Apparatus comprising a belt application head

Abstract

A digital panel cutter is described. The cutter includes a panel on which a workpiece can be positioned. A head unit is movable in a plane above the panel. A tape application head and a cutting head are mounted to the head unit. The tape application head includes a tape application roller for applying tape to the workpiece, the tape application roller being rotatable about an axis orthogonal to the plane to enable a strip of tape to be applied to the workpiece in any direction. The cutting head includes a knife or blade for cutting the workpiece. A creasing head can also be mounted to the head unit, the creasing head including a creasing wheel for creasing the workpiece.

Description

TECHNICAL FIELD

[0001] The present invention relates to an apparatus comprising at least one application head for applying a tape strip to a workpiece. The workpiece can for example comprise a sheet material such as cardboard or paperboard. BACKGROUND

[0002] It is known to use hand-held tape guns for applying tape strips to a workpiece.

[0003] It is also known to use tape applicators for applying tape strips to a workpiece. A conventional tape applicator generally comprises at least one tape application head which applies a tape strip in a conveying direction, i.e. the direction in which the workpiece moves along. The position of each tape application head can be adjusted in a lateral direction, i.e. perpendicular to the conveying direction. If two or more tape applicators are provided, a plurality of tape strips can be applied to the workpiece during a single pass through the tape applicators.

[0004] The workpiece is generally fed past the tape application heads, which are independently controlled to apply tape to the workpiece. Each tape strip travels in the conveying direction, the length of which is determined by the tape application head. If it is required to apply a tape strip to the workpiece in a plurality of directions, such as along all four edges of a rectangular workpiece or to adhesive panels arranged in different directions of a packaging blank, the tape strip must be applied a plurality of times through the tape applicator. For example, if the tape applicator has two tape application heads, a tape strip can be applied to two opposite edges of a rectangular workpiece during a first pass. The workpiece is then rotated by 90° and a second pass is made through the tape applicator so that a tape strip can be applied to the other two opposite edges of the workpiece.

[0005] Each tape application head can be controlled to apply a tape strip of a desired length to a particular portion of the workpiece. Each tape application head generally comprises a plurality of driven or non-driven rollers. At least one roller ("tape application roller") is used to apply the tape to the surface of the workpiece and the other rollers are guide rollers. The tape is generally supplied onto a roller shaft or spool and fed down to the tape application roller. The tape can be fed around each guide roller or between pairs of counter-rotating guide rollers. Each tape application head generally comprises a support for supporting a roll of tape and a knife or blade for cutting the tape to a desired length as it is applied to the workpiece.

[0006] The tape application head can be used to apply any suitable type of tape to the workpiece, such as double-sided adhesive tape or silicone tape. The tape application head is generally capable of accommodating different widths of tape.

[0007] The tape applicator can comprise a feeding mechanism for feeding the workpiece past the tape application head(s).

[0008] Digital flatbed cutters are known. In a typical cutter of this type, a workpiece, such as a sheet of cardboard or paperboard, is placed onto a flatbed. A cutting head is mounted above the flatbed on an assembly that can move the cutting head in a controlled manner in a parallel plane above the flatbed (i.e. in a plane defined by an x-axis and a perpendicular y-axis). The cutting head includes a knife or blade for cutting the workpiece. The knife or blade can typically be moved vertically (i.e. in a z-axis direction perpendicular to both the x and y axes) relative to the flatbed. In particular, the knife or blade can be moved between a first position in which the knife or blade is spaced apart from the workpiece and a second position in which the knife or blade is in contact with the workpiece for cutting.

[0009] The assembly can include a head unit to which the cutting head is mounted. The head unit can be movable in a first direction (i.e. the y-axis direction) along a support rail that extends above the flatbed. For example, the support rail itself can be movable in a second direction (i.e. the x-axis direction) along a side rail that is located alongside the flatbed itself.

[0010] The cutter can include a feeding mechanism for positioning the workpiece on the flatbed.

[0011] A creasing head can also be mounted to the head unit adjacent to the cutting head. The creasing head can include a creasing wheel for creasing the workpiece. The creasing wheel can typically be moved vertically relative to the flatbed, in particular the creasing wheel can be moved between a first position in which the creasing wheel is spaced apart from the workpiece and a second position in which the creasing wheel is in contact with the workpiece for creasing the workpiece.

[0012] The head unit can be accurately aligned with the workpiece prior to commencing the cutting and / or creasing process. For example, the head unit can include a camera and use optical recognition of one or more printed alignment marks on the workpiece. Once the head unit has been accurately aligned relative to the workpiece positioned on the flatbed, the workpiece can be cut by the cutting head and / or creased by the creasing head based on information stored in a digital file. In particular, the digital file can include cutting information and / or creasing information for controlling the cutter. The workpiece can be cut and then creased, or vice versa. After the workpiece has been cut and / or creased, the workpiece can be removed from the flatbed.

[0013] It is often necessary to apply one or more adhesive tapes to a workpiece that has been cut using a digital flatbed cutter. For example, if a workpiece has been cut and creased to form a packaging blank that is to be folded and assembled to form a box or container, it is often necessary to apply a double-sided adhesive tape to one or more flaps of the packaging blank. It is therefore necessary to either manually apply the tape to the packaging blank using a hand-held tape gun, or to pass the packaging blank through a separate tape applicator one or more times. SUMMARY

[0014] The present invention provides an apparatus comprising:

[0015] a platen on which a workpiece can be positioned;

[0016] a tape application head comprising a tape application roller for applying tape to the workpiece; and

[0017] a head unit to which the tape application head is mounted;

[0018] wherein the head unit is movable in a plane above the platen and at least the tape application roller is rotatable about an axis normal to the plane. In other words, the head unit is laterally movable in one or both of an x-axis direction and a perpendicular y-axis direction in a parallel plane above the platen, and at least the tape application roller is mounted for rotation about a z-axis normal to the x- and y-axes. The tape application roller can also be mounted for rotation about a longitudinal axis of the tape application roller parallel to the plane, and it will be appreciated that the roller will rotate about this longitudinal axis as tape is applied to the workpiece.

[0019] The tape application head can be substantially similar to the tape application head described above and can further comprise a support for supporting a roll of tape and one or more guide rollers that direct tape from the roll of tape to the tape application roller. For example, each guide roller can be a single roller or a pair of counter-rotating rollers. The roll of tape can be supported for free rotation as tape is being removed and applied to the workpiece. For example, the support can comprise a rotatable turret that is sized and shaped to be received in an opening of the roll of tape. Each roller can be a driven roller that is driven to rotate by an actuator or a non-driven roller that is free to rotate by movement of the tape. The tape application head can comprise other fixed guides. The support for the roll of tape can be positioned above the tape application roller shaft and any other guide rollers or fixed guides.

[0020] The tape application head can further comprise a knife or blade for cutting tape. The tape application head can be controlled to apply a specific length of tape to the workpiece, the start of the strip of tape on the workpiece being determined by positioning the tape application head above the workpiece, the direction or orientation of the strip of tape being determined by subsequent movement of the tape application head, and the length of the strip of tape being determined by cutting the tape.

[0021] The entire tape application head can be rotatable relative to the head unit, the tape application head comprising a support for supporting a roll of tape. Alternatively, the support can be fixed and at least the tape application roller can be rotatable relative to the head unit, provided that one or more guide rollers can accommodate relative rotation between the tape application roller and the roll of tape. In some constructions, such relative rotation can be limited to about 180°.

[0022] The tape application head can be used to apply any suitable tape to the workpiece, which can include double sided adhesive tape, silicone tape, etc. In the case of double sided adhesive tape, the tape will typically be applied to the workpiece with the backing layer still adhered; the backing layer is then subsequently removed manually to expose the underlying adhesive. However the backing layer can also be removed by the tape application head as the tape is applied to the workpiece.

[0023] At least the tape application roller is movable along an axis normal to the plane (i.e. along the z-axis direction) so that it can be moved into contact with the workpiece. In other words, at least the tape application roller can be mounted to move by an actuator between a first position in which it is spaced apart from the workpiece and a second position in which it is in contact with the workpiece to apply a strip of tape and optionally to apply a contact pressure to the workpiece by the tape application roller.

[0024] The apparatus can include a feed mechanism for positioning a workpiece on the flat plate. Any suitable feed mechanism can be used, for example a vacuum feed which can be integrated into the head unit or support rail and which can be used to pick a single workpiece from a stack and position it on the flat plate.

[0025] The flat plate can be a conveyor which can be used to move the workpiece out of the apparatus.

[0026] The head unit can be mounted to a support rail which extends above the flat plate. The head unit can be movable along the support rail (i.e. along the y-axis direction) by an actuator. The support rail can be mounted to one or more side rails. The support rail can be movable along the one or more side rails (i.e. along the x-axis direction) by one or more actuators. For example, the side rails can be located on opposite sides of the flat plate and arranged substantially perpendicular to the support rail. The support rail and side rails allow the head unit to be moved in any direction under precise control in one or both of the x and y axes (i.e. in a parallel plane above the flat plate). It will be appreciated that other ways of moving the head unit under precise control can also be used.

[0027] The movement of the head unit can be controlled by a control unit using a digital file with tape applicator information described in more detail below.

[0028] The present application also provides a method of applying a strip of tape to a workpiece positioned on a flat plate using the apparatus described above, wherein at least the tape application roller is rotated about an axis normal to the plane to align in a particular direction and the head unit is moved in that direction above the flat plate with the tape application roller in contact with the workpiece.

[0029] The present application provides a tape applicator comprising the apparatus described above.

[0030] The present invention provides a cutting machine, such as a digital flatbed cutting machine, comprising the apparatus described above. The head unit can further comprise a cutting head with a knife or blade for cutting the workpiece. The cutting head can be mounted to the head unit proximate the belt application head. The knife or blade can be movable along an axis normal to the plane, i.e. along the z-axis direction, so that it can be moved into contact with the workpiece. In particular, the knife or blade can be mounted to move between a first position, in which it is spaced apart from the workpiece, and a second position, in which it is in contact with the workpiece for cutting.

[0031] The head unit can further comprise a creasing unit with a creasing wheel for pressing a crease into the workpiece. The creasing unit can be mounted to the head unit proximate the cutting head and / or the belt application head. The creasing wheel can be movable along an axis normal to the plane, i.e. along the z-axis direction, so that it can be moved into contact with the workpiece. In particular, the creasing wheel can be mounted to move between a first position, in which it is spaced apart from the workpiece, and a second position, in which it is in contact with the workpiece for pressing a crease into the workpiece.

[0032] In use, a workpiece is positioned to the flatbed using the feed mechanism. The head unit is accurately aligned with the workpiece on the flatbed. For example, the head unit can comprise a camera or other optical device, and the control unit can use optical identification of one or more printed alignment marks on the workpiece or workpiece profile. The optical identification allows the control unit to know the precise position and orientation of the workpiece on the flatbed and to accurately align the head unit with the workpiece. Once the head unit has been accurately aligned, the workpiece can be cut by the cutting head and / or a crease pressed into the workpiece by the creasing head based on the digital file. One or more strips of adhesive tape can be applied to the workpiece using the belt application head. In particular, the belt application head is positioned over the workpiece by moving the head unit, at least the belt application roller is moved to a second position in which it is in contact with the workpiece and applies a contact pressure, and the head unit is moved in a particular direction, which can be along one or both of the x and y axes, with the belt application roller aligned with the particular direction and in contact with the workpiece to apply a strip of adhesive tape of a desired length to the workpiece. The belt application roller is moved to a first position, the belt application head is repositioned over the workpiece by moving the head unit. The taping process is repeated until all of the strips of adhesive tape have been applied at the end of the process. During the taping process, the belt application roller can be rotated about the z-axis to allow strips of adhesive tape to be applied to the workpiece in any direction. The belt application roller will be rotated about the z-axis so that it is aligned with the direction in which the head unit is moving when the adhesive tape is being applied to the workpiece. This is different to conventional belt applicators in which strips of adhesive tape can only be applied to the workpiece in the direction of conveyance, i.e. the direction in which the workpiece is passed by the fixed belt application head(s).

[0033] The cutting machine can be controlled using a digital file. The digital file includes glueing information specifying where each tape strip should be applied to the workpiece. The digital file also includes cutting information and / or creasing information specifying where the workpiece should be cut and / or creased. Typically, the workpiece will be cut, creased, and then the tape will be applied using a tape application head. However, it will be appreciated that the cutting, creasing, and glueing processes can be implemented in any order and can be split into several sub-processes implemented in any order, such that, for example, two separate cutting sub-processes can be implemented by inserting a creasing process or a glueing process.

[0034] In a preferred arrangement, the present application provides a digital platform cutting machine comprising:

[0035] a flat plate on which a workpiece can be positioned;

[0036] a tape application head comprising a tape application roller for applying a strip of tape to the workpiece;

[0037] a cutting head comprising a knife or blade for cutting the workpiece; and

[0038] a head unit to which the tape application head and the cutting head are mounted;

[0039] wherein the head unit is movable in a plane above the flat plate and at least the tape application roller is rotatable about an axis normal to the plane.

[0040] Additional features of the cutting machine are as described above. In particular, the cutting machine can comprise a creasing head mounted to the head unit, the feed unit, etc. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 is a schematic front view of a digital platform cutting machine according to the present application;

[0042] Figure 2 is a schematic side view of the cutting machine of Figure 1

[0043] Figure 3 is a visual identification of a digital file for controlling a cutting machine according to the present application;

[0044] Figure 4 is a top view of a workpiece; and

[0045] Figure 5 is a packaging blank for a container prepared from a workpiece using a cutting machine according to the present application. DETAILED DESCRIPTION

[0046] As Figure 1 and Figure 2 ​As shown, the digital flatbed cutter 1 comprises a flatbed 2 on which a workpiece W can be positioned.

[0047] A head unit 4 is mounted above the flatbed 2. The head unit 4 is mounted to a support rail 6 and can be moved from side to side along the support rail (i.e. along the y-axis direction) by means of an applicable actuator (not shown). The support rail 6 is mounted to a side rail (not shown) and can be moved back and forth along the side rail (i.e. along the x-axis direction) by means of one or more applicable actuators (not shown). The actuators can be controlled by a control unit (not shown), which can for example comprise an applicable processor and user input means such as a touch display or a keyboard. By controlling the actuators, the head unit 4 can be accurately positioned and can be moved in any direction within a parallel plane above the flatbed 2, which is defined by the perpendicular x and y axes.

[0048] The head unit 4 comprises a tape application head 8.

[0049] The tape application head 8 comprises a tape application roller 10 for applying tape to the workpiece 8. The tape application roller 10 is mounted so as to be rotatable about an axis orthogonal to the plane (i.e. about the z-axis). This is in addition to the normal rotation of the tape application roller 10 about its longitudinal axis parallel to the plane, and the tape application roller rotates about it when it is in contact with the workpiece and applies tape to the workpiece.

[0050] The tape application head 8 comprises a support frame 12 for supporting a tape roll TR and one or more guide rollers 14 for guiding tape from the tape roll towards the tape application roller 10. The tape roll TR is supported on the support frame 12 so as to be free to rotate as tape is being removed and applied to the workpiece. By means of freely interchanging tape rolls on the support frame 12, the tape application head 8 can be compatible with different tape types and widths. In particular, the support frame 12 comprises a rotatable hub which is dimensioned and shaped to be received in an opening in the tape roll TR.

[0051] Each guide roller 14 can be a driven roller or a non-driven roller (i.e. it can be free to rotate by movement of the tape). The tape application head 8 comprises a knife or blade (not shown) for cutting the tape.

[0052] The tape application roller 10 is mounted so as to be movable along an axis orthogonal to the plane (i.e. along the z-axis direction). The tape application roller 10 can be moved between a first position (shown in Figure 1 and 2 a second position by means of an actuator, which is spaced apart from the workpiece W in the first position and is in contact with the workpiece to apply tape in the second position, and optionally applies a contact pressure to the workpiece by the tape application roller in the second position.

[0053] The head unit 4 further comprises a cutting head 16 with a knife or blade 18 and an indenting head 20 with an indenting wheel 22. The belt application head 8, the cutting head 16 and the indenting head 20 are hereinafter conveniently referred to as "tool heads" and the belt application roller 10, the knife or blade 18 and the indenting wheel 22 as "tools". The knife or blade 18 is mounted so that it can be moved along an axis normal to the plane, i.e. in the z-axis direction. The knife or blade 18 can be moved between a first position (shown in Figure 1 and Figure 2 ) in which it is spaced from the workpiece W and a second position in which it is in contact with the workpiece for cutting. The indenting wheel 22 is also mounted so that it can be moved along an axis normal to the plane, i.e. in the z-axis direction. The indenting wheel 22 can be moved between a first position (shown in Figure 1 and 2 ) in which it is spaced from the workpiece W and a second position in which it is in contact with the workpiece for indenting.

[0054] The up and down movement of the tools in the z-axis direction is controlled by the control unit. The control unit can thus position the head unit 4 above the workpiece W to position the appropriate tool head in the required position, move the appropriate tool down into contact with the workpiece, move the head unit with the tool in contact with the workpiece to cut, indent or apply tape, move the tool up and away from the workpiece and reposition the head unit above the workpiece. If the tool is the belt application roller 10, it is rotated about the z-axis so that it is aligned with the direction in which the head unit 4 will move above the flat 2 (i.e. so that its longitudinal axis is substantially perpendicular to the direction of movement of the head unit).

[0055] The cutting machine 1 can comprise a feed mechanism (not shown) for positioning the workpiece on the flat 2. Any suitable feed mechanism can be used, for example a vacuum feed which can be integrated into the head unit 4 or the support rail 6 and which can be used to pick out individual workpieces from a stack and position them on the flat 2.

[0056] The flat 2 can be a conveyor which can be used to remove the workpiece from the cutting machine 1.

[0057] The movement of the head unit 4 can be controlled by the control unit using a digital file.

[0058] A visual representation of a digital file for a packaging blank is shown in Figure 3 in which the cutting information is shown in solid lines, the indenting information is shown in short horizontal dashed lines and the belt application information is shown in dotted lines. In particular, the solid lines indicate where the workpiece W shown in Figure 4 should be cut by the cutting head 16, the short horizontal dashed lines indicate where the workpiece should be indented by the indenting head 20 and the dotted lines indicate where a tape of predetermined width should be applied to the workpiece.

[0059] Figure 4 The workpiece W shown in FIG. 1 is a printed sheet of cardboard stock. The workpiece W has a printed area, indicated by shading, that will be the outer surface of an assembled container. The workpiece W also includes six printed alignment marks Ml, M2...M6.

[0060] Figure 4 The workpiece W shown in FIG. 1 is a printed sheet of cardboard stock. The workpiece W has a printed area, indicated by shading, that will be the outer surface of an assembled container. The workpiece W also includes six printed alignment marks Ml, M2...M6.

[0061] Figure 5A finished packaging blank B for a container is shown, with adhesive strips S1 and S2 applied to the glue tabs GT1 and GT2. If the adhesive strips S1, S2 are double-sided adhesive tape, the backing layer can be removed to expose the adhesive and the packaging blank folded and assembled to form the container.

Claims

1. A digital flatbed cutter comprising: a flatbed on which a workpiece can be positioned; a head unit movable in a plane above the flatbed in an x-axis direction and a perpendicular y-axis direction; a tape application head mounted to the head unit and comprising an application roller for applying double-sided adhesive tape to the workpiece, the application roller being rotatable about a z-axis perpendicular to the x-axis and y-axis, and the application roller being movable in the z-axis direction; wherein the head unit further comprises a creasing head with a creasing wheel for pressing a crease into the workpiece, the creasing wheel being movable in the z-axis direction; and a cutting head mounted to the head unit and comprising a knife or blade for cutting the workpiece, wherein the knife or blade is movable in the z-axis direction; and a control unit adapted to control the head unit movements using a digital file having glueing information and cutting information and creasing information, the glueing information specifying where each strip of tape should be applied to the workpiece by the application roller of the tape application head, and the cutting information and creasing information specifying where the workpiece should be cut by the knife or blade of the cutting head and pressed with a crease by the creasing head and the creasing wheel.

2. The digital flatbed cutter of claim 1, wherein the tape application head comprises a knife or blade for cutting the tape.

3. The digital flatbed cutter of claim 1 or 2, wherein the tape application head further comprises a support for supporting a roll of tape.

4. The digital flatbed cutter of claim 3, wherein the tape application head further comprises one or more guide rollers and / or one or more fixed guides for guiding the tape from the roll of tape towards the application roller.

5. The digital flatbed cutter of claim 3 or 4, wherein the entire tape application head is rotatable relative to the head unit, including the support for supporting a roll of tape.

6. The digital flatbed cutter of claim 3 or 4, wherein the support for supporting a roll of tape is not rotatable relative to the head unit.

7. The digital flatbed cutter of any one of the preceding claims, further comprising a feeding mechanism for positioning a workpiece to the flatbed.

8. The digital flatbed cutter of any one of the preceding claims, wherein the flatbed is a conveyor.

9. A method of making a packaging blank for a container using a digital flatbed cutter to glue, cut and crease a workpiece, wherein the digital flatbed cutter comprises: a flatbed; a head unit movable in a plane above the flatbed in an x-axis direction and a perpendicular y-axis direction; a tape application head mounted to the head unit and comprising an application roller, the application roller being rotatable about a z-axis perpendicular to the x-axis and y-axis, and the application roller being movable in the z-axis direction; a cutting head mounted to the head unit and comprising a knife or blade for cutting the workpiece, wherein the knife or blade is movable in the z-axis direction; and a creasing head mounted to the head unit and with a creasing wheel, the creasing wheel being movable in the z-axis direction; the method comprising: positioning a workpiece on the flatbed; and in any order: applying double-sided adhesive tape to the workpiece with the application roller; cutting the workpiece with a knife or blade; and pressing the workpiece out of a crease with a creasing wheel, to make a packaging blank for a container.

10. The method of claim 9, wherein, wherein applying double-sided adhesive tape to the workpiece comprises rotating the tape application roller about the z-axis to align the tape application roller with a particular direction and moving the head unit above the flat in that direction with the tape application roller in contact with the workpiece.

11. The method of claim 9 or 10, wherein, wherein the double-sided adhesive tape is applied to a tab of the packaging blank.

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