FOAM DUCT TAPE

An adhesive tape comprises a duct tape layer and a foam mounting tape layer. The duct tape layer comprises a polymer layer having a top surface and a bottom surface, a scrim, and an adhesive layer between the polymer layer and the scrim. The foam mounting tape layer comprises a foam layer having a top surface and a bottom surface, an optional adhesive layer on the top surface of the foam layer, and an adhesive layer on the bottom surface of the foam layer. The foam layer has a thickness in a range of about 0.01 inch to 0.75 inch. The adhesive tape optionally has a scrim arranged on a bottom surface of the foam mounting tape layer. The foam layer of the foam mounting tape layer is optionally embossed in a predetermined pattern to impart a pattern to the top surface of the adhesive tape.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Referring to the figures,FIG. 1illustrates a cross-sectional view of an adhesive tape in accordance with aspects of the present invention. As shown inFIG. 1, the adhesive tape100comprises at least two layers: a duct tape layer140and a foam mounting tape layer150.

The duct tape layer140comprises a polymer layer110, an adhesive layer120, a scrim130. Examples of commercially available duct tapes include the DUCK® brand duct tape of ShurTech Brands, LLC.

The foam mounting layer150comprises a foam layer170having a top surface and a bottom surface, a first adhesive layer160on the top surface of the foam layer, and a second adhesive layer180on the bottom surface of the foam layer.

Examples of polymeric materials that are suitable as the polymer layer110include, but are not limited to, polyester, nylon, polyethylene, vinyl, and other synthetic polymers. Preferably, the polymeric material is polyethylene. It is also preferable that the polymeric material is waterproof.

Examples of adhesives for adhesive layer120include, but are not limited to, pressure sensitive adhesives including those having low and high tack, rubber based adhesives (synthetic and natural), acrylic adhesive, hot melt adhesive, microsphere adhesive, and any other adhesive suitable for use in duct tape construction.

Examples of materials that are suitable for the scrim130include, but are not limited to, natural materials, synthetic materials, or combinations thereof. Examples of natural materials include, but are not limited to, cotton, cotton blends, silk, hemp, flax, and combinations thereof. Examples of synthetic materials include, but are not limited to, polypropylene, polyester, nylon, polyethylene, or combinations thereof. Natural materials are optionally treated or coated with synthetic materials. The scrim is in a form of a cloth, mesh, non-woven, or fabric. The scrim optionally comprises a pigment or a dye.

The polymer layer110, adhesive layer120, a scrim130are combined together to form a duct tape layer using a number of possible methods. One such method uses a calendar laminating process during which the layers are made separately and then laminated together under pressure. An alternative method involves ejecting polyethylene pellets onto a thin film, then blending the film with the scrim while the plastic is hot, and then spreading the adhesive onto the film.

The adhesive tape100of the present invention is preferably colored. Methods by which to provide a colored adhesive tape100include, but are not limited to, coloring the duct tape layer140or coloring the foam mounting tape layer150. In the case of coloring the duct tape layer, the polymer layer110comprises a pigment or a dye. For example, the polyethylene film of the duct tape preferably comprises a pigment or a dye. For example, a co-extrusion process utilizes colored polyethylene pellets (i.e. pellets comprising a pigment or a dye). The polyethylene film is then combined with a scrim and coated with an adhesive such as a rubber based pressure sensitive adhesive. In the case of a colored foam mounting tape, the foam layer comprises a pigment or a dye.

Examples of adhesives for adhesive layers160and180include, but are not limited to, pressure sensitive adhesives including those having low and high tack, rubber based adhesives (synthetic and natural), acrylic adhesive, hot melt adhesive, and microsphere adhesive. The adhesive of each of layers160and180are selected to be the same or different. High tack typically refers to a permanent adhesive and low tack typically refers to a removable adhesive.

The types of materials that are suitable for the foam layer170include, but are not limited to, polyethylene, polyurethane, foam rubber, vinyl foam, flexible vinyl foam, urethane foam and clear urethane foam. An example of suitable polyurethane foam includes, but is not limited to, visco-elastic polyurethane foam (referred to as memory foam).

AlthoughFIG. 1, illustrates the foam layer170having an adhesive layer160,180on the respective top and bottom surfaces of the foam layer170, in some instances the adhesive layer(s) may be optional depending upon the method by which the structure is manufactured.

The thickness of the foam layer170is in a range of about 0.01 inch to 0.75 inch, preferably in a range of about 0.06 inch to 0.4 inch. The thickness of the foam layer170is an important feature of the adhesive tape of the present invention as it provides the adhesive tape100with a three-dimensional effect. The thickness of the foam layer170also provides the adhesive tape with a soft touch effect that is desirable from an aesthetic standpoint, particularly for use of the adhesive tape in the field of arts and crafts, and more particularly in the field of arts and crafts for children who are developing hand dexterity. The thickness of the tape is a differentiating factor from other tapes such as in U.S. Patent Publication No. 2012/0028524 in which the foam is intended to be extremely thin such as in the range of mils and is an imperceptible attribute of the duct tape.

In another aspect of the present invention, the soft touch adhesive tape100is removable. An example of such a foam mounting tape layer comprises a 0.01 inch to 0.75 inch thick polyethylene foam layer with a low-tack rubber based adhesive on the bottom surface of the polyethylene foam layer. The foam layer is clear or of any color. The top layer can be either low-tack or high-tack rubber based adhesive. The foam mounting tape layer is removable without any residue and adheres to most dry and clean surfaces. The polyethylene foam layer is optionally coated or treated on each side with a pressure sensitive adhesive including those having low tack, rubber based adhesive (synthetic and natural), acrylic adhesive, hot melt adhesive, and microsphere adhesive. The foam mounting tape layer optionally has a silicone coated release liner. A release liner is to be removed during the manufacturing of the final adhesive tape product.

In another aspect of the present invention, the foam mounting tape layer150is suitable for permanent or long term use. An example of such a foam mounting tape comprises a 0.01 inch to 0.75 inch thick polyethylene foam layer with a high-tack rubber based adhesive on the top and bottom surfaces of the polyethylene foam layer. The foam layer is clear or of any color. The adhesive is highly aggressive in terms of degree of adhesion and allows for high shear objects. The foam mounting tape layer conforms to applied surfaces and is intended for the permanent or long term use. The foam mounting tape layer adheres to most dry and clean surfaces. The polyethylene foam layer is optionally coated on each side with a solvent synthetic rubber based pressure sensitive adhesive, rubber based adhesive (synthetic and natural), acrylic adhesive, hot melt adhesive, microsphere adhesive, or other adhesive. The foam mounting tape optionally has a silicone coated release liner. A release liner is to be removed during the manufacturing of the final adhesive tape product.

To form the adhesive tape100of the present invention, the duct tape layer140and the foam mounting tape layer150are combined. There are numerous methods by which the duct tape layer140and the foam mounting tape layer150are combined, either in a permanent or removable manner.

Examples of methods by which the duct tape layer140and the foam mounting tape layer150are combined include, but are not limited to, laminating the duct tape layer140to the foam mounting tape layer150, co-extruding the duct tape layer140and the foam mounting tape layer150, adhering the duct tape layer140to the foam mounting tape layer150using an adhesive, and incorporating the foam layer within the duct tape structure.

In an aspect of the present invention, the foam layer170is incorporated within the duct tape structure. The method comprises, preferably at ambient temperature ranging from 50° F. to 100° F., combining polyethylene film with the scrim and laminating onto the foam layer170as the polyethylene film is being laminated to the scrim.

A laminating machine unwinds the duct tape and releases any tension by creating a loop, which is controlled by an ultrasonic sensor. The ultrasonic sensor generates high frequency sound waves and evaluates the echo, which is received back to the ultrasonic sensor. The ultrasonic sensor calculates the time interval between sending the signal and receiving the echo and determines the measured distance to an object. The ultrasonic sensor then sends a signal to the speed control of the motor, that drives the duct tape layer. The feedback signal from the ultrasonic sensor controls the size of the loop of duct tape layer.

The foam with or without adhesive on one or both sides enters with or without a release liner on one or both sides. Any release liner is removed during processing. The foam layer is combined with the duct tape. The finished tape product optionally contains a release liner. The resulting tape product is a soft touch color adhesive tape in accordance with the present invention. The adhesive tape is slit into any desired slit width for rolls or laminated to a liner for individual sheets.

FIG. 2illustrates a cross-sectional view of a tape in accordance with an aspect of the present invention wherein the adhesive tape has two scrims. Referring toFIG. 2, the tape200comprises a polymer layer210, adhesive layer220and cloth mesh or scrim230forming a duct tape240. Adhesive layer260, foam layer270, and adhesive layer280form a foam mounting tape250. A second scrim290laminated to the foam layer270which is adjacent to the adhesive layer280. The duct tape240and the foam mounting tape250are combined by co-extruding the duct tape240and the foam mounting tape250together, laminating the duct tape240and the foam mounting tape250together, adhering the duct tape240and the foam mounting tape250together using an adhesive, incorporating the foam layer270within the duct tape structure, or combining by another method.

A second scrim is affixed by an adhesive or is laminated. Examples of materials that are suitable for the scrim include, but are not limited to, natural materials, synthetic materials, or combinations thereof. Examples of natural materials include, but are not limited to, cotton, cotton blends, silk, hemp, flax, and combinations thereof. Examples of synthetic materials include, but are not limited to, polyester, nylon, polyethylene, vinyl, fiberglass, and other synthetic polymers. Examples of coated materials that are suitable for the scrim include, but are not limited to, cotton, cotton blends, silk, hemp, flax, and combinations thereof coated with polyester, nylon, polyethylene, and other synthetic polymers. Examples of a blend of natural and/or synthetic materials include, but are not limited to, cotton, cotton blends, silk, hemp, flax, and combinations thereof, blended with synthetic materials which include, but are not limited to, polyester, nylon, polyethylene, and other synthetic polymers, vinyl, and fiberglass.

The scrim is in a form of a cloth, mesh, non-woven, or fabric. The adhesive tape of the present invention is not limited to a tape having one or two scrims. The scrim optionally comprises a pigment or a dye.

Referring to the figures,FIG. 3illustrates a cross-sectional view of an embossed adhesive tape300in accordance with aspects of the present invention. As shown inFIG. 3, the adhesive tape300is embossed and has a visible raised, three-dimensional effect on the top surface A of the adhesive tape300. In a preferred aspect of the present invention, the foam layer370of the foam mounting tape layer350has an embossed top surface B. As a result, a visible, three-dimensional effect is achieved on the top surface A of the adhesive tape300. This feature is achieved, for example, by embossing or imparting a predetermined pattern on the top surface B of the foam layer370before laminating or combining the duct tape layer340with the foam mounting tape layer350in order to transfer the physical characteristics to the duct tape layer340and to impart them to the top surface A of the adhesive tape300. Any foam layer370having an embossed surface is suitable to be used to provide this effect when combined with the duct tape layer340. The top surface A of the adhesive tape300mirrors the embossed or patterned surface of the foam mounting tape layer350.

The adhesive tape of the present invention thus is durable yet soft and pliable. The adhesive tape is tearable by hand or cuttable with scissors.

In another aspect of the present invention, referring toFIG. 4, a system and method of making the foam duct tape of the present invention is provided to eliminate curling of the foam duct tape. The method generally comprises providing a duct tape layer410, providing a foam mounting layer420, relaxing the duct tape layer410using an ultrasonic sensor440to eliminate tension in the duct tape layer410, and laminating the duct tape layer410to the foam mounting layer420.

An ultrasonic sensor440is used to relax the duct tape layer410prior to lamination with the foam mounting layer420. A non-obvious aspect of the method of the present invention to overcome the problem of curling of the foam duct tape is to laminate the foam mounting layer420under a condition of equilibrium and without tension on either the duct tape layer410or the foam mounting layer420.

Thus, an issue to address when manufacturing the foam duct tape is the amount of tension on the web of the duct tape and the roller pressure of the laminating rollers. In order to properly relax the duct tape layer, a bow roller430is installed prior to the ultrasonic sensor440. The bow roller430properly stretches the web of the duct tape layer410before entering a relaxed loop state as shown inFIG. 4. This eliminates the tension and thereby decreases the curling effect on the foam duct tape. The ultrasonic sensor440controls a loop prior to laminating the duct tape layer410to the mounting tape layer420. Thus, the method comprises laminating the foam mounting layer420under the condition that both layers are without tension and in a state or condition of equilibrium and joining them together at a temperature between 65° F. and 85° F.

Proper adjustment of the tension also eliminates any wrinkles during the manufacturing of the foam duct tape. Besides joining both layers together under an equilibrium condition or state to control the curling effect, the frictional bonding forces between the web and lamination rollers causes wrinkling or bending. Bending of the material is directly proportional to the thickness of the material and a function of tensioning. The wrinkles are controlled by lowering the speed of the web of the duct tape, thereby reducing the potential of wrinkles caused by entrapped air.

As shown inFIG. 4, a crown roller460is installed prior to die cutting station470. The crown roller is used to eliminate any residual wrinkles prior to cutting the foam tape product500. While laminating the duct tape layer and the foam mounting layer, the materials are cooled to between 65° F. and 85° F., at the point of lamination, to eliminate any thermal expansion, which causes wrinkles. The lamination rollers450are chilled and maintained at between about 65° F. and 85° F.

Thus, the foam duct tape of the present invention provides numerous benefits and advantages over other adhesive tapes including, but not limited to, its three-dimensionality, strength, stiffness, reduced likelihood to adhere to itself, and ability to float. Thus, it is suitable for use in numerous end use applications such as arts and crafts but also for uses where there is a need for protective padding such as cushioned grips for hammers, baseball bats, rakes, bicycle handles, among others.