Mechanisms for transferring items

A transfer mechanism for transferring items between one or more input streams and one or more output streams is disclosed. The transfer mechanism comprises a turret, an arm extending from the turret, and a carrier mechanism engaged with the arm. The carrier mechanism comprises a base and a plurality of rods extending from the base. At least one of the rods is movable relative to at least one other rod. The rods are configured to engage void areas in the items.

FIELD

The present disclosure generally relates to mechanisms for transferring items, and more particularly, relates to mechanisms for transferring items between one or more input streams and one or more output streams.

BACKGROUND

During manufacturing processes, it is often necessary to group, orient, arrange, and/or sort items for packaging or for other downstream operations. Such operations can be cumbersome if the items do not have flat sides, do not fit together in an orderly fashion, and/or if the items are hard to control (e.g., the products do not remain stationary on a flat conveyor), for example. Currently technologies use guide rails, stacking apparatuses, grouping apparatuses, and/or layering devices, for example, to handle the items. These technologies usually engage outer surfaces of the items during handling. Such current technologies have drawbacks, such as complexity. Further, current technologies usually do not provide great process flexibility and may be a limiting factor in production rates. In some instances, manufacturing equipment can be designed to be quite complex and perform a great number of functions or can be designed to be simpler and only perform limited number of functions. It would be beneficial to provide methods and mechanisms for transferring items that improve the state of the art, do not damage the outer surface of the items, do not limit the production rate of a manufacturing line, and provide for great flexibility in a manufacturing process.

SUMMARY

In one embodiment, the present disclosure is directed, in part, to a transfer mechanism for transferring items between one or more input streams and one or more output streams. The transfer mechanism comprises a turret, an arm extending from the turret, and a carrier mechanism engaged with the arm. The carrier mechanism comprises a base and a plurality of rods extending from the base. At least one of the rods is movable relative to at least one other rod.

In another embodiment, the present disclosure is directed, in part, to a transfer mechanism for transferring items between one or more input conveyors and one or more output conveyors. The transfer mechanism comprises a turret having a longitudinal axis and a carrier mechanism rotatable about the longitudinal axis of the turret. The carrier mechanism comprises a base and a plurality of rods extending from the base. The base is operably engaged with an actuator configured to move the carrier mechanism relative to the turret in a direction generally perpendicular to the longitudinal axis.

In still another embodiment, the present disclosure is directed, in part, to a transfer mechanism for transferring packaged items between one or more input streams and one or more output streams. The transfer mechanism comprises a turret and a carrier mechanism rotatable about the turret. The carrier mechanism comprises a base, a first support extending outwardly from the base, and a second support extending outwardly from the base. The first support and the second support are configured to engage the packaged items therebetween.

DETAILED DESCRIPTION

Various non-limiting embodiments of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, manufacture, and use of the methods and mechanisms for transferring items disclosed herein. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that the methods and mechanisms for transferring items described herein and illustrated in the accompanying drawings are non-limiting example embodiments and that the scope of the various non-limiting embodiments of the present disclosure are defined solely by the claims. The features illustrated or described in connection with one non-limiting embodiment can be combined with the features of other non-limiting embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure.

“Fiber” as used herein means an elongate physical structure having an apparent length greatly exceeding its apparent diameter (i.e. a length to diameter ratio of at least about 10.) Fibers having a non-circular cross-section and/or tubular shape are common; the “diameter” in this case can be considered to be the diameter of a circle having cross-sectional area equal to the cross-sectional area of the fiber. More specifically, as used herein, “fiber” refers to fibrous structure-making fibers. The present disclosure contemplates the use of a variety of fibrous structure-making fibers, such as, for example, natural fibers or synthetic fibers, or any other suitable fibers, and any combination thereof.

“Fibrous structure” as used herein means a structure that comprises one or more fibers. Nonlimiting examples of processes for making fibrous structures include known wet-laid papermaking processes and air-laid papermaking processes. Such processes typically comprise the steps of preparing a fiber composition in the form of a suspension in a medium, either wet, more specifically aqueous medium, or dry, more specifically gaseous, i.e. with air as medium. The aqueous medium used for wet-laid processes is oftentimes referred to as a fiber slurry. The fibrous suspension is then used to deposit a plurality of fibers onto a forming wire or belt such that an embryonic fibrous structure is formed, after which drying and/or bonding the fibers together results in a fibrous structure. Further processing the fibrous structure can be carried out such that a finished fibrous structure is formed. For example, in typical papermaking processes, the finished fibrous structure is the fibrous structure that is wound on the reel at the end of papermaking and can subsequently be converted into a finished product (e.g. a sanitary tissue product).

“Sanitary tissue product” as used herein means one or more finished fibrous structures, converted or not, that is useful as a wiping implement for post-urinary and post-bowel movement cleaning (e.g., toilet tissue and wet wipes), for otorhinolaryngological discharges (e.g., facial tissue), and multi-functional absorbent and cleaning uses (e.g., paper towels). The sanitary tissue products can be embossed or not embossed and creped or uncreped.

In various embodiments, transfer mechanisms that can transfer one or more items from one or more input streams or conveyors (together referred to herein as “streams”) to one or more output streams are provided by the present disclosure. Methods of transferring one or more items between one or more input streams and one or more output streams are also provided. The transfer mechanisms can each comprise a turret (or other rotating member), optionally one or more arms, and one or more carrier mechanisms. The one or more arms can extend from the turret and the one or more carrier mechanisms can extend from the arms. In one embodiment, the arms can be eliminated and the carrier mechanisms can be engaged with and/or extend from the turret. The turret can rotate to move the arms and the carrier mechanism or the arms and the carrier mechanism can rotate about the turret. In other various embodiments, a robot, for example, can be used in place of the turret to move and/or rotate the one or more carrier mechanisms.

In various embodiments, the transfer mechanisms of the present disclosure can be configured to transfer a plurality of items between one or more input streams and one or more output streams. Such items can include, but are not limited to, sanitary tissue products, rolls of sanitary tissue products, packaged sanitary tissue products—whether packaged in paperboard containers or films, rolls of wet wipes or cleaning wipes, bottles, containers, diapers, and sanitary napkins, for example.

In one embodiment, referring toFIG. 1, an example transfer mechanism10is illustrated. The transfer mechanism10is configured to receive one or more input streams12of items14and transfer the items14to one or more output streams16of the items14. The transfer mechanism10, or portions thereof, such as a carrier mechanism, for example, can manipulate, rotate, and/or move any suitable distance or rotational degree (e.g., an output stream can be positioned 160 degrees from an input stream) such that the items14can be transferred from the input stream12to the output stream16. This can allow for better process flow or manufacturing facility floor space management. In various embodiments, the configuration or arrangement of the items14in each input stream12can be different than the configuration or arrangement of the items14in each output stream16. For example, each input stream12can have 1 item three rows deep while an output stream16can have three columns of items14, 2 rows deep, and 3 rows wide.

In one embodiment, still referring toFIG. 1, the transfer mechanism10can comprise a turret18. The turret18can be fixed in a non-rotatable or non-moveable position or can be moveable and/or rotatable through the use of actuators. Any other suitable mechanism for moving and/or rotating one or more carrier mechanisms or having the same rotate about it can be used in place of the turret18. The turret18can have a longitudinal axis20. One or more arms22can extend from the turret18and/or can be attached to the turret18. Each of the arms22can be fixedly or rigidly attached to the turret18. In such an embodiment, the turret18can rotate about its longitudinal axis20through the use of one or more actuators to manipulate or rotate the arms22. In other various embodiments, the arms22can be rotatably attached to the turret18and can rotate about the longitudinal axis20and relative to the fixed turret18. In such an embodiment, the arms22can be operably engaged with one or more actuators (not illustrated) configured to rotate the arms22about the turret18. The actuator can be a motor operably coupled to a drive chain or belt or a rack and pinion system. The arms22, whether rotated by the turret18or rotated about the turret18, can make a full revolution (i.e., 360 degree movement) about the turret18. In other embodiments, the arms22may only make a partial revolution about the turret18(e.g., 180 degrees). In one embodiment, the arms22can rotate in the clockwise direction and/or in the counter-clockwise direction about the longitudinal axis20of the turret18. Although two arms22are illustrated inFIG. 1, one arm22can be provided or more than two arms22can be provided on a single turret18. In other various embodiments, the arms22can be positioned around, or around at least a portion of, the circumference or perimeter of the turret18. In various embodiments, if two or more of the arms22are provided on the turret18, the arms22can be positioned on the turret18at different heights on the turret18so as to allow the arms22to rotate about the turret18independent of the position of another arm22. In other various embodiments, if two or more of the arms22are provided on the turret18, the arms22can be positioned at the same height on the turret18. Each of the arms22can be formed with a carrier mechanism24or can be engaged with the carrier mechanism24. In an embodiment comprising two of the arms22(each engaged with a carrier mechanism24) at different heights on the turret18, the transfer mechanism can transfer items14from a first input stream12at a first height on the turret18and discharge the items14onto an output stream16at the first height using the first arm22and the first carrier mechanism24and can transfer items14from a second input stream12at a second height on the turret18and discharge the items14onto an output stream16at the second height using the second arm22and the second carrier mechanism24.

In one embodiment, still referring toFIG. 1, the carrier mechanism24can be engaged with or formed with the one or more arms22or attached directly to the turret18. The carrier mechanism24can comprise a base26and a plurality of rods28extending from the base26and/or operably engaged with the base26through the use of one or more actuators. Additional details regarding the rods28are discussed below. In other embodiments, the rods28may not be provided and the base26can comprise a plurality of item receiving areas or spaces and/or item receiving shelves. The item receiving areas or spaces and/or the item receiving shelves can be adjustable in size or spacing such that they can be configured to receive items14having different dimensions. For example, a first shelf may be movable relative to a second shelf to receive an item14having larger or smaller dimensions. In one embodiment, the shelves can be configured to receive items that are bottles, containers, and/or sanitary tissue products. In such an embodiment, once the shelves receive the bottles, containers, and/or sanitary tissue products, at least one shelf can move relative to another shelf to apply a force to the bottles, containers, and/or sanitary tissue products to aid in retaining the bottles, containers, and/or sanitary tissue products on the carrier mechanism24during rotation, manipulation, or movement of the carrier mechanism24(e.g., movement between one or more input streams and one or more output streams). The bottles, containers, and/or sanitary tissue products can be removed from the shelves and discharged onto an output stream using a pusher apparatus, such as a linear actuator, for example. The pusher apparatus can engage the bottles, containers, and/or sanitary tissue products and essentially push or force them onto the output stream. Other mechanisms or areas can also be provided on the base26for receiving other items. In one embodiment, the receiving areas or spaces and/or the item receiving shelves can each comprise a backstop or wall to prevent the bottles, containers, and/or sanitary tissue products from moving to deeply with the receiving areas or spaces and/or the item receiving shelves.

In one embodiment, referring toFIGS. 2 and 3, a guide30can be positioned around, or at least partially around, the transfer mechanism10. In various embodiments, the guide30can be used for safety or containment so that the items14do not slide out of or off of the carrier mechanism24during movement, manipulation, or rotation of the carrier mechanism24. The guide30can define openings32therein that align with one or more input streams12and one or more output streams16. An opening32can be defined in the guide30for each input stream12coming into the transfer mechanism10and for each output stream16exiting the transfer mechanism10. In one embodiment, the openings32can be blocked with covers (not illustrated) if only one input stream and one output stream is desired for a particular manufacturing process.

In one embodiment, referring toFIG. 2, the arm22can be fixedly attached to the turret18and the turret18can be rotatable about its longitudinal axis20. In such an embodiment, the turret18can rotate in the clockwise and counter-clockwise direction, as indicated by arrow A and the dashed lines, when loading items onto the rods28. Although the rods28are illustrated in various figures, those of skill in the art will understand that the item receiving areas, spaces, and shelves can be used in place of or in addition to the rods28. The rotation or manipulation of the turret18can occur during loading even if the rods28are not provided on a carrier mechanism24. In one example, if the rods are in a 6 wide×1 high pattern and the input streams12each have a single layer of items14entering the carrier mechanism24, and there are four input streams12, the turret18, and thereby the arms22and the carrier mechanism24, can rotate in the clockwise and counter-clockwise direction to fill all of the rods28with items14. The turret18can also move vertically when receiving the items14to load additional rows of the items14onto the carrier mechanism24. As another example, if the rods28are in a 6 wide×3 high pattern and the input streams12each have a single layer of items14moving towards the carrier mechanism24at a time, and there are four input streams12, to obtain additional rows of the items14on the carrier mechanism24, the turret18, the carrier mechanism24, and/or the arms22can move upward and/or downward in a vertical direction in addition to rotation about the longitudinal axis20. Also, at least some of the rods28can move relative to each other before, during, or after the item loading process and/or an item unloading process. In one embodiment, the input streams12can move upwardly and/or downwardly to load additional rows of the items14onto the carrier mechanism24if the turret18is fixed vertically or if the turret18is movable vertically. In such an embodiment, the carrier mechanism24, the arms22, and/or the turret18can be fixed vertically or can remain vertically stationary.

In one embodiment, one or more robots (not illustrated) can be used in place of the turret18. The robots can each have one or more of the arms22attached to them and the arms22can each be attached to a carrier mechanism24. Alternatively, the robot can be directly attached to one or of the more carrier mechanisms24. The robots can have the ability to position the arms22and/or the carrier mechanisms24relative to one or more input streams12, pick up items14on the rods28, and move the arms22and/or the carrier mechanisms24into alignment with one or more output streams16so that the items14can be discharged.

In other various embodiments, referring toFIG. 3, a portion of or all of the carrier mechanism24can move relative to the arm22and/or relative to the turret18. In one embodiment, the base26can move relative to the arm22. In such embodiments, the turret18can be rotatable or fixed. In one embodiment, the carrier mechanism24can move in a direction perpendicular to the longitudinal axis20of the turret18. The carrier mechanism24can be movable in an essentially reciprocating fashion, in the directions indicated by arrow B, and as indicated by the dashed lines inFIG. 3. Although the carrier mechanism24can move relative to the turret18to accept items14, the turret18can also rotate to provide additional maneuverability of the transfer mechanism10. In one example, if the rods28are in a 6 wide×1 high pattern and the input streams12each have one single layer of items14moving toward the carrier mechanism24, and there are four input streams12, the carrier mechanism24can move in the directions indicated by arrow B, and as indicated by the dashed lines inFIG. 3, such that all of the rods28can be filled. In various embodiments, if the rods28are in a 6 wide×2 high pattern, after filling a first row of items, the turret18and/or the carrier mechanism24can move vertically such that additional rows of items14can be loaded onto the rods28. In other various embodiments, the carrier mechanism24can move relative to the arm22and/or the turret18to adjust the vertical height of the rods28. In still other various embodiments, the rods28can move relative to the base26and/or relative to each other during the item loading process.

In one embodiment, referring toFIGS. 1-4B, for example, one or a plurality of the rods28can extend outwardly from the base26in a direction away from the longitudinal axis20of the turret18. In various embodiments, at least one of the rods28can be movable relative to at least one other rod28to adjust the spacing between the rods28and/or to compress, or slightly compress, items14, such as rolls of sanitary tissue products, for example, between the rods28during manipulation of the carrier mechanism24. In one embodiment, all of the rods28can be movable relative to at least one other rod28. The rods28can be moveable manually or through the use of actuators. The rods28can be formed of a rigid material, such as a metal, for example, and, in one embodiment, can be coated or covered with a resilient material, such as a rubber, for example. The resilient material can help the rods28in gripping items14and/or can protect the items14from crushing during gripping. In another embodiment, the rods28can be at least partially formed of or coated with a low coefficient of friction material to aid the rods28in engaging void areas within the cores of sanitary tissue products, for example. In one embodiment, the rods28can be positioned around, or at least partially around, a circumference or perimeter of the turret18.

In various embodiments, referring toFIGS. 4A and 4B, an example carrier mechanism24can comprise a base26and a plurality of rods28extending from the base26. Although four rods28are illustrated as an example, any suitable number of rods28can extend from the base26. Some example configurations of the rods28are a carrier mechanism24having a 4 rod wide×2 rod high configuration, a 4 rod wide×4 rod high configuration, a 4 rod wide×6 rod high configuration, a 6 rod wide×2 rod high configuration, a 6 rod wide by 3 rod high configuration, or a 6 rod wide by six rod high configuration. In one embodiment, the base26can comprise one or more plates34with slots36defined therein. A portion of the rods28can extend through the slots36. In various embodiments, the base26can comprise a first set of plates34and a second set of plates34′. The two plates of the first set of plates34can move toward and away from each other in unison using a scissor-like linkage operably engaged with an actuator, for example. Similarly, the two plates of the second set of plates34′ can move toward and away from each other in unison using a scissor-like linkage operably engaged with an actuator, for example. The movement of the sets of the plates34and34′ can allow the rods28to be moved toward and away from each other in more than one direction.FIG. 4Aillustrates the rods28in a first position, whileFIG. 4Billustrates the rods28moved into a second position. In one embodiment, at least one rod28or all of the rods28can have a pointed end portion, an arcuate end portion, and/or a conical portion38. Such a feature can aid the rods28in engaging void areas within the items14, such as void areas within the cores of rolled sanitary tissue products, for example, by essentially being self-centering during engagement. Each rod28can comprise a backstop that prevents items14from being positioned to deeply on the rods28. Further, each rod28can be any suitable length depending on how many of the items14will be loaded thereon. In such an embodiment, the backstop may be adjustable about the rods28depending on how many items14will be loaded onto the rods28. In various embodiments, one or more of the rods28and/or one or more of the carrier mechanism24can be configured to tilt for additional flexibility. In one embodiment, this tilting capability can be used to load additional rows of items14, for example.

Most conventional sanitary tissue product handling mechanisms do not manipulate the sanitary tissue products by void areas within the cores, but instead use outer surfaces or portions of the sanitary tissue products. By handling the sanitary tissue products, by void areas within the cores (and engaging inner surfaces of the cores with the rods28), instead of by outer surfaces or portions thereof, the outer surfaces or portions of the sanitary tissue products can be maintained in an undamaged state, which is desirable when the sanitary tissue products are on a shelf in a store.

One example of an item loading sequence is discussed below with reference toFIG. 5A. In this example, four input streams12, each three items14deep, are fed into the carrier mechanism24. This is an example of one group of items14being fed into the carrier mechanism24. In practice, multiple groups of items14will be sequentially fed into the carrier mechanism24on a continuous or a non-continuous basis. The carrier mechanism24, in this instance, comprises six rods28wide, by three rods28high (rods28are only illustrated in the first portion of the figure). The carrier mechanism24could also comprise six receiving spaces or shelves wide by three receiving spaces or shelves high. The rods28, receiving spaces, or receiving shelves are represented inFIGS. 5A-6Bby squares. The rods28can extend from the center of the squares, for example. The length of any of the rods28discussed herein can be suitable for accepting the desired number of the items14, such as rolled sanitary tissue products. First, a first item14from each of the four input streams12is loaded onto the four bottom and left-most rods28. This leaves four input streams12that are two items14deep. Next, the carrier mechanism24is shifted to the right relative to the position of the fixed input streams12. In other embodiments, the input streams12could be moved to the right with the carrier mechanism24being fixed. In still other embodiments, the plurality of rods28could be shifted to the right with the input streams12and the base26being fixed. The two right-most input streams12of the items14are then loaded onto the two remaining empty rods28in the bottom-most row of the rods28. This leaves four input streams12, with two input streams12being one item14deep and the other two input streams12being two items deep. Then, the carrier mechanism24is shifted downwardly with respect to the input streams12so that the four input streams12can feed four items14onto the right-most four rods28in the second row of rods28. This leaves two input streams12, each stream being one item14deep. Next, the carrier mechanism24is shifted to the left. The items14in the two remaining input streams12are then loaded onto the remaining two left-most empty rods28in the second row of rods28. Thereby, the carrier mechanism24is loaded with a two high, by six wide, by one item deep set of items14. Of course, this process can be repeated to load a grouping of items14that is two or more items deep.

In one embodiment, referring toFIG. 5B, once the carrier mechanism24has been manipulated or rotated from a position aligned, or substantially aligned, with the one or more input streams12into a position aligned, or substantially aligned, with the one or more output streams16, the items14can be unloaded from the carrier mechanism24. In one embodiment, a pusher apparatus (see e.g.,FIGS. 14A-14C,16A, and16B and their description below), and/or other mechanisms, can be used to unload the items14. The items14can be unloaded onto the one or more output streams16in two high by three wide item groupings. In various embodiments, the first grouping of items14can be unloaded onto a first output stream and a second grouping of items14can be unloaded onto a second output stream. In other embodiments, the first grouping of items14can be unloaded onto the same output stream as the second grouping of items14either at the same time or at different time intervals. It is important to note that all of the rods28or receiving spaces or shelves on each carrier mechanism do not always need to be used. Some can be left empty.

The carrier mechanism24can also be useful for layering items14, such as sanitary tissue products, for example. The carrier mechanism24can receive four input streams12of items14, then move vertically to accept four additional input streams12of items14, and then move into a positioned aligned with, or substantially aligned with, one or more output streams16. The carrier mechanism24can then output items14two or more layers high using a pusher apparatus or other device.

Another example of an item loading processes is discussed below with reference toFIGS. 6A-6B. In this example, three input streams12, each five items14deep, are fed into the carrier mechanism24. The carrier mechanism24, in this instance, comprises six rods28wide by three rods28high (rods28are only shown in the first portion of the figure). The carrier mechanism24could also comprise six receiving spaces or shelves wide by three receiving spaces or shelves high. First, a first item14from each of the three input streams12is loaded onto three rods28in the bottom row of rods28. This leaves three input streams12that are four items14deep. Next, the carrier mechanism24is shifted to the right relative to the fixed position of the input streams12. The input streams12could also be moved to the right with the carrier mechanism24being fixed, as discussed above. The two right-most input streams12of items14are then loaded onto the two right-most empty rods28in the bottom-most row of rods28. This leaves three input streams12, with two input streams12being three items14deep and the other input stream12being four items deep. Then, the carrier mechanism24is shifted downwardly with respect to the input streams12so that the three input streams12can feed three items14onto the right-most three rods28in the second row of rods28. This leaves three input streams12, two input streams12being two items14deep and the other input stream12being three items14deep. Next, the carrier mechanism24is shifted to the left and two items14are fed onto two rods28in the second row. This leaves three input streams12, the end two input streams12being two items14deep and the middle input stream12being one item14deep. The carrier mechanism24is then shifted downwardly and three items14are fed onto three rods28in the top row of rods28. This leaves a first input stream12that is a single item deep and a second input stream12that is a single item deep (the items14in the middle input stream12are now all loaded). The carrier mechanism24is then shifted to the left so that the single item14in the left input stream12is fed onto a rod28in the top row of rods28. This leaves the right-most input stream12with one item14deep. The carrier mechanism24is then shifted to the right so that the remaining item14can be positioned on the right-most rod28in the top row of rods28. Thereby, the carrier mechanism24is loaded a single item14deep, three items14high, and five items14wide. Of course, this process can be repeated to load a grouping of items14more than one item deep. Instead of the carrier mechanism24moving during loading, the input streams12can move relative to the carrier mechanism24.

In one embodiment, referring toFIG. 6B, when the carrier mechanism24has been manipulated or rotated from a position aligned, or substantially aligned, with the input streams12into a position aligned, or substantially aligned, with one or more output streams16, the carrier mechanism24can be unloaded. In one embodiment, a pusher apparatus (see e.g.,FIGS. 14A-14C,16A, and16B and their description below) and/or other mechanisms, can be used to unload the items14. The items14can be unloaded onto an output stream16by rows of rods28to output a grouping of items14that is one row deep, one row high, and five rows wide. Therefore, in this example, three groupings of items14can be unloaded. In various embodiments, the first grouping of items14can be unloaded onto a first output stream16, a second grouping of items14can be loaded onto a second output stream16, and a third grouping of items14can be unloaded onto a third output stream16. In other embodiments, the first grouping of items14, the second grouping of items14, and the third grouping of items14can all be unloaded or discharged onto the same output stream16at different time intervals and/or sequentially.

In various embodiments, each of the rods28can move toward and away from at least one other rod28to slightly compress the items14on the rods28at least during manipulation or rotation of the transfer mechanism28. This can maintain the items14on the rods28despite forces of acceleration created during rotation or manipulation of the transfer mechanism10. Stated another way, the compression of the items14by the rods28can inhibit the items14from sliding off of the rods28during rotation of the arms22or turret18. The rods28can move toward one another after the loading process and can then move away from each other when the carrier mechanism24is aligned with, or substantially aligned with, an output stream16. In various embodiments, movements of the rods28can be individually controlled to provide the ability to slightly compress certain items14without compressing others or to adjust for the dimensions (e.g., diameters) of the items14to be loaded.

The above are merely examples of loading and unloaded items14from carrier mechanisms24. Of course, a multitude of configurations and processes are possible and are within the scope of the present disclosure. In one embodiment, an input stream12can have a different number of items14than an output stream16. For example, inFIGS. 5A and 5B, each input stream12has one item14being loaded at a time, while each output stream16has six items14being unloaded at a time. InFIGS. 6A and 6B, each input stream12has one item being loaded at a time, while each output stream16has five items being unloaded at a time. In various embodiments, the items14in an input stream12can have a different configuration as the items14in the output stream16. Although each input stream12is illustrated as a single layer of items14, each input stream12could comprise multiple layers of items14that are loaded simultaneously or independently, for example.

Various example configurations of transfer mechanisms will now be discussed in reference to the figures. In one embodiment, referring toFIG. 7, a transfer mechanism10can comprise two arms22that can each rotate about a turret18or that are rotated by the turret18. The input stream12and the output stream16are positioned about 180 degrees apart from each other. The transfer mechanism10can receive four input streams12of one item14at a time and can output a grouping of items146items wide at a time. In various embodiments, the transfer mechanism10illustrated inFIG. 8comprises three arms22rotating about a turret18or that are rotated by the turret18. The transfer mechanism10has two separate locations of input streams12feeding therein and one location of an output stream16. The two separate locations of input streams12inFIG. 8are positioned about 90 degrees apart, for example, although the input streams12can be positioned at any other suitable angle with respect to each other. By providing two locations of input streams12, two different items14and15can be loaded onto the carrier mechanism24and discharged together at the output stream16. InFIG. 8, the two different items14and15are indicated by shading. The two arms22and carrier mechanisms24aligned with the two separate locations of input streams12, as shown inFIG. 8, can be loaded, or partially loaded, simultaneously or independently, at different time intervals. In other embodiments, only one position of input streams12may be used for loading with the other position of input streams12provided merely as a backup, for example. In still other various embodiments, each carrier mechanism24can be partially loaded by one location of input streams12prior to being rotated into a position aligned with, or substantially aligned with, one or more output streams16.

In one embodiment, referring toFIG. 9, the transfer mechanism10can be fed by multiple input streams12at a first location and can discharge two output streams16at different locations. In various embodiments, the first and second output streams16can be used to output items14simultaneously or independently, at different time intervals. In one embodiment, if the items14are sanitary tissue products, a first output stream16can be used to send the sanitary tissue products to a palletizer and a second output stream16can be used to send the sanitary tissue products to a bundler, for example. The sanitary tissue products can be conveyed to the palletizer and/or the bundler using a conveyor, for example. In various embodiments, one of the output streams16can also be used as an input stream12or as an output stream16and an input stream12depending on the desired manufacturing process. The locations of the input streams12and the locations of the output streams16can be positioned at any suitable angle away from each other. In one embodiment, the turret18(if the turret is rotating) may be configured to rotate in the clockwise and counter-clockwise directions. In another embodiment, the arms22(if the arms22are rotating about a non-rotatable turret18) can be configured to rotate in the clockwise and the counter-clockwise directions. In the example embodiment ofFIG. 9, at least one other input stream or output stream could be added to provide the transfer mechanism10with greater flexibility in its capabilities. In one embodiment, the carrier mechanism24can be partially unloaded at a first output stream16and partially unloaded at a second output stream16.

In one embodiment, referring toFIG. 10, the transfer mechanism may only have one location of input streams12and one location of an output stream16. The input streams12may be positioned about 100 or less degrees away from the output stream16, for example.

In one embodiment, referring toFIGS. 11 and 12, a transfer mechanism10′ can comprise a turret18′, similar to or the same as the turret18described above, one or more arms22′, similar to or the same as the arms22described above, a carrier mechanism24′ comprising a base26′ and two or more supports40. The carrier mechanism24′ can be engaged with or formed with the arms22′ similar to that described above with respect to the carrier mechanism24and the arms22. The base26′ of the carrier mechanism24′ can be engaged with or formed with two or more of the supports40. The supports40can extend outwardly from the base26′ in a direction away from the turret18′ and away from the longitudinal axis20′ of the turret18′. Example supports40are illustrated inFIGS. 11 and 12.FIG. 12is a front view of a single support40. The two or more supports40can optionally comprise one or more nubs42positioned about a surface of each of the supports40. The nubs42can be arranged in one or more columns44and one or more rows46on each of the supports42. At least one nub42on a support40can be moveable with respect to another nub42on the support40. Alternatively, all or most of the nubs42can be moveable relative to at least one other nub42. This adjustability feature can allow the nubs42to be moved relative to one another to accommodate items, such as sanitary tissue products, for example, having different diameters, void areas with the cores, and/or other dimensions. The nubs42can be comprised of or covered with a resilient material, such as a rubber, for example, to aid the nubs42in engaging and gripping items14or packaged items14, and to at least inhibit the nubs42from crushing portions of the items14or packaged items14. In another embodiment, the nubs42can be at least partially formed of or coated with a low coefficient of friction material configured to allow the nubs42to easily engage the items14or packaged items14. The supports40can be arranged on the base26′ such that the nubs42on a first support40can face the nubs42on a second support40, as illustrated inFIG. 11. The supports40and the nubs42can be used to engage sanitary tissue products48or packages of sanitary tissue products48therebetween. In one embodiment, the supports40can move relative to each other and/or relative to the base26′ using an actuator. In various embodiments, the supports40can be used to engage a plurality of sanitary tissue products48or a plurality of packages of sanitary tissue products48at the same time. In one embodiment, the nubs42can engage film wrapped packages of sanitary tissue products48in locations where the film does not contact the sanitary tissue products48within the film (i.e., non-product contacting areas). These non-product contacting areas can be aligned with, or substantially aligned with, void areas inside the cores of one or more sanitary tissue products48or can be present in between sanitary tissue products48. Owing to the circular shape of sanitary tissue products48, gaps can be provided intermediate a plurality of sanitary tissue products48. Such engagement of the non-product contacting areas of a package of sanitary tissue product48can prevent, or at least inhibit, compression of the cores in a direction substantially perpendicular to a longitudinal axis of the cores. If cores of sanitary tissue products48are compressed, they can have an ovate shape, which is generally undesirable for dispensing from a circular tube or bar. One or more of the nubs42can comprise ends having pointed portions, arcuate portions, and/or conical portions to aid the nubs' engagement with the non-product containing areas of the packages. Once the sanitary tissue products48and/or packages of sanitary tissue products48are engaged with the nubs42, the transfer mechanism10′ can manipulate or rotate from a positioned aligned with, or substantially aligned with, one or more input streams12′ to a position aligned with, or substantially aligned with, one or more output streams16′. The support40can also pivot with respect to the base26′ and/or the arm22′ to enable manipulation of the sanitary tissue products48or packages of the same from a vertical position into a horizontal position or other suitable position. In one embodiment, the base26′ can comprise a pusher apparatus comprising, for example, a linear actuator configured to aid in discharging packages of sanitary tissue products48from the carrier mechanism24. This pusher apparatus can be located intermediate the first support40and the second support40.

In one embodiment, a transfer mechanism can be used in a method of transferring packaged items. The method can comprise feeding packaged items, such as packaged sanitary tissue products48, for example, toward the carrier mechanism from one or more input streams, engaging the packaged items with the two or more supports extending from the carrier mechanism, manipulating the carrier mechanism relative to the one or more input streams into a position substantially aligned with one or more output streams, and feeding the packaged items onto the one or more output streams. The configuration of the packaged items in the one or more input streams can be different than the configuration of packaged items in the one or more output streams. The method can further comprise accelerating the carrier mechanism between at least one of the input streams and at least one of the output streams and retaining the packaged items in contact with the supports and/or the nubs during the accelerating step. The nubs42can contact the non-product containing areas on the packages.

In one embodiment, referring toFIG. 13, an example transfer mechanism10″ is illustrated. The transfer mechanism10″ can comprise a conveyor50rotating about at least two rolls or rollers52. The conveyor50can be a belt, a chain, or other mechanical mechanism. A plurality of rods28″ can extend from the conveyor50and rotate with the conveyor50. In one embodiment, the rods28″ can be accelerated about portions of the conveyor50(i.e., move at a speed faster than the conveyor50) or “dwelled” about the conveyor50(i.e., move at a speed slower than the conveyor50). In other embodiments, the rods28″ can be coupled to the conveyor50when movement of the rods28″ is desired and decoupled from the conveyor50when movement of the rods28″ is not desired. Such features can help in joining the rods28″ into groups, while loading and/or unloading items14″, for example, or separating the rods28″ from each other at appropriate times. AlthoughFIG. 13illustrates a top view, the rods28″ can be provided in single rod deep columns or can be provided in multiple rod deep columns. In one embodiment, at the loading and unloading areas, positive stops can be provided to ensure suitable alignment of the rods28″ with the loading and/or unloading areas.

In operation, the conveyor50can rotate about the rolls or rollers52, thereby rotating the rods28″ about the rolls52. The rods28″ can have any suitable length. The length can be appropriate for accepting one item14″ or multiple items14″. As an example, four input streams12″ of items14″ can be feed onto the rods28″. If more than one rod deep columns of rods28″ are provided, the rods28″ can move upwardly and downwardly relative to the conveyor50to load more than one row of items14″. In other various embodiments, the rods28″ can remain stationary on the conveyor50and the input streams12″ can move upwardly and downwardly relative to the conveyor to load multiple rows of rods28with items14″. Once loaded with the items14″, the rods28″ can then be rotated about the conveyor50to a point where the items14″ can be outputted to one or more output streams16″. The items14″ in the input streams12″ can have a different configuration than the items14″ in the output streams16″. For example, each input stream12″ can have a single layer of one item14, while each output stream16″ can have multiple items14in multiple rows and columns.

In one embodiment, referring toFIGS. 14A-14C, an example pusher apparatus is disclosed. The pusher apparatus can be used to push or force items, such as sanitary tissue products48, for example, off of the rods28onto one or more output streams16. The pusher apparatus can comprise a plurality of fingers54extending between at least some of the rods28. In one embodiment, a finger54can be positioned on each side of one or more rods28. In other embodiments, only one finger54may be positioned adjacent to a rod28. The fingers54can be operably engaged with one or more linear actuators56. In one embodiment, two or more fingers54can be engaged with one linear actuator56, for example. Referring toFIG. 14B, the linear actuator56can be configured to move the fingers54relative to the base26, as shown by arrow E, to disengage the sanitary tissue products48from the rods28. In one embodiment, referring toFIG. 14C, the base26can move relative to the fingers54such that less than all of the sanitary tissue products48on the rods28may be discharged at one point in time. In other various embodiments, the fingers54can be height adjustable relative to the base26such that less than all of the sanitary tissue products48on the rods28will be discharged at one point in time. In various embodiments, one or more linear actuators56can be activated independently from one or more other linear actuators56. This feature, along with the height adjustment of the fingers54and/or the base26, can allow for discharge of a plurality of configurations of output streams16.

In one embodiment, referring toFIGS. 15A and 15B, one or more of the rods28can expand from a first position (FIG. 15A) into a second position (FIG. 15B) once rolls of sanitary tissue product48are positioned on the rods28. This expansion can function to hold the rolls of the sanitary tissue product48on the rods28during rotation of the turret18, the arms22, and/or the carrier mechanism24, for example. After the rolls of the sanitary tissue products48are discharged from the rods28, the rods28can retract into the position shown inFIG. 15A. This expansion can be caused by an actuator within the rods28.

In one embodiment, referring toFIGS. 16A and 16B, the rods28can define one or more elongate slots58. A collar60can be movable along the elongate slots58from a first position where the collar60is located proximate to the base26(FIG. 16A) into a second position where the collar60is located distal from the base26(FIG. 16B). The collar60and the elongate slots58can together be referred to as a pusher apparatus. The collar60can be moved along the elongate slots58through the use of an actuator, such as a linear actuator, for example. The collar60can be used to discharge rolls of sanitary tissue products48from the rods28at the appropriate time. If each rod28has a collar60, each collar60can be independently activated to enable various configurations of sanitary tissue products48to be discharged at one point in time. In other embodiments, the collar60can be fixedly positioned on one or more rods28and can have a plurality of openings in an item-facing surface thereof. Air can be forced through the openings at the appropriate time to discharge the sanitary tissue products48from the rods28. In other various embodiments, belts or conveyors can be incorporated into one or more of the rods28. The belts or conveyors can engage the cores of the sanitary tissue products48on the rods28and move them in a direction away from the base26to disengage the sanitary tissue products48from the rods28. In still other various embodiments, the rods28can have a series of openings therein. Air can be forced through the openings to discharge the sanitary tissue products48from the rods28.

In various embodiments, the rods28can have one or more sensors thereon, therein, and/or associated therewith. The sensors can be used to detect the presence of sanitary tissue products48thereon. For instance, a collar60of a rod28may not need to be actuated if a sensor detects that sanitary tissue products48are not present on the rod28. In other various embodiments, the sensors can be configured to detect the number and size of the sanitary tissue products48on the rods28, for example.

In one embodiment, the various transfer mechanisms of the present disclosure, or other transfer mechanisms, can be used in methods for transferring items, such as methods for transferring sanitary tissue products, for example. One example method can comprise feeding items onto or toward a carrier mechanism from one or more input streams, wherein the carrier mechanism comprises a plurality of rods extending therefrom. The method further comprises engaging void areas (e.g., areas inside cores of sanitary tissue products) defined in the items with at least some of the plurality of rods, manipulating the carrier mechanism relative to the one or more input streams into a position substantially aligned with, or aligned with, one or more output streams, and feeding the items onto the one or more output streams. The configuration of items in each input stream can be different than the configuration of items in each output stream. The method can further comprise moving the carrier mechanism relative to the one or more input streams after the engaging step (above) and engaging void areas defined in a second group of items in the one or more input streams with at least some of the rods. One or more carrier mechanisms can simultaneously receive two separate input streams of items from different locations and/or can independently, at different time intervals, receive two separate input streams of items. Similarly, one or more carrier mechanisms can simultaneously feed two separate output streams of items or independently, at different time intervals, feed two separate output streams of items. One or more carrier mechanisms can also feed a first group of items to a first output stream and feed a second group of items to a second output stream, either simultaneously or independently, at different time intervals. The first group of items can comprise the same number of items as the second group of items or a different number of items. A pusher apparatus can be used to discharge the items onto the one or more output streams.

The manipulating step of the method can comprise rotating the carrier mechanism in a first direction from alignment with, or substantial alignment with, one or more input streams into alignment with a first output stream and rotating the carrier mechanism in the first direction into alignment with a second output stream. In addition to the rotating, the carrier mechanism can also be moved in a direction between the one or more input streams and the one or more output streams. The direction can be linear, non-linear, horizontal, vertical, and/or any other suitable direction. In one embodiment, items can be stored on the carrier mechanism, such as on the rods, for example, when the carrier mechanism is in the process of moving between the one or more input streams and the one or more output streams.

In one embodiment, items can be fed onto at least some of the rods from one or more input streams at a first speed (items per minute) and the items can be discharged from at least some of the rods onto one or more output streams at a second speed that is the same as or different than the first speed. Items can also be fed toward the carrier mechanism from different input streams at different speeds or at the same speed.

Another method of using the transfer mechanisms of the present disclosure can comprise feeding items onto or toward a carrier mechanism from one or more input streams, engaging void areas (e.g., void areas inside cores of sanitary tissue products) in the items with at least some of a plurality of rods extending from the carrier mechanism, radially expanding one or more of the rods, rotating the carrier mechanism relative to the one or more input streams into a position substantially aligned with one or more output streams, radially contracting the one or more of the rods, and discharging the items onto the one or more output streams using a pusher apparatus. The configuration of items in each of the input streams can be different than the configuration of items in each of the output streams. The items can be rolled sanitary tissue products having void areas inside cores thereof. The engaging step can comprise positioning the rods at least partially or fully through the void areas in the cores. The method can further comprise moving the carrier mechanism in a first direction and in a second direction during the step of engaging the void areas in the items with at least some of the plurality of rods.

While particular embodiments of the present invention have been illustrated and described, those of skill in the art will recognize 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.