Tape applicators

A bow taper having a clamping and cut-off station wherein the tape is pulled from a clamping and cut-off station to an extended position to provide a length of tape extending between said clamping and cut-off station to said extended position, and is clamped via a clamp in the station so that when the tape is applied to a case positioned to be taped by said taper on a leading corner of the case that is adjacent to said extended position tension is applied to a free span of tape between the leading corner and the clamp, cutting off tape adjacent to said clamping and cut-off station to leave a free end and releasing said clamp from clamping said tape.

FIELD OF INVENTION

The invention is related to improvements in tape applicators for the packaging art, more particularly to improvements to specific elements of a tape applicator and to a new bow taper of the type shown in U.S. Pat. No. 5,730,827.

BACKGROUND OF THE PRESENT INVENTION

U.S. Pat. No. 5,730,827 teaches a taper method and apparatus generally known as a “bow taper” which is particularly suitable for taping the top and/or bottom flaps of a carton closed and operates on the principal of pulling a tape from a roll and then with the carton in position (flaps in closed position) is activated to apply the tape to the carton by means of wipe down rollers etc. and wherein the wipe down rollers and cutoff knife for severing the tape from the source are all actuated by the same mechanism.

The term “bow taper” is used herein to broadly describe this type of taper wherein a ribbon of tape is pulled from a source to provide a span of tape and then the tape is wiped onto the case being sealed.

The recent internet phenomenon of selling discrete items that have to be shipped to the consumer has generated a whole new packaging niche requiring a highly compact and flexible packing cell. Existing technologies and solutions have failed to supply a suitable, compact and practical self contained case packing work cell particularly suitable for internet type marketing and shipping. Automated warehouses have expensive sophisticated infrastructures to pick a warehouse object, but the case packing end is still done manually. In most cases the product which may involve an almost infinite variety is delivered on totes or carriers to a packing station where operators choose a case size, pack the product and then fill it with void filler (Styrofoam peanuts or equiv), seal it and then label and palletize the case. Obviously this necessitates the ability to process products with large rapidly changing carton size requirements.

With such a variety of product to be packaged, packing cannot be done automatically. Currently there are several semi automatic packing systems available that are based on a small case erector and a length of conveyor between the erector and an automatic case sealer which is used to provide the packing area. The problem with these is that the operator has to lean over the box conveyor to reach the product which has to be located on the opposite side of the box conveyor. As well, the operator has to walk considerable distance to lift the finished (closed and sealed) case from the discharge conveyor located downstream from the case sealer and palletize it and then walk back to the packing station.

Another severe limitation of prior art tape applicators is that they require a power source to move the case to be sealed to and through the tape sealing mechanism. This usually involves a powered belt or belts to power the object. The current invention does not require relative movement of the object which is having tape applied to it, and can apply tape to a variety of objects that are static.

The bow taper device taught in above referred to U.S. Pat. No. 5,730,827 (the teaching of which is incorporated herein by reference) is the original version of tapers of the same family (bow tapers) as the bow taper of the present invention. This original version requires that the all the wipe down rollers (leading (left) and trailing (right)) and the cutoff knife all be activated by the same mechanism which limits its utility as the mechanism to actuate this large assembly required considerable space and does not permit the building of an efficient case packing station since product cannot not be easily be delivered close to the case to be packed. Also, the arrangement of U.S. Pat. No. 5,730,827 does not allow for the operating elements to be made modular so that the taping system could be constructed as a modular system and built into various types of tape application machinery. This prior art arrangement also makes adjustment of the device for different length objects to be taped difficult.

U.S. Pat. No. 6,726,613 B1 issued Apr. 27, 2004 to Sewell discloses a versatile packaging station that may be incorporated into the present invention

BRIEF DESCRIPTION OF THE PRESENT INVENTION

It is an object of the present invention to provide improved elements for a tape applying system and/or to an improved bow taper tape applying system

The present invention provides an improved bow taper that can be incorporated into a unique packing station the structure and operating method of which are described below. The inventions disclosed also include specific operating elements that prior to the present invention were unknown. By unique arrangement of the operating elements the current invention also allows for an easily adjustable, compact modular construction of a new bow taper tape applicator that can apply tape to a static object and be built into various types of packaging machinery. The present invention can apply the tape with controlled tension and with predictable application and precision.

The present invention is also arranged so that very little structure or mechanism exists above the article being taped. This allows for product to be delivered by various means very close to the case being packed, which was not possible with known systems such as that taught in U.S. Pat. No. 5,730,827.

Broadly the present invention relates to a method of taping a case using a bow taper having a clamping and cut-off station comprising pulling an adhesive tape ribbon from said clamping and cut-off station to an extended position using a puller and gripper to provide a length of tape extending between said clamping and cut-off station to said extended position, clamping said tape via a clamp in said clamping and cut-off station and applying said tape to a case positioned to be taped by said bow taper on a leading corner of said case adjacent to said extended position to thereby apply tension to a free span said length of tape between said corner and said clamping and cut-off station, wiping said tape adjacent thereto against a leading end wall of said case and releasing said tape from said gripper, wiping said tape adjacent to said clamping and cut-off station onto a trailing end wall of said case positioned adjacent to said clamping and cut-off station and remote from said leading end wall, cutting off said tape adjacent to said clamping and cut-off station to leave a free end and releasing said clamp from clamping said tape.

Preferably said case and said leading corner are positioned at a different elevation than said clamp so that said length extends between said corner and clamp as a substantially free span. Broadly the present invention also relates to a bow taper comprising a puller and gripper moveable from a clamping and cut-off station to an extended position to pull tape from said clamping and cut-off station and provide a length of tape between said clamping and cut-off station and said extended position, a clamping and cut-off mechanism in said clamping and cut-off station, cut-off knife and a releasable clamp forming part of said mechanism in said clamping and cut-off station, means to activate said cut-off knife to cut said tape and means to activate said clamp to release said tape.

Preferably, said clamp has a pad for engaging a adhesive side of said tape, and wherein said pad is made of silicone rubber.

Preferably, said puller and gripper is provided with jaws between which said tape is gripped and where said jaws are each provide with a pad of silicone rubber to engage said tape.

Preferably, said bow taper further comprising a backstop, said backstop being positioned to ensure that said case is proper taping position for tape application and is provided with means to eject said case from said taping position.

Preferably, said bow taper further comprising a transverse roller positioned to wipe said tape after application to said case against an adjacent wall of said case when said case is being removed from said taper.

DETAILED DESCRIPTION OF THE INVENTION

The construction of the device of the present invention provides for an improved the (del?) taping process permitting sequentially actuating the elements. The invention will therefore be described by first describing the combination of elements of the present invention and their sequence of operation with reference toFIGS. 1 to 11.

The bow taper9of the present invention includes a gripper and puller10for releasable gripping and pulling a ribbon of adhesive tape20which at the beginning of the sequence has grasped the tape20is at moved by a drive mechanism schematically represented by the two ended arrow12to the starting position defined by a clamping and cut off station14where, as will be described below, its jaws16grip the free end18of the tape20. Next the gripper10is moved to the left in the illustration by drive12to pull the tape20and move the free end18to the extended position22(seeFIGS. 3 and 4) the position of which is set by the adjustable stop11and which will be beyond the end of the case100remote from the clamping station14(this operation takes place before the carton or case100to be taped is put into the machine). This action provides a length of tape15extending from the clamping and cut-off station14to the extended position22

The clamping station14incorporates a suitable clamping and cut off mechanism24(seeFIG. 4,FIGS. 7 to 11inclusive andFIGS. 13 to 16that show the station14in more detail) that at the appropriate times in the sequence clamps or releases and cuts the tape20. The clamp is operated by an actuating mechanism schematically represented by pneumatic cylinder26which moves the clamping pad27at this point in the operation to a release the clamping pad27which clamps the tape against a fixed shoe29(seeFIGS. 13 to 16) thereby releasing the tape20to permit leading end of the tape to be pulled by the gripper10from the clamping and cut off station14to the extended position22beyond the location where the end of the case to be taped will be positioned.

After the tape20has been so extended so that the leading or free end18(leading in the direction of tape movement) is in the extended position22and a case100to be sealed is positioned between the extended position22and the station14in position to receive the tape the (left or leading) roller28which is moveable as indicated by the arrow30(which also represents the drive for so moving the roller28) between its retracted or home position32above the path of the gripper10and an extended tape applied position34starts downward movement (movement toward the case100which has been inserted into the machine) and is positioned to force the tape20against the leading top corner102of the case100and then along the leading panel104of the case100thereby attaching the tape20first to the corner of the case102which helps to pull the flaps106and108of the case100closed and then to the side104. It will be apparent that prior to using the invention on a specific case the location of the extended position22of the gripper10and thereby the location of the path of travel of the lead roller28between its home position32and its extended tape applied position34is defined by appropriately positioning the stop11the position of which is adjustable either manually of automatically as schematically represented by the arrow35. At the same time or slightly before the roller28is actuated, the tape clamping and cut off mechanism24of the clamping and cut off station14(located adjacent to the opposite end (trailing) of the carton or case100) is actuated by cylinder26to move the pad27into gripping position forcing the tape against the shoe29(seeFIG. 13 to 16) to grip the tape20and thereby ensure no excess tape20is unwound from the roll and the length15of tape20in its fee span portion between the corner102and the clamping and cut-off station14is tight (under tension) as it is applied by the trailing (right) roller50as will be described below.

The downward movement of the leading wipe down roller28presses the tape against the carton i.e. corner102so that the free span length15of tape20now extends at an angle α to the top of the case (flaps106and108) and in the illustrated arrangement to the horizontal (the top of the case in this case is horizontal). This movement applied tension to the free span15of the tape20. The angle α is dependent on the gap g i.e. in the illustrated arrangement difference in height between the top of the case (flaps106and108) and the location of the tape clamp shoe29. The angle α will normally be in the range of between 4 and 10 degrees and obviously is defined by the gap and the length of the case i.e. distance between the leading and trailing walls104and112(the machine is normally adjusted so that the gap is the same regardless of the height of the case100).

This movement of the leading wipe down roller28thus introduces tension into the tape20in the span between the shoe29and the point of attachment of the tape to the case100i.e. corner102. This tension is important to the quality of the taping job.

After the tape20is attached to the corner102of case100as above described, the jaws16of the gripper10are released by the trip finger23rotating the latch304downward (seeFIGS. 17 and 18) and the gripper10begins its travel toward the right as the tape is being pulled free of the jaw16by the continued movement of the leading wipe down roller28to it's extended position34.

The trip finger23moves in unison with the roller28so that the gripper10does not release the tape until the tape has positively been adhered to the corner of the case102and the flaps106and108have been firmly pulled closed, ensuring a tightly sealed case.

When the wipe down roller28has neared the end of its stroke i.e. approaches the extended position34the trailing (right) wipe down roller50positioned adjacent to the station14is moved from its retracted or home position52as illustrated inFIG. 1 to 6inclusive toward its extended position54(seeFIG. 16) as illustrated inFIGS. 7,8and9and as schematically indicated by the arrow56(seeFIG. 1) which also represents the drive for this roll50starts down and forces the tape20against trailing corner110of the carton100and pulls the flaps106and108firmly closed.

When the leading wipe down roller50has traveled far enough that the tape20has been wiped around the trailing corner110of the case100and the adhesive on the tape20has stuck to the trailing wall112(seeFIG. 7) the cutoff knife60forming part of the clamping and cut off mechanism24in station14is actuated via cylinder25to cut the tape20(seeFIGS. 7 and 8). After the trailing wipe down roller50finishes its travel to its extended position54both wipe down rollers28and50are returned to their retracted or home (top) positions32and52respectively and the pushback schematically indicated at70(seeFIGS. 10,16and17) is engaged to push the taped case100out of the machine.

The Backstop or push back70provides several functions. It acts as centering locator to position the case100so that the tape20is applied along the desired line symmetrically over the adjacent, preferably butted edges of the flaps106and108, and it triggers the taping cycle described above. At the completion of the taping operation it provides a mechanism to eject the taped case from the machine.

The pushback or backstop70also provides a means of ensuring a “flaps meeting” (adjacent edges106A and108A abutting seeFIG. 12B) in those cases where the flaps106and108are intended to abut in the closed carton100. The latter is achieved by the backstop providing a rigid stop for the operator to push the case firmly against prior to the tape being applied. This pressure ensures the adjacent edges106A and108A of the major flaps106and108are pushed together before the tape is applied. A case that has the major flaps in firm contact is considerably more rigid than one that has a gap across the major flaps.

The backstop70also provides a squaring device and guards the tape jaw.

Suitable guides290and292align the leading and trailing walls104and112respectively of the case100in proper position relative to the rollers50and28respectively. The guide292is moveable with the frame450as the machine is adjusted for a different size case (seeFIGS. 22 and 23and schematically inFIGS. 4 and 5.)

The packing fork patent, no.6,726,613referred to above discloses a backstop that functions as a squaring bar. The construction of the pushback so that it may be used to automatically eject heavy cases and to facilitate the zero gap closure is unique.

Turning toFIG. 12the operation of the hold down roller80which in the illustrated arrangement has a central shaft82covered with foam sleeve84that rotates with the shaft and is capable of following the surface of the closed carton whether it is properly filled as illustrated in A or overfilled as shown inFIG. 12A1or under-filled (FIG. 12P1) where the top flaps are folded to a position where their free edges are slightly within the case) and thus acts to press on the tape20as the carton is being ejected after taping and to better ensure that the tape is properly adhered to the article being taped. The rotational axis of this roller is perpendicular to the direction of movement of the carton100when it is being inserted or rejected from the bow taper9. In the prior art a roller oriented with its axis perpendicular to the axis of roller80namely roller80P shown in the Prior art section (FIG. 12P and band12P1) was applied to wipe down the tape20but could not effectively perform this operation if the carton was over or under filled as indicated in P and P1respectively.

Illustration12B shows that carton100being forced as indicated by the arrow89into the taping position of the machine against the resistance (as indicated by the arrow90) of the pusher70to force the edges106A and108A of the flaps106and108respectively together and square and rigidize the carton. The stop schematically indicated at92which may be adjustably positioned as schematically illustrated by the arrow94stops the rearward movement of the carton100when it is properly positions relative to the taper to apply the tape20along the desired line.

The corner pressure applied by the rollers28and50when they are operated as above described to apply the tape20in combination with the squaring pressure and the action of the hold down roller80all may be used to improve the diagonal strength of the packed and taped carton as shown in12C. This is generally not possible with existing machinery.

When the taping operation has been completed the pusher70driven by cylinder72ejects the taped carton100from the machine (seeFIG. 20 and 21and the description thereof herein below for further information on the pusher or backstop70)—this operation may be made to be automatic or manual. With a powered backstop, the filled case is forcibly ejected into the operator's hands so that he may more easily handle it further and palletize the case. As well, the operator does not have to make any effort to pull the case out of the machine

FIGS. 13 to 16inclusive show (with parts omitted for clarity) the clamping and cut off station14and its mechanisms24the operation of which has been described above. As shown the mechanism24includes a framework200which mounts the clamping system composed of the actuator26which moves the clamping pad27through a suitable hole202in the tape support plate204to force the tape20against the shoe29and thereby clamp the tape20between the pad27and the shoe29and prevent it from moving. A suitable hold down spring206extends from a bracket108on the shoe29to hold the tape against the plate204. The clamp27,29is released when the rollers28and50retract toward their home or start positions and is applied when the clamp10is in extended position as above described. The spring206also functions to prevent uncontrolled motion of the tape20on the return motion of the cutoff knife60and better ensures the tape20is properly located for the jaw16to pick up the leading end18of the tape ribbon20in subsequent motions.

The cut off knife60is mounted on a rocker arm212that is pivoted around the shaft214by the actuator25to move the knife60to cut the tape and then retract to the position shown in these figures. The switch210is tripped by movement of the roller50toward the extended position and this switch activates the actuator25of the cut off mechanism to cut the tape20. The ribbon of adhesive tape20passes over tape guiding roller216(adhesive side facing the roller216) and between the shoe29and the plate204i.e. over the upper surface of the plate204and below the shoe29with the adhesive side of the tape20facing the plate204. Positioned at the leading end of the frame200is a stop bolt218that contacts a portion of the gripper10as will be described below to close its jaws16.

Preferably the surface of the support plate204facing the tape will be covered with sandpaper or silicone rubber that supports the tape after its cut off. After the tape has been cut a short length of the tape as represented at the leading end18hangs out over the edge of this plate204The short length, shorter than ½ inch tends to prevent the tape from drooping and it supports itself so the gripper10can easily grip this leading portion18in the next cycle. The spring finger206rests lightly on the top of the tape20near the support plate edge keeps the tape from being pulled up with the cutoff knife60.

The clamping pad27preferably will also have the surface that contacts the adhesive side of the tape coated with a layer31silicone rubber to prevent the tape from sticking to it.

The gripper10will now be described in more detail with reference toFIGS. 17 and 18. The gripper10is composed of an outer housing300that contains a slide block302that is mounted to slide forward and backward in the housing300. The slide block302contacts the bolt stop218on the frame200of the station14and forces the slide block rearward relative to the housing300which causes the jaws16to close and clamp the leading end18of the tape20when the gripper10is moved against the frame20. When the block has moved to jaw closing position a latch304pivotably connected to the bock302moves via the influence of spring305as indicated by the arrow306to a position to engage an abutment shaft308extending rearward from the housing300in a pocket310(seeFIG. 18). When the gripper10is in its extended position (remote from the cutoff station14which is fixed in the machine) and the wipe down roll28is moved toward its extended position34the latch302is tripped (by the trip finger25which moves with the roller28) and the latch304is moved as indicated by arrow312to the position shown inFIG. 17thereby permitting relative movement between the sliding block302and the housing300permitting the jaws16to open and release the free end18of the tape20.

The jaws16comprise a pair of opposed jaw members314and316which are pivotable mounted to the slide block302and have plate elements318that cooperate with upper and lower guide rollers320and322respectively on the housing300to cam the jaws314and316into a closed gripping position (FIG. 18). Closing of the jaw members314and316is accomplished by the block302being held stationary by the stop bolt218so that further motion of the body300(which is attached to the drive mechanism) causes relative motion between the block302and housing300causing the rollers to cam the jaws314and316closed. This allows the jaw pads325to clamp on the tape20without imparting any movement to the tape20.

The gripping pads325(one on each of the jaws314and316) that contact and grip the fee end18of the tape20are formed of silicone rubber.

The use of a silicone pad31on the clamp pad27and pads325on the jaws314and316provides a significant advantage of other gripping surfaces as it provides a resilient pad that also provides a non stick surface. Tape adhesive does not adhere to silicone rubber and allows for the tape to be pulled free very easily after the jaws or clamp is, are opened. The very low surface energy of silicone rubbers make it ideal for this application compared to a silicone or Teflon coating that will wear off with use.

The support table400(seeFIGS. 19 to 24) used in the present invention preferably incorporates the teachings of U.S. Pat. No. 6,726,613 B1 issued Apr. 27, 2004 to Sewell the teachings of which are incorporated herein by reference.

FIGS. 19,20and21show the operation of the hold down roller80shown inFIG. 12. As shown this roller80extends across the front of the machine above the packing table generally indicated by the numeral400and is contained within a housing402. The carton100is moved under this roll80i.e. between the support table400and the roll80as above described, functions to roll the tape down and better insure the tape joint and ensure positive tape adhesion. Obviously the height of the housing402and thus the roll80is adjustable as schematically indicated by the arrow403to accommodate case of different heights. In operation the leading (in the direction of movement of the case into the bow taper9) major flap108hits the arced face of the front cover402, pushing it closed, and the trailing major flap106is pushed down by the operator prior to the case being inserted. Roller80then keeps them closed.

FIGS. 20 and 21show the mounting of the pusher70in more detail. As can be seen the pusher70comprises an arm74pivoted to the bottom of the main frame550on pivot pin76. The cylinder72referred to above is spring biased to resist rearward movement of the arm74to facilitate (provide backpressure as the carton100is inserted into the machine and drives the arm74to eject the taped carton). In the illustrated arrangement an L-shaped abutment element78is mounted at the free end of the arm74and is positioned to engage the adjacent carton wall.

The operating position of the pusher70(most rearward position of the element78) is determined by the position of a stop pin92which is adjustably position (to match with the width of the carton to be taped by the lead screw94the adjustment of which is described in more detail with reference toFIGS. 25 and 26. The arm74as it is moved rearward by the insertion of a carton into the machine until the arm74contacts the pin92which stops further movement and properly centers the carton. The backstop lead screw94is mounted to slide slightly so that when the backstop support arm74hits its stop pin92it pushes the lead screw back slightly and triggers the start valve96which initiates the taping operation. The start valve mechanism and mount is shown in more detail inFIG. 26.

The present invention preferably has a floating hub tape mounting in the form of an idler500(seeFIG. 22 and 23) wherein the tape roll502is mounted with it's rotational axis parallel to the direction of tape movement when it is pulled by the gripper10so that the tape must twist so that is adhesive surface rides over the roll216and onto the plate204. This is considerably less expensive than a conventional mount. Plus, the roll resting on a bottom idler500and unwinding around this idler500provides more constant unwind tension. A further advantage of this arrangement is that it provides for a very compact machine length and allows for product to be fed in alongside the operator, providing further flexibility.

FIGS. 22,23and24also show the frame450for mounting the leading wipe down roller28. The frame450is moveable as indicated by the arrow452relative to the main frame550of the machine and is clamped in adjusted position for the carton being taped by a suitable clamp the handle of which is shown at454inFIG. 24. The position of this frame450determines the position of the wipe down roller28as well as the stop position of draw cylinder (not shown) for moving the gripper10between the clamping and cut off station14and the extended position22of the gripper10.

Attention is directed toFIG. 25which illustrates the width and height adjustment mechanisms

The hand wheel250at the right hand side of the machine adjusts the relative height of the case support platform400to accommodate different case100heights. Movement of the hand wheel250rotates the vertically placed lead screw252through bevel gears254and adjusts the level of the frame256sliding on the support column258.

At the left hand side is another hand wheel260which drives the lead screw94to which the backstop stop pin94is coupled. As above described this lead screw94has slight fore and aft movement to allow the lead screw94to activate the start valve96through a ramp or bevel98at the rear end of the lead screw. When a case is advanced into the machine, the backstop support arm74rotates until it strikes the stop pin92. This drives the lead screw94back slightly and a beveled ramp98on the lead screw activates the start valve96.

With the construction of the present invention a conveyor552may easily be mounted on the top of the machine so product can be delivered to the edge of the open case and then simply dropped into the case and sealed. Other product delivery means can be brought very close to the open case facilitating packing.

The present invention allows for very rapid or even random adjustment. The leading wipe down frame450slides easily and quickly, and the case height can be easily configured to be rapidly or remotely set. (Rapid packing fork adjustments are described in U.S. Pat. No. 6,726,613 related to the packing forks) In remote configuration, if a self centering mechanism is added, the machine sequence can be changed so that the machine starts with the width and height at minimum. The gripper starts out at the clamping and cut off station and once the size is set, travels to the left as the operator is pushing a case in. When the case hits center, the backstop70is locked and the tape is applied.

The various drives that have been schematically indicated by the arrow such as arrows12,3056may be comprised of any suitable drive system; generally it is preferred to use pneumatic drives.

Having described the invention, modifications will be evident to those skilled in the art without departing from the scope of the invention as defined in the appended claims.