Note: Descriptions are shown in the official language in which they were submitted.
CA 02227374 1998-01-20
W O 97/05021 PCT~US96/0~6356
1 LINERLESS I~BEL APPLYING SYSTEM
2 Backaround of the Invention
3 The present invention relates generally to document
4 handling systems, and more particularly to a novel system for
forming labels from a continuous supply of linerless label
6 material and applying the labels in sequential fashion to
7 documents, such as mail pieces, as the documents are conveyed on
8 edge along a predetermined path.
9 The volume of mail handled daily by large businesses,
institutions and government entities, such as the postal service,
11 credit card companies, utilities, mail order houses and other
12 advertisers has steadily increased due in part to both an
13 increase in population and a greater volume of business
14 correspondence. Typically, the envelopes containing the ma~erial
to be mailed are addressed and then sorted into common
16 destination groups for mailing. Similarly, mail received by such
17 entities is commonly sorted into groups based on identi~iable
18 subject matter on the received material. A third category of
19 such envelopes is the returned mail category, the creation of
which is primarily due to the addressee having moved from a
21 particular address, or a smeared or non-readable bar code,
22 resulting in the envelope being undeliverable. The present
23 invention is directed to a system ~or solving the latte~ type
24 problem, namely, the correction of the address and/or destination
code on an envelope by application of a secondary label to the
26 envelope, with a correct forwarding address or destination code
27 either pre-printed on the label or applied to the label after it
28 is affixed to the envelope to cover an invalid or non-readable
29 address or bar code. Pre~erably, the label material inhibits the
passage of light, whereby a bar code or address material beneath
CA 02227374 1998-01-20
W O 97/05021 PCT~US9G~O~C~
1 the label cannot be read by a bar code reader or an optical
2 character reader.
3 Several different types of machines have been developed
4 to assist in the handling of such mail, other than manual review
and correction b~ an individual mail carrier. These prior art
6 devices typically comprise an envelope feeder, a read station,
7 a label selection station where a supply of labels permits
8 selection of an appropriate label and its application to an
9 envëlope, and a sorting and storage device. See, for example,
U.S. Patent No. 5,076,879. While some of the prior art machines
ll and systems have proven satisfactory, many are relatively large
12 unwieldy machines that require not only a large amount o~ space
13 but also require frequent replenishment of a vast array of pre-
14 printed labels and maintenance of the applicating equipment.
Also, labels furnished in a roll or ~an where pre-cut labels are
16 adhesively adhered to a substrate are expensive compared to the
17 cost of linerless or substrate-free label material.
18 Summarv of the Invention
19 The present invention provides a novel compact system
for applying linerless labels to documents such as mailing
21 envelopes and the like and which may be used as a stand-alone
22 label applicator or with conventional mail sorting machines to
23 greatly increase the label applying rate in a highly efficient
24 manner.
The system of the present invention includes a label
26 feeder for providing a continuous length web of linerless label
27 material having an adhesive surface and an opposite non-adhesive
28 surface. The linerless label material is fed along a
29 longitudinal path from a supply roll or fan folded source to a
label applying station positioned in juxtaposed relation to the
31 path traversed by documents in the form of mailing envelopes and
32 the like as they are conveyed on edge in sequential fashion along
33 a path transverse to the label material feeder path. The
34 linerless label material web is advanced through a cutter station
which is operative to sever the label material transversely and
36 create a label of desired height in timed relation to passing of
,
CA 02227374 1998-01-20 ,..
W O 97105021 PCT~US96/06356
1 a document through the label applying station. The label
2 applying station includes a paddle member supported at one end
3 for pivotal movement in a generally horizontal plane normal to
4 the upstanding documents as they are conveyed through the label
applying station~ The paddle member is operative to engage and
6 hold each successive label by vacuum force as the label is being
7 severed from the continuous length web of label material.
8 Simultaneously, the paddle is pivoted so that its outer end
9 presses a leading edge of the adhesive side of the label against
the document passing through the label applying station. As the
11 document and label move downstream, the paddle vacuum is
12 automatica'ly terminated, ~he label is released from the paddle,
13 and the paddle member adheres the label against the document in
14 a progressive fashion, after which the paddle member returns to
its original position and the document is passed through a nip
16 to ~irmly press the label onto the document.
17 The cutter station includes a cutter blade which
18 progressively severs the label material transversely to create
19 a label, and a stripper bar which moves with the cutter blade and
returns the newly created leading edge of the label material to
21 a position enabling advance of the label material web preparatory
22 to severing the next successive label. The label feeder includes
23 sensors operative to sense the path through which the label
24 material passes so as to maintain a feeder loop as the label
material advances towards the cutter blade, and also to sense
26 exhaustion of the supply of label material. Additional sensors
27 responsive to ~he position of each document as they pass into the
28 label application station initiate a timed control sequence to
29 operate the various label advancing and applying elements. The
various operating functions of the linerless label applying
31 system may be coordinated by conventional control logic.
32 Accordingly, one of the primary objects of the present
33 invention is to provide a novel system for applying linerless
34 labels to mailing documents or the like as they are conveyed on
edge in sequen~ial fashion through a label applying station, and
36 wherein the labels are formed from a continuous length web of
37 rolled linerless label material. The present system may also be
CA 02227374 1998-01-20
WO 97/05021 PCT~US9G~ 56
1 adapted to form labels from a continuous fan folded source of
2 label material, or any other suitable continuous label material
3 supply. n
4 A more particular object of the present invention is
5 to provide a novel system for applying linerless labels to
6 mailing documents or the like as the documents are conveyed on
7 edge through a label applying station, the linerless labels being
8 formed from a continuous length web of linerless label material
9 hav~ng a non-adhesive surface and an opposite adhesive surface
and fed longitudinally from a roll or fan fold source to a label
11 cutter and applying station operative to sever labels from the
12 label material and apply the labels successively to documents
13 being conveyed on edge through the label applying station.
14 A feature of the linerless label applying system in
accordance with the present invention lies in the provision of
16 a cutter blade which cooperates with the linerless label web
17 material to progressively sever the label material transversely
18 to create successive labels simultaneously with pivotal movement
19 of a paddle member operative to hold and progressively adhere the
adhesive surface of each label against a document being conveyed
21 on edge past the label conveying station.
22 Another feature of the linerless label applying system
23 in accordance with the present invention lies in providing a
24 paddle member operative to initially hold each label formed by
the cutter blade by vacuum and adhere the adhesive surface of the
26 label against a document in a progressive fashion as the label
27 advances with the document past the label applying station.
28 Another feature of the linerless label applying system
29 in accordance with the present invention lies in the provision
of a cutter blade assembly having a cutter blade movable in a
31 plane normal to the linerless label material web and having a
32 stripper bar fixed to the cutter blade in generally parallel
33 spaced relation so that the liner material web passes between the
34 cutter blade and stripper bar, the cutter blade being movable to
sever the label material web generally transversely thereof, and
36 the stripper bar being operative to return the newly formed
37 leading edge of the label material to a position enabling
CA 02227374 1998-01-20
W O 97/0~021 PCTAUS~C'0-~56
1 advancement o~ the label material web preparatory to cutting the
2 nex~ successive label therefrom.
3 Another feature of the linerless label applying system
4 in accordance with the present invention lies in the provision
of a label material web guide and advance manifold assembly
6 having a planar generally vertically disposed guide surface to
7 receive and guide the web to the cutter blade assembly, and a
8 drive roller operative to advance the label material web in
9 predetermined increments so as to vary the height of the labels
lo as desired for imprinting a full address, a bar code or other
11 indicia on the labels.
12 Still anGther ~eature of the present invention lies in
13 the provision of a linerless label material feeder arrangement
14 wherein a continuous length label material web is passed through
a loop path and includes sensors operative to maintain a free
16 loop of web material for rapid advance of the web through the
17 cutter.
18 Further objects, advantages and features of the present
19 invention will become apparent from the following detailed
description of the invention taken in conjunction with the
21 accompanying drawings wherein like reference numerals designate
22 like elements throughout the several views.
23 Brief Description of the Drawinqs
24 FIG. 1 is a fragmentary perspective view of a linerless
label applying system constructed in accordance with a preferred
26 embodiment of the present invention;
27 FIG. 2 is a plan view of the linerless label applying
28 system illustrated in FIG 1.;
29 FIG. 3 is a fragmentary vertical sectional view taken
substantially along line 3-3 of FIG. 2 with portions broken away
31 for purposes of clarity;
32 FIG. 4 is a fragmentary elevational view taken
33 substantially along line 4-4 of FIG. 1 and looking in the
34 direction of the arrowsi
CA 02227374 1998-01-20
W O 97/05021 PCTAUS96/06356
1 FIG. 5 is a fragmentary perspective view taken from the
2 opposite side of the apparatus shown in FIG. 3;
3 FIG. 6 is a fragmentary perspective view illustrating
4 the label material web guide and advancing assembly for advancing
5 the web to the cutter station;
6 FIG. 7 is a perspective view of the cutter blade and
7 stripper bar assembly removed from the base plate of the label
8 applying system illustrated in FIG. 1;
9 FIG. 8 is a fragmentary plan view illustrating the
10 label applying paddle member and associated actuator and vacuum
11 supply;
12 FIG. 9 is a fragmentary elevational view taken
13 substantially along line 9-9 of FIG. 2;
14 FIG. 10 is a logic diagram illustrating the sequence
15 of operation of the various operating functions of the label
16 applying system in accordance with the invention;
17 FIG. 11 is a schematic diagram o~ one aspect of the
18 label material feed operation sequence; and
19 FIG. 12 is a schematic diagram of the paddle vacuum
20 sensor apparatus.
21 Detailed DescriPtion of the Preferred Embodiment
22 Referring now to the drawings, and in particular to
23 FIGS. 1-3, a linerless label applying system constructed in
24 accordance with the present invention is indicated generally at
10. As will be described more fully below, the linerless label
26 application system 10 is operative to apply linerless labels to
27 documents, such as mailing envelopes and the like, as the
28 documents are conveyed on edge in a generally vertical
29 orientation along.a predetermined horizontally extending path
established by a conveyor belt system, indicated generally at 12
31 in FIG. 2. The label applying system 10 finds particular
32 application in conjunction with mail handling systems requiring
33 a ~acility for applying a corrective address label or a bar code
34 or the like to an envelope having an incorrect or defective
address or bar code thereon which requires correction. The
36 linerless label system 10 may be used as a stand-alone label
-
- CA 02227374 1998-01-20 p ~ ~ ~
S~3 JUL ~
1 label applying system operative to create linerless labels of
2 varying size and apply them to mailing envelopes and like
3 documents manually fed into the system, or may be utilized with
4 conventional mail sorting machines to create and apply labels to
mailing envelopes conveyed on edge from an upstream processing
6 station in which the improper or de~ective address or bar code
7 is detected and from which the document is passed through the
8 conveyor belt system 12 for applying a linerless label thereto.
g ~riefly, the linerless label applying system 10
includes a source or supply of continuous length linerless label
11 material, such as in the form o~ a roll 14 o~ linerless label web
12 material 16. The linerless label material 16 has an adhesive
13 surface on one side, such as the inwardly facing surface of the
14 wound web, and a non-adhesive outwardly facing surface on the
opposite side adapted to have indicia printed thereon, such as
16 an address or a bar code. The address or bar code may be printed
17 on the non-adhesive side of a linerless label by a conventional
18 printer (not shown) either prior to applying a label to a mailing
19 document or after applying the label thereto. The label applying
system 10 includes a label feeder means, indicated generally at
21 20, which is cooperative with the label material web 16 for
22 effecting unwinding from the roll 14 and feeding the label
23 material web longitudinally along a looped path to a cutter
24 station, indicated generally at 22. The cutter station 22 is
operative to sever the label material web generally transversely
26 of its longitudinal axis to create labels of selectively variable
27 height. A label applying means in the form of a paddle member
28 24 is supported adjacent the cutter station 22 and is operative
29 to engage the non-adhesive surface of a cut label and hold the
label by vacuum while moving it into engagement with a mailing
31 document being conveyed along the conveyor belt system 12 in
32 juxtaposed relation to the paddle member. As will be described,
33 the paddle member 24 is operative to initially lightly press the
34 leading edge of a label against a document juxtaposed to the
label applying paddle member and progressively adhere the
36 remainder of the label against the document as the document and
37 the label advance downstream from the paddle member.
r ~
- CA 02227374 1998-01-20 p ~ ~ q 6 l 0 6 3 5 6
~EANS~-~ JlIL 1997
1 Turning now to a more detailed description of the
2 linerless label applying system 10, the various components are
3 supported on or suspended from a generally planar base or top
4 plate 28. The base plate 28 is preferably supported at a
convenient operator height. When used with other mail document
6 handling apparatus, the base plate 28 is positioned so that the
7 conveyor belt system 12 is aligned with an upstream conveyor belt
8 system operative to convey mailing documents and the like in
g sequential order to the linerless label applying system 10. The
base plate 28 supports the roll 14 of linerless label web
11 material 16 through an upstanding support arm 30 which is :Eixed
12 at its lower end to the plate 28. The support arm 30 supports
13 a pair of parallel spaced horizontal support rollers 32a and 32b
14 which extend through an axial opening 14a of the roll 14 so as
to support the roll and enable free rotation of ~he roll during
16 unwinding of the linerless label web material 16. Enlarged
17 diameter discs on the outer ends of the rollers 32a,b prevent
18 inadvertent release of the roll 14 from the support rollers.
19 As illustrated in FIG. 1, the label web material 16 is
guided ~rom the roll 14 through a ~eed nip defined between a
21 driven feed roller 34 and a spring loaded pinch roller 36. The
22 feed roller 34 is connected through a suitable gear drive to an
23 electric motor 38 which, when energized, is operative to advance
24 the label web material 16 from the roll 14. The label web
material 16 is fed from the feed roller 34 downwardly through a
26 suitable opening in the base plate 28 to form a loop 16a (FIG.
27 3) as the label web material is passed to a web material guide
28 and advance assembly, indicated generally at 40 The web length
29 between the roll 14 and web guide and advance assembly 40 is
controlled by a set of photosensors, indicated schematically at
31 41a and 41b in FIG. 3, which sense the presence of the loop 16a
32 and are connected in circuit with the feed motor 38 to advance
33 the web and maintain a loop 16a so as to ~loat approximately six
34 to eight inches beneath the top plate 28. The web loop 16a forms
a buffer loop so that the web hangs free at the point o~ entry
36 into the web guide and advance assembly 40. As illustrated in
37 FIG. 5, a fan 42 and air deflector plate 44 may be mounted
~P~~PI~ S~
CA 02227374 1998-01-20 p ~ ~ ~ 9 ~ ( 0 6 3 5
1 beneath the base plate 28 to blow air onto the upwardly facing
2 sur~ace o~ the label material web loop 16a to assist in
3 maintaining the loop path.
4 In addition to the loop photosensors 41a and 41b, a
sensing system is provided to detect depletion of label web
6 material 16 from roll 14, and to provide a signal to a main
7 conveyor drive control to halt the introduction of new documents
8 into the label applying station after a short delay, for purposes
9 to be explained. Referring to FIG. 3, a pair o~ beam or
photosensor elements indicated schematically at 46a and 46b, or
ll other suitable sensors, are supported on opposite sides of the
12 web material 16 where it passes through the base plate 28 so that
13 the web material normally breaks the beam extending between the
14 sensor elements as it advances longitudinally to the cutter
station 22. As the roll 14 becomes depleted, the end of web 16
16 passes beyond sensor elements 46a,b, creating a signal which is
17 relayed to the conveyor system control to halt the further
18 advance of mailing envelopes or other documents in the conveyor
19 system 12. Because there is still a sufficient amount of label
material in loop 16a to supply labels to documents already in the
21 conveying system, the document conveyor system 12 is permitted
22 to continue to advance a small number of additional documents,
23 such as approximately 5-10, after receiving a web depletion
24 signal ~rom sensors 46a,b be~ore the conveyor system actually
stops.
26 Referring to FIGS. 5 and 6, taken in conjunction with
27 FIG. 3, the label web material guide and advance assembly 40
28 includes a generally vertically disposed guide plate or manifold
29 48 having a generally vertical planar sur~ace 48a bounded by a
pair of laterally spaced parallel edge guides 50a and 50b. The
31 edge guides 5Oa,b are spaced apart a distance generally equal to
32 the lateral width of the label web material 16 and define an open
33 channel to receive the lateral marginal edges of the web material
34 so as to guide it along the planar surface 48a as the web
material is advanced to the cutter station 22. A pair of
36 laterally spaced side plates 52 and 54 are secured to the
37 laterally opposite edges of the guide plate 48 so as to lie in
-
- CA 02227374 1998-01-20 p ~ I ~ 9 ~ 1 Q 6 ~ ~ ~
~PE~WS Z8 JU~ 1997
- 1 o -
1 paral~el planes and extend rearwardly from the guide plate. The
2 side plate 52 has its lower edge mounted on and slidable along
3 a guide rod 56 which is suitably supported below the base plate
4 28 in parallel relation thereto. The side plate 54 has a cam
follower or roller 58 mounted on its outer surface which is
6 received within a rectillnear groove or channel formed in a guide
7 plate 60 secured in normal relation to the underside of the base
8 plate 28 so that the guide channel is parallel to the
g longitudinal axis of the guide rod 56. In this manner, the side
plates 52 and 54 cooperate with the guide plate or manifold 48
11 to form a horizontally slidable carriage which may be moved along
12 the guide rod 56 to a rearward position facilitating initial or
-13 replacement threading or guiding of the label web material
14 between the edge guides 50a and 50b and along the planar surf~ce
48a of the guide plate 48.
16 To facilitate selective feeding or advancing of the
17 label web material 16 upwardly along the guide plate surface 48a,
18 a web advance or feed roll 64 is supported on a transverse drive
19 shaft 66 so that feed roll 64 is positioned within a recess
~ormed generally centrally in guide plate 48. The opposite ends
21 of drive shaft 66 are journaled in the side plates 52 and 54 so
22 that the outer peripheral surface of feed roll 64 extends
23 slightly forwardly from the planar guide plate surface 48a and
~4 engages the non-adhesive surface of the label web material as it
passes upwardly along the guide plate. As illustrated in FIG.
26 5, the drive shaft 66 extends through the side plate 52 and has
27 a timing belt pulley 68 fixed thereon which is connected through
28 a timing belt 70 to a drive pulley 72 mounted on the output shaft
29 of a stepping motor 74 supported on the inner surface of side
plate 52. A ribbed pinch roller 76 is supported below the base
31 plate 28 to cooperate with the feed roll 64 when in its forward
32 position to advance the label web material in response to
33 energizing the stepping motor 74. As will be described, the
34 stepping motor 74 enables selective incremental advance of the
label web material 16 to create labels of varying height, such
36 as 5/8 inch height labels for bar coding and 11~ inch height
37 labels for address labels.
- CA 02227374 1998-01-20 p ~ ~ ~ 9 ~ 1 ~ 6 ~ 5 6
~.P~Js~JuL~9g7~
1 The guide plate or mani~old sur~ace 48a includes a
2 plurality o~ vacuum ori~ices 48b which are connected to a source
3 of vacuum through a control valve (not shown). A relatively low
4 vacuum is applied to the ori~ices 48b so as to lightly retain the
label web material in sliding contact with the guide plate
6 surface 48a during cutting by the cutter blade 82 to create
7 labels and subsequent ~eeding o~ additional web material 16 to
8 cutter station 22.
9 The label web material 16 is advanced by the web guide
and advance assembly 40 to a predetermined vertical position
11 relative to the cutter station 22 which is operative to sever the
12 label web material transversely of its longitudinal axis and
13 create labels o~ any desired height. The cutter statlon 22
14 comprises a cutter blade assembly, inàicated generally at 80,
which includes a cutter blade 82 having a ~orward cutting edge
16 82a. The cutter blade 82 is secured to and carried by a
17 precision ball slide 84 mounted on a horizontal plate 86a of a
18 .generally U-shaped support frame 86 secured to the underslde of
l9 the base plate 28. The cutting blade 82 is adapted for
horizontal rectilinear movement in a path normal to the guide
21 plate surface 48a and lying in a vertical plane containing the
22 longitudinal axis of the label web material 16.
23 Reciprocating movement of the cutter blade 82 is
24 effected through a toggle link actuat-ng mechanism indicated
generally at 90. Referring to FIGS. 2 and 3, the toggle link
26 actuating mechanism 90 is mounted below the base plate 28 and
27 includes a pneumatic actuating cylinder 92 having a piston 92a
28 which, in response to pneumatic pressure being applied to the
29 actuating cylinder 92, acts through a coil compression spring 94
to move a slide block 96 in the axial direction of the piston
31 92a. The slide block 96 is biased in a direction toward the
32 operating cylinder 92 by a coil compression spring 98 which is
33 partially received within a blind bore in a support block 100
34 fixed to the underside of the base plate 28. The end of the coil
compression spring 98 disposed wi-hin the support block 100 seats
36 against a ball 102 ~hich enables ~ivota_ movement of the spring.
37 The opposite end of compression spring 38 is received within a
A~EI~D S~
CA 02227374 1998-01-20 P ~ 1~ S 9 L 1 06 3 5 6
~PEA~US 28 J~J~ 19~7
1 shallow recess or blind bore in the opposing end of the slide
2 block 96 and biases the slide block toward the adjacent end of
3 the operating cylinder 92 and against the compression spring 94.
4 The opposite end of the operating cylinder 92 is pivotally
interconnected through a ball 106 to a support block 104 fixed
6 to the underside of base plate 28.
7 A pair of substantially identical actuating links 110
8 and 112 are pivotally connected to the slide block 96 at llOa and
9 112a, respectively. The opposite end of actuating link ]10 is
lo pivotally connected at llOb to a block 114 fixed to the underside
11 of base plate 28. The opposite end of pivot link 112 is
12 pivotally connected at 112b to the ball slide 84. With the slide
13 block 96 positioned as illustrated in FIG. 2, pressurizing the
14 actuating cylinde~ 92 will extend the piston 92a and effect
movement o~ the slide block in a right-hand direction against the
16 ~orce o~ spring 98. This causes the actuating links 110 and 112
17 to undergo a toggle-like movement with link 110 pivoting about
18 its fixed pivot connection llOb and link 112 moving the ball
19 slide 84 and thereby cutter blade 82 in the longitudinal
direction of the ball slide. The ball connections 102 and 106
21 accommodate slight lateral movement of the slide block 96 as the
22 link 110 pivots about its pivot connection llOb. Release of
23 pressure from the actuating cylinder 92 allows the coil spring
24 98 to return the slide block 98 to its home or initial position,
which also returns the cutter blade to its orlginal position.
26 The geometry of the links 110 and 112 is selected to rapidly move
27 the cutter blade through a cutting stroke of approximately 1/8
28 inch.
29 As illustrated in FIGS. 2, 3 and 7, the cutter blade
82 is supported so that its cutting edge 82a is spaced a
31 predetermined distance above the upper surface of the base plate
32 28 as determined by the spacing desired between the lower edge
33 o~ a mailing envelope being conveyed by the conveyor belts 126
34 and 128 and the lower edge of a label applied to the envelope.
The cutter blade is also configured so that when it is in its
36 rearward non-cutting position, as illustrated in FIG. 2, the
37 cutting edge 32a is spaced slightly rearwardly from the plane of
' CA 02227374 1998-01-20
JIIS 9 ~ 3 5 6
~EAIUS ~ JIJL 1997,
i the planar surface 48a on the guide plate 48 and from the label
2 web material 16 being fed upwardly along the guide surface by
3 feed roll 64. During a cutting stroke, the cutting edge 82a
4 cooperates with a stationary shearing blade 120 to sever the
material web 16 transverse to lts longitudinal axis. The
6 shearing blade 120 is generally rectangular and is supported on
7 the upper surface of the base plate 28 through a spacer 121 and
8 bolts 120a so that a forward lower edge of the shearing blade
9 cooperates with the cutting edge 82a to effect shearing of the
label web material. The cutting edge 82a is formed on the cutter
11 blade 82 to be sightly inclined to the plane of the material web,
12 as considered in FIG. 2, so that the cutting edge effects a
13 progressive cutting of the web material beginning with the right-
14 hand edge as viewed in FIG. 2 and terminating with the left-hand
edge as the cutter blade is fully extended in a cutting stroke.
16 It will be appreciated that as the cutter blade 82 is
17 moved through a web severing stroke responsive to actuation of
18 the actuating cylinder 92, the newly formed leading edge of the
19 web material 16 will be moved slightly underneath the stationary
shearing blade 120. To insure that the newly formed leading edge
21 of the label web material 16 returns to a position enabling
22 advance of the web material to create the next successive label
23 without interference with the cutting blade, a stripper bar 122
24 is interconnected to the cutter blade 82 so as to lie in
generally parallel spaced relation ~orwardly from the cutting
26 edge 82a to enable the label web material to pass between the
27 cutting edge 82a and the stripper bar. To this end, the stripper
28 bar 122 has a rearward edge surface 122a which is spaced closely
29 adjacent the cutting edge 82a and extends slightly into the path
of the label web material 16 when the cutter blade is in its
31 retracted position. When the cutter blade 82 is actuated to
32 sever the label web material, the str pper bar moves with the
33 cutter blade and slides under the stationary shearing blade 120.
34 When the cutter blade 82 has completed a label severing stroke,
the stripper bar 122 ~ollows its return path and pushes the newly
36 formed leading edge of the web materia back into the original
37 label path, thereby enabling advancemen_ of the web material for
. . . .
CA 02227374 1998-01-20
PCTll~S 9 6 / 06 ~ 5 6
JS 2~ JUL 1997
-14-
1 creating the next successive label. The stripper bar 122 in
2 p~eferably generally U-shaped and secured to the cutter blade 8
3 by pins 124 (FIG. 2). The stripper blade may be made of a
4 suitable plastic material, such as DELRIN, and has an elongated
pocket 122b formed in its upper surface to receive a wicking
6 material which holds a lubricant, such as a lubricating oil. As
7 the stripper bar 122 moves forward and back with the cutting
8 blade 82, the lubricant is deposited on and lubricates the
g surrounding components so as to prevent the accumulation of
adhesive from the web material 16 as it is severed into labels.
11 As illustrated in FIG. 2, the conveyor belt system 12
12 includes a pair of endless conveyor belt 126 and 128 each of
13 which is reeved about a plurality of idler rollers, such as
14 indicated at 130. The belts 126 and 128 define a run or reach
of juxtaposed conveyor belts 126a and 128a and an enterlng nip
16 132 to receive mailing envelopes and the like from an upstream
17 conveyor or other conveying means (not shown) and convey them in
18 a downstream direction, or from left-to-right as considered in
19 FIG. 2. It will be understood that a drive roller is provided
for each of the conveyor belts 126 and 128 so as to drive them
21 at the same longitudinal speed. In the illustrated embodiment,
22 a backup conveyor belt 134 is supported on a pair o~ idler
23 rollers 136 so as to establish a reach of the conveyor belt 134
24 rearwardly of and engaging the conveyor belt reach 126a as it
traverses a path past the cutter assembly 22. The idler rollers
26 130 and 136 are supported on the upper surface of the base plate
27 28 so that the corresponding conveyor belts 126, 128 and 134 are
28 spaced above the base plate sufficiently to expose the lower
29 surface areas of mailing documents being conveyed by the belt
reaches 126a,b for applying labels to the exposed areas.
31 As briefly aforedescribed, the paddle member 24 is
32 operative in conjunction with severing of each successive label
33 from the label web material i6 by the cutter assembly 22 so that
34 the paddle member holds each label as it is being severed and
moves the label to a position adhering it to a document being
36 conveyed by the conveyor belt reaches 126a and 128a. Referring
37 to FIGS. 8 and 9, taken in conjunction with FIG. 2, the paddle
A~13 SlEET
CA 02227374 1998-01-20 p ~ ~ ~ 9 6 1 0 6 3 5 6
~JS ~ JUL 1997,
-15-
1 member 24 comprises an elongated hollow paddle member having a
2 generally rectangular transverse cross-section defined by a
3 planar ~orward label contact sur~ace 140 which terminates in an
4 outer curved end sur~ace 140a a rearwardly planar wall surface
142, and upper and lower planar wall surfaces 144a and 144b,
6 respectively. Paddle member 24 has a hollow internal vacuum
7 chamber 146 adapted to be connected to a source of vacuum through
8 an oblong port 148 ~ormed in the top wall 144a. The paddle
3 member 24 is fixed on the lower end o~ a vertical pivot shaft 150
whlch ~orms the output shaft of a fluid pressure controlled
11 actuator 152. The actuator 152 is mounted on a base plate 28 so
12 that the paddle member 24 is spaced above the height of the
13 cutting edge 82a for pivotal movement in a plane parallel to the
14 base plate 28. The actuator 152 is o~ the type commercially
1~ available ~rom MAC, Inc. under its model number 912B-PM-611BA.
16 The actuator 152 includes a four-way pneumatic control
17 valve whlch enables time rotational oscillation of the pivot
18 shaft 150 and thereby pivotal movement of paddle member 24 about
19 the longitudinal axis of shaft 150. The actuator 152 is
operative to pivot the paddle member between a position wherein
21 the forward surface 140 is spaced slightly behind the plane of
22 planar surface 48a of the web material guide plate, and a forward
23 position wherein the curved outer end 140a o~ the paddle member
~4 contacts the lower exposed areas of mailing envelopes or the like
being conveyed by the conveyor belt reaches 126 a and 128a.
26 The vacuum port 148 in the upper wall 144a of the
27 paddle member 24 is adapted for registration with a vacuum
28 orifice 156 formed in a bottom horizontal wall 158a o~ a vacuum
29 block 158. The vacuum block 158 is supported in overlying
relation to the paddle member 24 so that the upper wall 144a of
31 the paddle member is in sliding contact with the opposed lower
32 wall 158a o~ the vacuum block. As illustrated in FIG 8, the
33 vacuum orifice 156 is configured so as to register with the
34 vacuum port 148 in the paddle member 24 when the paddle member
is in its rearward position behind the label web material 16
36 advanced by the label feed roller 34, and continues to remain in
37 communication with port 148 until the paddle member reaches
CA 02227374 1998-01-20 p ~ ~ ~ 9 6 / 06 ~ 5 6
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1 substantially its forward position, as shown in phantom in FIG.
2 8, at which time the vacuum port 148 no longer underlies the
3 vacuum orifice 156. With this arrangement, a vacuum created
4 within the internal vacuum chamber 1~6 o~ the paddle member 24
and acts through a plurality of vacuum orifices 140b formed in
6 the forward wall sur~ace 140 of the paddle member to engage and
7 hold label as it is being severed from the label material web 16
8 by the cutter blade 82. Simultaneously with severing of a label
9 from the web material, the paddle member is pivoted in a counter
lo clockwise or ~orward direction about the pivot rod 154, as
ll considered in FIG. 8, by actuation of the pneumatic actuator 152
12 so that the leaving edge of the label engages and is adhered to
13 a document being conveyed in juxtaposed relation to the paddle
14 member. When the paddle member 24 reaches its outermost pivotal
position with the outer end 140a engaging a label against an
16 envelope or the like, the vacuum port 148 is no longer in
17 registration with the vacuum orifice 156 so that vacuum chamber
18 146 is no longer subjected to vacuum. As the mailing envelope
19 to which the label is being applied advances, it draws the label
along the surface 140 of the paddle member to expose the leftmost
21 orifice 140b in the paddle member to atmosphere. This allows the
22 label to release from the paddle member and allows the curved
23 paddle end 140a to progressively lightly adhere the remaining
24 length o~ the label to the passing envelope. The paddle member
24 is then returned to its initial position by actuation of the
26 actuator 152 preparatory to severing and applying the next
27 successful label. The paddle member 24 is preferably positioned
28 approximately one inch from the conveyor path traversed by
29 mailing envelopes when the paddle member is in its reward
position.
31 The present invention includes several sensor systems
32 to initiate and control the operation of the linerless label
33 applicator 10. As seen in FIG. 2, straddling conveyor belt
34 reaches 126a and 128a of the incoming document path are a
plurality of sensor elements, indicated schematically at A, B,
CA 02227374 l998-0l-20
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1C, and D, each of which emits a signal to the electronic system
2operating label applicator 10 when an advancing document passes
3between the respective sensor elements. As a document is
4advanced along the document path formed by conveyor belt reaches
5126a and 128a ~rom left to right, sensor element A is initially
6actuated by the leading edge of an advancing document. Sensor
7A is one of a plurality of sensor elements disposed linerally
8along the document path of the overall document handling system
9(not shown) of which the label applicator 10 forms a part These
10sensor elements A provide a tracking ~unction to maintain control
11over the location of each document as it is advanced through the
12entire document handling system.
13Sensor element B is an activate sensor which also emits
1~an electronic signal when the leading edge of an advancing
15document is detected. As illustrated in the timeline diagram of
16FIG. lO, the signal produced by sensor element B initially
17performs two functions simultaneously. First, the stepping motor
1874 operating stepping feed roll 64 i8 energized to advance web
1916 twenty five steps upward (each step equals .023 inches in the
20preferred embodiment) between stationary shearing blade 120 and
21moveable cutter blade 82 to place the top of web 16 adjacent
22paddle element 24. For this purpose, the stepping motor 74
23operates for approximately 12 milliseconds, which places the
2a~forward end of web 16 at the proper distance above cutter blades
2582, 120 to form a label of the appropriate height. The timing
26of the operation of stepping motor 74 can be varied to adjust the
27height of the label to any predetermined amount. Second, the
28control system inhibits operation of paddle member 24 for
29approximately 28 milliseconds from the start of the sequence for
30the purpose of preventing the paddle from striking the web 16
31after the web has been advanced twenty five steps and is located
32in the path of the paddle.
33After the web 16 has been advanced for 12 milliseconds
34with the paddle initially inhibited, the air valve (not shown)
35operating movable cutter blade 82 iS activated for approximately
3625 milliseconds to cut the upstanding web material above the
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1 cutter blades 82, 120 from the remaining portion o~ the web to
2 form the label.
3 Sensor elements C and D are similar in function to each
4 other. However, sensor C is configured to emit an electronic
signal when the leading edge of an advancing document is
6 detected, and sensor element D is configured to emit an
7 electronic signal when the trailing edge of an advancing document
8 is detected. During operation, the operator selects which sensor
9 C o~ D will be operative, since in certain document handling
processes, the label must be placed dimensionally from the
11 leading edge, and in other processes, the label is placed
12 dimensionally from the trailing edge of the document.
13 When either sensor element C or D is triggered by the
14 advancing document, a short delay in actuation of the paddle
element 24 is programmed into the system to compensate for the
16 distance between the sensor C or D and the label applying
17 station, taking into account the speed of the advancing document.
18 Then, as schematically shown in FIG. 10, the previous paddle
19 inhibit function is then terminated. Next, the valve associated
with the pneumatic actuator 152 for powering paddle element 24
21 is activated for approximately 25 milliseconds, causing paddle
22 24 to pivot outwardly whereby the label cut from web 16 is held
23 by vacuum force to the paddle with the adhesive side of the web
24 facing the document conveyor path. The label is then adhered to
the advancing document as previously described. At the same
26 time, sensor C or D initiates a signal which inhibits activation
27 of the control for the web advance sequence for 21 milliseconds
28 after detection of the advancing document by sensor C or D for
29 the purpose of insuring that the remaining web material doesn't
advance upward into the cutter station while the paddle 24 is
31 moving back and forth.
32 The web feed and cutter activation control sequence
33 under the influence of sensor element B causes the movable cutter
34 blade 82 to return to its original or stand-by position under
spring force after 25 milliseconds of operation. At the same
36 time the movable cutter blade 82 begins movement to its return
37 position, a delay signal is applied to the web advance motor 74
_
-
CA 02227374 1998-01-20
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~ -19 - ,
l to delay further web movement until the movable cutter blade 82
2 clears the path along which the next length o~ web will advance.
3 In this manner, the movable cutter blade will not interfere with
4 the web material advance.
At the~ end of this 12 millisecond delay, the web
6 advance inhibit ~unction under the influence of sensor C or D is
7 terminated, and the web material 16 is moved downward three steps
8 and then immediately upward ~ive steps over a period of 12
g milliseconds. The purpose of this slight downward and then
upward movement of the web at this juncture can be explained with
11 reference to FIG. 11 which schematically illustrates the position
12 o~ the movable cutting blade 82 immediately after a label 16b has
13 been severed from the web material 16 and the label is being held
14 by vacuum force to face 140 of paddle 24. As the movable cutter
blade 82 moves in direction "a" following a cutting operation,
16 the adhesive on face "b" of web 16 causes the uppermost tip of
17 the uncut web to adhere to the underside of the movable cutting
18 blade, as shown at "x" in FIG. ll. Allowing the web 16 to remain
19 in this position would substantially inhibit subsequent upward
advance of the web 16 by means of the stepping roller 64 and
21 ribbed pinch roller 76, and prevent proper forming of subsequent
22 labels.
23 To prevent this problem ~rom occurring, the control
24 system for the label applicator 10, under the influence of sensor
B, following each cutting operation, drives stepping roller 64
26 three steps backward in a period of 12 milliseconds after the
27 movable cutter blade 82 begins its movement back to its original
28 position. Dùring this 12 millisecond period, the movable cutter
29 blade 82 moves out of the way of the web path indicated at "y",
and cannot interfere with subsequent web advancement. As the
31 stepping roller 64 moves the web down, the tip of the uncut web
32 breaks free from the inclined underside of movable cutter blade
33 82, and is drawn leftward (as viewed in FIG. 11) by vacuum force
34 towards and against manifold 48. Once ~ree from any adhesive
grip with movable cutter blade 82, the web is now free to advance
36 upward towards the cutter station and paddle without
37 interference.
' CA 02227374 1998-01-20
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1 Next, stepping roller 64 rapidly advances web 16 upward
2 five steps to place the newly ~ormed top or leading edge of the
3 remaining label material 16 at a plane "z" vertically adjacent
4 the approximate mid-height of fixed cheering blade 120, which is
below the lower wall 144b of paddle member 24. At this time,
6 paddle member 24 hen returned to its original position by action
7 of the paddle actuator 152. The paddle member 24 and moveable
8 cutter blade 82 are now in their starting positions, and the
9 label web material 16 has been advanced above the cutting plane
and into position ready for the next label advance and
11 application cycle. This sequence is repeated to apply each
12 successive label.
13 Referring to FIG. 12, a vacuum sensor is illustrated
14 schematically at 180 connected to a vacuum line 182 to-the panel
member 24 through the vacuum block 158. Sensor 180 detects
16 whether a label 16b cut from the label web material 16 is in
17 proper position against the paddle forward surface 140
18 immediately following each label cutting operation, and also
19 detects whether the label feed system ls jammed or otherwise
dysfunctional. The vacuum line or conduit 182 supplying vacuum
21 to hollow chamber 146 of paddle 24 includes an orifice 184 to
22 which the vacuum sensor 180 is operatively connected. The vacuum
23 sensor 180 detects the vacuum level in conduit 182 and is
~4 programmed to emit a warning signal if the vacuum source falls
below a pre-established threshold amount. In the illustrated
26 embodiment, the vacuum source is supplied at approximately 15
27 inches Hg. Sensor 180 is programmed to emit a signal when the
28 vacuum in conduit 182 falls to approximately 5 inches Hg.
29 When a label 16b is disposed against the forward face
140 of paddle 24, the surface of the label prevents leakage of
31 vacuum from hollow vacuum chamber 146 through ports 140b, and the
32 vacuum in the chamber 146 and conduit 182 is maintained at 15
33 inches Hg. If label 16b is not present on the forward face of
34 paddle 24, vacuum pressure leaks from unobstructed ports 140b,
and the vacuum source immediately drops to 5 inches Hg, causing
36 sensor 180 to emit a signal which is conveyed to the document
37 ~eed control system to halt the advance of documents towards the
AM~3 SHEFr
CA 02227374 1998-01-20 ,.
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1 document labeling station. Upon correction of the error by an
2 operator, the label application system 10 resumes its normal
3 functions.
4 While a preferred embodiment of the present invention
have been illustrated and described, it will be understood by
6 those skilled in the art that changes and modification may be
7 made therein without departing from the invention in its broader
8 aspects. Various features of the inventions are defined in the
9 ~ol~:owing claims.
