LINER-LESS LABEL PRINTER SYSTEM AND METHOD

A pre-feed system and method for a liner-less label printer includes a drive roll that is configured to peel liner-less labels from a reel and pass the labels to an in-line label printer at a consistent rate. An idler roll disposed in proximity to the drive roll creates a nip for pulling labels from the reel. The idler roll is comprised of silicone which prevents the adhesive side of the liner-less label from sticking. A print controller monitors a non-contact reflective object sensor disposed in proximity to the path of the liner-less labels between the drive roll and the in-line printer. The print controller adjusts the speed of the drive roll to maintain a consistent rate for labels entering the print feed of the in-line label printer and reduces the amount of force required to feed labels into the printer.

TECHNICAL FIELD

This application relates generally to a label printing system and more particularly to a printer feed mechanism for printing liner-less labels.

BACKGROUND

Label printers typically print indicia, such as mailing addresses, onto a label that has adhesive on one side. The adhesive is generally covered with a release paper, or liner, that is removed prior to the label being placed onto the desired object, such as a letter or a box for shipping. These labels requires a person, or mechanism, to remove the release paper which is then discarded resulting in waste that must be disposed of appropriately. Alternatively, a clear plastic sleeve can be configured to accept a printed paper insert, however these sleeves also include a release paper that covers the adhesive portion that must be removed and discarded.

DETAILED DESCRIPTION

The systems and methods disclosed herein are described in detail by way of examples and with reference to the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, devices methods, systems, etc. can suitably be made and may be desired for a specific application. In this disclosure, any identification of specific techniques, arrangements, etc. are either related to a specific example presented or are merely a general description of such a technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such.

Existing label feed systems for printers generally accommodate labels that include release paper or liners that cover adhesive on one side of the labels. After printing such a label, the release paper or liner is removed and discarded. By printing onto a liner-less label, waste associated with release paper or liners can be eliminated, making liner-less label printers more environmentally friendly. Liner-less label printers also reduce extraneous costs associated with disposing of discarded release paper and liners, including labor costs and disposal costs.

A liner-less label can include a single sheet with a designated area on the front side for a customer's shipping address. A liner-less label can also include an adhesive area around the periphery of the back side of the label with a designated print area in the center for printing shipping and customer invoice information. In embodiments, the labels are received as a continuous form on a reel containing a plurality of labels. Liner-less labels on a reel have exposed adhesive which sticks to other labels and can generate relatively high forces on the feed mechanisms that are required to both peel labels off the reel and reliably pass those labels at a consistent speed across the print mechanism. Forces on the feed mechanism may be inconsistent as the labels are peeled off and released from the reel. Inconsistent or high forces on printer feed mechanisms can cause misfeeds or paper jams, and can reduce the quality of printing on the labels if the labels are not fed at a consistent rate across the print mechanism.

Example embodiments of the subject application include a pre-feed mechanism configured to peel continuous form labels off of the reel and present them to the feed mechanism associated with a print mechanism at a consistent rate with a lower force than required to peel the labels off the reel, a printer feed mechanism configured to reliably pass labels over a print mechanism, a print mechanism configured to print on one or both sides of a liner-less label from the reel, and a finisher mechanism configured to cut individual labels to size after printing.

In accordance with the subject application,FIGS. 1A and 1Billustrate an example embodiment of a liner-less print system100. The liner-less print system100includes a pre-feed mechanism102comprising a rubber, powered drive roll104, a silicone rubber idler roll106, and a non-contact reflective object sensor108. A reel of liner-less labels112is mounted on a rotatable spindle114. Liner-less labels116from the reel112are threaded through the nip118between the drive roll104and the idler roll106. The drive roll104is comprised of rubber or another similar material configured to contact the printable top surface of the liner-less labels116. The idler roll106advantageously is comprised of silicone or another similar material configured to contact the bottom surface of the liner-less label116without adhering to or sticking to the adhesive material on the bottom surface of the liner-less label116.

The drive roll104and idler roll106pass the liner-less labels116to the in-line printer120. A non-contact reflective object sensor108monitors the amount of slack110in the liner-less labels116in the path between the pre-feed mechanism102and the in-line printer120. The liner-less labels116are pulled into the in-line printer120at a consistent rate, indicia are printed on one or both sides of the liner-less labels116, and the label is cut to size by an associated finisher in the in-line printer120.

In operation, the drive roll104is rotated by a print controller122to pull liner-less labels116from the reel112into the nip118at approximately the same rate that the liner-less labels116are consumed by the in-line printer120. The print controller122monitors the sensor108and maintains the proper amount of slack110in the liner-less labels116that are passed to the in-line printer120. The pre-feed mechanism102advantageously pulls the liner-less labels116from the reel112and presents them to the input queue of the in-line printer120such that a low and consistent force is required by the in-line printer120to pull the liner-less labels116into the in-line printer120for printing and sizing. This low and consistent force advantageously not only reduces misfeeds and paper jams, but also improves the quality of printing on the liner-less labels116which are fed at a more consistent rate across the printer mechanism.

The liner-less labels116can include a printable top surface configured to accept address indicia associated with a shipping label and a bottom surface that includes adhesive. In embodiments, the adhesive is disposed over only a certain portion of the bottom surface, for example around the edges, leaving a second printable area for accepting additional printed indicia such as invoice information for the end customer. In these embodiments, the consumer can remove the label from a received shipment to view the printed indicia on the bottom surface of a liner-less label116.

Turning now toFIG. 2, illustrated is a flowchart200of example operations of a liner-less label printer. Operation commences at start block202and proceeds to block204where liner-less labels from a reel of labels are threaded through the nip between a drive roll and idler roll in the pre-feed mechanism, passed over a non-contact sensor, and inserted into the feed mechanism of the in-line printer. At block206, the liner-less label printer receives a print job for a label, such as a shipping label. At block208the print controller rotates the drive roll with a first, high torque to pull the liner-less labels from the reel into the nip between the drive roll and idler roll. At block210the print controller sensor monitors sensor to determine the slack in the liner-less labels between the pre-feed mechanism and the in-line printer. At block212the print controller adjusts the rate of the drive roller in accordance to the monitored sensor to maintain the determined amount of slack in the liner-less labels. At block214the print controller activates the feed mechanism of the in-line printer which pulls the liner-less labels at a second, lower torque to pull the liner-less labels into the in-line printer for printing. At block216the in-line printer prints indicia on one or both sides of the liner-less label. Note that the operations of blocks206through216can be performed essentially simultaneously or in sequence as would be appreciated by one of skill in the art. At block218a finisher mechanism associated with the in-line printer cuts the liner-less label to size and ejects the label from the in-line printer. At block220, the drive roll and in-line printer are idled and operation returns to block206to wait for the next label to be printed.

Turning now toFIG. 3, illustrated is an example of a digital device system300suitably comprising print controller132ofFIGS. 1A and 1B. Included are one or more processors, such as that illustrated by processor304. Each processor is suitably associated with non-volatile memory, such as read only memory (ROM)310and random access memory (RAM)312, via a data bus314.

Processor304is also in data communication with a storage interface306for reading or writing to a data storage system308, suitably comprised of a hard disk, optical disk, solid-state disk, or any other suitable data storage as will be appreciated by one of ordinary skill in the art.

Processor304is also in data communication with a network interface controller (NIC)330, which provides a data path to any suitable network or device connection, such as a suitable wireless data connection via wireless network interface338. A suitable data connection to a print server is via a data network, such as a local area network (LAN), a wide area network (WAN), which may comprise the Internet, or any suitable combination thereof. A digital data connection is also suitably directly with a print server, such as via Bluetooth, optical data transfer, Wi-Fi direct, or the like.

Processor304is also in data communication with a user input/output (I/O) interface340which provides data communication with user peripherals, such as touch screen display344via display generator346, as well as keyboards, control buttons, mice, track balls, touch screens, or the like. Processor304is also in data communication with sensor350, suitably comprised of non-contact reflective object sensor for sensing slack in a continuous ribbon of unprinted labels. It will be understood that functional units are suitably comprised of intelligent units, including any suitable hardware or software platform.