Patent Publication Number: US-8973735-B2

Title: Mechanisms for transferring items

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of U.S. Provisional Application No. 61/536,227, filed Sep. 19, 2011. 
    
    
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of the present disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of non-limiting embodiments of the disclosure taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a perspective illustration of a transfer mechanism transferring items between an input stream and an output stream in accordance with one non-limiting embodiment; 
         FIG. 2  is a top view illustration of a transfer mechanism in accordance with one non-limiting embodiment; 
         FIG. 3  is a top view illustration of another transfer mechanism in accordance with another non-limiting embodiment; 
         FIG. 4A  is a perspective view of a carrier mechanism comprising a base and a plurality of rods extending from the base in accordance with one non-limiting embodiment; 
         FIG. 4B  is another perspective view of a carrier mechanism having a base and a plurality of rods extending from the base in accordance with one non-limiting embodiment; 
         FIG. 5A  is an example loading sequence of a carrier mechanism in accordance with one non-limiting embodiment; 
         FIG. 5B  is an example unloading sequence of the carrier mechanism of  FIG. 5A  in accordance with one non-limiting embodiment; 
         FIG. 6A  is an example of another loading sequence of a carrier mechanism in accordance with one non-limiting embodiment; 
         FIG. 6B  is an example unloading sequence of the carrier mechanism of  FIG. 6A  in accordance with one non-limiting embodiment; 
         FIGS. 7-11  are top view illustrations of transfer mechanisms in accordance with various non-limiting embodiments; 
         FIG. 12  is a front view of an example support comprising a plurality of nubs thereon in accordance with one non-limiting embodiment; 
         FIG. 13  is a top view illustration of another transfer mechanism in accordance with one non-limiting embodiment; 
         FIG. 14A  is an end view of a pusher apparatus configured to disengage items from a carrier mechanism in accordance with one non-limiting embodiment; 
         FIG. 14B  is a side view of the pusher apparatus of  FIG. 14A  in accordance with one non-limiting embodiment; 
         FIG. 14C  is another side view of the pusher apparatus of  FIG. 14A  in accordance with one non-limiting embodiment; 
         FIGS. 15A and 15B  are side views of an expanding rod configured for use with the carrier mechanism of the present disclosure in accordance with various non-limiting embodiments; and 
         FIGS. 16A and 16B  are side views of a rod engaged with a movable collar configured for use with the rods of the carrier mechanism in accordance with various non-limiting embodiments. 
     
    
    
     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 to  FIG. 1 , an example transfer mechanism  10  is illustrated. The transfer mechanism  10  is configured to receive one or more input streams  12  of items  14  and transfer the items  14  to one or more output streams  16  of the items  14 . The transfer mechanism  10 , 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 items  14  can be transferred from the input stream  12  to the output stream  16 . This can allow for better process flow or manufacturing facility floor space management. In various embodiments, the configuration or arrangement of the items  14  in each input stream  12  can be different than the configuration or arrangement of the items  14  in each output stream  16 . For example, each input stream  12  can have 1 item three rows deep while an output stream  16  can have three columns of items  14 , 2 rows deep, and 3 rows wide. 
     In one embodiment, still referring to  FIG. 1 , the transfer mechanism  10  can comprise a turret  18 . The turret  18  can 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 turret  18 . The turret  18  can have a longitudinal axis  20 . One or more arms  22  can extend from the turret  18  and/or can be attached to the turret  18 . Each of the arms  22  can be fixedly or rigidly attached to the turret  18 . In such an embodiment, the turret  18  can rotate about its longitudinal axis  20  through the use of one or more actuators to manipulate or rotate the arms  22 . In other various embodiments, the arms  22  can be rotatably attached to the turret  18  and can rotate about the longitudinal axis  20  and relative to the fixed turret  18 . In such an embodiment, the arms  22  can be operably engaged with one or more actuators (not illustrated) configured to rotate the arms  22  about the turret  18 . The actuator can be a motor operably coupled to a drive chain or belt or a rack and pinion system. The arms  22 , whether rotated by the turret  18  or rotated about the turret  18 , can make a full revolution (i.e., 360 degree movement) about the turret  18 . In other embodiments, the arms  22  may only make a partial revolution about the turret  18  (e.g., 180 degrees). In one embodiment, the arms  22  can rotate in the clockwise direction and/or in the counter-clockwise direction about the longitudinal axis  20  of the turret  18 . Although two arms  22  are illustrated in  FIG. 1 , one arm  22  can be provided or more than two arms  22  can be provided on a single turret  18 . In other various embodiments, the arms  22  can be positioned around, or around at least a portion of, the circumference or perimeter of the turret  18 . In various embodiments, if two or more of the arms  22  are provided on the turret  18 , the arms  22  can be positioned on the turret  18  at different heights on the turret  18  so as to allow the arms  22  to rotate about the turret  18  independent of the position of another arm  22 . In other various embodiments, if two or more of the arms  22  are provided on the turret  18 , the arms  22  can be positioned at the same height on the turret  18 . Each of the arms  22  can be formed with a carrier mechanism  24  or can be engaged with the carrier mechanism  24 . In an embodiment comprising two of the arms  22  (each engaged with a carrier mechanism  24 ) at different heights on the turret  18 , the transfer mechanism can transfer items  14  from a first input stream  12  at a first height on the turret  18  and discharge the items  14  onto an output stream  16  at the first height using the first arm  22  and the first carrier mechanism  24  and can transfer items  14  from a second input stream  12  at a second height on the turret  18  and discharge the items  14  onto an output stream  16  at the second height using the second arm  22  and the second carrier mechanism  24 . 
     In one embodiment, still referring to  FIG. 1 , the carrier mechanism  24  can be engaged with or formed with the one or more arms  22  or attached directly to the turret  18 . The carrier mechanism  24  can comprise a base  26  and a plurality of rods  28  extending from the base  26  and/or operably engaged with the base  26  through the use of one or more actuators. Additional details regarding the rods  28  are discussed below. In other embodiments, the rods  28  may not be provided and the base  26  can 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 items  14  having different dimensions. For example, a first shelf may be movable relative to a second shelf to receive an item  14  having 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 mechanism  24  during rotation, manipulation, or movement of the carrier mechanism  24  (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 base  26  for 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 to  FIGS. 2 and 3 , a guide  30  can be positioned around, or at least partially around, the transfer mechanism  10 . In various embodiments, the guide  30  can be used for safety or containment so that the items  14  do not slide out of or off of the carrier mechanism  24  during movement, manipulation, or rotation of the carrier mechanism  24 . The guide  30  can define openings  32  therein that align with one or more input streams  12  and one or more output streams  16 . An opening  32  can be defined in the guide  30  for each input stream  12  coming into the transfer mechanism  10  and for each output stream  16  exiting the transfer mechanism  10 . In one embodiment, the openings  32  can 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 to  FIG. 2 , the arm  22  can be fixedly attached to the turret  18  and the turret  18  can be rotatable about its longitudinal axis  20 . In such an embodiment, the turret  18  can rotate in the clockwise and counter-clockwise direction, as indicated by arrow A and the dashed lines, when loading items onto the rods  28 . Although the rods  28  are 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 rods  28 . The rotation or manipulation of the turret  18  can occur during loading even if the rods  28  are not provided on a carrier mechanism  24 . In one example, if the rods are in a 6 wide×1 high pattern and the input streams  12  each have a single layer of items  14  entering the carrier mechanism  24 , and there are four input streams  12 , the turret  18 , and thereby the arms  22  and the carrier mechanism  24 , can rotate in the clockwise and counter-clockwise direction to fill all of the rods  28  with items  14 . The turret  18  can also move vertically when receiving the items  14  to load additional rows of the items  14  onto the carrier mechanism  24 . As another example, if the rods  28  are in a 6 wide×3 high pattern and the input streams  12  each have a single layer of items  14  moving towards the carrier mechanism  24  at a time, and there are four input streams  12 , to obtain additional rows of the items  14  on the carrier mechanism  24 , the turret  18 , the carrier mechanism  24 , and/or the arms  22  can move upward and/or downward in a vertical direction in addition to rotation about the longitudinal axis  20 . Also, at least some of the rods  28  can move relative to each other before, during, or after the item loading process and/or an item unloading process. In one embodiment, the input streams  12  can move upwardly and/or downwardly to load additional rows of the items  14  onto the carrier mechanism  24  if the turret  18  is fixed vertically or if the turret  18  is movable vertically. In such an embodiment, the carrier mechanism  24 , the arms  22 , and/or the turret  18  can be fixed vertically or can remain vertically stationary. 
     In one embodiment, one or more robots (not illustrated) can be used in place of the turret  18 . The robots can each have one or more of the arms  22  attached to them and the arms  22  can each be attached to a carrier mechanism  24 . Alternatively, the robot can be directly attached to one or of the more carrier mechanisms  24 . The robots can have the ability to position the arms  22  and/or the carrier mechanisms  24  relative to one or more input streams  12 , pick up items  14  on the rods  28 , and move the arms  22  and/or the carrier mechanisms  24  into alignment with one or more output streams  16  so that the items  14  can be discharged. 
     In other various embodiments, referring to  FIG. 3 , a portion of or all of the carrier mechanism  24  can move relative to the arm  22  and/or relative to the turret  18 . In one embodiment, the base  26  can move relative to the arm  22 . In such embodiments, the turret  18  can be rotatable or fixed. In one embodiment, the carrier mechanism  24  can move in a direction perpendicular to the longitudinal axis  20  of the turret  18 . The carrier mechanism  24  can be movable in an essentially reciprocating fashion, in the directions indicated by arrow B, and as indicated by the dashed lines in  FIG. 3 . Although the carrier mechanism  24  can move relative to the turret  18  to accept items  14 , the turret  18  can also rotate to provide additional maneuverability of the transfer mechanism  10 . In one example, if the rods  28  are in a 6 wide×1 high pattern and the input streams  12  each have one single layer of items  14  moving toward the carrier mechanism  24 , and there are four input streams  12 , the carrier mechanism  24  can move in the directions indicated by arrow B, and as indicated by the dashed lines in  FIG. 3 , such that all of the rods  28  can be filled. In various embodiments, if the rods  28  are in a 6 wide×2 high pattern, after filling a first row of items, the turret  18  and/or the carrier mechanism  24  can move vertically such that additional rows of items  14  can be loaded onto the rods  28 . In other various embodiments, the carrier mechanism  24  can move relative to the arm  22  and/or the turret  18  to adjust the vertical height of the rods  28 . In still other various embodiments, the rods  28  can move relative to the base  26  and/or relative to each other during the item loading process. 
     In one embodiment, referring to  FIGS. 1-4B , for example, one or a plurality of the rods  28  can extend outwardly from the base  26  in a direction away from the longitudinal axis  20  of the turret  18 . In various embodiments, at least one of the rods  28  can be movable relative to at least one other rod  28  to adjust the spacing between the rods  28  and/or to compress, or slightly compress, items  14 , such as rolls of sanitary tissue products, for example, between the rods  28  during manipulation of the carrier mechanism  24 . In one embodiment, all of the rods  28  can be movable relative to at least one other rod  28 . The rods  28  can be moveable manually or through the use of actuators. The rods  28  can 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 rods  28  in gripping items  14  and/or can protect the items  14  from crushing during gripping. In another embodiment, the rods  28  can be at least partially formed of or coated with a low coefficient of friction material to aid the rods  28  in engaging void areas within the cores of sanitary tissue products, for example. In one embodiment, the rods  28  can be positioned around, or at least partially around, a circumference or perimeter of the turret  18 . 
     In various embodiments, referring to  FIGS. 4A and 4B , an example carrier mechanism  24  can comprise a base  26  and a plurality of rods  28  extending from the base  26 . Although four rods  28  are illustrated as an example, any suitable number of rods  28  can extend from the base  26 . Some example configurations of the rods  28  are a carrier mechanism  24  having 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 base  26  can comprise one or more plates  34  with slots  36  defined therein. A portion of the rods  28  can extend through the slots  36 . In various embodiments, the base  26  can comprise a first set of plates  34  and a second set of plates  34 ′. The two plates of the first set of plates  34  can 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 plates  34 ′ 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 plates  34  and  34 ′ can allow the rods  28  to be moved toward and away from each other in more than one direction.  FIG. 4A  illustrates the rods  28  in a first position, while  FIG. 4B  illustrates the rods  28  moved into a second position. In one embodiment, at least one rod  28  or all of the rods  28  can have a pointed end portion, an arcuate end portion, and/or a conical portion  38 . Such a feature can aid the rods  28  in engaging void areas within the items  14 , such as void areas within the cores of rolled sanitary tissue products, for example, by essentially being self-centering during engagement. Each rod  28  can comprise a backstop that prevents items  14  from being positioned to deeply on the rods  28 . Further, each rod  28  can be any suitable length depending on how many of the items  14  will be loaded thereon. In such an embodiment, the backstop may be adjustable about the rods  28  depending on how many items  14  will be loaded onto the rods  28 . In various embodiments, one or more of the rods  28  and/or one or more of the carrier mechanism  24  can be configured to tilt for additional flexibility. In one embodiment, this tilting capability can be used to load additional rows of items  14 , 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 rods  28 ), 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 to  FIG. 5A . In this example, four input streams  12 , each three items  14  deep, are fed into the carrier mechanism  24 . This is an example of one group of items  14  being fed into the carrier mechanism  24 . In practice, multiple groups of items  14  will be sequentially fed into the carrier mechanism  24  on a continuous or a non-continuous basis. The carrier mechanism  24 , in this instance, comprises six rods  28  wide, by three rods  28  high (rods  28  are only illustrated in the first portion of the figure). The carrier mechanism  24  could also comprise six receiving spaces or shelves wide by three receiving spaces or shelves high. The rods  28 , receiving spaces, or receiving shelves are represented in  FIGS. 5A-6B  by squares. The rods  28  can extend from the center of the squares, for example. The length of any of the rods  28  discussed herein can be suitable for accepting the desired number of the items  14 , such as rolled sanitary tissue products. First, a first item  14  from each of the four input streams  12  is loaded onto the four bottom and left-most rods  28 . This leaves four input streams  12  that are two items  14  deep. Next, the carrier mechanism  24  is shifted to the right relative to the position of the fixed input streams  12 . In other embodiments, the input streams  12  could be moved to the right with the carrier mechanism  24  being fixed. In still other embodiments, the plurality of rods  28  could be shifted to the right with the input streams  12  and the base  26  being fixed. The two right-most input streams  12  of the items  14  are then loaded onto the two remaining empty rods  28  in the bottom-most row of the rods  28 . This leaves four input streams  12 , with two input streams  12  being one item  14  deep and the other two input streams  12  being two items deep. Then, the carrier mechanism  24  is shifted downwardly with respect to the input streams  12  so that the four input streams  12  can feed four items  14  onto the right-most four rods  28  in the second row of rods  28 . This leaves two input streams  12 , each stream being one item  14  deep. Next, the carrier mechanism  24  is shifted to the left. The items  14  in the two remaining input streams  12  are then loaded onto the remaining two left-most empty rods  28  in the second row of rods  28 . Thereby, the carrier mechanism  24  is loaded with a two high, by six wide, by one item deep set of items  14 . Of course, this process can be repeated to load a grouping of items  14  that is two or more items deep. 
     In one embodiment, referring to  FIG. 5B , once the carrier mechanism  24  has been manipulated or rotated from a position aligned, or substantially aligned, with the one or more input streams  12  into a position aligned, or substantially aligned, with the one or more output streams  16 , the items  14  can be unloaded from the carrier mechanism  24 . In one embodiment, a pusher apparatus (see e.g.,  FIGS. 14A-14C ,  16 A, and  16 B and their description below), and/or other mechanisms, can be used to unload the items  14 . The items  14  can be unloaded onto the one or more output streams  16  in two high by three wide item groupings. In various embodiments, the first grouping of items  14  can be unloaded onto a first output stream and a second grouping of items  14  can be unloaded onto a second output stream. In other embodiments, the first grouping of items  14  can be unloaded onto the same output stream as the second grouping of items  14  either at the same time or at different time intervals. It is important to note that all of the rods  28  or receiving spaces or shelves on each carrier mechanism do not always need to be used. Some can be left empty. 
     The carrier mechanism  24  can also be useful for layering items  14 , such as sanitary tissue products, for example. The carrier mechanism  24  can receive four input streams  12  of items  14 , then move vertically to accept four additional input streams  12  of items  14 , and then move into a positioned aligned with, or substantially aligned with, one or more output streams  16 . The carrier mechanism  24  can then output items  14  two or more layers high using a pusher apparatus or other device. 
     Another example of an item loading processes is discussed below with reference to  FIGS. 6A-6B . In this example, three input streams  12 , each five items  14  deep, are fed into the carrier mechanism  24 . The carrier mechanism  24 , in this instance, comprises six rods  28  wide by three rods  28  high (rods  28  are only shown in the first portion of the figure). The carrier mechanism  24  could also comprise six receiving spaces or shelves wide by three receiving spaces or shelves high. First, a first item  14  from each of the three input streams  12  is loaded onto three rods  28  in the bottom row of rods  28 . This leaves three input streams  12  that are four items  14  deep. Next, the carrier mechanism  24  is shifted to the right relative to the fixed position of the input streams  12 . The input streams  12  could also be moved to the right with the carrier mechanism  24  being fixed, as discussed above. The two right-most input streams  12  of items  14  are then loaded onto the two right-most empty rods  28  in the bottom-most row of rods  28 . This leaves three input streams  12 , with two input streams  12  being three items  14  deep and the other input stream  12  being four items deep. Then, the carrier mechanism  24  is shifted downwardly with respect to the input streams  12  so that the three input streams  12  can feed three items  14  onto the right-most three rods  28  in the second row of rods  28 . This leaves three input streams  12 , two input streams  12  being two items  14  deep and the other input stream  12  being three items  14  deep. Next, the carrier mechanism  24  is shifted to the left and two items  14  are fed onto two rods  28  in the second row. This leaves three input streams  12 , the end two input streams  12  being two items  14  deep and the middle input stream  12  being one item  14  deep. The carrier mechanism  24  is then shifted downwardly and three items  14  are fed onto three rods  28  in the top row of rods  28 . This leaves a first input stream  12  that is a single item deep and a second input stream  12  that is a single item deep (the items  14  in the middle input stream  12  are now all loaded). The carrier mechanism  24  is then shifted to the left so that the single item  14  in the left input stream  12  is fed onto a rod  28  in the top row of rods  28 . This leaves the right-most input stream  12  with one item  14  deep. The carrier mechanism  24  is then shifted to the right so that the remaining item  14  can be positioned on the right-most rod  28  in the top row of rods  28 . Thereby, the carrier mechanism  24  is loaded a single item  14  deep, three items  14  high, and five items  14  wide. Of course, this process can be repeated to load a grouping of items  14  more than one item deep. Instead of the carrier mechanism  24  moving during loading, the input streams  12  can move relative to the carrier mechanism  24 . 
     In one embodiment, referring to  FIG. 6B , when the carrier mechanism  24  has been manipulated or rotated from a position aligned, or substantially aligned, with the input streams  12  into a position aligned, or substantially aligned, with one or more output streams  16 , the carrier mechanism  24  can be unloaded. In one embodiment, a pusher apparatus (see e.g.,  FIGS. 14A-14C ,  16 A, and  16 B and their description below) and/or other mechanisms, can be used to unload the items  14 . The items  14  can be unloaded onto an output stream  16  by rows of rods  28  to output a grouping of items  14  that is one row deep, one row high, and five rows wide. Therefore, in this example, three groupings of items  14  can be unloaded. In various embodiments, the first grouping of items  14  can be unloaded onto a first output stream  16 , a second grouping of items  14  can be loaded onto a second output stream  16 , and a third grouping of items  14  can be unloaded onto a third output stream  16 . In other embodiments, the first grouping of items  14 , the second grouping of items  14 , and the third grouping of items  14  can all be unloaded or discharged onto the same output stream  16  at different time intervals and/or sequentially. 
     In various embodiments, each of the rods  28  can move toward and away from at least one other rod  28  to slightly compress the items  14  on the rods  28  at least during manipulation or rotation of the transfer mechanism  28 . This can maintain the items  14  on the rods  28  despite forces of acceleration created during rotation or manipulation of the transfer mechanism  10 . Stated another way, the compression of the items  14  by the rods  28  can inhibit the items  14  from sliding off of the rods  28  during rotation of the arms  22  or turret  18 . The rods  28  can move toward one another after the loading process and can then move away from each other when the carrier mechanism  24  is aligned with, or substantially aligned with, an output stream  16 . In various embodiments, movements of the rods  28  can be individually controlled to provide the ability to slightly compress certain items  14  without compressing others or to adjust for the dimensions (e.g., diameters) of the items  14  to be loaded. 
     The above are merely examples of loading and unloaded items  14  from carrier mechanisms  24 . Of course, a multitude of configurations and processes are possible and are within the scope of the present disclosure. In one embodiment, an input stream  12  can have a different number of items  14  than an output stream  16 . For example, in  FIGS. 5A and 5B , each input stream  12  has one item  14  being loaded at a time, while each output stream  16  has six items  14  being unloaded at a time. In  FIGS. 6A and 6B , each input stream  12  has one item being loaded at a time, while each output stream  16  has five items being unloaded at a time. In various embodiments, the items  14  in an input stream  12  can have a different configuration as the items  14  in the output stream  16 . Although each input stream  12  is illustrated as a single layer of items  14 , each input stream  12  could comprise multiple layers of items  14  that 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 to  FIG. 7 , a transfer mechanism  10  can comprise two arms  22  that can each rotate about a turret  18  or that are rotated by the turret  18 . The input stream  12  and the output stream  16  are positioned about 180 degrees apart from each other. The transfer mechanism  10  can receive four input streams  12  of one item  14  at a time and can output a grouping of items  14   6  items wide at a time. In various embodiments, the transfer mechanism  10  illustrated in  FIG. 8  comprises three arms  22  rotating about a turret  18  or that are rotated by the turret  18 . The transfer mechanism  10  has two separate locations of input streams  12  feeding therein and one location of an output stream  16 . The two separate locations of input streams  12  in  FIG. 8  are positioned about 90 degrees apart, for example, although the input streams  12  can be positioned at any other suitable angle with respect to each other. By providing two locations of input streams  12 , two different items  14  and  15  can be loaded onto the carrier mechanism  24  and discharged together at the output stream  16 . In  FIG. 8 , the two different items  14  and  15  are indicated by shading. The two arms  22  and carrier mechanisms  24  aligned with the two separate locations of input streams  12 , as shown in  FIG. 8 , can be loaded, or partially loaded, simultaneously or independently, at different time intervals. In other embodiments, only one position of input streams  12  may be used for loading with the other position of input streams  12  provided merely as a backup, for example. In still other various embodiments, each carrier mechanism  24  can be partially loaded by one location of input streams  12  prior to being rotated into a position aligned with, or substantially aligned with, one or more output streams  16 . 
     In one embodiment, referring to  FIG. 9 , the transfer mechanism  10  can be fed by multiple input streams  12  at a first location and can discharge two output streams  16  at different locations. In various embodiments, the first and second output streams  16  can be used to output items  14  simultaneously or independently, at different time intervals. In one embodiment, if the items  14  are sanitary tissue products, a first output stream  16  can be used to send the sanitary tissue products to a palletizer and a second output stream  16  can 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 streams  16  can also be used as an input stream  12  or as an output stream  16  and an input stream  12  depending on the desired manufacturing process. The locations of the input streams  12  and the locations of the output streams  16  can be positioned at any suitable angle away from each other. In one embodiment, the turret  18  (if the turret is rotating) may be configured to rotate in the clockwise and counter-clockwise directions. In another embodiment, the arms  22  (if the arms  22  are rotating about a non-rotatable turret  18 ) can be configured to rotate in the clockwise and the counter-clockwise directions. In the example embodiment of  FIG. 9 , at least one other input stream or output stream could be added to provide the transfer mechanism  10  with greater flexibility in its capabilities. In one embodiment, the carrier mechanism  24  can be partially unloaded at a first output stream  16  and partially unloaded at a second output stream  16 . 
     In one embodiment, referring to  FIG. 10 , the transfer mechanism may only have one location of input streams  12  and one location of an output stream  16 . The input streams  12  may be positioned about 100 or less degrees away from the output stream  16 , for example. 
     In one embodiment, referring to  FIGS. 11 and 12 , a transfer mechanism  10 ′ can comprise a turret  18 ′, similar to or the same as the turret  18  described above, one or more arms  22 ′, similar to or the same as the arms  22  described above, a carrier mechanism  24 ′ comprising a base  26 ′ and two or more supports  40 . The carrier mechanism  24 ′ can be engaged with or formed with the arms  22 ′ similar to that described above with respect to the carrier mechanism  24  and the arms  22 . The base  26 ′ of the carrier mechanism  24 ′ can be engaged with or formed with two or more of the supports  40 . The supports  40  can extend outwardly from the base  26 ′ in a direction away from the turret  18 ′ and away from the longitudinal axis  20 ′ of the turret  18 ′. Example supports  40  are illustrated in  FIGS. 11 and 12 .  FIG. 12  is a front view of a single support  40 . The two or more supports  40  can optionally comprise one or more nubs  42  positioned about a surface of each of the supports  40 . The nubs  42  can be arranged in one or more columns  44  and one or more rows  46  on each of the supports  42 . At least one nub  42  on a support  40  can be moveable with respect to another nub  42  on the support  40 . Alternatively, all or most of the nubs  42  can be moveable relative to at least one other nub  42 . This adjustability feature can allow the nubs  42  to 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 nubs  42  can be comprised of or covered with a resilient material, such as a rubber, for example, to aid the nubs  42  in engaging and gripping items  14  or packaged items  14 , and to at least inhibit the nubs  42  from crushing portions of the items  14  or packaged items  14 . In another embodiment, the nubs  42  can be at least partially formed of or coated with a low coefficient of friction material configured to allow the nubs  42  to easily engage the items  14  or packaged items  14 . The supports  40  can be arranged on the base  26 ′ such that the nubs  42  on a first support  40  can face the nubs  42  on a second support  40 , as illustrated in  FIG. 11 . The supports  40  and the nubs  42  can be used to engage sanitary tissue products  48  or packages of sanitary tissue products  48  therebetween. In one embodiment, the supports  40  can move relative to each other and/or relative to the base  26 ′ using an actuator. In various embodiments, the supports  40  can be used to engage a plurality of sanitary tissue products  48  or a plurality of packages of sanitary tissue products  48  at the same time. In one embodiment, the nubs  42  can engage film wrapped packages of sanitary tissue products  48  in locations where the film does not contact the sanitary tissue products  48  within 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 products  48  or can be present in between sanitary tissue products  48 . Owing to the circular shape of sanitary tissue products  48 , gaps can be provided intermediate a plurality of sanitary tissue products  48 . Such engagement of the non-product contacting areas of a package of sanitary tissue product  48  can 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 products  48  are compressed, they can have an ovate shape, which is generally undesirable for dispensing from a circular tube or bar. One or more of the nubs  42  can comprise ends having pointed portions, arcuate portions, and/or conical portions to aid the nubs&#39; engagement with the non-product containing areas of the packages. Once the sanitary tissue products  48  and/or packages of sanitary tissue products  48  are engaged with the nubs  42 , the transfer mechanism  10 ′ can manipulate or rotate from a positioned aligned with, or substantially aligned with, one or more input streams  12 ′ to a position aligned with, or substantially aligned with, one or more output streams  16 ′. The support  40  can also pivot with respect to the base  26 ′ and/or the arm  22 ′ to enable manipulation of the sanitary tissue products  48  or packages of the same from a vertical position into a horizontal position or other suitable position. In one embodiment, the base  26 ′ can comprise a pusher apparatus comprising, for example, a linear actuator configured to aid in discharging packages of sanitary tissue products  48  from the carrier mechanism  24 . This pusher apparatus can be located intermediate the first support  40  and the second support  40 . 
     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 products  48 , 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 nubs  42  can contact the non-product containing areas on the packages. 
     In one embodiment, referring to  FIG. 13 , an example transfer mechanism  10 ″ is illustrated. The transfer mechanism  10 ″ can comprise a conveyor  50  rotating about at least two rolls or rollers  52 . The conveyor  50  can be a belt, a chain, or other mechanical mechanism. A plurality of rods  28 ″ can extend from the conveyor  50  and rotate with the conveyor  50 . In one embodiment, the rods  28 ″ can be accelerated about portions of the conveyor  50  (i.e., move at a speed faster than the conveyor  50 ) or “dwelled” about the conveyor  50  (i.e., move at a speed slower than the conveyor  50 ). In other embodiments, the rods  28 ″ can be coupled to the conveyor  50  when movement of the rods  28 ″ is desired and decoupled from the conveyor  50  when movement of the rods  28 ″ is not desired. Such features can help in joining the rods  28 ″ into groups, while loading and/or unloading items  14 ″, for example, or separating the rods  28 ″ from each other at appropriate times. Although  FIG. 13  illustrates a top view, the rods  28 ″ 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 rods  28 ″ with the loading and/or unloading areas. 
     In operation, the conveyor  50  can rotate about the rolls or rollers  52 , thereby rotating the rods  28 ″ about the rolls  52 . The rods  28 ″ can have any suitable length. The length can be appropriate for accepting one item  14 ″ or multiple items  14 ″. As an example, four input streams  12 ″ of items  14 ″ can be feed onto the rods  28 ″. If more than one rod deep columns of rods  28 ″ are provided, the rods  28 ″ can move upwardly and downwardly relative to the conveyor  50  to load more than one row of items  14 ″. In other various embodiments, the rods  28 ″ can remain stationary on the conveyor  50  and the input streams  12 ″ can move upwardly and downwardly relative to the conveyor to load multiple rows of rods  28  with items  14 ″. Once loaded with the items  14 ″, the rods  28 ″ can then be rotated about the conveyor  50  to a point where the items  14 ″ can be outputted to one or more output streams  16 ″. The items  14 ″ in the input streams  12 ″ can have a different configuration than the items  14 ″ in the output streams  16 ″. For example, each input stream  12 ″ can have a single layer of one item  14 , while each output stream  16 ″ can have multiple items  14  in multiple rows and columns. 
     In one embodiment, referring to  FIGS. 14A-14C , an example pusher apparatus is disclosed. The pusher apparatus can be used to push or force items, such as sanitary tissue products  48 , for example, off of the rods  28  onto one or more output streams  16 . The pusher apparatus can comprise a plurality of fingers  54  extending between at least some of the rods  28 . In one embodiment, a finger  54  can be positioned on each side of one or more rods  28 . In other embodiments, only one finger  54  may be positioned adjacent to a rod  28 . The fingers  54  can be operably engaged with one or more linear actuators  56 . In one embodiment, two or more fingers  54  can be engaged with one linear actuator  56 , for example. Referring to  FIG. 14B , the linear actuator  56  can be configured to move the fingers  54  relative to the base  26 , as shown by arrow E, to disengage the sanitary tissue products  48  from the rods  28 . In one embodiment, referring to  FIG. 14C , the base  26  can move relative to the fingers  54  such that less than all of the sanitary tissue products  48  on the rods  28  may be discharged at one point in time. In other various embodiments, the fingers  54  can be height adjustable relative to the base  26  such that less than all of the sanitary tissue products  48  on the rods  28  will be discharged at one point in time. In various embodiments, one or more linear actuators  56  can be activated independently from one or more other linear actuators  56 . This feature, along with the height adjustment of the fingers  54  and/or the base  26 , can allow for discharge of a plurality of configurations of output streams  16 . 
     In one embodiment, referring to  FIGS. 15A and 15B , one or more of the rods  28  can expand from a first position ( FIG. 15A ) into a second position ( FIG. 15B ) once rolls of sanitary tissue product  48  are positioned on the rods  28 . This expansion can function to hold the rolls of the sanitary tissue product  48  on the rods  28  during rotation of the turret  18 , the arms  22 , and/or the carrier mechanism  24 , for example. After the rolls of the sanitary tissue products  48  are discharged from the rods  28 , the rods  28  can retract into the position shown in  FIG. 15A . This expansion can be caused by an actuator within the rods  28 . 
     In one embodiment, referring to  FIGS. 16A and 16B , the rods  28  can define one or more elongate slots  58 . A collar  60  can be movable along the elongate slots  58  from a first position where the collar  60  is located proximate to the base  26  ( FIG. 16A ) into a second position where the collar  60  is located distal from the base  26  ( FIG. 16B ). The collar  60  and the elongate slots  58  can together be referred to as a pusher apparatus. The collar  60  can be moved along the elongate slots  58  through the use of an actuator, such as a linear actuator, for example. The collar  60  can be used to discharge rolls of sanitary tissue products  48  from the rods  28  at the appropriate time. If each rod  28  has a collar  60 , each collar  60  can be independently activated to enable various configurations of sanitary tissue products  48  to be discharged at one point in time. In other embodiments, the collar  60  can be fixedly positioned on one or more rods  28  and 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 products  48  from the rods  28 . In other various embodiments, belts or conveyors can be incorporated into one or more of the rods  28 . The belts or conveyors can engage the cores of the sanitary tissue products  48  on the rods  28  and move them in a direction away from the base  26  to disengage the sanitary tissue products  48  from the rods  28 . In still other various embodiments, the rods  28  can have a series of openings therein. Air can be forced through the openings to discharge the sanitary tissue products  48  from the rods  28 . 
     In various embodiments, the rods  28  can have one or more sensors thereon, therein, and/or associated therewith. The sensors can be used to detect the presence of sanitary tissue products  48  thereon. For instance, a collar  60  of a rod  28  may not need to be actuated if a sensor detects that sanitary tissue products  48  are not present on the rod  28 . In other various embodiments, the sensors can be configured to detect the number and size of the sanitary tissue products  48  on the rods  28 , 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. 
     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, 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.