Vertical Carousel Padding System for Retail Signage

This invention relates generally to an automated padding system, and more particularly, to a vertical carousel padding system that creates adhesive based aisle stacks of retail signage destined for in-store shelves.

Retail stores often utilize media sheet signage (e.g., edge markers, retail edge marker strips, signage workpieces) to convey information regarding products offered for sale, e.g., product costs, unit cost, sale pricing, etc. Such signage must be updated and/or replaced on a periodic basis. For example, regular product pricing may change, or during a sale, a discounted price may be necessary. Changes to media sheet signage may be required for hundreds or even thousands of products and these changes may be required daily weekly or another periodic term. In addition, product placement may change which would require updating of the signage. In some states, it is critical that the media sheet signage be updated in a timely fashion as the retail store may be obligated to honor the price displayed adjacent the product. In other words, if the store fails to remove the media sheet signage that displays a discounted cost, the store must charge that cost if a customer relies upon that price when making a purchase selection. In view of the foregoing, it should be apparent that proper timing and placement of signage is a critical responsibility of a retail store.

Although some retail chain stores share common store layouts, also known as a store planogram, most retail locations, even within a chain store have unique store planograms. The changeover of store signage can incur significant time which in turn incurs significant cost. A common practice is to print sheets signage and an employee or group of employees are tasked with edge marker changeover. Such shelving signs are typically printed, cut, stacked by shore layout, banded, and then shipped to the stores in boxes. The banded stacks are then brought to each aisle for application. To apply the signs the stacks are unbanded and the signs are adhered to the shelving. This human labor is difficult and the signs are often dropped and scattered. Whereupon the operator must pick them up, and reorder the separated signs back into their proper order before they are applied.

In addition, the printing, cutting, stacking and banding of shelving signs may be carried out in a single continuous assembly. Typically banding a stack of signs may take a few seconds to wrap. Unfortunately, bottle necks in production may occur at the bander when processing small sets of retail sign stacks as the processes of printing, cutting and stacking become quicker than the bander. This slows down the shelving signage assembly system and may require temporary stops in production as the bander catches up an clears any backlog of stacks waiting to be wrapped. Obviously, there is a need for a more efficient media sheet signage binding system that presents shelf edge markers to store employees in a per store planogram order for in-store deployment.

The following presents a simplified summary in order to provide a basic understanding of some aspects of one or more embodiments or examples of the present teachings. This summary is not an extensive overview, nor is it intended to identify key or critical elements of the present teachings, nor to delineate the scope of the disclosure. Rather, its primary purpose is merely to present one or more concepts in simplified form as a prelude to the detailed description presented later. Additional goals and advantages will become more evident in the description of the figures, the detailed description of the disclosure, and the claims.

The foregoing and/or other aspects and utilities embodied in the present disclosure may be achieved by providing a system including a carousel and padding station for automatically binding stacks of media sheets exiting an upstream source. The carousel may be adjacent the upstream source and includes a plurality of stack housings attached to the carousel adjacent a periphery thereof. One of the stack housings is configured to receive a stack of media sheets from the upstream source and to rotate the received stack of media sheets incrementally around the carousel. The padding station is adjacent the stack housings and includes 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 cures/dries and binds the received stack of the media sheets together into a bound bundle of the media sheets.

According to aspects illustrated herein, an exemplary media sheet binding method includes receiving a stack of media sheets from the upstream source via a stack housing of a carousel that may be adjacent the upstream source, the stack housing being one of a plurality of stack housings attached to the carousel adjacent a periphery thereof; rotating, via the stack housing, the received stack of media sheets incrementally around the carousel; and 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. The method may also include removing the bound bundle from the stack housing via an exit conveyor mechanism adjacent the carousel.

According to aspects described herein, an exemplary media sheet binding device automatically binds stacks of media sheets exiting an upstream source. The device includes a vertically oriented carousel, a padding station and an exit conveyor mechanism. The vertical carousel may be adjacent the upstream source and includes stack housings attached to the vertical carousel adjacent a periphery thereof. Each of the stack housings is configured to receive a respective stack of media sheets from the upstream source and to rotate the received stack around the vertical carousel. The padding station is adjacent the stack housings and includes a container housing an adhesive and an adhesive applicator configured to deposit a layer of the adhesive onto a side of the media sheet stacks received the stack housings adjacent the padding station. The adhesive layer cures and binds the padded stack of media sheets into a bound bundle of the media sheets. The exit conveyor mechanism is adjacent the vertical carousel and removes the bound bundles from the stack housings.

Exemplary embodiments are described herein. It is envisioned, however, that any system that incorporates features of apparatus and systems described herein are encompassed by the scope and spirit of the exemplary embodiments.

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.

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.

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.

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.”

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).

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.

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.

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.

Referring now to the drawings, and more specifically to, what is illustrated is an exemplary automated media sheet processing system, which can be used with methods herein. The systemis 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, person) such as a conventional unwinder that roll feeds media sheets in continuous sheet form into a conventional cutterthat 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()) 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.

The systemincludes a controllerand at least one marking device (printing engine(s))operatively connected to the controller. The system may also include a communications port (Input/Output device) operatively connected to the controllerand to a computerized network external to the system. The Input/Output devicemay be used for communications to and from the system, as well understood by a skilled artisan.

The controllerincludes at least one processor and controls the various actions of the system, as described in greater detail below. A storage medium(e.g., non-transitory computer storage medium, which may be optical, magnetic, capacitor based, etc.) is readable by the controllerand stores instructions that the controllerexecutes to allow the systemto perform its various functions, such as those described herein. Thus, as shown in, a body housinghas one or more functional components that operate on power supplied from an external power source, which may comprise an alternating current (AC) power source, through a power supply. The power supplymay include a power storage element (e.g., a battery) and connects to the external power source. The power supplyconverts the power from the external power sourceinto the type of power needed by the various components of the system.

The systemmedia supplyprovides media to a media path. The media pathmay include any combination of belts, rollers, nips, drive wheels, vacuum devices, air devices, etc. that transport the media from the media supplythrough system, as well understood by a skilled artisan. The systemincludes a marking device (e.g., printing engine) positioned along the media path. The marking device prints marks on the media. Further, the cuttermay be positioned along the media path, and the cutter divides (cuts) the media into individual workpieces or media sheets(), such as retail edge marker strips or signs.

While signs are used as an example of a type of media sheet that can be processed with the systemherein, 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.

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

While not being limited to a particular configuration, systemmay include at least one accessory functional component, such as a graphic user interface (GUI) assembly, an optical scanner, or other accessory functional component (such as a document handler, automatic document feeder (ADF), etc.) that operate on power supplied from the external power sourcevia the power supply.

A transport deviceis additionally positioned along the media path. The transport devicemoves the media sheetsfrom the media pathand places the media sheets into a collating apparatus. After the media sheetsare compiled and collated, the collated media sheets may be forwarded (e.g., via a stack platform()) to additional stations, such as a binding system, for further processing as discussed in greater detail below.

As would be understood by those ordinarily skilled in the art, the systemshown inis 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, 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.

depict related art media sheet processing apparatus media path sections including an accumulation and collating devicelocated directly after a transport device.depicts a related art accumulation and collating devicein side view. The accumulation and collating deviceincludes a series of ramped angled bafflesthat accept and register media sheetsexiting the transport deviceand accumulates the registered media sheets. Each angled baffleis configured to allow the media sheetsto 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, such as the number of signage sheets for a retail store or part thereof. The angled bafflesmay also have an aperture(.) that splits the bafflesinto separate sections to permit transverse movement by a pusher, as will be described in greater detail below.

As may be seen in, the transport devicemoves media sheetsto the related art accumulation and collating device. The accumulation and collating devicemay include a buffer/compilerabove a sequential cross-process collatorhaving the angled baffles. The buffer/compilerholds one or more media sheetsin stacksabove the collatorto allow time for the collator to actuate and reset before the next stackof media sheetsare collated. In examples, the buffer/compilerincludes shelvesthat support the stacksabove respective angled baffles. The buffer/compiler may also include wallsbetween shelvesto help segregate the media sheetsinto separate stackson the shelves.

The compiling and collating process may be divided into stages. In a first stage, the media sheetsare output from the body housinginto the buffer/compilerwhere they are compiled in stackson the shelves. The media sheetsin the stacksmay be in a predetermined sequential order as controlled by the controller. In a second stage, also referred to as an accumulation state, the stacksare dropped onto the angle bafflesof the collator.

The stacksmay be dropped from the shelvesin various ways. For example, the shelvesmay be moveable and configured to slide out to a first position to support media sheetsoutput from the body housing, 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. In other examples the stacksmay be urged or pushed out of the shelvesonto the angled baffles, as well understood by a skilled artisan.

As can be seen in, the collatorincludes the series (e.g., more than one) of ramped angle bafflesand an automated pusherthat moves each of the stackstoward the combined collated stack. At the end of the accumulation stage, the pusheris moved generally orthogonally to the media sheetsto push the media sheets from each ramped angled baffleonto the top of media sheets in adjacent bins of bafflesin succession to collate the media sheets onto the stack platform. That is, during this stage, which may be considered a third stage, the pushersweeps the stacksin sequential order as an interim stack. Continued sweeping of the pusher across the bafflesto the stack platformresults in the interim stackof collated media sheetspushed onto the stack platform as the combined collated stack. The combined collated stackmay have a predetermined number of media sheetsin a known order (e.g., in-store planogram order) as controlled by the controller. Pushermay be arranged for automated pulling through the aperture() between bafflesonto and across the platformas desired to unload the dropped media sheet stacksfrom each baffle and simultaneously convey the interim stackonto the platform at a stacking position thereon laterally across from the angled baffles as the collated stackafter all of the predetermined number of media sheetshave been fed from the transport device.

The multi-stage process may allow the transport deviceto stack the media sheetsin the buffer/compilerfor temporary holding in order to provide the time needed for previous sets of media sheets to be collated underneath. This allows the pushertime to move the interim stacksinto a combined collated stackand to return to a starting (e.g., home) position prior to the buffer/compilerreleasing its temporary hold of the stacksand dropping the next stacks down into the collator.

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.

In examples of the vertical carousel padding system, collated stacksare 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 stackis 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.

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.

depict an exemplary vertical carousel padding system(e.g., binding system) in top perspective, side perspective and partial sectional views, respectively. The padding systemis an exemplary binding system() designed to automatically bind stacksof media sheetsforwarded 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. While not being limited to a particular configuration, the delivery unitmay include elements of the media sheet processing system, such as the stack platformand the automated pusherconfigured to move the combined collated stacksacross the platform to the padding systemlocated 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 stacksto the padding system, including a conveyor belt or arm, as readily understood by a skilled artisan.

The padding systemincludes a carouselthat may be adjacent the delivery unit(e.g., platformand pusher) to receive stackstherefrom. The carouselmay have a generally cylindrical shape and includes a plurality of stack housingsor receiving bins attached to the carousel adjacent the circumferential periphery thereof. The stack housingsare configured to receive stacksof the media sheetsfrom the delivery unitand rotate the received stacks of media sheets incrementally around the carousel. While not being limited to a particular theory, the carouselis 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.

A drive mechanism() may be attached to the carouselto rotate the carousel, as well understood by a skilled artisan. The drive mechanismmay include a motor (e.g., stepper motor) that incrementally indexes or rotates the carouseland enable the stack housingsto transfer media sheet stacksfrom the delivery unit around a padding stationto an exit station(), as will be discussed in greater detail below. Carouselincremental 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, as will be described in greater detail below.

Referring to, the stack housingseach include a bottom walland radially extending arm walls,configured to receive and hold a stackof the media sheetsduring 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,may be separated as needed to accept a stackof the media sheets, and then closed as needed to hold a stackvia a clamping device (e.g., cam system, spring loaded arms, pneumatics, stepper drive) operating via the controller, as well understood by a skilled artisan. Thus the stack housings can accept stacksof varying heights or thicknesses by opening the arm walls,wider than the stack forwarded to the carousel. With the arm walls opened, the delivery unitmay move a stackinto a stack housingwith a front edgeof the stack moved into contact with the bottom wall.

The stack housingsare catch bins configured to vibrate, for example via the drive mechanism, stepper motoror other vibration causing motor (e.g., Eccentric Rotating Mass (ERM) motor, Linear Resonant Actuator (LRA)) in contact with the housings. In examples, stack housingsvibrate after receipt of a stackof media sheetsfor registration of the media sheets. Referring to, the stack housingsmay vibrate the media sheetsof stacks placed into the housings, and register or align the sheets along the bottom wallas the carouselincrementally rotates the registering stacks in the housings from a generally horizontal orientation delivered from the delivery unitto a tilted increasingly vertical orientation as each rotating stack housing with a registering stack therein approaches the padding station. During stack registration, the stack housing holds the media sheetsof the stack loosely to allow relative sliding of vibrated media sheets into registration. Prior to arrival at the padding station(e.g., less than 20 degrees prior, less than 10 degrees prior, about 5 degrees prior), the stack housing arm walls,may close or clamp against the stack(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.

Referring still to, the carouselmay include outer ringsthat connect the stack housingstherebetween. The outer ringsstructurally 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 housingsmay be split into lateral sections, for example two lateral sections,that define a slotted aperturetherebetween. Each of the later sections may be connected to one of the outer rings, with the sections aligned across the slotted apertureto hold stacksas can be seen by example in. The slotted apertureallows access to the stack held by the stack housing lateral sections, for example as discussed in greater detail below.

The padding stationmay be located adjacent the carouselbetween the delivery unitand the exit stationin the rotational processing directionof the carousel. The padding stationmay include an adhesive containerand an adhesive applicator(e.g., roller, anilox roller, brush, sponge, doctor blade, sprayer, thermal or piezoelectric adhesive emitter) in communication with an adhesive(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 stackof media sheetsadjacent the adhesive applicator. In the example depicted in, the adhesive applicatorincludes a rollerin contact with adhesivein the containerand adjacent the front edgeof a stackvia the aperturein a stack housing. As the carouselrotates the indexed registered stackspast the padding station, the adhesive applicatordeposits a thin layerof adhesive along the front edge of the stackand creates a padded bundle.

The rollermay rotate and transfer adhesivefrom the containerto the stackthrough the apertureas a layerof adhesive along the front edge of the stack facing the roller with the media sheetsin the stack registered in a generally vertical orientation. While not being limited to a particular theory, the adhesive applicatormay use an anilox roller or doctor blade (not shown) to meter the adhesive from the adhesive containeronto the stackside 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 applicatormay include a jetting device (not shown—e.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.

After the strip or layerof adhesive is applied to a now padded bundle, the bundle continues its rotation in the carouseltowards the exit station. During this continued rotation, the adhesive strip is cured to securely bind together the individual media sheetsof the padded bundlealong the front edgeof the stack. The padding systemmay include a curing deviceadjacent the carouselthat further cures and/or accelerates curing of the adhesive strip. While not being limited to a particular theory, the curing devicemay 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 layerof adhesive to an amount of heat, air, chemical or other radiation emissionto at least partially cure/dry the adhesive to a tacky or solid state adequate for subsequent handling and shipping of the padded bundles. The curing devicemay 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 systemdepicted in, curing devicemay be positioned adjacent and radially inside the carouselto cure/dry adhesive strips to the front edgeof stacksbetween the padding stationand the exit station.

The exit stationis located adjacent the carouseldownstream the padding stationto remove bound padded bundlesfrom their respective stack housing. Still referring to the exemplary padding systemdepicted in, the exit stationincludes a conveyor mechanism having a conveyor beltconfigured to move the cured padded bundlesaway from the stack housingsfor exit and subsequent processing (e.g., packing, shipping). In some examples the conveyor mechanism may also include profile finsextending out from the conveyor beltthat help to remove the padded bundlesfrom their respective housingsfor exit from the padding stationon the conveyor belt. The conveyor beltand finsmay be sized to have a width less than a width of the slotted aperturesdefined by lateral sections,of the stack housingsso they can traverse through the slotted apertures and shift the padded bundlesaway from the housings and carousel. The beltmay be driven by a motor (not shown) that drives the belt, for example, via roller, as well understood by a skilled artisan.

To aid in the removal of the padded bundlesfrom stack housings, the arm walls,previously clamped at least a few degrees before glue application at the padding stationmay be unclamped or separated before stack housings reach the exit station. The unclamped padded bundlesare not held tightly by the separated arm walls,and may be easily removed from stack housingby the conveyor beltwithout need or assistance by profile fins. Accordingly, the conveyor mechanism may readily remove padded bundlesfrom opened housingswithout clamped friction via the conveyor beltwithout 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 beltis part of an exemplary exit conveyor mechanism and other conveyor mechanisms may be used in examples as understood by a skilled artisan.

In operation, the vertical carousel padding systemreceives a stackof previously collated loose media sheetswhere the stack is first placed into a catch bin or stack housing of the carousel. The stack is registered via a vibration jogging motor of the carousel drive mechanismas it is stepped through the vertical rotation of the carousel. The registered stack passes by a gluing/padding stationto receive a layer or strip of adhesive, and then incrementally is rotated to the exit station. The adhesive is cured during the last leg of the rotation of the padded bundle around the carouselprior to being delivered to the exit conveyor mechanism. The stacks of media sheetsare 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 housingsduring a first segment of rotational motion of incremented locations via spring load or motion activated clamping system, as well understood by a skilled artisan.

The disclosed embodiments may include an exemplary method for automatically binding stacks of media sheets exiting an upstream source, which may include the platformand delivery unit.illustrates a flowchart of such an exemplary method. As shown in, operation of the method commences at Step Sand proceeds to Step S, 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.

Operation of the method proceeds to Step S, 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.

Operation proceeds to Step S, 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.