Patent Description:
Elastic or plastic fasteners are commonly used to secure a variety of irregularly shaped products to packaging materials such as cardboard backing. The elastic fasteners are typically H-shaped in configuration, with two shortened parallel crossbars, or T-bars, being interconnected at their approximate midpoints by a thin, flexible filament that extends orthogonally there between. The elastic fasteners, or staples, are typically individually generated from a supply of ladder stock or from separate supplies of filament and T-bar stocks. The elastic fasteners may be formed from ladder stock, such as that presently manufactured and sold by Avery Dennison Corporation of Pasadena, California under PLASTIC STAPLE® and ELASTIC STAPLE™ lines of plastic fasteners.

<CIT> discloses machines for patching shipping tags with a flexible patch strip adapted to be fed endwise step by step by a feeding element of the machine. The strip including a row of patches partially prepared, by the operation of making the strip, for application by the machine to a tag or other body, the patches being so nearly completed during the manufacture of the strip that they are easily detachable by the machine from the strip, and thereby converted into operative patches, which are applied to the body by the machine.

<CIT> relates to a fastener assembly for coupling together two or more articles which includes a plastic fastener and an anchoring member. The plastic fastener includes a pair of parallel cross-bars that are interconnected by a transverse filament. The anchoring member is constructed as a unitary, solid, plastic disc with opposing flattened surfaces. In use, the anchoring member is disposed against an outer surface of the articles to be coupled together. During the fastener dispensing process, the ejected cross-bar penetrates through the articles as well as the anchoring member. Upon completion, the ejected cross-bar lies directly upon the exposed surface of the anchoring member. As such, the stiffened anchoring member provides structural integrity to articles that are deformable in construction. In this manner, the anchoring member prevents intact removal of a dispensed fastener by either intentional or unintentional widening of the hole in the articles through which the fastener extends.

<CIT> discloses a system for dispensing a fastener from a reel of fastener stock so as to secure a product onto a display card. The system includes a module for dispensing the fastener, a counterbalance for supporting the module, a mounting stand for supporting the counterbalance, a reel holder for supporting the reel of fastener stock and an anvil for supporting the product and display card. The module includes a hollowed needle, a retractable needle guard assembly disposed over the needle, a feed mechanism for advancing the fastener into the needle, a severing mechanism for severing the fastener from the fastener stock, and an ejection mechanism for ejecting the fastener through the needle. The retractable needle guard assembly is capable of being disposed between a protective position and a retracted position and includes a fixedly mounted needle guard and a movable needle guard which is slidably mounted on the fixedly mounted needle guard.

<CIT> relates to a method and apparatus for automatically tagging selected layers of multi-layered articles by the operation of a single switch that initiates the sequential stepped operation of a clamp for holding the selected layers in a tagging position while a tag is fed and tacked, as by a bar tack, to join the tag to the selected layers. When the tagging sequence is completed, the article is removed from the apparatus, thereby separating the joined bar tack and tag from the apparatus for similar subsequent automatic repetitive operations.

The elastic fasteners may be generated by a plastic fastener device, such as an IndES® <NUM> (IndES) manufactured and sold by Avery Dennison Corporation of Pasadena, California. These systems are designed to securely fasten items such as housewares, toys and hardware to backing cards typically manufactured from cardboard. The pneumatically driven IndES unit can operate as a standalone unit or integrated into an automatic packaging line. The plastic fastener devices secure the products to packaging by threading a pair of hollow needles loaded with fastener stock and puncturing the backing card on either side of the product to be secured. An individual elastic fastener is left behind securing the product with a filament to the backing with a pair of T-bars. The pair of T-bars engages the backside of the backing to attach the product to the packaging material.

When each needle penetrates the backing, a hole in the backing material is created. The T-bar portion of the fastener springs perpendicularly to the filament to engage the backing and keep the fastener in place. Heavier products or thin backing material can create a strain on the connection point between the fastener and the backing. This strain can lead to a tear or unwanted expansion of the insertion hole, leading to a loss of the connection. Once a connection is compromised, the product is no longer secured to the packaging.

Thus, there exists a need for a way to reinforce the connection point between the elastic fastener and the backing material. The present invention discloses an apparatus for supplying and deploying reinforcement to this vulnerable connection point. The apparatus generates and installs a plurality of reinforcing elements in conjunction with an elastic stapling device. Elastic fasteners are generated and deployed by the elastic stapling device simultaneously with the generation and deployment of reinforcing elements by the present invention in a single operation.

The invention is defined by the independent claim and preferred embodiments are defined in the dependent claims.

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

The subject matter disclosed and claimed herein, in one aspect thereof, comprises an apparatus for manufacturing and positioning a plurality of individual reinforcing elements according to claim <NUM> for use with a plurality of elastic fasteners. The apparatus comprises a base plate and a pair of modules mounted to the base plate. The pair of modules may feed a pair of rolls of reinforcing stock through the apparatus and cut off the individual reinforcing elements. The individual reinforcing elements are deployed and positioned by the pair of modules to align with the plurality of elastic fasteners generated and deployed by an elastic stapling apparatus, thereby reinforcing a connection point where the fasteners attach to a backing or packaging material.

Each of the pair of modules comprises a pneumatic element, a linkage drive block, a cutting block, and a cam element. The linkage drive block is engaged by the pneumatic element, and is moveably connected to the cutting block by the cam element. Each of the pair of modules may further comprise a strip feed block for feeding one of the pair of rolls of reinforcing stock through the apparatus. Each of the pair of modules may further comprise a module cover element for resisting backward movement of one of the pair of rolls of reinforcing stock as it moves through the apparatus, and a cutting element for cutting off the plurality of reinforcing elements once positioned to reinforce the plurality of elastic fasteners.

The pneumatic element may be extended, thereby pushing the linkage drive block forward along a guide slot in the cam element. This movement forces the cutting block downward allowing a portion of the reinforcing stock to extend over the cutting block. Once positioned, the pneumatic element may be retracted pulling the linkage drive block back forcing the cutting block upward. As the cutting block is pushed upward, the supply of reinforcing stock is forced against the cutting element, thereby severing off an individual reinforcing element.

To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

Referring initially to the drawings, <FIG> illustrate an apparatus <NUM> for generating a plurality of individual reinforcing elements <NUM> out of a supply of reinforcing stock <NUM> in accordance with the present invention. As illustrated in <FIG> and <FIG>, the apparatus <NUM> comprises a frame <NUM> and a base plate <NUM>. The base plate <NUM> comprises a top side <NUM>, a bottom side <NUM>, and is adapted to support an elastic stapling apparatus <NUM> and the supply of reinforcing stock <NUM>. One example of the elastic stapling apparatus <NUM> useable with the apparatus <NUM> is an IndES industrial elastic stapling system, as described supra. The IndES uses a pair of needles approximately <NUM>/<NUM> inches in diameter to fasten products to packaging material, such as cardboard backing, using an elastic staple. The IndES machine's needles puncture the packaging material and eject staple ends through the puncture holes. The staple ends flex into position to fix the elastic staple in place, thereby securing the product to the packaging material.

The apparatus <NUM> may be used to manufacture the plurality of individual reinforcing elements <NUM> to reinforce a plastic or elastic fastener in a fastener assembly as described in commonly assigned <CIT>. As illustrated in <FIG>, the plurality of individual reinforcing elements <NUM> are preferably formed as unitary, solid discs, which are constructed out of stiff plastic materials that resist deformation, such as but not limited to, polypropylene, polyethylene, polyethylene terephthalate. The plurality of individual reinforcing elements <NUM> are represented herein as generally square-shaped tabs. However, this is not meant as a limitation, as the plurality of individual reinforcing elements <NUM> may be constructed in any alternate configuration, size, or shape as to correspond to the dimensions necessary to reinforce the plastic fastener used.

The supply of reinforcing stock <NUM> for use with the apparatus <NUM> is typically configured as a pair of rolls of reinforcing stock material. In one embodiment, each of the pair of rolls of reinforcing material is formed from a strip of the stiff plastic material <NUM> approximately ½ inches in width with a plurality of holes <NUM> approximately centrally disposed along a centerline at approximately ½ inch intervals. The diameter of each of the plurality of holes <NUM> is sized slightly larger than the diameter of the needle of the elastic stapling apparatus <NUM>. The pair of rolls of reinforcing stock material are loaded on the apparatus <NUM>, as illustrated in <FIG>, <FIG> and <FIG>, which cuts each strip of the stiff plastic material <NUM> into approximately ½ inch square individual reinforcing elements <NUM> with a center hole <NUM>. While specific dimensions have been described with respect to this particular embodiment, the dimensions are not meant as a limitation as the dimensions may be customized for use with any sized plastic fastener as desired.

The apparatus <NUM> further comprises a pair of stock engaging components <NUM>, each comprising a reel <NUM> attached to a shaft <NUM>. Each of the pair of stock engaging components <NUM> are mounted to the frame <NUM> underneath the base plate <NUM>. The frame <NUM> serves as a support or foundation for the base <NUM>. The base <NUM> is generally rectangular in configuration and further comprises a centrally disposed opening <NUM>. Each roll of reinforcing stock material is loaded onto one of the reels <NUM>, which rotates along the shaft <NUM> feeding each strip of the reinforcing stock material <NUM> off of the roll of reinforcing stock material into the apparatus <NUM>.

With the plurality of individual reinforcing elements <NUM> positioned against or near a back side of the packaging, the elastic stapling apparatus <NUM> punches holes in the packaging material in-line with the plurality of individual reinforcing elements <NUM>, dispenses a plastic fasteners through the needles, and secures each plastic fastener to a reinforced connection point formed by the packaging and one of individual reinforcing elements <NUM>. As such, the plurality of individual reinforcing elements <NUM> provides structural stability to the packaging material.

As illustrated in <FIG>, <FIG>, and <FIG> the apparatus <NUM> further comprises a pair of modules <NUM> movably mounted to the base plate <NUM> within the centrally disposed opening <NUM> to align with the elastic stapling apparatus <NUM>. A first <NUM> and a second <NUM> of the pair of modules <NUM> are identically configured, adjustable in position within the centrally disposed opening <NUM>, and movably mounted in opposing directions. The pair of modules <NUM> are adapted to receive the supply of reinforcing stock <NUM>, sever the supply of reinforcing stock <NUM> into the plurality of individual reinforcing elements <NUM>, and to deploy the plurality of individual reinforcing elements <NUM> in conjunction with the elastic staples to reinforce the plurality of stapling connections.

As illustrated in <FIG> and <FIG>, each of the pair of modules <NUM> comprises a pneumatic element <NUM>, a linkage drive block <NUM>, a cam element <NUM>, and a cutting block <NUM>. The pneumatic element <NUM> is typically an air cylinder that moves a piston rod <NUM>. The piston rod <NUM> is connected to one end of the linkage drive block <NUM>. The cam element <NUM> comprises a first end <NUM> fixed to the module <NUM>, a second end <NUM> movably connected to the cutting block <NUM>, and a guide slot <NUM>. The other end of the linkage drive block <NUM> is movably retained within the guide slot <NUM> of the cam element <NUM>. As such, the cam element <NUM> movably connects the linkage drive block <NUM> and the cutting block <NUM>. The guide slot <NUM> is generally angularly configured so as to move the cutting block <NUM> up and down as the piston rod <NUM> is pushed or retracted by the pneumatic element <NUM>.

As illustrated in <FIG> and 6A, each module <NUM> further comprises a strip feed block <NUM> comprising a stock positioning element <NUM>. The strip feed block <NUM> is mounted to a top of the linkage drive block <NUM>. The stock positioning element <NUM> is typically a pin beveled so as to engage the plurality of holes <NUM> in a portion of the supply of reinforcing stock <NUM> running along the strip feed block <NUM>. The stock positioning element <NUM> advances the supply of reinforcing stock <NUM> through the module <NUM> as the linkage drive block <NUM> is pushed forward by the piston rod <NUM>.

As illustrated in <FIG>, and <FIG> each module <NUM> further comprises a module cover element <NUM> comprising a top plate <NUM> and a detent component <NUM>. The module cover element <NUM> is positioned within the centrally disposed opening <NUM> of the base plate <NUM>. The top plate <NUM> comprises a first end <NUM>, a second end <NUM>, and a center slot <NUM>. The second end <NUM> of the first module <NUM> is positioned to face the second end <NUM> of the second module <NUM> within the centrally disposed opening <NUM> of the base plate <NUM>. The detent component <NUM> is typically a ball, cylinder, or similar mechanism that penetrates the top plate <NUM> near the first end <NUM> that can align and engage with the plurality of holes <NUM> in the supply of reinforcing stock <NUM> to resist or arrest any backward movement of the supply of reinforcing stock <NUM> as it is advanced through the module <NUM> by the stock positioning element <NUM>.

Additionally, each module <NUM> further comprises a top cover block <NUM> as illustrated in <FIG>. The top cover block <NUM> is positioned within the center slot <NUM> of the top plate <NUM>. The top cover block <NUM> is substantially rectangular in configuration comprising a top side <NUM> and a bottom side <NUM> crowned or otherwise concavely shaped to permit the stock positioning element <NUM> to advance the supply of reinforcing stock <NUM> through the module <NUM>. As such, the bottom side <NUM> of the top cover block <NUM> generally abuts the strip feed block <NUM> sandwiching or otherwise substantially encapsulation the portion of the supply of reinforcing stock <NUM> engaged by the module <NUM>.

Each module <NUM> further comprises a top retaining plate <NUM> and a cutting element <NUM>. The top retaining plate <NUM> is attached to the second end <NUM> of the top plate <NUM> and comprises an opening <NUM> generally shaped in the same configuration as each of the individual reinforcing elements <NUM>. The cutting block <NUM> comprises a beveled top <NUM>, a center hole <NUM>, and a bottom <NUM>. The beveled top <NUM> of the cutting block <NUM> penetrates the opening <NUM>, thereby pushing the individual reinforcing elements <NUM> through the opening <NUM> once cut. The cutting element <NUM> is typically a stationary knife or blade attached to the second end <NUM> of the module cover element <NUM> where it movably abuts the cutting block <NUM>.

As illustrated in <FIG>, the beveled top <NUM> may be angled sideways with respect to the cutting element <NUM> to more easily cut the individual reinforcing elements <NUM>. In a preferred embodiment, the bevel is approximately set at <NUM> degrees. However, this is not meant as a limitation as the bevel may be changed to optimize cutting based on the material to be cut or the speed of cutting. The center hole <NUM> is dimensioned and configured to accept penetration of a needle from the elastic stapling apparatus <NUM>. The bottom <NUM> movably engages the cam element <NUM>.

To use the apparatus <NUM>, a user places each of the pair of rolls of the reinforcing stock material <NUM> onto one of the pair of stock engaging components <NUM>, as illustrated in <FIG>. A strip the reinforcing stock material <NUM> from each roll is individually fed into one of pair of modules <NUM> in opposing directions. Each strip feed block <NUM> engages one of the strips the reinforcing stock material <NUM> with the stock positioning element <NUM>. The apparatus <NUM> may be powered with a motor (not shown).

As illustrated in <FIG>, the strip of the reinforcing stock material <NUM> is positioned on the strip feed block <NUM> so that an end of the strip the reinforcing stock material <NUM> abuts the cutting block <NUM>. In a load position, the piston rod <NUM> is fully retracted holding the linkage drive block <NUM> away from the cutting block <NUM>. As the apparatus <NUM> is engaged, the piston rod <NUM> is extended by the pneumatic element <NUM> pushing the linkage drive block <NUM> along the guide slot <NUM> of the cam element <NUM> toward the cutting block <NUM>, as illustrated in <FIG>. As the linkage drive block <NUM> moves forward, the cam element <NUM> pulls the cutting block <NUM> downward so that the beveled top <NUM> drops below the level of the cutting element <NUM>. At the same time, the linkage drive block <NUM> advances the strip feed block <NUM> so that approximately a ½ inch portion of the supply of reinforcing stock, or any configured length of the plurality of individual reinforcing elements <NUM> as desired, is pushed past the cutting element <NUM> and over the cutting block <NUM>.

Finally, in a cutting position illustrated in <FIG>, the piston rod <NUM> is retracted by the pneumatic element <NUM> pulling the linkage drive block <NUM> back along the guide slot <NUM> of the cam element <NUM> away from the cutting block <NUM>. This retraction allows the cam element <NUM> to push the cutting block <NUM> upward against the portion of supply of reinforcing stock located over the beveled top <NUM>. The upward movement forces the beveled top <NUM> against the supply of reinforcing stock pushing it along the cutting element <NUM> and through the opening <NUM> in the top retaining plate <NUM> to form and detach an individual reinforcing element <NUM>. Simultaneously, the strip feed block <NUM> returns to its original position as the stock positioning element <NUM> slips out of the engaged hole <NUM>, and re-engages a distal hole <NUM> in the supply of reinforcing stock <NUM> so that the process may repeat. The apparatus <NUM> may be automatically adjustable to align the plurality of holes <NUM> of the individual reinforcing elements <NUM> with the needles of the elastic stapling apparatus <NUM>. As the elastic stapling apparatus <NUM> is cycled, the apparatus <NUM> may index the strips of reinforcing material <NUM> through the next application.

Claim 1:
An apparatus (<NUM>) for manufacturing and dispensing a plurality of individual reinforcing elements (<NUM>) from a supply of reinforcing stock (<NUM>) for use in conjunction with an elastic stapling apparatus (<NUM>) for reinforcing the stapling connection point on packaging material while securing products to the packaging material with the elastic stapling apparatus (<NUM>), characterized in that the apparatus (<NUM>) comprises:
a base plate (<NUM>) adapted to support the supply of reinforcing stock (<NUM>) and the elastic stapling apparatus (<NUM>), and
a pair of modules (<NUM>) mounted to the base plate (<NUM>), wherein the pair of modules is aligned with the elastic stapling apparatus (<NUM>),
wherein each module (<NUM>) comprises a pneumatic element (<NUM>), a linkage drive block (<NUM>) engaged by the pneumatic element (<NUM>), a cutting block (<NUM>), and a cam element (<NUM>) movably connecting the linkage drive block (<NUM>) and the cutting block (<NUM>), and
wherein the cutting block (<NUM>) is adapted to receive the supply of reinforcing stock (<NUM>), sever the individual reinforcing elements (<NUM>), and deploy the individual reinforcing elements (<NUM>).