Patent Application
20140245701
The present disclosure relates to methods and apparatuses for packaging absorbent articles, and more particularly, to methods and apparatuses for bundling packages of absorbent articles.
In some processes, fully assembled absorbent articles are packaged and stacked on a pallet for shipment and distribution to customers. Typically, the absorbent articles are packaged in primary packaging, such as polybags, which are then placed into secondary packaging, such as cardboard containers or poly overwrap. The manufacturer may provide printed indicia on either or both the primary packaging and the secondary packaging, depending on which is intended to be the product ultimately purchased by a consumer. For example, sometimes, a plurality of primary packages of absorbent articles may be bundled together in a secondary package and stacked on a pallet for shipment to a retailer. The secondary package may be a poly overwrap. Once the pallet reaches the retailer, the retailer may remove a secondary package from the stack, remove the primary packages from the secondary package, and place the individual polybags of absorbent articles on the shelf for consumers to purchase. Alternately, a secondary package may be removed from the pallet and placed directly on the shelf with the polybag overwrap, then a consumer purchases the secondary package, takes it home, and opens the polybag overwrap and disposes of it.
Some absorbent articles may have relatively low levels of pulp or no pulp at all. Such absorbent articles may be relatively thin compared to an absorbent article containing higher levels of pulp. However, packages of absorbent articles having little to no pulp may have a low resistance to deformation. As a result, when packages of such absorbent articles are stacked on a pallet, the packages near the top of the stack apply pressure to the packages near the bottom of the stack, causing the absorbent articles positioned near the bottom of the pallet to deform. If the absorbent articles deform, the stacks of packages may to lean and possibly fall off of the pallet during shipment and/or storage of the pallets.
Sometimes, in order to prevent the packages of absorbent articles from leaning and falling off of the pallet, the packages may be packaged into cardboard boxes. In other instances, cardboard separators may be placed between adjacent packages to provide additional support to the lower packages in the stack. In some instances, the stacks of packages may be wrapped with a thin thermoplastic film to hold the packages of absorbent articles on the pallet. However, the additional cardboard boxes, cardboard separators, and thermoplastic film may add cost and complexity to the packaging process.
Thus, it would be beneficial to provide a method and apparatus for packaging absorbent articles having relatively low levels of pulp or no pulp at all such that the absorbent articles are capable of resisting deformation. Also, it would be beneficial to provide a method for stacking bundles of absorbent articles on a pallet for stable shipment of the bundles.
Aspects of the present disclosure include a method of bundling primary packages of absorbent articles into secondary packages, the method comprising the steps of: advancing a first continuous length of film in a machine direction to a first metering device at a speed, V1; advancing the first continuous length of film in the machine direction to a first moving surface at a speed, V2, wherein the V2 is greater than V1, wherein the first continuous length of film stretches between the first metering device and the first moving surface; advancing a second continuous length of film in the machine direction to a second metering device at speed, V1; advancing the second continuous length of film in the machine direction to a second moving surface at speed, V2, wherein the second continuous length of film stretches between the second metering device and the second moving surface; advancing at least two primary packages of absorbent articles in the machine direction between the first continuous length of film and the second continuous length of film, wherein the first continuous length of film is positioned between the primary packages of absorbent articles and the first moving surface, wherein the second continuous length of film is positioned between the primary packages of absorbent articles and the second moving surface, wherein the primary packages are compressed in a first direction, wherein the first direction is orthogonal to the machine direction; and bonding the first and second continuous lengths of film together to form a bonded region while maintaining the first and second continuous lengths of film in the stretched state, wherein the first and second continuous lengths of film form a secondary package surrounding the primary packages of absorbent articles.
Aspects of the present disclosure include a method of bundling primary packages of absorbent articles into secondary packages, the method comprising the steps of: advancing a first film in a stretched state in a machine direction; advancing a second film in a stretched state in the machine direction; advancing at least two primary packages of absorbent articles in the machine direction; compressing the primary packages in a first direction, wherein the first direction is orthogonal to the machine direction; advancing the primary packages in a second direction, wherein the second direction is opposite the machine direction; and bonding the first and second films to form a bonded region while maintaining the first and second films in the stretched state, wherein the first and second films compress the primary packages of absorbent articles in the machine direction, wherein the first and second films form a secondary package surrounding the primary packages of absorbent articles.
Aspects of the present disclosure include a method of stacking secondary packages of absorbent articles, the method comprising the steps of: advancing first and second primary packages of absorbent articles in a machine direction; compressing the first and second primary packages in a first direction with a force, F1, wherein the first direction is orthogonal to the machine direction; bundling the first and second primary packages into a first secondary package in the compressed state; advancing third and fourth primary packages of absorbent articles in the machine direction; compressing the third and fourth primary packages in the first direction with the force, F1; bundling the third and fourth primary packages into a second secondary package in the compressed state; and stacking the second secondary package on the first secondary package, wherein the second secondary package applies a force, F2 to the first secondary package in the second direction, wherein F2 is less than or equal to F1.
The following definitions may be useful in understanding the present disclosure.
“Absorbent article” is used herein to refer to consumer products whose primary function is to absorb and retain soils and wastes. Absorbent articles may include disposable diapers, pads, and the like. “Diaper” is used herein to refer to an absorbent article generally worn by infants and incontinent persons about the lower torso of the wearer.
“Machine direction” (MD) refers herein to the direction of material flow through a process. In addition, relative placement and movement of material can be described as flowing in the machine direction through a process from upstream in the process to downstream in the process.
“Cross direction” (CD) refers herein to a direction that is not parallel with, and usually perpendicular to, the machine direction.
“Film” refers to a sheet-like material wherein the length and width of the material far exceed the thickness of the material. Typically, films have a thickness of about 0.5 mm or less.
In the context of the present description, an elongation of 0% refers to a material in relaxed state having a relaxed length of L, and elongation of 150% represents 2.5× the relaxed length, L, of the material. For example, a film having a relaxed length of 100 millimeters would have a length of 250 millimeters at 150% elongation. And a film having a relaxed length of 100 millimeters would have a length of 180 millimeters at 80% elongation.
The present disclosures relates to methods and apparatuses for packaging absorbent articles, and more particularly, to methods and apparatuses for preparing packages of absorbent articles for shipment. The methods and apparatuses of the present disclosure include packaging primary packages of absorbent articles in secondary packages and subsequently stacking the secondary packages of absorbent articles on a pallet for shipment. The absorbent articles may be packaged in primary packaging, such as polybags, which are then placed into secondary packaging, such as a film overwrap.
While the present disclosure discusses packaging absorbent articles, it is to be appreciated that the methods and apparatuses of the present disclosure may be used to package various other consumer products, such as paper towel, toilet paper, cleaning products, cosmetics, pharmaceutical products, and the like.
In an exemplary configuration, first and second films may advance in a machine direction in a stretched state to a bundling apparatus. Primary packages of absorbent articles may advance in the machine direction to the bundling apparatus and may be compressed in a first direction. The first direction is orthogonal to the machine direction. Next, the primary packages may advance in a second direction, wherein the second direction is opposite the machine direction. The first and second films may be bonded together to form a bonded region while maintaining the first and second films in the stretched state. The first and second films compress the primary packages of absorbent articles in the machine direction. The first and second films form a secondary package surrounding the primary packages of absorbent articles. The bonded region may be cut to form a first bond on a first secondary package and a second bond on a subsequently advancing second secondary package.
An exemplary bundling apparatus may comprise a first carrier apparatus and a second carrier apparatus. The first carrier apparatus may comprise a first moving surface and the second carrier apparatus may comprise a second moving surface. The first moving surface may be in a face-to-face relationship with the second moving surface. The first moving surface may be located a minimum distance from the second moving surface. In addition, the bundling apparatus may comprise a first metering device and a second metering device. In operation, the first film may advance from the first metering device to the first moving surface of the first carrier apparatus. Likewise, the second film may advance from the second metering device to the second moving surface of the second carrier apparatus. The first film may be stretched between the first metering device and the first moving surface and the second film may be stretched between the second metering device and the second moving surface. The primary packages of absorbent articles may advance between the first and second films. The primary packages may advance to the bundling apparatus in an uncompressed state. The height of the uncompressed primary packages may be less than the minimum distance between the first moving surface and the second moving surface such that the first and second carrier apparatuses compress the primary packages in the first direction.
The bundling apparatus may comprise a welding apparatus. The welding apparatus may comprise a first welding member and a second welding member. The welding apparatus may be configured to bond the first and second films together to form bonded regions. Moreover, the welding apparatus may be configured to cut the bonded region to form a first bond on a first secondary package and a second bond on a second secondary package.
In an exemplary configuration, a plurality of secondary packages may be stacked on a pallet for shipment. First and second primary packages of absorbent articles may advance in a machine direction to a bundling apparatus. The first and second primary packages may be compressed in a first direction with a force, F1, and bundled into a first secondary package in the compressed state. Next, third and fourth primary packages of absorbent articles may advance in the machine direction to the bundling apparatus. The third and fourth primary packages may be compressed in the first direction with the force, F1, and bundled into a second secondary package in the compressed state. The first secondary package may be placed on a pallet. Subsequently, the second secondary package may be stacked on the first secondary package. The second secondary package may apply a force, F2, to the first secondary package in the first direction, wherein F2 is less than or equal to F1. As a result, the absorbent articles in the first secondary package are able to withstand the force applied by the second secondary package of absorbent articles. Additionally, the first and second secondary packages may apply a force, F3, to the first and second and third and fourth primary packages, respectively, in the machine direction. The force, F3, applied by the secondary packages to the primary packages assists in uniformly distributing the force, F2, that is applied to the first secondary package.
Referring to
It is to be appreciated that various other apparatuses may be used for the metering devices. For example, the metering devices may include rollers, drums, conveyors, and combinations thereof. The metering devices may include one roller, drum, or conveyor. In some exemplary configurations, the first and second metering devices may include more than one roller, drum, conveyor, or combinations thereof.
As shown in
As shown in
As shown in
Next, with continuing reference to
In the bonding process, the first and second welding members 174 and 176 move in the first cross direction CD1 and the second cross direction CD2 toward each other and toward the first and second continuous lengths of film 206 and 208. Concurrently, the primary packages 200 advance in a second direction, shown in
As shown in
The first continuous length of film 206 may be stretched to various elongations between the first metering device and the first moving surface of the first carrier apparatus. Additionally, the second continuous length of film 208 may be stretched to various elongations between the second metering device and the second moving surface of the second carrier apparatus. For example, the first and second continuous lengths of film may be stretched to an elongation of greater than about 110%, greater than about 120%, greater than about 130%, greater than about 140%, greater than about 150%, or greater than about 200%. The first continuous length of film may be stretched to a first elongation and the second continuous length of film may be stretched to a second elongation. The first elongation and the second elongation may be the same. Or, in some exemplary configurations, the first and second elongations may be different. It is to be appreciated that the greater the elongation, the greater the compressive force, F3, that is applied to the primary packages in the machine direction MD. In some exemplary configurations, the compressive force, F3, may be greater than about 5 Newtons, greater than about 10 Newtons, greater than about 15 Newtons, greater than about 20 Newtons, greater than about 25 Newtons, greater than about 30 Newtons, greater than about 35 Newtons, or greater than about 40 Newtons.
Various compressive forces may be applied to the primary packages 200 of absorbent articles 204. In some exemplary configurations, the compressive force, F1, may be greater than about 5 Newtons, greater than about 10 Newtons, greater than about 15 Newtons, greater than about 20 Newtons, greater than about 25 Newtons, greater than about 30 Newtons, greater than about 35 Newtons, or greater than about 40 Newtons. It is to be appreciated that the smaller the minimum distance, D, between the first moving surface 124 and the second moving surface 32, the greater the compressive force, F1, applied to the primary packages 200 in direction, A.
As shown in
It is to be appreciated that various welding processes and apparatuses may be used to form the bonded regions in the first and second films. Exemplary welding processes include hot gas welding, contact or impulse welding, high frequency welding, or ultrasound welding.
Various films may be used for the first and second continuous lengths of film. For example, the film may be made of polyethylene, polypropylene, and the like. Exemplary polyethylene films are manufactured by Mondi Halle GmbH of Germany and Elif Plastik of Istanbul, Turkey.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
