U.S. patent number 3,920,122 [Application Number 05/428,362] was granted by the patent office on 1975-11-18 for label web and die making methods.
This patent grant is currently assigned to R. A. Jones & Co., Inc.. Invention is credited to Allen W. Koehlinger, Wesley J. Rece, Jr..
United States Patent |
3,920,122 |
Koehlinger , et al. |
November 18, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Label web and die making methods
Abstract
An improved label web includes an elongated web remnant having a
plurality of partially precut labels supported therein by bridges
of material which taper from one width near the remnant to a
smaller width near the label. Depressions receiving the bridges are
formed in the labels, when they are partially precut, but their
dimension and configuration is selected so that when the labels are
removed from the web and placed on a product, the depressions are
visually insignificant. The major portions of the bridges remain
with the remnant and any portion remaining with the label tends to
fill the depression enhancing the label's appearance. Improved die
structure and methods for making die structure to preferentially
form labels are included. In one method, the desired curved die
cutting edge is formed by displacing and nicking a straight die
cutting edge, from one side and at an angle to the general
perpendicular projection of the edge above the die surface.
Inventors: |
Koehlinger; Allen W.
(Cincinnati, OH), Rece, Jr.; Wesley J. (California, KY) |
Assignee: |
R. A. Jones & Co., Inc.
(Covington, KY)
|
Family
ID: |
23698570 |
Appl.
No.: |
05/428,362 |
Filed: |
December 26, 1973 |
Current U.S.
Class: |
206/390; 156/257;
428/43; 40/638; 206/820 |
Current CPC
Class: |
G09F
3/0286 (20130101); B31D 1/021 (20130101); B31D
1/026 (20130101); Y10S 206/82 (20130101); Y10T
428/15 (20150115); Y10T 156/1064 (20150115) |
Current International
Class: |
B31D
1/00 (20060101); B31D 1/02 (20060101); G09F
3/02 (20060101); B65D 085/67 (); B32B 003/10 ();
G09B 003/02 () |
Field of
Search: |
;206/390,820,411,225,389,409 ;242/1 ;161/167,109 ;156/247,257
;40/2R ;229/51TS,69,66 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Dixson, Jr.; William T.
Attorney, Agent or Firm: Wood, Herron & Evans
Claims
We claim:
1. A rolled, preprinted, precut label supply including an elongated
web supporting labels therein, for use in apparatus adapted to
apply labels to products, said apparatus including means for
establishing a tacky surface to one side of said labels, a
reciprocating resilient plunger means for engaging labels, for
passing through said web and detacning labels therefrom, for
carrying labels toward and applying labels to products, and
thereafter withdrawing through a web remnant, said resilient
plunger means having a forward label engaging face with a
predetermined shape, and sprocket means for transporting said web
through said label applying apparatus, said preprinted, precut
label supply comprising:
an elongated web in the form of a roll including a plurality of
labels and a web remnant to which said labels are attached, said
labels being located throughout said remnant from one end to the
other of said web,
said labels being partially cut from said web remnant by a
plurality of cuts extending completely through said web to define
label profiles therein, the ends of said cuts comprising curves
each having spaced apart from a corresponding curve of another cut
to leave bridging means between said labels and said web remnant
thereby to releasably hold said labels in said remnant,
each of said bridging means having a predetermined width varying
from a greater width at an end of said bridging means near said web
remnant to a lesser width at an opposite end of said briding means
near said label so as to permit the detachment of said labels by
said resilient plunger, transversely to said web remnant, without
indiscriminate tearing of the label and such that the major portion
of said bridging means remains with said web remnant,
said labels having two sides, at least one of which is adapted to
bear printed indicia, and
sprocket holes in said web remnant and extending therealong, said
sprocket holes disposed in said remnant to permit accurate
registration of said remnant and said labels with respect to said
resilient plunger.
2. A label supply as in claim 1 wherein depressions are formed in
edges of said labels when labels are removed from said web remnant,
and wherein said bridging means is parted when said label is
removed from said web, any portion of said bridging means remaining
with said label at least partially filling said depression in said
label edges.
3. A label supply as in claim 1 wherein said labels have a shape
corresponding to the predetermined shape of the plunger means.
4. A label supply as in claim 1 wherein said curves have an
internal radius in the approximate range of about 0.006 inches to
about 0.015 inches.
5. A label supply as in claim 4 wherein said radius is about 0.012
inches.
6. A label supply as in claim 4 wherein said greater width of said
briding means is in the approximate range of about 0.027 inches to
about 0.055 inches.
7. A label supply as in claim 4 wherein said greater width is about
0.040 inches.
8. A label supply as in claim 4 wherein said lesser width of said
bridging means is in the approximate range of about 0.015 inches to
about 0.045 inches.
9. A label supply as in claim 8 wherein said lesser width is about
0.020 inches.
10. A label supply as in claim 4 wherein said greater width of said
bridging means is in the approximate range of about 0.027 inches to
about 0.055 inches, and the lesser width of said bridging means is
in the approximate range of about 0.015 inches to about 0.045
inches.
11. A label supply as in claim 10 wherein said internal radius is
about 0.012 inches, said greater width is about 0.040 inches and
said lesser width is about 0.020 inches.
12. A label supply as in claim 11 wherein said elongated web
comprises 60-pound paper coated on one side and having a moisture
content by weight in the approximate range of about 4% to about
6%.
13. A label supply as claim 11 wherein said elongated web comprises
foil with a ground wood backing.
14. A label supply as in claim 11 wherein said elongated web
comprises foil with a bond backing.
15. A label supply as in claim 11 wherein said elongated web
comprises a plastic material.
16. A label supply for use in label applying apparatus having a
resilient plunger with a forward face of predetermined shape for
engaging a label carried in a web, for detaching the label from the
web, and for applying the label to a product, said label supply
comprising:
an elongated web in the form of a roll including a plurality of
labels and a web remnant to which said labels are attached, said
labels being located throughout said remnant from one end to the
other of said web,
said labels being partially cut from said web remnant by a
plurality of cuts extending completely through said web, the ends
of said cuts comprising curves, each curve being spaced apart from
a corresponding curve of another cut to leave bridging means
between said labels and said web remnant thereby to releasably hold
said labels in said remnant,
said bridging means having predetermined widths varying from a
greater width at an end of said bridging means near said remnant to
a lesser width at an opposite end of said bridging means near said
label so as to permit the detachment of said labels by said
resilient plunger, transversely to said web remnant, such that the
major portion of said bridging means remains with said web remnant,
and
said labels having two sides, at least one of which is adapted to
bear printed indicia.
17. A label supply as in claim 16 wherein depressions are formed in
edges of said labels when labels are removed from said web remnant,
and wherein said bridging means is parted when said label is
removed from said web, any portion of said bridging means remaining
with said label at least partially filling said depressions in said
label edges.
Description
This invention relates to label supply webs and to apparatus for
partially cutting labels from a web. More specifically, this
invention relates to improved label web structure wherein labels
removed from the web are substantially free of projections of web
material and present visually clean cut labels edges, and to
apparatus for partially cutting said labels from supporting
webs.
In U.S. Pat. No. 3,661,625, now owned by applicant, there is
disclosed a labeling apparatus operable to detach labels from an
elongated label web and to thereafter apply them to an item such as
a product container. Briefly, the apparatus disclosed in that
patent utilizes a lable supply comprising an elongated web remnant
supporting a plurality of removable labels therein. Each label is
held within a web opening by virtue of small nicks or bridges of
material extending between the web and the label. The elongated web
is advanced through the apparatus to an adhesive station where
adhesive is applied to the rear side of the labels. Thereafter the
labels are moved to an applying station where the web remnant is
held and a resilient plunger is actuated through the web to detach
the label, to carry it to a container, and to apply it thereto by
pressing the label against a container surface.
In the past, it has been the practice to partially precut labels
from the web remnant so as to leave supporting bridges of web
material between the label and the web remnant. While the number of
these bridges was minimized, consistent with the strenth required
to hold the label in the web until detachment, it was still noted
that when the labels were removed, bits of the web remnant, in the
form of portions of the bridges, stayed with the label. The label
edge, then, did not provide a clean cut appearance but rather
appeared to have a number of ragged projections or appendages
spaced all around the label. The ragged appearance was even more
pronounced when the color of the labels contrasted with that of the
surface to which the labels were applied.
While the ragged appearance could be minimized by the expedient of
reducing the number of bridges or by coloring the label edges
similarly to the labeled surfaces, the projections on the labels
still presented a disadvantage to the technique of labeling
disclosed in said patent. Manifestly, the bridges could not be cut
at the detaching station since a resilient plunger was used to
detach the labels from the web, but rather the bridges were torn
apart indiscriminately, frequently leaving bridge portions with the
label in a random manner. Thus, as contrasted with other types of
labeling, using label supplies such as magazine fed label stacks
wherein the labels are entirely die cut, the labels provided from
the partially cut web were at a disadvantage from an aesthetic
viewpoint.
The consideration of undesired projections on labels is an
important one in the marketplace where the product container must
be as immaculate as possible. For example, where the labels are
used on flexible containers of light duty liquid detergent products
it is desired, from a commercial standpoint, to provide a clean cut
label with no ragged appearance. Such containers are usually placed
on a supermarket shelf in the same areas as containers of competing
products. A ragged label thus might tend to detract from the
container, as contrasted with other containers where completely die
cut labels are used, for instance, and a sale may be lost to the
competition
It has been one objective of the invention to provide an improved
label supply wherein lables, removably held in a web remnant by
bridges of web material, can be detached from the remnant without
carrying portions or projections of bridge material therewith.
A further objective of the invention has been to provide an
improved label supply including a web remnant removably supporting
labels therein via bridges of web material connected to the labels,
and the labels when detached from the web by a resilient plunger
providing a surrounding label edge which appears to be clean cut
and attractive with no visible projections or appendages.
A still further objective of the invention has been to provide an
improved cutting die for partially cutting labels from a supporting
web.
To these ends, the invention provides an improved label supply
including an elongated web remnant supporting removable labels
therein via bridges of web material between the label and the
remnant, the bridges being preferentially formed so that when the
labels are detached from the web, the bridge material tends to
remain with the web remnant and small visually insignificant
depressions are formed in the label. It is desired that any portion
of the bridge remaining with the label will tend to fill the
depressions but will not extend beyond the label edge.
When the labels are partially precut from the web, the bridges are
formed between respective ends of the cuts around each label so
that the width of the bridge varies from a wider width near the
remnant, to a narrower width near the label. More specifically,
each label in the web is substantially defined by a plurality of
cuts therearound, each cut having ends curved toward the label on a
minimal radius. Each curved end of a cut terminates just short of a
respective curved end on an adjacent cut to define the desired
bridge. When the label is punched transversely from the web by a
resilient plunger, the bridge tends to remain with the web remnant,
separating from the label at its point of connection thereto,
within the label edge and within the depression which is partially
formed in the label, prior to detachment, by the curved cut
ends.
In a preferred embodiment, it was discovered that although the
bridge stayed with the web when the label was detached from the web
remnant, at least some fibers of the bridge material remained wit
the label. These fibers extended from the bottom of the visually
insignificant depression left in the label outwardly toward the
edge of the label and thereby enhanced the total label appearance
by at least partially filling the depression.
In prior patents such as Sherman U.S. Pat. No. 2,264,339, labels
are cut in the labeling machine by a cutting die which leaves
points of attachment between the labels and a strip. The patent is
devoid of any detail regarding the pertinent structure of the strip
or label. Apparently, the points of attachment must be strong
enough to carry the envelopes to which the labels are attached,
between stations in the apparatus and there is disclosed no
particular concern about the sightliness of the labels left on the
envelope.
In this connection, it should be appreciated that a further
objective of the invention has been to provide a label web supply
wherein partially precut labels are held within the web by bridges
of material having a predetermined configuration of specified
dimensions, and the labels are intentionally provided with
depressions receiving the bridges, the depressions also being
formed of a predetermined configuration of specified dimensions so
that they automatically become visually insignificant upon removal
of a label from a web. A connected objective of the invention has
been to particularly define the specific label supply web structure
and the specific characteristics of the bridges holding the labels
in the web so that the removed label has an apparently clean cut
label edge.
The invention also provides improved cutting die structure having
cutting edges terminating in curves of a minimal radius for forming
the preferred cuts in a label web as pointed out above. As will be
seen in the following detailed specification, normal mechanical
machining techniques of the die forming trade are not suitable for
forming the desired curved cutting edges since such techniques are
generally limited to a cutting radius of not less than about 0.032
inches (without extensive die modification and expense which might
reduce the radius to about 0.020inches.) A substantially smaller
radius is desired in the formation of the label and connecting
bridges. The improved die provided by the invention thus
incorporates a cutting edge having curved portions, each with a
radius substantially less than 0.032inches.
One method, contemplated by the invention, of forming an improved
die includes modifying a cutting die, having an essentially
unbroken cutting edge defining a desired label profile, by
displacing the metal on one side of the cutting edge from the other
side. The displaced metal forms a curved, minimal radius cutting
edge and, after the die has been so treated, it provides a
plurality of cutting edges terminating in curved ends, each of
which ends lies adjacent, but spaced from, a corresponding curved
end of another cutting edge. The nicked cutting edge thus can be
used to partially precut labels from a label web, leaving the
preferential bridges, as described above, between the label and the
web remnant.
These and other objects and advantages of the invention will become
readily apparent from the following detailed description and
drawings in which:
FIG. 1 is a diagrammatic view of a web supply cutting operation
wherein labels are partially precut from a supporting web;
FIG. 2 is a view of an improved label web taken along lines 2--2 of
FIG. 1 and showing label supporting bridges in magnified form;
FIG. 2a is a magnified view of one of the bridges shown in FIG.
2;
FIG. 3 is a view of an improved cutting die taken along lines 3--3
of FIG. 1;
FIG. 4 is a magnified cross-sectional view of a cutting edge of the
improved die taken along lines 4--4 of FIG. 3;
FIG. 5 is a magnified cross-sectional view of an improved die taken
along lines 5--5 of FIG. 3 and illustrating one mode of die
preparation;
FIG. 6 is a magnified view taken along lines 6--6 of FIG. 5 and
shows magnified curved cutting edges of an improved die;
FIG. 7 is a magnified view of a portion of an improved label,
according to the inventio, which has been removed from a supporting
web;
FIG. 8 is an illustration of a portion of a prior art label having
an edge which includes a plurality of projections of bridge
material after the label is removed from the web; and
FIG. 9 is an isometric view of a portion of a die formed according
to a different technique than the die in FIGS. 3-6.
Referring now particularly to the drawings, FIG. 1 diagrammatically
depicts the preparation of a partially precut label supply, a
potion of which is shown in FIG. 2. In FIG. 1 an elongated, uncunt
web of label stock in the form of a roll 10 is unwound the directed
through a cutting station 11 comprising a rotary cutting die 12 and
a platen roller 13. At the cutting station, the elongated web is
partially precut to provide an elongated label supply 14. After
cutting, the elongated label supply 14 is rewound upon itself to
form a roll 15. Prior to the formation of the roll 15, and either
before or after the web is drawn through the cutting station 11,
one side of the web can be subjected to a printing operation so
that the areas which are to form the labels to be removed from the
web are provided with desired printing indicia. Of course, both
sides of the label can be printed where transparent containers are
to be utilized, for example.
Once the percut web has been wound into the roll form as shown in
15, it is thus in a form where it can be advantageously utilized in
a labeling apparatus such as that disclosed in U.S. Pat. No.
3,661,625, the subject matter of which is incorporated herein by
reference. In that apparatus, the precut label supply is drawn
through an adhesive station where a tacky surface is established on
the rear side of the partially precut labels, and the label web is
than drawn into a detaching or an application station. At this
station, a resilient plunger is driven through the web 14 to detach
a label therefrom, to carry the label toward a product, and to
thereafter press the label against a label receiving surface on the
product. The resilient plungers utilized for this operation may be
as disclosed in the aforesaid patent or may be such as disclosed in
copending application Ser. No. 186,138 filed on Oct. 4, 1971,
Herbert LaMers, inventor. The subject matter of that application is
also incorporated herein by reference.
Returning now to the drawings of the present application, FIG. 2
shows a partially precut, elongated label web 14 comprising
partially precut labels 20 removably supported in a web remnant 21.
The labels 20 generally extend from one end of the web 14 to the
other and, as shown in FIG. 2, each label is completely surrounded
by portions of the web remnant 21. The labels are shown in the
drawings as having a generally square outline but it should be
appreciated that the labels may have any of a great number of
widely varying shapes and sizes.
Of course, the labels could be contiguous within the remnant 21,
that is adjacent labels could be connected to each other. In that
event, however, the portion of the material connecting adjacent
labels to eacch other would remain with one of the labels when the
labels were removed from the web. In this alternate configuration,
the adjacent label edges many possibly be completely severed from
each other at the cutting station 11, each label being held within
the web only along its sides.
In the preferred embodiment, however, each label is surrounded by
portions of the web remnant 21 and is removably held within the
remnant by connecting members which will be referred to as "nicks"
or bridges 22.
Each of the partially precut labels in the web 14 have a shape
which is substantially defined by a plurality of cuts 25 between
the web remnant 21 and the label 20. Each cut 25 has curved ends
26, the ends curving inwardly toward the label shape defined by the
cuts. Each of the cuts 25 lies generally in an end-to-end
relationship with another cut 25, each cut thus being, for purposes
of description, adjacent another cut so that the curved end 26 of
one cut is spaced from the curved end 26 of another or adjacent
cut. In FIG. 2, the curved ends of the cuts 25 and their spacing is
amplified for clarity, it being understood that the actual bridges
are smaller and less distinguishable than they actually appear on
the formal drawing.
As shown particularly in the amplified version of FIG. 2a,
corresponding curved ends 26 and 26a of adjacent cuts 25 and 25a
form briding means 22 extending between the web remnant 21 and the
label 20. The bridges 22 have a tapered shape of varying widths,
the width of the bridge near the remnant being relatively greater
than the width of the bridge near the label. When the label 20 is
removed in a transverse direction from the remnant 21, by a
resilient plunger as in the labeling apparatus disclosed in the
patent cited above, the bridges 22 are torn apart at some point
between the connection of the bridge to the label and to the web
remnant.
More specifically, the bridges tend to part at a point which is
interior of the label edge, as defined by the cuts 25, so that the
major portion of the bridge remains with the remnant 21 and only a
very small portion remains with the label 20. The portion of the
bridge which remains with the label 20, if any, is useful, however,
in that the fibers F of the bridge material extend from the bottom
of the depression formed along the cuts 25 and curved cuts 26, upon
removal of the label, and thereby tend to fill the depression and
minimize the depression's visual effect in the label edge. This is
shown diagrammatically in FIG. 7. Even where the depression is not
completely filled by the fibers of the bridge material which are
left with the label, the end result is a label having very slight
depressions which are visually insignificant insofar as a normal
viewing distance of, for example, eighteen inches to two feet and
beyond, it concerned. The result is a substantial improvement over
labels which are cut according to prior methods and which, when
removed from the label web, appear, for example, as shown in FIG. 8
of the drawings, the bridges forming projections or appendages on
the edge of the label and presenting a somewhat ragged
appearance.
The number and the actual dimensions of the bridges holding the
labels in the label web are dependent upon the nature of the label
web material, i.e., its thickness, moisture content, material
characteristics, etc. With respect to common paper type labels, it
has been found that a 60-pound litho paper coated on one side, such
as that produced by the Newton Falls Company, is suitable for many
labeling applications. It is generally contemplated that 40-pound
paper up to 80-pound paper of the same general type may be
utilized, and for special applications other types or forms of
paper, or other material in kind or degree, may have useful
application and can be treated according to the invention in a
preferred manner. For example, foil with a bond backing or foil
with a ground wood backing could also be used as a label web
material from which the labels are partially precut according to
this invention. Different kinds of plastic material could also be
utilized, such as polyvinyl chloride, mylar, and polypropylene. In
addition, it should be noted that the invention could also be used
with labels having pre-applied adhesive such as thermo-activated
adhesive. All of the above label web material specifications are
set out herein by way of example only and are not to be taken as
limiting.
With regard to the supporting of the labels within the web remnant
21, the specific working parameters are: (1) enough support should
be provided in order that the labels will not fall from the web
remnant prior to the time they reach the application or removal
station in the label apparatus; and (2) on the other end of the
spectrum, the number of the bridges around a given label should be
reduced as much as possible for appearance purposes. In this
regard, and considering the fact that the label web is drawn
longitudinally through a curved path within the label apparatus, it
has been found that the strongest support is required on the ends
of the label, (the ends being considered to be those portions
generally transverse to the elongated web), and relatively less
support is required along the sides of the labels. Thus, the number
of bridges along the label sides could be reduced as compared with
a number along the ends of the label, or in the alternative, the
varying width of the bridges along the ends of the label could be
increased as compared with the width of the bridges along the label
sides. As has been previously stated, the number of bridges and
their specific dimensions for a given label supply are determined
by the character of the label web material and the label
configuration.
In order to more specifically describe a preferred embodiment of
the invention and in the case where 60-pound litho paper coated on
one side is utilized, FIG. 2a depicts the general dimensions of a
bridge 22 having a narrow width W-1, a greater width W-2 and
generally tapered edges (26 and 26a), partially defining the
bridges. The tapered edges of the bridge may not be entirely curved
as shown but may include small straight portions as well. In any
event, and for all practical purposes, the actual bridge profile
closely approximates the corresponding depression in the label and
is generally tapered as described. In this regard, it is important
to note that the edge of the die used to make the cuts 26 and 26a
has a given thickness of, for example, about 0.002 inches. One side
of this edge, next to the label, is curved but the other side next
to the bridge 22 may have straight portions as well. (This is
hereinafter explained in more detail). Thus, the label edge has a
depression formed by curved edges while the bridge has tapered
edges which may be somewhat straighter. In any event, the curves 26
and 26a on the label edge each have a radius R for descriptive
purposes. With the 60-pound paper specified above, the dimension
W-1 can be in the approximate range of about 0.015 inches to about
0.045 inches and the dimension W-2 can be in the approximate range
of about 0.027 inches to about 0.055 inches. The radius R of the
curved label edge can be in the approximate range of about 0.006
inches to about 0.015 inches. In one specific embodiments, the
lesser width W-1 is about 0.020 inches, the greater width W-2 is
about 0.040 inches and the radius R is about 0.012 inches. The
preferred moisture content by weight of the paper is in the
approximate range of about 4 to 6%.
It will be understood that the dimensions discussed above are
approximations only and may vary by at least several thousandths
due to manufacturing tolerances and the like. Furthermore, it is to
be understood that cuts 25 and the curved ends 26 of the cuts are
themselves approximately 0.002 inches in width but may also vary by
several thousandths. For further explanation, the width W-1 refers
to the width of the bridge material between the cuts 26 near the
label, and the width W-2 refers to the width of the bridge at the
point where the tapering of the tapered bridge edges begins near
the web remnant. For descriptive purposes, reference to any radius
by the phrase, "internal radius", means the radius of the internal
edge of the cuts in the label 26 or of the die cutting projection
as the case may be.
Further, it should be noted that while the curved ends 26 are
generally cut on a radius, the imaginary center reference point
from which the radius is drawn can be located at various locations
so that the exact relationship of the layouts of the curved ends 26
can be varied to form somewhat differently shaped bridges than that
as shown in FIG. 2a. Thus, the curved ends 26 can be set more
deeply or less deeply into the label material during the cutting
operation. While the various dimensions W-1, W-2 and R can be
varied depending upon the character of the material of the
elongated web and upon the size of the label, it is preferable to
select those specific dimensions which provide the least amoung of
.-+.depression" in the label edge when the labels are removed from
the web remnant.
The depression in the label edge thus formed when the labels are
removed is diagrammatically shown in FIG. 7. Again, FIG. 7 is a
magnified version and is not to scale. The depression in the label
and the other elements of the figure are amplified or reduced for
clarity. In this figure, the label 20 has been removed from a web
remnant 21, the figure showing an amplified illustration of a
bridge 22 which has parted. As shown in FIG. 7, the major portion
of the bridge 22 has remained with the web remnant 21 and only a
very small portion of the bridge 22 remains with the label 20. As
seen in this figure, that small portion of the bridge material
(fibers F) which remains with the label 20 extends upwardly and
outwardly toward the edge of the label from the bottom of the
depression which is partially formed by the curved lines 26. In
this manner, the fibers F tend to fill the depression and to make
it less visible. As can be appreciated, the result of leaving the
major part of the bridge with the web remnant and utilizing any
portion of the bridge left with the label to partially fill up the
depression created therein is significantly improved over the prior
labels such as those illustrated in FIG. 8 wherein ragged
projections P of bridge material extend outwardly of the label edge
E and provide a ragged appearance to the label.
In addition to the partial cutting of the label from the elongated
web at the station 11, U-shaped sprocket holes partially defined by
predetermined shape cuts 30 are formed in marginal edges of the web
remnant 21. In FIG. 2, the sprocket holes are removably filled by
tabs 31 and, when the web is engaged by a web driving sprocket
means in the labeling apparatus, the tabs 31 are pushed outwardly
of the plane of the web so that the teeth of the sprocket means can
engage the web to drive it. Other suitable forms of sprocket holes
can be used.
The construction of the cutting apparatus utilized to partially
precut the labels in the elongated web is shown particularly in
FIGS. 3 and 6 of the drawing. While it should be understood that a
flat cutting die could be used, the rotary die to be described has
been found to be suitable. In FIG. 3 a rotary cutting die 12 is
illustrated and includes a body having a cylindrically-shaped die
surface 35. A plurality of cutting edges or projections 36 extend
radially outwardly from the surface 35 and are generally
perpendicular thereto. Each cutting edge or projection 36 provides
a cutting land 37 having, as shown in FIG. 4, a width L. In a
preferred embodiment, this width is approximately 0.002 inches, but
this can vary by several thousandths of an inch. Depending on the
size of the label to be cut from the elongated web and the size of
the rotary cutting die 12, a plurality of cutting edges 36 are
provided on the surface 35 to substantially define one or more
desired label shapes.
Each of said plurality of cutting edges has two opposite ends, such
as at 38 and 39. Each of the ends 38 and 39 are curved inwardly
toward the label shape substantially defined by the projections
36.
As discussed above, it is desired to render a cut in a label web so
that the cut defining the label edge has curved ends with an
internal radius in the approximate range of about 0.006 inches to
about 0.015 inches. As shown in FIG. 6 then, it is desired that the
radius R-1 of the curved ends 38 and 39, as shown in FIG. 6, must
be within the same approximate range.
To this end, the rotary cutting die 12 is formed by first providing
an unbroken cutting edge or cutting projection completely defining
the desired label shape and extending outwardly from the surface
35. The unbroken cutting edge is then preferentially .-+.nicked" to
form depressions in the cutting edge and thereby the plurality of
cutting edges as shown in FIG. 3.
The preferential treatment of the unbroken cutting edge is
specifically shown in FIG. 5 wherein a tool T (shown in phantom
lines) having a symmetrical, chisel-like edge 50, is forced at an
angle A against the cutting projection 36. The striking of the
cutting projection or edge 36 by the tool T results in a forcible
displacement of the edge in a transverse direction inwardly toward
the label shape so that the displaced portion or material of the
cutting edge 36 is thereby radiused to form the curved ends 38 and
39. The angle A, formed between the longitudinal axis of the tool,
which is perpendicular with respect to the cutting edge 50, and the
generally perpendicular direction of the cutting projection 36,
(with respect to surface 35), can be varied throughout an
approximate range of about 25.degree. to about 60.degree.; however,
it is preferred that this angle be in the approximate range of
about 30.degree. to about 45.degree.. It is to be understood that
even the broader range is approximate and may be extended depending
on the tool used, the die material, and the result desired.
Of course, the force with which the tool T is struck against the
cutting projection 36 controls the depth of material displacement,
which depth is defined by the bottom line 45 (FIGS. 4-6). In
addition, it will be appreciated that the widths W-3 and W-4 of the
nicked out portion also correspond to the striking force of the
tool T and to the angle A. In this respect, the angle and the
striking force can be adjusted so that the widths W-3 and W-4 of
the nicked out portion of the cutting projection correspond to the
respective widths W-1 and W-2 of the desired bridge 22. Thus, the
striking force and angle A is selected so that the width W-3 is
preferably in the approximate range of about 0.015 inches to about
0.045 inches and the width W-4 is in the approximate range of about
0.027 inches to about 0.055 inches. By this method, the unbroken
cutting edge is separated into a plurality of cutting edges, each
of which has opposite ends terminating, for example, along the
lines 46 and 39 and along the lines 47 and 38 as shown in FIG.
6.
When the tool T has generally parallel sides extending from edge
50, the lines 46 and 47 may have relatively straight portions but
they also include radiused portions as at 48 and 49, respectively
and which are formed by the displacement of metal or die material
by the tool. Thus, the actual sides of the bridges 22 (formed by
the die) are partially straight and partially curved, the curved
portions having a radius corresponding generally to the dimensions
specified for R and R-1. It is quite apparent, however, that
regardless of the actual profile of the edges of the bridge, the
edges are tapered so that the bridge has a greater width near the
web remnant and a lesser width near the label. It must be
remembered that since the cutting land 37 is approximately 0.002
inches in width, the shape of the bridge 22 formed by the die
closely approximates the general curved shape of the depression
which is cut into the label by the curved edges 38 and 39. It
should be appreciated that the actual "nicking" can either be done
by hand, with a tool as shown, or mechanically with a similar tool.
Further it should be appreciated that the various figures are not
drawn to scale but are for illustrative purposes only.
In addition to the above disclosure with regard to the cutting die
and the method of making the cutting die, it is to be appreciated
that other methods capable of providing the relatively small radius
curves on the cutting edge of the die are available. For example,
it is possible to form the cutting die by an electronic discharge
machining technique, known in the machining trade.
One such die having a cutting edge formed by the electronic
discharge machining technique is shown in FIG. 9 of the drawings.
In essence, this technique involves the initial shaping of the die
and its cutting edges by an electronic discharge operating to flake
away the workpiece or the material near the desired die cutting
edge. The desired die profile obtained by this method is shown
diagrammatically in FIG. 9; of course, the cutting edge shown in
FIG. 9 is not shown to scale.
FIG. 9 discloses a portion of a rotary cutting die useful, for
example, in the cutting operation depicted in FIG. 1, in place of
the cutting die 12. Specifically, the figure depicts only a portion
of the die at an area near the ends of two cutting edges, the scope
then of this view being somewhat similar to that of FIG. 6. The
cylindrical die in FIG. 9 includes a cylindrical die surface 60 and
a plurality of cutting edges or cutting projections 61. Each of the
projections extends generally perpendicularly and radially away
from the die surface 60 and tapers from a relatively wide base to a
relatively narrow cutting land 62. The cutting land 62 is, as in
the die described in FIGS. 3-6, approximately 0.002 inches in
width. Each of the plurality of projections 61 terminates at curved
ends such as is shown at 63 and 64.
In the electronic discharge process of die making, the cutting edge
or projection 61 is not displaced but rather the edge is completely
formed by the electronic process. As shown in FIG. 9, each of the
curved ends 63 and 64 of the projections 61 are spaced apart from
each other a given width, such as indicated at W-5, so that when
the cutting die is utilized on a web of paper, the spaced apart
curved ends leave a bridge of material between the web remnant and
the label, each of the curved ends cutting into the label and
forming a depression therein. The straight portions of the cutting
projection 61 are spaced apart at an even greater distance, such as
shown at W-6. Thus, it can be seen that when the cutting die is
utilized with a strip of paper, the bridge left between the label
and the web remnant tapers from a relatively wider dimension (W-6)
from a point near the web remnant to a narrower dimension (W-5) at
a point near the label. Actually, the cuts made in the label web by
this die ary very similar to the cuts shown in FIG. 2a.
With respect to the curved ends 63 and 64, it can be seen in FIG. 9
that each of the curves involves a complete curvature of both sides
of the cutting land 62. Each of the curved ends is formed on a
curvature having an internal radius such as diagrammatically
indicated at R-2. The imaginary point from which this radius is
drawn may be varied, however, so that the dimension indicated by
the Arrow B (between the imaginary straight line extension of the
projections 61 and the respective ends 65 and 66 of the curves 63
and 64) may be different from the value of R-2. The manufacture of
a die such as shown in FIG. 9 of the electronic machining process
is an advantageous one in that more control can be maintained over
the actual formation of the curved ends of the cutting edges, as
compared with the mechanical nicking process as shown in FIGS.
3-6.
While it is to be understood that the actual dimensions W-5, W-6
and R-2 of the die can suitably be in about the same approximate
ranges as earlier set out herein with respect to the die structure
shown in FIG. 6, a preferred embodiment of the structure of FIG. 9
would include an R-2 dimension in the approximate range of about
0.006 inches to about 0.015 inches, a W-5 dimension in the
approximate range of about 0.015 inches to about 0.045 inches, a
W-6 dimension of about 0.027 inches to about 0.055 inches and a B
dimension of about 0.008 inches to about 0.010 inches. Even more
specifically, one embodiment of a die such as shown in FIG. 9 could
include an R-2 dimension of about 0.012 inches, a W-5 dimension of
about 0.018 inches, a W-6 dimension of about 0.037 inches and a B
dimension of about 0.008 inches.
It should thus be appreciated that the applicants have provided a
highly unique and improved label supply web and improved die
structure for preferentially cutting the web in a unique novel
manner so that the label, when removed from the web and placed on
an object, presents an apparently clean cut label edge.
These and other modifications and alterations will become readily
apparent to those of ordinary skill in the art without departing
from the scope of the invention. For example, the various
dimensions of the essential elements of the die structure, of the
bridges between the web remnant and the label, or of the label
itself may be varied somewhat for any particular application. It is
to be understood that the ranges of the various dimensions set out
herein are by way of example only and not by limitation and
applicants thus intend to be bound only by the appended claims.
* * * * *