Abstract:
An automatic bulk loading apparatus loads bulk magnetic tape from a cartridge onto an empty cassette of a standard format. The loading apparatus includes a monitoring and control panel for selecting a desired amount of tape to be loaded for particular applications. Both the cartridge and the cassette are oriented to face the operator for ease of use. An automatic control circuit receives information concerning the desired quantity of tape and also monitors the amount of tape loaded onto the cassette. The circuit controls a drive motor in response to these parameters.

Description:
BACKGROUND OF THE INVENTION 
     This application pertains to the art of bulk loading apparatus and more particularly to apparatus for loading bulk magnetic tape onto an empty cassette. The invention is specifically applicable to loading magnetic video tape from a bulk cartridge onto cassettes for use by commercial and domestic consumers of those products and will be described with particular reference thereto. Currently popular magnetic tape sizes include one-half inch (1/2&#34;) VHS, VHS-C, eight millimeter (8 mm), three-fourths inch (3/4&#34;) regular, and three-fourths inch (1/4&#34;) compact, commonly referred to as &#34;U-MATIC&#34; tape. It will be appreciated, though, that the invention has broader applications such as the BETA or D.A.T. formats and other magnetic tape applications. 
     The recent widespread acceptance of VTR apparatus (video tape recording apparatus), particularly in private homes, has created a large market for blank cassettes of magnetic video tape for sale to consumers. The VHS standard blank cassette is typically loaded with a predetermined quantity of magnetic tape that provides one hundred twenty (120) minutes of recording and playback in standard play (SP) mode, two hundred forty (240) minutes in long play (LP) mode and three hundred sixty (360) minutes in super long play (SLP) mode.. Other video tape standards are similarly sold with a preselected quantity of blank tape that provides recording time at or near the capacity of the cassette. 
     The proliferation of portable cameras for recording events onto video tape, along with the practice of copying between cassettes using two VTRs or using a single dual-deck VTR, has created a need for blank video cassettes with varying amounts of magnetic tape based upon a particular application. For an event which requires five minutes of tape to record, it is deemed useless and wasteful to employ a standard one hundred twenty (120) minute VHS blank video cassette. A consumer faced with the one hundred twenty (120) minute standard VHS blank cassette, and corresponding similar standards for other formats, is often left with a library of largely blank cassettes, each having abbreviated portions of desired recorded material. 
     Alternatively, a consumer ends up with a tape having a potpourri of recorded events, oftentimes unrelated. To view a desired event, the consumer may be forced to either watch large portions of extraneous taped material or &#34;fast forward&#34; through undesired material mindful of the counter provided on most standard VTRs. In either situation, the consumer&#39;s choices are dictated by the major manufacturers that supply blank cassettes having a predetermined length. 
     Still another concern is the economic effect of buying tapes having a predetermined recording time and standard tape quality. The consumer still pays full price for a standard cassette whether he ultimately records on the full tape, or just a portion thereof. The situation is worse when the consumer desires a small amount of premium quality tape. Thus, the limited options offered adversely affect the consumer&#39;s flexibility and result in increased costs. It has, therefore, been deemed desirable to provide an economical solution that meets the variable needs of the consumer. 
     SUMMARY OF THE INVENTION 
     The present invention contemplates a new and improved bulk tape loading apparatus which overcomes the above-referenced problems and provides a consumer with the ability to load blank cassettes with a desired amount of tape from a bulk supply. 
     According to the present invention, a bulk tape loading apparatus for loading blank magnetic tape from a bulk cartridge onto an empty standard cassette is provided. 
     According to a more limited aspect of the invention, the apparatus includes a housing for receiving a cassette and a bulk tape cartridge. Means for automatically loading the tape onto the cassette and means for monitoring the amount of tape are disposed between the cassette and cartridge to load a desired amount of tape into the cassette. 
     According to another aspect of the invention, a splicer is secured to the housing to aid in attaching the tape to leaders provided on the cassette. 
     According to yet another aspect of the invention, the monitoring means includes control means for metering out selected increments of tape. 
     According to a still further aspect of the invention, the apparatus includes a counter means for displaying the amount of tape loaded into the cassette. 
     A primary advantage of the invention resides in the ability to load selected lengths of blank magnetic tape into a cassette. 
     Another advantage of the invention is found in the convenient arrangement of a housing that receives a bulk tape dispenser and empty cassette, control means and splicer. 
     Still another advantage of the invention is realized by the cost savings to the consumer. 
     Still other advantages and benefits of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take physical form in certain parts and arrangements of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
     FIG. 1 is an isometric view of the subject invention showing a bulk magnetic tape loading apparatus adapted to receive a blank cassette; 
     FIGS. 2A and 2B are longitudinal and vertical cross-sectional views of a bulk tape cartridge used in the bulk magnetic tape loading apparatus of FIG. 1; 
     FIG. 3 is an enlarged, detailed view of the control panel of the bulk magnetic tape loading apparatus of FIG. 1; 
     FIGS. 4A and 4B are schematic views showing a preferred mechanism for monitoring the amount of tape loaded onto the empty cassette from the bulk cartridge; 
     FIG. 5 is a schematic of a counter circuit for counting the amount of tape loaded onto the empty cassette; 
     FIG. 6 is an isometric view of an alternative embodiment of the bulk magnetic tape loading apparatus for receiving the bulk magnetic tape cartridge and video cassette; and, 
     FIG. 7 is a schematic detail view of the operative mechanisms of the embodiment shown in FIG. 6. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings, wherein showings are for purposes of illustrating the preferred embodiments of the invention only and not for purposes of limiting same, the FIGURES show a bulk magnetic tape loading apparatus A that receives a bulk magnetic tape cartridge or dispenser B and cassette C. A monitoring or control means D provides for operator control and display of the amount of magnetic tape fed from the cartridge B to the cassette c. A splicing/cut off mechanism E may also be included on the housing to facilitate attachment of the tape to conventional tape leaders associated with the cassette. 
     More particularly with reference to FIG. 1, the bulk magnetic tape loading apparatus A has a housing or base portion 10 generally divided into three regions 12, 14, 16. The first region is sized to receive the bulk tape cartridge B, the second region 14 receives the cassette 0, and the third region generally defines the monitoring and control means for controlling operation of the bulk loading apparatus. A first access door 20 is pivotally secured along hinge wall 22 to the housing. Likewise, a second access door 24, shown in its opened position, is pivotal about the common hinge wall 22. Alternatively, the second door may be attached to the housing 10 at a different location if desired. A power cord 26 supplies A.C. power to an internal electric motor (not shown) and control circuitry when power switch 28 is toggled to its ON position. As a further feature, the power switch 28 may be illuminated to visually indicate that the apparatus is operative. 
     Either or both of the access doors 20, 24 are formed of plastic to cover the bulk cartridge and cassette, respectively, during operation. Preferably, the doors are transparent to allow the operator to visually monitor the tape loading of the cassette while simultaneously acting as a safety cover. 
     With continued reference to FIG. 1, and additional reference to FIGS. 2A and 2B, details of the cartridge will now be provided. The cartridge B is a substantially closed container 32 provided with a spool 34 rotatable about axis &#34;x&#34;. The container and spool are dimensioned to store a large supply of bulk tape 36. For example, a cartridge of the type illustrated having an 81/2 inch diameter holds sufficient VHS format tape to record for approximately 131/2 hours in Standard Play (SP) mode and 40 hours in Super Long Play (SLP) mode. An end 38 of the tape extends from the cartridge so that the tape may be easily retrieved from the bulk cartridge by a consumer merely by pulling on the tape end. 
     The cartridge is further provided with a hub lock 40. The hub lock frictionally engages the spool 34 at a lock-spool interface area 42 to prevent the spool from inadvertently rotating during shipping and handling. More particularly, spring 44 urges brake 46 to pivot about pin 48. The brake thereby contacts the periphery of spool 34 and exerts a drag or braking force. Still other braking arrangements may be used without departing from the intent of the subject invention. 
     The bulk tape cartridge B is also provided with a tape clamp 60 peripherally spaced from the hub lock. The tape clamp preferably includes a roller guide pair 62 and a foam element 64. The roller guide pair directs the bulk tape 36 tangentially from the spool and toward the foam element. The foam element imposes a clamping force on the magnetic tape as it exits the cartridge. 
     Referring again to FIG. 1, and additionally to FIG. 3, the second and third regions 14, 16 of the apparatus housing are more particularly shown. The second region receives the cassette 0 beneath the second access door 24. The cassette is typically empty when inserted into the bulk loading apparatus. It does, though, include first and second spools or rods 70, 72 that each have a tape leader 74, 76, respectively, attached thereto in a conventional, known manner. The tape leaders extend from the cassette and are adapted for splicing as will be described in greater detail below. 
     A drive shaft 80 extends outwardly from the upper surface of the housing second region 14. The shaft is driven by a drive mechanism (not shown) which includes an electric motor contained in the housing. The motor is, in turn, connected to the shaft by gears or a belt, again, in a well known, conventional manner. 
     The cassette is shown with its bracket 82 in an upright or open position. If desired, the housing second region may be provided with a tab or other mechanism for maintaining the bracket 82 in the open position. As shown, both the bulk tape cartridge B and the empty cassette C are arranged adjacent one another and positioned so that the tape and leaders advantageously face the operator of the loading apparatus who is normally positioned adjacent the monitoring and control means D. Further, the illustrated cassette is VHS style, but may be a VHS-C, eight millimeter (8 mm), three-quarter inch (1/4&#34;) regular, three-quarter inch (3/4&#34;) compact, BETA, D.A.T., or any other desired format. 
     An outer fixed guide 90 and an inner fixed guide 92 are in spaced, generally parallel relation along the left-hand edge of second region 14 and adjacent the cassette. As apparent, the fixed guides are disposed adjacent the lower left-hand corner of the bulk cartridge and adapted to receive the tape end 38 that extends therefrom. The tape proceeds through the guides 90, 92. The pair of fixed guides may be provided with a surface layer of TEFLON, a registered trademark of E.I. DuPont de Nemours, or similar smooth material to reduce the effects of friction as the tape passes through the fixed guides. Alternatively, the elongated fixed guides may be replaced by a series of roller guides or other equivalent structure. 
     The tape continues toward a tensioning roller guide 94, and then a fixed roller guide 96 en route to the cassette. The tensioning roller guide is spring biased in groove 98 toward the position shown to provide for a tight winding of the magnetic tape onto the spool 70 of the target cassette c. If desired, the roller guides 94, 96 may be rotatable to provide for less wear on the magnetic tape during operation of the bulk loading apparatus. In addition, guide 96 may be a capstan for regulating the speed of the tape as it is wound onto the cassette C. 
     The bulk magnetic tape loading apparatus A also has a series of operator control buttons and indicia in the third region 16 of the housing. In addition to the previously identified power switch 28, there is also included a SET push button 100, a JOG push button 102, and a RUN push button 104. A display gauge 106 is disposed adjacent the control buttons to indicate the amount of tape fed, or to be fed, onto the cassette C The display gauge may be a series of LED&#39;s or other indicia reflective of the amount of bulk tape loaded onto the cassette. 
     In operation, the magnetic tape end 38 is first manually attached to the spool leader 74 for winding onto the first spool 70 of the cassette. The tape end is threaded between the outer and inner fixed guides 90, 92, around the tensioning roller guide 94, and then around the fixed roller guide 96. As the first spool 70 is rotated by shaft so, the tape end 38 attached to the tape leader 74 is unloaded or extracted from the bulk cartridge B and generally follows the tape path illustrated by arrows Y. The tensioning roller guide slides within the tensioning guide groove to take up any slack in the magnetic tape and insures that the tape is efficiently and tightly wound onto spool the 70. 
     After the tape end is attached to the tape leader 74 of the first spool 7o of the cassette, an operator may energize the loading apparatus using power switch 28. The switch is illuminated indicating that the loader is ready for operation. The operator next uses the JOG push button 102 to slow)y rotate the spool 70, eliminating any slack in the magnetic tape end between the spool 70, the fixed roller guide 96, tensioning roller guide 94 and the foam element 64. Once taut, the operator may terminate the slow rotation of the spool 70 by releasing the JOG push button. 
     Successive depressions of the SET push button are sensed by internal circuitry within the bulk loading apparatus to establish and store a signal representative of a quantity of tape to be loaded onto the cassette 0. By way of example only, if the SET push button 100 is depressed once, the display gauge will illuminate at the position &#34;15&#34;, indicating that fifteen (15) minutes worth of magnetic tape are to be loaded onto the cassette. A second depression of the SET push button causes the display gauge to illuminate at the position &#34;30&#34; indicating that thirty (30) minutes worth of magnetic tape are to be loaded onto the feed spool. Likewise, six successive depressions of the SET push button cause the display gauge to indicate that one hundred twenty (120) minutes of tape are to be loaded onto the cassette. Specifically, all six LED&#39;s 108 are illuminated to represent such a condition. Still other time increments or a different number of tape increments may be used without departing from the scope and intent of the subject invention. 
     Having established an amount of magnetic tape desired to be loaded onto the cassette, an operator next depresses the RUN push button 104, at which time the electric drive motor within the tape loading apparatus engages and begins to rotate the spool 70 via shaft 80 to wind the magnetic tape thereon. RUN lamp 110 reflects this condition of the loading apparatus when lit. As the drive motor rotates the spool 70, a count is maintained by the internal control circuit to determine the amount of tape stored on the cassette. When the counter value reaches a number corresponding to the value stored using the SET push button, a control signal is generated causing the drive motor to stop rotating. 
     Once the amount of magnetic tape desired to be loaded onto the cassette is so loaded according to the above the operator may easily attach the spool leader 76 to the trailing end of the bulk tape after manually cutting same. The cassette thus loaded must next be rewound in order to provide the end user with a proper starting point at which to begin recording. The apparatus further comprises a second drive means (shown in FIG. 7) for engaging the second rotatable reel 72&#39; when the cassette C&#39; is in position on the housing as shown for the embodiment illustrated in FIGS. 1 and 3. In addition, the tensioning roller guide 94 is useful for tensioning the magnetic tape during progression of the tape for the first reel 70&#39; to the second reel 72&#39; when spliced with the second leader 76&#39; and spooled onto the second reel 72&#39; as the second drive means rotates. 
     Referring now to FIGS. 4A and 4B, an LED 114 and photo-transistor 116 are used in conjunction with a rotating slotted shaft 118 to count the amount of tape loaded onto the spool 70. The LED emits infrared light and, accordingly, the photo-transistor is sensitive to infrared light. A capstan 120 rotates with the linear progression of the tape onto the cassette spool 7o. As will be understood, the capstan may be a separate element positioned anywhere along the tape path Y, but preferably is incorporated into the fixed guide roller 96. The capstan 120, connected to the shaft 118, is rotatable within spaced bearings 122 so as to cause a slotted end 124 of the shaft to interrupt the light beam from the LED 114 to the photo-transistor 116. 
     FIG. 4B shows the slotted end 124 positioned to permit the light emitted from the LED to strike the photo-transistor. As the capstan rotates with the linear progression of the magnetic tape, the slotted end selectively interrupts the light beam. This causes a square wave signal to be generated from the phototransistor 116 when connected to appropriate support circuitry. Beginning with the orientation shown in FIG. 4B, the photo-transistor senses four (4) state transitions for a three hundred sixty degree (360°) rotation of the capstan. 
     Turning now to FIG. 5, the control circuit 130 of the loading apparatus is illustrated. An opto-isolator 132 receives signals from the photo-transistor 116 and support circuitry to generate an equivalent but isolated signal to a divide-by-sixteen counter 134. The divide-by-sixteen counter generates one logic transition for every sixteen logic transitions inputted from the opto-isolator. A counter 136 counts logic transitions outputted by the divide-by-sixteen counter and generates a signal on signal lines 138 representative of the number of logic transitions outputted by the divide-by-sixteen counter 134. A reset signal may be used to clear the value stored in the counter 136. The SET push button 100 generates a signal received by a modulo-six counter 140 which, in turn, generates a signal on signal lines 142 representative of the quantity of logic transitions generated by an operator depressing the SET push button. Signal lines 138 and 142 are combined in an AND circuit 148 which generates a DONE signal indicative of a correspondence between the signals 138 and 142. The DONE signal is used to cause the electric motor within the bulk loading apparatus to stop rotation, the quantity of tape loaded into the cassette matching the quantity of tape desired. 
     FIGS. 6-8 show a second preferred embodiment of the bulk magnetic tape loading apparatus of the present invention. For ease of illustration and discussion, like elements will be referred to by like numerals with a primed (&#39;) suffix, and new elements will be referred to by new numerals A housing 10&#39; is provided having a bulk tape cartridge access door 20&#39; shown in an opened position A bulk video cartridge B&#39; having bulk tape 36&#39; is received into the housing for loading onto a cassette C&#39;. The bulk tape has a bulk tape end 38&#39; for attachment to the tape leader 74&#39; by a peel-away adhesive. 
     A digital counter 150 is provided to reflect the quantity of tape loaded onto the cassette. The counter may implement an LED and photo transistor arrangement as described above with respect to the first embodiment or may be the mechanical geared counter 150 driven by the spool 70&#39;. An operator depresses the RUN push button 104&#39; causing the electric motor within the bulk tape loading apparatus to feed the bulk tape onto the cassette and causing the digital counter 100 to increment. Alternatively, an operator may rotate a hand crank (not shown) causing the feed spool to rotate to wind the tape and to increment the mechanical digital counter 150. 
     A splice/cut-off mechanism E is provided for assisting an operator with the attachment of the magnetic tape 51 to the adhesive portion of the feed spool leader. The splice/cut-off mechanism E is provided with a guillotine for cutting the bulk tape 36&#39; and is also provided with guides for aligning the leaders 74&#39;, 76&#39; with the bulk tape for attachment using the peel-away adhesive. 
     In FIG. 7, a skeletal view of the operative components of the embodiment of FIG. 6 is shown. The bulk tape cartridge B&#39; is received onto a deck portion 152 of the housing. The cartridge is located by centering positioners 154 to provide alignment between the cartridge and the cassette. The cassette C&#39; is likewise loaded onto a cassette deck portion 156 of the housing. When inserted, the spool 70&#39; of the cassette selectively engages the drive shaft 80&#39;. In the orientation shown in FIG. 7, the bulk tape is directly fed into the cassette through a fixed roller guide 158. 
     The cassette is received onto the housing deck portion 156. The cassette bracket 82&#39; is shown in an opened position with the spool tape leader 74&#39; and the take-up spool tape leader 76&#39; extending from the cassette. FIG. 8A illustrates the splice/cut-off mechanism E. in use as an alignment tool for aligning the bulk tape end 38&#39; with the tape leader. After successful loading of the bulk tape onto the cassette, the splice/cut-off mechanism may be similarly used to align the trailing bulk tape end 160 for attachment to the take-up spool tape leader 74&#39;. 
     The invention has been described with reference to the preferred embodiments. Modification and alterations will occur to others upon reading and understanding of this specification. It is my intention to include all such modifications and alterations insofar as they come within the scope of the appended claims or equivalents thereof.