Apparatus for printing and applying tape and methods of printing and applying tape

TECHNICAL FIELD

[0001] The present invention generally relates to an apparatus for printing and applying tape. The present invention relates more particularly to an apparatus that includes a printer for printing on tape, a tape puller that pulls the printed tape out from the printer, and an applicator that applies the printed tape to an object. The present invention also generally relates to methods of printing and applying tape to objects.

BACKGROUND OF THE INVENTION

[0002] Containers, packages, and boxes for storing and shipping products typically use box sealing tape, such as an adhesive tape, to secure the flaps or covers so that the container, package, or box will not accidentally open during normal shipment, handling, and storage. Box sealing tape maintains the integrity of a container, package, or box throughout its entire distribution cycle. Box sealing tape can be used on other parts of container, package, or box and on other substrates, and can be used to function in a manner similar to labels. These tapes can be made in roll or pad form, and can have information printed or otherwise applied to, or contained within or on, the tape.

[0003] These containers, packages, or boxes generally display information about their contents. This information most commonly located on the container, package, or box might include lot numbers, date codes, product identification information, and bar codes. The information can be placed onto the container, package, or box using a number of methods. These include preprinting the container, package, or box when it is manufactured, printing this information onto the container, package, or box at the point of use with an inkjet code that sprays a pattern of ink dots to form the image, or by using a flexographic ink rolling coding system. Other approaches include the use of labels, typically white paper with preprinted information either applied manually, or with an online automatic label applicator.

[0004] A recent trend in conveying information related to the product is the requirement to have the information specific for each container, package, or box. For example, each container, package, or box can carry specific information about its contents and the final destination of the product, including lot numbers, serial numbers, and customer order numbers. The information is typically provided on labels that are customized and printed on demand at the point of application onto the container, package, or box. This is typically known as the ability to print “variable” information onto a label before it is applied onto the container, package, or box. Two patents that disclose printed labels are U.S. Pat. Nos. 5,292,713 and 5,661,099. U.S. Pat. No. 2,492,908 discloses a label applying mechanism.

[0005] One system for printing variable information involves thermal transfer ink printing onto labels using an ink ribbon and a special heat transfer print head. A computer controls the print head by providing input to the head, which heats discrete locations on the ink ribbon. The ink ribbon directly contacts the label so that when a discrete area is heated, the ink melts and is transferred to the label. Another approach using this system is to use labels that change color when heat is applied (direct thermal labels). In another system, variable information is directly printed onto a box or label by an inkjet printer including a print head. A computer can control the ink pattern sprayed onto the box or label.

[0006] Both thermal transfer and inkjet systems produce sharp images. Inkjet systems include piezo, thermal, continuous, and drop-on-demand. With both inkjet and thermal transfer systems, the print quality depends on the surface on which the ink is applied. It appears that the best system for printing variable information is one in which the ink and the print substrate can be properly matched to produce a repeatable quality image, especially bar codes, that must be read by an electronic scanner with a high degree of reliability.

[0007] Regardless of the specific printing technique, the printing apparatus includes a handling system for guiding a continuous web of label tape to the print head, as well as away from the print head following printing for subsequent placement on the article of interest (for example, a box). To this end, the web of label tape is normally provided in a rolled form (“tape supply roll”), such that the printing device includes a support that rotatably maintains the tape supply roll. Further, a series of guide components, such as rollers, transfer plates, festoons, etc., are utilized to establish a desired tape path both upstream and downstream of the print head, with the terms “upstream” and “downstream” in reference to a tape transport path initiating at the tape supply roll and terminating at the point label application to the article of interest (e.g., a box). An exact configuration of the guide components is directly related to the form of the label tape.

[0008] In particular, label tape is provided as either a linered tape or as a linerless tape. As suggested by its name, linered tape includes both a tape defined by a print side and an adhesive side, and a release liner encompassing the adhesive side. The liner serves as the carrier for the label tape. With this configuration, the printing device normally includes components that, in addition to delivering the web to and from the print head, also peel the liner away from the label tape. While widely accepted, linered tape material is relatively expensive due to the cost associated with inclusion of the release liner. Further, the liner adds to the overall thickness, thereby decreasing the available length of label tape for a given tape supply roll diameter. A decreased label tape length requires more frequent changeovers of the tape supply roll (where the exhausted tape supply roll is replaced by a new roll), and therefore a loss in productivity. Additionally, because the liner material is typically paper, resultant fibers, debris, and dust can contaminate the printing mechanism, potentially resulting in a reduced print head life. Also, a die cut operation is typically performed on the label stock to generate labels of discrete size. The die cut operation is an additional manufacturing step (and therefore expense), and prevents implementation of a variable label length processing approach.

[0009] To overcome the above-described problems associated with linered label tape, a linerless format has been developed. Generally speaking, linerless label tapes are similar to the linered configuration, except that the liner is no longer included. Thus, the linerless label tape is defined by a non-adhesive side or backing formulated to receive printing (“print side”) and an opposing side (or “non-print side”) that often times carries an adhesive (“adhesive side”). By eliminating the liner, linerless label tapes have a greatly increased length for a given roll diameter, and eliminate many of the other above-listed processing concerns associated with linered label tape. However, certain other handling issues are presented.

[0010] In particular, as the web of linerless tape is pulled or extended from the supply roll, the adhesive side is exposed, and will readily adhere to surfaces, and in particular the guide components associated with the printing device. A common difficulty encountered in the handling of linerless label tape is “wrap-around”, whereby the web adheres to and wraps around a roller otherwise in contact with the adhesive side. For example, with thermal transfer printing, a platen roller or drive roller is normally associated with the print head for supporting the label tape during printing by the print head and for driving the tape out the printer exit. In this regard, the adhesive side of the linerless tape is in contact with, and carried by, the drive roller. Invariably, instead of simply releasing from the drive roller, the adhesive side adheres to and wraps around the drive roller. This highly undesirable situation leads to printer malfunctions, such as misprinting, tape jams, etc. Wrap-around of the platen roller or drive roller is most commonly found in printing devices conforming with “next label out” protocol where, after the label is printed, it is immediately cut and applied to the article in question. In other words, there is no accumulation of printed labels between the print head and the application device, in contrast to typical “loose loop” systems where printed labels accumulate prior to cutting and thus includes guide components, such as festoons, to tension the linerless label tape off of the drive roller.

[0011] Many efforts have been made to address the “wrap-around” concern associated with linerless label tape in next label segment out printing systems, including those described in U.S. Pat. Nos. 5,674,345; 5,524,996; 5,487,337; 5,497,701; and 5,560,293. In summary, each of these references incorporates a device, such as a stripper bar, a stripper plate, or an air source, that interacts with the linerless label tape after it has undesirably adhered to the platen or drive roller. That is to say, the common technique for addressing drive roller wrap-around is to position a device adjacent the platen roller that effectively “scrapes” the linerless label tape off of the platen or drive roller in the event of platen or drive roller wrap-around.

[0012] Other efforts have been made to address the “wrap-around” concern associated with linerless label tape in printing systems, such as those described in U.S. Pat. Nos. 5,437,228; 5,940,107; 5, 879,507; and EP 0637547 B1 and EP 0834404.

[0013] Various apparatuses and methods for printing on tape and applying a length of printed tape to articles are known in the art. For example, apparatuses for printing and applying tape are described in U.S. Pat. No. 6,049,347 (Ewert et al.), “Apparatus for Variable Image Printing on Tape,” U.S. Pat. No. 6,067,103 (Ewert et al.) “Apparatus and Process for Variable Image Printing on Tape,” PCT Publication WO 98/42578 (Lenkl) “Device and Method for Applying Linerless Labels,” and PCT Publication WO 00/34131 (Faust et al.) “Variably Printed Tape And System For Printing And Applying Tape Onto Surfaces.” 3M Company located in St. Paul, Minn. has sold print and apply case sealing applicators and print and apply corner sealing applicators under the brand name 3M-Matic as CA2000 Corner Label Applicator and PS2000 Print & Seal Applicator.

[0014] Print and apply label applicators are commercially available from Etipack, S.p.A. located in Cinesello Balsamo (MI), Italy under the brand names Drinjet, Drinfit, Drinedge and AP Euro. Tape dispensers are also commercially available from Etipack, S.p.A. located in Cinesello Balsamo (MI), Italy under the brand name Strappy. Although the commercial success of available print and apply tape or label applicators have been impressive, it is desirable to further improve the performance of applicators handling linerless label tapes which print on the tape and apply the tape to objects, such as packages or boxes, while minimizing or eliminating the concern of platen or drive roller wraparound.

SUMMARY OF THE INVENTION

[0015] One aspect of the present invention provides an apparatus for printing and applying tape. This apparatus comprises: a tape supply holder; a printer for printing on tape; a tape puller for pulling printed tape from the printer; and a tape applicator for applying the printed tape to an object. In one preferred embodiment of the above apparatus, the tape puller keeps the printed tape under tension as the printed tape exits the printer.

[0016] In another preferred embodiment of the above apparatus, the tape puller is moveable between a first position adjacent the printer and a second position distant from the printer. In one aspect of this embodiment, when the tape puller moves from the first position to the second position, the tape puller pulls the printed tape in the path of the tape applicator. In another aspect of this embodiment, after the printer has finished printing, the tape puller releases the printed tape. In another aspect of this embodiment, the tape applicator includes a vacuum system, where after the tape puller releases the printed tape, the vacuum system holds the printed tape. In another aspect of this embodiment, the apparatus further comprises a tape cutter, where after the vacuum system holds the printed tape, the tape cutter cuts the printed tape to form a length of printed tape. In yet another aspect of this embodiment, the tape applicator is moveable between a first position and a second position to apply the printed tape to the object, and after the tape cutter cuts the printed tape, the tape applicator moves to the second position to apply the printed tape to an object. In another aspect of this embodiment, the printer includes a driven roller, when as the printer is printing the tape, the driven roller drives the tape along a tape path in a first direction, and when after the cutter cuts the printed tape, the driven roller drives the tape along the tape path in a second direction opposite the first direction.

[0017] In another preferred embodiment of the above apparatus, the apparatus includes a first actuator for moving the tape puller between the first position and the second position. In another preferred embodiment of the above apparatus, the tape applicator is moveable between a first position and a second position to apply the printed tape to the object. In another aspect of this embodiment, the apparatus includes a second actuator for moving the tape applicator between the first position and the second position. In another preferred embodiment of the above apparatus, the applicator further comprises a tape cutter. In yet another aspect of this embodiment, the tape applicator includes a vacuum system for holding the printed tape prior to application on an object. In another aspect of this embodiment, the apparatus further comprises a drive roller for pulling tape from the tape supply holder.

[0018] Another aspect of the present invention provides an alternative apparatus for printing and applying tape. This apparatus comprises: a tape supply holder; a printer; a gripper; a first actuator for moving the gripper between a first position adjacent the printer and a second position distant from the printer; and a tape applicator. In another preferred embodiment of the above apparatus, the gripper and actuator keep printed tape under tension as the printed tape exits the printer.

[0019] In another preferred embodiment of the above apparatus, when the gripper moves from the first position to the second position, the gripper pulls printed tape in the path of the tape applicator. In another aspect of this embodiment, after the printer has finished printing, the gripper releases the printed tape. In another aspect of this embodiment, the apparatus further comprises a vacuum system, where after the gripper releases the printed tape, the vacuum system holds the printed tape. In another aspect of this embodiment, the apparatus further comprises a tape cutter, where after the vacuum system holds the printed tape, the tape cutter cuts the printed tape to form a length of printed tape. In another aspect of this embodiment, the tape applicator is moveable between a first position and a second position to apply the printed tape to the object, and where after the tape cutter cuts the printed tape, the tape applicator moves to the second position to apply the printed tape to an object. In another aspect of this embodiment, the printer includes a driven roller, where as the printer is printing the tape, the driven roller drives the tape along a tape path in a first direction, where after the cutter cuts the printed tape, the driven roller drives the tape along the tape path in a second direction opposite the first direction.

[0020] In another preferred embodiment of the above apparatus, the tape applicator is moveable between a first position adjacent the printer and a second position to apply the printed tape to the object. In another aspect of this embodiment, the apparatus includes a second actuator for moving the tape applicator between the first position and the second position. In another preferred embodiment of the above apparatus, the apparatus further comprises a tape cutter. In another aspect of this embodiment, the tape applicator includes a vacuum system for holding the printed tape prior to application on an object. In another preferred embodiment of the above apparatus, the apparatus further comprises a driven roller for pulling tape from the tape supply holder.

[0021] Another aspect of the present invention provides a method of printing and applying tape, comprising the steps of: providing tape; printing on the tape with a printer; pulling printed tape under tension from the printer; and applying printed tape to an object. In one preferred embodiment of the above method, the pulling step occurs simultaneously during the printing step. In another preferred embodiment of the above method, the method comprising the further step of: prior to the applying step, holding the printed tape. In another aspect of this embodiment, the method comprising the further step of: after the holding step, cutting the printed tape to provide a length of printed tape. In another aspect of this embodiment, the pulling step includes pulling the printed tape across the path of a tape applicator for applying the printed tape to an object. In another aspect of this embodiment, after the printing step and pulling step are complete, releasing the printed tape. In another aspect of this embodiment, during the printing step, the tape moves along a tape path in the printer in a first direction, where after cutting step, the tape moves along the tape path in a second direction opposite the first direction. In another preferred embodiment of the above method, the applying step includes pushing on a non-adhesive side of the printed tape to apply an adhesive side of the printed tape to an object. In another aspect of this embodiment, the pushing step includes pushing the printed tape from a first position to a second position to apply the printed tape to the object across the direction of the pull step. In another preferred embodiment of the above method, the method further comprises the step of: providing an object where the printing step includes printing information on the tape corresponding to the object. In another aspect of this embodiment, the object is a package with contents, where the printing step includes printing information on the tape corresponding to the contents.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein:

[0023]FIG. 1 is an isometric view of a preferred embodiment of the apparatus for printing and applying tape of the present invention in a first position to apply printed tape to the top of an object;

[0024]FIG. 2 is a front view of the apparatus for printing and applying tape of FIG. 1;

[0025]FIG. 3 is an isometric view of the taping head of the apparatus for printing and applying tape of FIG. 1;

[0026]FIG. 4 is a blown-up view of the underside of the vacuum system and tape puller of the taping head of FIG. 3;

[0027]FIG. 5 is a side view of the taping head of FIG. 3, illustrating the tape puller starting to pull the tape from the printer;

[0028]FIG. 6 is a side view of the taping head of FIG. 5, illustrating the tape puller pulling the printed tape from the printer as the printer prints the tape;

[0029]FIG. 7 is a side view of the taping head of FIG. 6, illustrating the tape puller releasing the printed tape, the tape applicator holding the printed tape, and the tape cutter cutting the tape;

[0030]FIG. 8 is a side view of the taping head of FIG. 7, illustrating the tape applicator holding the length of printed tape;

[0031]FIG. 9 is a side view of the tape head of FIG. 8, illustrating the tape applicator initially applying the length of printed tape to a box; and

[0032]FIG. 10 a side view of the tape head of FIG. 9, illustrating the tape applicator finishing applying the length of printed tape to the box.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The apparatus for printing and applying tape prints information onto tape to form a length of printed tape and then applies the length of printed tape to an object, preferably a package or a box. The apparatus may vary the information printed on each length of printed tape and may vary the overall length of each length of printed tape, such that different lengths of printed tape may be produced from one supply roll of tape. The apparatus applies the length of printed tape onto an object, preferably a package or box, either while the package or box is stationary or while the box is moving (such as while the box is being closed and sealed). The apparatus can apply the length of printed tape anywhere on the package or box to serve as a conveyor of information. For example, the apparatus can apply the length of printed tape on the top, bottom, or sides of a package or box to convey information about the contents of the box. Alternatively, the apparatus can apply the length of printed tape along a seam of the box to convey information about the contents of the box and to seal the box.

[0034] A preferred embodiment of an apparatus <b>10</b> for printing and applying tape of the present invention is illustrated in FIGS. 1 and 2. The tape applicator <b>10</b> includes a taping head <b>12</b> and a stand <b>14</b>. The stand <b>14</b> includes a first end <b>16</b> and a second end <b>18</b> opposite the first end <b>16</b>. The stand <b>14</b> includes preferably three legs <b>20</b> attached to the second end <b>18</b> of the stand <b>14</b> to support the stand <b>14</b> and the taping head <b>12</b>. Each of the legs <b>20</b> includes at least one foot <b>19</b> for supporting the leg.

[0035] As illustrated in the FIG. 2, the taping head <b>12</b> is attached to the first end <b>16</b> of the stand <b>14</b>. Preferably, the taping head <b>12</b> is slideably attached to a first rod <b>110</b> that is perpendicular to the stand <b>14</b>. The tape head <b>12</b> may be moved anywhere along the first rod <b>110</b> by turning the lead screw <b>118</b>. The first rod <b>110</b> is attached to the second rod <b>114</b> by slider assembly <b>112</b>. The slider assembly <b>112</b> includes a pivot to allow the first rod <b>110</b> and the taping head <b>12</b> to rotate relative to second rod <b>114</b> to allow the taping head to be moved into an alternative position to apply tape to sides of boxes. The second rod <b>114</b> is perpendicular to the first rod <b>110</b>. By turning the lead screw <b>116</b>, the slider assembly <b>112</b> moves up or down the second rod <b>114</b> to adjust the height of the taping head <b>12</b> relative to the floor. The taping head <b>12</b> may be mounted on the stand <b>14</b> in any orientation or position that allows it to apply printed tape to an object.

[0036]FIGS. 3 and 4 illustrate a preferred embodiment of the taping head <b>12</b> of the apparatus <b>10</b>. FIGS. 3 and 4 are convenient for describing the parts of the taping head <b>12</b> and do not illustrate any tape in the taping head <b>12</b>. FIGS. <b>5</b>-<b>9</b> illustrate the taping head <b>12</b> in operation including tape.

[0037] The taping head <b>12</b> includes a base <b>21</b>. The taping head <b>12</b> includes a tape supply holder <b>22</b> attached to the base <b>21</b>. When the term “attached” is use herein, it shall broadly-mean any way known in the art of attaching two items together either directly or indirectly to each other. The tape supply holder <b>22</b> preferably includes two opposing guides <b>24</b> for laterally supporting a roll of tape. Alternatively, the tape supply holder <b>22</b> could be configured to hold a stack of individual lengths of tape. The taping head <b>12</b> also includes a drive roller <b>26</b> and a support <b>28</b> attached to the base <b>21</b> for supporting the drive roller <b>26</b>. A motor (not shown) drives the drive roller <b>26</b>. The drive roller <b>26</b> assists in stripping or pulling tape from a tape roll that will be mounted in the tape supply holder <b>22</b>. Idler rollers <b>30</b>, <b>32</b> are attached to the base <b>21</b>.

[0038] An accumulator <b>34</b> is attached to the base <b>21</b>. In one preferred embodiment, the accumulator is a dancer arm <b>34</b> with an idler roller <b>36</b>. The dancer arm <b>34</b> is attached to the base <b>21</b> by a pivot <b>38</b> opposite the idler roller <b>36</b>. Alternatively, the accumulator <b>34</b> could be any mechanism known in the art that allows the tape to accumulate along a tape path in the taping head <b>12</b>. For example, the accumulator <b>34</b> could be a linear slide, a festoon or a loose loop of tape. The taping head <b>12</b> also includes a sensor <b>44</b> attached to the base <b>21</b> located adjacent the dancer arm <b>34</b>. An example of a suitable sensor <b>44</b> is commercially available as a proximity sensor from Turk Inc. located in Minneapolis, Minn. under part number Ni-4-S12-AN6X-H114.

[0039]FIG. 3 illustrates the dancer arm <b>34</b> in a first position. When the dancer arm <b>34</b> pivots counter clockwise from the first position to an alternative position or second position, the dancer arm <b>34</b> triggers the sensor <b>44</b>. The dancer arm <b>34</b> includes a spring (not shown) that biases the dancer arm <b>34</b> into the first position. When sensor <b>44</b> is triggered, a signal is sent to the motor on the drive roller <b>26</b> to start rotating the roller <b>26</b> to pull tape from the tape supply roll. (FIG. 5 illustrates the first position of the accumulator <b>34</b> in solid lines and the second position of the accumulator <b>34</b> in dotted lines.) The dancer arm <b>34</b>, the drive roller <b>26</b>, idler rollers <b>30</b>, <b>32</b>, and sensor <b>44</b> are configured to help feed tape from the tape supply holder <b>22</b> to the entrance of the printer <b>40</b>, while the printer prints on the tape. In another preferred embodiment, the taping head <b>12</b> could include a roller with a load cell sensor (instead of an accumulator <b>34</b>), which senses when the tape is tensioned around the roller as it is being pulled toward the printer. When the sensor in the roller senses that the tape is being pulled around the roller to the printer, a signal is sent to the motor on the drive roller <b>26</b> to start rotating the roller <b>26</b> to pull tape from the tape supply roll. In either of the preferred embodiments, the taping head includes some type of mechanism that starts to pull tape from the tape supply roll when the printer <b>40</b> starts to print. This delivers the tape to the printer <b>40</b> in a uniform, low tension manner. Alternatively, other tape supply mechanisms known in the art may be used.

[0040] The taping head <b>12</b> includes a printer <b>40</b> attached to the base <b>21</b>. The printer <b>40</b> preferably includes a drive roller <b>41</b> or platen roller <b>41</b> at the exit of the printer. Preferably, the drive roller <b>41</b> serves as a support surface or a platen for the tape as it is being printed by a print head opposite the drive roller <b>41</b>. The drive roller <b>41</b> also pushes the printed tape out the exit of the printer as it rotates. Examples of a suitable printers <b>40</b> include a thermal transfer printer commercially available under model number M8485Se from Sato America Inc. located in Sunnyvale, Calif. or a thermal transfer printer under model number PE-42 from Datamax Inc. located in Orlando, Fla. or a thermal transfer printer under model DPM from NOVEXX OEM Printers and Labellers located in Philadelphia, Pa. In the case where a printer does not have a tape drive roller <b>41</b> for pushing the printed tape out the exit of the printer, the tape puller (explained below) independently could pull the tape of the printer. In this case, even though that type of printer may not have a driven platen roller, it may include an idle platen roller at the exit of the printer.

[0041] The taping head <b>12</b> includes a cutter <b>46</b> attached to the base <b>21</b> located adjacent the exit of the printer <b>40</b>. The cutter <b>46</b> cuts the printed tape after the printer <b>40</b> prints on the tape and the tape exits the printer. In one embodiment, the cutter <b>46</b> preferably includes an upper blade <b>50</b> and a lower blade <b>48</b>. The upper blade <b>50</b> is slideably attached to the base <b>21</b> by an upper blade support <b>54</b> and the lower blade <b>48</b> is attached to the base <b>21</b> by lower blade support <b>52</b>. Preferably both blades <b>48</b>, <b>50</b> are coated with an anti-stick coating, such as fluoropolymer or machine oil, to help prevent the tape from sticking to the blades and to minimize the transfer of the adhesive from the tape to the blades when the blades cut the tape. The cutter <b>46</b> also includes an actuator <b>56</b>, which is preferably an air cylinder. The actuator <b>56</b> moves the upper blade support <b>54</b> and thus, the upper blade <b>50</b> in a vertical direction along guides <b>58</b> towards the lower blade <b>48</b>. The lower blade <b>48</b> and lower blade support <b>52</b> are stationary. Alternatively, the actuator could move both blades <b>48</b>, <b>50</b> to cut the tape. Alternatively, the actuator could move the lower blade <b>48</b> towards the upper blade <b>50</b>. The upper blade <b>50</b> and lower blade <b>48</b> are preferably offset from each other, so that when the actuator <b>56</b> actuates the upper blade support <b>54</b>, the upper blade slides next the lower blade <b>48</b>, similar to a pair of blades of scissors. Alternatively, the tape cutter could be any cutter known in the art, for example, a single blade, a hot wire cutter, or a laser.

[0042] The taping head <b>12</b> includes a tape applicator <b>60</b> attached to the base <b>21</b> adjacent the cutter <b>46</b>. The tape applicator temporarily holds the printed tape after it exits the printer <b>40</b> and then applies the printed tape to an object, preferably a package or a box. The tape applicator <b>60</b> is movable along an applicator path between a first position (illustrated in FIG. 3) and a second position (illustrated in FIG. 9) adjacent the object for applying the printed tape to the object. The tape applicator <b>60</b> moves between these two positions by use of an actuator <b>68</b> and guides <b>70</b>. Preferably, the actuator <b>68</b> is an air cylinder. Preferably, the tape applicator <b>60</b> includes a vacuum system. The vacuum system includes a vacuum source <b>64</b> attached to a vacuum box <b>62</b> to hold the printed tape. Preferably, the vacuum source <b>64</b> includes two different types of vacuum sources. The first vacuum source is a low vacuum, high-flow source. A suitable example of this type of vacuum source <b>64</b> is commercially available as a fan from Grainger Industrial Supply located in St. Paul, Minn. under the brand Dayton, model number 4C548. The second vacuum source is a high vacuum, low-flow source. A suitable example of this type of vacuum source is commercially available as a vacuum pump, under the brand PIAB, model number M-20 from PIAB USA located in Hingham, Mass. The vacuum system <b>60</b> preferably includes a wipe down plate <b>65</b>, which assists in initially adhering the length of printed tape to the object and assists in wiping down the printed tape as it is applied. The wipe down plate <b>65</b> preferably includes an actuator <b>61</b> for moving the wipe down plate <b>65</b> to apply the tape. The apparatus <b>10</b> could include an optional buffing assembly, which buffs the printed tape after it has been applied to the object.

[0043] The taping head <b>12</b> includes a tape puller <b>72</b> slideably attached the base <b>21</b> located beneath the tape applicator <b>60</b>. The tape puller pulls the printed tape as the tape exits the printer <b>40</b>. The tape puller <b>72</b> includes an actuator <b>80</b> (shown in FIGS. <b>5</b>-<b>9</b>), which moves the tape puller from a first position adjacent the exit of the printer <b>40</b> to a second position that is distant from the exit of the printer <b>40</b>. Preferably, the actuator <b>80</b> is an air cylinder.

[0044]FIG. 4 is convenient for describing the tape applicator <b>60</b> and the tape puller <b>72</b> in more detail. As mentioned above, the tape applicator <b>60</b> includes a low vacuum, high-flow source and high vacuum, low-flow source (shown collectively as the vacuum source <b>64</b>), a vacuum box <b>62</b> attached to the vacuum source <b>64</b>, and a wipe down plate <b>65</b> attached to the vacuum box <b>62</b>. The low vacuum, high-flow source provides a vacuum through the vacuum box <b>62</b> and through holes <b>66</b> arranged throughout the wipe down plate <b>65</b>. Preferably the wipe down plate <b>65</b> includes at least two holes <b>67</b> located closest to the cutter <b>46</b>. The high vacuum, low-flow source provides a vacuum through the vacuum box <b>62</b> and through holes <b>67</b>. It is preferred that the tape applicator <b>60</b> includes both types of vacuum sources for holding the tape to the tape applicator <b>60</b>. If only the high vacuum, low-flow source was included, then all the holes in the vacuum box would need to be covered by the tape. If all the holes were not covered, then the vacuum would be lost and the tape applicator would not be able to adequately hold the tape. If only the low vacuum, high-flow source was included, then the tape would not be held securely or sufficiently by the tape applicator. By using both vacuum sources, the low vacuum, high-flow source gently holds the tape to the applicator through holes <b>66</b> all over the vacuum box <b>62</b> and the high vacuum, low-flow source securely holds the tape to the applicator through holes <b>67</b>. It is preferable to hold the tape strongly to the tape applicator <b>60</b> closest to the tape cutter <b>46</b> because the tape might otherwise change position on the box <b>62</b> after the cutter <b>46</b> cuts the tape. In addition, the tape normally covers the two holes <b>67</b> and as a result, the vacuum is not lost.

[0045] As explained above, the tape puller <b>72</b> preferably includes a tape gripper <b>74</b> and an actuator <b>80</b> for moving the tape gripper <b>74</b> along rods <b>82</b>. The tape gripper <b>74</b> preferably includes an upper jaw <b>76</b>, which in the illustrated embodiment remains stationary, and a lower jaw <b>78</b>, which is moved vertically by an actuator <b>84</b>. Preferably, the actuator <b>84</b> is an air cylinder. The lower jaw <b>78</b> is moved toward the upper jaw by the actuator <b>84</b> to close the jaws on the tape and to grab the end of the tape as it leaves the printer <b>40</b> from drive roller <b>41</b>. Alternatively, the upper jaw <b>76</b> may move and the lower jaw may be stationary or both jaws <b>76</b>, <b>78</b> may move to close the jaws on the tape and to grab the end of the tape. Preferably, the lower jaw <b>78</b> includes an anti-stick coating along its surface, such as a coating of fluoropolymer or silicone to help prevent the adhesive from the tape from sticking to the lower jaw <b>78</b>. The tape puller <b>72</b> is preferably configured to grab just enough of the end of the tape to adequately pull the tape from the printer, but not to grab too much of the tape so that the bottom jaw <b>78</b> sticks to the adhesive on the tape. For example, the jaws <b>76</b>, <b>78</b> grab between 0.25 and 0.50 inches (0.635 cm to 1.27 cm) of the length of the tape, as it exits the printer <b>40</b>. To reduce the contact surface area between the lower jaw <b>78</b> and the adhesive on the tape, the lower jaw <b>78</b> could include teeth, grooves, or other surface modifications. However, any portion of the tape extending from the printer could be grasped by the tape puller, so long as the tape puller can adequately disengage from the tape.

[0046] With respect to the gripper, the “upper” and “lower” jaw does not imply any orientation relative to up or down. The grippers maybe oriented sideways, or with the lower jaw above the upper jaw, depending on the application.

[0047] The tape gripper <b>74</b> is attached to a slider <b>85</b>, which is slideably engaged with the rods <b>82</b>. The actuator <b>80</b> moves the slider <b>86</b> and thus, the tape gripper <b>74</b>, between a first position located adjacent the tape cutter <b>46</b> and printer <b>40</b> and a second position towards the opposite ends of the rods <b>82</b> away from the tape cutter <b>46</b> and printer <b>40</b>. As the tape puller <b>72</b> moves from the first position to the second position opposite the first position, it pulls the tape from the printer <b>40</b> under or in the path of the tape applicator <b>60</b>. Preferably, when the tape puller <b>72</b> is in the second position, it is clear from the line of the motion of the tape applicator, so when the tape applicator moves from a first position to a second position to apply the tape to the object, the tape applicator <b>60</b> can move without interference from the tape puller <b>72</b>.

[0048]FIG. 5 is convenient for describing the preferred tape path through the taping head <b>12</b>. A tape roll <b>92</b> is mounted on the tape supply holder <b>22</b> supported by the tape guides <b>24</b>. The tape <b>90</b> includes a backing <b>86</b> and an adhesive <b>88</b> on the backing <b>86</b>. An example of a suitable tape is commercially available as Scotch brand tape, No. 3340 from 3M Company, located in St. Paul, Minn. The tape <b>90</b> preferably moves along the following tape path within the taping head <b>12</b>: a) from the tape supply holder <b>22</b> to the drive roller <b>26</b>; b) then to the idler roller <b>30</b>; c) then to the idler roller <b>36</b> on dancer arm <b>34</b>; d) then to the idler roller <b>32</b>; e) then to the entrance of the printer <b>40</b>; f) then through the printer to the drive roller <b>41</b> at the exit of the printer <b>40</b>; g) then between the upper blade <b>50</b> and the lower blade <b>48</b> of the tape cutter <b>46</b>; and h) then to the upper jaw <b>76</b> and lower jaw <b>78</b> of the tape puller, which will pull the tape across the path of the tape applicator <b>60</b>. When loading a new roll of tape <b>92</b> onto the tape supply holder <b>22</b>, the tape is initially threaded through the taping head <b>12</b> according to the tape path outlined above.

[0049] The preferred sequence of operations of the apparatus <b>10</b> for printing and applying tape is illustrated in FIGS. <b>5</b>-<b>9</b> and is as follows.

[0050]FIG. 5 illustrates the taping head <b>12</b> before the printer <b>40</b> starts printing on the tape <b>90</b>. To obtain this position, the first actuator <b>80</b> previously moved the tape puller <b>72</b> along the rods <b>82</b> (to the right in the Figure) to a first position adjacent the exit of the printer <b>40</b> and between the blades <b>48</b>, <b>50</b> of the tape cutter <b>46</b>. Also, the fifth actuator <b>84</b> previously moved the lower jaw <b>78</b> of the tape puller <b>72</b> to grasp the first end <b>96</b> of the tape <b>90</b> between the upper jaw <b>76</b> and the lower jaw <b>78</b>. Once in this position, the first actuator <b>80</b> applies a force to move the tape puller away from the printer (to the left in the Figure). However, the force is not great enough to pull the tape <b>90</b> from the printer <b>40</b> when the printer <b>40</b> is not printing. The gripper moves as the printer feeds the tape out the exit of the printer. In this position, the tape <b>90</b> is being held under tension.

[0051]FIG. 6 illustrates the taping head <b>12</b> as the printer <b>40</b> is printing on the tape <b>90</b>. Preferably, before the printer <b>40</b> prints, the vacuum system of the tape applicator <b>60</b> is turned on. As the printer <b>40</b> prints, the platen drive roller <b>41</b> rotates to push the tape <b>90</b> out of the exit of the printer <b>40</b>. Because the tape <b>90</b> is being pulled under tension by the tape puller <b>72</b>, the tape puller moves away from the printer and across the applicator path as the printer continues to feed out more printed tape <b>90</b>. During this time, the tape is continuously under tension and is pulled directly out of the printer exit. Because it is pulled directly under tension from the printer exit, the tape does not tend to “wrap around” the drive roller <b>41</b>. This configuration avoids the platen roller or drive roller “wrap-around” concern detailed in the Background section of this application. Without the use of the tape puller <b>72</b>, the tape might wrap around the drive roller <b>41</b> as it rotates. The tape puller <b>72</b> will continue to move away from the printer, as indicated by the arrow, pulling the tape <b>90</b> through the path of the tape applicator <b>60</b> and keeping the tape under tension, until the printer <b>40</b> stops printing the tape. Once the printer stops printing, the tape puller <b>72</b> will continue to pull the tape <b>90</b>, keeping the tape under tension. At this time, the tape puller <b>72</b> is moving towards the second position, which is located near the end of the rods <b>82</b> opposite the printer <b>40</b>. As the tape puller <b>72</b> moves from the first position towards the second position, it will pull the tape <b>90</b> past the path of the tape applicator <b>60</b>. The path of the tape applicator is the movement of the tape applicator <b>60</b> from its first position to its second position, as explained in more detail below.

[0052] After the printer <b>40</b> has stopped printing and is no longer feeding tape out the exit of the printer, a signal is sent to operate the fifth actuator <b>84</b> to move the lower jaw <b>78</b> of the tape puller away from the upper jaw <b>76</b>. In doing so, the printed tape is released from the tape puller <b>72</b> and no longer under tension. Depending on the length of the printed tape, the tape puller may need to move out of the path of the tape applicator that moves later to apply the printed tape. For example, if the length of printed tape <b>90</b> is shorter than the length of the tape applicator <b>60</b>, then after the tape is released by the tape puller <b>72</b>, the actuator <b>80</b> may continue to push the tape puller away from the printer out of the path of the tape applicator, towards the second position located near the end of the bars <b>82</b>. Because the vacuum system of the tape applicator <b>60</b> was previously turned on (prior to the printing step), the vacuum system draws the printed tape <b>90</b> toward the vacuum box <b>62</b>. This step is illustrated in FIG. 7, with the tape applicator <b>60</b> holding the printed tape. The printed side of the tape <b>90</b> is in contact with the wipe down plate <b>65</b>. The high vacuum, low-flow vacuum through holes <b>67</b> strongly holds the portion of the tape closest to the tape cutter <b>46</b> and printer <b>40</b>, while the low vacuum, high flow vacuum through holes <b>66</b> loosely holds the other portion of the tape.

[0053]FIG. 8 illustrates the cutter <b>46</b> cutting the tape. Once the printer <b>40</b> stops printing or feeding tape, and as a result, the tape puller <b>72</b> stops moving and is out from under the tape applicator <b>60</b>, a signal is sent to the third actuator <b>56</b> on the tape cutter <b>46</b> to actuate the upper blade <b>50</b> downward to slide next to the lower blade <b>48</b> to cut the tape <b>90</b>. After the tape <b>90</b> is cut, a length of tape <b>94</b> having a first end <b>96</b> and a second end <b>98</b> opposite the first end <b>96</b> is drawn towards the vacuum system <b>60</b> and held in place by the vacuum sources <b>64</b>. The apparatus <b>10</b> is configured to cut various lengths of tape. After the tape is cut, the drive roller <b>41</b> rotates in a reverse direction (clockwise) as shown in FIG. 8 to back the tape away from the cutter <b>46</b>. As the drive roller <b>41</b> rotates in the reverse direction, the accumulator <b>34</b> accommodates for the additional tape by rotating clockwise. The accumulator <b>34</b> provides back tension on the tape to keep it from adhering or wrapping around the drive roller <b>41</b>. Preferably, the drive roller <b>41</b> backs the tape <b>90</b> up between 0.1 to 1 inches (0.254 cm to 2.54 cm) and more preferably, backs the tape <b>90</b> up between 0.08 to 0.12 inches (0.2 to 0.3 cm). There are three benefits to the drive roller <b>41</b> backing the tape away from the cutter. First, the adhesive on the tape <b>90</b> may have a tendency to stick to the cutter blades and by backing the tape away from the cutter, this helps pull the tape from the cutter blades. Second, the end of the tape <b>90</b> is nearly always is the same location after backing up the tape so this provides a predictable location for the tape puller <b>72</b> to grasp the end of the tape on the next cycle. Lastly, by backing up the tape, it helps maximize the print area of the tape by starting to print at a location closer to the first end of the tape.

[0054] The taping head <b>12</b> may also continue to feed tape after the printer <b>40</b> has finished printing. For example, if the taping head <b>12</b> is creating a six-inch (15.24 cm) length of printed tape, the printer may continue to feed tape for another half inch (1.27 cm) without printing such that the second end of the six-inch length is positioned closer to the blades of the cutter <b>46</b>. After the cutter <b>46</b> cuts the length of tape to form a six inch length of tape, the drive roller of the printer will reverse to pull the extra half inch of tape back into the printer to start printing again.

[0055]FIG. 9 illustrates the tape applicator <b>60</b> moved along the applicator path from the first position to a second position to apply the cut length of tape <b>94</b> being initially applied to an object <b>100</b>, which is preferably a package or a box. As the tape applicator moves along the applicator path, is crosses perpendicular the prior tape puller path, when it moved from the first position to the second position. The second actuator <b>68</b> moves the tape applicator <b>60</b> with the length of tape held by the vacuum system. As the tape applicator <b>60</b> moves to the second position, the fourth actuator <b>61</b> pivots the wipe on plate <b>65</b> so as to adhere the second end <b>98</b> of the tape to the box <b>100</b>. The adhesive <b>88</b> of the second end <b>98</b> of the cut length of tape sticks the tape to the box <b>100</b>.

[0056]FIG. 10 illustrates the applicator <b>60</b> finishing applying the length of tape <b>94</b> to the box. As the box moves to the right, the wipe on plate <b>65</b> wipes down the entire length of tape <b>94</b> along the box, including the first end <b>96</b> of the tape <b>94</b>. The adhesive <b>88</b> of the cut length of tape sticks the tape to the box <b>100</b>.

[0057] Based on the teachings of this application, one skilled in the art could make various modifications to the apparatus or sequence of the operations describe above. For example, in one embodiment, the vacuum sources <b>64</b> could be turned on to operate just before the tape puller <b>72</b> releases the tape instead of the vacuum sources <b>64</b> operating during the entire time the tape puller <b>72</b> is pulling the tape under the tape applicator <b>60</b>. In another embodiment, the tape puller <b>72</b> could include any suitable mechanism to pull the tape, such as only one jaw or member or a stick-on plate as for grabbing the adhesive side of the tape. Once the printer has finished printing the tape and the tape remains stationary, the tape puller <b>72</b> could continue to move to disengage the jaw, member or stick-on plate from the adhesive side of the tape. In another embodiment, the tape puller <b>72</b> could include a roller instead of two jaws <b>76</b>, <b>78</b> for grabbing the adhesive side of the tape. In this embodiment, the roller would remain stationary when the tape puller attaches the roller to the adhesive side of the tape and when the tape puller moves to the second position. What is important is that the puller maintains the tape under tension as it is pulled across the tape applicator path. Once in the second position, the tape puller would continue to move to the left and the roller would rotate to release the tape from the roller. In another embodiment, the tape puller <b>72</b> could include any combination of rollers or jaws for pulling the tape from the printer.

[0058] In yet another embodiment, the tape applicator could temporarily hold the tape by static charge, by pressure-sensitive adhesive or other means known in the art instead of a vacuum system tape applicator temporarily holding the length of tape <b>94</b>. In this embodiment, the tape applicator <b>60</b> could move to an intermediate position between the first position and the second position to temporarily adhere the printed tape to the tape applicator and then proceed to the second position to adhere the printed tape to the box. In another embodiment, the tape applicator <b>60</b> does not need to include a wipe on pate <b>65</b>. Instead, the tape applicator <b>60</b> could attach the printed tape <b>94</b> to the box by tamping the printed tape on the package or box. The box may be stationary while the tape applicator <b>60</b> tamps the printed tape on the package or box or the tape applicator <b>60</b> could e move in the same direction as the box moves, when the tape applicator tamps the printed tape on the box. In another embodiment, the tape applicator could be stationary and tamp the printed tape on the box as the box moves past the applicator. In another embodiment, the tape applicator could include an air source for blowing the printed tape off the applicator onto the box to apply the printed tape to the box. In another embodiment, the tape cutter <b>46</b> and the tape applicator <b>60</b> could be one mechanism. In this embodiment, a single blade would be attached to the tape applicator <b>60</b>. As the tape applicator and blade move from the first position, above the printed tape, to the second position to apply the tape, the blade would cut through the tape and the vacuum system of the tape applicator would draw the cut tape to the vacuum box. The tape applicator and blade would then move the second position to apply the printed tape to the box. The blade could be configured to not contact the box when the applicator applies the printed tape to the box. In another embodiment, the tape cutter could be a single blade or hot wire cutter mounted to the tape head located below the exit of the printer. In this embodiment, as the tape applicator moves from the first position to the second position, the tape applicator would bring the printed tape <b>94</b> past the stationary blade or hot wire, thus cutting through the tape.

[0059] Examples of suitable actuators for the first actuator <b>80</b> for moving the tape puller <b>72</b>, the second actuator <b>68</b> for moving the tape applicator <b>60</b>, the third actuator <b>56</b> for moving the tape cutter, the fourth actuator <b>61</b> for moving the wipe on plate <b>65</b>, and the fifth actuator <b>84</b> for moving the lower jaw <b>78</b> of the tape puller <b>72</b> are commercially available as air cylinders, model number CM2C25-100A from SMC Corporation of America located in Eden Prairie, Minn. and air cylinders, model number, DSNU-16250-PPV-A, available from Festo Corporation located in Hauppauge, N.Y. Although the apparatus <b>10</b> is illustrated as including five actuators, the apparatus may include any number of actuators.

[0060] Preferably, the apparatus <b>10</b> for printing and applying tape includes a programmable logic controller for operating the various actuators, sensors, motors, and the printer in particular sequence. A suitable example of a commercially available controller is available as a controller under the brand name Micrologix, model number 1000 1761-L32BB from Allen Bradley located in Milwaukee, Wis.

[0061] The apparatus <b>10</b> for printing and applying tape prints information on a length of tape and then applies that length of tape to an object, preferably a box or package. The information printed on the tape can include a wide variety of information about the package or box to which it is adhered. For example, the printed length of tape may identity of the package or items in the package. It may include information about the shipping address, movement history of the package or about the items in the package, or about the weight of the items or package. The printed length of tape may include information about the contents of the package such as an inventory of the contents, value and manufacturer of the items in the package, when the package was sealed, hazard information regarding the contents of the package or transportation codes of the contents or package, required storage conditions of the package, or date of manufacture of the contents or warranty information concerning the contents.

[0062] The present invention has now been described with reference to several embodiments thereof. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. All patents and patent applications cited herein are hereby incorporated by reference. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the exact details and structures described herein, but rather by the structures described by the language of the claims, and the equivalents of those structures.