Patent Publication Number: US-6981537-B2

Title: Tail for attaching the trailing edge of one roll of tape to the leading edge of another roll of tape and method of using same

Description:
RELATED APPLICATIONS 
   This application is a continuation-in-part of application Ser. No. 09/963,190 filed Sep. 25, 2001, now U.S. Pat. No. 6,596,111, issued Jul. 22, 2003. 

   BACKGROUND AND SUMMARY OF THE INVENTION 
   The subject invention relates to a tail which is used to attach the trailing edge of tape from one roll to the leading edge of tape from another roll and to a method of using this tail to join rolls of tape together. 
   There are numerous applications where a continuous supply of tape material must be provided. When this occurs there needs to be a way of attaching the trailing edge of one roll of tape to the leading edge of another roll of tape without interrupting the feeding of the tape. This can be accomplished by placing a mechanical fastening device on the tape or by adhesively joining the two tapes together. An example of the latter is the system disclosed in U.S. patent application Ser. No. 09/398,153, now U.S. Pat. No. 6,325,324. Here the trailing edge of the tape on each roll is wrapped around a plate to provide an end piece which is thicker than the remainder of the tape. The leading edge of the tape on each roll has an adhesive coating applied to it. The leading edges of both rolls are then fed into a splicer block having a pair of spaced-apart pincher rollers which are separated by a distance which is greater than the thickness of two pieces of tape, but less than the thickness of one piece of tape and the end piece. Thus, when the tape from one of the rolls is pulled through the splicer block, as the tailing end of that roll passes through the pincher rollers the end piece is squeezed against the adhesive at the leading edge of the tape from the other roll, and the two pieces of tape are joined. While simple and inexpensive, this system does not always cause the two pieces of tape to be joined. Because the adhesive is exposed during the entire time the preceding roll of tape is being unwound, it can collect dust and other contaminants and become less adherent. In addition, in order for the adhesive to even be squeezed against the end piece it must be located precisely between the pincher rollers. If the operator does not do this correctly or if the moving tape drags the non-moving tape out of the pincher rollers the rolls will not be joined. In addition, the second roll can only be installed on the device which rotatively carries it in one direction in order that the adhesive side of the tape is facing the moving tape. If adhesive is put on both sides of the tape to make it reversible, the adhesive on the other side may very well stick to the pincher rollers enough that the short period of time the adhesive is exposed to the moving tape may not be enough to release it. 
   The subject invention overcomes the shortcomings and limitations of the prior art by providing a bulge in a tail that is attached to the trailing edge of the tape on each roll. This bulge has an adhesive coating on both sides. Protective elements are located on the tail on each side of the bulge in a manner that one of the protective elements covers the adhesive coating on each side of the bulge. As a result, when the tail is rolled onto a roll core the adhesive coating is protected by the protective element and will not stick to the roll core or to adjacent layers of the tail or tape. The protective element is configured such that it readily parts from the adhesive coating when the tail is unwound from the roll core. 
   In addition the leading edge of the tape from the second roll is wrapped around the tape from the first roll to form a loose knot. When the leading edge of the tape from the second roll is adhered to the adhesive on the bulge on the tail on the trailing edge of the second roll the knot is tightened so that the second roll becomes tied to the first roll as well. 
   In another embodiment the frame defines a pathway along which the tape travels. A pair of arms are rotatably attached to the frame, one on each side of the pathway. The extremities of the arms have outwardly projecting posts. The arms are movable between a first position where the posts are closer to the pathway and a second position where the posts are further from the pathway. The arms are normally biased to the second position. A catch mechanism holds the arms in the first position and can be released by a release mechanism to allow the arms to rotate back to the first position. The release mechanism releases the catches when a portion of the tape having a release indicia passes through the pathway. In operation, tape from a first roll is fed through the device. The leading edge of tape from a second roll is tied to the post on one of the arms, is looped around the first tape and passed back through the loop to form a loose knot around the first tape and then is tied to the post on the other arm. When the identifying indicia in the tail of the first tape passes through the pathway it causes the release mechanism to release the catch mechanism. The arms then rotate to the second position which tightens the loose knot in the second tape tightly onto the first tape. Continued movement of the first tape causes the knots in the second tape to pull off of the posts and the second tape is attached to the first tape. 
   The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded view showing a tail embodying the subject invention. 
       FIG. 2  is an exploded view showing how the tail of  FIG. 1  is wound onto a roll core. 
       FIG. 3  is a side elevation view of a splicer mechanism showing how the trailing edge of a first piece of tape is spliced to the leading edge of a second piece of tape. 
       FIG. 4  is a perspective view of another splicer mechanism embodying the subject invention. 
       FIG. 5  is a front elevational view of the splicer mechanism of  FIG. 4 . 
       FIG. 6  is a rear view of the splicer mechanism of  FIG. 4 . 
       FIGS. 7 and 8  are front views of the splicer mechanism of  FIG. 4  showing a sequence of operation. 
       FIG. 9  is a front view of another embodiment of the invention. 
       FIG. 10  is a front view of yet another embodiment of the invention. 
       FIG. 11  is a detailed view showing how a bulge is placed in the tape. 
   

   DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
   Referring to  FIG. 1  of the drawings, a transfer tail  10  is attached to the trailing edge of a length of tape or tape-like material  12  which is wound onto a cylindrical roll core  14  to form a roll of tape (not shown). The purpose of the transfer tail is to automatically attach the trailing edge of the tape as it is removed from the roll to the leading edge of the tape from another roll without stopping the supply of tape to its intended application. 
   The tail  10  includes a tail base  16  which is made from the same or a similar material as the tape  12 . The tail base preferably is 4–5 feet long, but its length is not limited. It does need to have a thickness which is similar to the thickness of the tape  12 . Located on the tail base  16  near its trailing edge is a bulge  18  having a thickness which is greater than the thickness of the tail base. The bulge has an inside face  20  and an outside face  22 , both of which have an adhesive coating. 
   In the preferred embodiment illustrated, the bulge is formed by placing a piece of double-sided tape  24 , with a the protective film removed from both sides, on the first side  26  of the tail base  16 . This provides the adhesive coating on the outside face  22  of the bulge. The length of the piece of double-sided tape  24  is important, as will be explained later. Another piece of double-sided tape  28 , which is slightly shorter than the piece of double-sided tape  24 , is placed on the second side  30  of the tail base  16  directly across from and centered over the piece of tape  24 . The protective film is removed from both sides of the piece of double-sided tape  28  also. An obstruction piece  32  is placed on top of the piece of double-sided tape  28  and the obstruction piece in turn is covered with another piece of double-sided tape  34  which has the protective film removed from both sides. The obstruction piece is thicker than the tail base  16  or the double-sided tape  24 ,  28 ,  34  and it is flexible. The obstruction piece  32  and the piece of double-sided tape  34  have the same length as a piece of double-sided tape  28 . A cover  36 , made from the same material as the tail base and having the same length as the piece of double-sided tape  24 , is then placed over the piece of double-sided tape  34 . Since the cover  36  is longer than the pieces of double-sided tape  28  and  34  and the obstruction piece  32 , it extends outwardly from each side of them. This permits the ends of the cover  36  to be attached to the tail base in order to make a smooth transition between the bulge and the remainder of the tail base. If the cover and the tail base are a heat-sealable material they can be heat sealed together. Otherwise they can be joined with an adhesive. Finally, another piece of double-sided tape  38 , having the same length as the cover  36 , is located on top of the cover. The film is removed from both sides of the piece of double-sided tape  38 . This provides the adhesive surface on the inside face  20  of the bulge. Thus, there is an exposed adhesive surface on both sides of the bulge. 
   Located on the first side  26  of the tail base  16 , towards its trailing edge from the bulge  18 , is a first protective element  40 . The protective element  40  will cover the exposed adhesive on the inside face  20  of the bulge when the tail  10  is wrapped onto the roll core. The length of the first protective element  40  is slightly greater than the length of the bulge  18 , as will be more fully explained later. In the embodiment illustrated, the first protective element includes a piece of double-sided tape  42  with the protective film removed from both sides. Another piece of protective film  44 , which is wider, is placed on top of the piece of double-sided tape  42 . 
   In the embodiment illustrated a portion of the first protective element  40   a  is placed on the leading edge side of the bulge  18  also. The protective element  40   a  includes a piece of double-sided tape  42   a  and a piece of wide protective film  44   a.  Placing a portion of the first protective element on the other side of the bulge is not required, but it may be useful for reasons that will be described later. 
   Located on the second side  30  of the tail base  16 , towards its leading edge from the bulge, is a second protective element  46 . The second protective element  46  preferably has substantially the same length as the first protective element  40 . All that is required, however, is that it be longer than the bulge. The second protective element  46  includes a piece of double-sided tape  48 , with the protective film removed from both sides. This piece of double-sided tape  48  is covered with a wider piece of protective film  50 . 
   Located on either side of the tail base  16 , at its leading edge, is a piece of double-sided tape  52 . The protective film is removed from this piece of double-sided tape when the tail  10  is joined to the trailing edge of the tape  12 . 
   Once the tail  10  is attached to the trailing end of the tape  12  the tail and tape are wound on top of itself onto a roll core  14 ,  FIG. 2 . To ensure that the unprotected segment of the adhesive coating on the bulge does not stick to the roll core, a piece of double-sided tape  54  with the protective film removed from one side only is wound around the center of the roll core. 
   As the tail  10  is wound onto the roll core  14  the first protective element  40  faces outwardly from the roll. The length of the first protective element should be equal to or slightly greater than the circumference of the roll core. Thus, the first protective element extends entirely around the roll. As the tail continues to be wound onto the roll core, the inside face  20  of the bulge will overlie the protective element  40 . Since the length of the bulge is less than the length of the first protective element the first protective element completely covers the inside face of the bulge. The protective film that is used to cover double-sided tape has a higher rate of adhesion on its inside surface than it does on its outside surface. Thus, when the tail is later unwound from the roll core the protective film will remain adhered to the protective element and will readily pull away from the adhesive layer on the bulge exposing the adhesive layer. 
   At this point the outside face  22  of the bulge faces outwardly from the roll. As the tail continues to be wound onto the roll the second protective element  46  overlies the outside face  22  of the bulge and the protective film covers the adhesive on this side of the bulge. 
   The second portion  40   a  of the first protective element is placed on the tail base  12  a spaced distance from the trailing edge of the bulge which ensures that the leading edge of the double-sided tape  24  does not extend past the end of the protective film  50 . 
   Referring now to  FIG. 3 , a splicer mechanism  55  that is used to join the tail  10  of one roll of tape to the leading edge of another roll includes a frame  56  having an entry passageway  57  located at its lower end. Located above the entry passageway  57  is a pair of spaced-apart guide rollers  58 . Located above the guide rollers is a bridge  60  with a guide orifice  62  passing centrally through it. Extending upwardly from the bridge  60  on each side of the guide orifice is a pair of pins  64  which angle toward one another. A tape-holding device, such as a spring  66 , is located above the bridge  60 , and a pair of side-by-side pincher rollers  68  are located above the spring. The distance between the pinching rollers is greater than the combined width of the tape  12  but less than twice the width of the tape and the bulge  18 . 
   The leading edge of the tape  12   a  from a first roll is fed through the passageway  57  and around one of the guide rollers  58 . It is then passed through the guide orifice  62 , between the coils of the springs  66 , and through the pincher rollers  68 . The leading edge of the tape  12   b  from a second roll is then inserted through the passageway  57 , around the other guide roller  58  and through the guide orifice  62 . The second tape  12   b  is then looped around the first tape and pins  64  and back through itself to form a loose half-hitch knot  70 . The second tape is then placed between the coils of the springs  66  and through the pincher rollers  68 . The first tape  12   a  is then pulled off of the roll by a device which applies the tape. The distance between the pinch rollers  68  allows the first tape  12   a  to run freely without effecting the stationary second tape  12   b.  The spring  66  creates a resistance against the movement of the second tape which also prevents it from moving with the first tape. 
   As the bulge  18  in the first tape passes through the pincher rollers,  FIG. 3 , the rollers pinch it against the second tape and the second tape is engaged by the adhesive surface of the bulge. Thus the second tape begins to move with the first tape  12   a.  As the second tape starts to move the loose knot  70  becomes tightened around the first tape  12   a  and a tight knot  72  is formed which mechanically attaches the leading edge of the second tape to the tail of the first tape. The first roll is then replaced with a third roll and the process is repeated. 
   In another embodiment of the invention, shown in  FIGS. 4–10 , the adhesive is eliminated altogether and tightening the loose knot in the leading edge of the tape from the second roll around the tail of the tape from the first roll is the only means of attachment. Referring to  FIG. 4 , a splicer mechanism  80  includes a frame  82 . Located at the lower edge of the frame is an entry passageway  84  and located at the upper end of the frame is an exit passageway  86 . Tape fed through the upper and lower passageways travels across the frame over a defined pathway  88 . Located near the upper end of the frame is a moveable roller  90  and a fixed roller  92 . The tape passes between these two rollers but the rollers are separated from one another by a sufficient distance that they create negligible drag on the tape and the tape causes little, if any, rotation of the rollers under normal operating conditions. The face  94  of the moveable roller  90  is flat, and the face  96  of the fixed roller  92  has a flat center  96   a  having a width which is slightly greater than the width of the face  94  of the moveable roller  90 . Located on each side of the center  96   a  are outwardly flared sections  96   b.  This shape causes the tape to remain centered between the two rollers. An idler roller  98 , which is located above the rollers  90  and  92 , pushes the tape toward the fixed roller  92  which also helps keep the tape centered. 
   Rotatably mounted at the bottom of the frame  82 , on the same side as the pathway  88 , are a pair of arms  100 . Posts  102  extend outwardly from the extremities of the arms. The arms are moveable between a first position,  FIG. 5 , and a second position,  FIG. 7 . In the first position the arms are generally vertical and the posts are generally aligned with the tape with one post being on each side of the pathway. In the second position the arms are angled away from the tape and the posts are moved further from the pathway. The arms are mounted on one end of shafts which extend rotatably through the frame. The other end of the shafts are attached to levers  106 . Thus, each lever  106  rotates with its associated arm  100 . The levers are mounted on the shafts such that they are generally horizontal when the arms are generally vertical. When in this position the inner ends  108  of the levers are located close to the center of the frame, and the outer ends  110  of the levers are located outwardly from the sides of the frame. 
   A spring  112  extends between the top of the frame and the inner ends  108  of the levers and causes the levers to normally be oriented such that the arms are in the second position. The spring is connected to the inner ends of the levers by a cable  109  which extends from one lever through a pulley  111  which is attached to the spring to the other lever. Thus, each arm can move independently of the other arm. 
   Located on the outer ends  110  of the levers  106  are cylindrical bearings  114  which can be rotated. Rotatably attached to each side of the frame is a catch  116 . The catches rotate between latched positions,  FIGS. 4–6 , and unlatched positions,  FIGS. 7 and 8 . In the latched positions the catches engage the bearings  114  when the arms are in their first position and prevent rotation of the levers, and thus the arms. When the catches are moved to their unlatched positions, the levers are released and the spring  112  moves the arms to the second position. 
   The catches are moved from their latched to unlatched positions by means, of a release mechanism  118 . A bar  120  is rotatably mounted to the back side of the frame intermediate its ends. One end of the bar  118  carries the movable roller  90  and the other end is attached to an activation arm  122 . When the movable roller is moved away from the fixed roller  92  the bar  112  is rotated and the extremity of the activation arm is raised. The extremity of the activation arm is connected to the catches through a linkage  124  such that when the extremity of the activation arm is raised the catches are moved out of their latched positions and the levers are released. 
   The tape used with the splicer mechanism  80  has a bulge  126  located in its tail,  FIG. 11 . In use, with the arms  100  latched in the first position by the catches  116 , the leading edge of tape  124  from a first roll of tape is inserted through the entry passageway  84  and out of the exit passageway  86  and is inserted into a machine which applies the tape. The leading edge of tape  128  from a second roll of tape is inserted through the entry passageway  84 . The leading edge of the tape  128  is then looped around one of the posts  102  and passed back through the loop and is pulled snug to provide a slip knot  130  on this post. The tape  128  is then looped around the tape  124  and is inserted back through the loop to form a loose knot  132  around the tape  124 . The tape is then looped around the other post  102  and is inserted back through the loop and is pulled snug to form a slip knot  134  on that post. Other types of loose knots could be formed around posts  102  and the tape  128  and the tape  124  could be releasably affixed to the post by other means. 
   When the bulge  126  in the trailing edge of the tape  124  passes between the rollers  90  and  92 , the movable roller  90  is moved sideways which acts as a trigger and causes the bar  120  to rotate and raise the activation arm  122  to release the catches  116  from the bearings  114  on the levers  106 . The spring  112  then causes the arms  100  to rotate and the arms pull the slip knots  130  and  134  away from the tape  124  to tighten the loose knot  132  onto the tape  124 ,  FIG. 7 . The tape  128  then moves with the tape  124 ,  FIG. 8 , and the slip knots  130  and  134  are pulled off of the posts  102  and the tape  124  is joined to the tape  128 . 
   If one of the slip knots pulls free of its post before the other, which will almost always occur, the associated arm will have less resistance to being pulled towards the second position by the spring  112 . The pulley  111  then allows this arm to move toward the first position quicker which slows down the movement of the other arm until the slip knot on it can pull free. 
   Referring now to  FIG. 9 , instead of mechanically linking the trigger element to the release mechanism, movement of the movable roller causes it to activate a proximity switch  136  which in turn causes a pair of solenoids  138  to release the catches  116 . Alternatively, a load cell (not shown), measures the tension in the tape and when the tension is momentarily increased due to the bulge passing between the rollers  90 ,  92 , the solenoids are activated by the load cell to release the catches. 
   In another alternative embodiment, shown in  FIG. 10 , rather than a bulge a patch  140 , which is optically distinct from the tape, is placed in the tail of the tape. The patch  140  can be clear, reflective, or just another color than the color of the tape. A photo cell  142 , located alongside the pathway  88 , detects when the patch passes by it and then activates the solenoids  138 . 
   The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.