Patent Application
20080223512
The invention disclosed herein relates generally to printing systems, and more particularly to systems and methods for printing variable length adhesive labels.
The use of automated self-service systems for processing mail items, e.g., letters, packages, parcels, and the like, continues to increase as technology makes such systems easier to use and more secure. In such systems, a user can typically weigh a mail item, select from one or more different service levels for delivery of the mail item, and print one or more adhesive labels that are applied to the mail item. Such adhesive labels can include, for example, an indicium that evidences payment for the fee associated with delivery of the item by a postal service or private carrier, destination address and/or return address labels, and labels associated with special services selected by the sender for delivery of the mail item, e.g., delivery confirmation, insurance, etc.
Because of the various types of labels that can be printed by the self-service systems, there are several different sizes of labels. For example, a label that includes only an indicium can measure 4″ by 1.5″, a label including an indicium and special services designation can measure 4″ by 2.5″, and a label including a destination address can measure 4″ by 6″. To provide such different size labels, several approaches are known, including the use of separate printers each adapted to print a different sized pre-cut label, or mechanisms to feed the appropriately sized pre-cut label into a single printer based on the label that will be printed. The former approach, however, can significantly increase the cost of the self-service system, as multiple printers are required to print all of the adhesive labels that system needs to print. The latter approach, while reducing the need for multiple printers, will also increase the cost of the system. The use of multiple feed paths for different sizes of pre-cut label stocks increases the complexity of the system as well as the risk of mechanical failure, thereby increasing the service costs over the life of the self-service system. Another approach to providing different size adhesive labels is to provide a continuous supply of adhesive label stock in the printer. A mechanical cutter is located at the output of the printer to cut the adhesive label stock at the desired length after printing. Such mechanical cutters utilize a sharpened edge that is passed through the label stock to cut the desired length label. One example of a mechanical cutter is similar to a guillotine, in which the label stock is passed through a slit in a frame that holds a cutting blade. The cutting blade is then moved in the frame transversely to the direction of movement of the label stock such that is passes through the slit, thereby cutting the label stock. After cutting has occurred, the separated label stock is transported to an opening where it is output from the self-service system. The label stock remaining in the self-service system is transported in the reverse direction back into the printer, such that printing of the next label will occur near the leading edge of the label stock. Other types of mechanical cutters include rotary style cutters, in which the edge of a circular blade is rolled over the label stock to cut the label stock. Such mechanical cutters are well known, and perform well in many applications including, for example, receipt printers and the like.
There are problems, however, with the use of such mechanical cutters, especially when being used to cut adhesive label stock. Mechanical cutters are not suitable for cutting through label stock that is provided with a self-adhesive, as the adhesive transfers to the blade during the cutting operation. The build up of adhesive on the blade reduces the effectiveness of the blade for cutting, resulting in tearing or ripping of the label stock instead of a clean cut. The ripped or torn edges can cause the label stock to jam during transport of either the separated label or the remaining label stock back into the printer. Eventually, build up of adhesive on the blade will cause the blade itself to jam, preventing any labels from being separated from the label stock. Either situation results in unacceptable performance of the self-service system.
Thus, there exists a need for systems and methods for printing variable length adhesive labels using a continuous supply of adhesive label stock and a mechanical cutter.
The present invention alleviates the problems associated with the prior art and provides systems and methods for printing various length adhesive labels using continuous adhesive label stock and a mechanical cutter that eliminates problems associated with the build up of adhesive on the cutter blade.
In accordance with embodiments of the present invention, a continuous supply of label stock is provided to a printer from, for example, either a roll or fanfold paper. The continuous label stock includes zones where adhesive is provided interspersed with zones where there is no adhesive provided. After printing has occurred, the continuous label stock is fed to a mechanical cutter that separates the printed label from the continuous label stock by cutting through a zone where there is no adhesive provided. By preferably alternating the different zones in which adhesive is and is not provided in a repeating pattern, it is possible to select any length label that is a multiple of the repeating pattern, while cutting through areas of the continuous label stock where there is no adhesive. As such, no adhesive will be transferred to the cutter blade, thereby removing any possibility of a build up of adhesive on the cutter blade. Since there will not be any build up of adhesive on the cutter blade, problems associated with the build up of adhesive on the cutter blade are eliminated.
Therefore, it should now be apparent that the invention substantially achieves all the above aspects and advantages. Additional aspects and advantages of the invention will be set forth in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the aspects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
The accompanying drawings illustrate a presently preferred embodiment of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
In describing the present invention, reference is made to the drawings, wherein there is seen in
When a supply of continuous label stock 24 is placed into the label supply 22, the transport 28 will transport the leading edge of the label stock 24 until it or a registration mark is sensed by the sensor 32. The transport 28 will then move the label stock 24 a predetermined distance, using, for example, a predetermined number of steps of a stepper motor, such that the leading edge of the label stock 24 is adjacent to the print head 30. The label stock 24 is then in position for printing. When a label is printed, the transport 28 transports the label stock 24 past the print head 30 and then into the cutter 34. The cutter 34, using the blade 36, cuts the label stock 24 to separate the portion having the printed image from the supply. The cut portion then passes through an opening 42 in the cutter 34 and can be applied to an article, e.g., a mail item or the like. The transport 28 is then reversed in direction to pull the new leading edge of the label stock 24 back from the cutter 34 and return it to a ready position for printing a subsequent label. Because the length of the labels being printed by the printing system 20 is variable, the control unit 40 coordinates the movement of the label stock 24 through the printer 26 and cutter 34, using, for example, the movement of the transport 28, in conjunction with sensor 32 and/or other sensors located along the path of transport 28 to detect the leading edge of the label stock 24 and the registration markings provided along the edge of the label stock 24. Such markings could include, for example, bars that are spaced along predetermined intervals. By coordinating movement of the label stock 24, the printable area of the label stock 24 is efficiently used and there is minimal waste of the label stock 24, i.e., there are no large areas of the label stock 24 that are not utilized for printing. Thus, the printing of an image on a portion of the label stock 24 starts very close to the leading edge of the label stock 24, and the label stock 24 is cut by the cutter 34 very close to the end of the printed image, thereby ensuring that as many labels as possible can be printed using the label stock 24.
The length of each region 64, as well as the length of each area of adhesive 54, can be based on the anticipated size of each of the labels that will be printed by the printing system 20. For example, for use in a self-service processing system for processing mail items, it is anticipated that the printing system 20 will print labels that are sized in one-half inch increments from the smallest to the largest. Such labels can include, for example, an indicium in which the label measures 4″ by 1.5″, a label including an indicium and special services designation that measures 4″ by 2.5″, and a label including a destination address that measures 4″ by 6″. In such a situation, each of the regions of adhesive 54 can be approximately ⅜″ long, and each of the regions 64 where no adhesive is provided can measure approximately ⅛″ long. Although
The registration marks 126 are provided on a first part of the roll of label stock 124 to indicate the locations of the regions 64 and regions of adhesive 54. Using the previous example of the regions of adhesive 54 being ⅜″ long and the regions 64 being ⅛″ long, the registration marks could be formed of, for example, printed marks that are approximately 5/32″ long by 5/16″ wide. The registration marks 126 preferably begin some predetermined distance, such as, for example, 1/16″, from the beginning edge 154 of each regions of adhesive 54. It should be understood that the actual dimensions are not important as long as the relationship between the registration marks 126 and beginning edge 154 of each region of adhesive 54 is known and repeatable. Thus, by sensing one of the registration marks 126 on the label stock using a sensor, e.g. sensor 32, and knowing the fixed distance between the sensor 32 and a downstream device, e.g., cutter 34, the position of the label stock 124 in the cutter 34 can be accurately determined, and therefore the control unit 40, using the transport 28, can accurately position the label stock 124 such that a region 64 is aligned with the cutter blade 36.
In many printing applications it is desirous to know when the end of the roll of label stock 124 is approaching to ensure that there will be sufficient label stock 124 to complete a label that has started to print. Thus, the label stock 124 is also preferably provided with registration marks 128 that are provided on a second part (designated “Paper Low Region” in
Thus, by utilizing the continuous label stock 24, 124 in conjunction with the printing system 20, it is possible to print variable length adhesive labels from a continuous supply of label stock without causing any adhesive build up on the cutter used to cut the label stock. Accordingly, any problems previously associated with the build up of adhesive on the cutter blade are eliminated.
While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Those skilled in the art will recognize that various additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description of the preferred embodiments but is defined by the appended claims and their equivalents.
