BANDING DEVICE

Abstract

A device for applying a non-elastic plastic band securely around an article of commerce and its associated packaging includes a substantially automated feed mechanism for extracting the band from a continuous film at a modifiable length and tension. The feed mechanism includes a pair of arcuate guides that assist in directing the band through a first hole in the packaging, across the article, and through a second hole in the packaging so the ends of the band are disposed on the same side of the packaging. A sensor uses machine readable features within the film to detect film positioning within the device. A clamping device retains the ends of the band together in an overlapping relationship. The trailing end of the band is separated from the remainder of the continuous film by a severing mechanism. Thereafter, the ends of the band are then permanently bonded together by a thermal bonding mechanism, thereby securing the band in its closed loop configuration around the article and its packaging.

Claims

1. A device for securing together first and second objects with a band derived from a continuous plastic film, the band having first and second ends, the device comprising: (a) a feed mechanism for extracting the band from the continuous plastic film and at least partially directing the band around the first and second objects; (b) a sensor that detects machine-readable features incorporated into the plastic film at defined intervals which are not detectable by the human eye; (c) a clamping mechanism for retaining the first and second ends of the band together in an overlapping relationship; (d) a tensioning mechanism for controlling loop tension in the band around the first and second objects; (e) a severing mechanism to release the band from the continuous plastic film; and (f) a bonding mechanism for bonding the first and second ends together to secure the band in a closed loop configuration.

2. The device as claimed in claim 1 further comprising a housing which includes a plurality of panels that together define an interior cavity dimensioned to receive at least a portion of the feed mechanism, at least a portion of the sensor, at least a portion of the clamping mechanism, at least a portion of the tensioning mechanism, at least a portion of the severing mechanism and at least a portion of the bonding mechanism.

3. The device as claimed in claim 2 wherein the feed mechanism includes a pair of opposing film guides that assist in directing the band around the first and second objects and each of the pair of opposing film guides is generally arcuate in shape.

4. The device as claimed in claim 3 wherein the pair of opposing film guides are adapted to fittingly penetrate through corresponding holes formed in one of the first or second objects.

5. The device as claimed in claim 3 wherein the pair of opposing film guides protrude through a slot defined in one of the plurality of panels in the housing.

6. The device as claimed in claim 5 wherein one of the pair of opposing film guides is fixed in place and the other of the opposing film guides is adapted to be displaced within the slot.

7. The device as claimed in claim 2 wherein the feed mechanism comprises a plurality of rollers that advance the band along a specified path.

8. The device as claimed in claim 7 wherein at least one of the plurality of rollers is motor-driven.

9. The device as claimed in claim 2 wherein the feed mechanism extracts a continuous, defined length of film.

10. The device as claimed in claim 2 wherein the feed mechanism includes a tensioning mode to control loop tension in the plastic film at a defined setting.

11. The device as claimed in claim 10 wherein the tension of the band is adjustable through an external control provided in one of the plurality of panels in the housing.

12. The device as claimed in claim 2 includes a sensor adapted to detect machine readable features in the continuous plastic film which may not be detectable to the human eye.

13. The device as claimed in claim 2 wherein the clamping mechanism includes a movable backing anvil and a movable clamp head that selectively abut against opposing surfaces of the band in order to retain the band in a closed loop configuration.

14. The device as claimed in claim 2 wherein the bonding mechanism includes a movable heat stake head that is adapted to thermally bond together the first and second ends of the band.

15. The device as claimed in claim 2 further comprising a severing mechanism for separating the band from the continuous plastic film.

16. The device as claimed in claim 2, wherein the continuous plastic film is embedded with covert identifiers that are not detectable by the human eye aid in operation of the device.

17. A method for securing together first and second objects with a band derived from a continuous plastic film, the band having first and second ends, at least one of the first and second objects having a pair of holes, the method comprising the steps of: (a) extracting the band from the continuous plastic film and at least partially directing the band through the pair of holes and around the first and second objects; (b) sensing and retaining the first end of the band in an overlapping relationship; (c) tensioning the band around the first and second objects; and (d) bonding the first and second ends together to secure the band in a closed loop configuration.

18. The method as claimed in claim 17 further comprising the step of severing the band from the continuous plastic film.

19. The method as claimed in claim 17 wherein, in the extracting step, the band is extracted from the continuous plastic film at a modifiable length.

20. The method as claimed in claim 17 wherein, in the tensioning step, the band is tensioned along the continuous plastic film at a modifiable tension.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the drawings wherein like reference numerals represent like parts:

[0028] FIG. 1 is a top perspective view of a banding device constructed according to the teachings of the present invention, the banding device being shown in relation to an article and its associated packaging which are to be secured together;

[0029] FIGS. 1(a)-(d) are magnified views of selected components from FIG. 1;

[0030] FIG. 2 is a side view of the article secured to its packaging by a band applied from the banding device shown in FIG. 1;

[0031] FIG. 2(a) is a top view of the article secured to its packaging as shown in FIG. 2;

[0032] FIG. 2(b) is an isometric view of the article secured to its packaging as shown in FIG. 2;

[0033] FIGS. 3(a)-(i) are simplified section views of selected components of the banding device shown in FIG. 1, taken along lines A-A, at various stages during the process of banding the article to its associated packaging; and

[0034] FIGS. 4(a)-(e) are various shapes, patterns or geometries that can assist in directing heat from a heat stake head to overlapping ends of a closed loop band.

DETAILED DESCRIPTION OF THE INVENTION

Construction of Banding Device 11

[0035] Referring now to FIG. 1, there is shown a banding device constructed according to the teachings of the present invention, the banding device being identified generally by reference numeral 11. As will be explained in detail below, banding device 11 is specifically designed to apply a non-elastic plastic band securely around an article of commerce and its corresponding packaging in a simple, effective and largely automated fashion.

[0036] In the description that follows, device 11 is shown securing an article of commerce 12 to its associated packaging 13. As defined herein, article of commerce 12 represents any product that is typically secured to packaging as part of its transport and/or display for sale. For instance, article 12 may be in the form of a conventional retail article, such as a handheld tool, toy or the like.

[0037] Packaging 13 is represented herein as a display, or line card constructed out of, but not limited to, a thick, paper-based material, such as paperboard, chipboard, cardboard or the like. As can be seen, packaging 13 has a generally planar construction with a substantially flat top surface 14 and a substantially flat bottom surface 15. Additionally, packaging 13 is shaped to define a pair of pre-punched slots 16-1 and 16-2, the function of which will become apparent below.

[0038] It should be noted that device 11 is not limited for use with card-type packaging 13. Rather, it is to be understood that device 11 could be used with alternative forms of packaging (e.g. a cardboard box or plastic clam shell) without departing from the spirit of the present invention. Accordingly, as defined herein, packaging 13 represents any item of any shape, style or material to which an article of commerce can be secured.

[0039] Referring now to FIGS. 1 and 2, banding device 11 is constructed as a compact and unitary machine that is designed to apply a non-elastic plastic band securely around article 12 and packaging 13 in a simple, effective and largely automated fashion. As will be described in detail below, banding device 11 is adapted to receive a continuous supply of a non-elastic plastic film 18, wrap a separable segment, or band, 17 of film 18 around commercial article 12 and packaging 13, apply tension with film 18, and weld together the free ends of band 17 to form a closed-loop. Due to its low elongation properties and welded form of connection, band 17 serves to retain article 12 to packaging 13 in a secure and reliable fashion, which is highly desirable.

[0040] Film 18 is preferably in the form of any thin film plastic material with relatively low elongation properties. As referenced briefly above, film 18 is preferably provided as a continuous web which is wound onto an enlarged rotatable reel, or spool, 19 for ease of storage and subsequent usage by device 11.

[0041] The particular design and construction of film 18 is preferably dependent upon the designated packaging application. As an example, film 18 may be clear or colored to provide a particular aesthetical effect. Additionally, film 18 may be branded or otherwise visibly marked (e.g. with a corporate logo) for marketing purposes. Lastly, film 18 may be provided with a security device (e.g. an embedded radio frequency identification (RFID) chip or the like) to deter theft of article 12.

[0042] Referring to FIG. 3(a), device 11 includes an outer housing 20 adapted to receive packaging 13 and article 12, a feed mechanism 21 for advancing a segment of film 18, a sensor 42 for detecting that film 18 is in place to begin the banding sequence, a clamping mechanism 22 for retaining the overlapping portion of band 17 in place, a tensioning mode in mechanism 21 for controlling the loop tension in band 17, a bonding mechanism 23 for securing together the overlapping portion of band 17, and a severing mechanism 24 for separating band 17 from the remainder of film 18. As a product of the operation of device 11, a single band 17 wraps article 12 securely to packaging 13 through slots 16-1 and 16-2 of packaging 13, as shown in FIG. 2.

[0043] As seen in FIG. 1, housing 20 is represented herein as a rectangular, box-shaped enclosure that includes a front panel 25, a rear panel 26, a left side panel 27, a right side panel 28, a top panel 29 and a bottom panel 30 that together define a substantially enclosed interior cavity 31 into which the majority of the components of device 11 are disposed. As can be seen, top panel 29 is shaped to define a narrow lateral slot 44 which provides access to interior cavity 31.

[0044] It should be noted that reel 19 of film 18 may be disposed outside of housing 20 and fed into interior cavity 31 for banding through a corresponding opening (e.g. in side panel 28), as represented in FIG. 1. Alternatively, housing 20 may be dimensioned to receive reel 19 of film 18 within interior cavity 31.

[0045] As seen most clearly in FIG. 3(a), device 11 includes a feed mechanism 21 disposed within interior cavity 31 of housing 20 that advances a segment of film. Feed mechanism 21 includes a series of rollers 32-1 thru 32-4 that feed film 18 along a specified path. Film guide 33-2 directs film 18 through slot 16-2 of packaging 13. Film 18 is placed around article 12 and directed through slot 16-1 of packaging 13 via film guide 33-1. A stepper motor (not shown) is used for regulating the tautness of film 18 during the tensioning mode of feed mechanism 21.

[0046] Feed mechanism 21 includes both active, or drive, rollers and passive, or pinch, rollers 32-1 thru 32-4. Active rollers are directly or indirectly driven by a stepper motor (not shown), the operation of which is regulated by an electronic controller (not shown). In turn, activation of the device motor is achieved through control panel 46 provided on the exterior of housing 20.

[0047] Specifically, as seen most clearly in FIG. 1, an externally accessible, depressible lighted power toggle switch coupled with a power input receptacle 43 is provided on side panel 28 of housing 20 and serves to deliver power to the electronic controller for device 11 when a powered input cord (not shown) is attached. The lighted power toggle switch coupled with a power input receptacle 43 on side panel 28 of housing 20, when lit, indicates that power is being delivered to the controller for device 11.

[0048] Additionally, an externally accessible, depressible film advance button 34 is provided in control panel 46 and is in electrical connection with the electronic controller for device 11. Upon depression of button 34, the electronic controller delivers power to the motor, which in turn activates feed mechanism 21 to the extent that a defined length of film 18 is automatically delivered for use in securing article 12 to packaging 13, as will be explained further below.

[0049] Film guides 33-1 and 33-2 are a pair of opposing arcuate chutes that serve to facilitate directing film 18 around packaging 13 and article 12. Each guide 33 is generally arc shaped in transverse cross-section and is dimensioned to fittingly receive and direct band 17 along the appropriate path.

[0050] Each guide 33 is positioned within interior cavity 31 such that its distal end projects partially through slot 44 in housing 20. Accordingly, as will be explained further below, the distal end of each guide 33 is dimensioned to fittingly project through a corresponding slot 16 in packaging 13. In this manner, guides 33 serve to not only hold packaging 13 in position on device 11 but also assist in feeding film 18 through slots 16 in packaging 13.

[0051] Preferably, film guide 33-1 is a fixed, or stationary, chute that is located at one end of slot 31. By contrast, film guide 33-2 is a movable chute that is adapted to slide linearly within slot 44 in both directions relative to fixed film guide 33-1. In this manner, the spacing between film guides 33 can be adjusted to compensate for variances in the spacing between the pair of pre-punched slots 16 in packaging 13 (i.e. to accommodate a wide range of possible packaging applications).

[0052] As referenced above, activation of button 34 extracts a defined length of film 18 for use in securing article 12 to packaging 13. Note that activation includes but is not limited to button 34. (i.e a foot pedal or other switching device may be used). The ability to extract a section of film 18 to a defined length is achieved using a stepper motor (not shown) coupled with the controller (not shown) for device 11. Accordingly, the controller for device 11, which is electrically connected to the stepper motor, can calculate the proper length of film 18 to be extracted (e.g. by counting the number of steps the stepper motor has moved radially).

[0053] The length of the extracted portion of film 18 (i.e. the portion of film 18 to ultimately serve as band 17) can be varied by the user through manual adjustment of a numeric length indicator 35 provided in control panel 46 of housing 20. As can be appreciated, the numeric length indicator 35 is coupled to the controller for device 11 and can thereby modify the measured length (e.g. adjusting the panel to read 200 indicates a defined length of extracted film 18) and activate the feed mechanism 21 accordingly. The ability to modify the length of film 18 is useful since different packaging applications will typically have different banding requirements. In particular, the length of film 18 is often largely dictated by the shape of article 12 with which it is used.

[0054] As referenced briefly above, feed mechanism 21 extracts a defined length of film 18 (i.e. band 17) that is, in turn, wrapped around article 12 and packaging 13 in a partially overlapping fashion. To maintain film 18 tightly wrapped around article 12 and packaging 13, a clamping mechanism 22 located within interior cavity 31 selectively applies a retaining force onto film 18 when initiated by sensor 42. Specifically, sensor 42 is designed to detect machine-readable features incorporated into film 18 at defined intervals. For instance, the entire length of film 18 may include markings, such as a sequence of equally-spaced printed lines, which are not detectable by the human eye (e.g. using ultraviolet dyes or inks) but are detectable by sensor 42. Sensor 42 can utilize markings on film 18 to calculate the proper overlap length of film 18 required for band 17, as it is inserted into film guide 33-1, to initiate the banding sequence.

[0055] As seen most clearly in FIG. 3(a), clamping mechanism 22 includes, inter alia, a backing anvil 37, a tail clamp head 38 and a holding clamp head 39 that apply forces on film 18 to the extent necessary to retain film 18 in its properly wrapped configuration. Anvil 37 is a planar member that is slidably mounted within interior cavity 31. As will be described further below, anvil 37 is disposed to selectively project between bottom surface 15 of packaging 13 and film 18 (band 17).

[0056] Tail clamp head 38 is a block-type member that is slidably mounted within interior cavity 31. Tail clamp head 38 is disposed to selectively protrude towards the underside of backing anvil 37 with film 18 disposed there between. As such, backing anvil 37 and tail clamp head 38 apply pressure onto opposite sides of the tail portion of film 18 so as to define the overlap portion of band 17.

[0057] The non-secured end of the film 18 passes through a cutout portion of tail clamp head 38. The feed mechanism 21 has a tensioning mode as the device motor rotates the active rollers in a direction opposite of the extracted film 18. This operation enables film 18 to achieve a predetermined loop tension. Accordingly, through the adjustment of an external tension control knob 36, which is provided in control panel 46 the tension of film 18 can be modified to suit the needs of the intended packaging application. Accordingly, the controller for device 11, which is electrically connected to the stepper motor, can calculate the proper tension to be applied and then deactivate feed mechanism 21. Holding clamp head 39 is a block-type member that is slidably mounted within interior cavity 31. Similar to tail clamp head 38, holding clamp head 39 is disposed to selectively protrude towards the underside of backing anvil 37 with film 18 disposed there between. As such, backing anvil 37 and holding clamp head 39 apply pressure onto opposite sides of the tail portion of film 18 so as to secure its shape in a closed loop configuration.

[0058] Severing mechanism 24 includes a movable knife blade 41 that is located in interior cavity 31 and regulated by the device controller. The present invention also contemplates that a shearing mechanism may be used instead of knife blade 41. As will be explained further below, knife blade 41 is disposed between heat stake head 40, tail clamp head 38 and holding clamp head 39, and is adapted to be selectively driven into contact with film 18. Based on its location, knife blade 41 severs the enclosed band 17 from the remainder of film 18.

[0059] With band 17 retained in a closed-loop configuration by clamping mechanism 22, bonding mechanism 23 secures together the overlapping portion (i.e. the free ends) of band 17. Bonding mechanism 23 comprises a movable heat stake head 40 that is located in interior cavity 31 and regulated by the device controller. As will be explained further below, heat stake head 40 is driven into contact against the overlapping portion of band 17, with backing anvil 37 providing support for the opposite surface of the overlapping portion. The heat applied from head 40 is of a sufficient temperature to weld together the overlapping segments of band 17, thereby permanently securing band 17 in its closed loop configuration. Backing anvil 37 then retracts to free the band from the banding device, thereby resulting in the securely packaged product shown in FIG. 2

[0060] It should be noted that bonding mechanism 23 is not limited to the use of heat to bond together the overlapping segments of film 18 to form band 17. Rather, it is to be understood that bonding mechanism 23 could bond the overlapping segments of film 18 to form band 17 by alternative means (e.g. through ultrasonic welding) without departing from the spirit of the present invention.

Operation of Banding Device 11

[0061] Referring now to FIGS. 3(a)-(i), banding device 11 can be used in the following manner to apply non-elastic plastic band 17 securely around article of commerce 12 and packaging 13 in a simple, effective, and largely automated fashion. To commence the banding process, packaging 13 is disposed on housing 20 such that arcuate guides 33-1 and 33-2 fittingly protrude through corresponding slots 16-1 and 16-2, respectively, as shown in FIG. 3(a). If necessary, movable guide 33-2 can be displaced within slot 44 to accommodate the particular width between slots 16-1 and 16-2. Once properly mounted, bottom surface 15 of packaging 13 lies generally flat against top panel 29 of housing 20. The fitted relationship between guides 33 and slots 16 retain packaging 13 fixedly in place on housing 20.

[0062] With packaging 13 mounted on housing 20 in the manner set forth above, article 12 is disposed on top surface 14 of packaging 13 between slots 16-1 and 16-2. Any fine adjustment of the position of article 12 relative to packaging 13 is then undertaken until the items are disposed in their desired relationship for packaging.

[0063] The operator then activates device 11 by depressing run button 34, with indication of operability being provided by an indicator light which is illuminated on run button 34. Prior to commencing the band delivery operation, the operator sets the desired length and tension of film 18 via controls 35 and 36, respectively. As can be appreciated, the length and tension of resultant band 17 is largely dependent upon the particular packaging application.

[0064] To commence the band delivery process, the operator depresses button 34 which delivers a signal to the device controller. In response thereto, the device controller activates device motor, which rotably drives active rollers in feed mechanism 21. Accordingly, rollers 32-1 thru 32-4 extract a section of film 18 at the desired length, as specified above. It is to be understood that the proper length of the extracted section of film 18 is determined by a stepper motor (not shown), which counts the number of radial steps and the controller of device 11 calculates the proper length of film 18 to extract.

[0065] As seen in FIG. 3(b), the free end 18-1 of the extracted section of film 18 is directed by guide 33-2 upward through slot 16-2 in packaging 13 and is thereby externally accessible. The operator then pulls a portion of the extracted section across article 12 and, in turn, manually inserts free end 18-1 through slot 16-1 using guide 33-1, as shown in FIG. 3(c).

[0066] Device 11 detects the insertion of free end 18-1 back into interior cavity 31 by sensor 42. Sensor 42 is designed to detect machine-readable features incorporated into film 18 at defined intervals. Film 18 includes markings, such as a sequence of equally-spaced printed lines (e.g. spacing may range, between 0.5 mm and 50.0 mm), which are not detectable by the human eye (e.g. using ultraviolet dyes or inks) but are detectable by sensor 42. Sensor 42 can utilize markings on film 18 to calculate the proper overlap length of film 18 required, as it is inserted into film guide 33-1. When the proper overlap length of film 18 is detected by sensor 42, the banding sequence is initiated. As seen in FIG. 3(d), tail clamp head 38 of clamping mechanism 22 is displaced inward by the device motor upon activation and urges free end 18-1 of film 18 against the underside of backing anvil 37. In this capacity, the extracted section (i.e. film 18) is formed into a generally closed loop, with tail clamp head 38 directing free end 18-1 inside the trailing segment of film 18 in an overlapping fashion. Once the tail clamp head 38 engages the free end 18-1 of film 18 against backing anvil 37, the device motor rotates the active rollers in feed mechanism 21 in a direction opposite of the extracted film 18 operation enabling film 18 to achieve a predetermined loop tension as set by tension control knob 36.

[0067] With film 18 at a predetermined loop tension as set by tension control knob 36, holding clamp head 39 is displaced, commencing formation of band 17. Holding clamp head 39 of clamping mechanism 22 urges trailing end 17-2 of band 17 against tail end 17-1 and presses both the overlapping trailing end 17-2 and the tail end 17-1 against the underside of backing anvil 37, as seen in FIG. 3(e). In this capacity, a band 17 is formed.

[0068] Upon completion of the holding clamp sequence, knife blade 41 of severing mechanism 24 is driven upward by the device motor sliding along tail clamp head 38 with suitable force to sever band 17 from the remainder of film 18, as represented in FIG. 3(f). With knife blade 41 positioned to sever film 17 in the manner set forth above, it is to be understood that no excess or unused film 18 (i.e. scrap) is produced by device 11, thereby maximizing the overall efficiency and cost-effectiveness of device 11.

[0069] Thereafter, heat stake head 40 of heat stake mechanism 23 is driven upward by the device motor towards backing anvil 37, as represented in FIG. 3(g). The heat applied from heat stake head 40 is imparted onto the overlapping portion of band 17 and is of a sufficient temperature to permanently weld together the two overlapping segments. The heat stake head 40 may contain one of various patterns or combinations thereof, but is not limited to, the patterns seen in FIG. 4a-e to direct heat to band 17.

[0070] As shown in FIG. 3(h), immediately after the aforementioned film severing step, knife blade 41, holding clamp head 39, tail clamp head 38 and heat stake head 40 retract back toward bottom panel 30 to its original starting position. During this motion, as shown in FIG. 3(i), anvil 37 retracts toward front panel 25, allowing commercial article 12, packaging 13 and band 17 to release from device 11. After releasing commercial article 12, packaging 13 and band 17 from device 11, anvil 37 returns to the starting position. In this manner, device 11 is prepared to repeat the above-described banding process as often as needed.

[0071] As a result of the aforementioned banding process, an individual, non-elastic band 17 is permanently retained in a closed loop configuration around article 12 and packaging 13, as shown in FIG. 2. As can be seen, ends 17-1 and 17-2 overlap one another and are permanently bonded together to securely retain band 17 in its closed loop configuration. Once banded together, article 12 and packaging 13 can be simply lifted off of housing 20.

[0072] As a feature of the present invention, the non-elastic nature of band 17 serves to retain article 12 securely to packaging 13 with greater force than a traditional elastic-type fastener. Additionally, the largely automated operation of device 11 renders the application of band 17 around article 12 and packaging 13 easier to implement than traditional cable ties or other similar types of harnessing devices that are typically installed by hand. Lastly, device 11 is able to direct band 17 through preformed slots 16 in packaging 13, rather than envelope the entire display card, thereby resulting in a packaged article that is aesthetically pleasing and less susceptible to damage (e.g. bowing or tearing of packaging 15).

[0073] The embodiment shown above is intended to be merely exemplary and those skilled in the art shall be able to make numerous variations and modifications to it without departing from the spirit of the present invention. All such variations and modifications are intended to be within the scope of the present invention as defined in the appended claims.