VERTICAL CAROUSEL PADDING SYSTEM FOR RETAIL SIGNAGE

Abstract

A vertical carousel padding system and method to create an adhesive retail signage pack based on aisles and aisle groupings where the adhesive is applied along the long edge of the stack to make a solid pack that allows for the operator at the store to remove one sign at a time. This system creates a unique and novel system that can accept stacks of varying heights and apply a padded layer of adhesive to the stacks as the clamped stacks move orthogonally around the carousel motion to the glue roller application station. By gripping and then incrementing the stacks in a vertical carousel configuration, the correct edge of the stack can have the adhesive applied to it while the stack height (i.e., size based on the number of signs in the stack) does not require the gluer to adjust to the stack height.

Claims

1. A system for automatically binding stacks of media sheets, the system comprising: a carousel including a plurality of stack housings attached to the carousel adjacent a periphery thereof, one of the stack housings configured to receive a stack of media sheets and to rotate the received stack of media sheets incrementally around the carousel; and a padding station adjacent the one of the plurality of stack housings, the padding station including a container housing an adhesive and an adhesive applicator configured to deposit a layer of the adhesive onto a side of the received stack of the media sheets, the adhesive layer curing and binding the received stack of the media sheets together into a bound bundle of the media sheets.

2. The system of claim 1, further comprising an exit conveyor mechanism adjacent the carousel and configured to remove the bound bundle from the one of the stack housings.

3. The system of claim 2, wherein the exit conveyor includes a conveyor belt.

4. The system of claim 1, wherein the adhesive applicator includes a roller configured to roll the layer of adhesive across the side of the stack of the media sheets rotated by the one of the stack housings rotating around the carousel.

5. The system of claim 1, wherein the stack housings include an aperture on a side of the stack housings adjacent the side of the stack of the media sheets configured to receive the layer of the adhesive, and the adhesive applicator deposits the layer of the adhesive through the aperture onto the side of the stack.

6. The system of claim 1, wherein the stack housings include a first support configured to abut one side of the received stack of media sheets, and a second support configures to abut another side of the received stack of media sheets to hold the received stack together during a rotation of the received stack and adhesive deposition onto the side of the received stack.

7. The system of claim 1, further comprising a delivery unit having an automated pusher, the automated pusher configured to move the stack of media sheets from an upstream source adjacent the carousel to the one of the stack housings for rotation thereof around the carousel.

8. The system of claim 1, further comprising a drive mechanism attached to the carousel and configured to rotate the carousel and transfer the stack of media sheets received in the one of the stack housing from a first orientation to a second orientation normal to the first orientation via the rotation of the carousel.

9. The system of claim 8, wherein the drive mechanism includes a stepper motor configured to incrementally rotate the carousel.

10. The system of claim 1, wherein the carousel is a vertically oriented carousel.

11. The system of claim 1, further comprising a curing device adjacent the carousel, the curing station configured to cure the adhesive layer to the side of the received stack of the media sheets and bind the media sheets at the side of the received stack together into the bound bundle of the media sheets.

12. A method for automatically binding stacks of media sheets, the system comprising: a) receiving a stack of media sheets via a stack housing of a carousel, the stack housing being one of a plurality of stack housings attached to the carousel adjacent a periphery thereof; b) rotating, via the stack housing, the received stack of media sheets incrementally around the carousel; and c) depositing a layer of an adhesive onto a side of the received stack of the media sheets during the incremental rotation via a padding station adjacent the stack housing, the padding station including a container housing the adhesive and an adhesive applicator, the adhesive layer curing and binding the received stack of the media sheets together into a bound bundle of the media sheets.

13. The method of claim 12, further comprising removing the bound bundle from the stack housing via an exit conveyor mechanism adjacent the carousel.

14. The method of claim 13, further comprising, after step c), continuing rotation of the received stack of media sheets via the stack housing to the exit conveyor mechanism, and during the continuing rotation, curing the deposited layer of the adhesive on the side of the received stack of the media sheets together into the bound bundle of the media sheets.

15. The method of claim 12, the step c) including the adhesive applicator rolling the layer of adhesive from the container across the side of the stack of the received media sheets.

16. The method of claim 12, further comprising, during the step b), the stack housing registering the received stack of media sheets within the stack housing, and abutting opposite sides of the registered received stack to hold the stack together during step c).

17. The method of claim 12, wherein step a) includes moving the stack of media sheets from an upstream source adjacent the carousel to the stack housing via an automated pusher.

18. The method of claim 12, wherein step a) includes receiving the stack of media sheets with the stack having a first orientation, and step b) includes incrementally rotating the received stack of media sheets in the stack housing from the first orientation to a second orientation normal to the first orientation via a drive mechanism attached to the carousel rotating the carousel.

19. The method of claim 18, wherein the step b) further includes incrementally rotating the received stack of media sheets in the stack housing from the second orientation to a third orientation opposite to the first orientation via the drive mechanism, and the method further comprises removing the bound bundle from the stack housing via an exit conveyor mechanism adjacent the carousel with the stack having the third orientation.

20. A device for automatically binding stacks of media sheets, the device comprising: a vertical carousel including a plurality of stack housings attached to the vertical carousel adjacent a periphery thereof, each of the stack housings configured to receive a respective stack of media sheets from an upstream source and to rotate the received stack around the vertical carousel; a padding station adjacent the stack housings, the padding station including a container housing an adhesive and an adhesive applicator configured to deposit a layer of the adhesive onto a side of the respective stack of media sheets received by one of the stack housings adjacent the padding station, the adhesive layer curing and binding the respective stack of media sheets into a bound bundle of the media sheets; and an exit conveyor mechanism adjacent the vertical carousel and configured to remove the bound bundle from the one of the stack housings.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Various exemplary embodiments of the disclosed apparatuses, mechanisms and methods will be described, in detail, with reference to the following drawings, in which like referenced numerals designate similar or identical elements, and:

[0011] FIG. 1 is a schematic diagram of an exemplary media sheet processing system according to systems, apparatuses and methods herein;

[0012] FIG. 2 is a partial perspective view of a related art media sheet processing apparatus;

[0013] FIG. 3 is a perspective view schematic diagram of a related art media sheet processing apparatus;

[0014] FIG. 4 is a side view of a related art stacking/collating device showing a series of angled baffles;

[0015] FIG. 5 is a top perspective view of a media sheet padding system in accordance with examples;

[0016] FIG. 6 is a side perspective view of the padding system in accordance with examples of the embodiments;

[0017] FIG. 7 is a side perspective view partially in section of a padding system in accordance with examples of the embodiments;

[0018] FIG. 8 is a flowchart depicting the operation of an exemplary automated media sheet padding system; and

[0019] FIG. 9 is a block diagram of a controller for executing instructions to control the automated media sheet padding system.

DETAILED DESCRIPTION

[0020] Illustrative examples of the devices, systems, and methods disclosed herein are provided below. An embodiment of the devices, systems, and methods may include any one or more, and any combination of, the examples described below. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth below. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Accordingly, the exemplary embodiments are intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the apparatuses, mechanisms and methods as described herein.

[0021] We initially point out that description of well-known starting materials, processing techniques, components, equipment and other well-known details may merely be summarized or are omitted so as not to unnecessarily obscure the details of the present disclosure. Thus, where details are otherwise well known, we leave it to the application of the present disclosure to suggest or dictate choices relating to those details. The drawings depict various examples related to embodiments of illustrative methods, apparatuses, and systems for automatically collecting, collating and transporting media sheets (e.g., workpieces, retail edge marker strips) destined for in-store shelves.

[0022] When referring to any numerical range of values herein, such ranges are understood to include each and every number and/or fraction between the stated range minimum and maximum. For example, a range of 0.5-6% would expressly include the endpoints 0.5% and 6%, plus all intermediate values of 0.6%, 0.7%, and 0.9%, all the way up to and including 5.95%, 5.97%, and 5.99%. The same applies to each other numerical property and/or elemental range set forth herein, unless the context clearly dictates otherwise.

[0023] The modifiers about and substantially used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (for example, it includes at least the degree of error associated with the measurement of the particular quantity). When used with a specific value, it should also be considered as disclosing that value. For example, the term substantially 2 also discloses the value 2 and the range from about 2 to about 4 also discloses the range from 2 to 4.

[0024] The term controller or control system is used herein generally to describe various apparatus such as a computing device relating to the operation of one or more device that directs or regulates a process or machine. A controller can be implemented in numerous ways (e.g., such as with dedicated hardware) to perform various functions discussed herein. A processor is one example of a controller which employs one or more microprocessors that may be programmed using software (e.g., microcode) to perform various functions discussed herein. A controller may be implemented with or without employing a processor, and also may be implemented as a combination of dedicated hardware to perform some functions and a processor (e.g., one or more programmed microprocessors and associated circuitry) to perform other functions. Examples of controller components that may be employed in various embodiments of the present disclosure include, but are not limited to, conventional microprocessors, application specific integrated circuits (ASICs), and field-programmable gate arrays (FPGAs).

[0025] Embodiments as disclosed herein may also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code means in the form of computer-executable instructions or data structures. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or combination thereof) to a computer, the computer properly views the connection as a computer-readable medium. Thus, any such connection is properly termed a computer-readable medium. Combinations of the above should also be included within the scope of the computer-readable media.

[0026] Computer-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, objects, components, and data structures, and the like that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described therein.

[0027] Although embodiments of the invention are not limited in this regard, discussions utilizing terms such as, for example, processing, computing, calculating, determining, using, establishing, analyzing, checking, or the like, may refer to operation(s) and/or process(es) of a controller, computer, computing platform, computing system, or other electronic computing device, that manipulate and/or transform data represented as physical (e.g., electronic) quantities within the computer's registers and/or memories into other data similarly represented as physical quantities within the computer's registers and/or memories or other information storage medium that may store instructions to perform operations and/or processes.

[0028] Referring now to the drawings, and more specifically to FIG. 1, what is illustrated is an exemplary automated media sheet processing system 10, which can be used with methods herein. The system 10 is an example of a multidirectionally stepped auto-collator system that may automatically collate and transfer media sheets exiting an upstream source (e.g., media supply 12, person) such as a conventional unwinder that roll feeds media sheets in continuous sheet form into a conventional cutter 14 that cuts the continuous roll fed sheet media sheets into predetermined lengths of, e.g., about 5 inches to 8 feet, or about 8 inches to 2 feet, or about 13-14 inches. In examples, each predetermined sheet length may be cut into four separate and individual workpieces (e.g., media sheets 32 (FIG. 3)) and each workpiece may be perforated into a number (e.g., four) of parallel sections to accommodate different in-store requirements. It is understood that the predetermined sheet lengths may be cut into other numbers of separate and individual workpieces, and that each individual workpiece may be perforated into other numbers of different parallel sections.

[0029] The system 10 includes a controller 16 and at least one marking device (printing engine(s)) 18 operatively connected to the controller. The system may also include a communications port (Input/Output device 20) operatively connected to the controller 16 and to a computerized network external to the system 10. The Input/Output device 20 may be used for communications to and from the system 10, as well understood by a skilled artisan.

[0030] The controller 16 includes at least one processor and controls the various actions of the system 10, as described in greater detail below. A storage medium 22 (e.g., non-transitory computer storage medium, which may be optical, magnetic, capacitor based, etc.) is readable by the controller 16 and stores instructions that the controller 16 executes to allow the system 10 to perform its various functions, such as those described herein. Thus, as shown in FIG. 1, a body housing 24 has one or more functional components that operate on power supplied from an external power source 26, which may comprise an alternating current (AC) power source, through a power supply 28. The power supply 28 may include a power storage element (e.g., a battery) and connects to the external power source 26. The power supply 28 converts the power from the external power source 26 into the type of power needed by the various components of the system 10.

[0031] The system 10 media supply 12 provides media to a media path 30. The media path 30 may include any combination of belts, rollers, nips, drive wheels, vacuum devices, air devices, etc. that transport the media from the media supply 12 through system 10, as well understood by a skilled artisan. The system 10 includes a marking device (e.g., printing engine 18) positioned along the media path 30. The marking device prints marks on the media. Further, the cutter 14 may be positioned along the media path 30, and the cutter divides (cuts) the media into individual workpieces or media sheets 32 (FIG. 3), such as retail edge marker strips or signs.

[0032] While signs are used as an example of a type of media sheet that can be processed with the system 10 herein, those ordinarily skilled in the art understand that virtually any form of workpiece that can be stacked could be used with the disclosed structures and methods, and the claims are not limited only to signs. Therefore, signs, sheets of paper, cards, pieces of plastic, etc., as well as many other items could be the media sheets processed by the systems and methods herein.

[0033] A patterning device 34 may be positioned along the media path 30. The patterning device 34 may include cutters in addition to the cutter 14 to further cut the media sheets into smaller media sheets (e.g., orthogonally to the first direction slit of the cutter 13), such that each further cut media sheet may correspond to an individual sign. The patterning device 34 may also insert additional patterns into the media sheets 32, such as perforations. The cutter 14 and the patterning device 34 may be combined into a single device or can be separate devices, depending upon the specific configuration. Further, the printing engine 18, cutter 14, and patterning device 34 may be positioned in any order along the media path 30, and the order shown is purely arbitrary.

[0034] While not being limited to a particular configuration, system 10 may include at least one accessory functional component, such as a graphic user interface (GUI) assembly 36, an optical scanner 38, or other accessory functional component (such as a document handler, automatic document feeder (ADF), etc.) that operate on power supplied from the external power source 26 via the power supply 28.

[0035] A transport device 40 is additionally positioned along the media path 30. The transport device 40 moves the media sheets 32 from the media path 128 and places the media sheets into a collating apparatus 42. After the media sheets 32 are compiled and collated, the collated media sheets may be forwarded (e.g., via a stack platform 64 (FIG. 4)) to additional stations, such as a binding system 44, for further processing as discussed in greater detail below.

[0036] As would be understood by those ordinarily skilled in the art, the system 10 shown in FIG. 1 is only one example and the systems and methods herein are equally applicable to other types of devices that may include fewer components or more components. For example, while a limited number of printing engines and media paths are illustrated in FIG. 1, those ordinarily skilled in the art would understand that many more media paths and additional printing engines may be included within any device used with embodiments herein.

[0037] FIGS. 2 and 3 depict related art media sheet processing apparatus media path sections including an accumulation and collating device 52 located directly after a transport device 40. FIG. 3 depicts a related art accumulation and collating device 52 in side view. The accumulation and collating device 52 includes a series of ramped angled baffles 54 that accept and register media sheets 32 exiting the transport device 40 and accumulates the registered media sheets. Each angled baffle 54 is configured to allow the media sheets 32 to fall into place during an accumulation stage and then allow the media sheets to be collated into a compiled stack after a predetermined number of the media sheets have been fed from transport device 40, such as the number of signage sheets for a retail store or part thereof. The angled baffles 54 may also have an aperture 94 (FIG. 2.) that splits the baffles 54 into separate sections to permit transverse movement by a pusher 56, as will be described in greater detail below.

[0038] As may be seen in FIGS. 2 and 3, the transport device 40 moves media sheets 32 to the related art accumulation and collating device 52. The accumulation and collating device 52 may include a buffer/compiler 58 above a sequential cross-process collator 60 having the angled baffles 54. The buffer/compiler 58 holds one or more media sheets 32 in stacks 62 above the collator 60 to allow time for the collator to actuate and reset before the next stack 62 of media sheets 32 are collated. In examples, the buffer/compiler 58 includes shelves 46 that support the stacks 62 above respective angled baffles 54. The buffer/compiler may also include walls 48 between shelves 46 to help segregate the media sheets 32 into separate stacks 62 on the shelves.

[0039] The compiling and collating process may be divided into stages. In a first stage, the media sheets 32 are output from the body housing 24 into the buffer/compiler 58 where they are compiled in stacks 62 on the shelves 46. The media sheets 32 in the stacks 62 may be in a predetermined sequential order as controlled by the controller 16. In a second stage, also referred to as an accumulation state, the stacks 62 are dropped onto the angle baffles 54 of the collator 60.

[0040] The stacks 62 may be dropped from the shelves 46 in various ways. For example, the shelves 46 may be moveable and configured to slide out to a first position to support media sheets 32 output from the body housing 24, and also to retract or otherwise move to a second position that allows the stacked media sheets to fall or move onto the angled baffles 54. In other examples the stacks 62 may be urged or pushed out of the shelves 46 onto the angled baffles, as well understood by a skilled artisan.

[0041] As can be seen in FIG. 3, the collator 60 includes the series (e.g., more than one) of ramped angle baffles 54 and an automated pusher 56 that moves each of the stacks 62 toward the combined collated stack 66. At the end of the accumulation stage, the pusher 56 is moved generally orthogonally to the media sheets 32 to push the media sheets from each ramped angled baffle 54 onto the top of media sheets in adjacent bins of baffles 54 in succession to collate the media sheets onto the stack platform 64. That is, during this stage, which may be considered a third stage, the pusher 56 sweeps the stacks 62 in sequential order as an interim stack 68. Continued sweeping of the pusher across the baffles 54 to the stack platform 64 results in the interim stack 68 of collated media sheets 32 pushed onto the stack platform as the combined collated stack 66. The combined collated stack 66 may have a predetermined number of media sheets 32 in a known order (e.g., in-store planogram order) as controlled by the controller 16. Pusher 56 may be arranged for automated pulling through the aperture 94 (FIG. 2) between baffles 54 onto and across the platform 64 as desired to unload the dropped media sheet stacks 62 from each baffle and simultaneously convey the interim stack 68 onto the platform at a stacking position thereon laterally across from the angled baffles as the collated stack 66 after all of the predetermined number of media sheets 32 have been fed from the transport device 40.

[0042] The multi-stage process may allow the transport device 40 to stack the media sheets 32 in the buffer/compiler 58 for temporary holding in order to provide the time needed for previous sets of media sheets to be collated underneath. This allows the pusher 56 time to move the interim stacks 68 into a combined collated stack 66 and to return to a starting (e.g., home) position prior to the buffer/compiler 58 releasing its temporary hold of the stacks 62 and dropping the next stacks down into the collator 60.

[0043] As discussed above, prior art banding systems have proven to be problematic in their execution and delivery. Exemplary embodiments overcome the shortcomings of current banding operations by introducing a vertical carousel padding system that binds stacks of media sheets. The vertical carousel padding system creates adhesive based aisle stacks of media sheet signage that eliminates current banding operation while improving both instore performance and print/finishing efficiencies at the media sheet processing facility. The vertical carousel padding system may create an adhesive retail signage pack (bundle) based on aisles and aisle groupings where the adhesive is applied along the long edge of the stack to make a bound bundle that allows for an operator at a store to remove one sign at a time. The system can accept stacks of varying heights and apply a padded layer of adhesive to the stacks as the clamped stacks move orthogonally around the carousel motion to the glue roller application station.

[0044] In examples of the vertical carousel padding system, collated stacks 66 are delivered to a pocket or stack housing on the carousel that is then incremented in a quick rotational motion to make another pocket/housing available for a next incoming stack. The stack 66 is then registered, for example, by vibrating the angled catch (stack) housing and then clamped to hold and compress the stack. The system indexes one step each time the next new collated stack is delivered to the carousel, with each step being at least one rotational increment around the carousel. As the carousel rotates, the indexed stacks pass a padding/gluing station that dispenses a thin layer of hotmelt adhesive or other adhesive designed to at least temporarily bind media sheets together along a near edge of the stack and creates a padded stack or bundle. The padding system may pad each stack with the stack housings accommodating variable stack heights and the clamping surface moved to meet and clamp the stack during the padding process. The padded stacks continue to index as the carousel is rotated and cure as the system indexes. The bundles/stacks are then removed from the carousel to be transported to the boxing area.

[0045] By gripping and then incrementing the stacks in a vertical carousel configuration, the correct edge of the stack can have the adhesive applied to it while the stack height (size based on the number of media sheets in the stack) does not require the padding station to adjust to the stack height. The incrementing carousel motion allows for additional time to be added to the process without increasing the time that a new set can be delivered to the system. By incrementing the carousel, the dry or cure time is increased since multiple sets can be contained within the carousel system at any one time with no reciprocating motion.

[0046] FIGS. 5-7 depict an exemplary vertical carousel padding system 70 (e.g., binding system 44) in top perspective, side perspective and partial sectional views, respectively. The padding system 70 is an exemplary binding system 44 (FIG. 1) designed to automatically bind stacks 66 of media sheets 32 forwarded to the padding system into bound bundles of the media sheets. In examples, the stacks may be forwarded to the padding system by a delivery unit 72. While not being limited to a particular configuration, the delivery unit 72 may include elements of the media sheet processing system 10, such as the stack platform 64 and the automated pusher 56 configured to move the combined collated stacks 66 across the platform to the padding system 70 located adjacent the stack platform. It is understood that the examples are not limited to a particular delivery unit, and the delivery unit may be other devices that forward the stacks 66 to the padding system, including a conveyor belt or arm, as readily understood by a skilled artisan.

[0047] The padding system 70 includes a carousel 74 that may be adjacent the delivery unit 72 (e.g., platform 64 and pusher 56) to receive stacks 66 therefrom. The carousel 74 may have a generally cylindrical shape and includes a plurality of stack housings 76 or receiving bins attached to the carousel adjacent the circumferential periphery thereof. The stack housings 76 are configured to receive stacks 66 of the media sheets 32 from the delivery unit 72 and rotate the received stacks of media sheets incrementally around the carousel. While not being limited to a particular theory, the carousel 74 is shown as vertical or substantially vertical in certain examples. It is understood that the carousel is not limited to a vertical configuration, and may be other angles, including tilted or even horizontal in some examples.

[0048] A drive mechanism 78 (FIG. 6) may be attached to the carousel 74 to rotate the carousel, as well understood by a skilled artisan. The drive mechanism 78 may include a motor (e.g., stepper motor 80) that incrementally indexes or rotates the carousel 74 and enable the stack housings 76 to transfer media sheet stacks 66 from the delivery unit around a padding station 90 to an exit station 82 (FIG. 6), as will be discussed in greater detail below. Carousel 74 incremental indexes are not limited to a particular increment distance or angle of rotation. In examples the increments may allow the carousel to pause temporarily between incremental rotation for easier delivery of the stacks into the stack housings and exit from the housings at the exit station 82, as will be described in greater detail below.

[0049] Referring to FIG. 7, the stack housings 76 each include a bottom wall 84 and radially extending arm walls 86, 88 configured to receive and hold a stack 66 of the media sheets 32 during rotation of the received stack incrementally around the carousel. The arm walls may be opened or closed relative to each other. For example, the arm walls 86, 88 may be separated as needed to accept a stack 66 of the media sheets, and then closed as needed to hold a stack 66 via a clamping device (e.g., cam system, spring loaded arms, pneumatics, stepper drive) operating via the controller 16, as well understood by a skilled artisan. Thus the stack housings can accept stacks 66 of varying heights or thicknesses by opening the arm walls 86, 88 wider than the stack forwarded to the carousel 74. With the arm walls opened, the delivery unit 72 may move a stack 66 into a stack housing 76 with a front edge 85 of the stack moved into contact with the bottom wall 84.

[0050] The stack housings 76 are catch bins configured to vibrate, for example via the drive mechanism 78, stepper motor 80 or other vibration causing motor (e.g., Eccentric Rotating Mass (ERM) motor, Linear Resonant Actuator (LRA)) in contact with the housings. In examples, stack housings 76 vibrate after receipt of a stack 66 of media sheets 32 for registration of the media sheets. Referring to FIG. 7, the stack housings 76 may vibrate the media sheets 32 of stacks placed into the housings, and register or align the sheets along the bottom wall 84 as the carousel 74 incrementally rotates the registering stacks in the housings from a generally horizontal orientation delivered from the delivery unit 72 to a tilted increasingly vertical orientation as each rotating stack housing with a registering stack therein approaches the padding station 90. During stack registration, the stack housing holds the media sheets 32 of the stack loosely to allow relative sliding of vibrated media sheets into registration. Prior to arrival at the padding station 90 (e.g., less than 20 degrees prior, less than 10 degrees prior, about 5 degrees prior), the stack housing arm walls 86, 88 may close or clamp against the stack 66 (e.g., via cam system, spring loaded arm walls, pneumatics, stepper drive) to grip the stack securely as the stack advances across the padding station.

[0051] Referring still to FIGS. 5-7, the carousel 74 may include outer rings 92 that connect the stack housings 76 therebetween. The outer rings 92 structurally keep the stack housings spatially separate around the circumference of the carousel rings, and are not otherwise limited to a particular size or thickness. Stack housings 76 may be split into lateral sections, for example two lateral sections 96, 98 that define a slotted aperture 100 therebetween. Each of the later sections may be connected to one of the outer rings 92, with the sections aligned across the slotted aperture 100 to hold stacks 64 as can be seen by example in FIGS. 5-7. The slotted aperture 100 allows access to the stack held by the stack housing lateral sections, for example as discussed in greater detail below.

[0052] The padding station 90 may be located adjacent the carousel 74 between the delivery unit 72 and the exit station 82 in the rotational processing direction 102 of the carousel. The padding station 90 may include an adhesive container 104 and an adhesive applicator 106 (e.g., roller, anilox roller, brush, sponge, doctor blade, sprayer, thermal or piezoelectric adhesive emitter) in communication with an adhesive 108 (e.g., hotmelt, liquid, gel, aerosol, particle) held in the adhesive container for applying or depositing a strip of the adhesive onto a side (e.g., front edge) of a stack 66 of media sheets 32 adjacent the adhesive applicator. In the example depicted in FIG. 7, the adhesive applicator 106 includes a roller 110 in contact with adhesive 108 in the container 104 and adjacent the front edge 85 of a stack 66 via the aperture 100 in a stack housing 76. As the carousel 74 rotates the indexed registered stacks 66 past the padding station 90, the adhesive applicator 106 deposits a thin layer 112 of adhesive along the front edge of the stack 66 and creates a padded bundle 114.

[0053] The roller 10 may rotate and transfer adhesive 108 from the container 104 to the stack 66 through the aperture 100 as a layer 112 of adhesive along the front edge of the stack facing the roller with the media sheets 32 in the stack registered in a generally vertical orientation. While not being limited to a particular theory, the adhesive applicator 106 may use an anilox roller or doctor blade (not shown) to meter the adhesive from the adhesive container 104 onto the stack 66 side surface, either directly or via one or more adhesive applicator rollers that are in contact with the stack side surface. In some examples, the adhesive applicator 106 may include a jetting device (not showne.g., sprayer, jetting nozzles, aerosol generator, jet nebulizer, piezo-based atomizer) that may spray, shoot, deposit, or otherwise apply the adhesive to the stack side surface.

[0054] After the strip or layer 112 of adhesive is applied to a now padded bundle 114, the bundle continues its rotation in the carousel 74 towards the exit station 82. During this continued rotation, the adhesive strip is cured to securely bind together the individual media sheets 32 of the padded bundle 114 along the front edge 85 of the stack. The padding system 70 may include a curing device 116 adjacent the carousel 74 that further cures and/or accelerates curing of the adhesive strip. While not being limited to a particular theory, the curing device 116 may help expedite the drying/curing of the adhesive strips with a curing mechanism such as a curing lamp (e.g., laser, UV laser, UV LED light source), wavelength tunable photoinitiator, heat lamp, forced heat, forced air or other drying/curing source that exposes the layer 112 of adhesive to an amount of heat, air, chemical or other radiation emission 118 to at least partially cure/dry the adhesive to a tacky or solid state adequate for subsequent handling and shipping of the padded bundles 114. The curing device 116 may include various forms of optical or photo curing, thermal curing, electron beam curing, drying, or chemical curing, as well understood by a skilled artisan. In the exemplary padding system 70 depicted in FIG. 7, curing device 116 may be positioned adjacent and radially inside the carousel 74 to cure/dry adhesive strips to the front edge 85 of stacks 66 between the padding station 90 and the exit station 82.

[0055] The exit station 82 is located adjacent the carousel 74 downstream the padding station 90 to remove bound padded bundles 114 from their respective stack housing 76. Still referring to the exemplary padding system 70 depicted in FIG. 7, the exit station 82 includes a conveyor mechanism having a conveyor belt 120 configured to move the cured padded bundles 114 away from the stack housings 76 for exit and subsequent processing (e.g., packing, shipping). In some examples the conveyor mechanism may also include profile fins 122 extending out from the conveyor belt 120 that help to remove the padded bundles 114 from their respective housings 76 for exit from the padding station 70 on the conveyor belt 120. The conveyor belt 120 and fins 122 may be sized to have a width less than a width of the slotted apertures 100 defined by lateral sections 96, 98 of the stack housings 76 so they can traverse through the slotted apertures and shift the padded bundles 114 away from the housings and carousel 74. The belt 120 may be driven by a motor (not shown) that drives the belt, for example, via roller 24, as well understood by a skilled artisan.

[0056] To aid in the removal of the padded bundles 114 from stack housings 77, the arm walls 86, 88 previously clamped at least a few degrees before glue application at the padding station 90 may be unclamped or separated before stack housings reach the exit station. The unclamped padded bundles 114 are not held tightly by the separated arm walls 86, 88 and may be easily removed from stack housing 77 by the conveyor belt 120 without need or assistance by profile fins 122. Accordingly, the conveyor mechanism may readily remove padded bundles 144 from opened housings 77 without clamped friction via the conveyor belt 120 without profile fins, which provides an additional benefit of allowing the adhesive strips additional time to cure or dry to the touch prior to subsequent contact or handling. It is understood that the conveyor belt 120 is part of an exemplary exit conveyor mechanism and other conveyor mechanisms may be used in examples as understood by a skilled artisan.

[0057] In operation, the vertical carousel padding system 70 receives a stack 66 of previously collated loose media sheets 32 where the stack is first placed into a catch bin or stack housing of the carousel 74. The stack is registered via a vibration jogging motor of the carousel drive mechanism 78 as it is stepped through the vertical rotation of the carousel 74. The registered stack passes by a gluing/padding station 90 to receive a layer or strip of adhesive, and then incrementally is rotated to the exit station 82. The adhesive is cured during the last leg of the rotation of the padded bundle around the carousel 74 prior to being delivered to the exit conveyor mechanism. The stacks of media sheets 32 are gripped during the rotation of the stacks before and after gluing until just before the stacks exit the carousel. This stack housings are automatically activated to grip the signs once they are registered in the stack housings 76 during a first segment of rotational motion of incremented locations via spring load or motion activated clamping system, as well understood by a skilled artisan.

[0058] The disclosed embodiments may include an exemplary method for automatically binding stacks of media sheets exiting an upstream source, which may include the platform 64 and delivery unit 72. FIG. 8 illustrates a flowchart of such an exemplary method. As shown in FIG. 8, operation of the method commences at Step S100 and proceeds to Step S110, where a padding system receives a stack of media sheets from the upstream source via a stack housing of a carousel adjacent the stack platform. The stack housing is one of a plurality of stack housings attached to the carousel adjacent a periphery thereof. This step may include moving the stack of media sheets from the upstream source to the stack housing via an automated pusher adjacent the platform. The received stack may have a horizontal orientation with its media sheets generally horizontal.

[0059] Operation of the method proceeds to Step S120, where the received stack of media sheets in the stack housing is rotated incrementally around the carousel. During this rotation, the received stack may rotate from a first orientation (e.g., media sheets generally horizontal) to a second orientation that may be normal (e.g., media sheets generally vertical) or orthogonal to the first orientation. This rotation may further include continued rotation of the received stack to a third orientation that may be normal (e.g., media sheets generally horizontal and opposite or upside down from the first orientation) to the second orientation. Increments may be stepped (e.g., a fraction of 90 degrees, about 30 degrees, less than about 15 degrees) and allow the carousel to pause temporarily between incremental rotations.

[0060] Operation proceeds to Step S130, the media sheets in the rotating stack housing are registered, for example, along a front edge of the stack abutting a wall of the stack housing. In other words, stack housings may vibrate the media sheets of stacks placed into the housings, and register or align the sheets along the bottom wall thereof as the carousel incrementally rotates the registering stacks from a generally horizontal orientation delivered from the delivery unit to a tilted increasingly vertical orientation. During stack registration, the stack housing may hold the media sheets of the stack loosely to allow relative sliding of vibrated media sheets into registration. After registration, the stack housing may clamp the registered media sheets and hold the stack together securely during continued rotation for further processing.

[0061] At Step S140 a padding station deposits a layer of an adhesive onto a side of the received stack of the media sheets and creates a padded stack of the media sheets. The padding station may include a container housing the adhesive and an adhesive applicator, and the adhesive applicator may roll a strip of the adhesive from the container across the side of the stack. The adhesive layer cures and binds the padded stack of the media sheets together into a bound bundle of the media sheets. Operation proceeds to Step S150, where a curing device adjacent the carousel may further cure and/or accelerate curing of the adhesive strip on the side of the padded stack into the bound bundle with the media sheets bound together via the adhesive strip.

[0062] The bound bundle continues its rotation around the carousel 74 towards an exit station. At Step S160, an exit conveyor mechanism at the exit station removes the bound bundle from the stack housing. The conveyor mechanism may include a conveyor belt that rotates adjacent the stack housings to move the cured bound bundles away from the stack housings for exit of the carousel and subsequent processing. Operation may continue by repeating back to Step S110 for binding of additional stacks of media sheets or stop as Step S170 upon completion of a desired group of stacks.

[0063] The exemplary depicted sequence of executable method steps represents one example of a corresponding sequence of acts for implementing the functions described in the steps. The exemplary depicted steps may be executed in any reasonable order to carry into effect the objectives of the disclosed embodiments. No particular order to the disclosed steps of the method is necessarily implied by the depiction in FIG. 8, and the accompanying description, except where any particular method step is reasonably considered to be a necessary precondition to execution of any other method step. Individual method steps may be carried out in sequence or in parallel in simultaneous or near simultaneous timing. Additionally, not all of the depicted and described method steps need to be included in any particular scheme according to disclosure.

[0064] FIG. 9 illustrates a block diagram of the controller 16 for executing instructions to automatically control the automated media sheet processing system 10 and components thereof (e.g., binding system 44, vertical carousel padding system 70). The exemplary controller 16 may provide input to or be a component of a controller for executing the media sheet processing method for automatically binding stacks of media sheets exiting an upstream source in a system such as that depicted in FIGS. 1, 5-8, and described in greater detail below.

[0065] The exemplary controller 16 may include an operating interface 132 by which a user may communicate with the exemplary control systems. The operating interface 132 may be a locally-accessible user interface associated with the automated media sheet processing system 10. The operating interface 132 may be configured as one or more conventional mechanism common to controllers and/or computing devices that may permit a user to input information to the exemplary controller 16. The operating interface 132 may include, for example, a conventional keyboard, a touchscreen with soft buttons or with various components for use with a compatible stylus, a microphone by which a user may provide oral commands to the exemplary controller 16 to be translated by a voice recognition program, or other like device by which a user may communicate specific operating instructions to the exemplary controller. The operating interface 132 may be a part or a function of the graphical user interface (GUI) 36 mounted on, integral to, or associated with, the automated media sheet processing system 10 with which the exemplary controller 16 is associated.

[0066] The exemplary controller 16 may include one or more local processors 134 for individually operating the exemplary controller 16 and for carrying into effect control and operating functions for automated processing of media sheets 32 for distribution to associated retail stores, including accumulating the sheets onto baffles 72, collating the accumulated sheets into collated stacks 66, transferring the collated stacks to platforms 64, and/or binding the collated stacks into bound bundles for further processing. For example, in real-time upon receipt of collated stacks 66 exiting an upstream source, processors 134 may trigger an automated vertical carousel padding system 70 bind the media sheets in collated stacks together into padded bundles in store planogram order, and then move the padded bundles for subsequent packaging and shipment as needed to an associated retail store. Processor(s) 134 may include at least one conventional processor or microprocessor that interprets and executes instructions to direct specific functioning of the exemplary controller 16, and control media sheet processing with the exemplary controller.

[0067] The exemplary controller 16 may include one or more data storage devices 136, including the computer storage medium 22. Such data storage device(s) 136 may be used to store data or operating programs to be used by the exemplary controller 16, and specifically the processor(s) 134. Data storage device(s) 136 may be used to store information regarding, for example, media sheet status information, media sheet accumulation information, media sheet compilation information, media sheet stack information, media sheet stack binding information, and other processing information with which the automated media sheet processing system 10 is associated. Stored media sheet and stack data may be devolved into data to generate a recurring, continuous or automated media sheet vertical carousel padding system in the manner generally described by examples herein.

[0068] The data storage device(s) 136 may include a random access memory (RAM) or another type of dynamic storage device that is capable of storing updatable database information, and for separately storing instructions for execution of media sheet processing by, for example, processor(s) 134. For example, a data storage device 136 may be coupled to the processor 134, and may include instructions which when executed by the processor, cause the processor to direct the vertical carousel padding system 70 to rotate received stacks of media sheets around a carousel, register the media sheets, pad the media sheets into a bound bundle and deliver the bound bundles from the carousel downstream for further processing. Data storage device(s) 136 may also include a read-only memory (ROM), which may include a conventional ROM device or another type of static storage device that stores static information and instructions for processor(s) 134. Further, the data storage device(s) 136 may be integral to the exemplary controller 16, or may be provided external to, and in wired or wireless communication with, the exemplary controller 16, including as cloud-based data storage components.

[0069] The data storage device(s) 136 may include non-transitory machine-readable storage medium used to store the device queue manager logic persistently. While a non-transitory machine-readable storage medium is may be discussed as a single medium, the term machine-readable storage medium should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store one or more sets of instructions. The term machine-readable storage medium shall also be taken to include any medium that is capable of storing or encoding a set of instruction for execution by the controller 16 and that causes the automated media sheet processing system 10 and binding system 44 to perform any one or more of the methodologies of the present invention. The term machine-readable storage medium shall accordingly be taken to include, but not be limited to, solid-state memories, and optical and magnetic media.

[0070] The exemplary controller 16 may include at least one data output/display device 138, which may be configured as one or more conventional mechanisms that output information to a user, including, but not limited to, a display screen on a GUI 36 of the automated media sheet processing system 10 device with which the exemplary controller 16 may be associated. The data output/display device 138 may be used to indicate to a user a status of the automated media sheet processing system 10 with which the exemplary controller 16 may be associated including an operation of one or more individually controlled components at one or more of a plurality of separate media sheet processing stations or subsystems associated with the automated media sheet processing system, including but not limited to the media supply 12, the buffer/compiler 58, the transport device 40, the collating apparatus 42, the delivery unit 72, and the binding system 44.

[0071] The exemplary controller 16 may include one or more separate external communication interfaces 140 by which the exemplary controller 16 may communicate with components that may be external to the exemplary media sheet processing system such as the media supply 12 and cutter 14. At least one of the external communication interfaces 140 may include the input/output device 20 and be configured as an input port to support connecting an external CAD/CAM device storing modeling information for execution of the control functions in the media sheet processing operations. Any suitable data connection to provide wired or wireless communication between the exemplary controller 16 and external and/or associated components is contemplated to be encompassed by the depicted external communication interface 140.

[0072] The exemplary controller 16 may include a media sheet processing control device 142 that may be used to control a media sheet processing process including media sheet accumulation, collating, padding and transfer. The media sheet processing control device 142 may operate as a part or a function of the processor 134 coupled to one or more of the data storage devices 136 and the automated media sheet processing system 10, or may operate as a separate stand-alone component module or circuit in the exemplary controller 16.

[0073] All of the various components of the exemplary controller 16, as depicted in FIG. 9, may be connected internally, and to the automated media sheet processing system 10, associated media sheet formation and processing devices upstream or downstream the automated media sheet processing system and/or components thereof, by one or more data/control busses 144. These data/control busses 144 may provide wired or wireless communication between the various components of the automated media sheet processing system 10 and any associated media sheet formation and processing devices, whether all of those components are housed integrally in, or are otherwise external and connected to the automated media sheet processing system with which the exemplary controller 16 may be associated.

[0074] It should be appreciated that, although depicted in FIG. 9 as an integral unit, the various disclosed elements of the exemplary controller 16 may be arranged in any combination of subsystems as individual components or combinations of components, integral to a single unit, or external to, and in wired or wireless communication with the single unit of the exemplary control system. In other words, no specific configuration as an integral unit or as a support unit is to be implied by the depiction in FIG. 9. Further, although depicted as individual units for ease of understanding of the details provided in this disclosure regarding the exemplary controller 16, it should be understood that the described functions of any of the individually-depicted components, and particularly each of the depicted control devices, may be undertaken, for example, by one or more processors 134 connected to, and in communication with, one or more data storage device(s) 136.

[0075] Those skilled in the art will appreciate that other embodiments of the disclosed subject matter may be practiced with many types of media sheet processing elements common to automated media sheet processing systems in many different configurations. For example, although automated media sheet processing systems and methods are shown in the discussed embodiments, the examples may apply to other types of media sheet processing systems and methods. It should be understood that these are non-limiting examples of the variations that may be undertaken according to the disclosed schemes. In other words, no particular limiting configuration is to be implied from the above description and the accompanying drawings.

[0076] It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art.