Adhesive transfer device

The present application generally relates to adhesive transfer devices. One embodiment of the application discloses a hand-held actuatorless adhesive transfer device. Another embodiment of the application discloses an adhesive transfer device for applying adhesive to a side edge portion of a selected substrate.

FIELD OF THE INVENTION

The present invention relates to an adhesive transfer device for applying adhesive to a selected substrate.

BACKGROUND AND SUMMARY OF THE INVENTION

U.S. Pat. Nos. 5,584,962 and 5,580,417 disclose devices that can be used for performing an adhesive transfer operation wherein pressure-sensitive adhesive is applied to one side of a selected substrate, such as a printed label or a photograph. These devices each comprise a frame, structure for mounting a set of supply rolls, a pair of nip rollers for applying pressure to the substrates being advanced therethrough, and a manual crank handle for imparting rotation to the nip rollers. One of the supply rolls carries a wound-up supply of an adhesive carrying substrate coated on one side thereof with a layer of pressure-sensitive adhesive. The other supply roll carries a wound-up supply of an adhesive mask substrate that has a greater affinity for adhesive bonding than the adhesive carrying substrate.

To perform an adhesive transfer operation using the devices of the aforementioned patents, the mask and adhesive carrying substrates are unwound and fed in between the nip rollers with the adhesive layer engaging the mask substrate. Then, the selected substrate is fed into the nip roller between the adhesive carrying and mask substrates and the user rotates the crank handle to rotate the nip rollers. The rotation of the nip rollers advances the substrates therethrough and discharges them out from the device. The rotation of the nip rollers also applies pressure to the substrates so that the adhesive bonds or adheres to the selected substrate and any portion of the mask substrate extending around the periphery of the selected substrate.

The user then cuts the bonded substrates and peels the mask substrate back from the adhesive carrying substrate to uncover the selected substrate. As the mask substrate is peeled back, any excess adhesive around the periphery of the selected substrate remains bonded to the mask substrate and is removed from the adhesive carrying substrate. Thus, the user can discard the mask substrate, and peel back the selected substrate for adherence to a contact surface as desired. Because the excess adhesive around the periphery of the selected substrate is removed along with the mask substrate, the portions of the adhesive carrying substrate are relatively clean, thereby reducing the potential for adhesive sticking to the user's hands as he/she peels back the selected substrate.

While the devices of the '962 and '417 patents have proven quite effective at the above-described adhesive transfer operation, the costs associated with purchasing these devices can be prohibitive for the occasional user who does not plan on using the device on a regular basis. To date, unless the occasional user is willing to invest in such a device, the only commercially available options are prior adhesive transfer devices, such as glue sticks or spray-on adhesives.

Furthermore, the commercial embodiments of the devices disclosed in the '962 and '417 patents use supply rolls that range between 8 ½ inches and 25 inches in axial length. For users that desire to make small labels, such as 2 inches by 2 inches, for example, these patented devices may not necessarily be the most cost-effective solutions. In other words, the user may end up with “too much” machine for his small label making needs.

Consequently, there exists a need in the art for a small, hand-held adhesive transfer device that can be manufactured at a low cost, which results in a lower cost machine for the ultimate end user.

It is therefore an object of the present invention to meet the above-described need. To achieve this object, one aspect of the invention provides a hand-held actuatorless adhesive transfer device for performing an adhesive transfer operation wherein adhesive is applied to a selected substrate. The device comprises a frame having a feeding side and a discharge side. The frame is sized and configured to be received in one hand of a user for manual handling and transport. A first supply roll is rotatably mounted within the frame and carries a wound up supply of an adhesive carrying substrate that has an adhesive carrying surface coated with a layer of pressure-sensitive adhesive. A second supply roll is rotatably mounted and carries a wound up supply of an adhesive mask substrate. The adhesive carrying substrate is unwound from the first supply roll with a lead end portion thereof extending outwardly from the discharge side of the frame. The mask substrate is unwound from the second supply roll with a lead end portion thereof extending outwardly from the discharge side of the frame adjacent the lead end portion of the carrying substrate.

The frame is constructed and arranged to enable the adhesive transfer operation to be initiated by manually grasping the frame with one hand and inserting a leading edge portion of the selected substrate between the adhesive carrying and mask substrates. The adhesive transfer device further comprising pressure applying structure constructed and arranged such that the adhesive transfer operation can be continued while continuing to manually grasp the frame with the one hand by manually grasping the lead end portions of the adhesive carrying and mask substrates at the discharge side of the frame with the other hand and manually pulling the lead end portions so as to advance the mask, adhesive carrying, and selected substrates together outwardly from the discharge side of the frame. The pressure applying structure applies pressure to the substrates being advanced through the device, thereby causing the pressure-sensitive adhesive on the adhesive carrying substrate to bond to the selected substrate.

Because the device constructed in accordance with this aspect of the invention is hand-held, material costs can be realized over the larger sized prior devices discussed above. Further, because the device is “actuatorless” and instead is operated by pulling on the lead end portion of the substrates, the manufacturing costs associated with making the actuator and connecting the same to associated components within the frame is obviated. Thus, the object of providing a low cost, hand-held adhesive transfer device has been effectively achieved.

Another disadvantage of the prior art devices discussed above is that they are not well-suited for applying adhesive to the edge of a selected substrate. For example, with a large window sign it may be desirable to apply adhesive only to the edge portions so as to make the sign easier to remove after mounting and to reduce the potential for residual adhesive sticking to the window glass. Instead, the device is adapted to apply adhesive over the entire substrate and the only plausible way of limiting the application of adhesive to the edge is by covering the portion that is not to receive adhesive with another substrate during the operation. However, performing such an operation is inefficient and ends up wasting the material used to cover the portion that is not to be adhered. Further, such an operation is not intuitive and it may not be appreciated by many users that such an option is available.

Consequently, there exists a need in the art for an adhesive transfer device that can be used to apply adhesive to the edge portion of a selected substrate. To achieve this object, another aspect of the invention provides an adhesive transfer device for performing an adhesive transfer operation wherein adhesive is applied to one side of a side edge portion of a selected substrate. The device comprises a frame having a feeding side and a discharge side. A first supply roll is rotatably mounted within the frame and carries a wound up supply of an adhesive carrying substrate that has an adhesive carrying surface coated with a layer of pressure-sensitive adhesive. A second supply roll is rotatably mounted within the frame and carries a wound up supply of an adhesive mask substrate that has a mask surface.

The frame has a substrate receiving opening extending from the feeding side thereof to the discharge side thereof and opening to an exterior of the frame. The substrate receiving opening is positioned and configured to enable a corner portion of the selected substrate at which a leading edge portion and the side edge portion of the selected substrate intersect to be inserted between the adhesive carrying and adhesive carrying and mask substrates. The opening may be of any size and configuration so long as the side edge of the selected substrate can be inserted between the substrate. The device further comprises pressure applying structure constructed and arranged such that the adhesive transfer operation can be performed by inserting the corner portion of the selected substrate between the adhesive carrying and mask substrates with a portion of the selected substrate extending outwardly from the substrate receiving opening and then advancing the mask substrate, the adhesive carrying substrate, and the side edge portion of the selected substrate together through the device and outwardly from the discharge side of the frame. The pressure applying structure applies pressure to the substrates being advanced through the device, thereby causing the pressure-sensitive adhesive on the adhesive carrying substrate to bond to the selected substrate.

Besides being capable of applying adhesive to a single edge of a selected substrate, the device of this aspect of the invention can allow for entire adhesive coverage for a selected substrate that is approximately twice the width normally accommodated by the device. Specifically, the user first applies adhesive using the device to one side edge of the selected substrate so that the adhesive covers about one-half the substrate. Then, the user flips the substrate around and applies adhesive using the device to the other side edge of the selected substrate so that the other half of the substrate is covered.

It should be noted that this aspect of the invention is not limited to the hand-held and actuatorless feature of the earlier aspect of the invention. To the contrary, this aspect of the invention may be practiced on an adhesive transfer device of any size with or without an actuator. For example, the substrate receiving opening feature of this aspect of the invention may be used with either of the above-mentioned U.S. Pat. Nos. 5,584,962 or 5,580,417, or U.S. patent appl. of Ensign, Ser. No. 09/564,587, filed May 5, 2000, the entirety of which are hereby incorporated into the present application in their entirety. In the arrangements of these incorporated patents, the nip rollers would correspond to the pressure applying structure.

Other objects, features and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a perspective view of an actuatorless, hand-held adhesive transfer device, generally indicated at10, constructed in accordance with one aspect of the present invention. The device10comprises a frame, generally indicated at12, that has a feeding opening14defined at a feeding side16thereof and a discharge opening18defined at a discharge side20thereof. The frame12has a main frame portion22and a removable cartridge24that removably mounts within a cartridge receiving space26provided by the main frame portion22(FIG. 3). In the illustrated embodiment, the frame12is about 3 inches wide, 6 inches long and 6 inches high. However, these dimensions may be larger or smaller and the overall shape of the frame12may vary so long as the frame12is of suitable size to be accommodated in one hand of a person.

The main frame portion22is formed by coupling two halves28,30together in a snap fit relation. As best seen inFIG. 3, the main frame portion22has a pair of opposing generally parallel side walls32,34, a bottom wall36extending generally perpendicularly and laterally between the side walls32,34, and a rear wall38extending generally perpendicularly and laterally between the side walls32,34. Further, the main frame portion22also has a pair of substrate supporting walls40,42extending inwardly from the feeding and discharges sides16,20thereof, respectively, at approximately 45° angles with respect to the bottom and rear walls36,38. As with the bottom and rear walls36,38, these supporting walls40,42extend generally perpendicularly to and laterally between the side walls32,34. These substrate supporting walls40,42each provide a substrate supporting surface44,46that are in line with one another.

The main frame portion22also has a pair of cartridge supporting walls48,50extending generally perpendicular to and laterally between the side walls32,34. These supporting walls48,50extend generally perpendicular to and intersect with the substrate supporting walls40,42, respectively, and provide a pair of generally parallel cartridge guiding surfaces52,54that intersect the substrate supporting surfaces44,46at generally perpendicular angles. These cartridge guiding surfaces52,54cooperate with interior surfaces on the side walls32,34and interior surfaces on the bottom wall36to define the aforementioned cartridge receiving space26.

The removable cartridge24comprises a pair of side walls60,62, an upper generally U-shaped wall64, and a lower generally U-shaped wall66. The leg portions of the U-shaped walls64,66on the feeding side of the cartridge24provide a relatively narrow feeding opening68and the leg portions of the U-shaped walls64,66on the discharge side of the cartridge24provide a relatively wide discharge opening70. A serrated cutting blade72is fixedly mounted to the upper U-shaped wall64at the upper edge of the discharge opening70. An L-shaped manually engageable wall structure74is fixedly mounted to the upper U-shaped wall64. The removable cartridge24also has a substrate supporting wall76that extends generally perpendicularly to and laterally between the side walls60,62. When the cartridge24is inserted into the cartridge receiving space26of the main frame portion22, the substrate supporting surface78of wall76is positioned generally in line with the substrate supporting surfaces44,46of the main frame portion22. Also, the rear edge of the L-shaped wall structure74cooperates with the edges of the side and rear walls32,34,38of the main frame portion22to define the feeding opening14. Likewise, the bottom edge of the L-shaped wall structure74cooperates with edges of the side walls32,34and substrate supporting wall42of the main frame portion22to define the discharge opening18.

The removable cartridge24also has a first supply roll80and a second supply roll82rotatably mounted between the side walls60,62thereof. The first supply roll80has a supply of an adhesive carrying substrate84wound up on a generally cylindrical core86. The carrying substrate84has an adhesive carrying surface88coated with a layer of pressure-sensitive adhesive83, such as an acrylic-based emulsion adhesive. The adhesive may be a single layer of permanent or repositionable adhesive or it may be constituted by multiple layers of permanent and repositionable adhesive, such as is disclosed in U.S. Appln. of Neuburger, Ser. No. 09/343,676, filed Jun. 30, 1999. The second supply roll82has a supply of an adhesive mask substrate90wound up on a generally cylindrical core92. The mask substrate90has a mask surface94that has a greater affinity for adhesive bonding than the adhesive carrying surface88of the carrying substrate84. Alternatively, the mask substrate90may have a lower affinity for adhesive bonding that the adhesive carrying surface88of the carrying substrate84. Preferably, the mask substrate90is a thin plastic film which is left uncoated to give it the higher affinity for adhesive bonding, or which is coated with a release material, such as silicone, to give it the lower affinity.

A pair of fixed generally cylindrical members96,98extend between the side walls60,62of the removable cartridge24. The substrates84,90are unwound from their respective supply rolls80,82, fed around these cylindrical members96,98, and fed through the discharge opening70of the cartridge24.

The upper cylindrical member96may be considered a first substrate engaging structure that is associated with the first supply roll80and that provides a first substrate engaging surface in the form of the cylindrical member's exterior surface. The substrate supporting wall76in the cartridge24may be considered a second substrate engaging structure that is associated with the second supply roll82and that provides a second substrate engaging surface in the form of surface78. The upper cylindrical member96and the substrate supporting wall76are spaced apart from one another so that the substrate engaging surfaces thereof define a relatively narrow substrate receiving slot100therebetween. Preferably, the maximum thickness of the slot100is 0.200 in. and the minimum thickness of the slot100is 0.010 in. The preferred thickness of the slot100, however, is 0.050–0.060 in. The surfaces of the adhesive carrying and mask substrates84,90opposite the carrying and mask surfaces88,94, respectively, slidably engage these first and second substrate engaging surfaces.

To perform an adhesive transfer operation using the device10, the removable cartridge24is inserted into the cartridge receiving space26with the surface defining that space26supporting the cartridge24and restricting the cartridge24against relative movement within the main frame portion22. The lead end portions of the carrying and mask substrates84,90extend outwardly from the discharge side20of the frame12. By inserting the cartridge24into space26as shown, the substrate receiving slot100is positioned with respect to the main frame portion22such that the adhesive transfer operation can be initiated by manually grasping the frame12in one hand and inserting a lead edge portion of a selected substrate102between the adhesive carrying and mask substrates84,90into the substrate receiving slot100.

The upper cylindrical member96and the substrate supporting wall76are constructed and arranged such that the adhesive transfer operation can be continued while continuing to grasp the frame12in a one-handed manner by manually grasping the lead end portions of the adhesive carrying and mask substrates84,90at the discharge side20of the frame12and manually pulling the lead end portions so as to advance the mask, adhesive carrying, and selected substrates90,84,102together through the substrate receiving slot100and outwardly through the discharge opening18from the discharge side20of the frame12. The substrate receiving slot100functions as a pressure applying structure and is configured such that the first and second substrate engaging surfaces apply pressure to the substrates advancing through the slot100, thereby causing the pressure-sensitive adhesive on the carrying surface88of the carrying substrate84to bond to both the selected substrate102and any portions of the mask surface94of the mask substrate90extending around a peripheral edge104of the selected substrate102. More specifically, the combined thickness of the substrates84,90,102and the adhesive layer83causes the mask and carrying substrates to be pressed against the first and second substrate engaging surfaces of the upper cylindrical member96and the substrate supporting wall76that defines the slot100so as to compress the substrates84,90,102together and cause the pressure-activated bonding of the adhesive83.

After the selected substrate102has been manually pulled out through the discharge opening18along with the carrying and mask substrates84,90, the substrates can then be pulled upwardly so as to bring the carrying and mask substrates84,90into contact with the serrated blade72. This severs the discharged portions of these substrates84,90from the remainder of the substrate material left connected to the supply rolls80,82. Finally, the adhesive mask substrate90can be peeled back from the carrying substrate14to expose the selected substrate102.

Because the mask surface94of the mask substrate90has a greater affinity for adhesive bonding than the carrying surface88of the adhesive mask substrate84, any of the excess adhesive83bonded to the mask surface94will remain bonded to the mask surface94and be removed from the adhesive carrying substrate84. The mask substrate90can then be discarded along with the excess adhesive bonded thereto. This leaves the selected substrate102bonded to the carrying surface88of the carrying substrate84with substantially no excess adhesive exposed around the periphery of the selected substrate102. The selected substrate102can then be peeled back from the carrying substrate84, taking the adhesive thereon along with it, for adherence as desired to any suitable surface.

Preferably, the carrying surface88is treated with a release material, such as a silicone coating or the like, to ensure that it has a lower affinity for adhesive bonding than the selected substrate102and that the adhesive83is taken along with the selected substrate102when it is peeled back.

In an arrangement where the mask surface94has a lower affinity for adhesive bonding than the adhesive carrying surface88, the mask substrate90simply serves to cover and protect both the selected substrate102and the excess adhesive. The mask substrate90does not serve to strip away the excess adhesive from around the periphery of the selected substrate102.

The use of the cartridge24provides for easy removal and replacement of both supply rolls80,82in a single operation as opposed to removably mounting each supply roll separately.

Although the embodiment illustrated in a cartridge-based unit, it is to be understood that the principles of the present invention may be practiced in a device that uses individually mounted feed rolls or in a disposable-type device where the entire device is discarded rather than replacing the supplies using a cartridge. In fact, the cartridge24disclosed may be used to practice the principles of the present invention separate from the main frame portion22. However, the use of the main frame portion22is preferred to provide the user with both a larger grasping surface and the substrate supporting surfaces44,46for easier usage.

The use of rigid structures defining the slot100as the pressure applying structure is advantageous because such structures can be provided in the device10at a relatively low cost. Alternatively, a pair of freely rotating nip rollers could be used as the pressure applying structure. The nip rollers could be fixed relative to one another or spring biased toward one another. For reference with respect to these alternatives, see the above-incorporated '962 patent, '417 patent, and/or '587 application. As another alternative, the adhesive carrying substrate could be wound with the adhesive thereon facing radially outwardly and one or more biasing elements, such as springs or tensioned roller bands, could be used as the pressure applying structure to press the supply rolls together. This pressed engagement creates the requisite pressure for applying the adhesive to the selected substrate102. Reference may be made to U.S. Provisional Appln. of Miller, entitled Low Cost Adhesive Transfer Device, filed Oct. 2, 2000, the entirety of which is hereby incorporated into the present application by reference for all purposes.

FIG. 5shows a device200constructed in accordance with the principles of a second aspect of the invention. The construction of the device200is substantially identical to the one shown inFIGS. 1–4with certain exceptions which are discussed hereinbelow. Thus, corresponding structures in these two devices10,200will be denoted with identical reference numbers.

The device200is designed for applying adhesive to the edge portions of selected substrates, such as the one shown at202inFIG. 6. This is particularly advantageous for adhesively mounting large selected substrates without wasting adhesive because the adhesive can be applied where it counts most—at the edges—rather at the central area of the substrates.

The device200has a substrate receiving opening in the form of an elongated slot204that extends form the feeding side16of the frame12to the discharge side20of the frame12. Specifically, the slot204opens at one end thereof to the feeding opening14and at the other end thereof to the discharge opening18. Likewise, the cartridge24has a slot (not shown) formed in side wall60thereof that aligns with the slot204. These slots are oriented so that they extend between the supply rolls80,82and the first and second substrate structures provided by upper cylindrical member96and substrate supporting wall76in the lateral direction of the device200. In particular, these slots align with the substrate receiving slot100in the lateral direction of the device100.

The adhesive transfer operation is performed by inserting a corner portion206of the selected substrate202through the slot204from the feeding side16of the frame12into the substrate receiving slot100with a portion of the substrate202extending outwardly from the slot204to the exterior of the frame12. The corner portion206is the portion at which a side edge portion208and a lead edge portion210of the substrate202intersect.

The transfer operation can be continued by advancing the mask substrate90, the adhesive carrying substrate84, and the selected substrate together through the substrate receiving slot100and the slot204and outwardly from discharge site20of the frame12. The surfaces defining the substrate receiving slot100apply pressure to the substrates84,90,202as they advance through the substrate receiving slot100, thereby causing the pressure-sensitive adhesive on the carrying substrate84to bond to both the side edge portion208of the selected substrate202and any portions of the mask surface94of the mask substrate90extending around the periphery of the side edge portion208.

The substrates84,90discharged from the discharge opening20can then be cut using the blade72as described above. Then, the mask substrate90can be peeled apart from the selected substrate202and the carrying substrate84. As a result, any excess adhesive bonded to the mask substrate90is removed from the carrying substrate84, thereby leaving the side edge portion208bonded to the carrying substrate84with substantially no adhesive exposed around the side edge portion208of the selected substrate202. Then, the side edge portion208can be peeled back from the carrying substrate84and adhered to a surface as desired.

The adhesive transfer operation described above may be repeated for each edge of the selected substrate202to provide the substrate202with a peripheral border of adhesive along the edges thereof.

It should be noted that the use of the substrate receiving opening204is not limited to specific embodiment disclosed herein and it may be used on any type of adhesive transfer device, including any of the patents and patent applications incorporated herein. For example, the opening204could be formed in the frame wall of a power-operated desktop adhesive transfer device, or one that operates under manual power by a hand crank actuator.

The principles of the invention may be practiced in a device that does not have substrate engaging structures for applying pressure to the substrates, and instead may be practiced in a device having any kind of pressure applying structure suitable for applying the requisite pressure for affecting adhesive transfer. For example, the adhesive carrying substrate could be wound with the adhesive thereon facing radially outwardly and one or more biasing elements, such as springs or tensioned rubber bands, could be used as the pressure applying structure to press the supply rolls together. This pressed engagement creates the requisite pressure for applying the adhesive to the selected substrate102. Reference may be made to the above-incorporated U.S. Provisional Appln. of Miller.

It can thus be appreciated that the objects of the present invention have been fully and effectively accomplished by the foregoing specific embodiments. It is to be understood, however, that the preferred specific embodiments have been provided solely to illustrate the structural and functional principles of the present invention and are not intended to be limiting. To the contrary, the principles of the present invention are intended to encompass all modifications, alterations and changes within the spirit and scope of the appended claims.

Any patents and patent applications mentioned herein and not specifically incorporated into the present application are hereby incorporated into the present application by reference.