Patent Publication Number: US-2022219429-A1

Title: Splice Tape with Internal, Interlayer Separation Interface

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 15/826,397, filed Nov. 29, 2017, which is a divisional of U.S. application Ser. No. 15/430,020, now U.S. Pat. No. 9,855,724, filed Feb. 10, 2017, each of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to splice tapes. The present invention relates specifically to a splice tape with internal support layers having an internal separation interface. 
     In general, splice tapes are double sided tapes used in roll manufacturing processes, such as roll-based printing processes. A “flying” splice is a common term for referring to a splice that occurs at line speed (i.e., without stopping the process), and a flying splice tape is a tape that allows such splicing at line speed. The flying splice tape is used to attach the trailing end of a roll of material that is being paid off to the leading end of a new roll of material. This splicing arrangement allows the new roll of material to be fed into the manufacturing process as the prior roll of material is used up without interrupting or stopping the process to form the splice. 
     SUMMARY OF THE INVENTION 
     One embodiment of the invention relates to a method of forming a splittable splice tape. The method includes providing a first internal support layer including a first major surface and a second major surface. The method includes applying a liquid material onto the second major surface of the first internal support layer, and the liquid material includes a polymer material supported by a carrier liquid. The method includes forming a second internal support layer from the liquid material via removal of the carrier liquid and cross-linking of the polymer material. The second internal support layer includes an inner surface bonded to the second major surface of the first internal support layer. The method includes applying a first layer of adhesive material to the first major surface of the first internal support layer. The method includes applying a second layer of adhesive material to an outer major surface of the second internal support layer. 
     Another embodiment of the invention relates to a splittable splice tape. The splittable splice tape includes a first internal support layer including a first polymer material, an outer major surface and an inner major surface. The splittable splice tape includes a first adhesive layer directly bonded to the outer major surface of the first internal support layer. The splittable splice tape includes a second internal support layer including a second polymer material, an outer major surface and an inner major surface. The inner major surface of the second internal support layer is directly bonded to the inner major surface of the first internal support layer defining an interface between the first and second internal support layers. The splittable splice tape includes an anti-adhesion material dispersed within the second polymer material of the second internal support layer, at least some of which is located adjacent the interface. The splittable splice tape includes a second adhesive layer directly bonded to the outer major surface of the second internal support layer. The second polymer material is different from the first material and the second polymer material is a cross-linked polymer material. The anti-adhesion material decreases bonding between the first polymer material and the second polymer material such that a bond strength between the first internal support layer and the second internal support layer along the interface is less than a bond strength between second internal support layer and the second adhesive layer such that upon application of a force away from the interface, the splice tape separates in two portions along the interface. 
     Another embodiment of the invention relates to a splittable splice tape. The splittable splice tape includes a first support layer having an outer major surface and an inner major surface. The splittable splice tape includes a first pressure sensitive adhesive layer coupled to and in contact with the outer major surface of the first support layer. The splittable splice tape includes a second support layer including an outer major surface and an inner major surface, and the inner major surface of the second support layer is in contact with the inner major surface of the first support layer. The splittable splice tape includes a first bond coupling the inner major surface of the first support layer to the inner major surface of the second support layer. The splittable splice tape includes a second pressure sensitive adhesive layer coupled to and in contact with the outer major surface of the second support layer. The splittable splice tape includes a second bond coupling the outer major surface of the second support layer to the second pressure sensitive adhesive layer. The first bond is weaker than the second bond. 
     Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary. 
     The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and together with the description serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a splice tape, according to an exemplary embodiment. 
         FIG. 2  is a cross-sectional view of the splice tape of  FIG. 1 , according to an exemplary embodiment. 
         FIG. 3  is a detailed view of an internal, interlayer separation interface of the splice tape of  FIG. 1 , according to an exemplary embodiment. 
         FIG. 4  shows a process for manufacturing the splice tape of  FIG. 1 , according to an exemplary embodiment. 
         FIGS. 5A-5D  show use of the splice tape of  FIG. 1  during splicing in a roll manufacturing process, according to an exemplary embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the figures, a splittable splice tape is shown and described. In general, the splittable splice tape disclosed herein includes two internal support layers each having inner major surfaces that are in contact with and bonded to each other. The level of bonding along this interface is low enough that it forms a splittable interface located between the two internal support layers. Thus, when the tape discussed herein is used for splicing in roll manufacturing processes (e.g., roll-based printing processes), the tape separates along the interface between the two internal support layers which allows a new roll of material to be spliced to the existing roll such that the new role is fed into the manufacturing process without interruption. 
     The two internal support layers of the tape discussed herein are precisely engineered to provide enough bonding to allow the tape to hold together during handling and application to the rolled material. In addition, the bonding between the two internal support layers is low enough to allow the tape to separate reliably during use. In addition, the materials of the various tape layers also need to be robust enough to traverse the roll manufacturing process without deteriorating or it will otherwise cause problems as the tape traverses the manufacturing system. For example, in specific embodiments, in addition to providing the precise bonding control that allows for predictable separation, the tape material also has various properties, such as high tensile strength, elongation properties and/or heat resistance, that allows the tape to traverse the manufacturing system attached to the roll material without degrading, breaking, melting, etc. 
     Achieving reliable separation of splice tape is important to roll manufacturing processes, and in the past has typically involved tape structures with many internal layers and complicated structures for providing the various properties needed for reliable separation along with other material properties. For example, in some prior designs, a complicated series of multiple internal layers is used to achieve bond control that provides separation or a complicated internal pattern of adhesive material is used to achieve bond control. In some of these prior designs, the multiple internal layers are formed via lamination of sheets of material. In addition, in some other prior designs, an internal paper layer is used that splits within the layer to provide separation. 
     In contrast to such designs, the tape discussed herein achieves a precisely controlled interlayer bonding force (which results in controlled separation) at the interface between two internal layers of the tape material. In various embodiments, the two internal layers are polymer materials that are bonded together along their interface via bonding of the layer materials (rather than via an intervening adhesive), and the bond level is controlled via an anti-adhesion material dispersed in one of the polymer materials. Applicant has found that this tape design allows for highly controlled and predictable separation behavior, particularly when compared to splice tapes that utilize intralayer splitting or that use additional intervening layers to control internal tape bonding and separation. In addition, by using separable polymer layers without bonding adhesive, the tape discussed herein passes through manufacturing systems without sticking to machinery or the roll material at unintended times. Similarly, in contrast to designs that separate by creating a tear within a layer of material (typically believed to be a paper material), the design discussed herein separates cleanly along the internal layer interface which Applicant believes provides more predicable separation and prevents debris from the torn layer from interfering with the manufacturing process. In comparison to these prior designs, Applicant believes that Applicant&#39;s non-laminate structure at the separation interface and a separation interface formed utilizing a liquid applied and cured material provides a superior level of splice control that provides a significant improvement over prior splice tape designs. 
     In addition, in some role manufacturing processes, line speeds are very high (e.g., in excess of 3000 feet per minute) and the incoming role is accelerated to the process speed prior to being fed into the process. Thus, given these high speeds and acceleration, the splice tape discussed herein is engineered to have enough bond strength to hold the tape together during the acceleration/speed match process but also to separate at the appropriate time to smoothly allow the new role to be fed into the manufacturing process without splice failure. As discussed in detail below, the interface bonding of the tape of the present application is believed to provide the precision needed to allow for more consistent separation at the desired time while avoiding early splitting during roll acceleration. 
     Referring to  FIG. 1  and  FIG. 2 , a splittable splice tape, such as tape  10 , is shown according to an exemplary embodiment. In general, tape  10  includes a first internal support layer, shown as layer  12 , and a second internal support layer, shown as layer  14 . In specific embodiments, layer  14  is a polymer based lacquer layer formed from a cured, liquid material. Tape  10  includes a first adhesive layer  16  and a second adhesive layer  18 . 
     Layer  12  includes a first major surface, shown as outer major surface  20 , and a second major surface, shown as inner major surface  22 . Layer  14  includes a first major surface, shown as outer major surface  24 , and a second major surface, shown as inner major surface  26 . First adhesive layer  16  is bonded directly to outer major surface  20  of layer  12 , and second adhesive layer  18  is bonded directly to outer major surface  24  of layer  14 . 
     In general (and as will be described in more detail below), adhesive layers  16  and  18  are adhesive materials configured to adhere tape  10  to both a new incoming roll of material and the trailing end of the current, expiring roll of material to form the splice between the two rolls. In various embodiments, adhesive layers  16  and  18  are formed from pressure sensitive adhesive materials. In specific embodiments, adhesive layers  16  and  18  are formed from any of a variety of adhesive materials, including acrylic, rubber, or silicone based pressure sensitive adhesives. In some embodiments, adhesive layers  16  and  18  are formed from the same adhesive material as each other, and in other embodiments, adhesive layers  16  and  18  are formed from different adhesive materials from each other. 
     In specific embodiments, adhesive layers  16  and  18  are formed from an adhesive material having high tack, high shear and a temperature resistance of −20 degrees F. to 500 degrees F. In this context, temperature resistance indicates that the adhesive will not degrade and/or the level of adhesive bonding will not decrease when exposed to the noted temperature range. In a specific embodiment, adhesive layers  16  and  18  are formed from an adhesive material that will maintain at least 90%, specifically at least 95% and more specifically at least 99% of its original adhesive bond strength when exposed to temperatures in the range of −20 degrees F. to 500 degrees F. In various embodiments, layers  16  and  18  have an average thickness between 0.25 mils and 8.0 mils, and specifically between 1.0 mil and 5 mils. In some embodiments, the pressure sensitive adhesive materials are liquid or aqueous materials coated to the outer surfaces of support layers  12  and  14 , and in such embodiments, the thicknesses discussed herein are dry thicknesses measured after the applied liquid adhesive has dried. 
     To protect adhesive layers  16  and/or  18 , tape  10  includes one or more layer of liner material, shown as release liner  28 , coupled to the outer surfaces of layers  16  and/or  18  (release liner  28  is shown in  FIG. 1  and  FIG. 2  coupled to layer  16 ). In general, release liner  28  is coupled to and protects adhesive layers  16  and/or  18  during production and prior to use of tape  10  for splicing. In general, release liner  28  is removed by the end user, exposing adhesive layers  16  and/or  18  for attachment of tape  10  to a roll of material for splicing. In one embodiment, release liner  28  is a Kraft paper coated on both sides with a silicone material. In other embodiments, other silicone and non-silicone coated materials may be used for release liner  28 . 
     As shown in  FIG. 1 , release liner  28  includes a cut or slit  30  dividing release liner  28  into two sections. Slit  30  allows one portion of release liner  28  to be removed to expose a portion of layer  16  while the other section of adhesive layer  16  remains covered. As will be shown and explained in more detail below, this allows the first exposed section of layer  16  to be adhered to the leading edge of the new roll of material while the other portion of layer  16  remains covered, and once the leading edge of the new roll of material is attached to tape  10 , the second section of release liner  28  is removed allowing the second portion of layer  16  to be adhered to the trailing edge of an expiring roll of material. In some embodiments, the split release liner  28  works in conjunction with the splittable internal interface of tape  10  by decreasing the chance that the end user inadvertently splits tape  10  apart during removal of liner  28 . 
     Referring to  FIG. 2  and  FIG. 3 , internal support layers  12  and  14  and the splittable interface of tape  10  is shown and described in more detail. In general, layers  12  and  14  are layers of polymer material that support adhesive layers  16  and  18  of tape  10  and that also define the splittable interface  40  of tape  10 . 
     As shown in  FIG. 3 , inner major surface  22  of layer  12  is directly bonded to inner major surface  26  of layer  14  defining interface  40  between the two distinct inner layers of tape  10 . In general, layers  12  and  14  are designed such that the bonding force between layers  12  and  14  is low enough to that tape  10  separates along interface  40  as the new roll of material is pulled into the manufacturing process during splicing but is strong enough to prevent early separation (e.g., during handling and transport before use in splicing and to prevent separation during acceleration of the new roll that occurs immediately before being fed into the manufacturing process). In addition, the bond at interface  40  is configured relative to the other materials and layers to ensure that tape only separates at interface  40  during splicing. 
     To achieve this specific separation at interface  40 , the strength of the bond at interface  40  is less than the strength of the bond between layer  12  and adhesive layer  16  and/or is less than the strength of the bond between layer  14  and adhesive layer  18 . This differential bond strength allows tape  10  to separate along interface  40  during use while ensuring that layer  12  stays bonded to layer  16  and that layer  14  stays bonded to layer  18  during splicing. This precise control of bonding properties and separation consistency is provided through the manufacturing process of tape  10  and/or via the properties of the materials of layers  12  and  14  discussed herein. 
     In various embodiments, layer  12  is formed from a first polymer material, and layer  14  is formed from a second polymer material that is different from the first polymer material. Applicant has found that by selecting the combination of materials for layer  12  and layer  14 , the degree of bonding at interface  40  can be controlled (at least when combined with other aspects of the tape and process discussed herein). In various embodiments, the first polymer material of layer  12  is a thermoplastic material, and the second polymer material of layer  14  is a cross-linked polymer material, and in a specific embodiment, the first polymer material of layer  12  is a polyester material, and the second polymer material of layer  14  is a cross-linked polymer polyurethane material. In specific embodiments, the polymer material of layer  14  is a 2K polyurethane material that is cross-linked or activated with an aliphatic isocyanate (specifically polyisocyanate). In particular embodiments, Applicant has found that this material, when cured, crosslinked and hardened, provides the chemical and temperature resistance needed to withstand splice process conditions, while at the same time remaining conformable enough to bend. Further, Applicant found that this material does not soften and adhere to anything (e.g., equipment) during the splice process. 
     In specific embodiments, layer  12  may be formed from a film, sheet or web of polyester material. In other embodiments, layer  12  may be formed from a film of nylon, polypropylene, polyethylene, vinyl, unplasticized polyvinyl chloride, polyimide, other polyolefins or various blended film materials. Applicant has found that thermoplastics generally, and polyesters, specifically have good strength, elongation properties and heat resistance which allows layer  12  to be passed through a variety of roll-based manufacturing processes without degradation. In one embodiment, the material of layer  12  (and specifically a polyester material) has a tensile strength greater than 20 lbs/in, elongation of 80% and/or a melting temperature greater than 230 degrees C. In another embodiment, the material of layer  12  (and specifically a polyester material) has a tensile strength greater than 23 lbs/in, elongation of 90% and/or a melting temperature greater than 250 degrees C. Applicant has found that forming layer  12  from a material having these properties performs well in a splicing process. In various embodiments, layer  12  has an average thickness of between 0.25 mils to 10 mils, and specifically between 1.0 mil and 5.0 mils. 
     In specific embodiments, the second polymer material of layer  14  is a cross-linked polymer material, specifically a cross-linked polyurethane, that includes one or more additive  42  that limits or controls the degree of adhesion between layer  12  and layer  14  present at interface  40 . Applicant has found that use of the anti-adhesion material (at least in the materials and processes discussed herein) provides a high level of control and consistency of the bond at interface  40  which translates to a high level of control over the separation at interface  40  during splicing. In a specific embodiment, anti-adhesion additive is Additol EX  6568  commercially available from Allnex Belgium SA/NV. 
     In specific embodiments, layer  14  is formed from a liquid polymer material or lacquer which is coated in liquid form onto surface  22  of layer  12 . In various embodiments, the liquid material includes a carrier liquid (e.g., water, solvent, etc.) which supports the polymer component (and any other component of the liquid material). Following application onto layer  12 , the liquid polymer material is cured which causes crosslinking between the polymer components and removal of the liquid component resulting in the solid, cross-linked polymer layer  14 . In specific embodiments, curing of the applied liquid polymer material is achieved through heating, and in some specific embodiments, the applied liquid material includes a catalyst material (e.g., a metal based catalyst, such as tin or non-tin based catalysts) to further facilitate cross-link. In other embodiments, curing and cross-linking may be achieved through aging at ambient temperatures at longer time intervals, e.g., ambient aging for times up to three weeks. 
     Applicant has discovered that controlling the curing and/or cross-linking rate, in combination with the anti-adhesion material concentration, allows the bond strength and consistency at interface  40  to be controlled. Applicant has found that if the cure rate is too high (for a given material combination of layers  12  and  14 ), the bond strength at interface  40  will be too high, which in turn prevents separation along interface  40  during use in a splicing operation. In particular, Applicant believes that by forming layer  14  (and consequently interface  40 ) from a liquid application and cure process as discussed herein allow the bond strength at interface  40  to be more controlled and consistent as compared to splice tapes formed using a sheet-to-sheet lamination process. In embodiments utilizing a liquid application and cure to form layer  40 , the control and consistency of bond strength at interface  40  is believed to be the result of the cure process rate (as discussed below) and/or the inclusion of the adhesion additive  42  and its incorporation during the cure process. Applicant believes that this high level bond consistency is difficult/impossible to achieve utilizing typical laminated structure. In specific embodiments, tape  10  including liquid applied/cured layer  14  includes residual carrier fluid (e.g., water or a solvent such as buytl acetate) within cured layer  14  which is not present in a tape formed from a lamination process. In specific embodiments, layer  14  includes residual carrier fluid in amounts greater than 0% and less than 1% and more specifically greater than 0.01% and less than 1%. 
     In various embodiments, curing and/or anti-adhesion material ensures that tape  10  has a bond strength between layers  12  and  14  at interface  40  and is between 0.01 oz. per inch of tape width and 5 oz. per inch of tape width such that when a force is applied that is greater than bond strength, tape  10  separates along interface  40 . In a specific embodiment, the cure rate and/or anti-adhesion material ensures that the bond strength between layers  12  and  14  at interface  40  is between 0.1 oz. per inch of tape width and 5 oz. per inch of tape width such that when a force is applied that is greater than bond strength, tape  10  separates along interface  40 . In a more specific embodiment, Applicant has found that the cure rate and/or anti-adhesion material ensures that the bond strength between layers  12  and  14  at interface  40  is between 0.1 oz. per inch and 2 oz. per inch of tape width such that when a force is applied that is greater than bond strength, tape  10  separates along interface  40 . 
     In particular embodiments discussed herein, bond strength is measured using the test method defined by PSTC-101 modified, 180 degree peel adhesion at 12 inches/minute peel speed, to measure the bond strength between layer  12  and layer  14 . This test procedure measures the force required to separate layer  12  from layer  14 . Applicant has determined that in a specific embodiment, the bond strength (e.g., peel force) between layer  12  and layer  14  is found to be between 0.3 oz per inch and 1.12 oz per inch of tape width. In a specific embodiment, Applicant has determined that a cure time of 1 week in combination with use of the anti-adhesion promotor, results in formation of a tape having the bond strength between layer  12  and layer  14  of between 0.3 oz per inch and 1.12 oz per inch of tape width. 
     Applicant has tested the bond strength at interface  40  at various times during the curing process to determine the length of cure time that results in various desirable bond strengths. Applicant&#39;s tests have correlated the cure time with bond strength at interface  40  as follows: 24 hours results in 5.6-6.4 oz/in of bond strength, 48 hours results in 1.28-2.24 oz/in of bond strength, 120 hours results in 0.96-1.12 oz/in of bond strength, 144 hours results in 0.80-0.96 oz/in of bond strength, 168 hours results in 0.48-0.96 oz/in of bond strength, 192 hours results in 0.48-0.96 oz/in of bond strength and 90 days results in 0.48-0.96 oz/in of bond strength. Thus, Applicant has found that cure rate and cure time correlates to the bond strength at interface  40 , and if the bond strength is too high due to a cure rate that is too high (e.g., because of heating too quickly, drying too quickly, use of too much crosslinker, use of too little anti-adhesive promotor, etc.), layer  14  will not split properly from layer  12 . Further Applicant has found that if cure rate is too high, the cure time based reduction in bond strength is not achieved, and layer  14  essentially will be permanently adhered to layer  12 . In specific embodiments, curing occurs at room temperature and in other embodiments curing occurs at an elevated temperature (e.g., a temperature between 150 and 220 degrees F. for between 5 and 10 minutes) which then may be followed by room temperature curing for the times set forth above. 
     Applicant has discovered that the use of anti-adhesion additive  42  in combination with a liquid-applied, cross-linked polymer layer  14  further allows for control of bonding at interface  40 . In specific embodiments, anti-adhesion material  42  is evenly distributed throughout the material of layer  14  when in liquid form for application. As shown in  FIG. 3 , layer  14  includes anti-adhesion additive  42  adjacent to interface  40  (e.g., within a depth of 50 microns from interface  40 ) which allows additive  42  to influence or decrease bonding between layers  12  and  14  at interface  40 . Without being bound by theory, Applicant believes that some of the anti-adhesion additive  42  migrates toward the surface of layer  14  during the cure process and effects (e.g., decreases) the bond strength to layer  12 . Without the anti-adhesion material  42 , Applicant has found that layer  14  bonds permanently to layer  12 . Similarly, if layer  14  is cured too fast, layer  14  bonds permanently to layer  12 . Applicant has found that if layer  14  is cured too fast, the polyurethane structure and bond strength to layer  12  is not affected by the anti-adhesion material  42 . Based on this finding, if layer  14  is cured too fast, Applicant hypothesizes that the anti-adhesion material  42  becomes trapped within the material of layer  14  preventing the anti-adhesion material from decreasing the bond strength at interface  40 . Thus, Applicant hypothesizes that under proper cure rate as discussed above, the anti-adhesion material  42  is permitted to move toward interface  40  changing the surface tension of layer  14  and effectively reducing the bond strength to levels discussed above, which allow tape  10  to function in the splice application. 
     In addition, Applicant believes that by utilizing additive  42  dispersed within the liquid applied material, additive  42  is permitted to influence bond strength relatively slowly during and after curing such that additive  42  decreases the amount of bonding at interface  40  over time. This time-based bond differential may be advantageous, providing a stronger bond at interface  40  during tape manufacturing, but then a weaker bond at a later time when tape  10  is used for splicing. In specific embodiments, the liquid material that forms layer  14  includes a relatively low concentration of additive  42 , such as between 1% and 10% of additive  42 . In a specific embodiment, the liquid material that forms layer  14  includes between 1% and 10% Additol EX  6568 . In some embodiments, these percentages are weight percentages and/or volume percentages. As noted above, additive  42  remains in layer  14  following curing, and thus, cured layer  14  of tape  10  includes between 1% and 10% of additive  42 . 
     In addition to the material type, liquid application and degree of cure/crosslinking, layer  14  includes a variety of other properties that Applicant believes contributes to the high degree of bond control discussed herein. In various embodiments, layer  14  is formed from a material that is impermeable to the material of adhesive layer  18 . This impermeability limits/prevents the material of adhesive layer  18  from penetrating through layer  14 . Applicant believes that without layer  14  acting as an impermeable barrier, the material of adhesive layer  18  may influence the degree of bond strength at interface  40 . 
     In addition, the material of layer  14  is such that the surface  26  of layer  14  is non-tacky/non-adhesive. In such embodiments, this ensures that surface  26  of layer  14  does not adhere to various materials, machinery, etc. of the roll manufacturing process following splitting at interface  40 . In various embodiments, to ensure that surface  26  remains non-tacky following separation, the material of layer  14  remains impermeable to the adhesive material of layer  18  at high temperatures that tape  10  may be exposed to during roll manufacturing processes following splicing. In such embodiments, the material of layer  14  remains impermeable to the adhesive material of layer  18  at temperatures greater than 400 degrees F., more specifically at temperatures greater than 550 degrees F. In specific embodiments, the material of layer  14  remains impermeable to the adhesive material of layer  18  at temperatures between 50 degrees F. and 550 degrees F. given exposure times between 0.5 seconds to 300 seconds. 
     In various embodiments, the thickness of layer  14  also provides the barrier between surface  26  and adhesive material  18 . In various embodiments, layer  14  has an average thickness between 0.25 mils and 15 mils, specifically between 1.0 mil and 8 mils. In specific embodiments, these thicknesses are the dry thicknesses of layer  14  following curing and crosslinking. 
     In specific embodiments, layer  14  is formed from a material that does not degrade at high temperatures or when exposed to various solvents. In specific embodiments, layer  14  does not degrade when exposed to temperatures between 50 degrees F. and 550 degrees F. given exposure times between 0.5 seconds to 300 seconds. Applicant has found that the cross-linked polyurethane material discussed herein is one example of a material that provides resistance to heat and/or solvent based degradation. 
     As noted above, in various embodiments, tape  10  generally, and layer  14  specifically, is formed via a process that provides the precise bonding level at interface  40  as discussed. Referring to  FIG. 4 , a process  50  for forming a splittable splice tape, such as tape  10 , is shown according to an exemplary embodiment. At step  52 , a sheet, film or web of support material is provided, and this material is used to form a first internal support layer, such as layer  12 , discussed above. 
     At step  54 , a liquid material is applied onto one of the major surfaces (e.g., an inner major surface, such as surface  22  discussed above), and the liquid material includes a polymer material supported in a carrier fluid. In an embodiment, the polymer material is a polyurethane material and the carrier fluid is a solvent, and specifically is buytl acetate. In an alternative embodiment, the polymer material is a polyurethane material and the carrier fluid is water. 
     At step  56 , a second internal support layer, such as layer  14  discussed above, is formed from the liquid polymer containing liquid. In a specific embodiment, the solid second internal support layer is formed by a curing and crosslinking process that causes the polymer material of the applied liquid to form crosslinks with each other and that removes the carrier liquid. The formation of the second internal support layer via curing and cross-linking also creates the separable bond along the interface (e.g., interface  40 ) between the two internal support layers. 
     In specific embodiments, the curing and crosslink process is a heating process. Heat is applied to the liquid coated first support layer, and the heat causes crosslinking of the polymer material of the liquid and also causes evaporation of the carrier liquid resulting in the formation of the second internal support layer. In specific embodiments, the heating and curing rate has been determined to relate to the bond strength formed at interface  40 . In specific embodiments, the liquid coated first support layer is heated to a temperature between 150 and 220 degrees F. for between 5 and 10 minutes, which Applicant has found forms the desired level of bonding at interface  40 . As discussed above, the applied liquid material may include anti-adhesion material  42  to further control the level of bonding that occurs at interface  40 . In addition, the liquid material may include a catalyst material that facilitates crosslink formation, as discussed above. 
     At step  58 , adhesive material is applied to the outer major surfaces of both of the support layers such that outer adhesive layers, such as layers  16  and  18 , are formed. In specific embodiments, the adhesive material is a liquid (e.g., aqueous) adhesive material, and in such embodiments, the material of layer  12  acts as an impermeable barrier to the material of layer  16 , and the material of layer  14  acts as an impermeable barrier to the material of layer  18 . As noted above, this impermeability ensures that the bond strength at interface  40  is controlled by preventing alteration of the bond at interface  40  by presence of the adhesive materials of layers  16  and  18 . In addition, the impermeability ensures that the adhesive material of layers  16  and  18  does not migrate through layers  12  and  14 , respectively, which may otherwise cause the surfaces of layers  16  and  18  at interface  40  (which are exposed during splicing) to be tacky. Lastly, in some embodiments, a release lining material, such as layer  28 , is applied to the outer surface of one or both of the exposed outer surfaces of adhesive layers  16  and  18 . 
     Referring to  FIGS. 5A-5D , use of splittable splice tape  10  for splicing together two rolls of material is shown, according to an exemplary embodiment. An incoming or new roll  60  of web/sheet material is provided which will be spliced to a similar roll  62  of web/sheet material (see  FIG. 5C ) that is currently being paid off and processed through a manufacturing process  64  (e.g., a printing process). As shown in  FIG. 5C , the sheet material of rolls  60  and  62  will be spooled on an uptake reel  66  following completion of the manufacturing process  64 . In general, process  64  may be any of a wide variety of roll-based manufacturing processes in which splicing in of new rolls of material without interruption is desirable. In various embodiments, process  64  may be a variety of printing or coating processes, and the materials of rolls  60  and  62  may be any of a wide variety of paper, film, foil, web, etc. materials utilized in such processes. 
     Referring back to  FIG. 5A , roll  60  includes a leading edge  68  and an exposed, outer surface  70  which is the outer surface of the second layer of rolled material following leading edge  68 . To begin the splicing process using tape  10 , the outer surface of adhesive layer  18  is adhered to outer surface  70  such that tape  10  is held in place on roll  60 . A portion of release liner  28  is also removed exposing a portion of the outer surface of adhesive layer  16  that is facing the leading edge  68  of roll  60 . 
     As shown in  FIG. 5B , the portion of roll  60  adjacent leading edge  68  is pulled over and adhered to the exposed portion of adhesive layer  16 . In this arrangement, leading edge  68  is adjacent to the remaining portion of release liner  28 . In the arrangement shown in  FIG. 5B , roll  60  is ready for splicing onto the existing roll  62 . In particular, the portion of roll  60  adjacent leading edge  68  is completely sealed onto adhesive layer  16  such that air is not permitted to move between leading edge  68  and adhesive  16 . This tight sealing improves splice integrity by preventing air from moving between the material of roll  60  and adhesive  16  as roll  60  is unspooled into process  64 . Because some processes move at high rates of speed (e.g., up to 3000 feet per minute or more for some processes) air, if permitted to flow between the material of roll  60  and adhesive  16 , may separate the material of roll  60  from adhesive  16 , which will cause the splice to fail. 
     Splicing of existing roll  62  to new, incoming roll  60  is shown in  FIGS. 5C and 5D . As shown in  FIG. 5C , the remaining portion of release liner  28  is removed exposing the remaining portion of adhesive layer  16 . A trailing edge  72  of roll  62  is adhered to the exposed remaining portion of adhesive layer  16 . 
     As shown in  FIG. 5D , this positioning results in trailing edge  72  of roll  62  closely abutting leading edge  68  of incoming roll  60  with the splice tape  10  adhered across this abutment maintaining the relative positioning between trailing edge  72  and leading edge  68 . Thus, when the material of roll  62  runs out (i.e., is no longer being unspooled) the movement of the material of roll  62  pulls on the material of roll  60  via the splice created by splice tape  10 . As shown in  FIG. 5D , this causes tape  10  to split along interface  40  and causes leading edge  68  and material of roll  60  to be advanced through process  64  without requiring the process to be stopped. 
     Thus, as can be seen, the bond formed between layers  12  and  14  at interface must reliably separate as the material of roll  60  gets pulled into process  64  in order to keep the processing moving without interruption. Similarly, all layers  12 ,  14 ,  16  and  18  of tape  10  eventually pass through process  64 . Thus, the materials of these layers must be able to traverse the manufacturing process  64  without degradation, without sticking to machinery, without causing discoloration to the material of being processed, etc. As discussed above, in various embodiments, tape  10  is uniquely manufactured and structured to provide both controlled bond strength and separation utilizing materials that do not cause problems in process  64 . 
     It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting. 
     Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one. 
     Various embodiments of the invention relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above. 
     In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description. In addition, in various embodiments, the present disclosure extends to a variety of ranges (e.g., plus or minus 30%, 20%, or 10%) around any of the absolute or relative dimensions disclosed herein or determinable from the Figures.