Adhesive tape applicator

Provided herein are applicators and methods for dispensing adhesive tape. Such adhesive tape applicators include a housing adapted to contain a roll of adhesive tape; a compressible tape hub attached to an inner surface of the housing and adapted to rotatably support the roll of adhesive tape; and an adhesive roller apparatus for applying the adhesive tape to a substrate. The compressibility of the compressible tape hub provides a means of braking and tearing the adhesive tape roll.

FIELD OF THE DISCLOSURE

The present invention relates to the field of adhesive tape applicators and methods of using the same. Such adhesive tape applicators include a housing adapted to contain a roll of adhesive tape; a compressible tape hub attached to an inner surface of the housing and adapted to rotatably support the roll of adhesive tape; and an adhesive roller apparatus for applying the adhesive tape to a substrate.

BACKGROUND OF THE DISCLOSURE

Adhesive tapes and their dispensers have been known in the art for many years. Adhesive tapes may include a backing such as paper, plastic film, cloth, or metal, and an adhesive on one or both sides of the backing. Hand-held tape dispensers are typically designed to allow a user to dispense a length of tape using one hand by securing the start of the tape to a substrate, using the adhesion of the tape to the object to unspool the desired length of tape, then cutting the tape by biasing a saw-like cutter against the tape. Such devices are relatively simple to operate in principle, but in practice, managing the tape and cutting it at the desired length can be problematic as it may be difficult to remove the tape from the roll and keep the tape from doubling back on itself.

Double-sided tape typically includes a liner to prevent the tape from sticking to itself in an adhesive roll. Traditionally, a double-sided tape with a liner is unwound from a roll by hand, a section of the tape is cut, and a first adhesive tape side is applied to a first surface. The liner is then removed from a second adhesive tape side and the second adhesive tape side is attached to a second surface. This process may be inefficient and cumbersome. Other devices for dispensing double-sided adhesive tape have also been known, but such devices typically include a series of gears and wheels that are subject to jamming as the adhesive finds its way into the gears. Some of such devices are also too large for handheld use and may be prohibitively expensive.

There remains a need in the art for hand-held tape dispensers that can reliably affix a length of tape to a substrate. There is also a need for a hand-held tape dispenser that can both reliably affix a length of tape and also efficiently separate a double-sided tape from its liner.

SUMMARY OF THE DISCLOSURE

Accordingly, provided according to embodiments of the invention are adhesive tape applicators and methods of using the same. Such adhesive tape applicators include a housing adapted to contain a roll of adhesive tape; a compressible tape hub attached to an inner surface of the housing and adapted to rotatably support the roll of adhesive tape, and an adhesive roller apparatus for applying the adhesive tape to a substrate.

The compressibility of the compressible tape hub provides a means of braking and tearing the adhesive tape roll. In use, when the desired length of adhesive has been applied, an operator may depress or squeeze the adhesive tape applicator. When the outer face is depressed, thereby compressing the compressible tape hub, the outer face is brought into frictional or forceful contact with the adhesive tape roll, and in some cases with the edge of the adhesive tape roll spool, thus stopping its rotation. This creates a tension between the length of tape being applied to a substrate and the lack of rotation of the adhesive roll. Thus, twisting or lateral motion of the applicator (while the frictional or forceful contact between the outer face and the adhesive roll is maintained) will tear the adhesive at the point of contact with the substrate. When the compressive force is removed, the compressible tape hub and outer surface of the housing may revert back to their non-compressed states, allowing the adhesive tape roll to rotate for the next use.

In some embodiments of the invention, the roll of adhesive tape is a dual-sided adhesive tape includes an adhesive liner releasably attached to one side of the dual-sided adhesive tape. In such embodiments, the applicator may include a liner outlet, and a scraper adjacent to the adhesive roller apparatus. The scraper inserts between the liner and the adhesive to detach the liner from the adhesive and push the liner out of the applicator's housing through the liner outlet.

Also provided in embodiments of the invention are methods of using adhesive tape applicators according to embodiments of the invention. In some embodiments, methods of applying adhesive tape include gripping the first face and the second face of an applicator according to an embodiment of the invention by one hand; rolling a length of adhesive tape onto a substrate with the applicator's transfer roll; compressing the outer face of the applicator to frictionally contact the outer face of the housing with the roll of adhesive tape, thereby halting its rotation; and applying a lateral force to the adhesive tape applicator to create a lateral force on the length of adhesive tape, thereby tearing the adhesive tape on the substrate from the roll of adhesive tape.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Several embodiments of the present disclosure have been described. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any disclosures or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the present disclosure. While embodiments of the present disclosure are described herein by way of example using several illustrative drawings, those skilled in the art will recognize the present disclosure is not limited to the embodiments or drawings described. It should be understood the drawings and the detailed description thereto are not intended to limit the present disclosure to the form disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of embodiments of the present disclosure as defined by the appended claims.

Provided according to embodiments of the invention are adhesive tape applicators and methods of using the same. Such adhesive tape applicators include a housing adapted to contain a roll of adhesive tape; a compressible tape hub attached to an inner surface of the housing and adapted to rotatably support the roll of adhesive tape, and an adhesive roller apparatus for applying the adhesive tape to a substrate. The adhesive tape applicators may further include several other optional elements as described in further detail below.

As used herein, the term “adhesive tape” refers any type of adhesive tape known, including those use for desktop uses, industrial uses, and the like, and may be of any suitable tensile or adhesive strength. In some embodiments, the tape is a repulpable paper tape. In some embodiments, the adhesive tape is a pressure sensitive adhesive tape (PSAT). The adhesive tape may have an adhesive on one or both sides (also referred to as one-sided or dual-sided adhesive tape, respectively). The adhesive tape may further include a liner, also referred to as a release liner, which may be releasably attached to one or both sides of the adhesive tape. Such release liners are generally used with dual-sided adhesive tapes. The release liner may be formed of any material that allows for release from the tape's adhesive by a mechanism described herein, but in some cases, the release liner includes silicone, including a silicone-coated surface.

Referring toFIG. 1, a roll of adhesive tape100includes a length of adhesive tape101spooled around a spool member102. The spool member102is generally a cylindrical device (although any suitable shape may be used) on which a length of adhesive tape may be wound. In particular embodiments, the spool member102is shaped to allow for at least three points of contact with the compressible tape hub (not shown). The spool member102includes an aperture103defined therethrough, wherein the aperture103is sufficiently sized to allow for the compressible tape hub to be inserted therein and pass therethrough. While the aperture103of the spool member102is typically void, any spool member may be used provided that it allows sufficient space in the aperture103for the compressible tape hub to pass therethrough and is configured such that the adhesive tape roll100can rotate about the compressible tape hub. In some embodiments of the invention, the spool member102is a paper core, such as a laminated paper core. Other materials may be used for the spool member102, including metal, plastic, and the like.

The housing in which the adhesive roll is contained may take many configurations. Referring toFIG. 2, the housing204of an adhesive tape applicator205is generally adapted to enclose all or a portion of the adhesive tape roll (not shown) and the compressible tape hub (not shown). The adhesive roller apparatus206is attached to the housing204. A portion of the adhesive roller apparatus206may be enclosed by the housing204but, as shown inFIG. 2, some or all of the adhesive roller apparatus may be exposed. The housing204typically comprises a first face207and a second face (not shown) and at least one sidewall208connecting the two faces. In some cases, the first face and the second face are substantially flat and substantially parallel to each other. However, numerous other possibilities are envisioned, including housing that is shaped to be gripped by a hand. For example, one face may be shaped to receive a thumb of the operator, a sidewall may be shaped or configured to receive an index finger, and the opposite face may be shaped to receive the remaining fingers. In some embodiments of the invention, a first face207or a portion thereof is a cover that may be removed to access the adhesive tape roll, as will be discussed in further detail below.

Referring toFIG. 3, adhesive tape applicator305(with the outer face removed) includes compressible tape hub309secured to an inner face310face of the housing. The compressible tape hub309is configured to rotatably support a roll of adhesive tape300(sometimes referred to as an adhesive tape roll300) such that the adhesive tape roll300can rotate around the compressible tape hub309. The compressible tape hub may also provide a drag on the rotation of the tape roll spool member302, for example, via an interference fit, so that the adhesive tape roll300does not rotate too quickly about the compressible tape hub309. As shown by the arrows inFIG. 3, the compressible tape hub309is configured to insert through the aperture303of the adhesive tape roll spool member302. Although the compressible tape hub is shown as square, any suitable shape, including round, polygon, or irregular shaped, may be used provided that the adhesive tape roll300can rotate about the compressible tape hub309.

FIGS. 4A and 4Bshow a cross section of an adhesive tape applicator405according to an embodiment of the invention and an adhesive tape roll400therein. The compressible tape hub409is attached to the inner face410of the housing, such as, for example, by an adhesive. In an uncompressed state (FIG. 4A), the width411of the compressible tape hub409is greater than the width412of the adhesive tape roll400. Thus, once the adhesive tape roll400is inserted through the compressible tape hub409, a compressible protrusion413from the end of the spool402is formed. InFIG. 4A, the compressible protrusion413prevents the outer face407of the housing from contacting the adhesive tape roll400. As such, the use of the compressible tape hub409both rotatably supports the adhesive tape roll400and prevents the outer face407of the housing from contacting the adhesive tape roll400so that it may rotate. As described above, the compressible tape hub409may also engage an inner surface of the spool402to create a drag on the rotation of the adhesive tape roll400.

The compressibility of the compressible tape hub409provides a means of braking and tearing the adhesive tape roll400. The compressible protrusion413tends to separate the outer face407from the adhesive tape roll400when the operator's grip on the applicator405is relaxed, as when applying adhesive. Referring toFIG. 4B, when the compressible tape hub409is compressed, such as by squeezing the inner face410or outer face407, the outer face407frictionally or forcefully contacts the adhesive tape roll400, which may prevent the adhesive tape roll400from rotating about the compressible tape hub409. In some embodiments, a portion of the inner surface414of the outer face407may be roughened or otherwise texturized to increase the friction of the applicator405against the adhesive tape spool402, reducing the force necessary to squeeze the outer face407enough to stop the adhesive tape roll400from turning. In some embodiments, the textured or roughened surface414is slightly greater in diameter than the adhesive tape spool402exposed to the outer face407.

In use, when the desired length of adhesive has been applied, an operator may depress or squeeze the outer face407of the applicator405(FIG. 4B). When the outer face407is depressed, thereby compressing the compressible tape hub409, the outer face407is brought into frictional or forceful contact with the adhesive tape roll400, and in particular, in some cases with the edge of the adhesive tape roll spool402, thus stopping its rotation, whereupon a twisting or lateral motion of the applicator405(while the frictional or forceful contact between the outer face407and the adhesive roll400is maintained) will tear the adhesive between the applicator405and the substrate. When the compressive force is removed from the compressible tape hub409, the compressible tape hub409resumes its non-compressed state and shape and may thereby expand, maintaining the outer face407away from adhesive tape roll400, allowing it to rotate for the next use. The compressible tape hub409may force the outer face407into an uncompressed position, or the outer face407may itself revert to its uncompressed state once the compression is removed.

In some embodiments of the invention, the compressible tape hub409includes, consists essentially of, or consists of, a compressible material. The compressible tape hub409can include any compressible material that is sufficiently rigid to prevent the outer face414from contacting the adhesive tape roll400when in an uncompressed state but sufficiently compressible so that the compressible protrusion413of the compressible tape hub409may be reduced or eliminated by compressing the outer face407of the housing with the operator's hand. In some cases, the compressible tape hub409comprises a polymer foam. Furthermore, in particular embodiments, the entire compressible tape hub409is a polymer foam.

A compressible material on which the adhesive roll rotates may be preferred for its simplicity and combination of locating, friction, and spring functions without separate parts. However, several other configurations of the compressible tape hub409are also envisioned as within the scope of the present invention. An alternative embodiment may include a molded hub with flexible fingers radiating in a spiral to engage the inside diameter of the spool aperture to engage the spool and provide friction to prevent free rotation. The engagement of the flexible fingers within the interior of the spool may depend on the radial force applied from a spring member in the center of such a hub, wherein when the spring is compressed, the spring exerts a radial force on the flexible fingers such that they engage the interior of the spool and stop rotation. In another possible configuration of the compressible tape hub409, a hub may include pivoted petals that may be pushed apart by inserting a spacer into the center of the arrangement such that squeezing the cover would push the spacer into the arrangement and expand the hub to stop the roll from turning. In yet another configuration, an adhesive tape roll may be located by a disk held in place by a thumb screw acting against a spring such that tightening the thumb screw would adjust the pressure and friction to establish the drag necessary to prevent free rotation of the adhesive tape roll, while squeezing the outer face would force the disk against the adhesive tape roll with additional pressure to perform the braking function. All of these embodiments and any others that allow for a compressed state and an expanded state are within the scope of the present invention. However, such alternate embodiments may require more parts, greater manufacturing expense, and more time to assemble, and may have greater ease of failure than a simple hub made of a compressible material.

As described above, the adhesive tape applicator includes a roller apparatus. The adhesive roller apparatus applies the adhesive tape onto a substrate. Referring toFIG. 5, in some embodiments, the adhesive roller apparatus includes a pinch roll515and a transfer roll516adjacent to the pinch roll515, wherein the pinch roll515and the transfer roll516are each rotatably engaged to the housing504and adapted to roll the adhesive tape501therebetween. The transfer roll516is engaged to the housing504via transfer roll shaft519and the pinch wheel515is engaged to housing504via pinch wheel shaft520. The transfer roll516is adapted to apply the adhesive tape501to a substrate by rolling the transfer roll516on the substrate518. Thus, an operator may dispense the adhesive tape501by rolling the adhesive tape501onto the substrate518using the transfer wheel516as the tape roll500rotates about the compressible tape hub509. Then, when the operator wishes to cut the tape, the operator compresses the side of the housing504, which compresses the tape hub509and allows the housing to frictionally or forcefully contact the adhesive tape roll500, stopping the rotation. This creates a tension between the static adhesive tape roll500and the adhesive tape501being applied to the substrate518. The operator may then twist or move the applicator505in a lateral direction, typically causing adhesive tape501to be torn between transfer roll516and substrate518.

In some embodiments, the transfer roll516comprises a transfer roll core521and an applicator sleeve522thereon. The adhesive tape501will preferably have less affinity for the surface of the applicator sleeve522than it has for the substrate518. In some cases, a silicone material is used on the surface of the applicator sleeve522. The relative affinity of the adhesive for the substrate518over the applicator sleeve522can be enhanced by reducing the surface area of the applicator sleeve522by embossing ridges, dots, or grooves into the surface. In addition to balancing the adhesive's affinity for the applicator sleeve522and substrate518, adhesion to the substrate518can be enhanced by using a compressible material for the applicator sleeve522that may result in the adhesive being more intimately embedded in the surface texture of the substrate518.

In some embodiments of the invention, the position of the transfer roll is moveable such that a distance between the pinch roll and the transfer roll may be varied. The radial movement closes or opens the nip point between the pinch and transfer rolls and facilitates loading the adhesive as it may be inconvenient to position the adhesive tape relative to the transfer roll while the pinch roll and transfer roll are closed. Being able to open the nip point allows the operator to position the adhesive tape properly before securing it to the transfer roll.FIGS. 6A and 6Billustrate positioning between a pinch roll615and a transfer roll616. In some embodiments, the transfer roll616is capable of radial movement across a centerline of a shaft619to approach a pinch roll615or move away from pinch roll615. Thus, the nip point617may be increased or decreased by change of this position. This may be accomplished by having sufficient clearance between the transfer roll shaft619and its bore623. Alternatively, or additionally, a pinch roll shaft620may be able to move radially to approach or withdraw from the transfer roll616.

In some embodiments of the invention, the applicator includes a pawl member in contact with a surface of the transfer roll. The pawl member may be a flexible pawl member that may contact the transfer roll so that the transfer roll is free to turn clockwise for dispensing the adhesive tape, but is prevented from rotating counterclockwise if the operator pushes the applicator rather than pulls it across the substrate. The pawl prevents misdirection of the adhesive tape and the possible consequences of it adhering to the interior of the applicator or completely wrapping around the transfer roll. This improves the function of the applicator by reducing the need to open the applicator to clean and rethread it. The pawl member will be discussed further with respect toFIG. 7below.

In some embodiments of the invention, the roll of adhesive tape is a dual-sided adhesive tape and includes an adhesive liner releasably attached to one side of the dual-sided adhesive tape. In such embodiments, the adhesive tape applicator may further include a liner outlet, and a scraper adjacent to a nip point between the pinch roll and the transfer roll, wherein the scraper inserts between the liner and the adhesive on the tape to detach the liner and push the liner out of the housing through the liner outlet.

Referring toFIG. 7, a dual-sided adhesive tape applicator705is shown wherein an adhesive tape roll700is inserted onto a compressible tape hub709, and a length of adhesive tape701is wound through the nip point717between the pinch roll715and the transfer roll716. The scraper724is positioned adjacent to the nip point717, so that when the adhesive tape701passes through the nip point717, the scraper724peels the liner725away from the adhesive by virtue of the proximity of the scraper724to the adhesive and the relative stiffness of the liner725. Furthermore, the liner725is generally not tightly bound to the adhesive so that the liner725can be readily detached by scraper724. The adhesive tape701(with liner) is tracked around (or proximate to) a pinch roll715until the adhesive on the tape is pressed into contact with transfer roll716, and the liner725is directed by scraper toward the liner outlet726. When the transfer roll is pressed against a substrate718, the adhesive is pressed against and thus applied to the substrate718while the expelled liner725exits the device through the liner outlet726.

The scraper724may be used in some embodiments to improve the function of the applicator705with the dual-sided adhesive tape701by largely ensuring that the liner725separates as desired and is pushed to the liner outlet726, also referred to as a vent, and out of the applicator reliably. If the liner725remained bonded to the adhesive and wrapped around the transfer roll716, it may prevent the adhesive from being applied to the substrate718and would necessitate opening and rethreading the applicator705to correct the error. The scraper724may be any knife (including serrated or straight edged), blade, edge or other device that is able to detach the liner725from the tape adhesive. Also shown inFIG. 7is a flexible pawl727bearing on the surface of transfer roll716in such a manner that the transfer roll716is free to turn clockwise for the dispensing of the adhesive tape701, but is prevented from rotating counterclockwise if the operator pushes the applicator705rather than pulls it across the substrate718.

In some embodiments, transfer roll716can pinch the adhesive tape701and its liner725to the pinch roll715to cause sufficient adhesion of the tape701to the transfer roll716to overcome the adhesion of the tape701to liner725. Furthermore, transfer roll716and pinch roll715may touch during adhesive application to the substrate718so the motive force of the turning transfer roll716can be imparted to the liner725so it can rotate the roll of adhesive tape700in the applicator705. If the nip point717between the pinch roll715and transfer roll716is open, the adhesive tape701may separate in tension and the applicator705may fail to apply a continuous length of adhesive tape701to the substrate718.FIG. 8provides a magnified view of the nip point817between the pinch roll815and transfer roll816. Scraper824and pawl member827are also more clearly illustrated. Scraper824is adjacent to the nip point817and acts to detach liner825from the adhesive tape801and direct it toward the liner outlet (not shown).

As described above, in some embodiments of the invention, the adhesive tape applicator may include a cover member that secures to a base member. Any configuration of cover and base members that allows an adhesive tape roll to be inserted into the applicator may be used, and in some cases, the applicator could be inserted via a sidewall opening or other exposed area within the housing. However, in certain embodiments, all or part of a face of the tape adhesive applicator may be removable or displaceable in order to allow for the adhesive tape roll be inserted into the applicator. One example is shown inFIG. 9. The cover member928of applicator905includes a pivot element929, whereby the cover member928is secured to the base member930by the pivot element929. The cover member928may swing clockwise or counterclockwise to expose the cavity (not shown) of the housing, and wherein when the cover member928is swung to the closed position, it may be secured by a magnet, a spring catch or other securing means in the closed position over the body of the applicator. Referring toFIG. 9, in some cases, the securing means may be a hook and loop tab931. Other devices may also be effective depending on the manufacture of the individual parts and the labor the manufacturer is willing to commit to assembly. Some of these alternate configurations include: a) shoe-box fit of body and cover, wherein the cover member frictionally secures over the top of the base member; b) captive screw(s) that engage a threaded hole in the base member; c) spring detent pins; and d) thumb nuts on threaded studs through holes or a slot allowing the cover to pivot.

The external surfaces of the housing may also include means of gripping the adhesive tape applicator. As described above, the housing may itself be shaped to facilitate grip by an operator's hand. However, the external surfaces of the housing may further have grips, roughened or textured surfaces, foam or other gripping material. This may be particularly useful on the two faces of the applicator. In addition, in some embodiments, a finger sleeve may be included on a sidewall of the housing. Referring toFIG. 10, in some embodiments, a finger sleeve device1032, such as the adjustable hook and loop sleeve, may attached to a sidewall1008, and in particular, a sidewall1008above the transfer roll1016. When grasping an object with the index finger1033extended, grip is naturally accomplished by squeezing the applicator between the thumb and remaining fingers. However, this natural grip is contrary to the use of the applicator1005whereby squeezing the applicator stops the adhesive roll (not shown) from turning. A sleeve1032over the index finger1033allows the entire weight of the applicator1005to be carried by the index finger1033, reducing the dependence on squeezing to hold the applicator1005. The sleeve1032also positions the index finger1032in the optimum position to apply the amount and direction of force necessary to efficiently apply the adhesive to the substrate and to effectively twist and pull the applicator to tear the adhesive when desired. The sleeve1032and its function in the use of the applicator1005could also be accomplished by a sheet metal hook or encircling loop, a wire ring, a flexible split ring of molded plastic that would accommodate a range of finger sizes, and the like. Any means of securing the index finger (or even middle finger) to the applicator sidewall could be used.

Also provided according to embodiments of the invention are methods of using the adhesive tape applicators of the invention. In some embodiments, methods of applying adhesive tape include gripping a first face and a second face of the housing with a hand; rolling a length of adhesive tape onto a substrate with the transfer roll; compressing the outer face of the housing to frictionally or forcefully contact the roll of adhesive tape, thereby halting rotation of the roll of the adhesive tape; and applying a lateral motion to the adhesive tape applicator to create a lateral force on the adhesive tape, thereby tearing the length of adhesive tape on the substrate from the roll of adhesive tape. Methods may further include the step of threading the length of adhesive tape from a roll of adhesive tape through the pinch roll and transfer roll of the adhesive tape applicator and inserting the roll of adhesive tape into the adhesive tape applicator prior to use.

FIG. 11illustrates the use of an assembled device according to an embodiment of the invention. Here, the applicator1105is held by one hand1134whereby the index finger1133applies force to the interface of the adhesive tape1101and substrate1118via the sidewall1108of applicator1105and the transfer roll1116. The squeezing/compression of the applicator1105to stop the adhesive application and tear off the tape1101is applied by the thumb1135and remaining fingers (not shown) as the expelled liner1125exits via the liner outlet (not shown).

An advantage of an applicator according to the present invention is the simplicity of its design and elimination of unnecessary parts, which thereby reduces the cost of manufacture and increases the ease of use of the applicator. In the following sections, detailed descriptions of examples and methods of the disclosure will be given. The description of both preferred and alternative examples though, are exemplary only, and it is understood that to those skilled in the art that variations, modifications, and alterations may be apparent. It is therefore to be understood that the examples do not limit the broadness of the aspects of the underlying disclosure as defined by the claims.