Abstract:
By providing a system for controllably applying and wrapping a label into direct, secure, affixed adhesive engagement with the flange or lip of a container, a dependable, effective, and reliable label applying apparatus and label application method is realized which securely affixes a tamper evident label in its entirety to a product container on a continuous production basis, totally eliminating unwanted tenting of labels. By employing the present invention, a product holding container, having a forwardly protruding lip or flange, is advanced towards a label dispensing zone with the label positioned for contacting the top surface of the forwardly protruding flange. Once the label is attached thereto, the label bearing flange/lip is advanced into contact with the label wrapping cam means for placing the label in the desired position. Thereafter, the label wrapped flange or lip is passed through cooperating rollers which force the label into secure affixation with the top and bottom surfaces of the protruding lip or flange.

Description:
TECHNICAL FIELD 
     This invention relates to production equipment and application methods for applying and affixing labels to packages on a production basis and, more particularly, to such production equipment and application methods which assure secure affixation of the label in its entirety to the package. 
     BACKGROUND ART 
     Numerous systems have been developed for applying and affixing labels to a wide variety of packages for a wide variety of different purposes. One such application that has received substantial attention is the affixation of product identifying labels to pre-packaged food products such as fresh bakery items. Typically, fresh bakery items are packaged in transparent plastic containers and product identification labels and/or tamper-evident labels are affixed to the containers. 
     In many instances, the transparent plastic container comprises a clamshell construction, with one edge of the container forming the entry zone, with the entry zone incorporating locking means for holding the container in the closed position. In order to provide for the secure retention of the fresh bakery product in the container, as well as provide a tamper evident construction, the product identifying or tamper-evident label is placed over the leading edge of the container which forms the entry zone. In this way, a consumer is immediately aware if any package has been opened. 
     Although this type of construction is widely used in the food industry, particularly with bakery items, one problem that has continued to plague the industry is the inability of the production equipment to eliminate tenting of the label as a label is affixed to the product containing packages. In most packages of this nature, a forwardly protruding ledge or lip is employed on which the locking means are mounted. As a result, when product identifying or tamper evident labels are mounted to these packages in a manner that surrounds the protruding lip or ledge, the label is affixed to the edge of the lip and the top and bottom surfaces of the package or the sides of the package. However, the label is not affixed directly or completely to the top and bottom surfaces of the protruding lip or ledge of the package. 
     As a result, the label has a characteristic tenting effect, wherein the label is secured along one of its ends to the top or upper side surface of the package and, at its other end, to the package bottom or its lower side surface, with the middle of the label affixed to the edge of the protruding lip. However, the middle portion of the label is spaced away from the top and bottom surfaces of the protruding lip, leaving an open spaced zone therebetween. This construction is often referred to as tenting. 
     In some products of this general nature, a product identifying label is placed on the top of the package in order to enable the consumer to easily read the information printed thereon. As a result, a separate, small fastening label is typically mounted to the protruding lip of the container in order to provide a tamper-evident seal. 
     Although both consumers and manufacturers prefer to have this tamper evident label wrapped tightly around the protruding container lip or flange, prior art systems have been incapable of providing an assembly system which satisfies this need. Instead, these tamper evident labels typically contact the front edge of the protruding lip or flange and extend therefrom into contact with the side surfaces of the container which are formed directly above and below the protruding lip/flange. However, little or no contact is made with the top surface and/or bottom surface of the protruding lip/flange, producing a similar tenting effect. 
     Although most producers and product packaging companies have sought to eliminate this tenting effect by using a wide variety of alternate constructions, no system has been developed for effectively resolving this problem. As a result, although substantial effort has been expended in an attempt to reduce or eliminate this visually undesirable tenting effect, no production equipment or method has been produced, prior to the present invention, which satisfies this long-felt need. 
     Therefore, it is a principal object of the present invention to provide label applying apparatus and label application methods which are capable of securely affixing labels to products on an automated basis with the entire label being secured to the desired product. 
     Another object of the present invention is to provide label applying apparatus and label application methods having the characteristic features described above wherein the labels are securely affixed to product retaining packages regardless of the construction employed for the product retaining package. 
     Another object of the present invention is to provide label applying apparatus and label application methods having the characteristic features described above wherein labels are securely affixed to packages spanning the entry portal for the package and providing secure tamper-free and/or tamper-evident closure of the package. 
     Other and more specific objects will in part be obvious and will in part appear hereinafter. 
     SUMMARY OF THE INVENTION 
     By employing the present invention, all of the difficulties and drawbacks found in the prior art are eliminated and a dependable, effective, reliable label applying apparatus and label application method is attained which assures continuous application of labels to products on a production basis in a continuous, substantially trouble-free operation. In accordance with the present invention, means are provided for securely affixing the label in its entirety to the protruding lip or flange of the container in a manner which securely wraps the label about the surfaces forming the protruding lip/flange. As a result, secure affixation of the label in its entirety to the lip/flange of the product container is realized and the unwanted, prior art tenting of labels is eliminated. 
     In order to provide the secure affixation of a label in its entirety to a product container having a forwardly protruding lip or flange, with the label being effectively wrapped about the protruding lip or flange, precise timing during the label affixation process is required, along with label wrapping cam means. In addition, a pair of cooperating compression rollers are employed with at least one roller being formed from soft, flexible material, for controllably securing the label in its entirety to the protruding lip/flange of the container, regardless of the configuration or shape of the lip/flange. In this way, unwanted label tenting is eliminated and the desired secure, continuous, affixation of the label in its entirety to the product retaining package is assured. 
     In accordance with the present invention, a product retaining package having a forwardly protruding lip or flange is advanced towards a label dispensing zone with the label positioned for contacting the top surface of the forwardly protruding lip/flange. Due to the variety of containers which are employed in this industry, protruding flanges and lips comprise widely, diverse configurations. However, one typical configuration, which is also one of the most difficult to have a tamper evident seal securely wrapped thereon, comprises an L-shaped upper flange member and a flat lower flange member which is held in contact with the upper flange member. As a result, the upper flange member has a vertical front-facing edge about which the label must be wrapped. 
     Once the label is attached to the top surface of the upper flange portion of the forwardly protruding lip or flange, the label extends from the container in a substantially horizontal plane. Then, the label bearing container is brought into contact with label wrapping cam means which folds the label about the upper flange member and lower flange member. 
     Although the label wrapping cam means is able to arcuately fold and wrap the tamper evident label about both the upper flange member and lower flange member, the cam means is incapable of securely affixing the tamper evident label to both the top and bottom surfaces of the protruding lip/flange. Typically, if no further label securement steps were taken, the tamper evident label would become dislodged from the lower flange member and tend to return to its original, horizontal configuration. 
     In accordance with the present invention, this desired secure affixation of the tamper evident label to the top and bottom surfaces of the lip/flange is achieved by advancing the label wrapped container to a pair of rollers and guiding the protruding lip/flange to pass between the rollers. In the preferred embodiment, the upper roller is formed from generally hard material, while the lower roller comprises comparatively soft, flexible or compressible material. 
     By passing the label wrapped flange between the two cooperating rollers, the tamper evident label is compressed onto the lip/flange of the container, effectively forcing the label into secure bonded engagement with the top surface and bottom surface of the protruding lip/flange. In addition, in view of the configuration of the flange, as detailed above, the lower roller is preferably formed from compressible, flexible, or deformable material in order to directly contact the flat surface of the lower flange member as well as the surfaces of the L-shaped upper flange member. In this way, the tamper evident label is securely affixed to the flange, in its entirety, thereby preventing any dislodgement of the label therefrom. 
     By employing this invention, each and every label is securely affixed, in its entirety, to any desired lip/flange configuration employed on a product retaining package, regardless of the construction of the lip/flange. In addition, by assuring secure, adhesive bonded engagement of the label with the bottom surfaces of the forwardly protruding lip or flange, as well as the front end surfaces and the top surface of the flange, unwanted label tenting is eliminated and securement of the label in its entirety to the package is provided. 
     The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the apparatus embodied in the features of construction, combination of elements and arrangement of parts which are adapted to effect such steps, all as exemplified in the following detailed disclosure, with the scope of the invention being indicated in the claims. 
    
    
     THE DRAWINGS 
     For fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which: 
     FIG. 1 is a side elevation view of the label applying apparatus of the present invention; 
     FIG. 2 is a top plan view of the label applying apparatus of FIG. 1; 
     FIG. 3 is a side elevation view of a product container incorporating a label completely wrapped on the protruding lip/flange thereof after passing through the label applying apparatus of the present invention; 
     FIG. 4 is a side elevation view depicting the label dispensing system which forms a part of the label applying apparatus of the present invention; 
     FIG. 5 is a perspective view of the label wrapping cam member employed in the label applying apparatus of the present invention; 
     FIGS. 6-8 are bottom plan views of the label wrapping cam member of FIG. 5 shown in cooperating association with a container and label in various stages of wrapping the label to the protruding lip/flange of the container; 
     FIGS. 9 and 10 are side elevation views, partially broken away, of portions of the label applying apparatus of the present invention depicting alternate stages of the label applying process; and 
     FIG. 11 is an end view depicting the cooperating rollers of the label applying apparatus of the present invention in combination with a container passing therethrough. 
    
    
     DETAILED DESCRIPTION 
     By referring to FIGS. 1-11 along with the following detailed disclosure, the construction and operation of the label applying and securing apparatus and the label application method of the present invention can best be understood. In this detailed disclosure, the preferred construction and method are fully detailed and shown. However, as will be evident to one of ordinary skill in the art, alternate embodiments of this invention can be made without departing from the scope of this invention. Consequently, the embodiment depicted in FIGS. 1-11 and detailed in the following disclosure exemplifies the preferred embodiment of the present invention without limiting the present invention to this particular embodiment. 
     As shown in FIGS. 1 and 2, label applying and securing apparatus  20  comprises supporting frame structure  21  on which is mounted supporting table  22  which incorporates conveyor  23 . In the preferred construction, conveyor  23  comprises an endless or continuous belt on which the desired product containers  24  are positioned and advanced in the direction of arrow  33  for secure affixation of label  25  to container  24 . 
     Product container  24  typically comprises a protruding lip or flange  28  having virtually any desired size or shape. However, by employing label applying and securing apparatus  20  label  25  is able to be securely affixed to lip/flange  28  of container  24  in the desired manner. For exemplary purposes, product container  24  is depicted in the drawings as a generally rectangular shaped container having a clamshell configuration. In addition, container  24  comprises upper portion  26 , lower portion  27 , and protruding lip or flange  28  which defines the forward edge of product container  24  and the interconnecting juncture between upper portion  26  and lower portion  27 , forming the entry portal for product container  24 . 
     As discussed above, lip/flange  28  may comprise a wide variety of alternate configurations or constructions. However, in FIG. 3, one typical construction is depicted which represents a construction which is one of the most difficult configurations on which a tamper evident label is secured. 
     In this construction, container  24  comprises a clam-shell design formed from upper portion  26  and lower portion  27 , which are affixed to each other along a rear edge  29  which forms the pivot axis therefor. Upper portion  26  comprises an L-shaped forwardly protruding lip member defined by substantially flat enlarged top surface  30 , shown in a generally horizontal position, and short, flat wall member  31  extending substantially perpendicularly from flat top surface  30  at its distal end. As depicted, when container  24  is closed, wall member  31  forms a vertically depending flat, forward-facing wall or edge as the leading element of lip/flange  28 . 
     In addition, lower portion  27  comprises an outwardly extending flat bottom surface  32  which is constructed for mating, contacting underlying alignment with flat surface  30  of upper portion  26 . Typically, container  24  comprises locking tabs or lugs formed on lip/flange  28  to securely maintain flat surface  30  and  32  in secure, engaged, juxtaposed, overlying relationship with each other. 
     As shown in FIG. 3, label  25  is securely affixed to protruding lip/flange  28  of container  24  in the desired manner. As depicted, label  25  is securely wrapped about lip/flange  28 , with label  25  in secure, affixed interengagement with top surface  30 , depending wall  31  of upper portion  26 , as well as bottom surface  32  of lower portion  27 . In addition, by employing label applying and securing apparatus  20  of the present invention, label  25  is also secured to the inside surface of wall member  31 , assuring secure, intimate, bonded engagement of label  25  with all exposed surfaces of protruding lip/flange  28 . 
     By employing label applying and securing apparatus  20  of the present invention, unwanted tenting of label  25  on container  24  is completely eliminated. Instead, label  25  is securely affixed to lip/flange  28  of container  24 , in complete wrapped interengaged relationship therewith, providing the consumer with a dependable and reliable method for determining if a package has been opened by another customer. 
     In order to securely affix tamper evident label  25  to each product container  24  in the desired manner and securely close the entry portal thereof, product container  24  is advanced into cooperative operational engagement with labeling dispensing station  35  of label applying and securing apparatus  20 . As detailed below, labeling dispensing station  35  dispenses the desired tamper evident label  25  for affixation on product container  24  and secures one portion of label  25  to top surface  30  of the protruding lip/flange  28  of product container  24 . Thereafter, as detailed herein, the remainder of label  25  is secured to container  24 , along both the side and bottom surfaces of lip/flange  28 . Each of the steps involved in achieving the desired, secure affixation of label  25  to lip/flange  28  are performed sequentially in a precisely timed manner, in order to assure the desired result of securely closing and sealing upper portion  26  and lower portion  27  to each other along flange  28 , with label  25  snugly wrapped directly to flange  28 . 
     In FIGS. 1,  2  and  4 , label dispensing station  35  is shown as preferably incorporating a supply of labels retained on spool  36 . In the typical construction, an elongated, substantially continuous backing sheet or web  37  is employed for supportingly retaining a plurality of labels  25  thereon. Each label  25  is separated from each adjacent label  25  along its ends by die cutting the labels after printing. In this way, ease of separation of each label  25  from an adjacent label  25  is provided. Labels  25  and web  37  extend from spool  36  onto guide rails  34  and  38  which controllingly advance and direct labels  25  and web  37  from spool  36  to the precisely desired position. 
     In order to assure the secure affixation of label  25  to container  24 , each label  25  comprises an adhesive surface, using any desired prior art adhesives or adhesive systems. Preferably, labels  25  are coated with adhesive material when manufactured and then covered with protective backing sheet or web  37 , as discussed above. 
     As shown in FIGS. 1,  2 , and  4 , in order to separate labels  25  from web  37  and enable the adhesive faced surface of label  25  to be positioned in the path of container  24 , guide rail  38  incorporates a stripper or peeling element at its distal, terminating end which continuously separates web  37  from label  25 . In addition, a take-up reel  39  is preferably employed for continuously rolling web  37  onto reel  39  as labels  25  are removed therefrom. In this way, each label  25  is positioned with the adhesive surface thereof facing lip/flange  28  of on-coming product container  24 . 
     As best seen in FIGS. 2 and 4, each label  25  is suspended from web  37  at the terminating end of guide rail  38 , extending in the flow path of product container  24 . The adhesive surface of label  25  is positioned facing the approaching container  24  to assure abutting contacting interengagement of label  25  with top surface  30  of lip/flange  28  of product container  24 . As product container  24  is advanced into contact with label  25 , the label automatically adheres to top surface  30  of lip/flange  28 . 
     In addition, in order to assure the secure bonded engagement of label  25  with top surface  30  of lip/flange  28 , roller  40  is preferably employed. By positioning roller  40  directly adjacent the location at which label  25  is affixed to lip/flange  28 , with a height from conveyor  23  substantially equivalent to the height of top surface  30  of lip/flange  28 , roller  40  contacts label  25  and forces label  25  into secure engagement with lip/flange  28 . Once label  25  is affixed to the top surface  30  of flange  28  in the manner detailed above, label  25  extends from lip/flange  28  in a substantially horizontal configuration and remains in this position until reaching label wrapping cam member  46 . 
     By referring to FIGS. 5-9, along with the following detailed discussion, the construction and operation of the preferred embodiment of label wrapping cam member  46  can best be understood. In this embodiment, label wrapping cam member  46  comprises an elongated, continuous upper plate  47  and a lower plate  48  positioned in juxtaposed, spaced, aligned relationship with each other. However, if desired, cam member  46  may be constructed in a variety of alternate configurations such as in a single piece construction or using tubular or round stock. 
     Upper plate  47  comprises a substantially flat, elongated, rear section  49 , which is operationally mounted in a substantially horizontal plane. The front or forward portion of upper plate  47  comprises ramped, sloping section  50  which is engaged with rear section  49  and extends therefrom at an angle ranging between about 5° and 70°. The construction of upper plate  47  is completed by top surface  52 , bottom surface  53 , and smooth, rounded side edge  51  which extends continuously along sloping section  50  and rear section  49 , forming a flange guiding surface as detailed below. 
     Lower plate  48  is mounted below upper plate  47  in juxtaposed, spaced, vertical alignment therewith. In the preferred embodiment, lower plate  48  comprises top surface  56 , bottom surface  57 , and smooth, rounded side edge  58 . In addition, lower plate  48  also comprises an overall length substantially equal to rear section  49  of upper plate  47 . As best seen in FIG. 5, lower plate  48  is mounted in close proximity with bottom surface  53  of rear section  49  of upper plate  47  at the rear thereof. In addition, lower plate  48  gently slopes downwardly the front portion thereof, establishing gap  59  with upper plate  47 . 
     As best seen in FIGS. 6-8, the width of lower plate  48  varies throughout its length, thereby enabling side edge  58  to function as a label contacting and guiding cam surface. In the preferred construction, side edge  58  of lower plate  48  comprises curved zone  64 , intermediate zone  65 , and terminating zone  66 . In this preferred construction, curved zone  64  of side edge  58  extends from the forwardmost tip of lower plate  48  in an arcuately curved manner which causes side edge  58  to initially be below bottom surface  53  of upper plate  47  and, about midway along its length, to extend outwardly from upper plate  47 , causing side edge  58  of lower plate  48  to be positioned outwardly from side edge  51  of upper plate  47 . 
     Intermediate zone  65  forms a smooth, arcuate transition between curved zone  64  and terminating zone  66 . In this preferred embodiment, terminating zone  66  comprises a substantially straight section which is substantially parallel to side edge  51  of upper plate  47 . However, terminating zone  66  is positioned outwardly from and spaced away from side edge  51  of upper plate  47  by a distance substantially equal to the width of the lip/flange  28  about which label  25  is being wrapped. In this way, as detailed below, the desired wrapping of label  25  is efficiently attained. 
     As detailed above, label  25  is affixed to top surface  30  of protruding lip/flange  28  of product container  24  by label dispensing station  35 . Immediately thereafter, container  24 , with label  25  horizontally extending therefrom, is advanced into cooperating engagement with label wrapping cam member  46 , as shown in FIG.  9 . 
     In the preferred construction, label wrapping cam member  46  is adjustable both vertically and horizontally in order to assure the precisely desired alignment of cam member  46  with container  24 . In this regard, side edge  51  of rear section  49  of upper plate  47  is positioned at a vertical height from conveyor  23  which is substantially equivalent to the vertical height of flange  28  of container  24  from conveyor  23 . As a result, as a container  24  is advanced into cooperating association with label wrapping cam member  46 , wall member  31  of protruding lip/flange  28  is brought into sliding, frictional, guiding engagement with smooth, rounded, side edge  51  of upper plate  47 . 
     As container  24  advances toward label wrapping cam member  46 , wall member  31  of lip/flange  28  of container  24  passes sloping section  50  of upper plate  47  until the leading portion of wall member  31  reaches the juncture between sloping section  50  and rear section  49 . At this time, wall member  31  is brought into sliding, guiding, frictional engagement with side edge  51  of rear section  49 . 
     In view of the sloped angle of section  50  relative to rear section  49 , label  25  passes below sloping section  50  in juxtaposed spaced relationship with bottom surface  53  thereof. However, as the leading edge of label  25  approaches the juncture between sloping section  50  and rear section  49 , as shown in FIG. 6, smooth, rounded, side edge  51  causes label  25  to arcuately pivot downwardly, bringing label  25  into contact with the outer surface of wall member  31 . 
     As container  24  continues to advance along label wrapping cam member  46 , label  25  is arcuately pivoted into a position substantially perpendicularly to protruding lip/flange  28 . Once in this position, as shown in FIG. 7, the leading edge of label  25  begins to contract curved zone  64  of side edge  58  of lower plate  48  in the area where side edge  58  extends horizontally away from edge  51  of upper plate  47 . 
     As container  24  continues to advance relative to label wrapping cam member  46 , the cam surface formed by side edge  58  continues to guide the movement of label  25  relative to lip/flange  28 . In this regard, the movement of label  25  along arcuately curved zone  64  and intermediate zone  65  of edge  58  causes label  25  to be arcuately pivoted into overlying, juxtaposed, spaced relationship with bottom surface  32  of lip/flange  28 . Finally, as shown in FIG. 8, when label  25  is advanced into contact with terminating zone  66  of side edge  58 , label  25  is completely folded, causing the exposed top surface  56  of lower plate  58  to be brought into contact with label  25 . This contact causes label  25  to be adhesively engaged with bottom surface  32  of lip/flange  28 . 
     When container  24  emerges from cooperative engagement with label wrapping cam member  46 , label  25  is wrapped about protruding lip/flange  28 . However, label  25  is not intimately bonded in secure interengagement with lip/flange  28 , since lower plate  48  is only able to bring label  25  into contact with bottom surface  32  of lip/flange  28 . As a result, if additional secure affixation steps were not taken, label  25  would become dislodged from bottom surface  32  and return to its original horizontal configuration. 
     In order to assure the secure affixation of label  25  to protruding lip/flange  28  of container  24 , container  24  is advanced by conveyor  23  into engagement with cooperating rollers  70  and  71 , as shown in FIGS. 10 and 11. As depicted therein, rollers  70  and  71  are mounted in juxtaposed, spaced, cooperating relationship with each other. In this preferred construction, rollers  70  and  71  rotate about separate axes which are parallel to each other, with the outer surfaces of rollers  70  and  71  being in close proximity to each other, either in contact or spaced apart a sufficient distance which enables protruding lip/flange  28  of container  24  to pass therebetween, while still being compressed thereby. 
     By employing this construction, once label  25  has been wrapped about protruding lip/flange  28  of container  24  by label wrapping cam member  46 , container  24  is advanced into cooperation with rollers  70  and  71  so as to cause protruding lip/flange  28  to pass between rollers  70  and  71 . Due to the proximity of the outer surfaces of rollers  70  and  71  to each other, rollers  70  and  71  contact label  25 , forcing label  25  into secure, bonded affixation with protruding lip/flange  28  of container  24 . In this way, the desired securement of label  25  to lip/flange  28  of container  24  is achieved and a trouble-free, aesthetically pleasing tamper evident label is realized. 
     In order to accommodate the wide variety of constructions employed by manufacturers of product holding containers for the flange or lip associated therewith, it has been found that roller  70  is preferably formed from a comparatively hard material, while roller  71 , either entirely or partially, is formed from a compressible material. In this regard, if roller  71  is formed partially from a compressible material, the material must be formed as the outer surface thereof which is brought into engagement with lip/flange  28  of container  24 . 
     As best seen in FIG. 11, roller  70  contracts the top surface of protruding lip/flange  28  of container  24  which typically comprises a substantially flat surface. Consequently, roller  70  may comprise a generally conventional hard material in order to assure the securement of label  25  to top surface  30  of lip/flange  28 . However, since the lower surface of lip/flange  28  comprises vertically depending wall member  31  and flat bottom surface  32 , roller  71  must be capable of compressibility and deflectability in order to contact flat bottom surface  32  without deforming vertically depending wall member  31 . 
     In order to accommodate this configuration, roller  71  comprises compressible material which is capable of being deflected by wall member  31 , while still being able to force label  25  into secure, bonded contacting engagement with the exposed surfaces of wall member  31  and bottom surface  32 . By employing this construction, any flange or lip configuration is capable of being accommodated, with any desired tamper evident label being forced into secure, bonded, peripherally wrapped engagement with the flange or lip. As a result, all of the prior art difficulties and inabilities are overcome and a label applying and securing apparatus and method is realized which is capable of satisfying the long felt needs of this industry. 
     It will must be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and since certain changes may be made in carrying out the above process and in the construction set forth without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.