CA2227374A1 - Linerless label applying system - Google Patents

Abstract

A system for applying linerless labels to mailing envelopes including label feeder (20) for feeding a continuous length web of linerless label material (16) through a loop path under base plate (28) to a label applying station juxtaposed to a path traversed by the mailing envelopes conveyed sequentially on edge by a belt conveyor system (12). The material passes to a cutter station (22) operative to sever the material transversely and create labels of a desired height. A paddle member (24) is operative to engage and hold each label as it is severed from the material and to adhere the adhesive side of the label against the mailing envelope passing through the label applying station. The various operating functions of the linerless label applying system may be coordinated by convention control logic.

Description

W O 97/05021 PCT~US96/0~6356 1 LINERLESS I~BEL APPLYING SYSTEM

2 Backaround of the Invention 3 The present invention relates generally to document 4 handling systems, and more particularly to a novel system for forming labels from a continuous supply of linerless label 6 material and applying the labels in sequential fashion to 7 documents, such as mail pieces, as the documents are conveyed on 8 edge along a predetermined path.
9 The volume of mail handled daily by large businesses, institutions and government entities, such as the postal service, 11 credit card companies, utilities, mail order houses and other 12 advertisers has steadily increased due in part to both an 13 increase in population and a greater volume of business 14 correspondence. Typically, the envelopes containing the ma~erial to be mailed are addressed and then sorted into common 16 destination groups for mailing. Similarly, mail received by such 17 entities is commonly sorted into groups based on identi~iable 18 subject matter on the received material. A third category of 19 such envelopes is the returned mail category, the creation of which is primarily due to the addressee having moved from a 21 particular address, or a smeared or non-readable bar code, 22 resulting in the envelope being undeliverable. The present 23 invention is directed to a system ~or solving the latte~ type 24 problem, namely, the correction of the address and/or destination code on an envelope by application of a secondary label to the 26 envelope, with a correct forwarding address or destination code 27 either pre-printed on the label or applied to the label after it 28 is affixed to the envelope to cover an invalid or non-readable 29 address or bar code. Pre~erably, the label material inhibits the passage of light, whereby a bar code or address material beneath W O 97/05021 PCT~US9G~O~C~

1 the label cannot be read by a bar code reader or an optical 2 character reader.
3 Several different types of machines have been developed 4 to assist in the handling of such mail, other than manual review and correction b~ an individual mail carrier. These prior art 6 devices typically comprise an envelope feeder, a read station, 7 a label selection station where a supply of labels permits 8 selection of an appropriate label and its application to an 9 envëlope, and a sorting and storage device. See, for example, U.S. Patent No. 5,076,879. While some of the prior art machines ll and systems have proven satisfactory, many are relatively large 12 unwieldy machines that require not only a large amount o~ space 13 but also require frequent replenishment of a vast array of pre-14 printed labels and maintenance of the applicating equipment.
Also, labels furnished in a roll or ~an where pre-cut labels are 16 adhesively adhered to a substrate are expensive compared to the 17 cost of linerless or substrate-free label material.

18 Summarv of the Invention 19 The present invention provides a novel compact system for applying linerless labels to documents such as mailing 21 envelopes and the like and which may be used as a stand-alone 22 label applicator or with conventional mail sorting machines to 23 greatly increase the label applying rate in a highly efficient 24 manner.
The system of the present invention includes a label 26 feeder for providing a continuous length web of linerless label 27 material having an adhesive surface and an opposite non-adhesive 28 surface. The linerless label material is fed along a 29 longitudinal path from a supply roll or fan folded source to a label applying station positioned in juxtaposed relation to the 31 path traversed by documents in the form of mailing envelopes and 32 the like as they are conveyed on edge in sequential fashion along 33 a path transverse to the label material feeder path. The 34 linerless label material web is advanced through a cutter station which is operative to sever the label material transversely and 36 create a label of desired height in timed relation to passing of , CA 02227374 1998-01-20 ,..
W O 97105021 PCT~US96/06356 1 a document through the label applying station. The label 2 applying station includes a paddle member supported at one end 3 for pivotal movement in a generally horizontal plane normal to 4 the upstanding documents as they are conveyed through the label applying station~ The paddle member is operative to engage and 6 hold each successive label by vacuum force as the label is being 7 severed from the continuous length web of label material.
8 Simultaneously, the paddle is pivoted so that its outer end 9 presses a leading edge of the adhesive side of the label against the document passing through the label applying station. As the 11 document and label move downstream, the paddle vacuum is 12 automatica'ly terminated, ~he label is released from the paddle, 13 and the paddle member adheres the label against the document in 14 a progressive fashion, after which the paddle member returns to its original position and the document is passed through a nip 16 to ~irmly press the label onto the document.
17 The cutter station includes a cutter blade which 18 progressively severs the label material transversely to create 19 a label, and a stripper bar which moves with the cutter blade and returns the newly created leading edge of the label material to 21 a position enabling advance of the label material web preparatory 22 to severing the next successive label. The label feeder includes 23 sensors operative to sense the path through which the label 24 material passes so as to maintain a feeder loop as the label material advances towards the cutter blade, and also to sense 26 exhaustion of the supply of label material. Additional sensors 27 responsive to ~he position of each document as they pass into the 28 label application station initiate a timed control sequence to 29 operate the various label advancing and applying elements. The various operating functions of the linerless label applying 31 system may be coordinated by conventional control logic.
32 Accordingly, one of the primary objects of the present 33 invention is to provide a novel system for applying linerless 34 labels to mailing documents or the like as they are conveyed on edge in sequen~ial fashion through a label applying station, and 36 wherein the labels are formed from a continuous length web of 37 rolled linerless label material. The present system may also be WO 97/05021 PCT~US9G~ 56 1 adapted to form labels from a continuous fan folded source of 2 label material, or any other suitable continuous label material 3 supply. n 4 A more particular object of the present invention is 5 to provide a novel system for applying linerless labels to 6 mailing documents or the like as the documents are conveyed on 7 edge through a label applying station, the linerless labels being 8 formed from a continuous length web of linerless label material 9 hav~ng a non-adhesive surface and an opposite adhesive surface and fed longitudinally from a roll or fan fold source to a label 11 cutter and applying station operative to sever labels from the 12 label material and apply the labels successively to documents 13 being conveyed on edge through the label applying station.
14 A feature of the linerless label applying system in accordance with the present invention lies in the provision of 16 a cutter blade which cooperates with the linerless label web 17 material to progressively sever the label material transversely 18 to create successive labels simultaneously with pivotal movement 19 of a paddle member operative to hold and progressively adhere the adhesive surface of each label against a document being conveyed 21 on edge past the label conveying station.
22 Another feature of the linerless label applying system 23 in accordance with the present invention lies in providing a 24 paddle member operative to initially hold each label formed by the cutter blade by vacuum and adhere the adhesive surface of the 26 label against a document in a progressive fashion as the label 27 advances with the document past the label applying station.
28 Another feature of the linerless label applying system 29 in accordance with the present invention lies in the provision of a cutter blade assembly having a cutter blade movable in a 31 plane normal to the linerless label material web and having a 32 stripper bar fixed to the cutter blade in generally parallel 33 spaced relation so that the liner material web passes between the 34 cutter blade and stripper bar, the cutter blade being movable to sever the label material web generally transversely thereof, and 36 the stripper bar being operative to return the newly formed 37 leading edge of the label material to a position enabling W O 97/0~021 PCTAUS~C'0-~56 1 advancement o~ the label material web preparatory to cutting the 2 nex~ successive label therefrom.
3 Another feature of the linerless label applying system 4 in accordance with the present invention lies in the provision of a label material web guide and advance manifold assembly 6 having a planar generally vertically disposed guide surface to 7 receive and guide the web to the cutter blade assembly, and a 8 drive roller operative to advance the label material web in 9 predetermined increments so as to vary the height of the labels lo as desired for imprinting a full address, a bar code or other 11 indicia on the labels.
12 Still anGther ~eature of the present invention lies in 13 the provision of a linerless label material feeder arrangement 14 wherein a continuous length label material web is passed through a loop path and includes sensors operative to maintain a free 16 loop of web material for rapid advance of the web through the 17 cutter.
18 Further objects, advantages and features of the present 19 invention will become apparent from the following detailed description of the invention taken in conjunction with the 21 accompanying drawings wherein like reference numerals designate 22 like elements throughout the several views.

23 Brief Description of the Drawinqs 24 FIG. 1 is a fragmentary perspective view of a linerless label applying system constructed in accordance with a preferred 26 embodiment of the present invention;
27 FIG. 2 is a plan view of the linerless label applying 28 system illustrated in FIG 1.;
29 FIG. 3 is a fragmentary vertical sectional view taken substantially along line 3-3 of FIG. 2 with portions broken away 31 for purposes of clarity;
32 FIG. 4 is a fragmentary elevational view taken 33 substantially along line 4-4 of FIG. 1 and looking in the 34 direction of the arrowsi 1 FIG. 5 is a fragmentary perspective view taken from the 2 opposite side of the apparatus shown in FIG. 3;
3 FIG. 6 is a fragmentary perspective view illustrating 4 the label material web guide and advancing assembly for advancing 5 the web to the cutter station;
6 FIG. 7 is a perspective view of the cutter blade and 7 stripper bar assembly removed from the base plate of the label 8 applying system illustrated in FIG. 1;
9 FIG. 8 is a fragmentary plan view illustrating the 10 label applying paddle member and associated actuator and vacuum 11 supply;

12 FIG. 9 is a fragmentary elevational view taken 13 substantially along line 9-9 of FIG. 2;

14 FIG. 10 is a logic diagram illustrating the sequence 15 of operation of the various operating functions of the label 16 applying system in accordance with the invention;

17 FIG. 11 is a schematic diagram o~ one aspect of the 18 label material feed operation sequence; and 19 FIG. 12 is a schematic diagram of the paddle vacuum 20 sensor apparatus.

21 Detailed DescriPtion of the Preferred Embodiment 22 Referring now to the drawings, and in particular to 23 FIGS. 1-3, a linerless label applying system constructed in 24 accordance with the present invention is indicated generally at 10. As will be described more fully below, the linerless label 26 application system 10 is operative to apply linerless labels to 27 documents, such as mailing envelopes and the like, as the 28 documents are conveyed on edge in a generally vertical 29 orientation along.a predetermined horizontally extending path established by a conveyor belt system, indicated generally at 12 31 in FIG. 2. The label applying system 10 finds particular 32 application in conjunction with mail handling systems requiring 33 a ~acility for applying a corrective address label or a bar code 34 or the like to an envelope having an incorrect or defective address or bar code thereon which requires correction. The 36 linerless label system 10 may be used as a stand-alone label -- CA 02227374 1998-01-20 p ~ ~ ~
S~3 JUL ~

1 label applying system operative to create linerless labels of 2 varying size and apply them to mailing envelopes and like 3 documents manually fed into the system, or may be utilized with 4 conventional mail sorting machines to create and apply labels to mailing envelopes conveyed on edge from an upstream processing 6 station in which the improper or de~ective address or bar code 7 is detected and from which the document is passed through the 8 conveyor belt system 12 for applying a linerless label thereto.
g ~riefly, the linerless label applying system 10 includes a source or supply of continuous length linerless label 11 material, such as in the form o~ a roll 14 o~ linerless label web 12 material 16. The linerless label material 16 has an adhesive 13 surface on one side, such as the inwardly facing surface of the 14 wound web, and a non-adhesive outwardly facing surface on the opposite side adapted to have indicia printed thereon, such as 16 an address or a bar code. The address or bar code may be printed 17 on the non-adhesive side of a linerless label by a conventional 18 printer (not shown) either prior to applying a label to a mailing 19 document or after applying the label thereto. The label applying system 10 includes a label feeder means, indicated generally at 21 20, which is cooperative with the label material web 16 for 22 effecting unwinding from the roll 14 and feeding the label 23 material web longitudinally along a looped path to a cutter 24 station, indicated generally at 22. The cutter station 22 is operative to sever the label material web generally transversely 26 of its longitudinal axis to create labels of selectively variable 27 height. A label applying means in the form of a paddle member 28 24 is supported adjacent the cutter station 22 and is operative 29 to engage the non-adhesive surface of a cut label and hold the label by vacuum while moving it into engagement with a mailing 31 document being conveyed along the conveyor belt system 12 in 32 juxtaposed relation to the paddle member. As will be described, 33 the paddle member 24 is operative to initially lightly press the 34 leading edge of a label against a document juxtaposed to the label applying paddle member and progressively adhere the 36 remainder of the label against the document as the document and 37 the label advance downstream from the paddle member.

r ~

- CA 02227374 1998-01-20 p ~ ~ q 6 l 0 6 3 5 6 ~EANS~-~ JlIL 1997 1 Turning now to a more detailed description of the 2 linerless label applying system 10, the various components are 3 supported on or suspended from a generally planar base or top 4 plate 28. The base plate 28 is preferably supported at a convenient operator height. When used with other mail document 6 handling apparatus, the base plate 28 is positioned so that the 7 conveyor belt system 12 is aligned with an upstream conveyor belt 8 system operative to convey mailing documents and the like in g sequential order to the linerless label applying system 10. The base plate 28 supports the roll 14 of linerless label web 11 material 16 through an upstanding support arm 30 which is :Eixed 12 at its lower end to the plate 28. The support arm 30 supports 13 a pair of parallel spaced horizontal support rollers 32a and 32b 14 which extend through an axial opening 14a of the roll 14 so as to support the roll and enable free rotation of ~he roll during 16 unwinding of the linerless label web material 16. Enlarged 17 diameter discs on the outer ends of the rollers 32a,b prevent 18 inadvertent release of the roll 14 from the support rollers.
19 As illustrated in FIG. 1, the label web material 16 is guided ~rom the roll 14 through a ~eed nip defined between a 21 driven feed roller 34 and a spring loaded pinch roller 36. The 22 feed roller 34 is connected through a suitable gear drive to an 23 electric motor 38 which, when energized, is operative to advance 24 the label web material 16 from the roll 14. The label web material 16 is fed from the feed roller 34 downwardly through a 26 suitable opening in the base plate 28 to form a loop 16a (FIG.
27 3) as the label web material is passed to a web material guide 28 and advance assembly, indicated generally at 40 The web length 29 between the roll 14 and web guide and advance assembly 40 is controlled by a set of photosensors, indicated schematically at 31 41a and 41b in FIG. 3, which sense the presence of the loop 16a 32 and are connected in circuit with the feed motor 38 to advance 33 the web and maintain a loop 16a so as to ~loat approximately six 34 to eight inches beneath the top plate 28. The web loop 16a forms a buffer loop so that the web hangs free at the point o~ entry 36 into the web guide and advance assembly 40. As illustrated in 37 FIG. 5, a fan 42 and air deflector plate 44 may be mounted ~P~~PI~ S~

CA 02227374 1998-01-20 p ~ ~ ~ 9 ~ ( 0 6 3 5 1 beneath the base plate 28 to blow air onto the upwardly facing 2 sur~ace o~ the label material web loop 16a to assist in 3 maintaining the loop path.
4 In addition to the loop photosensors 41a and 41b, a sensing system is provided to detect depletion of label web 6 material 16 from roll 14, and to provide a signal to a main 7 conveyor drive control to halt the introduction of new documents 8 into the label applying station after a short delay, for purposes 9 to be explained. Referring to FIG. 3, a pair o~ beam or photosensor elements indicated schematically at 46a and 46b, or ll other suitable sensors, are supported on opposite sides of the 12 web material 16 where it passes through the base plate 28 so that 13 the web material normally breaks the beam extending between the 14 sensor elements as it advances longitudinally to the cutter station 22. As the roll 14 becomes depleted, the end of web 16 16 passes beyond sensor elements 46a,b, creating a signal which is 17 relayed to the conveyor system control to halt the further 18 advance of mailing envelopes or other documents in the conveyor 19 system 12. Because there is still a sufficient amount of label material in loop 16a to supply labels to documents already in the 21 conveying system, the document conveyor system 12 is permitted 22 to continue to advance a small number of additional documents, 23 such as approximately 5-10, after receiving a web depletion 24 signal ~rom sensors 46a,b be~ore the conveyor system actually stops.
26 Referring to FIGS. 5 and 6, taken in conjunction with 27 FIG. 3, the label web material guide and advance assembly 40 28 includes a generally vertically disposed guide plate or manifold 29 48 having a generally vertical planar sur~ace 48a bounded by a pair of laterally spaced parallel edge guides 50a and 50b. The 31 edge guides 5Oa,b are spaced apart a distance generally equal to 32 the lateral width of the label web material 16 and define an open 33 channel to receive the lateral marginal edges of the web material 34 so as to guide it along the planar surface 48a as the web material is advanced to the cutter station 22. A pair of 36 laterally spaced side plates 52 and 54 are secured to the 37 laterally opposite edges of the guide plate 48 so as to lie in -- CA 02227374 1998-01-20 p ~ I ~ 9 ~ 1 Q 6 ~ ~ ~
~PE~WS Z8 JU~ 1997 - 1 o -1 paral~el planes and extend rearwardly from the guide plate. The 2 side plate 52 has its lower edge mounted on and slidable along 3 a guide rod 56 which is suitably supported below the base plate 4 28 in parallel relation thereto. The side plate 54 has a cam follower or roller 58 mounted on its outer surface which is 6 received within a rectillnear groove or channel formed in a guide 7 plate 60 secured in normal relation to the underside of the base 8 plate 28 so that the guide channel is parallel to the g longitudinal axis of the guide rod 56. In this manner, the side plates 52 and 54 cooperate with the guide plate or manifold 48 11 to form a horizontally slidable carriage which may be moved along 12 the guide rod 56 to a rearward position facilitating initial or -13 replacement threading or guiding of the label web material 14 between the edge guides 50a and 50b and along the planar surf~ce 48a of the guide plate 48.
16 To facilitate selective feeding or advancing of the 17 label web material 16 upwardly along the guide plate surface 48a, 18 a web advance or feed roll 64 is supported on a transverse drive 19 shaft 66 so that feed roll 64 is positioned within a recess ~ormed generally centrally in guide plate 48. The opposite ends 21 of drive shaft 66 are journaled in the side plates 52 and 54 so 22 that the outer peripheral surface of feed roll 64 extends 23 slightly forwardly from the planar guide plate surface 48a and ~4 engages the non-adhesive surface of the label web material as it passes upwardly along the guide plate. As illustrated in FIG.
26 5, the drive shaft 66 extends through the side plate 52 and has 27 a timing belt pulley 68 fixed thereon which is connected through 28 a timing belt 70 to a drive pulley 72 mounted on the output shaft 29 of a stepping motor 74 supported on the inner surface of side plate 52. A ribbed pinch roller 76 is supported below the base 31 plate 28 to cooperate with the feed roll 64 when in its forward 32 position to advance the label web material in response to 33 energizing the stepping motor 74. As will be described, the 34 stepping motor 74 enables selective incremental advance of the label web material 16 to create labels of varying height, such 36 as 5/8 inch height labels for bar coding and 11~ inch height 37 labels for address labels.

- CA 02227374 1998-01-20 p ~ ~ ~ 9 ~ 1 ~ 6 ~ 5 6 ~.P~Js~JuL~9g7~

1 The guide plate or mani~old sur~ace 48a includes a 2 plurality o~ vacuum ori~ices 48b which are connected to a source 3 of vacuum through a control valve (not shown). A relatively low 4 vacuum is applied to the ori~ices 48b so as to lightly retain the label web material in sliding contact with the guide plate 6 surface 48a during cutting by the cutter blade 82 to create 7 labels and subsequent ~eeding o~ additional web material 16 to 8 cutter station 22.
9 The label web material 16 is advanced by the web guide and advance assembly 40 to a predetermined vertical position 11 relative to the cutter station 22 which is operative to sever the 12 label web material transversely of its longitudinal axis and 13 create labels o~ any desired height. The cutter statlon 22 14 comprises a cutter blade assembly, inàicated generally at 80, which includes a cutter blade 82 having a ~orward cutting edge 16 82a. The cutter blade 82 is secured to and carried by a 17 precision ball slide 84 mounted on a horizontal plate 86a of a 18 .generally U-shaped support frame 86 secured to the underslde of l9 the base plate 28. The cutting blade 82 is adapted for horizontal rectilinear movement in a path normal to the guide 21 plate surface 48a and lying in a vertical plane containing the 22 longitudinal axis of the label web material 16.
23 Reciprocating movement of the cutter blade 82 is 24 effected through a toggle link actuat-ng mechanism indicated generally at 90. Referring to FIGS. 2 and 3, the toggle link 26 actuating mechanism 90 is mounted below the base plate 28 and 27 includes a pneumatic actuating cylinder 92 having a piston 92a 28 which, in response to pneumatic pressure being applied to the 29 actuating cylinder 92, acts through a coil compression spring 94 to move a slide block 96 in the axial direction of the piston 31 92a. The slide block 96 is biased in a direction toward the 32 operating cylinder 92 by a coil compression spring 98 which is 33 partially received within a blind bore in a support block 100 34 fixed to the underside of the base plate 28. The end of the coil compression spring 98 disposed wi-hin the support block 100 seats 36 against a ball 102 ~hich enables ~ivota_ movement of the spring.
37 The opposite end of compression spring 38 is received within a A~EI~D S~

CA 02227374 1998-01-20 P ~ 1~ S 9 L 1 06 3 5 6 ~PEA~US 28 J~J~ 19~7 1 shallow recess or blind bore in the opposing end of the slide 2 block 96 and biases the slide block toward the adjacent end of 3 the operating cylinder 92 and against the compression spring 94.
4 The opposite end of the operating cylinder 92 is pivotally interconnected through a ball 106 to a support block 104 fixed 6 to the underside of base plate 28.
7 A pair of substantially identical actuating links 110 8 and 112 are pivotally connected to the slide block 96 at llOa and 9 112a, respectively. The opposite end of actuating link ]10 is lo pivotally connected at llOb to a block 114 fixed to the underside 11 of base plate 28. The opposite end of pivot link 112 is 12 pivotally connected at 112b to the ball slide 84. With the slide 13 block 96 positioned as illustrated in FIG. 2, pressurizing the 14 actuating cylinde~ 92 will extend the piston 92a and effect movement o~ the slide block in a right-hand direction against the 16 ~orce o~ spring 98. This causes the actuating links 110 and 112 17 to undergo a toggle-like movement with link 110 pivoting about 18 its fixed pivot connection llOb and link 112 moving the ball 19 slide 84 and thereby cutter blade 82 in the longitudinal direction of the ball slide. The ball connections 102 and 106 21 accommodate slight lateral movement of the slide block 96 as the 22 link 110 pivots about its pivot connection llOb. Release of 23 pressure from the actuating cylinder 92 allows the coil spring 24 98 to return the slide block 98 to its home or initial position, which also returns the cutter blade to its orlginal position.
26 The geometry of the links 110 and 112 is selected to rapidly move 27 the cutter blade through a cutting stroke of approximately 1/8 28 inch.
29 As illustrated in FIGS. 2, 3 and 7, the cutter blade 82 is supported so that its cutting edge 82a is spaced a 31 predetermined distance above the upper surface of the base plate 32 28 as determined by the spacing desired between the lower edge 33 o~ a mailing envelope being conveyed by the conveyor belts 126 34 and 128 and the lower edge of a label applied to the envelope.
The cutter blade is also configured so that when it is in its 36 rearward non-cutting position, as illustrated in FIG. 2, the 37 cutting edge 32a is spaced slightly rearwardly from the plane of ' CA 02227374 1998-01-20 JIIS 9 ~ 3 5 6 ~EAIUS ~ JIJL 1997, i the planar surface 48a on the guide plate 48 and from the label 2 web material 16 being fed upwardly along the guide surface by 3 feed roll 64. During a cutting stroke, the cutting edge 82a 4 cooperates with a stationary shearing blade 120 to sever the material web 16 transverse to lts longitudinal axis. The 6 shearing blade 120 is generally rectangular and is supported on 7 the upper surface of the base plate 28 through a spacer 121 and 8 bolts 120a so that a forward lower edge of the shearing blade 9 cooperates with the cutting edge 82a to effect shearing of the label web material. The cutting edge 82a is formed on the cutter 11 blade 82 to be sightly inclined to the plane of the material web, 12 as considered in FIG. 2, so that the cutting edge effects a 13 progressive cutting of the web material beginning with the right-14 hand edge as viewed in FIG. 2 and terminating with the left-hand edge as the cutter blade is fully extended in a cutting stroke.
16 It will be appreciated that as the cutter blade 82 is 17 moved through a web severing stroke responsive to actuation of 18 the actuating cylinder 92, the newly formed leading edge of the 19 web material 16 will be moved slightly underneath the stationary shearing blade 120. To insure that the newly formed leading edge 21 of the label web material 16 returns to a position enabling 22 advance of the web material to create the next successive label 23 without interference with the cutting blade, a stripper bar 122 24 is interconnected to the cutter blade 82 so as to lie in generally parallel spaced relation ~orwardly from the cutting 26 edge 82a to enable the label web material to pass between the 27 cutting edge 82a and the stripper bar. To this end, the stripper 28 bar 122 has a rearward edge surface 122a which is spaced closely 29 adjacent the cutting edge 82a and extends slightly into the path of the label web material 16 when the cutter blade is in its 31 retracted position. When the cutter blade 82 is actuated to 32 sever the label web material, the str pper bar moves with the 33 cutter blade and slides under the stationary shearing blade 120.
34 When the cutter blade 82 has completed a label severing stroke, the stripper bar 122 ~ollows its return path and pushes the newly 36 formed leading edge of the web materia back into the original 37 label path, thereby enabling advancemen_ of the web material for . . . .

PCTll~S 9 6 / 06 ~ 5 6 JS 2~ JUL 1997 1 creating the next successive label. The stripper bar 122 in 2 p~eferably generally U-shaped and secured to the cutter blade 8 3 by pins 124 (FIG. 2). The stripper blade may be made of a 4 suitable plastic material, such as DELRIN, and has an elongated pocket 122b formed in its upper surface to receive a wicking 6 material which holds a lubricant, such as a lubricating oil. As 7 the stripper bar 122 moves forward and back with the cutting 8 blade 82, the lubricant is deposited on and lubricates the g surrounding components so as to prevent the accumulation of adhesive from the web material 16 as it is severed into labels.
11 As illustrated in FIG. 2, the conveyor belt system 12 12 includes a pair of endless conveyor belt 126 and 128 each of 13 which is reeved about a plurality of idler rollers, such as 14 indicated at 130. The belts 126 and 128 define a run or reach of juxtaposed conveyor belts 126a and 128a and an enterlng nip 16 132 to receive mailing envelopes and the like from an upstream 17 conveyor or other conveying means (not shown) and convey them in 18 a downstream direction, or from left-to-right as considered in 19 FIG. 2. It will be understood that a drive roller is provided for each of the conveyor belts 126 and 128 so as to drive them 21 at the same longitudinal speed. In the illustrated embodiment, 22 a backup conveyor belt 134 is supported on a pair o~ idler 23 rollers 136 so as to establish a reach of the conveyor belt 134 24 rearwardly of and engaging the conveyor belt reach 126a as it traverses a path past the cutter assembly 22. The idler rollers 26 130 and 136 are supported on the upper surface of the base plate 27 28 so that the corresponding conveyor belts 126, 128 and 134 are 28 spaced above the base plate sufficiently to expose the lower 29 surface areas of mailing documents being conveyed by the belt reaches 126a,b for applying labels to the exposed areas.
31 As briefly aforedescribed, the paddle member 24 is 32 operative in conjunction with severing of each successive label 33 from the label web material i6 by the cutter assembly 22 so that 34 the paddle member holds each label as it is being severed and moves the label to a position adhering it to a document being 36 conveyed by the conveyor belt reaches 126a and 128a. Referring 37 to FIGS. 8 and 9, taken in conjunction with FIG. 2, the paddle A~13 SlEET

CA 02227374 1998-01-20 p ~ ~ ~ 9 6 1 0 6 3 5 6 ~JS ~ JUL 1997, 1 member 24 comprises an elongated hollow paddle member having a 2 generally rectangular transverse cross-section defined by a 3 planar ~orward label contact sur~ace 140 which terminates in an 4 outer curved end sur~ace 140a a rearwardly planar wall surface 142, and upper and lower planar wall surfaces 144a and 144b, 6 respectively. Paddle member 24 has a hollow internal vacuum 7 chamber 146 adapted to be connected to a source of vacuum through 8 an oblong port 148 ~ormed in the top wall 144a. The paddle 3 member 24 is fixed on the lower end o~ a vertical pivot shaft 150 whlch ~orms the output shaft of a fluid pressure controlled 11 actuator 152. The actuator 152 is mounted on a base plate 28 so 12 that the paddle member 24 is spaced above the height of the 13 cutting edge 82a for pivotal movement in a plane parallel to the 14 base plate 28. The actuator 152 is o~ the type commercially 1~ available ~rom MAC, Inc. under its model number 912B-PM-611BA.
16 The actuator 152 includes a four-way pneumatic control 17 valve whlch enables time rotational oscillation of the pivot 18 shaft 150 and thereby pivotal movement of paddle member 24 about 19 the longitudinal axis of shaft 150. The actuator 152 is operative to pivot the paddle member between a position wherein 21 the forward surface 140 is spaced slightly behind the plane of 22 planar surface 48a of the web material guide plate, and a forward 23 position wherein the curved outer end 140a o~ the paddle member ~4 contacts the lower exposed areas of mailing envelopes or the like being conveyed by the conveyor belt reaches 126 a and 128a.
26 The vacuum port 148 in the upper wall 144a of the 27 paddle member 24 is adapted for registration with a vacuum 28 orifice 156 formed in a bottom horizontal wall 158a o~ a vacuum 29 block 158. The vacuum block 158 is supported in overlying relation to the paddle member 24 so that the upper wall 144a of 31 the paddle member is in sliding contact with the opposed lower 32 wall 158a o~ the vacuum block. As illustrated in FIG 8, the 33 vacuum orifice 156 is configured so as to register with the 34 vacuum port 148 in the paddle member 24 when the paddle member is in its rearward position behind the label web material 16 36 advanced by the label feed roller 34, and continues to remain in 37 communication with port 148 until the paddle member reaches CA 02227374 1998-01-20 p ~ ~ ~ 9 6 / 06 ~ 5 6 lPEWS~8 ~UL l997J

1 substantially its forward position, as shown in phantom in FIG.
2 8, at which time the vacuum port 148 no longer underlies the 3 vacuum orifice 156. With this arrangement, a vacuum created 4 within the internal vacuum chamber 1~6 o~ the paddle member 24 and acts through a plurality of vacuum orifices 140b formed in 6 the forward wall sur~ace 140 of the paddle member to engage and 7 hold label as it is being severed from the label material web 16 8 by the cutter blade 82. Simultaneously with severing of a label 9 from the web material, the paddle member is pivoted in a counter lo clockwise or ~orward direction about the pivot rod 154, as ll considered in FIG. 8, by actuation of the pneumatic actuator 152 12 so that the leaving edge of the label engages and is adhered to 13 a document being conveyed in juxtaposed relation to the paddle 14 member. When the paddle member 24 reaches its outermost pivotal position with the outer end 140a engaging a label against an 16 envelope or the like, the vacuum port 148 is no longer in 17 registration with the vacuum orifice 156 so that vacuum chamber 18 146 is no longer subjected to vacuum. As the mailing envelope 19 to which the label is being applied advances, it draws the label along the surface 140 of the paddle member to expose the leftmost 21 orifice 140b in the paddle member to atmosphere. This allows the 22 label to release from the paddle member and allows the curved 23 paddle end 140a to progressively lightly adhere the remaining 24 length o~ the label to the passing envelope. The paddle member 24 is then returned to its initial position by actuation of the 26 actuator 152 preparatory to severing and applying the next 27 successful label. The paddle member 24 is preferably positioned 28 approximately one inch from the conveyor path traversed by 29 mailing envelopes when the paddle member is in its reward position.
31 The present invention includes several sensor systems 32 to initiate and control the operation of the linerless label 33 applicator 10. As seen in FIG. 2, straddling conveyor belt 34 reaches 126a and 128a of the incoming document path are a plurality of sensor elements, indicated schematically at A, B, CA 02227374 l998-0l-20 WO 97105021 PCT~US96/06356 1C, and D, each of which emits a signal to the electronic system 2operating label applicator 10 when an advancing document passes 3between the respective sensor elements. As a document is 4advanced along the document path formed by conveyor belt reaches 5126a and 128a ~rom left to right, sensor element A is initially 6actuated by the leading edge of an advancing document. Sensor 7A is one of a plurality of sensor elements disposed linerally 8along the document path of the overall document handling system 9(not shown) of which the label applicator 10 forms a part These 10sensor elements A provide a tracking ~unction to maintain control 11over the location of each document as it is advanced through the 12entire document handling system.
13Sensor element B is an activate sensor which also emits 1~an electronic signal when the leading edge of an advancing 15document is detected. As illustrated in the timeline diagram of 16FIG. lO, the signal produced by sensor element B initially 17performs two functions simultaneously. First, the stepping motor 1874 operating stepping feed roll 64 i8 energized to advance web 1916 twenty five steps upward (each step equals .023 inches in the 20preferred embodiment) between stationary shearing blade 120 and 21moveable cutter blade 82 to place the top of web 16 adjacent 22paddle element 24. For this purpose, the stepping motor 74 23operates for approximately 12 milliseconds, which places the 2a~forward end of web 16 at the proper distance above cutter blades 2582, 120 to form a label of the appropriate height. The timing 26of the operation of stepping motor 74 can be varied to adjust the 27height of the label to any predetermined amount. Second, the 28control system inhibits operation of paddle member 24 for 29approximately 28 milliseconds from the start of the sequence for 30the purpose of preventing the paddle from striking the web 16 31after the web has been advanced twenty five steps and is located 32in the path of the paddle.
33After the web 16 has been advanced for 12 milliseconds 34with the paddle initially inhibited, the air valve (not shown) 35operating movable cutter blade 82 iS activated for approximately 3625 milliseconds to cut the upstanding web material above the CA 02227374 l998-0l-20 1 cutter blades 82, 120 from the remaining portion o~ the web to 2 form the label.
3 Sensor elements C and D are similar in function to each 4 other. However, sensor C is configured to emit an electronic signal when the leading edge of an advancing document is 6 detected, and sensor element D is configured to emit an 7 electronic signal when the trailing edge of an advancing document 8 is detected. During operation, the operator selects which sensor 9 C o~ D will be operative, since in certain document handling processes, the label must be placed dimensionally from the 11 leading edge, and in other processes, the label is placed 12 dimensionally from the trailing edge of the document.
13 When either sensor element C or D is triggered by the 14 advancing document, a short delay in actuation of the paddle element 24 is programmed into the system to compensate for the 16 distance between the sensor C or D and the label applying 17 station, taking into account the speed of the advancing document.
18 Then, as schematically shown in FIG. 10, the previous paddle 19 inhibit function is then terminated. Next, the valve associated with the pneumatic actuator 152 for powering paddle element 24 21 is activated for approximately 25 milliseconds, causing paddle 22 24 to pivot outwardly whereby the label cut from web 16 is held 23 by vacuum force to the paddle with the adhesive side of the web 24 facing the document conveyor path. The label is then adhered to the advancing document as previously described. At the same 26 time, sensor C or D initiates a signal which inhibits activation 27 of the control for the web advance sequence for 21 milliseconds 28 after detection of the advancing document by sensor C or D for 29 the purpose of insuring that the remaining web material doesn't advance upward into the cutter station while the paddle 24 is 31 moving back and forth.
32 The web feed and cutter activation control sequence 33 under the influence of sensor element B causes the movable cutter 34 blade 82 to return to its original or stand-by position under spring force after 25 milliseconds of operation. At the same 36 time the movable cutter blade 82 begins movement to its return 37 position, a delay signal is applied to the web advance motor 74 _ -w o 9710s021 PCT~US96~6356 ~ -19 - , l to delay further web movement until the movable cutter blade 82 2 clears the path along which the next length o~ web will advance.
3 In this manner, the movable cutter blade will not interfere with 4 the web material advance.
At the~ end of this 12 millisecond delay, the web 6 advance inhibit ~unction under the influence of sensor C or D is 7 terminated, and the web material 16 is moved downward three steps 8 and then immediately upward ~ive steps over a period of 12 g milliseconds. The purpose of this slight downward and then upward movement of the web at this juncture can be explained with 11 reference to FIG. 11 which schematically illustrates the position 12 o~ the movable cutting blade 82 immediately after a label 16b has 13 been severed from the web material 16 and the label is being held 14 by vacuum force to face 140 of paddle 24. As the movable cutter blade 82 moves in direction "a" following a cutting operation, 16 the adhesive on face "b" of web 16 causes the uppermost tip of 17 the uncut web to adhere to the underside of the movable cutting 18 blade, as shown at "x" in FIG. ll. Allowing the web 16 to remain 19 in this position would substantially inhibit subsequent upward advance of the web 16 by means of the stepping roller 64 and 21 ribbed pinch roller 76, and prevent proper forming of subsequent 22 labels.
23 To prevent this problem ~rom occurring, the control 24 system for the label applicator 10, under the influence of sensor B, following each cutting operation, drives stepping roller 64 26 three steps backward in a period of 12 milliseconds after the 27 movable cutter blade 82 begins its movement back to its original 28 position. Dùring this 12 millisecond period, the movable cutter 29 blade 82 moves out of the way of the web path indicated at "y", and cannot interfere with subsequent web advancement. As the 31 stepping roller 64 moves the web down, the tip of the uncut web 32 breaks free from the inclined underside of movable cutter blade 33 82, and is drawn leftward (as viewed in FIG. 11) by vacuum force 34 towards and against manifold 48. Once ~ree from any adhesive grip with movable cutter blade 82, the web is now free to advance 36 upward towards the cutter station and paddle without 37 interference.

' CA 02227374 1998-01-20 ~PEAIIIS ~3 JUL 1997.

1 Next, stepping roller 64 rapidly advances web 16 upward 2 five steps to place the newly ~ormed top or leading edge of the 3 remaining label material 16 at a plane "z" vertically adjacent 4 the approximate mid-height of fixed cheering blade 120, which is below the lower wall 144b of paddle member 24. At this time, 6 paddle member 24 hen returned to its original position by action 7 of the paddle actuator 152. The paddle member 24 and moveable 8 cutter blade 82 are now in their starting positions, and the 9 label web material 16 has been advanced above the cutting plane and into position ready for the next label advance and 11 application cycle. This sequence is repeated to apply each 12 successive label.
13 Referring to FIG. 12, a vacuum sensor is illustrated 14 schematically at 180 connected to a vacuum line 182 to-the panel member 24 through the vacuum block 158. Sensor 180 detects 16 whether a label 16b cut from the label web material 16 is in 17 proper position against the paddle forward surface 140 18 immediately following each label cutting operation, and also 19 detects whether the label feed system ls jammed or otherwise dysfunctional. The vacuum line or conduit 182 supplying vacuum 21 to hollow chamber 146 of paddle 24 includes an orifice 184 to 22 which the vacuum sensor 180 is operatively connected. The vacuum 23 sensor 180 detects the vacuum level in conduit 182 and is ~4 programmed to emit a warning signal if the vacuum source falls below a pre-established threshold amount. In the illustrated 26 embodiment, the vacuum source is supplied at approximately 15 27 inches Hg. Sensor 180 is programmed to emit a signal when the 28 vacuum in conduit 182 falls to approximately 5 inches Hg.
29 When a label 16b is disposed against the forward face 140 of paddle 24, the surface of the label prevents leakage of 31 vacuum from hollow vacuum chamber 146 through ports 140b, and the 32 vacuum in the chamber 146 and conduit 182 is maintained at 15 33 inches Hg. If label 16b is not present on the forward face of 34 paddle 24, vacuum pressure leaks from unobstructed ports 140b, and the vacuum source immediately drops to 5 inches Hg, causing 36 sensor 180 to emit a signal which is conveyed to the document 37 ~eed control system to halt the advance of documents towards the AM~3 SHEFr CA 02227374 1998-01-20 ,.
W og7soso ~ PCT~USj6~ 56 1 document labeling station. Upon correction of the error by an 2 operator, the label application system 10 resumes its normal 3 functions.
4 While a preferred embodiment of the present invention have been illustrated and described, it will be understood by 6 those skilled in the art that changes and modification may be 7 made therein without departing from the invention in its broader 8 aspects. Various features of the inventions are defined in the 9 ~ol~:owing claims.

Claims (13)

What is claimed is:

1. A linerless label application system for applying a source of continuous length linerless label material to documents being conveyed in a non-overlapping sequential on-edge fashion along a first predetermined path through the system, the label material having an adhesive surface and an opposite non-adhesive surface adapted to have indicia printed thereon, the system comprising:
a conveyer transporting said documents along said first predetermined path in a non-overlapping sequential on-edge fashion;
a label feeder adapted for effecting progressive longitudinal movement of the label material along a second predetermined path so that a leading edge of the label material is in a predetermined juxtaposed relation to the first path;
a cutter station positioned in predetermined relation to the label feeder, the cutter station including cutting means operative to sever the label material generally transversely thereof a predetermined selectable distance from the leading edge so as to create a label of preselected height; and a paddle assembly including a moveable paddle member supported adjacent the cutter station and adapted to engage the non-adhesive side of the label material between the leading edge of the label material and the cutting means, the moveable paddle member operative to support and releasably retain the severed label and press the adhesive surface of the label against a face of an on-edge document as the document travels in a continuous on-edge, non-overlapping, and non-interrupted manner along the first path through the label applying system.

2. The system as defined in claim 13 including control means operative to actuate said moveable blade and cut a transverse leading reference edge on said label material.

3. The system as defined in claim 1 wherein said source of linerless label material is a roll having an axial opening therethrough, said label feeder further including a pair of freely rotatable rollers extending through said axial opening in a parallel spaced relation to a rotational axis of the roll, said roll being supported by said rollers so as to enable free rotation of said roll as the linerless label material is drawn therefrom.

4. The system as defined in claim 3 wherein said label feeder is operative to effect progressive movement of said linerless label material longitudinally from said roll through a looped path, said label feeder further including sensors operative to sense said looped path and advance the label material if the label material length through said looped path shortens so as to deviate from said looped path.

5. The system as defined in claim 1 wherein said paddle member is operative to apply a suction attachment to the label material to releasably retain the label material as the label material is severed by said cutting means.

6. The system as defined in claim 5 wherein said paddle member comprises an elongated paddle pivotally supported adjacent one end for pivotal movement between a first position spaced from said first path and a second position closely adjacent said first path, said paddle having a hollow interior and a label engaging surface having at least one vacuum orifice communicating with said hollow interior, said paddle further having a valve orifice communicating with said hollow interior and adapted for connection to a source of vacuum so as to create a vacuum at said vacuum orifice, said valve orifice being operative to apply vacuum to said vacuum orifice when said paddle is in first position and isolate said vacuum orifice from said vacuum source when said paddle is in said second position.

7. The system as defined in claim 1 wherein said cutter station includes a guide plate having a guide surface disposed in a generally vertical plane, said guide surface lying in said second path so that said label material slides over said guide surface as said label material approaches said cutting means.

8. The system as defined in claim 7 wherein said guide surface has at least one vacuum orifice connected to a source of vacuum, and including a control valve associated with said source of vacuum and operative to apply a vacuum to said orifice to secure said label material to said guide surface as said cutting means severs the label material, said control valve being operative to disconnect said vacuum source from the orifice during advancement of said label material along said second path after each severing of the label material to create a label.

9. The system as defined in claim 1 wherein said cutter station includes a stripper bar supported in substantially parallel spaced relation to said cutting means so as to define an opening therebetween through which said label material passes, said stripper bar being moveable with said cutter blade and operative to return each newly formed transverse leading edge of the continuous length label material to a position preparatory to advancing the label material longitudinally and severing the next successive label from the label material.

10. The system as defined in claim 1 wherein said cutting means includes a cutting edge inclined to the plane of the label material disposed in said cutter station so as to progressively sever the label material transversely thereof in creating a label.

11. The system as defined in claim 10 wherein said paddle member is moveable between a position spaced from a document disposed in said label applying station and a position closely adjacent thereto, said cutter blade being coordinated with said paddle member so as to complete severing of said label material after movement of said paddle member to initiate pressing of the label being severed against a document traversing the label apply station.

12. The system as defined in claim 1 wherein the cutting means includes a fixed blade and a moveable blade, including an actuating drive operatively associated with moveable blade so as to effect reciprocating movement of the moveable blade to sever a label from the label material in timed relation to longitudinal movement of the label material to said cutter station.

13. The system according to claim l where the cutting means includes a fixed blade and a moveable blade, said moveable blade disposed in a predetermined orientation relative to the fixed blade and operative to sever the label material transversely as the label material passes between the fixed blade and the moveable blade.