Patent Grant
8168280
The present disclosure relates to a lint roller. In particular, the present disclosure relates to a lint roller including a leading edge containing a low adhesion zone.
Lint removal tape is used on a roll to remove lint and other small particles from surfaces such as fabric, carpeting, furniture, etc. The tape is removed from the roll only after use, to discard it. In roll form, lint removal tape typically has the adhesive side of the tape wound outwardly for use. A roll of lint removal tape is generally used on an applicator.
Rolls of tape are often perforated for easier removal of individual sheets.
In use, the tape roll is rolled back and forth over a surface to remove loose particles of lint and other debris. The debris clings to the exposed adhesive of the top sheet of the tape roll, which is then removed and discarded, revealing a fresh tape sheet for the next use. In use, the sheets should not separate or unwind from the roll, yet the sheets must be easily removable from the roll when discarding. When such a tape roll is used to clean a smooth or flat surface, it often fails because the tape sticks aggressively to the surface and unwinds from the roll. This failure is referred to as “lanemarking.”
A variety of methods have been used to minimize lanemarking. The adhesive used on the tape could be made less sticky. The backing used may be highly structured, so that during use on a flat surface, the adhesive contacts the flat surface at fewer points. However, a less sticky adhesive and/or decreased contact with the surface being cleaned may harm the roller's ability to pick up and retain lint and debris. Another option is to select a release coating (on the back side of the tape sheet) that adheres more strongly to the adhesive. However, the sheets become difficult to remove when trying to expose a clean sheet. Tape wound in a spiral pattern minimizes lanemarking because only a small corner of the lint tape is lifted to start removing a sheet. However, for these rollers each spiral-wound sheet does not fully cover the underlying sheet. Therefore, when a used, dirty sheet is removed from the spiral wound roller, a pattern of dirt is still exposed on the underlying sheet. Lanemarking can be minimized by mechanical means. However, these systems are inconvenient.
Unwinding, or “lanemarking,” of a lint roll tape during use can be greatly minimized or even eliminated by providing a low adhesion zone at the separation line of a roll of tape. Including the low adhesion zone at the separation line minimizes the adhesion of the tape at the separation line of the outermost sheet to the surface being cleaned. Also, when the low adhesion zone slightly overlaps the underlying low adhesion zone, the low adhesion zone of the outermost overlying sheet is secured by the underlying adhesive. Further, the low adhesion zone located adjacent the separation line prevents the separation line from strongly adhering to the surface being cleaned.
As used throughout this disclosure “low adhesion zone” will mean an area having lower adhesion than the adhesive areas of the main body of the roller. The low adhesion zone may have an adhesion ranging from essentially zero adhesion to slightly less than the adhesion of the adhesive area of the main body of the roller.
In one embodiment, the roll of tape comprises a backing having a first side and a second side, an adhesive on the first side of the backing, a plurality of separation lines separating the tape into sheets, a low adhesion zone adjacent each separation lines extending in an upweb direction along the tape from the separation line. The low adhesion zone has a lower adhesion than the adhesive. Each separation line extends beyond the next adjacent and underlying low adhesion zone.
While the above-identified drawings and figures set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of this invention.
The figures may not be drawn to scale.
The backing layer 22 has a first side 26 and a second side 28 and can be made of, for example, paper or plastic film. Suitable paper backings include saturated flatstock and crepe. Suitable plastic film backings include polypropylene, polyethylene, copolymers of polypropylene and polyethylene, polyesters, and vinyl acetates. The polypropylene can be cast polypropylene, calendared polypropylene, biaxially oriented polypropylene (BOPP) or simultaneously biaxially oriented polypropylene (SBOPP). The backing material can be compostible, degradable, colored, printed, and can be of different surface textures or embossed, such as disclosed in U.S. Pat. No. 6,865,765 to Aalbers.
The adhesive layer 24 is placed on the first side 26 of the backing layer 22. It can be formed on the entire first side, or the backing layer can be uncoated by adhesive along one or both side edges. Alternatively, the side edges can be adhesive coated and then detackified by using waxes, lacquers, or inks for example.
Useful adhesives according to the present invention include all pressure sensitive adhesives. Pressure sensitive adhesives are normally tacky at room temperature and can be adhered to a surface by application of, at most, light finger pressure. Examples of adhesives useful in the invention include those based on general compositions of polyacrylate; polyvinyl ether; diene-containing rubber such as natural rubber, polyisoprene, and polyisobutylene; polychloroprene; butyl rubber; butadiene-acrylonitrile polymer; thermoplastic elastomer; block copolymers such as styrene-isoprene and styrene-isoprene-styrene block copolymers, styrene-butadiene-styrene block copolymers, ethylene-propylene-diene polymers, and styrene-butadiene polymer; poly-alpha-olefin; amorphous polyolefin; silicone; ethylene-containing copolymer such as ethylene vinyl acetate, ethylacrylate, and ethyl methacrylate; polyurethane; polyamide; epoxy; polyvinylpyrrolidone and vinylpyrrolidone copolymers; polyesters; and mixtures of the above. Additionally, the adhesives can contain additives such as tackifiers, plasticizers, oils, fillers, antioxidants, stabilizers, pigments, diffusing particles, curatives, perfumes, microcapsules, and solvents. The adhesive can include hotmelt-coated formulations, transfer-coated formulations, solvent-coated formulations, and latex formulations.
The tape 12 is formed into a roll 10 having a plurality of wraps with the adhesive layer 24 facing outwardly by rolling the tape on only itself. Support material, such as a core, a liner, or any other material that could lend support and provide rigidity and strength to the roll of tape, is optional. In the illustrated embodiments, none is used.
The roll 10 of tape could also include a third layer. A release material or low adhesion backside (LAB) layer 30 can be formed on the second side 28 of the backing layer 22 to facilitate removing the outer wrap of tape from the roll 10. Suitable LAB layers include silicones, fluorochemicals, acrylates, and polyvinylacetates. Numerous other layers can be added to the tape, such as primers to increase the adhesion of adhesive layer 24 to backing layer 22. Also, printed material can be located on the first side of the backing layer under the adhesive, or on the second side of the backing layer either under or over any LAB layer 30. This printed material can be advertising, instructions, or other information. The tape could contain deodorants, perfumes, antistatic materials, and encapsulated cleaning chemicals. Also, the backing layer 22 can be modified by flame treatment, corona treatment, or roughening.
A plurality of separation lines 32 divide the tape into discrete sheets, to help remove the outer wrap of tape from the roll 10. Each separation line 32 can be formed from any number of through-cuts ranging from a micro-perforated line to a continuous, nearly complete cut from the first side edge 18 to the second side edge 20. In this embodiment, each separation line 32 is a perforated line. The separation lines 32 are made before the tape 12 is formed into a roll 10. Each sheet is defined by the first and second side edges 18, 20, and two successive separation lines 32.
There are n separation lines 32 extending across at least most of the width of the tape 12 between the first and second side edges 18, 20 to separate the tape into n+1 sheets. The plurality of separation lines 32 can extend partially or completely across the width of the tape. The sheets may have progressively increasing lengths, uniform length, or random length from the first longitudinal end 14 to the second longitudinal end 16 such that when the sheets are wound into a roll each separation line 32 overlaps the successive, underlying separation line 32.
When the tape 12 forms a roll 10, the outermost sheet 34 has a free, leading edge 36 and a trailing end 38. As shown in
Adjacent the separation line 32 is a low adhesion zone 40. The low adhesion zone 40 includes an adhesion less that the adhesive 24 section of the tape 12. There are a variety of ways to achieve an adhesion in the low adhesion zone 40 less than the adhesion of the adhesive 24 of the tape 12. In one embodiment, the adhesive 24 may be omitted entirely from being applied in the low adhesion zone 40. In such an instance, the low adhesion zone 40 essentially has no adhesion. In another embodiment, adhesive 24 may be a coating of a higher adhesion adhesive, while a lower adhesion adhesive can be applied in the low adhesion zone 40. In another embodiment, the adhesive 24 within the low adhesion zone 40 can be detackified. To detackify the adhesive 24 an adhesive coating of ink, varnish, powder, or wax can be applied over the adhesive 24 in the desired low adhesion zone 40. It is possible to depict the low adhesion zone 40 by a color different that the adhesive 24 of the tape 12.
As shown in
As discussed above, the separation lines 32 overlap one another. It is desirable to cause enough overlap that the low adhesion zone 40 is at least partially secured to the underlying adhesive 24 (which may actually be part of the same sheet). Without an overlap, where the low adhesion zones 40 of the outermost sheet 34 is arranged on top of the underlying low adhesion zone 40, a flap or tab may be formed because the outer low adhesion zone 40 is not secured down by the underlying adhesive. As shown by
As discussed above, the separation lines 32 overlap one another. It is desirable to cause enough overlap so that the low adhesion zone 40 is at least partially secured to the underlying adhesive 24. As shown by
As discussed above, the separation lines 32 overlap one another. It is desirable to cause enough overlap so that the low adhesion zone 40 is at least partially secured to the underlying adhesive 24. As shown by
The low adhesion zone 40 may extend across 100% of the tape 12 along the separation line 32, such as shown in the embodiments of
As depicted, the low adhesion zone 40 is shown rectangular. It is understood that any variety of sizes, shape and number of low adhesion zones 40 may be suitable so long as a portion of the low adhesion zone 40 is along a portion of the separation line 32. For example the low adhesion zone 40 may be oval, circular, wavy, zigzag, square, stars, hearts, small pixels of a shape like circles, stripes, or any variety of random or repeating pattern.
The size of distances A and B depend on a number of factors including the adhesion of the adhesive 24, the adhesion of the low adhesion zone 40, the surfaces that the roller will be applied over, etc. Also, it is understood that because the low adhesion zone 40 is not necessarily rectangular, then distance A and/or B may vary along the length of the separation line.
Generally, the free leading edge 36 of the outer sheet 34 extends beyond the underlying low adhesion zone 40. Distance B should be a positive number, indicating that the free leading edge 36 has extended beyond the underlying low adhesion zone 40. In one embodiment, especially when the low adhesion zone 40 is rectangular, distance A and distance B are approximately equal. If distance B is too small, then the leading edge may not be sufficiently secured to the underlying adhesive. If distance B is much larger than A, then the unused portion (refer to
In one embodiment, distance A is at least 1 mm and distance B is at least 1 mm. In another embodiment, distance A is at least 5 mm and distance B is at least 5 mm. In another embodiment, distance A is at least 8 mm and distance B is at least 8 mm. In one embodiment, distance A is between 10 and 18 mm and distance B is between 13 and 19 mm.
The description above has generally been with respect to separation lines overlapping one another such that the adjacent low adhesion zone overlaps the underlying low adhesion zone. It is understood that an underlap may achieve the same objective. In such an embodiment, the low adhesion zone may be secured by the underlying adhesive. Preferably in this embodiment, the separation line of the outermost sheet is secured by the underlying adhesive.
Although specific embodiments of this invention have been shown and described herein, it is understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the invention. Numerous and varied other arrangements can be devised in accordance with these principles by those of ordinary skill in the art without departing from the spirit and scope of the invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by the structures described by the language of the claims and the equivalents of those structures.
Test Method for Lanemarking
Tendency to lanemark on a particular surface was determined using the following test: A roll of test tape was placed on a roller handle or floor roller tool, and any cover wrap was removed. The distance from the free end of the sheet to the end of the low adhesion zone (distance A) was measured with a ruler and recorded. The side sectional distance from the free end of the sheet to the start of the next underlying low adhesion zone (distance B) was measured and recorded. When the free end of the tape did not completely overlay the low adhesion zone on the next sheet, the distance B was recorded as a negative number. Using moderate force, the tape roll was rolled across the test surface, back and forth, at least twice, using a stroke distance of two or three feet. If the lint tape unwound from the roller and stuck to the test surface during the test, the recorded lanemark score was 1, otherwise the score was recorded as 0. To continue with additional tests, the used top sheet and any sheets that may have unwound were removed, and the test was repeated with freshly exposed tape.
Example Lint Tape Rolls 1-19
Lint tapes were prepared having the properties shown in Table 1. The tape backings (cast polypropylene) and the adhesive compositions (synthetic rubber-resin based) that were used were similar to that used for the Scotch™ Lint Roller product (available from 3M Company, St. Paul, Minn.). The adhesive coatings covered the entire width of the lint tape, except for an approximately 0.25 inch longitudinal strip left uncoated at each edge.
1Peel Adhesion to Steel was measured according to PSTC 101, Test Method A (Pressure Sensitive Tape Council, 15th Edition, 2007).
2Roll Unwind Force was measured according to PSTC 8 (Pressure Sensitive Tape Council, 15th Edition, 2007).
Each lint tape was printed with green printing ink (Graflex pH Neutral 376 Green, KMB-10376-AD, available from Kohl & Madden Printing Ink Corporation, Carlstadt, N.J., a member of the Sun Chemical Group) to fully cover the adhesive coating in the center of the tape, resulting in rectangular detackified low adhesion zones extending across the width of the lint tape, at fixed downweb intervals. The printed lint tapes were then converted into 4 inch or 8 inch wide coreless lint rolls (1.75 inch inner diameter) of varying lengths. Coreless lint tape rolls are described and disclosed in U.S. Pat. No. 5,878,457. The lint tape rolls were perforated during converting using techniques known in the art such that the perforation or separation lines occurred within the low adhesion zones, similar to the low adhesion zones shown on the lint tape roll shown in
The lint tape rolls were then evaluated for their tendency for lanemarking as described above. The data obtained for 4 inch wide lint tape rolls (Examples 1-8) are given in Table 2. The data obtained for 8 inch wide lint tape rolls (Examples 9-19) are given in Table 3.
Example Lint Tape Rolls 20-35
Example Lint Rolls 20-35 were prepared in order to determine whether the lint rollers required a low adhesion zone along the entire leading edge of the tape roll.
Lint tape samples were prepared having the properties shown in Table 4. The tape backings (cast polypropylene) and the adhesive compositions (synthetic rubber-resin based) that were used were similar to that used for the Scotch™ Lint Roller product (available from 3M Company, St. Paul, Minn.). The adhesive coatings covered the entire width of the tape, except for an approximately 0.25 inch longitudinal strip left uncoated at each edge.
1Peel Adhesion to Steel was measured according to PSTC 101, Test Method A (Pressure Sensitive Tape Council, 15th Edition, 2007).
2Roll Unwind Force was measured according to PSTC 8 (Pressure Sensitive Tape Council, 15th Edition, 2007).
The lint tapes were then wound into stock rolls for further converting. These stock rolls were converted and made into coreless progressively printed and perforated lint rolls using techniques known in the art. Progressively perforated lint tape rolls are described and disclosed in U.S. Pat. No. 5,763,038, and lint tape rolls having printed areas registered with the perforation lines are described and disclosed in U.S. Patent Publication No. 2006/0003129. The lint rolls were printed and perforated during converting such that each low adhesion zone had a 1/32 inch wide or 3/32 inch wide unprinted area or gap extending along the length of the low adhesion zone, at the center between the edges of the tape, and such that the perforation or separation lines occurred within the low adhesion zones as shown in
The lint rolls were then evaluated for their tendency for lanemarking as described above. The data obtained are given in Table 5.
Although the data are not presented here, similar results were obtained when the lint tape rolls were tested against glass, PERGO® laminate flooring, and office cubicle type carpeting having a tight weave and low profile.
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