Non-Contact Web Control for Adhesive Label Application
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Solution Overview
Problem
Conventional web control systems for applying adhesive labels from a continuous web are not suitable as they may damage the labels or web, especially when dealing with delicate or small decorative elements, and often require physical contact with the adhesive side, which can lead to fouling or improper application.
Innovation Solution
A system and method for applying decorations from a continuous web using a web control system that controls web characteristics like tension, direction, and velocity without physical contact with the adhesive side, employing non-contact guides such as pressurized air or vacuum belts, and including an application station with actuators to assist in label separation and adhesion to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional web control systems use contact rollers to guide and control the web, then web positioning and velocity control are achieved, but the adhesive layer on the decoration is damaged and the web control system is fouled
Solution Approach 1:
The patent replaces mechanical contact-based web control rollers with a non-contact imaging system (camera 140) and digital control system. The imaging system captures web position and decoration information without physical contact, while the processor determines optimal application parameters, eliminating mechanical contact that causes adhesive damage and system fouling.
Solution Approach 2:
The patent introduces an imaging system as an intermediary between the web control system and the decoration application process. The camera captures visual information about web position and decoration characteristics, allowing the system to control web positioning and determine application parameters without direct mechanical contact with the adhesive layer.
2Stability of the object's composition
If contact rollers are used to control web tension and positioning, then web stability is maintained, but delicate decorative elements are damaged
Solution Approach 1:
The patent replaces mechanical contact rollers with a non-contact imaging system that captures web position and decoration information. The processor then determines application parameters based on this visual data, maintaining web stability through digital control while eliminating mechanical contact that could damage delicate decorative elements.
Solution Approach 2:
The system uses imaging to detect web position and decoration characteristics, then dynamically adjusts application parameters (positioning, timing, force) based on the captured information. This allows web stability to be maintained through parameter optimization without requiring physical contact that could compromise decoration integrity.
3Productivity
If the adhesive side is exposed for direct application, then labeling speed is increased, but the adhesive layer becomes vulnerable to damage from web control components
Solution Approach 1:
The patent maintains high labeling speed by using a non-contact imaging system to monitor and control the web and decoration positioning. The camera captures real-time information about web position and decoration orientation, allowing the processor to determine optimal application timing and parameters without introducing mechanical contact that would expose the adhesive layer to damage.
Solution Approach 2:
The imaging system creates a visual copy or representation of the web and decoration state, allowing the control system to plan and execute application based on this information copy rather than requiring physical interaction. This enables high-speed operation while protecting the vulnerable adhesive layer from mechanical contact.
4Manufacturing precision
If web control rollers contact the front side of the web, then web guidance is improved, but the adhesive layer is fouled or damaged
Solution Approach 1:
The patent replaces mechanical web control rollers with a non-contact imaging system that provides web guidance information through visual detection. The camera captures web position and orientation data, and the processor uses this information to determine precise application parameters, achieving accurate web guidance without mechanical contact that would foul or damage the adhesive layer.
Solution Approach 2:
The imaging system serves as an intermediary that provides web guidance information without direct contact. The camera captures visual data about web position and decoration orientation, acting as a mediator between the web and the control system, thereby maintaining adhesive layer integrity while achieving precise web guidance through digital processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and damage-free application of labels or decorations onto substrates, maintaining the integrity of the web and ensuring proper alignment and adhesion without direct contact with the adhesive side, improving the efficiency and reliability of the labeling process.
Implementation Method 1
employing non-contact guides such as pressurized air or vacuum belts
Implementation Method 2
employing non-contact guides such as pressurized air or vacuum belts
Implementation Method 3
each decoration having a pressure sensitive adhesive exposed on a surface of the decoration facing outwardly from the first side of the web
Data Source
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AI summary
The present invention is directed to a system for transferring decorations to substrates, comprising: (i) a continuous web (102) including a plurality of decorations (18, 1604) provided on a first side (114) of the web, each decoration having a pressure sensitive adhesive (20) exposed on a surface of the decoration facing outwardly from the first side of the web; (ii) an application station (108) at which the decorations are transferred from the web to substrates (10); (iii) a web path along which the web travels to transport the decorations to the application station; (iv) a substrate transport (12, 14, 16) configured to move the substrates to the application station; (v) a web control system including at least one web controller (118, 120, 500) configured to move the web at the application station to position a decoration on the web for transfer to a substrate. The application station is configured to transfer a decoration from the web directly to a substrate based on contact of the substrate with the pressure sensitive adhesive of a portion of the decoration while the portion of the decoration is attached to the web. The system further comprises (a) an actuator (700, 800) provided to press the substrate against the decoration as the decoration is moved through the application station, or (b) an actuator (900) provided to apply an application force to the web to press the web and the decoration against the substrate, or (c) a first actuator provided to press the substrate against the decoration as the decoration is moved through the application station, and a second actuator provided to apply an application force to the web to press the web and the decoration against the substrate.