U.S. patent application number 10/625206 was filed with the patent office on 2005-01-27 for packaging machine and method for wrapping and folding flexible photoreceptor belts.
This patent application is currently assigned to Xerox Corporation. Invention is credited to Darcy, John J. III, Dildine, James F. JR., Martin, David W., Olesiuk, J. Stephen, Roetker, Michael S., Wagner, Moritz P..
Application Number | 20050016128 10/625206 |
Document ID | / |
Family ID | 34080156 |
Filed Date | 2005-01-27 |
United States Patent
Application |
20050016128 |
Kind Code |
A1 |
Darcy, John J. III ; et
al. |
January 27, 2005 |
PACKAGING MACHINE AND METHOD FOR WRAPPING AND FOLDING FLEXIBLE
PHOTORECEPTOR BELTS
Abstract
A packaging machine and method are provided for wrapping,
folding and taping a flexible photoconductive belt loop to prevent
light from shocking such photoconductive belt loop during shipping
and during loading into a machine. The packaging machine for the
method includes mandrels holding cylindrical cores for supporting,
tensioning and folding the flexible photoconductive belt loop;
devices for feeding a light occluding and protective flexible sheet
over the flexible photoconductive belt loop to form a belt and
sheet assembly; an aperture former for forming a loop tacking
aperture through a loop tacking portion of one end of the light
occluding and protective flexible sheet; folding and end-tucking
mechanisms for folding the belt and sheet assembly into a tightly
folded pattern around the cylindrical cores; and first and second
taping stations for applying an end pull tab tape, and a loop
tacking tape over the loop tacking portion and through the loop
tacking aperture onto a portion of the light occluding and
protective flexible sheet underneath the loop tacking portion
thereof.
Inventors: |
Darcy, John J. III;
(Webster, NY) ; Martin, David W.; (Walworth,
NY) ; Roetker, Michael S.; (Webster, NY) ;
Dildine, James F. JR.; (Williamson, NY) ; Wagner,
Moritz P.; (Walworth, NY) ; Olesiuk, J. Stephen;
(Rochester, NY) |
Correspondence
Address: |
PATENT DOCUMENTATION CENTER
XEROX CORPORATION
100 CLINTON AVE., SOUTH, XEROX SQUARE, 20TH FLOOR
ROCHESTER
NY
14644
US
|
Assignee: |
Xerox Corporation
|
Family ID: |
34080156 |
Appl. No.: |
10/625206 |
Filed: |
July 23, 2003 |
Current U.S.
Class: |
53/429 ; 53/116;
53/136.3; 53/415 |
Current CPC
Class: |
B65B 25/146
20130101 |
Class at
Publication: |
053/429 ;
053/415; 053/116; 053/136.3 |
International
Class: |
B65B 063/04; B65B
061/00 |
Claims
1. A packaging machine for wrapping, folding and taping a flexible
photoconductive belt loop to prevent light from shocking such
photoconductive belt loop during shipping and during loading into a
machine, the packaging machine comprising; (a) a series of movable
mandrels holding removable cylindrical cores for supporting,
tensioning and folding the flexible photoconductive belt loop; (b)
means for feeding a light occluding and protective flexible sheet
over an external surface of the flexible photoconductive belt loop
to form a photoconductive belt loop and protective sheet assembly
thereof, said light occluding and protective flexible sheet having
a first end, and a second end including a loop tacking portion
adjacent said second end for overlapping said first end; (c) an
aperture former for forming at least one loop tacking aperture
through said loop tacking portion of said second end; (d) folding
and end-tucking mechanisms for folding the photoconductive belt
loop and protective sheet assembly into a tightly folded belt and
protective sheet assembly around said cylindrical cores; and (e)
first and second taping stations for applying an end pull tab piece
of tape, and a loop tacking piece of tape over said loop tacking
portion and through said at least one loop tacking aperture onto a
portion of said first end of said light occluding and protective
flexible sheet.
2. The machine of claim 1, including a folding station having a
tucking device for tucking an overlapping portion of the lead end
of the cut sheet of photo paper around said tightly folded belt and
paper assembly of the cut sheet of photo paper and the
photoconductive belt loop.
3. The machine of claim 1, wherein said light occluding and
protective flexible member is comprised of black photo paper.
4. The machine of claim 1, wherein a plurality of said at least one
aperture is formed through said loop tacking portion.
5. A packaging machine for wrapping, folding and taping a flexible
photoconductive belt loop to prevent light from shocking such
photoconductive belt loop during shipping and during loading into a
machine, the packaging machine including: (a) a protective photo
paper holding and supply assembly for holding and feeding a web of
protective photo paper; (b) an arc-shaped paper guide for guiding
and positioning a section of fed web of protective photo paper; (c)
a photoconductive belt loop support and folding assembly for
supporting and folding the photoconductive belt loop and a sheet of
fed photo paper, said photoconductive belt loop support and folding
assembly including (i) a wrapping station located above a first
portion and underneath a second portion of said arc-shaped paper
guide, (ii) a travel track, (iii) a translational first drive means
and a rotational second drive means, (iv) a first movable carriage
having a first mandrel and a second mandrel each for supporting a
first packaging core member and a second packaging core member, and
(v) a second movable carriage having a third mandrel for supporting
a third packaging core member; (d) means for folding an assembly of
the sheet of fed photo paper and the photoconductive belt loop into
a tightly folded belt and paper assembly around said first, said
second, and said third packaging core members; and (e) a first
taping station and a second taping station located adjacent said
travel track for applying an instruction and loop tacking tape over
a loop tacking aperture, and a pull tab tape over a second end of
said sheet of photo paper and over a portion of said tightly folded
belt and paper assembly of the sheet of photo paper and the
photoconductive belt loop.
6. The packaging machine of claim 5, wherein said protective photo
paper holding and supply assembly includes (i) feed wheels for
feeding the web of protective photo paper, (ii) a lead-end sensor
for limit-sensing a lead end of a fed web of photo paper; and (iii)
a web cutter located upstream of said lead-end sensor relative to a
direction of web feed for cutting the fed web of photo paper to a
desired length.
7. The packaging machine of claim 5, wherein said arc-shaped paper
guide includes a gate therein for reciprocal movement of said first
movable carriage and said second movable carriage therethrough.
8. The packaging machine of claim 5, including a folding station
having a tucking device for tucking an overlapping portion of a
lead end of the sheet of photo paper around said tightly folded
belt and paper assembly of the cut sheet of photo paper and the
photoconductive belt loop.
9. The packaging machine of claim 5, wherein said second carriage
includes a hold-down finger for tucking a trail end portion of said
sheet of photo paper over a tucked overlapping portion of the lead
end of said cut sheet of photo paper.
10. The packaging machine of claim 5, wherein said wrapping station
includes (i) a loading position having said first carriage and said
second carriage spaced a first distance from each other for
receiving the photoconductive belt loop in a non-tensioned form,
(ii) a tensioning position having said first carriage and said
second carriage spaced a second distance from each other for
tensioning the photoconductive belt loop about said second and said
third packaging core members, and (iii) a threading position having
a threading gap between a portion of said photoconductive loop over
said second packaging core member and said first packaging core
member is located across a gate in said arc-shaped paper guide for
receiving a threaded lead end of said fed web of photo paper.
11. The packaging machine of claim 5, wherein each said packaging
core member comprises a cylindrical hollow paper core.
12. The packaging machine of claim 5, wherein said first carriage
is coupled to both said translational first drive means, and said
rotational second drive means.
13. The packaging machine of claim 5, wherein said first mandrel
and said second mandrel are rotatable about each other for folding
a tensioned photoconductive belt loop and cut sheet of photo paper
assembly into said tightly folded belt and paper assembly.
14. The packaging machine of claim 7, wherein said arc-shaped paper
guide includes a removable shutter for closing said gate during
feeding of a lead end of a fed web of photo paper across said
gate.
15. The packaging machine of claim 7 wherein said gate is located
along said are-shaped paper guide such that a first section of the
fed web of photo paper, within said arc-shaped paper guide between
a lead-end sensor and said gate, is longer than a second section of
the fed web of photo paper within said arc-shaped paper guide
between said gate and a web cutter.
16. The packaging machine of claim 8, wherein said tucking device
includes a curved finger and vertical moving means for moving said
curved finger into and out of a tucking position.
17. The packaging machine of claim 8, including a horizontal bar
for pressing a tucked trail end of said cut sheet of photo paper
over a tucked said overlapping portion of the lead end of said cut
sheet of photo paper.
18. The packaging machine of claim 8, including means for rotating
said hold-down finger at the folding station from a home position
into a deflecting and tucking position for tucking said trail end
portion of said cut sheet of photo paper.
19. The packaging machine of claim 10, including means for moving
the photoconductive belt loop tensioned about said second and said
third packaging core members through said gate and against said
threaded lead end of said fed web of photo paper, thereby pulling
an upper section and a lower section of a cut sheet of photo paper
web within said arc-shaped paper guide over the tensioned
photoconductive belt loop.
20. The packaging machine of claim 10, wherein said first mandrel
having said first packaging core member thereon is movable
translationally against said second packaging core member for
pinching the fed web of photoconductive paper within said threading
gap.
21. A packaging method for wrapping, folding and taping a flexible
photoconductive belt loop to prevent light from shocking such
photoconductive belt loop during shipping and during loading into a
machine, the packaging method comprising: (a) supporting and
tensioning the flexible photoconductive belt loop over first and
second packaging cores mounted on mandrels; (b) feeding a light
occluding and protective flexible sheet having a lead end and a
trail end over the flexible photoconductive belt loop to form a
belt and sheet assembly; (c) forming a loop tacking aperture
through a loop tacking portion of said trail end of said light
occluding and protective flexible sheet; (d) folding said belt and
sheet assembly into a tightly folded pattern around a third
packaging core and around one of said first and second packaging
cores; (e) applying an end pull tab adhesive tape over said trail
end and over a portion of said light occluding and protective
flexible sheet underneath said trail end; and (f) applying a loop
tacking tape over said loop tacking portion, through said loop
tacking aperture, and onto a portion of said light occluding and
protective flexible sheet underneath said loop tacking portion
thereof.
22. A packaging method of packaging a flexible photoconductive belt
loop to prevent light from shocking said flexible photoconductive
belt loop during shipping and during loading into a machine, the
method comprising: (a) loading the flexible photoconductive belt
loop having a circumference L1 over a first movable core and a
second movable core; (b) moving at least one of said first movable
core and said second movable core to tension said flexible
photoconductive belt loop; (c) feeding a length L2 of a light
occluding and protective flexible member through a fixed are into a
position over said tensioned flexible photoconductive belt loop;
(d) first moving said tensioned flexible photoconductive loop
horizontally to a first side to position said movable first movable
core and a third movable core under said length L2 of said light
occluding and protective flexible member; (e) threading said length
L2 of said light occluding and protective flexible member over a
portion of said flexible photoconductive belt loop within a
threading gap between said first movable core and said third
movable core; (f) feeding a rest of said total length L3 of said
light occluding and protective flexible member through said
threading gap and forming a larger arc thereof; (g) pinching the
threaded light occluding and protective flexible member and
flexible photoconductive belt loop within said threading gap by
moving said third packaging core against said first packaging core;
(h) forming at least one loop tacking aperture through a portion of
said trail end of said trailing length portions (i) secondly
further moving said tensioned flexible photoconductive belt loop
horizontally to said first side causing said light occluding and
protective flexible member to wrap itself onto the outside surface
of the flexible photoconductive belt loop forming a wrapped
assembly; (j) rotating said third packaging core and said first
packaging core thereby folding the wrapped assembly into a tightly
folded belt and paper assembly; (k) tucking said lead end of the
light occluding and protective flexible member under the trail end
thereof; (l) moving the tightly folded belt and paper assembly
horizontally to a second and opposite direction; (m) vacuum
grasping, tensioning and wrapping the trail end of the light
occluding and protective flexible member around and under the
tightly folded belt and paper assembly; (n) applying an adhesive
backed loop tacking tape over said trail end, through said at least
one loop tacking aperture and onto said lead end; and (o) applying
a pull tab adhesive tape over the trailing end, thereby holding the
whole tightly folded belt and paper assembly together.
Description
RELATED CASE
[0001] This application is related to U.S. Application Serial
No.______ (Applicants' Docket NO. D/A1754Q) entitled "PACKAGING
APPARATUS FOR WRAPPING AND FOLDING FLEXIBLE PHOTORECEPTOR BELTS"
filed on even date herewith, and having at least one common
inventor.
[0002] The present invention relates generally to flexible
photoreceptor belts, and more particularly to a packaging machine
and method for wrapping and folding a flexible photoconductive belt
loop so as to prevent light from shocking it during shipping and
during loading into an image producing machine, such as an
electrostatographic image reproduction machine.
[0003] In the art of electrostatography, a photoconductive member
including an insulating photoconductive layer on a conductive layer
is imaged by first electrostatically charging the imaging surface
of the photoconductive insulating layer. The photoconductive member
is then exposed to a pattern of activating electromagnetic
radiation such as light, which selectively dissipates the charge in
the illuminated areas of the photoconductive insulating layer while
leaving behind an electrostatic latent image in the non-illuminated
area. This electrostatic latent image may then be developed to form
a visible image by depositing finely divided electroscopic toner
particles on the surface of the photoconductive insulating layer.
The resulting visible toner image can be transferred to a suitable
receiving member such as paper. This imaging process may be
repeated many times with reusable photoconductive insulating
layers.
[0004] As is well known, the photoconductive member may be in the
form of a flexible photoreceptor belt. These flexible belts have a
substrate and sensitive layers that include an electrically
conductive surface and at least one photoconductive layer. A common
flexible photoreceptor belt comprises a substrate, a conductive
layer, an optional hole blocking layer, an optional adhesive layer,
a charge generating layer, a charge transport layer and, in some
embodiments, an anti-curl backing layer.
[0005] These photoreceptor belts are usually thin and flimsy, but
most importantly, they are very sensitive to light. Accordingly,
during handling of these belts when shipping or loading them into
an image reproduction machine, damage such as scratches, dents can
result, and light shock can result if the belts are exposed for
significant periods to light. Such damage ordinarily can lead to
degradation in the quality of images produced thereon by the
reproduction machine.
[0006] There is therefore a need for a packaging machine that can
wrap and fold a flexible photoconductive belt loop so as to prevent
light from shocking it during shipping and during loading into an
image producing machine.
[0007] In accordance with the present invention, there is provided
a packaging machine and method for wrapping, folding and taping a
flexible photoconductive belt loop to prevent light from shocking
such photoconductive belt loop during shipping and during loading
into a machine. The packaging machine for the method includes
mandrels holding cylindrical cores for supporting, tensioning and
folding the flexible photoconductive belt loop; devices for feeding
a light occluding and protective flexible sheet over the flexible
photoconductive belt loop to form a belt and sheet assembly; an
aperture former for forming a loop tacking aperture through a loop
tacking portion of one end of the light occluding and protective
flexible sheet; folding and end-tucking mechanisms for folding the
belt and sheet assembly into a tightly folded pattern around the
cylindrical cores; and first and second taping stations for
applying an end pull tab ape, and a loop tacking tape over the loop
tacking portion and through the loop tacking aperture onto a
portion of the light occluding and protective flexible sheet
underneath the loop tacking portion thereof.
[0008] In the detailed description of the invention presented
below, reference is made to the drawings, in which:
[0009] FIG. 1 is a schematic vertical view, in an idle mode, of the
packaging machine of the present invention for wrapping photo paper
about a flexible photoconductive belt loop;
[0010] FIG. 2 is a schematic of the machine of FIG. 1 in a loop
loading mode showing a just loaded flexible photoconductive belt
loop;
[0011] FIG. 3 is a schematic of the machine of FIG. 2 in a loop
tensioning mode showing the loaded flexible photoconductive belt
loop tensioned;
[0012] FIG. 4 is a schematic of the machine of FIG. 3 in a photo
paper feeding mode showing the loaded flexible photoconductive belt
carrying carriages positioned for receiving a photo paper web
section;
[0013] FIG. 5A is a schematic of the machine of FIG. 4 showing a
belt and paper wrapped assembly moved to the folding station;
[0014] FIG. 5B is a schematic illustration of a part of the wrapped
assembly showing the portions of the cut sheet of photo paper in
accordance with the present invention;
[0015] FIG. 6 is an enlarged illustration of the folding station
showing a portion of the belt and paper wrapped assembly about to
be folded;
[0016] FIGS. 7-12 are schematic illustrations of the folding and
taping of the belt and paper wrap-assembly in accordance with the
present invention;
[0017] FIG. 13 is an illustration of the taped, tightly folded belt
and paper assembly produced in accordance with the present
invention.
[0018] While the present invention will be described in connection
with a preferred embodiment thereof, it will be understood that it
is not intended to limit the invention to that embodiment. On the
contrary, it is intended to cover all alternatives, modifications,
and equivalents as may be included within the spirit and scope of
the invention as defined by the appended claims.
[0019] Referring to FIG. 1, It depicts a schematic illustration of
a packaging machine 100 of the present invention for automatically
wrapping a light occluding and protective flexible member, such as
protective photo paper 121, about a light sensitive flexible
photoconductive belt loop 110. The flexible light occluding photo
paper in one embodiment is black photo paper. The light sensitive
photoconductive belt loop 110 is a flexible photoreceptor or
photoconductive belt having a length or circumference L1, and a
width W1. The packaging machine 100 includes a machine frame 102, a
protective photo paper supply assembly 104, and photoconductive
belt support and folding assembly 106.
[0020] The protective photo paper supply assembly 104 includes a
web supply stand (not shown) for holding a photo paper web 120, a
paper guide, for example an arc-shaped paper guide 130 for guiding
and freely holding a cut length L2 of photo paper web 121, and a
feeding device 132 for feeding photo paper web 120 along the
arc-shaped paper guide 130. The paper guide 130 as illustrated may
be an arc-shaped baffle that has an opening or gate 134 through it,
at approximately the mid-point thereof. In order to facilitate
efficient paper feeding, a movable shutter 136 is provided for
closing the opening or gate 134 during feeding of a lead end 122 of
paper to the lead-end sensor 138.
[0021] The protective photo paper supply assembly 104 also includes
a paper lead-end sensor 138 for detecting the absence or presence
of a lead end 122 of the length L2 of photo paper web 120 fed along
the paper guide 130. Back upstream of the lead-end sensor 138,
relative to a direction of photo paper feed, there is provided a
paper cutter 140 for cutting the photo paper web 120 when the lead
end 122 of such web triggers the lead-end sensor 138. Cutting the
web as such defines a trail end 124 of a cut sheet of the photo
paper web having the desired length L2 for use in completely
wrapping the flexible photoconductive belt 104.
[0022] According to one aspect of the present invention, the
protective photo paper supply assembly 104 also includes an
aperture former 142 located along the paper guide 130. The aperture
former 142 is located as such slightly downstream of the paper
cutter 140 for forming at least one loop tacking aperture 128, 129
completely through a trail-end or loop tacking portion 126 of the
cut sheet of photo paper 121. In one embodiment, the aperture
former 142 forms two such tacking apertures 128, 129 and in a
centralized manner relative to the width W2 of the cut sheet of
photo paper.
[0023] The photoconductive belt support and folding assembly 106
includes a loading/unloading and wrapping station AA that is
located above a first portion 131 of the arc-shaped paper guide
130, and underneath a second portion 133 of the arc-shaped paper
guide. A translational travel track 150 as well as a translational
first drive means 152 and a rotational second drive means 154, form
parts of the wrapping station AA and photoconductive belt support
and folding assembly 106. The photoconductive belt support and
folding assembly 106 also includes a first movable carriage 156
having a first mandrel 161 and a second mandrel 162 each for
supporting first and second packaging core members C1 and C2,
respectively. In one embodiment, the packaging core members
comprise cylindrical paper cores. The first movable carriage 156 is
coupled both to the translational first drive means 152, and to the
rotational second drive means 154. As mounted on the first movable
carriage 156, the first mandrel 161 and the second mandrel 162 can
be rotated on a pivot Pv about each other, by means of the
rotational second drive means 154. The photoconductive belt support
and folding assembly 106 further includes a second movable carriage
158 having a third mandrel 163 for supporting a third packaging
paper core C3, and a photo paper web hold-down finger 164. The
hold-down finger 164 has a home position and tucking position, and
is rotatable about 180 degrees between the home and tucking
positions.
[0024] As further illustrated, the photoconductive belt support and
folding assembly 106 includes a folding station BB that has a
tucking device 170 for tucking the trail end overhanging portion
122, 123 of the cut sheet of photo paper around a folded assembly
200 of the photoconductive belt loop and the cut sheet of photo
paper. The photoconductive belt support and folding assembly 106
further includes a first taping station 180 for applying a loop
tacking tape and label 184, and a second taping station 182 for
applying a pull tab tape 186 to the tightly folded belt and paper
assembly 200. The first and second taping stations 180, 182 are
located adjacent the travel track 150, and include appropriate tape
supplies 181, 183, and each station is provided with necessary
proximity sensors for sensing the reciprocal travels of the first
and second movable carriages 156, 158 along he travel track
150.
[0025] Referring in general to FIGS. 1-9, the packaging machine 100
is shown in FIG. 1 in an idle mode with nothing on the mandrels
161, 162, 163. In FIG. 2, it is shown in loop loading mode with
removable hollow packaging cores or core members C1, C2, and C3
mounted over the mandrels 161, 162, 163 respectively, and a
flexible photoconductive belt loop 110 loaded over the first and
second cores C1 and C2. In FIG. 3 the machine 100 is in a loop
tensioning mode showing the loaded flexible photoconductive belt
loop 110 tensioned by the second movable carriage 158 for example
being moved leftwards from its FIG. 2 position.
[0026] In FIG. 4, the machine 100 is in a photo paper feeding mode
showing the loaded flexible photoconductive belt loop carrying
carriages 156, 158 positioned with the threading gap 112 under the
arc-shaped paper guide 130 for receiving a photo paper web 120.
FIG. 5A shows a belt and paper wrapped assembly 116 moved to the
folding station BB ready to be folded and taped in accordance with
the present invention. FIG. 5B is a schematic illustration of
portions of the cut sheet of photo paper 121 and the loop is
tacking and pull tab tapes 184, 186 in accordance with the present
invention.
[0027] FIG. 6 is an enlarged illustration of the folding station BB
showing a portion of the wrapped assembly 190 about to be folded,
and FIGS. 7-12 are schematic illustrations of the folding and
taping of the wrapped assembly 190 into a tightly folded belt and
paper assembly 190 in accordance with the present invention.
Finally, FIG. 13 is an illustration of the taped, tightly folded
belt and paper assembly 200 produced in accordance with the present
invention.
[0028] Referring specifically now to FIGS. 1-4, with the first and
second carriages are arranged in their first positions at the
loading/unloading and wrapping station AA of the machine 100 as
shown in FIG. 2. The hollow cylindrical packaging core members C1,
C2, C3, for example cylindrical paper cores, are initially inserted
over the first, second and third mandrels 161, 162, 163 of the
first and second movable carriages 156, 158. The flexible
photoconductive loop 110 is then hung over the second core C2 on
the second mandrel 162 of the first movable carriage 156, and over
the third core C3 on the third mandrel 163 of the second movable
carriage 158, in a non-tensioned manner with a large portion 111 of
the loop hanging gravitationally below the carriages 156, 158. The
first mandrel/first core assembly 161/C1 is hinged so as to have an
open position (defining the threading gap) and a closed or clamping
position relative to the second mandrel/second core assembly
162/C2. In this manner, it allows for the feeding of the photo
paper web through the threading gap, as well as for clamping the
fed web against the loop 110 on the second mandrel/second core
assembly 162/C2.
[0029] As shown in FIGS. 1 and 3, one or both of the first and
second movable carriages 156, 158 is/are then moved translationally
apart into their second positions (FIG. 3) for tensioning the
photoconductive loop 110. As shown in FIG. 4, the first and second
movable carriages 156, 158 are then moved to the right for locating
the first movable carriage across the opening or gate 134 in the
arc-shaped paper guide 130. The first carriage is located as such
so that the first core C1 is to a first side of the paper guide
130, and the photoconductive belt loop 110 (as tensioned by the
second and third mandrel/core assemblies 162/C2, 163/C3) is to the
opposite side of the paper guide 130. As such, a threading gap 112
between the first and second cores C1, C2 is in line with a lead
end of photo paper we being fed through the arc-shaped paper guide
130. The gate shutter 136 is then moved into place to close the
gate 134 in the paper guide 130. A lead end 122 of the photo paper
web 120 is then fed from the upper portion of the arc-shaped paper
guide 130, across the closed gate 134 through the threading gap
112, to the lead-end sensor 138.
[0030] When the lead end 122 is sensed by the lead-end sensor 138,
feeding is stopped. The cutter 140 then cuts the web resulting in a
cut sheet of photo paper 121 having the length L2. The aperture
former 142 forms the required number of apertures 128, 129 through
the loop tacking portion 126 of the trail end of the cut sheet of
photo paper 121. The cut sheet of photo paper 121 of length L2 is
thus resting freely within the arc-shaped paper guide 130 with a
first section S1 thereof below the gate 134 and a second section S2
above the gate. The arc-shaped paper guide is arranged such that a
mid-point of the cut sheet of photo paper within the arc-shaped
guide will be located below the gate 134 when the lead end 122
thereof is at the lead-end sensor 138. This results in the lower
section S1 of photo paper being shorter than the upper section S2
thereof.
[0031] With the photo paper pinched as such, the aperture former
142 then punches at least one (e.g. 0.625 inch diameter) tacking
hole or aperture 128, 129, (and in one embodiment two (e.g. 0.625
inch diameter) tacking holes or apertures 128, 129) through the
loop tacking portion 126 of the trail end 124. The at least one
tacking hole or aperture 128, 129 is punched centered width-wise
relative to the paper width W2, and about five inches in from the
trail end 124. The at least one tacking hole or aperture 128, 129,
is provided for latter allowing the instruction and loop tacking
tape 184 to fasten and tack the loop tacking portion 126 over, and
to a portion of the lead end portion of the photo paper 121. This
thus forms a photo paper protective loop 119 over the
photoconductive belt loop 110. After the holes 128, 129 are punched
as such, the photo paper web is then sheared or cut to provide the
cut sheet of photo paper 121 of length L2 within the photo paper
guide 130. The cut is such that L2 is significantly longer than L1
in order to provide the lead end and trail end overhanging portions
123, 125 (FIGS. 7 and 8) thereto.
[0032] With the cut sheet of photo paper 121 in the guide as such,
the gate shutter 136 is removed leaving only the cut sheet of photo
paper 121 across the opening or gate 134. With the first and second
carriages 156, 158 in their second positions relative to each
other, and with the photoconductive belt loop 110 tensioned as
shown in FIGS. 3 and 4, the first mandrel/first core assembly
161/C1 is closed against the second mandrel/second core assembly
162/C2. Both carriages (with the tensioned photoconductive belt
loop thereon) are then moved translationally (to the right) towards
the folding station BB. During such translational movement, the
first mandrel/core assembly 161/C1 with no belt or paper over it,
(and located downstream of the gate 134 and downstream of the cut
sheet of photo paper 121 relative to such movement), leads the way.
However, the portion of tensioned photoconductive belt loop 110
over the second mandrel/core assembly 162/C2 (on the first
carriage) will catch against the free cut sheet of photo paper 121
across the gate 134 and push it along and thus wrap sections S1 and
S2 thereof over bottom and top portions of the outside surface of
the tensioned photoconductive belt loop to form the wrapped
assembly (paper on is belt) 116.
[0033] Thus both the bottom section S1 and top section S2 of the
free cut sheet of photo paper 121 in the arc-shaped paper guide
will be pulled over the rest of the tensioned photoconductive belt
loop 110. As such, the entire cut sheet of photo paper 121 having a
length L2 is pulled out of the arc-shaped paper guide 130 and
around most of the circumference L1 of the photoconductive belt
loop 110. Translational movement as such continues across the
taping stations, 182, 180 until the leading and free mandrel/core
assembly 161/C1 reaches its position at the folding station BB. In
accordance with the present invention, the length L2 of the cut
sheet of photo paper is greater than the circumference L1 of the
photoconductive belt loop 110, thus allowing for significant
overlap (123, 125) by the photo paper at both lead end 122 and
trail end 124 thereof.
[0034] After the leading and free, first mandrel/core assembly
161/C1 reaches its position at the folding station BB as described
above, the rotational second drive means 154 is activated to
rotatably move the first mandrel/first core assembly 161/C1
clockwise (FIG. 8) as shown by the arrow 193 around the second
mandrel/second core assembly 162/C2, and vice versa (arrow 194)
(with belt 110 and cut sheet of paper 121 over it). The first
mandrel/first core assembly 161/C1 is referred to as the pinch core
assembly, and the second mandrel/second core assembly 162/C2 is
referred to as the winding core assembly. As pointed out above, as
mounted on the first movable carriage 156, the first mandrel 161
and the second mandrel 162 can be rotated about each other on a
pivot Pv by the rotational second drive means 154.
[0035] As illustrated in FIGS. 8-12, repeated and continuous
clockwise rotation of the first mandrel/first core assembly 161/C1
about the second mandrel/second core assembly 162/C2, and vice
versa, as well as continued sliding movement (arrow 192) of the
third mandrel/third core assembly 163/C3 towards the first
mandrel/first core assembly 161/C1, effectively causes the
tensioned length of the photoconductive belt and paper or wrapped
assembly 190 to be folded repeatedly about the first mandrel/first
core assembly 161/C1 and about the second mandrel/second core
assembly 162/C2. After each rotation, the remaining tensioned
length of the wrapped assembly 190 becomes shorter and shorter as
the second carriage 158 and the third mandrel/third core 163/C3 are
pulled in the direction of arrow 192 closer and closer to the first
mandrel/first core assembly 161/C1 and the second mandrel/second
core assembly 162/C2.
[0036] When the remaining tensioned length of the photoconductive
belt and paper assembly 190 is essentially zero, the folding is
complete, and the three mandrel/core assemblies 161/C1, 162/C2,
163/C3 will be in a row, in perfect alignment with each other, and
separated from each adjacent other by the folds of belt 110 and
paper 121 between them. Because L2 was greater than L1, when the
folding is complete as such, the upper or trail end 124 of the
photo paper will be overlapping or overhanging, 125, the resulting
or folded belt and paper assembly 200 by about 6 inches. The lower
or lead end 122 similarly will be overlapping or overhanging the
resulting or folded belt and paper assembly 200 by about 3
inches.
[0037] To complete the folding into a tight belt and paper assembly
200, the tucking device 170 is activated and moves upwardly from a
position below the overhanging portion 123 of the lower or lead end
122. The purpose of the upward movement is for first tucking the
lead end overlapping or overhanging portion 123 of the cut sheet of
photo paper around the third mandrel/third core 163/C3 portion of
the belt and paper folded assembly 200. The tucking device 170 as
such has an upward projecting arm 172 that includes a left to right
fixed bend 174 in it (as shown in the drawings). The bend 174 is
such that upward motion of the device 170 causes the lead end
overhanging portion 123 to be bent up and rightwards (tucked under
the upper or trail end overhanging portion 125), as well as around
the third mandrel/third core 163/C3 portion of the tightly folded
belt and paper assembly 200.
[0038] After the lead end overhanging portion 123 of the photo
paper has been tucked as above, the hold-down finger 164 (on the
second movable carriage) is moved rotatably as shown from a home
position above the trail end overhanging portion 125 (that includes
the loop tacking portion 126), to deflect such trail end
overhanging portion 125 downwards over the tucked lead end
overhanging portion 123. The tightly folded belt and paper assembly
200 then starts to move back towards the first and second taping
stations, with the tucked trail end being pressed and held tight
against the tightly folded belt and paper assembly by the hold-down
finger 164.
[0039] The tightly folded belt and paper assembly 200 then
continues and moves horizontally (to the left) over a vacuum plenum
185 that further grabs the top, tucked trail end 124 of the photo
paper, tensions it, and wraps it around a bottom portion of the
tightly folded belt and paper assembly 200. The tightly folded belt
and paper assembly 200 then continues to move to the left over the
first taping station 180 where an adhesive backed loop tacking tape
184 is applied over the tucked trail end overhanging portion 125,
through the two punched loop tacking holes or apertures 128, 129,
and onto a portion of the tucked lead end 122 underneath. Next,
with such continued movement, the second taping station 182 then
applies a closure tape or "pull tab" tape 186 over the trail end
124 of the photo paper and over the bottom portion of the tightly
folded belt and paper assembly 200. The pull tab tape 186 as such
holds the tightly folded belt and paper assembly 200 together. The
packaging consisting of wrapping, folding and taping procedures is
now complete. The taped tightly folded belt and paper assembly 200
is then moved along the track 150 back to the loading and unloading
position AA where the taped tightly folded belt and paper assembly
200, including the packaging core members C1, C2, C3, is unloaded
from the packaging machine 100.
[0040] The packaging by wrapping, folding and taping in accordance
with the present invention is suitable for preventing the
photoconductive belt loop 110 from experiencing "light shock"
during shipping and installation. This is because it takes the
photoconductive belt loop 110 days to fully recover from light
shock. In cases where the photoconductive belt loop 110 is
relatively large, it is ordinarily very cumbersome to install it
onto the photoconductive belt module (not shown) of an image
reproduction machine (not shown), and therefore there is even more
of a risk of exposing it to room lighting for a longer period of
time. In addition, such packaging also prevents the folded portions
of the photosensitive layer of the photoconductive belt loop 110
from touching each other, and from being scratched.
[0041] In one aspect, the packaging method of the present invention
for wrapping, folding and taping a flexible photoconductive belt
loop 110 to prevent light from shocking such photoconductive belt
loop during shipping and during loading into an image reproduction
machine includes (a) supporting and tensioning the flexible
photoconductive belt loop 110 over first and second packaging cores
C1, C2 mounted on mandrels 161, 162; (b) feeding a light occluding
and protective flexible sheet 121 having a lead end 122 and a trail
end 124, over the flexible photoconductive belt loop 110 to form a
wrapped assembly 190; and (c) forming a loop tacking aperture 128,
129 through a loop tacking portion 126 of the trail end 124 of he
light occluding and protective flexible sheet 121.
[0042] The method also includes (d) folding the wrapped assembly
190 into a tightly folded pattern around a third packaging core C3
and around one (C1) of the first and second packaging cores C1, C2;
(e) applying an end pull tab adhesive tape 186 over the trail end
124 and over a portion of the light occluding and protective
flexible sheet 121 underneath the trail end; and (f) applying a
loop tacking tape 184 over the loop tacking portion 126, through
the loop tacking aperture 128, 129, and onto a portion of the light
occluding and protective flexible sheet underneath the loop tacking
portion thereof.
[0043] In another aspect, the packaging method includes loading the
flexible photoconductive belt loop 110 having a circumference L1
over a second movable core C2 and a third movable core C3; moving
at least one of the second movable core and the third movable core
to tension the flexible photoconductive belt loop; feeding a length
of a light occluding and protective flexible member 120 through a
fixed arc into a position over the tensioned flexible
photoconductive belt loop; first moving the tensioned flexible
photoconductive loop horizontally to a first side to position the
movable second movable core and a first movable core under the
length of the light occluding and protective flexible member; and
threading the length of the light occluding and protective flexible
member over a portion of the flexible photoconductive belt loop
within a threading gap between the second movable core and the
first movable core.
[0044] The method further includes feeding a rest of the total
length of the light occluding and protective flexible member
through the threading gap and forming a larger arc thereof;
pinching the threaded light occluding and protective flexible
member and flexible photoconductive belt loop within the threading
gap by moving the first packaging core against the third packaging
core; forming at least one loop tacking aperture through a portion
of the trail end of the trailing length portion; further moving the
tensioned flexible photoconductive belt loop horizontally to the
first side causing the light occluding and protective flexible
member to wrap itself onto the outside surface of the flexible
photoconductive belt loop forming a wrapped assembly 190; rotating
the first packaging core and the second packaging core thereby
folding the wrapped assembly into a tightly folded belt and paper
assembly 200; and tucking the lead end of the light occluding and
protective flexible member under the trail end thereof;
[0045] Finally, the method includes moving the tightly folded belt
and paper assembly horizontally to a second and opposite direction;
vacuum grasping, tensioning and wrapping the trail end of the light
occluding and protective flexible member (at vacuum plenum 185)
around and under the tightly folded belt and paper assembly;
applying an adhesive backed loop tacking tape 184 over the trail
end, through the at least one loop tacking aperture 128, 129 and
onto the lead end; and applying a pull tab adhesive tape 186 over
the trailing end, thereby holding the whole tightly folded belt and
paper assembly together.
[0046] As can be seen, there has been provided a packaging machine
and method for wrapping, folding and taping a flexible
photoconductive belt loop to prevent light from shocking such
photoconductive belt loop during shipping and during loading into a
machine. The packaging machine for the method includes mandrels
holding cylindrical cores for supporting, tensioning and folding
the flexible photoconductive belt loop; devices for feeding a light
occluding and protective flexible sheet over the flexible
photoconductive belt loop to form a belt and sheet assembly; an
aperture former for forming a loop tacking aperture through a loop
tacking portion of one end of the light occluding and protective
flexible sheet; folding and end-tucking mechanisms for folding the
belt sheet assembly into a tightly folded pattern around the
cylindrical cores; and first and second taping stations for
applying an end pull tab ape, and a loop tacking tape over the loop
tacking portion and through the loop tacking aperture onto a
portion of the light occluding and protective flexible sheet
underneath the loop tacking portion thereof.
[0047] While the embodiment of the present invention disclosed
herein is preferred, it will be appreciated from this teaching that
various alternative, modifications, variations or improvements
therein may be made by those skilled in the art, which are intended
to be encompassed by the following claims:
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