Patent Description:
Material handling systems are used many different industries and often include complex packaging and conveyor systems that convey items quickly from one place to the next within a facility or multiple facilities. Labeling is often necessary to convey information about the items so that the items can be identified, categorized, and/or properly routed, among other reasons. Placing labels on items that are moving along a conveyance path within a material handling system presents unique challenges, which industry has sought to overcome by using complex electro-mechanical or electro-pneumatic systems that rely on many moving parts and a high degree of complexity. Examples of these existing systems include label applicators that use pneumatic cylinders to press labels on as the items go by and label applicators that employ complex arrangements of electrical motors and mechanical components to apply the labels to the items. Moreover, in labeling devices that incorporate a printer, the label print speed must generally be matched to the speed of item conveyance for proper system operation. More specifically, the current state of the art is referred to as a "reels up" print and apply machine that dispenses the label directly onto the product from the printer. The product line speed must be synchronized with the print speed. If the product line is too slow, the label will bunch up (wrinkle). Conversely, if the product line is too fast, the label will be ripped out of the printer.

Additionally, label feedstock support shafts on current "reels up" print and apply machines are disposed vertically and utilize a label feedstock where the labels are orientated on the feedstock such that the long axis of the label, typically <NUM>", is aligned with the feed direction. This configuration results in several drawbacks, including inefficiencies in production line space and label feedstock rolls, increased wear on the machine due to the inefficiencies, and the label feedstock roll potentially "telescoping" when applied to the reel because it must be handled in a horizontal configuration. Also, because of the orientation of the labels on the feedstock relative to the printer, indicia, such as one dimensional (or 1D) barcodes, must be printed in a "ladder" manner, leading to poor print quality. Generally, one-dimensional (or 1D) barcodes systematically represent data by varying the widths and spacing of parallel lines.

It would be desirable to provide a label applying apparatus that enables label print speed to vary from the conveyance speed of items being labeled, efficient use of production line space and label feedstock rolls, and increased print quality. <CIT> discloses a label roll having the longer of two edge dimensions extending across the width of the roll such that the circumferential size may be smaller than a roll with the labels mounted longitudinially, and a method of printing and applying a label to an item moving in a conveyance direction along a conveyance path, the method comprising: utilizing a print and labeling assembly that includes a label stock path that feeds label stock past a printer to print on a label of the label stock to produce a printed label wherein the label is dispensed in a first direction onto a label applying belt where it is printed, the belt moves in a second direction, wherein the first direction is substantially perpendicular to the second direction such that the label moves onto the label applying belt from a lateral side of the label applying belt; and the label applying belt moves the printed label into position to engage with the item as it moves along the conveyance path. <CIT> discloses a label applicator including a wrap around label applicator, a transport for transporting labels to the wrap around label applicator, and a label dispenser for sequentially supplying labels to the transport.

The invention proposes a method of printing and applying a label according to claim <NUM> and a label print and apply system according to claim <NUM>.

In one aspect, a method of printing and applying a label to an item moving in a conveyance direction along a conveyance path involves the steps of: utilizing a label stock having a liner with a plurality of labels thereon; moving the label stock along a label stock path in a feed direction past a printer to print a given one of the labels, wherein a parallel line bar code is printed on the given label and each line of the parallel line bar code runs parallel to the feed direction and the length of the liner; separating the given label from the liner and dispensing the given label out of the label stock path in a first direction onto a label applying belt system for movement of the label in a second direction, wherein the first direction is substantially perpendicular to the second direction, wherein the first direction is substantially perpendicular to the conveyance direction, and the second direction is either substantially parallel to the conveyance direction or includes a directional component that is substantially parallel to the conveyance direction; the label applying belt assembly moves the label into position to be contacted by the item moving in the conveyance direction for application of the label to the item as the item moves.

In another aspect, a method of printing and applying a label to an item moving in a conveyance direction along a conveyance path involves the steps of: utilizing a print and labeling assembly that includes a label stock path that feeds label stock past a printer to print on a label of the label stock to produce a printed label that is dispensed in a first direction onto a label applying belt that moves in a second direction, wherein the first direction is substantially perpendicular to the second direction such that the printed label moves onto the label applying belt from a lateral side of the label applying belt; and the label applying belt moves the printed label into position to engage with the item as it moves along the conveyance path.

In a further aspect, a label print and apply system includes a conveyor for moving items to be labeled in a conveyance direction. A label roll support shaft is oriented substantially horizontally, and a roll of label stock formed by a liner with a plurality of labels thereon is mounted for rotation on the label roll support shaft. A label printer is positioned along a label stock path for printing labels of the label stock as the label stock moves along the label stock path past the label printer. A label separation station is positioned along the label stock path, and at which labels separate from the liner and are dispensed out of the label stock path in a first direction. A label applying belt system is positioned to receive labels as the labels are dispensed in the first direction, wherein the label applying belt system moves in a second direction that is substantially perpendicular to the first direction.

In one implementation of the foregoing aspect, the first direction is substantially perpendicular to the conveyance direction, and the second direction is either substantially parallel to the conveyance direction or includes a directional component that is substantially parallel to the conveyance direction. The label belt applying system is configured to move labels into position to be contacted by items moving in the conveyance direction for application of the labels to the items as the items move.

Referring to <FIG>, a labeling apparatus <NUM> is disclosed for labeling moving items, which may, by way of example, include, but are not limited to, boxes, cartons, cases, containers, skids/pallets, packaging, plastic packaging, shrink-wrapped containers, or other items. The labeling apparatus <NUM> includes, in the operational configuration, a horizontally disposed label stock supply shaft <NUM> (e.g., about which the label roll and/or a reel <NUM> that holds the label roll will rotate), a label printer <NUM> (disposed behind indicated plate), a label release mechanism <NUM>, a label applying zone <NUM>, and a horizontally disposed label backing/liner take-up shaft <NUM>. In one embodiment, the label printer is a conventional print engine, which can print in thermal transfer or direct thermal mode. In some embodiments, the labeling apparatus <NUM> may be used to apply pre-printed labels, in which case the label printer <NUM> would be optional. In the labeling apparatus <NUM> of <FIG>, the label feedstock, which includes both a liner or backing <NUM> and multiple labels <NUM> applied to a release surface of the liner or backing, generally travels along the label stock path from the label stock supply reel <NUM>, past the label printer <NUM> for printing and then by a release mechanism <NUM> (e.g., a peel bar or edge about which the label backing sharply turns to effect label release). A label feedstock drive arrangement (not shown) may include one or more motors that operate to rotate one or more rollers associated with one or more roller nips through which the label stock passes and/or operate to rotate the take-up reel <NUM>. Once released, the label is then applied to a moving item by the label applying assembly <NUM> at the label applying zone <NUM>. The label stock backing is then accumulated on the backing take-up reel <NUM>.

<FIG> depicts an example of a roll of label stock <NUM> that may be applied to moving items using the label applying apparatus <NUM>. The label stock <NUM> includes labels <NUM> removably/releaseably coupled to a backing <NUM> (also referred to as liner or label stock backing) that facilitates conveyance of the labels <NUM> through the labeling apparatus <NUM>. Each label <NUM> has a leading edge <NUM>, which is the first edge of the label <NUM> to travel along the label stock path <NUM>, a trailing edge <NUM>, which is the last edge of the label <NUM> to travel along the label stock path <NUM>, and side edges <NUM>. In various embodiments, the dimension of the leading and trailing edges are greater than the dimensions of the side edges. In one embodiment, the leading and trailing edges are about <NUM>" in dimension while the sides edges are about <NUM>" in dimension, but other variations are possible. The dimension of the leading and trailing edges of the label defines the label width, and the dimension of the side edges of the label define the label height (i.e., label height runs substantially parallel to the length of the label stock liner). This is in contrast to conventional print and apply machines which typically use a label stock where the labels are arranged with their long axis being parallel to the feed direction, and typically correspond to sides edges of <NUM>" and leading/trailing edges of <NUM>". Thus, the present design not only allows for twice as many labels on a label stock roll of any given diameter, the described machine also provides an increase in the effective output of the machine. This is because the maximum throughput is limited by the maximum practical print speed of the printer, and the feed length of labels running on the described machine is half the feed length of a conventional print and apply machine. Furthermore, because the described labels are being printed in "landscape" format, indicia, such as barcodes, are printed in a "picket-fence" format, that is, the parallel lines of each barcode <NUM> are printed parallel to the direction <NUM> of label stock movement past the label printer <NUM>. The presently described machine thus also provides increased print quality. Also, because the label feed length during printing is half of what is required in conventional print and apply machines, the useful life of wear parts is doubled.

The labels <NUM> may generally be pressure sensitive adhesive labels having an adhesive label side facing the liner prior to separation from the liner, such adhesive side for engagement of the label <NUM> with the moving item intended to be labeled, and a non-adhesive label side that is generally the printed side. The non-adhesive label side may be a printable substrate, a non-printable substrate, or a pre-printed surface. In other embodiments, the label stock <NUM> used may be liner-less label stock, in which case the label release mechanism <NUM> may operate to separate each label from the trailing length of label stock <NUM>.

The label applying assembly <NUM> may be of module configuration, enabling it to be installed and removed from the apparatus <NUM> without impacting the function or operation of the other parts of the apparatus. Importantly, the label applying assemble <NUM> provides a "buffer" between the printer and the application point, so that the print speed and the product speed do not have to be synchronized because the two processes are decoupled. Conversely, conventional print and apply machines dispense the label directly onto the product from the printer, requiring the product speed to be synchronized with the print speed. If the product speed is too slow, the label will bunch up (wrinkle), and if the product speed is too fast, the label will be ripped out of the printer.

The label applying belt assembly or system <NUM>, which may also be referred to herein as a label merge module in the alternative, includes a first conveyor <NUM>, a second conveyor <NUM>', a roller <NUM>, at least a first fan <NUM>, and a plenum <NUM> (internal of the assembly housing). The first and second conveyors <NUM>, <NUM>' have a support surface <NUM>, <NUM>' positioned to receive a label <NUM> that has been released from the backing <NUM>, an upstream end <NUM> positioned proximate to the label release mechanism <NUM>, and a downstream end <NUM> positioned proximate to the roller <NUM>. The conveyor <NUM>, <NUM>' has one or more openings <NUM> to enable a negative pressure effect to occur at the support surface <NUM>. The openings <NUM> can have any convenient shape, which can include, but is not limited to, circular, slotted, elliptical, square, rectangular, other shape, or combinations thereof. As shown, the conveyor <NUM>, <NUM>' can have a plurality of openings <NUM> arranged as rows of evenly spaced slots. In other embodiments, the shape and orientation of the openings <NUM> in the plate <NUM> may vary. The primary portion of the conveyor <NUM>, <NUM>' defining the support surface <NUM> may typically be planar as shown, but other variations are possible including conveyor configurations that result in some curvature in the support surface <NUM> and/or one or more angle changes in the support surface <NUM>. The conveyor <NUM> may have any convenient thickness ranging from a thin plate to a thick plate.

As shown, the fan <NUM> is positioned to draw an air flow F through the openings <NUM> in the conveyor <NUM>, <NUM>', which air flow passes through the plenum <NUM> and is then exhausted from another side of the assembly. By drawing the air flow F through the openings <NUM> in the conveyor <NUM>, <NUM>', the fan <NUM> creates a negative pressure effect at the support surface <NUM> of the conveyor <NUM>, <NUM>'. The fan <NUM> can be any convenient type or size of commercially available fan. The plenum <NUM> is defined by the rear surface <NUM> of the conveyor <NUM>, <NUM>', an end wall <NUM> opposite the conveyor <NUM>, <NUM>', and a plurality of side walls <NUM> extending from the conveyor <NUM>, <NUM>' to the end wall <NUM>. It is recognized that the fan <NUM> may be positioned in any one of the plurality of side walls <NUM> or in the end wall <NUM>. The plenum <NUM> may be sealed to prevent air leakage, but embodiments having some air leakage may also be implemented. Although the use of a fan is described above, alternative means for creating a negative pressure effect at the support surface <NUM> of the conveyor <NUM>, <NUM>' may be used, which may include any means of creating a negative pressure known in the art. Such means for creating a negative pressure effect at the support surface <NUM> may include a Venturi apparatus, a vacuum pump, or other device capable of creating a negative pressure effect at the support surface <NUM> by drawing air through the openings <NUM> in the conveyor <NUM>, <NUM>'.

As shown in <FIG>, the roller <NUM> is positioned proximate to the downstream end <NUM> of the conveyor <NUM>, <NUM>'. The roller <NUM> is free-spinning and has an outer surface portion <NUM> that is positioned proximate to a moving item <NUM> (e.g., moved along by a conveyor <NUM>) to be labeled such that the outer surface portion <NUM> is in contact with an application surface <NUM> of the moving item <NUM> (also referred to herein as a moving item application surface). Contact between the outer surface portion <NUM> of the roller <NUM> and the application surface <NUM> of the moving item <NUM> creates a nip zone <NUM> where the outer surface portion <NUM> contacts the application surface <NUM>. The nip zone <NUM> receives the leading edge <NUM> of a label <NUM> and pulls the label <NUM> forward into contact with the application surface <NUM> of the moving item <NUM>. Because the roller <NUM> is free-spinning, contact between the outer surface portion <NUM> of the roller <NUM> and the application surface <NUM> of the moving item <NUM> causes a speed of the label <NUM> to be matched to a speed of the application surface <NUM> of the moving item <NUM> when the label <NUM> enters the nip zone <NUM>. The free-spinning roller <NUM> matches the speed of the label <NUM> to the speed of the application surface <NUM> without having to synchronize the speed of the label <NUM> (or the speed of label printer in embodiments using a label printer) with the speed of the moving item <NUM> using electric motors, timers, controllers and other electronic equipment.

The outer surface portion <NUM> of the roller <NUM> may be compliant such that it conforms to irregular surfaces and/or varying distances. The outer surface portion <NUM> of the roller <NUM> may also be resilient so that the outer surface portion <NUM> durably and consistently re-conforms to an original shape in response to any deformation. The compliant and resilient properties of the outer surface portion <NUM> of the roller <NUM> allows the passing application surface <NUM> of the moving item <NUM> to partially displace the outer surface portion <NUM> of the roller <NUM>, which re-conforms after the application surface <NUM> has passed. A roller <NUM> having an outer surface portion <NUM> that is compliant and/or resilient may also be referred to herein in the alternative as a compliant roller without implying a lack of resilience. The outer surface portion <NUM> of the roller <NUM> may also be non-stick so that adhesive and/or label faults do not accumulate on the outer surface portion <NUM> of the roller <NUM> to impede performance. The outer surface portion <NUM> of the roller <NUM> may be made from a resilient material, such as plastic, rubber, silicone rubber, or foam, for example. One or more surface treatments may be applied to the outer surface portion <NUM> to provide non-stick properties to the roller <NUM>. In one embodiment, the outer surface portion <NUM> of the roller <NUM> may be a highly resilient, non-stick silicone rubber. In some embodiments, the roller <NUM> may have hollow windows <NUM> extending lengthwise through the roller <NUM>, the windows <NUM> enabling the outer surface portion <NUM> to deform towards a central axis of the roller <NUM> to provide resilience. In operation, the application surface <NUM> of the moving item <NUM> partially displaces the outer surface portion <NUM> of the roller <NUM>, which may deform. Because of the resilient nature of the roller <NUM>, the outer surface portion <NUM> of the roller <NUM> seeks to maintain its original shape and exerts a force back against the application surface <NUM> of the moving item <NUM>. When a label <NUM> moves through the nip zone <NUM>, this force acts on the label <NUM>, pressing the adhesive label side against the application surface <NUM> to adhere the label <NUM> to the moving item <NUM>. Also due to the resilience of the roller <NUM>, a degree of displacement/deformation of the outer surface portion <NUM> of the roller <NUM> constantly changes in response to changes in a contour of the application surface <NUM> of the moving item <NUM>. This dynamic nature of the outer surface portion <NUM> of the roller <NUM> enables the roller <NUM> to maintain contact with the application surface <NUM> of the moving item <NUM> despite one or more contour irregularities in the application surface <NUM> and allows smooth application of the label <NUM> to the application surface <NUM>.

Also, and as shown in <FIG>, the space in a label applying line occupied by the described apparatus is minimized because, as described in detail above, the prior print and apply machines have a "reels up" configuration, which would roughly equate with moving the described apparatus on its side with the label stock supply shaft and label backing take-up shaft disposed vertically. But with the present design, the label stock supply shaft and label backing take-up shaft are disposed horizontally, resulting in the reels and labels rolls being oriented vertically, with the result being a decrease in the effective processing line space occupied by the described apparatus, thus increasing efficiency of the processing line.

As shown in <FIG>, the conveyors <NUM>, <NUM>' are positioned to extend from the release mechanism <NUM> to the roller <NUM>. The conveyors <NUM>, <NUM>' have a width W in a direction generally parallel to a rotational axis of the roller <NUM>, and the width W may be selected to adequately support a lateral dimension of the label <NUM> (lateral referring to a cross-machine direction). The conveyor <NUM> has a length L in a direction generally parallel to the item conveyance direction D (<FIG>) and conveyor <NUM>' has a length L' in a direction angled toward the path of the moving item, where direction L' has a directional component parallel to the conveyance direction D.

As shown in <FIG>, the label stock <NUM>, which includes labels <NUM> removably/releaseably coupled to a backing <NUM>, travels in direction <NUM> behind plate <NUM> where indicia is printed on the labels <NUM> by the printer <NUM> (also behind plate <NUM>). The printed labels <NUM> then continue traveling along direction <NUM> until they reach the label release mechanism <NUM> where the label stock <NUM> passes tightly over the release mechanism <NUM>, and the tight travel path of the label stock <NUM> around the release mechanism <NUM> causes the leading edge <NUM> of the label <NUM> to separate from the label stock backing <NUM>. The leading edge <NUM> of the label <NUM> continues to travel downward in direction <NUM> (into the paper in <FIG>) towards the conveyor <NUM> as the label <NUM> continues to release from the label stock backing <NUM>. The adhesive label side of the label <NUM> faces generally away from the support surface <NUM> of the conveyor <NUM>. The backing <NUM> travels upward along direction <NUM>, and onto the backing take up reel <NUM>. Label stock <NUM> is fed by the label drive mechanism (not shown) from the label stock supply reel (not shown) to the label printer <NUM> (behind plate <NUM>). The label release mechanism <NUM> may include, but is not limited to, a release bar, release roller, release plate, peel bar, peel edge, or other release mechanism.

The fan <NUM> creates an air flow through the openings <NUM> in the conveyor <NUM>, <NUM>', and the air flow in turn creates a negative pressure effect (partial vacuum effect) along the support surface <NUM> of the conveyor <NUM>, <NUM>'. The negative pressure effect at the support surface <NUM> maintains the label <NUM> in contact with the support surface <NUM> and keeps the label <NUM> straight as the label <NUM> moves along the label release path.

A controller <NUM> is provided for controlling the various components. The controller may take on various forms, incorporating electrical and electronic circuitry and/or other components. As used herein, the term controller is intended to broadly encompass any circuit (e.g., solid state, application specific integrated circuit (ASIC), an electronic circuit, a combinational logic circuit, a field programmable gate array (FPGA)), processor(s) (e.g., shared, dedicated, or group - including hardware or software that executes code), software, firmware and/or other components, or a combination of some or all of the above, that carries out the control functions of the device or the control functions of any component thereof.

As shown in <FIG>, in an additional embodiment, a sensor support arm <NUM> is positioned on the rear, e.g., non-conveyor side, of the label applying assembly <NUM>. In one embodiment, the sensor support arm <NUM> generally has a curved shape such that a terminal end of the sensor support arm <NUM> is directed to a position which is downstream of the roller <NUM>, thus enabling a sensor <NUM> positioned at the terminal end of the sensor support arm <NUM> to detect proper application of the label <NUM> to the moving item <NUM>. In one embodiment, the sensor <NUM> is a camera. In one embodiment, a second sensor is placed behind conveyor <NUM>' to detect proper release of the label <NUM> from the conveyor <NUM>'. In one embodiment, the second sensor is an optical sensor. In one embodiment, the second sensor and sensor <NUM> is employed.

As shown in <FIG>, in an additional embodiment, roller <NUM> is replaced with a plurality of fingers <NUM>. The fingers <NUM> have a medial flat portion that is positioned proximate to a moving item <NUM> (e.g., moved along by a conveyor <NUM>) to be labeled such that the medial flat portion is in contact with an application surface <NUM> of the moving item <NUM> (also referred to herein as a moving item application surface). Contact between the medial flat portion of the fingers <NUM> and the application surface <NUM> of the moving item <NUM> creates a nip zone where the medial flat portion contacts the application surface <NUM>. The nip zone receives the leading edge <NUM> of a label <NUM> and pulls the label <NUM> forward into contact with the application surface <NUM> of the moving item <NUM>. In one embodiment, the fingers <NUM> are flexible, such that they may flex during application of the label <NUM>. In one embodiment, the fingers <NUM> are metal.

As shown in <FIG>, in an additional embodiment, the labeling apparatus <NUM> includes a stand <NUM> which is used to mount the labeling apparatus <NUM>. In one embodiment, the stand <NUM> comprises a main body which may be fixed to a surface, such as a floor, via attachment points <NUM>. In one embodiment, the attachment points <NUM> are bolts. In one embodiment, the stand <NUM> comprises a pivot point <NUM>, such that the labeling apparatus <NUM> may be rotated about a vertical axis. In addition, the stand <NUM> may comprise a locking mechanism <NUM> for locking the rotation of the labeling apparatus <NUM> at a desired position.

Thus, the described embodiment provides a label print and apply system that includes a conveyor for moving items to be labeled in a conveyance direction. A label roll support shaft is oriented substantially horizontally, and a roll of label stock formed by a liner with a plurality of labels thereon is mounted for rotation on the label roll support reel. Aa label printer positioned along a label stock path for printing labels of the label stock as the label stock moves along the label stock path past the label printer. A label separation station is positioned along the label stock path, and at which labels separate from the liner and are dispensed out of the label stock path in a first direction. A label applying belt system is positioned to receive labels as the labels are dispensed in the first direction, wherein the label applying belt system moves in a second direction that is substantially perpendicular to the first direction. The first direction is substantially perpendicular to the conveyance direction, and the second direction is either substantially parallel to the conveyance direction or includes a directional component that is substantially parallel to the conveyance direction. The label belt applying system is configured to move labels into position to be contacted by items moving in the conveyance direction for application of the labels to the items as the items move. The described embodiment also provides a method of printing and applying a label to an item moving in a conveyance direction along a conveyance path. The method involves the steps of: utilizing a label stock having a liner with a plurality of labels thereon, wherein the liner has a length and a width, and each label on the liner has a height that runs parallel to the length of the liner and a width that runs parallel to the width of the liner, and the width of each label is at least <NUM> times greater than the height of each label; moving the label stock along a label stock path in a feed direction past a printer to print a given one of the labels, wherein a parallel line bar code is printed on the given label and each line of the parallel line bar code runs parallel to the feed direction and the length of the liner; separating the given label from the liner and dispensing the given label out of the label stock path in a first direction onto a label applying belt system for movement of the label in a second direction, wherein the first direction is substantially perpendicular to the second direction, wherein the first direction is substantially perpendicular to the conveyance direction, and the second direction is either substantially parallel to the conveyance direction or includes a directional component that is substantially parallel to the conveyance direction; the label applying belt assembly moves the label into position to be contacted by the item moving in the conveyance direction for application of the label to the item as the item moves.

The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of labeling apparatus. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this application.

Claim 1:
A method of printing and applying a label (<NUM>) to an item (<NUM>) moving in a conveyance direction along a conveyance path, the method comprising:
utilizing a print and labeling assembly (<NUM>) that includes a label stock path that feeds label stock (<NUM>) past a printer (<NUM>) to print on a label (<NUM>) of the label stock (<NUM>) to produce a printed label (<NUM>) that is then separated from a liner (<NUM>) of the label stock (<NUM>) and dispensed in a first direction onto a label applying belt (<NUM>) that moves in a second direction, wherein the first direction is substantially perpendicular to the second direction such that the printed label (<NUM>) moves onto the label applying belt (<NUM>) from a lateral side of the label applying belt (<NUM>); and the label applying belt moves the printed label (<NUM>) into position to engage with the item (<NUM>) as it moves along the conveyance path;
wherein a feed rate of the label stock (<NUM>) past the printer (<NUM>) during printing is less than a conveyance rate of the label applying belt (<NUM>), and the printed label (<NUM>) fully releases from the label stock (<NUM>) before engaging onto the label applying belt (<NUM>)..