TAPE APPLICATOR HEAD WITH GUIDES

Abstract

A tape applicator head is described. The tape applicator head includes an applicator roller for applying a strip of tape to a workpiece positioned on a flatbed of an apparatus such as a flatbed digital cutter. A support of the tape applicator head supports a tape roll. A plurality of guides are each configured for guiding a different tape width. The tape applicator head includes a guide mount configured for removably mounting a selected one of the plurality of guides. The mounted guide is positioned to guide tape from the tape roll to the applicator roller.

Claims

1. A tape applicator head for an apparatus, the tape applicator head comprising: an applicator roller for applying a strip of tape to a workpiece positioned on a flatbed of the apparatus; a support for supporting a tape roll; a plurality of guides that are each configured for guiding a different tape width; and a guide mount configured for removably mounting a selected one of the plurality of guides; wherein the mounted guide is positioned to guide tape from the tape roll to the applicator roller.

2. The tape applicator head of claim 1, wherein each guide is a guide roller.

3. The tape applicator head of claim 1, wherein each guide includes a pair of tape edge guide members.

4. The tape applicator head of claim 3, wherein the tape edge guide members are defined by the sides of a channel or groove in the guide.

5. The tape applicator head of claim 1, further comprising a plurality of spacers that each have a different thickness, wherein a selected one of the spacers is positioned between the tape roll and the support.

6. The tape applicator head of claim 1, further comprising a knife or blade for cutting the tape.

7. The tape applicator head of claim 6, wherein the knife or blade is mounted on a support that is movable between a rest position and a cutting position.

8. The tape applicator head of claim 7, wherein the support is pivotally mounted.

9. The tape applicator head of claim 7, wherein the support further comprises at least one retaining means configured to contact the workpiece when the support is in the cutting position.

10. The tape applicator head of claim 9, wherein each retaining means is a wheel that is rotatably mounted to the support.

11. An apparatus comprising: a flatbed on which a workpiece can be positioned; a tape applicator head comprising: an applicator roller for applying a strip of tape to the workpiece positioned on the flatbed; a support for supporting a tape roll; a plurality of guides that are each configured for guiding a different tape width; and a guide mount configured for removably mounting a selected one of the plurality of guides; and a head unit to which the tape applicator head is mounted; wherein the mounted guide is positioned to guide tape from the tape roll to the applicator roller; and wherein the head unit is movable in a plane above the flatbed and at least the applicator roller is rotatable about an axis that is normal to the plane.

12. The apparatus of claim 11, wherein at least the applicator roller is movable along the axis that is normal to the plane.

13. The apparatus of claim 11, further comprising a control unit adapted to control the movement of the head unit.

14. A tape applicator comprising: a flatbed on which a workpiece can be positioned; a tape applicator head comprising: an applicator roller for applying a strip of tape to the workpiece positioned on the flatbed; a support for supporting a tape roll; a plurality of guides that are each configured for guiding a different tape width; and a guide mount configured for removably mounting a selected one of the plurality of guides; and a head unit to which the tape applicator head is mounted; wherein the mounted guide is positioned to guide tape from the tape roll to the applicator roller; and wherein the head unit is movable in a plane above the flatbed and at least the applicator roller is rotatable about an axis that is normal to the plane.

15. A cutter comprising: a flatbed on which a workpiece can be positioned; a tape applicator head comprising: an applicator roller for applying a strip of tape to the workpiece positioned on the flatbed; a support for supporting a tape roll; a plurality of guides that are each configured for guiding a different tape width; and a guide mount configured for removably mounting a selected one of the plurality of guides; and a head unit to which the tape applicator head is mounted; wherein the mounted guide is positioned to guide tape from the tape roll to the applicator roller; and wherein the head unit is movable in a plane above the flatbed and at least the applicator roller is rotatable about an axis that is normal to the plane.

16. The cutter of claim 15, wherein the head unit further comprises a cutter head with a knife or blade for cutting the workpiece.

17. The cutter of claim 15, wherein the head unit further comprises a creaser head with a creaser wheel for creasing the workpiece.

Description

DRAWINGS

[0059] FIG. 1 is a schematic front view of a digital flatbed cutter according to the present invention;

[0060] FIG. 2 is a schematic side view of the cutter of FIG. 1;

[0061] FIG. 3 is a schematic side view of a tape applicator head according to the present invention;

[0062] FIG. 4 is a schematic front view of the tape applicator head of FIG. 3;

[0063] FIG. 5 is a schematic front view of a pair of guide rollers;

[0064] FIG. 6 is a schematic detail view showing an arrangement of guide rollers;

[0065] FIG. 7 is a schematic side view showing the tape applicator head in a second position where the applicator roller is in contact with a workpiece and the blade support is in a rest position;

[0066] FIG. 8 is a schematic side view showing the tape applicator head in a first position where the applicator roller is spaced away from the workpiece and the blade support is in a cutting position;

[0067] FIG. 9 is a visual representation of a digital file for controlling the cutter according to the present invention;

[0068] FIG. 10 is a top view of a workpiece; and

[0069] FIG. 11 is a packaging blank for a container produced from the workpiece using the cutter according to the present invention.

[0070] As shown in FIGS. 1 and 2, a digital flatbed cutter 1 includes a flatbed 2 on which a workpiece W can be positioned.

[0071] A head unit 4 is mounted above the flatbed 2. The head unit 4 is mounted on a support rail 6 and can move from side to side along the support rail (i.e., along a y-axis direction) by a suitable actuator (not shown). The support rail 6 is mounted on side rails (not shown) and can move backwards and forwards along the side rails (i.e., along an x-axis direction) by one or more suitable actuators (not shown). The actuators are controlled by a control unit (not shown) which can include a suitable processor and a user input device such as a touch display screen or keypad, for example. By controlling the actuators, the head unit 4 can be positioned precisely and can be moved in any direction in a parallel plane above the flatbed 2 defined by the perpendicular x- and y-axes.

[0072] The head unit 4 includes a tape applicator head 8, which is just shown schematically in FIGS. 1 and 2.

[0073] An example of a tape applicator head 8 is shown in more detail in FIGS. 3 to 8.

[0074] The tape applicator head 8 includes a pair of spaced plates 8a, 8b. An upper part of the plate 8b defines an L-shaped support bracket for rotatably supporting a tape roll TR. The support bracket is capable of supporting tape rolls having different widths. To ensure that the supported tape roll is properly aligned with the centre of an applicator roller 14 for applying a strip of tape to a workpiece, a spacer 10 can be positioned between the tape roll TR and the plate 8b. The spacer 10 can be selected from a plurality of spacers having different thicknesses. For example, if a first tape roll has a first width, the user may select a first spacer having a first thickness that is determined so that the first tape roll is aligned with the centre of the applicator roller 14, and if a second tape roll has a second width that is greater than the first width, the user may select a second spacer having a second thickness that is less than the first thickness and is determined so that the second tape roll is aligned with the centre of the applicator roller 14. The spacers can have different colours to indicate different thicknesses or suitability for use with a tape roll of a certain width. In FIG. 4 the dashed vertical line shows how, with the spacer 10 of selected thickness spacing the tape roll TR away from the plate 8b, the tape roll is accurately aligned with the centre of the applicator roller 14.

[0075] A plurality of guide rollers 12 are removably mounted between the plates 8a, 8b. Each guide roller 12 includes an annular groove or channel 12a having a width that corresponds to the tape width. The guide rollers 12 can be selected from a plurality of guide roller sets. For example, if a first tape roll has a first width, the user may select guide rollers from a first guide roller set where each guide roller has a groove or channel with a first width that corresponds to the first tape width, and if a second tape roll has a second width that is greater than the first width, the user may select guide rollers from a second guide roller set where each guide roller has a groove or channel with a second width that is greater than the first width and corresponds to the second tape width. The selected guide rollers 12 are removably mounted between the plates 8a, 8b and positioned at intervals to guide tape from the supported tape roll TR down to the applicator roller 14. FIG. 5 shows a pair of guide rollers 12 with different groove widths W1 and W2 which can be mounted to the tape applicator head 8. The first guide roller set could include a plurality of guide rollers with groove width W1 and the second guide roller set could include a plurality of guide rollers with groove width W2, for example. The guide rollers 12 can be removably mounted to the tape applicator head 8 using any suitable means, e.g., fixings that are inserted or screwed into the axial ends of the guide rollers through openings in the plates 8a, 8b.

[0076] The guide rollers 12 of each guide roller set can have different colours to indicate different groove or channel widths or suitability for use with a tape roll of a certain width.

[0077] The guide rollers 12 contact the backing liner that is adhered to the double-sided tape. One or more additional guide rollers 12′ can contact the other side of the tape where the adhesive is exposed. These additional guide rollers 12′ can be formed with a grooved or dimpled surface so that they have minimal surface contact area and do not become adhered to the tape. FIG. 6 shows an arrangement of guide rollers 12′ that may be located close to the applicator roller 14, for example. In FIG. 6, the double-sided tape is indicated by the dashed line and the backing liner is indicated by the solid line.

[0078] The tape applicator head 8 is mounted to be rotatable about an axis that is normal to the plane (i.e., about the z-axis). Consequently, the applicator roller 14 is also rotatable about the z-axis. This is in addition to the normal rotation of the applicator roller 14 about its longitudinal axis that is parallel to the plane and about which the applicator roller rotates when it is in contact with the workpiece and applying tape to the workpiece.

[0079] The tape applicator head 8 includes a knife or blade 16 for cutting the tape. The knife or blade 16 is mounted on a pivotable support 18. The support 18 is pivotally mounted to a pair of lower plates 20a, 20b of the tape applicator head 8 adjacent the applicator roller 14 and is moved between a rest position (FIGS. 3, 4 and 7) and a cutting position (FIG. 8) by an actuator (not shown). The support 18 includes a pair of retaining wheels 22 which are in contact with the workpiece W when the support is in the cutting position - see FIG. 8. Only a single wheel is visible in FIGS. 3, 7 and 8 but it will be readily understood that another wheel is provided on the other side of the support 18.

[0080] The tape applicator head 8 is mounted so that it can move along the axis that is normal to the plane (i.e., along the z-axis direction). The tape applicator head 8 can be moved by an actuator between a first position - shown in FIGS. 1 to 4 and 8 - where the applicator roller 14 is spaced apart from the workpiece W and a second position -shown in FIG. 7 - where the applicator roller is in contact with the workpiece for applying a strip of tape, and optionally where contact pressure is applied to the workpiece by the applicator roller.

[0081] To apply a strip of tape, when the tape applicator head 8 has been accurately positioned over the workpiece, the tape applicator head is lowered to the second position and the head unit 4 is moved in the plane above the flatbed (i.e., in the x- and/or y-direction) with the applicator roller 14 in contact with the workpiece so that the tape strip is adhered to the workpiece by the applicator roller. The tape applicator head 8 is moved back to the first position and the support 18 is pivoted to the cutting position to cut the tape close to the workpiece. As shown in FIG. 8, the retaining wheels 22 of the support contact and hold the workpiece W as the support 18 moves towards the cutting position. This prevents the workpiece W from being lifted off the flatbed 2 when the tape is cut by the blade or knife 16.

[0082] The head unit 4 also includes a cutter head 24 with a knife or blade 26 and a creaser head 28 with a creaser wheel 30. The tape applicator head 8, cutter head 24 and creaser head 28 are conveniently referred to below as “tool heads” and the applicator roller 14, knife or blade 26 and creaser wheel 30 as “tools”. The up and down movement of the tools in the z-axis direction is controlled by the control unit. The control unit can therefore position the head unit 4 over the workpiece W so that the appropriate tool head is at the required position, move the appropriate tool down into contact with the workpiece, move the head unit with the tool in contact with the workpiece to cut, crease or apply tape, move the tool up and away from the workpiece, and reposition the head unit over the workpiece. If the tool is the applicator roller 14, the tape applicator head 8 is rotated about the z-axis relative to the head unit 4 so that it is aligned with the direction in which the head unit will be moved over the flatbed 2 (i.e., so that its longitudinal axis is substantially perpendicular to the movement direction of the head unit).

[0083] The cutter 1 can include a feed mechanism (not shown) for positioning a workpiece on the flatbed 2. Any suitable feed mechanism can be used, e.g., a vacuum feed that can be integrated into the head unit 4 or the support rail 6 and which can be used to pick up an individual workpiece from a stack and position it on the flatbed 2.

[0084] The flatbed 2 can be a conveyor which can be used to remove a workpiece from the cutter 1.

[0085] The movement of the head unit 4 can be controlled by the control unit using a digital file.

[0086] A visual representation of the digital file for a packaging blank is shown in FIG. 9 where cutting information is shown in solid line, creasing information is shown in dashed line and tape application information is shown in dotted line. In particular, the solid line indicates where the workpiece W shown in FIG. 10 should be cut by the cutter head 24, the dashed line indicates where the workpiece should be creased by the creaser head 28, and the dotted line indicates where a strip of tape of pre-determined width should be applied to the workpiece.

[0087] The workpiece W shown in FIG. 10 is a printed sheet of card stock. The workpiece W has printed areas that are indicated by the shading and which will be the outer surfaces of an assembled container. The workpiece W also includes six printed registration marks M1, M2, ..., M6.

[0088] The workpiece W shown in FIG. 10 is positioned on the flatbed 2 using the feed mechanism (not shown). A stack of identical workpieces can be located at an end of the flatbed 2 and an individual workpiece can be picked from the stack and positioned on the flatbed. The head unit 4 is precisely aligned with the workpiece W. For example, the head unit 4 can include a camera (not shown) and the control unit can use optical recognition of the printed registration marks M1, M2, ..., M6 to determine the precise position and orientation of the workpiece W on the flatbed 2. Once the head unit 4 has been precisely aligned relative to the workpiece, the workpiece can be creased by the creaser head 28, tape can be applied by the tape applicator head 14, and it can be cut by the cutter head 24 based on the respective information in the digital file. More particularly, after the workpiece W has been creased, in a tape application process, the head unit 4 can be positioned over a first glue tab GT1, the applicator roller 14 can be rotated about the z-axis to be aligned with the x-axis and moved down into contact with the workpiece, the head unit can be moved in the x-axis direction to apply a first tape strip S1 to the first glue tab GT1, the applicator roller can be moved up and away from the workpiece, the head unit can be re-positioned over a second glue tab GT2, the applicator roller can be rotated about the z-axis to be aligned with the y-axis and moved down into contact with the workpiece, the head unit can be moved in the y-axis direction to apply a second tape strip S1 to the second glue tab GT2, and the applicator roller 14 can be moved up and away from the workpiece. (This assumes that the workpiece W has been positioned on the flatbed 2 such that its edges are exactly aligned with the x-and y-axes of the cutter. In practice, the edges of the workpiece W are likely to be misaligned with the x- and y-axes of the cutter such that the head unit 4 is moved along directions that are angled slightly with respect to the x-axis direction and the y-axis direction with the tape applicator head 8 being rotated about the z-axis accordingly.) It will be understood that the applicator roller 14 is not limited to applying tape strips that are aligned with the x-axis direction or the y-axis direction. In practice, the tape applicator head 8 can be rotated about the z-axis to be aligned with any direction in which the head unit 4 can be moved. For example, the applicator roller 14 can be used to apply a diagonal tape strip that is not aligned with either the x-axis direction or the y-axis direction. In some arrangements, the applicator roller 14 can be rotated about the z-axis while it is in contact with the workpiece and is applying tape if the movement direction of the head unit 4 changes.

[0089] FIG. 11 shows a finished packaging blank B for a container with the tape strips S1 and S2 applied to the glue tabs GT1 and GT2. If the tape strips S1, S2 are double-sided tape, the backing layer can be removed to expose the adhesive and the packaging blank can be folded and assembled to form a container.