Abstract:
A method of manufacturing a roll of adhesive labels. The method includes the step of providing a plurality of adhesive labels fixed to a backing sheet. A predetermined number of labels are removed from the backing sheet to thereby form a leading edge of the sheet that only includes the backing sheet and no labels. The leading edge includes no labels to thereby facilitate mounting the sheet of carrier material on a printing or applicator machine.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/108,736, filed on Jan. 28, 2015. The foregoing provisional application is incorporated by reference herein in its entirety. 
     
    
     BACKGROUND 
       [0002]    Rolls of labels are converted on high speed label presses. A master roll is loaded into the press and feed through a series of ink rollers, image rollers, dryers, die cutting rollers and slitter to a rewinder. The rewinder typically can be set to sense a number of labels on the web or footage of media it is winding, when the target number of labels is reached. The rewinder automatically cuts the web and starts the roll onto a new core. This creates a conventional roll of labels ( FIG. 3 ) with labels from the start to the end of the liner on a roll. A typical manufacturer who uses labels, will have to remove 1 to 4 feet of labels from the roll, so that the labels can be threaded through a bar code printer or label applicator. Leaving the labels on the roll and feeding them through a machine can cause the labels to stick to components within the machines, such as rollers, guides, creating a mess that requires extra time to correct. Thus, most manufacturers have to take the time remove the labels manually and dispose of the them, which can be a costly problem with conventionally rolled labels. 
         [0003]    Some label suppliers will manually remove the labels, and charge an increased cost to the manufacturers for this service. The label supplier will use a crew of people to manually count and remove each label from the roll. For production runs of 100,000 or more labels, this becomes a substantial task. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    Features, aspects, and advantages of the present invention will become apparent from the following description and the accompanying exemplary embodiments shown in the drawings, which are briefly described below. 
           [0005]      FIG. 1  is a perspective view of a roll of labels with the labels extending to the end of the roll. 
           [0006]      FIG. 2  is a perspective view of a roll of inside wound labels with a number of labels removed automatically, according to an exemplary embodiment. 
           [0007]      FIG. 3  is a perspective view of a roll of outside wound labels with a number of labels removed automatically, according to an exemplary embodiment. 
           [0008]      FIG. 4  is a perspective view of a label removal apparatus in an inactive state, according to an exemplary embodiment. 
           [0009]      FIG. 5  is a perspective view of the label removal apparatus of  FIG. 4 , in an active state to remove labels from the label sheet. 
           [0010]      FIG. 6  is a side view of the label removal apparatus of  FIG. 4  in an inactive state. 
           [0011]      FIG. 7  is a side view of the label removal apparatus of  FIG. 4  in an active state. 
           [0012]      FIG. 8  is a side view of the label removal apparatus of  FIG. 4  in an inactive state and installed in a label converting press, according to an exemplary embodiment. 
           [0013]      FIG. 9  is a side view of the label removal apparatus of  FIG. 4  in an active state and installed in a label converting press, according to an exemplary embodiment. 
           [0014]      FIG. 10  is a side view of a label removal apparatus in an inactive state, according to another exemplary embodiment. 
           [0015]      FIG. 11  is a side view of the label removal apparatus of  FIG. 10  in an active state. 
           [0016]      FIG. 12  is a side view of the label removal apparatus of  FIG. 10  in an inactive state and installed in a label converting press, according to an exemplary embodiment. 
           [0017]      FIG. 13  is a side view of the label removal apparatus of  FIG. 10  in an active state and installed in a label converting press, according to an exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    It is to be understood that the following detailed description are exemplary and explanatory only, and are not restrictive of the invention. 
         [0019]    It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples). 
         [0020]    References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. 
         [0021]    A label removal apparatus automatically removes labels from the backing web while the labels are being processed, such as in a conversion press. The web and remaining labels may be wound in another device to creates a roll of labels with labels automatically removed to form a leader. 
         [0022]    Referring to  FIG. 1 , labels  10  may be affixed to a web  12  (e.g., liner, backing sheet, etc.) and provided in a roll  14 . The labels  10  are formed from a flexible material (e.g., film, paper, laminate) and include an adhesive applied to the back side of the labels  10 . The web  12  may be coated with a material, such as silicone, that allows for the easy removal of the labels  10  from the web  12 . The web  12  with the labels  10  may be provided in the form of a roll  14  wrapped around a core  15 . The roll  14  be configured with the labels  10  affixed to the inside surface of the web  12  ( FIGS. 1 and 2 ) (i.e., inside wound) or on the outside surface of the web  12  ( FIG. 3 ) (i.e., outside wound). As shown in  FIGS. 2 and 3 , a number of labels  10  may be removed from the free end  16  of the roll  14  such that a length of the web  12  lacks labels  10  to form a leader  18 . Such a roll  14  may be utilized, for example, in a mechanism where it is desirable to feed the leader  18  through the mechanism without the possibility of labels  10  becoming dislodged from the web  12  and disrupting the mechanism. 
         [0023]    Referring to  FIGS. 4-9 , a label removal apparatus  20  is shown according to an exemplary embodiment. The label remover apparatus  20  is configured to automatically remove a number of labels  10  from the web  12  while the labels  10  are being processed to form the roll  14 . In this way, the roll  14  may be produced with a number of labels  10  already removed from the end of the roll  14  to form a leader  18 , negating the need for an end user or a manufacturer to manually remove the labels  10  to form the leader  18 . The label removal apparatus  20  includes a frame  22 , a plate  24  that is moveable relative to the frame  22 , an actuator  26  configured to move the plate  24  between a first position and a second position, one or more rollers  28 , a removal device, a sensor device  32 , and a controller  40  configured to control the actuator  26  and the removal device. 
         [0024]    The plate  24  is mounted below the web  12  passing through the label removal apparatus  10 . As shown in  FIGS. 6-7 , the plate  24  is coupled to the frame  22  at the leading edge with a pinned connection  23 . The plate  24  is coupled to the actuator  26  at the trailing edge with a pivoting joint  25 . The frame  22  is a stationary body that is coupled to a structure that is generally fixed vertically relative to the ground (e.g., the floor, a base, another mechanism, etc.). The actuator  26  is shown as a pair of pneumatic cylinders mounted on either side of the plate  24  with one end coupled to the plate  24  and the opposite end coupled to the frame  22 . In other embodiments, the actuator  26  may include any number of linear or rotary actuators (e.g., hydraulic cylinders, motor driven devices, or any other devices). The actuator  26  moves the plate  24  between a first position (e.g., lowered position, horizontal position, home position, inactive position, etc.) and a second position (e.g., raised position, angled position, active position, etc.). The plate  24  may be limited by one or more mechanical stops  29 . The positions of the stops  29  may be adjustable. In the first position, the plate  24  is lowered in a horizontal orientation such that the web  12  can pass over the plate  24  unencumbered through the label removal apparatus  10 . In the second position, the actuator  24  moves the trailing edge of the plate  24  upward. The pinned connection  23  and the pivoting joint  25  allow the plate  24  to be angled relative to horizontal in the second position. In the second position, the plate  24  reroutes the web  12  and labels  10  to another angle. The web  12  engages one or more rollers  28 , which are coupled to the frame  22 , such that displacement of the web  12  by the plate  24  is localized and the web  12  enters and exits the label removal apparatus  10  at the same points whether the plate  24  is in the first position or the second position. 
         [0025]    According to an exemplary embodiment, the removal device is a vacuum take away device  30  that uses a vacuum to pull the labels  10  off of the web  12 . The vacuum take away device  30  is configured to selectively remove or peel off the labels  10  from the web  12 . The angle of the web  12  proximate the vacuum take away device  30  (i.e., the peel angle) may be adjusted to facilitate the removal of the labels  10  from the web  12 . For example, the vacuum take away device  30  may be able to more easily remove the labels  10  as the angle increases. The peel angle may be adjusted via the mechanical stops  29 , to limit the angle. 
         [0026]    The vacuum take away device  30  may be connected to an existing vacuum system in use with the mechanisms processing the labels  10  before or after the label removal apparatus  20 . The labels  10  removed from the web  12  by the vacuum take away device  30  may be routed to a vacuum duct and automatically discarded in a receptacle for disposal. 
         [0027]    The actuator  26  is controlled by a controller  40  that monitors the passage of the labels  10  and web  12  through the label removal apparatus  20  and determines how many labels  10  to remove from the web  12 . In an exemplary embodiment, the control system  40  includes a processor  42 , a memory device  44 , a user input device  46 , and an output device  48 . According to an exemplary embodiment, components of the control system  40  may be housed in an industrial cabinet to protect the components from the elements. 
         [0028]    The processor  42  can be implemented as a general purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a group of processing components, or other suitable electronic processing components. In another exemplary embodiment, the control system  40  may include a controller lacking a processor or memory. For example, the control system may be a linear circuit. 
         [0029]    The memory device  44  (e.g., memory, memory unit, storage device, etc.) is one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present application. The memory device  44  may be or include volatile memory or nonvolatile memory. The memory device  44  may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present application. According to an exemplary embodiment, the memory device  44  is communicably connected to the processor via the processing circuit and includes computer code for executing (e.g., by processing circuit and/or processor) one or more processes described herein. 
         [0030]    The input device  46  is one or more devices that allow a user to input commands and control variables for the label removal apparatus  20  (e.g., timing changes as required for different size labels  10 , different desired leader lengths, etc.). The input device  46  may be, for example, a touch screen monitor, a keyboard or keypad, push buttons, dials, switches, or any combination of devices. The output device  48  is one or more devices that allow a user to monitor the properties of the label removal apparatus  20  and may be integrated with the input device  46 . The output device  48  may be, for example, a monitor, a touch screen monitor, a text display, a numeric display, or a combination of devices. 
         [0031]    The controller  40  monitors the passage of the labels  10  through the label removal apparatus  20  with the sensor device  32 . The sensor device  32  detects the difference between the labels  10  and the web  12  (e.g., the gaps between the labels  10 ) to determine the rate with which the labels  10  and web  12  are passing through the label removal apparatus and the number of labels  10 . The sensor device  32  transmits a signal to the controller  50 . According to an exemplary embodiment, the sensor device  32  is a photoelectric eye. In other exemplary embodiments, the sensor device  32  may be any suitable device capable of detecting the labels  10  and/or the gaps between the labels  10  and transmitting a signal to the controller  50 , such as a mechanical switch or a laser sensor. 
         [0032]    As the labels  10  path beneath sensor device  32 , the sensor device  32  transmits a signal or trigger to the controller  50 . The controller  50  counts the number of triggers it receives. Once a predetermined count has been reached, the controller  50  activates the actuator  26  to raise the plate  24  from the first position to the second position. In the second position, the plate  24  locally deflects the web  12  at an angle (i.e., the peel angle) to bring it closer to the vacuum take away device  30 , which peels or otherwise removes the labels  10  from the web  12 . 
         [0033]    The sensor device  32  continues to send signals to the controller  50  with the plate  24  in the second position. After the predetermined number of labels  10  have been removed from the web  12  by the vacuum take away device  30 , the controller  50  activates the actuator  26  to lower the plate  24  to the first position. The cycle repeats until the operator stops the apparatus. 
         [0034]    Referring now to  FIGS. 8-9 , the label removal apparatus  20  is shown mounted in line with a label converting press  60  configured to print and cut a plurality of labels  10  on the web  12  and a turret rewinder  70  configured to wind the labels  10  and web  12  into the roll  14 . 
         [0035]    The label converting press  60 , for example, may include a roll  62  of label media comprising a strip of label material and web. The label media is routed through multiple idle rollers  65 . A print roller  64  prints the text and/or graphic designs on the labels  12  and a die cutter  66  cuts the label material into individual labels  10  while leaving the web  12  uncut. The label material removed to form the gaps between the labels  10  may be removed with a vacuum take away system  68 . 
         [0036]    The web  12  exit the label converting press  60 . Instead of being routed directly to the turret rewinder  70 , the web  12  is run through the label removal apparatus  20  where a desired number of labels  10  are removed from the web  12 . After exiting the label removal apparatus  20 , the web  12  is run through the turret rewinder  70 . 
         [0037]    The turret rewinder  70 , for example, may include a web cutter  72  configured to cut the web  12  into discreet lengths with the portion of the web  12  lacking the predetermined number of labels  10  and forming the leader  18  on one end. The web  12  is wound onto a core mounted to a turret  74 . Once the roll  14  is completely wound, the turret  74  is advanced so that a new roll  14  can be started and the finished roll  14  removed. The controller  50  controls the web cutter  72  and the turret  74  to produce a finished roll  14  with a desired number of labels  10  and a leader  18  of a desired length. 
         [0038]    Referring now to  FIGS. 10-13 , a label removal apparatus  20  is shown according to another exemplary embodiment in which the removal device is a drum accumulator  80 . Such a drum accumulator  80  includes a cylindrical drum  82  with an array of vacuum holes  84  disposed, about the circumference of the drum  82 . A vacuum is drawn on the drum  82  and the labels  10  are held against the drum  82  at the vacuum holes  82 . The drum  82  rotates to bring the labels  10  away from the web  12  until they reach an accumulation roller  86 . According to an exemplary embodiment, the accumulator roller includes a discardable core  88  that is formed from a material to which the labels  10  will adhere (e.g., cardboard, etc.). The labels  10  are held on the drum  82  with the adhesive side facing outward. As the labels  10  reach the accumulation roller  86 , the labels sticks to the core  88 , overcoming the force of the vacuum and removing the labels  10  from the drum  82 . The core  88  may periodically be removed as a number of labels  10  are collected and replaced with a fresh core  88 . 
         [0039]    A vacuum blocker plate  85  may be disposed on the interior of the vacuum drum  82  opposite of the side of the drum on which the labels  10  travel from the web  12  to the accumulation roller  86 . The vacuum blocker plate  85  is curved to match the interior surface of the drum  82  and includes sealing elements (e.g., gaskets, etc.) to form a seal against the interior surface of the drum  82 . The vacuum blocker plate  85  minimizes vacuum losses on the side of the drum  82  on which the vacuum holes  82  are not covered by the labels  10 . 
         [0040]    The drum accumulator  80  may be utilized for a label removal apparatus  20  installed in line with an apparatus lacking an existing vacuum disposal system. A vacuum need only by applied to the drum accumulator  80  with the labels  10  disposed manually through the removal of the core  88 . 
         [0041]    The present disclosure contemplates methods, systems and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a machine, the machine properly views the connection as a machine-readable medium. Thus, any such connection is properly termed a machine-readable medium. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions. 
         [0042]    It is important to note that the label removal apparatus as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.