Patent Publication Number: US-7712287-B2

Title: Coupon insertion apparatus and method

Description:
TECHNICAL FIELD 
   The invention relates generally to insertion devices and methods and, more specifically, to separating coupons from a continuous coupon web and inserting the separated coupons into containers. 
   BACKGROUND 
   The goal of coupon inserters is to consistently place coupons into bags of cereal, candy, rice, coffee, and snack food, and into boxes and packages of pretzels, pasta, cookies, crackers, and more. Inserters operate at speeds over 300 pieces per minute, utilizing the continuous perforated or non-perforated coupon format. Known inserters can be utilized to insert both overwrapped and non-overwrapped pieces in a bandolier or roll format. 
   Reliability and consistency is extremely important for coupon insertion at the high rates of speed that are required. Such reliability and consistency needs improvement in the area of coupon inserters that use a bursting operation to remove a coupon from a coupon web and then insert the coupon into a container. 
   Thus, there is a need in the art for an improved coupon inserter. 
   SUMMARY 
   One embodiment of the present method and apparatus encompasses an apparatus. This embodiment of the apparatus may comprise: a feeding roll assembly and a burst roll assembly that defines a predefined bight whereby a foremost coupon is separated at the predefined bight from a next coupon of a continuous web of coupons; and a coupon sensor located before the feeding roll assembly and for locating, at the predefined bight, coupons of the continuous web of coupons. 
   A further embodiment of the present method and apparatus encompasses an apparatus. This embodiment of the apparatus may comprise: a positioning functionality that sequentially locates, at a predefined bight, coupons of a continuous web of coupons; a burst functionality whereby a foremost coupon is separated at the predefined bight from a next coupon of the continuous web of coupons; a staging functionality whereby the separated foremost coupon is moved to a staging position; and an insertion functionality whereby the first coupon is inserted into a container only after the next coupon is separated from the continuous web. 
   Another embodiment of the present method and apparatus encompasses a method. This embodiment of the method may comprise: sequentially positioning, at a predefined bight, coupons of a continuous web of coupons; bursting at the predefined bight a foremost coupon from a next coupon of the continuous web of coupons; moving the separated foremost coupon to a staging position; bursting at the predefined bight the second coupon from a further coupon of the continuous web of coupons; and inserting the first coupon into a container. In a further embodiment the first coupon is inserted into a container only after the next coupon is separated from the continuous web. 

   
     DESCRIPTION OF THE DRAWINGS 
     The features of the embodiments of the present method and apparatus are set forth with particularity in the appended claims. These embodiments may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements, and in which: 
       FIG. 1  depicts one embodiment of a continuous coupon web; 
       FIG. 2  depicts another embodiment of a continuous coupon web; 
       FIG. 3  schematically depicts one view on an embodiment of a coupon insertion device according to the present method and apparatus; 
       FIG. 4  schematically depicts another view on an embodiment of a coupon insertion device according to the present method and apparatus; 
       FIGS. 5-9  depict one embodiment of feeding and bursting operations according to the present method and apparatus; 
       FIGS. 10-13  depict one embodiment for insertion of coupons into containers according to the present method and apparatus; and 
       FIG. 14  is a flow diagram depicting operation of an embodiment of a coupon insertion device according to the present method and apparatus. 
   

   DETAILED DESCRIPTION 
   Inserts and containers containing the inserts are well known. An insert may take various forms and may be any coupon, card, sheet, receipt, warranty, premium or other part that may be advantageously handled as described hereinafter. In the following the term “coupon” will be used as representative of any form of an insert. Also, an insert may be two-dimensional or three-dimensional. Furthermore, a container may be any type of container, such as boxes, tubs, cans and vessels of all kinds as well as any other coupon-receiver which can advantageously be used as described hereinafter. 
     FIG. 1  depicts one embodiment of a continuous coupon web. In this embodiment the coupons  111 - 114  may be contained in a continuous web  101 . Each coupon  111 - 114  may comprise, for example, a printed item  115 - 118  respectively enclosed in an envelope  119 - 122  (also referred to as an overwrap), which may be made of cellophane, plastic, etc. The coupons  111 - 114  may be temporarily coupled to one another via a perforated or weakened areas  123 - 126 . Also, the coupons  111 - 114  may be of unequal lengths, that is some coupons may be longer than other coupons. For example, coupon  113  is depicted as being longer than coupons  111 ,  112  and  114 . It is a feature of embodiments according to the present method and apparatus that different lengths of coupons are automatically handled without any need to change the structure of the embodiments or by re-programming the embodiments. Also in embodiments according to the present method and apparatus a coupon sensor may sense a leading edge  152  of the printed item  117  in the coupon  113 , a juncture  151  between coupons  112  and  113 , and a register mark  150  on the coupon  113 . 
     FIG. 2  depicts another embodiment of a continuous coupon web  201 . In this embodiment coupons  211 - 214  are coupled to one another by perforated or weakened areas  215 - 218 . Other materials and configurations of the coupons may be utilized. Typically, the continuous coupon web  201  may be stored on a reel or may have a fan-fold configuration and be stored in a box. 
     FIG. 3  depicts one view on an embodiment of a coupon insertion device according to the present method and apparatus. This embodiment may have a delivery assembly  321  that includes roller pairs  316 ,  318 ,  312 ,  314  and belts  320 ,  322 , a burst roll assembly  323  that includes roller pair  306 ,  308 , and a feeding roll assembly  325  that includes roller pair  307 ,  309 . The feeding roll assembly  325  may receive a leading edge of a foremost coupon of a coupon web  324 , and may be driven by an intermittent positioning drive motor system  304  at a predetermined speed. The delivery assembly  321  and the burst roll assembly  323  may be driven by an intermittent feeding drive motor system  310 . A foremost coupon may be separated from a next coupon of the continuous web  324  by stopping or slowing the roller pair  307 ,  309  relative to the driven roller pair  306 ,  308  to effect a bursting operation. 
   A programmable controller  302  or other equivalent control device may be operatively coupled to the motor systems  304  and  310 . In general the programmable controller may be programmed such that the embodiment depicted in  FIG. 3  may have: a positioning functionality that sequentially locates, at a predefined bight, coupons of a continuous web of coupons; a burst functionality whereby a foremost coupon is separated at the predefined bight from a next coupon of the continuous web of coupons; a staging functionality whereby the separated foremost coupon is moved to a staging position; and an insertion functionality whereby the first coupon is inserted into a container only after the next coupon is separated from the continuous web. 
   The programmable controller  302  may be coupled to at least a coupon sensor  328  and a container sensor  332 . The coupon sensor  328  detects the coupons that are attached to the coupon web  324  that may be stored on a coupon reel  326 . Information from the coupon sensor  328  may be utilized for effecting the positioning functionality, the burst functionality, and the staging functionality. A further sensor  350  may be provided for detecting jams and may also be operatively coupled to the programmable controller  302 . 
   The container sensor  332  detects a container  336  on a conveyor  334  for containers. Alternatively, other equipment (not shown) in a production line may supply information regarding the moving container. Information from the container sensor  334  may be utilized in effecting the insertion functionality whereby, in one embodiment, a foremost coupon is inserted into a container only after a next coupon is separated from the continuous web. A coupon may be ejected from the delivery roll assembly  321  along coupon path  338  and into the container  336  as the container  336  travels along the conveyor  334 . This results in increased reliability and operation of inserting coupons in containers. 
     FIG. 4  depicts another view of the  FIG. 3  embodiment of a coupon insertion device according to the present method and apparatus. A coupon web  424  is supplied from a coupon reel  426  to a feeding roll assembly  425 . Sensors  428 ,  432  and  450  operate as described above in  FIG. 3 . 
   As depicted in  FIG. 4  a foremost coupon may be ejected along path  444  from the delivery assembly  421  toward an approaching first container  403  on a conveyor for containers  434 . In one embodiment, before the foremost coupon reaches the first container  403 , the next coupon is separated from the coupon web  424 . This next coupon will eventually be inserted into the second container  404 . 
     FIGS. 5-9  depict one embodiment of feeding and bursting operations according to the present method and apparatus. In  FIG. 5  first, second, third, and fourth coupons  501 ,  502 ,  503 ,  504  are fed to a feeding roll assembly  507 . The juncture of the first and second coupons  501 ,  502  or alternatively the leading edge of the second coupon  502  may be sensed by the coupon sensor  510 . At this stage of operation the feeding roll assembly  507  is stopped. The burst roll assembly  506  may be continuously rotating in one embodiment or may be turned on and off at different stages of operations in another embodiment. This is referred to as indexing. 
   In  FIG. 6  the feeding roll assembly  507  is turned on which advances the first, second, third, and fourth coupons  501 ,  502 ,  503 ,  504  approximately a predetermined distance such that a juncture of the first and second coupons  501 ,  502  is positioned between the feeding roll assembly  507  and the burst roll assembly  506 . 
   In  FIG. 7  the feeding roll assembly  507  is turned off which causes the first coupon  501  to be separated from the second coupon  502  in a burst operation. The burst roll assembly  506  continues to run and move the first coupon  501 . 
   In  FIG. 8  the feeding roll assembly  507  is again turned on which advances the second, third, and fourth coupons  502 ,  503 ,  504 . After the coupon sensor  510  detects the juncture of the second and third coupons  502 ,  503 , the second, third, and fourth coupons  502 ,  503 ,  504  are advanced approximately predetermined distance such that the juncture of the second and third coupons  502 ,  503  is positioned between the feeding roll assembly  507  and the burst roll assembly  506 . 
   In  FIG. 9  the juncture of the second and third coupons  502 ,  503  is positioned between the feeding roll assembly  507  and the burst roll assembly  506 . The operation now repeats with the bursting of the second and third coupons  502 ,  503 . This operation my be used with a continuous running burst roll assembly  506  or an indexing burst roll assembly  506 . It also may be used with sequential coupons of varying lengths in a coupon web. It may further be used with systems in which a foremost coupon is inserted into a container only after a next coupon is separated from the continuous web, or in a system in which a foremost coupon is inserted into a container before a next coupon is separated from the continuous web. 
     FIGS. 10-13  depict operation according to the present method and apparatus for inserting a coupon into a container. In each of the  FIGS. 10-13  a continuous web of coupons  505  having first, second, third, and fourth coupons  501 ,  502 ,  503 ,  504  is supplied to a feeding roll assembly  507 . In the each of the coupons is separated in a burst function from the continuous web of coupons  505 . The burst operation may be effected as described above with a burst roll assembly  506  and the feeding roll assembly  507 . Each of the coupons is then transferred to a delivery roll assembly  508 . At least two sensors, a coupon sensor  510  and a container sensor  512 , are provided. It is to be understood that the information supplied by these sensors may be, alternatively, supplied by other inputs in the overall system. The first, second, and third coupons  501 ,  502 ,  503 , for example, may also be referred to as a foremost coupon, a next coupon, and a further coupon. 
   In  FIG. 10  the feeding roll assembly  508  has advanced the first coupon  501  to a staging location  509 . The staging location may be at other locations, such as at either end of the feeding roll assembly  508 . 
   In  FIG. 11  the second, third and fourth coupons  502 ,  503 ,  504  of the continuous web of coupons  505  are advanced such that a juncture of the second coupon  502  and the third coupon  503  is positioned at a bight  516  defined by the burst roll assembly  506  and the feeding roll assembly  508 . A container  520  is detected by the container sensor  512  and the delivery assembly  508  begins to move the first coupon  501  out of the delivery assembly  508 . 
   In  FIG. 12  the second coupon  502  is separated from the third coupon  503  in a burst function and the first coupon  501  continues to move out of the delivery assembly  508 . The container  520  continues to move as depicted. 
   In  FIG. 13  the first coupon  501  is inserted into the container  520 , and the second coupon  502  moves toward the staging location  509  in the delivery assembly  508 . The process continues as described above with the approach of another container. 
   Some of the operations described in  FIGS. 10-13  may occur substantially simultaneously or in a different order. In the depicted embodiment the first coupon is inserted into a container only after the next coupon is separated from the continuous web. 
     FIG. 14  depicts an embodiment according to the present method and apparatus that may have the following steps: sequentially positioning, at a predefined bight, coupons of a continuous web of coupons ( 1401 ); bursting at the predefined bight a foremost coupon from a next coupon of the continuous web of coupons ( 1402 ); moving the separated foremost coupon to a staging position ( 1403 ); bursting at the predefined bight the second coupon from a further coupon of the continuous web of coupons ( 1404 ); sensing a presence of a container at a predetermined location relative to the staging position ( 1405 ); and inserting the first coupon into the container only after the next coupon is separated from the further coupon of the continuous web ( 1406 ). In this embodiment the foremost coupon may be ejected from the feeding roll assembly such that the foremost coupon is inserted into the container, wherein the container is moving at a predetermined speed. 
   One embodiment according to the present method and apparatus may further have the steps of sensing, by the coupon sensor at a coupon sensor location, a leading edge of a respective coupon of the continuous web of coupons, and, in response to the sensing of the leading edge of the respective coupon, advancing the respective coupon a predetermined distance from the coupon sensor location such that the leading edge of the respective coupon is positioned at the predefined bight. 
   The continuous web of coupons may have at least two coupons having different lengths, or the continuous web of coupons may have a plurality of coupons having different lengths. 
   The present apparatus in one example may comprise a plurality of components such as one or more of electronic components, hardware components, and computer software components. A number of such components may be combined or divided in the apparatus. 
   The present method and apparatus are not limited to the particular details of the depicted embodiments and other modifications and applications are contemplated. Certain other changes may be made in the above-described embodiments without departing from the true spirit and scope of the present method and apparatus herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense.