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[0001]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[0002]1. Field of Disclosure[0003]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.[0004]2. Description of Related Art[0005]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.[0006]However, conventional packaging techniques for a continuous thread of material or of a finished ...

AI Technical Summary

Benefits of technology

[0012]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.

[0013]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.

[0014]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.

[0015]The present method also maximizes the amount of the woven material or finished product that can be wound about the circumference of the spool.

[0016]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.

[0017]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.

Problems solved by technology

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.

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