Abstract:
Labels are permanently attached to a substrate, e.g., a tissue cassette, by use of a staking device. The device comprises a staker assembly and a cassette fixture assembly. The cassette fixture assembly includes a slot and a clamping assembly for securing the cassette within the device. The staker assembly includes a set of probes that are heated and sequentially moved into a position to burn a hole in a label that is provisionally attached to the cassette, and then the substrate is melted and displaced through the hole to form a collar bond that permanently attaches the label to the cassette. The label remains attached to the cassette when exposed to harsh environmental conditions, e.g., high heat, high humidity, solvents, etc.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part application of U.S. application Ser. No. 11/470,300 filed on Sep. 6, 2006 now U.S. Pat. No. 7,691,218 and claims priority to U.S. Provisional Application Ser. No. 60/986,169 filed on Nov. 7, 2007 and U.S. Provisional Application Ser. No. 61/028,647 filed on Feb. 14, 2008. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to a device or machine for attaching a label to a substrate. In one aspect, the invention relates to a device for mechanically attaching a label to a substrate while in another aspect, the invention relates to a device comprising at least one heated probe and at least one cassette fixture assembly. In yet another aspect, the invention relates to a method of using the device. 
     BACKGROUND OF THE INVENTION 
     In the field of identification, labeling is commonly employed. One common form of the label consists of a (i) middle or substrate layer, e.g., film, foil, nonwoven such as Tyvek® (spun-bonded polyolefin), synthetic paper such as Valeron®, or paper, (ii) top or indicia layer providing the identification, e.g., ink, pigment, etc., and (iii) bottom or adhesive layer for attaching the label to the surface of an object. Many types of adhesives are available for use on a label, e.g., pressure-sensitive adhesives (PSAs), hot melt adhesives and the like, but PSAs are widely used because they allow fast and convenient attachment of the label to an object. 
     As convenient as PSA-bearing labels are, they are not without their limitations. For example, their use in harsh environments is of limited value. Under conditions of high heat (or extreme cold), elevated or reduced pressure and/or exposure to various solvents, particularly over extended periods of time, the PSA can lose its ability to bind the label to the object. 
     One such case is in the field of providing identification for tissue cassettes. Tissue cassettes are typically made of a thermoplastic material, and they are designed to hold biological tissue specimens while the specimen is subjected to dehydration followed by encapsulation in wax. The dehydration process requires exposure to a range of solvents such as formalin, ethanol or xylene. This is followed by embedding the dehydrated specimen in hot wax (e.g., molten paraffin). These processes can last for hours and can include exposure to heat and vacuum. Notwithstanding the wide range of PSAs available, e.g., acrylates, tackified natural and synthetic rubbers, silicones and urethanes, none have shown resistance to the complete range of conditions to which a tissue cassette is typically exposed. 
     As such, PSAs are generally unsuitable for reliable attachment of identification labels to tissue cassettes and, for that matter, to many consumer and industrial process containers that are also exposed to harsh environmental conditions, such as those used in the food and dairy industries, or those used for storage of hazardous materials, or those used in subzero storage (where many PSAs lose their adhesive properties). Moreover, PSAs can provide inadequate adhesion in those situations where the substrate is not exposed to harsh environmental conditions, but where the surface of the substrate is too rough or textured to allow for good adhesion between it and the label. 
     Aside from the various forms of adhesive attachment, various forms of mechanical attachment are known. For example, the use of staples, pins and other mechanical fasteners is common, although problematic, because the fasteners interfere with the handling of the cassette. Moreover, the design and construction of the label and substrate often do not lend themselves for use with mechanical fasteners. 
     BRIEF SUMMARY OF THE INVENTION 
     In one embodiment, the invention is a device or machine for permanently attaching a label that is provisionally attached to a substrate, particularly a label to a tissue-holding cassette. As here used, “provisionally attached” means a label that is positioned on a substrate in a manner that it is sufficiently held in place to allow the staking operation to be performed without the label shifting. Labels are traditionally affixed with the use of suitable adhesive, e.g., a pressure sensitive adhesive (PSA). “Permanently attached” means the label as affixed to the substrate after it has undergone the staking operation, and is affixed in such a manner that it cannot be removed without physically damaging the label (e.g. tearing). The device comprises a staker assembly and a cassette fixture assembly. In at least one embodiment, the staker assembly comprises (i) a probe plate, (ii) a backstop, (iii) a block assembly, (iv) a lower rotation assembly, and (v) an upper rotation assembly. The block assembly comprises (vi) a probe block which itself comprises (vi-a) a burn probe, and (vi-b) a plunge probe, (vii) a heater block, (viii) a carrier, and (ix) a spring plate. The cassette fixture assembly comprises (x) a cassette fixture, (xi) a fixture plate, and (xii) a clamping assembly. In at least one embodiment, the clamping assembly comprises (xiii) a fixture clamp, (xiv) a clamp lever, (xv) a clamp cam, (xvi) a clamp motor, and (xvii) a fixture pin. In at least one embodiment, the staker assembly further includes at least one of a fan, a cooling mechanism and a fuming mechanism. In another embodiment, the clamping assembly further comprises a pivot arm. 
     In the provisional attachment of a label to a cassette or other substrate, the label is pre-positioned on the cassette using a suitable adhesive, e.g., a PSA. The cassette is inserted into the slot of the cassette fixture either manually or by automated means, such that the front edge of the label-bearing face of the cassette is in contact with the forward face of the fixture plate. The cassette is then locked into place using the clamping assembly by activating the fixture clamp such that the label-bearing face of the cassette is pressed against the forward face fixture plate. The burn probe and plunge probe are situated to extend from a probe stand and are pre-heated to the required temperature. After the label is in secured contact with the fixture plate, then the heated burn probe is brought into contact with the label such that a hole is burned through the label. The burn probe is then retracted, and the plunge probe is advanced through the hole in the label. The plunge probe is smaller in cross-section and longer in length than the burn probe. The plunge probe is advanced into the cassette such that a portion of the cassette is melted and is displaced through the hole and against a shoulder surface that extends beyond the cross-section of the plunge probe and cross-section of the hole, onto the surface of the label. Upon removal of the plunge probe, the melted, displaced substrate solidifies on the label in the form of a collar bond which securely attaches the label to the cassette. The cassette is then released from the fixture clamp and removed from the device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1   a   1  is an exemplary front perspective view of at least one embodiment of a device for staking labels. 
         FIG. 1   a   2  is an exemplary back perspective view of the staking device of  FIG. 1   a   1 . 
         FIG. 1   b   1  is a semi-exploded perspective view of the staking device. 
         FIG. 1   b   2  is a semi-exploded perspective view of an alternate embodiment of  FIG. 1   b   1 . 
         FIG. 1   b   3  is a semi-exploded perspective view of another alternate embodiment of  FIG. 1   b   1 . 
         FIGS. 1   c   1  and  1   c   2  are side and perspective views of an exemplary tissue cassette  15  that may be used with the staking device. 
         FIG. 1   c   3  is a front perspective view of an alternate embodiment of the label-bearing face  19  of  FIG. 1   c   2 . 
         FIG. 2   a  is an exploded perspective view of the staking device of  FIG. 1   b   1 . 
         FIG. 2   b  is an exploded perspective view of the staking device of  FIG. 1   b   2 . 
         FIG. 2   c  is an exploded perspective view of the staking device of  FIG. 1   b   3 . 
         FIGS. 3   a  and  3   b  are perspective views of an exemplary cassette fixture  16 . 
         FIGS. 3   c  and  3   d  are perspective views of alternate embodiments of  FIGS. 3   a  and  3   b , respectively. 
         FIG. 4   a  is an exploded perspective view of the cassette fixture assembly  4  of  FIG. 2   a.    
         FIG. 4   b  is an exploded perspective view of the cassette fixture assembly  4  of  FIG. 2   b.    
         FIG. 4   c  is an exploded perspective view of the cassette fixture assembly  4  of  FIG. 2   c.    
         FIG. 4   d  is an exploded perspective view of the fixture plate  22  of  FIG. 2   b.    
         FIG. 4   e  is an exploded perspective view of the fixture plate  22  of  FIG. 2   c.    
         FIG. 5   a  is a cross-sectional view of the staking device of  FIG. 2   a  in a default position. 
         FIG. 5   b  is a cross-sectional view of the staking device of  FIG. 2   b  in a default position. 
         FIG. 5   c  is a cross-sectional view of the staking device of  FIG. 2   c  in a default position. 
         FIG. 6   a  is a cross-sectional view of the staking device of  FIG. 2   a  in a burn position. 
         FIG. 6   b  is a cross-sectional view of the staking device of  FIG. 2   b  in a burn position. 
         FIG. 6   c  is a cross-sectional view of the staking device of  FIG. 2   c  in a burn position. 
         FIG. 7   a  is a perspective view of the probe plate  44  of  FIG. 2   c.    
         FIG. 8   a  is an exploded view of the block assembly  52  of  FIG. 2   a.    
         FIG. 8   b  is an exploded view of the block assembly  52  of  FIG. 2   b.    
         FIG. 8   c  is an exploded view of the block assembly  52  of  FIG. 2   c.    
         FIG. 9   a  is a cross-sectional view of the staking device of  FIG. 2   a  in a plunge position. 
         FIG. 9   b  is a cross-sectional view of the staking device of  FIG. 2   b  in a plunge position. 
         FIG. 9   c  is a cross-sectional view of the staking device of  FIG. 2   c  in a plunge position. 
         FIG. 10   a  is an exploded view of a lower rotation assembly  56  of  FIG. 2   a.    
         FIG. 10   b  is a perspective view of the lower rotation assembly  56  of  FIG. 2   b  secured to the probe plate  44 . 
         FIG. 10   c  is a perspective view of the lower rotation assembly  56  of  FIG. 2   c  secured to the probe plate  44 . 
         FIG. 11   a  is an exploded view of an upper rotation assembly  58  of  FIGS. 2   a  and  2   b , including a plunge sensor  120  and a burn sensor  122 . 
         FIG. 11   b  is an exploded view of the upper rotation assembly  58  of  FIG. 2   c , including a plunge sensor  120  and a burn sensor  122 . 
         FIG. 12   a  is a cross-section view of an exemplary burn probe  74  forming a label aperture  125  in a label  53 . 
         FIG. 12   b  is a cross-section view of an exemplary plunge probe  72  forming an exemplary collar bond  33 . 
         FIG. 12   c  is a cross-section view of the collar bond  33  of  FIG. 12   b , that is fully formed to permanently attach the label  53  to the label-bearing face  19  of the tissue cassette  15 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Staking device  1 , as shown in  FIGS. 1   a   1  and  1   a   2 , is described in terms of permanently attaching a thermoplastic label that has been provisionally attached to a tissue cassette made of thermoplastic material. Those skilled in the art understand that various modifications to the device can be made to accommodate labels and substrates comprising other materials and designs. Various items of equipment such as electrical connections, circuit boards, power supplies, fittings and the like have been selectively omitted so as to simplify the drawings. The following description does not limit the scope of the device, but particularly points out several embodiments. Additionally, like numerals have been used to identify like parts throughout. 
     The staking device  1  creates a collar bond  33  that bonds a label  53  to a label-bearing face  19  of a substrate  24  (see  FIG. 12   c ). The collar bond  33  as referenced in this application is defined as a substrate  24  that has been melted and displaced onto the surface of the label  53  and re-solidified such that it is continuous with the underlying substrate  24 . The term “collar bond” is not intended to be limited in size or shape although in the embodiment described below the collar bond  33  is collar shaped. 
       FIGS. 1   a   1  and  1   a   2  depict one embodiment of the staking device  1  in a fully assembled form.  FIG. 1   b   1  depicts an exploded view of at least one embodiment of the staking device  1  in  FIG. 1   a   1 , comprising a staker assembly  2 , a cassette fixture assembly  4 , a base  5 , a top cover  6  and a front cover  8 . An exemplary fuming mechanism  7   a , such as a blower  9   a  and a filter  11   a  may be removably mounted in the rear portion of the base  5 , to cool the device and/or to vent any harmful fumes from the staking device  1  created by the staking process. Referring to  FIG. 1   b   2 , another embodiment of the staking device  1  is shown with an exemplary cooling mechanism  17   a , such as cooling fan  10   a  and a fan duct  12   a  connected to the staker assembly  2  for cooling at least a portion of the cassette fixture assembly  4 . In reference to  FIG. 1   b   3 , an alternate embodiment of the staking device  1  is shown that includes one embodiment of the fuming mechanism  7   b  that includes a fuming blower  9   b , a filter  11   b  and a fan duct  12   b , configured to filter and vent fumes produced by the staking process adjacent the cassette fixture assembly  4 . Additionally,  FIG. 1   b   3  includes one embodiment of the cooling mechanism  17   b  that includes a cooling fan  10   b  having a flow duct  13  for directing outside air to at least a portion of the cassette fixture assembly  4 , and another cooling mechanism  17   c  that includes at least a device fan  14  for venting the inside of the staking device  1  by pulling outside air through one side of the top cover  6  and exhausting it out the other side. In at least some embodiments, the fuming mechanism  7   a ,  7   b  and/or cooling mechanism  17   a ,  17   b ,  17   c  may include isolating barriers (not shown) to vent direct or indirect fumes/air to a location remote from the user. 
       FIGS. 1   c   1  and  1   c   2  depict at least one embodiment of a substrate  24 , namely an exemplary tissue-sampling cassette  15 , as discussed in this application. Cassette  15  as shown in these Figures includes a cassette top face  15   a , a cassette bottom face  15   b , a pair of cassette side faces  15   c , a cassette back face  15   d , and a label-bearing face  19 . Tissue-sampling cassettes  15  come in various sizes and shapes, and an ordinary person skilled in the art can modify this device to any shape or size. An alternate cassette front is depicted in  1   c   3  having a label-bearing face  19  with an adjacent beveled face  19   a . A typical tissue cassette  15  is flat on the bottom with a label-bearing face  19  that is situated at approximately a 45-degree angle from the bottom. The angle of the label-bearing face  19  relative to the cassette bottom face  15   b  can vary substantially without effect, as the cassette fixture assembly  4  compensates for various angles. Although the discussed embodiment references a thermoplastic cassette material, the cassette  15  may be of any material that would melt and displace to form a collar bond  33  when in contact with the heated plunge probe  72 . 
     Referring to  FIG. 2   a , in at least one embodiment the components of the staker assembly  2  and the cassette fixture assembly  4  are depicted in an exploded format. Alternate embodiments of the components of the staker assembly  2  and the cassette fixture assembly  4  are shown in  FIGS. 2   b  and  2   c  in an exploded format. The cassette fixture assembly  4  is designed to accommodate and secure a tissue sample cassette  15 . The cassette fixture assembly  4  includes in at least one embodiment a cassette fixture  16 , as seen in  FIGS. 3   a  and  3   b , which is made from a material that dissipates heat well, such as aluminum. Referring to  FIGS. 3   a  and  3   b , the cassette fixture  16  has a cassette slot  20  situated near its top, and a cassette fixture face  18  that is directed towards the staker assembly  2 . The cassette slot  20  is shaped to accommodate the cassette  15  as substantially depicted in  FIGS. 1   c   1 - 1   c   3 ; the slot  20  has a width marginally larger than the width of the cassette  15  such that the slot  20  provides self-centering of the cassette  15 . Further, in at least one alternate embodiment not shown, the cassette fixture  16  has a slot that may be adjusted in width, allowing the slot to accommodate various-sized cassettes  15 . Additionally, in another alternate embodiment (not shown), the cassette fixture  16  is removable and replaceable with other cassette fixtures  16  each having different slot dimensions. 
     In another embodiment, referring to  FIGS. 3   c  and  3   d , the cassette fixture  16  further includes a pivot arm depression  39  ( FIG. 3   c ) extending from the cassette fixture face  18  inward, with a pivot arm  41   a  as shown in  FIG. 3   d  situated at least partially inside the pivot arm depression  39 . Further referring to  FIG. 3   d , the pivot arm  41   a  is comprised of a hinge mechanism  41   b , a lower portion  41   c , and an upper portion  41   d  having pivot tabs  41   e . Further, at least one pivot spring hole  43 , as seen in  FIG. 3   c , extends from the pivot arm depression  39  inward, whereby a pivot spring  45  and spring cap  47  are situated within (best seen in  FIGS. 4   b ,  4   c ,  5   b  and  5   c ). The pivot spring  45  provides a pushing force against the lower portion  41   c  away from the pivot arm depression  39 . Additionally, in at least one embodiment, the cassette fixture  16  may include a cassette sensor  35 , such as an infra-red sensor, to sense when a cassette  15  is situated in the cassette slot  20 . 
     In reference to  FIGS. 4   a - 4   c , in at least one embodiment, cassette fixture assembly  4  further includes a fixture plate  22 . As the cassette slot  20  is preferably angled downward towards the cassette fixture face  18 , the downward angle provides a biasing position to hold the cassette  15  adjacent to the fixture plate  22 . The fixture plate  22  is affixed to the cassette fixture face  18  such that when a cassette  15  is inserted in the cassette slot  20  with the cassette bottom  15   b  against the bottom of the cassette slot  20 , the front edge of the label-bearing face  19  at least partially abuts the fixture plate  22  (shown in position in  FIGS. 5   a ,  5   b  and  5   c ). Additionally, the fixture plate  22  has a pair of fixture plate slots  23  in a vertical orientation ( FIGS. 4   a - 4   c ). To provide precise alignment tolerances, it is preferable that the fixture plate  22  has a pair of dowels  21  ( FIGS. 4   a ,  4   b  and  4   c ) that engage a pair of mating holes  25  in the cassette fixture face  18  ( FIGS. 3   b , and  3   c ), although other means of alignment could be used. 
     Referring to  FIG. 4   d , in at least one embodiment, the fixture plate  22  includes a plate channel  22   a  that extends from a bottom opening  22   b  upwards around at least one fixture plate slot  23  and at least one probe spacer stop  22   c . Additionally, the back portion  22   d  of the fixture plate  22  further includes an air draw vent  22   e  and at least one probe spacer stop opening  22   f . Further, the air draw vent  22   e  is in communication with the fan duct  12   a  which is connected to the cooling fan  10   a  as shown in  FIG. 5   b . The cooling fan  10   a  may be operated to cool the interface between the staker assembly  2  and the cassette fixture assembly  4  during the staking process by pulling air up through the fixture plate  22  and exhausting it either inside or outside the staking device  1 . Further, an alternate embodiment of the fixture plate  22  is shown in  FIG. 4   e , where the cooling fan  10   b  pushes outside air through the flow duct  13  (as seen in  FIG. 1   b   3 ) and into the air draw vent  22   e . The outside air is guided across the fixture plate  22  by one or more flow vanes  61 . 
     Referring to  FIGS. 4   a  and  4   b , the cassette fixture assembly  4  includes a clamping assembly  31  having a fixture clamp  26 , a clamp lever  30 , a clamp cam  34 , a clamp motor  36 , and a fixture pin  32 . The clamping assembly  31  in another embodiment further includes the pivot arm  41   a . The fixture clamp  26  includes fixture clamp arms  27  and a clamp engaging portion  28 . In at least one embodiment, the clamp engaging portion  28  includes a ridge protrusion having a gap, where the ridge may act as a guide. In another embodiment, the clamp engaging portion  28  may be formed as an aperture that extends through the clamp  26  ( FIG. 4   c ), with a separate ridge that may act as a guide. The fixture clamp  26  is slidably mounted in a channel  29  ( FIGS. 3   b  and  3   c ) inside the cassette fixture  16  and moves in a substantially horizontal plane perpendicular to the cassette fixture face  18 . The fixture pin  32  hingedly supports the clamp lever  30  having a motor end  38  and a clamp end  40  ( FIGS. 4   a - 4   c  and  5   a - 5   c ). The clamp lever  30  and fixture pin  32  are located at least partially inside the cassette fixture  16 . The clamp end  40  of the clamp lever  30  engages the clamp engaging portion  28 . The clamp cam  34  is attached to the clamp motor  36 , engages the motor end  38  of the clamp lever  30  at least partially outside the cassette fixture  16 . The clamp motor  36  is preferably a gear motor, but it has been contemplated that various types of other motors would suffice such as a stepper motor or servomotor. Although considered part of the cassette fixture assembly  4 , the clamp motor  36  is preferably mounted at least indirectly to the staker assembly  2  ( FIGS. 5   a - 5   c ). 
     The primary purpose of the cassette fixture assembly  4  is to place and hold the label-bearing face  19  flat against the fixture plate  22  during the staking process. After a cassette  15  is placed inside the cassette slot  20 , the staking device  1  is then activated.  FIGS. 5   a ,  5   b  and  5   c  illustrate the cassette securing position before activation of the cassette fixture assembly  4 , and  FIGS. 6   a ,  6   b  and  6   c  show the completed cassette  15  securing position after activation. 
     Referring to  FIGS. 5   a  and  6   a ,  FIG. 5   a  shows the device in a default position prior to activation having a cassette  15  resting in the slot  20 . Upon device activation, the clamp motor  36  rotates the clamp cam  34  in a counter-clockwise direction, which rotates the motor end  38  of the clamp lever  30  downward. Due to the rotation point at the fixture pin  32 , the downward motion of the motor end  38  of the clamp lever  30  forces the clamp end  40  to move substantially toward the cassette fixture face  18 , thereby sliding the engaged fixture clamp  26  towards the fixture plate  22 . In at least one embodiment, the clamp motor  36  stops in an engaged biasing position after the fixture clamp arms  27  have engaged the back of the label-bearing face  19  and forced the label-bearing face  19  against the fixture plate  22 . At this point, the cassette  15  is in position to be staked. 
     In other embodiments, referring to  FIGS. 5   b ,  5   c ,  6   b  and  6   c , the sliding fixture clamp  26 , at least indirectly via the fixture clamp arms  27 , rotates the adjacent pivot arm upper portion  41   d  about the hinge mechanism  41   b , the rotation being against the biasing of the pivot spring  45  pushing against the pivot arm lower portion  41   c . The clamp motor  36  stops in an engaged biasing position after the pivot tabs  41   e  have engaged the back of the label-bearing face  19  and forced the label-bearing face  19  against the fixture plate  22  (as in  FIG. 6   b ). These clamping mechanisms provide the flexibility for the device to engage cassettes  15  with various angled label-bearing faces  19 . 
     Referring again to  FIGS. 2   a - 2   c , the staker assembly  2  utilizes a probe plate  44  to connect to the cassette fixture assembly  4 . As shown in  FIGS. 2   a - 2   c  and  5   a - 5   c , the cassette fixture assembly  4  attaches to the staker assembly  2  by a pair of fixture screws  42 . The fixture screws  42  are inserted through holes in the cassette fixture  16  and the fixture plate  22 , and then engage the probe plate  44 . The probe plate  44  is preferably made from a material that dissipates heat well, such as aluminum. In at least one embodiment, referring to  FIG. 7   a , the probe plate  44  includes a probe plate wall  46  in a vertical orientation, a probe plate base  48  that is in a horizontal plane normal to the wall  46 , and probe plate supports  50  extending normal from the wall  46  at least partially in a direction opposite of the cassette fixture assembly  4 . The probe plate base  48  includes at least one backstop tab slot  57 . 
     In at least one embodiment, the staker assembly  2  includes the probe plate  44  and a backstop  54  for mounting and guiding support, a block assembly  52  that stakes a label  53  to the cassette  15 , a lower rotation assembly  56  that moves the block assembly  52  into a horizontal position, and an upper rotation assembly  58  that moves the block assembly  52  into a vertical position. 
     Referring to  FIG. 8   a , in at least one embodiment the block assembly  52  includes a probe block  60 , a heater block  62  with at least one heater cartridge  64  (to heat the probe block  60 ), a carrier  66  (for securing the heater block  62  and probe block  60 ), and a spring plate  68  mounted to the carrier  66 . In other embodiments, referring to  FIGS. 8   b  and  8   c , the block assembly  52  may further include a heat shield  37  secured to the probe block  60  and a temperature sensor  69  situated between the carrier  66  and the heater block  62 . 
     Referring to  FIGS. 8   a - 8   c , the probe block  60  includes at least one probe stand  70  that provides a mounting point for at least one plunge probe  72 , and at least one burn probe  74 . The probe stand  70  is also configured to set the depth that the plunge probe  72  will enter the label  53  and the depth that the burn probe  74  will enter the label-bearing face  19 . The probe stand  70  is preferably a raised protrusion normal to a probe block face  76  with a flat shoulder surface  78  from which the plunge and burn probes  72 ,  74  extend. Additionally, the probe stand  70  may have multiple tiers extending from the probe block face  76 , as shown in  FIGS. 8   b  and  8   c . In at least one embodiment, two linear probe spacers  80  extending from opposite sides of the probe block face  76  may include at least one notch  77  ( FIGS. 8   b  and  8   c ) for securing the heat shield  37  to the probe block face  76  using a pair of screws or other securing means. 
     Referencing  FIGS. 6   a - 6   c  and  9   a - 9   c , when the block assembly  52  is moved towards the cassette fixture  16  (to either plunge or burn the label  53  and cassette  15 ) the probe spacer  80  abuts the fixture plate  22  stopping the block assembly  52  at a desired depth from the cassette fixture face  18 . The probe stand  70  extends at least partially through the fixture plate  22 , positioning the plunge and burn probes  72 ,  74  into a plunging or burning position. The plunge probe  72  and burn probe  74  are preferably circular but any shape could suffice, such as square or hexagonal. The burn probe  74  extends a short distance from the probe stand  70  and has a wide circumference. The plunge probe  72  extends a further distance from the probe stand  70  and has a narrower circumference than the burn probe  74 . The short and wide dimensions of the burn probe  74  allow the burn probe  74  to create a wide hole in the label  53  affixed to the label-bearing face  19 , while the narrower and longer plunge probe  72  avoids the label  53  and penetrates into the label-bearing face  19  with minimal or no contact with the label  53 . 
     Additionally, the probe block  60  has a block top stop  82  and a block bottom stop  84  ( FIGS. 8   a - 8   c ). As seen in  FIGS. 6   a - 6   c , the block top stop  82  abuts the bottom of the probe plate supports  50  when the probe block  60  is held in its top vertical position by at least one vertical spring  86 . As seen in  FIGS. 9   a - 9   c , the block bottom stop  84  abuts the top of the probe plate base  48  when the probe block  60  is forced vertically downward against the vertical spring  86  bias; this provides a fixed vertical stop. The probe block  60  is preferably formed from a single piece of copper, although several pieces may be secured together to form the probe block  60 . Also, other materials may be used to form the probe block  60 , such as a ceramic. Additionally, the probe block  60  may be plated with nickel or silver to minimize corrosion. 
     To accomplish the staking process, the plunge and burn probes  72 ,  74  are heated to a temperature adequate to melt (without burning) material the cassette  15  and label  53  are made of. In this embodiment, the probes  72 ,  74  are heated to approximately the same temperature; although in another embodiment, the plunge probe  72  may be heated to a temperature necessary to melt the cassette  15  material. The burn probe  74  may be heated to a separate temperature necessary to melt the label  53  material. Heat is transferred the heater block  62  to the probes  72 ,  74 , which is preferably made from a material that conducts heat well, such as copper. Referring to  FIG. 8   a , the heater block  62  in at least one embodiment is configured to receive at least one heater cartridge  64 ; the heater cartridge  64  having a temperature sensor incorporated within (not shown). Although in other embodiments as shown in  FIGS. 8   b  and  8   c , the heater block  62  may utilize a separate temperature sensor  69  situated in a temperature sensor slot  75 . 
     In reference to  FIGS. 8   a - 8   c , the probe block  60  is secured to one side of the heater block  62  with a pair of screws that may be easily removed once the cassette fixture assembly  4  has been removed from the staker assembly  2 . This provides simple and rapid replacement of the probe block  60  in the field. The heater block  62  is substantially situated inside the carrier  66 . The carrier  66  is configured to substantially encase the portion of the heater block  62  that is not in contact with the probe block  60 . Further, the carrier  66  has slots and indents that receivably engage the mating slots and indents of the probe block  60 . The carrier  66  is preferably ceramic, although other materials that insulate well may be used. 
     Referencing  FIGS. 2   a - 2   c , the carrier  66  is partially centered by a probe post  67  that is inserted through the bottom of the probe plate base  48  and through an oblong hole  71  in the carrier  66 . The probe post  67  guides the block assembly  52  as it moves horizontally towards the cassette fixture  16  (burn and plunge position) and backward to its resting position (default position). Additionally, the probe post  67  may be used to guide the block assembly  52  as it moves vertically between the burn and plunge positions. 
     In at least one embodiment, the spring plate  68  is made from a single piece of shaped spring steel, although other materials and multiple pieces may be used. As shown in  FIGS. 8   a - 8   c , the spring plate  68  is affixed to the carrier  66  using a fastener such as screws that pass through the spring plate  68  and the carrier  66  and engage the heater block  62 . The spring plate  68  has a horizontal surface  68   a  that is substantially parallel to and situated above the top of the carrier  66  (also see  FIGS. 5   a - 5   c ); this surface  68   a  supports at least one vertical spring arm  90 . The spring plate  68  also has a vertical surface  68   b  that is substantially parallel to the backside of the carrier  66  (also see  FIGS. 5   a - 5   c ); this surface  68   b  supports at least one horizontal spring arm  92 . Further, the spring plate  68  is secured to the backstop  54  by at least one horizontal spring  88  and one vertical spring  86  ( FIGS. 5   a - 5   c ). In at least one embodiment, as shown in  FIG. 8   a , both spring plate ends  68   c ,  68   d  have a horizontal spring hole  94  and a vertical spring hole  96  for attaching to one end of a horizontal spring  88  and a vertical springs  86 , respectively. In other embodiments as shown in  FIGS. 8   b  and  8   c , the spring plate  68  has one vertical spring arm  90  and two horizontal spring arms  92  extending from the spring plate  68 ; further, the spring plate  68  has one horizontal spring hole  94  (see  FIGS. 5   b  and  5   c ) and two vertical spring holes  96 . Additionally, the spring arms  90 ,  92  may be formed therefrom or otherwise secured to their respective surfaces  68   a ,  68   b . Further, in at least one embodiment, as shown in  FIG. 8   c , the vertical spring arm  90  may be the same as the horizontal surface  68   a.    
     The backstop  54  further encloses and supports the block assembly  52  as seen in  FIGS. 5   a - 5   c . Referring to  FIGS. 2   a - 2   c , the backstop  54  includes at least one backstop support tab  100  for engaging at least one backstop tab slot  57  in the probe plate base  48 , at least one backstop vertical tab  102  for securing one end of the vertical spring  86 , and at least one backstop horizontal tab  104  for securing the end of the horizontal spring  88 . At least one embodiment includes one horizontal tab  104  and two vertical tabs  102  as shown in  FIGS. 2   b  and  2   c  along with one horizontal spring  88  and two vertical springs  86 . Additionally, in at least one embodiment a pair of backstop slots  98  is included to provide clearance for the block assembly screws  55  (as shown in  FIG. 2   a - 2   c ). The backstop  54  is secured to the probe plate  44  by inserting the backstop support tabs  100  into the backstop tab slots  57  and fastening the backstop  54  to the probe plate supports  50  using at least one backstop screw  59  (as shown in  FIGS. 5   a - 5   c ). Additionally, in at least one embodiment, a plate spacer  117  may be used between the probe plate supports  50  and the backstop  54  to create an offset for the addition of a probe plate extension  49  or for a motor mount  99  (best shown in  FIGS. 2   b  and  2   c ). 
     A lower rotation assembly  56  ( FIGS. 10   a - 10   c ) and an upper rotation assembly  58  ( FIGS. 11   a  and  11   b ) are used to move the block assembly  52  horizontally and vertically, respectively. Referring to  FIGS. 10   a - 10   c , the lower rotation assembly  56  includes in at least one embodiment, a lower motor  106  (preferably a stepper motor, although a gear or servo motor could be used), at least one lower cam assembly  108 , at least one lower cam bearing  110 , and at least one lower cam sensor  112 . The lower cam assembly  108  may further include a lower cam disc  111  having a lower disc notch  103  that is monitored by the lower cam sensor  112 . 
     In at least one embodiment, the lower motor  106  is affixed to the bottom of the probe plate base  48  and the lower cam assembly  108  is affixed to the shaft of the lower motor  106  such that the lower cam bearing  110  rests adjacent to the horizontal spring arm  92  as shown in  FIG. 5   a . In another embodiment, referring to  FIG. 10   b , a probe plate extension  49  may be adjustably secured to the probe plate base  48 , with the lower motor  106  secured to the probe plate extension  49 . The probe plate base  48  having at least one extension slot  51  to adjustably secure the probe plate extension  49  to the probe plate base  48 . Additionally, in another embodiment as shown in  FIG. 10   c , a motor mount  99  is secured to the probe plate base  48 , and the lower motor  106  is secured to the motor mount  99 . 
     In another embodiment, referring to  FIGS. 10   b  and  10   c , the lower cam assembly  108  additionally includes a pulley  107  and at least one support bearing  109 . Further, referring to  FIG. 10   b , the lower motor  106  is affixed to the probe plate extension  49  and has the pulley  107  affixed to the shaft of the lower motor  106 . Additionally, two lower cam assemblies  108  are affixed to the probe plate base  48  via their support bearings  109 , with their lower cam bearings  110  thereby resting adjacent to the horizontal spring arms  92 . Further, the lower motor  106  uses a drive belt  113  connected to all three pulleys  107  to rotate the lower cam assemblies  108 . Referring to  FIG. 10   c , in another embodiment the lower motor  106  is shown affixed to the motor mount  99  with the motor mount  99  further affixed to the probe plate base  48 . 
     Referring to  FIG. 11   a , the upper rotation assembly  58  includes an upper motor  114  (preferably a stepper motor, although a gear or servo motor could be used), a plunge sensor  120 , a burn sensor  122 , and an upper cam assembly  116  that includes an upper cam bearing  118 . The upper motor  114  is affixed to the side of the backstop  54 , with a thermal gasket  115  therebetween ( FIGS. 5   a - 5   c ). The upper cam assembly  116  is affixed to the shaft of the upper motor  114  such that the upper cam  118  rests adjacent to the vertical spring arm  90  as shown in  FIGS. 5   a - 5   c . Additionally, in at least one embodiment the upper cam assembly  116  has an upper cam disc  119  that includes all upper disc notch  105  ( FIG. 11   a ). In another embodiment, shown in  FIG. 11   b , the upper cam disc  119  is mounted separate from the upper cam assembly  116 , at an opposite end of the shaft of the upper motor  114 . 
     Referencing  FIGS. 2   a  and  2   b , the plunge and burn sensors  120 ,  122  are mounted opposite each other such that when the upper disc notch  105  is sensed by the plunge sensor  120 , the upper cam assembly  116  is in a position with the lobe pushing the vertical spring arm  90  downward (as in  FIGS. 9   a - 9   c ), and when the upper disc notch  105  is sensed by the burn sensor  122 , the upper cam assembly  116  is in a position with the lobe not pushing the vertical spring arm  90  downward (default or burn position) ( FIGS. 6   a - 6   c ). These positions are communicated to a processor. In one embodiment, the plunge and burn sensors  120 ,  122  are mounted to the backstop  54  ( FIGS. 6   a  and  6   b ), although in another embodiment, the plunge and burn sensors  120 ,  122  are secured at least indirectly to the upper motor  114  ( FIG. 6   c ). 
     The electrical components of the staker device  1  are monitored and controlled by the processor on an integrated circuit board (not shown) that is mounted adjacent the base  5 . A process activation switch such as a pushbutton may be locally mounted on the front cover  8  or be remotely situated. To stake a label  53  on a cassette  15 , a user would typically first position the label  53  on the label-bearing face  19  with a pressure sensitive adhesive. The positioning of the label  53  may be accomplished manually or by automation the user then inserts the cassette  15  in the cassette slot  20  with the label-bearing face  19  pointing downward such that it abuts the fixture plate  22  ( FIGS. 5   a - 5   c ). The insertion of the cassette  15  may also be accomplished by automation. 
     Once the cassette  15  is inserted, the cassette sensor  35  indicates the presence of the cassette  15  and relays the information to the processor. Upon receipt by the processor of a signal that a cassette  15  is in position in the slot  20  (either manually or automatically), the processor commands the clamp motor  36  to rotate the clamp cam  34 , thereby engaging the clamp lever  30 , which engages and slides the fixture clamp  26  toward the fixture plate  22 . In at least one embodiment the fixture clamp arms  27  engage the back of the label-bearing face  19  and force the label-bearing face  19  against the fixture plate  22  ( FIG. 6   a ). In another embodiment, the sliding of the fixture clamp  26  pushes the fixture clamp arms  27  against the upper portion  41   d  of the pivot arm  41   a , thereby rotating the upper portion  41   d  about the hinge mechanism  41   b  and moving the associated pivot tabs  41   e  into engagement with the back of the label-bearing face  19  thereby moving the label-bearing face  19  against the fixture plate  22  ( FIGS. 6   b  and  6   c ). Once the label-bearing face  19  is against the fixture plate  22  the clamp motor  36  is either stalled (if a gear motor) or positioned (if a stepper motor) so as to maintain pressure on the clamp lever  30 , holding the label-bearing face  19  firmly in place until the process is complete. 
     To stake the label  53  to the cassette  15 , the burn and plunge probes  74 ,  72  must be heated to an adequate temperature to melt the label  53  and label-bearing face  19  material. To heat the probes  74 ,  72 , the heater cartridges  64  are activated by the processor and their temperature is monitored by the processor in at least one embodiment by integrated temperature sensors, although another embodiment may use a separate temperature sensor  69 . A preset temperature is pre-programmed in the processor based on the materials being staked. The heater cartridges  64  heat the highly conductive heater block  62  that is mounted to the probe block  60 . The probe block  60  heats the probe stands  70  and burn and plunge probes  74 ,  72  to the requisite temperature. This heating process may occur prior to a cassette  15  being inserted or after the staking process has been activated. 
     With the burn and plunge probes  74 ,  72  heated and the cassette  15  in position, the staking process begins. Referencing  FIGS. 5   a - 5   c , the staker assembly  2  is shown in a default position with the block assembly  52  biased vertically upwards by the vertical springs  86 , the top of the spring plate  68   a  abutting the bottom of the probe plate supports  50 , the block top stop  82  abutting the probe plate wall  46  and the vertical spring arm  90  adjacent to the upper cam bearing  118 . Additionally, the block assembly  52  is further biased in a rearward position by at least one horizontal spring  88 , with the back of the spring plate  68   b  resting against the backstop  54  and at least one horizontal spring arm  92  adjacent to at least one lower cam bearing  110 . 
     To stake the label  53 , the cassette fixture assembly  4  secures the label-bearing face  19  against the fixture plate  22  (cassette  15  positioned as in  FIGS. 6   a - 6   c ). The staker assembly  2  moves to a burn position, as shown in  FIGS. 6   a - 6   c ; this involves moving the block assembly  52  forward towards the fixture plate  22 . The processor first verifies via the burn sensor  122  that the upper cam assembly  116  is in the burn position (no upper cam assembly  116  force on the vertical spring arm  90 ) before moving the block assembly  52 . Then, in at least one embodiment, the processor activates the lower motor  106  advancing at least one lower cam assembly  108  from a default position (low lobe) as shown in  FIGS. 5   a - 5   c , to a burn position (high lobe) as shown in  FIGS. 6   a - 6   c . The default position is sensed by the lower cam sensor  112  when the lower disc notch  103  is aligned with the lower cam sensor  112 . Further, when the lower cam assembly  108  is in the burn position the lower cam bearing  110  is pushed against the at least one horizontal spring arm  92  forcing the block assembly  52  forward against the bias of the horizontal springs  88 . The block assembly  52  moves forward with the burn probes  74  advancing through the fixture plate slots  23  and through the label  53 , until the probe spacers  80  abut the fixture plate  22 . The depth of the burn required is dependent on the depth of the label  53  and may be adjusted as needed by increasing or decreasing the probe spacer  80  heights.  FIG. 12   a  depicts the burn probe  74  in the burn position with reference to the label  53  and the cassette  15 . Once the pre-programmed burn time (a factor of the probe temperature and label material) has expired, the processor commands the lower motor  106  to rotate the lower cam assembly  108  back to the default position, relieving the force on the at least one horizontal spring arm  92  and allowing the block assembly  52  to move backward under the bias of the at least one horizontal spring  88 , returning the block assembly  52  to a default position. 
     To complete the staking process, the block assembly  52  moves from the default position to a plunge position as shown in  FIGS. 9   a - 9   c . This position involves both a vertical and horizontal movement of the block assembly  52 . To achieve the plunge position, the processor activates the upper motor  114  advancing the lobe of the upper cam assembly  116  to a plunge position (high lobe position) as seen in  FIGS. 9   a - 9   c . The plunge position is sensed by the processor when the upper disc notch  105  is aligned with the plunge sensor  120 . When the upper cam assembly  116  is in the plunge position the upper cam bearing  118  is pushed against the vertical spring arm  90  forcing the block assembly  52  downward against the bias of the vertical springs  86 . The block assembly  52  is moved downward by the upper cam assembly  116  until the block bottom stop  84  abuts the probe plate base  48 ; this position ensures the plunge probes  72  are in the same vertical position as the burn probes  74  had been while in the burn position. This alignment is necessary because the plunge probes  72  enter the label-bearing face  19  through the burn holes in the label  53 . 
     After the vertical plunge position has been established (preferably by the plunge sensor  120 ), the horizontal plunge positioning may be initiated. The plunge horizontal positioning is identical to the burn horizontal positioning with the lower motor  106  and at least one lower cam assembly  108  advancing the block assembly  52  towards the fixture plate  22 . The plunge probes  72  pass through the fixture plate slots  23  and through the burn holes in the label  53 , and are pushed into the label-bearing face  19  ( FIGS. 9   a - 9   c ). The depth of the plunge probes  72  into the label-bearing face  19  is fixed by the probe spacers  80  abutting the fixture plate  22 . The amount of time required for the plunge probes  72  to melt the label-bearing face  19  material depends on the temperature of the probes  72  and the melting point of the label-bearing face  19  material. The necessary time is calculated and pre-entered into the processor prior to staking. While the plunge probes  72  are melting into the label-bearing face  19  the melted plastic is flowing out towards the probe stand  70 , more particularly to the shoulder surface  78 . When the melted plastic abuts the shoulder surface  78 , it is forced to flow outwards away from the plunge probe  72  and over the label  53  forming the shape of a collar bond  33  as seen in  FIGS. 12   b  and  12   c . When a pre-determined time has expired, the processor commands the lower motor  106  to rotate the at least one lower cam assembly  108  to a default position, thereby removing the forward pressure on the at least one horizontal spring arm  92  and the block assembly  52 , allowing horizontal spring  88  bias to return the block assembly  52  to its default horizontal position. The processor then commands the upper motor  114  to rotate the upper cam assembly  116  to a default position, thereby removing the downward pressure on the vertical spring arm  90  and the block assembly  52 , allowing the vertical spring  86  bias to return the block assembly  52  to its default vertical position.  FIG. 12   c  depicts the fully formed collar bond  33  after retraction of the plunge probes  72 . The collar bond  33  in at least one embodiment includes a neck portion  124 , consisting of the cassette material, that extends from cassette  15  through the label aperture  125  created by the burn probe  74  and then tapers radially outward from the aperture to form a shoulder portion  126  at least partially over the label  53 . 
     Once the staking process is complete the processor commands the clamp motor  36  to reverse direction thereby sliding the fixture clamp  26  away from the cassette  15 . In at least one embodiment this moves the fixture clamp arms  27  away from the cassette  15 , allowing the label-bearing front face  19  to be released from the fixture plate  22 . In another embodiment, moving the fixture clamp  26  away from the cassette  15  allows the pivot arm tabs  41   e  to move away from the label-bearing front face  19  (assisted by the at least one pivot spring  45  moving against the lower portion  41   c  of the pivot arm  41   a ), thereby releasing the label-bearing front face  19  and allowing the cassette  15  to be removed. 
     Any portion of the staking process may be accomplished manually or by automation, including various movements of the assemblies and sub-assemblies. The insertion and removal of cassettes may also be automated. 
     One embodiment of the device (not shown) eliminates the burn probes  74 , and the upper rotation assembly  58  with the associated hardware required to move the block assembly  52  in a vertical manner. This process would only involve a horizontal movement and would advance the plunge probe  72  forward into the label-bearing face  19 , burning the label  53  for the necessary time. After the label  53  is burned, the plunge probe  72  would be advanced further into the label-bearing face  19  and perform the plunge action. After the plunge action is complete the probe  72  would be moved away, completing the process. 
     Although the invention has been described in considerable detail by reference to the drawings, this detail is for the purpose of illustration. Many variations and modifications can be made to the invention by one skilled in the art without departing from the spirit and letter of the appended claims.