Systems and methods for packaging rolled products in canisters

Abstract

A sustainable packaging apparatus is provided for packaging rolled paper products in canisters, such as paper canisters. The packaging apparatus includes a canister drive system configured for moving a plurality of canisters and a rolled product feeder configured for loading one or more rolled products into the plurality of canisters.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Ser. No. 63 / 478,136, filed Dec. 31, 2022, which is incorporated herein by reference in its entirety.BACKGROUND

[0002] Rolled paper products, such as toilet paper and paper towels, are conventionally packaged by wrapping one or more rolled products in a plastic material. Often, several rolls are aligned or stacked before wrapping the entire stack in a plastic wrap. This packaging process requires the use of significant amounts of plastic and leads to plastic waste, which may not align with goals for sustainability and / or recyclability. Additionally, the plastic wrap offers little protection against outside forces. Wrapped rolled products may suffer impacts, punctures, tearing, or deformation during transit or when handled in-store. Therefore, there exists a need in the industry for effective and more sustainable packaging systems and methods for rolled paper products.SUMMARY

[0003] Some aspects of the present disclosure relate to a packaging apparatus for packing a rolled product. The packaging apparatus includes a canister drive system configured for moving a plurality of canisters in a first direction, and a rolled product feeder configured for loading one or more rolled products into the plurality of canisters by moving the one or more rolled products in a second direction substantially perpendicular to the first direction.

[0004] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system includes a rotating drive belt having a plurality of protruding members.

[0005] In some aspects, in addition, or in the alternative, to any preceding aspects, the protruding members extend outwardly from the rotating drive belt and are configured for engaging and advancing the plurality of containers in the first direction.

[0006] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system includes a first drive wheel and a second drive wheel, wherein the first drive wheel spaced apart from the second drive wheel and wherein the rotating drive belt is secured around and extends between the first drive wheel and the second drive wheel.

[0007] In some aspects, in addition, or in the alternative, to any preceding aspects, the rolled product feeder is configured for loading the one or more rolled products in the plurality of canisters at a position between the first drive wheel and the second drive wheel.

[0008] In some aspects, in addition, or in the alternative, to any preceding aspects, the packaging apparatus includes a sliding table configured for supporting the plurality of canisters.

[0009] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system is positioned above the sliding table and configured for advancing the plurality of canisters in the first direction across the sliding table.

[0010] In some aspects, in addition, or in the alternative, to any preceding aspects, the rolled product feeder defines one or more rolled product feed paths and is configured for advancing the rolled products in the second direction along the one or more rolled product feed paths.

[0011] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system is configured for aligning the plurality of canisters with the one or more rolled product feed paths to facilitate insertion of the rolled products into the plurality of canisters.

[0012] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system is configured to align the plurality of canisters with the one or more rolled product feed paths such that an open end of each of the plurality of canisters faces the one or more rolled product feed paths.

[0013] In some aspects, in addition, or in the alternative, to any preceding aspects, the packaging apparatus includes a cap feeder configured for attaching at least one cap to an end of each of the plurality of canisters after each respective canister has been loaded with at least one rolled product by the rolled product feeder.

[0014] In some aspects, in addition, or in the alternative, to any preceding aspects, the cap feeder is configured for moving the at least one cap in a second direction substantially perpendicular to the first direction.

[0015] In some aspects, in addition, or in the alternative, to any preceding aspects, the cap feeder defines at least one cap feed path and is configured for advancing at least one cap in the second direction along the at least one cap feed path.

[0016] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister drive system is configured for aligning the plurality of canisters with the at least one cap feed path to facilitate attachment of the at least one cap to an end of each of the plurality of canisters.

[0017] In some aspects, in addition, or in the alternative, to any preceding aspects, the packaging apparatus includes a canister feeder configured for advancing the one or more canisters in the first direction.

[0018] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister feeder is configured for advancing the one or more canisters toward the canister drive system such that the one or more canisters are engaged by the canister drive system.

[0019] In some aspects, in addition, or in the alternative, to any preceding aspects, the canister feeder is configured for advancing the one or more canisters away from the canister drive system after the one or more canisters have been filed with the one or more rolled products.

[0020] In some aspects, in addition, or in the alternative, to any preceding aspects, the plurality of canisters are each constructed from a recyclable material.

[0021] In some aspects, in addition, or in the alternative, to any preceding aspects, the plurality of canisters are each constructed from rigid cardstock.BRIEF DESCRIPTION OF DRAWINGS

[0022] Example features and implementations of the present disclosure are disclosed in the accompanying drawings. However, the present disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings, like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.

[0023] FIG. 1 is a perspective view of a packaging apparatus for packaging rolled paper products according to one implementation.

[0024] FIG. 2 is a side view of the packaging apparatus of FIG. 1.

[0025] FIG. 3 is a top view of the packaging apparatus of FIG. 1.

[0026] FIG. 4 is a top view of a rolled product feeder according to one implementation.

[0027] FIG. 5 is a top view of a cap feeder according to one implementation.

[0028] FIG. 6 is a perspective view of a portion of a canister drive system according to one implementation.

[0029] FIG. 7 is a perspective view of a portion of an inserting device of a canister drive system according to one implementation. FIG. 8 is a perspective view of a cap inserting device of a cap feeder according to one implementation.DETAILED DESCRIPTION

[0030] Reference now will be made in detail to various implementations of the disclosure, one or more examples of which are set forth below. Each example is provided by way of explanation and not limitation. In view of the disclosure, it will be apparent to those skilled in the art that various modifications and variations may be made to the various implementations described herein without departing from the scope or spirit of the disclosure.

[0031] As used herein, forms of the words “comprise,”“have,” and “include” are legally equivalent and open-ended. Therefore, additional non-recited elements, functions, steps or limitations may be present in addition to the recited elements, functions, steps, or limitations.

[0032] Various implementations of a sustainable packaging apparatus for rolled paper products are described herein. In various implementations, canisters are provided, which may be constructed from paper board (e.g., similar to that used for making cores for rolled products, such as toilet paper tube material). Generally, the packaging apparatus uses the canisters for packaging rolled paper products. In various implementations, the packaging apparatus includes a canister drive system configured for moving a plurality of canisters in a first direction, a canister feeder configured for delivering canisters to the canister drive system, and a rolled product feeder configured for loading one or more rolled products into the plurality of canisters by moving the one or more rolled products in a second direction substantially perpendicular to the first direction. In addition, the packaging apparatus may include a cap feeder configured for securing caps to the end of the filled canisters. Together, the components of the packaging apparatus provide an automated system for packaging rolled products in a more sustainable manner.Packaging Apparatus

[0033] FIGS. 1-8 show a packaging apparatus 100 for packaging rolled products according to one implementation. As shown in FIG. 1, the packaging apparatus 100 generally includes a canister feeder 150, a canister drive system 110, a rolled product feeder 130, and a cap feeder 190.

[0034] As shown in FIG. 1, the packaging apparatus 100 generally defines a first end 104 and a second end 106. In the illustrated implementation, the canister drive system 110 is positioned in a suspended, overhead position between the packaging apparatus'first end 104 and second 106. As depicted in FIGS. 1-3 and 6-8, the canister drive system 110 includes a drive belt 111 having a plurality of protruding members 118 extending radially outwardly from the drive belt 111.

[0035] The drive belt 111 is positioned around a pair of drive wheels 114, which are each rotatably supported by side supports 122. In this way, the wheels 114 and drive belt 111 are suspended over the canister feeder's sliding table 102 (described in greater detail herein). The drive wheels 114 may be driven by a motor (not shown) and are generally configured for rotating the drive belt 111 (e.g., in a counter-clockwise direction around the drive wheels 114).

[0036] In the illustrated implementation of FIG. 1, the drive belt 111 is comprised of a plurality of flexible members 112 movably connected to one another to form the drive belt 111. However, as will be appreciated from the description herein, the drive belt 111 may be constructed of any suitable material (e.g., a continuous rubber, metal, or fabric belt). As is further depicted in FIG. 1, the flexible members 112 include cross members 116 which provide a more rigid connection point for each set of protruding members 118. In the illustrated implementation, the protruding members 118 are coupled to the flexible member 112 via the cross members 116.

[0037] In various implementations, the protruding members 118 (also referred to as “fingers”) are substantially rigid members extending outwardly from the surface of the drive belt 111. As shown in FIG. 1, the protruding members 118 may be disposed in sets of protrusions that move together (e.g., two or three or four or six protrusions in a set). As shown in FIGS. 1, 2, and 6, pairs of protruding members 118 are spaced apart from each other to form a seat 120. In some implementations, the protruding members 118 may be slidably connected to the cross members 116 such that the protruding members 118 may be spaced apart from each other in sets (e.g., in a direction perpendicular to the direction of travel AA). In other words, the distance between the protruding members 118 may be adjusted to accommodate different sizes of rolled products. As explained in greater detail herein, the protruding members 118 are configured for advancing a plurality of canisters 152 through the packaging apparatus 100.

[0038] Referring to FIGS. 1-4 and 6, the canister feeder 150 extends from the packaging apparatus'first end 104 to the second end 106. In various implementations, the canister feeder 150 includes a sliding table 102 disposed underneath the overhead canister drive system 110. In the illustrated implementations, the sliding table 102 is configured to allow the plurality of canisters 152 to move from the first end 104 of the packaging apparatus to the second end 106 of the packaging apparatus. In some implementations, the sliding table 102 comprises a conveyor belt and actively moves the plurality of canisters 152 in a first direction (from the first end 104 to the second end 106). In some implementations, the sliding table 102 includes additional protrusions to define the seat 120 from the bottom side.

[0039] In certain implementations, the sliding table 102 may be a fixed, non-moving table configured to permit canisters 152 to slide or roll across the sliding table 102 (e.g., by gravity or being driven by the canister drive system 110) to advance through the packaging apparatus 100. In some implementations, the canisters 152 may move continuously or may stop for a period of time (e.g., to allow a roll 132 to be inserted).

[0040] In various implementations, the canisters 152 may be constructed from paper board (e.g., similar to that used for making the cores for rolled products, such as toilet paper tube material). For example, in one implementation, the canisters 152 are comprised of a rigid cardstock core (e.g., covered with coated, glossy paper). In various implementations, the canisters 152 may be produced in line by winding flat base stock on a mandrel (e.g., similar to existing core material production). Each wound base stock is cut to a desired length based on the number of rolls to be contained (e.g., 1 or 2 or 4 rolls). As explained in greater detail herein, the ends of each canister 152 may be filled with a cap by the cap feeder 190, which could be metal, paper board, paper label with adhesive, or any other recyclable material. Additionally, paper labels may be adhered to the canisters 152.

[0041] The canister feeder 150 further defines a cannister channel 156 bounded by walls or dividers 154. The canisters 152 are aligned in the cannister channel 156 such that an open end of each canister 152 is facing one side of the system 100 (e.g., facing the rolled product feeder 130 such that rolls 132 may be inserted into the canister 152). The dividers 154 and sliding table 102 together define the canister channel 156, through which the canisters 152 move. In some implementations, the dividers 154 are removed so that the canister channel 156 includes only a movement portion (e.g., a conveyor belt). As shown in FIG. 1, the canister feeder 150 runs along the same substantially linear path as the canister drive system 110. However, in some implementations, the canister feeder 150 may be disposed at an angle to other components of the packaging apparatus 100. In some implementations, the canister channel 156 and sliding table 102 are coexistent such that they form two parts of a single conveyor.

[0042] As shown in FIGS. 1-4 and 7, the rolled product feeder 130, includes a plurality of rolled products 132 (or “rolls”132), a plurality of dividers 134 defining four channels 136 (or rolled product rows), a first portion 138, a second portion 140, an indexing portion 142, and an inserting device 170. In FIG. 1, the canister feeder 130 has a first portion 138 with four channels 136 and a second portion 140 with two channels 136.

[0043] The channels 136 are generally configured to permit the rolls 132 to be advanced toward the canister drive system 110. As shown in FIGS. 1-3, the channels 136 are generally oriented in a second direction that is substantially perpendicular to the direction of the canister feeder 150 (i.e., the rolled products 132 are advanced in a direction substantially perpendicular to the direction the canisters 152 travel through the packaging apparatus 100).

[0044] The dividers 134 are straight in some portions and may be disposed at an angle in other portions of the canister feeder 130. In FIG. 1, four of the dividers are angled towards the start of the second portion 140. In FIG. 1, two of the dividers 134 terminate at the start of the second portion 140, thus creating only two channels 136.

[0045] The indexing portion 142 includes arms or stoppers movable between two positions to either allow a roll to pass through the channel 136 or stop in place. In some implementations, the indexing portion 142 is configured to allow a different number of rolls 132 to enter the second portion 140 (e.g., one or three or four or six or ten rolls 132). In some implementations, the indexing portion 142 may slow or stop the rolls 132 before allowing the rolls 132 to continue in stages (e.g., one or two or three or four or six or eight rolls 132 at once).

[0046] In some implementations, the rolled product feeder 130 contains a different number of channels 136 (e.g., one or two or six or eight or twelve or twenty or thirty channels 136 feeding towards the canister drive system 110). In some implementations, the second portion 140 contains a different number of channels 136 which may be less than or equal to the number of channels 136 in the first portion 138 (e.g., one or two or four or eight or ten channels 136).

[0047] The rolled product feeder's inserting device 170 is configured for inserting rolls 132 into canisters 152. The inserting device 170 includes a plurality of insertion seats 172 (shown as two (2) insertion seats 172 in FIG. 1). The insertion seats 172 align with two of the seats 120 defined by the drive belt's protruding members 118. In various implementations, any suitable alignment device (e.g., optical sensors or other position sensors) may be used to ensure the seats 120 defined by the drive belt's protruding members 118 are aligned with the insertion seats 172, thereby ensuring that the rolls 132 can be inserted into the canisters 152.

[0048] The inserting device 170 further includes an insertion arm 174 configured for pushing one or more rolls 132 out of the rolled product feeder 130 and into an open end of a respective canister 152 (the canister being held in alignment by the canister drive system 110). In various other implementations, the inserting device 170 may alternatively include other rolled product moving devices (e.g., a conveyor, an angled slide, or the like).

[0049] As shown in FIGS. 1-3, 5, and 8, the cap feeder 190 includes a plurality of caps 192, a cap feed path 191, a capping seat 194, and a cap inserting device 195. The cap feed path 191 contains the caps 192 and moves them from a bulk section towards the capping seat 194. In some implementations, the cap feed path 191 includes a conveyor belt or other common product moving devices (e.g., an array of racks to hold the caps and move along a belt). The capping seat 194 corresponds to the seat 120 at which a filled canister 175 (i.e., a canister 152 filled with a roll 132) may receive a cap 192. In some implementations, the capping seat 194 is configured to place a label or sticker on the filled canister 175. The cap insertion device 195 includes a movement arm 196 configured to push to the caps 192 from the cap feed path 191 towards the capping seat 194 and the filled cannister 175.

[0050] In some implementations, a second cap feeder is disposed on the opposite side of the canister 152 such that caps 192 or labels may be applied to both sides of the canister 152. In some implementations, multiple stations adjacent to the cap feeder 190 are provided for performing different labeling and sealing operations (e.g., a labeling station may place a sticker label on the outer surface of the filled cannister 175). In some implementations, a labeling station may be provided further towards the second end 106.Method and Operation of Packaging Apparatus

[0051] A method of use and operation of the packaging apparatus 100 will now be described according to various implementations. Upon actuation, one or more of the wheels 114 drive the canister drive system's drive belt 111 around the wheels 114 in a direction marked by arc A′ on the wheel 114 closer to the first end 104 of the system 100. In some implementations, an electric motor drives the wheels 114. The drive belt 111 on the top side of the canister drive system 110 moves toward the first end 104 of the canister drive system 110, along a dashed line marking direction AA. The drive belt 111 carries the protruding members 118 around the wheels 114, following direction of arc A′. On the bottom side of the canister drive system 110, the drive belt 111 and protruding members 118 move toward the second end 106 of the system 100 in a direction opposite that of direction AA. Finally, the drive belt 111 and protruding members 118 move around the wheel 114 closest to the second end 106 before wrapping around the top side of the canister drive system 110 to start the cycle again. By the movement of the protruding members 118 around the canister drive system 110, each seat 120 moves around the canister drive system 110 in a similar manner.

[0052] In implementations in which the sliding table 102 is movable, the canister feeder's sliding table 102 moves in a direction from the first end 104 to the second end 106. The speed and timing of the sliding table 102 matches that of the canister drive system 110 such that each seat 120 lines up a section of the sliding table. In some implementations, the sliding table 102 and canister drive system 110 move continuously. In other implementations, the sliding table 102 and canister drive system 110 move together for a portion of time, stop moving for a portion of time, and begin moving again for a portion of time (e.g., stopping to allow insertion of rolled product before continuing down the line).

[0053] Upon actuation, the canisters 152 move from a bulk area (not shown) towards the canister drive system 110. The canisters 152 move along the canister channel 156 and sliding table 102, which may be a separate conveyor or the same conveyor system as that used in canister channel 156. The canisters 152 move beneath the canister drive system 110 such that the protruding members 118 may surround and capture each canister 152. The canisters 152 are then disposed within a seat 120. In some implementations, the canister feeder 150 includes sections defining discrete seats along the cannister channel 156, which may separate each canister 152 by a preset distance corresponding to other distances in the system 100 (e.g., the seat 120 of the canister drive system 110). In some implementations, the wheels 114 of the canister drive system 110 are stopped during the canister infeed process. In some implementations, the canisters 152 are filled with rolls 132 with a continuous movement of each infeed line and the canister drive system 110.

[0054] In use, the rolls 132 move from a bulk area (not shown) along the rolled product feeder 130 towards the canister drive system 110. As rolls 132 are fed into the canister feeder 130, they are aligned with the channels 136. The movement of the rolls 132 is in a direction substantially perpendicular to the movement of the canisters 152, and in a direction that is substantially aligned with a longitudinal axis of the canisters 152 (e.g., such that the rolls 132 can be directed into an open end of the canisters 152). The movement of rolls 132 may be accomplished by a conveyor belt, a plurality of pushing arms, a sloped surface taking advantage of gravity, or any other common product movement technique.

[0055] As the rolls 132 move toward the second portion 140, an indexing portion 142 selectively slows or stops the movement of rolls 132. By controlling the movement of rolls 132, the indexing portion 142 may allow one or two rolls 132 at a time to enter the second portion 140.

[0056] Rolls 132 move along the rolled product feeder 130 until they reach the inserting device 170. Rolls 132 are moved into each of the canisters 152 via the insertion mechanism 174. In some implementations, a single roll 132 may be inserted at a time, or multiple rolls 132 may be inserted at once. In some implementations, both the rolls 132 and canisters 152 arrive at the seat 120 at the same time. In some implementations, the seat 120 allows the canister 152 to sit lower than the roll side of the inserting device 170 such that the rolls 132 will clear the lip of the canister 152 when being inserted.

[0057] Once a canister 152 is filled with a desired number of rolls 132, the canister drive system 110 actuates the wheels 114, and the flexible members 112 moves along with the protruding members 118 and the sliding table 102. Each filled canister 175 moves towards the second end 106 of the system 100. In some implementations, the canisters 152 are filled with rolls 132 with a continuous movement of each infeed line and the canister drive system 110.

[0058] Once the filled canister 175 is disposed within the capping seat 194, the cap movement arm 196 causes the cap 192 to couple with and close the filled canister 175. As shown in FIG. 1, the cap movement arm 196 is an arm that may engage with and push each cap 192 towards the open end of each filled canister 175, sealing the rolls 132 inside. Once capped, the filled and capped canisters 177 proceed down the sliding table 102 toward an outlet path 108 on the second end 106 of the system 100.

[0059] FIG. 2 shows a side view of the system 100. Although different embodiments are possible, FIG. 2 is substantially the same as FIG. 1. Therefore, like numbering represents like elements. Not all numbered elements will be numbered once again in FIG. 2, but those of interest in FIG. 2 may be numbered for ease of description. The same is true of all FIGS. 2-8, all of which depict different views of the same system 100. Most noticeable from the FIG. 2 view is the overall structure of the canister drive system 110.

[0060] As discussed herein, the canister drive system 110 is supported by side supports 122 fixably coupled to each wheel 114. The canister drive system 110 includes an array of protruding members 118 defining an array of seats 120. Each seat 120 is sized appropriately to fit a canister 152. Each protruding member 118 is fixably attached to cross members 116, which are fixably attached to a flexible member 112. Each protruding member 118 includes a first protrusion end 123 and a second protrusion end 125 separated and spaced apart from each other. The first protrusion end 123 includes the connection point to the cross members 116.

[0061] The first protrusion end 123 has a wider base, while the second protrusion end 125 is narrower. Each protruding member 118 is arranged in opposing pairs 124. Each opposing pair 124 moves as a single unit around the drive belt 111 with flexible members 112 and wheels 114. In this way, each protruding member 118 of the opposing pair 124 defines a side of the seat 120 to contain the canister 152.

[0062] In some implementations, the protruding members 118 may have a different shape than shown in FIG. 2. For example, each protruding member 118 may have a constant size from the first protrusion end 123 to the second protrusion end 125. In other implementations, the protruding members 118 may be a solid wall extending along the cross member 116. In other implementations, the protruding members 118 may not move in opposing pairs 124 but may move as units of single protruding members 118. In other implementations, the overhead system may include a number of protruding members 118 far less or far greater than that shown in FIG. 2, corresponding to a longer or shorter flexible member 112. In some implementations, one wheel 114 drives the drive belt 111 with flexible members 112 while the other wheel 114 rotates freely. In other implementations, both wheels 114 are driven. In some implementations, more than two wheels 114 may be present (e.g., a central support wheel disposed between the two existing wheels 114).

[0063] Also shown in FIG. 2 is the supporting table system 200. As shown, the supporting table system 200 includes several vertical wall supports disposed underneath each movement portion or conveyor of the system 100. In some implementations, the supporting table system 200 may include table legs disposed at specific points around the system 100. In some implementations, the table legs may include casters capable of rolling a portion of the system. For example, the capping infeed line 190 and cap feed path 191 may be rolled away, moved to a different location, or replaced with a different station.

[0064] FIG. 3 shows a top view of the system 100 which makes clear how the overall system 100 may function and where each element will enter the system. For example, the canister feeder 150, the sliding table 102, the rolled product feeder 130, the cap feed path 191, and the outlet path 108 with filled and capped canisters 177 are all shown in FIG. 3. In some implementations, each feed path may be moved to align with a different seat 120 of the canister drive system 110. In other implementations, additional feed paths may be included (e.g., a labeling station with label infeed line).

[0065] FIG. 4 shows a detailed view of the system 100 showing the rolled product feeder 130. As shown, the rolled product feeder 130 includes five dividers 134 defining four channels 136. Each channel 136 is configured to contain a plurality of rolls 132 as they move down the first movement portion 138 towards the sliding table 102. The rolls 132 reach the indexing portion 142 which may slow or stop the movement of the rolls 132. As shown in FIG. 4, the indexing portion 142 splits the rolls 132 into pairs of rolls 144 which move along the second movement portion 140 together. While one pair of rolls 144 is released from the indexing portion 142, the other pair of rolls (shown as 144′) is held back from being released along the second movement portion.

[0066] In some implementations, the rolled product feeder 130 includes more or less than four channels (e.g., one or two or four or eight or ten channels 136). In some implementations, the indexing portion 142 simply slows the movement of the rolls 132, while in other implementations it may stop the rolls 132 completely. In some implementations, the indexing portion 142 allows a different number of rolls 132 to move towards the sliding table 102 at a time (e.g., a single roll 132, or three or four or six rolls 132).

[0067] FIG. 5 shows a detailed view of the system 100 showing the cap feeder 190 and cap feed path 191. As shown, a lineup of caps 192 is disposed on the cap feed path 191 and moved along by a cap movement arm 196. Once a filled canister 175 (not shown) is seated within the capping seat 194 (not shown), the cap movement arm 196 causes the cap 192 to couple with and close the filled canister 175.

[0068] In some implementations, the cap movement arm 196 may include a plurality of arms, fingers, suction cups, rods, or any other movable member capable of moving the cap 192 from the cap feed path 191 onto the filled canister 175. In some implementations, the cap 192 is an adhesive cap capable of sticking to the filled canister 175. In some implementations, the cap movement arm 196 includes multiple movable members at multiple angles capable of sealing the filled canister with the adhesive cap. In some implementations, the cap 192 may include readable information printed or etched onto the cap 192. In some implementations, multiple cap feeders 190 with multiple cap feed paths 191 are included in the system 100 (e.g., one station for sealing and one for labeling).

[0069] FIG. 6 shows a detailed view of a portion of the system 100. Each canister 152 moves along canister channel 156 towards an opposing pair 124 of protruding member 118, defining a seat 120. As shown, canister 152′has just been captured by an opposing pair 124′. The timing of both the canister drive system 110 (with the drive belt 111, flexible member 112, and drive wheel 114), the canister feeder 150, and the sliding table 102 is such that each opposing pair 124 will capture a canister 152. In some implementations, movement is stopped between each capturing action to allow for operations further up the line to complete before starting up again. In other implementations, the movement is continuous.

[0070] FIG. 7 shows a detailed view of the inserting device 170 of the system 100. The inserting device 170 includes two insertion seats 172 (shown as insertion seats 172′ and 172″). In use, canisters 152 are disposed within seats 120 (corresponding to insertion seats 172′ and 172″ shown in FIG. 7) on the sliding table 102. Rolls 132 move along the rolled product feeder 130 until they reach the inserting device 170. Rolls 132 are moved into each of the canisters 152 via the insertion mechanism 174. As shown in FIG. 7, two rolls 132 are being inserted into two canisters 152.

[0071] In some implementations, a single roll 132 may be inserted at a time, or multiple rolls 132 may be inserted at once. In some implementations, both the rolls 132 and canisters 152 arrive at the seat 120 at the same time. In some implementations, the seat 120 allows the canister 152 to sit lower than the roll side of the inserting device 170 such that the rolls 132 will clear the lip of the canister 152 when being inserted. In some implementations, the rolled product feeder 130 is angled such that gravity does the work of sliding the rolls 132 into the canisters 152, eliminating the need for an active insertion mechanism 174.

[0072] Once a canister 152 is filled with a desired number of rolls 132, the canister drive system 110 actuates the wheels 114, and the drive belt 111 with flexible members 112 moves along with the protruding members 118 and the sliding table 102. Each filled canister 175 moves towards the second end 106 of the system 100, towards an outlet path 108.

[0073] FIG. 8 shows a detailed view of the cap feeder 190. FIG. 8 shows several filled canisters 175 disposed in seats 120. One canister (shown as 175′) sits in the capping seat 194. In the capping seat 194, the canister 175′ is placed to receive a cap 192 via the cap movement arm 196. Once capped, the filled and capped canisters 177 exit the overhead portion 110 on their way towards the outlet path 108 of the system 100.

[0074] A number of example implementations are provided herein. However, it is understood that various modifications can be made without departing from the spirit and scope of the disclosure herein. As used in the specification, and in the appended claims, the singular forms “a,”“an,”“the” include plural referents unless the context clearly dictates otherwise. The term “comprising” and variations thereof as used herein is used synonymously with the term “including” and variations thereof and are open, non-limiting terms. Although the terms “comprising” and “including” have been used herein to describe various implementations, the terms “consisting essentially of” and “consisting of” can be used in place of “comprising” and “including” to provide for more specific implementations and are also disclosed.

[0075] Disclosed are materials, systems, devices, methods, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed methods, systems, and devices. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutations of these components may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a device is disclosed and discussed each and every combination and permutation of the device are disclosed herein, and the modifications that are possible are specifically contemplated unless specifically indicated to the contrary. Likewise, any subset or combination of these is also specifically contemplated and disclosed. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods using the disclosed systems or devices. Thus, if there are a variety of additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific method steps or combination of method steps of the disclosed methods, and that each such combination or subset of combinations is specifically contemplated and should be considered disclosed.

Claims

1. A packaging apparatus for packing a rolled product, comprising:a canister drive system configured for moving a plurality of canisters in a first direction; anda rolled product feeder configured for loading one or more rolled products into the plurality of canisters by moving the one or more rolled products in a second direction substantially perpendicular to the first direction.

2. The packaging apparatus of claim 1, wherein the canister drive system comprises a rotating drive belt having a plurality of protruding members, wherein the protruding members extend outwardly from the rotating drive belt and are configured for engaging and advancing the plurality of containers in the first direction.

3. The packaging apparatus of claim 2, wherein the canister drive system includes a first drive wheel and a second drive wheel, wherein the first drive wheel is spaced apart from the second drive wheel and wherein the rotating drive belt is secured around and extends between the first drive wheel and the second drive wheel.

4. The packaging apparatus of claim 3, wherein the rolled product feeder is configured for loading the one or more rolled products in the plurality of canisters at a position between the first drive wheel and the second drive wheel.

5. The packaging apparatus of claim 1, further comprising a sliding table configured for supporting the plurality of canisters; andwherein the canister drive system is positioned above the sliding table and configured for advancing the plurality of canisters in the first direction across the sliding table.

6. The packaging apparatus of claim 1, wherein the rolled product feeder defines one or more rolled product feed paths and is configured for advancing the rolled products in the second direction along the one or more rolled product feed paths; andwherein the canister drive system is configured for aligning the plurality of canisters with the one or more rolled product feed paths to facilitate insertion of the rolled products into the plurality of canisters.

7. The packaging apparatus of claim 6, wherein the canister drive system is configured to align the plurality of canisters with the one or more rolled product feed paths such that an open end of each of the plurality of canisters faces the one or more rolled product feed paths.

8. The packaging apparatus of claim 1, further comprising a cap feeder configured for attaching at least one cap to an end of each of the plurality of canisters after each respective canister has been loaded with at least one rolled product by the rolled product feeder.

9. The packaging apparatus of claim 1, wherein the cap feeder is configured for moving the at least one cap in a second direction substantially perpendicular to the first direction.

10. The packaging apparatus of claim 9, wherein the cap feeder defines at least one cap feed path and is configured for advancing at least one cap in the second direction along the at least one cap feed path; andwherein the canister drive system is configured for aligning the plurality of canisters with the at least one cap feed path to facilitate attachment of the at least one cap to an end of each of the plurality of canisters.

11. The packaging apparatus of claim 1, further comprising a canister feeder configured for advancing the one or more canisters in the first direction.

12. The packaging apparatus of claim 1, wherein the canister feeder is configured for advancing the one or more canisters toward the canister drive system such that the one or more canisters are engaged by the canister drive system.

13. The packaging apparatus of claim 1, wherein the canister feeder is configured for advancing the one or more canisters away from the canister drive system after the one or more canisters have been filed with the one or more rolled products.

14. The packaging apparatus of claim 1, wherein the plurality of canisters are each constructed from a recyclable material.

15. The packaging apparatus of claim 1, wherein the plurality of canisters are each constructed from rigid cardstock.

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