Adhesive Tape Areal Splitting for Thin Splices
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Solution Overview
Problem
Existing adhesive tapes for on-the-fly roll changeover in paper mills and similar applications are thick, leading to web tearing and quality issues due to their thickness and fibrous structure, which affects coating and printing processes.
Innovation Solution
An adhesive tape with a main carrier and two adhesive layers, where the second layer's surface coating has modified regions with higher adhesion to the adhesive than to the carrier, allowing areal splitting to minimize thickness and maintain maximum tensile force, ensuring smooth surfaces post-splitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing adhesive tapes with multilayer splitting systems are used, then the splice preparation and implementation are improved, but the bond thickness becomes too large causing web tearing
Solution Approach 1:
The patent extracts and removes the multilayer splitting system from the adhesive tape structure, retaining only the essential adhesive layers on a thin carrier. This extraction eliminates the thickness problem while preserving the core splicing function, as the simplified structure reduces bond thickness to avoid web tearing during coating and printing processes.
Solution Approach 2:
The patent employs a thin-film adhesive tape structure with adhesive layers directly applied to a thin carrier, replacing the bulky multilayer splitting system. This thin-film approach minimizes bond thickness while maintaining the necessary adhesive properties for reliable splice preparation and implementation.
2Strength
If adhesive tapes with multilayer splitting systems are used, then the splice bond strength is improved, but the fibrous structure causes surface roughness leading to fiber deposition
Solution Approach 1:
The patent removes the fibrous multilayer splitting system and replaces it with a simplified adhesive layer on a thin carrier. This extraction eliminates the source of surface roughness and fiber deposition, providing smooth surfaces that prevent contamination in coating and printing processes while maintaining adequate bond strength through optimized adhesive formulation.
Solution Approach 2:
The patent changes the physical and chemical parameters of the adhesive system by using a simplified single or double adhesive layer instead of a multilayer fibrous structure. This parameter change achieves both smooth surfaces and sufficient bond strength, as the adhesive composition and thickness are optimized to provide necessary strength without creating surface irregularities.
3Object-affected harmful factors
If the adhesive tape thickness is reduced, then the web tearing risk is minimized, but the tensile force transmission capability may be compromised
Solution Approach 1:
The patent changes the parameters of the adhesive layers, including composition, thickness, and bonding properties, to achieve optimal balance between thin profile and tensile strength. The adhesive formulation is specifically designed to provide high bond strength in a thin layer, ensuring adequate tensile force transmission while minimizing web tearing risk through reduced bond thickness.
Solution Approach 2:
The patent uses composite material structures where the adhesive layers are formulated with specific polymers and additives to achieve high strength-to-thickness ratio. This composite approach allows the thin adhesive tape to transmit tensile forces effectively while maintaining a profile thin enough to prevent web tearing in subsequent processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adhesive tape achieves a significant reduction in bond thickness, minimizing web tearing risks and maintaining high tensile strength, while providing smooth surfaces that prevent fiber deposition and ensure uniform coating and printing.
Implementation Method 1
the forces of adhesion of the second layer (K2) of adhesive to the surface coating (K4) are greater than the forces of adhesion of the surface coating (K4) to the carrier layer (K3)
Data Source
AI summary
Adhesive tape for the on-the-fly roll changeover of flat web material wound up into rolls, comprising a carrier layer having a first surface and a second surface, a first layer of adhesive on the side of the first surface over at least part of the area, and a second layer of adhesive on one or more areas of the second surface, wherein the adhesive tape has regions suitable for areal splitting, at least those areal regions of the second surface on which the second layer of adhesive is provided being surface coated, the forces of adhesion of the lower layer of adhesive to the surface coating being greater than the forces of adhesion of the surface coating to the carrier layer, and/or the forces of adhesion of the lower layer of adhesive to the surface coating being greater than the forces of cohesion within the surface coating.