Tape applicator and method

Abstract

A tape applicator for a tape with adhesive on a first side includes a sealing assembly having a vacuum belt. The vacuum belt has a vacuum surface to releasably hold lengths of tape by applying a vacuum to a second side of the tape opposite the first side. The sealing assembly moves between loading and sealing positions. In the loading position the sealing assembly loads a length of tape onto the vacuum surface, and in the sealing position the sealing assembly is lowered relative to the loading position to press the tape onto the shipping container.

Description

[0001] TAPE APPLICATOR AND METHOD

[0002] Field of the Invention

[0003] The invention is related to an apparatus and method for applying an adhesive- backed paper tape to a shipping container.

[0004] Background

[0005] In the process of shipping one or more articles from one location to another, a packer typically places the article or articles in a shipping container, such as a cardboard box, to hold and protect the articles during shipment. Often, tape is used to seal the shipping container. Typically, the tape applicator engages a shipping container on a conveyor. As the container moves along the conveyor, the applicator engages the first end of the container and applies the start of the tape, then the shipping container runs under the tape dispenser which unrolls the tape along the surface and the tape is applied to the top. Then as the shipping container moves along the conveyor, the applicator engages the rear end of the container and cuts the tape and finishes the sealing process. Plastic-backed adhesive tape is commonly used because it bonds quickly and thus the sealing step in the packaging operation can be performed quickly.

[0006] Water-activated adhesives on paper tape are more environmentally-friendly, but water-activated tape is slower to cure and bond with the shipping container, and the process of applying water-activated tape is more complex. Water-activated tape is typically made of paper and a layer of water-activated adhesive, primarily modified corn starch. The adhesive is activated by water from a dispensing device, and usually dries in 15 to 60 seconds, depending on conditions (e.g. temperature, humidity). When the wetted tape is applied to a cardboard shipping package, it bonds with the cardboard as it dries.

[0007] Brief Summary of the Invention

[0008] The present invention provides an apparatus and method that results in a faster container-taping process. Additionally, the apparatus and method described herein can use more environmentally-friendly paper-backed adhesives, including water-activated tape. The apparatus and method provided by the invention improves the taping process by applying a pre-cut section of tape onto the shipping container at once, instead of sequentially applying tape along the front end, the top, and then the rear end of the shipping container.

[0009] An exemplary apparatus and method for applying tape to a package includes a tape applicator for a tape having first and second sides and an adhesive disposed on the first side. The tape applicator includes a moveable sealing assembly including at least one vacuum belt. The at least one vacuum belt has a vacuum surface configured to accept and releasably hold lengths of tape by applying a vacuum to the second side of the tape. The sealing assembly is configured to move vertically between a loading position and a sealing position. In the loading position, the sealing assembly is situated to receive and load a length of tape onto the vacuum surface. In the sealing position, the sealing assembly is vertically displaced relative to the loading position and, upon contact with a shipping container, press the tape onto the shipping container.

[0010] In one or more embodiments, the tape applicator further includes one or more deformable members disposed adjacent to and coextensive with the vacuum belt. The deformable members are configured to move between a retracted position and a deployed position. In the retracted position, the members are recessed relative to the vacuum surface. In the deployed position, the members extend beyond the vacuum surface to space the tape from the vacuum surface. The deformable members are configured to, upon contact with a shipping container, deform to conform to a shape of the shipping container to press the tape onto the shipping container.

[0011] In one or more embodiments of the tape applicator the deformable member is a soft rubber foam.

[0012] In one or more embodiments, the deformable members include one or more of: (a) two deformable members, and the at least one vacuum belt may be disposed between the two deformable members; and (b) three deformable members, and the at least one vacuum belt includes two vacuum belts alternatingly disposed between the three deformable members. In one or more embodiments, in the deployed position the deformable members may be configured to simultaneously engage a top and adjoining opposing ends of the shipping container.

[0013] An exemplary tape applicator may include a conveyor configured to supply one or more shipping containers to a sealing station, the sealing assembly disposed above the sealing station.

[0014] The shipping containers may have one or more flaps, and the tape may be configured to affix to the flaps to seal the shipping container.

[0015] An exemplary tape applicator may include a supply of tape upstream of the movable sealing assembly and may alternatively or additionally include a dispenser configured to draw the tape from the supply and advance the tape to the movable sealing assembly.

[0016] An exemplary tape includes a water-activated adhesive, and one or more embodiments of the tape applicator may further include a wetting assembly between the supply of tape and the movable sealing assembly. The wetting assembly may include a supply of water for applying the water to the adhesive as the tape is drawn from the supply and advanced to the movable sealing assembly. An exemplary wetting assembly may include a water-coated roller.

[0017] An exemplary tape applicator may further include a severing mechanism between the supply of tape and the movable sealing assembly. The severing mechanism may be configured to sever discrete lengths of tape from the supply.

[0018] In one or more embodiments, the tape applicator may include a sealing position sensor configured to identify when the sealing assembly has reached the sealing position.

[0019] An exemplary tape applicator may include a deployed position sensor configured to identify when the deformable members have reached the deployed position.

[0020] An exemplary tape applicator may include a controller in communication with at least the sealing assembly configured to control movement of the sealing assembly. In one or more embodiments, the tape applicator may include a controller in communication with one or more of the sealing assembly, the deformable members, one or more conveyors, and one or more sensors. The controller may be configured to control one or more of movement of the sealing assembly, movement of the deformable members, application of the vacuum, and movement of the one or more conveyors.

[0021] An exemplary method for sealing a container using a tape, includes the following steps: (i) providing a supply of tape having first and second sides, with an adhesive disposed on the first side; (ii) drawing the tape from the supply; (iii) cutting a discrete length of the tape from the tape drawn from the supply; (iv) providing a moveable sealing assembly. An exemplary sealing assembly includes at least one vacuum belt and, optionally, one or more deformable members disposed adjacent to and coextensive with the vacuum belt. The at least one vacuum belt has a vacuum surface configured to accept and releasably hold lengths of tape by applying a vacuum to the second side of the tape. The exemplary method may further include the steps of (v) positioning the sealing assembly in a loading position and applying a vacuum to the vacuum belt to receive a leading end of the tape drawn from the supply, and to advance the vacuum belt and the leading end to hold a length of the tape; (vi) supplying one or more shipping containers to a sealing position under the sealing assembly; (vii) moving the sealing assembly vertically between the loading position and the sealing position to apply the length of tape to a top of the shipping container;; and (viii) raising the sealing assembly to the loading position.

[0022] After moving the sealing assembly vertically between the loading position and the sealing position, the method may include the step of moving the deformable members from a retracted position to a deployed position to press the tape against the ends of the shipping container, thereby affixing the tape onto the flaps and ends of the shipping container to seal the shipping container; and retracting the deformable members, before raising the sealing assembly to the loading position. After moving the sealing assembly vertically between the loading position and the sealing position, the method may include the step of switching off the vacuum to the vacuum belt before moving the deformable members from the retracted position to the deployed position. If the adhesive is water-activated, the method may further include the step of applying water to the water-activated adhesive after the step of drawing the tape from the supply.

[0023] An exemplary method may include the step of providing a controller in communication with at least the sealing assembly, the controller being configured to control movement of the sealing assembly.

[0024] Brief Description of the Drawings

[0025] FIG. 1 shows components of an exemplary vacuum belt system,

[0026] FIG. 2 is front view of an exemplary sealing assembly,

[0027] FIG. 3 is a side view of an exemplary tape applicator,

[0028] FIG. 4 is a side view of an exemplary tape applicator with the sealing assembly in the loading position,

[0029] FIG. 5 is a front view of the tape applicator of FIG. 4,

[0030] FIG. 6 is a side view of an exemplary sealing assembly in the sealing position,

[0031] FIG. 7 is a front view of the sealing assembly of FIG. 6,

[0032] FIG. 8 is a side view of an exemplary sealing assembly in the sealing position with the deformable members beginning to be deployed,

[0033] FIG. 9 is a front view of the sealing assembly of FIG. 8,

[0034] FIG. 10 is a side view of an exemplary sealing assembly in the sealing position with the deformable members fully deployed,

[0035] FIG. 11 is a front view of the sealing assembly of FIG. 10,

[0036] FIG. 12 is a side view of an exemplary sealing assembly returned to the loading position,

[0037] FIG. 13 is a front view of the sealing assembly of FIG. 12, FIG. 14 is a side view of an alternate embodiment of an exemplary sealing assembly, without deformable members, and

[0038] FIG. 15 is a side view of the sealing assembly of FIG. 14 in the sealing position.

[0039] Detailed Description

[0040] As will be explained in more detail below, the present invention provides an apparatus and method that results in a faster container-taping process. Additionally, the apparatus and method described herein can use more environmentally-friendly paperbacked adhesives, including water-activated tape. The apparatus and method provided by the invention improves the taping process by applying a pre-cut section of tape onto the shipping container at once, instead of sequentially applying tape along the front end, the top, and then the rear end of the shipping container.

[0041] Referring now to the drawings, and initially to FIG. 1 , an exemplary apparatus is an applicator 100 for applying a tape 116 (including a water-activated tape) to a shipping container 132. The terms “shipping container,” “packaging container,” “package,” and “box” generally mean the same thing for purposes of this disclosure. The tape has a paper backing with first and second sides, and an adhesive disposed on the first side; the second side being free of adhesive. An exemplary tape has a water- activated adhesive and may be referred to as a water-activated tape.

[0042] In addition to the environmental benefits of using paper instead of plastic backing for the adhesive, another benefit of water-activated tape is its ability to seal a heavy box. Water-activated tape often has a high tensile strength and durability that makes it one of the strongest options available for sealing packages. In addition, because water- activated tape bonds to the shipping container, it can create a tamper-proof seal. Removing the tape can permanently mark or cosmetically damage the surface of the shipping container, highlighting any attempts to open the package or tamper with the seal.

[0043] Because a water-activated tape is made with a paper backing, the paper backing is an environmentally-friendly material that is recyclable, composed of a renewable resource, and is biodegradable. Water-activated tape can be reinforced with nylon or fiberglass to improve its tensile strength and durability. Water-activated tape also may be able to withstand a variety of harsh conditions, including extreme temperatures, that may cause plastic packing tapes to fail.

[0044] A common shipping container is a cardboard box, and a common type of cardboard box is referred to as a regular slotted container (RSC), which has flaps that are foldable to close an open side of the container after articles to be shipped are placed in the container. The flaps are then sealed with tape to close the container for shipment.

[0045] An exemplary tape applicator 100 is shown in FIG. 1 and includes a movable sealing assembly 102, which includes at least one vacuum belt or vacuum conveyor 104 (FIG. 2). The vacuum belt or vacuum conveyor 104 is a conveyor system that uses a set of rollers 106 to move a belt 104 having a series of perforations 110 along its length. The vacuum conveyor is an enclosed volume that includes a vacuum pump 108 that reduces the air pressure in the enclosed volume. One portion of the conveyor surface contains perforations 112 and is in contact with the perforated vacuum belt 104. The surface where the vacuum belt and perforated conveyor surface align is referred to as the vacuum surface 114; the rest of the enclosed surface is solid with no perforations. The vacuum surface 114 is configured to accept and releasably hold lengths of tape 116 by applying a vacuum to the second side of the tape 116. The low pressure interior of the conveyor creates a suction force 118 through the perforations 110, 112 at the vacuum surface 114. (For ease of illustration, the outer housing components that seal the enclosed volume are not shown.) The perforations 110 in the belt 104 permit air flow caused by the suction to pass through the belt 104 and the perforated conveyor to hold an object, such as a length of tape 116, to the belt 104 using air pressure 120, unless and until the suction or vacuum is discontinued. As used herein, the term “belt” generally refers to a continuous loop of flexible material that is movable along a path defined by the belt 104, whereby as the belt moves, the leading end of the tape 116 is captured and held to the belt 104 on the vacuum surface 114 via the suction force 118 generated by the vacuum pump 108. As the belt 104 advances, the tape 116 is carried along with the belt 104 and the belt 104 continues to capture sequential longitudinal sections of the tape 116 as the sections of tape 116 contact the belt 104.

[0046] In use, the tape applicator 100 also includes a supply 115 of tape. The supply

[0047] 115 can be any form known in the art. An exemplary supply 115 includes a roll of tape. The tape applicator 100 includes a dispenser 122 that draws the tape 116 from the supply 115 and feeds it to the vacuum surface 114. The dispenser 122 can include a cutter or severing mechanism 124 between the supply of tape 115 and the movable sealing assembly 102. The severing mechanism 124 is configured to sever discrete lengths of tape 116 from the supply. A schematic severing mechanism 124 is shown in FIG. 3.

[0048] If the tape 116 is a water-activated tape, the tape applicator 100 includes a wetting assembly 126 to apply water to the water-activated adhesive as the tape 116 is drawn from the supply 115. The wetting assembly 126 includes a supply of water, which optionally may include a roller arranged to apply the water to the tape 116. The dispenser 122 advances the water-activated tape 116 in a dry state, drawing the tape

[0049] 116 from the supply 115 and through the wetting assembly 126 before dispensing the tape 116 to the movable sealing assembly 102.

[0050] A packaging system 128 that includes the tape applicator 100 typically also includes a package conveyor 130 that supplies a series of shipping containers 132 to be sealed. Each shipping container 132 has a top side that was previously closed in a packing operation for that shipping container, but not yet sealed. Each shipping container 132 is moved on the conveyor 130 to a sealing station 144 located under the sealing assembly 102.

[0051] An exemplary shipping container 132 is a box or carton generally shaped like a cube or rectangular prism, delivered to the sealing station 144 with an unsealed top side. The shipping container 132 has upright parallel opposing first 134 and second 136 sides and upright parallel opposing front 138 and rear 140 ends orthogonal to the opposing sides 134, 136 and joined at the edges by a fold or a fastened joint. The shipping container 132 has a sealed bottom 146 that is orthogonal to the opposing sides 134, 136 and opposing ends 138, 140. The first and second sides 134, 136 and the front and rear ends 138, 140 include portions that extend vertically and are foldable at a joint to form one or more external flaps 148. The one or more flaps 148 can be folded down to be parallel to the bottom 146 and contact the edge of the opposing ends 138, 140, sides 134, 136, and / or opposing flaps 148 to close the otherwise unsealed top side. In an alternate embodiment, the one or more flaps 148 can overlap one or more neighboring flaps 148. The folded flaps 148 define a top 142 of the shipping container 132. The top 142 is parallel to the bottom 146 and is orthogonal to the opposing ends 140, 142 and opposing sides 134, 136. Alternatively, a shipping container 132 may be closed with a lid, and the tape applicator 100 may apply tape 116 over the lid and down the ends 138, 140 of the container 132 to seal the lid onto the container 132.

[0052] As used herein the terms front 138 and rear 140 ends of the shipping container are interchangeable and generally indistinguishable. The front end 138 is designated as the end that faces the direction of travel along the conveyor 130 toward the sealing station 144, and the rear end 140 is the end that faces away from the direction of travel of the conveyor 130 as the shipping container moves along the conveyor toward the sealing station 144. As used herein the terms first and second sides 134, 136 of the shipping container 132 are interchangeable and generally indistinguishable.

[0053] The sealing assembly 102 is configured to move vertically between a loading position (FIGS. 4 and 5) and a sealing position (FIGS. 6-11 ). The sealing assembly 102 is positioned above the sealing station 144 on the conveyor 130. In the loading position the sealing assembly 102 is in a raised position, situated to receive and load a length of tape 116 onto the vacuum surface 114. In the sealing position the sealing assembly 102 is in a lowered position near the top side of the shipping container 132. In the lowered sealing position, the sealing assembly 102 is situated to remove the length of tape 116 and apply the tape 116 to the shipping container 132. In other words, in the sealing position, the sealing assembly 102 is closer to the conveyer 130 than when in the loading position. In an exemplary embodiment, the sealing assembly 102 is moved to the sealing position so that the vacuum belt 104 makes contact with the unsealed top 142 of the shipping container 132 and applies the tape 116 to the top 142 of the shipping container 132, sealing the shipping container. The sealing assembly 102 also presses the tape 116 over adjacent ends 138, 140 of the shipping container 132 to ensure maintenance of the adhesive seal with the container 132. The vacuum can be switched off and the sealing assembly 102 moved to the loading position. In this embodiment, the deformable members 150 (discussed below) are omitted.

[0054] FIG. 3 shows the sealing assembly 102 in the loading position, showing a length of tape 116 being loaded onto the vacuum surface 114. The vacuum belt 104 moves as the tape 116 is advanced, sequentially capturing and holding longitudinal sections of the tape 116 via the vacuum surface 114. The sealing assembly 102 further includes one or more deformable members 150 disposed adjacent to and coextensive with the vacuum belt 104. The deformable members 150 are configured to move between a retracted position and a deployed position. In the retracted position the members 150 are recessed relative to the vacuum surface 114. This is the usual state of the deformable members 150 in the loading position. In an exemplary embodiment, in the deployed position the members 150 extend beyond the vacuum surface 114 to space or dislodge the tape 116 away from the vacuum belt 104 and press the tape 116 to the top 142 of the shipping container 132. The vacuum belt 104 can apply the tape 116 and the deformable members 150 can provide additional pressure to the tape 116 to further secure the tape 116 to the shipping container 132. Optionally, the vacuum may be switched off prior to deploying the deformable members 150. The deformable members 150 move from the retracted position to the deployed position after the sealing assembly 102 has moved to the lower sealing position, and in doing so press the tape 116 to the top and end walls of the shipping container 132. In an alternate embodiment, the vacuum surface 114 presses the tape 116 onto the shipping container 132 and the deformable members 150 help to press the tape 116 onto the top of the shipping container 132 when the shipping container 132 has an uneven surface. The deformable members 150 also press the tape against the front and back walls of the shipping container 132.

[0055] FIGs. 15 and 16 show a further alternate embodiment, without deformable members, wherein the vacuum belt 104 is configured to conform to the shape of the shipping container 132, by letting the vacuum belt 104 wrap around the edges of the shipping container 132 to ensure the pressing of the tape against the back / front ends.

[0056] The front and back rollers 106 are released to slide freely on their horizontal axis while letting the vacuum enclosure raise between them.

[0057] In an exemplary embodiment, the deformable members 150 are a soft rubber foam. In an alternate embodiment, the deformable members are selected from a series of wheels (with or without a coating of soft rubber), brushes, and / or spring blades (spring loaded and / or mounted on a swing mechanism). Optionally, the deformable members 150 include two deformable members 150, and at least one vacuum belt 104 may be disposed between the two deformable members 150. The deformable members 150 optionally may include three deformable members 150, and two parallel vacuum belts 104 may be alternatingly disposed between the three deformable members 150, as shown in FIG. 2.

[0058] As shown in FIGS. 4 and 5, a shipping container 132 is positioned at the sealing station 144 via the package conveyor 130. The sealing assembly 102 is shown in the loading position, positioned over the shipping container 132 at the sealing station 144, with the length of tape 116 fully loaded onto the vacuum surface 114 and ready for application.

[0059] The sealing assembly 102 can further include one or more sensors 152 to facilitate use of shipping containers of various sizes. For example, when a tall shipping container 132 is used, the sealing assembly 102 needs to travel a shorter distance to engage the top of the shipping container 132, while a shorter shipping container 132 requires the sealing assembly 102 to be lowered further to engage the top of the shipping container 132. The sealing assembly can include a sensor 152 configured to identify when the sealing assembly 102 has reached the sealing position, and a sensor 152 configured to identify when deformable members 150 have reached the deployed position. The sensors 152 can include sensors 152 to verify that the shipping container 132 is properly positioned under the sealing assembly 102 at the sealing station 144 prior to actuating the sealing assembly 102. The one or more sensors 152 can include a pressure sensor, a light beam, a laser, a camera, or any other senser known in the art. The tape applicator 100 can further include a controller 154 in communication with the sealing assembly 102, deformable members 150, vacuum belt 104, vacuum pump 108, package conveyor 130, and sensors 152 that is configured to control operations of the sealing assembly 102, deformable members 150, vacuum belt 104, vacuum pump 108, and package conveyor 130. The controller 154 may include a processor, a memory, and software configured to communicate with and control operations of the packaging system 148.

[0060] The deformable members 150 are configured to make contact with a shipping container 132. The shipping container 132 can have one or more flaps 148. The deformable members 150 move to the deployed position to move the tape 116 from the vacuum belt 104 and press the tape 116 onto the shipping container 132. As the deformable members 150 contact the shipping container 132, they deform to conform to the shape of the shipping container 132 to press and affix the tape 116 onto the flaps 148 of the shipping container 132, sealing the shipping container 132. In an exemplary embodiment, the tape 116 contacts and extends along the top 142 and opposing ends 138, 140 of the shipping container 132, the deformable members 150 pressing the tape 116 to the ends 138, 140 of the shipping container 132, simultaneously engaging the opposing front 138 and rear 140 ends of the shipping container 132.

[0061] In an exemplary embodiment, the sealing assembly 102 includes a pressure sensor 152, for example, a pressure sensor attached to the movement mechanism of the sealing assembly 102. When the sealing assembly 102 contacts the top 142 of a shipping container 132, the sensor 152 detects the pressure change from making contact with the shipping container 132. The sensor 152 sends a signal to the controller 154 to stop the travel of the sealing assembly 102. The controller 154 then sends a signal to cause the deformable members 150 to deploy to press the tape 116 down the ends 138, 140 of the container 132. In an exemplary embodiment, the controller 154 can signal the vacuum pump 108 to cut off the vacuum prior to retraction. The controller 154 then signals the deformable members 150 and sealing assembly 102 to retract. The retraction of the deformable members 150 and sealing assembly 102 can be simultaneous or sequential. Then the controller 154 signals the conveyor 130 to advance the sealed shipping container 132 for further processing and to advance the conveyor 130 to supply a fresh shipping container 132 to be sealed.

[0062] FIG. 6 and 7 show the sealing assembly 102 in the sealing position, with the deformable members 150 still in the retracted position, not yet deployed. Here, the tape 116 is in contact with the top 142 of the shipping container 132 and vacuum surface 114 still holds the tape 116. In an exemplary embodiment, the vacuum is switched off once the tape 116 contacts the top 142 of the shipping container 132.

[0063] FIGS. 8 and 9 show the sealing assembly 102 in the sealing position, with the deformable members 150 deployed. Here, the tape 116 is in contact with the top 142 of the shipping container 132 and the deformable members 150 have dislodged the tape 116 from the vacuum surface 114. The deformable members 150 are shown in a deformed shape, conforming to the shape of the shipping container 132 as the deformable members 150 are pressed against the shipping container 132.

[0064] FIGS. 10 and 11 show the sealing assembly 102 in the sealing position, with the deformable members 150 fully deployed. Here, the deformable members 150 have fully extended and press the tape 116 to the front end 138 and rear end 140 of the shipping container 132. The deformable members 150 are shown simultaneously engaging both ends 138, 140 of the shipping container 132, while also contacting the top 142 of the shipping container 132. In other words, the deformable members 150 engage three faces of the shipping container: the top 142 and the adjoining two opposing ends 138, 140.

[0065] Once the tape 116 is affixed to the shipping container 132, the sealing assembly 102 rises and returns to the loading position, ready to accept another length of tape 116. FIGS. 12 and 13 show the sealing assembly 102 returned to the loading position, and the deformable members 150 retracted to the recessed position relative to the vacuum surface 114. In an alternate embodiment, if the vacuum had been switched off, the vacuum is switched on once the sealing assembly 102 has returned to the loading position. The operation of the sealing assembly 102 provides a method of sealing a shipping container 132 employing one or more of the steps described above. Another exemplary method for sealing a container 132 using a water-activated tape 116 includes the following steps: (i) providing a supply of tape having first and second sides, with an adhesive disposed on the first side; (ii) drawing the tape from the supply; (iii) cutting a discrete length of the tape from the tape drawn from the supply; and (iv) providing a moveable sealing assembly including at least one vacuum belt and one or more deformable members disposed adjacent to and coextensive with the vacuum belt. The at least one vacuum belt has a vacuum surface configured to accept and releasably hold lengths of tape by applying a vacuum to the second side of the tape.

[0066] The method further includes the step of (v) positioning the sealing assembly in a loading position and applying a vacuum to the vacuum belt to receive a leading end of the tape drawn from the supply, and to advance the vacuum belt and the leading end to hold a length of the tape; (vi) supplying one or more shipping containers to a sealing position under the sealing assembly; and (vii) moving the sealing assembly vertically between the loading position and the sealing position to apply the length of tape to a top of the shipping container. The method further includes (viii) moving the deformable members from a retracted position to a deployed position to press the water-activated tape against the ends of the shipping container, thereby affixing the tape onto the flaps and ends of the shipping container to seal the shipping container.

[0067] Finally, the method includes the steps of (ix) retracting the deformable members; and (x) raising the sealing assembly to the loading position. The providing and drawing steps may include one or more additional steps, such as (a) providing a supply of water- activated tape having first and second sides, a water-activated adhesive disposed on the first side; (b) drawing the water-activated tape from the supply; (c) applying water to the water-activated adhesive; and (d) cutting the water-activated tape into discrete lengths.

[0068] The supplying step may include supplying one or more shipping containers having one or more external flaps. Optionally, the method may include the step of switching off the vacuum to the vacuum belt before the retracting step (ix). The method can optionally include a final step of reapplying the vacuum if the vacuum had been switched off.

[0069] In summary, the present invention provides a tape applicator 100 for a tape 116 with adhesive on a first side includes a sealing assembly 102 having a vacuum belt 104 and optional deformable members 150 coextensive with the vacuum belt 104. The vacuum belt 104 has a vacuum surface 114 to releasably hold lengths of tape 116 by applying a vacuum to a second side of the tape 116 opposite the first side. The sealing assembly 102 moves between loading and sealing positions. In the loading position the sealing assembly 102 loads a length of tape 116 onto the vacuum surface 114, and in the sealing position the sealing assembly 102 is lowered relative to the loading position to press the tape 116 onto the shipping container 132. The deformable members 150 move between retracted and deployed positions. In the retracted position the members 150 are recessed, and in the deployed position the members 150 extend beyond the vacuum surface 114 to space the tape 116 from the vacuum surface 114 and deform to conform to the shipping container 132 shape to press the tape 116 onto the shipping container 132.

[0070] Although the invention has been shown and described with respect to certain embodiments, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described integers (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such integers are intended to correspond, unless otherwise indicated, to any integer which performs the specified function of the described integer (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment of the invention.

Claims

ClaimsWhat is claimed is:1 . A tape applicator (100) for a tape (116) having first and second sides and an adhesive disposed on the first side, the tape applicator (100) comprising: a moveable sealing assembly (102) including at least one vacuum belt (104), the at least one vacuum belt (104) having a vacuum surface (114) configured to accept and releasably hold lengths of tape (116) by applying a vacuum to the second side of the tape (116); wherein the sealing assembly (102) is configured to move vertically between a loading position and a sealing position, wherein in the loading position the sealing assembly (102) is situated to receive and load a length of tape (116) onto the vacuum surface (114), and in the sealing position the sealing assembly (102) is vertically displaced relative to the loading position; wherein the at least one vacuum belt (104) is configured to, upon contact with a shipping container (132), press the tape (116) onto the shipping container (132).

2. The tape applicator as claimed in claim 1 , further comprising one or more deformable members (150) disposed adjacent to and coextensive with the vacuum belt (104), wherein the deformable members (150) are configured to move between a retracted position and a deployed position, wherein in the retracted position the members (150) are recessed relative to the vacuum surface (114), and in the deployed position the members (150) extend beyond the vacuum surface (114) to space the tape (116) from the vacuum surface (114), wherein the deformable members (150) are configured to, upon contact with a shipping container (132), deform to conform to a shape of the shipping container (132) to press the tape (116) onto the shipping container (132).

3. The tape applicator as claimed in claim 2, wherein the deformable members (150) include two deformable members (150), and wherein the at least one vacuum belt (104) is disposed between the two deformable members (150).

4. The tape applicator as claimed in claim 2 or any of claims 2 to 3, wherein the deformable members (150) include three deformable members (150), and wherein the at least one vacuum belt (104) includes two vacuum belts (104) alternatingly disposed between the three deformable members (150).

5. The tape applicator as claimed in claim 2 or any of claims 2 to 4, wherein in the deployed position, the deformable members (150) are configured to simultaneously engage a top (142) and adjoining opposing ends (138, 140) of the shipping container (132).

6. The tape applicator as claimed in claim 1 or any of claims 1 to 5, further comprising a conveyor (130) configured to supply one or more shipping containers (132) to a sealing station (144), the sealing assembly (102) disposed above the sealing station (144).

7. The tape applicator as claimed in claim 1 or any of claims 1 to 6, wherein the shipping containers (132) have one or more flaps (148), and the tape (116) is configured to affix to the flaps (148) to seal the shipping container (132).

8. The tape applicator as claimed in claim 1 or any of claims 1 to 6, wherein the shipping containers (132) have a lid, and the tape (116) is configured to affix the lid to the shipping container^ 32) to seal the shipping container (132).

9. The tape applicator as claimed in claim 1 or any of claims 1 to 8, further comprising a supply of tape upstream of the movable sealing assembly (102).

10. The tape applicator as claimed in claim 9, further comprising a dispenser (122) configured to draw the tape (116) from the supply and advance the tape (116) to the movable sealing assembly (102).11 . The tape applicator as claimed in claim 9 or any of claims 9 to 10, wherein the adhesive is water-activated, and further comprising a wetting assembly (126) betweenthe supply of tape and the movable sealing assembly (102), the wetting assembly (126) including a supply of water for applying the water to the adhesive as the tape (116) is drawn from the supply and advanced to the movable sealing assembly (102).

12. The tape applicator of claim 11 , wherein the wetting assembly (126) is a water- coated roller.

13. The tape applicator as claimed in claim 9 or any of claims 9 to 11 , further comprising a severing mechanism (124) between the supply of tape and the movable sealing assembly (102), the severing mechanism (124) being configured to sever discrete lengths of tape (116) from the supply.

14. The tape applicator as claimed in claim 1 , further comprising a sealing position sensor (152) configured to identify when the sealing assembly (102) has reached the sealing position.

15. The tape applicator as claimed in claim 2, further comprising a deployed position sensor (152) configured to identify when the deformable members (150) have reached the deployed position.

16. The tape applicator as claimed in claim 1 or any of claims 1 to 15, further comprising a controller (154) in communication with at least the sealing assembly (102) configured to control movement of the sealing assembly (102).

17. The tape applicator as claimed in claim 2 or any of claims 2 to 15, further comprising a controller (154) in communication with one or more of the sealing assembly (102), the deformable members (150), one or more conveyors (130), the vacuum belt (104), and one or more sensors (152), and configured to control one or more of movement of the sealing assembly (102), movement of the deformable members (150), movement of the vacuum belt (104), application of the vacuum, and movement of the one or more conveyors (130).

18. A method for sealing a container using a tape, the method comprising the following steps: providing a supply of tape having first and second sides, with an adhesive disposed on the first side; drawing the tape from the supply; cutting a discrete length of the tape from the tape drawn from the supply; providing a moveable sealing assembly including at least one vacuum belt, the at least one vacuum belt having a vacuum surface configured to accept and releasably hold lengths of tape by applying a vacuum to the second side of the tape; positioning the sealing assembly in a loading position and applying a vacuum to the vacuum belt to receive a leading end of the tape drawn from the supply, and to advance the vacuum belt and the leading end to hold a length of the tape; supplying one or more shipping containers having an unsealed end to a sealing position under the sealing assembly; moving the sealing assembly vertically between the loading position and the sealing position to apply the length of tape to a top of the shipping container, thereby affixing the tape onto the unsealed end of the shipping container to seal the shipping container; and raising the sealing assembly to the loading position.

19. The method as claimed in claim 18, further comprising providing one or more deformable members disposed adjacent to and coextensive with the vacuum belt, and wherein after moving the sealing assembly vertically between the loading position and the sealing position, moving the deformable members from a retracted position to a deployed position to press the tape against the unsealed end of the shipping container, thereby affixing the tape onto the end of the shipping container to seal the shipping container.

20. The method as claimed in claim 18, wherein after applying the length of tape to the top of the shipping container, the vacuum to the vacuum belt is switched off before moving the sealing assembly to the loading position. 21 . The method as claimed in claim 19, wherein after moving the sealing assembly vertically between the loading position and the sealing position, the vacuum to the vacuum belt is switched off before moving the deformable members from the retracted position to the deployed position.

22. The method as claimed in claim 18 or any of claims 18 to 21 , wherein the adhesive is water-activated, and further comprises the step of applying water to the water- activated adhesive after drawing the tape from the supply.

23. The method as claimed in claim 18, or any of claims 18 to 22, further comprising the step of providing a controller in communication with at least the sealing assembly configured to control movement of the sealing assembly.

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