Patent Publication Number: US-8124209-B2

Title: Transfer tape for cutting and spooling a paper web

Description:
This application is a continuation-in-part of and claims the benefit of U.S. patent application Ser. No. 10/794,022, filed Mar. 5, 2004 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates generally to the field of devices, apparatuses and methods of effecting high speed severing and transfer of a rapidly advancing paper web from one spool onto an empty spool, and more particularly where such an operation is performed utilizing a transfer or turn-up tape. More particularly, the invention relates to an improved transfer tape and its use in a paper web severing/transfer method, wherein the transfer tape is the effecting means for severing, transferring and securing the paper web onto an empty spool. 
     Modern paper manufacture is typically performed by producing continuous sheets of paper having widths of up to 330 inches in some cases, referred to as paper webs, which are wound onto spools for subsequent processing, storage, transfer or the like. The spooling operation for the paper web occurs at high speeds, in some cases as high as 8000 feet per minute, and in order to maximize production by minimizing downtime it is desirable to sever and transfer the web from a full spool to an empty spool without stopping or slowing movement of the web. Methods and apparatuses for accomplishing this severing and transfer utilizing what is known as a transfer or turn-up tape have long been known. An early example of such a system is shown in U.S. Pat. No. 2,461,246 to Weyenberg, issued in 1949. Other examples are shown in my U.S. Pat. Nos. 4,659,029, 4,757,950, 4,783,018, 5,046,675, 5,453,141, 5,637,170, and 5,954,290. Examples of different types of transfer systems are shown in my U.S. Pat. Nos. 4,467,719 and 5,810,279. 
     The transfer tape utilized in severing and transferring the paper web has at least one adhesive side, preferably comprised of a pressure sensitive adhesive (PSA), that contacts and adheres to the web, such that in certain systems the web is transversely severed as the tape is brought onto the empty spool. In other systems, the transfer tape is already adhered to the empty spool, in which case the web adheres to the tape as the spool rotates, the web severing as the travel direction of the tape pulls away from the direction of travel of the paper web. 
     The high speed transfer of lightweight paper webs, such as newsprint or tissue paper, is more difficult to accomplish due to the weaker structure of the paper. In addition, where adhesive transfer tapes are used, the exposed adhesive side of the transfer tape is often contaminated with airborne dust, floating paper fibers and other debris, such that the adhesion is weakened or even blinded completely, which can result in a failed transfer. 
     It is an object of this invention to provide an improved transfer tape and an improved method of severing and transferring a continuous paper web from a full spool to an empty spool, such as are especially useful in transferring lightweight papers such as tissue or newsprint, wherein the transfer tape is improved by providing a longitudinally extensive cover flap member that protects a pressure sensitive adhesive layer on the tape by preventing contamination from airborne dust, paper fibers or other debris. It is a further object to provide such a transfer tape and method of utilizing tape wherein the cover flap is self-opening as a result of the air resistance encountered due to rotation of the empty spool. It is a further object to provide additional embodiments of the transfer tape wherein an adhesive tab member is provided on the exterior of the cover flap to initiate the opening of the flap. It is a further object to provide additional embodiments for the method wherein pressurized jets of air are utilized to open the cover flap to expose the adhesive on the tape. These and other objects not expressly set forth in this paragraph will be addressed in the disclosure to follow. 
     SUMMARY OF THE INVENTION 
     The invention is a new structure for a paper web transfer tape used in web spooling, transfer or turn-up operations where a continuously and rapidly advancing paper web being wound onto a first spool is cut and transferred onto a second spool without stopping or slowing the advancing paper web. The transfer tape comprises an elongated and thin carrier member having a pressure sensitive adhesive (PSA) coating applied to both sides. The PSA coating on the first side is temporarily covered by a cover flap comprising a flap member composed of paper or the like that is provided with a release layer coating of silicone or the like such that the cover flap does not adhere to the PSA coating. The cover flap is adhered to the carrier member along or adjacent a longitudinal edge of the carrier member such that the cover flap easily opens in a hinged manner to expose the PSA coating yet remains attached to the transfer tape so that it does not foul the equipment. The cover flap prevents adhesion of environmental dust, paper fibers and other airborne debris that will diminish the adhesive strength of the PSA coating, possibly to the point where the tape will not adhere to the paper web. An alternative construction for the transfer tape provides a small adhesive tab member disposed on the outer surface of the cover flap, with the adhesive tab member used to initiate the opening of the cover flap to expose the PSA layer. 
     The transfer tape is adhered to an empty spool such that free or leading edge of the cover flap faces in the direction of rotation of the spool, such that air pressure encountered by rotation of the tape causes the cover flap to fold or pivot backward, thus exposing the PSA coating just prior to its coming in contact with the advancing paper web. As the tape adheres to the paper web, the paper web is torn transversely and is transferred to the new spool. In a further embodiment of the methodology, air pressure jets or nozzles are disposed to initiate the opening of the cover flap to expose the PSA layer immediately prior to contact with the paper web and to initiate the transverse tear in the paper web. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portion of an embodiment of the transfer tape of the invention. 
         FIG. 2  is a perspective view of an alternative embodiment, wherein an adhesive tab member is provided on the cover flap of the transfer tape of  FIG. 1 . 
         FIG. 3  is a perspective view of a portion of an alternative embodiment of the transfer tape, wherein the cover flap is not folded. 
         FIG. 4  is a perspective view of an alternative embodiment, wherein an adhesive tab member is provided on the cover flap of the transfer tape of  FIG. 3 . 
         FIG. 5  is a perspective view of an alternative embodiment, wherein the cover flap is attached to the underside of the carrier member. 
         FIG. 6  is a perspective view of an alternative embodiment, wherein the carrier member of the transfer tape is longitudinally embossed. 
         FIG. 7  is an illustration of the transfer tape in use in the web transfer operation. 
         FIG. 8  is a side view of the web transfer operation, showing the addition of high pressure air jets to open the cover flap of the transfer tape and to initiate severing of the web. 
         FIG. 9  is a perspective view of the web transfer operation, wherein high pressure water jets are used to cut the paper web longitudinally. 
         FIG. 10  is a perspective view of an alternative and preferred embodiment, similar to the embodiment of  FIG. 3 , wherein a longitudinal fold line is provided. 
         FIG. 11  is a perspective view of an alternative embodiment, similar to the embodiment of  FIG. 10 , wherein the corner of the leading edge is folded so as to expose a small portion of the first pressure sensitive adhesive layer. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the drawings, the invention will now be described with regard for the best mode and the preferred embodiment. In general, the invention is a device or apparatus for cutting, transferring and spooling a rapidly traveling web of paper, the apparatus comprising a transfer tape of novel structure, and the method or process utilizing such transfer tape whereby a rapidly traveling paper web being wound onto a first spool is cut and directed onto a second spool. 
     The transfer tape  10 , various embodiments of which are illustrated in  FIGS. 1 through 6 , and  11  (wherein the representative layers are not drawn to scale but are provided with enlarged thicknesses for illustrative purposes), is a longitudinally extended member having a ribbon-like configuration, such that it is relatively thin with a relatively small width, with representative dimensions being for example approximately one inch in width and less than approximately one mm in thickness. It is understood that particular dimensions will vary dependent on the particular spooling system or application parameters. As shown in  FIG. 1 , the transfer tape  10  comprises a carrier member  11  having a first pressure sensitive adhesive (PSA) layer  12  applied to or coated on a first side of said carrier member  11  and a second pressure sensitive adhesive layer  13  applied to or coated on a second side of said carrier member  11 . The PSA layers  12  and  13  preferably cover the full extent of both sides of the carrier member  11 , but may also be applied intermittently in localized regions, in longitudinal stripes, etc. The carrier member  11  provides strength and structural integrity to the transfer tape  10  and is composed of any suitable material known in the industry capable of receiving and retaining an adhesive. Carrier members  11  composed of paper are well known in the industry. Preferably, the carrier member  11  and other components of the transfer tape  10  are composed of a paper or similar material that is recyclable or re-pulpable. The PSA layers  12  and  13  are composed of any such adhesive suitable for application to and retention by the carrier member  11  that is also suitable for adhesion to the paper web being spooled. A removable release liner member  14  is temporarily applied to cover the second PSA layer  13  on the carrier member  11 . The release liner member  14  is composed of a material or incorporates a release material, such as for example a silicone coating or impregnation, such that the release liner member  14  adheres in only a limited manner to the carrier member  11  in order to prevent undesired adhesion of the second PSA layer  13  to other objects prior to use, but which is easily removed therefrom when required. 
     A cover flap  20  comprising a flap member  15  composed of a kraft paper or similar material that will adhere to the first PSA layer  12  is provided, with the interior side of the flap member  15  being provided with a release coating or layer  16 , composed for example of a silicone coating or the like, characterized in that the interior side of the flap member  15  does not adhere to the first PSA layer  12  on the carrier member  11 . The flap member  15  is of greater overall width than the carrier member  11 , such as for example approximately 1.5 inches for a carrier member  11  having a width of approximately one inch. The flap member  15  is folded longitudinally to create a short attachment flange member  17 , such as for example approximately 0.25 inches in width for a flap member  15  width of approximately 1.5 inches, and is folded such that the flap release layer  16  is folded upon itself. The flap member  15  is then attached to the carrier member  11  by adhering the flap member  15  along one longitudinal edge of the first PSA layer  12  on the carrier member  11 , with the remainder of the flap member  15  extending laterally across the first PSA layer  12  of the carrier member  11  and slightly beyond—approximately 0.25 inches for the representative dimensions given above. The flap release layer  16  prevents the interior side of the flap member  15  from adhering to the first PSA layer  12 , and for this purpose must be correspondingly disposed opposite to all of the exposed first PSA layer  12 . The longitudinal edge of the transfer tape  10  to which the flap member  15  is joined defines the trailing edge  18 , with the opposite longitudinal edge of the transfer tape  10  being the leading edge  19 . The cover flap  20  is thus able to open in a hinged manner to expose the first PSA layer  12 , with the cover flap  20  remaining attached to the carrier member when opened. 
     With this construction, the first PSA layer  12  of the transfer tape  10  is covered by the cover flap  20  such that the first PSA layer  12  is protected from environmental dust, floating paper fibers and other atmospheric debris prior to use. In this manner, environmental dust, fibers and debris will not detrimentally reduce the adhesion properties of the first PSA layer  12 . As explained in detail below, the cover flap  20  is opened to expose the first PSA layer  12  only immediately prior to the cutting and transfer operation, thus insuring that sufficient adhesive surface area remains for the transfer tape  10  to adhere to the paper web being transferred. 
     An alternative embodiment for the transfer tape  10  is shown in  FIG. 3 , wherein the transfer tape  10  is composed of a carrier member  11 , a first PSA layer  12 , a second PSA layer  13  and a release liner member  14  as described above. The cover flap  20  is again comprised of a flap member  15  composed of a kraft paper or similar material that will adhere to the first PSA layer  12 . The flap member  15  is preferably slightly wider than the carrier member  11  such that it will extend slightly beyond the leading edge  19 . For example, for a carrier member  11  having a width of approximately one inch, the flap member  15  may be 1.25 inches in width. The interior side of the flap member  15  is partially coated with a flap release layer  16  comprising a material that prevents the flap member  15  from adhering to the first PSA layer  12 , such as for example a silicone coating. The flap member  15  is coated such that all or a suitable intermittent portions of the strip or edge of the interior side of flap member  15  along the trailing edge  18  is uncoated, such that this uncoated strip portion will permanently adhere directly to the first PSA layer  12  of the carrier member  11 . For example, the flap release layer  16  may be applied in an approximately one inch width, leaving an uncoated strip of approximately of 0.25 inches on the 1.25 inch flap member  15  to adhere to the carrier member  11 . In this construction, the flap member  15  is not in a folded configuration, which allows the transfer tape  10  to be rolled upon itself prior to use for ease of storage and transport. 
     An improvement to the embodiment shown in  FIG. 3  is illustrated in  FIG. 10 , which is the preferred embodiment, wherein the flap member  15  is provided with a structural fold line  21  that extends longitudinally and parallel to the trailing edge  18 , preferably at the location adjacent the trailing edge side of the flap release layer  16  such that the non-adhered cover flap  20  opens in a hinged manner along this fold line  21 . In other words, the fold line  21  is positioned along the junction between the attachment flange member  17 , the portion of the flap member  15  permanently adhered to the carrier member  11 , and the portion of the flap member  15  having the flap release layer  16 . The fold line  21 , which may be produced by scoring, creasing or otherwise imparting a defined hinging line on the flap member, defines the attachment flange member  17  and enables the flap member  15  to more easily and more fully open when used. 
     In still another embodiment similar to the embodiments shown in  FIGS. 3 and 10 , the flap member  15  and its flap release layer  16  are folded or creased along corner fold line  22  in order to define a folded corner  23 , such that the folded corner  23  extends away from the carrier member  11  to expose a small triangular portion of the PSA layer  12 , as shown in  FIG. 11 . With this structure, the cover flap  20  will “peel” open longitudinally when in use as described in more detail below. 
     In  FIGS. 2 and 4 , alternative embodiments are illustrated wherein in each structure the cover flap  20  is provided with an adhesive tab member  30  of relatively short longitudinal and width dimensions in comparison to the transfer tape  10 .  FIG. 2  shows the tab member  30  as applied to the transfer tape  10  of  FIG. 1 , and  FIG. 4  shows the tab member  30  as applied to the transfer tape of  FIG. 3 . The tab member  30  is disposed at or adjacent the corner of the leading edge  19  of the transfer tape  10  on the flap member  15 . The tab member  30  comprises a tab carrier member  31  composed of a paper or similar material able to retain or absorb a PSA coating, such that a first PSA layer  32  and a second PSA layer  33  are applied to opposing sides of the tab carrier member  31 . The second PSA layer  33  adheres the tab member  30  to the exterior side of the flap member  15 . A removable release liner member  34  composed of a material or a coating that allows slight adhesion to the first PSA layer  32  is positioned on the external side of the tab carrier member  31 . The tab release liner member  34  is removed prior to use of the transfer tape  10 . The adhesive tab member  30  is used to assist in opening the cover flap  20  when heavier grade papers are being spooled by bringing the tab member  30  into contact with the reel drum beyond the edge of the advancing paper web  50 . 
       FIG. 5  illustrates another alternative embodiment for the transfer tape  10 . In this embodiment, the cover flap  20  adheres to the paper web  50  being transferred. The cover flap  20  comprises the flap member  15  and a first PSA layer  12 , which is applied to the underside or interior side of flap member  15 . A flap release layer  16  is disposed on the upper side or interior of carrier member  11 , such that it is disposed between the carrier member  11  and the flap member  15 . The cover flap  20  folds or wraps around the trailing edge  18 , such that a portion of the first PSA layer  12  adheres the flap member  15  to the carrier member  11 . The carrier member  11  is provided on the underside or exterior with a second PSA layer  13  which is covered by a removable release liner member  14 . The presence of flap release layer  16  allows the cover flap  20  to be easily opened to expose the first PSA layer  12  to the paper web  50 . 
       FIG. 6  illustrates another alternative embodiment of the transfer tape  10 . In this embodiment, the layers of the transfer tape correspond to the layers as shown in  FIG. 1 , but the assembly formed by the combination of the first PSA layer  12 , the carrier member  11 , the second PSA layer  13  and the release liner member  14  are longitudinally embossed to create a series of alternating ridges  41  and valleys  42 . This configuration increases the structural rigidity of the transfer tape  10 , while retaining sufficient adhesive contact area for the first and second PSA layers  12  and  13  to perform as required in the web transfer operation. The increased thickness of the transfer tape  10  and the compressibility of the transfer tape  10  increases the efficiency of the interference fit within the nip during the transfer operation. 
     In paper web spooling, cutting, turn-up and transfer operations, a rapidly moving paper web  50  passes over a reel drum  51  of relatively large diameter in comparison to the spools  52  upon which the paper web  50  is wound to create a paper reel  53 . When a first spool  52  is fully loaded, the paper web  50  must be cut and directed onto a second, empty spool  52 , which is mounted onto a primary arm  54  that positions the second spool  52  in the location now vacated by the loaded first spool  52 . The cutting and transfer operation is performed by use of a transfer tape having an adhesive layer on both sides, such that the tape itself cuts the paper web  50 , adheres to the newly created leading edge of the paper web  50  and secures the paper web  50  to the new spool  52 . Such operations and techniques are well known in the industry. 
     This operation is illustrated in  FIGS. 7 ,  8  and  9 . The release liner member  14  is first removed to expose the second PSA adhesive layer  13  and the transfer tape  10  is applied generally longitudinally to the empty spool  52  mounted on the primary arm  54 . The transfer tape  10  may be applied in a straight or helical manner to the empty spool  52 . The spool  52  rotates in the direction opposite to the rotation direction of the reel drum  51 , so that where the reel drum  51  is seen as rotating in a clockwise manner as shown in the drawings, the spool  52  will be rotating in a counter-clockwise manner. The transfer tape  10  is applied to the spool  52  such that the leading edge  19  of the transfer tape  10  is in the forward direction of rotation on the spool  52 . Because the cover flap  20  is prevented from adhering to the first PSA layer  12 , the air pressure encountered due to the rapid forward motion of the transfer tape  10  causes the cover flap  20  to open and bend backward from the first PSA layer  12 , completely exposing first PSA layer  12  as the spool  52  rotates and is brought into contact with the advancing paper web  50 . The now exposed first PSA layer  12  contacts and adheres to the paper web  50 . This adhesion causes the paper web  50  to tear and transfer onto the spool  52 , such that the paper web  50  is now being spooled onto an empty spool  52 . Because the cover flap  20  has covered the first PSA layer  12  until the time of actual use, the adhesive properties of the transfer tape  10  have not been denigrated by environmental dust, floating paper fibers and other atmospheric debris. 
     In an alternative method, where the transfer tape  10  is constructed as shown in  FIGS. 2 and 4  with an adhesive tab member  30 , after applying the tape  10  to the empty spool  52  the opening of the cover flap  10  is initiated by removing the tab release liner member  34  to expose the second PSA layer  33 , such that on a first revolution the tab member  30  adheres briefly to the reel drum  51 , the tab member  30  being positioned on the spool  52  beyond the edge of the paper web  50 . The continued rotation causes the cover flap  20  to then fully open such that the first PSA layer  12  contacts and adheres to the paper web  50 , tearing it and transferring it to the spool  52 . This embodiment is useful where the rotation speed of the spool  52  is not sufficient by itself to open the cover flap  20 . 
     In a further alternative method, the opening of the cover flap  20  and tearing of the paper web  50  after the transfer tape  10  has been adhered to the paper web  50  may be assisted by providing pressurized air directed through nozzles or jets of pressurized air means  55  and  56 , as shown in  FIG. 8 . A blast of pressurized air from pressurized air means  55  is directed against the leading edge  19  of the cover flap  20  immediately prior to the transfer tape  10  first contacting the paper web, causing the cover flap  20  to open to expose the first PSA layer  12 . This application of forced air from pressurized air means  55  is useful in circumstances where the rotation speed of the spool  52  is not sufficient by itself to expose the first PSA layer  12 . Furthermore, where the paper web  50  is relatively heavy, pressurized air means  56  may be disposed on the edge of the paper web  50  at the location where the transfer tape  10  adheres to the spool  52  and the paper web  50  begins to rotate away from the reel drum  51 , such that a pressurized air blast from pressurized air means  56  initiates the tear in the paper web  50 , such that the adhesion to the transfer tape  10  propagates the tear across the full width of the paper web  50 . 
     In still another alternative methodology, as shown in  FIG. 10 , the transfer tape  10  is applied to the spool  52  in segments rather than in a continuous length, where the discontinuities of the adjacent tape segments correspond to longitudinal cuts made in the paper web  50  by high pressure water jets  57  or the like prior to reaching the reel drum  51 . In this manner, each of the longitudinal segments of the paper  50  can now be simultaneously transferred to the spool  52  as previously discussed. 
     It is contemplated that equivalents and substitutions to certain elements and features set forth above may be obvious to those skilled in the art, and thus the true scope and definition of the invention is to be as set forth in the following claims.