Packaging a continuous length of products using indexed layers

Abstract

The present disclosure provides a method of packaging a continuous length of a product or material in a container using rows or layers that are indexed a pre-determined distance when placed on a previous row or layer. The method permits an end-user to dispense the entire contents of a container with one set-up, and eliminates the need to splice within the box to obtain a continuous supply of the product. The indexed layers form horizontal layers that provide stability and balance to the container while the product or material is dispensed by an end-user. Indexed layers provide a natural separation plane between adjacent layers so that the product or material can be dispensed more quickly. A container that is packaged and filled using indexed rows or layers of a product or material by the method is also disclosed.

1 . A method for packaging a continuous length of products in a container comprising:
 dispensing said products into the container with a dispensing machine to form a first row across a lengthwise dimension;   indexing said products by an index distance that is shifted in relation to said first row;   dispensing a second row of said products into the container with said dispensing machine to form a partial overlap of said second row along a lengthwise dimension of said first row, wherein said second row is offset in relation to said first row by said index distance;   dispensing one or more additional rows of said products into the container, wherein each of said one or more additional rows is offset from an immediate previous row by an index distance,   wherein said first row, said second row, and said one or more additional rows of said products form a horizontal layer of said products in the container.   
   
   
       2 . The method according to  claim 1 , wherein said dispensing machine moves back-and-forth across the container for dispensing said first row, said second row, and said one or more additional rows of said products into the container. 
   
   
       3 . The method according to  claim 1 , wherein the container moves back-and-forth under a dispensing machine for dispensing said first row, said second row, and said one or more additional rows of said products into the container. 
   
   
       4 . The method according to  claim 1 , wherein said indexing is performed by shifting said dispensing machine in relation to the container, shifting the container in relation to said dispensing machine, or shifting both said dispensing machine and the container, wherein each row is offset from an earlier row by an amount of said index distance. 
   
   
       5 . The method according to  claim 1 , further comprising:
 tilting the container or said dispensing machine to assist dispensing of said products into the container.   
   
   
       6 . The method according to  claim 5 , wherein said tilting is by positioning the container or said dispensing machine on a moveable device to move and/or rock the container or said dispensing machine during said dispensing. 
   
   
       7 . The method according to  claim 1 , further comprising:
 reversing direction of dispensing after said horizontal layer of indexed rows of products reaches a widthwise edge of the container.   
   
   
       8 . The method according to  claim 1 , further comprising:
 inserting a mechanical device between adjacent rows to press the ends of said first row, second row, and said one or more additional rows closer to the edge of the container to maximize use of space.   
   
   
       9 . The method according to  claim 1 , further comprising:
 inserting a tamping device to press down the ends of said first row, second row, and said one or more additional rows to flatten in the container to maximize use of space.   
   
   
       10 . The method according to  claim 1 , further comprising repeating said dispensing and said indexing to form a second horizontal layer of indexed rows of products in the container. 
   
   
       11 . The method according to  claim 8 , further comprising repeating said dispensing and said indexing to form three or more horizontal layers of indexed rows of products in the container. 
   
   
       12 . The method according to  claim 1 , wherein the container is filled with a continuous length of products formed into horizontal, indexed layers. 
   
   
       13 . The method according to  claim 10 , wherein the container is filled with a continuous length of products without splicing. 
   
   
       14 . The method according to  claim 1 , wherein the container is a large box that can rest flat upon a pallet. 
   
   
       15 . The method according to  claim 1 , further comprising a tail of said products extending beyond the container as an attachment site for continuous feed of said products.