Flat continuous wound adhesive tape dispenser and method of manufacture

Abstract

A flat tape dispenser of a continuous length of pressure-sensitive-adhesive (PSA) tape is wound around a flat panel core producing a more compact, more convenient and easier to carry PSA tape dispenser. The tape utilizes an easy-tear feature. The flat tape dispenser is manufactured by winding the PSA tape on a round shaft of Teflon or a shaft covered by a release liner or release coating. The fully wound PSA tape is removed from the shaft, a flat panel core is inserted and the roll is flattened so the inside seals against the core. Alternatively, the PSA tape is wound on a deformable core and then flattened to its final shape.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to improvements in dispensing of pressure-sensitive adhesive tape and more particularly pertains to a new and improved continuous length of pressure-sensitive-adhesive (PSA) tape packaged in a flat form.

[0003] 2. Description of Prior Art

[0004] In the field of dispensing pressure-sensitive-adhesive tape, it has been the practice to employ a cylindrical core upon which to wind the continuous length of tape. The resulting rolls of tape have been unsatisfactory in that they are bulky to carry. As a result, the prior art has attempted to devise a flat pad for dispensing pressure-sensitive-adhesive tape. However, the prior art approach to such flat pads has itself produced a shortcoming in that the flat pads are necessarily made up of a number of individual strips of tape having predefined lengths. This prevents a user from dispensing a tape from the pad that is longer than the length of the individual strips in the pad. Other attempts to make flat pad tape dispensers have resulted in simply flattening a core and winding tape around the flat core, or flattening a wound roll of tape. Those approaches are either time consuming, result in a flat tape dispenser with wrinkled tape, or produce a dispenser with a relatively short length of tape.

SUMMARY OF THE INVENTION

[0005] The present invention provides a flat tape dispenser of a continuous length of pressure-sensitive-adhesive (PSA) tape of up to 100 meters (m) in length wound around a flat panel core. The flat tape dispenser is more compact and can be more conveniently carried and used than tape dispensers using a cylindrical core. The PSA tape preferably uses an easy-tear feature. The flat tape dispenser is manufactured by winding the desired length of PSA tape on a shaft that is either made of Teflon, is Teflon coated, or has a release coating or release liner coating it. The PSA tape, when fully wound, is removed from the shaft. The roll is pressed flat. A panel of an appropriate size is inserted in the resulting slot in the center of the flattened tape roll. The somewhat flattened tape roll is then pressed again to seal the inside against the inserted panel to form a flat tape dispenser.

[0006] In an alternate embodiment, the tape is wound on a core of corrugated paper or a thin film plastic core, both of which are deformable. The wound roll with its deformable core is then pressed flat to produce the flat tape dispenser without wrinkling the wound tape.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The exact nature of this invention as well as its objects and advantages will be readily appreciated as it becomes better understood by reference to the following detailed description when considered in conjunction with accompanying drawings in which like reference numerals designate like parts throughout the figures thereof and wherein:

[0008] FIG. 1 is a perspective view of a first step in the manufacture of the present invention;

[0009] FIG. 2 is a perspective view of a core of an element of the present invention;

[0010] FIG. 3 is a perspective view of the present invention in its final form;

[0011] FIG. 4 is a perspective view of an alternate approach to the manufacture of the present invention;

[0012] FIG. 5 is perspective view of the resulting product;

[0013] FIG. 6 is a block diagram showing the sequence of steps in a preferred process of manufacture of the present invention; and

[0014] FIG. 7 is a block diagram showing the sequence of steps in an alternate preferred method of manufacture.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0015] Refer first to FIGS. 1, 2, and 3 which indicate a first preferred embodiment of the flat continuous tape dispenser of the present invention. FIG. 1 illustrates the winding of a continuous length of tape 11 into a standard roll 15 on a cylinder 13. The cylinder 13 is coated with a release material or is wound with a release liner, or in the alternative, may be made out of Teflon or be Teflon coated, all for the purpose of allowing the roll 15, when it is wound to its desired length, to be removed from cylinder 13. The tape 11 wound into the roll 15 may be up to 100 meters long, for example. The PSA tape itself would be in the range of 0.001 to 0.005 inches thick. The result is a roll 15 of pressure-sensitive-adhesive (PSA) tape wound about itself without a core with the inside 17 of the roll 15 being coated with adhesive.

[0016] If a release liner is used to permit the removal of roll 15 from cylinder 13, the release liner is removed prior to the next step. The roll is then pressed flat, causing the round central aperture 17 to become more or less of a slot.

[0017] A panel 19, which is preferably the same width as the roll of tape 15, is inserted into the flattened aperture 17. The panel may have a thickness of between 1 to 10 mm, and preferably between 3 to 5 mm. It may be rectangular in shape, for example, being two inches wide and five inches long.

[0018] After the panel 19 is inserted into the flattened aperture 17, the roll 18 is pressed again causing a flat, continuous wound adhesive tape dispenser, as shown in FIG. 3, with the inside of the tape aperture 17 bonded to the panel 19.

[0019] The tape 11 utilized to create this flat, continuous wound adhesive tape dispenser is preferably the kind of tape described in U.S. patent application Ser. No. 09/373,314 filed Aug. 12, 1999 for A Tape Having Finger-Tearing Feature assigned to the same assignee as in the present application. The disclosure of that application is hereby incorporated by reference as is fully set forth herein.

[0020] The panel 19 may have decorative designs thereon or advertising as desired by the wholesale customer. It is further contemplated that the flat roll 15 can be delivered to a customer without a panel 19 inserted therein. This allows the customer to insert a panel 19 of his own design as desired. The customer would then seal the internal surfaces 17 of the roll 15 to panel 19. The resulting flattened adhesive tape dispenser shown in FIG. 3 allows the designs or advertisements present on panel 19 to show through the tape. More important, the resulting shape of the tape dispenser is more convenient to carry in one's pocket than a round roll 15, especially one that has 100 meters (m) of tape thereon.

[0021] Referring now to FIGS. 4 and 5, an alternate preferred embodiment of the invention is to wind a pressure-sensitive-adhesive (PSA) tape 23 in a roll onto a cylindrical core 27 which is deformable. The inventors have found that a deformable core made from corrugated material or thin film plastic would be effective. The roll 25 is then flattened to produce the flat continuous wound tape dispenser shown in FIG. 5. Prior to flattening, the inside of the core 27 is coated with an adhesive so that once flattened, core 27 will stay flat.

[0022] It has been discovered by the inventors that the inside diameter of rolls 15 and 25 should preferably be no greater than 3 inches, the preferable range of diameters being from 1 inch to 3 inches. Utilizing a larger diameter core will cause the tape roll 15 and 25 to wrinkle when being flattened as a result of the tape delaminating from the core.

[0023] Referring to FIG. 6, which shows the steps of the process for producing the product illustrated in FIG. 3, the first step 29 is to wind the tape 11 on a cylinder 13 which has a release surface. Once the tape is wound, the roll is capable of being removed. The second step 31 is to remove the roll from cylinder 13. The roll is then flattened as the third step 33. A flat panel core 19 is then inserted into the center as the fourth step 35. The flat panel core is sealed into the center slot of the flattened roll, as the fifth and last step 37, producing the product shown in FIG. 3.

[0024] FIG. 7 illustrates the process of manufacturing using a deformable core. The first step is to wind the tape 25 on a deformable core 27 which is traditionally held on a spindle (not shown). Once the tape is fully wound, adhesive is placed inside the inside surfaces of the core 27 as the second step 41. The third step 43 is to flatten the tape and core, creating the product shown in FIG. 5.

Claims

1. A tape dispenser for pressure-sensitive-adhesive (PSA) tape, comprising: a flat core; and a length of said PSA tape under 100 meters in length wound around said flat core; whereby a flat pad of continuous tape that can be conveniently carried is produced.

2. The tape dispenser of claim 1 wherein said flat core is up to two inches wide, up to 5 inches long and up to 3 mm thick.

3. The tape dispenser of claim 2 wherein said PSA tape is between 0.001 and 0.005 inches thick.

4. The tape dispenser of claim 1 wherein said flat core is the same width as the tape and is 1 to 10 mm thick.

5. The tape dispenser of claim 1 wherein the flat core is 3 to 5 mm thick.

6. The tape dispenser of claim 1 wherein the flat core has designs or advertisements thereon that is seen through the clear PSA tape wound around it.

7. The tape dispenser of claim 1 wherein the PSA tape utilizes an easy-tear feature that allows any length of tape to be separated from the dispenser pad by hand, without a cutting edge.

8. A method of manufacturing a tape dispenser of continuous pressure-sensitive-adhesive tape, the steps of the method comprising: winding a continuous length of said tape on a cylinder coated with a release material to a desired roll; removing the wound roll of tape from the cylinder, wherein the roll of tape is without a core at its center; flattening the coreless roll of tape without completely collapsing the space in the center of the roll; inserting a substantially flat core into the center; and flattening the tape again so that the center seals against the flat core; whereby a flat tape dispenser of continuous tape results.

9. The method of claim 8 wherein the release material on the cylinder is a release liner.

10. The method of claim 8 wherein the cylinder is made of Teflon material.

11. The method of claim 8 wherein the substantially flat core is the same width as the tape and between 1 to 10 mm thick.

12. The method of claim 8 wherein the substantially flat core is the same width as the tape and between 3 to 5 mm thick.

13. The method of claim 8 wherein the continuous length of tape is about 0.003 inches thick.

14. The method of claim 8 wherein the continuous length of tape is up to 2 inches wide and up to 100 meters in length.

15. The method of claim 8 wherein the substantially flat core is up to two inches wide, up to five inches long and about 3 mm thick.

16. The method of claim 9 wherein the release liner is removed from the center of the roll before the tape roll is flattened.

17. The method of claim 8 wherein the substantially flat core has designs or advertising on both sides which show through the tape after being flattened.

18. The method of claim 8 wherein the cylinder is between one inch and three inches in diameter.

19. A method of manufacturing a tape dispenser of continuous pressure-sensitive-adhesive tape, the steps of the method comprising: winding a continuous length of said tape on a deformable core; placing an adhesive on the internal surfaces of the deformable core; and flattening the tape so that the internal surfaces of the core seals against themselves causing a flat tape dispenser of continuous tape.

20. The method of claim 19 wherein the deformable core is corrugated.

21. The method of claim 19 wherein the deformable core is made of thin film plastic.

22. The method of claim 19 wherein the deformable core is between 1 to 10 mm thick.

23. The method of claim 19 wherein the deformable core is between 3 to 5 mm thick.

24. The method of claim 19 wherein the tape is about 0.003 inches thick.

25. The method of claim 19 wherein the tape is up to 2 inches wide and up to 100 meters in length.

26. The method of claim 19 wherein the core is between one inch and three inches in diameter.