WO2004080813A2

WO2004080813A2 - Double ferris wheel printer for labeling synthetic corks

Info

Publication number: WO2004080813A2
Application number: PCT/US2004/007016
Authority: WO
Inventors: Philip G. Scherer; Gregg O. Coningsby
Original assignee: Apex Machine Company
Priority date: 2003-03-10
Filing date: 2004-03-09
Publication date: 2004-09-23
Also published as: WO2004080813A3

Abstract

A printing machine (10) for printing on the outer surface of a cork, having a rotatable carrier assembly (11) having first and second Ferris wheels (25, 26) mounted about a common axis for synchronous rotation. Each of the Ferris wheels includes respective first and second pluralities of cork carriers (38) laterally-mounted thereon for rotation relative to the Ferris wheels. Each of the cork carriers is adapted for holding and carrying a cork to be printed during rotation. A feeder (13) simultaneously presents successive corks to successive cork carriers of both the first and second Ferris and for loading the corks into the cork carriers. An indexing drive system provides synchronous, incremental rotation of the carriers around the circumference of a respective one of the Ferris wheels and through a predetermined sequence of cork processing steps and ejection from the printing machine. A printer (15) prints an image on an exterior surface of the cork as the cork is rotated by the cork carrier in which the cork is carried.

Description

DOUBLE FERRIS WHEEL PRINTER FOR LABELING SYNTHETIC CORKS

Technical Field and Background of the Invention

This invention relates to aulomaied printing machines; and more particularly, to dry offset printing machines. The printer can be used for printing on any suitably-sized cylindrical object, but has particular application in the embodiment disclosed herein for printing on stoppers, such as synthetic cork stoppers. As the demand for wine has increased, so has the demand for natural cork stoppers. To reduce demand for natural cork stoppers, containers other than bottles requiring cork stoppers, such as collapsible bags in boxes and bottles with screw cap lids, have been used. However, the buying public typically perceives collapsible bags stored in boxes with exposed spigots and screw cap bottles as indicators of inferior quality wine. To meet the demand for cork stoppers, synthetic cork stoppers have been developed. These synthetic cork stoppers are made from polymeric materials that have been extruded, or molded during a molding process. These synthetic corks have characteristics similar to their natural counterparts.

[0002] In the wine industry, corks are frequently printed with words and other indicia identifying the vineyard where the wine was produced or where the wine is bottled. Printing of natural cork stoppers is typically done using a rotary letter press or rotary letter flex printing system which utilizes a reverse reading hard or soft printing plate which has ink placed on the raised surface. The raised surface of the plate then makes contact with the natural cork, thus transferring the appropriate image. This printing process is typically limited to single color printing.

[0003] Printing machines used for printing indicia on natural cork stoppers have been found to be ineffective when used with synthetic cork stoppers. The synthetic stoppers are not as absorbent as natural cork and the printing on such corks, regardless of transfer method, require a forced drying of the printed ink. Additionally, the synthetic corks have a lower coefficient of friction at their surface and require a surface treatment, which oxidizes the surface allowing the printing ink to "flow out" when applied to the surface.

[0004] It is the principal purpose of this application to disclose a printing machine for printing corks and the like that permits at least two corks to be printed simultaneously by the same machine, without unnecessary duplication of machine parts and assemblies.

[0005] A printing machine is therefore disclosed herein that is capable of imprinting synthetic corks at a high rate of production with forced surface pretreatment and forced ink drying. The printing machine is capable of printing corks at a high production rate that is more compact than previously known synthetic cork printing machines. Furthermore, the printing machine is capable of printing two or more corks at a time but at a rate of speed no higher than a machine that prints only one cork at a time, with an attendant savings in machine wear.

[0006] Applicant's prior U.S. Patent Nos. 6,526,880 and 6,220,154 disclose machines for dry offset printing on synthetic cork stoppers. These machines have a single Ferris wheel that operates as the means for moving the corks through the various processing stations. This application provides a novel way of printing two or more corks at a time by placing two or more Ferris wheels adjacent each other in a concentric arrangement that permits the printing machine to act essentially in the same manner as a single Ferris wheel machine.

Summary of the Invention

[0007] Therefore, it is an object of the invention to provide a printing machine that prints two or more corks or other objects simultaneously in a compact, efficient machine. [0008] Therefore, it is an object of the invention to provide a printing machine capable of imprinting synthetic cork stoppers with little smearing. [0009] It is another object of the invention to provide a printing machine capable of printing synthetic cork stoppers that more securely holds the synthetic stoppers to reduce the likelihood of machine jams.

[0010] It is another object of the invention to provide a printing machine capable of printing synthetic cork stoppers which is more compact than previously known synthetic cork printing machines.

[0011] It is another object of the invention to provide a printing machine which completely processes a synthetic cork in a single, continuous process. [0012] It is another object of the invention to provide a printing machine which imprints synthetic corks which includes both forced surface treatment before printing and forced drying of the cork after printing.

[0013] It is another object of the invention to provide a printing machine which imprints two synthetic corks at a time, effectively doubling production without a corresponding increase in machine speed and without unnecessary duplication of parts. [0014] These and other objects of the present invention are achieved in the preferred embodiments disclosed below by providing a rotary printing machine for the printing of synthetic cork stoppers of the type having a surface which is normally non-ink receptive. A dual Ferris wheel-style turret assembly is provided, having a plurality of evenly spaced carriers mounted a predetermined radial distance from and parallel to the axis of rotation for the Ferris wheel assembly, each carrier for rotatably holding a synthetic cork stopper. An indexing drive system controls incremental rotation of the Ferris wheel assembly through a predetermined sequence of steps, and a cork feeder introduces two synthetic cork stoppers into carriers as empty ones of the carriers are presented two-by-two at the cork feeder. A corona discharger treats the surface of each synthetic cork stopper prior to being printed with sufficient energy to alter the surface energy of the cork sufficiently to permit receptivity of printing ink. A rotary printing system rotatably imprints with ink the surface of each held synthetic cork stopper with an image.

[0015] According to one embodiment of the invention, a printing machine for printing on the outer surface of a cork is provided, and comprises a rotatable carrier assembly having first and second Ferris wheels mounted about a common axis for synchronous rotation, each of the Ferris wheels including respective first and second pluralities of cork carriers laterally-mounted thereon for rotation relative to the Ferris wheels, each of the cork carriers adapted for holding and carrying a cork to be printed during rotation. A feeder simultaneously presents successive corks to successive cork carriers of both the first and second Ferris and for loading the corks into the cork carriers. An indexing drive system provides synchronous, incremental rotation of the carriers around the circumference of a respective one of the Ferris wheels and through a predetermined sequence of cork processing steps and ejection from the printing machine. A printer is provides for printing an image on an exterior surface of the cork as the cork is rotated by the cork carrier in which the cork is carried. [0016] According to one preferred embodiment of the invention, the cork carriers of the first Ferris wheel are mounted for concentric rotation relative to respective cork carriers of the second Ferris wheel.

[0017] According to a further preferred embodiment of the invention, the Ferris wheels comprise first, second and third parallel, spaced-apart plates coaxially mounted for rotation on a common drive axle. The first Ferris wheel is defined by the first and second plates and carries the first plurality of cork carriers therebetween, and the second Ferris wheel is defined by the second and third plates, and carries the second plurality of cork carriers therebetween.

[0018] According to a further preferred embodiment of the invention, each cork carrier comprises a stationary holder, a movable holder coaxially-mounted in relation to the stationary holder, the moveable holder being moveable between an open position and an engaged position with respect to the stationary holder such that when in the open position the cork drops out of the carrier, and when in the engaged position the cork is held between the moveable and stationary holders. The indexing drive system acts in synchronization with the carriers for moving the moveable holder between the open and engaged positions.

[0019] Preferably, the stationary holder and the moveable holders each have concave ends for engaging and centering the cork therebetween. [0020] The printing machine preferably includes a plurality of carrier spin drivers positioned adjacent the carrier assembly at each step where the cork is being treated, printed and dried, each carrier spin driver having a continuously rotating drive wheel. A spin pulley is coaxially mounted on one of the rotatable holders in each carrier, the spin pulley removably engageable with the drive wheel of a carrier spin driver when the carrier is positioned at a step where the cork is being treated, printed and dried. [0021] According to yet another embodiment of the invention, the printer includes a dry offset rotary printer having a plurality of rotary print heads, with each print head adapted to provide a different color in a printed image.

[0022] A method for printing indicia on a cork according to an embodiment of the invention comprises the steps of simultaneously mounting a pair of the corks onto respective pairs of cork carriers mounted on respective first and second Ferris wheels mounted on a common axis for synchronous rotation, each of the cork carriers mounted for rotation relative to the Ferris wheels, each of the carriers adapted for holding and carrying a cork to be printed during rotation. An image is simultaneously printed on the surface at least one pair of the corks while mounted on respective concentric pairs of carriers. The steps are repeated with respect to successive pairs of corks. [0023] The method further comprises the step of moving a moveable holder of the carrier with respect to a stationary holder of the carrier between an open position and an engaged position such that the cork drops out of the carrier in the open position and the cork is held between the moveable and stationary holders in the engaged position. [0024] According to a further embodiment of the invention, the method includes the steps of indexing the first and second Ferris wheels through a predetermined sequence of steps, introducing a single cork into selected ones of empty carriers presented sequentially at a cork feeder; and printing an image on an exterior surface of the pairs of cork as successive pairs of the corks are rotated by respective cork carriers in which the corks are carried.

[0025] According to one preferred embodiment of the invention, each carrier has one fixed end and one adjustable end to adjust for different length corks. A rapid adjustment feature is incorporated to facilitate a rapid changeover or adjustment between different size corks.

[0026] Because each cork is individually held in place during the steps of corona treatment, printing and drying, the down time caused by corks not properly releasing from the print drums is reduced. Further, the Ferris wheel assembly allows a missed cork to drop through the mechanism and out of the machine. Lastly, the dual wheel design of the Ferris wheel assembly doubles the output of prior rotary printers, such as those disclosed in U.S. Patent Nos. 6,220,154 and 6,526,880, which are incorporated herein by reference.

Brief Description of the Drawings [0027] Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:

[0028] Figure 1 is a side elevation of a double Ferris wheel printer in accordance with an embodiment of the invention;

[0029] Figure 2 s a perspective view of the printer shown in Figure 1 ;

[0030] Figure 3 s a side elevation of the Ferris wheel assembly;

[0031] Figure 4 s a top plan view of the Ferris wheel assembly; [0032] Figure 5 is a fragmentary view of one of the plates of the Ferris wheel assembly:

[0033] Figure 6 is perspective view of the cork feed mechanism;

[0034] Figure 7 is a side elevation of the cork feed mechanism; and

[0035] Figure 8 is an exploded top plan view of the cork feed mechanism.

Description of the Preferred Embodiment and Best Mode [0036] Referring now specifically to the drawings, a cork printer according to the present invention is illustrated in Figs. 1 and 2, and shown generally at reference numeral 10. As used herein, the terms "cork," "corks," and "cork stopper" refer to synthetic and natural cork stoppers as well as other cylindrical objects. [0037] The dry offset rotary printing machine 10 comprises a rotatable dual Ferris wheel mechanism 11 mounted on a chassis 12. The printing machine 10 includes a loader assembly 13, corona treatment center 14 having two coronas for pre-treating the corks to make the surface receptive to the ink, and a four-color carriage and blanket drum assembly 15. A UV dryer assembly 16 quickly dries the ink by curing to prevent smearing and set the ink, and an optional silicone applicator assembly 17 applies a thin coat of silicone to facilitate insertion and removal of the cork into and out of a bottle before the cork is discharged through the discharge chute 18. A motor assembly 20 drives the printer 10. The corona power supplies 21 and 22 supply power to a pair of corona discharge units 23 and 24. See Figure 2. A flame treatment center can be used as an alternative to the corona treatment center 14. A separate power supply 27 supplies power to the UV dryer assembly 16.

[0038] The Ferris wheel mechanism 11 includes two Ferris wheels, 25 and 26.

As shown in Figure 3, Ferris wheel 25, exemplary of both Ferris wheels, is a 24 station unit capable of processing 24 corks during each revolution. The two Ferris wheels 25, 26 sit side-by-side and operate in unison to output 2 corks at a time, or a total of 48 corks for each revolution of the Ferris wheels 25 and 26. [0039] Referring to Figure 4, the two Ferris wheels 25 and 26 are formed by a center datum plate 30 and two outboard side spindle plates 31 and 32 to form two adjacent in-feed lanes 34, 35 having evenly spaced cork carriers 38, each including a spindle pulley 39, The Ferris wheels 25 and 26 are concentrically mounted on a common drive shaft 40. The carriers 38 on each Ferris wheel are mounted a predetermined, uniform circumferential distance from each other and parallel to the axis of rotation of the Ferris wheels 25 and 26. Each carrier 38 in infeed lane 34 is laterally aligned with a carrier 38 of the in-feed lane 35. Each carrier 38 is adapted to hold a cylindrical object, such as the synthetic cork stopper, to be treated, printed and dried in the machine 10. See, also, Figure 5.

[0040] The carriers 38 successively capture corks fed into the Ferris wheels 25 and 26, and transport the corks successively throughout the various stations, as described above. Each carrier 38 has one fixed element 38A and one adjustable element 38B to adjust for differently-sized corks. A rapid adjustment feature is incorporated to facilitate a rapid changeover or adjustment between different size corks. [0041] A feed conveyor, not shown feeds the corks to a bulk loader where the corks are captured in bulk and transported to a double cork rotary feed system in a predetermined quantity. Preferably, a 5-cubicfoot stainless steel accumulation bin and matching elevator conveyor feeding system maintain a supply of corks and feed them to a rotary bowl feed system mounted adjacent the Ferris wheels 25 and 26. This rotary feed system is conventional. As is shown in Figures 6, 7 and 8, the loader assembly 13 includes two belt conveyors 44, 45 that transfer the corks from the feeder to an automatic escapement mechanism. The corks are singulated from the conveyors into cups 18 spaced along the belt conveyors 44, 45. A single servo motor 47 indexes the belt conveyors 44, 45 simultaneously, bringing two corks successively to respective Ferris wheel carriers 38 of the two Ferris wheels 25, 26. The servo motor 47 drives the belt conveyors 44, 45 in cyclical movement, in which a cork from each belt conveyor 44, 45 is presented to a carrier 38 on each of the two Ferris wheels 25, 26 simultaneously with each movement. The servo motor 47 and dual belt conveyors 44, 45 move the corks into respective carriers 38 in one continuous motion, thereby eliminating the retraction movement present in prior art rotary printers. Note in Figure 6 that corks are feed in to end-to-end arrays into the printing machine 10-one array being fed into the carriers 38 of the Ferris wheel 25 and the other parallel array being fed across the top of Ferris wheel 25 to the carriers 38 of Ferris wheel 26. This permits use of a single bulk loader and rotary feed system.

[0042] Following the escapement mechanism is a pretreatment station where the dual head corona treatment unit 14 conditions the entire outer peripheral surface of the the corks prior to entering the print station. The corona treatment unit 14 imparts sufficient energy to the surface of the corks to make them receptive to dry offset printing ink for a short period of time sufficient to transfer the corks to the print station 15. [0043] In the print station 15 desired text and/or graphical material is printed on two corks at the same time in up to four different colors. As noted above, the corks are transferred by both Ferris wheels 25 and 26 in unison parallel alignment from station to station.

[0044] In a preferred embodiment, the corks are then indexed to the ultraviolet dryer 16 where the ink on both corks is cured before they are presented to the silicone applicator assembly 17. In the preferred silicone applicator 17, a uniform thickness of silicone is applied to the surface of corks before they are indexed into the ejection chute 18. The preferred silicone applicator assembly 17 includes a silicone distribution system and applicator pads. A diverter can be supplied with the machine at the bottom of the ejection chute to divert a predetermined quantity of corks from the machine into a receiving container.

[0045] Preferably, a standard Apex ultraviolet dryer is used to cure the ink, and it includes a power supply, irradiator module, and all guarding and electrical interlocks. The drying assembly comprises an UV light along with fan and drying elements. [0046] The complete system has a maximum production rate of about 300 parts per minute, with the exact speed being dictated by the consistency and quality of the corks used.

[0047] In operation, the indexing drive system moves the Ferris wheels 25, 26 through a predetermined amount of rotation. The length of time at which Ferris wheel 25, 26 is stopped at each station is determined primarily by the length of time needed to imprint the cork. An indexing drive system for use in the present invention is Model P-325 indexer manufactured by Ferguson Company of St. Louis, Missouri. A slip clutch mechanism as is known in the art may be interconnected between indexing drive system and drive axle to reduce the likelihood of damage to the indexing drive and printing machine in the event that there is a jam in the printing machine. One such slip clutch mechanism is Model Size 1 manufactured by Mayr Corporation of Waldwick, New Jersey or Torque Limiter Model 250A manufactured by Morse Industrial Corporation of Ithaca, New York.

[0048] The carriers 38A, 38B are linearly movable between an open position and an engaged position with respect to their corresponding stationary holder when a cork is clamped in position. The carriers 38A, 38B may be moved between these two positions by springs, linkages, linear actuators or the like, as is well known. [0049] The print drum 15 prints the surface of the cork while the cork is rotating.

This direct rotation of the cork ensures that the cork is effectively treated, printed and dried. A carrier spin unit is provided at each carrier position at which a treating, drying or printing operation occurs, as is fully disclosed in applicant's prior United States Patent Nos. 6,526,880 and 6,220,154. The spin drive unit has a continuously spinning drive wheel that engages a carrier 38 to spin or rotate the carrier. The drive wheel engages the stationary carrier 38A that is adjacent the print drum. The moveable carrier 38A may also be used to engage the drive wheel.

[0050] The drive wheel may engage more than one carrier 38 at a time, depending, of course, on the diameter of the drive wheel used. The drive wheel engages a respective carrier 38 as the Ferris wheels 25, 26 index into position. When the Ferris wheels 25, 26 index and rotate to the next position, the spinning carrier 38 disengages from the drive wheel due to the rotational motion of the Ferris wheels 25, 26. The drive wheel is sized so the drive wheel rotational path and carrier path are tangent or coincident only about a given carrier position or only about positions adjacent to that given position.

[0051] The use of the carrier spin drive allows the cork to be rotated when being treated, printed or dried. This ensures that the entire surface of the cork is properly treated at each of the respective stops in the machine. Spinning the carriers may be accomplished by means other than the drive wheel and spin pulleys. For instance, gears, belts or linkages may be used to achieve the same effect. A planetary gearing system may also be employed, as is known in the art. Further, carrier rotation may be provided at every carrier position between the carrier position where new corks enter the Ferris wheel 11 and the exit carrier positions.

[0052] Referring now to Figures 1 , 4 and 6, to load the carriers 38, two corks are simultaneously presented to separate, laterally-aligned carriers 38 in respective infeed lanes 34, 35 as the Ferris wheels 25, 26 are rotated. Corks are queued and aligned in two single files, Figure 6, ready to exit the feed tube and are biased to do so if a free space is available on a receiving platform. Biasing preferably is done using a gravity feed system for the cork. Each cork stopper upon exiting the feed tube comes to rest against a stop. The belts 44, 45 are positioned intermediate the end of the supply tube and the stop. Each belt 44, 45 forms a triangular shape in cross section Positioned on each of the belts 44, 15 is a series of cups 18 for holding corks. The cups 18 are curved to be approximately the same radius as that of the cork stoppers to be printed. Should larger or smaller cork diameter stoppers need to be printed, the curvature may be adjusted or a new cradle having the appropriate curvature may be installed. When a carrier 38 is present at the entry carrier position, the cup 18 is positioned intermediate the stationary and moveable holders. A carrier 38 engages or clamps the cork that is in the cup 18, and when the Ferris wheels 25, 26 are rotated to the next position, each cup 18 is emptied of its new cork.

[0053] A printing machine for printing synthetic corks is described above.

Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.

Claims

We claim:

1. A printing machine for printing on the outer surface of a cork, and comprising:

(a) a rotatable carrier assembly having first and second Ferris wheels mounted about a common axis for synchronous rotation, each of the Ferris wheels including respective first and second pluralities of cork carriers laterally-mounted thereon for rotation relative to the Ferris wheels, each of the cork carriers adapted for holding and carrying a cork to be printed during rotation;

(b) a feeder for simultaneously presenting successive corks to successive cork carriers of both the first and second Ferris wheels and for loading the corks into the cork carriers;

(c) an indexing drive system for synchronous, incremental rotation of the carriers around the circumference of a respective one of the Ferris wheels and through a predetermined sequence of cork processing steps and ejection from the printing machine; and

(d) a printer for imprinting an image on an exterior surface of the cork as the cork is rotated by the cork carrier in which the cork is carried.

2. The printing machine of claim 1 , and further wherein the cork carriers of the first Ferris wheel are mounted for concentric rotation relative to respective cork carriers of the second Ferris wheel.

3. The printing machine of claim 1 , wherein the first and second Ferris wheels comprise: (a) first, second and third parallel, spaced-apart plates coaxially mounted for rotation on a common drive axle;

(b) the first Ferris wheel defined by the first and second plates and carrying the first plurality of cork carriers therebetween; and

(c) the second Ferris wheel defined by the second and third plates, and carrying the second plurality of cork carriers therebetween.

4. The printing machine of claim 3, wherein each cork carrier further comprises:

(a) a stationary holder;

(b) a movable holder coaxially-mounted in relation to the stationary holder, the moveable holder being moveable between an open position and an engaged position with respect to the stationary holder such that when in the open position the cork drops out of the carrier, and when in the engaged position the cork is held between the moveable and stationary holders; and

(c) the indexing drive system acting in synchronization with the carriers for moving the moveable holder between the open and engaged positions.

5. The printing machine of claim 4, wherein the stationary holder and the moveable holders each have concave ends for engaging and centering the cork therebetween.

6. The printing machine of claim 1 , and including a dryer for drying the printed image after printing and before ejection of the cork from the carrier.

7. The printing machine of claim 5, wherein the dryer comprises an ultraviolet (UV) dryer.

8. The printing machine of claim 1 , wherein the cork comprises a cork having a printing surface not normally receptive to printing, and wherein the printing machine includes an energy source for applying sufficient energy to the surface to render the surface temporarily receptive to a printed image.

9. The printing machine of claim 1 or 8, wherein the cork comprises a synthetic bottle stopper.

10. The printing machine according to claim 1 , and including:

(a) a plurality of carrier spin drivers positioned adjacent the carrier assembly at each step where the cork is being treated, printed and dried, each carrier spin driver having a continuously rotating drive wheel; and

(b) a spin pulley coaxially mounted on one of the rotatable holders in each carrier, the spin pulley removably engageable with the drive wheel of a carrier spin driver when the carrier is positioned at a step where the cork is being treated, printed and dried.

11. The printing machine of claim 1 , wherein the printer comprises a dry offset rotary printer having a plurality of rotary print heads with each print head adapted to provide a different color in a printed image.

12. A method for printing indicia on a cylindrical cork, comprising:

(a) simultaneously mounting a pair of the corks onto respective pairs of cork carriers mounted on respective first and second Ferris wheels mounted on a common axis for synchronous rotation, each of the cork carriers mounted for rotation relative to the Ferris wheels, each of the carriers adapted for holding and carrying a cork to be printed during rotation;

(b) simultaneously imprinting an image on the surface at least one pair of the corks while mounted on respective concentric pairs of carriers; and

(c) repeating steps (a)-(b) with respect to successive pairs of corks.

13. The method of claim 12, and further comprising the step of moving a moveable holder of the carrier with respect to a stationary holder of the carrier between an open position and an engaged position such that the cork drops out of the carrier in the open position and the cork is held between the moveable and stationary holders in the engaged position.

14. The method of claim 12, and including the steps of;

(a) indexing the first and second Ferris wheels through a predetermined sequence of steps;

(c) introducing a single cork into selected ones of empty carriers presented sequentially at a cork feeder; and

(d) printing an image on an exterior surface of the pairs of cork as successive pairs of the corks are rotated by respective cork carriers in which the corks are carried.

15. The method of claim 14, and including the step of treating the surface of the corks with sufficient energy to impart ink retentive characteristics to a surface of the cork that is normally not ink retentive.

16. The method of claim 12, wherein the corks comprise bottle stoppers.

17. The method of claim 12, wherein the corks comprise synthetic bottle stoppers.

18. A printed cork stopper wherein the image is applied according to the steps of claim 12.

19. A printed cork stopper according to claim 18, wherein the cork stopper is made from a synthetic material.

20. A printed cork stopper according to claim 18, wherein the cork stopper is made from natural cork.