Note: Descriptions are shown in the official language in which they were submitted.
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BUNDLED PRINTED SHEETS
This application is being filed on 3 June 2004, as a PCT International Patent
application in the name of Precision Press, Inc., a U.S. national corporation,
claiming priority to U.S. Provisional Application No. 60/45,935, filed 3 June
2003
and U.S. Utility Patent Application No. Unknown, filed 3 June 2004.
Background
There exists a need for improved bundled printed sheet articles. There also
exists a need for an effective apparatus for the manufacture of bundled
printed sheet
articles. There also exists a need for improved methods of making and methods
of
use of bundled printed sheet articles.
Summary
The present disclosure is directed to bundled printed sheet articles, to an
apparatus for their manufacture, and to methods of malting and using the
articles.
The present disclosure, in embodiments, provides a bundle of printed sheets,
comprising:
a plurality of printed sheets in a staclc;
a band around the staclc; and
an optional overwrapper on the banded stack,
each printed sheet having a narrow cut-to-print registration variance, and
each printed sheet having the same length and width dimensions as the other
printed sheets in the staclc to within a narrow variance.
The present disclosure, in embodiments, also provides an apparatus for
malting bundled printed sheets, the apparatus comprising:
a printable web;
a print module to print on the printable web;
a cutter module to cut the printed web into a stream of printed sheets;
a collator to collate each stream of printed sheets into a registered stack;
a conveyor module to convey each registered staclc into a staclc stream; and
a packaging module to package each registered staclc in the stack stream into
a package of bundled printed sheets.
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The present disclosure, in embodiments, also provides a method of making
bundled printed sheets, comprising:
printing on a printable web;
cutting the printed web into a stream of printed sheets and a waste matrix;
collating each stream of printed sheets into a registered stack;
conveying each registered staclc into a stack stream; and
paclcaging each registered stack in the stack stream to form a bundle of
printed sheets.
The present disclosure, in embodiments, also provides a method of making
bundled printed sheets, comprising:
providing single-sheets;
optionally printing on the single-sheets with a print engine;
cutting each single-sheet into a stream of cut printed sheets and a waste
matrix;
collating each stream of cut-printed sheets into a registered stack;
conveying each registered stack into a stack stream; and
packaging each registered stack in the stack stream into a bundle of printed
sheets.
The present disclosure, in embodiments, also provides a method of affixing
printed sheets to articles.
In embodiments of the present disclosure, there is also provided a stack or
bundle of printed sheets in a label applicator machine.
The present disclosure, in embodiments, also provides an article having a
printed sheet attached thereto, the printed sheet being obtained from
unpackaging a
bundle of printed sheets of the disclosure.
The present disclosure, in embodiments, also provides a printing system for
making and packaging bundles of precision printed and cut sheets.
These and other embodiments of the present disclosure will become apparent
after a review of the following detailed description of the disclosed
embodiments
_30 and the appended claims.
Brief Description of the Drawings
FIG. 1 is a schematic of a web-based apparatus for malting the bundled
printed sheet articles, in embodiments of the present disclosure.
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FIG. 2 is a schematic of a sheet-fed based apparatus for malting the bundled
printed sheet articles, in embodiments of the present disclosure.
FIG. 3 illustrates a block diagram overview of a web-based process of FIG. 1
for preparing bundle printed sheets, in embodiments of the present disclosure.
FIG. 4A illustrates a perspective of a portion of a web-based apparatus for
preparing bundle printed sheets, in embodiments of the present disclosure.
FIG. 4B illustrates a section view of a cutter module in a web-based
apparatus for preparing bundle printed sheets, in embodiments of the present
disclosure.
FIG. 5 illustrates a bloclc diagram overview of a sheet-fed based process of
FIG. 2 for preparing bundle printed sheets, in embodiments of the present
disclosure.
FIG. 6A and 6B illustrate alternative configurations of a collator module and
a conveyor module of an apparatus for preparing bundled printed sheets, in
embodiments of the present disclosure.
FIG. 7A and 7B illustrate alternative conveyor modules of an apparatus for
preparing bundled printed sheets, in embodiments of the present disclosure.
FIG. 8A-8D illustrate examples of cut patterns for forming cut printed sheets,
in embodiments of the present disclosure.
FIG. 9A and 9B illustrate bundled printed sheets, in embodiments of the
present disclosure.
FIG. 9C and 9D illustrate other examples of bundled of printed sheets having
alternative staclc or bundle geometries, in embodiments of the present
disclosure.
Detailed Description
To promote an understanding of the principles of the present disclosure,
descriptions of specific embodiments of the disclosure follow and specific
language
is used to describe the specific embodiments. It will nevertheless be
understood that
no limitation of the scope of the disclosure is intended by the use of
specific
language. Alterations, further modifications, and such further applications of
the
principles of the present disclosure are contemplated as would normally occur
to one
ordinarily slcilled in the art to which the disclosure pertains.
In embodiments, the present disclosure is directed to bundled printed sheet
articles. The bundled printed sheet articles can have, in embodiments, for
example
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high print quality, high length and width dimensional attributes, and high
print-to-
cut registration attributes. The present disclosure, in embodiments, is also
directed
to an apparatus for making the bundled printed sheet articles. The present
disclosure, in embodiments, is also directed to methods of malting and to
methods of
using the bundled printed sheet articles.
Definitions
"Substrate" refers to a web-fed or a sheet-fed material from which cut printed
sheets are prepared by the process of the present disclosure.
"Module" refers to a component or subassembly of the apparatus of the
disclosure which can accomplish a defined function or operation; such as a
print
module for printing, a coater module for coating, a cutter module for cutting,
a
collator module for collating, a conveyor module for conveying, and a
packaging
module for packaging. The modules of the disclosure can be adapted to be
serially
(i.e., modules linked in series) or multiply (e.g., one or more coating
modules)
integrated with other modules of the apparatus. The modules of the disclosure
preferably can be readily modified or serviced in place, or additionally or
alternatively, preferably readily replaced or interchanged with a similar or
different
module (e.g., a web-based four color print module interchanged with a sheet-
fed
xerographic color print module).
"Cut-to-print registration," "cut-edges to print registration," "print
registration to cut edges, " "print-to-cut registration" or like phases refer
the position
of a printed image with respect to its exact, ideal, or desired cut-out
pattern of the
printed image compared to the actual or achieved cut-out pattern of the
printed
image in web-feed or sheet-feed embodiments of the present disclosure.
"Print-to-print registration" refers the position of a printed image with
respect to adj acent printed images on a moving web. '
"Angle-cut," "angle cutting," and like terms refer to cutting of printed
sheets
from the web or from fed-sheets at an angle other than square to the process
direction, for example, where at least the edges of the printed sheets
approximately
parallel to the process direction are cut at a slight angle to parallel.
Alternatively,
"angle cutting" printed sheets from the web- or from fed-sheets can be
accomplished
where at least the lead and trail edges of the printed sheet are normal
(perpendicular)
to the process direction are cut at a slight angle to normal. In preferred
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embodiments the printed sheets preferably are angle-cut on both parallel edges
and
the lead and trail edges.
"Sheet stream" refers to a continuous or semi-continuous intermediate
transport or flow of cut printed sheets from the cutter to further processing.
A sheet
stream originates upon cutting the web or sheet-fed substrate and ceases when
the
individual cut sheets of a stream are received by a collator and collated into
a stack.
Additionally, a sheet stream is formed from successive cutting events in a
specific
reference location on the web or the same region of successively fed-sheets,
which
produce a series of cut printed sheets.
"Collate," "collated," "collation," "collating," and like terms refer to
collecting a portion of the cut printed sheets from each sheet stream to form
an
individual stack of cut printed sheets having uniform geometry or having
unitary
three-dimensional ordering.
"Stack" refers to a plurality of unsupported cut printed sheets piled atop one
another and having substantially the same orientation. "Staclc" also refers to
a loose
but ordered ream of cut printed sheets of the disclosure.
"Stack stream" refers to a continuous or semi-continuous transport or flow of
registered stacks from the collator to further processing.
"Bundle" refers to a stack of cut printed sheets having a securing band, a
protective overwrapper, a partial overwrapper, or combinations thereof.
"Banding," "banded," and like terms, refer to surrounding at least a portion
of a registered staclc with a band.
"High bundle-to-bundle uniformity" refers to such aspects as appearance
uniformity, dimensional uniformity, performance or use uniformity, and like
uniformity aspects, between or among bundles produced in the same print job.
Additionally or alternatively, high bundle-to-bundle uniformity refers to low
bundle-
to-bundle variability.
"Print engine" refers generally to any print system or marking technology
that is compatible with image or print formation aspects of the present
disclosure,
for example, as illustrated herein; "print engine" is not limited to j for
example,
digital print technologies.
As used herein the singular forms "a," "an," and "the" include plural
referents
unless the content clearly dictates otherwise. Thus, for example, reference to
a
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product or article containing "a sheet" can include one or more sheets, or
reference
to a sheet printed with "an ink" can include one or more inks.
"About" modifying, for example, the quantity, dimension, duration, or like
metrics of an article, apparatus, process, and like values, and ranges
thereof,
employed in the disclosure, refers to expected variations in the ntunerical
quantity
that can occur, for example, through typical measuring and handling procedures
used to describe or quantitate aspects of the disclosure; through inadvertent
error in
these procedures; and through differences in the manufacture, source,
environmental
sensitivity, or purity of the materials used in the articles, apparatus, or
processes of
the disclosure.
"Consisting essentially of refers to the recited items in the claim and
includes unrecited items or aspects that do not materially affect the basic
and novel
properties of the articles, apparatus, or processes of the disclosure. Aspects
or items
that can materially affect the basic properties of the articles, apparatus, or
processes
of the present disclosure are those which impart undesirable characteristics
or
impose undesirable results thereon, for example, slow drying or non-curable
ink or
coating formulations, web- or sheet-stock which is dimensionally unstable or
environmentally highly variable, cutting or collating which is highly
imprecise or
highly variable, or packaging materials which are not robust to the rigors of
transport, handling, storage, or industrial use.
Referring to the figures, FIG. 1 illustrates a schematic overview of an
apparatus for making the bundled printed sheet articles, in embodiments of the
present disclosure. The apparatus or production system 10 is an automated
continuous web-based system for high volume production of individual printed
sheets from the web, free standing or supported staclcs of the printed sheets,
and
packaged stacks of the printed sheets, that is a plurality of bundles of
printed sheets.
The web can be printed or imaged to form a plurality of substantially
identical printed regions on the web, which printed web can be, for example,
subsequently precision cut into individual printed sheets. The individual
printed
sheets can be staclced. The stacks can be bundled, and the bundles can be
boxed for
shipping or storage. The foregoing illustrative steps can be accomplished
continuously and without interruption. Other steps, such as a finish coating,
anti-
static treatment, and like steps, can optionally be incorporated into the
apparatus and
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process of the present disclosure and illustrated herein. The apparatus and
process
of the present disclosure provide for the continuous high volume and high
quality
manufacture of bundled printed sheets. FIG. 1 shows various individually
numbered
modules, stations, or components only by way of example and to illustrate
various
preferred embodiments.
SUBSTRATE STAGING (WEB- OR SHEET-FED)
Substrate feed module or station 11 preferably can be a web-stock loading
area where, for example, unprinted paper, plastic ftlm, or other suitable
sheet stoclc
is fed into the system using supply rolls and unroll festoons to control
tension and
other relevant parameters, and to permit adding additional web rolls so as to
enable
continuous operation over extended periods and without interruption or shut-
down.
Such web loading and change-over equipment is commercially available from, for
example, Keene Technology, Inc., Beloit, IL; and Martin Automatic, Inc.,
Rockford,
IL. A preferred component for this station is the model ZG 2650-10 shaftless
butt
splicer from Keene Technology, Inc.
SUBSTRATE MARK1NG AND INSPECTION
Printing module 12 or station can be, for example, a web offset print engine
or like printing equipment, which module images or prints desired patterns or
marks
on one or both sides of the web.
In embodiments printing on the web or on fed-sheets (discussed in FIG 2
below) can comprise any suitable print method, including for example, offset,
lithography, flexography, gravure, non-impact printing methods,
electrophotography, or combinations thereof. Offset printing typically
includes an
intermediate image receiver such as a printing plate. Lithography typically
includes
a printing member having ink receptive regions and ink rejecting regions,
which
opposite regions result in image and non-image regions on the printing member.
Gravure printing methods typically include a printing member having a metal
cylinder etched with numerous tiny wells that hold and release inlc. Non-
impact
printing methods can use, for example, lasers as in laserography, ions as in
ionography, inlc jet as in thermal ink jet or bubble ink jet, thermal transfer
imaging,
and like methods and devices to form or transfer images on or to 'a receiver,
such as
a continuous web or a single sheet receiver. Electrophotographic printing
methods
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include, but are not limited to, for example, xerography (e.g., frorn Xerox
Corp),
liquid immersion development (LID, e.g., from Indigo), ionography (e.g., from
Delphax), and like methods.
In embodiments, the print module can comprise a single print engine, or two
or more print engines, and which print engines can have the same or different
marking technology or capabilities. Thus, for example, a first print engine,
such as
an offset print engine, can print constant image information, such as CMYK
four-
color image and text, and a second print engine, such as an ink jet or
xerographic
print engine, can print variable image information, such as custom color,
specialty
graphics, production information, customer information, lot or serial numbers,
expiration dates, or like image or indicia information. It is understood that
two or
more different print engines can be configured to print on the same side of
the
substrate, opposites sides of the substrate, or both.
The printing and subsequent processing of the printed images, such as
cutting and stacking, is preferably monitored and performed with at least one,
and
preferably four or more, different inspection systems, such as inspection
station 25.
One system, a video print inspection system, can aid a system operator or
automated
controller in the inspection of print quality. Another system, a print
registration
control, can check and automatically correct the print register. Yet another
system, a
closed-loop color control, can analyze and adjust ink density according to the
pre-
defined desired print specifications. Still another system, for example, a
video die-
cut inspection system, can aid the operator in the inspection of web- or fed-
sheet cut-
quality. The order of the inspection stations may be rearranged. The use of
each of
these specific inspections is not required, but the use of all of them can be
preferred
in embodiments.
The apparatus and method can further include monitoring the registration of
the printing to the cutting. In embodiments, monitoring the registration of
the
printing to the cutting enables, for example, the elimination of a
characteristic
telltale white strip or unprinted area artifacts from the printed sheets.
An ability to accurately measure or monitor basic aspects, such as the above
mentioned product, process, and operational aspects of the apparatus, is
frequently
facilitated by a pre-defined product or process target specification for
quality control
or quality assurance. Such target specifications and achievement of the target
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specifications can provide useful documented "proofs" of the process leading
to the
product.
Measuring or monitoring aspects of the printing and packaging system, such
as mentioned above, can be accomplished, for example, on-line, off line, or
combinations thereof. The measurements are preferably accomplished on-line
using
process automation tools, for example, positional sensors, video microscopy or
magnification, in conjunction with analytic or diagnostic software, for
observing and
maintaining print, image, color fidelity, cut-to-print registration, print-to-
print
registration, reproducibility, and like quality parameters.
In embodiments, monitoring the registration of the print-to-cut can be
accomplished by continuously detecting a reference mark on the web matrix
region
prior to cutting, and continuously adjusting, as needed, the web relative to
the cutter,
the cutter relative to the web or both, (e.g., using web guides, web
compensator
rollers, and like adjustable components), to achieve a predetermined alignment
of
the cutter relative to printed items on the printed web. The aforementioned
adjustment of the cutter can include, for example, controllably varying the
speed of
' the web, controllably varying the position of the web, continuously
adjusting the
die-cutter (e.g., circumferentially, laterally, or both) or combinations
thereof. Here
"predetermined alignment" refers to proper alignment needed to achieve target
print-
to-print and cut-to-print registration specifications. Continuous registration
and like
adjustments can provide a number of advantages including avoiding problems
associated with cutters, such as a guillotine cutter, for example, unreliable
or
unpredictable dimensional consistency and uniformity, alignment, registration,
and
like issues. Thus, the present process and apparatus can cut each,printed
sheet
individually. The present process and apparatus can also cut a plurality of
sheets
individually and at the same time.
The following documents disclose or illustrate suitable command and control
equipment, monitoring or measurement equipment, or related components or
features which, in embodiments, can be adapted for use in-part in the present
disclosure without departing from inventive aspects of the present disclosure:
U.S.
Patent No. 5,460,359, discloses a binding apparatus for binding sheets of cut
paper
printed by a printing machine including a control system; U.S. Patent No.
4,891,681,
discloses a hard copy apparatus for producing center fastened sheet sets
including
trapezoidal stacks for folded binding, and a control system; U.S. Patent No.
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4,785,731, discloses a bundle count verifier (e.g., for newspaper bundles);
U.S.
Patent No. 4,727,803, discloses a conveyor device with an article lifting
unit; U.S.
Patent No. 4,566,244, discloses a paper sheet grip and transfer apparatus for
a
counting and half wrapping device, see also disclosed therein Japanese Laid-
Open
Patent Specification No. 57-8616 (transport of paper sheets) and Japanese Laid-
Open Utility Model Specification No. SO-98791 (transfer a pile of paper sheets
on a
belt without holding the sheets on the belt); and U.S. Patent No. 4, ,424,660,
discloses
an apparatus for binding paper sheets stacked within a hopper into
bundles.each
consisting of a predetermined number of paper sheets including a method of
sheet
transport, for example, sheets sandwiched between belts.
SUBSTRATE COATING, CONDITIONING, OR TREATMENT
The method of malting can further comprise optionally applying a coating to
the first face, the second face, or both faces of the printed web. The coating
can be
applied to the printed side of the web, the unprinted side of the web, or both
the
unprinted side of the web and the printed side of the web, depending for
example, on
the properties desired for the printed sheets and the bundled printed sheets.
The
coating can be, for example, a varnish coat, a gloss coat, a clear coat, a
seal coat, an
antistatic treatment, and like coatings, or combinations thereof.
Optional coating, conditioning, or treatment modules 13 or stations can
include, for example, optional in-line coaters 13a-c, which can apply, for
example, a
functional coating to one or both sides of the web, such as gloss coat or
varnish coat.
In embodiments, the web after leaving the coater 13a can, if desired, be
diverted by
re-routing to extend the web's path and to permit satisfactory leveling or
drying of
the applied functional coating before further processing steps are
accomplished.
One or more additional in-line coating units 13b-c (not shown) can apply a
second
or a third functional coating to one or both sides of the web, such as an
antistatic or
static-preventing coat, a silicone based antistatic coating, and like
coatings, or
combinations thereof, or other performance or appearance enhancing chemical
coats.
Antistatic compounds, such as quaternary ammonium salts, and antistatic
formulations are known and are commercially available. Coating the web, for
example, with varnish or similar materials, can be used to protect or to
enhance the
appearance of the printed product, such as labels, in some printing
embodiments. If
foil or laminate print technologies are used, coating with varnish may not be
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necessary. The coating module may be integrated into the print module, and
therefore may be provided by a cormnercial manufacturer. Preferred equipment
for
use in modules 12 and 13, in embodiments, can be, for example, the model
QUANTUM 1250CM press commercially available from Sanden Machine Ltd., of
Cambridge, Ontario, Canada. Equipment, processes, and control systems for
coating
web materials are generally disclosed, for example, in U.S. Patent No.
4,886,680. In
embodiments, optional interstation web chilling modules (not shown) can be
employed, for example, after or between each print tower or print station to,
for
example, remove excess heat, facilitate cure or drying of the printed or
coated web,
promote proper finishing or surface textures, and like enhancements, such as
in a
mufti-color (e.g., 4 to 15 print towers) web offset press using UV' curable
inks.
The method of making can further include chilling the printed web. An
optional web chiller 13d or chilling mechanism, such as one or more
refrigerated
rollers, coolant chilled rollers, cool conditioned air, or like chilling
mechanism,
which can be non-contact with the web or preferably in-contact with the web,
can be
employed to cool and thereby stabilize the post-print or post-coat web product
and
can provide improved registration prior to cutting the web into individual
printed
sheets.
The apparatus and method can also further include a web guide system for
web substrate regulation. An optional web guide system 13e can be employed in
embodiments for substrate regulation and to provide improved registration of
the
printed web presented to the cutting module, such as a die-cutter.
In embodiments, an optional corona charger or lilce charging devices, such as
charger 23, or discharging devices, such as antistatic bar or static
eliminator 26, can
be use to electrostatically condition or treat the web before or after the
print module.
Charging the web can, for example, make the web, such as a plastic film,
composite,
or laminate-based web, more receptive than otherwise to inks, coatings, or
like
treatments. Discharging or removing static from the web or from the resulting
cut
printed sheets can, for example, facilitate sheet transport and staclcing by
reducing or
eliminating sheet charging, lilce-charge repulsion, and like problems.
SUBSTRATE CUTTING
After the web has been printed and optionally conditioned or surface treated,
the web is guided to a cutter module 14. The cutter module can include, for
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example, a rotary die-cutter, a flat-bed die-cutter, a slit-and-gap cutter, a
slit-and-but
cutter, a guillotine cutter, and like cutters, or combinations thereof. A
preferred
cutter module can include, for example, an in-line rotary die-cutting system,
which
die-cutter can cut individual printed sheets from the printed web to create a
corresponding continuous sheet stream and a continuous cut-out waste stream or
waste matrix.
In embodiments where two or more die cutters are employed, a first die
cutter can be adapted to cut customized details or features from the incipient
(not-
yet-cut) printed sheets, such as notches, holes, hang tag apertures, concave
curves,
convex curves, or both, and like geometric or design details, and without
severing or
separating the printed sheet from the web or fed-sheet. A second die cutter
can be
adapted to further cut the printed sheets, or completely cut-out individual
printed
sheets from the substrate. In embodiments the cutter module can optionally be
adapted so that a die cutter cuts the substrate to the desired and defined
dimensions
for each printed sheet except for a small fiber region or umbilical thread,
for
example, of about 10 to about 1,000 microns, and preferably about 100 to about
200
microns, between the substrate and the sheet, preferably at the lead and
trailing
edges of the sheet and the substrate, which can momentarily retain the
material
connection and force continuity between the nearly completely cut printed
sheet, in-
line nearest neighbor printed sheets, the moving substrate, or combinations
thereof.
An optional edger or slicer can subsequently "burst" the umbilical thread at a
more
favorable location down stream. An optional debris collector, such as a vacuum
line
or vacuum manifold, can be situated in close proximity, such as from about 1
centimeter to about 100 centimeters to remove potentially objectionable dust
and
like debris generated from the bursting operation.
In embodiments, a continuous sheet stream is preferred for productivity and
economy. However, occasionally the bundled printed sheet production process of
the disclosure may need to be briefly suspended to make, for example, change-
overs,
adjustments, repairs, and like maintenance or production optimization. The
process
and apparatus of the present disclosure can be adapted with, for example,
controls
and quality specifications, to permit as-needed temporary suspension or
interruption
of production without jeopardizing an entire print job. In this sense a sheet
stream
can have a semi-continuous character when, for example, its flow is
temporarily
interrupted.
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In embodiments, the cutter module can include a static eliminator. The static
eliminator can facilitate separation of cut sheets and waste matrix, and
prevent the
cut sheets from following or adhering to the matrix, the cutter, other sheets,
or to the
sheet transporter. Methods of static charge or frictional charge suppression
or
elimination, for use in place of or in conjunction with humidity control, can
include,
for example, a conductive or non-conductive disturber brush, an air ionizer
such as a
charge corotron, a de-ionizer, and lilce articles or devices. Other methods of
static
charge or frictional charge suppression or elimination, for use in place of or
in
conjunction with humidity control, can include, for example, applying an anti-
static
coating or like surface treatment, where for example one or both side of the
web or
fed-sheets are treated before or after printing.
In-line die-cutting of a printed web to produce individual cut printed sheets,
such as printed labels, as in the present disclosure saves time and,lowers
cost
compared to processing the cut printed sheets or labels individually at
various
stages. W -line die-cutting can also produce an exact or substantially exact
duplication of the cut features in each and every printed sheet produced. In
contrast,
cutting labels with, for example, a guillotine cutter, can often be prone to
operator
error or mechanical error (e.g., attributable to cumulative machine wear)
which can
lead to greater variation and lower quality in the finished product. An in-
line die-
cutting system can provide ideal duplication of specified product dimensions
as well
as accurate print-to-cut registration. If desired, a cutting module having a
die-cutter
can be preferably integrated into a print module similar to the abovementioned
integrated coating module. Rotary die-cutting equipment, such as rotary dies
and
flexible dies, print cylinders, and other rotary tooling for precision die-
cutting, is
commercially available from, for example, Rotometrics of Eurelca, MO; and
Bernal
Inc., of Rochester Hills, MI. Various other wide format cutters and related in-
line
finishing equipment is commercially available from, for example, Advance
Graphic
Equipment (www.advancegraphicsequip.com).
In embodiments, the apparatus and method of the disclosure which employs,
for example, a die-cutter, can provide cut printed sheets having a print-to-
cut
registration, that is print registration to cut edges variance, for example,
from less
than or equal to about plus or minus 0.0625 inches (1/l6th inch), more
preferably
from less than or equal to about plus or minus 0.046875 inches (3/64th inch),
even
more preferably from less than or equal to about plus or minus 0.03125 inches
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(1/32"d inch), and even still more preferably less than or equal to about plus
or minus
0.015625 inches (1/64th inch). In embodiments, the apparatus and method of the
disclosure which employ, for example, a rotary die-cutter, can routinely
provide cut
printed sheets having a print registration to cut edges variance, for example,
less
than or equal to about plus or minus 0.03 inches.
In embodiments, the apparatus and method of the disclosure which employ,
for example, a rotary die-cutter, can provide cut printed sheets such that
each sheet
has substantially the same length and width dimensions as substantially all
the other
cut printed sheets produced in the job, for example, to within a variance of
less than
or equal to about 0.010 inches (1/100th inch), more preferably less than or
equal to
about 0.0075 inches (1/133rd inch), even more preferably less than or equal to
about
0.00666 inches (11150th inch), and even still more preferably less'than or
equal to
about 0.005 inches (1/200th inch).
Preferences for the above mentioned narrower print-to-cut registration
variance and narrower length and width dimensional variance, will be readily
appreciated by one of ordinary skill in the art, and can include, for example,
higher
quality printed sheets, higher stack and bundle uniformity and quality,
greater
latitude for print layout, artwork, sheet design, and sheet geometry, greater
intermediate-user and end-user customer acceptance, greater reliability in
methods
of application of the printed sheets to articles, greater ease-of handling and
ease-of
use, and like intrinsic and extrinsic benefits.
In embodiments, the apparatus and method of the disclosure which employ,
for example, a rotary die-cutter can provide cut printed sheets and in their
corresponding bundled printed sheets where each cut printed sheet produced can
have a cut-to-print registration variance of, for example, from less than or
equal to
about 0.0625 inches, and the same length and width dimensions as the other
printed
sheets in the stack to within a variance of less than or equal to about 0.010
inches.
In embodiments, the apparatus and method of the disclosure which employ, for
example, a rotary die-cutter can provide cut printed sheets and corresponding
bundled printed sheets where each cut printed sheet produced can have both a
cut-to-
print registration variance of, for example, from less than or equal to about
0.046875
inches, and the same length and width dimensions as the other printed sheets
in the
stack to within a variance of less than or equal to about 0.0075 inches. In
embodiments, the apparatus and method of the disclosure which employ, for
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example, a rotary die-cutter can provide cut printed sheets where each cut
printed
sheet produced has both a cut-to-print registration variance of, for example,
from
less than or equal to about 0.03 inches, and substantially the same length and
width
dimensions, for example, to within a variance of less than or equal to about
0.005
inches, as substantially all the other cut printed sheets in a job, for
example, over a
24 to 48 hour period, or more, of continuous production or apparatus
operation. In
other like recitations of cut-to-print registration variance, length
dimensional
variance, and width dimensional variance, it will be understood to include
"less than
or equal to" if not explicitly indicated. It will also be understood that
variances can
be determined by any suitable measurement methods, for example, video
microscopy, microscopy with a calibrated vernier or reference standard, a
micrometer, and like measurement methods.
In embodiments each cutting event of the printed web can be accomplished,
for example, widthwise across the web process direction or in a variety of
alternative
schemes, for example, as disclosed herein. Alternatively or additionally, the
cutting
can be accomplished simultaneously or semi-simultaneously with a die-cutter.
The
die-cutter can cut printed sheets from the web in a variety of ways, such as
web
printed items which are, for example, aligned adjacent sheets, staggered
adjacent
sheets, angle-cut adjacent sheets, or combinations thereof. In embodiments,
die-
cutting of printed sheets can be accomplished simultaneously, having stagger
between or among adjacent latent or incipient streams of printed sheets. In
preferred
embodiments, die-cutting can be accomplished with angle-cut of one or more of
the
edges of the printed sheets. Angle-cutting the web- or fed-sheets produces
sheets
which can be, for example, square shaped or rectangular shaped and can
optionally
have square corners of about 90 degrees. These sheets are cut by a die that
has a
minor skew angle or orientational off set of the cut edges from parallel,
perpendicular, or both, relative to the web's process direction edges, so as
to allow
the rotary die cutter to achieve cuts which provide more shear-type cut forces
and
minimizes or eliminates "bounce" or recoil associated with simultaneous
cutting of
like pieces from the moving web at high speeds. Thus, in angle-cut die-cutting
the
die-cut blade is preferably slightly skewed by, for example, about one half of
a
degree so that the lead edge of each die-cutting blade provides web cross-cut
action
from a point and proceeds in a line rather than a perpendicular "all-at-once"
cut
normal to the edges of the web or the fed-sheet.
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In embodiments, die-cutting the printed web can be configured to
continuously produce a stream of printed sheets from a corresponding width of
the
printed web. Die-cutting is preferably accomplished in a continuous fashion,
for
example, without hesitation or interruption in the speed or movemenf of the
printed
web or printed fed-sheets. The preference for continuously die-cutting is
evident
from, for example, measured economic efficiencies, product throughput, and
minimized or minimal operator intervention. In embodiments, each die-cutting
or
die-cut event can be accomplished in one of several alternative schemes or
variations on the schemes and combinations thereof, for example,
"simultaneous"
die-cutting wherein the lead edge of each sheet of an array of printed pieces
on an
advancing web or a fed-sheet substrate is first cut by a suitably adjusted and
configured die-cutter. The die-cutting continues to cut out the printed pieces
from
the web or the fed-sheets arnving from an upstream process direction to
generate
individual printed sheets or an array of individual printed sheets across the
process
direction. In embodiments of the presently disclosed methods of making bundled
printed sheets, each cutting event can produce, for example, from 1 to about
80 of
individually cut and printed sheets width-wise across the web process
direction,
depending on for example, the desired (x- and y-) dimensions of the resulting
cut
printed sheets and their bundles.
In embodiments, the cutter module can be configured to have one or more
cutters, such as two or more rotary die-cutters in series, for cutting the
printed web
or printed fed-sheets, for example, where it is necessary or convenient to
accomplish
multiple cuts or special-effect cuts on or within a single sheet, such as
"doughnut
hole" or "window" cut-outs within a sheet, notches on the edge of a sheet, and
like
cuts, or combinations thereof. Alternatively, a single cutter, such. as a
rotary die-
cutter having an appropriately configured die, can often accomplish many, if
not
most, examples of multiple cuts or special-effect cuts on each sheet with a
single
die-cut pass or impression.
MATRIX REMOVAL, SHEET CONVEYANCE, AND SHEET COLLATION
The abovementioned waste matrix or residual web slceleton can be optionally
continuously removed and discarded with a waste matrix management module 15,
for example, with a vacuum talce-off or a windable talce-up reel. A vacuum
take-off
is generally preferred since it can provide higher capacity waste matrix
removal,
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continuous operation, and enhanced safety and handling convenience by
directing
the waste to an area away from production. After the web is cut the transport
integrity of the original web no longer exists thus the resulting cut printed
sheets
preferably need to be individually, continuously, and orderly transported to a
sheet
starker in the collator module 16 in one or more cut printed sheet product
streams.
Each cut sheet product stream can be transported to the sheet starker or
"batch
starker" with a sheet delivery system employing, for example, opposing belts,
rollers, vacuum transporters, and like apparatus, or combinations thereof.
Examples
of preferred suppliers of commercially available equipment for the waste
matrix
removal module include Quickdraft of Canton, OH; and individual sheet delivery
or
transport systems and sheet starkers include, Gannicott, Ltd. of Toronto,
Ontario,
Canada, see also U.S. Patent No. 4,102,253.
In embodiments, the collating can be accomplished with a sheet transport
and stacking machine which has been suitably modified to receive and collate
multiple individual cut printed sheets of one or more sheet streams at the
same time.
In embodiments, each stream of printed sheets can be transported from the
cutter to
the collator with a sheet transport system comprised of at least orie
transport belt and
at least one backing roller opposing the transport belt. In embodiments,
individual
sheet transport, alternatively or additionally, can be accomplished with a
vacuum
assist transfer machine as disclosed, for example, in U.S. Patent Application
20030164587 (Gronbjerg).
The sheet delivery system preferably is adapted to simultaneously transport a
plurality of the cut sheets in adjacent parallel sheet streams. At the sheet
starker the
individual sheet delivery system feeds the respective sheet streams,
containing the
cut printed sheets, into bins to form respective stacks. The stacks can be
collectively
or individually customized with respect to, for example: staclc dimensions and
the
number of stacks formed based, for example, on cutting criteria, and the
number of
printed sheets in each stack. Stack dimensions can depend on, for example,
sheet
thickness, sheet-count, stack-height, stack-weight, or like criteria. In
embodiments,
sheet-count is a preferred stack customization criterion, which is typically
driven or
determined, for example, by customer use requirements and ergonomic handling
factors. Stack customization criteria can be readily translated and programmed
into
the apparatus and production process of the disclosure by appropriate manual
or
automated, adjustment or modification, of the process equipment, controls, or
both,
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such as replacing the die-cutter plate to provide customized cut sheet
dimensions,
reprogramming the sheet counters or stack height sensors to customize the
stack
height, adjusting sheet alignment tolerance within each stack, and like
changes.
When stack customization criteria and related quality criteria, such as print
quality,
are fulfilled in production, the resulting stack can be deemed to be
"registered" and
those stacks are acceptable for fiuther processing within the apparatus.
"Unregistered" or out-of register stacks can optionally be identified, marked,
rejected, such as removed from the product stream, or like remediation, at
this or
later points in the apparatus or production process and analogously to the
abovementioned removal of individually rej ected cut sheets from the sheet
stream
transport.
In embodiments, the cut printed sheet transport system can be adapted, in
conjunction with known or the abovementioned command and control equipment, to
reject cut printed sheets which do not have substantially the same cut-to-
print
registration, sheet dimensions, or both 'attributes, as all other shects in
the job. The
cut-to-print registration, sheet dimensions, or both specifications, can
preferably be
established manually or programmably during job set-up or can be called-up
from a
computer or controller's memory. Rejected or out-of spec cut printed sheets
can be
readily diverted and removed from a sheet stream at a point between the cutter
and
the collator, for example, by a sheet grabber or a sheet diverter.
In embodiments of the present disclosure, the collator module for the cut
sheet stream can alternatively be a rotary sorter as disclosed, for example,
in U.S.
Patent No. 4,52,421 (copying machine with rotary sorter and adhesive binding
apparatus), appropriately modified to receive multiple sheet streams into
multiple
staclcs. In embodiments such a rotary sorter can be further optionally adapted
to
receive and further transport the staclcs to the conveyor module, with
inversion of
orientation or optional retention of stack orientation upon delivery to the
conveyor
module.
STACK CONVEYANCE
In embodiments, a conveyor module 17 can be adapted to receive, for
example in continuous batches, one or more registered stacks from the collator
module and to convey each registered stack, in batches, into a stack stream.
In
embodiments, a conveyor module conveys (e.g., in the web process-direction) on
a
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first conveyor the registered stacks away from the collator for a distance to
further
processing, such as packaging. In embodiments, a conveyor module conveys
(e.g.,
in the web process-direction) on a first conveyor the registered stacks away
from the
collator for a distance and thereafter the registered stacks can be displaced
laterally
or perpendicularly (i.e., with respect to web-process direction), onto a
second
conveyor to form a merged stack stream. In embodiments, a stack stream as used
herein can arise from, for example, a plurality of registered stacks being
merged into
a single stream of stacks. In embodiments, a stack stream can also arise from,
for
example, bifurcating or splitting the abovementioned merged single stream of
staclcs
into two or more stack streams. In embodiments a plurality of stack streams
can
also arise from, for example, bifurcating or splitting the registered staclcs
soon after
being formed, into a plurality of stack streams.
In embodiments, a single conveyor, for example, oriented perpendicular to
the sheet stream flow and the incipient batch stack formation, and situated in
close
proximity to each batch stacker can be adapted to directly receive the cut
printed
sheets and incipient staclcs. Thus, the conveyor surface, when stationary, can
serve
as the base of the batch staclcer where the sheet streams are compiled into
stacks.
Thereafter, the completed registered stacks are intermittently conveyed from
the
batch stacker to subsequent packaging modules in a single stack stream. This
single
conveyor configuration eliminates the need for two conveyors to get to the
first
paclcaging module, such as the first conveyor as illustrated and discussed for
in FIG.
7 below, since a preferred stack stream merger into a single stream can be
accomplished as the staclcs are formed and there is no need to extend or "turn-
the-
corner" with a hand-off to a second conveyor.
Conveyor module 17 transports the stack stream or streams to and through
the remainder of the apparatus and process modules. In embodiments, the stacks
can
be transported unsupported to subsequent stages of production without damaging
or
disturbing the integrity of the unsupported stacks. "Unsupported" means that
accessory support or supplemental structural materials, such as sheets of
cardboard,
chipboard, stiffener sheets, or the lilce, are not necessary to maintain side-
to-side
registration or shape, such as "squareness" or verticality of the stacks for
square,
rectangular, or irregularly shaped sheets. Various conventional belt-driven
conveyor
systems are known, available commercially, and suitable for this purpose and
as
illustrated herein. Alternatively or additionally, the conveyor module can
have a
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belt or equivalent conveyor means equipped with stack or bundle supports which
are
external to the bundle, for example, one or more tractor blades, fins, cleats,
ribs,
sidewalls, "one-way grass," mole skin, and like rigid or resilient structures
or
textures, or combinations thereof, and which supports can be integral with
(e.g.,
molded) or affixed to the conveyor, and optionally can have a hinge. Conveyors
having external supports are widely commercially available.
BUNDLE FORMATION AND PACKAGING
In embodiments, packaging each registered stack in the stack stream to form
a bundle of printed sheets can include banding, overwrapping, optionally
shrinlc-
wrapping the applied overwrapper, stretch-banding, or combinations thereof. If
desired, the packaging can be accomplished by simply banding the stacked
printed
sheets. A function of the band is to maintain the integrity and order of the
stack to,
for example, facilitate subsequent packaging steps if any, improve ease and
quality
of the dispensed printed sheets at the point of use, such as a label
application
operation or facility. Surrounding a registered stack with a band can be
accomplished in many ways, for example, wrapping an end of a continuous band
around the stack to size the band, cutting the sized band, and fixing the ends
of the
band to form a continuous or semi-continuous band, such as by gluing, welding,
thermal fusing, dimpling, crimping, and like methods for forming a band or
flexible
holder about at least a portion of the stack. Alternative banding approaches
can
include, for example, inserting the registered stack into a pre-formed banding
sleeve
and optionally shrinking the sleeve, wrapping a pre-cut band around the stack
and
fixing the ends of the band, and like banding methods. Bands can be made of
any
suitable material, for example, rubber, plastic, paper, string, adhesive tape,
non
adhesive tape, overwrap film, and lilce materials, or combinations thereof.
If desired and for reasons disclosed herein, the packaging can be
accomplished by placing two or more bands around a registered staclc. The
packaging can also be accomplished by placing one or a single band around a
registered staclc.
In embodiments, the packaging can be accomplished by over-wrapping each
registered staclc, banded or un-banded, to form a wrapped stack or bundle of
printed
sheets. Over-wrapping of each registered stack can form a sealed enclosure
about
the entire stack. Over-wrapping can provide an important environmental barrier
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which protects the printed sheets from, for example, moisture, spills,
humidity
changes, dust, pollutants, and like contaminants, which can damage or detract
from
the aesthetics or performance properties of the printed sheets in downstream
commerce applications, such as labeling operations, label appearance, label
performance, and consumer acceptance. Over-wrapping can be accomplished with
any suitable wrapping material such as plastic, synthetic or natural films,
such as
cellophane, acetate, polyvinyl acetate, and like materials.
In embodiments, the method can further include, for example, placing the
resulting bundled printed sheets in suitable container, such as a box and
sealing the
box with tape. In embodiments, the method can further include placing a number
of
the sealed containers on a skid for convenient handling and shipping, and
optionally
stretch-banding the collected sealed containers into secure monolith for
transport or
storage.
In embodiments, the method can further include, for example, further
collating the bundled printed sheets into larger or secondary bundles (bundles
of
bundles), having for example from about 2 to about 20 primary bundles, and
which
secondary bundles can also be optionally overwrapped, shrink-wrapped, stretch-
banded (with e.g. polyethylene or like materials), and like packaging, or
combinations thereof to complete the packaging or optionally further
containerized.
In embodiments, packaging can include, in the order recited, a first banding,
a second over-wrapping, and an optional third shrink-wrapping. Alternatively,
packaging can include, applying a band to each stack, placing one or more
banded
stacks in a container, and sealing the container. Containers can be, for
example,
cartons, boxes, bags, cans, drums, supersacks, cargo-tamers, and like
articles. The
container can be made from, for example, cardboard, wood, plastic, metal, or
like
materials of construction. The container can include, if desired, a sealable
liner,
such as a plastic bag or like membrane, which protects the bundled printed
sheets
paclced in the container. Thus, the banded staclcs without an overwrapper but
contained and sealed in the container with a sealable liner can resist changes
in
humidity and like potential environmental or external effects.
In preferred embodiments, the conveyor module transports and feeds
unsupported staclcs through an optional bander module 18, which bander applies
at
least one band around each stack to form a banded stack. Banding is often a
requirement for proper and convenient handling of stacks by an end-user of the
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printed sheets, such as a label applicator concern. Banded stacks may also be
conveyed in the packing portion of the apparatus at higher speeds than without
banding. Banding is not, in general, a requirement of the process or apparatus
of the
disclosure, but is a preferred embodiment where higher productivity and
economy
are desired. A commercial supplier of equipment for a hander module is, for
example, Sollas Holland BV of Wormer, The Netherlands. The Sollas model AB50
banding machine is a preferred example.
The conveyor module next optionally conveys the stacks, banded or
unhanded, through an overwrapping module 19, which wraps each registered
staclc
of printed sheets in an easy-to-peel overwrap film. In embodiments, the
overwrapper can be adapted to overwrap two or more banded or unhanded stacks
if
desired. Suitable films include those supplied by RTG Films of Chalfont, PA. A
commercial supplier of preferred equipment for an overwrap module is, for
example,
Sollas Holland BV. The Sollas model 20 wrapping machine is a preferred
example.
Other commercial suppliers of overwrap equipment includes Mai ten Edwards and
Petri, see Linfo Systems Ltd., mentioned below, which machines can be adapted
to
overwrap from between 100 to 265 pieces (bundles) per minutes.
Overwrapping can prevent problems associated with handling or
manipulating exposed printed sheets in subsequent processing. Overwrapping can
also protect the bundled printed sheet product from moisture and,humidity,
especially after it leaves the label manufacturer. Although preferably
produced in a
stable environment, the bundled printed sheets, such as for label application,
may be
shipped into substantially different climates, for example, a dry canning
factory in
New Mexico where ambient humidity at the application site may less than about
10-
30 %, or a water bottling plant in Oregon where ambient humidity at the
application
site may exceed 60 %. The overwrap preferably is not removed from the wrapped
bundle until just prior to application, so that exposure of the labels to the
ambient
enviromnent is minimized to, for example, as little as 15 minutes or less.
The conveyor module can next deliver the resulting stacks, overwrapped or
unwrapped, to an optional containerizer module 20 where, for example, a robot
or an
operator places the staclcs or bundles of printed sheet product, banded or
unhanded,
overwrapped or unwrapped, in a suitable container, such as cardboard boxes or
like
suitable containers. An optional seal module 21 can be used to, for example,
apply a
tape seal to the containers containing the bundled printed sheets. The sealed
boxes
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can then be optionally placed, manually or robotically onto, for example,
pallets or
skids at an optional carrier module 22 for staging, shipping, or delivery to a
customer or warehouse. Commercially available equipment from manufacturers of
.
various conveyer systems, parcel handling systems, or robotic systems can be
readily adapted for the boxing, sealing, skidding, or like paclcing
operations. For
examples of commercial suppliers and details of fully automatic and
customizable
sheet feeders, overwrap equipment, shrink-wrap equipment, shrink tunnels, bag
sealers, and like secure packaging equipment, see Linfo Systems Limited, of
Toronto, Ontario, Canada, (www.linfo.ca).
In embodiments, advantages of the apparatus and process of malting bundled
printed sheets of the disclosure includes overall accelerated production speed
and
increased volume throughput compared to known production processes for bundled
printed sheets. The total time required between, for example, printed sheet
formation (at 11 to 14) and application of packaging materials (at 18 to 22)
is greatly
decreased to less than about 1 to 4 minutes. For example, in current high
volume
printed label production systems, considerable time passes, such as from about
6 to
about 48 hours or more, from the time the labels are printed and until the
time the
labels are packaged, such as boxed, because of the need for inks or coatings
to
properly dry or cure. Such time lapses can increase the lilcelihood that
moisture will
evaporate from, or penetrate into a printed sheet and potentially cause print
quality
or handling issues for individual sheets in use.
FIG. 2 illustrates in embodiments, an alternative sheet-fed based apparatus
for making the bundled printed sheet articles of the present disclosure. The
apparatus or production system of FIG. 2, is an automated sheet-fed based
system
for high volume production of individual printed sheets cut from the fed-
sheets in
accordance with the present disclosure. Sheet feeding module 210 can be, for
example, a sheet-feeder capable of loading pre-cut sheets and which pre-cut
sheets
are further cut to size. Sheet-feeder devices are known and commercially
available
and can be readily adapted for use in the apparatus and process of the present
disclosure.
The feed-sheets can be either unprinted or pre-printed. In either instance,
the
feed-sheets can be further processed including, for example, charging,
printing,
coating, treating, drying, chilling, and like processes, or combinations
thereof,
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analogously to the web-based system of FIG. 1 described above, such as
embodied
by the aforementioned apparatus and processing associated with modules or
components of 12 to 22, 23, 25, and 26. Thus, for example, prior to cutter
module
240 there can be incorporated an optional print module (not shown) having a
print
engine suitable for printing on the fed-sheets, simplex or duplex, or like
printing
equipment. Similarly and optionally available for incorporation into the
system of
FIG. 2, but not shown, are modules or stations corresponding to those shown or
mentioned for optional modules 13 (a-e) in FIG 1. Other modules schematically
shown in FIG. 2, include a matrix removal module 250, a discharging device
255,
such as antistatic bar or static eliminator which can be use to
electrostatically
condition or treat the web before or after the print module, collating module
260,
conveyor module 270, banding module 280, overwrapping module 290,
containerizing module 291, labeling module 292, optional sealing module 293,
and
carrier module 294. It will be readily understood that conveyor modules 17 and
270
in FIGS. 1 and 2 and as described herein, are not limited to a single linear
conveyor
as schematically illustrated in FIGS. 1 and 2. A sheet-fed or discontinuous
printing
and finishing system employing, for example, a xerographic imager and a
vertical
collating bin array for sheet stacking or sorting, is disclosed for example,
in U.S.
Patent Nos. 4,444,491, and 4,368,972. Commercial suppliers of automatic and
customizable sheet feeders, and like paper handling equipment or accessories
include, for example, Xerox Corp., Hewlett-Packard Corp., and Canon, Inc.
The present disclosure, in embodiments, is directed to an apparatus and
method for preparing substantially identical bundled printed sheets where, for
example, the dimensions of each sheet are substantially the same as every
other
sheet in the bundle and where the dimensions of each bundle are substantially
the
same as every other bundle. Thus, the present disclosure in embodiments is
distinguished from known document printings reproduction, or reprographic
systems
having, for example, printing, collating, finishing, and like capabilities,
but where,
for example, the resulting printed sheets are not precisely cut into a two or
more
smaller identical printed sheets from fed-sheets or a continuous web. However,
in
embodiments, the present disclosure can include aspects of known web-based or
sheet-fed document printing, reproduction, or reprographic systei'ns without
departing from inventive aspects of the present disclosure. Thus, in
embodiments of
the present disclosure, the bundled printed sheets can have for example, sheet-
to-
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sheet print or image content which is constant, variable, or both.
Additionally,
embodiments of the present disclosure can provide substantially identically
dimensioned printed sheets and substantially identically dimensioned bundled
printed sheets which can be fashioned into, for example, mufti-page documents,
such as bound booklets, manuals, brochures, coupons booklets, check bundles,
or
lilce printed publications or collateral materials, see for example, U.S.
Patent No.
4,368,972, or used to modify multiple page documents, such as with correction
labels, advertising labels, bookmarks, promotional inserts, and like
applications.
FIG. 3 illustrates in embodiments, a bloclc diagram overview of a web-based
process for preparing bundle printed sheets of the present disclosure, with
for
example the apparatus illustrated and described in FIG. 1. For example,
printing
310 can be on, for example, a liner-less printable web, followed by optional
application of a web coating 320, for example an adhesive or other suitable
coating
material 322 to one side (e.g., back-side) of the web, and a varnish or
antistatic
coating material 324 to the other side (e.g., front-side) of the web. The
printed and
optionally coated web can be preferably die-cut 330 into one or more printed
sheet
streams with any accompanying waste matrix being discarded 335. The printed
sheet streams are collated 340 into registered stacks, the stacks are conveyed
350
into one or more stack streams, and each stack is packaged 360 with one or
more
packing materials or steps into a bundle of printed sheets. The packaged
bundle of
printed sheets can optionally be further containerized 370 or packaged, for
example,
with a banding machine, an overwrapping machine, a heat-shrink machine, a
containerizes machine (e.g., a box malcer or box loader), a stretch banding
machine,
a palletizes, and lilce operations and devices, or combinations thereof.
FIG. 4A illustrates in embodiments, a perspective of a portion of a web-
based apparatus for preparing bundle printed sheets including, for example, a
web-
based substrate feeding 405, a printing module 410 which can include, for
example,
one or more or a plurality of print engines or print towers having the same or
different print technology (e.g., offset and inkjet), one or more coating or
treatment
stations such as UV light cure of printed inks or coatings, or combinations
thereof, a
drum mounted die-cutting module 430, waste matrix generation and removal 435,
resulting individual cut printed sheets 432 the linear flow of which comprises
a
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printed sheet stream 440. Collation (not shown) of a-portion of the printed
sheet
stream provides a registered stack 442. "W" represents the width dimension of
the
web, " w"' represents the width dimension of one or more cut printed sheet, "
l"'
represents the length dimension of the cut printed sheets, and "h" represents
the
height dimension of a registered stack. It is readily apparent that W is
greater than
w' even when only a single w' sheet is cut from across the web using a die-
cutter
which also generates a waste matrix. It is also readily apparent that w' can
be greater
than, less than or equal to l'.
FIG. 4B illustrates in embodiments, a section view of a cutter module in a
web-based apparatus for preparing bundle printed sheets of the present
disclosure
including a web substrate feed 410, a rotary die-cutter including a drum 430
having
readily interchangeable die-cutting elements 431, juxtaposed die anvil 433,
optional
juxtaposed nip roller 450, nip roller pair 455, and optional non-contact
separator
device 460. In operation the cutter module configuration of FIG. 4B provides
enhanced performance and process reliability having, for example, reduced
jams,
complete separation of cut sheets 432 from the waste matrix 435, reduced cut
sheet
"fly-away," and like enhancements. Juxtaposed nip roller 450 ensures reliable
substrate feed to the cutter. Nip roller pair 455, having for example cutter
synchronized and regulated speed, provides a controlled constant tension and
pull
force to facilitate removal of the waste matrix from the separation area and
delivery
to a matrix take-off (not shown). Separator device 460 can be, for example, a
static
charger, a static eliminator, an air knife, a fan, and like devices, or
combinations
thereof. A preferred combination for use in the separator device 460 is a
static
charger and an air jet, which combination disperses electrostatic charge to
the
separation region between the cut sheet and the matrix. Although not desired
to be
limited by theory, the combined action of the mechanical forces of the air
jet, nip
roller pair 455, and the electrostatic repulsion of lilce-charged surfaces or
charge
neutralized surfaces of the waste matrix and the incipient cut sheet appear to
facilitate smooth and reliable separation between the cut sheets at~d the
waste matrix.
In embodiments, the cutter module of FIG. 4B can optionally include a bottom-
side
vacuum transport belt 475 to transport or assist in the transport of cut
printed sheets
to down stream processing, such as stacking. The cutter module of FIG. 4B can
also
optionally include a debris disturber 465, such as an air knife or lilce non-
contact
device to assist in the removal of debris from the cut printed sheet products
prior to
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stacking. The cutter module of FIG. 4B can also optionally include an abrader
or
sander article 470, such as a metal plate or sheet coated with a high
durability
abrasive material affixed to the surface of the article, for example, carbide
particles,
carborundum particles, diamond grit, sand, and like abrasive materials, or
combinations thereof, to further assist in the removal of debris from the cut
printed
sheet products, and optionally buffing the printed sheet, prior to stacking.
In
embodiments, the cutter module of FIG. 4B can include one or more debris
disturber
465, such as an air knife, one or more abrader or sander article 470, and one
or more
debris removal device, such as a vacuum collector manifold 480. In a preferred
embodiment, the cutter module of FIG. 4B can include a debris disturber 465,
such
as an air knife, an abrader or sander article 470 for each sheet stream, and
at least
one debris removal device, such as a vacuum collector manifold 480. In
embodiments, the cutter module of FIG. 4B can optionally include the
abovementioned components for accomplishing bursting, such as an edger or
slitter
(not shown) and debris removal device such as a vacuum collector manifold 480.
The foregoing web-based embodiment of FIG. 4B can adapted for use in a sheet-
fed
based apparatus and process embodiments of the present disclosure.
FIG. 5 illustrates, in embodiments, a block diagram overview of a sheet-fed
based process for preparing the bundle printed sheets of the present
disclosure, with
for example the apparatus illustrated and described in FIG. 2. For example,
feeding
cut-sheets 505, followed by printing 510 can be on, for example, a plain or
bond cut
sheet paper stock, followed by optional coating 520 on either or both sides of
the
printed cut sheets, for example, an adhesive, varnish, antistat, or like
coating
materials. The printed and optionally coated sheets can be die-cut 530 into
one or
more printed sheet streams. The printed sheet streams are collated 540 into
registered stacks, the stacks are conveyed 550 into one or more stack streams,
and
each stack is paclcaged 560 into a bundle of printed sheets. The paclcaged
bundle of
printed sheets 560 can optionally be further containerized 570 or packaged,
for
example, with a banding machine, an overwrapping machine, a heat-shrink
machine,
a containerizer machine (e.g., a box maker or box loader), a stretch banding
machine, a palletizer, and like operations and devices, or combinations
thereof.
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FIG. 6A illustrates in embodiments, a perspective view of a portion of a
collator module 16 in communication with a portion of a conveyor module 17 of
an
apparatus for preparing bundled printed sheets. Sheet stream transport 610,
such as
belts, rollers, vacuum transport belts, and like devices, or combinations
thereof,
transport and deliver the cut sheet streams to a batch stackers 620,
preferably an
optional second batch staclcer 625, or optional additional batch stackers (not
shown),
to form, for example, a plurality of neatly stacked and registered sheets in
adj acent
stacks 630. Side walls 623, tab-stops 650, and like structures, can be
included in the
stacker to form a bin or chute for receiving the sheets and forming stacks. An
optional elevator 660 can be employed when, for example, more than one batch
staclcer is stacking to shuttle completed batches of stacks 680 (e.g., 5
stacks across in
each batch of stacks shown) from their respective stacker unit to a batch
stack
conveyor 670. The sheets received by the stacker can optionally be registered
to
achieve a unitary shape or uniform stack dimensions by, for example, jogging.
Jogging can be accomplished by, for example, vibrating the side walls 623, tab-
stops
650, and like structures, or combinations thereof, while the sheets are being
collated
into stacks in the stacker.
FIG. 6B illustrates in embodiments a related alternative to the conveyor
module shown in FIG. 6A. Here the collator module (16 in FIG. 6A), again
collating individual sheets into stacks within bins or chutes with sidewalk
623, is in
communication with a reconfigured conveyor 675 situated next to the optional
elevator 660 (hidden). This conveyor configuration is adapted to directly
receive the
stack batches from the elevator conveyor. Conveyor 675 is equipped with
multiple
rollers 685 (six shown) which facilitate a smooth transfer or "hand-off' of
the batch
stacks from the elevator conveyor in the multi-staclc stream process direction
to
perpendicularly (in a horizontal plane) situated conveyor 675. It will be
readily
evident that conveyor 675 can be operated uni- or bi-directionally and as
described
for conveyor 690 in FIG. 7a below. Once the stacks reach a proper position on
conveyor 675, a system controller, like controls, or an operator can cause a
plurality
of conveyor belts 677 to raise-up and above the level of the rollers 685 and
cause the
belts 677 to convey the staclcs in a single stack stream to further down
stream
processing. Additional details of the conveyor configuration of FIG. 6B are
shown
in FIG. 7B and discussed below.
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Collating the cut printed sheets can be accomplished, for example, with a
collator having a receiver for receiving and registering each stream of
printed sheets
into an incipient registered stack. The receiver can be any suitable member
for
receiving the printed sheets, such as a bin, a tray, a pocket, a chute, and
like
members or structures. An example of a suitable receiver member or structure
is
associated with a commercially available Gannicott machine, for example,
modified
to simultaneously receive multiple cut printed sheets into separated bins or
trays.
Each bin or tray can have, in embodiments, two side-walls, a front wall, and
an
optional baclc wall. The tray or bindexer can have, in embodiments, sidewall
forgers
which permit mechanical "jogging" of the printed sheets as they are received
from
the die-cutter or other cutting device by the collator's respective stacker
bins.
Collating of a number of streams of printed sheets preferably produces a
correspondingly equal number of registered stacks. In embodiments, registered
stacks or their resulting bundle of printed sheets can have, for example, from
about
10 to about 10,000 printed sheets, preferably from about 10 to about 5,000
printed
sheets, and more preferably from about 10 to about 1,500 printed sheets, where
the
preference here reflects, in embodiments, a balance between minimized
packaging
(larger stacks and economies of scale) and adequate stack or bundle size for
convenient manual handling (smaller stacks and human factors) in a particular
industrial application, such as label applicators. Other bundled printed sheet
sheet-
counts may preferred in other applications.
In embodiments, the registered stacks can be, for example: vertical and
unsupported, (i.e. sheets laying flat with one face oriented downward and the
other
face oriented upward, wherein the sheets are staclced upward atop one
another);
vertical and supported; or horizontal and supported. Stack "support" in this
regard
refers to, for example, any suitable support structure or a mechanism suitable
for
maintaining the stack in a localized position while it is being formed, and to
maintain the stack's desired properties, such as shape, handling, and
appearance,
during and after the time the stack is formed. A support structure or a
mechanism
can be, for example, a portion of the collator, such as a wall or stop.
"Jogging" the
stack with respect to a mechanical collator and collating the printed sheets
refers to
mild agitation or a shuffling disturbance which causes the cut sheets to align
into
more uniform or unitary stacks. "Jogging" of the stack with respect to an
operator
refers to mild manual agitation or shuffling disturbance, such as tapping the
stack or
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bundle with a wood block, which also causes the cut sheets to align into more
uniform or unitary stacks or bundles. In embodiments the stacks,can be
supported
for a time, fox example, while being formed, that is, during the stacking of
sheets,
and unsupported for a time, for example, while being transported on a
conveyor.
The registered stacks can be, for example, edge-to-edge registered, side-to-
side registered, height-registered, edge-registered, width-registered, weight
registered, or combinations thereof. In embodiments, the stack height is
predetermined, for example, by customer preferences, limits on the change
range in
the collator tooling, optimizing space utilization in, for example,
containerizing or
like packaging or storing considerations. In embodiments, achieving the
predetermined staclc height can be accomplished by, for example, a sheet
counter, or
similar mechanism associated with the collator. A Gannicott die~cutting
machine
having a stack height counter is commercially available. Preferably, each
registered
stack is at least height registered and edge-to-edge registered. More
preferably each
registered stack is at least edge-to-edge registered.
FIG. 7A illustrates, in embodiments, a perspective view of a portion of a
conveyor module 17 of an apparatus for preparing bundled printed sheets of
FIG. 6A
including the above mentioned first batch stack conveyor 670 for conveying
completed batches of stacks 680 to a second batch stack conveyor 690. As
shown, a
stack stream comprised of successively produced batches of stacks 680, for
example,
having five stacks each, is conveyed on conveyor 670 and transferred to
conveyor
690 to form a merged single stack stream 710. Optionally, conveyor 690 can be
adapted to operate bi-directionally or reciprocate to permit the merged stack
stream
to provide a second staclc stream 720 when the conveyor 690 is operated in the
reverse direction 720. The merged stack streams 710 or 720 convey the stacks
in
"single-file" fashion on conveyor 690 to subsequent packaging stations.
Conveyors
670 and 690 can be a single belt, a plurality of belts, rollers,'and like
conveyor
devices, or combinations thereof.
FIG. 7B illustrates in embodiments, a view of a portion of the conveyor
module shown in FIG. 6B and discussed above. A first conveyor 660, for example
in embodiments, the elevator conveyor of FIG. 6B transfers batch staclcs to a
second
conveyor 760. Optional support 750 having an optional roller can be included
to
further facilitated the transfer and avoid or minimize, for example, staclc
tipping or
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disruption of sheets within the uniform stacks. Second conveyor 760 can
include
plural rollers 765 for receiving and positioning the batch stacks on conveyor
760. In
one example, plural belts 770 on conveyor 760 were situated perpendicular to
plural
belts of first conveyor 660. Stack batches advanced on conveyor 660 were
transferred to conveyor 760 on rollers 765 and thereafter plural belts 770
were
engaged to convey a single stack stream to further processing 780
In embodiments, a first conveyor conveys one or more stacks, such as from
about 1 to about 80 stacks, more preferably 2 to about 40 stacks, and even
more
preferably about 5 to about 20 stacks, at the same time from the stacker to a
second
conveyor. Here the preference reflects a desire to optimize or match sheet
handling
and stack handling hardware and capacity with total throughput economics. The
second conveyor's path or process direction can be situated perpendicular to
the first
conveyor. In embodiments, to provide greater stack handling and stack through-
put,
the first conveyor can include an elevator which permits switching stack
staging and
conveyance between an upper first conveyor and a lower first conveyor. For
example, while the upper first conveyor conveys stacks to the second conveyor
the
lower first conveyor is held stationary to receive stacks. When the upper
first
conveyor has completed conveyance of its stacks to the second conveyor and the
lower first conveyor has received its stacks the elevator changes the
positions and
the roles of the upper and lower first conveyors to stack staging and stack
conveyor,
respectively. Thus, in embodiments, the collator forms one or more stacks by
continuously collating printed sheets. The completed stacks are placed onto
one or
more conveyors and conveyed to a second conveyor situated, for example,
perpendicular to the first conveyor. The perpendicular orientation of the
second
conveyor relative to the first conveyor causes the stacks conveyed by the
second
conveyor to be conveyed in the same direction and in a single stream, that is
"single-
file." In embodiments the second conveyor can convey alternating staclc
batches or
loads received from the first conveyor in different directions, such as the
opposite
(180 degrees) direction, perpendicular (90 degrees) direction, and like acute
or
obtuse intermediate angle directions, to provide two stack streams ("split-
stream")
where each stack stream is separately packaged in one or more packaging
operations.
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In embodiments, where for example, the collator module has two batch stackers
operating in and situated in an over-under relation, the conveyor module can
include, for example, a conveying elevator, the elevator being operable to
alternately
receive a batch of stacks from each batch stackers, and to convey the received
batch
of stacks to a first conveyor for further processing. The first conveyor can
convey
the received batch of stacks as a stack stream uni-directionally to the
packaging
module. The first conveyor can also be configured to split the merges single
stack
stream into two or more stack streams, and to convey the received batch of
stacks as
a stack stream bi-directionally to two or more packaging modules.
In embodiments, where for example, the collator module has two batch
stackers operating in an over-under relation, the conveyor module can include,
for
example, two conveyors, with each batch stackers having one of the two
conveyors
dedicated to receiving its hatched stacks, and each conveyor being adapted to
convey the hatched stacks to further packaging as batches of stacks (e.g.,
five stacks
abreast) or as a single stack stream (i.e., one stack abreast or single-file).
Thus in
embodiments of the disclosure, there are number of conveyor configurations,
which
can accomplish efficient conveyance of batch stacks or staclc streams and
without an
elevator shuttling between batch stackers or otherwise.
FIG. 8A-8D illustrates, in embodiments, examples of various cut patterns for
forming cut printed sheets.
FIG. 8A illustrates an example of an "aligned-cut" pattern where a web 810
traveling in process direction 812 is cut with a cutter module, such as a die-
cutter, to
produce a cut sheet 815 which sheet is separated from the web to form a sheet
stream and its corresponding cut-out void which is part of the waste matrix.
Imaginary reference lines 820 show the relative "aligned" orientation of the
cut sheet
815 to the normal (perpendicular in-plane) direction across or traversing the
web
process direction.
FIG. 8B illustrates an example of a "staggered-cut" pattern where a web 810
traveling in process direction 812 is cut with a cutter module, such as a die-
cutter, to
produce a cut sheet 815 which sheet is separated from the web to' form a sheet
stream and its corresponding cut-out void which is part of the waste matrix.
Reference lines 820 show the relative "stagger" orientation of cut sheet 81 S
to
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adjacent stagger cut sheets 830 to the normal direction across the web process
direction.
FIG. 8C illustrates an example of a "skewed" angle-cut pattern where a web
810 traveling in process direction 812 is cut with a cutter module, such as a
die-
s cutter, to produce a skewed-cut sheet 840 having a very slight parallelogram
shape
which sheet is separated from the web to form a sheet stream and its
corresponding
cut-out void which is part of the waste matrix. Reference regions 845 show the
relative "skew" or angle-cut orientation of the cut lines in the process
direction of
cut sheet 840.
FIG. 8D illustrates an example of a "square" angle-cut pattern where a web
8I0 traveling in process direction 812 is cut with a cutter module, such as a
die-
cutter, to produce a square-cut sheet 850, that is having all square corners
855, and
which sheet is separated from the web to form a sheet stream and its
corresponding
cut-out void which is part of the waste matrix. Reference regions 860 and 86S
show
the slight shift or slcew angles of the cut lines in the process direction and
the across
the process direction, respectively.
It is understood that the abovementioned cut patterns and methods for web
cutting can be readily adapted to and are applicable to sheet-fed cutting
embodiments. It is also understood that the abovementioned cut patterns are
illustrative and are not intended to restrict the possible shapes or
dimensions of the
cut sheets, stacks, or bundles of the disclosure.
FIG. 9A illustrates, in embodiments, an exemplary bundle of printed sheets
900 of the present disclosure, having a plurality of registered, neatly
stacked, cut
sheets 910, having printing (e.g., images, patterns, line art, and like
marlcs), printed
indicia (e.g., text, figures, and like marlcs), or both 920, on one or both
sides, such as
label or product information, a band 930 encompassing the stack of printed
sheets of
the bundle, and a band overlap region 935 which can provide a point of
attachment
or fastening of the band to itself. '
FIG. 9B illustrates, in embodiments, the banded bundle of printed sheets 900
of FIG 9A further including a clear or translucent protective overwrapper 950,
and
one or more optional tear-tapes or pull-tabs 960 to facilitate unwrapping of
the
overwrapped bundle. In embodiments, the overwrapper 950 can be shrunlc by, for
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example, lcnown shrink-wrapping methods, such as the application of heat or
radiation, to form a tightly sealed bundle.
FIG. 9C and 9D illustrate, in embodiments, other examples of bundle of
printed sheets 900 of the present disclosure having alternative stack or
bundle
geometries while still having a plurality of registered, neatly staclced, cut
sheets 915,
images, printed indicia, or both 920, on one or both sides, such as Iabel or
product
information, a band 930 encompassing the stack of printed sheets to form a
bundle,
and an optional band overlap region 935 which can provide a point of
attachment or
fastening of the band to itself. FIG. 9C and 9D additionally illustrate that,
in
embodiments, the sheets and their resulting stack and bundles of printed
sheets can
have a unitary shape other than a cube or a parallelepiped, including for
example
irregular aspects, curved aspects, notched aspects, peaked aspects, and like
aspects,
or combinations thereof, which aspects taken together can be functional,
aesthetic,
or both. The bundle of printed sheets of FIG. 9C can be for example a food
product
label or a promotional item. FIG. 9D can be for example a sports product label
or
insignia label.
In embodiments, other advantages of the in-line apparatus and production
process for making bundled printed sheets of the present disclosure can
include, for
example, particularly when a precision rotary die-cutter is used: chipboard or
like
rigid stack supports are not required to maintain stack integrity during or
after
manufacture; the apparatus and production axe less costly to operate compared
to
alternative systems; and the apparatus and production process, in embodiments,
provide improved product-to-product consistency, such as sheet-to-sheet and
bundle-to-bundle size uniformity, lot-to-lot uniformity, that is where there
is time
gap between identical print jobs, print registration, and print registration
to cut edges
of the sheets and their bundles. By comparison current state of the art
guillotine
cutting systems provide cut sheet variance of greater than about X3/64 inches.
The
improved print registration to cut edges reduces paper waste, ink waste,
reject waste,
and improves the appearance and customer acceptance of the bundled printed
sheets
and the individual printed sheets, such as in consumer product label
applications.
Furthermore, the apparatus and process of the disclosure can reduce the total
time to
manufacture a supply of printed sheets, such as labels, from 12 to 24 hours
to, for
example, about 1 to 4 minutes. Standing or storing of cut printed sheets or
bundles
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of printed sheets, for drying, curing, or like processes, is not necessary in
embodiments of the disclosure. The bundles of printed sheets and the cut
printed
sheets therein, in embodiments of the disclosure, can be ready, if desired,
for
immediate customer use, for example, in the application of labels to articles.
In
embodiments the high cut-to-print registration can provide printing processes
and
products with design or artwork freedom advantages, for example, having
artwork
capabilities with uncommon bleeds, and avoiding the requirement for solid
"banded"
borders which are typically required, for example, in conventionally prepared
guillotine cut-labels.
Table 1 provides an exemplary operation-time summary of a web-based
production system for the manufacture, start-to-finish, of a single bundle of
printed
sheets product of the disclosure. In embodiments of the disclosure, in the
manufacture of bundled printed sheets there can be incidental or intentional
"holdup," that is a slight delay or a slow-step in one or more manufacturing
steps,
for example, to accommodate limitations on equipment or operators, such as in
manual packaging operations, shift changes, and like circumstances. Holdup can
be
minimized or eliminated, as desired, with different configurations, equipment,
belt
speeds, and like modifications, or combinations thereof.
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Table 1. Approximate operation-time summary for web-based manufacture of
a single bundle of printed sheets.
OPERATION/MODULE TIME
web printing (8 color offset1-30 seconds
with
concurrent intermediate UV
cure; web
speed average =300 feet per
min.)
web coatin (varnish - single
side) <1 second
web drying (air)
<5 seconds
web chillin (chilled rollers)1-5 seconds
cutting (die-cutter)
<1 second
sheet transfer (sheet stream)1-2 seconds
collating (for stacks of 30 seconds - 120 seconds
1,000 sheets
each with 2 batch stackers)
conveying (one stack to banding;5-30 seconds
lst and
2"a conveyors)
acka in 100=160 seconds
(banding - 2 bands applied (5-10 seconds)
simultaneously)
(complete plastic overwrap) (90-120 seconds)
(containerizing - corrugated
box (<5 seconds)
wrap)
(box sealing - tape) (1-10 seconds)
(carrier loading - each box , (5-15 seconds)
staclced by an operator)
about 140 to about 350
TOTAL seconds
(about 2.5 to about
6 minutes)
The bundled printed sheet products of the present disclosure provide a
superior product for print-to-cut quality and stack uniformity properties,
produced in
less time, and a lower relative cost, compared to other available apparatus
and
methods. The bundled printed sheet products of the present disclosure, with or
without additional packaging, are suitable for immediate use by a customer or
user,
for example, a packaging or labeling vendor-customer engaged in a high speed
label
application operations. Such a product is more responsive to current and
future
customer needs, for example, for print-on-demand availability or just-in-time
inventory, and their concomitant advantages. The bundled printed sheet
products of
the present disclosure can provide a vendor-customer with bundled sheet
products,
in high quality and in high volumes, which products have less overall waste,
for
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example, less waste packaging and less waste or unusable printed sheets which
sheets historically had to be detected and discarded, and typically caused
costly
disruption or unnecessary down-time in customer operations.
The bundle printed sheets of the present disclosure, such as a banded and
overwrapped bundle of labels, provide benefits to the process of applying or
attaching a printed sheet to an article, such as a consumer product container
or
package. With previous label manufacturing methods, the printed labels often
needed to be supported with chipboard, or other similar cumbersome materials,
and
shrink-wrapped to unify the stack. To use those bundled labels in a labeling
machine, the shrink-wrap is cut off, the chipboard support is removed, and the
label
stack is placed in a label applicator machine to be fed onto the receiver
package.
This method of placing labels in a label applicator machine is prone to
produce
misaligned labels, which can in turn cause label misfeeds or jams, and can
result in
inferior label application, waste or reworlc, and compromised label
application
productivity. The present disclosure provides solutions to these problems. In
embodiment, the combination of banding and overwrapping the stacks simplifies
placing printed sheet labels in a label applicator machine. The equipment
operator
or robot can simply unwrap the stack with a highly visible tear-strip or tear-
tape
similar to that used on clear cigarette packaging. While the stack is still
supported
by the band, the label bundle can optionally be fanned-out and then loaded in
the
label applicator machine. Then, using for example a band cutter, the band can
be slit
and removed, leaving the resulting label stack in ideal position and alignment
for
feeding through the label machine.
The printed sheets of the present disclosure can each have high uniformity,
such as the abovementioned low variance in cut-to-print registration, and the
low
variance of the length and width dimensions. Consequently, when the
substantially
identical sheets are stacked, such as prior to or subsequent to bundling by
banding,
overwrapping, or both, highly uniform stacks and ultimately uniform bundles of
printed sheets result. Highly uniform stacks or bundles of printed sheets of
the
present disclosure are enabled by, for example, the method of making and the
apparatus for making as disclosed herein. The high print-to-cut uniformity and
the
high dimensional uniformity of the printed sheets can be attributed to
precision
printing methods and precision cutting methods of the present disclosure. The
high
uniformity of a stack, that is a group or ream of stacked sheets, flows the
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combination of the accurately dimensioned sheets (i.e., low sheet-to-sheet
dimensional variation) and the apparatus and methods used for stacking the
sheets
and the apparatus and methods used to package the sheets into bundles. The
abovementioned high uniformity of a stack enables one to readily obtain a high
uniformity bundle of printed sheets, for example, after the uniform stacks are
paclcaged, such as when the stacks are banded, overwrapped, boxed, or
combinations
thereof. The apparatus and methods of the present disclosure used to make and
paclcage the sheets and their resultant bundles, also provide an apparatus and
method
for making large numbers of bundled printed sheets with high bundle-to-bundle
uniformity. Thus, as an example of high bundle-to-bundle uniformity, the first
bundles manufactured in a print job, such as bundles 1 to 10, are
substantially
identical in all aspects to bundles manufactured in the middle, such as
bundles
18,490 to 18,500, or the end, such as bundles 36,990 to 37,000, of a
continuous 24
hour print job.
In embodiments of the present disclosure, the apparatus and methods can
enable the manufacture of on-average, for example, from about 1~ to about 150
stacks
or bundles of printed sheets per minute. It will be evident that the actual
number
bundles made or production rate can depend upon many different variables, for
example, web speed, web width, printed piece cut dimensions, number pieces cut
per web width, conveyor number and speed, banding and wrapping efficiencies,
and
like considerations. The production rate in this or similar linear productions
systems
of the present disclosure is typically rate limited by the slowest step or
operation.
The present disclosure can be adapted to escape from the above mentioned
limitations of a linear or assembly line, for example, by "splitting" or
dividing the
stack streams to permit parallel or concurrent processing and increased
through put
productivity. In embodiments, the bundles can contain any arbitrary number of
printed sheets. It will be evident to one of ordinary skill in the art that,
for example,
economic, operational, handling, customer requirements, and like
considerations,
that the bundles preferably have, although not required, approximately the
same
number of sheets in each bundle prepared during the same job. In embodiments
each stack or bundle of printed sheets can contain, for example, from about 10
to
about 10,000 printed sheets, preferably from about 10 to about 5,'000 printed
sheets,
and more preferably from about 50 to about 1,500 printed sheets. Other sheets-
per-
bundle counts can be readily prepared if desired. It will be readily
appreciated the
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number of bundles of printed sheets produced per minute can be multiplied by a
factor which corresponds to operating additional production lines under
approximately the same conditions and parameters.
It will be readily appreciated and understood from the present disclosure that
the dimensions of a stack and the resulting packaged bundle can depend upon,
for
example, the thickness (height or z-dimension) of the web stock or sheet-fed
stock
selected, the thiclaless added to the web stock or sheet-fed stock as a result
of, for
example, printing, coating, conditioning, or like additions or treatments, the
area size
(x-y dimensions) of printed sheets cut from the web stoclc or sheet-fed stock,
and the
contribution of the packaging materials to the overall bundle dimensions. In
embodiments of the present disclosure, the size of the bundle of printed
sheets can
be any suitable dimensions, for example, to provide bundles that are
particularly
useful to a user, consumer, or processor of bundled printed sheets, such as a
person
or machine, such as a robot, which handles the bundles or the constituent
individual
printed sheets within a bundle, such as, a label applicator machine and its
operator.
In the example of a label applicator machine and it's operator, bundles
preferably
have dimensions which make handling of the bundles by the operator convenient,
such as readily held in a typical human hand, and unwrapped, unbanded, or
both,
with the other hand. Thus, in embodiments, a finished bundle of,printed sheets
can
be, for example, about 1 to about 2 inches wide, about 2 to about 4 inches
high, and
about 3 to about 10 inches long. The foregoing dimensions being preferred, in
embodiments, by operators or handlers and in view of human factor
considerations.
Other bundle dimensions can be readily selected and achieved in embodiments of
the disclosure.
The high dimensional uniformity of each sheet in the bundle, the high
dimensional uniformity of each bundle itself, and the high bundle-to-bundle
dimensional uniformity provides, for example, bundles and printed sheets which
are
readily loaded and dispensed from a label applicator machine and with high
reliability, for example, with minimal or free-from stack or label jamming or
stack
or label rejection from the label machine.
The bundled printed sheet product or the printed sheets within the bundles of
the present disclosure can have a number of desirable aspects or advantages
depending upon the details of their manufacture and the details of their use
or
application as mentioned below. In one aspect, the printed sheets can have
superior
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gloss properties, for example, when the printed web or sheets during
manufacture
are coated with a gloss layer or varnish overcoat. Generally, the gloss coated
or
varnish coated printed sheets can have, for example, a reduced glue use or
reduced
glue requirement by a label applicator machine in applying the printed sheets,
such
as a label, to an article, such as a bottle, can, and the like, where for
example, the
ends of the coated printed sheet are overlapped and attached to each other
with an
adhesive. Alternatively, an adhesive can be applied to all or a portion of one
side of
the printed sheet to contact and affix the printed sheet to an article.
Accordingly, the bundles, the printed sheets within bundles, or the printed
sheets when used, have lower rej ection rates and higher acceptance rates
among
users, such as downstream manufacturers, customers, or consumers, compared to
printed sheets made by known processes. In still yet another aspect, the
printed
sheets within the bundles and the bundles can be used without or~with minimal
"fanning" by a user or operator prior to use. "Fanning" refers to the practice
of, for
example, quickly parsing the sheets in the stack, for example, to separate or
aerate
adjacent sheets in a stack.
In embodiments, the printed sheets in the bundles can be used immediately
or very soon after their manufacture, for example, within seconds or minutes,
especially if the web or fed-sheets are printed and cured with ultra-violet
(UV)
curable inks) or with a UV curable overcoating, such as an ultraviolet curable
varnish formulation, and thereafter cured with a suitable UV source to provide
printed or coated printed sheets. UV curable over-coatings, in-line or web
coating
devices, and UV light sources for curing are commercially available. Thus,
printed
sheets and their subsequently formed bundles can be made and used on-demand
and
do not required extended or lengthy time delays associated with an
intermediate
drying step and which drying step may additionally require special
environmental
conditions, such as temperature or humidity control, or handling precaution,
intermediate storage or warehousing, and like considerations. Uncoated printed
sheets or sheets coated with water or aqueous based UV varnishes or coatings
typically tend to be more porous compared to organic based UV varnishes or
coatings and tend therefore more absorbent of glue formulations, and
consequently
may have a greater glue requirement and total glue cost, such as by about two-
fold,
to achieve satisfactory fixing of the printed sheets to articles.
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In embodiments, the cut-to-print registration variance can be from less than
or equal to about 30 thousandths of an inch, for example, less than or equal
to about
1/32 inch, and each printed sheet can have the same length and width
dimensions as
the other printed sheets in the staclc to within a variance of less than about
5
thousandths of an inch. In embodiments, the cut-to-print registration variance
can
be from about 0.03 to about 0.015 inches, that is about 30 thousandths of an
inch to
about 15 thousandths of an inch, for example, from about 1/32 inch to about
1/64
inch, and each printed sheet can have the same length and width dimensions as
the
other printed sheets in the stack to within a variance of, for example, from
about
0.001 to about 0.005 inches, or from about 1 thousandth of an inch to about 5
thousandths of an inch.
In embodiments, the band around the stack can encompass a portion of two
opposite sides including the full height of the stack, and a portion of the
outer facing
top and bottom sheets of the stack including the full width of the stack.
In embodiments, two opposite sides of the stack can be parallel where, for
example, the bundle resembles a cube comprised of square sheets, or for
example,
where the bundle resembles a parallelepiped or a rectangular block comprised
of
rectangular sheets. In embodiments, two opposite sides are other than parallel
(i.e.,
not parallel), for example, where the bundle is other than a cube or
parallelepiped.
The bundle can have a unitary shape or uniform shape but for the irregular
shape of
the constituent sheets. Thus, because of the high uniformity or similarity of
sheet-
to-sheet dimensions the resulting bundle formed from irregularly shaped
stacked
sheets can also have high dimensional uniformity in the x-, y-, and z-
directions.
Bundles can have at least one set of non-parallel opposite sides, such as
where sheets
have an irregular shape, for example, sheets having a bow-tie shaped outline,
such as
in an arbitrary x-y plane, sheets having a paisley shape, sheets having a tear-
drop
shape, sheets having a lightening bolt shape, and like irregular shapes. Other
sheet
shapes can include, for example, circles, ovals, square or rectangular sheets
having
square corners, rounded corners, or angled corners. It will be readily
apparent that
certain sheet shapes can have parallel edges yet still appear irregular, such
as a sheet
having saw-tooth or diagonal cut-out pattern on one or more edges. It is also
readily
evident that sheet edges of the sheets when stacked (compounded) become part
of
the sides of the stack or bundle. It will also be apparent that sheets can be
made
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which include perforations, for example, for preparing labeled articles with a
detachable label portion.
The ends of a band around the stack can preferably overlap each other and
the overlap portion can preferably include a point of attachment. The point of
attachment can be accomplished, for example, with an adhesive, a weld, a
crimp,
Velcro~, and like fastening or joining tecluuques, or combinations thereof.
The
band can be any suitable binding material, such as plastic, paper, metal,
rubber,
elastomer, string, and like materials, or combinations thereof. The bundle of
printed
sheets can have, in embodiments, for example, from 1 to 5 bands, or more. In
embodiments, for example, where the bundle of sheets is long and rectangular
the
bundle can have 2 to more bands, such as 2 to 3 bands. In embodiments, for
example, where the bundle and its stacked sheets are relatively stable against
skewing without a band or where cost or use considerations suggest, one or a
single
band around the bundle can suffice to maintain a useful and unitary shape of
the
bundle.
The overwrapper can be, for example, any suitable wrapper material or
shrink-wrap material, such as clear, translucent, or opaque materials
including but
not limited to natural or synthetics, such as plastic, paper, and like
materials, or
combinations thereof. The overwrapper on the banded stack can include one or
more
pull-tab or tear-strip to facilitate removal of the overwrapper from the
bundle. In
embodiments, the overwrapper on the banded stack can completely enclose the
bundle. In other embodiments, the overwrapper on the banded stack incompletely
encloses the bundle, for example, having open-end regions or open-side
regions, or
for example where the overwrapper does not cover all or a substantial portion
of the
stack covered by a band.
W embodiments, although not required, the bundles can include, if desired, a
chipboard, a stiffener panel, or combinations thereof, see for example USP
4,830,186, assigned to Xerox Corp., to provide for example, a removal support
structure to stabilize the stack or bundle from inadvertently skewing or
toppling
during handling or use. For reasons mentioned above, the bundled printed
sheets of
the present disclosure are preferably free of a chipboard, a stiffener panel,
or lilce
articles.
In embodiments, bundles of printed sheets can be prepared, if desired, with a
band but without an overwrapper and still retain their unitary shape, cut-to-
print
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registration variance, with individual sheets having the same length and width
dimensional variance as the other printed sheets in the staclc or bundle. Each
sheet
can have substantially the same x- and y-dimensions as all other sheets in the
stack,
for example, as measured in an x-y plane. The "same x and y dimensions" refers
to
sheet-to-sheet uniformity of the x-dimension and the y-dimension. In
embodiments,
the x- and y- dimensions for each sheet can be the same (x = y), such as a
square
sheet. In embodiments, the x- and y- dimensions for each sheet can be
different (x ~
y), such as a rectangular sheet. In embodiments, the x-dimension for each
sheet can
be substantially the same to provide a staclc having sheets all having the
same
variation in the x-dimension, for example, a sheet having an irregular x-
dimension.
In embodiments, the y-dimension for each sheet can be substantially the same
to
provide a stack having sheets all having about the same variation in the y-
dimension,
for example, a sheet having an irregular y-dimension. ,
In embodiments, the x- and the y-dimensions for each sheet can vary to provide
a
stack or bundle having sheets which all have about the same variation in the x-
and
y-dimensions, for example, a sheet having irregular x- and y-dimensions. The
present disclosure in embodiments, provides bundles of printed sheets where
the
individual sheets can have a variety of shapes, for example, square, diamond,
heart,
rectangular, circular, oval, triangular, and like regular shapes or irregular
shapes.
The present disclosure in embodiments, provides bundles of printed sheets
where the
sheets can have, for example, a regular or an irregular shape, such as
irregular or
non-uniform dimensions, but where all the sheets in the bundle have
substantially
the same shape and dimensions as all other sheets in the bundle. Each sheet in
the
bundle preferably has substantially the same orientation in an arbitrary
orthogonal x-
y-z coordinate system. Each sheet preferably occupies an x-y plane and the
sheets
are stacked one-on-top another about the z-axis in the orthogonal x-y-z
coordinate
system or Cartesian coordinate system, that is having right angles between
each axis.
"Cartesian coordinate system" refers to any of three coordinates (x-y-z) that
locate a
point in space and measure its distance from any of three intersecting
coordinate
planes (x-y-z planes) measured parallel to that one of three straight-line
axes, that is,
the intersection of the other two planes.
In embodiments, an apparatus for making bundled printed sheets of the
disclosure can comprise:
a printable web;
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a print module to print on the printable web;
a cutter module to cut the printed web into a stream of printed sheets and a
waste matrix;
a collator module to collate each stream of printed sheets into a registered
stack;
a conveyor module to convey each registered stack into a,stack stream; and
a packaging module to package each registered stack in the stack stream into
a package containing bundled printed sheets,
wherein, for example,
the printable web and the print module can be a high speed lithographic press
adapted to:
print and cure multiple color UV curable inks on a paper substrate;
apply a protective coating;
chill the protectively coated web; and
apply an antistatic coating;
the cutter module can be a rotary die-cutter adapted to angle-cut the printed
web, the cutter further including a static eliminator to facilitate sheet and
matrix
separation;
the collator module can be a sheet stream transporter and batch-stacker to
transport and collate each stream of printed sheets from the cutter module
into a
registered stack;
the conveyor module can be a conveyor for each batch-stacker and adapted
to directly receive the stack batch and transport the stack batch as a single
stack
stream to the packaging module;
each of the bundle of printed sheets can have from about 10 to about 1,500
cut printed sheets, each printed sheet can have a narrow cut-to-print
registration
variance of, for example, from less than or equal to about 0.03 inches, and
each
printed sheet can have the same length and width dimensions as the other
printed
sheets in the bundle to within a variance of, for example, less than or equal
to about
0.005 inches; and
the packaging module can include, for example, a banding machine, an
overwrapping machine, a heat-shrink machine, a containerizer machine, a
stretch
banding machine, a palletizer, or combinations thereof; and
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the apparatus additionally having an humidity controller, a web-nip just
before the chiller module, and a web-nip just before the cutter module.
In embodiments, each registered stack can be vertical or horizontal.
Preferably, each registered stack is formed in a vertical orientation, that
is, having
sheets stacked or layered on top of one another and which verticality can
avoid the
need for additional structural supports, that is, the stacks are preferably
unsupported.
The printable web and the print module in combination, in embodiments, can
comprise a high speed offset printing press. "High speed" refers to, for
example, a
linear speed of from about 300 to about 1,200 feet per minute or more. The
cutter
module of the apparatus can comprise a rotary die-cutter, a flat-bed die-
cutter, a slit-
and-gap cutter, a slit-and-but cutter, a guillotine cutter, or combinations
thereof. hi a
preferred embodiment, the cutter module comprises a rotary die-cutter adapted
to
angle-cut the printed web into at least one sheet stream and a waste matrix.
The
angle-cut can be, for example, as shown in FIGS 8C or 8D, and preferably as
shown
in FIG. 8D.
In embodiments, for example, in high volume applications such as high
speed offset, the printable web can have a relatively wide width and a
relatively high
speed, such as a width from about 16 to about 40 inches and a linear speed of
from
about 300 to about 900 feet per minute, or more. In other embodiments, for
example, in lower volume applications such as certain flexography
applications, the
printable web or substrate can have a relatively narrow width and relatively
slow
speed, such as a width of less than about 18 inches and a speed of less than
400 feet
per minute, such as from about 10 to less than about 300 feet per minute. In
other
embodiments, for example, in mid-volume applications, the printable web or
sheet
feeding can have a relatively narrower width and faster speed, such as a width
of
less than about 16 inches and a speed of from about 200 to less than about 500
feet
per minute. In still other embodiments, for example, high-speed narrow-width
offset
applications, the printable web can have a relatively narrow width and
relatively fast
speed, such as a width of less than about 20 inches, and a speed of from about
300 to
about 1,200 feet per minute.
In embodiments, the conveyor module can comprise an endless belt, such as
one or more belts, or lilce transport devices. In embodiments, the conveyor
module
can comprise a first conveyor having two over-under parallel endless belts and
an
elevator, and a second conveyor, wherein the two over-under parallel endless
belts
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each carry a stack stream from the collator to the second conveyor, the
elevator
being operable to alternate the position of the two over-under parallel
endless belts
relative to the collator and the second conveyor. The conveyor module can be
configured so that each stack stream on the first conveyor is merged or
combined
into a single stack stream on the second conveyor. Other suitable conveyor
module
configurations are readily apparent and can depend on, for example,
convenience,
throughput, cost of operation, cost and speed of packing equipment, and like
considerations. Thus, in one configuration, a second conveyor can convey the
stack
stream uni-directionally to the packaging module. In another alternative
configuration, the second conveyor can convey the stack stream bi-
directionally to
two separate packaging modules, that is, the merged stack stream on the second
conveyor provides two stack streams alternately flowing in opposite directions
from
the second conveyor to two separate pack lines, as illustrated and discussed
in FIG.
7.
In embodiments, the packaging module can comprise a first banding station,
a second over-wrapping station, and an optional third shrink-wrapping station.
This
paclcaging module can further optionally comprise a containerizer module
having,
for example, a boxing station, a box sealing station, or both. In embodiments,
the
packaging module can comprise a first banding station for making bundled
printed
sheets which applies a band around each stack of printed sheets, and a
containerizer
module, such as a boxing station, where the bundled printed sheets are boxed
in a
box having a sealable liner. In embodiments, the containerizer module, such as
a
boxing station, can be adapted to wrap a container material around a plurality
of
bundles (bundle of bundles), such as cardboard stock or plastic, to form the
container in-line. In-line container formation has a number of advantages
including
just-in-time container generation, automatic or robotic handling, reduced
space
requirement for containers prior to filing, and like advantages.
In embodiments, the apparatus can further comprise a debris collector
situated near, such as for about 0.1 inch to about 36 inches, the cutter
module. The
debris collector can be, for example, a vacuum take-off or manifold, a non-
contact
taclcy-surface roller, a contact tacky-surface roller, a disturber brush
member, or
combinations thereof. The debris can be, for example, ambient dust or dust
created
from the cutting, web- or sheet transport, printing, coating, treating,
jogging, and
like manipulations of the substrate, before or after cutting. Thus, the method
can
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further include removing debris, such as paper or plastic dust or cuttings
already
present on the web or fed-sheets or generated from cutting or manipulating the
web-
or fed-sheets into cut printed sheets.
In embodiments, the printable web can be comprised of, for example, paper,
film, synthetic materials, foils, metalized version thereof, and like
materials, or
combinations thereof. A preferred printable web material for economy and
versatility is, for example, rolled paper or rolled plastic film.
In embodiments, the apparatus can further comprise an ambient humidity
control system, for example, having a localized spray or mist nozzle or having
a
large scale humidity environmental control systems capable of ambient humidity
control over one or more production systems or modules of the disclosure.
Although not required the method of making bundled printed sheets is
preferably
accomplished in a controlled environment, such as where ambient humidity and
temperature can be regulated, to safe-guard the quality of the processes and
the
~ products. "Ambient humidity" refers to the humidity of the immediate
atmosphere,
which surrounds the apparatus, particularly in the cutting and stacking
operations
where static charge, frictional charge, or streaming charge generation or
accumulation may occur. The methods of making bundled printed sheets of the
disclosure can be accomplished over a range of relative humidity conditions
although very low humidity conditions, such as below about 25 percent are
contraindicated, especially in the absence of alternative methods of static
charge
suppression or elimination in web-based production systems. The sensitivity of
the
methods of making to ambient humidity can depend upon many factors, such as
temperature, barometric pressure, operating speed(s), web or sheet substrate
type
selected (e.g., paper, plastic, etc.), the printing inlcs selected and the
amounts
applied, coating or other treatment formulations selected and the amounts
applied,
and like considerations. In embodiments, a suitable relative humidity range
for use
in the methods of making which employ a paper web or paper fed-sheets is, for
example, from about 50 to about 80 percent, and a preferred relative humidity
range
is from about 65 to about 75 percent. Methods for controlling ambient humidity
are
known, such as HVAC climate-controlled facilities, local application of a
humidifier, intermittent water-mist sprayers, and like humidification methods.
It
will be readily understood by one of ordinary skill in the art that the
humidity
requirements and humidity sensitivity of the apparatus and process of the
disclosure
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can depend upon the print engine or print technologies selected and can even
depend
upon the different configurations of the same print engine. For example, high-
speed
offset methods generally tend to favor higher humidity conditions while
xerographic
methods generally tend to favor lower humidity conditions.
In embodiments, the apparatus and method of making of the disclosure are
preferably maintained at, or accomplished at, an ambient temperature of from
about
50 to about 90 degrees °C.
In embodiments, the apparatus can further comprise a web coating module.
The web coating module can be configured to apply one or more coatings to
either
or both sides of the web after the print module. Coatings which can be applied
to
the printed web, or prior to printing on the web, and can include, for
example, a
varnish coating, a gloss coating, a protective coating, an anti-static
coating, an
opaque coating for example to conceal printed images beneath such as in some
scratch-off game cards, and like coatings, or combinations thereof. In
embodiments,
in-line high gloss UV varnish application to a continuous web-based substrate
can
provide considerable savings, for example, in time, steps, set-up, handling,
rework,
discards, and lilce savings.
In embodiments, the apparatus can further include a web-chiller module.
The web-chiller module can be situated anywhere along the web's path, for
example,
between the print module and the cutter module, and preferably just after the
in-line
coating station or web coating module. The web-chiller module provides a
convenient way to, for example, remove excess latent heat from the web arising
from one or more printing operations, UV light exposure or curing, frictional
contact
with web propulsion or guidance devices, and like sources of heating.
In embodiments, the apparatus can further include a web nip situated
between a nip roller and a backing roller, the web-nip preferably being
situated just
before the chiller in the chiller module 13c and as discussed and illustrated
in FIG 1.
In embodiments, the apparatus can further include a web-nip between a nip
roller
and an anvil roller. This web-nip can preferably be situated just before the
cutter in
the cutter module as illustrated and discussed in FIG 4B.
In embodiments, the cutter module can provide from 2 to about 80 streams of
printed sheets, the collator can provide from 2 to about 80 registered stacks
corresponding to the number of collated sheet streams, and the conveyor module
can
convey from 2 to 80 registered stack streams into a single stack stream.
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Alternatively, the conveyor module can convey from 2 to ~0 registered stack
streams
into two stack streams. In embodiments, the packaging module can comprise an
optional stack jogger, a stack bander, an optional stack overwrapper, and an
optional
containerizer. The containerizer can comprise, for example, a person or device
for
placing the bundled printed sheets within a container, for sealing the
container, and
optionally placing a plurality of sealed containers on a earner. For example,
a
manual operator, a programmable industrial grade robot, or like devices, can
be
programmed to pick-and-place the bundled printed sheets into a container, such
as a
box or carton, and thereafter seal the container, and optionally place a
plurality of
the sealed containers on a carrier, such as a pallet or skid, and thereafter
optionally
overwrap the plurality of containers on the earner with stretch banding to
prevent
containers from separating for the others or to prevent containers from
falling off the
earner.
In embodiments, the package can comprise a bundled pri~ited sheets
comprising: a plurality of printed sheets in a staclc; a band around the
stack; and an
optional overwrapper on the banded stack, each printed sheet having a narrow
cut-
to-print registration variance, for example, of from less than or equal to
about 0.03
inches, and each printed sheet having the same length and width dimensions as
the
other printed sheets in the stack to within a variance of less than or equal
to about
0.005 inches; and a container for the bundled printed sheets. The package can
further comprise a plurality of the containers on a pallet, the plurality of
containers
optionally being partially overwrapped with an overwrapper.
In embodiments, the present disclosure provides a sheet-fed based apparatus
for making bundled printed sheets, comprising, for example, a sheet feeder; a
print
module to print on the fed-sheets; a cutter module to cut the printed fed
sheets into a
stream of cut printed sheets; a collator to transport and collate each stream
of cut
printed sheets into a registered stack; a conveyor module to convey each
registered
stack into a stack stream; and a paclcaging module which packages each
registered
stack in the staclc stream into a package having a bundled printed sheets. In
embodiments of the sheet-fed apparatus, the sheet-feeder and the~print module
in
combination can comprise, for example, a high-speed sheet-fed print engine.
The
cutter module can comprise, for example, a rotary die-cutter to angle-cut the
printed
sheets into at least one sheet stream and a waste matrix. The packaging module
can
comprise, for example, an optional stack jogger, a stack bander, an optional
stack
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overwrapper, an optional source of heat energy to shrink the overwrapper if
desired,
and an optional containerizes. The package can further comprise' a plurality
of
containerized bundled printed sheets.
In embodiments, the present disclosure provides a method of malting
bundled printed sheets, comprising:
printing on a printable web;
cutting the printed web into a stream of printed sheets anc~ a waste matrix;
collating each stream of printed sheets into a registered stack;
conveying each registered stack into a stack stream; and
packaging each registered stack in the stack stream to form a bundle of
printed sheets.
In embodiments the apparatus and method of making can employ a rotary
die-cutter which cuts printed sheets from the web, which printed sheets prior
to
cutting can be, aligned adj acent sheets, staggered adj acent sheets, angle-
cut adj acent
sheets, or combination's thereof.
In embodiments, the method of making steps, such as printing, cutting,
collating, conveying, and packaging, can preferably be accomplished
continuously.
"Continuously," "continuous," or like terms, in this context refer to non-stop
operation during a job, or without interruption, for example, for a period of
from
about 10 minutes to about 1,000 hours or more. In embodiments, the method and
apparatus are capable of operating non-stop or without interruption for
extended
periods of time such, as 2417 for up to a month and beyond, when for example,
web-
or fed-sheet stock, inks, coatings, surface treatment material or agents,
banding
materials, wrapping materials, and the like consumables, can be replenished as
needed to sustain the continuous operation and production of printed sheets
and the
resulting bundles. In embodiments, the method of making bundled printed sheets
of
the present disclosure is highly efficient and can provide continuous
manufacture of
bundled printed sheets in relatively high volumes, starting from the uncoated
or
untreated web- or fed-sheet stock to the bundled and packaged printed sheets,
for
example, in from about 1 to about 10 minutes, preferably from about 1 to about
8
minutes, and more preferably from about 1 to about 6 minutes, to go from paper
roll
feed stoclc to a boxed bundle.
The printed sheets can be used for, but are not limited to, for example,
labels,
business cards, greeting cards, trading cards, tickets, game cards,'banlc
cards, phone
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cards, identification cards, note pad sheets, paper currency, negotiable
instruments,
interlaced images, coupons, chits, ballots, maps, forms, time sheets, and like
applications, or combinations thereof. The printed sheets can be used in, but
are not
limited to, a variety of applications including, for example, individual
product labels,
such as used on beverage containers or canned goods, signage, bumper
sticlcers, and
like applications.
In embodiments the present disclosure provides a method of making bundled
printed sheets, comprising:
printing on a printable web;
die-cutting the printed web into a stream of printed sheets and a waste
matrix;
collating each stream of printed sheets into a vertical registered stack;
conveying each registered stack into a single stack stream;
banding each registered stack in the conveyed single stack stream to form a
banded stack of bmdled printed sheets wherein a band circumscribes a portion
of
two opposite sides and the entire height of the vertical stack and a portion
of the
width of the first sheet and a portion of the width of the last sheet in the
stack;
overwrapping each banded stack; and
optionally placing each overwrapped banded stack in a container.
Similarly, in embodiments the present disclosure provides a method of
making bmdled printed sheets from single-sheets or fed-sheets, comprising:
providing single-sheets;
optionally printing on the single-sheets with a print engine;
cutting each printed single-sheet into a stream of cut-printed sheets and a
waste matrix;
collating each stream of cut-printed sheets into a registered staclc;
conveying each registered staclc into a stack stream; and ,
paclcaging each registered stack in the staclc stream into a bundle of printed
sheets.
In embodiments, the provided single-sheets can be, for example, free of
printed images or have printed images on one or both faces of the sheet. As
mentioned with other embodiments for methods of malting of the present
disclosure,
the cutting can be preferably accomplished by die-cutting. The die-cutting can
preferably be accomplished with an angle-cut rotary die-cutting machine. In
other
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embodiments, the cutting can be accomplished using slit-and-gap cutting
methods.
"Slit-and-gap" cutting generally refers to cutting which is capable of
slitting and
cutting-out or creating a gap between adjacent sheets or work pieces in the
process
direction.
In embodiments the present disclosure provides a method of affixing printed
sheets to articles, comprising:
optionally slitting the over-wrapper on an over-wrapped bundle of
printed sheets;
removing the over-wrapping from over-wrapped bundled printed
sheets comprising:
a plurality of printed sheets in a stack;
a band around the stack; and
an overwrapper on the banded stack,
each printed sheet having a cut-to-print registration variance of from less
than or
equal to about 1/l6th inch, and each printed sheet having the same length and
width
dimensions as the other printed sheets in the stack to within a variance of
less'than
or equal to about 1/100th inch;
optionally fanning the unwrapped bundled printed sheets;
removing the banding from the unwrapped bundled printed sheets;
inserting the staclced printed sheets into a sheet applicator machine;
optionally activating an adhesive on, or applying an adhesive to a
portion of the individual printed sheets; and
contacting the individual printed sheets with an article.
In embodiments, the present disclosure provides an article having a printed
sheet attached thereto prepared by the abovementioned method of affixing
printed
sheets to articles. hi embodiments, the present disclosure provides an article
having
a printed sheet attached thereto, the printed sheet being obtained from
unpaclcaging a
bundle of printed sheets of the disclosure comprising a plurality of printed
sheets in
a stack having a band around the stack and an overwrapper on the banded
staclc, and
affixing the printed sheet to the article with a label applicator machine.
In embodiments the present disclosure provides a stack of printed sheets,
comprising: a plurality of printed sheets in a unitary form, each printed
sheet having
a narrow cut-to-print registration variance, for example, of from less than or
equal to
about 0.03 inches, and each printed sheet having the substantially same length
and
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width dimensions as the other printed sheets in the staclc to within a narrow
variance
of less than or equal to about 0.005 inches, and the stack being situated in a
label
applicator machine.
In embodiments, the printed sheets of the stack can be product labels having
product collateral information, images, text, and like markings, or
combinations
thereof, printed thereon. The stack of printed sheets can be a unitary form
such as a
parallelepiped, having for example, all square corners of about 90 degrees,
such as a
cube or an elongated cube. A cube has substantially identical length, width,
and
height dimensions. An elongated cube may have one, two, or three of its
length,
wide, or height dimensions being different from one another.
In embodiments the present disclosure provides an article having a printed
sheet attached thereto, the printed sheet being obtained from unpackaging a
bundle
of substantially identically shaped printed sheets, the bundle of printed
sheets
comprising:
a plurality of printed sheets in a stack;
a band around the stack; and
an overwrapper on the banded stack,
each printed sheet having a narrow cut-to-print registration variance of, for
example, from less than or equal to about 1/l6th inch, and each printed sheet
having
, substantially the same length and width dimensions as the other printed
sheets in the
stack to within a narrow variance of, for example, less than or equal to about
1/100th
inch.
Methods for manufacturing labels, such as self adhesive labels, for use in a
label applicator machines are known, see for example, U.S. Patent No.
6,273,987.
Label applicator machines and methods for applying labels to articles or
containers
are known, see for example, U.S. Patent No. 4,793,891. U.S. Patent No.
4,798,648,
discloses an article-feeding device for use in a label applicator machine, and
also
discloses forming adhesive labels by die-cutting from a web, intermediate
transfer of
the cut labels, and application of the labels to articles. High speed label
applicator
machines for high volume solutions using hot melt adhesives, cold adhesives,
pressure sensitive adhesives, or combinations thereof, and conveyor equipment
are
also commercially available from, for example, Abacus Label Applications,
Maple
Ridge, B.C. Canada (www.abacuslabel.com).
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All publications, patents, and patent documents are incorporated by reference
herein in their entirety, as though individually incorporated by reference.
The
disclosure has been described with reference to various specific and preferred
embodiments and techniques. However, it should be understood that many
variations and modifications can be made while remaining within the spirit and
scope of the disclosure.
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