Method and apparatus for forming raised profile adhesive strips

Abstract

A method and apparatus for forming a raised profile in an attached, turn-up raised profile tape for paper processing. In some embodiments, the raised profile tape can be a combination of a tape substrate coated with a web-acquiring adhesive on one side and an attachment adhesive on the other side, and a release liner substrate fully coated with a release layer on one side and zone coated with a release layer on the second side. In some embodiments, the raised profile can be formed during application of the raised profile tape using specialized equipment.

Description

[Technical Field]

[0001] This invention relates generally to a method and apparatus for forming an adhesive strip having a raised profile, and more particularly to forming a raised profile turn-up tape for high speed cutting and transfer of a rapidly advancing paper web from a rotating full web spool to an empty web spool. [Background technology]

[0002] This application claims priority to non-provisional patent application Ser. No. 18 / 311,420, entitled "Method and Apparatus for Forming Raised Profile Adhesive Strips," filed May 3, 2023, which claims the benefit of provisional patent application Ser. No. 63 / 480,424, entitled "Method and Apparatus for Forming Raised Profile Adhesive Substrates," filed January 18, 2023, the entire contents of each of which are incorporated herein by reference.

[0003] Flat adhesive tapes are known products that have proven useful in a variety of applications. The adhesives and substrates used in flat adhesive tapes have varied widely to suit specific applications. One application of flat adhesive tapes is the turn-up process of a paper machine, which uses a flat paper band constructed with properties that adhere to an empty paper spool and help transfer the paper web from a full spool to an empty spool.

[0004] Modern paper manufacturing typically involves producing continuous webs, sometimes exceeding 400 inches in width, called paper webs, which are wound onto web spools for subsequent processing, storage, transfer, etc. The winding or spooling of paper webs, such as tissue grades, occurs at high speeds, sometimes exceeding 6,000 feet per minute. To minimize downtime and waste and maximize productivity, it is desirable to simultaneously cut and transfer the moving paper web from a full-web spool to an empty-web spool without stopping, adjusting the draw (i.e., the speed differential between the incoming and outgoing web rotating support members that are not driven by a common drive source), or slowing the web motion. If a gap exists between the empty spool and the surface of the paper web, the gap must be overcome to perform the paper web turn-up process.

[0005] Other uses for flat tape include fastening items to surfaces and / or fastening two different surfaces together. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 2,461,246 [Patent Document 2] U.S. Patent No. 4,659,029 [Patent Document 3] U.S. Patent No. 4,757,950 [Patent Document 4] U.S. Patent No. 4,783,018 [Patent Document 5] U.S. Patent No. 5,046,675 [Patent Document 6] U.S. Patent No. 5,417,383 [Patent Document 7] U.S. Patent No. 5,453,141 [Patent Document 8] U.S. Patent No. 5,637,170 [Patent Document 9] U.S. Patent No. 5,954,290 [Patent Document 10] U.S. Patent No. 6,467,719 [Patent Document 11] U.S. Patent No. 6,578,788 [Patent Document 12] U.S. Patent No. 7,875,152 [Patent Document 13] U.S. Patent No. 8,124,209 [Patent Document 14] U.S. Patent No. 8,178,181 [Patent Document 15] U.S. Patent No. 8,580,062 Summary of the Invention

[0007] Thus, the present invention provides an apparatus and method for generating three-dimensional profiles on a two-dimensional substrate, such as a tape having adhesive on one or both sides. The three-dimensional profiles may include, for example, peaks or domes, or other apex-forming shapes.

[0008] In one general aspect, the method can include winding a substrate in a dispenser and positioning the substrate parallel to a receiving surface using a roller. The substrate can be fed in a plane parallel to the receiving surface. The substrate can be shaped with a forming profile along a longitudinal axis to form a three-dimensional substrate that can be applied to the receiving surface.

[0009] In an embodiment, the method may further include moving the substrate along a gradual gradient of the ternary change included in the forming profile, and forming the substrate using the wheel and the forming profile.

[0010] In some embodiments, at least a portion of the substrate may be protected from airborne contaminants with a cover, which may include paper particles.

[0011] The method of the present invention may further include varying the length of the forming profile surface by extending the retractable wand. The paper web may contact the peaks having the three-dimensional substrate molded in the forming profile, and in some embodiments, the peaks may be compressed as the empty spool approaches the paper web.

[0012] In another embodiment, the distance between the dispenser and the receiving surface can be maintained by one or more wheels disposed on the dispenser, and the distance and angle of the wand relative to the receiving surface can be maintained by one or more wheels on the distal end of the wand.

[0013] In some embodiments, a portion of the flat adhesive strip can be raised and used as a raised profile tape in the turn-up process of a paper machine. By raising a portion of the adhesive strip that can be used as a turn-up raised profile tape, the raised portion increases the profile height of the raised profile tape, which can be used to fill open nips, without increasing the overall thickness of the tape. Benefits also come from the forces generated when manipulating the shape of the raised profile of the raised portion of the flat adhesive strip, and this energy helps enhance web severing. Furthermore, the raised portion of the raised profile tape can be made to deform during use and conform to the height of any gaps that occur.

[0014] In some embodiments, a portion of the raised profile tape may be raised by the apparatus and methods described herein, resulting in a raised profile adhesive strip having an underlying volume filled with atmospheric gas. In additional embodiments, some or all of the underlying volume may include a continuous object, such as, by way of non-limiting example, one or more of a cable, a wire, or a filament. Embodiments may also include multiple different items disposed within the underlying volume, such as, by way of non-limiting example, beads, electronic devices, electromechanical devices, sensors, transceivers, and various shapes of pulpable fiber products. The items within the underlying volume included in the raised profile tape structure may provide increased support, texture, and rigidity to the raised profile tape. In some preferred embodiments, the raised profile tape structure is constructed from a material suitable for repulping and inclusion in paper products. This suitability for repulping may significantly reduce waste in paper processing.

[0015] In some embodiments, the present invention may include a method having processing steps including one or more of the following: holding a coil of two-dimensional substrate having an adhesive layer in a dispenser; feeding the substrate into dimensional forming features; reshaping the substrate based on the shape of the dimensional forming features to form a substrate having a three-dimensional profile; and adhering the substrate having the three-dimensional profile to a receiving surface of an empty web spool.

[0016] Embodiments may include one or more of the following additional processing steps: rotating the empty web spool and the substrate having a three-dimensional profile, adhering the adhesive layer to the paper web of the full web spool, cutting the paper web, and continuing to rotate the empty web spool and the substrate having the three-dimensional profile to form a roll of paper web on the empty web spool.

[0017] The method may further include one or more of the following steps: attaching a distal end of the substrate having the three-dimensional profile to a second position of the empty web spool; protecting at least a portion of the adhesive layer from airborne contaminants with a cover of the dispenser, wherein the airborne contaminants include paper particles; forming a peak comprising the substrate and the adhesive layer by placing a rod under the adhesive layer; contacting the paper web with the peak comprising the substrate and the adhesive layer; compressing the peak comprising the substrate and the adhesive layer as the empty web spool approaches the paper web; and, following collapse of the peak comprising the pulpable substrate and the adhesive layer, contacting and bonding a further surface area of ​​the adhesive layer to the paper web.

[0018] Some embodiments may further include one or more of the steps of crushing the peaks. The substrate may include one or more materials suitable for being repulped and included in a paper product. The substrate may be adhered to the paper web by the adhesive layer. The adhesive layer may include a pressure-sensitive coating.

[0019] In some embodiments, the three-dimensional profiled substrate may include a plurality of kiss cuts, which may be located across one or both sides of the width of the three-dimensional profiled substrate. The release layer may include a portion of its surface treated with a reduced adhesive strength substance, which may include a silicone-based formulation. Further, the three-dimensional profiled substrate may include a carrier paper having a repeating pattern of stripes of a release coating.

[0020] Methods and apparatus for cutting and transferring utilizing what is called transfer tape or turn-up tape have been described. An early example of such a system is shown in U.S. Patent No. 6,229,623 to Weyenberg. Other examples are shown in U.S. Patent Nos. 6,229,623, 6,229,623, 6,229,623, 6,229,623, 6,229,623, 6,229,623, 6,229,623, and 6,229,623. Further examples and detailed descriptions of related equipment, systems, and methods can be found in U.S. Patent Nos. 6,229,623, ... [Brief explanation of the drawings]

[0021] Referring to the drawings, which are provided for purposes of explanation and illustration and not to limit the scope of the invention, the present invention in a broad and general sense comprises, in various embodiments, an apparatus and method for dispensing a multi-layer adhesive tape having a raised profile tape, such as a tape useful in paper web turn-up operations.

[0022] [Figure 1] FIG. 1 shows a paper processing system with an empty web spool set up for paper web transfer. [Figure 1A] FIG. 1A shows a close-up view of an exemplary raised profile turn-up tape structure for a turn-up. [Figure 2] FIG. 2 shows a paper handling system with a raised profile turn-up tape structure approaching the nip. [Figure 2A] FIG. 2A shows a close-up view of an exemplary raised profile turn-up tape structure as it approaches the nip. [Figure 3] FIG. 3 shows a paper handling system with a raised profile turn-up tape structure compressed between an empty web spool and a reel drum. [Figure 3A] FIG. 3A shows a close-up view of an exemplary cover flap transfer paper structure in a compressed state. [Figure 4] FIG. 4 shows a paper handling system in which a raised profile turn-up tape structure adheres to an advancing paper web. [Figure 4A] FIG. 4A shows an exploded view of a raised profile turn-up tape structure adhered to an advancing paper web. [Figure 5] FIG. 5 shows a paper processing system in which a turn-up has occurred. [Figure 5A] FIG. 5A shows an exploded view of an exemplary paper processing system in which turn-up has occurred. [Figure 5B] FIG. 5B shows an exemplary longitudinal centerline of the free span. [Figure 6] FIG. 6 shows a schematic diagram of a substrate with vertices formed thereon. [Figure 7] FIG. 7 is a schematic diagram showing a state in which the substrate is stored in a reel shape. [Figure 8] FIG. 8 shows a schematic diagram of the substrate and forming wand. [Figure 9] FIG. 9 shows a schematic diagram of a guide in a set position relative to a three-dimensional formed feature. [Figure 10] FIG. 10 shows a schematic diagram of the forming features and rollers. [Figure 11] FIG. 11 shows a schematic diagram of a cover flap protecting the raised profile. [Figure 12] FIG. 12 shows the cover flap raised profile tape with the cavity structure formed therein with the cover flap in an open position. [Figure 12A] FIG. 12A shows the cover flap raised profile tape with the cavity structure formed therein with the cover flap in an open position. [Figure 13] FIG. 13 shows an example of a raised profile tape with cavities formed on the rod. [Figure 14] FIG. 14 illustrates exemplary method steps that may be performed in some embodiments of the present invention. [Figure 15] FIG. 15 shows an exemplary profile of an adhesive substrate. [Figure 16]FIG. 16 shows an exemplary raised profile tape with an item secured underneath the tape. [Figure 17] FIG. 17 illustrates method steps that may be performed in some exemplary embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0023] The present invention provides an apparatus and method for forming a raised profile tape from a two-dimensional adhesive substrate. Some raised profile tapes can include adhesive on one or both sides. A forming structure having three-dimensional forming features can progressively transform a two-dimensional substrate into a substrate having a three-dimensional profile. In some embodiments, the taper rate and corresponding length of a forming structure, such as a wand, are designed to impart a controlled amount of stress to the formed substrate. In some embodiments, the taper rate and corresponding length of the wand are user-controllable via the telescoping wand, allowing the user to adjust the progressive rate at which the two-dimensional substrate is transformed into a substrate having a three-dimensional profile. The wand can include forming features, the length of which includes a gradual slope of the forming features, resulting in a minimum amount of forming at the proximal end of the wand and a maximum amount of forming at the distal end.

[0024] An embodiment includes a double-sided adhesive tape with a raised profile that can be useful for cutting and transferring a paper web. The raised profile tape includes a substrate with a first adhesive surface and a spool attachment surface, preferably including a pressure-sensitive adhesive, and can be adapted to contact and adhere to the longitudinal cylindrical surface of an empty web spool. The opposite, web side (or web capture side) of the raised profile tape substrate has a second adhesive surface adapted to contact and adhere to the moving paper web when the rotating empty web spool contacts the paper web. Once the paper web is attached to the empty web spool via the raised profile tape, the web can be cut from the full web spool, and a new tip formed at the cut line created by the raised profile tape can be attached to the rotating empty web spool, completing the transfer.

[0025] Some embodiments of the present invention include a raised profile tape having a cover flap extending over the web-side adhesive on the raised profile tape substrate. The cover flap is adhered longitudinally along one edge of the raised profile tape, and the cover flap is provided with a release coating, such as a silicone layer, with the majority of the cover flap facing the adhesive. This configuration allows the cover flap to remain closed, protecting the web-side adhesive from contaminants such as dust and debris, until the empty web spool rotates to a speed that matches the speed of the web. As the empty web spool rotates, aerodynamic effects peel the cover flap apart, pulling the release-coated portion of the flap away from the adhesive. The cover flap opens at its leading edge, the end of the raised profile tape that first encounters the airflow generated by the rotation of the empty web spool. Because the cover flap lacks a silicone release layer in that narrow area, it remains adhered to the web-side adhesive at the trailing edge of the raised profile tape. The raised profile tape now has its protective cover flap peeled away to expose fresh, uncontaminated adhesive that can be adhered to a target paper web, cut, and transferred to an empty web spool.

[0026] In some embodiments, the effectiveness of the transfer process may be limited because the interaction between the paper tape and the paper web may not be optimal. It may be advantageous to elevate at least a portion of the adhesive-coated portion of the paper tape above the web spool.

[0027] Lifting a portion of the attached raised profile tape may increase the profile of the raised profile tape sufficiently to fill the open nip, and may also have the advantage of enhancing the severance of the contacted web by concentrating the forces required for three-dimensional profile fracture.

[0028] Embodiments of the present disclosure may include a method for performing a turn-up process on a paper machine, the process including attaching a proximal end of a raised profile tape composite to a first position on an empty web spool, the raised profile tape composite including a folded adhesive layer, a release coating layer, and a pulpable substrate having a raised profile portion that forms a peak with the pulpable substrate and the adhesive layer. The raised profile includes the pulpable substrate and the adhesive layer and fills a gap between the empty web spool and a surface of a paper web rotating on the full web spool. Embodiments may also include adhering the adhesive layer to the paper web. Embodiments may also include continuing to rotate the empty web spool and the raised profile tape composite until the paper web is severed due to separation of fibers contained in the paper web.

[0029] In some embodiments, the method may further include, after adhering the adhesive layer to the paper web and cutting the paper web, continuing to rotate the empty web spool and the raised profile tape composite to form a roll of paper web on the empty web spool. In some embodiments, the method may further include attaching a distal end of the raised profile tape composite to a second location on the empty web spool.

[0030] In some embodiments, the method may further include protecting at least a portion of the adhesive layer from airborne contaminants with a folded adhesive layer, a release coating layer, and a pulpable substrate, hi some embodiments, the airborne contaminants may include paper particles.

[0031] Glossary

[0032] Composite: As used herein, composite means an item that is constructed from separate parts or elements.

[0033] Empty Spool: As used herein, an empty web spool (sometimes called an empty reel, new spool, reel spool, web spool, or empty spool) refers to a spool with substantially no paper web present on its spool surface. The spool surface is suitable for wrapping and removably attaching a paper band composite. The spool surface of an empty spool is typically used to adhere transfer tape and to receive the transferred paper web accumulated on a full spool.

[0034] Full Spool: As used herein, a full spool (sometimes called a full web roll or full roll) refers to a web spool that is nearly at its capacity to hold a paper web.

[0035] Nip: As used herein, nip refers to the area where a paper web or sheet is pressed between two rolls / spools.

[0036] Turn-up Tape Composite: As used herein, refers to a paper band having a first side and a second side, the first side having at least one layer of adhesive thereon. A turn-up tape composite may include multiple distinct elements or components.

[0037] Paper Web: As used herein, refers to the continuous body of newly formed paper that has been processed on a paper machine and wound up.

[0038] Raised Profile Tape Composite: as used herein refers to at least one layer of structural material, such as paper fiber, and at least one layer of adhesive material, forming a turn-up tape having a profile that includes raised portions.

[0039] Reel Drum: As used herein, a reel drum refers to a spool used to drive the movement of a paper web; in some embodiments, the reel drum may impart rotational motion to a web spool that receives the paper web in a winding action.

[0040] Transfer Tape: As used herein, transfer tape (sometimes called turn-up tape or paper band) refers to a substrate adapted to span the entire longitudinal cylindrical surface of one or both of an empty spool and a loaded web spool. Transfer tapes can include multiple layers.

[0041] Turn-up: As used herein, turn-up refers to the process of switching a paper web from being wound onto a nearly full spool to being wound onto an empty spool. The turn-up process can include cutting the paper web from a rotating parent web roll that is approaching paper-holding capacity, transferring the paper web to the empty spool, and securing the paper web to the empty spool.

[0042] Web Spool: As used herein, web spool refers to a metal roll onto which a web, such as, for example, a paper web, is wound during a winding operation. Web spools are also referred to as reel spools. Web spools can include empty spools, full spools, and / or parent rolls.

[0043] The present invention provides an improved method for severing and transferring a continuous paper web from one spool to another, utilizing a raised profile tape composite, which may be particularly useful in transferring lightweight paper, such as tissue or newsprint, to an empty web spool. The raised profile tape composite is applied to an empty web spool in a closed position, temporarily adhering the raised profile to a portion of its surface, and then opens due to both aerodynamic and centrifugal forces while the attached spool increases in speed. In the present application's example, a structure is created such that, as the raised profile opens, it releases the adhesive from the surface of the spool, opening the adhesive layer. The adhesive layer may be raised to interact with the paper web.

[0044] The present invention provides a method and apparatus for creating and applying a raised profile transfer tape to an empty spool to transfer a paper web from a full spool to an empty spool during operation without altering or stopping the flow of the paper web. It is understood that the disclosure of the apparatus and methods relating to paper web turn-up operations is an exemplary disclosure and not intended to be limiting, as the raised profile tape composite, methods of making the raised profile tape composite, and related application methods may be suitable for use in a variety of configurations.

[0045] According to the present invention, a raised profile tape composite can be produced by combining a layer of structural material, such as paper, with a layer of adhesive material, such as double-sided adhesive tape. Various types of coatings can be applied to the surface of the layer to alter the properties of the surface. A release layer can be formed by coating a portion of the surface with, for example, a silicone coating, thereby reducing adhesion to adhesives that may be attached to the surface. As a non-limiting example, when a portion of the surface of the structural layer is release-coated, the attached adhesive layer will adhere strongly to the uncoated portion and weakly to the coated portion, causing the adhesive to peel and lift off the coated surface when force is applied.

[0046] Referring to FIG. 1, steps in a paper turn-up process utilizing the concepts herein are shown. As shown, a raised profile tape composite 105 is placed on an empty web spool 103. The empty web spool 103 can be used to wind a new paper web 100 as it moves by a reel drum 101 in the direction indicated by the arrow. In the start-up step, the full web spool 102 is approaching its maximum capacity to wind the paper web 100. Inset FIG. 1A shows a close-up of the empty web spool 103. On the face of the empty web spool 103 is a raised profile tape composite 105, which is secured to the empty web spool 103 by an adhesive layer 104.

[0047] Referring now to FIG. 2, an empty web spool 103 moves toward the reel drum 101 and approaches the nip 202. The paper web 100 is still wound on the full web spool 102. As shown in FIG. 2A, an attached raised profile tape composite 201 is placed on the face of the empty web spool 103. As the empty web spool approaches the nip 202, it contacts the paper web 203 that is resting on the face 204 of the reel drum and rotates as indicated by the arrow. The rotation can be achieved, for example, by an electric or air-driven motor (not shown). In some embodiments, the motor described can increase the speed of the empty web spool 103 before approaching the spool and closing the nip 202.

[0048] The rotational speed (in revolutions per minute) of the empty web spool 103 may be a speed at which the face speed of the empty web spool 103 equals the face speed of the paper web 100 and reel drum 101. During that speed increase, the raised profile of the attached raised profile tape composite 201 may lift up due to the increasing centrifugal force on the attached raised profile tape composite 201 by the rotational speed of the spool.

[0049] The rotation causes the attached raised profile tape composite 201 to enter the nip 202 and apply pressure to the exposed adhesive surface. In some embodiments, the raised profile adhesive approaches the paper web 100 as the empty web spool 103 presses against the paper web 100 on the reel drum 101, compressing the attached raised profile tape composite 201.

[0050] 3 and 3A, in one embodiment, when the attached raised profile tape composite 201 is in the nip 302, the raised profile 301 of the attached raised profile tape composite 201 may be pressed to adhere to the paper web 100 within the nip 302. Note that the proportions of the components in the figures may be exaggerated to account for the thickness and relative sizes of the spools and are shown for clarity.

[0051] 4 and 4A, a schematic diagram is shown illustrating how adhesive bonding of the paper web 400 occurs as the reel drum 408 rotates and, at time 1 (410), the raised profile tape composite 401 is compressed within the nip 405, adhesively bonding to the paper web 400 and lifting the paper web 400 toward the empty web spool 407. At time 2 (411), the raised profile tape composite 401 rotates out of position from the nip 405, and new paper from the paper web 400 begins to be adhesively bonded by the raised profile tape composite 401 and wound onto the empty web spool 407. The paper web 400 continues to be wound onto the empty web spool 407, which becomes a full web spool 409. As noted above, the diagrams are exemplary and are provided to illustrate basic aspects of various embodiments. The scale of the diagrams is not intended to be limiting, including the thickness of the paper, the distance between the nip, or the relative size of the adhesive layer compared to the spool size.

[0052] Referring now to FIG. 5 , a two-dimensional substrate 501 (which may include an adhesive substrate, such as a flat substrate with adhesive on one or both sides) is shown in a coil-packaged format suitable for many applications, as well as an unwound segment 502 of the substrate 501. In accordance with the present invention, the uses of the flat, adhesive-coated substrate 501 are expanded by forming or otherwise reshaping the substrate 501 so that it includes three-dimensional features 503A-504A. The three-dimensional features may include, for example, an arcuate apex 503 and / or a raised, angular apex 504. As shown, the apex 503 may be at the center 505, 506 of the width of the adhesive-bearing substrate 501. In other embodiments, the apex 503 may be offset from the centerline 505, 506 to better accommodate a particular application of the substrate 501.

[0053] In applications utilizing the adhesive-bearing substrate 501 as a turn-up tape, the empty spool to which the substrate 501 is adhered is rotated, bringing the three-dimensional features 503A-504A (e.g., ridges) of the adhesive substrate 501 into the nip and applying pressure to the exposed adhesive surface. In some embodiments, when the empty web spool is pressed against a paper web on a reel drum, compressing the adhesive substrate 501, the vertices 503-504 of the three-dimensional features 503A-504A of the substrate 501 approach the paper web.

[0054] Other useful applications of the substrate 501 extend to applications where the adhesive-bearing substrate 501 is applied in three-dimensional configurations, where achieving specialized three-dimensional configurations is hindered or made more complicated by the adhesive properties of the tape, which stick to surfaces, tools, fingers, and the tape itself when a user attempts to apply the tape to achieve complex configurations.

[0055] The present invention provides devices, apparatus, and methods for providing, preparing, and positioning a substrate 501 (having one or both of a first surface 510 and a second surface 511 coated with an adhesive) into the shape of a three-dimensional profile. In some embodiments, a thin, inelastic web can be formed into a three-dimensional structure with restraints at both ends to control or compensate for coplanar lateral and longitudinal stresses with little or no permanent deformation of the tape other than achieving the three-dimensional profile.

[0056] The substrate 501 may initially be constrained by a cylindrical roll 512, which only requires that the substrate 501 bend into an arch shape about an axis 508 parallel to the plane of the substrate 501. As the substrate 501 is unwound from the cylindrical roll 512, the substrate 501 unwinds into a flat, unwound, two-dimensional configuration 513, constrained by a transverse line 507 at a tangent line 509 to the roll.

[0057] Substrate 501 may also be constrained where it adheres to the surface to which it is applied. In a simple model of transferring substrate 501 from roll 512 to a surface (not shown in FIG. 5), bending axis 508, transverse line 507 at the point of tangent 509, and transverse line 507 at the point of adhesion to the surface may be parallel.

[0058] In some embodiments, if there is little or no twist of the roll 512 relative to the long axis of the free span of the tape and no lateral displacement of the roll 512 relative to the free span of the tape, the stress on the web may be insignificant under static conditions (no tensile load). However, if the roll 512 twists about the longitudinal centerline of the free span, wrinkles may occur (see FIG. 5B).

[0059] 5A, before twisting, line E515 and line D514 have approximately equal lengths. After twisting, line E'516 may be longer than line D514 (if the web or other substrate is stretchable), or line D514 may be shorter than line E515' (if the web is instretchable). If line E'516 cannot be stretched and D=E'519, line D514 will sag.

[0060] Twist may generally refer to the displacement of any point along a plane to a position away from the plane. If the substrate 501 is flat as it is unwound from the roll 512 and a three-dimensional profile is created, wrinkles 520 may be formed by the offset of a point in the plane.

[0061] Another dynamic that may be encountered when creating a three-dimensional profile from 2D tape, which involves increasing the three-dimensional height of substrate 501 between edges adhered to surfaces 510-511, may include narrowing of the resulting profile. Because the perimeter of the cross section of substrate 501 does not change, displacing a point out of plane creates a force that pulls on the edges of substrate 501, either causing the edges to shrink or stretching the substrate 501.

[0062] Additionally, if the long axis of a portion of the two-dimensional substrate 501 bearing the adhesive tape is to change direction (bend) along the plane on which it is placed to attach the edge of the 3D profile, several variables are preferably addressed.

[0063] Referring now to FIG. 5B, in situations where line E′ is larger than line D (517) or line D is larger than line E′ (518), line D will sag and / or wrinkle 520 if substrate 501 is not stretchable.

[0064] 6, in some embodiments, it may be preferable to maintain a fixed perimeter of a portion of substrate 601 (e.g., when it is undesirable for the substrate to be deformed). In such embodiments, by drawing edges 607-608 of substrate 601 together and reducing width F601 of substrate 601, the portion of substrate 601 may be shaped to form vertex 603 or other ternary shape. Drawing edges 607-608 together creates a narrower footprint F'602 of adhesive substrate 601.

[0065] If a portion of the substrate 604 cannot stretch or shrink, bending the longitudinal axis of the adhesive substrate 604 will result in deformations such as "wrinkles" 605. Because the outer edges of the adhesive substrate 604 determine the "length" of the adhesive substrate 604, if the opposite edge of the adhesive substrate 604 inside the curve formed by the adhesive substrate 604 is too long to lay flat (is not compressible), the force applied to the adhesive substrate 604 attempting to bend it will also cause deformation in the excess portion of the adhesive tape inside the curve. The deformations may include, for example, one or more humps 606.

[0066] 7, there is shown a reel-based storage dispenser 701 for a substrate 705 having a first flat surface (e.g., a top surface) and a second flat surface (e.g., a bottom surface). If the substrate 705 is an adhesive substrate, it may include one or more layers of adhesive applied to one or both flat surfaces. The reel-based storage dispenser may include a dispensing roller 702 for feeding the substrate 705 to a feeding portion 704 that is generally parallel to a flat surface 703. In some embodiments, the flat surface 703 may be an application surface or a shape that forms a flat surface.

[0067] In some embodiments, three-dimensional profiles are created from two-dimensional substrates in a continuous process. In preferred embodiments, the process involves effectively controlling the difference in length between lines parallel to the edges of the substrate. In embodiments where it is desired that the formed three-dimensional profile match in length, it is preferred that the edges are parallel to each other. The parallel edges can be parallel to another longitudinal line useful for the profile.

[0068] Some preferred embodiments include a formable substrate 705 (capable of expanding and contracting in one or more dimensions). The formable aspects of the substrate 705 can be manipulated to prevent, reduce, and / or eliminate wrinkling in the substrate 705. As a non-limiting example, necessary or desirable stretch properties can be provided by using a substrate such as stretchable paper, but stretchable paper may not be suitable for providing contraction properties. A substrate 705 with both expansion (stretching) and contraction (shrinking) properties can include a feedstock that is pleated along one or both the length and axis of the substrate 705 and the width of the substrate 705. The pleats may provide an additional feature, with or without adhesive, depending on the particular application and the tendency of the adhesive to transfer to surfaces the substrate contacts. For example, in some embodiments, adhesive may be applied only to the pleats. To make the pleats resistant to loosening, a coating can also be applied to control the effects of humidity on the pleats.

[0069] As shown in FIG. 7, the roll of substrate 705 may be oriented such that it connects to supply rollers 702-702A near the exit from dispenser 701, or may be further contained within dispenser 701.

[0070] 8, in some embodiments, the width-to-length ratio of the portion of substrate 807 involved in the forming process to create a three-dimensional appearance on substrate 807 is controlled. For example, forcing some substrates with a relatively wide crossover width to form within a short distance may exacerbate the difference in the lengths of the parallel lines. Conversely, increasing the distance involved in the forming process may reduce the difference. The dynamics of forming three-dimensional profiles from two-dimensional substrates (and particularly continuous lengths of adhesive tape) are addressed by the substrate dispenser and profile-forming apparatus designs shown and described earlier in this specification.

[0071] 8 , a wand 801 (or other structure having three-dimensional formed features 802) extends from a housing of a coiled substrate 808 and can include a gradual transformation of the two-dimensional shape of substrate 807 into a substrate having a three-dimensional profile 803. In some embodiments, the taper rate and corresponding length of wand 801 are designed to impart a controlled amount of stress to substrate 807. In other embodiments, the taper rate and corresponding length of wand 801 are controllable by a user via a retractable wand, allowing a user to adjust the gradual rate of transformation of two-dimensional substrate 807 into a substrate having a three-dimensional profile 803. Wand 801 can include formed features 802, the length of wand 801 including a gradual slope of formed features 802, such that the proximal end of wand 801 experiences the least amount of formation and the distal end experiences the greatest amount of formation.

[0072] Cross-sections 804-806 show instantaneous profile views 804-806 of substrate 807 as the three-dimensional profile is generated. Cross-section A-A 804 shows the start of the desired three-dimensional profile to be generated. Cross-section B-B 805 shows a simplified representation of the desired three-dimensional profile to be generated, and cross-section C-C 806 shows the generated desired three-dimensional profile.

[0073] 9 , in some embodiments, a guide or shoe 901 is positioned to receive a substrate 905 from a substrate container 908 and is maintained in a set position relative to a structure having a three-dimensional formed feature 904. The shoe 901 (or other guide or formed feature) is used to guide the substrate 905 to form into a desired shape when the substrate 905 reaches a finished position 902. In some embodiments, the shoe 901 is mounted with a gap 903 between the shoe 901 and the surface of the three-dimensional formed feature 904. Some embodiments may include a gap 903 that gradually narrows as the substrate 905 passes through the gap 903.

[0074] Additionally, in some embodiments, one or both of the shoe 901 and the three-dimensional forming feature 904 (e.g., the wand 906) may be coated with or made from a non-stick coating. Non-stick coatings may include, by way of non-limiting example, Teflon, PFA, PTFE (polytetrafluoroethylene), UHMW (ultra-high molecular weight polyethylene), ceramic, nylon, or other materials with the appropriate molecular structure. The non-stick coating is suitable for preventing adhesives and substrates from adhering to or contaminating the forming device. The surfaces of the associated forming features 904 may also include area-limiting structures, such as ridges, that reduce the surface area in contact with the adhesive.

[0075] In some embodiments, the shoe 901 may be divided into multiple sections and the three-dimensional formed features 904 may be softened in the corresponding sections to reduce the surface area.

[0076] 10 , some embodiments may include functionality achieved via rollers. The specifications and guides of the three-dimensional formed feature 1003, as well as the properties of the substrate 1601 or composite laminate, may influence the type of three-dimensional formed feature 1003 utilized. As shown, the three-dimensional formed feature 1003 is provided with forming rollers 1001 on either side of the formed feature 1003, which press a portion of the substrate 1000 (sometimes referred to as one or more feet of the substrate 1000) against the surface to which the profile will be applied. In preferred embodiments, adhesion of the substrate 1000 to the surface to which it will be applied is sufficient to pull the substrate 1000 through the wand 1006 or other formed feature 1003.

[0077] In some embodiments of the application method, managing stress on the substrate 1000 is managed by controlling how parallel the applied substrate 1000 is to the receiving surface, so that the wand 1006 or other forming feature 1003 remains while forming the two-dimensional substrate into a substrate 1000 with three-dimensional features. If a portion of the forming feature 1003 (e.g., an end of the forming feature 1003) is lifted, further stress on the substrate 1000 can be created.

[0078] In some embodiments, a feed roller 1002 is included to maintain a parallel position of the dispenser 1005 relative to the surface to which the substrate 1000 is applied. Additionally, in some embodiments, one or more forming rollers 1001 may be used in combination with the feed roller 1002 to maintain the angle of application of the substrate 1000 relative to the surface to which the substrate 1000 is applied. For example, the feed roller 1002 may be used to maintain the dispenser 1005 and wand 1006 in a slightly elevated position relative to the forming roller 1001, such that the substrate 1000 may be dispensed at a slight angle. Other embodiments may include maintaining the wand 1006 in a parallel position to the surface to which the substrate 1000 is applied.

[0079] 11 , in some embodiments, it may be desirable to protect the adhesive on the substrate 1110 dispensed from the dispenser 1108 from contact with dust, debris, and / or foreign matter. In such embodiments, the cover 1101 may protect the formed features 1109 and / or the substrate 1110 disposed on the formed features 1109.

[0080] In another aspect, in some embodiments, one or more handles 1102-1103 may be used to manipulate the application of a substrate 1110 formed to have a three-dimensional profile. As shown, the substrate 1110 forming and application device 1100 is suitable for use in conjunction with a linear track or tram, where the linearity of the receiving surface is suitable for limiting wrinkles and other anomalies after the substrate 1110 is applied.

[0081] Additionally, application device 1100 may include portions 1104-1107 that focus on specific functions and / or method steps. Functions may include, by way of non-limiting example, providing a substrate 1104, preparing a substrate 1105, forming the substrate into a three-dimensional profile 1106, and applying the substrate with the three-dimensional profile to a receiving surface 1107.

[0082] 12 , the raised profile tape 1200 can be assembled and attached in such a way that a raised channel 1201 is formed. The formed area of ​​the raised channel 1201 elevates the cover flap 1202. Otherwise, the structure of the raised profile tape composite 1200 can be similar to other embodiments having a zone-coated release liner substrate 1204. There can be a longitudinally extending uncoated bond region 1205 that defines a structure to secure and hold the cover flap 1202 in place when it is open. The underside structure 1206 can be formed of a raised profile tape substrate 1208 with a layer of attachment-side pressure-sensitive adhesive 1207 underneath the raised profile tape substrate 1200, as previously described. As with other embodiments, the web-catching pressure-sensitive adhesive 1207 can be protected underneath the cover flap 1202.

[0083] The raised channels 1201 have various effects, including the potential for greater aerodynamic interaction when the spool to which the raised profile tape composite 1200 is attached reaches rotational speed.

[0084] Referring now to FIG. 12A, when the cover flap 1202 is opened, the web-catching pressure-sensitive adhesive 1207 is slightly raised, which can enhance the interaction between the pressure-sensitive adhesive 1207 and the paper web and increase aspects such as the pressure generated between the web-catching pressure-sensitive adhesive 1207 and the paper web.

[0085] The cover flap 1202 can open into an open raised channel structure 1200A. When the cover flap 1202 opens, it exposes the web-acquiring pressure-sensitive adhesive 1207. The raised channel 1201 lifts the web-acquiring pressure-sensitive adhesive 1207 in that area.

[0086] Referring to FIG. 13 , a schematic diagram illustrates a method for creating a raised profile tape composite 1300. A portion of the raised profile tape composite 1300 is shown applied onto a rod 1302 or similarly shaped protrusion that can be pulled along a surface using an applicator 1303. The presence of the rod 1302 allows the upper layer of the raised profile tape composite 1300 to be shaped into a raised channel feature, as previously described. The dotted features are examples of features that may appear when an applicator applies the raised profile tape composite 1300. These features may include a portion of the raised profile tape substrate 1304 as it is applied to a surface, and a wiper feature 1303 that applies pressure to the surface on the edge of the raised profile tape substrate 1304 to apply the pressure-sensitive tape 1301 to the surface below. Because the rod 1302 or similarly shaped element will be subjected to some pressure between it and the pressure-sensitive adhesive of the raised profile tape composite 1300, in some embodiments, one or both of the raised profile tape composite 1300 and the rod 1302 are treated with a non-stick surface treatment, such as, for example, a polytetrafluoroethylene (PTFE) coating 1305 or other coating.

[0087] Referring now to FIG. 14, a flowchart illustrates method steps that may be performed according to some embodiments of the present disclosure.

[0088] In step 1401, the method may include attaching a proximal end of a raised profile tape composite to a first position on an empty web spool, the raised profile tape composite including a layer of adhesive, a release coating, and a pulpable substrate, the raised profile portion forming a peak together with the pulpable substrate and the layer of adhesive.

[0089] At 1402, the method may include a peak including a layer of pulpable substrate and adhesive, filling a gap between a surface of a paper web rotating on an empty web spool and a full web spool.

[0090] At 1403, the method may include adhering an adhesive layer to the paper web, such that at 1404, the method may include continuing to rotate the empty web spool and raised profile tape composite until the paper web is severed due to separation of fibers contained therein. The raised profile portion may include a combination of adhesive, release coating, and pulpable substrate, forming a peak with the layer of pulpable substrate and adhesive.

[0091] 15, layers that may be included in an adhesive substrate 1500, according to some embodiments of the present invention, are shown in an essentially flat, two-dimensional format. The adhesive substrate 1500 may include a substrate 1501 having a first side 1504 and a second side 1505. The adhesive substrate 1500 includes adhesive layers 1502-1503 on one or both of the first side 1504 and the second side 1505 of the substrate 1501. Some embodiments may additionally include a release layer 1506.

[0092] 16, although the three-dimensional substrate 1601 formed from the two-dimensional substrate has been discussed with a papermaking environment in mind, the concepts, methods, apparatus, and devices presented herein are applicable to many industrial, hobby, professional, and personal applications. For example, the raised profile substrate 1601 may be used to cover and / or secure an article 1602 between the raised profile substrate 1601 and a receiving surface 1603. By way of non-limiting example, the article 1602 suitable for securing with the raised profile substrate 1601 may include one or more of a wire, a cable, an electronic device, a sensor, a bead of sealant or adhesive, an optical fiber, a cord, a rope, a gasket, a seam (an interlocking seam and / or a butting seam), and virtually any other object suitable for securing to a surface with tape.

[0093] Referring now to FIG. 17 , method steps that can be performed in accordance with the present invention can include winding up a substrate in a dispenser (block 1702). For example, a device can wind up the substrate in a dispenser, as described above. As also shown in FIG. 17 , the method can include positioning the substrate parallel to a receiving surface using a roller (block 1704). For example, a device can position the substrate parallel to the receiving surface using a roller, as described above. As further shown in FIG. 17 , process 1700 can include supplying the substrate in a plane parallel to the receiving surface (block 1706). For example, a device can supply the substrate in a plane parallel to the receiving surface, as described above. As also shown in FIG. 1 , the method can include shaping the substrate with a forming profile along the longitudinal axis to form a three-dimensional substrate (block 1708). For example, a device can shape the substrate with a forming profile along the longitudinal axis to form a three-dimensional substrate, as described above. As further shown in FIG. 17 , the method can include applying the three-dimensional substrate to a receiving surface (block 1710). For example, the device may be applied to a receiving surface of a three-dimensional substrate, as described above.

[0094] The method may further include moving the substrate along a gradual gradient of three-dimensional changes included in the forming profile (block 1712).

[0095] The method may further include forming the substrate using the wheel and forming profile (block 1714).

[0096] The method may further include protecting at least a portion of the substrate with a cover from airborne contaminants (block 1716), which may include paper particles.

[0097] The method may further include changing the length of the receiving surface by extending the retractable wand (block 1718).

[0098] The method may further include maintaining a distance between the dispenser and the receiving surface by one or more wheels disposed on the dispenser (block 1720).

[0099] The method may further include maintaining the distance and angle of the wand from the receiving surface by one or more wheels at the distal end of the wand (block 1722).

[0100] Although Figure 17 illustrates example blocks of a method, in some embodiments, a method may include additional, fewer, different, or differently arranged blocks than those shown in Figure 17. Additionally or alternatively, two or more of the blocks of the method may be performed in parallel.

[0101] In some embodiments, the method may include continuing to rotate or otherwise rotate the empty web spool after adhering the adhesive layer to the paper web and cutting the paper web, whereby a new roll of paper web is formed on the empty web spool.

[0102] In some embodiments, the method may include protecting at least a portion of the adhesive layer from airborne contaminants, such as paper particles, with a folded layer that may include one or more of an adhesive, a release coating, and a pulpable substrate.

[0103] Alternatively, a method of supplying and applying raised profile tape features to be broken onto an empty web spool in a web turn-up operation and used to cut and secure a paper web from a first web spool to the empty web spool includes winding raised profile tape onto a raised profile tape spool in a dispenser cartridge housing and extending the raised profile tape through a slot in the housing adapted for passage of the raised profile tape, the raised profile tape comprising a tape substrate coated with a web-acquiring pressure-sensitive adhesive on one side and an attachment pressure-sensitive adhesive on the other side, and a release liner substrate fully coated with a release layer on a first side and zone-coated with a release layer on a second side. The release liner includes a release layer made of a material that prevents the pressure-sensitive adhesive from adhering to the release liner substrate, the zone-coated release layer defining a longitudinally extending uncoated bond area at the longitudinal edge of the release liner substrate to which the web-acquiring adhesive adheres, and the zone-coated release layer defining a cover flap that is not adhered to the web-acquiring pressure-sensitive adhesive, and the step of winding the raised profile tape onto the raised profile tape spool includes winding the raised profile tape onto the raised profile tape spool with the release liner facing inward and the attachment side pressure-sensitive adhesive facing outward, and the release layer fully coated on the first surface of the release liner substrate prevents the attachment side pressure-sensitive adhesive from adhering to the release liner substrate. Further, the method further includes the steps of applying the raised profile tape to the empty web spool by passing the segment of the raised profile tape through a slot, pressing the raised profile tape against the empty web spool using a wiper, and cutting the segment of the raised profile tape, and / or the step of applying the raised profile tape to the empty web spool includes orienting the raised profile tape on the empty web spool so that the cover flap extends in the direction of rotation of the empty web spool.

[0104] Alternatively, the raised profile tape is formed by assembling a tape substrate coated with a web-acquiring adhesive on one side and an attachment adhesive on the other side, and a release liner having a release liner substrate fully coated with a release layer on one side and zone coated with a release layer on the second side, the release layer being made of a material that prevents the adhesive from sticking to the release liner substrate.

[0105] Alternatively, a raised profile tape can be formed by assembling a tape substrate coated with a web-acquiring adhesive on one side and an attachment adhesive on the other side with a release liner having a release liner substrate fully coated with a release layer on one side and zone coated with a release layer on the second side, the release layer being made of a material that prevents the adhesive from adhering to the release liner substrate. In some embodiments, a cordless raised profile tape can be attached to the surface of a spool using an associated fastener that keeps the tape away from the surface of the spool at the center of the tape while allowing the peripheral adhesive surface to interact with and adhere to the surface of the spool. The fastener can be formed with a coating that prevents adhesive bonding.

[0106] In some embodiments, the zone-coated release layer can define a longitudinally extending uncoated bond area on the release liner substrate, the web acquisition adhesive adheres to the uncoated bond area of ​​the release liner substrate, and the zone-coated release layer defines a cover flap that is not adhered to the web acquisition adhesive.

[0107] A higher surface profile may improve the efficiency of adhering to the paper web because the surface profile helps fill the open nip. In addition to aiding in the adhesion of the adhesive to the paper web, the novelty of embodiments of the present invention may also improve the efficiency of breaking the paper web as it is severed from the parent web spool. The increased height of the raised profile tape concentrates greater force as the spool approaches the nip, which forces fracture the raised profile. The increased energy from the interaction may enhance the severing of the web.

[0108] Specific embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. Moreover, the processes depicted in the accompanying figures do not necessarily require a particular order, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. However, it will be understood that various modifications are possible without departing from the spirit and scope of the claimed invention.

[0109] The headings used herein are for organizational purposes only and are not intended to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in its permissive sense (i.e., meaning may) rather than its mandatory sense (i.e., meaning must). Similarly, the words "include," "including," and "includes" mean including, but not limited to. For ease of understanding, like reference numerals have been used, where possible, to indicate like elements common to the figures.

[0110] The phrases "at least one," "one or more," and "and / or" are open-ended expressions that function as both conjunctions and disjuncts. For example, the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" mean A only, B only, C only, both A and B, both A and C, both B and C, or all of A, B, and C, respectively.

[0111] The term "a" or "an" refers to one or more of that entity. Thus, the terms "a" (or "an"), "one or more," and "at least one" can be used interchangeably herein. Also, the terms "comprising," "including," and "having" can be used interchangeably.

[0112] Certain features that are described herein in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments individually or in any suitable subcombination. Furthermore, even if features are described above as working in a particular combination and are initially claimed as such, in some cases one or more features may be excluded from the claimed combination, and the claimed combination may be directed to a subcombination or variation of the subcombination.

[0113] As previously mentioned, the figures illustrate aspects of example embodiments, and the relative scale of the illustrated features may be exaggerated to illustrate various aspects. Thus, the scale of the illustrated features is not intended to limit the scope of elements of various embodiments consistent with this application.

Claims

1. 1. A method for forming a substrate having a three-dimensional profile, the method comprising: a) holding a coil of a two-dimensional substrate having an adhesive layer in a dispenser; b) providing said substrate with dimensionally formed features; c) reshaping the substrate based on the shape of the dimensional forming features to form a substrate having a three-dimensional profile; d) adhering the three-dimensionally profiled substrate to a receiving surface of an empty web spool; A method comprising:

2. rotating the empty web spool and the substrate having the three-dimensional profile; adhering the adhesive layer to a paper web of a full web spool; cutting the paper web; continuing to rotate the empty web spool and the substrate having the three-dimensional profile to form a roll of paper web on the empty web spool; further comprising: The method of claim 1.

3. further comprising attaching a distal end of the three-dimensionally profiled substrate to a second location on the empty web spool. The method of claim 2.

4. and further comprising the step of protecting at least a portion of the adhesive layer from airborne contaminants with a cover of the dispenser. The method of claim 3.

5. The airborne contaminants include paper particles. The method of claim 4.

6. forming a peak comprising the substrate and the adhesive layer by placing a rod under the adhesive layer; The method of claim 4.

7. contacting the paper web with the peak comprising the substrate and the adhesive layer; The method of claim 6.

8. further comprising compressing the peaks, including the substrate and the adhesive layer, as the empty web spool approaches the paper web. The method of claim 7.

9. further comprising the step of collapsing the peaks. The method of claim 7.

10. the substrate comprises one or more materials suitable for being repulped and included in a paper product; 10. The method of claim 9.

11. the cord is made of one or more materials, each material being suitable for being repulped and included in a paper product; The method of claim 10.

12. further comprising adhering the substrate to the paper web with the adhesive layer. The method of claim 10.

13. the adhesive layer comprises a pressure-sensitive coating; The method of claim 12.

14. following collapse of the peak comprising the pulpable substrate and the adhesive layer, contacting and bonding an additional surface area of ​​the adhesive layer to the paper web; The method of claim 8.

15. further comprising the step of winding the paper web onto the empty web spool.

10. The method of claim 9.

16. the release layer includes a portion of the surface treated with a substance having reduced adhesive strength; The method of claim 10.

17. The reduced adhesive strength material comprises a silicone-based formulation.

17. The method of claim 16.

18. the substrate having a three-dimensional profile comprises a carrier paper having a repeating pattern of stripes of a release coating; The method of claim 10.

19. the substrate having a three-dimensional profile includes a plurality of kiss cuts; The method of claim 13.

20. the plurality of kiss cuts are disposed at one or both of one-quarter and three-quarters of the width of the three-dimensional profiled substrate; 20. The method of claim 19.

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