Abstract:
A label folding apparatus and methods for its use are disclosed. Such a label folding apparatus comprises a label folding assembly and a label holding assembly, and may be used to fold a foldable label placed onto the label holding assembly.

Description:
BACKGROUND 
     Labels are commonly used to secure printed indicia to packages to indicate shipping or other information. In the instance of a shipping use, a separate packing list may be enclosed within a package shipped to the customer containing a purchased item. 
     There is significant demand for a labeling method that allows automatic printing and application of a lower label and an upper label to a surface. For example, there is significant demand for a labeling method that allows automatic printing and application of a packing list and shipping label to the surface of a sealed carton. Because the carton is sealed prior to packing list generation, it is not efficient to open it to insert a packing list. High volume shipping of such packages requires rapid attachment of a packing list and a shipping label to the package. It is preferred to conceal the information of the packing list until the final recipient receives the shipped package. 
     Complicated methods have been implemented for application of a lower label and an upper label to a surface. For example, where a packing list and shipping label are to be applied to the surface of a sealed carton, complicated methods have been implemented in which a packing list is applied and adhered atop a carton, using a first roll of labels (packing list labels) and a first label applicator. After the packing list label is applied, an address label is applied and adhered atop the packing list label, to conceal the packing list information, using a second roll of labels (address labels) and a second label applicator. Such methods have many shortcomings. For example, precise timing between the packing list application and the shipping label application is required to properly align the two labels, and to avoid mismatches between the packing list and the shipping label (e.g., where the packing list contains information about goods to be shipped to a first customer and the shipping label contains the address of a different customer. In addition, because two printers and two label applicators, along with related hardware and software, are required to apply a packing list and shipping label in sequence, such methods require significant floor space and investment. For the foregoing reasons, it is desired to provide labeling methods that allows automatic printing and application of a lower label and an upper label to a surface while avoiding the many shortcomings of existing labeling methods. 
     For the foregoing reasons, it is desired to provide labeling methods that allows automatic printing and application of a packing list label and shipping label to the surface of a sealed carton while avoiding the many shortcomings of existing labeling methods. 
     SUMMARY 
     The present disclosure includes disclosure of at least one embodiment of a label folding assembly comprising a label deflector and a label folding device. In a label folding assembly according to at least one embodiment of the present disclosure, a label deflector is mounted to a moveable carriage. In a label folding assembly according to at least one embodiment of the present disclosure, a label deflector comprises an axis, and the axis of the label deflector is not in alignment with a direction of travel of a moveable carriage on which the label deflector is mounted. In a label folding assembly according to at least one embodiment of the present disclosure, a label deflector comprises a curved surface. In a label folding assembly according to at least one embodiment of the present disclosure, a label folding device is mounted to a moveable carriage. In a label folding assembly according to at least one embodiment of the present disclosure, a label folding device comprises a member that extends and retracts. 
     The present disclosure includes disclosure of at least one embodiment of a label folding apparatus comprising a label folding assembly and a label holding assembly. In a label folding apparatus according to at least one embodiment of the present disclosure, the label folding apparatus comprises a label folding assembly, the label folding assembly comprising a label deflector and a label folding device; and a label holding assembly adjacent the label folding assembly, the label holding assembly comprising a first surface suitable for placing a label thereagainst. In a label folding apparatus according to at least one embodiment of the present disclosure, a label holding assembly comprises at least one aperture through a first surface. In a label folding apparatus according to at least one embodiment of the present disclosure, when a label is placed onto a label holding assembly, the label is held against the label holding assembly by a vacuum force acting through at least one aperture in a first surface of the label holding assembly. In a label folding apparatus according to at least one embodiment of the present disclosure, a first surface of a label holding assembly comprises at least one boundary adjacent a label folding assembly, and when a label is placed onto the label holding assembly, the label extends past the boundary. In a label folding apparatus according to at least one embodiment of the present disclosure, a label deflector is mounted to a moveable carriage. In a label folding apparatus according to at least one embodiment of the present disclosure, a moveable carriage of a label folding assembly is moveable in relation to an adjacent label holding apparatus. In a label folding apparatus according to at least one embodiment of the present disclosure, a moveable carriage of a label folding assembly is moveable between a first position and a second position. In a label folding apparatus according to at least one embodiment of the present disclosure, when a label is placed onto a label holding assembly, movement of a moveable carriage between a first position and a second position causes a label deflector to displace a portion of the label. In a label folding apparatus according to at least one embodiment of the present disclosure, a label folding device is mounted to a moveable carriage. In a label folding apparatus according to at least one embodiment of the present disclosure, when a label is placed onto a label holding assembly, movement of a moveable carriage between a first position and a second position brings a label folding device into alignment with the label. In a label folding apparatus according to at least one embodiment of the present disclosure, a label folding device comprises a member that is moveable between a first configuration and a second configuration. In a label folding apparatus according to at least one embodiment of the present disclosure, when a label is placed onto the label holding assembly, movement of the member between a first configuration and a second configuration folds the label. In a label folding apparatus according to at least one embodiment of the present disclosure, a label holding assembly further comprises a label applicator configured to apply the label to a substrate. In a label folding apparatus according to at least one embodiment of the present disclosure, a label deflector and a label folding device comprise a single mechanism. 
     The present disclosure includes disclosure of at least one embodiment of a method for folding a foldable label. In at least one embodiment of the present disclosure, a method for folding a foldable label comprising the steps of: placing a foldable label onto a label holding assembly, the label holding assembly comprising a first surface against which the label is held; moving a movable carriage past an end of the label holding assembly, the movable carriage comprising a label deflector and a label folding device, wherein the movement of the movable carriage displaces a portion of the label; aligning the label folding device with the portion of the label that was displaced; and actuating the label folding device, thereby folding the displaced portion of the label. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and advantages of this disclosure, and the manner of attaining them, will be more apparent and better understood by reference to the following descriptions of the disclosed methods and systems, taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 2  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 3  shows an end view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 4  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 5  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 6  shows an end view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 7  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 8  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 9  shows a flowchart illustrating the use of label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 10  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 11  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 12  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 13  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 14  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 15  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 16  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 17  shows a perspective view of a label folding apparatus according to at least one embodiment of the present disclosure. 
         FIG. 18  shows a front view of a label folding apparatus according to at least one embodiment of the present disclosure. 
     
    
    
     DESCRIPTION 
     For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended. 
       FIG. 1  shows a perspective view of label folding apparatus  10  according to at least one embodiment of the present disclosure.  FIG. 2  shows a front view of label apparatus  10  according to at least one embodiment of the present disclosure.  FIG. 3  shows an end view of label folding apparatus  10  according to at least one embodiment of the present disclosure. 
     In the embodiment shown in  FIGS. 1-3 , label folding apparatus  10  comprises label pad assembly  20 , slide support assembly  40 , slide assembly  60 , and label folding apparatus mounting fixture  80 . 
     In the embodiment shown in  FIGS. 1-3 , label pad assembly  20  comprises label pad surface  22 , first end  24 , second end  26 , third end  28 , and fourth end  30 . Label pad assembly  20  further comprises at least one aperture  32  that extends through label pad surface  22 . Although label pad assembly  20  is shown in  FIGS. 1-3  as a rectangular piece, in other embodiments of label folding apparatus  10  label pad  20  may take on other shapes. 
     In the embodiment shown in  FIGS. 1-3 , slide support assembly  40  comprises first surface  41 , first side  42 , second side  44 , third side  46 , and fourth side  48 . First guide rail mount  52  and second guide rail mount  54  are fastened to first surface  41  of slide mount assembly  40 . In the embodiment shown in  FIGS. 1-3 , first guide rail mount  52  is fastened to first surface  41  near second side  44 , and second guide rail mount  54  is fastened to first surface  41  near fourth side  48 . At least one guide rail  50  extends between first guide rail mount  52  and second guide rail mount  54 . In the embodiment of slide support assembly  40  shown in  FIGS. 1-3 , three guide rails  50  are deployed. However, in other embodiments of label folding apparatus  10  according to the present disclosure, a greater or lesser number of guide rails  50  may be deployed. In the embodiment shown in  FIGS. 1-3 , and particularly in  FIG. 3 , there is a gap between guide rails  50  and first surface  41 . However, in other embodiments of label folding apparatus  10  according to the present disclosure, guide rails  50  may be in contact with first surface  41 . 
     In the embodiment shown in  FIGS. 1-3 , slide assembly  60  comprises first surface  61  and opposing second surface  65 . Sheath  62  is affixed to mounting piece  63 , which in turn is affixed to first surface  61 . Guide  72  is affixed to second surface  65  of slide assembly  60 . Guide  72  is slidingly coupled to at least one guide rail  50 . Sheath  62  encloses member  64  (not shown in  FIGS. 1-3 ). Roller  66  is affixed to end of member  64 . Label deflector  68  is affixed to first surface  61  of slide assembly  63 . Label deflector  68  comprises label deflector surface  70 , which in the embodiment shown in  FIGS. 1-3  is a curved surface. Although label deflector  68  is shown in  FIGS. 1-3  with a curved label deflector surface  70 , other configurations of label deflector surface  70  are possible and within the scope of the present disclosure. In the embodiment shown in  FIGS. 1-3 , label deflector  68  is affixed to first surface  61  of slide apparatus  60  such that an axis of label deflector  68  is not in alignment with an axis of guide rails  50 . Other configurations of label deflector  68  are possible and within the scope of the present disclosure. 
     Label folding apparatus mounting fixture  80  comprises a structure to which label pad assembly  20  and slide support assembly  40  are mounted. 
       FIGS. 1-3  show label folding apparatus  10  with slide assembly  60  in a first position. In the embodiment shown in  FIGS. 1-3 , guide  72  of slide assembly  60  is positioned closer to first guide rail mount  52 .  FIGS. 4-6  show label folding apparatus  10  with slide assembly  60  in a second position. In the embodiment shown in  FIGS. 4-6 , guide  72  is closer to second guide rail mount  54 .  FIG. 4  shows a perspective view of label folding apparatus  10  according to at least one embodiment of the present disclosure with slide apparatus  60  in the second position.  FIG. 5  shows a front view of label folding apparatus  10  according to at least one embodiment of the present disclosure with slide apparatus  60  in the second position.  FIG. 6  shows an end view of label folding apparatus  10  according to at least one embodiment of the present disclosure with slide apparatus  60  in the second position. As slide assembly  60  travels along guide rail  50  between the first position shown in  FIGS. 1-3  and the second position shown in  FIGS. 4-6 , label deflector  68  passes by and/or over first end  24  of label pad assembly  22 . When slide assembly  60  is in the second position shown in  FIGS. 4-6 , roller  66  is aligned with label pad assembly  20 . The movement of slide assembly  60  along guide rails  50  may be accomplished by any means that may occur to one skilled in the art after being presented with the disclosure herein, including pneumatic means and electromechanical means. 
       FIG. 7  shows a perspective view of label folding apparatus  10  according to at least one embodiment of the present disclosure, with slide assembly  60  in a second position and member  64  extended from sheath  62 .  FIG. 8  shows a front view of label folding apparatus  10  according to at least one embodiment of the present disclosure, with slide assembly  60  in a second position and member  64  extended from sheath  62 . In the embodiment shown in  FIGS. 7-8 , when member  64  is extended from sheath  62 , roller  66  engages with label pad surface  22 . In at least one embodiment of label folding apparatus  10 , roller  66  is in contact with label pad surface  22  when member  64  is extended from sheath  62 . In at least one embodiment of label folding apparatus  10 , roller  66  is not in contact with label pad surface  22  when member  64  is extended from sheath  62 . The movement of member  64  may be accomplished by any means that may occur to one skilled in the art after being presented with the disclosure herein, including pneumatic means and electromechanical means. 
       FIG. 9  shows a flowchart illustrating the operation of a label folding apparatus according to at least one embodiment of the present disclosure. As shown in step  92  of  FIG. 9 , an at least partially adhesive-backed label is dispensed onto a label folding apparatus. For example, a label assembly comprising release coated liner with one or more at least partially adhesive-backed labels removably adhered thereto may be routed through a dispensing mechanism (not shown) causing an at least partially adhesive-backed label to be separated from the release coated liner and dispensed onto a label folding apparatus with the adhesive exposed. In at least one embodiment, such an at least partially adhesive-backed label comprises a covering portion and a foldable portion. In at least one such embodiment, the covering portion comprises a surface area larger than the surface area of the foldable portion. In step  94  of  FIG. 9 , the foldable portion of the at least partially adhesive-backed label is displaced by the label folding apparatus. In at least one embodiment of the present disclosure, a label folding apparatus comprises a label deflector on a moveable carriage. In such an embodiment, when moved past the at least partially adhesive-backed label, the label deflector on the moveable carriage displaces at least a portion of the at least partially adhesive-backed label. In at least one embodiment of the present disclosure, the label folding apparatus comprises a stationary label deflector. In such an embodiment, the step of dispensing an at least partially adhesive-backed label onto a label folding apparatus forces the label against or over the stationary label deflector, thereby displacing at least a portion of the at least partially adhesive-backed label. In at least one embodiment of the present disclosure, the label folding apparatus comprises a forced-air label deflector. In such an embodiment, after an at least partially adhesive-backed label is dispensed onto a label folding apparatus, air is blown against the at least partially adhesive-backed label, thereby displacing at least a portion of the at least partially adhesive-backed label. In step  96  of  FIG. 9 , the foldable portion of the at least partially adhesive-backed label is folded, so that the adhesive of the foldable portion is brought into contact with the adhesive of the covering portion. In step  98  of  FIG. 9 , the label is applied to a substrate, such as a container or package. 
       FIGS. 10-11  shows a perspective view of label folding apparatus  10  according to at least one embodiment of the present disclosure with label  100  dispensed thereon. In the embodiment shown in  FIGS. 10-11 , slide assembly  60  is in the first position as shown in  FIGS. 1-3 . In the embodiment shown in  FIGS. 10-11 , label  100  comprises covering portion  102  and foldable portion  104 . In at least one such embodiment, covering portion  102  comprises a surface area larger than the surface area of foldable portion  104 . As shown in  FIGS. 10-11 , at least a portion of covering portion  102  and foldable portion  104  comprise an adhesive backing. Label  100  is dispensed onto label pad assembly  20  so that the adhesive backing of covering portion  102  and foldable portion  104  faces away from label pad surface  22 . In the embodiment shown in  FIGS. 10-11 , label  100  is larger than label pad surface  22 , so at least a portion of foldable portion  104  extends beyond first end  24  and into the path of label deflector  68 . Covering portion  102  is held against label pad surface  22  by a vacuum engaged against covering portion  102  through apertures  32 . 
       FIG. 12  shows label folding apparatus  10  with label  100  dispensed thereon. In the embodiment shown in  FIG. 12 , slide assembly  60  has traveled from the first position shown in  FIGS. 1-3  to the second position shown in  FIGS. 4-6 . When slide assembly  60  travels from the first position to the second position, label deflector  68  engages foldable portion  104  of label  100 , thereby displacing foldable portion  104  of label  100  from its planar alignment with covering portion  102  of label  100 . In an embodiment of the present disclosure where label deflector  68  comprises a curved label deflector surface such as curved label deflector surface  70 , label deflector  68  progressively engages foldable portion  104  of label  100  as slide assembly  60  travels from the first position to the second position, thereby reducing the risk that label  100  will be torn as label deflector  68  engages foldable portion  104  of label  100 . In an embodiment of the present disclosure where label deflector  68  is affixed to first surface  61  of slide apparatus  60  at an angle to an axis of guide rails  50 , label deflector  68  progressively engages foldable portion  104  of label  100  as slide assembly  60  travels from the first position to the second position, thereby reducing the risk that label  100  will be torn as label deflector  68  engages foldable portion  104  of label  100 . In at least one embodiment of label  100 , there may be one or more lines of weakness between covering portion  102  and foldable portion  104  so that displacement of foldable portion  104  by label deflector  68  is facilitated. 
       FIGS. 13-14  show label folding apparatus  10  with label  100  dispensed thereon according to at least embodiment of the present disclosure. In the embodiment shown in  FIGS. 13-14 , member  64  is extended from sheath  62 . Roller  66  thereby contacts foldable portion  104  of label  100 , folding foldable portion  104  on label  100  against covering portion  102  of label  100 . The adhesive backing on a least a part of covering portion  102  of label  100  and/or foldable portion  104  of label  100  causes foldable portion  104  to be adhered against covering portion  102 . In at least one embodiment of the present disclosure, a label folding device (such as, for example, a sheath, member, and roller device like sheath  62 , member  64 , and roller  66 ) is not affixed to a moveable carriage such as, for example, slide assembly  60 . In such an embodiment, such a label folding device is in a fixed position in alignment with label pad assembly  20 . In this fixed position, such a label folding device is aligned with the eventual position of a label that is dispensed onto label pad assembly  20 . After a label is dispensed onto such a label pad assembly and portion of such a label has been displaced by a label deflector, such a label folding device then is actuated, thereby folding the label. 
       FIGS. 15-16  show label folding apparatus  10  according to at least one embodiment of the present disclosure with label  100  dispensed thereon. In the embodiment shown in  FIGS. 15-16 , member  64  is retracted into sheath  62 , and roller  66  is brought out of engagement with foldable portion  104 . 
       FIGS. 17-18  show label folding apparatus  10  according to at least one embodiment of the present disclosure with label  100  dispensed thereon. In the embodiment shown in  FIGS. 17-18 , slide assembly  60  is returned to the first position shown in  FIGS. 1-3 . Label  100  then may be applied to a substrate, such as the surface of a container or the surface of a package. In at least one embodiment, label  100  may be removed from label pad surface  202  manually and manually applied to such a surface. In at least one embodiment, label pad assembly  20  comprises a label applicator mechanism. In such an embodiment, label pad assembly  20  with label  100  attached thereto may be moved into alignment with such a surface so that the exposed adhesive on label  100  will be brought into contact with such a surface. 
     While this disclosure has been described as having preferred designs, the apparatus and methods according to the present disclosure can be further modified within the scope and spirit of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. For example, any method disclosed herein and in the appended claims represent one possible sequence of performing the steps thereof. A practitioner may determine in a particular implementation that a plurality of steps of one or more of the disclosed methods may be combinable, or that a different sequence of steps may be employed to accomplish the same results. Each such implementation falls within the scope of the present disclosure as disclosed herein and in the appended claims. Furthermore, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.