Abstract:
Disclosed are various embodiments of packaging for a roll of a web which is attached to a take-up core. The web is arranged so that it packages the roll together with the core, ready for shipment without the need for additional packaging. The web can include an ink ribbon and a leader connected to the ink ribbon.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the art of packages and packaging and to methods of making and using packages. 
     2. Brief Description of the Prior Art 
     The following U.S. patents are made of record: U.S. Pat. Nos. 1,850,718; 2,732,063; 2,912,102; 3,460,671; 3,476,238; 5,415,486; 5,492,221; 5,536,094; 5,547,298; and 5,839,839. 
     It is known to provide an ink ribbon package including a web having an ink ribbon portion wound onto and adhesively adhered to a supply core and having an outwardly extending leader portion. The web is wound into a roll and the take-up core is adhesively attached to the end of the leader portion. One or more strips of pressure sensitive tape, separate from the web, extend generally longitudinally or lengthwise of the web beyond the leader portion and are adhered to the outside of the take-up core and/or the leader portion and to the outer surface of the roll to hold the roll and the take-up core together. The free end portions of the pressure sensitive adhesive tapes can be folded onto themselves to provide manually graspable tabs. The pressure sensitive tapes can be grasped by their tabs and peeled from the outer surface of the roll to unwrap the take-up core with respect to the roll. During the manufacturing process, the leader portion is connected to the ink ribbon portion using a commercially available leader-trailer bed and thereafter the ink ribbon portion and the leader portion are rewound in a commercially available rewinder. 
     SUMMARY OF THE INVENTION 
     It is a feature of the invention to provide improved packages and improved methods of making same, wherein the packages can be manufactured on conventional manufacturing equipment. 
     It is another feature of the invention to provide improved packages and improved methods of making same, wherein the web itself serves not only as the product to be used by the user, but the web also serves as the packaging material, without the need for additional packaging materials such as a shrink-wrap plastic outer wrapper, a carton or the like. 
     It is another feature of the invention to provide improved packages wherein a web roll is attached to a take-up core and wherein the web itself extends beyond the outside of the roll and serves as the packaging or wrapping. 
     It is another feature of the invention to provide an improved ink ribbon roll package which is economical to manufacture and is easy for the user to unwrap and use. 
     It is still another feature of the invention to provide an improved package for a web roll with an outer outwardly extending portion, wherein a take-up core is permanently transversely attached to the outer portion of the web and the web is removably attached to itself at a transversely extending stripe of adhesive. 
     Other features will be apparent to those skilled in the art upon reference to the following description and the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DIAGRAMMATIC DRAWINGS 
     FIG. 1 is a perspective view of a package of the embodiment of FIGS. 1 through 8 including a web in roll form and a take-up core, wherein the web is also used as the wrapper or packaging; 
     FIG. 2 is a developed, exploded, perspective view showing fragmentary portions of the web and the supply and take-up cores; 
     FIG. 3 is a bottom plan view of the web shown in detail in FIG. 2; 
     FIG. 4 is a side elevational view of the package; 
     FIG. 5 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 6 is a top plan view showing a composite leader connecting two wide webs; 
     FIG. 7 is a diagrammatic view of a turret rewinder useful for practicing the invention, showing an ink ribbon as having been wound on a supply core; 
     FIG. 8 is a view similar to FIG. 7, but showing the rewinder as having been indexed to a position where the take-up core is attached to the web and the next web is ready to be wound onto the next supply core; 
     FIG. 9 is a perspective view of a package of the embodiment of FIGS. 9 through 11; 
     FIG. 10 is a side elevational view of the package; 
     FIG. 11 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 12 is a perspective view of a package in accordance with the embodiment of FIGS. 12 through 14. 
     FIG. 13 is a side elevational view of the package; 
     FIG. 14 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 15 is a perspective view of a package in accordance with the embodiment of FIGS. 15 through 17; 
     FIG. 16 is a side elevational view of the package; 
     FIG. 17 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 18 is a perspective view of a package in accordance with the embodiment of FIGS. 18 through 20; 
     FIG. 19 is a side elevational view of the package; 
     FIG. 20 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 21 is a perspective view of a package in accordance with the embodiment of FIGS. 21 through 25; 
     FIG. 22 is a developed, exploded, perspective view showing fragmentary portions of the web and the supply and take-up cores; 
     FIG. 23 is a bottom plan view of the web; 
     FIG. 24 is a side elevational view of the package; 
     FIG. 25 is a developed, exploded, fragmentary, side elevational view of the package; 
     FIG. 26 is a perspective view of a package in accordance with the embodiment of FIGS. 26 through 28; 
     FIG. 27 is a side elevational view of the package; 
     FIG. 28 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores; 
     FIG. 29 is a perspective view of a package in accordance with the embodiment of FIGS. 29 through 31; 
     FIG. 30 is a side elevational view of the package; 
     FIG. 31 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores. 
     FIG. 32 is a perspective view of a package in accordance with the embodiment of FIGS. 32 through 34; 
     FIG. 33 is a side elevational view of the package; and 
     FIG. 34 is a developed, exploded, fragmentary, side elevational view of the web and the supply and take-up cores. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to the embodiment of FIGS. 1 through 8, and initially to FIG. 1, there is shown a package generally indicated at  40  including a roll  41  having a supply core  42  and a take-up core  43 . The core  42  is shown to have notches  44 , and the core  43  is shown to have notches  45 . The notches  44  and  45  are typically used in a printer for advancing a web generally indicated at  46 . Although notches  44  and  45  are illustrated, a greater or lesser number of notches, or no notches at all can be provided depending on the machine with which the cores are to be used. 
     FIG. 2 shows the web  46  as including a main web portion  47  which occupies most of the length of the web  46 . In this and in the other embodiments, the main web portion  47  has a coating and in particular a coating of ink and thus comprises an ink ribbon which includes a thin coating or layer of ink on a web of plastics film. The web  47  has a marginal end  48  to which a strip of pressure sensitive adhesive tape  49  is adhesively secured. The tape  49  is comprised of a flexible plastics film  50  with a uniform coating of adhesive  51 . The adhesive  51  adheres the tape  49  to the marginal end  48  and adheres the web  46  to the core  42 . The tape  49  overlaps the marginal end  48  and presents an exposed transversely extending adhesive stripe to the outer surface of the supply core  42 . The web  46  includes a main web portion  52  which comprises almost all of the web  46 , and the web  46  also includes a leader portion  52 ′. A transversely extending strip of adhesive tape  53  is comprised of a flexible plastics film  54  having a uniform coating of pressure sensitive adhesive  55 . The tape  53  is shown connecting the overlapped ink ribbon portion  47  and leader portion  52 ′. The leader portion  52 ′ is shown to be comprised of flexible leader strips  56 ,  57  and  58 . The leader strips  56  and  57  are shown connected to each other by a transversely extending strip of adhesive tape generally indicated at  59  comprised of flexible plastics film  60  with a uniform coating of pressure sensitive adhesive  61 . Terminal first ends  62  and  63  (FIG. 3) of the respective leader strips  56  and  57  are spaced apart and the tape  59  spans the space therebetween and is adhered to respective marginal first ends  64  and  65  of the leader strips  56  and  57 . A stripe of the exposed adhesive  61  shown by stippling in FIG. 3 is face-to-face with the take-up core  43  as best shown in FIG.  4 . The core  43  is secured to the stripe of adhesive  61  on the tape  59 . The adhesive  61  preferably permanently attaches or adheres the take-up core  43  to the leader portion  52 ′. 
     A transversely extending strip of adhesive tape generally indicated at  66  connects the leader strips  57  and  58  to each other. The tape  66  has a flexible plastics film  67  and a uniform coating of pressure sensitive adhesive  68 . Terminal ends  69  and  70  (FIG. 3) of the respective leader strips  57  and  58  are spaced apart. The tape  66  spans across the space between the terminal ends  69  and  70  and is adhered to marginal ends  71  and  72  of respective leader strips  57  and  58 . The leader strip  58  provides a manually graspable tab. While the leader portion  52 ′ is illustrated as being a composite of leader strips  56 ,  57  and  58  and tapes  59  and  66 , the leader portion  52 ′ can be comprised of a single film or leader portion with transverse stripes of adhesive at the locations where the exposed adhesive  61  and  68  exists. 
     The leader strip  57  is shown to have weakening  73  along a line transversely across the web  46 . The weakening  73  is preferably a line of perforations illustrated in FIGS. 2,  3  and  6  of the drawings by broken lines and intervening circles and in FIGS. 4,  5 ,  7  and  8  by small circles. The flexible adhesive strips  49 ,  53 ,  59  and  66  are shown to have considerable thickness for the sake of clarity, but one skilled in the art will recognize that these adhesive strips are thin, by way of example not limitation, on the order of between about 15 to 100 Microns and preferably about 6 Microns thick and the coated web portion or ink ribbon  47  is between about 3 to 15 Microns and preferably about 8 Microns thick. 
     FIG. 2 shows indicia  74  stating instructions for use, for example the words “Pull Here”. A label  75  also bears indicia providing desired information. 
     In the embodiment of FIGS. 1 through 8, the web  46  is preferably essentially entirely an ink ribbon except for the leader portion  52 ′. The web  46  is wound into the configuration best shown in FIGS. 1 and 4. The exposed adhesive  68  is shown to hold the web  46  to itself. The adhesive  68  releasably adheres the web  46  to itself. For this purpose the adhesive  68 , like the adhesive  61 , may be of the permanent type. In that the adhesive  61  adheres to a take-up core  43  which is of paperboard material, the adherence is permanent. In the event the take-up core  43  were to be made of plastics material the aggressiveness of the adhesive should preferably be such as to adhere the web  46  permanently to the core  43 . The adhesive  68  may also be of the permanent type, but because the adhesive  68  is adhered to the leader portion  52 ′ comprised of plastics film such as polyethylene film the adhesive  68  is actually removably adhered to the film. If necessary, the adhesive  68  can be less aggressive than the adhesive  61 . 
     The web  46  extends beyond the roll  41  to provide an outwardly extending portion. The web  46  encircles both the roll  41  and the core  43  to provide the packaging or wrapping for the package  40 . In order to open or unwrap the package  40 , the user manually grasps the tab  58  and pulls in a direction away from the roll  41 , thereby releasing the web  46  from itself. Then the user tears the leader strip  57  along the line of weakening  73 . The part of the leader portion  52 ′ outwardly of the line of weakening  73  can now be discarded. Now the roll  41  and the take-up core  43  can be inserted into the utilization device, e.g. a printer, in which the web  46  is progressively unwound from the roll  41  and wound onto the take-up core  43 . In the illustrated embodiment of FIGS. 1 through 8, the main portion of the web  46  of the roll  41  is an ink ribbon suitable for use in a printer for example a thermal printer. Indeed, almost the entire web  46  is comprised of ink ribbon. 
     In the manufacture of a package  40 , the ink ribbon is advanced from the ink ribbon production equipment to a leader-trailer bed (not shown) in the direction of arrow A in FIG.  6 . While in the leader-trailer bed, the ink ribbon is slit transversely into wide webs  80  and  81  and the wide web  80  is advanced in the direction of the arrow A while the wide web  81  remains stationary. Next, a composite leader web  52 W corresponding to the leader portion  52 ′ is advanced in the direction of arrow B, but at a level above the plane of the webs  80  and  81 . The composite leader web  52 W is wider than the distance between the wide webs  80  and  81 . The composite leader web  52 W has leader strips  56 W,  57 W and  58 W corresponding to leader strips  56 ,  57  and  58  and has pressure sensitive adhesive tape or strips  53 W,  59 W and  66 W corresponding to the tape or strips  53 ,  59  and  66 . The adhesive tape strip  49 W is attached to the tab strip  58 W and to the wide ink ribbon web  81 . Next the leader web  52 W is trimmed by slitting along lines  82  and  83  which run along the side edges of the webs  80  and  81 . Thus, the webs  80  and  81  are connected by a leader web  52 W for advancement to a rewinder diagrammatically illustrated in FIGS. 7 and 8. As the webs  80  and  81  and the intervening leader web  52 W are advanced, slitting knives (not shown) slit the webs  80  and  81  and the web  52 W along lines  83  into, for example, three narrow webs such as the web  46 . 
     With reference to FIGS. 7 and 8, the rewinder  84  can rewind the three narrow webs. The rewinder  84  has two opposed turrets  85  and  86  on which supply cores  42  can be mounted. Each turret  85  and  86  also has opposed pairs of holders  87  and  88  on which take-up cores  43  can be mounted. The rewinder  84  also has opposed edge guides  89  and  90 . 
     With reference to FIG. 7, the rewinder  84  is shown in a position in which the ink ribbon  47  is almost entirely wound onto the core  42  on the turret  86 . The turret  84  is now indexed clockwise into the FIG. 8 position at which the exposed stripe of adhesive  61  on the tape  59  is against and in contact with the outer periphery of the take-up core  43 . The machine operator now lightly presses the tape  59  against the take-up core  43  to better adhere the adhesive  61  to the take-up core  43 . Next the operator presses the tape  49  against the core  42  so that the adhesive  51  adheres permanently against the core  42 . The operator then peels the tape  49  from the leader strip  58  and presses the remainder of the tape  49  against the core  42 . The operator now removes the take-up core  43  from the turret and between edge guides  90 , takes up any slack by winding the leader portion  52 ′ around the ink ribbon roll  41  (shown at the bottom of FIG.  8 ), and adheres the exposed stripe of adhesive  68  of the tape  66  to the outer surface of the web  46 . Although the adhesive  68  is adhered to the outer surface of the roll  41  it can be attached anyplace on the outer wrap. The now-completed package  41  is slipped off the turret  85 , and the same process can proceed for the next ink ribbon. 
     In the embodiment of FIGS. 9 through 11, the same reference characters are used as in the embodiment of FIGS. 1 through 8 for components having the same structure, function and relative location, with the addition of the letter “a”. The package  40   a  differs from the package  40  only in that there is no line of weakening such as the line of weakening  73  of the package  46 . The manner of use of the package  40   a  differs from that of the package  40  in that after the user pulls on the tab  58   a  to unstick the adhesive  68   a  of the tape  66   a  from the outer surface of the roll  41   a , the leader strip  57   a  and the tab strip  58   a  can simply be wrapped up about the take-up core  42  as after the take-up core  42  and the supply core  44   a  are installed in the printer. 
     In the embodiment of FIGS. 12 through 14, the same reference characters are used as in the embodiment of FIGS. 1 through 8 for components having the same structure, function and relative location, with the addition of the letter “b”. The package  40   b  differs from the package  40 , as follows: The leader strip  56   b  is permanently secured to the core  43   b  by a transversely extending strip of adhesive tape generally indicated at  91 . The tape  91  is comprised of flexible plastics film  92  with a coating of permanent pressure sensitive adhesive  93 . A portion of the width of the tape  91  is adhered to the leader strip  56   b  and the remainder is adhered to the take-up core  43   b . A marginal end of a transversely extending strip or tab  94  is spaced from the leader strip  57   b . A transversely extending strip of pressure sensitive tape  95  spans across the respective marginal ends of the tab strip  94  and the leader strip  57 . The tape  95  comprises film  96  and a coating of permanent pressure sensitive adhesive  97 . The adhesive  97  is releasably adhered to the tape  91 . As best shown in FIG. 13, the tape  66   b  releasably adheres the leader strip  57   b  to the outer surface of the web  46   b  at the roll  41   b . When it is desired to unwrap the package  40   b , the user pulls the tab  94  and separates the tape  95  from the tape  91 . By continuing to pull on the tab  94  the user pulls the tape  66   b  loose from the outer surface of the web  46   b . The user can then discard the leader strip  57   b  the tapes  66   b  and  95  and the tab  94  as a unit. 
     In the embodiment of FIGS. 15 through 17, the same reference characters are used as in the embodiment of FIGS. 1 through 8 for components having the same structure, function and relative location, with the addition of the letter “c”. The leader strip  56   c  is shown to have a marginal end  98  located between a transversely extending transverse strip of double-faced adhesive tape generally indicated at  99  and the take-up core  43   c . The tape  99  is comprised of a flexible plastics film  100  with a coating of permanent adhesive  101  on one side and a coating of permanent adhesive  102  on the other side. The tape  99  overlays the marginal end  98  and the outer periphery of the take-up roll  43   c  as best shown in FIG.  16 . The adhesive  101  is releasably adhered to the outer surface of the roll  41   c . In order to unwrap the package, the user simply grips the outside of the roll  41   c  and the outside of the take-up core  42   c  and pulls the adhesive  101  free from the outer surface of the roll  41   c . The tape  99  stays with the take-up core  43   c  as the ink ribbon  47  is used in the printer. 
     In the embodiment of FIGS. 18 through 20, the same reference characters are used as in the embodiment of FIGS. 1 through 8 for components having the same structure, function and relative location, with the addition of the letter “d”. The package  40   d  includes a transversely extending strip of tape generally indicated at  103  comprising a plastics film  104  having a coating of permanent adhesive  105 . The tape  103  is adhered to a marginal end  106  of the leader strip  56   d , to the outer periphery of the take-up core  43   d , to marginal end  107  of the tab  58   d  and to the other surface of the roll  41   d  as best shown in FIG.  19 . To unwrap the package  40   d , the user pulls on the tab  58   d  and separates the tape  103  from the outer surface of the roll  41   d . In use, the tape  103  and the tab  58   d  thereon can be wound around the take-up core  42   d  as the ink ribbon  47   d  is being used in the printer. 
     It is evident that in the embodiments of FIGS. 1 through 20 to the take-up core is within or is enclosed by the portion of the web that forms the wrapper. In these embodiments, by way of example not limitation, the main web portion  52  is about 200 meters in length and the leader portion  52 ′ is about 0.5 meter in length. 
     In the embodiments of FIGS. 21 through 34 the take-up core is on the outside of the portion of the web that is attached to the outer surface of the roll. In these embodiments, by way of example not limitation, the main web portion  52  is about 200 meters in length and the leader portion  52 ′ is about 0.35 meter in length. 
     With reference to the embodiment of FIGS. 21 through 25, there is shown a transversely extending strip of adhesive tape generally indicated at  108  having a plastics film  109  and a coating of permanent pressure sensitive adhesive  110 . There is also a transversely extending strip of adhesive tape generally indicated at  111  having a plastics film  112  and a coating of permanent pressure sensitive adhesive  113 . The tapes  108  and  111  partially overlap each other as best shown in FIGS. 22,  24  and  25 . The tape  111  is adhered to end portion  114  of the ink ribbon  47   e  and to the adhesive  110  on the tape  108 . The adhesive  110  is adhered to the outer surface of the supply core  42   e . A strip of adhesive tape generally indicated at  115  connects the ink ribbon  47   e  to a leader or leader strip  56   e . A strip of adhesive tape generally indicated at  116  connects the leader strip  56   e  to a leader strip  117 . The leader strips  56   e  and  117  are spaced apart and the adhesive tape  116  spans across and connects marginal ends of the leader strips  56   e  and  117 . The strip of tape  116  includes a film  118  and a coating of permanent pressure sensitive adhesive  119 . The adhesive  119  is permanently adhered to the take-up core  43   e . The leader  117  is shown to have a transversely extending line of weakening generally indicated at  120 . A transversely extending pressure sensitive tape generally indicated at  121  includes a plastics film  122  and a coating of permanent pressure sensitive adhesive  123 . The tape  121  connects the leader strip  117  and a transversely extending leader strip or tab  124 . The leader strip  117  and the tab  124  are spaced apart so that there is a stripe of exposed adhesive  123  as best shown in FIG.  23 . The adhesive  123  is used to adhere the tape  121  to the outer surface of the roll  41   e  as best shown in FIGS. 21 and 24. When it is desired to unwrap the package  40   e , the user pulls on the tab  124  and pulls the tape  123  from the outer surface of the roll  41   e . Next, the user can tear the leader strip  117  at the line of weakening  120 . The ink ribbon is now ready to be used in the printer or other device. 
     The package  40   f  of the embodiment of FIGS. 26 through 28 is identical to the embodiment of FIGS. 21 through 25 except that there is no line of weakening as in the embodiment of FIGS. 21 through 25 and except as noted hereafter. Accordingly, the same reference characters are used for components having the same structure, function and relative location with the addition of the letter “f”. The package  40   f  includes the roll  41   f . A transversely extending strip of tape  125  has a flexible film  126  and a coating of permanent pressure sensitive adhesive  127 . The adhesive  127  connects the ink ribbon  47   f  to the supply core  42   f . A transversely extending strip of pressure sensitive adhesive tape  128  includes a flexible plastics film  129  and a coating of permanent pressure sensitive adhesive  130  adhered to the overlapped marginal ends of the ink ribbon  47   f  and a transversely extending leader strip  131 . The leader strip  131  adheres to the permanent pressure sensitive adhesive  119   f  on the tape  116   f . To unwrap the package, the user pulls on the tab  124   f  and loosens the tape  121   f  from the outer surface of the roll  41   f . The leader strip  117   f , the tape  121   f  and the tab  124   f  as a unit can be wound onto the take-up core  42   f  while the ink ribbon  47   f  is being used in the printer or other device. 
     Except as noted, the embodiment of FIGS. 29 through 31 is the same as the embodiment of FIGS. 26 through 28 so that the components having the same structure, function and relative location use the same reference characters with the addition of the letter “g”. The package  40   g  omits the leader strip  117   f  and adheres a transversely extending strip of tape  132  to the tape  116   g . The tape  132  has a plastics film  133  and a coating of permanent pressure sensitive adhesive  134 . The adhesive  134  adheres to the adhesive  119   g  on the tape  116   g  and to the tab  124   g . The adhesive  119   g  also adheres to the outer periphery of the take-up core  43   g . FIG. 30 shows the adhesive  134  on the tape  132  is adhered to the outer surface of the and to the leader  131   g . To unwrap the package  40   g , the user pulls on the tab  124   g  which pulls the tape  132  from the surface of the roll  41   g.    
     The package  40   h  of the embodiment of FIGS. 32 through 34 is identical to the embodiment of FIGS. 29 through 31 except as noted hereafter. Accordingly, the same reference characters are used with the addition of the letter “h” for components having the same structure, function and relative location. The package  40   h  includes a transversely extending strip of double-faced pressure sensitive adhesive tape generally indicated at  135  having a flexible plastics film  136  with a coating of permanent pressure sensitive adhesive  137  on one side and a coating of permanent pressure sensitive adhesive  138  on the other side. The adhesive  137  adheres to the outer periphery of the take-up core  43   h  and the adhesive  138  adheres to a marginal end  139  of the leader strip  131   h  and to a marginal end  140  of the tab or leader strip  124   h . The marginal ends  139  and  140  are spaced apart leaving some adhesive  138  exposed. As best shown in FIG. 33, the adhesive  138  is adhered to the outer surface of the roll  41   h . When it is desired to unwrap the package  40   h , the user pulls on the tab  124   h  and loosens the adhesive  138  from the surface to which it is adhered. 
     In the case of an ink ribbon in the various embodiments, the ink ribbon  47  through  47   h  is comprised of a flexible plastics film onto which ink has been coated. The film is for example polyethylene. The adhesives used in the various embodiments are made with adequate aggressiveness to serve their intended function. 
     The invention is not limited to ink ribbons unless an ink ribbon is recited in a particular claim. Rather the invention is useful with various types of webs. 
     Unless otherwise indicated, the particular order of the steps recited in the appended claims is not critical; the particular order of steps can be changed without departing from the spirit of the invention. 
     Other embodiments and modifications of the invention will suggest themselves to those skilled in the art, and all such of these as come within the spirit of this invention are included within its scope as best defined by the appended claims.