Note: Descriptions are shown in the official language in which they were submitted.
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LINERLESS LABEL DISPENSER
BACKGROUND AND SUN~IARY OF THE INVENTION
The use of linerless labels is becoming widespread
due to relatively low cost of such labels and due to their
relative environmental friendliness. A number of different
dispensers has been developed - such as shown in U.S.
Patents 6,142,049, 5,375,752 and 5,417,783, European
published application 0577241, and published PCT
Application W09610489 Al - to facilitate dispensing of such
labels. Each of those dispensers is particularly suited for
certain dispensing requirements and can successfully
dispense linerless labels without prohibitive difficulties.
However, there are some circumstances for which such
dispensers are not ideally suited, and therefore the
linerless label dispenser according to the above-mentioned
U.S. Patent 6,142,049 - and its associated cutting mechanism
- have been developed.
The linerless label dispenser, and its associated
cutting mechanism, according to the invention disclosed in
U.S. Patent 6,142,049 are ideally suited for dispensing
linerless labels from a roll even when the labels are not
perforated on the roll. The dispenser can automatically
print the labels
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just prior to dispensing, and dispenses them in a manner that
substantially avoids jamming of the printer or the cutting mechanism.
According to one aspect of that invention a linerless label
dispenser is provided comprising the following components: A support
for a supply of continuous form linerless labels, each label havihg a
pressure sensitive adhesive face and an adhesive-release material
coated face. An adhesive-release material guide structure for engaging
the adhesive face of labels from the supply of labels. A print head, on
the opposite side of the guide structure from the supply of labels, for
printing the release material coated face of labels from the supply of
labels. A stripper surface, on the opposite side of the print head from
the release material structure, the stripper surface of adhesive-release
material. A stationary anvil blade, on the opposite side of the stripper
surface from the print head, for engaging the adhesive face of labels
from the supply of labels. And an automatic rotary cutter cooperating
with the stationary anvil blade for engaging the release material coated
face of labels from the supply of labels, and cutting individual labels to
be dispensed from the supply of continuous form of linerless labels.
The support far the continuous form linerless labels of that
invention comprised a conventional shaft mounting a hub about 25% of
the length of the core of a roll of linerless labels mounted on the hub.
The linerless labels may either be perforated, or may have marks
applied thereto indicating the approximate position at which the web of
labels from the roll are to be severed into individual labels.
1i
a
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The adhesive-release material guide structure is mounted
adjacent a plastic guide which engages the release material face of the
labels, and preferably the adhesive-release material thereof is a plasma
coating such as disclosed in U.S. Patent 5,375,752.
After the guide structure, the labels typically pass under a sensor
which either senses the perforations or marks indicating the division
between labels, which cooperates with a control mechanism for the
printer and subsequent rotary cutter. The print head may be of any
conventional type that is capable of printing on the release material,
preferably a non-impact printer such as an ink jet printer. Where a
thermosensitive coating is also provided for the labels, the print head
may be a thermal print head or a thermal transfer print head. Typically
the print head cooperates with a print roller, which may be plasma
coated, but preferably is a silicone roller.
Just downstream of the print head is a support which supports the
stripper surface and the stationary anvil blade. The adhesive-release
material of the stripper surface preferably also is a plasma coating, and
the stripper surface is disposed at an upwardly directed (from the print
head) angle of between about 20-35° (preferably about 27°) with
respect
to the horizontal so that the labels printed by the print head move
upwardly at an angle from the print head to the rotary cutter. The
provision of such an angle has been found to minimize jams of the
printer and the cutter. A stripper surface also may have a plurality of
upwardly extending extensions formed on at least a part thereof (e.g. a
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portion of between 5-20% of the width of a linerless label passing
thereover) for decreasing the surface tension thereof.
The stationary anvil blade is preferably also coated with a release
material such as plasma coatings or textured paint and is immediately
adjacent the stripper surface. It has been found according to the present
invention that jamming of the printer and rotary cutter are minimized if
the anvil blade projects upwardly from a support surface and downwardly
spaced for a stripper surface a sufficient distance to insure that the
leading edge of the label (the edge being cut) is not smashed. It has
been found that being set slightly below the stripper surface in a range
between about .001-.008 inches (preferably about .002-.004 inches) is
most effective.
The rotary cutter may comprise a conventional off the shelf
structure, except for the release coated rotary blade, such as a Hitachi
rotary cutter Model #V15A. The release coat may be plasma coatings or
textured paint.
Under some circumstances it is desirable to have an exit roller
downstream of the rotary cutoff mechanism to facilitate dispensing of the
cut labels, such as through an exit opening in a housing. Such an exit
roller, when provided, also preferably has a release coated surface, and
that surface is also preferably grooved (between about 5-20% of the
width of a linerless label engaged thereby) and typically cooperates with
a hold down mechanism of any conventional type.
i:
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While the dispenser as described in U.S. Patent 6,142,049
is condsidered eminently
suitable for its purposes, it has been found that many thermal and other
non-impact printers are typically placed on their side due to space
5 constraints or cabinet constructions rather than on their base or vertical
axis. Wiper elements are conventionally used to prevent the
accumulation of adhesive on the rotary cutting blade. Such wiper
elements are typica(Iy formed of felt or other cloth material which have a
tendency to allow the silicone oil necessary to clean the blade to migrate
toward the side of the blade which is face down. That is, the silicone oil
migrates toward one end of the wiper due to the forces of gravity.
Consequently, an unacceptable situation arises as only part of the blade
is being coated with silicone oil while adhesive is allowed to build up on
another part of the blade. This requires cleaning or replacement of the
blade, as wel! as replacement or refilling of the wiper element.
According to the present invention, it has been discovered that an
open-celled foam wiper or sponge retains the silicone oil substantially
across the entirety of its surface such that the silicone oil is applied to
the entire surface of the blade notwithstanding an orientation of the
rotary cutter and wiper other than horizontally as intended. It is believed
that the enhanced wicking action of the foam material maintains the
silicone oil along the entire surface of the wiper element whether it
extends horizontally or vertically. Thus, the open-celled foam material is
the material of choice for the wiper element due to its superior wicking
ability.
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A further difficulty with linerless label dispensers resides in the
tendency of exit rollers of printers to continue to drive the label after the
label has been severed from the web by a cutter. If there is insufficient
area for the label to rest at the exit port of the housing, then the label
can simply fall out of the printer requiring the user to pick the label up off
the floor. If the adhesive side falls face down, the label is lost and the
user has to print a second label and take the time to remove the label
from the floor. Also, the label may catch itself on the exterior of the
housing and then swing into contact with the housing itself. This causes
the label to stick to the outside of the housing and repeated instances
can cause blockage of the exit port of the housing.
In accordance with the present invention and to alleviate that
problem, the exit port of the printer housing is provided with a plate
which not only provides a surface area for the label to rest until needed
but also serves to lift the label slightly from the guide path of the labels
egressing from the printer to avoid the problem of the label getting
caught and swinging down into contact with the housing. The upward
angle of the plate extends within a range of 5° to about 25°
relative to
the guide path and an optimum angle is about 10-20°. Thus, an obtuse
angle of approximately 155° to 175° with a preferred obtuse
angle of
160-170° is provided relative to the path of movement of the label
exiting
the housing. The plate may extend from the housing about 1I2 inch but
longer or shorter lengths of plates can be used depending upon the
length of the label. The plate can either be coated with a plasma
coating or, more preferably, with a textured paint which prevents the
label from sticking to the surface. Because the plate is not an active
transport surface for the label material, a textured paint rather than a
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plasma coating is preferred. The textured paint affords a release surface
but not as great a release surface as that provided by a plasma coating.
Thus, the label can beneficially cling to the plate having the textured
paint coating yet can be easily removed when needed. If the printer is
orientated on its side, the label is ejected from the printer and grasps the
plate so that it is still substantially perpendicular to the floor thus
facilitating grasping of the label.
In another aspect of the present invention, feeding linered base
material through a printer from a supply has not caused problems for the
supply to track through the printer because the stock simply unwinds
itself due to the low coefficient of friction created by the release liner.
Thus, the label supply would not wobble nor would the label stock skew
when entering the printing section of the printer. Many conventional
label printers are provided with a shaft on which a small hub is provided
to accommodate the label material. The size of the hub did not matter
with the liner-based stock as there was no additional forces applied to
the stock. Thus, a very small hub, having a contacting area
approximately 25% of the contact area of the core of the supply of
linered stock, was typically provided. However, this standard hub did not
operate satisfactorily in a linerless environment.
Linerless labels, due to the absence of the release layer, have a
substantially increased peeling force to remove the label material from
the next layer of labels due to the pressure sensitive adhesive face on
the supply. This creates an additional force which causes tracking
problems within the printer. Thus, the linerless label material would
sometimes be skewed when it entered the printhead or may contact
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surfaces beyond the active transport surfaces which are not
protected with release coatings so that the label material
may stick to the unprotected portions of the dispenser.
In accordance with the present invention, an
adapter hub is provided on the shaft so that the contact
area between the adapter hub and the conventional machine
hub with the inside diameter of the core of the linerless
label supply is in excess of 500 of the area of the core of
the label supply. Thus, by adding an additional hub, the
problem of skewing and tracking of the supply label through
the dispenser and printer can be eliminated. The area
covered by the hub can be as high as 1000 of the area of
the core but a hub combination which covers up to about 750
of the surface area works well. Additionally, because of
the different sizes of the labels, an adapter hub which
increases the contact area of 750, for example, for a 4
inch wide label web, may fit a 3 inch wide label led
affording 100% contact area. Consequently, a single
adapter hub may serve a number of different sizes of cores.
In a preferred embodiment according to the present
invention, there is provided a dispensing mechanism for
linerless labels each having a pressure sensitive adhesive
face and an adhesive-release material coated face, said
mechanism comprising: a housing defining a guide path for
said linerless labels including a stripper surface of
adhesive-release material for engaging the pressure
sensitive adhesive face of said linerless labels and an exit
opening for supplying linerless labels from said mechanism
along a predetermined path; an anvil blade adjacent said
stripper surface for engaging the pressure sensitive
adhesive face of said linerless labels; a cutter cooperating
with said anvil blade for engaging the release material
coated face of said linerless labels and cutting the labels;
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and a plate carried by said housing and extending outwardly
of said exit opening, said plate being angled to form an
obtuse angle with the predetermined path and lying along the
pressure sensitive adhesive face of the linerless label
passing through the exit opening for deviating the label
from said predetermined path by contact with the pressure
sensitive adhesive face of the label.
In a further preferred embodiment according to the
present invention, there is provided a cutting mechanism for
linerless labels each having a pressure sensitive adhesive
face and an adhesive-release material coated face, said
mechanism comprising: a stripper surface of adhesive-release
material for engaging the pressure sensitive adhesive face of
said linerless labels; an anvil blade adjacent said stripper
surface for engaging one of the pressure sensitive adhesive
face and release material coated face of said linerless
labels; a rotary cutter cooperating with said blade for
engaging another of the pressure sensitive adhesive face and
the release material coated face of linerless labels and
cutting the labels; and a wiper impregnated with silicone oil
for wiping the rotary cutter to prevent build up of adhesive
on the rotary cutter, said wiper being formed of an open-cell
material.
In a still further preferred embodiment according
to the present invention, there is provided a linerless label
dispenser comprising a support for a supply of continuous
form linerless labels wound on a core, each label having a
pressure sensitive adhesive face and an adhesive-release
material coated face, the support including a hub mounted for
rotation and having a contact area with the core in excess of
500 of the area of the core of the supply of linerless
labels, a guide structure for engaging the labels from the
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supply of labels, a printhead, on the opposite side of the
guide structure from the supply of labels, for
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printing the release material coated face of the labels from the supply of
labels, a stripper surface on the opposite side of the printhead from the
release material structure, and formed of adhesive-release material, an
anvil blade, on the opposite side of the stripper surface from the _
5 printhead, for engaging one of the adhesive release material coated face
and the pressure sensitive adhesive face of labels from the supply of
labels and a rotatory cutter cooperating with the anvil blade for engaging
another of the adhesive-release material coated face and the pressure
sensitive adhesive face of labels from the supply of labels, and cutting
10 individual labels to be dispensed from the supply of continuous form of
linerless labels.
It is a primary object of the present invention to provide an
effective lineriess label dispenser and a cutting mechanism for use
therewith. This and other objects of the invention will become clear from
an inspection of the detailed description of the invention, and from the
appended claims.
BRIEF DESCRIPT10N OF THE DRAWINGS
FIGURE 1 is a side schematic view of an exemplary linerless
label dispenser according to the present invention;
FIGURE 1A is an enlarged cross sectional view illustrating the
mounting of the core for the supply of linerless labels on the shaft of the
dispenser;
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FIGURE 1 B is an enlarged view of the exit opening of the
dispenser illustrating the angled plate;
FIGURE 2 is a detail side elevational view, with portions cut away
for clarity of illustration, of the stripper surface and cutting mechanism of
the dispenser of FIGURE 1;
FIGURE 3 is an enlarged partial front end view of the stripper
surface of FIGURES 1 and 2 showing the linerless label, also enlarged
for clarity of illustration, in association therewith; and
FIGURE 4 is a partial front end view of an exemplary construction
of an exit roller of the dispenser of FIGURE 1.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGURE 1 schematically illustrates an exemplary dispenser that
may be provided according to the present invention for dispensing
linerless labels e.g. in a roll 10 which is a supply of continuous form
linerless labels. The linerless labels in the roll 10 may either have
perforations between the labels, or may be devoid of perforations.
Sensor marks may be provided so that where a label begins and ends
may be determined. The dispenser illustrated in FIGURE 1 may include
a common housing shown merely in dotted lines schematically at 11 in
FIGURE 1.
The supply of linerless labels 10 is mounted on a support. The
support is illustrated only schematically at 12 in FIGURE 1 and in detail
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in FIGURE 1A described hereafter. The roll 10 rotates in a direction
indicated by arrow 13 as the labels are taken off the roll 10, decreasing
in size. The linerless labels forming the roll 10 are - as is common for
all linerless labels - formed by (see the schematic illustration in FIGURE
3) a substrate 14, typically of paper, with a pressure sensitive adhesive
coating 15 on one face thereof and an adhesive release material coating
(e.g. silicone) 16 on the other face thereof.
From the roll 10 the linerless labels preferably pass underneath a
plastic guide 18 which engages the release material coating 16 face
thereof, and then to an adhesive-release material guide structure 19
which engages the adhesive face 15. Preferably the structure 19
comprises a plasma coated ramp, for example disposed at an angle ~i
with respect to the horizontal (indicated at 20 in FIGURE 1 ). The angle
~ is typically between about 20-35° (e.g. about 27°). The ramp
19
preferably includes an arcuate lead-in portion 21.
Linerless labels in continuous form, illustrated schematically at 22
in the drawings, typically pass underneath the sensor 24, such as a
conventional optical sensor. The sensor 24 senses either the perforation
lines between individual labels of the web 22, or applied marks for that
purpose indicating the demarcation between labels. Sensor 24 may
cooperate with a computer control 25 or the like, computer control 25
also typically controlling a print head illustrated schematically at 26 in
FIGURE 1, and a rotary cutter, illustrated schematically at 27 in FIGURE
1, and in more detail in FIGURE 2. After receiving input from sensor 24
the control 25 properly controls the print head 26 and cutter 27.
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The print head 26 cooperates with the release material face 16 of
the web 22 to print indicia thereon, typically variable indicia under the
control of the computer control 25. The printer 26 may be any suitable
type that can print on the release material face 16, such as a non-impact
printer like an ink jet printer. Where the web 22 comprises linerless
labels with a thermosensitive coat beneath a release coating 16, or
surrounded thereby (as is conventional in the art), the print head 26 may
be a thermal or thermal transfer print head. Normally the print head 26
cooperates with the print roller 28, which is a silicone roller but may also
be plasma coated so as to have adhesive-release properties.
Downstream in the direction of movement of the label 22, which
direction is illustrated by the arrow 29 in FIGURES 1 and 2, is a support
30. The support 30 preferably supports a stripper surface 31, seen in
FIGURES 1 through 3, and a stationary anvil blade 32. The stripper
surface 31 is preferably a generally planar surface of a block or other
shape of metal 33, the surface 31 being plasma coated so that it will not
stick to the adhesive 15 which it engages. The stripper surface 31 is
disposed at the angle a (see FIGURE 2) with respect to the horizontal
20, the angle a typically being about the same as the angle Vii, that is
between about 20-35°, preferably about 27°. As seen in FIGURES 1
and 2, the surface 31 is upwardly directed from the print head 26 toward
the rotary cutting mechanism 27, which has been found to minimize
jam m ing.
As illustrated schematically in FIGURE 3, the surface 31 may
include a plurality of upwardly extending extensions 34 formed on at
least a part thereof. For example, twenty such extensions 34 may be
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formed on the surface 31, the total extent of the extensions 34 being
between about 5-20% of the width of the linerless label 22 passing
thereover. The purpose of the extensions 34 (which are also plasma
coated) is to decrease the surface tension of the stripper surface 31 and
thereby minimize the possibility of the adhesive sticking thereto. While
the extensions 34 are illustrated as dimples in FIGURE 3, they~may have
any desired operable configuration and relative dimensions.
Immediately downstream of the stripper surface 31 is the anvil
blade 32. The anvil blade 32 is of hardened steel or the like, and
preferably also is plasma coated or covered by textured paint, at least
the portions thereof that are likely to come into contact with the adhesive
of labels being cut. The hardened blade 32 has a portion 36 thereof
which projects upwardly from the support 30 a distance t and
15 downwardly from the stripper surface 31 at distance s. The amount of
upward and downward spacing is preferably between about .001-.008
inches, most preferably between about .002-.004 inches. It has been
found that this slight, but significant, projection of the portion 36 of the
blade 32 also minimizes jamming of the entire dispenser, particularly the
print head 26 and the rotary cutter 27.
The rotary cutter 27 typically includes a rotary blade 38 mounted
on a rotating, powered, shaft 39 (e.g. typically powered by an electrical
motor under the control of computer control 25). The rotary blade 38 -
even though it initially engages only the release material face 16 of the
web 22 - may also be plasma coated. Preferably, however, the blade
38 may be coated with a textured paint or varnish. The blade 38
cooperates with the blade 32 to sever the linerless label web 22 into
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individual labels, such as the individual label 41 illustrated schematically
in FIGURE 1 downstream of the rotary cutter mechanism 27 in the
direction 29. The rotary cutting mechanism 27 may be an off-the-shelf
rotary cutter, such as a Hitachi rotary cutter Model #V15A and provided
5 with a release coating such as textured paint or the like.
In order to even further prevent sticking of the adhesive 15 of the
web 22 to the anvil blade 32, after a cut is made the web 22 may be
retracted slightly (moved in a direction opposite the direction 29), on the
10 order of about one-eighth to one inch. This would be accomplished by
the computer control 25 reversing the direction of the print roll 28, or
reversing the direction of other conveyance mechanisms (such as rollers,
belts, or the like) that may be associated with the dispenser of FIGURE
1, but are not illustrated in FIGURE 1.
Downstream of the cutter 27 an exit roller 43 may be provided.
While the exit roller 43 is not essential, it does help in dispensing cut
labels 41 through an exit opening 44 in the housing 11. The exit roller
43 also is preferably plasma coated, and since it is very important the
labels not stick to it (since that would preclude dispensing thereof
through the opening 44), the plasma coated surface of the roller 43 may
be grooved to reduce the overall surface tension of the roller 43. One
configuration the grooving might take is illustrated schematically in
FIGURE 4 where annular depressions 45 are provided between annular
lands 46. The grooving of the roller 43 need not necessarily be over the
entire width thereof, but -- as with the extension 34 of the surface 31 --
- may be provided over a portion equal to about 5-20% of a width of a
linerless label passing thereover.
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The exit roller 43 may cooperate with a conventional hold down
mechanism, illustrated only schematically at 48 in FIGURE 1. The hold
down mechanism may be of any conventional type, engaging the release
material coated face 16 of the label 41. For example, it may be another
roller either gravity or spring pressed into place, or a low friction material
slide either gravity or spring pressed into place, or spring fingers exerting
light downward pressure, or other conventional mechanisms.
With respect to all of the adhesive release surfaces described
above it is preferred that they are plasma coated. However, under some
circumstances they may comprise other release materials, such as
silicone coatings.
Referring back now to FIGURE 1, it will be appreciated that there
is the possibility of a build up of adhesive on the rotary cutter blade 38
and that wipers formed of traditional felt or cloth containing silicone oil
have previously been used to maintain the cutter blade free of adhesive
build up. However, because of the possibility of different orientations of
the dispenser, it has been found that the silicone oil, with such
conventional wiper elements, is not applied uniformly or at all along
portions of the wiper in other than horizontal orientations of the
dispenser. To enable the entirety of blade 38 to be continuously cleaned
with a wiper element containing silicone oil, the wiper element 50 of the
present invention is formed of an open-celled foam sponge-like material.
The foam material retains the silicone oil substantially uniformly across
its entire surface due to its superior wicking action notwithstanding
changes in orientation of the wiper. That is, even with the wiper element
on its side, the wicking action of the foam material will pull the silicone
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oil from any pool or source of oil such that it may be substantially
uniformly applied across the cutter blade 38 to maintain the latter clear
of adhesive residue.
Referring to FIGURE 1A, there is illustrated a mounting for the
supply of labels 10. Typically, labels 10 are supplied in roll form about a
core 52 preferably formed of a cardboard material. In prior liner-labelled
constructions, a single hub 54 was mounted on a shaft 56 forming part
of the dispenser. The hub was typically approximately 25% of the
length, i.e., had a contact area approximately 25% of the contact area
available on the interior surface of the core 52. Tracking, wobbling or
skewing problems did not occur in the linered labels. However, because
the peel strength of linerless labels is substantially greater than the peel
strength of linered labels, it has been found that this arrangement does
in fact cause skewing and out of track movement of the labels as they
pass through the dispenser. To preclude this, an additional adapter hub
58 is provided on the axle 56. The adapter hub 58 has the same
diameter as the conventional hub 54. However, the two hubs combined
provide a contact area in excess of 50% of the available contact area
along the inside of the core 52. The area covered by the hubs can be
as high as 100% of the area of the core but it has been found that a hub
combination which covers up to 75% of the available area of the core
works well.
It will thus be seen that according to the present invention a
simple yet versatile yet effective linerless label dispenser, and cutting
mechanism for linerless labels, have been provided. While the invention
has been herein shown and described in what is presently conceived to
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be the most practical and preferred embodiment thereof, it will be
apparent to those ordinary skill in the art that many modifications may be
made thereof within the scope of the invention, which scope is to be
accorded the broadest interpretation of the appended claims so as to
encompass all equivalent structures and devices.
