Web burster/inserter

A web burster/inserter assembly receives a continuous supply of coupons in the form of a web where the forwardmost coupon is attached to the following coupon. The web burster/inserter separates individual coupons from the web and directs the coupons to a desired location. A ram may be used to effectuate the separation. The web burster/inserter is capable of being used with coupons of varying thickness such as plastic prizes and game pieces.

FIELD OF THE INVENTION

This invention relates generally to an apparatus for separating discrete pieces from a continuous web, and, in particular, to a web burster/inserter apparatus that can separate pieces of various sizes and shapes from a continuous web and place the separated pieces into containers that are moving along a high volume handling system or place the separated pieces into a desired location such as the fill tube of a form, fill, and seal bagging machine.

BACKGROUND OF THE INVENTION

It is a common advertising and promotional technique to place coupons, discount cards, prizes or other promotional materials into containers such as cartons for breakfast cereal or snack items or into bagged products such as potato chips. The coupon is highly visible to the consumer who can then use the coupon for the intended purpose, such as for discounts on future purchases or rebates. The coupon itself may also contain a prize or other premium, often a molded plastic figure or other piece. Accordingly, the term “coupon” used herein includes any type of insert, coupon, card, sheet, receipt, warranty, prize, premium, or other part that can be advantageously handled in accordance with the invention hereinafter described. Similarly, the terms “container” and “receiving product” are used in the broadest possible context to include containers such as boxes, tubs, cans, and vessels of all kinds as well as other coupon receiving objects that can be advantageously used with the present invention, such as the fill tube of a form, fill, and seal packaging machine.

Placing coupons by hand is very expensive as it is labor intensive and human hands cannot always keep up with the speed of modern automated packaging equipment. Thus, packaging equipment manufacturers have developed a variety of automated coupon inserter machines for placing coupons on or into products. Typically, coupon inserting devices operate by discharging or positioning a single coupon in each container rapidly moving along a conveyor system or into a chute or tube of some other type of product handling system. There are several methods and apparatus for placing single coupons. One requires a stack of pre-cut coupons that are individually dispensed from a downwardly sloping channel, such as the system shown in Prewer, U.S. Pat. No. 4,530,200. In that system, pusher elements and advancing rollers coact to withdraw the forwardmost coupon from the pre-cut stack. The coupon is then drawn into the downwardly sloping channel to a dispensing location. In another apparatus, shown in Gallimore, U.S. Pat. No. 4,197,113, a reciprocal vacuum head picks a coupon from a stack of pre-cut coupons and places the coupon on a conveyor system, which in turn transports the coupons to the containers. Another system, shown in Lewis et al., U.S. Pat. No. 4,354,894, requires the use of a mechanical cutting device to separate each coupon from a continuous web. Once separated, the coupons are dispensed to the containers using a conveyor system. In yet another system, a device separates a single coupon from a continuous web of coupons using a bursting technique and places the coupon into the container or places the coupon into the fill tube of a form-fill-seal packaging system. Such devices are disclosed in U.S. Pat. Nos. 5,845,462 and 6,082,079, respectively, which are assigned to the assignee of the present invention. While such systems are generally effective with flat coupons, they have not been found to be entirely effective for use in connection with thick or bulky coupons such as overwrapped plastic prizes or parts (such coupons shall be referred to herein generally as “three-dimensional coupons”). This invention relates to an improved coupon delivery system as compared to the systems described above and to solutions to some of the problems raised or not solved thereby.

SUMMARY OF THE INVENTION

The present invention provides a burster-type coupon insertion machine that is capable of handling three-dimensional coupons without damaging the coupon. The coupon insertion machine quickly and reliably dispenses a coupon with each activation of the device and is capable of reliably operating at high speeds. The coupon insertion machine is further capable of separating a variety of coupon sizes, shapes, and burst strengths and includes an integrated coupon delivery mechanism to provide a highly reliable coupon insertion machine at a reasonable price. The coupon inserter in accordance with the present invention easily dispenses overwrapped three-dimensional coupons such as toys, prizes, and other objects. These and other advantages of the present invention will become apparent from the detailed description, claims, and accompanying drawings.

One embodiment of an inserter manufactured in accordance the present invention includes an infeed assembly, a delivery assembly, a ram, a controller, and a number of sensors and motors. Both the infeed and the delivery assemblies include upper and lower belts that are disposed around rollers. The upper and lower belts are functionally connected to one another by a biased linkage. This linkage allows either one or both of the belts to move so as to accommodate coupons of varying dimensions. The lower belts are driven by motors and are fixed in position. In one embodiment, the upper belts are not power-driven and are adjustable and spring-biased. In another embodiment, the upper belts are driven by the same motors driving the lower belts using a drive belt including an automatic tensioning device so as to allow movement of the upper belt. The controller receives input from an activation input, the coupon staging sensor, and the coupon delivery sensor and controls the operation and speed of the infeed assembly, the delivery assembly and the ram. The coupon staging sensor is mounted between the infeed and delivery assemblies and is adjacent the ram. The coupon delivery sensor is mounted beyond the delivery assembly. A container sensor that functions as the activation input is positioned with respect to the production conveyor line such that it can detect the packages into which the coupons are to be inserted. In the case where the device is to be used with a form, fill, and seal packaging machine, the activation input is connected to the form, fill, and seal packaging machine, and is typically linked to a “dump” signal from a statistical weighing machine.

In one embodiment, the device is used with a perforated or otherwise weakened web of coupons and a dull ram end is used in the ram. In another embodiment, a non-perforated web of coupons is used, and a sharp knife end is used in the ram to ensure a clean separation. While it has been found effective to use a pneumatic ram, other electrical or mechanical configurations such as a servo-motor driven ram could also be used. Such an embodiment is particularly useful where a pneumatic power source is not available near the product manufacturing line.

The coupon inserter has a relatively simple operational sequence. In one embodiment, the motor driving the delivery assembly is stopped and started during operation of the coupon inserter. In another embodiment, the motor driving the delivery assembly is continually running during operation of the coupon inserter.

In one embodiment, the motor operating the delivery assembly and the delivery assembly itself are stopped and started. In the embodiment where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device, prior to any containers coming down the line, a continuous web of coupons is fed into the infeed assembly and a coupon is staged in the delivery assembly. When a container comes down the line, the container sensor identifies the container and sends an activation signal to the controller through the activation input. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the container. At the same time, the infeed assembly slightly backs-up the coupon web to ensure that the area near the coupon staging sensor is clear. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins forward rotation. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now moving infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the thin portion of the web (perforated or otherwise weakened in one embodiment) between the two coupons immediately below the ram. After the web stops moving, the ram fires, breaking the coupons apart. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next signal from the activation input (a container sensor in this embodiment). The process is repeated each time a container passes the container sensor.

If the inserter is used with a form, fill, and seal packaging machine, when the activation input receives a signal from the form, fill, and seal packaging machine, the signal is transmitted to the controller. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the fill tube. At the same time, the infeed assembly slightly backs-up the coupon web to ensure that the area near the coupon staging sensor is clear. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins forward rotation. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now rotating infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the thin portion of the web (perforated or otherwise weakened in one embodiment) between the two coupons immediately below the pneumatic ram. After the web stops moving, the ram fires, breaking the coupons apart. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next activation signal from the form, fill, and seal packaging machine. The process is repeated each time an activation signal is received by the activation input from the form, fill, and seal packaging machine.

In another alternative embodiment, the ram is not used. In this embodiment, which may be used in a conveyor-line installation, in a form, fill, and seal packaging machine installation, or in any other suitable environment, the operational process is slightly different. Installation in an environment where the three-dimensional coupons are being placed into containers moving along a conveyor is used for illustrative purposes. Prior to any containers coming down the line, a continuous web of coupons is fed into the infeed assembly and a coupon is staged in the delivery assembly. When a container comes down the line, the container sensor identifies the container and sends an activation signal to the controller through the activation input. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the container. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins moving. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now rotating infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the perforated portion of the web between the two coupons between the infeed assembly and the delivery assembly. After the web stops moving, the infeed assembly reverses direction so as to apply a tension to the web thereby breaking the coupons apart at the perforation. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next activation signal from the container sensor and the continuous web remains held in the infeed assembly. The process is repeated each time a container passes the container sensor.

In another embodiment, the motor operating the delivery assembly and the delivery assembly itself are continually running. In one embodiment, the delivery assembly has at least one delivery belt that is continuously moving. The continuous web is fed into the infeed assembly thereby securing the continuous web between the upper infeed belt and the lower infeed belt of the infeed assembly. The infeed assembly advances the continuous web a predetermined length/distance toward a continuously running delivery assembly. Such advancement causes the continuous web to come into contact and engage the delivery assembly. Once the continuous web has been advanced the predetermined length/distance, the infeed assembly is stopped thereby stopping movement of the continuous web. In one embodiment the infeed assembly is stopped when a web portion between successive coupons is positioned between the infeed assembly and the delivery assembly. The infeed assembly then retracts the continuous web the predetermined length/distance from the continuously running delivery assembly. The advancement and retraction of the continuous web while the web is in contact with the continuously running delivery assembly acts to separate the forwardmost coupon from the continuous web. In one embodiment, a ram or knife strikes the continuous web near the web portion to help separate the forwardmost coupon from the continuous web. The delivery assembly then moves the forwardmost coupon to a desired delivery location.

DETAILED DESCRIPTION

FIGS. 1–4show a coupon inserter (identified generally as20) manufactured in accordance with one embodiment of the present invention. The coupon inserter20includes an infeed assembly22, a delivery assembly24, a ram26, a controller28(seeFIG. 3), and a number of sensors and motors that are assembled together on a first frame piece30and a second frame piece32. A coupon source, such as the roll35shown inFIG. 1, is used to supply bandoleer format coupons to the coupon inserter20.

The infeed assembly22includes an upper infeed belt34disposed about upper infeed rollers34and a lower infeed belt36disposed around lower infeed rollers40. In one embodiment, the upper infeed belt34and the lower infeed belt36are functionally connected to one another by a biased linkage48. The biased linkage48can take a variety of forms such as springs, belts, hydraulics, pneumatics, any combination thereof, or the like. The biased linkage48allows the infeed assembly22to accommodate three-dimensional coupons. While, as shown inFIG. 4, using three rollers for each belt has been found to be an effective design, other numbers of rollers and belt configurations could certainly be used. In the embodiment shown inFIG. 3, at least one of the lower infeed rollers40is driven by infeed drive motor42which in turn causes the lower infeed belt38to move. In this embodiment, the upper infeed belt34is not power-driven but is caused to move by the coupons between the lower infeed belt38and the upper infeed belt34and/or a linkage between the upper infeed belt34and the lower infeed belt38. In an alternative embodiment, the upper infeed belt34is power-driven by infeed drive motor42and an automatic tensioning device is used to maintain a connection between the upper infeed belt34and the infeed drive motor42when the upper infeed belt34moves to accommodate a three-dimensional coupon. In still another embodiment, both the upper infeed belt34and the lower infeed belt36are power-driven by infeed motor42. It has been found effective to use a stepper motor, such as the QCI 34-H-1-E-01 motor manufactured by Quicksilver Controls or the 34N1125-LW8 motor manufactured by Anaheim Automation for infeed drive motor42although a servo motor or other type of motor that can be selectively driven at a variety of speeds could also be effectively used.

In one embodiment, upper infeed belt34and upper delivery belt52are moveable so as to accommodate three-dimensional coupons. This is accomplished by allowing the first and second upper infeed frame pieces44and46to move with respect to first and second frame pieces30and32so as to allow a gap sufficient to accommodate the three-dimensional coupon between upper infeed belt34and lower infeed belt38. Similarly, in this embodiment, the first and second upper delivery frame pieces62and64are also allowed to move with respect to first and second frame pieces30and32so as to allow a gap sufficient to accommodate the three-dimensional coupon. In an alternative embodiment, lower infeed frame pieces43and lower delivery frame pieces60are allowed to move with respect to first and second frame pieces62and64so as to accommodate the three-dimensional coupon.

As best seen by reference toFIGS. 2 and 4, upper infeed rollers36are secured between a first upper infeed frame piece44and a second upper infeed frame piece46(FIG. 3), each of which may have one or more posts47extending therefrom. First upper infeed frame piece44is attached to first frame piece30such that posts47fall within a guide track50on the first frame piece30. Similarly, second upper infeed frame piece46is attached to the second frame piece32such that posts47fall within a similar guide track50on the second frame piece32. While one post47/guide track50configuration is shown on each side of the infeed assembly22, additional such combinations may be used to further stabilize the infeed assembly22. Because of this manner of securing the upper infeed rollers36, the upper infeed belt34is allowed to move with respect to the lower infeed belt38so as to accommodate coupons of varying dimensions. The pressure on the coupons in the infeed assembly22is adjusted by using a biased linkage48of varying tension or resistance, adjusting the tension of resistance of the biased linkage48, and/or by adjusting stops within the guide tracks50. The infeed assembly22may also be configured such that the upper infeed belt34is fixed and driven and the lower infeed belt38is the one that is free to move to accommodate the three-dimensional coupon.

Like the infeed assembly22, the delivery assembly24includes an upper delivery belt52disposed about upper delivery rollers54and a lower delivery belt56disposed around lower delivery rollers58. In one embodiment, the upper delivery belt54and the lower delivery belt56are functionally connected to one another by a biased linkage48. The biased linkage48can take a variety of forms such as springs, belts, hydraulics, pneumatics, any combination thereof, or the like. The biased linkage48allows the delivery assembly24to accommodate three-dimensional coupons. While, as shown inFIG. 4, three rollers for each belt has been found to be an effective design, other numbers of rollers and belt configurations could certainly be used. In the embodiment shown inFIG. 3, one of the lower delivery rollers58is driven by delivery drive motor59which in turn causes the lower delivery belt56to move. In this embodiment, the upper delivery belt52is not power-driven but is caused to move by the coupons between the lower delivery belt56and the upper delivery belt52and/or a linkage between the upper delivery belt52and the lower delivery belt56. In one embodiment, the biased linage48functions to move the upper delivery belt52. It has been found effective to use a stepper motor for delivery drive motor59, preferably, for ease of maintenance and replacement, of the same type as the infeed drive motor42, although another type of motor that can be selectively driven at a variety of speeds could also be effectively used. In another embodiment, the upper delivery belt52is power-driven and lower delivery belt56is not. In still another embodiment, both the upper delivery belt52and the lower delivery belt56are power-driven.

As best seen by reference toFIGS. 2 and 4, upper delivery rollers54are secured between a first upper delivery frame piece62and a second upper delivery frame piece64(FIG. 3), each of which may have one or more posts47extending therefrom. First upper delivery frame piece62is attached to first frame piece30such that posts47fall within another guide track50on the first frame piece30. Similarly, second upper delivery frame piece64is attached to the second frame piece32such that posts47fall within yet another guide track50on the second frame piece32. While one post47/guide track50combination is shown on each side of the delivery assembly24, additional such combinations could be used to further stabilize the delivery assembly24. Because of this manner of securing the upper delivery rollers54, the upper delivery belt52is allowed to move with respect to the lower delivery belt56so as to accommodate coupons of varying dimensions. As in the infeed assembly22, the pressure on the coupons is adjusted by using a biased linkage of varying tension or resistance, adjusting the tension or resistance of the biased linkage48, and/or by using stops within the guide tracks50. The delivery assembly24may also be configured such that the upper delivery belt52is fixed and driven and the lower delivery belt56is free to move and not driven.

As shown inFIG. 3, a controller28is used to control the operation of the coupon inserter20. The controller28may be a programmable logic control device or other device of similar capabilities such as a computer. The controller28receives signals from an activation input66, a coupon staging sensor68, and the coupon delivery sensor70. The activation input66may be a container sensor where the coupon inserter20is installed to place coupons into boxes90moving along a conveyor line (FIG. 1A), may be attached to a form, fill, and seal machine where the coupon inserter20is installed to place coupons into the fill tube92of the machine (FIG. 1B), or may be attached to any other device that is being used to activated the coupon inserter20in a particular installation. The coupon staging sensor68is mounted on the first frame piece30between the infeed assembly22and delivery assembly24adjacent the ram26. The coupon delivery sensor70is mounted beyond the delivery assembly24such that it can sense a coupon being dispensed from the coupon inserter20. Based on signals from the activation input66, the coupon staging sensor68, and the coupon delivery sensor70, and any time delay and speed settings that are required for a particular application, the controller28controls (1) the operation and speed of the infeed assembly22by controlling infeed drive motor42; (2) the operation and speed of the delivery assembly24by controlling delivery drive motor59; and (3) the breaking of the coupon web by controlling the function of the ram24.

Ram26is attached to the first and second frame pieces,30and32, of the coupon inserter20and is positioned between the infeed assembly22and the delivery assembly24. Other means of positioning the ram26within the coupon inserter20could also be used. In the embodiment where a pneumatic ram is used, it has been found effective to use the Bimba Flat2device manufactured by Bimba Manufacturing Company. In the embodiment where an electromechanical ram is used, it has been found effective to use the QCI-17H-3-01 device manufactured by Quicksilver Controls. In one embodiment, the coupon inserter20is used with a bandoleer format coupon where each successive coupon is connected to the next one with a perforated or otherwise weakened web portion in between each. If such coupons are used, a dull wedge is used as ram end72in the ram26. In another embodiment, a non-perforated web of coupons is used, and a sharp knife is used as ram end72in the ram26to ensure a clean separation of the coupon from the web.

The coupon inserter20has a relatively simple operational sequence. In one embodiment, the motor driving the delivery assembly24and the delivery assembly24are stopped and started during operation of the coupon inserter20. In another embodiment, the motor driving the delivery assembly24and the delivery assembly24are continually running during operation of the coupon inserter20.

In one embodiment, the motor driving the delivery assembly24is stopped and started. In the embodiment shown inFIGS. 5–8where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device (FIG. 1A), prior to any containers90coming down the line, a continuous web of coupons74is fed into the infeed assembly22and a pre-staged coupon76is staged in the delivery assembly24(FIG. 5). When a container90comes down the line, the activation input66(in this case a container sensor that identifies the container) sends a signal to the controller28. The delivery drive motor59connected to the delivery assembly24is then activated by the controller28to rapidly deliver the pre-staged coupon76into the container as indicated by arrow78. At the same time, by operation of the infeed drive motor42, the infeed assembly22slightly backs-up the coupon web74to ensure that the area near the coupon staging sensor68is clear. When the pre-staged coupon76passes the coupon delivery sensor70and is inserted into the container90, the infeed drive motor42attached to the infeed assembly22begins moving so as to advance the coupon web74as indicated by arrow82(FIG. 6). At the same time, the delivery drive motor59moving the delivery assembly24is slowed to match the speed of the infeed assembly22. The now moving infeed assembly22causes the web of coupons74to be fed toward the delivery assembly24(FIG. 7). The coupon staging sensor68senses the presence of the leading edge of the forwardmost coupon68and, after a short delay determined by the coupon length and the speed of the infeed assembly22, both the infeed drive motor42and the delivery drive motor59stop thereby placing the thin portion of the web (perforated in one embodiment) between two coupons immediately below the ram26. After the coupon web74stops moving, the ram26fires causing the ram end72to break (or cut in the knifed embodiment) the coupons apart (FIG. 8). After separation, the now-separated forwardmost coupon80is staged in the delivery assembly24to await the next signal from the activation input. The process is repeated each time a container90passes the container sensor.

Also illustrated inFIGS. 5–8, is the operation of the embodiment where the coupon inserter20is used with a form, fill, and seal packaging machine to place the coupons into the fill tube92of the machine (FIG. 1B). When the activation input66receives a signal from the form, fill, and seal packaging machine, it forwards that signal to the controller28. The delivery drive motor59connected to the delivery assembly24is then activated by the controller28to rapidly deliver the pre-staged coupon76into the fill tube92of the form, fill, and seal machine (FIG. 5). At the same time, the infeed drive motor42attached to the infeed assembly22slightly backs-up the coupon web74to ensure that the area near the coupon staging sensor68is clear. When the pre-staged coupon76passes the coupon delivery sensor70, the infeed drive motor42attached to the infeed assembly22begins moving so as to advance the coupon web74. At the same time, the delivery drive motor59operating the delivery assembly24is slowed to match the speed of the infeed assembly22. The now moving infeed assembly22causes the web of coupons74to be fed toward the delivery assembly24(FIG. 6). The coupon staging sensor68senses the presence of the leading edge of the forwardmost coupon68and, depending on coupon length, after a short delay, both the infeed drive motor42and the delivery drive motor59stop, thereby placing the thin portion of the web (perforated in one embodiment) between the two coupons immediately below the ram26(FIG. 7). After the web stops moving, the ram26fires causing the ram end72to break (or cut in the knifed embodiment) the coupons apart (FIG. 8). After separation, the now-separated forwardmost coupon68is staged in the delivery assembly24to await the next signal from the form, fill, and seal packaging machine through the activation input66. The process is repeated each time an activation signal is received from the form, fill, and seal packaging machine to indicate that a coupon should be placed into the fill tube92.

In another embodiment, shown inFIGS. 9–12, the ram26is not used. In this embodiment, which may be used in a conveyor-line installation, in a form, fill, and seal packaging machine installation, or in any other suitable environment, the operational process is somewhat similar and the following description of installation in an environment where the three-dimensional coupons are being placed into containers90moving along a conveyor is used for illustration purposes only. As shown inFIG. 9, prior to any containers coming down the line, a continuous web of coupons74is fed into the infeed assembly22and a pre-staged coupon76is staged in the delivery assembly24. When a container90comes down the line, the activation input66(in this case a container sensor that identifies the container) sends a signal to the controller28. The delivery drive motor59connected to the delivery assembly24is then activated by the controller28to rapidly deliver the pre-staged coupon76into the container90as indicated by arrow84. When the pre-staged coupon76passes the coupon delivery sensor70, the infeed drive motor42attached to the infeed assembly22begins moving the coupon web74toward the delivery assembly24as indicated by arrow86inFIG. 10. At the same time, the delivery drive motor59operating the delivery assembly24is slowed to match the speed of the infeed assembly22. The coupon staging sensor68senses the presence of the leading edge of the forwardmost coupon80and, depending on coupon length, after a short delay, both the infeed drive motor42and the delivery drive motor59stop, thereby placing the perforated portion of the web between the infeed assembly22and the delivery assembly24(FIG. 11). After the coupon web74stops moving, the infeed drive motor42reverses direction as indicated by arrow88inFIG. 12, causing the infeed assembly22to also reverse direction so as to apply a tension to the web, thereby breaking the forwardmost coupon80apart from the web74at the perforation. After separation, the now-separated forwardmost coupon80is staged in the delivery assembly24to await the next signal from the activation input66and the continuous web74remains held in the infeed assembly22. The process is repeated each time a container passes the container sensor.

In another embodiment shown inFIGS. 13–15and16–17, the motor driving the delivery assembly24is continually running. In this embodiment where the delivery assembly24has at least one delivery belt52or56that is continuously moving. In the embodiment shown inFIG. 13where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device (SeeFIG. 1A), prior to any container90coming down in the line, a continuous web74is fed into the infeed assembly22. A coupon76is not staged in the delivery assembly24. The delivery drive motor59continuously drives delivery assembly24. In one embodiment, at least one of the lower delivery belt56and the upper delivery belt52is continuously moving. When a container90comes down the line, the activation input66(in this case a container sensor that identifies the container) sends a signal to the controller28. The infeed drive motor42attached to the infeed assembly22is then activated by the controller28. The infeed drive motor42operates the infeed assembly22, thereby feeding the leading edge of the continuous web74from the infeed assembly22to the delivery assembly24(FIG. 14). In one embodiment, the continuous web74is fed from the infeed assembly22into the delivery assembly24at predetermined linear speed. In another embodiment where the container90is traveling on a conveyor, the continuous web74is fed from the infeed assembly22into the delivery assembly24at the same linear speed as the conveyor.

Regardless of the embodiment, feeding the continuous web from the infeed assembly22to the delivery assembly24causes the continuous web74to pass the coupon staging sensor68. The coupon staging sensor68triggers the controller28to retrieve a programmed length/distance from memory. The controller28then activates the infeed drive motor42and operates the infeed assembly22to advance the continuous web74the programmed length/distance. After the infeed assembly22has advanced the continuous web74, the infeed drive motor42stops and restarts the infeed assembly42in the opposite direction. The infeed assembly42moves the continuous web74in the direction toward the delivery assembly. The continuous web74is moved the programmed length/distance in this direction. In one embodiment shown inFIG. 16–18, a ram26fires causing the ram end72to help break (or cut in a knifed embodiment) the coupons apart. Advancement and retraction of the continuous web74combined with contact of the continuous web74with a continuously running delivery assembly24functions to separate a single coupon from the leading edge of the continuous web74. Further, this combination functions to advance the separated coupon through the continuously operating delivery assembly24. The process is repeated each time a container90passes the container sensor.

As illustrated by the foregoing description and shown in the Figures, the present invention is more suitable as a coupon inserter for use with three-dimensional coupons than existing systems. Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims.