Abstract:
An inline tape cutter system that manufactures taped packages that can be later-opened without the needed for cutting tools to manual cut packing tape. The inline tape cutter system provides a package engagement assembly having a drive assembly, a cutting arm and an engagement arm, wherein physical contact between the engagement arm and a closed package on a conveyor assembly imparts rotational motion to the drive assembly and directs the cutting arm into contact with the closed package. The cutting arm can include a cutting wire form from a resistive heating element that is capable of burning/cutting packaging tape on the closed package. The inline tape cutter system can include a horizontal positioning assembly and a vertical positioning assembly such that the package engagement assembly can engage a wide variety of package sizes and configuration.

Description:
PRIORITY CLAIM 
       [0001]    The present application claims the benefit of U.S. Provisional Application No. 61/055,479, filed May 23, 2008, and entitled, “INLINE TAPE CUTTER”, which is incorporated herein in its entirety by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to the field of automated packaging equipment. More specifically, the present invention is directed to an inline tape cutter for pre-cutting packing tape that has been applied to a package or box to provide an easy-open package. 
       BACKGROUND 
       [0003]    In warehouse style stores, sometimes referred to as “Club Stores,” products are often displayed it its original shipping packaging or format. In this manner, warehouse stores can utilize basic racks or floor displays as opposed to investing in expensive display shelves. 
         [0004]    One drawback associated with utilizing packaging as a display device is that store personnel must typically remove taping and in some instance, portions of the packaging using a cutting device such as, for example, a razor blade, utility knife, scissors or the like. Unfortunately, the use of cutting devices can lead to users suffering cutting and piercing injuries, such as when cutting cardboard and other heavy-duty packaging materials. Not only does the use of these cutting devices increase the likelihood for injury, they also require individuals to spend time to cut open each package. The costs associated with treatment of injuries coupled with the time necessary to manually open each package can be cost prohibitive, especially in warehouse stores where operating margins may be tight to begin with. As such, it would be advantageous to avoid manual cutting of such packages. 
       SUMMARY 
       [0005]    The inline tape cutter system of the present disclosure addresses the aforementioned needs by providing an apparatus that enables users to access products inside a box or open the box, without using a cutting tool to cut the packing tape or closure. Generally, the inline tape cutter system provides a package engagement assembly comprising a drive assembly, a cutting arm and an engagement arm, wherein physical contact between the engagement arm and a closed package on a conveyor assembly imparts rotational motion to the drive assembly and directs the cutting arm into contact with the closed package. The cutting arm can include a cutting wire form from a resistive heating element that is capable of burning/cutting packaging tape on the closed package. The inline tape cutter system can comprise a horizontal positioning assembly and a vertical positioning assembly such that the package engagement assembly can engage a variety of package sizes and configuration. In some embodiments, the inline tape cutter system can be utilized in conjunction with additional processing/manufacturing equipment so as to allow packages of raw materials to be continually opened for use during the manufacturing process. 
         [0006]    In one aspect of the present disclosure, an inline tape cutter system can comprise a package engagement assembly including a drive assembly, a cutting arm and an engagement arm. The engagement arm originally contacts a closed package on a conveyor assembly causing the drive assembly to rotate and direct the cutting arm into a downward direction and into contact with the closed package. The cutting arm generally includes a cutting wire capable of burning/cutting packaging tape holding the package closed. In some embodiments, the cutting wire comprises a resistive heating wire. The inline tape cutter system further includes a horizontal positioning assembly and a vertical positioning assembly such that the package engagement assembly can be adjusted to engage packages having a wide variety of sizes and configuration. 
         [0007]    In another aspect of the present disclosure, a method for opening packages closed with packing tape can comprise providing an inline tape cutter assembly in conjunction with a conveyor assembly. The method can further comprise interfacing with a closed package with an engagement arm on the inline taper cutter so as to rotatably direct a cutting arm into contact with the closed package. The method can further comprise cutting the packing tape with a cutting wire on the cutting arm. In some embodiments, the method can further comprise powering the cutting wire such that the cutting wire is heated to burn the packing tape. The method can further comprise adjusting the inline taper cutter in one or both of a vertical or horizontal direction to interface with a variety of different sized closed packages. 
         [0008]    The above summary of the various aspects of the disclosure is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0009]    These, as well as other objects and advantages of this invention, will be more completely understood and appreciated by referring to the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings, of which: 
           [0010]      FIG. 1  is a perspective view of an embodiment of an inline tape cutter of the present disclosure. 
           [0011]      FIG. 2  is a plan view of the inline tape cutter of  FIG. 1 . 
           [0012]      FIG. 3  is a partial, side view of the inline tape cutter of  FIG. 1 . 
           [0013]      FIG. 4  is a partial, perspective view of the inline tape cutter of  FIG. 1 . 
           [0014]      FIG. 5  is a partially hidden, plan view of the inline tape cutter of  FIG. 1 . 
           [0015]      FIG. 6  is a front view of an embodiment of a tape cutter utilized with the inline tape cutter of  FIG. 1 . 
           [0016]      FIG. 6   a  is a front view of an embodiment of a tape cutter according to the present invention. 
           [0017]      FIG. 7  is a plan view of an embodiment of a display package for opening with the inline tape cutter of  FIG. 1 . 
           [0018]      FIG. 8  is a front, perspective view of an embodiment of a package engagement assembly according to the present invention. 
           [0019]      FIG. 9  is a rear, perspective view of the package engagement assembly of  FIG. 8 . 
           [0020]      FIG. 10  is a front view of the package engagement assembly of  FIG. 8 . 
       
    
    
       [0021]    While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. 
       DETAILED DESCRIPTION 
       [0022]    As illustrated in  FIGS. 1-5 , an inline tape cutter system  100  according to one embodiment of the present disclosure can comprise a cutting system  102  and a conveyor assembly  104 . Though conveyor assembly  104  is illustrated simply with no additional manipulation or packaging equipment, it will be understood that conveyor assembly could comprise additional packaging components and that in some embodiments, conveyor assembly  104  can be integral to an automated taping line in which, cutting assembly  102  is located after a taping assembly. 
         [0023]    With reference to  FIGS. 1-5 , cutting system  102  generally comprises a package positioning assembly  106 , a vertical positioning assembly  108 , a horizontal positioning assembly  110  and a tape cutting assembly  112 . Generally, the main structural components of cutting system  102  can comprise materials suitable for integration with conveyor assembly  104  and can include materials such as, for example, aluminum, painted carbon steel, stainless, steel, rigid polymers and the like. 
         [0024]    Referring again to  FIGS. 1-5 , package positioning assembly  106  generally comprises a plurality of mounting members  114  and a pair of guide assemblies  116   a,    116   b.  Each guide assembly  116   a,    116   b  can comprise a pair of adjustment arms  118   a,    118   b  and a package interface arm  120  connected there between. Package interface arm  120  includes a tapered guide portion  122  and an interface portion  124 . Each mounting member  114  includes a guide aperture  126  for slidably receiving adjustment arms  118   a,    118   b.    
         [0025]    As shown in  FIGS. 1-5 , vertical positioning assembly  108  can comprise a pair of mounting brackets  126 , a pair of vertical positioning arms  128   a,    128   b  and a pair of vertical adjustment members  130   a,    130   b.  Mounting brackets  126  can each comprise a mounting flange  132  and a pair of receiving members  134 . Each receiving member  134  includes a receiving aperture  136  dimensioned so as to accommodate the slidable insertion of vertical positioning arms  128   a,    128   b.  Vertical adjustment members  130   a,    130   b  each comprise an adjustment body  138  having a vertical adjustment aperture  140  and a horizontal receiving aperture  142 . Vertical adjustment members  130   a,    130   b  further comprise a vertical tightening member  144  and a horizontal tightening member  146 . Vertical adjustment aperture  140  is dimensioned for slidable placement over the vertical positioning arms  128   a,    128   b  whereby vertical tightening member  144  can be used to selectively position and retain the vertical adjustment members  130   a,    130   b  at a desired height. 
         [0026]    Horizontal positioning assembly  110  generally comprises a horizontal arm  148  mounted between the vertical adjustment members  130   a,    130   b.  Horizontal arm  148  is sized for slidable insertion into the horizontal receiving apertures  142 . Once horizontal arm  148  is positioned within horizontal receiving apertures  142 , the horizontal tightening members  146  can be tightened such that the horizontal arm  148  is captured between the vertical adjustment members  130   a,    130   b.  In this fashion, vertical adjustment of the vertical adjustment members  130   a,    130   b  along vertical positioning arms  128   a,    128   b  results in the simultaneous vertical adjustment of horizontal arm  148 . 
         [0027]    Referring to  FIGS. 1-5 , tape cutting assembly  112  generally comprises a housing  150  and a package engagement assembly  152 . Housing  150  generally comprises a retaining portion  154  and a cover portion  156 . Retaining portion  154  comprises at least two mounting projections  162  and two mounting apertures  164  for attaching the cover portion  156 . Package engagement assembly  152  generally comprises a drive assembly  166 , a tape cutter  168  and a package engagement member  170 . Drive assembly  166  can comprise a leading bearing assembly  172 , a trailing bearing assembly  174  and a belt  176 . Leading bearing assembly  172  and trailing bearing assembly  174  are operably mounted to retaining portion  154  with mounting apertures  164 . 
         [0028]    As shown in  FIG. 6 , tape cutter  168  generally comprises a cutting arm  177 , a cutter body  178 , a pair of insulating members  179   a,    179   b,  a pair of tensioning members  180   a,    180   b,  a central projecting member  182  and a cutting wire  184 . Cutter body  178  includes a pair of tension apertures for receiving a tensioning fastener  186  so as to attach the tensioning members  180   a,    180   b  to the cutter body  178  while simultaneously attaching the cutting wire  184 . Central projecting member  182  projects outwardly from the cutter  178  and physically engages the cutting wire  184  so as to cause the projecting wire  182  to assume a generally arcuate disposition  188 . Cutting wire  184  generally comprises a suitable resistive element such as, for example, nichrome wire. Cutting arm  176  is generally attached to leading bearing assembly  172 . In an alternative embodiment illustrated in  FIG. 6   a,  a taper cutter  190  can similarly comprise cutting arm  177  and cutter body  178  but with the inclusion of a serrated blade  192 . 
         [0029]    Package engagement member  170  generally comprises an engagement arm  186  operably attached to trailing bearing assembly  174 . 
         [0030]    In use, inline tape cutter system  100  is most beneficial in a setting in which a plurality of packages that are dimensionally similar are processed consecutively. In this setting, each package is preferably loaded, closed and taped using an automated system. A representative display package  200  for use with inline tape cutter system  100  is illustrated in generally in  FIG. 7 . Display package  200  generally comprises a first end  202 , a second end  204 , sides  206   a,    206   b,  bottom surface  208  and top surface  210 . Bottom surface  208  and top surface  210  are generally defined by a pair of exterior flaps  212   a,    212   b  and can include interior flaps  214   a,    214   b  based upon the desired strength and holding capacity of each individual display package  200 . Within top surface  210  and second end  204 , a display portion  216  can be predefined by a perforated or scored perimeter  218  such that the display portion  216  can be knocked-out so as to display the interior contents to potential purchasers. Generally, display package  200  is retained in a closed disposition following packaging by holding exterior flaps  212   a,    212   b  with a length of packaging tape  220 . Typically, packaging tape  220  is of sufficient length to cover the interface of exterior flaps  212   a,    212   b  and extend to first end  202  and second end  204 . 
         [0031]    Referring now to  FIGS. 1-5 , an operator initially adjusts the package positioning assembly  106  relative to the width of display package  200 . Generally, the operator adjusts the guide assemblies  116   a,    116   b  such that a distance between the package interface arms  120  slightly exceeds the width of first end  202  and second end  204 . With the guide assemblies  116   a,    116   b  properly positioned, packaging tape  220  should be arranged generally parallel and centered with respect to the guide assemblies  116   a,    116   b.    
         [0032]    Once positioning assembly  106  has been set, the operator can adjust vertical positioning member  108  to correspond with the height of display package  200 . By loosening the vertical tightening members  144 , vertical adjustment members  130   a,    130   b  can be slidably positioned along vertical positioning arms  128   a,    128   b.  In this fashion, the tape cutting assembly  112  and more specifically, the vertical position of tape cutter  168  and package engagement member  170  are adjusted to properly interface with display package  200 . 
         [0033]    With the inline tape cutter system  100  adjusted to horizontally and vertically interface with display package  200 , operators can begin placing unopened display packages  200  on the conveyor assembly  104 . Generally, each display package  200  is placed on conveyor assembly  104  such that the length of packaging tape  220  is parallel with the path of travel of the conveyor assembly  104 . As the unopened display package  200  advances along the conveyor assembly  104  toward the inline tap cutter system  100 , a leading edge  222 , corresponding to either first end  202  or second end  204 , comes into physical contact with the engagement arm  186  of package engagement member  170 . As the unopened display package  200  continues its advancement along the conveyor assembly  104 , continued contact between the engagement arm  186  and leading edge  222  results in rotational motion being imparted upon the trailing bearing assembly  174 , and correspondingly the belt  176 . As belt  176  rotates about the trailing bearing assembly  174  and the leading bearing assembly  172 , cutting arm  177  is directed in a downward direction such that cutter body  178  approaches top surface  210 . As the unopened display package  200  continues along conveyor assembly  104 , cutter body  178 , and more specifically, cutting wire  184  ultimately comes into contact with the top surface  210   a  the interface between exterior flaps  212   a,    212   b.    
         [0034]    During operation of the conveyor assembly  104 , cutting wire  184  can be continually or intermittently powered such that the cutting wire  184  is heated to a desired operating temperature. In the case of intermittent heating, a switch such as, for example, a proximity switch, photoeye or other motion and/or position based sensor/switch can be used to initiate heating of the cutting wire  184  based upon the position of the unopened display package  200 , or any of the components of the package engagement assembly  152 . Regardless of the operational mode of cutting wire  184 , contact of the cutting wire  184  with the top surface  210  results in burning/cutting of the length of packaging tape  200 . 
         [0035]    As the display package  200  proceeds to an end of the conveyor assembly  104 , the now opened display package  200  can be unloaded from the conveyor assembly  104  for unpacking of any product within the display package  200 , or alternatively, the display package  200  can be arranged for stackable presentation in a warehouse purchasing environment. 
         [0036]    Referring now to  FIGS. 8-10 , an alternative embodiment of a package engagement assembly  300  can be utilized with inline tape cutter system  100 . Package engagement assembly  300  generally comprises a linkage-based drive assembly  302  including a leading bearing assembly  304 , a trailing bearing assembly  306  and a linkage member  308 . Linkage member  308  is generally operably mounted between an engagement arm  310  and a cutting arm  312 . Engagement arm  310  can comprise one or more engagement members  314  configured to engage display package  200  as it carried along conveyor assembly. As the engagement members  314  contact the display package  200 , rotational motion is imparted to the engagement arm  310  and to the cutting arm  312  by linkage member  308 . Thus, cutting arm  312  is rotatably positioned such that tape cutter  168  can cut or otherwise serrate packaging tape  220 . 
         [0037]    Through the use of inline tape cutter assembly  100 , it can be seen that the use of cutting implements such as, for example, knives, razor blades, scissors and the like can be avoided during unpackaging and display of packaged products. In addition, the vertical and horizontal adjustability of the inline tape cutter assembly  100  allows for application of the inline tape cutter assembly  100  with a wide variety of packaging sizes, shapes and configuration without requiring expensive and time consuming changes to software and other electronic controls. In addition, inline tape cutter assembly  100  can be similarly implemented in a batch or continuous manufacturing environment where packaging containing raw materials used during manufacturing can be continually opened for subsequent use. 
         [0038]    While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiment, that many modifications and equivalent arrangements may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.