Method of Packaging a Continuous Length of Product on a Spool using Indexed Layers

Abstract

A method is provided for packaging a continuous thread of a woven material or finished product, such as an absorbent food pad, onto a spool, spindle, or other large roll in indexed layers forming rows, for efficient loading and unloading of the product from the spool. A finished spool formed by rows of indexed layers of a continuous thread of the product is also provided.

What is claimed is: 
     
         1 . A method for packaging a continuous length of a product onto a spool comprising:
 dispensing the product onto the spool with a dispensing device to form a first layer of the product that is wrapped around the spool;   indexing the product by an index distance that is shifted in relation to the first layer;   dispensing a second layer of the product onto the spool with the dispensing device to form an indexed layer that partly overlaps the first layer, wherein the second layer is offset in relation to the first layer by the index distance;   dispensing one or more additional indexed layers of the product onto the spool, wherein each of the one or more additional indexed layers is offset from the immediate previous layer by the index distance,   wherein the first layer, the second layer, and the one or more additional indexed layers of the product form a first horizontal row of the product along an axial extent of the spool.   
     
     
         2 . The method according to  claim 1 , further comprising:
 reversing the direction of the dispensing device when the first horizontal row of the product reaches a first end of the spool; and   dispensing one or more indexed layers of the product onto the spool in an opposite direction from the first horizontal row, to form a second horizontal row of product along the axial extent of the spool.   
     
     
         3 . The method according to  claim 2 , further comprising:
 reversing the direction of the dispensing device when the second horizontal row of the product reaches a second end of the spool opposite the first end of the spool; and   dispensing one or more indexed layers of the product onto the spool in an opposite direction from the second horizontal row, to form a third horizontal row of the product along the axial extent of the spool.   
     
     
         4 . The method according to  claim 3 , further comprising:
 repeating the reversing and the dispensing steps until the spool is loaded with a continuous length of the product to form a finished spool having indexed layers and horizontal rows of the product.   
     
     
         5 . The method according to  claim 1 , wherein the dispensing device further comprises a guide that directs the product onto the spool, wherein the guide is selected from the group consisting of: loop, bar, funnel, and any combinations thereof. 
     
     
         6 . The method according to  claim 5 , wherein the indexed layers are formed by movement of the dispensing device, guide, and/or spool. 
     
     
         7 . The method according to  claim 5 , wherein the size of the index distance is established by the size of the movement of the dispensing device, guide, and/or spool. 
     
     
         8 . The method according to  claim 1 , wherein the size of the index distance is from one-fifth of an inch (0.20″) to about two inches (2″). 
     
     
         9 . The method according to  claim 1 , wherein the axial extent of the spool is about 4 to about 6 times as wide across as compared with the width of the product dispensed onto the spool. 
     
     
         10 . The method according to  claim 1 , wherein the indexed layers of the product are dispensed onto the spool at high production speeds. 
     
     
         11 . The method according to  claim 1 , wherein the product is an absorbent food pad. 
     
     
         12 . The method according to  claim 1 , further comprising a spindle on which the spool is mounted during dispensing of the product. 
     
     
         13 . The method according to  claim 1 , further comprising a floor fixture on which the spool is mounted, wherein the floor fixture mitigates the weight of the spool and provides stability while dispensing the product onto the spool. 
     
     
         14 . A spool for packaging a continuous length of a product, comprising:
 a removable hollow spool; and   a continuous length of the product that is wound around the spool in indexed layers that form one or more horizontal rows of the product along an axial extent of the spool.