Patent Grant
8474503
1. Field of the Invention
The present invention relates generally to a system and method for sealing the trailing edge of folded articles, and particularly to a system and method for sealing the trailing edge of folded articles with one or more sealing tabs or stickers to facilitate mailing.
2. Background of Related Art
The United States Postal Service (“USPS”) establishes requirements for articles that are sent through the mail. These requirements ensure that articles of mail received by the USPS can be, for example, sorted in automatic machines without causing jams or other malfunctions. These requirements also ensure that mailed articles can be easily packed, carried, and delivered by postal workers.
Many articles, such as folded self mailers and booklets, are required to be sealed to prevent them from opening and, for example, becoming caught in the aforementioned sorting machines. This is often done by placing a small sticker, or tab, to the edge of the article and folding it over to seal open edges. Conventionally, a tabbing machine is used to apply tabs to folded self mailers. The tabs are then folded and sealed using either a side apply and fold or a leading edge apply and fold method (or “crash” method). The side apply uses a shaped rail to bend the tab over and adhere it to opposite side of the article. A leading edge apply generally blows down a tab on the leading edge of the article as the article passes over a slot in the table of the machine. As the article moves forward, the tab “crashes” into the trailing edge of the slot folding the tab under and adhering it to the article.
The edge fold and crash techniques (or, “conventional techniques”) work well enough for sealing tabs located on the sides and/or leading edge of the article. Recent changes to USPS regulations, however, specify that folded articles must be sealed on up to three open sides (i.e., the fourth side being the fold). See, 39 C.F.R. §111 as amended Sep. 8, 2009. This requires the article to be sealed on the trailing edge.
Using conventional edge fold and crash techniques under this new regime requires the used of multiple tabbing machines. This is because conventional tabbers are unable to seal the trailing edge of an article as it passes through the machine. For example, two tabbing machines using side apply and fold can be used to place tabs on opposite sides as needed based on product flow. Sealing all three sides of the article, however, requires up to three tabbers (e.g., the Kirk Rudy Model # KR535 or KR435) and a product-turning machine (e.g., the Kirk Rudy Model # KR730).
The article passes through the first tabber and is tabbed on one side. The article then passes through a turner that rotates the article 90 degrees (e.g., turning the tabbed edge to the leading edge or the trailing edge). A second tabber can then apply tabs to one of the (now) edges. A third tabber can then apply tabs to the opposite edge. This arrangement avoids a machine from tabbing a trailing edge. Using conventional technology, therefore, the new USPS regulations require two, three, or four machines to be purchased, operated, and maintained to achieve an acceptable product. This represents a significant expense and requires additional floor space on the production floor. A single tabbing machine such as the Kirk-Rudy Model # KR535, for example, costs approximately $20,000. In addition, two, three, or four machines must be recalibrated each time a new product is introduced with a different material, thickness, or size.
What is needed, therefore, is a device that enables tabs to be placed on the trailing edge of a product. The device should be compatible for use with existing technologies to enable an article to be tabbed on three sides without turning or flipping the article. The device should enable an article to be tabbed on at least three sides using a single machine in substantially less space than is occupied by the two, three, or four conventional machines currently required. It is to such a device that embodiments of the present invention are directed.
Embodiments of the present invention relate generally to a system and method for sealing the trailing edge of folded articles, and particularly to a system and method for sealing the trailing edge of printed articles with one or more sealing tabs or stickers.
Embodiments of the present invention can comprise a kicker wheel. The kicker wheel can comprise a thin product support rail, a profiled tab swipe, one or more kicker rails, and a counterweight to balance the kicker about an axis, preferably a central axis. The thin product support rail can be disposed on the leading edge of the kicker wheel and can support the edge of the article. The profiled tab swipe can have a bump, or protrusion, that lies outside the path of rotation for the rest of the kicker wheel. In this manner, the kicker wheel can move the article upward during part of its rotation. The kicker rails can be disposed on the sides of the kicker wheel and can support the edges of the article as it passes over the kicker wheel. In some embodiments, the profiled tab swipe and the thin product support rail can define a valley in the kicker wheel.
The kicker wheel can further comprise an axle hole enabling it to be mounted on an axle. In some embodiments, the kicker wheel can be keyed or press fit on the axle. In some embodiments, the kicker wheel can be weight balance about the axle, though this is not strictly necessary and other configurations are contemplated. The kicker wheel can be manufactured using, for example and not limitation, CNC machining, casting, or various molding techniques. The kicker wheel can comprise many materials, including but not limited to, aluminum, steel, pot metal, plastic, fiberglass, and carbon fiber.
In some embodiments, the kicker wheel can be used in conjunction with a tabbing machine and can enable the article to be sealed on all four sides, if desired. The tabbing machine can comprise one or more drive belts for moving the article across a table. In some embodiments, the table can have an opening, or window, enabling the kicker wheels access to the article as it passes over the kicker wheel. One or more kicker wheels can be mounted below the window, depending on the number of trailing edge tabs to be applied. The kicker wheel can be mounted such that the thin product support rail and the kicker rails are substantially even with the table, while the protrusion on the profiled tab swipe is slightly above the table.
The tabbing machine can further comprise a spring-loaded brake arm equipped with a brake pad. The brake pad can comprise a high friction material such as, for example and not limitation, natural rubber, synthetic rubber, or urethane. The brake arm can be adjusted such that the brake pad does not touch the article unless the profiled tab swipe on the kicker wheel is adjacent the brake pad. In this position, the brake pad can create sufficient friction to stop the article briefly, while the drive belts slip over the article.
The tabbing machine can further comprise one or more air nozzles to blow the tab down into the valley of the kicker wheel as the article passes. The tabbing machine can utilize a sensor to detect when the article enters the window. The sensor can be, for example and not limitation, a light sensor, a proximity sensor, or a laser. The sensor can be used to time, for example, the air nozzle blasts and the rotation of the kicker wheel.
The kicker wheel can be driven, directly or indirectly, by a servomotor. In some embodiments, the servomotor can drive the kicker wheel via a belt. The belt can comprise, for example and not limitation, a v-belt, a serpentine belt, or a toothed belt. The servomotor can be, for example and not limitation, an electric, air, or hydraulic motor capable of quickly accelerating the kicker wheel and turning it precisely through one rotation. In use, the kicker wheel can be rotated at a higher speed than the translational speed of the drive belts. In a preferred embodiment, the kicker wheel is rotated at approximately three times the speed of the drive belts.
Embodiments of the present invention can also comprise a method for sealing the trailing edge of an article. The article can be moved across the table by the drive belts. As the article approaches the window in the table, the sensor can detect the presence of the article. The sensor can then trigger the kicker wheel to rotate one revolution and the air nozzle(s) to provide a blast of air. The rotation of the kicker wheel can be timed such that the trailing edge of the article is aligned with the thin product support rail at the same time the air nozzles are triggered. The air nozzles can blow the tab down into the valley of the kicker wheel, while the thin product support rail prevents the article from bending.
In some embodiments, the kicker wheel can continue to rotate until the leading edge of the profiled tab swipe crashes into the tab. This can fold the tab under the article. The kicker wheel can then continue to rotate such that the protrusion on the profiled tab swipe traps the article between the kicker wheel and the brake pad. In the position, the article is temporarily stopped and the protrusion can fold the tab flat against the bottom of the article and press it firmly for proper adhesion. The kicker wheel can then return to its starting position, having made one revolution, and the article is released and can continue down the table for collating, additional processing, etc.
In some embodiments, the kicker wheel can be used in conjunction with traditional methods, such as crashing and side apply methods, to apply tabs to two, three, or four sides of an article. In other embodiments, multiple kicker wheels and multiple crash and side apply rails can be used to apply multiple tabs to each side of the article. These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.
a illustrates a front, perspective view of a kicker wheel, in accordance with some embodiments of the present invention.
b illustrates a rear, perspective view of a kicker wheel, in accordance with some embodiments of the present invention.
c illustrates a side view of a kicker wheel, in accordance with some embodiments of the present invention.
a-4f illustrate a side view of a tabbing machine in use, in accordance with some embodiments of the present invention.
Embodiments of the present invention relate generally to a device, system, and method for sealing the trailing edge of folded articles, and particularly to a device, system, and method for sealing the trailing edge of printed articles with one or more sealing tabs or stickers. The system can comprise, among other things, a kicker wheel and a brake arm equipped with a brake pad. The system can enable articles to be sealed on the trailing edge without the need to turn or flip the article. This reduces capital investment and speeds production. The system can be added to a conventional tabbing machine or can be implemented in stand-alone equipment.
To simplify and clarify explanation, the system is described below as a system for use with folded paper articles (“articles”). One skilled in the art will recognize, however, that the invention is not so limited. The system can be deployed to seal the edges for various substantially flat, flexible articles such as, for example and not limitation, envelopes, magazines, catalogs, and mailers. The system is also described for use to meet various USPS mailing regulations, but can also be used anytime folded articles need to be sealed to facilitate, for example and not limitation, machine sorting, printing, or labeling.
The materials described hereinafter as making up the various elements of the present invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, materials that are developed after the time of the development of the invention. The dimensions listed in the various drawings are for illustrative purposes only and are not intended to be limiting. Other dimensions and proportions are contemplated and intended to be included within the scope of the invention.
As described above, a problem with conventional tabbing machines is that they are unable to apply a tab to the trailing edge of article using conventional techniques. Many conventional tabbing machines are capable of applying tabs to at most three sides (i.e., the leading edge and the two sides). As a result, in the past, it has been necessary to turn or flip the article in some manner to apply additional tabs. In other words, by rotating the article 90 degrees, the once trailing edge now becomes the side edge, facilitating tabbing.
Conventionally, an article passes through a tabbing machine and has tabs applied to, for example, one side. The article then passes through a turning machine and is turned so that the former trailing edge of the article is now the side edge. The article then passes through a second tabbing machine to seal a second edge. The article then passes through a third tabbing machine to seal the third edge (opposite the second edge). These four machines (i.e., tabber #1, turning machine, tabber #2, and tabber #3) represent a significant capital investment. A tabbing machine, for example, such as the Kirk-Rudy KR535 can cost as much as approximately $20,000.
What is needed, therefore, is a machine that can seal multiple sides of an article, including the trailing edge, in a single pass and with a single machine. It is to such a machine that embodiments of the present invention are primarily directed.
As shown in
The tabber 100 can further comprise one or more air nozzles 120. The air nozzles 120 can be used to blow down a tab on the trailing edge of the article 110 as the article passes. As shown in
Referring back to
The tabber 100 can further comprise a brake arm 140 with a brake pad 145. The brake arm 140 can be disposed such that the brake pad 145 is positioned slightly above the article 110 as it crosses the table 115. In other words, the brake pad 145 does not touch the article 110 unless the article 110 is lifted slightly off the table 115. In some embodiments, the brake arm 140 can be spring-loaded such that it provides resistance to being displaced in an upward direction. The brake arm 140 can be adjustable to adjust the position of the brake pad 145 relative to the table 115. This can be useful to adapt the tabber 100 for articles 110 of different thicknesses. The brake pad 145 can comprise, for example and not limitation, rubber, plastic, or nylon. In a preferred embodiment, the brake pad 145 can comprise Nitrile Butadiene Rubber.
The tabber 100 can further comprise an article sensor 150. The sensor 150 can be used to detect when the article 110 is entering the window 155 in the table 115. The sensor 150 can be for example and not limitation, a proximity switch, a light sensor, or a laser. In a preferred embodiment, the sensor 150 is a Self-contained Photoelectric Sensor. The sensor 150 is used, in conjunction with the shaft encoder 109, to properly time the operation of the servomotor 135 and thus, the kicker wheel 125.
As shown in
In some embodiments, the counterweight 304 can be sized and shaped such that the mass of the kicker wheel 125 is balance about a central axis of rotation R. This configuration tends to reduce component wear caused by forces and vibrations due to the imbalance. Due to its relatively small size, however, it is not strictly necessary that the kicker wheel 125 be balanced about the axis of rotation R. The kicker wheel 125 can be manufactured using a variety of methods, including but not limited to, molded, cast, or machined from billet. The kicker wheel 125 can comprise, for example and not limitation, metal, plastic, or other suitably rigid material. In a preferred embodiment, the kicker wheel 125 can be CNC machined from Nylatron.
In some embodiments, the kicker wheel 125 can comprise a thin product support rail 305. The thin product support rail 305 can span substantially the entire width of the kicker wheel 125. In use, the kicker wheel 125 can be rotated such that the thin product support rail 305 is positioned under the article 110 to support the article 110 across its width. The thin product support rail 305 supports the article 110 to prevent it from bending downward when the air nozzle(s) 120 are activated.
The kicker wheel 125 can further comprise a profiled tab swipe 310. The profiled tab swipe 310 can span substantially the entire width of the kicker wheel 125 and can be disposed opposite the thin product support rail 305. The profiled tab swipe 310 can further comprise a hump, or projection 335. The projection 335 and the matching profile 340 on the kicker rails 315 can be slightly above the profile of the kicker wheel 125. In other words, when the kicker wheel 125 is rotated, the path of rotation for the projection 335 is slightly outside that of the remainder of the kicker wheel 125. This enables the kicker wheel 125 to lift the article 110 up slightly pressing it against the brake pad 145 promoting proper adhesion of the tab 205.
In some embodiments, the thin product support rail 305 and the profiled tab swipe 310 can define extensions, or arms 360, 365, projecting out from the main body 370 of the kicker wheel 125 and defining a valley 380 thereon. In other embodiments, the thin product support rail 305 and the profiled tab swipe 310 may be separate pieces bolted, or otherwise affixed, to the main body 370 of the kicker. In some embodiments, the arms 360, 365 can further define one or more holes 375. The holes 375 can be used, among other things, to lighten and/or balance the kicker wheel 125. Lightening the kicker wheel 125 reduces its rotational inertia enabling it to be rotated more easily. This, in turn, can reduce wear on, among other things, the axle 130 and servomotor 135 and can enable the kicker wheel 125 to be accelerated more quickly.
The kicker wheel 125 can further comprise one or more kicker rails 315. The kicker rails 315 can be disposed on either side of the kicker wheel 125 and are configured to support the edges of the article 110 as it passes over the window 155. The kicker rails 315 can be integral to the kicker wheel 125 or can be attached thereto. The kicker rails 315 can be, for example, and not limitation, bolted, screwed, glued, or welded to the kicker wheel 125. In a preferred embodiment, the kicker rails 315 can be affixed to the kicker wheel 125 using one or more bolts 330.
As shown in
The kicker wheel 125 can further comprise a set screw 345. The set screw 345 can be threadably engaged with the kicker wheel 125 such that it is substantially perpendicular to the axle hole 320. In a preferred embodiment, the set screw 345 can be disposed on the counterweight 304, though this location is not critical and other configurations are contemplated (e.g., in the valley 380). In a first position, the shaft of the set screw 345 can be unscrewed such that it is retracted from the axle hole 320. The can enable the kicker wheel 125 can be repositioned on, or removed from, the axle 130. In a second position, the set screw 345 can be screwed in such that the shaft of the set screw 345 protrudes into the axle hole 320. In this position, the kicker wheel 125 can be frictionally engaged with the axle 130, substantially preventing movement.
In some embodiments, the kicker wheel 125 can further comprise a set screw stop 350. The set screw stop 350 can be threadably engaged with the counterweight 304 and disposed such that it interferes with the operation of the set screw 345. In other words, with the set screw stop 350 in place, the set screw 345 can only be partially loosened. So, for example, this may enable the kicker wheel 125 to be repositioned on the axle 130, but not removed from it. The set screw stop 350 can also prevent the set screw from vibrating out of the kicker wheel 125 if it is inadvertently left loose. If the kicker wheel 125 needs to be removed from the axle 130, for example, the set screw stop 350 can be removed first and then the set screw 345.
a-4f depict the process of sealing the trailing edge of an article 110 as it passes the through the tabber 100, in accordance with some embodiments of the present invention.
As the article 110 passes the sensor 150, the kicker servomotor 135 can be activated to start rotating the kicker wheel 125. In some embodiments, the kicker servomotor 135 is activated when the leading edge of the article 110 breaks the sensor 150 beam. The kicker wheel 125 is preferably accelerated up to a higher speed than the translational speed of the belts 105. The kicker can be rotated, for example, at a speed of between 1.5 and ten times the speed of the belts 105. In a preferred embodiment, the kicker wheel is rotated at approximately three times the speed of the belts 105. In this manner, the kicker wheel 125 can act upon the article 110, while only stopping the article 110 momentarily.
In
In
In
As shown in
In some embodiments, a single, wide kicker wheel 125 can be used to fold multiple trailing edge tabs 205. In other embodiments, multiple kicker wheels 125 can be used to fold multiple trailing edge tabs 205 (e.g., one kicker wheel 125 per tab). In still other embodiments, the kicker wheel 125 can comprise multiple sets of kicker rails 315 disposed along the width of the kicker wheel 125 to fold multiple tabs with one kicker wheel 125 (e.g., at least one kicker rail 315 disposed on either side of each tab 205).
In some embodiments, the kicker wheel 125 can be used in conjunction with conventional techniques to apply tabs 205 to all four sides of an article 110 if desired. In other words, tabs 205 can be placed on all four sides of the article 110. As the article 110 travels down the table 115, the tabs 205 on the leading edge can be crash folded, the tabs on the sides can be side apply folded, and the tabs in the trailing edge can be folded and sealed using one or more kicker wheels 125.
The spring-loaded brake arm 140 can be adjusted such that, in the rest position, the space between the brake pad 145 and the table is slightly greater than the thickness of the article 110. In other words, the brake pad 145 does not contact or stop the article 110 unless the kicker wheel 125 is activated. In this manner, applying trailing edge tabs can be optional. In other words, the kicker wheel 125 servo can be deactivated and the tabber 100 can perform as a conventional leading edge/side edge tabber with no interference from the kicker wheel 125 or the brake pad 145.
In a preferred embodiment, the kicker wheel 125 can be CNC machined from Nylatron. Embodiments of the present invention, however, are not so limited. For example, the kicker wheel could be machined from steel or could me molded from a suitably strong plastic. The kicker wheel could also be cast from a variety of metals, including but not limited to, steel, brass, bronze, and pot metal. The kicker wheel 125 could also be constructed from a variety of composite materials, such as for example, fiberglass and carbon fiber.
While several possible embodiments are disclosed above, embodiments of the present invention are not so limited. For instance, while several possible configurations of materials for the kicker wheel have been disclosed, other suitable materials and combinations of materials could be selected without departing from the spirit of embodiments of the invention. In addition, the location and configuration used for various features of embodiments of the present invention can be varied according to a particular tabbing machine or article size that requires a slight variation due to, for example, the size or construction of the tabbing machine, space requirements, or article size and material. Such changes are intended to be embraced within the scope of the invention.
The specific configurations, choice of materials, and the size and shape of various elements can be varied according to particular design specifications or constraints requiring a device, system, or method constructed according to the principles of the invention. Such changes are intended to be embraced within the scope of the invention. The presently disclosed embodiments, therefore, are considered in all respects to be illustrative and not restrictive. The scope of the invention is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced therein.
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|---|---|---|---|
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| Number | Date | Country | |
|---|---|---|---|
| 20120060998 A1 | Mar 2012 | US |
