such as a large box that is
48"
wide. The straight member is shown as unjointed, which completely avoids any
hang-up point for the continuous web that might hamper free flow. However, in
an
alternative embodiment, the articulating paddles can have one or more joints,
like
an elbow.
[0079] FIG. 34 illustrates another embodiment of the festooning device
having articulating paddles, as an alternative to the "belt" versions in FIG.
29
through FIG. 33. In FIG. 34, a cam follower in a cam track is used to pivot
the
articulating paddle. The shuttle and nipped rolls move 36" from one end of
travel to
the other, and the tip of the articulating paddle moves 48" from one end of
travel
CA 02844303 2014-02-28
("extreme south position") to the other ("extreme north position").
,
[0080] The "belt" embodiment in FIG. 29 through FIG. 33 offers advantages
of less severe mechanical action at high operating speeds, potentially less
equipment wear, and possibly less jam risk than associated with other options,
including those using a cam.
[0081] The festooning device of the present disclosure can be used in a
variety of systems for packaging a continuous web (or thread) of a product or
material into a container. As a non-limiting example, the festooning device in
this
disclosure can be used with the methods and components described below.
[0082] The festooning device of the present disclosure provides for a more
complete fill of a continuous web of a material or product in the container as
compared with conventional techniques. As an example, a 48" x 48" box can be
filled with a continuous web of about 42,000 absorbent food pads having
individual
dimensions of about 4" x 7".
'
[0083] The festooning device of the present disclosure also permits
dispensing a continuous web of a material or product in a container at much
faster
operating speeds as compared with conventional techniques. For example, the
present festooning device permits operating speeds of about 280 feet per
minute to
about 400 feet per minute, as compared with conventional techniques that can
accurately operate at speeds of about 150 feet per minute.
[0084] The festooning device of the present disclosure can be used as part
of
a production system where synchronized movements of two or three components
are used to fill container more precisely to the edges, with a larger total
amount of
the product and at much higher operating speeds described above. The separate
16
CA 02844303 2014-02-28
movements of the shuttle arm, the articulating paddle, and/or the container
(or any
two of these movements) can be synchronized for faster, level, and complete
filling
of the container. For example, in one embodiment, if the movement of the
shuttle
arm is "North-South," the synchronized movement of the container is "East-
West."
A further (swinging) movement of the articulated paddles, which is
synchronized to
one or both of the shuttle arm movement and the container movement, permits
still
finer adjustments to the fill at the high operating speeds described above.
Stated
another way, if the movement of the shuttle arm is considered to be on an X-
axis,
the movement of the container is on a Y-axis. The fill depth of the container
is
measured by a sensor an a Z-axis. Measurement of fill depth on the Z-axis by
the
sensor affects the movement(s) of the shuttle arm, articulating paddles, and
the
container on the X-axis and Y-axis.
[0085] Another advantage of synchronizing any two movements of the shuttle
arm, articulating paddles, and the container, is minimizing the movement(s) of
each
of these components, and still achieve better fill of the container at higher
production speeds than conventional techniques. Synchronizing all three
movements (shuttle arm, articulating paddles, and container) provides still
further
minimizing the movements of each component, and optimizing the fill at high
production speeds.
[0086] By contrast, conventional filling methods employ only one (1)
movement at a time to dispense the product into a container, namely, moving
the
shuttle arm back-and forth over the top of the container until an entire
vertical stack
(lane) of the product reaches the top, after which the material is cut and
spliced,
and the shuttle arm is indexed by one width of the product to start a new
stack in
the container. Depending on the thickness and/or stiffness of the product, as
well
as the amount of hysteresis in the "throw" of the material, the operator for
conventional techniques must make frequent adjustments to the filling of the
17
CA 02844303 2014-02-28
container. This is in contrast to the festooning device of the present
disclosure, for
which the operator is not required to make any adjustments until the entire
container is filled with a single, continuous web of the material or product,
and
completely eliminates the need to cut and splice as a container is filled.
[0087] The festooning device of the present disclosure has improved
reliability, longevity of the equipment, and still more increase in speed of
operation
as compared with conventional equipment and techniques for dispensing a
continuous web of products into a container. Current festooning devices
reciprocate a shuttle plate that carries nipped rolls to pull the web through
the
device, a drive motor and gearbox to drive the nipped rolled, and air
cylinders to
open and close the nipped rolls. Air lines to the cylinders and electrical
cables to
the motor are suspended overhead and flex back and forth with each round trip
completed by the shuttle. Air lines and electrical cable are subject to damage
due
to the constant flexing. All of the equipment mounted on the shuttle plate
adds up
to about 75 pounds of additional weight to move back and forth.
[0088] As shown in FIGS. 1 to 3, the exemplary embodiment of the
festooning device disclosed herein removes everything from the shuttle plate
except the nipped rolls and two small mechanical clamps in place of the air
cylinders to open and close the nipped rolls. This is a reduction in weight of
about
65 pounds. The drive motor is mounted above the shuttle in a fixed location
and
the drive to the nipped rolls will be accomplished by a drive belt and an
articulating
arm that follows the shuttle motion. The shuttle is mounted on two self-
contained
linear actuating units whose speed and acceleration capabilities exceed what
is
actually needed. These mechanical changes provide improvements of reliability,
speed, and efficiency of the present festooning device as compared with
conventional devices.
18
CA 02844303 2014-02-28
[0089] In alternative embodiments, the festooning device further includes
electronic controls that improve changeover time between production runs,
automatically stop the festooning machine when the target material length or
product count in the container is obtained, and/or automatically monitor and
adjust
the travel distance of the shuttle and nipped rolls depending on the fill
level of the
container. Such controls also help minimize the required movements of the
shuttle
arm, articulated paddles, and container to achieve the desired fill at high
production
speeds.
[0090] The dispensing shuttle may move north-south and/or east-west to
dispense fan-folded rows of the continuous web in the container. The servo
drives
and servo motors replace AC drive motors to provide motive force to the
traversing
mechanisms. The servo drives and servo motors improve reaction time and
precise starting, stopping, reversal and positioning of traversing mechanisms.
[0091] Movement of the festooning device and/or the container while the
continuous web is being dispensed therein can improve the speed and efficiency
of
the present method. The container can be positioned on a mechanical device
that
can tilt, rock, or move the container in any direction during filling. Tilting
the
container as the continuous web approaches each edge of the container also
assists the fan folding close to each edge, thereby maximizing the use of
space
inside the container. Similarly, after the container has been shipped to an
end-
user, tilting and/or moving the container can increase the speed and
efficiency by
which the continuous web is dispensed from the container.
[0092] The container of the present disclosure can be a large box, or any
container that is able to hold a large quantity of a product or material. The
container can be made of any material, including, but not limited to,
cardboard,
wood, metal, paper, plastic, composite, or polymer. The container preferably
has
19
CA 02844303 2014-02-28
dimensions of about forty inches (40") by about forty-eight inches (48") by
about
forty-six inches (46"), in order to fit easily on a pallet. However, the
container can
be of any dimension that permits indexed rows or layers of a continuous web of
material or product to be packaged therein.
[0093] As used herein, an "end-user" is a customer or employee who
removes and uses the continuous web of a material or product that has been
previously packaged in a container for its intended use,
[0094] The present festooning device can be used for packaging and
dispensing a continuous web of a variety of products or materials, including
those
that are fibrous materials, such as fabrics and non-wovens. The present method
for packaging can also be used for packaging and/or dispensing finished
products,
including products that can be dispensed as a continuous piece and cut by the
end-user, for example, absorbent food pads and/or other absorbent articles.
The
product or materials that are packaged by the present method are typically
uniform
in thickness, size, and/or texture. However, the present method can also be
used
for packaging a continuous length of a product having varied parameters at
various
locations along in its continuous length, as long as the successive rows could
be
laid into the container.
[0095] As an example, a continuous length of absorbent food pads of more
than 21,000 linear feet can be packaged in the container by the present
festooning
device as a single, continuous length, with marks or perforations to indicate
the
individual food pads. To remove the absorbent food pads from the container, an
end-user is able to set up the packaged container one time to permit all of
the
absorbent food pads to be removed continuously and quickly. The absorbent food
pads, in this example, can be cut (or separated along pre-made perforations)
to a
desired size to fit in a food tray as they are dispensed.
CA 02844303 2014-02-28
[0096] The festooning device of the present disclosure also offers several
other advantages over conventional packaging techniques that places long
strips of
products or material in a container. Conventional packaging techniques lay
successive rows of product or material to form a series of stacks or "lanes"
in the
container, which can cause the container to become unstable during the
dispensing process as the stacks are depleted, and risks having the remaining
stacks fall over into the interior of the container that is vacated during the
dispensing process. By comparison, the horizontal layers laid in by the
present
festooning device can be dispensed by an end-user without causing instability
of
the container, as the continuous web of the material or product is dispensed
evenly
from the length and width of the entire container.
[0097] The present festooning device can also be used to avoid the need to
place dividers between the vertical stacks or lanes that are formed by
conventional
packaging techniques. The horizontal layers that are laid in by the present
festooning device offer greater stability when removing the product from the
container, eliminate the use of dividers, and maximize the use of space within
the
container, thereby providing the end-user with greater safety and speed.
[0098] Referring to FIG. 35 and FIGS. 36A through 36C, there is provided an
exemplary embodiment of a production line, or system, generally represented by
reference number 10, for packaging a continuous web 20 of absorbent pads 22 by
festooning into a container 60 according to the method of the present
disclosure.
[0099] As shown in FIG. 35, a feeder roll 12 supplies a continuous web 20
that is packaged in a large rectangular container. Feeder roll 12 has an inner
tube
14 to form that is mounted onto spindle 16. A drive motor 32 drives (spins)
feeder
roll 12 so that continuous web 20 unwinds and is dispensed from the top side
of
21
CA 02844303 2014-02-28
feeder roll 12 at commercial production speeds.
[00100] Continuous web 20 passes around one or more pulleys in production
line 10. In the exemplary embodiment in FIG. 35, production line 10 has four
pulleys 52, 54, 56, 58 that help guide and control continuous web 20 in the
production line.
[00101] After being dispensed from feeder roll 12 and, optionally, one or
more
pulley 52, continuous web 20 passes around a "dancer assembly" 35. Dancer
assembly 35 includes a fixed arm 41 (also called fixed rod) that is connected
to two
rollers at opposite ends; namely, a first dancer pulley 36 at one end affixed
arm
41, and a second dancer pulley 38 at its other end. Fixed arm 41 of dancer
assembly 35 has a pivot point 40 about which the fixed arm pivots, or rotates.
Consequently, when the top roller (first dancer pulley 36) goes to the right,
then the
bottom roller (second dancer pulley 38) must go left. Mechanical tension of
continuous web 20 causes dancer assembly 35 to oscillate back-and-forth. In a
preferred embodiment, such mechanical tension generates the oscillation of
fixed
arm 41 of dancer assembly 35. However, in another exemplary embodiment, a
combination of mechanical tension and electrical control may be used to
regulate
oscillation of dancer assembly 35.
[00102] Fixed arm 41 of dancer assembly can freely rotate until it reaches
a
mechanical stop (not shown) that permits about 450 of rotation from neutral.
The
mechanical stop may be integral to a framework (not shown) that supports part
of
production line 10. In another embodiment, the mechanical stop is part of the
dancer assembly itself. The mechanical stop prevents fixed arm 41 from
rotating
360 . In a preferred embodiment, fixed arm 41 is able to oscillate (to rotate
or pivot
about pivot point 40) about 20 in either direction (- 20 ) from a neutral
position.
22
CA 02844303 2014-02-28
[001031 Dancer assembly 35 has a dancer belt pulley 42 at pivot point 40
that
is about half-way between first dancer pulley 36 and second dancer pulley 38.
Dancer belt pulley 42 is connected by a dancer belt 46 to a second dancer belt
pulley 44, which is set a small distance away from the first belt pulley.
[00104] The position of dancer assembly 35 is detected by one or more
dancer
position sensor 48. In a preferred embodiment, dancer position sensor 48 is a
single-turn potentiometer. As dancer belt 46 turns and continuous web 20
passes
around the dancer assembly, dancer position sensor 48 measures the position of
dancer assembly 35 from its "low point" to its "high point," and generates a
signal
49 that goes to motor 32 to adjust speed. Dancer position sensor 48 is
typically
positioned outside of the framework of the production line.
[00105] Motor 32 is also connected to PLC (Programmable Logic Controller)
34. PLC Controller 34 measures speed differentials between incoming and
outgoing speeds, and generates a signal 39 that is sent to motor 32. PLC
Controller 34 generates a master speed reference based on a dial setting that
the
operator controls to either accelerate or decelerate the speed of motor 32 a
certain
amount. The speed of motor 32 (and thus the speed by which continuous web 20
is dispensed from feeder roll 12) is initially set by the operator based on
the size,
thickness, and other physical characteristics of the particular feeder roll 12
that is
loaded on spindle 16. After the motor is running, its speed may be altered
based
on signal 49 received from dancer position sensor 48 and/or reference signal
39
received from PLC controller 34, as required to maintain a constant feed and
tension control based on how fast the production line calls for additional
material. If
feeder rolls of the same size are used consistently, the production line
operator
may not need to adjust the initial settings for motor 32. However, the
operator may
have to adjust the speed input data for motor 32 if the size of the feeder
roll is
either smaller or larger than the feeder roll for which the speed input data
was
23
CA 02844303 2014-02-28
previously set. For example, if the production is set up for a feeder roll
that is a 50"
roll, and the next production run requires a 25" feeder roll (or, conversely,
requires
a 55" feeder roll), the operator may have to input different speed data to
motor 32.
Generally, the operator needs only to input such data at motor 32, rather than
re-
selling any data in PLC Controller 34.
[00106] An example of motor 32 includes, but is not limited to, an ABB
motor
drive. The ABB motor drive can be programmed to receive input data from the
operator, as well as signals 39 and 49 from PLC Controller 34 and dancer
position
sensor 48, respectively.
[00107] For example, if the feed of continuous web 20 to dancer assembly 35
is too slow for the production line, the dancer assembly will rotate in a
counterclockwise direction. Dancer position sensor 48 and PLC controller 34
will
generate and signals 49 and 39, respectively, that are received by the driver
software in motor 32. These signals will cause motor 32 to increase speed and
thereby increase the speed of unwinding of continuous web 20 to meet the
increased demand for material (continuous web 20) in the production line.
[00108] Dancer assembly 35 allows the present method to automatically
adjust
for continuous webs that vary in thickness, without requiring operator
adjustment of
the settings for motor 32 or other parts of production line 10. If the
production line
always used the same thickness of continuous web 20 every time it was used,
there would be no need for a dancer assembly, once the initial settings were
fine-
tuned by the operator. Without the dancer assembly device, motor 32 is
sensitive
enough to variations in the thickness of the continuous web to detect a
difference
of thickness of as little as 0.025 inches, and thereby require operator
adjustment.
However, the dancer assembly device of the present method allows production
line
to use continuous webs 20 that can vary in thickness by as much as about
24
CA 02844303 2014-02-28
0.125" (1/8th of an inch), without requiring an operator to adjust any
production line
settings. This flexibility of the present method is due to the ability of the
dancer
assembly device to pivot about 200
.
[00109] For example, the dancer assembly of the present method enables the
method to accommodate, without requiring the system to be adjusted by the
operator, a continuous web of absorbent food pads that are 4-ply of tissue
with
polyethylene film on either side (thin), which is approximately 1/32hd of an
inch, to
those absorbent food pads that are 18-ply of tissue with polyethylene film on
either
side (thick) that are approximately 118th of an inch. The present method could
accommodate absorbent food pads that are 3/16th of an inch and 1/4", up to
those
thick absorbent food pads having 30-ply of tissue between polyethylene outer
layers, without requiring adjustment by the operator.
[00110] After passing around dancer assembly 35, continuous web 20 then
continues on production line 10 to pass over or under one or more pulleys 54,
56,
58, which guide and control the material. As shown in FIG. 35, continuous web
20
then exits production line 10 at about exit point 59.
[00111] After leaving production line 10 at exit point 59, continuous web
20
proceeds to the festooning unit shown in FIGS. 36A to 36C. In FIG. 36A,
container
60 is illustrated in cross-section to more clearly show that it is partially
filled with
continuous web 20 by festooning device 80 by the present method. In each of
the
embodiments shown in FIG, 36A to 36C, festooning device 80 is a pair of rubber-
nipped rolls that pull continuous web 20 to dispense a continuous web of
material
or product (for example, absorbent food pads) into the rectangular container.
Another example of a festooning device 80 includes, but is not limited to, a
gantry.
Nipped rolls 80 can be mounted on a traversing mechanism and move back-and-
forth above the container, traveling from one edge of the container to the
other to
CA 02844303 2014-02-28
form the fan-folded rows of continuous web 20 that will fill the container.
[00112] Festooning device 80 may move north-south and/or east-west to
dispense fan-folded rows of continuous web 20 in container 60. Servo drives
and
servo motors replace AC drive motors to provide motive force to the traversing
mechanisms. The servo drives and servo motors improve reaction time and
precise starting, stopping, reversal and positioning of traversing mechanisms.
[00113] Movement of the festooning device and/or the container while the
continuous web is being dispensed therein can improve the speed and efficiency
of
the present method. The container can be positioned on a mechanical device
that
can tilt, rock, or move the container in any direction during filling. Tilting
the
container as the continuous web approaches each edge of the container also
assists the fan folding close to each edge, thereby maximizing the use of
space
inside the container. Similarly, after the container has been shipped to an
end-
user, tilting and/or moving the container can increase the speed and
efficiency by
which the continuous web is dispensed from the container.
[00114] Festooning device 80 may be lighter (or at least is a consistent
weight)
and more maneuverable than container 60, which can vary considerably in weight
as the container fills. However, placing container 60 on a mechanical device,
such
as one or more cams, that permits container 60 to be easily tilted, rocked,
and
moved in any direction, can also be employed, so that the continuous web fills
the
maximum amount of available space inside the container. The movement of
container 60 can also create an offset among successive rows of the continuous
web for efficient layering for packaging, as well as creating a natural
separation
plane between layers when the continuous web is dispensed for use.
[00115] For example, festooning device 80 can move straight back and forth,
26
CA 02844303 2014-02-28
while container 60 shifts a certain distance between adjacent rows of
continuous
web 20. Combining the movements of festooning device 80 and container 60 can
be an aid to efficient dispensing of products or materials into container 60
by the
present method. The movements can achieve different ends: i.e., container 60
can
be tilted at the end of placing each row into the container, to help the rows
fall all
the way toward the edges to provide maximum filling of space inside container
60,
while festooning device 80 is moved a certain distance to create a slight
offset
between successive rows of the continuous web.
[00116] Container 60 can be tilted from a neutral level position by
movement
of the cams so that the upper edge of container 60 is between about 1 to about
70
degrees above or below neutral position, and preferably between about 5 to
about
45 degrees from neutral position. After a row of the continuous web 20 is
placed in
container 60, and festooning device 80 reverses direction and begins to place
the
next row in the opposite direction in relation to the previous row, container
60
returns to a neutral position, and then is tilted toward the opposite side
just as the
new row approaches the opposite edge of container 60, helping to extend the
new
row closer to the edge of container 60.
[00117] Later, when continuous web 20 is being removed from container 60 by
an end-user, container 60 can again be advantageously placed on a moveable
device, including one or more cams that permit container 60 to be moved and/or
rocked back and forth to assist removing the continuous web 20 from container
60.
[00118] FIG. 36B illustrates a potential problem with filling container 60
at the
high operating speeds required for commercial production. At high operating
speeds, a strip of continuous web 20 can be "thrown" too far by festooning
device
80 so that a small portion of continuous web 20 flies over the outer edge of
container 60 to form an overhang portion 29 shown in FIG. 36B.
27
CA 02844303 2014-02-28
[001191 However, the problem of forming an overhang portion 29 can be
avoided by placing deflector plates 74, 76 at the upper edges of container 60,
as
shown in FIG. 36C.
[00120] Deflector plates 74, 76 stop the horizontal travel of continuous
web 20
and directing the web to slide downward along one of the inside walls of
container
60. The deflector also provides more consistent filling of the container, and
minimizes empty space at the edges of the container walls. Although the
embodiment shown in FIG. 360 illustrates two deflector plates, there may be
one,
two, three, four, or more deflector plates that are positioned around the
upper edge
of container 60. Deflector plates 74, 76 can be made of a rigid or flexible
material,
depending on the size and weight of continuous web 20, operating speed of the
festooning device, and the nature of container 60. In an exemplary embodiment,
deflectors 74, 76 are each made of metal. In a preferred embodiment, deflector
plates 74, 76 are made of polished metal that reduces or eliminates friction
as
continuous web 20 strikes it at the end of each pass. Deflector plates 74, 76
can
be adjustable in any direction. In a preferred embodiment, deflector plates
74, 76
are adjustable in the vertical direction.
[001211 Container 60 has four vertical sides (two of these sides 62, 64 are
shown in FIGS, 36A to 36C), a bottom 70, and a top 72. Top 72 can be a single
piece (i.e., a lid) that is removed while the container is being filled, or
divided into
two portions (such as a box top) so that the halves of top 72 can be pulled
away
from the top opening of container 60.
[001221 Container 60 can be a large box, or any container that is able to
hold a
large quantity of a product or material. Container 60 can be made of any
material,
including, but not limited to, cardboard, wood, metal, paper, plastic,
composite, or
28
CA 02844303 2014-02-28
polymer. Container 60 preferably has dimensions of about forty inches (40") by
about forty-eight inches (48") by about forty-six inches (46"), in order to
fit easily on
a pallet, However, container 60 can be of any dimension that permits indexed
rows
or layers of continuous web 20 to be packaged therein by the present method.
[00123] FIGS. 37A and 37B illustrate yet another embodiment in which
continuous web 120 is dispensed into container 160 as a plurality of rows 122
that
are each indexed (offset) from the previous row by a certain distance. The
plurality
of rows form a first horizontal layer, second horizontal layer, and so on
until
container 160 is filled to a desired height, weight, or quantity of continuous
web
120. In FIG. 37A, container 160 is positioned on pallet 97.
[00124] Indexed rows are formed by dispensing a first row 124 of continuous
web 120 into container 160 by festooning device 180, starting at a first edge
163 in
container 160. Alternatively, first row 124 can start at any position on the
bottom of
container 160, After first row 124 is dispensed into container 160 and reaches
an
opposite edge 165 (opposite in relation to starting edge 163), festooning
device
180 reverses direction, thereby folding over continuous web 120 to produce a
fold
125. Festooning device 180 then dispenses a second row 126 of continuous web
120 into container 160 that partially overlaps first row 124 but is indexed
(shifted) in
relation to first row 124 by a certain distance that is called an index
distance 130,
as illustrated in FIG, 376, and in FIGS. 38A and 3811
[00125] When second row 126 is dispensed by festooning device 80 and
reaches edge of container 60, festooning device 180 reverses direction again,
forming a fan fold of continuous web 120, and starting a third row 128 of
continuous web 20 that partially overlaps second row 126 but is indexed
(shifted)
by index distance 130 relative to second row 126 away from first row 124. This
is
also illustrated in FIGS. 38B and 38C. In this way, continuous web 120 is fan
CA 02844303 2014-02-28
folded in container 160.
[00126] Further steps may be taken to increase the amount of continuous web
20 that can be dispensed into container 60. To help anchor first row 124 to
container 60, a portion of first row 124 can be fastened or adhered to
container 60
with a fastener such as, but not limited to, glue, tape, and hook-and-eye
devices
such as VELCR06.
[00127j A mechanical device, such as a "fork" (not shown) can be inserted
into
fold 125 to press and force fold 125 as close as possible to edge 165 of
container
160, in order to provide a maximum "footprint" of continuous web 120 in
container
160. Alternatively, a device that provides a burst of compressed air can be
used to
accomplish this. For instance, with reference to FIG. 37B, a fork or similar
device
could be inserted between first row 124 and second row 126 to press fold 125
toward edge 165. Pressing a fold toward an edge is particularly useful when
continuous web 120 is thick or stiff and the row would otherwise end some
distance
short of edge 165.
[00128] In another embodiment, a delay can be programmed so that
festooning device 180 makes several extra passes to dispense additional
amounts
of continuous web 120 at the edge of container 160, to make the fill more
level and
stable.
[001291 The usual back-and-forth dispensing of continuous web 120 can
cause "crowning" of the product in container 160. "Crowning" means forming a
higher mound of material in the center portion of the container as compared
with
the edges. Crowning tends to occur when the continuous web is a higher-ply,
thicker material. Crowning creates wasted space in the container, and can make
the container unstable and unbalanced.
CA 02844303 2014-02-28
[00130] To reduce or eliminate crowning, an embodiment of the present
method includes providing one or more extra passes of the festooning device to
dispense extra material at the edge of the container before reversing
direction.
This can be achieved by programming the PLC Controller to provide extra passes
at each edge. Generally, when the container reaches the end of the conveyor
(not
shown), the festooning device changes directions. However, there can be a
slight
delay programmed in the PLC Controller that causes the festooning device to
make
extra passes that lay down extra material at the edges of the container.
Preferably,
the PLC Controller is programmed for two (2) to four (4) extra passes at each
edge.
The extra material laid down at the container edges creates a more "level
fill" of the
container as compared with conventional packaging techniques. By contrast, an
"unlevel-fill" container empties unevenly, and the remaining rows of material
may
tip over. By providing extra material at the edge for a level fill from bottom
to top of
the container, the container produced by the present method empties evenly and
securely for an end-user or customer.
[00131] In one embodiment, the above process can be automated by using a
level sensor (not shown) to sense whether or not the container has a level
fill, and
programming one or more extra passes at the edges of the container based on
that
input before reversing direction. In another embodiment, conveyor speed (on
which the container is resting) can be changed to increase or decrease the
number
of extra passes at the edge of the container. Changes in conveyor speed and/or
extra passes of the festooning device can be used to generate a level fill of
the
container. In yet another embodiment, the operator can manually temporarily
block
the sensor beam to cause the festooning device to lay down one or more extra
layers at the edge of the container.
[00132] As noted above and illustrated in FIG. 37B, first row 124 and
second
31
=
CA 02844303 2014-02-28
row 126 are offset or displaced in relation to each other by index distance
130. In
the particular exemplary embodiment in FIG. 37B, index distance 130 is shown
as
1/4". However, index distance 130 can be any amount or distance that is less
than
an extent (usually width) of continuous web 120, as long as there is a partial
overlap between two adjacent rows, Index distance 130 depends on the
dimensions and characteristics of continuous web 120 being dispensed into
container 160. Typically, index distance 130 can be from about five-hundredths
of
an inch (0,05") to about ten inches (10"). Index distance 130 is preferably
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 two inches (2"). Index
distance 130
can be identical between successive adjacent rows (e.g., index distance 130
between first row 124 and second row 126 would be identical to index distance
130
between second row 126 and third row 128), or can have an index distance 130
that varies among successive rows. Index distance 130, when not a uniform
amount, can vary according to a fixed ratio among rows or can vary randomly.
For
example, index distance 130 can be made to vary among successive rows
according to a certain ratio (e.g., a ratio of 1:3, where index distance 130
is 1/4"
between first row 124 and second row 126, and is %" between second row 126 and
third row 128, and is 1/4" between third row 128 and a fourth row (not shown),
and
so on). The physical characteristics of continuous web 120, such as its
thickness,
stiffness, coefficient of friction, can affect the choice of index distance
130 between
rows.
[00133] The
offset of adjacent rows, such as between first row 124 and second
row 126, is created by a movement by festooning device 180, or by a movement
of
container 160, and/or by a combination of both, that displaces the row of
continuous web 120 being dispensed into container 160 by a specified amount
from the previous row. As illustrated in FIG. 37A and FIG. 37B, second row 126
is
dispensed into container 160 so as to partially overlap first row 124 (in an
opposite
32
CA 02844303 2014-02-28
or reciprocal direction in this exemplary embodiment), but is offset from
first row
124 by index distance 130. Such movement of festooning device 180 and/or
container 160 is repeated for a plurality of rows 122 of continuous web 120,
with
each new row placed in an opposite direction to form a fan fold, and is
indexed in
relation to the previous row. Such indexed rows form a first horizontal layer
of
continuous web 20 that extends from end 167 to its opposite end 169 of
container
160. After completion of a first horizontal layer, the process is repeated
toward the
opposite direction to form a second horizontal layer that extends from end 169
back to opposite end 167. This continues until container 160 is filled with
horizontal layers of continuous web 120 up to a desired height, weight, or
quantity.
This method can be used to dispense a single, continuous length of continuous
web 120 into container 160; or, alternatively, to dispense more than one
length of
continuous web 120 in container 160.
[00134] FIGS. 38A through 38C illustrate an exemplary embodiment of the
present method to placing successive rows of continuous web 120 in container
160. FIG. 38A illustrates laying a first row 124 of continuous web 120 along
the
bottom of container 160, starting at the edge marked Al and dispensing the
first
row 124 to reach edge A2.
[00135] FIG. 38B shows that, after first row 124 of continuous web 120
reaches edge A2, the festooning device reverses direction and dispenses a
second
row 126 of the same continuous web 120 in container 160 in an opposite (or
reciprocal) direction from first row 124, that is, from the edge marked A2' to
edge
Al'. However, as shown in FIG, 38B, second row 126 does not completely overlap
first row 124, but rather overlaps only a part of first row 124. The amount
that
second row 126 is offset from first row 124 is index distance 130.
[00136] Referring to FIG. 38C, the method continues as a third row 128 of
the
33
CA 02844303 2014-02-28
same continuous web 120 is placed in container 160 in an opposite (or
reciprocal)
direction on second row 126, i.e., from the edge marked Al" to edge A2", but
third
row 128 is displaced or offset from second row 126 by an index distance 130,
such
that third row 128 partly, but not completely, overlaps second row 126.
[00137] The process shown in FIG. 38A through FIG. 38C illustrate a pattern
by which three rows of continuous web 120 are placed into container 160 by an
embodiment of the present method. The method continues in this same way,
along the direction indicated by the large arrow underneath each of FIGS. 38A
¨
38C, with successive rows (fourth row, fifth row, and higher, not shown) being
placed in container 160 such that the entire bottom of the container is
covered with
continuous web 120, from first end A1/A2 to opposite (second) end B1/B2. The
fan
folded, indexed rows thereby form a first horizontal layer across an extent of
the
container. In the exemplary embodiment illustrated in FIGS. 38A to 38C, the
first
row 124, second row 126, and third row 128, each of which is indexed by index
distance 130 in relation to the next-previous row, together comprise a portion
of
one horizontal layer in container 160.
[00138] When each horizontal row of continuous web 120 is placed in
container 160 ¨ for instance, when a row is laid between along end B1/B2 in
FIG.
38C ¨ the method proceeds in the same manner as before but in the opposite
direction, placing successive rows of continuous web 20 from end B1/B2 toward
end Al /A2, each row of which is offset or displaced from the next-earlier row
by an
index distance 130. In this way, a second horizontal layer of continuous web
120 is
placed over the first horizontal layer in container 160.
[00139] Once the second horizontal row is completed (i.e., when the row of
continuous web 120 reaches end Al/A2), the method begins a third horizontal
row
in the opposite direction, laying down rows of continuous web 120 from A1/A2
to
34
CA 02844303 2014-02-28
B1/B2, to form a third horizontal layer that rests on the second horizontal
layer and
first horizontal layer. A plurality of horizontal layers is laid in container
160 until
filled to a desired height, weight, or number of units of continuous web 120.
[00140] Although FIGS. 38A to 380 show an exemplary embodiment of rows
laid in patterns of first row from Al to A2, then a second row from A2' to Al'
and a
third row Al" to A2", a variety of other patterns to lay down the rows of
confinuous
web 120 can also be used. Using the same identifiers as used in FIGS. 38A to
380, the continuous web 120 can be laid down in a pattern that starts around
the
perimeter of container 160 (Al to A2, A2 to B2, B2 to B1, B1 to Al ¨ in a
"box"
pattern), and then adds a second layer of continuous web 20 that is indexed
(offset) a desired distance from the first layer, following the same pattern.
Other
patterns, such as cross-hatching (Al/A2 to BI/B2, followed by zig-zag patterns
Al
to B2, 82 to A2, A2 to B1, B1 to Al) are also possible in the present method,
depending on the shape, thickness, and stiffness of continuous web 120, as
long
as successive rows are indexed (offset) a certain distance from the previous
row to
provide a partial overlap.
[00141] Continuous web 120 can be a single continuous strip among first row
124, second row 126, third row 128, and all subsequent rows, until container
160 is
filled, thereby producing a container 160 that is packaged with a continuous
length
or strip of continuous web 120 that is fan folded, and has indexed layers.
Alternatively, a cut or break in continuous web 120 can be made by the
manufacturer when a desired length of material is reached; for example, after
a
certain number of linear feet have been packaged. In this way, two or more
lengths of a strip of continuous web 120 can be placed in container 160.
[00142] Although continuous web 120 is continuous, there can be
perforations
or cut-lines made on continuous web 120 to assist the end-user to identify
CA 02844303 2014-02-28
individual products in the continuous web. For example, continuous web 120 may
be a long strip of absorbent food pads, with perforations between individual
absorbent food pads.
[00143] The preceding disclosure refers to a single pass of a continuous
material as a "row," but the same could also be referred to as a "layer,"
Thus, the
present method comprises a method of packaging a container 160 using a series
of passes of festooning device 180 to place indexed layers of continuous web
120
that are each offset or shifted in relation to an underlying layer by a
certain index
distance 130, so that the individual layers partially overlap to form indexed
layers.
A series (or set) of such indexed layers across a level of container 160 forms
a
horizontal layer. Horizontal layers are formed in this manner to fill
container 160
with a desired amount of continuous web 120.
[00144] As used herein, an "end-user" is a customer or employee who
removes and uses continuous web 120 that has been previously packaged in
container 160 for its intended use.
[00145] The present method can be used for packaging and dispensing a
continuous web of a variety of products or materials, including those that are
fibrous materials, such as fabrics and non-wovens. The present method for
packaging can also be used for packaging and/or dispensing finished products,
including products that can be dispensed as a continuous piece and cut by the
end-user, for example, absorbent food pads and/or other absorbent articles.
The
product or materials that are packaged by the present method are typically
uniform
in thickness, size, and/or texture, but the present method also can be used
for
packaging a continuous length of a product having varied parameters at various
locations along in its continuous length, as long as the successive rows could
be
laid into container 160.
36
CA 02844303 2014-02-28
[00146] As an example, a continuous length of absorbent food pads of more
than 21,000 linear feet can be packaged in container 160 by the present method
as
a single, continuous length, with marks or perforations to indicate the
individual
food pads. To remove the absorbent food pads from container 160 that were
placed therein using the present method, an end-user is able to set up the
packaged container one time to permit all of the absorbent food pads to be
dispensed continuously and quickly from container 160. The absorbent food
pads,
in this example, can be cut (or separated along pre-made perforations) to a
desired
size to fit in a food tray as they are dispensed.
[00147] The present method offers several other advantages over packaging
the same product by winding on a large-diameter roll. A roll does not hold as
many
linear feet of a product as can be packaged in container 160 by the present
method. Also, a roll is more difficult for an end-user to load, as a roll must
be lifted
onto a spindle before the product could be dispensed. Also, a large roll
requires
more space for shipping, with more wasted space between rolls, as compared
with
container 160. Also, container 160 fits on pallet 97, and so can be more
easily
transported than the same material packaged on a roll.
[00148] The present method also offers several other advantages over
conventional packaging techniques that places long strips of products or
material in
a container. Conventional packaging techniques lay successive rows of product
or
material to form a series of stacks or "lanes" in the container, which can
cause the
container to become unstable during the dispensing process as the stacks are
depleted, and risks having the remaining stacks fall over into the interior of
the
container that is vacated during the dispensing process. By comparison, the
horizontal layers formed by the present method can be dispensed by an end-user
without causing instability of the container 160, as continuous web 120 is
37
CA 02844303 2014-02-28
dispensed evenly from the length and width of the entire container. Also,
conventional packaging techniques do not permit art entire container to be
dispensed as a single, continuous feed unless the adjacent lanes are spliced
together. By contrast, the present method permits all of continuous web 120 to
be
dispensed from container 160 as a single, continuous length (if desired),
without
splicing.
[00149] The present method also avoids the need to place dividers between
the vertical stacks or lanes that are formed by conventional packaging
techniques.
By comparison, the horizontal layers formed by the present method offer the
advantages of stability when removing continuous web 120 from container 160,
eliminate the need to use dividers, and maximize the use of space within
container
60, thereby providing an end-user with greater safety and speed.
[00150] Each container that is packaged or filled by the present method can
have a "tar of product or material 120. The tail can extend outside of
container
160 or can be contained inside of it. If desired, a tail from a first
container can be
connected to a tail in a second container, to further increase the efficiency
of the
method to dispense a continuous feed from the first and second containers with
a
single set-up.
[00151] Packaging the continuous web in a container by the present method
has advantages as compared to conventional methods that wind the web around a
central tube to form a large-diameter product roll. The present method allows
a
greater amount of the continuous web to be packaged in a container as compared
with rolling up the continuous web onto a large roll. Also, the container
packaged
using the present method is able to rest solidly and securely on a pallet, and
so is
safer and easier to transport than a continuous web wound onto a large roll.
Also,
a container packaged by the present method can be placed on a floor or table
for
38
CA 02844303 2014-02-28
. .
unloading as a continuous feed by an end-user, which avoids the need to lift
and
load a large roll onto a spindle.
[00162] 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,
[00153] 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,
,
39
