Patent Description:
<CIT> describes a machine with a folding channel that forms a sleeve for wrapping goods inside the sleeve. The folding channel forms a tube with an overlapped seam on a bottom edge of the tube, which seam can be welded or left unwelded, as desired.

As described in more detail below, there is presented one machine that is capable of forming the longitudinal seal at any position on a horizontal face, a vertical face, or at a corner of the wrapped package of the product, as desired. Although the description that follows below involves the wrapping and packaging of rolls, for instance, toilet tissue and paper towels, the principles of the disclosure may be used in connection with packaging lines used for packaging other products with an overwrap material where the seal location may vary depending upon product format. Further, the rolls or packs wrapped within the <NUM> overwrap material may be delivered to the overwrap infeed station in multiple orientations and not limited to what is shown in the drawings.

<FIG> generally show partial views of a packaging line <NUM> with an overwrap feed station <NUM> in one configuration. <FIG> generally show partial views of a packaging line <NUM> with an overwrap feed station <NUM> in another configuration. <FIG> generally show partial views of a packaging line <NUM> with an overwrap feed station <NUM> in another configuration. <FIG> shows a view of the overwrap feed station <NUM> in yet another configuration. Although not shown in all of the views, the packaging line overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> generally has left and right vertical supports, and bottom and top horizontal supports that define an enclosure with a hollow interior for the overwrap feed station. For purposes of illustration, <FIG> and <FIG> show typical top supports <NUM> and right side supports <NUM> albeit in cut-away to provide additional detail of the product configuration as it is being wrapped. Similar supports may be provided on the left and bottom sides. For ease of illustration, the supports are otherwise not shown in the views of the Figures. Product <NUM>,<NUM>,<NUM>,<NUM> to be wrapped moves through the enclosure of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> from an entrance <NUM>,<NUM>,<NUM>,<NUM> to a discharge <NUM>,<NUM>,<NUM> of the overwrap feed station.

The product <NUM>,<NUM>,<NUM>,<NUM> may move through the enclosure of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> via a conveyor, which may be integrated with the enclosure. The conveyor may be a belt and/or roller conveyor. For purposes of illustration and not in any limiting sense, <FIG> and <FIG> show top and right side belt conveyors <NUM>,<NUM>. Similar conveyors may be provided on the left and bottom sides. For ease of illustration, the conveyors are otherwise not shown in the views of the Figures. The product to be wrapped may also move through the enclosure via a vacuum or through over pressure. The vacuum or over pressure may be coupled with conveyor, for instance, a belt and/or roller conveyor, which may be integrated with the enclosure. The product to be wrapped may also move through the enclosure with a pushing or pulling mechanism. In integrating the conveyor with the enclosure, the conveyor may be arranged on at least one of the left vertical support, right vertical support, top horizontal support, and bottom horizontal supports of the enclosure. To provide even feeding, the conveyor may be arranged on both vertical supports and/or both horizontal supports. There may be a part of the conveyor on the vertical supports for a portion of enclosure and part of the conveyor on the horizontal supports for another portion of the enclosure. In one aspect, driven belts grab the product as it enters into the enclosure to pull the product evenly with the overwrap material <NUM>,<NUM>,<NUM>,<NUM>.

The overwrap feed station <NUM>,<NUM>,<NUM> receives at the entrance <NUM>,<NUM>,<NUM>,<NUM> the overwrap material <NUM>,<NUM>,<NUM>,<NUM> for the product <NUM>,<NUM>,<NUM>,<NUM> to be packaged in a tube of overwrap material. By way of example and not in any limiting sense, the overwrap material may be a polyethylene film. As the product <NUM>,<NUM>,<NUM>,<NUM> to be wrapped moves through the enclosure of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> the overwrap material <NUM>,<NUM>,<NUM>,<NUM> is drawn around the product to form a tube of the overwrap material around the product. As will be described in more detail below, the single overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> may be configured in several configurations depending upon the desired location of the longitudinal seal used to form the package containing the product <NUM>,<NUM>,<NUM>,<NUM>.

In one configuration of the overwrap feed station <NUM>,<NUM>, which is shown by way of example in <FIG>, the wrapped rolls or packs of products <NUM>,<NUM> may have its seal <NUM>,<NUM> on a face of the tubular package configuration which is generally opposite of (<NUM> degrees from) the side of the entrance <NUM>,<NUM> of the overwrap feed station to which the overwrap material was directed, and more in particular, at the center of the face. The longitudinal seal <NUM>,<NUM> may be created by heating the adjacent and overlapping longitudinal edges to fuse the edges to together and then directing cooling air over the fused edges to cure the seal. The seal <NUM>,<NUM> may also be created by a fin seal, or gluing or bonding the edges or flaps on the longitudinal edges of the overwrap material. The seal may also be created by ultrasonically welding the edges or flaps on the longitudinal edges of the overwrap material or by applying a heated element directly against the longitudinal edges of the film. Additionally, lasers could also be used to weld the edges together. A longitudinal seal unit <NUM>,<NUM> for forming the desired seal (e.g., heat, glue, ultrasonic, etc.) may be provided in the hollow interior of the enclosure on supports adjacent to the desired location of the seal.

<FIG> show the overwrap material <NUM> being unwound from an unwind stand <NUM> about a horizontal axis <NUM> and being directed to the entrance <NUM> of the overwrap feed station <NUM> from generally the bottom of the overwrap feed station with a width of the overwrap material being oriented horizontally. The longitudinal seal unit <NUM> forms the seal adjacent to the top horizontal support of the overwrap feed station <NUM> on the top face of the package of wrapped product <NUM> which is generally opposite of (<NUM> degrees from) the bottom horizontal support and where the overwrap material entered the entrance to the overwrap feed station. <FIG> show an alternate embodiment where the overwrap material <NUM> is being directed to the entrance <NUM> of the overwrap feed station <NUM> from generally the left side of the overwrap feed station (as shown in Figures or facing the entrance to the overwrap feed station). The longitudinal seal unit <NUM> forms the seal <NUM> adjacent to the right vertical support of the overwrap feed station on the right vertical face of the package of wrapped product, which is generally opposite of (<NUM> degrees from) the left vertical support and where the overwrap material entered the entrance to the overwrap feed station. While <FIG> show the unwind stand <NUM> having a horizontal center axis <NUM> for unwinding, and the overwrap material travelling to the entrance of the overwrap feed station in a generally horizontal format (i.e., the width arranged horizontally), the overwrap material may be unwound from the unwind stand at an angle or vertically and may be oriented as desired prior to being guided into the entrance of the overwrap feed station with turn bars. For instance, in the embodiment of <FIG>, the overwrap material <NUM> may be unwound from an unwind stand (not shown) about a vertical axis so the overwrap material may travel to the entrance of the overwrap feed station in a generally vertical plane with one longitudinal edge vertically above the other across a width of the overwrap material (i.e., the width of the overwrap material extending vertically). In the alternative to that described above relative to <FIG> and <FIG>, the overwrap material may be unwound from an unwind stand about a horizontal axis and may be initially directed to the entrance of the overwrap feed station in a generally horizontal format with the longitudinal edges of the overwrap material at the same vertical distance across the width (i.e., the width of the overwrap material extending horizontally), and a <NUM> degree turn bar may be used to reorient the overwrap material prior to being guided into the entrance of the overwrap feed station.

In both embodiments of <FIG> and <FIG>, the overwrap material <NUM>,<NUM> may be directed to the entrance of the overwrap feed station, and a former <NUM>,<NUM> arranged around the entrance <NUM>,<NUM> of the overwrap feed station <NUM>,<NUM> may guide the overwrap material into the hollow interior of the enclosure. As the overwrap feed station <NUM>,<NUM> draws the overwrap material <NUM>,<NUM> into and through the hollow interior of the enclosure with the product <NUM>,<NUM> to be packaged, the former <NUM>,<NUM> manipulates the overwrap material so that the opposite longitudinal edges of the overwrap material <NUM>,<NUM> are brought adjacent to and overlapping with one another on a side of the overwrap feed station opposite of the side from which the overwrap material was directed to the entrance of the overwrap feed station, and more in particular, at the center of the respective face. Thus, the longitudinal seal unit <NUM>,<NUM> may be arranged (and the resultant longitudinal seal <NUM>,<NUM> may be formed) on the side of the overwrap feed station opposite of the side from which the overwrap material <NUM>,<NUM> was directed to the entrance <NUM>,<NUM> of the overwrap feed station, and may be placed on the package on the side of the package opposite of the side from which the overwrap material was directed to the entrance of the overwrap feed station. For instance, as best shown in <FIG>, the seal <NUM> is formed on the top face of the tubular package roughly <NUM> degrees from the center of the bottom face of the package which is the general direction from which the overwrap material was directed to the entrance of the overwrap feed station. In <FIG>, the seal <NUM> is formed roughly <NUM> degrees from the center of the left face of the package which is the general direction from which the overwrap material was directed to the entrance of the overwrap feed station. Although the drawings show the seal being formed in the center of the top face of the package, the seal may be formed at any position on the horizontal or side face as may be desired with a former having a geometry configured to align the longitudinal edges of the overwrap material in the desired position.

In a second configuration of the packaging line <NUM> with an overwrap infeed station <NUM>, which is shown by way of example in <FIG>, the wrapped rolls or packs of products <NUM> may have its seal <NUM> on a vertical face of the tubular package configuration which is generally <NUM> degrees (or <NUM> degrees) from the side of the entrance <NUM> to which the overwrap material <NUM> was directed to the entrance of the overwrap feed station, and more in particular, at the center of the face. The former <NUM> adjacent the entrance <NUM> of the overwrap feed station is adapted and configured to direct the overwrap material <NUM> for packaging the product to be packaged through the hollow interior of the enclosure with longitudinal edges of the overwrap material overlapping each other adjacent to one of the left and right vertical support. Again, the longitudinal seal <NUM> may be created by heating the adjacent and overlapping longitudinal edges to fuse the edges to together and then directing cooling air over the fused edges to cure the seal, or using one of the aforementioned other methods. A longitudinal seal unit <NUM> may be provided in the hollow interior of the enclosure on supports adjacent to the desired location of the seal. For instance, <FIG> show the overwrap material <NUM> being unwound from an unwind stand <NUM> about a horizontal axis <NUM> and being directed to the entrance of the overwrap feed station <NUM> from generally the bottom of the overwrap feed station in a horizontal format. As best shown in <FIG>, the longitudinal seal unit <NUM> forms the seal <NUM> adjacent to the right horizontal support of the overwrap feed station <NUM> on the right face of the package of wrapped product. In the embodiment of <FIG>, the overwrap material <NUM> is delivered to the entrance <NUM> of the overwrap feed station <NUM> in a manner similar to that shown in <FIG>, but the overwrap material comes together on a vertical face of the package rather than adjacent to the horizontal supports of the overwrap feed station.

The former of <FIG> creates a very short path on one side of the tubular package of the product <NUM> (about <NUM> degrees from the side of the entrance of the overwrap feed station from which the overwrap material enters), and a much longer path around the other side of the tubular package of the product (about <NUM> degrees from the side of the entrance of the overwrap feed station from which the overwrap material enters). To assist in moving the opposite longitudinal edges to become adjacent and overlapping with each other on a side <NUM> degrees from the side to which the overwrap material enters the overwrap feed station, the overwrap material <NUM> may be significantly offset relative to the entrance <NUM> such that the longitudinal edges overlap on a side <NUM> degrees from the side to which the overwrap material enters the overwrap feed station. For instance, by way of example as shown in <FIG>, the overwrap material <NUM> may be unwound from an unwind stand <NUM> about a horizontal axis <NUM> and may be directed to the entrance <NUM> of the overwrap feed station <NUM> in a generally horizontal format with the longitudinal edges of the overwrap material at the same vertical distance across the width (i.e., the width of the overwrap material extending horizontally), which is the general form of unwinding shown in <FIG>. However, in <FIG>, the relative position of the overwrap material <NUM> on the unwind stand may be significantly shifted in the direction of the center axis <NUM> of unwind stand <NUM> so that the overwrap material is guided to the entrance of the overwrap feed station significantly off center. In <FIG>, the roll of overwrap material <NUM> on the unwind stand <NUM> has been shifted to the left. Thus, the same manner of delivery of the overwrap material and the same unwind stand may be used regardless of the whether the application process calls for the longitudinal seal to be formed on a horizontal face or vertical face of the tubular package. By way of example, the unwind stand <NUM> may be placed be on linear rails and moved perpendicular to the direction of the flow the overwrap material <NUM> as it is being unwound from the stand. In a further example, the overwrap material <NUM> may be wound on a mandrel and the mandrel may be disposed on a spindle with the spindle disposed on a linear slide. The linear slide may be movable along a direction of the center axis <NUM> of the spindle between a position in which the overwrap material is centered relative to the entrance of the overwrap feed station and off center relative to the entrance of the overwrap feed station. Thus, for orientations of the longitudinal seal on the vertical face and the horizontal face, the same unwind stand <NUM> may be used and the overwrap material <NUM>,<NUM>,<NUM> may follow the same general flow path being fed underneath the overwrap feed station, which is out of the way and less inconvenient for an operator when operating the overwrap feed station. Although <FIG> show the seal being formed in the center of the side face of the package, the seal may be formed at any position on the vertical face as may be desired with a former having a geometry configured to align the longitudinal edges of the overwrap material in the desired position.

For the ease of illustration, a single roll of overwrap film <NUM>,<NUM> is shown on an unwind stand <NUM>. A double drum unwind stand may also be used to deliver the over wrap material to the overwrap feed station. The overwrap material may be unwound with either the overwrap material coming off the top of the roll or the bottom of the roll. When the application process calls for the seal to be oriented <NUM> degrees from the side to which the overwrap material enters the entrance of the overwrap feed station, the overwrap material may be centered on the unwind stand so it is generally centered to the former. When the application process calls for the seal to be oriented <NUM> degrees (<NUM> degrees) from the side to which the overwrap material enters the entrance of the overwrap feed station or at the corner, the overwrap material may be significantly off center on the unwind stand (e.g., shifted in the direction of the center axis of rotation during unwinding of the overwrap material on the unwind stand) so it is off center to the former. The position of the overwrap material relative to the entrance of the former may be shifted as necessary to allow the former to align the longitudinal edges of the overwrap material in the desired position on the top and/or side face of the package. The off center position of the overwrap material could be calculated in the central processing unit of the packaging line and moved automatically into position or communicated to the operator through an operator interface. The tension of overwrap material as it is unwound from the double drum unwind stand may be monitored and changed using by way of example, a load cell, a dancer roller and a potentiometer. A measuring roller may be used to pull the overwrap material from the double drum unwind stand through the dancer roller and to feed the overwrap material through the former and the overwrap feed station at a desired speed. An eye mark reader may be used to synchronize the product delivered to the entrance of the overwrap feed station with the overwrap material so that a graphic material arranged on the overwrap material may be located in a desired position on the tubular package of wrapped product.

When the product <NUM>,<NUM>,<NUM>,<NUM> is delivered to the entrance <NUM>,<NUM>,<NUM>,<NUM> of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM>, the product is directed into the overwrap material at an opening in the former <NUM>,<NUM>,<NUM>,<NUM>. The former <NUM>,<NUM>,<NUM>,<NUM> shapes the overwrap material <NUM>,<NUM>,<NUM>,<NUM> into a tube to enclose the bundled product. The former <NUM>,<NUM>,<NUM>,<NUM> may comprise an assembly of plates or in the alternative, the former <NUM>,<NUM>,<NUM>,<NUM> may be a single, monolithic piece. Additionally, the former <NUM>,<NUM>,<NUM>,<NUM> may have adjustability to work with multiple formats or it could be specialized for one single product format. The former may also be comprised of cables or any other mechanical structure or mechanism to form a tube from a web.

In one aspect of using the overwrap feed station, e.g., a first configuration of the overwrap feed station, a first former <NUM> may be used to guide the overwrap material through the entrance of the overwrap feed station such that the longitudinal seal may be formed on a horizontal face of the tubular package (for instance, as shown in <FIG>), and more in particular, at the center of the face. In another aspect of using the same overwrap feed station, e.g., a second configuration of the overwrap feed station, a second former <NUM> may be used to guide the overwrap material through the entrance of the overwrap feed station such that the longitudinal seal may be formed on a vertical face of the tubular package (for instance, as shown in <FIG>), and more in particular, at the center of the face. In another aspect of using the same overwrap feed station, e.g., a third configuration of the overwrap feed station, a third former <NUM> may be used to guide the overwrap material through the entrance of the overwrap feed station such that the longitudinal seal may be formed on a transitional corner of the tubular package (for instance, as shown in <FIG>). As mentioned above, the former may have a geometry as needed to place the seal in any position on the top face or side face, or at the corner of the package.

A former <NUM>,<NUM>,<NUM>,<NUM> may comprise a base <NUM>,<NUM>,<NUM>,<NUM> with a cap portion <NUM>,<NUM>,<NUM>,<NUM>. A base <NUM>,<NUM>,<NUM>,<NUM> of each of the formers <NUM>,<NUM>,<NUM>,<NUM> may be common but the cap portion <NUM>,<NUM>,<NUM>,<NUM> of each of the formers may be differently shaped in order to manipulate the overwrap material <NUM>,<NUM>,<NUM>,<NUM> so that the longitudinal edges of the overwrap material are arranged in an overlapping and adjacent manner on a desired location on the tubular package. The cap portion <NUM>,<NUM>,<NUM>,<NUM> of each of the formers <NUM>,<NUM>,<NUM>,<NUM> may cooperate with the common base <NUM>,<NUM>,<NUM>,<NUM>. In one example, there may be two sets of bases for a particular overwrap feed station. One base may be used when the process calls for the product to be delivered to the overwrap feed station in a "cores up" (standing upright) format, and the second base may be used when the process calls for the product to be delivered to the overwrap feed station in a "cores down" (laying down) format. The first base may be used regardless of the whether the overwrap feed station is in the first configuration or second configuration, and the second base may be used regardless of the whether the overwrap feed station is in the first configuration or second configuration. Thus, the bases would not need to change based on longitudinal seal position, and first, second, and third configurations of the overwrap feed station, but the bases may change based on the incoming product orientation. In this example, the cap portions that work with particular base may change depending upon the longitudinal seal position and first, second and third configurations of the overwrap feed station. When the process calls for the longitudinal seal to be formed adjacent to the top or bottom horizontal supports, the cap portion of the former may use two top cap plates (one on each side, for instance, as shown in <FIG>, '<NUM>'). In distinction, when the process calls for the longitudinal seal to be formed adjacent to the left or right vertical supports, the cap portion of the former may use one top plate (for instance, as shown in <FIG>, '<NUM>'), and depending upon the application, a small, generally straight, second piece on the opposite side of the first portion (not shown). In yet another aspect, when the process calls for the longitudinal seal to be formed adjacent to a point of intersection of one of the left or right vertical supports with one of the corresponding top and bottom supports, the cap portion of the former <NUM> may use one top plate (for instance, as shown in <FIG>, '<NUM>'), and depending upon the application, a small, generally straight, second piece on the opposite side of the first portion (Fig. '<NUM>'). The cap portions may also change based on the incoming product orientation ("cores up" format versus a "cores down" format). Thus, depending upon the overwrap feed station configuration and the incoming product orientation ("cores up" format versus a "cores down" format), the cap portion may be comprise multiple pieces to accommodate different size products and different bundle configurations. Additionally it is possible that the base plates could be changed for different formats or longitudinal seal position. This may be done to optimize the quality of the bundle. That said, it is preferred that one base is compatible with the multiple cap portions so that when a processing application changes and the process calls for a different longitudinal seal position but the same product orientation, switching between the first and second configurations of the overwrap feed station merely involves swapping out the cap portions, and to the extent necessary, shifting the position of the unwind stand, as described above.

By way of example (see, e.g., the embodiment shown in <FIG>), for the former used to form the longitudinal seal in the center of the top face (e.g., the face <NUM> degrees from the side to which the overwrap material <NUM> enters the entrance of the overwrap feed station) with a "cores up" orientation of the product <NUM>, the base <NUM> may comprise two base plates and the cap portion <NUM> may comprise two cap plates. The overwrap material wraps <NUM> equally around each side of the former <NUM> based on product width and product height. The former <NUM> is shaped such that the opposite longitudinal edges of the overwrap material come together at a point <NUM> degrees relative to the incoming path of the overwrap material into entrance of the overwrap feed station. In the embodiment of <FIG>, the base plates may be moved laterally apart and the cap plates may be moved laterally apart the same distance to accommodate a different product width. The lateral spacing between the two cap plates and the lateral spacing between the two base plates (as well as the lateral spacing between the side pull belts on the conveyor) may be adjustable by use of a hand wheel, a motor driven slide, pneumatic actuator, or mechanical spacers. In a similar manner, the cap plates may be moved vertically relative to the base plates to accommodate a different product height. The vertical spacing between the two cap plates and the two base plates (as well as the vertical spacing between the upper and lower pull belts) may be adjustable by use of a hand wheel, a motor driven slide, pneumatic actuator, or mechanical spacers. In this example, the pull belts may be extended into the former opening to receive the product. Since both sides of the former have space inside, the pull belts can grab evenly to receive the product and overwrap material and pull it through the former. Thus, depending upon the size of the product, the same former plates may be used for different wrapped product format sizes having a longitudinal seal <NUM> degrees from the side to which the overwrap material enters the entrance of the overwrap feed station. Should the process change and call for a "cores down" orientation of the product, a new base may be used and a new cap portion may be used, each functioning in a way similar to that described above.

By way of example (see, e.g., the embodiment shown in <FIG>), for the former <NUM> used to form the longitudinal seal in the center of the right vertical face (e.g., the face at <NUM> degrees (<NUM> degrees) from the side to which the overwrap material enters the entrance <NUM> of the overwrap feed station) in a "cores down" orientation of the product <NUM>, the base <NUM> may comprise two base plates and the cap portion <NUM> may comprise one cap plate. The former <NUM> is shaped such that the opposite longitudinal edges of the overwrap material come together at a point <NUM> degrees (<NUM> degrees) relative to the incoming path of the overwrap material <NUM> into entrance <NUM> of the overwrap feed station <NUM>. In another of example (see, e.g., the embodiment shown in <FIG>), for the former <NUM> used to form the longitudinal seal in the transition corner (e.g., point of intersection between one of the top and bottom horizontal supports and one of the corresponding left and right vertical supports (<NUM> degrees/<NUM> degrees from the side to which the overwrap material enters the entrance <NUM> of the overwrap feed station) in a "cores down" orientation of the product <NUM>, the base <NUM> may comprise two base plates and the cap portion <NUM> may comprise one cap plate. The former <NUM> is shaped such that the opposite longitudinal edges of the overwrap material come together at the corner of the package. In the embodiment of <FIG> and the embodiment of <FIG>, the base plates may be moved laterally apart and a different cap plate may be used to accommodate different product widths, heights, and diameters. The lateral spacing between the two base plates (as well as the lateral spacing between the side pull belts on the conveyor) may be adjustable by use of a hand wheel, a motor driven slide, or pneumatic actuator. The vertical spacing between the cap plate and the two base plates (as well as the vertical spacing between the upper and lower pull belts) may be adjustable by use of a hand wheel, a motor driven slide, pneumatic actuator, or mechanical spacers. In this example, the pull belts may be extended into the former on only one side of the opening to receive the product. Because the other side of the former is generally open and the seal unit or heater is arranged in that position to apply the longitudinal seal, the pull belts on the side of the longitudinal seal unit or heater may be retracted out of the way. A lost motion design may be used to accommodate the space. Multiple former pieces may also be used, and changing from one mode to the other may involve manual or automated assembly of the former pieces. Automated assembly may be accomplished via pneumatic or motorized actuators. Additionally, a secondary assembly may be mounted in front (i.e., upstream) of the location of and on the same side as the longitudinal sealer to help receive and contain the product as it enters the former. As seen in <FIG>, there is a significant gap between the top and bottom plate on the right side, and a secondary assembly may be used to capture that product and help move it through the former. The secondary assembly may be a small belt assembly driven from other belts in the area. The secondary assembly may also comprise a small guide plate with roller wheels or beads. The secondary assembly may comprise a housing with a drive for driving a set of smaller belts integrated with the longitudinal seal unit. Alternatively, as shown in <FIG>, a belt driven assembly <NUM> may be moved in a direction laterally toward the product flow and the opening of the former into the gap between the top and bottom plate <NUM>,<NUM> on the right side of the former <NUM>. For a configuration as shown in <FIG>, the belt driven assembly may be moved in a direction toward the inlet of the former to capture the product as soon as possible. In the configuration as shown in <FIG>, the belt driven assembly <NUM> may have sections <NUM> that are arranged to create a lateral spacing between the belt and the product which allows the bottom part of the cap plate (e.g., the portion extending downward just before the seal unit) to fit between product and the belt of the belt driven assembly <NUM>. The section <NUM> (and thus the spacing) may be adjustable in width or position to accommodate different sizes of cap plates and bottom plates, and different product sizes and formats. The belt driven assembly may reduce the number of different parts required for different product sizes and formats, and may reduce set-up time in changing the packaging line and overwrap feed station from one format to another. Thus, depending upon the height of the product, the same cap plate and base plates may be used for different wrapped product format height sizes having a longitudinal seal <NUM> degrees (<NUM> degrees) from the side to which the overwrap material enters the entrance of the overwrap feed station. Should the process change and call for a "cores up" product orientation, a new base may be used and a new cap portion may be used, each functioning in a way similar to that described above.

A third configuration of the packaging line <NUM> with an overwrap infeed station <NUM> is shown by way of example in <FIG>. The wrapped rolls or packs of products <NUM> have its seal <NUM> on a corner of the tubular package configuration which is generally <NUM> degrees (or <NUM> degrees) from the side of the entrance <NUM> to which the overwrap material <NUM> was directed to the entrance of the overwrap feed station. The former <NUM> adjacent the entrance <NUM> of the overwrap feed station is adapted and configured to direct the overwrap material <NUM> for packaging the product to be packaged through the hollow interior of the enclosure with longitudinal edges of the overwrap material overlapping each other adjacent to the corner of the left and right vertical support. Again, the longitudinal seal <NUM> may be created by heating the adjacent and overlapping longitudinal edges to fuse the edges to together and then directing cooling air over the fused edges to cure the seal, or using one of the aforementioned other methods. A longitudinal seal unit <NUM> may be provided in the hollow interior of the enclosure on supports adjacent to the desired location of the seal. For instance, <FIG> shows the overwrap material <NUM> being unwound from an unwind stand <NUM> about a horizontal axis <NUM> and being directed to the entrance of the overwrap feed station <NUM> from generally the bottom of the overwrap feed station in a horizontal format. The longitudinal seal unit <NUM> forms the seal <NUM> adjacent to the right horizontal support of the overwrap feed station <NUM> on the top right corner of the package of wrapped product. In the embodiment of <FIG>, the overwrap material <NUM> is delivered to the entrance <NUM> of the overwrap feed station <NUM> in a manner similar to that shown in <FIG>, but the overwrap material comes together on the top corner of the package rather than adjacent to the horizontal supports of the overwrap feed station.

The former of <FIG> is similar to the former of <FIG> and creates a very short path on one side of the tubular package of the product <NUM> (about <NUM> degrees from the side of the entrance of the overwrap feed station from which the overwrap material enters), and a much longer path around the other side of the tubular package of the product (about <NUM> degrees from the side of the entrance of the overwrap feed station from which the overwrap material enters). To assist in moving the opposite longitudinal edges to become adjacent and overlapping with each other on the corner of the package (e.g., a side <NUM> degrees from the side to which the overwrap material enters the overwrap feed station), the overwrap material <NUM> may be significantly offset relative to the entrance <NUM> such that the longitudinal edges overlap on a side <NUM> degrees from the side to which the overwrap material enters the overwrap feed station. For instance, by way of example as shown in <FIG>, the overwrap material <NUM> may be unwound from an unwind stand <NUM> about a horizontal axis <NUM> and may be directed to the entrance <NUM> of the overwrap feed station <NUM> in a generally horizontal format with the longitudinal edges of the overwrap material at the same vertical distance across the width (i.e., the width of the overwrap material extending horizontally), which is the general form of unwinding shown in <FIG>. However, in <FIG> (like in <FIG>), the relative position of the overwrap material <NUM> on the unwind stand may be significantly shifted in the direction of the center axis <NUM> of unwind stand <NUM> so that the overwrap material is guided to the entrance of the overwrap feed station significantly off center. In <FIG>, the roll of overwrap material <NUM> on the unwind stand <NUM> has been shifted to the left. By way of example, as described above with reference to the configuration of <FIG>, the unwind stand <NUM> may be placed be on linear rails and moved perpendicular to the direction of the flow the overwrap material <NUM> as it is being unwound from the stand. The amount of shift may be less than that needed for a side lap seal, for instance, as shown in <FIG>, given the same product and film size. This provides an advantage in reducing space and the overall footprint of the machine range as the same manner of delivery of the overwrap material and the same unwind stand may be used regardless of the whether the application process calls for the longitudinal seal to be formed on a horizontal face, vertical face, or corner of the tubular package.

The configuration of <FIG> may provide more flexibility over the configurations for <FIG>, <FIG> and <FIG>, in allowing for a relatively larger area on the package for graphics depending upon the product format, particularly, with a "cores down" format where the rolls provide a roll radius in which to place the seal.

In the configurations of <FIG>, <FIG>, and <FIG>, a flat surface or a flat backing plate may be used to create a barrier between the overwrap material and the rolls being packaged so that when the longitudinal edges of the overwrap film are sealed, they are not welded to the rolls or a film used to contain inner packages of the rolls. In the embodiment of <FIG>, a backing plate may be provided that is formed to match the radius or corner of the rolls. In the alternative, a flexible member may be provided. The flexible member may be deflectable/formable to form to the required corner shape and provide the necessary backing for the seal without needing to change parts from one format to the next, which may be advantageous reduce changeover time, part count, and cost.

Generally speaking, in the embodiments of <FIG>, <FIG>, and <FIG>, the longitudinal seal <NUM>,<NUM>,<NUM>,<NUM> unit may be manually or automatically adjusted for height and may be manually or automatically adjusted in the direction of the movement the product as it is being moved through the hollow interior of the enclosure. One longitudinal seal <NUM>,<NUM>,<NUM>,<NUM> unit may be provided and may be oriented as needed to provide the longitudinal seal on the desired side of the package. The longitudinal seal <NUM>,<NUM>,<NUM>,<NUM> unit may be disposed on a mechanism that moves from a position adjacent the top horizontal support of the overwrap feed station and to a position adjacent one of the left and right vertical supports of the overwrap feed station. The longitudinal seal unit may be configured to move to any position relative to the horizontal and vertical faces, and the corner to allow the longitudinal seal to be formed as desired. The movement could be performed by a motorized assembly that allows the longitudinal seal unit <NUM>,<NUM>,<NUM>,<NUM> to pivot to either location and to move in a secondary actuation direction that allows the longitudinal seal unit to be brought to a close distance to the path of the overwrap material <NUM>,<NUM>,<NUM>,<NUM>. The index movement may be performed manually or via a rotary actuator. Alternatively, a second longitudinal seal unit (see, e. g, <FIG>, '<NUM>') may be provided with one longitudinal seal unit <NUM> arranged adjacent the top horizontal support of the overwrap feed station and used for applying the longitudinal seal at any position on the horizontal face of the package (e.g., <NUM> degrees from the side to which the overwrap material enters the entrance of the overwrap feed station) and the other longitudinal seal unit <NUM> arranged adjacent the left and/or right vertical horizontal support of the overwrap feed station and used for applying the longitudinal seal at any position on the vertical face of the package (e.g., <NUM> degrees (<NUM> degrees) from the side to which the overwrap material enters the entrance of the overwrap feed station). The longitudinal seal unit that is not used for the application process may be moved to a disengaged position. For instance, as shown in <FIG>, the second longitudinal seal unit <NUM> is moved out of position. For desired movement or disengagement from use, a longitudinal seal unit may be moved manually, with a motor driven slide, or via pneumatic actuator.

During normal operation of the packaging line <NUM>,<NUM>,<NUM>,<NUM> and overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> the overwrap material <NUM>,<NUM>,<NUM>,<NUM> is directed from the unwind stand <NUM>, pulled around the outside of the former <NUM>,<NUM>,<NUM>,<NUM> and then through an opening of the former into the entrance <NUM>,<NUM>,<NUM>,<NUM> of the overwrap feed station to form a tube around the product <NUM>,<NUM>,<NUM>,<NUM> and the tube of overwrap material around the product is sealed by the longitudinal sealer (not shown). A vacuum lance (not shown) may be used to extract any air from the bundle that was introduced and as a backing for formation of the longitudinal seal preventing the overwrap material from melting onto the product during heating to form the longitudinal seal. Additionally, a passive means of allowing the air to exit the bundle may be used, such as holes punched in the film upstream. The upper and lower end seal dies (not shown) may be disposed at the discharge <NUM>,<NUM>,<NUM>,<NUM> of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> to form end seals in the tubular wrapped product. Mechanical tuckers (not shown) or an air blast (not shown) may be disposed at the discharge <NUM>,<NUM>,<NUM>,<NUM> of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> to form the gussets in the tubular package. A plunge knife (not shown), or a knife that is either mechanically or pneumatically actuated (not shown), may be disposed at the discharge <NUM>,<NUM>,<NUM>,<NUM> of the overwrap feed station <NUM>,<NUM>,<NUM>,<NUM> to cut adjacent bundles of the tubular packages at the end seals. A separate cut and seal ribbon may also be used to separate the tube and seal the ends together.

As is evident from the foregoing description, a single overwrap feed station may be arranged in multiple alternative configurations to allow the user to place the longitudinal seal at different positions on the horizontal and side faces, and the corner of the package. It should be realized that a former may be configured to arrange the seal at any position on the horizontal or vertical face of the package, including the corner of the package, and that the overwrap material may be positioned as needed (for instance, by moving the unwind stand) to facilitate locating overlapping edges of the overwrap material as desired at any position on the horizontal or vertical face of the package, including the corner of the package.

Claim 1:
A packaging line (<NUM>, <NUM>) comprising an overwrap feed station (<NUM>, <NUM>), the overwrap feed station (<NUM>, <NUM>) having left and right vertical supports, and bottom and top horizontal supports defining an enclosure with a hollow interior for the overwrap feed station (<NUM>, <NUM>) where the product (<NUM>, <NUM>) to be packaged is movable from an entrance (<NUM>, <NUM>) of the overwrap feed station (<NUM>, <NUM>) to a discharge (<NUM>, <NUM>) of the overwrap feed station (<NUM>, <NUM>) through the hollow interior of the enclosure, the overwrap feed station (<NUM>, <NUM>) receiving at the entrance (<NUM>, <NUM>) overwrap material (<NUM>, <NUM>) for packaging the product (<NUM>, <NUM>) to be packaged in a tube of overwrap material, (<NUM>, <NUM>)
characterized by
the overwrap feed station (<NUM>, <NUM>) being configurable in one of a first configuration and a second configuration;
wherein in the first configuration, a first former (<NUM>) adjacent the overwrap feed station entrance (<NUM>) is adapted and configured to direct the overwrap material (<NUM>) for packaging the product (<NUM>) to be packaged through the hollow interior of the enclosure with longitudinal edges of the overwrap material (<NUM>) overlapping each other adjacent to one of the top and the bottom horizontal supports and the overlapping longitudinal edges being sealed to a horizontal face of the tube of overwrap material (<NUM>) forming the packaging of the product (<NUM>); and
wherein in the second configuration, a second former (<NUM>) adjacent the overwrap feed station entrance (<NUM>) is adapted and configured to direct the overwrap material (<NUM>) for packaging the product (<NUM>) to be packaged through the hollow interior of the enclosure with longitudinal edges of the overwrap material (<NUM>) overlapping each other adjacent to one of the left and right vertical supports and the overlapping longitudinal edges being sealed to a vertical face of the tube of overwrap material (<NUM>) forming the packaging of the product (<NUM>).