Packaging system

Abstract

A package includes discrete units of a fibrous material (e.g., fiberglass rovings, carbon tows) that are positioned in multiple layers on a pallet, with each layer of the fibrous material units having a separator plate supported over it. According to this configuration, the package is able to deliver the fibrous material from each fibrous material unit at the same time. The fibrous material from the units on the pallet can be delivered to one or more fiber-requiring processes, such as a knitting process, a weaving process, a winding process, a chopping process, a pultrusion process, etc.

Description

PACKAGING SYSTEMCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 520,950, filed August 22, 2023, the entire disclosure of which is incorporated by reference herein.FIELD

[0002] The general inventive concepts relate to fibrous materials and, more particularly, to packages of fibrous materials, including systems for and methods of packaging the fibrous materials.BACKGROUND

[0003] The formation of glass fibers is a well-known technology. For example, U.S. Pat. Nos. 3,653,860; 3,972,702; and 4,207,086 all disclose formation of glass fibers. Each of these references is incorporated herein, in its entirety, by reference.

[0004] A generalized overview of a conventional system 100 for forming glass fibers is shown in FIG. 1. In the system 100 of FIG. 1, a furnace 102 receives a mixture of raw materials (commonly referred to as a “batch”) for producing the desired glass formulation. The batch is reduced to a molten state in the furnace 102. The molten glass exits the furnace 102 and flows along a forehearth channel 104 where it is fed to at least one bushing 106. The bushing 106 is typically heated by electrical resistance to control the viscosity of the molten glass. The bushing 106 includes an orifice plate including a plurality of orifices. Often, tips are interfaced with the orifices to extend slightly below the orifice plate. The molten glass flows through the tips in the bushing 106 for attenuation into glass fibers 108. A moisture applicator 110 applies water to the glass fibers 108 as they exit the bushing 106 to speed cooling of the glass fibers 108. Thereafter, the glass fibers 108 are gathered together to form at least one strand 112. A sizing applicator 114 applies a chemical composition (commonly referred to as a “size”) to the strand 112. The size could also be applied to the glass fibers 108 prior to formation of the strand 112. The size can serve many purposes, such as protecting the glass fibers 108 in the strand 112 from abrading against one another and providing an improved interface between the glass fibers 108 and a downstream matrix (e.g., resin system). The strand 112 then continues downstream for further processing, for example,packaging (e.g., winding on spool) or chopping into smaller segments (commonly referred to as “chopped strand”). The arrows 120, 122, and 124 illustrate the flow of the glass between the furnace 102 and the forehearth 104, between the forehearth 104 and the bushing 106, and from the bushing 106, respectively.

[0005] As noted above, the strand 112 can be wound into a discrete package. Such wound packages of the fibrous material may go by many names, for example, rovings, bobbins, doffs. As shown in FIG. 2, an exemplary roving 200 is formed by a strand (e.g., the strand 112) being wound or otherwise manipulated into a hollow cylindrical body 202 having a central cavity 204. One end of the strand forms a head end 206 of the roving 200 and the other end of the strand forms a tail end 208 of the roving 200. The strand 112 is continuous between the head end 206 and the tail end 208. The distance between the head end 206 and the tail end 208 defines a length of the strand.

[0006] Industrial processes that utilize fiberglass (e.g., knitting, weaving, winding) often require a continuous supply of many (e.g., hundreds) of separate fiberglass strands. For example, a pultrusion process requires a continuous stream of glass fibers that are combined with a resin and fed through one or more dies to make a pultruded part. Conventionally, as shown in FIG. 3 A, many individual packages of glass fibers (e.g., rovings 200) are stacked on a pallet 302 to form a package 300. For example, four (4) layers of sixteen (16) rovings 200 could be situated on the pallet 302, providing for a total of sixty-four (64) rovings 200.

[0007] In the conventional package 300, the pallet 302 with the stacked rovings 200 can be wrapped (e.g., shrink-wrapped) to prevent movement of the rovings 200 during shipping and storage. Additionally (or alternatively), as shown in FIG. 3B, a lower cardboard tray 304 is situated between the pallet 302 and the bottom layer of the rovings 200. Likewise, an upper cardboard tray 306 is placed over the top layer of the rovings 200. The trays 304, 306 help prevent movement of the rovings 200 during shipping and storage.

[0008] Thereafter, when it is time to use the rovings 200, the pallet 302 is moved relatively close to the pultrusion or other process, the shrink wrap (not shown) and / or trays 304, 306 are removed from the pallet 302, and the individual rovings 200 are removed from the pallet 302 and introduced into fiber dispensing equipment (e.g., a creel), as known in the art. As noted above, each roving 200 has a head end 206 and a tail end 208. The head end 206 of each roving 200 in the creel is introduced into the pultrusion process in the first instance, with the tail end 208 spliced to the head end 206 of a next roving 200 in the creel, so that each roving being used in the pultrusion process (z.e., being delivered by the fiber dispensing equipment) is actually a continuous “chain” of rovings connected to one another. The creelcan include shelves or the like that are as high as twelve (12) feet off the ground. Thus, with each roving 200 weighing approximately forty (40) pounds and with the rovings needing to be manually transferred from the pallet 302 to the creel, this is a labor-intensive process presenting an increased risk of injury and / or fatigue.

[0009] However, some processes can utilize the rovings 200 directly off the pallet 302, thus, preventing the aforementioned time / labor issues. In such a case, the package 300 of rovings 200 limits access to a single layer (e.g., 16 rovings 200) at a time. In the package 300 of FIG. 3 comprising a 4 x 4 x 4 arrangement of rovings 200 on the pallet 302, each layer of rovings 200 is supported by the layer(s) below it, with the bottom layer supported by the pallet 302 itself. Thus, only the top sixteen (16) rovings 200 in the uppermost layer can be paid out first, with the tail end of each roving 200 in this layer connected to the head end of the roving 200 immediately below it. This connectivity is repeated for each layer so that the entire pallet 302 can be exhausted, one layer at a time. Access to the sixteen (16) rovings 200 of the top layer can facilitated by a side carboard insert 308 that arranges the respective head ends 310 of the top rovings 200 to one side of the package 300, as shown in FIG. 3B.

[0010] In view of the above, it would be more efficient (e.g., from a utilization of floor space) if every roving 200 on the pallet 302 could be simultaneously paid out to the fiber-requiring process. Thus, there is an unmet need for a new package (and related fiberdelivery) system that allows for all sixty -four (64) rovings 200 on the pallet 302 to be paid out at the same time.SUMMARY

[0011] The general inventive concepts relate to an improved package (and related fiber-delivery) system in which strands from individual rovings situated on a pallet can each be paid out simultaneously to a fiber-requiring process. In particular, structure is added to the pallet to support each layer of rovings on the pallet, independently of the other layers of rovings on the pallet. Such a package is particularly useful for a continuous process that may require tens, hundreds, or even thousands of individual strands to be fed to the process. Examples of such fiber-requiring processes may include, but are not limited to, a knitting process, a weaving process, a winding process, a chopping process, and a pultrusion process.

[0012] In one exemplary embodiment, a package comprises: a support; a plurality of rovings, each roving comprising a length of fiber extending between a head end of the fiber and a tail end of the fiber; a first separator plate; a plurality of first support legs; a second separator plate; and a plurality of second support legs; wherein the rovings are arranged in nrows, m columns, and o layers on the support; wherein n > 2, m > 2, and o > 2; wherein the first separator plate is positioned between a first layer of the rovings and a second layer of the rovings; wherein the first support legs hold the first separator plate above the first layer of the rovings and substantially parallel to the support; wherein the second separator plate is positioned above the second layer of the rovings; wherein the second support legs hold the second separator plate above the second layer of the rovings and substantially parallel to the first separator plate; wherein the first separator plate includes n x m first slots; wherein each of the first slots allows at least one of the head end and the tail end of a roving in the first layer of the rovings to pass therethrough; wherein the second separator plate includes n x m second slots; and wherein each of the second slots allows at least one of the head end and the tail end of a roving in the second layer of the rovings to pass therethrough.

[0013] In some exemplary embodiments, the support is a pallet (e.g., a standard 48 inches x 40 inches wooden pallet).

[0014] In some exemplary embodiments, the fiber is a glass fiber. In some exemplary embodiments, the fiber is a carbon fiber. In some exemplary embodiments, the fiber is a synthetic fiber.

[0015] In some exemplary embodiments, n > 3, m > 3, and o > 3. In some exemplary embodiments, n > 4, m > 4, and o > 4. In some exemplary embodiments, n = m = o. In some exemplary embodiments, n = 4, m = 4, and o = 4.

[0016] In some exemplary embodiments, at least four (4) of the first support legs hold the first separator plate over the support. In some exemplary embodiments, at least eight (8) of the first support legs hold the first separator plate over the support.

[0017] In some exemplary embodiments, at least four (4) of the second support legs connect the first separator plate and the second separator plate. In some exemplary embodiments, at least eight (8) of the second support legs connect the first separator plate and the second separator plate.

[0018] In some exemplary embodiments, m channels are formed in the first separator plate and n of the first slots are located in each of the channels.

[0019] In some exemplary embodiments, each of the first slots has a first portion and a second portion, and a maximum width of the first portion is different from a maximum width of the second portion.

[0020] In some exemplary embodiments, the package further comprises: a third separator plate; and a plurality of third support legs; wherein the third separator plate is positioned above a third layer of the rovings; wherein the third support legs hold the thirdseparator plate above the third layer of the rovings and substantially parallel to the second separator plate; wherein the third separator plate includes n x m third slots; and wherein each of the third slots allows at least one of the head end and the tail end of a roving in the third layer of the rovings to pass therethrough.

[0021] In some exemplary embodiments, at least four (4) of the third support legs connect the second separator plate and the third separator plate. In some exemplary embodiments, at least eight (8) of the third support legs connect the second separator plate and the third separator plate.

[0022] In some exemplary embodiments, the package further comprises: a fourth separator plate; and a plurality of fourth support legs; wherein the fourth separator plate is positioned above a fourth layer of the rovings; wherein the fourth support legs hold the fourth separator plate above the fourth layer of the rovings and substantially parallel to the third separator plate; wherein the fourth separator plate includes n x m fourth slots; and wherein each of the fourth slots allows at least one of the head end and the tail end of a roving in the fourth layer of the rovings to pass therethrough.

[0023] In some exemplary embodiments, at least four (4) of the fourth support legs connect the third separator plate and the fourth separator plate. In some exemplary embodiments, at least eight (8) of the fourth support legs connect the third separator plate and the fourth separator plate.

[0024] Numerous other aspects, advantages, and / or features of the general inventive concepts will become more readily apparent from the following detailed description of exemplary embodiments, from the claims, and from the accompanying drawings being submitted herewith.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

[0026] Figure l is a diagram illustrating various aspects of a conventional fiber forming system.

[0027] Figure 2 is a diagram of a conventional roving formed from a strand of fibrous material.

[0028] Figures 3 A-3B are diagrams that illustrate a conventional package of multiple rovings situated on a pallet.

[0029] Figures 4A-4B are diagrams that illustrate an inventive package of multiple rovings situated on a pallet, according to one exemplary embodiment.

[0030] Figure 5 is a diagram of an inventive plate for separating two adjacent layers of rovings situated on a pallet, according to one exemplary embodiment.

[0031] Figure 6 is a diagram of a slot formed in the plate of FIG. 5, according to one exemplary embodiment.

[0032] Figure 7 is a (partial) top plan view of an inventive plate for separating two adjacent layers of rovings situated on a pallet, according to one exemplary embodiment.

[0033] Figure 8A is a (partial) perspective, cross-sectional view of the plate of FIG. 7 situated above a layer of rovings.

[0034] Figure 8B is front elevation view of the guide plate of FIG. 8 A, according to one exemplary embodiment.

[0035] Figure 9A is a top plan view of a continuous raised edge extending above a separator plate and around a periphery of the separator plate, according to one exemplary embodiment.

[0036] Figure 9B is a top plan view of a discontinuous raised edge extending above a separator plate and around a periphery of the separator plate, according to one exemplary embodiment.

[0037] Figure 10 is a diagram of an inventive plate illustrating the distribution of slots within each channel of the plate, relative to a central axis of the channel, according to one exemplary embodiment.

[0038] Figures 11 A-l IB illustrate the use of a guide plate within a channel of an inventive separator plate, according to one exemplary embodiment. FIG. 11 A is a (partial) front perspective view of the separator plate. FIG. 1 IB is a (partial) rear perspective view of the separator plate.

[0039] Figures 11C-1 IE illustrate an exemplary guide plate suitable for use with the separator plate of FIGS. 11 A-l IB. FIG. 11C is a front elevation view of the guide plate. FIG. 1 ID is an upper perspective view of the guide plate. FIG. 1 IE is a top plan view of the guide plate.DETAILED DESCRIPTION

[0040] While the general inventive concepts are susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to beconsidered as an exemplification of the principles of the general inventive concepts.Accordingly, the general inventive concepts are not intended to be limited to the specific embodiments illustrated herein.

[0041] The general inventive concepts encompass a new packing system and method, wherein multiple rovings of fibrous material can be situated on a pallet for shipping and / or storage, and wherein the fibrous material of each individual roving can simultaneously be paid out to a fiber-requiring process while the rovings are situated on the pallet. By consuming the rovings on the pallet at essentially the same time, the floor space occupied by the pallet (typically positioned near the consuming process) can be freed up more quickly. Additionally, the costs and risks associated with manually moving the rovings from the pallet are avoided. The inventive package design may allow for a substantial reduction in conventional packaging materials, such as cardboard inserts, wrapping films, etc. Furthermore, the stability provided by the inventive package design increases reliability of the simultaneous payout of the rovings from the package. These and other advantages of the general inventive concepts will become more apparent from the following description of various exemplary embodiments.

[0042] In one exemplary embodiment of the general inventive concepts, an inventive package 400 includes multiple discrete units of fibrous material (e.g., rovings 402) arranged on a base support, such as a pallet 404, as shown in FIGS. 4A-4B. In some exemplary embodiments, the fibrous material is glass. Typically, the base support is a pallet or palletlike structure, which is capable of being lifted for movement by a forklift or other lifting device.

[0043] The package 400 includes multiple layers, rows, and columns of the rovings 402. In particular, the package 400 includes o layers of the rovings 402, with each layer comprising an array formed by n rows of the rovings 402 and m columns of the rovings 402. In general, n > 2, m > 2, and o > 2. In some exemplary embodiments, n > 3, m > 3, and o > 3. In some exemplary embodiments, n > 4, m > 4, and o > 4. In the exemplary embodiment shown in FIGS. 4A-4B, n = 4, m = 4, and o = 4, such that sixty -four (64) of the rovings 402 are situated on the pallet 404.

[0044] In some exemplary embodiments nm. In some exemplary embodiments no. In some exemplary embodiments m o. In some alternative exemplary embodiments, a number of the rovings 402 in one of the layers can differ from a number of the rovings 402 in another one of the layers. In some alternative exemplary embodiments, a height of the rovings 402 in one of the layers can differ from a height of the rovings 402 in another one ofthe layers. In some alternative exemplary embodiments, a type of material forming the rovings 402 in one of the layers can differ from a type of material forming the rovings 402 in another one of the layers.

[0045] Construction of the package 400 shown in FIG. 4A will be further explained with reference to the exploded view of the package 400 shown in FIG. 4B. This description is also illustrative of a method of forming the package 400 and / or a method of packaging the rovings 402.

[0046] As shown in FIG. 4B, a first layer 420 of the rovings 402 is placed on the pallet 404, wherein the rovings 402 are arranged into a 4 x 4 array. The size, shape, number, and arrangement of the rovings 402 is selected to ensure that a lower surface of each of the rovings 402 rests fully on an upper surface of the pallet 404. Next, a plurality of first support legs 422, posts, or the like are placed on or otherwise interfaced with the pallet 404.

[0047] In some exemplary embodiments, at least one first support leg 422 is placed on each side of the pallet 404. In some exemplary embodiments, at least two first support legs 422 are placed on each side of the pallet 404. In some exemplary embodiments, a first support leg 422 is placed at each comer of the pallet 404. In some exemplary embodiments, at least one first support leg 422 is placed near a center of the pallet 404. In some exemplary embodiments, a lower surface of each of the first support legs 422 (i.e., a surface intended to contact the pallet 404) is texturized or otherwise treated to increase its grip with respect to the upper surface of the pallet 404. In some exemplary embodiments, a lower surface of each of the first support legs 422 (i.e., a surface intended to contact the pallet 404) is secured (e.g., adhered) to the pallet 404.

[0048] An upper surface of each of the first support legs 422 includes a protrusion 424. A height of the first support legs 422 is greater than a height of the rovings 402 in the first layer 420. In this manner, a first plate 426 can interface with the first support legs 422 to form a stable, rigid support surface covering the first layer 420 of the rovings 402 on the pallet 404. In particular the protrusions 424 of the first support legs 422 each extend through a corresponding opening (see FIG. 5) in the first plate 426. In some exemplary embodiments, some or all of the first support legs 422 can be interfaced with the first plate 426 prior to positioning the combined elements onto the pallet 404. In some exemplary embodiments, some or all of the first support legs 422 could be integrally formed with or permanently affixed to the first plate 426.

[0049] In some exemplary embodiments, the first support legs 422 can have at least a partial wedge or triangular shape that fits into the void between a pair of adjacent outerrovings 402 on the pallet 404, thereby further preventing lateral movements of the rovings 402 of the first layer 420.

[0050] A head end of each roving 402 of the first layer 420 can be directed to a common output side of the package 400. In some exemplary embodiments, each head end of the rovings 402 of the first layer 420 passes through the first plate 426 before being directed to the common output side of the package 400. Likewise, a tail end of each roving 402 of the first layer 420 can be directed to a common input side of the package 400. In some exemplary embodiments, each tail end of the rovings 402 of the first layer 420 passes through the first plate 426 before being directed to the common input side of the package 400. The tail ends of the rovings 402 of the first layer 420 on the pallet 404 can be spliced to head ends of rovings of a corresponding layer on another pallet to provide a continuous supply of the fibrous material to the fiber-requiring process.

[0051] With the first layer 420 of the rovings 402 on the pallet 404 covered by the first plate 426, a second layer 430 of the rovings 402 is placed on the first plate 426, wherein the rovings 402 are arranged into a 4 x 4 array. In this manner, each of the rovings 402 of the second layer 430 rests on (and is supported by) the first plate 426.

[0052] Next, a plurality of second support legs 432, posts, or the like are placed on or otherwise interfaced with the first plate 426. In some exemplary embodiments, a lower portion of each second support leg 432 is hollow so as to fit over and receive the protrusion 424 of a corresponding one of the first support legs 422 extending through the first plate 426.

[0053] In some exemplary embodiments, at least one second support leg 432 is placed on each side of the first plate 426. In some exemplary embodiments, at least two second support legs 432 are placed on each side of the first plate 426. In some exemplary embodiments, a second support leg 432 is placed at each comer of the first plate 426. In some exemplary embodiments, at least one second support leg 432 is placed near a center of the first plate 426.

[0054] An upper surface of each of the second support legs 432 includes a protrusion 434. A height of the second support legs 432 is greater than a height of the rovings 402 in the second layer 430. In this manner, a second plate 436 can interface with the second support legs 432 to form a stable, rigid support surface covering the second layer 430 of the rovings 402 on the first plate 426. In particular the protrusions 434 of the second support legs 432 each extend through a corresponding opening (see FIG. 5) in the second plate 436. In some exemplary embodiments, some or all of the second support legs 432 can be interfaced with the second plate 436 prior to positioning the combined elements onto the first plate 426. Insome exemplary embodiments, some or all of the second support legs 432 could be integrally formed with or permanently affixed to the second plate 436.

[0055] In some exemplary embodiments, the second support legs 432 can have at least a partial wedge or triangular shape that fits into the void between a pair of adjacent outer rovings 402 on the first plate 426, thereby further preventing lateral movements of the rovings 402 of the second layer 430.

[0056] A head end of each roving 402 of the second layer 430 can be directed to the common output side of the package 400. In some exemplary embodiments, each head end of the rovings 402 of the second layer 430 passes through the second plate 436 before being directed to the common output side of the package 400. Likewise, a tail end of each roving 402 of the second layer 430 can be directed to the common input side of the package 400. In some exemplary embodiments, each tail end of the rovings 402 of the second layer 430 passes through the second plate 436 before being directed to the common input side of the package 400. The tail ends of the rovings 402 of the second layer 430 on the first plate 426 can be spliced to head ends of rovings of a corresponding layer on another pallet to provide a continuous supply of the fibrous material to the fiber-requiring process.

[0057] With the second layer 430 of the rovings 402 on the first plate 426 covered by the second plate 436, a third layer 440 of the rovings 402 is placed on the second plate 436, wherein the rovings 402 are arranged into a 4 x 4 array. In this manner, each of the rovings 402 of the third layer 440 rests on (and is supported by) the second plate 436.

[0058] Next, a plurality of third support legs 442, posts, or the like are placed on or otherwise interfaced with the second plate 436. In some exemplary embodiments, a lower portion of each third support leg 442 is hollow so as to fit over and receive the protrusion 434 of a corresponding one of the second support legs 432 extending through the second plate 436.

[0059] In some exemplary embodiments, at least one third support leg 442 is placed on each side of the second plate 436. In some exemplary embodiments, at least two third support legs 442 are placed on each side of the second plate 436. In some exemplary embodiments, a third support leg 442 is placed at each corner of the second plate 436. In some exemplary embodiments, at least one third support leg 442 is placed near a center of the second plate 436.

[0060] An upper surface of each of the third support legs 442 includes a protrusion 444. A height of the third support legs 442 is greater than a height of the rovings 402 in the third layer 440. In this manner, a third plate 446 can interface with the third support legs 442to form a stable, rigid support surface covering the third layer 440 of the rovings 402 on the second plate 436. In particular the protrusions 444 of the third support legs 442 each extend through a corresponding opening (see FIG. 5) in the third plate 446. In some exemplary embodiments, some or all of the third support legs 442 can be interfaced with the third plate 446 prior to positioning the combined elements onto the second plate 436. In some exemplary embodiments, some or all of the third support legs 442 could be integrally formed with or permanently affixed to the third plate 446.

[0061] The third support legs 442 can have at least a partial wedge shape that fits into the void between a pair of adjacent outer rovings 402 on the second plate 436, thereby further preventing lateral movements of the rovings 402 of the third layer 440.

[0062] A head end of each roving 402 of the third layer 440 can be directed to the common output side of the package 400. In some exemplary embodiments, each head end of the rovings 402 of the third layer 440 passes through the third plate 446 before being directed to the common output side of the package 400. Likewise, a tail end of each roving 402 of the third layer 440 can be directed to the common input side of the package 400. In some exemplary embodiments, each tail end of the rovings 402 of the third layer 440 passes through the third plate 446 before being directed to the common input side of the package 400. The tail ends of the rovings 402 of the third layer 440 on the second plate 436 can be spliced to head ends of rovings of a corresponding layer on another pallet to provide a continuous supply of the fibrous material to the fiber-requiring process.

[0063] With the third layer 440 of the rovings 402 on the second plate 436 covered by the third plate 446, a fourth layer 450 of the rovings 402 is placed on the third plate 446, wherein the rovings 402 are arranged into a 4 x 4 array. In this manner, each of the rovings 402 of the fourth layer 450 rests on (and is supported by) the third plate 446.

[0064] Next, a plurality of fourth support legs 452, posts, or the like are placed on or otherwise interfaced with the third plate 446. In some exemplary embodiments, a lower portion of each fourth support leg 452 is hollow so as to fit over and receive the protrusion 444 of a corresponding one of the third support legs 442 extending through the third plate 446.

[0065] In some exemplary embodiments, at least one fourth support leg 452 is placed on each side of the third plate 446. In some exemplary embodiments, at least two fourth support legs 452 are placed on each side of the third plate 446. In some exemplary embodiments, a fourth support leg 452 is placed at each corner of the third plate 446. In someexemplary embodiments, at least one fourth support leg 452 is placed near a center of the third plate 446.

[0066] An upper surface of each of the fourth support legs 452 includes a protrusion 454. A height of the fourth support legs 452 is greater than a height of the rovings 402 in the fourth layer 450. In this manner, a fourth plate 456 can interface with the fourth support legs 452 to form a stable, rigid support surface covering the fourth layer 450 of the rovings 402 on the third plate 446. In particular the protrusions 454 of the fourth support legs 452 each extend through a corresponding opening (see FIG. 5) in the fourth plate 456. In some exemplary embodiments, some or all of the fourth support legs 452 can be interfaced with the fourth plate 456 prior to positioning the combined elements onto the third plate 446. In some exemplary embodiments, some or all of the fourth support legs 452 could be integrally formed with or permanently affixed to the fourth plate 456.

[0067] In some exemplary embodiments, the fourth support legs 452 can have at least a partial wedge or triangular shape that fits into the void between a pair of adjacent outer rovings 402 on the third plate 446, thereby further preventing lateral movements of the rovings 402 of the fourth layer 450.

[0068] A head end of each roving 402 of the fourth layer 450 can be directed to the common output side of the package 400. In some exemplary embodiments, each head end of the rovings 402 of the fourth layer 450 passes through the fourth plate 456 before being directed to the common output side of the package 400. Likewise, a tail end of each roving 402 of the fourth layer 450 can be directed to the common input side of the package 400. In some exemplary embodiments, each tail end of the rovings 402 of the fourth layer 450 passes through the fourth plate 456 before being directed to the common input side of the package 400. The tail ends of the rovings 402 of the fourth layer 450 on the third plate 446 can be spliced to head ends of rovings of a corresponding layer on another pallet to provide a continuous supply of the fibrous material to the fiber-requiring process.

[0069] While this process could be continued to add additional segregated layers of rovings to the package, the exemplary package 400 is complete (with sixty-four (64) rovings 402) once the fourth plate 456 is installed on the package 400.

[0070] Because the plates 426, 436, 446, and 456 compartmentalize the layers 420, 430, 440, and 450 of rovings 402, a head end of each of the sixty-four (64) rovings 402 can be simultaneously fed out to a fiber-requiring process, such as a pultrusion process. Consequently, while four separate pallets of a conventional package (e.g., the package 300) would be required to deliver sixty -four (64) ends to a fiber-requiring process, a single palletof the inventive package (e.g., the package 400) could deliver sixty-four (64) ends to the fiber-requiring process.

[0071] While the plates 426, 436, 446, and 456 act as separators, the general inventive concepts encompass many variations to these separators, as long as the separators are sufficient to support the weight of any rovings placed thereon.

[0072] One exemplary embodiment of a plate 500 for use as a separator in an inventive package (e.g., the package 400) is shown in FIG. 5. The plate 500 may be made of any suitable material, such as a hard plastic or a metal. In some exemplary embodiments, the plate 500 is formed (e.g., molded) as a unitary body.

[0073] In some exemplary embodiments, the plate 500 has a width and a length that approximates that of a base support of the package, such as a pallet. In some exemplary embodiments, the plate 500 has a thickness that is less than that of the base support of the package. In some exemplary embodiments, the plate 500 has a weight that is less than that of the base support of the package.

[0074] The plate 500 is shown with ten (10) support legs 502 interfaced therewith, as evidenced by the ten (10) protrusions 504 extending through the plate 500. As noted above, other embodiments of a suitable plate may include fewer or more than ten (10) support legs. In some exemplary embodiments, the support legs 502 are removably attached to the plate 500.

[0075] The plate 500 includes multiple channels 506 that are recessed below an upper surface of the plate 500 that would support any rovings placed thereon. Each of the channels 506 includes a plurality of spaced-apart slots 508 that extend through the plate 500.

[0076] A depth of the channels 506 is such that a lower surface of the channels 506 will be in close proximity to upper surfaces of the rovings situated below the plate 500. In particular, each of the slots 508 in a channel 506 will be located above a corresponding roving positioned below the plate 500.

[0077] For example, if the plate 500 is sized and shaped to be positioned above sixteen (16) rovings forming a 4 x 4 array of the rovings (i.e., m = 4 columns and n = 4 rows), the plate 500 will include m channels, with each channel 506 including n slots 508.

[0078] The channels 506 provide a path for the head end and / or the tail end of each roving situated below the plate 500 to pass through a corresponding slot 508 positioned above the roving, along the channel 506, and out a respective end of the channel 506 toward an output end 520 of the package and an input end 522 of the package, respectively.

[0079] In some exemplary embodiments, the slots 508 have a keyhole shape (see FIG. 6) with a first end 530 that is larger (i.e., wider) than a second end 532. These ends can have rounded edges and / or include a surface composition (e.g., Teflon) to reduce friction on the strands of the rovings as they pass through the slots 508, particularly at higher line speeds (e.g., 2 m / min). In some exemplary embodiments, the first end 530 of the slot 508 receives the head end of the roving situated below the slot 508, while the second end 532 of the slot 508 receives the tail end of the roving situated below the slot 508. The ends of the rovings then travel through the channel 506 to opposite ends of the channel 506, with the head end of each roving delivering the strand of the roving a fiber-forming process and the tail end of the each roving allowing the nearly consumed strand of the roving to be spliced to the head end of a new roving of another package.

[0080] In some exemplary embodiments, a plate 700 has a channel 702 with slots 704 formed therein, wherein the slots 704 are angled relative to a central axis of the channel 702, as shown FIG. 7. The angled alignment of the slots 704 enables tension on the strands without snapping adjacent strands. Consequently, this angling of the slots 704 helps keep the strands from the different rovings traveling through the channel 702 spaced apart from one another.

[0081] In some exemplary embodiments, as shown in FIG. 8 A, a guide plate 710 is situated at each end of the channel 702 to assist in keeping the strands from the different rovings traveling through the channel 702 spaced apart from one another. Each of the guide plates 710 includes a number of curved notches 712 that corresponds to the number of strands passing through that end of the channel 702. These notches 712 can have rounded edges and / or include a surface composition (e.g., Teflon) to reduce friction on the strands of the rovings as they pass through the notches 712, particularly at higher line speeds (e.g., 2 m / min).

[0082] An exemplary embodiment of the guide plate 710 is shown in FIG. 8B. The guide plate 710 includes four notches 712, which correspond to the four ends being paid out through that end of the channel 702. As shown in FIG. 8B, the notches 712 are distributed across a width of the guide plate 710, such that the guide plate 710 is not symmetrical about a central axis 714 of the guide plate 710. In some exemplary embodiments, simply rotating the guide plate 710 180 degrees renders it suitable for use at the opposite end of the channel 702. The guide plate 710 will generally be at least as wide as the channel 702. In some exemplary embodiments, the guide plate 710 has a width in the range of 5 inches to 9 inches. The guide plate 710 can have any suitable height, so long as the notches 712 can be formed therein. Insome exemplary embodiments, the guide plate 710 has a height in the range of 1 inches to 3 inches. The guide plate 710 can have any thickness suitable for withstanding the forces placed thereon, which can depend on the material composition of the guide plate 710. In some exemplary embodiments, the guide plate 710 is made of a hard plastic or a metal. In some exemplary embodiments, the guide plate 710 has a thickness in the range of 1 / 8 inch to 3 / 8 inch.

[0083] The guide plates 710 can be interfaced with the plate 700 in any suitable manner. In some exemplary embodiments, the guide plate 710 can be fastened (e.g., screwed) to the plate 700 near an end of the associated channel 702. Since the guide plate 710 may be susceptible to wear and tear, it could need replacing on occasion. Thus, in some exemplary embodiments, the guide plate 710 is interfaced with the plate 700 in a manner that allows for relatively efficient replacement (i.e., insertion and removal) of the guide plate 710. For example, the guide plate 710 can be held (e.g., friction fit) between opposing members formed with or secured to the plate 700 near an end of the associated channel 702.

[0084] The plates encompassed by the general inventive concepts (e.g., the plate 500) may include additional structure that contributes to an improved package (e.g., the package 400). For example, as shown in FIG. 5, recesses 510 formed in the plate 500 above the channels 506 help guide proper placement of the rovings on the plate 500. Additionally, the recesses 510 help secure the rovings on the plate 500, such that the rovings are more resistant to lateral movement relative to the plate 500.

[0085] As another example, in addition to (or instead of) the recesses 510, the plate 500 may be formed with a raised edge (not shown) or rim around its periphery. The edge could extend above an upper surface of the plate 500 and / or below a lower surface of the plate 500. The edge 910 of a plate 900 could be continuous (see FIG. 9A) or discontinuous (see FIG. 9B). In a discontinuous embodiment of the edge, the gaps (discontinuities) in the edge should be narrower than a width of the rovings. In either case, the edge should not block the ends of the channels 906 so that the strands from the rovings can pass therethrough (including through the aforementioned guide plates 908) and out of the package.Alternatively, in some exemplary embodiments, the guide plate structure 908 could be formed in those portions of a continuous edge that would otherwise occlude the channels 906. Like the recesses 510, the edge 910 would help secure the rovings on the plate 500, such that the rovings are more resistant to lateral movement relative to the plate 500.

[0086] As another example, a plate 1000 has a channel 1002 with multiple slots 1004 formed therein, wherein a central axis of a first one of the slots 1004 forms a positive anglewith a central axis 1006 of the channel 1002 and a central axis of a second one of the slots 1004 forms a negative angle with the central axis 1006 of the channel 1002, as shown FIG. 10. Furthermore, a maximum distance of a first one of the slots 1004 from the central axis 1006 of the channel 1002 differs from a maximum distance of a second one of the slots 1004 from the central axis 1006 of the channel 1002, as shown in FIG. 10. The angled and / or spaced alignment of the slots 1004 enables tension on the strands without snapping adjacent strands. Consequently, this angling and / or spacing of the slots 1004 helps keep the strands from the different rovings traveling through the channel 1002 spaced apart from one another.

[0087] As yet another example, in some embodiments, a plate 1100 is designed so that all of the ends (i.e., the head ends and the tail ends) of all of the rovings immediately under the plate 1100 can pass through the plate 1100 and be paid out of the same side of the package. In this manner, an output end (e.g., the output end 520) of the package and an input end (e.g., the input end 522) of the package are the same side of the package.

[0088] To facilitate this same side payout, a guide plate 1110 having eight notches 1112 is provided, as shown in FIGS. 11 A-l IE. The notches 1112 correspond to the eight ends (i.e., four head ends and four tail ends) being paid out through the guide plate 1110. As shown in FIG. 11C, the notches 1112 are distributed across a width of the guide plate 1110, such that the guide plate 1110 is symmetrical about a central axis 724 of the guide plate 1110.

[0089] The guide plate 1110 also includes four integrated ramps 1114. In some exemplary embodiments, the ramps 1114 extend perpendicular from the notched portion of the guide plate 1110, as shown in FIG. 1 IE. The ramps 1114 act to lift and / or otherwise direct each fiber passing thereover to its corresponding exit notch 1112, while promoting separation between the adjacent head end and tail end exiting the same slot 1104. In some exemplary embodiments, the ramps 1114 are positioned to terminate between adjacent pairs of the notches 1112 and / or to be adjacent to the slots 1104 formed in the channel 1102 of the plate 1100, as show in FIGS. 11 A-l IB. The ramps 1114 can be formed with any suitable slope sufficient to lift the crossing fiber off the floor of the channel 1102 and maintain separation between the adjacent fiber ends. In some exemplary embodiments, the ramps 1114 have a slope (defined by angle a) in the range of 15 degrees to 45 degrees.

[0090] The guide plate 1110 can have the same width, height, and thickness as the guide plate 710. The guide plate 1110 can be made of the same material as the guide plate 710. In the guide plate 1110, a maximum height of the ramps 1114 can be less than or equal to the height of the guide plate 1110. In the guide plate 1110, a thickness of the ramps 1114 can be greater than or equal to the thickness of the guide plate 1110.

[0091] It will be appreciated that the scope of the general inventive concepts is not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the methods and systems disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and claimed herein, and any equivalents thereof. For example, while the exemplary embodiments shown and described herein often reference packaging of sixty- four (64) fiberglass rovings, the general inventive concepts are not so limited and instead are applicable to the packaging of other similar fibrous materials in quantities greater than and less than sixty -four (64) units, as well as in varying arrangements of rows, column, and layers.

Claims

CLAIMS1. A package comprising: a support; a plurality of rovings, each roving comprising a length of fiber extending between a head end of the fiber and a tail end of the fiber; a first separator plate; a plurality of first support legs; a second separator plate; and a plurality of second support legs; wherein the rovings are arranged in n rows, m columns, and o layers on the support; wherein n > 2, m > 2, and o > 2; wherein the first separator plate is positioned between a first layer of the rovings and a second layer of the rovings; wherein the first support legs hold the first separator plate above the first layer of the rovings and substantially parallel to the support; wherein the second separator plate is positioned above the second layer of the rovings; wherein the second support legs hold the second separator plate above the second layer of the rovings and substantially parallel to the first separator plate; wherein the first separator plate includes n x m first slots; wherein each of the first slots allows at least one of the head end and the tail end of a roving in the first layer of the rovings to pass therethrough; wherein the second separator plate includes n x m second slots; andwherein each of the second slots allows at least one of the head end and the tail end of a roving in the second layer of the rovings to pass therethrough.

2. The package of claim 1, wherein the support is a pallet.

3. The package of claim 1, wherein the fiber is a glass fiber.

4. The package of claim 1, wherein n = 4, m = 4, and o = 4.

5. The package of claim 1, wherein at least 8 of the second support legs connect the first separator plate and the second separator plate.

6. The package of claim 1, wherein m channels are formed in the first separator plate and n of the first slots are located in each of the channels.

7. The package of claim 1, wherein each of the first slots has a first portion and a second portion, and wherein a maximum width of the first portion is different from a maximum width of the second portion.

8. The package of claim 1, further comprising: a third separator plate; and a plurality of third support legs; wherein the third separator plate is positioned above a third layer of the rovings; wherein the third support legs hold the third separator plate above the third layer of the rovings and substantially parallel to the second separator plate; wherein the third separator plate includes n x m third slots; and wherein each of the third slots allows at least one of the head end and the tail end of a roving in the third layer of the rovings to pass therethrough.

9. The package of claim 8, further comprising: a fourth separator plate; anda plurality of fourth support legs; wherein the fourth separator plate is positioned above a fourth layer of the rovings; wherein the fourth support legs hold the fourth separator plate above the fourth layer of the rovings and substantially parallel to the third separator plate; wherein the fourth separator plate includes n x m fourth slots; and wherein each of the fourth slots allows at least one of the head end and the tail end of a roving in the fourth layer of the rovings to pass therethrough.

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