U.S. patent application number 11/668250 was filed with the patent office on 2007-08-02 for apparatus and method for conforming a label to the contour of a container.
Invention is credited to Douglas Crank.
Application Number | 20070175574 11/668250 |
Document ID | / |
Family ID | 38320853 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175574 |
Kind Code |
A1 |
Crank; Douglas |
August 2, 2007 |
APPARATUS AND METHOD FOR CONFORMING A LABEL TO THE CONTOUR OF A
CONTAINER
Abstract
An apparatus and method are provided for conforming a label to
the contour of a container. The apparatus includes a conveyor
configured to move the container along a travel path, a heat source
positioned along the conveyor and configured to heat at least a
portion of the label to a sufficient temperature to achieve a
sufficient degree of plasticity as the container moves along the
travel path, and a mechanical pressure applicator positioned along
the conveyor downstream from the heat source. The mechanical
pressure applicator is configured to apply pressure to at least a
portion of the heated label to conform it to the contour of the
container as the container moves along the travel path. The method
includes heating at least a portion of the label to a sufficient
temperature to achieve a sufficient degree of plasticity, and
applying mechanical pressure to at least a portion of the heated
label to conform it to the contour of the container.
Inventors: |
Crank; Douglas; (Holland,
MI) |
Correspondence
Address: |
BENESCH, FRIEDLANDER, COPLAN & ARONOFF LLP;ATTN: IP DEPARTMENT DOCKET
CLERK
2300 BP TOWER
200 PUBLIC SQUARE
CLEVELAND
OH
44114
US
|
Family ID: |
38320853 |
Appl. No.: |
11/668250 |
Filed: |
January 29, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60762854 |
Jan 27, 2006 |
|
|
|
Current U.S.
Class: |
156/215 ;
156/212; 156/447; 156/475; 156/497; 156/499; 156/DIG.11;
156/DIG.13; 156/DIG.36; 156/DIG.9 |
Current CPC
Class: |
Y10T 156/1028 20150115;
B29C 63/423 20130101; Y10T 156/1705 20150115; Y10T 156/1033
20150115; B29L 2031/744 20130101; B29C 2035/046 20130101; B65C 3/14
20130101; Y10T 156/17 20150115; B65C 3/166 20130101; B65C 3/16
20130101; B65C 9/26 20130101 |
Class at
Publication: |
156/215 ;
156/212; 156/475; 156/499; 156/447; 156/497; 156/DIG.009;
156/DIG.036; 156/DIG.011; 156/DIG.013 |
International
Class: |
B65C 3/08 20060101
B65C003/08; B29C 51/16 20060101 B29C051/16; B32B 37/06 20060101
B32B037/06; B65C 3/12 20060101 B65C003/12; B65C 3/16 20060101
B65C003/16 |
Claims
1. A method of conforming a detached edge portion of a label to a
contoured section of a container, the method comprising: heating at
least the detached edge portion of the label to a sufficient
temperature to achieve a sufficient degree of plasticity; and
applying mechanical pressure to at least the heated detached edge
portion of the label to conform it to the contoured section of the
container.
2. The method of claim 1, wherein the sufficient temperature is
between about 95.degree. F. and about 165.degree. F.
3. The method of claim 1, wherein the heating step includes:
rotating the container about its longitudinal axis in front of a
stationary heat source.
4. The method of claim 1, wherein the applying step includes:
rotating the container about its longitudinal axis in front of a
stationary mechanical pressure applicator.
5. An apparatus for conforming a detached edge portion of a label
to a contoured section of a container, the apparatus comprising: a
conveyor configured to move the container along a travel path, a
heat source positioned along the conveyor, the heat source
configured to heat at least the detached edge portion of the label
to a sufficient temperature to achieve a sufficient degree of
plasticity as the container moves along the travel path; a
mechanical pressure applicator positioned along the conveyor
downstream from the heat source, the mechanical pressure applicator
configured to apply pressure to at least the heated detached edge
portion of the label to conform it to the contoured section of the
container as the container moves along the travel path.
6. The apparatus of claim 5, further comprising: a rotation
mechanism configured to rotate the container as it passes in front
of the heat source and the mechanical pressure applicator.
7. The apparatus of claim 5, wherein the conveyor includes a flat,
segmented chain conveyor having a first edge and a second edge
opposite the first edge.
8. The apparatus of claim 7, wherein the heat source includes at
least one hot air blower connected to a nozzle positioned along the
second edge of the conveyor, the nozzle configured to focus the
heat on the detached edge portions of the label.
9. The apparatus of claim 7, wherein the mechanical pressure
applicator includes at least one linear brush positioned along the
second edge of the conveyor.
10. The apparatus of claim 7, wherein the rotation mechanism
includes a vertically oriented belt positioned along the first edge
of the conveyor and a compression plate positioned along the second
edge of the conveyor, the belt configured to move in the same
direction as the travel path of the container.
11. The apparatus of claim 10, wherein the belt is positioned a
sufficient distance away from the compression plate such that the
belt is capable of engaging the container as it travels along the
travel path and pressing it against the compression plate, thereby
causing the container to rotate about its longitudinal axis.
12. A method of conforming upper and lower detached edge portions
of a label to upper and lower contoured sections of a container,
respectively, the method comprising: heating at least the upper and
lower detached edge portions of the label to a sufficient
temperature to achieve a sufficient degree of plasticity; and
applying mechanical pressure to at least the heated upper and lower
detached edge portions of the label to conform them to the upper
and lower contoured sections of the container, respectively.
13. A method of conforming a label to the contour of a container,
the method comprising: heating at least a portion of the label to a
sufficient temperature to achieve a sufficient degree of
plasticity; and applying mechanical pressure to at least a portion
of the heated label to conform it to the contour of the
container.
14. The method of claim 13, wherein the sufficient temperature is
between about 95.degree. F. and about 165.degree. F.
15. The method of claim 13, wherein the heating step includes:
rotating the container about its longitudinal axis in front of a
stationary heat source.
16. The method of claim 13, wherein the applying step includes:
rotating the container about its longitudinal axis in front of a
stationary mechanical pressure applicator.
17. An apparatus for conforming a label to the contour of a
container, the apparatus comprising: a conveyor configured to move
the container along a travel path, a heat source positioned along
the conveyor, the heat source configured to heat at least a portion
of the label to a sufficient temperature to achieve a sufficient
degree of plasticity as the container moves along the travel path;
a mechanical pressure applicator positioned along the conveyor
downstream from the heat source, the mechanical pressure applicator
configured to apply pressure to at least a portion of the heated
label to conform it to the contour of the container as the
container moves along the travel path.
18. The apparatus of claim 17, further comprising: a rotation
mechanism configured to rotate the container as it passes in front
of the heat source and the mechanical pressure applicator.
19. The apparatus of claim 17, wherein the conveyor includes a
flat, segmented chain conveyor having a first edge and a second
edge opposite the first edge.
20. The apparatus of claim 19, wherein the heat source includes at
least one hot air blower connected to a nozzle positioned along the
second edge of the conveyor, the nozzle configured to focus the
heat on the label.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/762,854 filed on Jan. 27, 2006, the disclosure
of which is hereby incorporated by reference in its entirety
herein.
BACKGROUND
[0002] It is well recognized that in certain applications, heat
shrink labels provide a number of distinct advantages over paper
and non-shrinkable plastic labels. For example, if the label or
film is to be applied to a container or article having a curved,
conical, or irregular surface underlying the label, the heat-shrink
label can readily be shrunk to conform to the surface anomalies of
the container. This conforming capability, in turn, provides an
aesthetically pleasing appearance for the labeled container.
[0003] Prior known methods of closely forming film labels wrapped
around containers utilize exclusively the application of heat
impinging directly upon the film label causing the label's plastic
film structure to shrink until the label closely conforms to the
container's contours. Prior known methods and apparatuses utilize
mainly heated air, or direct infrared irradiation, to initiate and
complete the shrinking process of the laminated film labels to the
containers. In most applications, the film label must be heated to
a temperature of at least 470.degree. F in order to elevate the
film's temperature sufficiently so that the film label will shrink
enough to conform to the contour of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] It will be appreciated that the illustrated boundaries of
elements (e.g., boxes or groups of boxes) in the figures represent
one example of the boundaries. One of ordinary skill in the art
will appreciate that one element may be designed as multiple
elements or that multiple elements may be designed as one element.
An element shown as an internal component of another element may be
implemented as an external component and vice versa.
[0005] Further, in the accompanying drawings and description that
follow, like parts are indicated throughout the drawings and
description with the same reference numerals, respectively. The
figures are not drawn to scale and the proportions of certain parts
have been exaggerated for convenience of illustration.
[0006] FIG. 1 illustrates a schematic of one embodiment of a
conveyor system 100 for labeling containers.
[0007] FIG. 2 illustrates a front view of one embodiment of a
container 200 having an irregular shape.
[0008] FIG. 3 illustrates a front view of one configuration of a
labeled container 300 after it exits the labeling apparatus
120.
[0009] FIG. 4 illustrates a top view of one embodiment of a label
conforming apparatus 400.
[0010] FIG. 5 illustrates a side view of a labeled container C as
it travels along the container travel path B in front of two of the
hot air blowing nozzles 445 of the label conforming apparatus
400.
[0011] FIG. 6 illustrates a side view of a labeled container C as
it travels along the container travel path B through the linear
brushes 455a, b of the label conforming apparatus 400.
[0012] FIG. 7 illustrates a front view of one configuration of a
finished container C after it exits the label conforming apparatus
400.
[0013] FIG. 8 illustrates one embodiment of a methodology for
conforming a label to the contour of a container.
DETAILED DESCRIPTION
[0014] This application is directed to an apparatus and method for
conforming a label to the contour of a container. The apparatus and
method employ a reduced amount of heat in combination with
mechanical pressure to conform the label to the contour of the
container ensuring a tight fit.
[0015] Illustrated in FIG. 1 is a schematic of one embodiment of a
conveyor system 100 for labeling containers. In this embodiment,
the conveyor system 100 includes an article handling mechanism such
as an article feeder 110. The article feeder 110 is configured to
supply containers in a single file lane along a travel path to a
labeling apparatus 120. The article feeder 110 can be, for example,
a chain or link conveyor.
[0016] Containers that can be used in conveyor system 100 include,
without limitation, aerosol containers, paint cans, beverage
containers, and other liquid or dry goods containers, and may be
constructed from metal, plastic, or glass. Additionally, these
containers can take the form of a variety of sizes and shapes. For
example, the container can include straight walls from top to
bottom (e.g., a true cylindrical container). Alternatively, the
containers can have a more complex or irregular shape.
[0017] Illustrated in FIG. 2 is a front view of one embodiment of a
container having an irregular shape. As shown in FIG. 2, the
container 200 includes a cylindrical body 210, a top 220, a bottom
230, and a longitudinal axis A. The container 200 also includes an
upper contoured section 240 that curves toward the longitudinal
axis A and serves as a transition between the cylindrical body 210
and the top 220, and a lower contoured section 250 that curves
toward the longitudinal axis A and serves as a transition between
the cylindrical body 210 and the bottom 230. Of course, it will be
appreciated that the container can take the form of a variety of
other shapes and sizes.
[0018] With reference back to FIG. 1, the labeling apparatus 120 is
configured to apply a label to each container as it passes through
the labeling apparatus 120. The film label may be a single layer
film label or a multi-layer film label (e.g., a laminate film).
Each layer of film may be constructed from a variety of materials
such as polypropylene, polyolefin, polyethylene, polystyrene foam,
or combinations thereof.
[0019] In one embodiment, the film label is a laminate film label
having a base layer and an overlay layer. One suitable example of a
base layer is Label-Lyte 350 LLG-202 film manufactured by
Exxon-Mobil. This film is opaque white in color and made from
oriented polypropylene (OPP). The base layer is 1.45 mils (37
microns) thick and has a top surface that is treated for printing.
One suitable example of an overlay layer is Label-Lyte 408 LLG-112
film manufactured by Exxon-Mobil. This film is clear and made from
biaxially oriented polypropylene (BOPP). The overlay layer is 0.75
mils (19 microns) thick and is pressure-sensitive for lamination
over the printed Label-Lyte 350 LLG-202 base layer film.
[0020] In one embodiment, the labeling apparatus 120 is a roll-fed
labeling apparatus such as the one described in U.S. Pat. No.
4,108,710, which is hereby incorporated by reference in its
entirety herein. In such an apparatus, a continuous length of film
material is provided in the form of a roll. It passes continuously
through a cutting station where predetermined lengths are severed
into individual film labels. Once severed, a vacuum on a constantly
rotating vacuum drum grips the leading edge of each film label, and
glue (e.g., a hot melt adhesive) is applied to the leading edge and
trailing edge of each label. Alternatively, a glue line may be
applied directly to the container such that the leading edge of
each film label is unglued and is adhered to the container by means
of the glue line on the container, and the trailing edge of each
label is provided with glue and laps over the leading edge of the
label on the container to form a seam. After the glue is applied to
the film label and/or the container, the film label is wrapped
around the container to apply it to the container.
[0021] The container can exit the labeling apparatus 120 with the
label applied thereon in various configurations depending on the
shape of the container to be labeled and the desired label
orientation.
[0022] Illustrated in FIG. 3 is a front view of one configuration
of a labeled container 300 after it exits the labeling apparatus
120. In this configuration, the labeled container 300 includes the
container 200 illustrated in FIG. 2 and described above and a label
310 wrapped around the entire cylindrical body 210 of the container
200. The label 310 includes an upper edge portion 320 that extends
above (e.g., about 3-5 mm) the cylindrical body 210 of the
container 200, such that it overlaps (but does not contact) the
upper contoured section 240 of the container 200, while the label
310 includes a lower edge portion 330 that extends below (e.g.,
about 3-5 mm) the cylindrical body 210 of the container 200, such
that it overlaps (but does not contact) the lower contoured section
250 of the container 200. The upper edge portion 320 and the lower
edge portion 330 will be hereinafter referred to as "upper detached
edge portion 320" and "lower detached edge portion 330,"
respectively, because these edges of the label 310 are not in
contact with the container 200 and stand freely.
[0023] In an alternative embodiment (not shown), the label may be
applied to the container in such a way that it overlaps only one of
the contoured sections (e.g., the upper contoured section 240 or
the lower contoured section 250 of the container 200). In another
alternative embodiment (not shown), if the container to be labeled
has only one contoured section (i.e., the container departs from a
cylindrical shape at only one end), then the label may be applied
to the container in a manner such that it will overlap only the one
contoured section. In yet another embodiment (not shown), if the
container to be labeled does not have any contoured sections (e.g.,
a true cylindrical container), then the label may be applied only
to the straight wall of the container. Although several
configurations of a labeled container have been discussed above, in
the following description and in the drawings, it will be assumed
that the containers exit the labeling apparatus 120 in the
configuration as illustrated in FIG. 3 and described above. These
containers that exit the labeling apparatus 120 in the
configuration as illustrated in FIG. 3 and described above will be
hereinafter referred to as "labeled containers," "labeled
containers C," or "containers C."
[0024] With reference back to FIG. 1, after the labeled containers
exit the labeling apparatus 120, they are fed to a label conforming
apparatus 130. The label conforming apparatus 130, which will be
discussed in further detail below, is configured to conform the
label to the contour of the container to ensure a tight fit
thereof. More specifically, the label conforming apparatus 130 is
configured to conform the upper detached edge portion 320 of the
label 310 to the upper contoured section 240 of the labeled
container, and the lower detached edge portion 330 of the label 310
to the lower contoured section 250 of the labeled container to
ensure a tight fit of the label to the container.
[0025] After the finished containers exit the label conforming
apparatus 130, they can then be advanced to an output station 140.
In one embodiment, the output station 140 can include a packager
for packaging the containers. For example, the containers may be
packaged as 2-packs, 4-packs, 6-packs, etc. or in boxes. In
alternative embodiments (not shown), the output station 140 can
include other apparatuses including a palletizer, reject station,
quality control checking station, or any combination thereof.
[0026] Illustrated in FIG. 4 is a top view of one embodiment of a
label conforming apparatus 400. As discussed above, the apparatus
400 is configured to conform the upper and lower detached edge
portions 320, 330 of the label 310 to the upper and lower contoured
sections 240, 250, respectively, of the labeled container C to
ensure a tight fit of the label to the labeled container C.
[0027] In this embodiment, the apparatus 400 includes an article
carrier 405 that engages and moves labeled containers C along a
travel path, represented by arrow B, in a single lane. The article
carrier 405 can include, for example, a flat, segmented tabletop
chain conveyor. In alternative embodiments (not shown), other types
of article carriers may be used instead of a flat, segmented
tabletop chain conveyor such as an endless belt conveyor, an air
conveyor or a roller conveyor.
[0028] With continued reference to FIG. 4, the label conforming
apparatus 400 includes a rotation mechanism configured to rotate
each labeled container C about its longitudinal axis A. In the
illustrated embodiment, the rotation mechanism includes a movable
belt 410 positioned along a first edge 415 of the article carrier
405 and a compression plate 420 positioned along the second edge
425 of the article carrier 405 opposite the movable belt 410. As
shown in FIG. 4, the movable belt 410 is a vertically oriented,
endless belt that travels about two spaced-apart rotatable drums
430, each of which rotates about an axis of rotation R that is
oriented at an angle perpendicular to the article carrier 405. A
motor 435 or other driving mechanism can drive the movable belt
410.
[0029] The movable belt 410 and the compression plate 420 work in
conjunction with each other to cause each labeled container C to
rotate about its longitudinal axis A as it moves along the
container travel path B. Individually, the movable belt 410 is
configured to travel in the same direction as the container travel
path B. However, in combination, the movable belt 410 and the
compression plate 420 together cause each labeled container C to
rotate about its longitudinal axis A in a counterclockwise
direction as represented by arrow D. More specifically, as the
labeled containers C travel through the apparatus 400, the movable
belt 410 engages the labeled containers C and presses them against
the compression plate 420. The combination of forces acting upon
each labeled container C (i.e., the force caused by the movable
belt 410 and the force imparted by the compression plate 420)
causes each labeled container C to rotate about its longitudinal
axis A in the counterclockwise direction D. Of course, it will be
appreciated that if the direction of the container travel path B
was the opposite direction, then the labeled containers C would
rotation in a clockwise direction.
[0030] Although the rotation mechanism discussed above includes a
movable belt in combination with an opposing compression plate, it
will be appreciated that any conventional rotation mechanism may be
employed to rotate each labeled container C as it moves along the
container travel path B. By way of example, an alternative rotation
mechanism may include the same movable belt discussed above, but
instead of being used in combination with an opposing compression
plate, it can be used in combination with an opposing movable belt
traveling in an opposite direction.
[0031] With continued reference to FIG. 4, the label conforming
apparatus 400 also includes one or more heat sources configured to
heat the label 310 on the labeled container C to a sufficient
temperature to achieve a sufficient degree of plasticity to render
the label pliable. More specifically, the apparatus 400 includes
one or more heat sources configured to heat the upper and lower
detached edge portions 320, 330 of the label 310 to a sufficient
temperature to achieve a sufficient degree of plasticity to render
the label pliable.
[0032] In one embodiment, the sufficient temperature to achieve
plasticity of the label 310 is between the range of about
95.degree. F. and about 165.degree. F. This temperature range is
significantly below the temperatures required in conventional heat
shrinking processes, which require heated air in excess of
470.degree. F. to be impinged upon the label in order to shrink the
label to conform to the contour of the container.
[0033] In the illustrated embodiment, the heat sources include four
hot air blowers 440a-d positioned along the second edge 425 of the
article carrier 405. To direct and focus the heated air along a
certain air path, nozzles 445a-d are connected to the hot air
blowers 440a-d, respectively, and positioned adjacent to the
compression plate 420 along the second edge 425 of the article
carrier 405. In this embodiment, each nozzle 445 has a
substantially rectangular exit opening that directs the heated air
along a substantially rectangular path. In alternative embodiments
(not shown), one or more of the nozzles can have an exit opening
with a different shape.
[0034] The hot air blowers discussed above can be an integrated
unit (e.g., a heater and blower packaged together in one unit) or a
combination of two separate components (e.g., a heater and a blower
that can be married together at the time of installation). One
suitable example of a separate heater is a Hot Air Tool 5000 heater
manufactured by Leister Process Technologies, Sarnan, Switzerland,
which is rated at 8,000 watts and is capable of achieving a maximum
temperature of 700.degree. C. One suitable example of a separate
blower is a medium pressure blower such as the Leister ASO blower
manufactured by Leister Process Technologies, Sarnan, Switzerland,
which has a pressure rated at 2400 Pascals and is capable of
achieving a delivery volume of 15,900 1/min. Of course, other types
of hot air blowers can be used. Additionally, other types of
heaters can be used instead of hot air blowers such as direct
infrared heaters or steam heaters.
[0035] Illustrated in FIG. 5 is a view of a labeled container C as
it travels along the container travel path B in front of two of the
hot air blowing nozzles 445 of the label conforming apparatus 400.
As shown in FIG. 5, the nozzles 445a-d are arranged in two
side-by-side pairs adjacent to the compression plate 420.
Specifically, one of the two pairs of nozzles (i.e., nozzles
445a,b) is positioned above the compression plate 420 to focus the
heated air at the upper detached edge portion 320 of the labeled
container C, while the other pair of nozzles (i.e., nozzles 445c,d)
is positioned below the compression plate 420 to focus the heated
air at the lower detached edge portion 330 of the labeled container
C. In the illustrated embodiment, the two pairs of nozzles 445 are
staggered or offset from each other, such that they are not
vertically aligned. For example, the nozzle 445a is not vertically
aligned with the nozzle 445c. In an alternative embodiment (not
shown), the two pairs of nozzles 445 can be vertically aligned. In
other embodiments (not shown), one or both pairs of side-by-side
nozzles can be replaced with a single nozzle that has substantially
the same length as the two side-by-side nozzles. Alternatively,
three or more side-by-side nozzles can be used above or below the
compression plate 420.
[0036] With continued reference to FIG. 5, the distance between the
furthest upstream end of the lower nozzle (i.e., nozzle 445c) and
the furthest downstream end of the upper nozzle (i.e., nozzle 445b)
is defined as a heating zone 450. Thus, as the labeled containers C
enter the heating zone 450 of the label conforming apparatus 400,
heating of the upper and lower detached edges 320, 330 of the
labeled containers C is initiated. Once the labeled containers C
complete their travel through the heating zone 450, the upper and
lower detached edges 320, 330 of the labeled containers C should be
heated to the temperature range of between about 95.degree. F. and
about 165.degree. F.
[0037] In one embodiment, each labeled container C is rotated three
times via the rotation mechanism during its travel through the
heating zone 450 of the label conforming apparatus 400 in order to
heat the upper and lower detached edge 320, 330 of the label 310 to
the sufficient temperature. However, in alternative embodiments,
the label conforming apparatus 400 can be configured to rotate each
labeled container C less than three times or more than three times
as it travels through the label conforming apparatus 400. To
accomplish this, the length of the heating zone 450 (e.g., the
length and/or spacing of the hot air blowing nozzles 445a-d) can be
adjusted and/or the speed of the movable belt 410 can be
varied.
[0038] With reference back to FIG. 4, the label conforming
apparatus 400 further includes a mechanical force applicator
positioned along the second edge 425 of the article carrier 405
downstream from the heating zone 450. The mechanical force
applicator is configured to apply mechanical pressure to the heated
label to force it to conform to the contour of the labeled
container C. More specifically, the mechanical force applicator is
configured to apply mechanical pressure to the upper and lower
detached edge portions 320, 330 of the heated label 310 to conform
these edges to the upper and lower contoured sections, 240, 250,
respectively, of the container C. In the illustrated embodiment,
the mechanical force applicator includes two linear brushes--an
upper linear brush 455a and a lower linear brush 455b (not shown in
FIG. 4) that are utilized to apply mechanical forces to the upper
and lower detached edge portions 320, 330 of the heated label
310.
[0039] In one embodiment, the primary bristles of the linear
brushes are horsehair, which are captured and held in a rigid
supporting metallic structure. One suitable example of a linear
horsehair brush is supplied by McMaster-Carr Corporation. This
linear horsehair brush includes horsehair bristles that are 0.008
inches in diameter and 1.0 inch in length, which are captured in a
stainless steel base that is 5/16 inches thick at the base and one
foot in length. In alternative embodiments, the linear brushes may
be replaced with one or more linear pads made from a sufficiently
compliant material that is capable of applying the necessary
pressure to force the upper and lower detached edges of the label
against the container such that it conforms to the contour of the
container. Exemplary materials include, without limitation, foam
(closed cell or open cell), felt, carpet strips, coarse fibers, and
the like. Generally, any material may be used so long as it has a
sufficient amount of compliance necessary to conform the detached
edges of the label to the contoured sections of the container and
has the ability to withstand temperatures of at least 100.degree.
F. In other alternative embodiments, the linear brushes may be
replaced with one or more rotary brushes (e.g., foam roller covers)
that can have an outer profile that matches the contour of the
curved section of the container.
[0040] Illustrated in FIG. 6 is a view of a labeled container C as
it travels along the container travel path B through the linear
brushes 455a,b of the label conforming apparatus 400. As shown in
FIG. 6, the upper linear brush 455a is positioned above the
compression plate 420 and configured to apply sufficient pressure
to the heated upper detached edge portion 320 of the label 310 to
conform it to the upper contoured section 240 of the container C
resulting in a tight fit. Similarly, the lower linear brush 455b is
positioned below the compression plate 420 and configured to apply
sufficient pressure to the heated lower detached edge portion 330
of the label 310 to conform it to the upper contoured section 250
of the container C resulting in a tight fit. As shown in FIG. 6,
the upper and lower linear brushes 455a,b are vertically aligned
with each other. In an alternative embodiment (not shown), the
upper and lower linear brushes 455a,b may be staggered or offset
from each other.
[0041] With continued reference to FIG. 6, the distance between the
upstream and downstream ends of the upper and lower linear brushes
455a,b is defined as a mechanical pressure applying zone 460. Thus,
as the labeled container C enters the mechanical pressure applying
zone 460 of the label conforming apparatus 400, the upper and lower
linear brushes 455a,b begin to apply pressure to the heated upper
and lower detached edge portions 320, 330, respectively, to conform
these edges to the upper and lower contoured sections 240, 250,
respectively, of the container C. Once the labeled container C
completes its travel through the mechanical pressure applying zone
460, the upper and lower detached edge portions 320, 330 of the
labeled container C are conformed to the upper and lower contoured
sections 240, 250, respectively, of the container C as shown in
FIG. 7.
[0042] In one embodiment, each labeled container C is rotated one
and one half times via the rotation mechanism as it travels through
the mechanical pressure applying zone 460 of the label conforming
apparatus 400 in order to conform the heated upper and lower
detached edge 320, 330 of the label 310 to the upper and lower
contoured sections 240, 250, respectively, of the container C.
However, in alternative embodiments, the label conforming apparatus
400 can be configured to rotate each container less than one and
one half times or more than one and one half times while it travels
through the mechanical pressure applying zone 460 of the label
conforming apparatus 400. To accomplish this, the length of the
mechanical pressure applying zone 460 (e.g., the length of the
linear brushes 455a,b) can be adjusted and/or the speed of the
movable belt 410 can be varied.
[0043] After the mechanical pressure is applied to the upper and
lower detached edges of the label to conform them to the upper and
lower contoured sections of the container, the finished containers
enter a continuous conveyor (not shown) of sufficient length to
provide an ample amount of ambient cooling before being subjected
to subsequent processes. For example, the total length of the
continuous conveyor can be 200 linear feet to provide at least two
minutes of ambient cooling. Of course, the length and/or the
operation speed of the conveyor can be adjusted to provide more or
less ambient cooling. Furthermore, it will be appreciated that the
finished containers may be cooled by another cooling process such
as an active cooling process.
[0044] In alternative embodiments (not shown), the heat sources and
mechanical force applicators discussed above may be directed at
only one portion of the labeled container. For example, if the
labeled container only has one contoured section, then the label
conforming apparatus may include one or more heat sources and one
or more mechanical force applicators directed to the lone contoured
section. In another example, the label conforming apparatus may
include one or more heat sources and one or more mechanical force
applicators directed to one or more portions of the labeled
container even though the labeled container lacks a detached edge.
In this case, the application of heat and mechanical force to the
labeled container assists in providing a tight fit of the label to
the container.
[0045] Furthermore, it will be appreciated that a labeled container
may still be used in the apparatus 400 discussed above even though
it lacks a detached edge. If this is the case, the application of
heat and mechanical force to the upper and lower portions of the
container assists in providing a tighter fit of the label to the
container.
[0046] Illustrated in FIG. 8 is one embodiment of a methodology
associated with conforming a label to the contour of a container.
The illustrated elements denote "processing blocks" and represent
functions and/or actions taken for conforming a label to the
contour of a container. In one embodiment, the processing blocks
may represent computer software instructions or groups of
instructions that cause a computer or processor to perform an
action(s) and/or to make decisions that control another device or
machine to perform the processing. It will be appreciated that the
methodology may involve dynamic and flexible processes such that
the illustrated blocks can be performed in other sequences
different than the one shown and/or blocks may be combined or,
separated into multiple components. The foregoing applies to all
methodologies described herein.
[0047] With reference to FIG. 8, the process 800 involves a process
for conforming a label to the contour of a container. The process
400 includes heating the label or portions thereof (e.g., the
detached edge portions 320, 330 of the label 310 discussed above)
to a sufficient temperature to achieve a sufficient degree of
plasticity to render the label pliable (block 805). In one
embodiment, the label or portions thereof are heated to a
temperature between about 95.degree. F. and about 165.degree. F.
After the label or portions thereof are heated to the sufficient
temperature, the process further includes applying mechanical
pressure to the label or portions thereof (e.g., the detached edge
portions 320, 330 of the label 310 discussed above) to conform the
label or portions thereof to the contour of the container (e.g.,
the upper and lower contoured sections 240, 250 of the container C
discussed above) (block 810).
[0048] The label conforming apparatus 400 and methodology 800
described above have several potential advantages. One advantage is
that it can eliminate defects in the labeling process (which
includes label applying and conforming) due to overheating such as
distortion or wrinkling. A second potential advantage is that a
broader range of label materials may be employed (e.g., thinner
film labels) since the dependence upon the shrinkage
characteristics of film label materials is reduced. A third
potential advantage is that many of the critical closely controlled
process requirements of the known prior methods, such as precisely
heated air temperature process control and dynamic dwell timing
control, can be eliminated. The reduction of these critical process
control factors allows for an improvement in both the subjective
appearance and quality of the finished labeled containers, as well
as providing the opportunity for improved process yields and
efficiencies. A fourth potential advantage is that there is a
significant advantage in terms of reduced energy consumption due to
the reduced label-heating requirement. A final potential advantage
is that current heat shrinking equipment can be retrofitted to
accommodate the process described above. For example, existing hot
air blowers can be utilized without the need to update or change
controllers. However, the hot air blowers can be operated at
reduced power (e.g., twenty percent (20%) of their maximum output
rating), thereby reducing energy consumption as discussed
above.
[0049] To the extent that the term "includes" or "including" is
used in the specification or the claims, it is intended to be
inclusive in a manner similar to the term "comprising" as that term
is interpreted when employed as a transitional word in a claim.
Furthermore, to the extent that the term "or" is employed (e.g., A
or B) it is intended to mean "A or B or both." When the applicants
intend to indicate "only A or B but not both" then the term "only A
or B but not both" will be employed. Thus, use of the term "or"
herein is the inclusive, and not the exclusive use. See, Bryan A.
Gamer, A Dictionary of Modem Legal Usage 624 (2d. Ed. 1995). Also,
to the extent that the terms "in" or "into" are used in the
specification or the claims, it is intended to additionally mean
"on" or "onto." Furthermore, to the extent the term "connect" is
used in the specification or claims, it is intended to mean not
only "directly connected to," but also "indirectly connected to"
such as connected through another component or multiple
components.
[0050] While the present application illustrates various
embodiments, and while these embodiments have been described in
some detail, it is not the intention of the applicant to restrict
or in any way limit the scope of the claimed invention to such
detail. Additional advantages and modifications will readily appear
to those skilled in the art. Therefore, the invention, in its
broader aspects, is not limited to the specific details, the
representative apparatus, and illustrative examples shown and
described. Accordingly, departures may be made from such details
without departing from the spirit or scope of the applicant's
claimed invention.
* * * * *