Labeling apparatus with web registration, web cutting and carrier mechanisms, and methods thereof

An apparatus, comprising:

• (a) a web supply configured to supply a web of material;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface;
• (c) a first drive mechanism coupled to the drum and configured to continuously rotate the drum and advance the outer surface thereof at a first predetermined rate;
• (d) a second drive mechanism configured to continuously advance the web of material at a second predetermined rate, wherein the first and second predetermined rates are different from one another;
• (e) a cutter mechanism configured to sever a segment from the web of material at a predetermined rotational position of the drum while at least a portion of the web of material engages the outer surface of the drum;
• (f) a controller configured to dynamically control at least one of the first and second drive mechanisms such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the predetermined rotational position;
• and
• (g) a linear feed rate sensor disposed between the web supply and the drum and coupled to the controller, the linear feed rate sensor generating an output signal associated with a linear feed rate for the web of material.

A labeling apparatus, comprising:

• (a) a web supply configured to supply a web of label material, the label material including indicia disposed at predetermined positions thereon, the web supply including a supply roll;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface providing a source of attraction for the web of label material;
• (c) a registration sensor configured to detect the indicia on the web of label material;
• (d) a first drive mechanism coupled to the drum and configured to rotate the drum at a first predetermined rate;
• (e) a second drive mechanism coupled directly to the supply roll of the web supply and configured to supply the web of label material at a second predetermined rate, wherein the first predetermined rate is greater than the second predetermined rate;
• (f) a stationary knife disposed proximate the drum at a stationary position;
• (g) a retractable knife coupled to the drum and configured to rotate with the drum and engage the stationary knife when the drum is disposed at a predetermined rotational position;
• (h) a linear feed rate sensor disposed between the web supply and the drum and coupled to a controller, the linear feed rate sensor generating an output signal associated with a linear feed rate for the web of material;
• and
• (i) the controller, coupled to the linear feed rate sensor, the first and second drive mechanisms and the registration sensor, the controller configured to control at least one of the first and second predetermined rates such that a desired length of label material is advanced forward of the rotating knife on the drum as the rotating knife engages the stationary knife at the predetermined rotational position of the drum and thereby severs the desired length of label material from the web of material.

A method of severing labels of predetermined length from a web of material, the method comprising:

• (a) advancing a web of material toward a rotating drum, the web of material including a sequence of unsevered labels;
• (b) attracting the web of material into engagement with the outer surface of the drum;
• (c) severing a label from the web of material while at least a portion of the web of material engages the outer surface of the drum using a retractable knife coupled to the drum and configured to rotate with the drum;
• (d) rotating the drum and advancing the outer surface thereof at a rate greater than the rate at which the web of material is advanced from the web supply;
• (e) applying an adhesive with an adhesive applicator to at least a portion of the label while at least a portion of the label engages the outer surface of the drum;
• and
• (f) retracting the retractable knife within the outer surface of the drum when the knife is proximate the adhesive applicator.

A method of severing segments of predetermined length from a web of material, the method comprising:

• (a) continuously rotating a drum at a first predetermined rate;
• (b) continuously advancing a web of material at a second predetermined rate such that the web of material engages an outer surface of the drum, wherein the first and second predetermined rates are different;
• (c) severing a segment from the web of material at a predetermined rotational position of the drum and as at least a portion of the web of material engages the outer surface of the drum;
• (d) dynamically controlling at least one of the first and second predetermined rates such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the predetermined rotational position;
• and
• (e) sensing the second predetermined rate using a rotational sensor coupled to a free wheeling roller having a fixed diameter and engaging the web of material upstream of the drum.

A method of severing segments of predetermined length from a web of material, the method comprising:

• (a) continuously rotating a drum at a first predetermined rate;
• (b) continuously advancing a web of material at a second predetermined rate such that the web of material engages an outer surface of the drum, wherein the first and second predetermined rates are different;
• (c) severing a segment from the web of material at a predetermined rotational position of the drum and as at least a portion of the web of material engages the outer surface of the drum;
• (d) dynamically controlling at least one of the first and second predetermined rates such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the predetermined rotational position;
• and
• (e) attracting the web of material into engagement with the outer surface of the drum, wherein dynamically controlling includes rotating the drum and advancing the outer surface thereof at a rate greater than the rate at which the web of material is advanced from the web supply, and wherein the attraction of the web of material to the drum is the sole source of tension between the web supply and the drum.

An apparatus, comprising:

• (a) a web supply configured to supply a web of material, the web of material including a sequence of unsevered labels;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface;
• (c) an attraction mechanism disposed on the outer surface of the drum and configured to attract the web of material to the outer surface of the drum;
• (d) a drive mechanism coupled to the drum and configured to rotate the drum and advance the outer surface thereof at a rate greater than a rate at which the web of material is advanced from the web supply;
• (e) a cutter mechanism coupled to the drum and configured to sever a label from the web of material while at least a portion of the web of material engages the outer surface of the drum, the cutter mechanism including a retractable knife disposed on the drum and configured to rotate with the drum;
• and
• (f) an application station configured to pass a container past the drum to engage the label and thereby transfer the segment from the outer surface of the drum to an outer surface of the container.

An apparatus, comprising:

• (a) a web supply configured to supply a web of material;
• (b) a rotatable drum configured to receive the web of material, the drum including an outer surface;
• (c) an attraction mechanism disposed on the outer surface of the drum and configured to attract the web of material to the outer surface of the drum;
• (d) a drive mechanism coupled to the drum and configured to rotate the drum and advance the outer surface thereof at a rate greater than a rate at which the web of material is advanced from the web supply, wherein the attraction of the web of material to the drum is the sole source of tension between the web supply and the drum;
• (e) a cutter mechanism coupled to the drum and configured to sever a segment from the web of material while at least a portion of the web of material engages the outer surface of the drum, wherein the cutter mechanism includes a knife configured to rotate with the drum and sever the segment from the web of material at a predetermined rotational position of the drum, wherein the knife is a retractable knife coupled to the drum, wherein the cutter mechanism further includes a knife retraction mechanism, coupled to the retractable knife and configured to selectively retract the knife within the outer surface of the drum, wherein the web of material includes a sequence of unsevered labels, and wherein the cutter mechanism severs labels from the web of material;
• (f) an adhesive applicator positioned proximate the drum to apply an adhesive to at least a portion of the segment;
• and
• (g) a conveyor configured to pass a container past the, drun to engage the segment after the application of adhesive and thereby transfer the segment to an outer surface of the container.

An apparatus, comprising:

• (a) a web supply configured to supply a web of material;
• (b ) a rotatable drum configured to receive the web of material, the drum including an outer surface;
• (c) an attraction mechanism disposed on the outer surface of the drum and configured to attract the web of material to the outer surface of the drum;
• (d) a drive mechanism coupled to the drum and configured to rotate the drum and advance the outer surface thereof at a rate greater than a rate at which the web of material is advanced from the web supply;
• and
• (e) a cutter mechanism coupled to the drum and configured to sever a segment from the web of material while at least a portion of the web of material engages the outer surface of the drum, the cutter mechanism including:
• (i) a retractable knife coupled to the drum and configured to rotate with the drum, the retractable knife configured to sever the segment from the web of material at a predetermined rotational position of the drum;
• and
• (ii) a knife retraction mechanism, coupled to the retractable knife and configured to selectively retract the knife within the outer surface of the drum, the knife retraction mechanism including a rocker assembly mounted to the drum and configured to pivot about a pivot axis parallel to a rotational axis of the drum.

method of severing labels of predetermined length from a web of material, the method comprising:

• (a) advancing a web of material toward a rotating drum, the web of material including a sequence of unsevered labels;
• (b) attracting the web of material into engagement with the outer surface of the drum;
• (c) severing a label from the web of material while at least a portion of the web of material engages the outer surface of the drum using a retractable knife coupled to the drum and configured to rotate with the drum;
• (d) rotating the drum and advancing the outer surface thereof at a rate greater than the rate at which the web of material is advanced from the web supply;
• and
• (e) transferring the label from the drum to a surface of a container.

A method of severing segments of predetermined length from a web of material, the method comprising:

• (a) continuously rotating a drum at a first predetermined rate;
• (b) continuously advancing a web of material at a second predetermined rate such that the web of material engages an outer surface of the drum, wherein the first and second predetermined rates are different;
• (c) severing a segment from the web of material at a first predetermined rotational position of the drum and as at least a portion of the web of material engages the outer surface using a retractable knife coupled to the drum and configured to rotate with the drum;
• (d) retracting the knife within the outer surface of the drum at a second predetermined position of the drum via pivoting motion of the knife about a pivot axis oriented parallel to a rotational axis of the drum;
• and
• (e) dynamically controlling at least one of the first and second predetermined rates such that a predetermined length of material is advanced forward of the predetermined rotational position of the drum as such time as the drum is positioned at the first predetermined rotational position.