EP0831029A1

EP0831029A1 - Mechanism for applying labels to the inside of a carton

Info

Publication number: EP0831029A1
Application number: EP97202793A
Authority: EP
Inventors: William J. Eastman Kodak Company Meyers; Alex Eastman Kodak Company Saveliev
Original assignee: Eastman Kodak Co
Current assignee: Eastman Kodak Co
Priority date: 1996-09-23
Filing date: 1997-09-11
Publication date: 1998-03-25
Also published as: JPH10175623A; CA2213959A1

Abstract

A method for applying labels to the inside of containers and a label applicator comprises moving containers through a packaging process, moving a vacuum head (2) by a translator mechanism to a first position to pick up a label, moving the translation mechanism to a second position where a second label is fed to a second vacuum head (3), advancing the heads to a third position, a registration position moving the labels at the same speed as that of the moving containers, entering the containers and to the fourth position where the labels are blown off the vacuum heads and onto the inside of the containers, returning to the first position and continuously repeating the process.

Description

This is a continuation-in-part of application Serial No. 08/710,800 filed September 23, 1996 entitled "Mechanism for Applying Labels to the Inside of a Carton" by William J. Meyers and Alex Saveliev.

This invention relates to a label feeder. More particularly, the invention relates to a label applicator mechanism and method which delivers individual labels to open-ended containers as the containers move along a packaging conveyor.

Label applicators typically apply labels to articles as the articles are conveyed past the label applicator. Usually, the labels are releasably adhered, in a single column, to an elongated backing strip. The label applicator removes one of the labels from the backing strip and releasably retains it at a labeling station. As the articles to be labeled near the removed label, it is applied to the articles. Label applicators of this type are shown, for example, in US-A-3,093,528; 3,729,362; 4,024,011 and Re. 30,149.

US-A-Re. 23,668 to Von Hofe describes the application of labels to the inside of hollow stationary articles by means of a reciprocating suction head which moves in only one direction to apply labels. There is no movement of apparatus in the X-Y plane and the mechanism cannot be used to apply labels to the inside of hollow transversally moving articles without stopping the conveying process.

Label applicators of this type, while satisfactory for many applications can introduce delay into an assembly or packaging operation in which labeling must be carried out. For example, label indexing or advancement; that is, the removal of a label from a backing strip and applying it to a suitable retaining means, is relatively slow while the transfer of a retained label to the article can be rapidly carried out. Label indexing can be sufficiently slow so that the labeling function is the slowest operation on the production line.

Other work operations also involve US-A-Re. 23,668 to Von Hofe describes application of labels to the inside of hollow stationary articles by movement of a reciprocating suction head which moves in only one direction to apply labels. There is no movement of apparatus in the x-y plane and the mechanism should be used to apply labels to the inside of hollow transversally moving articles without stopping the conveying process. The repetitive supply of elements to a work station so that such elements can be affixed, assembled, laminated, and so forth, to articles being conveyed through the work station. In some of the work operations, the repetitive supply of the elements is the slowest step in the process, and accordingly, this limits the speed with which the articles can be conveyed through the work station. Thus, other work operations involve problems similar to the label application problem described above.

An additional problem in the high speed labeling of articles is to provide labels containing unique information for each individual package, such as weight, product size, a bar code, or a product identification number.

Most labels are applied directly on the outside of the container using direct applications to apply the label to the outside of the carton or container for the goods sold. However, in many applications, for instance in the sale of consumer goods such a photographic film and like materials to be sold in department stores or discount stores where shoplifting is a major problem, the labels that are adhered to the cartons are treated either electrically or magnetically to register that the carton has been paid for before it left the premises. Thus, counter salespeople will deactivate the labels as they are paid for so that a store's detectors will not be activated in order to prevent theft.

The problem with these labels is that they are still susceptible to theft. In many cases, the labels on the outside of the container can be removed or switched prior to its reaching the cash register. Because of this problem, many department stores and other retailers are asking manufacturers of these goods to put the labels in the inside of the carton or container so they can be read accurately and the label can not be tampered with. This represents a major problem for manufacturers, it is very inconvenient to apply labels to the inside of a carton. To use the processes described above that are used to apply the labels to the outside of the containers will require tedious apparatus and extreme difficulty applying to the inside of containers. It would be very difficult to do so without stopping or, at least substantially slowing down the packaging process. This results in much higher costs for the product to be sold.

The use of a label applying apparatus to the processing system which can be done expeditiously and at high speeds while applying the labels to the inside of containers without holding up or slowing down the packaging process has heretofore alluded the efforts of those in the industry.

Accordingly it is an object of the present invention to provide a label device which can apply labels at high speed to individual product units on a continuous flow basis.

It is an additional object of the present invention to provide such a device which can apply the label to the inside of the containers at at a speed that is commensurate with the processing speed.

It is a further object of the present invention to provide a method using this apparatus to label containers in the inside without slowing down the packaging operation.

In accordance with these and other objects of the invention, an automatic labeling device is provided for applying the labels to product units. The device includes a conveyor for continuously conveying a series of identified product containers in which the product is to be sold.

The system or device for applying tags or labels to the inside of cartons consists of a commercially available labeling machine that is interfaced to a translation mechanism. The mechanism is mechanically linked and driven by the main line shaft of a cartoning machine. With this apparatus, tags or labels can be placed in the inside of a carton at relatively high speed. The novel features of the system can include a barrel cam translation device that would provide movement along the "X" and "Y" axis of the plane of travel of the cartons and labels. This device is integrated with a labeling machine such that a tag or label is dispensed to a vacuum grid which is mounted on the translation device. Since the translation device is mechanically linked to the carton, a predetermined motion can be executed that will permit the vacuum grids to enter the cartons and apply the tags or labels. The advantage of this method are: tags or labels can be applied to the inside of cartons while the product is being packaged; the percentage of product tagged or labeled can be 25, 33, 50 or 100 depending on the request by the customer; packaging of the product is not dependent upon receiving pre-tagged or labeled cartons which could be a scheduling concern; and all product currently requiring tags or labels need not be done manually.

The translation mechanism is driven by mechanically coupling a drive component on the cartoner, such as a line drive shaft to the input shaft on the translation mechanism. This may be accomplished using a sprocket on each shaft and linking them together using a roller chain. The cartoner in this process has a ratio of (1/2) rotation of the line drive shaft to (1) pitch travel of the carton nest; for example, if the nests are spaced 4.50" apart on the cartoner carrier chain then (1) pitch equals 4.50".

The barrel cam translation device, thus, provides movement along the carton nest travel direction ("X" direction) and along the label insertion direction ("Y" direction). The (2) directions are 90° apart. The movement along both "X" and "Y" directions may be given with reference to a known period in the cycle of the cartoner, such as the carton travel of (2) pitches, which equals (1) rotation of the cartoner line drive shaft. This may be equated to degrees of rotation such that 360° equals (1) rotation of the cartoner line drive shaft and a movement of (2) pitches of the carton nest. A rotation of 180° would mean a (1/2) rotation of the line shaft and a single pitch movement of the carton nest. The translation device also has a known ratio between the input shaft and the (2) cams that provide "X" and "Y" travel of the support arm. This is a rotation of the translation mechanism of 1:1 ratio, 1 x infeed shaft , equals 1 rotation of cams or a complete cycle of the support arm travel. Degrees may also be used to define location of the support arm 10 in the cycle. If 0° is defined as the start of a cycle, then going through 360° defines all the movements that occur as you go through each step in the cycle.

Figure 1, A, B, C, and D describe the process of dispensing and applying labels to the inside of a carton.

Figure 2, illustrates the movement of vacuum grids relative to cartons.

Figure 3 shows x and y displacement relative to degrees of motion.

Figure 4 a, b and c shows location of carton flaps during labeling.

Figure 5 shows a barrel cam translation device.

For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following detailed description and appended claims in connection with the preceding drawings and description of some aspects of the invention.

Figure 1 shows the process of dispensing either one or a multiplicity (2 shown in Figure 1) of labels to the inside of cartons which are moving through a packaging process. The process of the present invention allows the labeling of the inside of a carton, such as photographic film-containing cartons, while not slowing down or stopping the packaging process.

In Figure 1, the process begins at 0°, the degree location of the input drive shaft of the translation mechanism. At this point the translation device is at its start position ready to receive a label from the label feeder. The first label is fed from the label feeder 1 to the first vacuum head 2 containing a vacuum grid (not shown). The vacuum head is supported by support arm 7.

The vacuum mechanism comprises a support 7 for vacuum heads 2 and 3. The vacuum grid is a component which consists of a series and pattern of holes which allow the transfer of the label from the label liner to the vacuum grid. This component maintains position of the label until the appropriate time for placement into the carton.

The translation mechanism creates motion in the x-y plane and moves the support arm 7 from the label pick up position, into the carton, for label application, and back to the label pick up position.

Most commercially available pick-and-place translation mechanisms combine 2 linear ball bearing slides. One travels in the "X" direction while the second which is mounted to the first, travels in the "Y" direction. Both are driven independently by cams, usually through the engagement of a cam follower bearing, mounted off the slide, to a precision machined recessed groove in the cam. Cam paths are machined in each cam to give precise "X" and "Y" motion for each slide. Since the transfer mechanism is mechanically linked to the cartoner nest drive, the "X" direction cam is machined to accelerate the support arm to match speed and location with the moving nests. When the arm reaches the end of its movement, it reverses direction to pick up new tags and the cycle repeats. In the "Y" direction the cam is machined to move the support arm towards the carton nest as the "X" cam starts matching speed with the nest After speeds are equaled in the "X" direction, "Y" cam moves the support arm into the carton to apply the tag. After applying the tag the arm moves back to a position in line with the label feeder, ready to pick up new tags.

Thus, Figure 1 shows the entire process of dispensing two tags or labels and applying them to the inside of a carton. The process begins at 0° when the first tag or label is fed from the label feeder to the first vacuum head. The translation device advances to 100° where the next label is fed to the second vacuum grid. The device advances to 160° where the tags are moved to a registered location. Between 160° and 215 ° the vacuum grids (device) accelerate and achieve the same linear speed as the cartons while the vacuum grids enter the opened cartons. The tags are blown onto the inside of the carton. At 270°, the device moves the vacuum grids out of the cartons and returns to the first label feed position. The device is now ready for the next cycle. Figure 2 shows the movement and/or location of the vacuum grids relative to the cartons.

Figure 3 shows "X" and "Y" displacement relative to degrees of motion.

Figure 4 shows possible locations of the carton flaps during tag application.

Figure 5 shows a typical barrel cam translation device.

A novel feature of the apparatus is a cam such as a barrel cam translation device which is linked to a vacuum grid that provides movement along the x-y axis of the plane of travel of the cartons and labels. This device is integrated with a labeling machine such that the label is dispersed to a vacuum grid which is mounted on the translation device. Since the translation device is mechanically linked to the carton or container, a predetermined motion can be devised that permits the vacuum grids to enter the cartons and apply the labels.

The advantages of the apparatus and method are that the labels can be applied to the inside of cartons while the product is being packaged. All product currently requires labels to be applied manually or to stop or slow down the packaging process when the labels are applied. In addition, the packaging of the product is not dependent on receiving prelabeled cartons which causes packaging problems. In addition, a certain percentage of product can be labeled rather than all. Thus, the percentage of product labeled using the apparatus and method of this invention could be anywhere from 1% to 100% of products labeled.

As shown in Figures 2 and 3, the travel of the vacuum grid follows along an x and y axis. This travel is basically a plane along which the carton and tags lie.

A labeling machine (which is not shown) can be conventional such as is commonly and commercially available. The labels are to be applied to

cartons

5 and 6.

The labeling machine advances the label and liner upon demand. As the label liner passes over a peel bar the label separates from the liner and is placed on the vacuum head.

Labeling machines that apply labels to containers are commercially available such as the label application model 2111 by Label-Aire which allows high speed label application up to 1600 inches of label liner per minute.

This labeling machine contains microprocessor controls and can handle a wide variety of label sizes and can be moved from one production line to another.

The cartons are positioned at a fixed pitch to the vacuum heads. This is done so the cartons and vacuum grids remain in phase with each other.

In position 2, the translation mechanism advances to 100° where the next label is fed to the second vacuum head 3.

The device next advances to position 3 at 160° where the labels are moved to a registered location. The registered location is determined by fixed

posts

8, 9 to locate label location. At this point the heads are advanced in the X direction. This is accomplished by moving the labels against the stop posts to achieve consistent label location.

Between the 3rd and 4th positions, the support and heads accelerate by motion of the translation mechanism so that they achieve the same linear speed as that of the cartons while the vacuum heads enter the opened cartons.

At position 4, at 270°, the vacuum support and heads are moved out of the cartons by the translation mechanism.

The vacuum heads are then moved back to position 1 and the apparatus is ready for the next cycle.

Figure 2 shows the movement and location of the vacuum grid and heads relative to the cartons. At position 1 the second label is fed to the vacuum grid, at position 2, the labels are moved against stop points 5 and 6 which register the labels by sliding the labels on the vacuum grid to the fixed position. At position 3, the speed of the support is matched to the speed of the cartons. At position 4, the labels are blown onto the cartons, at position 5 the support begins to accelerate out of the cartons; and at position 6, vacuum head 2 is ready to receive the next label.

Figure 3 is an X-Y displacement sample which shows the relative motion per degrees of rotation of the input drive shaft to the translation mechanism in the x-y plane.

Figure 4 shows some possible locations of the carton flaps during the labeling. In (a) the minor flaps 4 of the carton are trailing. The application head pushes one flap in during insertion in to the carton and the flap springs back after retraction.

In (b) the minor flaps are pushed back to the open position and there is no contact between the head and the carton.

In (c) the carton flaps are not moved and there is no contact with the application head.

Figure 5 shows the barrel cam translation device which creates the x-y motion required.

The labels in Figure 1 are blown off the vacuum head and onto the carton by air. The vacuum apparatus contains one or a plurality of heads. The translation device is mechanically linked to the carton machine by mechanical drive elements so that the predetermined motion will permit the vacuum head to enter the cartons and apply the labels. The vacuum support is mounted on the translation device by mechanical hardware.

Claims

Apparatus for applying labels to the inside of product containers being conveyed through a packaging process comprising:

a carton machine containing a main line shalt which is linked to a stationary translation mechanism;

a stationary translation mechanism which interfaces with the carton machine and container and is driven off the main line shaft; and

a vacuum head containing a vacuum grid on a vacuum support which moves inside the carton to apply the label and moves out of the carton and returns to pick up the next label to apply.
The apparatus of claim 1 wherein the translation device is a cam translation device.
The apparatus of claim 1 wherein the vacuum support is mounted on the translation device.
The apparatus of claim 1 wherein the translation device is mechanically linked to the carton machine so that a predetermined motion will be executed that permits the vacuum head to enter the container and apply the labels.
The apparatus of claim 1 wherein the apparatus contains a plurality of vacuum heads.
The apparatus of claim 1 wherein the vacuum head contains means to blow labels onto the inside of cartons.
A process of applying labels to cartons which are moving through a packaging process comprising;

i) moving cartons through a packaging process and picking up labels to be applied to the containers with a first vacuum head containing vacuum grids on a vacuum support which is set at 0° to the drive shaft;

ii) moving the labels on the vacuum head by a translation mechanism to and from 0 to 100° to the plane of motion of the cartons where the next label is fed to the second vacuum head;

iii) advancing the translation mechanism to 100° to the plane of motion of the cartons where the labels are moved to a registered location;

iv) moving the labels from 160 to 215° to the plane of motion of the cartons at the same speed as the cartons are moving;

v) entering the inside of the opened cartons with the respective vacuum heads;

vi) blowing the labels onto the inside of the cartons;

vii) moving the vacuum heads out of the cartons and returning to the 0° position; and

viii) continuously repeating steps i to vii.
The method of claim 7 wherein the vacuum grids are part of the vacuum head.
The method of claim 7 wherein the vacuum support is moved by a translation mechanism.
The method of claim 7 wherein the vacuum heads are in phase with the cartons during the application process while in continuous motion.
The method of claim 7 wherein the labels are blown onto the container by air.