Apparatus for in-line folding and affixing of tuck label

Information

  • Patent Grant
  • 6378588
  • Patent Number
    6,378,588
  • Date Filed
    Friday, May 28, 1999
    25 years ago
  • Date Issued
    Tuesday, April 30, 2002
    22 years ago
Abstract
An apparatus is provided for in-line folding and affixing a label to an article, the label having a fold line thereacross defining a foldable portion and a cover portion of the label. The apparatus comprises a transfer grid having one or more rollers to convey the label from a first end of the transfer grid to a second end of the transfer grid. An opening is defined between two of the rollers intermediate the first and second ends of the transfer grid. The transfer grid conveys the label in a substantially unfolded orientation from the first end of the transfer grid to the opening of the transfer grid such that the foldable portion of the label is projective through the opening. A folding station is adjacent the opening and receives the foldable portion of the label, urging a projecting portion of the foldable portion over the cover portion to define a substantially folded-over orientation of the label. The transfer grid conveys the label being in the substantially folded-over orientation from the opening of the transfer grid to the second end of the transfer grid, whereat an affixing station is provided adjacent the second end of the transfer grid to receive the label and affix the label to the article.
Description




BACKGROUND OF THE INVENTION




1. Technical Field of the Invention




The present invention relates to apparatuses and methods for affixing a self-adhesive label to an article. More particularly, the present invention relates to an apparatus and a method for affixing a self-adhesive label to an article, wherein the apparatus folds the label prior to affixing the label to the article.




2. Description of the Related Art




Containers used to ship articles, such as corrugated cardboard boxes, often have a label adhesively affixed thereto for the purpose of displaying therefrom information relating to, for example, the shipping instructions, the customer's identity or the container's contents. Particularly, businesses shipping goods based on customer orders require a substantial amount of information to be generated so that persons taking the order, filling the order, shipping the order, billing the order, etc., can perform their respective jobs to insure that the goods reach their intended destination. Typically, this information is printed on one or more labels which are affixed to the container, and which may contain printable items, such as, invoices, customer receipts, common carrier tracking labels, warehouse picking lists and returned goods forms.




For example, U.S. Pat. No. 5,413,383 to Laurash, et al., teaches a printable, foldable, self-adhesive “tuck label” having one or more flaps defining detachable portions thereof which may be removed from the tuck label even after the label has been adhesively affixed to a container. The detachable portions may have information and items such as those described above either pre-printed thereon or contained therein to facilitate shipping and handling of the container and its contents. A tuck label, such as the those described in the Laurash '383 patent, are typically affixed to a container by a worker's removing the unfolded tuck label from a release sheet, folding the tuck label into the proper orientation and manually affixing the folded tuck label to the container. Thus, it is desirable to provide an apparatus and method for automatedly affixing a label, such as, a tuck label, to an article, such as, a shipping container or the like.




For example, U.S. Pat. No. 5,674,334 to Instance teaches an apparatus for manufacturing a folded label wherein a continuous strip of label material is cut into predetermined lengths, folded, adhered to a pressure-sensitive adhesive backing and applied to a release sheet in a folded-over orientation. The folded-over label is then removed from the release sheet and affixed to an article, such as, as shipping container. However, it is furthermore desirable to provide an apparatus for removing an unfolded label from a release sheet, automatedly folding the label into a predetermined orientation and affixing the folded label to an article, such as a shipping container or the like. It is even furthermore desirable to provide a method for folding and affixing a self-adhesive label to a container, wherein the steps of folding and affixing the self-adhesive label to the container are performed in an in-line process.




Accordingly, there remains a need in the art for an apparatus and method for in-line folding and affixing a self-adhesive label to an article, such as, for example, a shipping container or the like.




SUMMARY OF THE INVENTION




The present invention is for an apparatus and method for in-line folding and affixing a self-adhesive label to an article, such as, for example, a shipping container or the like. The apparatus for in-line folding and affixing a self-adhesive label to an article, such as a shipping container, according to a preferred embodiment of the present invention includes a printing station, a label transfer grid, a folding station and an affixing station.




The labels, which may be affixed to a release liner, are individually fed into the printing station, which prints indicia thereon, such as invoice, receipt, shipping or inventory information. Labels exiting the printing station are fed into a first end of the transfer grid, which generally comprises two curved rows of rollers in spaced relation to one another to transfer the labels therethrough. An opening is defined, preferably between two rollers of the second row, through which a leading edge of the label is guided to project outwardly from the grid towards the folding station. As the label is conveyed forwardly through the grid, a foldable portion of the label is temporarily diverted into the folding station and thereby guided into a substantially folded-over orientation. Once the foldable portion of the label substantially projects through the opening, an air blast emitted from an air blast nozzle urges a folded edge of the label back through the opening and again into the grid, which conveys the folded-over label towards a second end thereof. The grid deposits the folded-over label onto a transfer plate of the affixing station, which includes one or more vacuum nozzles to hold the folded-over label temporarily thereagainst. Once the label is positioned over a portion of the transfer plate, a reciprocating arm, affixed to the transfer plate, presses the label against an article positioned nearby. One or more adhesive strips provided on the exposed surface of the folded-over label, then, adhesively affix the label to the article.




One aspect of the present invention is to provide an apparatus for in-line folding and affixing a label to an article, the label having a fold line thereacross, the fold line defining a foldable portion of the label and a cover portion of the label, the apparatus comprising a transfer grid having one or more rollers to convey the label from a first end of the transfer grid to a second end of the transfer grid, the one or more rollers defining an opening intermediate the first and second ends of the transfer grid, the transfer grid conveying the label being in a substantially unfolded orientation from the first end of the transfer grid to the opening of the transfer grid, the foldable portion of the label being projective through the opening; a folding station adjacent the opening, the folding station urging a portion of the foldable portion projecting through the opening over the cover portion to define a substantially folded-over orientation of the label, the transfer grid conveying the label being in the substantially folded-over orientation from the opening to the second end of the transfer grid; and, an affixing station adjacent the second end of the transfer grid, the affixing station receiving the label being in the substantially folded-over orientation and affixing the label to the article.




Another aspect of the present invention is to provide a method of in-line folding and affixing a label to an article, the label having a fold line thereacross, the fold line defining a foldable portion of the label and a cover portion of the label, the method comprising the steps of providing a transfer grid for conveying the label from a first end of the transfer grid to a second end of the transfer grid, the transfer grid having an opening intermediate the first and second ends; providing a folding station adjacent the opening; providing an affixing station adjacent the second end of the transfer grid; inserting the label into the first end of the transfer grid; the transfer grid conveying the label in a substantially unfolded orientation from the first end of the transfer grid to the opening, the foldable portion of the label being projective through the opening; the folding station folding the foldable portion of the label over the cover portion of the label to define a substantially folded-over orientation of the label; the transfer grid conveying the label being in the substantially folded-over orientation from the opening to the second end of the transfer grid; the affixing station receiving the label being in the substantially folded-over orientation from the second end of the transfer grid; and, the affixing station affixing the label to the article.




It is an object of the present invention to provide an apparatus and method for automatedly affixing a label, such as, a tuck label, to an article, such as, a shipping container or the like.




It is another object of the present invention to provide an apparatus for removing an unfolded label from a release sheet, folding the label into a predetermined orientation and affixing the folded label to an article, such as a shipping container or the like.




It is still another object of the present invention to provide a method for folding and affixing a self-adhesive label to a container, wherein the steps of folding and affixing the self-adhesive label to the container are performed in an in-line process.




These and additional objects, features and advantages of the present invention will become apparent to those reasonably skilled in the art from the description which follows, and may be realized by means of the instrumentalities and combinations particularly pointed out in the claims appended hereto.











BRIEF DESCRIPTION OF THE DRAWINGS




A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like reference numerals represent like parts, and wherein:





FIG. 1

is an oblique perspective view of a tuck label shown affixed to a container by an apparatus and method according to a preferred embodiment of the present invention;





FIG. 2

is a front view of the tuck label of

FIG. 1

, shown in an unfolded orientation;





FIG. 3

is the tuck label of

FIG. 1

, shown in a partially-folded orientation;





FIG. 4

is a side section view of the tuck label and container of

FIG. 1

, shown along section line


4





4


of

FIG. 1

;





FIG. 5

is an oblique perspective view of the tuck label of

FIG. 1

, shown with a removable portion having been detached therefrom;





FIG. 6

is an oblique perspective view of a plurality of tuck labels of

FIG. 1

, shown removably affixed to a release sheet and wound into a roll;





FIG. 7

is a diagrammatic elevation view of an in-line tuck label folding and affixing apparatus according to a preferred embodiment of the present invention, showing a tuck label entering a folding station thereof;





FIG. 8

is a diagrammatic elevation view of the apparatus of

FIG. 7

, showing a portion of the tuck label being folded in the folding station thereof;





FIG. 9

is a diagrammatic elevation view of the apparatus of

FIG. 7

, showing the tuck label in a folded orientation leaving the folding station thereof;





FIG. 10

is a diagrammatic elevation view of the apparatus of

FIG. 7

, showing the tuck label in a folded orientation entering a transfer station thereof;





FIG. 11

is a diagrammatic elevation view of the apparatus of

FIG. 7

, showing the tuck label being affixed to the container of

FIG. 1

;





FIG. 12

is a diagrammatic perspective view of a transfer grid section of an apparatus according to an alternative embodiment of the present invention;





FIG. 13

is a diagrammatic cut-away perspective view of one portion of the apparatus of

FIG. 12

, further showing an alternative means for sideways folding a label thereby;





FIG. 14

is a diagrammatic perspective view of a section of an affixing station of an apparatus according to another alternative embodiment of the present invention; and,





FIG. 15

is a diagrammatic perspective view of a section of an affixing station of an apparatus according to another alternative embodiment of the present invention.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




With combined reference to

FIGS. 1-5

, a conventional tuck label


10


is affixable, such as, for example, by adhesive, to one surface


31


of a container


30


, for example, a corrugated cardboard box used to ship articles therein. Any foldable label known to those of ordinary skill in the art may be used for the purposes herein described and the within description is not intended to limit the scope of the present invention to only those foldable tuck labels of the type shown and described herein. For example, although the preferred embodiment hereof will be described with reference to a tuck label having one fold line thereacross defining two flaps thereby, the apparatus and method of the present invention are adaptable by those of ordinary skill in the art to fold and affix tuck labels having a plurality of fold lines thereacross, in any orientation thereon, defining any number of flaps thereby.




The preferred tuck label


10


is constructed from a planar sheet of foldable, printable material, such as, for example, plain paper, having a first planar surface


12


and a second planar surface


14


. The first planar surface


12


of the tuck label


10


is adapted to be coated with an adhesive film, for example, pressure-sensitive or re-wettable adhesive, for the purpose of adhesively affixing the tuck label


10


to the surface


31


of the container


30


as described in greater detail below. The second planar surface


14


of the tuck label


10


is adapted to have indicia printed thereon, such as, for example, shipping, billing or customer information, or any additional information relating to the contents of the container


30


.




The tuck label


10


is divided by a fold line


16


, which defines a cover portion


20


of the tuck label


10


and a foldable portion


22


of the tuck label


10


, wherein the foldable portion


22


is upwardly foldable about the fold line


16


such that the first planar surface


12


of the foldable portion


22


is adhesively affixable to the first planar surface


12


of the cover portion


20


. A strip of adhesive


24


coats a distal end


23


of the foldable portion


22


and is positioned thereon such that, when the foldable portion


22


is folded upwardly over the first planar surface


12


of the cover portion


20


, adhesive strip


24


is removably adhesively affixed to a release strip


25


, such as, for example, of silicone, which coats a portion of the first planar surface


12


of the cover portion


20


. Although adhesive strip


24


and release strip


25


have been described herein as being separate layers superimposed over portions of the tuck label


10


, it will be understood that these layers need not be self-supporting layers at all, but rather are shown herein as such for clarity.




An inverted “U”-shaped adhesive border


26


coats the first planar surface


12


of the tuck label


10


along three edges of the cover portion


20


and is sized, shaped, and positioned such that, when the foldable portion


22


is folded over the cover portion


20


, the foldable portion


22


resides within the border


26


, but is not adhesively affixed thereto. As such, cover portion


20


defines shoulders


27




a


,


27




b


between which foldable portion


22


is positioned.




The cover portion


20


includes a perforation line


28


which is offset inwardly along an inner edge


26




a


of the adhesive border


26


defining a removable portion


20




b


of the cover portion


20


which is sized substantially as the foldable portion


22


of the tuck label


10


. The perforation line


28


permits a removable portion


20




b


of the cover portion


20


to be separated from a frame portion


20




a


of the cover portion


20


and to be removed therefrom even after the tuck label


10


has been affixed to the container


30


, as described in greater detail below. Adhesive strip


24


and release strip


25


are preferably sized, shaped and positioned to reside within the perforation line


28


such that the foldable portion


22


of the label


10


may be removed from the frame portion


20




a


, along with the removable portion


20




b


of the cover portion


20


.




The tuck label


10


is typically affixed to the surface


31


of the container


30


by folding the foldable portion


22


over the cover portion


20


and by releasably adhesively affixing the first planar surface


12


of the foldable portion


22


to the first planar surface


12


of the cover portion


20


, such as, for example, as between adhesive strip


24


and release strip


25


. The tuck label


10


, then, is adhesively affixed to the surface


31


of the container


30


, such as, by adhesive border


26


, whereby the foldable portion


22


is sandwiched between the cover portion


20


and the container


30


, but wherein the foldable portion


22


, itself, is not adhesively affixed to the container


30


because the foldable portion


22


resides within adhesive border


26


. With specific reference to

FIG. 5

, tearing the cover portion


20


of the tuck label


10


along perforation line


28


detaches the removable portion


20




b


of the cover portion


20


(and the foldable portion


22


) from the frame portion


20




a


of the cover portion


20


, thereby permitting removal of the removable portion


20




b


, which may contain invoice, shipping or other information printed thereon.




With reference now to

FIGS. 6 and 7

, a preferred apparatus and method for in-line folding and affixing the tuck label


10


to the surface


31


of the container


30


is illustrated. Preferably, a plurality of tuck labels


10


are provided in an unfolded (such as is shown in FIG.


2


), end-to-end orientation with the foldable portion


22


of each tuck label


10


leading the cover portion


20


thereof. Alternatively, the labels


10


may be in a side-by-side orientation (not shown), wherein a sideways edge of each label


10


defines the leading edge thereof (FIG.


13


), or in a backwards end-to-end orientation (not shown), wherein the cover portion


20


leads the foldable portion


22


thereof.




The labels


10


are removably adhesively affixed to a continuous release sheet


80


, such as, for example, a paper liner coated with silicone, thereby defining a label web


85


, to permit each label


10


to be removed from the release sheet


80


for individual attachment thereof to a container


30


. The labels


10


are preferably affixed to the release sheet


80


such that the first planar surface


12


of the cover portion


20


of the labels


10


, on which adhesive strip


24


and adhesive border


26


are provided, contacts the release sheet


80


, whereby adhesive strip


24


and adhesive border


26


adhesively affix the label


10


to the release sheet


80


. The silicone coating on the release sheet, however, permits each label


10


to be removed from the release sheet


80


with the adhesive strip


24


and the adhesive border


26


remaining on the first planar surface


12


of the label


10


for later affixing the label


10


to the container


30


. The release sheet


80


, with the labels


10


adhesively affixed thereto, is preferably wound into a roll


82


to facilitate transportation and handling thereof, wherein labels may be continuously fed into the apparatus


100


. Alternatively, labels


10


may be provided on individual release sheets which are stacked or fan-folded for individual feeding into the apparatus


100


.




The apparatus


100


for in-line folding and affixing the tuck label


10


to the surface


31


of the container


30


includes a printing station


110


, a label transfer grid


120


, a folding station


140


, first, second and third air blast nozzles


150


,


155


,


158


, respectively, and an affixing station


160


. The printing station


110


includes any conventional impact or non-impact printing device adapted to print information on individual tuck labels


10


. The label web


85


may be fed into the printing station


110


with the labels


10


affixed to the release sheet


80


during printing, in which case, the printing station


110


prints predetermined information on the exposed second planar surface


14


of the tuck label


10


. The information printed on the labels


10


may be the same for each label


10


, for example, to indicate the shipper's address, or may vary as between the labels


10


, such as, to indicate the destination address. Alternatively, the labels


10


may not be affixed to a release sheet at all, such as, for example, with respect to linerless labels or labels having a re-wettable adhesive on one surface thereof, in which case, the printing station


110


may print information on the first planar surface


12


of the label


10


, such as between adhesive strip


24


and release strip


25


, in addition to printing information on the second planar surface


14


of the label


10


. In either case, however, labels


10


exit the printing station


110


one at a time, and, where a release sheet


80


has been provided, the individual labels


10


have been removed from the release sheet


80


, which may then be re-wound into a roll either before or after the printing station


110


. That is, if the labels


10


pass through the printing station


110


affixed to the release sheet


80


and are removed from the release sheet


80


after the printing station


110


(such as is shown in FIGS.


7


-


10


), then the release sheet


80


is wound into a roll after the printing station


110


. The printing station


110


prints information on the second planar surface


14


of the labels


10


which are then removed from the release sheet


80


as the label web


85


exits the printing station


110


. The individual labels


10


enter the label transfer grid


120


, one at a time, as the continuous release sheet


80


is rewound for re-use or discarding thereof.




The label transfer grid


120


includes an inner row


121


of rollers


121




a


and an outer row


122


of rollers


122




a


, wherein the rollers


122




a


of the outer row


122


are spaced from the rollers


121




a


of the inner row


121


by a sufficient distance to grip the tuck label


10


therebetween and to convey the tuck label


10


from the printing station


110


to the transfer station


160


along a generally upwardly-curved path. At least one of the rollers


122




a


in the outer row


122


is motorized, although not all rollers


122




a


need to be motorized. Moreover, one or more rollers


121




a


of the inner row


121


may be motorized, although none of the rollers


121




a


need to be motorized. Although the spacing between rows


121


,


122


is shown in the Figures as being much larger than the thickness of the label


10


being conveyed thereby, this exaggerated distance is shown for clarity only and those of ordinary skill in the art will understand that the spacing between rows


121


,


122


will, in fact, be much smaller than that shown, and preferably be only slightly larger than the thickness of the labels


10


being conveyed thereby. The spacing between rows


121


,


122


may also be adjustable using any known technique which permits labels having varying thicknesses to be conveyed thereby. It will also be obvious to those of ordinary skill in the art that, because the tuck label


10


being conveyed by the label transfer grid


120


has been removed from the release sheet


80


, the adhesive strip


24


and the adhesive border


26


of the label


10


are exposed to the rollers


121


. Accordingly, rollers


121




a


,


122




a


, and particularly, outer rollers


122




a


, may be coated with silicone or another similar material to prevent the label


10


from sticking to the rollers


121




a


,


122




a.






As can be clearly seen in

FIG. 7

, transfer grid


120


includes a first end


120


A, located adjacent printing station


110


, and a second end


120


B, located adjacent affixing station


160


. Generally, label transfer grid


120


conveys the label


10


from the printing station


110


, from which the label


110


typically exits in a substantially horizontal orientation, to the affixing station


160


, wherein the label


10


is in a substantially vertical orientation to be affixed to the substantially vertical sidewall surface


31


of the container


30


. The label transfer grid


120


, then, includes a generally upwardly-curved bend, by which the flexible label


10


moves from a substantially horizontal orientation to a substantially vertical orientation for affixing to the container


30


. However, the orientation of the label


10


need not be altered by a bend in the grid


120


, and the label


10


may be of any orientation suitable to be affixed to the container


30


as it exits the grid


120


. For example, if surface


31


of container


30


is substantially horizontal, label


10


should exit the grid


120


in an orientation suitable to be affixed to the horizontal surface of the container


30


.




The outer row


122


of rollers


122




a


includes an opening


123


which is defined as an absence of one or more rollers in the outer row


122


. Alternatively, the opening


123


may be defined by the spacing between two consecutively-spaced rollers


122




a


in the outer row


122


, wherein the spacing between two consecutively-spaced rollers


122




a


is sufficient to permit the label


10


to pass therebetween. Remaining rollers


122




a


are spaced to pass the label


10


therealong and to convey the label


10


through the grid


120


.




The opening


123


is sized to allow the leading edge


23


, that being in the preferred embodiment, the foldable portion


22


of the tuck label


10


, to pass outwardly from within the grid


120


, through the opening


123


and towards the folding station


140


as the label


10


is conveyed through the generally upwardly-curved bend of the transfer grid


120


. The third air blast nozzle


158


is positioned alongside the inner row


121


of rollers


121


a and is directed towards the outer row


122


of rollers


122




a


to emit a stream of pressurized air through the grid


120


, as shown generally by reference numeral


159


. Air stream


159


urges the leading edge


23


of the foldable portion


22


of the label


10


through the opening


123


, to project from within the grid


120


and outwardly towards the folding station


140


. A conventional timing control circuit, such as a programmable logic controller, is provided with sensors and valves to signal the air blast


159


to urge the leading edge


23


of the foldable portion


22


of the label through the opening


123


. Alternatively, rollers


121




a


,


122




a


may be driven by one or more stepper motors, in which case, air blast


159


may be controlled with reference to movement of the stepper motor (and, as such, by the location of the label


10


in the grid


120


), instead of by the programmable timing controller. Alternatively still, the air blast


159


may be a continuous stream of pressurized air being emitted from the air blast nozzle


158


.




As the grid


120


conveys the label


10


towards the second end thereof, forward movement of the label


10


along the rollers


121




a


,


122




a


is diverted temporarily through the opening


123


towards the folding station


140


. Forward movement of the label


10


by the grid


120


, then, advances the foldable portion


22


of the label


10


further out of the grid


120


.




With reference to

FIGS. 8 and 9

, the folding station


140


includes a reversing block


141


having a curved surface


142


, or any surface having a shape adapted to receive the foldable portion


22


of the tuck label


10


therein and to guide the foldable portion


22


of the tuck label


10


towards the grid


120


in a direction substantially opposite to the forward motion of the foldable portion


22


of the tuck label


10


as it exits the transfer grid


120


through the opening


123


. The foldable portion


22


of the tuck label


10


exits the grid


120


through the opening


123


due to the forward movement of the label


10


by the grid


120


, the foldable portion


22


of the tuck label


10


is thereby further folded backwardly, over the cover portion


20


of the tuck label


10


, still being held within the grid


120


, but moving towards the opening


123


. When the fold line


16


, which adjoins shoulders


27




a


,


27




b


, nears the opening


123


, air blast nozzle


150


emits a temporary blast of pressurized air in the direction shown generally by reference numeral


152


towards the partially-folded foldable portion


22


of the tuck label


10


projecting from within the grid


120


. The air blast


152


folds the foldable portion


22


of the label


10


further over the cover portion


20


thereof and urges the folded edge


29


of the tuck label


10


back into the opening


123


and into the grid


120


, where rollers


121




a


,


122




a


grab the folded edge


29


of the tuck label


10


and convey the tuck label


10


, now with the folded edge


29


thereof leading, upwardly towards the affixing station


160


.




A conventional timing control circuit, such as a programmable logic controller, is provided with sensors and valves to signal the air blast


152


when the label


10


is positioned within the grid


120


to permit folding thereof according as described, and which may also control the timing of the air blast


159


from the third air blast nozzle


158


in relation to the air blast


152


of the first air blast nozzle


150


. Alternatively, the air blast


152


may be a continuous stream of pressurized air being emitted from the air blast nozzle


150


. As the tuck label


10


passes upwardly alongside the opening


123


, the foldable portion


22


thereof is drawn back into the grid


120


, through the opening


123


. When the foldable portion


22


of the tuck label


10


is again fully within the grid, now folded over the cover portion


20


, the strip of adhesive


24


is pressed against the release strip (

FIG. 2

) by opposing rollers


121




a


,


122




b.






With reference to

FIGS. 10 and 11

, the affixing station


160


includes a reciprocating member


161


, such as a translatable rod reciprocally connected to a pneumatic cylinder, and a transfer plate


162


fixedly secured to a distal end of the member


161


. The reciprocating member


161


moves between a retracted position, shown generally in

FIG. 10

, and an extended position, shown generally in FIG.


11


. While in the retracted position, the transfer plate


162


is positioned upwardly adjacent the vertical portion of the label transfer grid


120


, to receive a label


10


thereover. As the label


10


exits the vertical portion of the grid


120


, an air blast, shown generally in

FIG. 10

by reference numeral


157


, is emitted from air blast nozzle


155


to urge the label


10


against the transfer plate


162


. Transfer plate


162


includes a plurality of vacuum nozzles connected to a vacuum source which cooperates to hold the label


10


thereagainst as the reciprocating member


161


moves the transfer plate


162


from the retracted position to the extended position and presses the first planar surface


12


of the cover portion


20


, and the second planar surface


14


of the foldable portion


22


, against the surface


31


of the container


30


. A conventional timing control circuit, such as a programmable logic controller, is provided with sensors and valves to signal the air blast


157


when the label


10


is exiting the transfer grid


120


. Alternatively, the air blast


157


may be a continuous stream of pressurized air being emitted from the air blast nozzle


155


.




Once the label


10


is positioned over the transfer plate


162


, a control circuit energizes the reciprocating member


161


to move the transfer plate


162


towards the container


30


, which has moved into the position shown generally in the Figures by an external conveying device (not shown). The container


30


is restrained to permit the reciprocating arm


161


to apply sufficient force to adhesively affix the label


10


to the surface


31


of the container


30


. Once the label


10


has been affixed to the surface


31


of the container


30


, the vacuum source may be deactivated to permit withdrawal of the transfer plate


162


from the label


10


without tearing the label


10


from the surface


1


of the container


30


. The reciprocating arm


161


moves the transfer plate


162


back to the retracted position to receive another label


10


. Although the apparatus


100


has been described with reference to a vacuum-sourced reciprocating transfer affixing


160


, those of ordinary skill in the art will understand that any conventional means of receiving the folded-over label


10


from the transfer grid


120


and affixing the label


10


to the container


30


may be substituted in place thereof without departing from either the spirit or the scope of the present invention. Moreover, the orientation of the label


10


as it is affixed to the container


30


may take many forms. For example, the label


10


may be affixed to a vertical sidewall


31


of the container


30


, as described in the preferred embodiment hereof. Alternatively, however, the label


10


may be affixed to any other surface of the container


30


, such as the underside surface thereof. For example, the so-called “tamp pad” described as a preferred affixing station


160


may be replaced with a device which rolls the label


10


onto the surface


31


of the container


30


. Alternatively still, the affixing station


160


may include a device which uses one or more blasts of pressurized air to affix the label


10


to the container


30


.




With reference to

FIG. 12

, a transfer grid


220


according to another embodiment of the present invention includes one or more curved guide plates


221


and a row


222


of rollers


222




a


spaced from the guide plates


221


to convey the label


10


therebetween as described above with respect to the preferred embodiment hereof. The guide plates


221


of the present embodiment replace the inner row


121


of rollers


121




a


(

FIG. 7

) of the preferred embodiment described above. The row


222


of rollers


222




a


of the present embodiment may be identical to the row


122


of rollers


122




a


(FIG.


7


), or may include one or more wheels


222




b


spaced between guide plates


221


for contacting the label


10


and for conveying the label


10


through the transfer grid


220


as described with reference to the preferred embodiment hereof. The transfer grid


220


includes an opening


223


defined between two rollers


222




a


of row


222


which permits the label


10


to project from the grid


220


towards the folding station


140


(

FIG. 7

) as described with reference to the preferred embodiment hereof. Guide plates


221


may also be one continuous guide (not shown) spanning the width of the transfer grid


220


. Two or more rollers


222




a


or wheels


222




b


may also be connected to one another in positive drive relationship by a belt


225


.




With additional reference to

FIG. 13

, label


10


may alternatively be conveyed through the transfer grid


220


is a sideways orientation, whereby foldable portion


22


projects from cover portion


20


in a direction substantially perpendicular to the forward direction of the label


10


as it is conveyed through the transfer grid


220


. Opening


223


, then, is sufficiently wide to permit the foldable portion


22


to fall thereinto as the label


10


is conveyed thereby. An air blast nozzle


250


may be positioned to emit a stream of air, generally indicated in the Figures by reference numeral


252


, in the direction of the label


10


to urge the foldable portion


22


thereof into a substantially folded-over orientation.




With reference to

FIG. 14

, an affixing station


360


according to another alternative embodiment of the present invention includes an air blast nozzle


370


which is adapted to emit a controlled, temporary blast of air, shown generally in the Figures by reference numeral


372


, to urge the foldable portion


22


of the label


10


in the substantially folded-over orientation (FIG.


1


). In the present embodiment, however, transfer grid


220


is not provided with an opening


223


(FIG.


12


), or if it is, transfer grid


220


is provided with means (not shown) for bypassing the opening


223


(FIG.


12


), such that label


10


is deposited onto the transfer plate


362


of the affixing station


360


in a substantially unfolded orientation. One or more vacuum nozzles


364


are provided to hold the label


10


thereagainst as it is deposited thereonto as it exits the transfer grid


220


. However, prior to affixing the label


10


to the container


30


(FIG.


1


), air blast


372


forces the foldable portion


22


of the label


10


away from the transfer plate


362


and urges it over the cover portion


20


of the label


10


such that adhesive strip


245


is affixed to silicone strip


25


. Arm


161


then extends to affix the folded-over label


10


to the container


30


. Air blast nozzle


370


may also be replaced with an arm or some other reciprocating mechanical device to force the label


10


into the folded-over orientation.




Transfer plate


362


may also be stationary, that is, arm


161


may be a fixed arm which does not reciprocate as described above, but rather, supports transfer plate


362


is in a fixed position above the second end of the transfer grid


220


. Container


30


(FIG.


1


), then, is conveyed by conveying means (not shown), for example, a conveyor known to one of ordinary skill in the art, alongside fixed transfer plate


362


and is spaced therefrom by a nominal distance, for example, about 1 inch. Vacuum source (not shown) connected to vacuum nozzles


364


, then, is adapted to switch between negative (i.e., vacuum) pressure and positive (i.e., blowing) pressure to permit the transfer plate


362


to hold the label


10


thereagainst until the container


30


is adjacent thereto, at which time, the negative pressure supplied to the vacuum nozzles


364


is switched to positive pressure, thereby blowing the label


10


onto the container


30


and adhesively affixing the label


10


thereto.




With reference to

FIG. 15

, an affixing station


460


according to another alternative embodiment of the present invention includes one or more affixing rollers


462


, each affixing roller


462


having one or more wheels


464


spaced therealong. Affixing rollers


462


may be driven, for example, by a belt (not shown) connected to positive drive means, such as, a motor (not shown). Affixing rollers


462


and wheels


464


are positioned such that wheels


464


contact the surface


31


of the container


30


as the container


30


is being conveyed alongside the rollers


462


in the direction shown generally as reference letter “C”. As such, affixing rollers


462


may be biased, for example, by springs (not shown), against the container


30


to apply nominal pressure thereto. Label


10


, exiting the transfer grid


220


, is directed between a first row


462




a


of wheels


464




a


and the container


30


, such that the label


10


is adhesively affixed thereto, such as, by adhesive border


26


.




Although the present invention has been described in terms of specific embodiments which are set forth in detail, it should be understood that this is by illustration only and that the present invention is not necessarily limited thereto, since alternative embodiments not described in detail herein will become apparent to those skilled in the art in view of the above description, the attached drawings and the appended claims. Accordingly, modifications are contemplated which can be made without departing from either the spirit or the scope of the present invention.



Claims
  • 1. An apparatus for in-line folding and affixing a label to a shipping container, said label having a fold line thereacross, said fold line defining a foldable portion of said label and a cover portion of said label, said apparatus comprising:a transfer grid having one or more rollers to convey said label from a first end of said transfer grid to a second end of said transfer grid, said one or more rollers defining an opening intermediate said first and second ends of said transfer grid, said transfer grid configured to convey said foldable portion of said label in a substantially unfolded orientation from said first end of said transfer grid to said opening of said transfer grid such that said foldable portion of said label projects through said opening, while said cover portion of said label is adapted to travel from said first end to said second end without passing through said opening; a folding station adjacent said opening, said folding station urging a portion of said foldable portion projecting through said opening over said cover portion to define a substantially folded-over orientation of said label, said transfer grid conveying said label in a substantially folded-over orientation from said opening to said second end of said transfer grid; and an affixing station adjacent said second end of said transfer grid, said affixing station receiving said label in said substantially folded-over orientation and affixing said label to said shipping container.
  • 2. The apparatus of claim 1, further comprising means for urging said foldable portion of said label out of said transfer grid through said opening.
  • 3. The apparatus of claim 2, in which said means for urging said foldable portion of said label out of said transfer grid through said opening includes a first air blast nozzle, said first air blast nozzle emitting a stream of pressurized air towards said foldable portion when a portion of said foldable portion is over said opening.
  • 4. The apparatus of claim 1, further comprising means for urging said foldable portion into said transfer grid through said opening after said foldable portion has been urged over said cover portion.
  • 5. The apparatus of claim 4, in which said means for urging said foldable portion into said transfer grid through said opening after said foldable portion has been urged over said cover portion includes a second air blast nozzle, said second air blast nozzle emitting a stream of pressurized air towards said foldable portion when a substantial portion of said foldable portion projects through said opening.
  • 6. The apparatus of claim 1, further comprising means for urging said label in said substantially folded-over orientation onto said affixing station.
  • 7. The apparatus of claim 6, in which said means for urging said label in said substantially folded-over orientation onto said affixing station includes a third air blast nozzle, said third air blast nozzle emitting a stream of pressurized air towards said affixing station as said label being in said substantially folded-over orientation exits said transfer grid.
  • 8. The apparatus of claim 1, in which said affixing station includes a transfer plate, said transfer plate having one or more orifices therein, at least one of said one or more orifices being connected to a vacuum source, said vacuum source being adapted to hold said label in said substantially folded-over orientation against said transfer plate.
  • 9. The apparatus of claim 8, in which said vacuum source is adapted to supply positive pressure to said orifices to blow said label against said article.
  • 10. The apparatus of claim 1, in which said affixing station includes a reciprocating arm and a transfer plate connected to said reciprocating arm, said reciprocating arm moving between a retracted position and an extended position, said transfer plate being adjacent said second end of said transfer grid when said reciprocating arm is in said retracted position, said transfer plate being adjacent said article when said reciprocating arm is in said extended position.
  • 11. The apparatus of claim 1, further comprising a printing station for printing indicia on said label, said first end of said transfer grid receiving said label from said printing station.
  • 12. The apparatus of claim 1, in which said folding station includes a folding block with a curved portion thereof, said curved portion of said folding block urging said foldable portion over said cover portion.
  • 13. The apparatus of claim 1, in which said folding station includes an air blast nozzle, said air blast nozzle urging said foldable portion of said label over said cover portion of said label.
  • 14. The apparatus of claim 1, in which said transfer grid includes a guide spaced from said one or more rollers, said label being conveyed through said transfer grid between said one or more rollers and said guide.
  • 15. The apparatus of claim 14, in which said guide comprises one or more guide rollers.
  • 16. The apparatus of claim 14, in which said guide comprises one or more fixed guide plates.
  • 17. The apparatus of claim 1, in which said one or more rollers includes a first roller and a second roller, said first and second rollers being connected in positive drive relationship to one another by a belt.
  • 18. The apparatus of claim 1, in which at least one of said one or more rollers is motorized.
  • 19. An apparatus for in-line folding and affixing a label to a shipping container, said label having a fold line thereacross, said fold line defining a foldable portion of said label and a cover portion of said label, said apparatus comprising:a transfer grid including: a first end configured to receive said label in a substantially unfolded orientation; a second end configured to dispense said label in a substantially folded-over orientation; and a plurality of rollers configured to convey said label from said first end to said second end, said plurality of rollers defining an opening intermediate said first end and said second end such that said foldable portion of said label is adapted to pass through said opening on the way from said first end to said second end, while said cover portion of said label is adapted to travel from said first end to said second end without passing through said opening; a folding station disposed between said first end and said second end of said transfer grid, said folding station configured to urge a portion of said foldable portion of said label projecting through said opening over said cover portion to define a substantially folded-over orientation of said label; and an affixing station adjacent said second end of said transfer grid, said affixing station configured to receive said label from said transfer grid in said substantially folded-over orientation, said affixing station also configured to affix said label to said shipping container.
  • 20. An apparatus for in-line folding and affixing according to claim 19, wherein said affixing station further includes a vacuum to temporarily hold said label.
  • 21. An apparatus for in-line folding and affixing according to claim 19, wherein a majority of said transfer grid is curvilinear.
  • 22. An apparatus for in-line folding and affixing according to claim 21, wherein said plurality of rollers comprises an inner row of rollers and an outer row of rollers such that said label is adapted to contact said rollers exclusively.
  • 23. An apparatus for in-line folding and affixing according to claim 19, wherein said folding station is configured to impart no more than one fold in said label.
  • 24. An apparatus for in-line folding and affixing according to claim 1, wherein said folding station is configured to impart no more than one fold in said label.
US Referenced Citations (7)
Number Name Date Kind
5031939 Webendorfer et al. Jul 1991 A
5137506 Haenel et al. Aug 1992 A
5413383 Laurash et al. May 1995 A
5626710 Moll May 1997 A
5636017 Morrow Jun 1997 A
5674334 Instance Oct 1997 A
6006808 Ewert et al. Dec 1999 A