Patent Document

CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a continuation-in-part application of and claims benefit under 35 U.S.C. § 120 to U.S. patent application Ser. No. 09/680,892, filed on Oct. 6, 2000, now abandoned which is specifically incorporated herein by reference in its entirety for all purposes. 

   FIELD OF THE INVENTION 
   This invention relates generally to an apparatus for separating discrete pieces from a continuous web, and, in particular, to a web burster/inserter apparatus that can separate pieces of various sizes and shapes from a continuous web and place the separated pieces into containers that are moving along a high volume handling system or place the separated pieces into a desired location such as the fill tube of a form, fill, and seal bagging machine. 
   BACKGROUND OF THE INVENTION 
   It is a common advertising and promotional technique to place coupons, discount cards, prizes or other promotional materials into containers such as cartons for breakfast cereal or snack items or into bagged products such as potato chips. The coupon is highly visible to the consumer who can then use the coupon for the intended purpose, such as for discounts on future purchases or rebates. The coupon itself may also contain a prize or other premium, often a molded plastic figure or other piece. Accordingly, the term “coupon” used herein includes any type of insert, coupon, card, sheet, receipt, warranty, prize, premium, or other part that can be advantageously handled in accordance with the invention hereinafter described. Similarly, the terms “container” and “receiving product” are used in the broadest possible context to include containers such as boxes, tubs, cans, and vessels of all kinds as well as other coupon receiving objects that can be advantageously used with the present invention, such as the fill tube of a form, fill, and seal packaging machine. 
   Placing coupons by hand is very expensive as it is labor intensive and human hands cannot always keep up with the speed of modern automated packaging equipment. Thus, packaging equipment manufacturers have developed a variety of automated coupon inserter machines for placing coupons on or into products. Typically, coupon inserting devices operate by discharging or positioning a single coupon in each container rapidly moving along a conveyor system or into a chute or tube of some other type of product handling system. There are several methods and apparatus for placing single coupons. One requires a stack of pre-cut coupons that are individually dispensed from a downwardly sloping channel, such as the system shown in Prewer, U.S. Pat. No. 4,530,200. In that system, pusher elements and advancing rollers coact to withdraw the forwardmost coupon from the pre-cut stack. The coupon is then drawn into the downwardly sloping channel to a dispensing location. In another apparatus, shown in Gallimore, U.S. Pat. No. 4,197,113, a reciprocal vacuum head picks a coupon from a stack of pre-cut coupons and places the coupon on a conveyor system, which in turn transports the coupons to the containers. Another system, shown in Lewis et al., U.S. Pat. No. 4,354,894, requires the use of a mechanical cutting device to separate each coupon from a continuous web. Once separated, the coupons are dispensed to the containers using a conveyor system. In yet another system, a device separates a single coupon from a continuous web of coupons using a bursting technique and places the coupon into the container or places the coupon into the fill tube of a form-fill-seal packaging system. Such devices are disclosed in U.S. Pat. Nos. 5,845,462 and 6,082,079, respectively, which are assigned to the assignee of the present invention. While such systems are generally effective with flat coupons, they have not been found to be entirely effective for use in connection with thick or bulky coupons such as overwrapped plastic prizes or parts (such coupons shall be referred to herein generally as “three-dimensional coupons”). This invention relates to an improved coupon delivery system as compared to the systems described above and to solutions to some of the problems raised or not solved thereby. 
   SUMMARY OF THE INVENTION 
   The present invention provides a burster-type coupon insertion machine that is capable of handling three-dimensional coupons without damaging the coupon. The coupon insertion machine quickly and reliably dispenses a coupon with each activation of the device and is capable of reliably operating at high speeds. The coupon insertion machine is further capable of separating a variety of coupon sizes, shapes, and burst strengths and includes an integrated coupon delivery mechanism to provide a highly reliable coupon insertion machine at a reasonable price. The coupon inserter in accordance with the present invention easily dispenses overwrapped three-dimensional coupons such as toys, prizes, and other objects. These and other advantages of the present invention will become apparent from the detailed description, claims, and accompanying drawings. 
   One embodiment of an inserter manufactured in accordance the present invention includes an infeed assembly, a delivery assembly, a ram, a controller, and a number of sensors and motors. Both the infeed and the delivery assemblies include upper and lower belts that are disposed around rollers. The upper and lower belts are functionally connected to one another by a biased linkage. This linkage allows either one or both of the belts to move so as to accommodate coupons of varying dimensions. The lower belts are driven by motors and are fixed in position. In one embodiment, the upper belts are not power-driven and are adjustable and spring-biased. In another embodiment, the upper belts are driven by the same motors driving the lower belts using a drive belt including an automatic tensioning device so as to allow movement of the upper belt. The controller receives input from an activation input, the coupon staging sensor, and the coupon delivery sensor and controls the operation and speed of the infeed assembly, the delivery assembly and the ram. The coupon staging sensor is mounted between the infeed and delivery assemblies and is adjacent the ram. The coupon delivery sensor is mounted beyond the delivery assembly. A container sensor that functions as the activation input is positioned with respect to the production conveyor line such that it can detect the packages into which the coupons are to be inserted. In the case where the device is to be used with a form, fill, and seal packaging machine, the activation input is connected to the form, fill, and seal packaging machine, and is typically linked to a “dump” signal from a statistical weighing machine. 
   In one embodiment, the device is used with a perforated or otherwise weakened web of coupons and a dull ram end is used in the ram. In another embodiment, a non-perforated web of coupons is used, and a sharp knife end is used in the ram to ensure a clean separation. While it has been found effective to use a pneumatic ram, other electrical or mechanical configurations such as a servo-motor driven ram could also be used. Such an embodiment is particularly useful where a pneumatic power source is not available near the product manufacturing line. 
   The coupon inserter has a relatively simple operational sequence. In one embodiment, the motor driving the delivery assembly is stopped and started during operation of the coupon inserter. In another embodiment, the motor driving the delivery assembly is continually running during operation of the coupon inserter. 
   In one embodiment, the motor operating the delivery assembly and the delivery assembly itself are stopped and started. In the embodiment where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device, prior to any containers coming down the line, a continuous web of coupons is fed into the infeed assembly and a coupon is staged in the delivery assembly. When a container comes down the line, the container sensor identifies the container and sends an activation signal to the controller through the activation input. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the container. At the same time, the infeed assembly slightly backs-up the coupon web to ensure that the area near the coupon staging sensor is clear. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins forward rotation. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now moving infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the thin portion of the web (perforated or otherwise weakened in one embodiment) between the two coupons immediately below the ram. After the web stops moving, the ram fires, breaking the coupons apart. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next signal from the activation input (a container sensor in this embodiment). The process is repeated each time a container passes the container sensor. 
   If the inserter is used with a form, fill, and seal packaging machine, when the activation input receives a signal from the form, fill, and seal packaging machine, the signal is transmitted to the controller. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the fill tube. At the same time, the infeed assembly slightly backs-up the coupon web to ensure that the area near the coupon staging sensor is clear. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins forward rotation. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now rotating infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the thin portion of the web (perforated or otherwise weakened in one embodiment) between the two coupons immediately below the pneumatic ram. After the web stops moving, the ram fires, breaking the coupons apart. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next activation signal from the form, fill, and seal packaging machine. The process is repeated each time an activation signal is received by the activation input from the form, fill, and seal packaging machine. 
   In another alternative embodiment, the ram is not used. In this embodiment, which may be used in a conveyor-line installation, in a form, fill, and seal packaging machine installation, or in any other suitable environment, the operational process is slightly different. Installation in an environment where the three-dimensional coupons are being placed into containers moving along a conveyor is used for illustrative purposes. Prior to any containers coming down the line, a continuous web of coupons is fed into the infeed assembly and a coupon is staged in the delivery assembly. When a container comes down the line, the container sensor identifies the container and sends an activation signal to the controller through the activation input. The motor connected to the delivery assembly is then activated by the controller to rapidly deliver the pre-staged coupon into the container. When the pre-staged coupon passes the coupon delivery sensor, the motor attached to the infeed assembly begins moving. At the same time, the motor operating the delivery assembly is slowed to match the speed of the infeed assembly. The now rotating infeed assembly causes the web of coupons to be fed toward the delivery assembly. The coupon staging sensor senses the presence of the leading edge of the forwardmost coupon and, depending on coupon length, after a short delay, both motors stop thereby placing the perforated portion of the web between the two coupons between the infeed assembly and the delivery assembly. After the web stops moving, the infeed assembly reverses direction so as to apply a tension to the web thereby breaking the coupons apart at the perforation. After separation, the now-separated forwardmost coupon is staged in the delivery assembly to await the next activation signal from the container sensor and the continuous web remains held in the infeed assembly. The process is repeated each time a container passes the container sensor. 
   In another embodiment, the motor operating the delivery assembly and the delivery assembly itself are continually running. In one embodiment, the delivery assembly has at least one delivery belt that is continuously moving. The continuous web is fed into the infeed assembly thereby securing the continuous web between the upper infeed belt and the lower infeed belt of the infeed assembly. The infeed assembly advances the continuous web a predetermined length/distance toward a continuously running delivery assembly. Such advancement causes the continuous web to come into contact and engage the delivery assembly. Once the continuous web has been advanced the predetermined length/distance, the infeed assembly is stopped thereby stopping movement of the continuous web. In one embodiment the infeed assembly is stopped when a web portion between successive coupons is positioned between the infeed assembly and the delivery assembly. The infeed assembly then retracts the continuous web the predetermined length/distance from the continuously running delivery assembly. The advancement and retraction of the continuous web while the web is in contact with the continuously running delivery assembly acts to separate the forwardmost coupon from the continuous web. In one embodiment, a ram or knife strikes the continuous web near the web portion to help separate the forwardmost coupon from the continuous web. The delivery assembly then moves the forwardmost coupon to a desired delivery location. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a coupon inserter in accordance with one embodiment of the invention; 
       FIG. 1A  is a side elevational view of a coupon inserter in accordance with the embodiment of the invention shown in  FIG. 1 , shown with the second frame piece removed and installed to deliver coupons to containers; 
       FIG. 1B  is a side elevational view of a coupon inserter in accordance with the embodiment of the invention shown in  FIG. 1 , shown with the second frame piece removed and installed to deliver coupons to the fill tube of a form, fill, and seal machine; 
       FIG. 2  is a partially-exploded perspective view of a coupon inserter in accordance with the embodiment of the invention shown in  FIG. 1 ; 
       FIG. 3  is a top plan view of a coupon inserter in accordance with the embodiment of the invention shown in  FIG. 1  with links to a controller shown schematically; 
       FIG. 4  is a side elevational view of a coupon inserter in accordance with the embodiment of the present invention shown in  FIG. 1 , shown with a second frame piece removed; 
       FIGS. 5–8  illustrate the operational sequence of a coupon inserter in accordance with one embodiment of the present invention with  FIG. 5  schematically showing connections between the controller and the inserter; 
       FIGS. 9–12  illustrate the operation sequence of a coupon inserter in accordance with one embodiment of the present invention with  FIG. 9  schematically showing connections between the controller and the inserter; 
       FIGS. 13–15  illustrates the operation and sequence of a coupon inserter in accordance with one embodiment of the present invention with  FIG. 13  schematically showing connections between the controller and the inserter; and, 
       FIGS. 16–18  illustrate the operation and sequence of a coupon inserter in accordance with one embodiment of the present invention with  FIG. 16  schematically showing connections between the controller and the inserter. 
   

   DETAILED DESCRIPTION 
     FIGS. 1–4  show a coupon inserter (identified generally as  20 ) manufactured in accordance with one embodiment of the present invention. The coupon inserter  20  includes an infeed assembly  22 , a delivery assembly  24 , a ram  26 , a controller  28  (see  FIG. 3 ), and a number of sensors and motors that are assembled together on a first frame piece  30  and a second frame piece  32 . A coupon source, such as the roll  35  shown in  FIG. 1 , is used to supply bandoleer format coupons to the coupon inserter  20 . 
   The infeed assembly  22  includes an upper infeed belt  34  disposed about upper infeed rollers  34  and a lower infeed belt  36  disposed around lower infeed rollers  40 . In one embodiment, the upper infeed belt  34  and the lower infeed belt  36  are functionally connected to one another by a biased linkage  48 . The biased linkage  48  can take a variety of forms such as springs, belts, hydraulics, pneumatics, any combination thereof, or the like. The biased linkage  48  allows the infeed assembly  22  to accommodate three-dimensional coupons. While, as shown in  FIG. 4 , using three rollers for each belt has been found to be an effective design, other numbers of rollers and belt configurations could certainly be used. In the embodiment shown in  FIG. 3 , at least one of the lower infeed rollers  40  is driven by infeed drive motor  42  which in turn causes the lower infeed belt  38  to move. In this embodiment, the upper infeed belt  34  is not power-driven but is caused to move by the coupons between the lower infeed belt  38  and the upper infeed belt  34  and/or a linkage between the upper infeed belt  34  and the lower infeed belt  38 . In an alternative embodiment, the upper infeed belt  34  is power-driven by infeed drive motor  42  and an automatic tensioning device is used to maintain a connection between the upper infeed belt  34  and the infeed drive motor  42  when the upper infeed belt  34  moves to accommodate a three-dimensional coupon. In still another embodiment, both the upper infeed belt  34  and the lower infeed belt  36  are power-driven by infeed motor  42 . It has been found effective to use a stepper motor, such as the QCI 34-H-1-E-01 motor manufactured by Quicksilver Controls or the 34N1125-LW8 motor manufactured by Anaheim Automation for infeed drive motor  42  although a servo motor or other type of motor that can be selectively driven at a variety of speeds could also be effectively used. 
   In one embodiment, upper infeed belt  34  and upper delivery belt  52  are moveable so as to accommodate three-dimensional coupons. This is accomplished by allowing the first and second upper infeed frame pieces  44  and  46  to move with respect to first and second frame pieces  30  and  32  so as to allow a gap sufficient to accommodate the three-dimensional coupon between upper infeed belt  34  and lower infeed belt  38 . Similarly, in this embodiment, the first and second upper delivery frame pieces  62  and  64  are also allowed to move with respect to first and second frame pieces  30  and  32  so as to allow a gap sufficient to accommodate the three-dimensional coupon. In an alternative embodiment, lower infeed frame pieces  43  and lower delivery frame pieces  60  are allowed to move with respect to first and second frame pieces  62  and  64  so as to accommodate the three-dimensional coupon. 
   As best seen by reference to  FIGS. 2 and 4 , upper infeed rollers  36  are secured between a first upper infeed frame piece  44  and a second upper infeed frame piece  46  ( FIG. 3 ), each of which may have one or more posts  47  extending therefrom. First upper infeed frame piece  44  is attached to first frame piece  30  such that posts  47  fall within a guide track  50  on the first frame piece  30 . Similarly, second upper infeed frame piece  46  is attached to the second frame piece  32  such that posts  47  fall within a similar guide track  50  on the second frame piece  32 . While one post  47 /guide track  50  configuration is shown on each side of the infeed assembly  22 , additional such combinations may be used to further stabilize the infeed assembly  22 . Because of this manner of securing the upper infeed rollers  36 , the upper infeed belt  34  is allowed to move with respect to the lower infeed belt  38  so as to accommodate coupons of varying dimensions. The pressure on the coupons in the infeed assembly  22  is adjusted by using a biased linkage  48  of varying tension or resistance, adjusting the tension of resistance of the biased linkage  48 , and/or by adjusting stops within the guide tracks  50 . The infeed assembly  22  may also be configured such that the upper infeed belt  34  is fixed and driven and the lower infeed belt  38  is the one that is free to move to accommodate the three-dimensional coupon. 
   Like the infeed assembly  22 , the delivery assembly  24  includes an upper delivery belt  52  disposed about upper delivery rollers  54  and a lower delivery belt  56  disposed around lower delivery rollers  58 . In one embodiment, the upper delivery belt  54  and the lower delivery belt  56  are functionally connected to one another by a biased linkage  48 . The biased linkage  48  can take a variety of forms such as springs, belts, hydraulics, pneumatics, any combination thereof, or the like. The biased linkage  48  allows the delivery assembly  24  to accommodate three-dimensional coupons. While, as shown in  FIG. 4 , three rollers for each belt has been found to be an effective design, other numbers of rollers and belt configurations could certainly be used. In the embodiment shown in  FIG. 3 , one of the lower delivery rollers  58  is driven by delivery drive motor  59  which in turn causes the lower delivery belt  56  to move. In this embodiment, the upper delivery belt  52  is not power-driven but is caused to move by the coupons between the lower delivery belt  56  and the upper delivery belt  52  and/or a linkage between the upper delivery belt  52  and the lower delivery belt  56 . In one embodiment, the biased linage  48  functions to move the upper delivery belt  52 . It has been found effective to use a stepper motor for delivery drive motor  59 , preferably, for ease of maintenance and replacement, of the same type as the infeed drive motor  42 , although another type of motor that can be selectively driven at a variety of speeds could also be effectively used. In another embodiment, the upper delivery belt  52  is power-driven and lower delivery belt  56  is not. In still another embodiment, both the upper delivery belt  52  and the lower delivery belt  56  are power-driven. 
   As best seen by reference to  FIGS. 2 and 4 , upper delivery rollers  54  are secured between a first upper delivery frame piece  62  and a second upper delivery frame piece  64  ( FIG. 3 ), each of which may have one or more posts  47  extending therefrom. First upper delivery frame piece  62  is attached to first frame piece  30  such that posts  47  fall within another guide track  50  on the first frame piece  30 . Similarly, second upper delivery frame piece  64  is attached to the second frame piece  32  such that posts  47  fall within yet another guide track  50  on the second frame piece  32 . While one post  47 /guide track  50  combination is shown on each side of the delivery assembly  24 , additional such combinations could be used to further stabilize the delivery assembly  24 . Because of this manner of securing the upper delivery rollers  54 , the upper delivery belt  52  is allowed to move with respect to the lower delivery belt  56  so as to accommodate coupons of varying dimensions. As in the infeed assembly  22 , the pressure on the coupons is adjusted by using a biased linkage of varying tension or resistance, adjusting the tension or resistance of the biased linkage  48 , and/or by using stops within the guide tracks  50 . The delivery assembly  24  may also be configured such that the upper delivery belt  52  is fixed and driven and the lower delivery belt  56  is free to move and not driven. 
   As shown in  FIG. 3 , a controller  28  is used to control the operation of the coupon inserter  20 . The controller  28  may be a programmable logic control device or other device of similar capabilities such as a computer. The controller  28  receives signals from an activation input  66 , a coupon staging sensor  68 , and the coupon delivery sensor  70 . The activation input  66  may be a container sensor where the coupon inserter  20  is installed to place coupons into boxes  90  moving along a conveyor line ( FIG. 1A ), may be attached to a form, fill, and seal machine where the coupon inserter  20  is installed to place coupons into the fill tube  92  of the machine ( FIG. 1B ), or may be attached to any other device that is being used to activated the coupon inserter  20  in a particular installation. The coupon staging sensor  68  is mounted on the first frame piece  30  between the infeed assembly  22  and delivery assembly  24  adjacent the ram  26 . The coupon delivery sensor  70  is mounted beyond the delivery assembly  24  such that it can sense a coupon being dispensed from the coupon inserter  20 . Based on signals from the activation input  66 , the coupon staging sensor  68 , and the coupon delivery sensor  70 , and any time delay and speed settings that are required for a particular application, the controller  28  controls (1) the operation and speed of the infeed assembly  22  by controlling infeed drive motor  42 ; (2) the operation and speed of the delivery assembly  24  by controlling delivery drive motor  59 ; and (3) the breaking of the coupon web by controlling the function of the ram  24 . 
   Ram  26  is attached to the first and second frame pieces,  30  and  32 , of the coupon inserter  20  and is positioned between the infeed assembly  22  and the delivery assembly  24 . Other means of positioning the ram  26  within the coupon inserter  20  could also be used. In the embodiment where a pneumatic ram is used, it has been found effective to use the Bimba Flat  2  device manufactured by Bimba Manufacturing Company. In the embodiment where an electromechanical ram is used, it has been found effective to use the QCI-17H-3-01 device manufactured by Quicksilver Controls. In one embodiment, the coupon inserter  20  is used with a bandoleer format coupon where each successive coupon is connected to the next one with a perforated or otherwise weakened web portion in between each. If such coupons are used, a dull wedge is used as ram end  72  in the ram  26 . In another embodiment, a non-perforated web of coupons is used, and a sharp knife is used as ram end  72  in the ram  26  to ensure a clean separation of the coupon from the web. 
   The coupon inserter  20  has a relatively simple operational sequence. In one embodiment, the motor driving the delivery assembly  24  and the delivery assembly  24  are stopped and started during operation of the coupon inserter  20 . In another embodiment, the motor driving the delivery assembly  24  and the delivery assembly  24  are continually running during operation of the coupon inserter  20 . 
   In one embodiment, the motor driving the delivery assembly  24  is stopped and started. In the embodiment shown in  FIGS. 5–8  where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device ( FIG. 1A ), prior to any containers  90  coming down the line, a continuous web of coupons  74  is fed into the infeed assembly  22  and a pre-staged coupon  76  is staged in the delivery assembly  24  ( FIG. 5 ). When a container  90  comes down the line, the activation input  66  (in this case a container sensor that identifies the container) sends a signal to the controller  28 . The delivery drive motor  59  connected to the delivery assembly  24  is then activated by the controller  28  to rapidly deliver the pre-staged coupon  76  into the container as indicated by arrow  78 . At the same time, by operation of the infeed drive motor  42 , the infeed assembly  22  slightly backs-up the coupon web  74  to ensure that the area near the coupon staging sensor  68  is clear. When the pre-staged coupon  76  passes the coupon delivery sensor  70  and is inserted into the container  90 , the infeed drive motor  42  attached to the infeed assembly  22  begins moving so as to advance the coupon web  74  as indicated by arrow  82  ( FIG. 6 ). At the same time, the delivery drive motor  59  moving the delivery assembly  24  is slowed to match the speed of the infeed assembly  22 . The now moving infeed assembly  22  causes the web of coupons  74  to be fed toward the delivery assembly  24  ( FIG. 7 ). The coupon staging sensor  68  senses the presence of the leading edge of the forwardmost coupon  68  and, after a short delay determined by the coupon length and the speed of the infeed assembly  22 , both the infeed drive motor  42  and the delivery drive motor  59  stop thereby placing the thin portion of the web (perforated in one embodiment) between two coupons immediately below the ram  26 . After the coupon web  74  stops moving, the ram  26  fires causing the ram end  72  to break (or cut in the knifed embodiment) the coupons apart ( FIG. 8 ). After separation, the now-separated forwardmost coupon  80  is staged in the delivery assembly  24  to await the next signal from the activation input. The process is repeated each time a container  90  passes the container sensor. 
   Also illustrated in  FIGS. 5–8 , is the operation of the embodiment where the coupon inserter  20  is used with a form, fill, and seal packaging machine to place the coupons into the fill tube  92  of the machine ( FIG. 1B ). When the activation input  66  receives a signal from the form, fill, and seal packaging machine, it forwards that signal to the controller  28 . The delivery drive motor  59  connected to the delivery assembly  24  is then activated by the controller  28  to rapidly deliver the pre-staged coupon  76  into the fill tube  92  of the form, fill, and seal machine ( FIG. 5 ). At the same time, the infeed drive motor  42  attached to the infeed assembly  22  slightly backs-up the coupon web  74  to ensure that the area near the coupon staging sensor  68  is clear. When the pre-staged coupon  76  passes the coupon delivery sensor  70 , the infeed drive motor  42  attached to the infeed assembly  22  begins moving so as to advance the coupon web  74 . At the same time, the delivery drive motor  59  operating the delivery assembly  24  is slowed to match the speed of the infeed assembly  22 . The now moving infeed assembly  22  causes the web of coupons  74  to be fed toward the delivery assembly  24  ( FIG. 6 ). The coupon staging sensor  68  senses the presence of the leading edge of the forwardmost coupon  68  and, depending on coupon length, after a short delay, both the infeed drive motor  42  and the delivery drive motor  59  stop, thereby placing the thin portion of the web (perforated in one embodiment) between the two coupons immediately below the ram  26  ( FIG. 7 ). After the web stops moving, the ram  26  fires causing the ram end  72  to break (or cut in the knifed embodiment) the coupons apart ( FIG. 8 ). After separation, the now-separated forwardmost coupon  68  is staged in the delivery assembly  24  to await the next signal from the form, fill, and seal packaging machine through the activation input  66 . The process is repeated each time an activation signal is received from the form, fill, and seal packaging machine to indicate that a coupon should be placed into the fill tube  92 . 
   In another embodiment, shown in  FIGS. 9–12 , the ram  26  is not used. In this embodiment, which may be used in a conveyor-line installation, in a form, fill, and seal packaging machine installation, or in any other suitable environment, the operational process is somewhat similar and the following description of installation in an environment where the three-dimensional coupons are being placed into containers  90  moving along a conveyor is used for illustration purposes only. As shown in  FIG. 9 , prior to any containers coming down the line, a continuous web of coupons  74  is fed into the infeed assembly  22  and a pre-staged coupon  76  is staged in the delivery assembly  24 . When a container  90  comes down the line, the activation input  66  (in this case a container sensor that identifies the container) sends a signal to the controller  28 . The delivery drive motor  59  connected to the delivery assembly  24  is then activated by the controller  28  to rapidly deliver the pre-staged coupon  76  into the container  90  as indicated by arrow  84 . When the pre-staged coupon  76  passes the coupon delivery sensor  70 , the infeed drive motor  42  attached to the infeed assembly  22  begins moving the coupon web  74  toward the delivery assembly  24  as indicated by arrow  86  in  FIG. 10 . At the same time, the delivery drive motor  59  operating the delivery assembly  24  is slowed to match the speed of the infeed assembly  22 . The coupon staging sensor  68  senses the presence of the leading edge of the forwardmost coupon  80  and, depending on coupon length, after a short delay, both the infeed drive motor  42  and the delivery drive motor  59  stop, thereby placing the perforated portion of the web between the infeed assembly  22  and the delivery assembly  24  ( FIG. 11 ). After the coupon web  74  stops moving, the infeed drive motor  42  reverses direction as indicated by arrow  88  in  FIG. 12 , causing the infeed assembly  22  to also reverse direction so as to apply a tension to the web, thereby breaking the forwardmost coupon  80  apart from the web  74  at the perforation. After separation, the now-separated forwardmost coupon  80  is staged in the delivery assembly  24  to await the next signal from the activation input  66  and the continuous web  74  remains held in the infeed assembly  22 . The process is repeated each time a container passes the container sensor. 
   In another embodiment shown in  FIGS. 13–15  and  16 – 17 , the motor driving the delivery assembly  24  is continually running. In this embodiment where the delivery assembly  24  has at least one delivery belt  52  or  56  that is continuously moving. In the embodiment shown in  FIG. 13  where the three-dimensional coupons are being placed into containers moving along a conveyor or other product handling device (See  FIG. 1A ), prior to any container  90  coming down in the line, a continuous web  74  is fed into the infeed assembly  22 . A coupon  76  is not staged in the delivery assembly  24 . The delivery drive motor  59  continuously drives delivery assembly  24 . In one embodiment, at least one of the lower delivery belt  56  and the upper delivery belt  52  is continuously moving. When a container  90  comes down the line, the activation input  66  (in this case a container sensor that identifies the container) sends a signal to the controller  28 . The infeed drive motor  42  attached to the infeed assembly  22  is then activated by the controller  28 . The infeed drive motor  42  operates the infeed assembly  22 , thereby feeding the leading edge of the continuous web  74  from the infeed assembly  22  to the delivery assembly  24  ( FIG. 14 ). In one embodiment, the continuous web  74  is fed from the infeed assembly  22  into the delivery assembly  24  at predetermined linear speed. In another embodiment where the container  90  is traveling on a conveyor, the continuous web  74  is fed from the infeed assembly  22  into the delivery assembly  24  at the same linear speed as the conveyor. 
   Regardless of the embodiment, feeding the continuous web from the infeed assembly  22  to the delivery assembly  24  causes the continuous web  74  to pass the coupon staging sensor  68 . The coupon staging sensor  68  triggers the controller  28  to retrieve a programmed length/distance from memory. The controller  28  then activates the infeed drive motor  42  and operates the infeed assembly  22  to advance the continuous web  74  the programmed length/distance. After the infeed assembly  22  has advanced the continuous web  74 , the infeed drive motor  42  stops and restarts the infeed assembly  42  in the opposite direction. The infeed assembly  42  moves the continuous web  74  in the direction toward the delivery assembly. The continuous web  74  is moved the programmed length/distance in this direction. In one embodiment shown in  FIG. 16–18 , a ram  26  fires causing the ram end  72  to help break (or cut in a knifed embodiment) the coupons apart. Advancement and retraction of the continuous web  74  combined with contact of the continuous web  74  with a continuously running delivery assembly  24  functions to separate a single coupon from the leading edge of the continuous web  74 . Further, this combination functions to advance the separated coupon through the continuously operating delivery assembly  24 . The process is repeated each time a container  90  passes the container sensor. 
   As illustrated by the foregoing description and shown in the Figures, the present invention is more suitable as a coupon inserter for use with three-dimensional coupons than existing systems. Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims.

Technology Category: b