Abstract:
A coupon insertion apparatus configured for sequentially inserting coupons into receiving containers, including a machine frame, at least one pair of opposed rollers mounted to the frame and adjustable between a closed position and an open position. A drive system includes a drive belt for simultaneously driving the opposed rollers in both of the positions. A tensioner is connected to the belt and is movable generally transversely to a direction of the adjustment of the drive rollers to maintain a designated tension on the drive belt.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to apparatus for inserting coupons into containers moving along a high volume handling system. Such systems separate the forwardmost coupon from a continuous web and inject the coupon into a container as the container passes a designated location for insertion. 
         [0002]    It is a common advertising and promotional technique to place coupons or other leaflets into containers, such as cartons for breakfast cereal or snack items, along with the product to be sold. The consumer may use the coupon for whatever purpose intended, such as for discount or future purchases or a rebate. Many devices have been provided for depositing coupons into containers in the present day packaging industry. 
         [0003]    This is just one use for the insertion apparatus described below. However, it should be understood that the word “coupon” is used in its broadest possible sense to include any coupon, card, sheet, receipt, warranty, prize, premium or other part that can advantageously be handled as described hereinafter. Similarly, “container” is used in the broadest possible sense to include containers such as boxes, tubs, cans and vessels of all kinds as well as any other coupon-receiver which can advantageously be used with the present system. 
         [0004]    Commonly assigned U.S. Pat. No. 5,784,861, incorporated by reference herein, discloses a coupon insertion device receiving a supply of coupons from a reel and inserting them sequentially into an array of containers. The reel is fed between first and second pairs of opposing rollers. Differential speeds of the first and second pairs of rollers create a tear and burst action on the reel through which the forwardmost coupon is separated from the reel and projected into the container. 
         [0005]    While this apparatus is very effective in inserting flat or two-dimensional coupons into containers, there has been a need for similar equipment used for three dimensional coupons having a height or thickness which is significantly greater than conventional flat coupons and/or which are irregular in configuration. 
         [0006]    Coupon insertion apparatus have been introduced in which the opposing pairs of rollers are vertically adjustable relative to each other to accommodate coupons of varying sizes and shapes. Such systems typically employ drive belts to power the rollers in the opposing sets. However, a corresponding design issue is maintaining desired control of the drive rollers as the apparatus is adjusted between wide and narrow spacings to accommodate coupons of varying thicknesses. 
         [0007]    Conventional coupon insertion apparatus have addressed this problem through the use of spring-loaded pulleys or tensioners for adjusting drive system drive belt tension. However, these systems increase the complexity of the apparatus and the associated manufacturing and repair cost. Also, these systems have been found to increase wear of the drive belts. 
         [0008]    Thus, there is a need for an improved coupon insertion apparatus in which variations in the separation between opposing pairs of rollers is achieved in a relatively less complicated and more easily maintained manner. There is also a need for an improved coupon insertion apparatus in which drive belt wear is reduced at the same time movement between closed and open roller positioning is accomplished while maintaining adequate drive belt tension. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    The above-listed needs are met or exceeded by the present drive system for a coupon insertion apparatus including upper and lower drive rollers powered by a drive belt. The rollers are adjustable between a closed and an open position for accommodating coupons of varying shapes. A drive belt tensioner is provided which accommodates variation in the spacing of opposing rollers without the use of spring tensioners. A cam follower associated with the drive system and connected to an idler pulley is provided on a laterally slidable carriage and is engaged on the drive belt. A fixed, curved cam track receiving the cam follower is employed to allow separation of the rollers while maintaining belt tension. As the opposing rollers are vertically separated, the cam follows a curved path in the cam track which causes lateral shifting of the pulley in the carriage to adjust belt tension. As the spacing of the opposing rollers changes, the cam follower moves laterally and vertically in the track to maintain tension on the drive belt. 
         [0010]    More specifically, a coupon insertion apparatus is configured for sequentially inserting coupons into receiving containers, including a machine frame, at least one pair of opposed rollers mounted to the frame and adjustable between a closed position and an open position. A drive system includes a drive belt for simultaneously driving the opposed rollers in both of the positions. A tensioner is connected to the belt and is movable generally transversely to a direction of the adjustment of the drive rollers to maintain a designated tension on the drive belt. 
         [0011]    In another embodiment, a coupon insertion apparatus is configured for sequentially inserting coupons into receiving containers, including a machine frame, at least one pair of opposed rollers mounted to the frame and adjustable between a closed position and at least one open position. A drive system includes a drive belt for simultaneously driving the opposed rollers in both of the positions. A tensioner is connected to the belt and is movable between a first position associated with the closed position and a second position associated with one open position. The tensioner includes a cam follower formation. A guide plate is associated with the frame and defines a track configured for accommodating the cam follower formation between the first and second positions so that the tensioner maintains a specified tension on the drive belt as the rollers move between the open and closed positions. 
         [0012]    In yet another embodiment, a tensioner assembly is provided for use in a coupon insertion apparatus having a machine frame and at least one pair of opposed rollers movable between an open and a closed position and being driven by a drive belt, and the apparatus includes a guide plate defining a track configured for accommodating the tensioner assembly. The tensioner assembly includes a bracket having a pair of spaced, parallel rails and defining first and second stops, a carriage linearly slidable on the rails, a shaft disposed on the carriage for common movement, a pulley rotatable on the shaft and configured for engaging the drive belt, a cam follower rotatable on the shaft. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0013]      FIG. 1  is a front view of the present coupon insertion apparatus provided with the present belt tensioning apparatus shown in a partially open position; 
           [0014]      FIG. 2  is a front view of the present coupon insertion apparatus provided with the present belt tensioning apparatus shown in a fully open position; 
           [0015]      FIG. 3  is a side view of the apparatus of  FIG. 1 ; 
           [0016]      FIG. 4  is a fragmentary assembled view of the coupon insertion apparatus of  FIG. 1  showing the drive system in a first position where the drive rolls are in close proximity to each other; 
           [0017]      FIG. 5  is a fragmentary assembled view of the coupon insertion apparatus of  FIG. 1  showing the drive system in a second position where the drive rolls are in a partially separated relationship to each other; 
           [0018]      FIG. 6  is an exploded perspective view of the cam follower apparatus of  FIG. 4 ; 
           [0019]      FIG. 7   a  is a schematic fragmentary elevation of a guide plate shown with the apparatus of  FIG. 1  in a partially open position; and 
           [0020]      FIG. 7   b  is a schematic fragmentary elevation of the guide plate shown with the apparatus of  FIG. 1  in fully closed and open positions. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    Generally, the present coupon insertion apparatus receives a continuous web of coupons separatable, pulls the forwardmost coupon away from the continuous web, and dispenses the coupon at a predetermined time into a rapidly moving container as it passes a predetermined location. The present coupon insertion apparatus is intended to be integrated into a full service container processing system, and will supply coupons into the containers at a location at which the containers have been formed, usually have not yet been filled and have not yet been closed. An exemplary conventional coupon insertion apparatus is described in greater detail in commonly assigned U.S. Pat. No. 5,784,861, incorporated by reference. 
         [0022]    Referring now to  FIGS. 1-3 , a coupon insertion apparatus is generally designated  10  and is shown in a front view. Prior to operation, the apparatus  10  is located relative to a container conveyor line to accurately sequentially dispense or project coupons into passing containers. As is customary in the art, the apparatus  10  is commonly referred to as having a left side  12  and a right side  14 , which are opposite to the views as seen in  FIG. 1 . While the apparatus  10  can be fed a supply of coupons from either direction, for purposes of the present explanation it will be assumed that the coupons are being fed from the left side  12  and are projected from the right side  14  into the container (not shown). 
         [0023]    The apparatus  10  includes a machine frame  16  which remains stationary during coupon insertion, and to which are mounted a drive frame  17  and a plurality of opposed upper and lower positioning rollers  18  and  20 , each plurality of rollers being surrounded by a respective suitable endless conveyor belt  22 ,  23 . The belts  22 ,  23  are preferably made of a resilient, rubber or rubber-like material with enhanced coupon gripping properties to facilitate the movement of coupons through the apparatus  10 . 
         [0024]    While the lower positioning rollers  20  are positioned on the drive frame  17  at a fixed location, the upper positioning rollers  18  are vertically movable between a closed position ( FIG. 4 ), and a totally open position ( FIG. 2 ), with a semi or partial open position also available ( FIGS. 1 and 5 ). It will be understood that the distance or displacement between the upper and lower rollers  18 ,  20  is determined by the user and is a function of the configuration of the coupon. In the preferred embodiment, there is an approximate 2 inch gap between the closed and open positions; however it will be understood that this dimension may vary to suit the application. Generally flat or planar coupons will require the apparatus to be adjusted to the closed position, while three dimensional inserts such as small plastic toys or other prizes may require the fully open position, depending on their size. 
         [0025]    The vertical adjustment of the upper rollers  18  is accomplished through the use of a linear slide  24  which includes a main support block  26  secured to the machine frame  16 . A captured, rotatable threaded rod  28  ( FIG. 3 ) is axially rotatable in a support bracket  30  through suitable bearings (not shown) and is rotated using a crank  32 . Other conventional rotation technologies, including motorized rotation, are contemplated. The upper rollers  18  are secured to a movable block  34 , also referred to as the moving frame, having a portion threadably engaged on the threaded rod  28  so that rotation of the rod causes the block  34 , and with it the upper rollers  18 , to move incrementally vertically relative to the lower rollers  20 . Thus, while three basic positions have been described, depending on the amount of rotation of the crank  32 , there are many possible distances between the upper and lower positioning rollers  18 ,  20  to provide for accommodation of a variety of coupons. 
         [0026]    In the preferred coupon insertion apparatus  10 , there are two sets of upper rollers, the upper positioning rollers  18 , and a plurality of upper feed rollers  36 , also provided with a corresponding endless conveyor belt  38 . The upper feed rollers  36  oppose a corresponding set of lower feed rollers  40 , also provided with a corresponding conveyor belt  42 . The belts  22 ,  23 ,  38  and  42  are preferably of similar construction. It will be understood that the feed rollers  36 ,  40  are duplicates of the positioning rollers  18 ,  20 , and as such the following description of the positioning rollers will apply to the feed rollers as well. 
         [0027]    The feed rollers  36 ,  40  are so named due to their receiving the coupons from the feed roll or bandolier, depending on the particular coupon, and passing the coupons to the positioning rollers  18 ,  20 , which ultimately transmit or project the coupons into the waiting container. However, as discussed above, the apparatus  10  is usable in either direction, so that the feed rollers  36 ,  40  can become the positioning rollers  18 ,  20 . 
         [0028]    During bursting, the positioning rollers  18 ,  20  are driven at a predetermined rotational speed by a drive source  44  such as a servo drive motor. A stepper motor may also be used, resulting in lower cost. Similarly, the feed rollers  36 ,  40  are stopped. The feed rollers  36 ,  40  draw a web of coupons toward a bight  48  formed by the positioning rollers  18 ,  20 . 
         [0029]    At a predetermined time, the positioning rolls  18 ,  20  tear the forwardmost coupon from the next succeeding coupon along the perforated line of separation and inject forwardmost coupon at a predetermined location. The feed rollers  36 ,  40  then cause the leading edge of the forwardmost coupon to enter the bight  48  between positioning rolls  18 ,  20 . At least one photoelectric coupon sensor  50  is provided in operational relationship to the rollers  18 ,  20  and  36 ,  40  to provide an electronic controller (not shown) with sensed coupon location information. The location of the sensor  50  may vary to suit the application. As is known in the art, and described in greater detail in U.S. Pat. No. 5,784,861, variations in the speeds of the motors  44 ,  46  cause coupons to be sequentially separated from the web of coupons and projected at high speed into a designated container. The control of the operation of the apparatus  10  is considered outside the scope of the present belt tensioner and is not repeated here. 
         [0030]    Referring now to  FIGS. 4 and 5 , which depict the present apparatus  10  as seen behind the movable block  34  and the drive frame  17  in the preferred embodiment, only one drive roller  52  is provided to each of the sets of opposed rollers  18 ,  20  and  36 ,  40 , and transmits power to the rollers via a drive belt  54 . A design factor of conventional coupon insertion devices is that the drive belt  54  must be maintained at a specified or predetermined tension for proper operation of the apparatus  10 . This specified tension needs to be maintained regardless of whether the apparatus  10  is in the closed position or the open position. Conventional coupon insertion apparatus employed spring-biased belt tensioners which have been found to have sufficient drawbacks to require a replacement technology. 
         [0031]    Referring now to  FIGS. 4 and 5 , the roller drive system is shown in greater detail. The drive roller  52  is driven by one of the servo motors  44 ,  46  and is toothed to drive the preferably similarly constructed drive belt  54 . While a belt  54  is preferred, other power transmission systems are contemplated, including but not limited to linked chains. A pair of preferably toothed upper idler rollers  56 ,  58  is fixed to the machine frame  16 . An upper, preferably toothed conveyor drive roller  60  directly moves the corresponding upper conveyor belt  22 . At least one and preferably three standoffs  61  are provided for maintaining a desired spacing between the roller drive system and the drive frame  17  as well as the movable block  34 . A lower, preferably toothed conveyor drive roller  62  drives the lower conveyor belt  23 , and is accompanied by a lower idler roller  63 . While the rollers  60 ,  62  are designated drive rollers, they are actually idlers in that they are powered by the drive belt  54  through the drive roller  52  and are not independently driven. It will be seen that the rollers  60 ,  62  are disposed relative to the drive belt  54  so that they are rotated in opposite directions. However, this arrangement is needed so that the upper and lower belts  22 ,  23  can cooperate to convey a coupon in the desired direction. 
         [0032]    Referring now to  FIGS. 4-6 , a belt tensioner, generally designated  64  is preferably mounted to the movable block  22 , however may alternately be mounted to the machine frame  16 , and exerts a desired tension on the drive belt  54  regardless of the displacement of the upper positioning rolls  18  to the lower positioning rolls  20 . Unlike prior systems, this tensioning is exerted without the use of springs. The tensioner  64  accommodates movement of the upper rollers  18  relative to the lower rollers  20  by movement generally transverse to the movement of the rollers relative to each other. 
         [0033]    Included on the belt tensioner  64  is a bracket  66  having a pair of spaced, parallel rails  68  and defining first and second stops  70 ,  72 . The stops  70 ,  72  are joined by a rear wall  74  so that the bracket  66  is generally “[”-shaped when viewed from above. A block-like carriage  76  has a pair of parallel throughbores  78  dimensioned to form linear bearings and slidably engage the rails  68 . Thus, the carriage  76  is linearly slidable along the rails  68  between the first and second stops  70 ,  72  in a direction transverse to the direction of movement of the movable block  34  along the threaded rod  28 . 
         [0034]    Generally centrally located on the carriage  76  is a shaft bore  80  into which is inserted a shaft  82  for secure attachment. A toothed pulley  84  is rotatable about the shaft  82 , and a cam follower  86  is rotatably mounted to a tip  88  of the shaft  82 . Upon assembly, the cam follower  86 , the pulley  84  and the shaft  82  are all laterally slidable as a unit upon the carriage  76  relative to the bracket  66  between a first position against the stop  70  ( FIG. 4 ) and a second position against the stop  72  ( FIG. 5 ). 
         [0035]    Referring now to  FIGS. 1 and 7 , a guide plate  90  is disposed on the machine frame  16 , however if the tensioner  64  is placed on the machine frame, the guide plate is mounted to the movable block  34 . The guide plate  90  defines a curved or arcuate track  92  dimensioned to slidably accommodate edges of the cam follower  86 . With the curved shape, as the upper positioning rollers  18  move vertically, the curved track  92  causes the cam follower  86  to move laterally on the rails  68 . Also, the track  92  is sufficiently long to accommodate the travel of the upper positioning rollers  18  relative to the lower positioning rollers  20  between the closed position and the open position so that the tensioner  64  maintains a designated tension on the drive belt  54  as the rollers  18  move between the positions. 
         [0036]    Referring now to  FIG. 7   a , the cam follower  86  is shown mid-way in the track  92 , which represents its position approximately mid-way between the fully closed and fully open positions. This position, also depicted in  FIGS. 2 and 5 , represents the greatest displacement of the drive belt  54  by the tensioner  64 . Referring now to  FIG. 7   b , the cam follower  86  is shown in the fully open position at the top of the track  92 , and in the fully closed position at the bottom of the track. 
         [0037]    Thus, it will be seen that the present coupon insertion apparatus  10  provided with the belt tensioner  64  provides for more efficient operation of the apparatus, in that constant, predetermined tension is maintained on the drive belt  54  as the upper frame  34  is moved relative to the machine frame  16  to accommodate various sizes of coupons. The cam follower  86  moves laterally in the bracket  66  to accommodate various positions of the upper frame. 
         [0038]    While a particular embodiment of the present coupon insertion apparatus has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.