Abstract:
An apparatus for applying labels to products includes a label application station at which the labels are applied to a product and an application head movably mounted relative to a base for movement between a first operative loading position spaced from the label application station and a second operative application position at which the application head applies at least one label to a product positioned at the label application station. An electrically actuated solenoid is operatively connected to the application head to move the application head between the first and second operative positions.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This patent application claims the benefit of U.S. Provisional Patent Application No. 61/230,896, filed Aug. 3, 2009, which is incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention generally relates to an apparatus for applying labels to products and, more particularly, to a solenoid driven mechanism for applying labels to products. 
         [0003]    Revenue or tax stamps must be applied to individual packs of cigarettes and, because the taxes and stamps vary by state, county and even by city, these stamps are typically not applied to the packs until they reach their final destination. For ease of handling, cigarette packs are packaged in the cartons in which they will ultimately be sold or displayed and the cartons are packaged in relatively large boxes that are shipped to the desired location. 
         [0004]    The tax stamps are typically applied by a stamp head that uses a combination of heat and pressure to release the stamps from a carrier roll and deposit them on the individual cigarette packs. This tax stamping operation is usually performed at a distribution warehouse with automated equipment that is capable of applying stamps at rates of up to 120 cartons per minute. However, there are situations where the expense of high volume automation equipment cannot be justified such as low volume stamping operations, or situations in which technical issues exist due to the size of the packs or cartons or the orientation of the packs within the cartons. In such situations, the typical manner of applying tax stamps is to use a hand iron, which includes a stationary base with an iron positioned thereon, together with a tax stamp feed mechanism so as to provide and align tax stamps with the stationary iron. 
         [0005]    In order to apply tax stamps with a stationary iron, a user aligns an open carton of cigarettes with the stationary iron and presses the cigarette carton against the stationary iron. The stationary iron applies the heat and the user applies the pressure in order to transfer the tax stamps from the tax stamp carrier roll to the individual packs within the carton. Unfortunately, such manual process often results in poor and inconsistent application of tax stamps to the packs as the manual process is highly dependent upon the skill level of the operator. 
         [0006]    High volume automated systems for applying tax stamps typically include multiple stations for processing the cartons of cigarettes. The cartons are unloaded at a first station and individually transported and processed in an automated manner. The cartons move from a first station at which the cartons are opened to a tax stamp application station at which the stamps are applied and then the cartons are transported to a station at which the cartons are resealed and loaded into boxes for subsequent distribution. Automated application stations typically utilize one of two types of mechanisms for applying tax stamps. In one type, a pneumatic cylinder is used to drive the stamp head in a reciprocating manner. While the reliability or performance of pneumatic powered automation equipment is generally not an issue, such systems require the additional expense, maintenance and complexity of providing an air supply within a manufacturing environment. Accordingly, the use of pneumatic systems increases the initial expense and reduces the flexibility of a stamp application operation. 
         [0007]    A second type of automated application system is electrically driven and uses a motor and a series of gears and cams drive the linear movement of the stamp head. Due to the complexity and functionality of the gear and cam mechanisms, the length of displacement or stroke of the electrically heated iron is relatively fixed for each set of gears and cams and the systems are generally expensive. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    Accordingly, it is an object to solve the above-described problems encountered with existing tax stamp application equipment by providing an electrical solenoid driven tax stamp application apparatus that may be used in either manual or with automated processing of cigarette packs. More specifically, it would be desirable to provide an apparatus for applying labels to products having a label application station at which the labels may be applied and an application head movably mounted on base for movement between a first operative position spaced from a product positioned at the label application station and a second operative position at which the application head applies a label to the product positioned at the label application station. A solenoid is operatively connected to the application head to move the application head between the first and second operative positions and an actuator mechanism provides a triggering signal to an electricity source upon a triggering event to actuate the solenoid and move the application head from the first operative position to the second operative position. A label feeding mechanism provides a supply of labels for application to the products. 
         [0009]    If desired, the actuator mechanism may include a switch that is actuated upon engagement of the actuator mechanism by a force approximately equal to a force generated by actuation of the solenoid. The actuator mechanism may include a movable trip plate configured to be engaged by the product to actuate the switch. The actuator mechanism may include an electronic sensor for sensing a predetermined desired positioning of a product at the label application station. 
         [0010]    If desired, a drive structure may interconnect the application head and the solenoid with the drive structure being configured to guide the application head along a linear path between the first and second operative positions. The drive structure may include a drive block operatively connected to the solenoid on a side of the solenoid opposite the application head and actuation of the solenoid may move the drive block towards the solenoid and the application head away from solenoid and towards the product located at the label application station. The drive structure may include a pair of spaced apart guide shafts positioned on opposite sides of the solenoid for guiding the application head along the linear path with the guide shafts being operatively connected to the drive block and the application head. A pair of return springs may be provided for assisting in moving the application head from the second operative position to the first operative position with each return spring being concentrically positioned relative to one of the guide shafts. 
         [0011]    If desired, means may be provided for returning the application head from the second operative position to the first operative position. Such returning means may include at least one spring. The label may be applied to the product by applying heat to the label and pressure between the application head and the product. The label feeding mechanism may supply labels to an operative position between the first and second operative positions of the application head. The application head may be configured to removably receive any of a plurality of differently configured removable application irons to permit labels to be applied to the product in different arrays. 
         [0012]    An apparatus for applying labels to products may include a label application station at which the labels are applied to a product and an application head movably mounted relative to the base for movement between a first operative loading position spaced from the label application station and a second operative application position at which the application head applies at least one label to a product positioned at the label application station. An electrically actuated solenoid is operatively connected to the application head to move the application head between the first and second operative positions. 
         [0013]    If desired, an actuator mechanism may provide a triggering signal to an electricity source upon a triggering event to actuate the solenoid and move the application head from the first operative loading position to the second operative application position. A switch may be provided that is actuated upon engagement of the actuator mechanism by a force approximately equal to a force generated by actuation of the solenoid. The actuator mechanism may include a movable trip plate configured to be engaged by the product to actuate the switch. A drive structure may be provided interconnecting the application head and the solenoid and configured to guide the application head along a linear path between the first and second operative positions. The drive structure may include a pair of spaced apart guide shafts positioned on opposite sides of the solenoid for guiding the application head along the linear path. 
         [0014]    A method of applying a label to a product may also be provided including providing a label application station at which labels may be applied to product, providing a plurality of labels, positioning at the application station a product having a plurality of surfaces in a desired orientation to present a desired one of the surfaces to the label application station, generating a triggering signal to designate positioning of the product at a desired, predetermined position at the label application station, and providing electrical current to a solenoid to move an application head from a first position spaced from the label application station to a second position at the label application station in order to engage the product with at least one label positioned between the application head and the product. The method may also include actuating a switch by movement of the product to apply at least a predetermined force to an actuator. The method may also include utilizing heat and pressure to secure the at least one label to the product. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING(S) 
         [0015]    Various other objects, features and advantages of the present invention will become more fully appreciated and better understood when considered in conjunction with the accompanying drawings, in which like-referenced characters designate the same or similar parts throughout the several views, wherein: 
           [0016]      FIG. 1  is a perspective view of a manual revenue stamp application machine including the revenue stamp application mechanism of the present invention; 
           [0017]      FIG. 2  is a perspective view of the carton positioning assembly, the actuator assembly and the revenue stamp application mechanism of  FIG. 1 ; 
           [0018]      FIG. 3  is a rear perspective view of the carton positioning assembly, the actuator assembly and the revenue stamp application mechanism of  FIG. 2 ; 
           [0019]      FIG. 4  is an enlarged perspective view of the actuator assembly and the revenue stamp application mechanism of  FIG. 2 ; 
           [0020]      FIG. 5  is a top plan view of the carton positioning assembly, the actuator assembly and the revenue stamp application mechanism at a stamp application station with a carton of cigarettes positioned thereat and spaced from an actuator mechanism; 
           [0021]      FIG. 6  is a top plan view similar to  FIG. 5  but with the carton of cigarettes engaging the actuator mechanism but prior to energizing the solenoid and displacement of the stamp application head; 
           [0022]      FIG. 7  is a top plan view similar to  FIG. 6  but with the carton engaging the actuator mechanism and with the solenoid in its energized position in order to move the stamp application head into engagement with the packs of cigarettes; and 
           [0023]      FIG. 8  is a top plan view of an automated revenue stamp applying system. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0024]    The following description is intended to convey the operation of exemplary embodiments of the invention to those skilled in the art. It will be appreciated that this description is intended to aid the reader, not limit the invention. As such, references to a feature or aspect of the invention are intended to describe the feature or aspect of the embodiment of the invention, not to imply that every embodiment of the invention must have the described characteristic. 
         [0025]    Referring to  FIG. 1 , a semi-automatic apparatus  10  for applying revenue stamps to packs of cigarettes is shown. The revenue stamp applying apparatus  10  includes a base  12 , a carton positioning assembly  20 , a revenue stamp feed mechanism  30 , a programmable controller assembly  44 , an actuator assembly  50  and a revenue stamp application mechanism  60 . If desired, an optional hot glue station  84  may also be provided. Carton positioning assembly  20  includes a pair of oppositely facing sidewalls  21  interconnecting oppositely facing front wall  22  and rear wall  23  to form a generally rectangular pedestal. A top plate  24  is positioned on top of the assembly formed by the two sidewalls  21  and the front wall  22 . Top plate  24  includes a generally planar section  25  that is generally parallel to base  12  and a vertically upstanding guide plate  26  extending above a rear edge  23  of top plate  24 . Guide plate  26  includes a generally rectangular aperture  26   a  through which carton  15  (shown in phantom in  FIGS. 5-7 ) is slid during the revenue stamp application process. A horizontal carton alignment block  27  is generally L-shaped and slidably mounted on top plate  24  through the use of a pair of spaced apart parallel slots  27   a  in alignment block  27  and thumb screws  31  that are screwed into top plate  24  once the horizontal carton alignment block  27  is properly positioned so as to facilitate longitudinal alignment of the carton with the stamp head assembly  72 . A movable push bar  32  is slidably mounted on top plate  24  and includes a guiding structure (not shown) that interacts within parallel grooves  24   a  in top plate  24  so that movable push bar  32  may slide along grooves  24   a  to facilitate pushing the carton  15  towards the stamp head assembly  72 . 
         [0026]    The revenue stamps (not shown) are carried on a roll that is rotatably mounted on revenue stamp feed mechanism  40 . Feed mechanism  40  may be set up to either rotate to advance the reel of stamps a predetermined distance each time the stamp head assembly  72  returns to its initial position or to laterally index the stamps a predetermined number of times and then rotate to advance the stamps a predetermined distance. In either case, the revenue stamps are properly aligned and ready to be affixed to a carton  15  of cigarettes upon actuation of the revenue stamp application mechanism  60 . 
         [0027]    Programmable controller assembly  44  includes controls for providing electricity to revenue stamp application mechanism  60  upon sufficient movement of actuator trip plate  53  so that switch  46  is tripped. In addition, assembly  44  also provides the electricity and controls the timing of the revenue stamp feed mechanism  40  so that the revenue stamps are properly positioned prior to actuation of the revenue stamp application mechanism  60 . Finally, assembly  44  also controls the length of time that solenoid  62  remains energized once switch  55  is actuated. 
         [0028]    Actuator assembly  50  includes a pair of L-shaped actuator support arms  51  that are spaced apart and mounted on base plate  12 . Each support arm  51  has a pair of apertures  51   a  extending therethrough and through which a pair of guide pins  52  secured to actuator trip plate  53  extend. A return spring  57  is positioned between each L-shaped actuator support arm  51  and actuator trip plate  53  with a guide pin  52  extending therethrough. A travel stop member  54  extends from each actuator support arm  51  and includes a post  54   a  and a resilient member  54   b  that engages actuator trip plate  53  as the actuator trip plate reaches the end of its sliding movement and actuates switch  55 . Switch  55  is depicted as including a fixed non-contact proximity switch  55   a  and a movable proximity switch target  55   b  mounted on one of guide pins  52 . Other types of switches could also be used. Actuator trip plate  53  includes a generally rectangular opening  53   a  dimensioned so as to be large enough to permit stamp head assembly  72  to pass therethrough in order to apply the revenue stamps to each pack of cigarettes but small enough so that the outer portions of the carton may engage the actuator trip plate  53  to affect linear movement thereof. 
         [0029]    Revenue stamp application mechanism  60  includes a U-shaped base  61  mounted on base plate  12 . Solenoid  62  is secured to U-shaped base  61  through L-shaped solenoid mounting block  63 . A pair of slide guide blocks  64  are spaced apart and mounted on U-shaped base  61  on opposite sides of solenoid  62 . The guide blocks  64  include linear bearings  65  through which guide shafts  66  extend to facilitate smooth linear motion of the guide shafts. Each guide shaft  66  is secured at one end to solenoid drive block  67  and at an opposite end to mounting bracket  71  that is secured to the stamp head assembly  72 . 
         [0030]    Stamp head assembly  72  is a multi-component assembly including a mounting plate  73  configured to be secured to mounting bracket  71 . Stamp head assembly  72  further includes a heating assembly formed of a heating element (not shown) that is contained within a heater retainer  74  and an adjacent iron base  75  that functions as a thermal mass. A removable stamp iron  76  is secured to the iron base  75  and includes projections  76   a , each being configured to align with one of the revenue stamps and a pack of cigarettes. The heating assembly of the heating element, heater retainer  74 , iron base  75  and stamp iron  76  is generally thermally insulated from mounting plate  73  through an insulator  77  that is sandwiched between mounting plate  73  and heater retainer  74 . As depicted, insulator  77  is formed of mechanical grade virgin Teflon, but may alternatively be made of any heat resistant material with low thermal conductivity. 
         [0031]    It should be noted that in  FIGS. 1 and 4 , the stamp iron  76  has ten linearly aligned projections  76   a  and in FIGS.  2  and  5 - 7 , the stamp iron  76  has five pairs of vertically aligned projections  76   a . Accordingly, the stamp iron in  FIGS. 1 and 4  is configured to apply stamps to cartons having packs arranged in a 1×10 configuration and the stamp iron in FIGS.  2  and  5 - 7  is configured to apply stamps to cartons having packs arranged in a 2×5 configuration. In practice, a stamp iron  76  is mounted on the stamp head assembly  72  and apparatus  10  operated until the operator desires to change the stamp iron to one of a different configuration. The alternate stamp irons are depicted herein merely to show alternate operative configurations. 
         [0032]    Slide guide blocks  64  are generally U-shaped and include a pair of spaced apart linear bearings  65 . Between the linear bearings is positioned a collar  81  secured to guide shaft  66  and a washer  82  spaced from the collar. A return spring  83  is positioned between collar  81  and washer  82  with guide shaft  66  extending through collar  81 , washer  82  and return spring  83 . Upon actuation of or energizing the solenoid  62 , shaft  62   a  of the solenoid is pulled into the solenoid which moves the solenoid drive block  67  towards the carton  15  of cigarettes and likewise moves guide shafts  66  together with the entire stamp head assembly  72  towards the carton  15  and compresses return springs  83  between collars  81  and washers  82 . Upon de-energizing solenoid  62 , the return springs  83  provide sufficient force to move the entire slidable assembly (including the guide shafts  66 , solenoid drive block  67 , mounting bracket  71  and stamp head assembly  72 ) to the initial or loading position so that the stamp iron  76  is spaced from the carton  15  of cigarettes. 
         [0033]    If desired, a hot glue station  84  may be positioned on base  12  adjacent carton positioning assembly  20 . Hot glue station  84  includes a rectangular base or pedestal  85  with a glue station top plate  86  generally co-planar with planar section  25  of top plate  24  of carton positioning assembly  20  and generally acting as an extension thereof. A vertically upstanding glue station guide plate  87  is generally planar with vertically upstanding guide plate  26  of top plate  24  of carton positioning assembly  20  and generally acting as an extension thereof. A slot  86   a  is provided in glue station top plate  86  to permit hot glue contained in a reservoir (not shown) within base  85  to be applied to the flaps of a carton  15  of cigarettes after the tax stamps have been applied to the individual packs within the carton in order to facilitate re-sealing of the carton. 
         [0034]    In operation, a user places an open carton  15  of cigarettes on top of top plate  24  so that the open end of the carton is facing the stamp head assembly  72  and actuator trip plate  53 . The operator slides the carton  15  so that it engages horizontal carton alignment block  27  in order to laterally position the carton along the longitudinal axis “L” of the carton relative to the revenue stamp applying apparatus  10  as shown in  FIG. 5 . In such position, actuator trip plate  53  is in its unengaged position as are solenoid  62  and stamp head assembly  72 . The user then moves the carton of cigarettes towards the actuator trip plate  53  and the stamp head assembly  72  by pushing on movable push bar  32  in the direction of arrow “A” in  FIG. 5 . This moves the carton  15  of cigarettes laterally relative to longitudinal axis “L” and towards actuator trip plate  53  and stamp head assembly  72  as shown in  FIG. 6 . As the operator slides the carton  15  of cigarettes towards stamp head assembly  72 , the carton slides through aperture  26   a  in guide plate  26  and engages actuator trip plate  53  to slide the actuator trip plate  53  towards solenoid  62 , which compresses actuator return springs  54  as the carton approaches stamp iron  76 . Once the actuator trip plate is moved from its disengaged position ( FIG. 5 ) to its fully deflected position as shown in  FIG. 6 , proximity switch target  55   b  is close enough to proximity switch  55   a  in order to trigger switch  55  and send a signal to the programmable controller assembly  44  to carry out actuation of solenoid  62 . 
         [0035]    It has been determined that return guide springs  54  and the length of displacement of actuator trip plate  53  should be sized so that the force necessary to move actuator trip plate  53  from the disengaged position to its fully deflected position is approximately equal to or greater than the force provided by solenoid  62  in order to move stamp head assembly  72  into engagement with the carton of cigarettes. This configuration results in a high quality and repeatable transfer of revenue stamps to the packs of cigarettes without requiring significant skill on the part of each individual operator. 
         [0036]    Once the actuator trip plate  53  moves to its fully deflected position and triggers switch  55 , programmable controller assembly  44  sends a signal energizing solenoid  62  which retracts solenoid shaft  62   a  and moves guide shafts  66 , solenoid drive block  67 , mounting bracket  71  and stamp head assembly  72  into engagement with the revenue stamps and then into engagement with the individual packs of cigarettes in order to transfer the revenue stamps from their carrier to the cigarette packs. The programmable controller assembly  44  maintains solenoid  62  in an energized state for a predetermined period of time (typically 0.1 to 1.0 second depending on the details of the process used) and then de-energizes solenoid  62  and the return springs  83  apply a force on collars  81  in order to move guide shafts  66 , solenoid drive block  67 , mounting bracket  71  and stamp head assembly  72  away from the carton  15  to its original, de-energized position. The programmable controller assembly  44  then provides a signal to the revenue stamp feed mechanism  40  which either advances the roll of revenue stamps or laterally indexes the revenue stamps so that a new set of stamps is properly positioned and aligned with the stamp iron  76  so that the revenue stamp application apparatus  10  is ready to apply revenue stamps to the next carton of cigarettes. 
         [0037]    Although the revenue stamp application mechanism  60  is shown in connection with a manual application apparatus, the solenoid actuated application mechanism could also be utilized with an automated system  90  as depicted in  FIG. 8 . In such case, unopened cartons  15  are typically loaded onto a feed conveyor  91  and then moved laterally or perpendicular (in the direction of arrow “B”) relative to the longitudinal axes of the cigarette cartons. Drive conveyor  92  is provided to move the cartons sequentially along a linear path (in the direction of arrow “C”) from the feed conveyor  91  towards the revenue stamp application station  93  at which the revenue stamps are applied. Prior to reaching the application station  93 , each carton is opened by a carton opening member  94 . After opening each carton and applying revenue stamps to the cigarette packs, drive conveyor  92  moves each carton along linear path “C” to a glue station  95 , which is located downstream from revenue stamp application station  93 , to apply glue to each carton in order to re-seal the cartons after the revenue stamps have been applied. The re-sealed cartons are then removed from system  90  and may be returned to the boxes in which they were originally shipped or to some other boxes or containers as desired. The revenue stamp application station  93  would include a revenue stamp application apparatus similar to manual stamp application apparatus  60  and would also include components for automated sensing, triggering and alignment prior to the stamping operation. 
         [0038]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0039]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.