A label applicator for applying a label to a cylindrical portion of an object may comprise a roller and a label handler, with the roller rotating the object to which the label is being applied and the label handler separating a label from its backer and extending the label towards the object being rotated by the roller. The distance between the label handler and the object rotated by the roller is less than a length of the label. The label applicator may further comprise a printer, such as a thermal transfer printer, which may be configured to print labels for a plurality of objects to which different labels are applied consecutively.

FIELD OF THE INVENTION

A syringe labeling device that prints and wraps a label around a syringe or other cylindrical object.

BACKGROUND

Typically, labels are applied to syringes manually. This chore is tedious and time consuming. The task of manually printing and applying individualized labels to a large number of syringes is, accordingly, a major source of inefficiency in various settings, such as pharmacies and hospitals.

In addition to such inefficiencies, applying labels by hand may lead to inconsistencies and mistakes. Further, there are a variety of styles in which labels are applied to syringes, including, for example, flagging styles.

Accordingly, there is a need for a system and device to consistently and flexibly automate the label application process. There is a further need for such a system and device that facilitates the application of printed labels onto syringes as would typically be required by a pharmacist in a hospital pharmacy who must prepare syringes with medication for delivery to nurses and physicians to intravenously inject medication into various patients.

SUMMARY

The syringe label applicator is a device that prints and wraps a label around a syringe or other cylindrical object or portion of an object. It is a semi-automatic system that allows a user to place the objects to be labeled into a labeling zone of the labeling device. When the presence of the object is detected by an optical sensor the label applicator begins the application process. A single drive motor rotates and pivots a drive arm having a roller forward, pressing the object against the base and a brace within the labeling zone. Once this forward motion has stopped, a slip clutch starts slipping and the drive arm assembly motor continues to spin, transferring the force of the motor from the drive arm to the roller by the use of pulleys. The belt on the pulley is configured to rotate the roller in a reverse direction which corrects the direction of the spinning object. The label printing then begins as the drive roller is spinning. As the label ejects from the printer it passes under a stripper bar acting as a label handler and is removed from the backer. The label is then passed between the object and base causing the label to stick to and wrap around the object. After the printing sequence is completed, and the label applicator is done rotating, the motor reverses direction causing the arm to return to the home position. The user may then remove the object from the labeling zone.

Accordingly, a label applicator for applying a label to a cylindrical portion of an object may comprise a roller and a label handler, with the roller rotating the object to which the label is being applied and the label handler separating a label from its backer and extending the label towards the object being rotated by the roller. The distance between the label handler and the object rotated by the roller in the labeling zone may be less than a length of the label. The label applicator may further comprise a printer, such as a thermal transfer printer, which may be configured to print labels for a plurality of objects to which different labels are applied consecutively. In some embodiments, the printed label may be determined by a detected feature of the object or the cylindrical portion of the object, such as a diameter.

The roller may be mounted on a motorized arm, and the roller may be moved into contact with the cylindrical portion of the object on the motorized arm after the object is placed in the labeling zone and is detected by a sensor. When the roller contacts the object, the object may be braced between the roller, the base of a platform, and an associated bracing element.

In some embodiments, a single motor may control both the motion of the motorized arm and the rotation of the roller using a slip clutch.

In some embodiments, the label handler is a stripper, and the label is stripped from a label backer by forcing the label backer around a sharp turn so that the label separates from the backer.

The label may have different configurations and may have different segments with different adhesives applied thereto, allowing for a variety of label applications.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure describes the best mode or modes of practicing the invention as presently contemplated. This description is not intended to be understood in a limiting sense, but provides an example of the invention presented solely for illustrative purposes by reference to the accompanying drawings to advise one of ordinary skill in the art of the advantages and construction of the invention. In the various views of the drawings, like reference characters designate like or similar parts.

FIG. 1shows a syringe label applicator100andFIGS. 2A-2Bshow detail views of a roller and drive arm assembly110for the syringe label applicator100.FIG. 3shows a schematic view of the applicator shown inFIG. 1. The syringe label applicator100typically comprises the roller and drive arm assembly110, occasionally referred to as a labeling station, a printer assembly120, label stock130mounted on a label stock roller140, and a label stock take up reel150. Roller and drive arm assembly110comprises a roller160for rotating an object to be wrapped, such as a syringe, and a label handler170for positioning a label135from the label stock130for application to the object.

Labels135of the label stock130are typically provided spaced apart on a label backer145provided in the form of an elongated strip. The roller160and the label handler170are positioned within the assembly110such that a label135removed from a label backer145of the label stock130by the label handler170and extending from the label handler contacts the object rotated by the roller. Further, once removed from the label backer145, the label will have exposed adhesive facing the object, and as the object is rotated by the roller160, the adhesive backing of the label135sticks to and is picked up by the rotating object and wraps around the object.

The label135, with its exposed adhesive facing upwards, for example, may be passed between the object and a base180of the roller and drive arm assembly110, and the object may be located in a labeling zone190on the base180. The labeling zone190may be demarcated by a brace200. After the object enters the labeling zone190, the roller is then placed in contact with the object, securing it in the labeling zone190between brace200and roller160. The label135is then pressed against the object rotating on base180within the labeling zone190and the adhesive sticks to the object. Accordingly, the roller and drive arm assembly110wraps a label around a cylindrical portion of the object.

Typically, the object is substantially cylindrical, but the syringe label applicator100may also apply labels135to cylindrical portions of larger objects, such as a syringe with elongated flanges. In such embodiments, the base180may be narrow enough such that the cylindrical portion of the syringe rests on the base and the flanges are suspended on either side of the base.

Typically, the system is operated by a user, and the user places the object to be labeled into the labeling zone190between roller160, base180, and brace200. When the presence of the object is indicated or detected, the label applicator begins an application sequence. The indication may be by having the user press a button or may be by using a sensor, such as an optical sensor to sense the presence of the object, for example. A drive arm assembly motor240rotates and pivots a drive arm210carrying roller160, pressing the object against base180and brace200within labeling zone190. Once the object is positioned against brace200, the resistance of the object causes the forward motion of the drive arm210to stop, releasing a slip clutch220and transmitting the rotational force from the drive arm assembly motor240to the roller160instead of the drive arm210. Accordingly, a single drive arm assembly motor240may both move the drive arm210and rotate the roller160consecutively.

The printer assembly120of the applicator is for printing the labels135of the label stock130prior to the application of the label to the objects at the roller and drive arm assembly110. The printer assembly may be, for example, a thermal transfer printer for the label stock130to pass through. Accordingly, each label135may be passed through the printer assembly120. The label is then removed from label backer145at label handler170, in this case a stripper bar, and applied to a the object, while the label backer continues to a label backing take-up reel150. Label stock130continuously passes through the printer assembly120as new objects to be labeled are placed in the labeling zone190, and printer ink ribbon270is taken from a ribbon stock roller280, and passes through the printer assembly120, where ink is applied to the label stock130using, for example, a pressure roller290. Used printer ribbon270continues to the ribbon take-up reel300.

Within the printer assembly, stepper motors are used to rotate spools as required to imprint desired information onto each label, whereby successive labels135are typically imprinted with different information for labeling associated objects.

While an object, such as a syringe, is rolled by the roller160in the labeling zone190, a label135is passed through the printer assembly120, removed from the label backer145by the label handler170, and applied to the object. As shown, where the label handler170is a stripper bar, the label135may be removed from the label backer145by bending the label backer around the label handler170such that the label separates from the label backer. The label135may separate from the backer145due to the label having a higher stiffness than the backer, or it may separate because the backer is tensioned by the backer take-up reel150, while the label is not so tensioned.

While a specific configuration of label stock130, ink ribbon stock280, and printer assembly120are shown and described, it will be understood that alternate printing systems are contemplated and may be used in conjunction with the label applicator.

The syringe label applicator100may further include sensors for determining if printer ribbon270, or thermal transfer ribbon, is present. Similarly, the device may further include sensors for determining the position of the label stock130based on, for example, index marks, and to confirm the presence of label stock, for evaluating the head position of a print head in the printer assembly120, and to determine whether an object has been placed in the labeling zone190. Several readily available sensors, such as photoelectric sensors, may be appropriate for detecting the presence of the object to be labeled. The device may further include a sensor for detecting the position of a pressure roller knob and the label backer take-up150.

FIG. 4shows a side view of the roller and drive assembly110, including a view of the slip clutch220, andFIG. 5shows a back view of the syringe label applicator100, including views of a variety of motors driving various components of the applicator and printer assembly120, as well as circuitry. As shown, the drive arm assembly motor240controls both the movement of drive arm210and the rotation of roller160by way of slip clutch220. When an object is placed in the labeling zone190, drive arm assembly motor240begins rotating, moving drive arm210into position, thereby bringing roller160into contact with the object. When the forward motion of drive arm210is impeded by the object, such as when the object is braced against brace200within the labeling zone190, the slip clutch220begins to slip, thereby transferring the force of drive arm assembly motor240to roller160, which begins to rotate. The surface of roller160, in contact with a cylindrical segment of the object, begins to rotate the object.

When the slip clutch220begins to slip, the force of the rotation is transferred to a pulley system310including two wheels325,330, and a belt340. Belt340changes the direction of motion of the second wheel330such that roller160rotates in the opposite direction of the rotation of the drive arm210about its axis. Accordingly, in the embodiment shown, the transmission of rotation to the object results in counter-clockwise rotation of the object within the labeling zone190when the applicator100is viewed from the front.

Typically, when the drive arm assembly motor240begins rotating, the printer assembly120, as well as the backer take-up reel150and the ribbon take-up reel300are activated as well.

After the printing sequence is completed and the roller160is done rotating, the drive arm assembly motor240reverses direction, with the slip clutch220transmitting the force of the motor to the drive arm150, thereby causing the arm to return to the home position. The user then removes the object from the labeling zone190.

The applicator100further includes a controller provided on a printed circuit board320. The controller includes a microprocessor and memory for storing information to be printed on successive labels135. Further, as described below, a number of modes may be preprogrammed into typical embodiments of the applicator100, and different printing and labeling sequences may be implemented. It will be understood that while the embodiment shown includes a controller on a printed circuit board, many different types of controllers are contemplated, including controllers external to the syringe label applicator100entirely, such that different components of the syringe label applicator, such as the printer assembly120and the roller and drive arm assembly110may be controlled directly and independently. Similarly, the hardware components may be configured to interface with external software and may be controlled through standardized connections therewith.

The syringe label applicator100of the embodiment shown includes five motor drives capable of performing full and micro stepping modes of operation, each controlled by the controller on the circuit board320. Each motor drive is enabled under software control. In some embodiments, the enable signal shuts down output transistors and allows the same driver software to control up to four motors simultaneously.

In the embodiment shown, the five drive motors include (1) the drive arm assembly motor240, which controls the label applicator and has already been discussed in detail, (2) the platen drive motor350, shown inFIG. 3, which drives the platen and pressure roller290within the printer assembly120, (3) the head position motor360which raises and lowers the print head of the printer assembly120, (4) the ribbon take-up motor370, which collects used printer ribbon270passing through the printer assembly120and (5) the label backer take-up motor380which drives the label backer take-up reel150.

Accordingly, the printer ribbon270and the elongated strip of label backer145are both tensioned in the syringe label applicator100by the motors370,380at their respective take-up reels300,150.

Many of the motors are typically operated simultaneously and may therefore work in concert. The platen drive motor350, the drive arm assembly motor240and the two take-up motors370,380, may all be driven simultaneously in order to apply a label to an object. Other motor types and configurations may be implemented as well to, for example, reduce the number of motors or to render the label application process more efficient.

FIG. 6shows a side view of the syringe label applicator100ofFIG. 1, including views of label stock roller140and label backing take up reel150. As shown, labels135are typically provided on a label backer145and the take up reel150collects the label backer after labels are removed from the backing. In some embodiments, the label backer145contains index marks390for use by sensors to locate the labels for printing and application.

FIG. 7shows a front view of the syringe label applicator100with a syringe410in the labeling zone190. When the syringe410is detected by a sensor, the roller160moves into contact, pressing the syringe between the base180and the brace200, and begins to rotate the syringe. Simultaneously, the printer assembly120begins to print on a label135on label backer145as it gets pulled through the printer assembly120by the label backing take up reel150. In some embodiments, no sensor is provided or the sensor may be deactivated. In such embodiments, the sequence may be started by placing the syringe410in the labeling zone190and pushing the “print” button430to begin the sequence.

The Syringe Label Applicator100may print in either batch or demand modes. Batch mode will repeat the same label135each time a syringe410is placed in the labeling zone190until the mode is cancelled by a user. Demand mode, instead, maintains communication with a host computer or some alternate input method, printing a new label135for each syringe410placed in the labeling zone190. Such a mode may be for label serialization or for patient specific labelling. While these two modes are described, other modes are contemplated, and the device may be user programmable for other modes as well.

Typically, the length of time for the sequence is controlled by a wrap time setting maintained within a memory of the syringe label applicator. The wrap time may be set based on the length of a label135or the size of a syringe410to be labeled. Alternatively, a sensor may be provided to detect the completion of the wrapping process, or the wrapping may be limited based on the rotation of the object or some other criteria. Similarly, a delay between cycles may be applied to prevent the system from beginning a new application sequence before each element of the system is ready. The system may include a “ready” light420which changes color to indicate that it is ready for a new cycle.

Typically, the system uses first-out label printing where the label135that is being printed is the same label that is immediately applied to the syringe410. In such a scenario, no label queue may be provided. Alternatively, a printer assembly120may instead print several labels and control which label gets applied to which syringe.

In the device shown, the printer assembly120may be installed near the label handler170. In some embodiments, the distance between the printer head in the printer assembly120and the label handler170may be less than the length of the label135. Accordingly, the label handler170may begin to remove the label135from the label backer145before the printing sequence is completed. Similarly, the elements of the device may be positioned such that the label135begins to wrap around the syringe410before the printing sequence is completed.

FIG. 8shows a perspective view of an alternate assembly500for rotating the roller160. While the roller is described above as rotated by pulley system310, in alternate embodiments, other mechanisms may be used to transfer the force of rotation from the drive arm assembly motor240to the roller160, such as a gearing assembly500.

In the gearing assembly500, when the slip clutch220begins to slip, the force of rotation is transferred to a first gear510, which in turn transfers rotation to a second gear520. A series of interim gears530are arranged between the first gear510and the second gear520which change the direction of motion of the second gear, such that roller160rotates in the opposite direction of the rotation of the drive arm210about its axis. While a pulley system310and a gearing assembly500are shown, alternative implementations are contemplated as well.

The labels135may each include a back portion upon which an adhesive is applied prior to being placed on the label backer220, typically prior to being installed in the syringe label applicator100. The adhesive may be applied in a variety of manners, such that, for example different portions of the label have different adhesives applied, or such that the adhesive applied to one portion of the label is deadened relative to another portion. For example a first portion may have a semi-permanent adhesive applied such that it sticks to the object while a second portion may have a deadened adhesive or no adhesive applied such that it extends from the object as a flag. Similarly, the first portion may have a permanent adhesive and the second portion may have a semi-permanent adhesive such that the second portion may initially stick to the object, but may be removed from the object and extended as a flag later, during use of the object. These adhesive application techniques may be used to generate labeled syringes consistent with different labeling styles.

FIG. 9Ashows a flagged style, where a clear portion of a label is wrapped around the syringe with semi-permanent adhesive. In such a configuration, a printed portion of the syringe label extends and hangs from the syringe as a flag. The adhesive behind the white area is deadened to prevent it from sticking to the syringe or other objects when the label is applied, so it can be easily propped up and used as a flag, allowing for easy identification of the contents of the syringe.

FIG. 9Bshows a tacked style, where the clear portion of the label is wrapped around the syringe with a semi-permanent adhesive. In this style, the printed portion has less adhesive causing it to remain fixed to the syringe when applied, but allowing it to be pulled away in order to read the text on the label and see the contents in the syringe. This arrangement allows for easier storage initially, while also allowing for more flexible label viewing options during use of the syringe.

FIG. 9Cshows a complete and permanent labeling. In such a configuration, the printed and clear portions of this label are completely wrapped around the syringe, and often, the printed portion overlays the clear portion. The label arrangement is considered permanent, and is used where the need to see behind the label is not as important. Similarly, shorter labels made only of printable portions with permanent adhesive backings may be provided for applying to a syringe in this manner.

Accordingly, the label135may be one of a variety of standard label types. Typically, the first 1.5″ clear portion of any label remains unprinted and contains an adhesive backing. This portion of the label135is wrapped around the syringe410, while the remaining printed portion of the label may remain extended from the syringe as a flag, for example, as shown inFIGS. 8A-C. In the embodiment shown, the minimum label length is 3″ and there is no set maximum label length. Label width would typically be 1.0″, 1.5″ or 2.0.″ While these configurations and measurements are used in the embodiment shown, other measurements may be implemented as well to apply labels sized or shaped differently to a variety of syringes410or other objects.

In some embodiments, the portion of the label having a permanent adhesive may be transparent and the portion having the semi-permanent or deadened adhesive may be opaque and prepared for printing. For example, the opaque portion may have a matte finish designed for retaining ink.

The syringe label applicator100shown is capable of wrapping any cylindrical object with a diameter of 0.25″ to 1.25.″ These measurements encompass syringes raging from 0.5 ml to 60 ml. However, systems configured differently may accommodate larger or smaller cylindrical objects.

The syringe label applicator100may have a print only mode where the printer assembly120may be used to print a label210to be manually removed and applied to an object by hand. In such an embodiment, the system may be activated by pressing the “print” button430.

The syringe label applicator100may operate at 115 or 230 Volts, and the voltage may be determined by a user selectable switch. Alternatively, the device may be adapted for use in other electrical systems.

The syringe label applicator100may include a variety of inputs, including the “print” button430and a “cancel” button420for stopping a sequence. Additional features may be implemented utilizing these buttons, such as a counter reset activated by pushing the “cancel” button420twice. Further, commands may be provided using a USB or Ethernet port435included in the device, as well as additional input ports.

As shown, a “ready” LED420will illuminate in green when the system is ready for the next object. A “status” LED440will illuminate in red when a label has been loaded or otherwise not ready. The LEDs420,440may flash to indicate specific conditions as well. In the embodiment shown, information may be output to a provided 16 character LCD display450and through LED lights provided. In other embodiments, additional or alternative outputs, such as an output to a computerized interface or more sophisticated integrated displays, may be implemented as well.

Accordingly, the syringe label applicator100may interface with a computer using proprietary software. For example, using appropriate interfacing software, the host computer instruct the applicator100to (1) load a label135into the printer assembly120, (2) set a demand or batch print mode, (3) set a wrap time, (4) set a cycle delay period, and (5) set a wrap mode as auto or manual.

Once the instructions and/or the label are in memory, the LCD display450displays “Label Loaded” and the “ready” LED420illuminates. The user may then place a syringe410into the device and the operation is automatically initiated by the optical sensor (if in auto mode) or by pressing the “print” button430(in manual mode).

Once the process is initiated, the controller raises the print head turns on both take-up motors370,380, activates the platen drive motor350, print head position motor360, and the drive arm assembly motor240, and implements the cycle discussed above. When the print cycle is complete the print head will lower, and the ribbon take-up300will turn off after a short period of time in order to keep tension on the ribbon. The platen drive motor350will continue to run until a sensor provided finds an index mark, at which time the backer take-up motor370will turn off. After the wrap time is complete the drive arm assembly motor240may turn off as well. The system will then wait the cycle delay time before the “ready” light220re-illuminates, indicating the system is ready for the next syringe410.