Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CORT1'T.~..~S AI)~SIVE TAPE W~DING M~NDREL AND METEIOD
E~ACKGROIJND OF THE ~VENTION
S The invention relates to a process and apparatus for forming coreless rolls of
;ssul~ sensitive adhesive tape.
There are many known methods and apparatus for forming individual spools or
rolls of web m~f~ The web material is often supplied in buLk in roll form, which is then
unrolled, slit lor~ihldin~lly and wound into individual strips of web material about a
plurality of pre-aligned cores of ~;a.~oald or plastic. In the case of pressure sensitive
adhesive tape, for ~Y~mple, typical cores are formed of paper, cardboard or plastic.
Because it is useful to provide such tape in di~le..L widths, an inventory of cores of
di~ w-l widths is thus also I t;~uu c;d. The ~,vinding of tape onto a core n~c~ es
~d~ition~l material h~ g (e.g., core loading) during the tape roll production process. In
l5 ~ ition, it is il--pe-~-Li~re during tape roll production that there be no m~ f.~l between
the core and the advancing strip of web material during winding. ~fi.c~ ."~. .,1 can cause
tape t~ ,scoping during winding or an axial offset wul~lulg ofthe tape onto the core (lloff
core" winding), both of which can lead to product ~sthF!tic issues and ~ .g
~iffi~llti~s
,!0 The use of a core presents ~ 1ition~l material inventory s~h~ -ling and storage
requirements, and results in extra shipping weight and volume for the tape roll product. In
~lrlitinn, the cost of the core itself, particularly for shorter length tape rolls, can ~ ellL a
nific~nt ~ pOI Lion of the product's cost. Further, the disposal of the core may present
waste and em/i o~ concerns when the supply of tape from the core has been
2'5 depleted. Even if the core is formed from a material or composite that is l ~-;yclable, its use
requires ~ lition~l h~nfllinf~ by the user in order to be salvaged for reuse or reprocessing.
Under certain COll li~iOllS over time (e.g., variable hurnidity and Le.llpt;l~ re), the
c~",l;,.,lity between the different core and wound tape materials can cause deformations
to occur in the tape rolls, such as rippling or bulging, which are ~psthp~tir~lly undesirahle.
Coreless rolls of pressure sensitive adhesive tape have been developed, along with
~ processes for wu~ lg such rolls. One such process is ~licrl~sPd in Hall et al. U.S. Patents
Nos. 3,770,542 and 3,899,075. A diametrically ~xp~nrl~hle and retractable mandrel is used
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for winding pressure sensitive adhesive tape thereon. Tape winding is initiated on this
mandrel by leaving exposed a short se~ . .1 of adhesive at the leading end of the tape. A
next segmPnt ofthe adhesive on the tape is covered with a backing sheet which p.cS~ S a
non adhesive surf~ce to the mandrel for the r~m~in-ler of the innermost wrap of tape about
S the mandrel. Af'ler a desired length oftape has been wound into a roll on this mandrel.(in
its f~n~ed state), the tape is cut, winding stopped and the rnandrel rli~m~tri~lly
retracl ed. Rotation in an oppo~ile relative direction between the mandrel and the tape then
folds back the short adhesive bearing leading edge se~ -l onto the backing sheet, thereby
leaving no adhesive exposed on the innermost wrap of the tape roll. While this process
10 results in a coreless roll of pressure sensitive adhesive tape, it is necessary to pP.riorli~lly
stop the advance of web material th~ough the apparatus for in-l~i~ purposes during tape
roll prori--cti~m, thereby inhibiting high speed and contimlol~ m~m~r~4u~ g of a coreless
tape product. In ~ ition, the further processing on the tape roll (rotation reversal of the
mandrel relative to the roll) is n~ y in order to fully achieve an inn~orml~st wrap of the
15 tape roll which is free of adhesive. As ...~..I;nnefl this process also requires a mandrel
which ~xp~nrl~ and co..l.~;ls di~,wL,i-,ally. A pn~llm~ti~ y ~ 1e mandrel isrlr se l, which, of course, requires pn~llm~tic couplings and plc~,_.-ls a more complex and
expensive mandrel ~~ lp~ .I than desired.
SUMMARY OF THE INVENI~ON
The present invention includes a method of se~lu~ lly forming a plurality of
coreless rolls of p. ~ ,u, c sensitive adhesive tape, and apparatus ll,c, cru, c. The inventive
method in~ d~,s providing a first rotating winding mandrel in a first windihg station,
di. c ;t --~, a leading edge of an advancing strip of pressure sensitive adhesive tape around
and directly against the first mandrel, and winding the tape successively upon itself and the
first mandrel to form an in process coreless tape roll. The first mandrel and in process
coreless tape roll are advanced to a second transfer station while advancing a second
rotating mandrel into the first winding station for ~ong,qgem~.nt with the advancing tape. The
tape is severed between the first and second ~--~-d. cls to define a trailing edge with the tape
wound upon the first mandrel and the tape is then wound on the first mandrel in the second
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transfer station until the trailing edge is also wound thereon to form a c~ r If ~e~ coreless
tape roll on the first mandrel.
To ~ t~te the coreless winding ofthe tape on a winding mandrel, in one
embodiment the winding mandrel is rotated about a tape winding axis in a first &ection
S and at a first rate. A cinch roller absf ..~l~ly rotates in a second, oppos.le dil é~;liOll. A
support for the cinch roller assG~ ly is movable relative to the winding mandrel between a
first position spaced from the winding mandrel and a second position wherein the cinch
roller a~Gnll,ly is urged into contact with the winding mandrel. When the support is in its
second position, the cinch roller ~e.l.~ly is rotated at a second, faster rate, and a leading
10 edge portion of an advancing strip oftape is wound about the winding mandrel. In the
;r~ d embo-limf~ntc, the leading edge portion ofthe strip oftape has a liner sllffi~i~nt to
at least mask the adhesive on an innermost wrap oftape being wound on the winding
mandrel. In one plerelled embodiment, the support also has a strand feed roller assell-l)ly,
which rotates in the second dil_-;lioll, at the second faster rate, when the support is in its
L5 second position
~ n one embodiment ofthe winding mandreL it includes a cylindrical shaft having an
axis of rotation, with at least a portion of the sha~ having a Cil ~;ulllre t;nLial tape su~u- Lii~g
se~ f~ adapted for receiving tape wound thereon. The circulllrGIGllLial tape sup~ lg
se~ F ~ ~ has a tape f~g;"g surface portion that, in a radial Ol jf~ iS COIIIIJl G:~SilJ!C yet
2 0 sllffi~i~ntly stiff to support the tape as it is successively wound about the shaft to form a
tape rolL and that is sllffll ;.ontly pliant to peImit ready axial removal of a wound tape roll
from the shaft.
In another embodiment, the process for se~luPnti~lly forming a plurality of coreless
tape rolls of ,~,- eS~ul G sensitive adhesive tape includes k)n it~l~iin~lly advancing a web having
25 first and second major surfaces, with one surface thereofbearing pressure sensitive adhesive
thereon. A liner/tab is applied across a lateral width of the advancing web on the adhesive
bearing surface thereo~ The advancing web is then wound about a mandrel member to
define a tape roll, whereby an innermost wrap ofthe web for each tape roll includes an
extent ofthe liner/tab .sllffi~i~nt to mask the adhesive thereon. Pler~ y~ the inventive
3 0 method also includes cutting the liner/tab and web laterally into two se~ f . ,1 -; with a first
segm~nt ofthe liner/tab defining said extent for one tape roll, and a second segment ofthe
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liner/tab defining a mask for adhesive along an outermost end portion of a web for a
previously wound tape roll.
BRIEF DESCRIPTION OF THE DRAW~GS
The present invention will be further ~ ,~p~ ed with l~re;l~;nce to the drawing
5 figures ltirel~.~ced below, wherein lilce structure is referred to by like numerals throughout
the several views.
F~G. 1 is a s. l,~ ;c illustration of a tape roD winding apparatus ofthe presentinvention.
F~G. 2 is a pe~ e~ e illustration of a, ~ d tape roll formed by the tape roll
10 winding apparatus and method of the present invention.
~ FIG. 3 is an elevational view as taken gcnel ~lly along lines 3-3 in FIG. 1.
FIGS. 4a and 4b are side elevational views, as taken along line 4-4 in FIG. 3, with
some parts removed and some parts broken away.
FIGS. Sa and 5b are se~tion~l views as taken along line S-S in FIG. 3, with some15 cc,---pone--ls shown s~ ly for illu~L~Li~re l ul~oses.
FIG. 6 is a s- ~ ic illustra~ion of the tape w-nul~l1g section of the tape roll winding
apparatus of the present invention sl-~,w.llg the a~ng~.m~.nt of coll~pol1ellL~ configured for
tape winding.
FIG. 7 is an elevational view of a winding mandrel ofthe present invention, broken
20 away laterally and with po- liolls thereof shown in section.
FIG. 8 is a pe-~e~iLi~e view of one end of the winding mandrel of FIG. 7.
FIG. 9 is a secti--n~l view as taken along line 9-9 in FIG. 7.
FIG. 10 is a section~l view as taken along line 10-10 in FIG. 7.
FIG. 11 is an e..l~ged sectional view ofthe encircled portion in FIG. 10, illustrating
25 the co.,-p.~il,;lily ofthe winding mandrel material upon which tape is wound in the
inventive method and apparatus.
FIG. 12 is an enlarged view ofthe encircled portion in FIG. 7, illustrating axial
removal of wound tape rolls from the winding mandrel.
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_S_
FIG. 13 is a s~ ;r illustration ofthe tape winding section ofthe tape roll
winding apparatus ofthe present inven~ion ~howill~ the a~ p,r...~ of cc~ )ol1ell~s just
prior to severing of the advancing tape strips to initiate the rulllldlion of coreless tape rolls.
FIGS 14a-141 are s~-,l.~...,.l;c views, partly in section and partly in elevation, ofthe
S enveloper ~ ",l,lics used for severing the advancing tape strips and ;~ g winding
about the ~i~ lg mandrel, in the apparatus and method ofthe present invention.
FIG. 15 is a partial elevational view as taken along lines 15-15 in ~IG. 14a
While the above-i~l~ ..l;l;~ drawing features set forth a preferred embodiment, other
embc-limPntc ofthe present invention are also ~ pl~Pri, as noted in the (li~ )n
10 This rli~rlns lre p,est;l"s illustrative embo.l;~ ofthe present invention by way of
PS~ l;on and not l;...~ Numerous other m~lrlifir.~tinn~ and embodiments can be
devised by those skilled in the art which fall within the scope and spirit ofthe prinrirles of
this invention. The drawing figures have not been drawn to scale as it has been neces~y
to er~arge certain p." ~,.J,~ for clarity.
]lS DETAILED DESCRIPTION OF THE PREFERRED E~IBODIMENTS
Intro~ction and Overview
FIG. 1 illustrates an apparatus for pe~ llllg the tape roll production method ofthe present invention. F~S~nti~lly, the process involves starting with a relatively wide and
long roll of a p~ u~e sensitive adhesive web, and processing that roll into a plurality of
narrower and shorter rolls of pressure sensitive adhesive tape. One such small roll of tape is
illustrated in FIG. 2, as tape roll 15.
A tape roll winding apparatus 20 for forming coreless adhesive tape rolls is
illustrated srl~ ;r,q11y in FIG. 1. The process begins at a web ~ dil~g station 22,
where a supply 25 of pressure sensitive adhesive sheet or web material 26 is aligned to feed
web material 26 onto a travel path for the web material 26 through the tape roll winding
apparatus 20. As shown, the supply 25 is in large roll form. For purposes of this
s~losl~re, the terms "sheet" and "web" are deemed equivalent. The terms "length'l and
"Icn~ 1in~1" are used in l~r~,t;nce to the rlim~n~ion of movement ofthe web material 26
along the travel path, while the terms "width" and "lateral" are used to refer to the
d.nlel~loll at right angles to the travel path ofthe web material 26. The direction ofthe
-
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web travel path is at right angles to the axes of the supply roll 25 and other process rollers
shown in FIG. 1.
The web material 26 may be forrned from any suitable m~t~.n~l~ such as paper,
plastic, L~ tape, nonwoven material or foil, and has first and second major surfaces. A
5 pressure sensitive adhesive (tacky) layer 27 is bome on one ofthose major surfaces, while
the other major surface has release properties (e.g., it is non-adhesive or nontacky). As is
typical, the supply roll 25 is wound with the adhesive side ofthe web material facing
inwardly toward the axis of the roll and the non-adhesive side of the web material facing
outwardly
lC~ For procec~ing, the web material 26 is unwound from supply roll 25 over a peel-off
roller 28 which is movable toward and away from the axis of the supply roll 2~i in order to
...~;,.li.;l. contact with the pt;lil)h~ly ofthe supply roll 25 as it unwinds. The non-adhesive
surface of the web material 26 is thus drawn over the peel-o~roller 28 (which is an idler
roller) and then over idler po~;~ ;o~ , rollers 29,30 and 31 to align the web material 26 for
1 'i liner/tab applic~ion. As seen in ~;IG. 1, the adhesive surface of the web material 26 is
drawn over and around idler rollers 30 and 31 (those rollers are release coated rollers). In
an alternative embodiment, one or more ofthe "idler" rollers di~losed herein may be dnven
to aid in the unwinding and advance ofthe web material 26 through the tape roll winding
apparatus 20.
2() The non-adhesive surface of the advancing web material 26 is then drawn over a
back-up idler roller 32 in a liner/tab application station 35. In the liner/tab a~)plic,1l;f n
station 35, a liner/tab applic~lor 37 is selectively activated to apply a liner/tab laterally
across the advancing web material 26. The liner/tab serves to mask certain selected
portions ofthe adl-e~ e layer 27 on the web material 26. From the liner/tab applic~lion
2.5 station 35, the web material 26 advances to a splicing station 39, where a splice table 40 is
pivotally mounted to provide a surface for manually splicing successive rolls of web
material together. Altematively, an on-line or "flying splice" ",~..1",.,;~", may be provided
to connect successive rolls of web material together.
As it cnntim ~es along the travel path the non-adhesive surface of the web material
26 then passes over an idler positioning roller 42 and through an edge trim station 43. Each
lateral side edge of the advancing web material 26 (and liner/tab thereon) is trimmed to
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define a precise width for the web material 26 for further processing. From the edge tnm
station 43, trimmed web material 43a along each side edge ofthe advancing web material
26 is directed over an idler roller 44 and then to a collection me~ . . 43b. As is typical
in tape winding apparatus, the collection mç(cl .~ . . . 43b may constitute a level wind
collector for the material trimmed from each side ofthe advancing web material 26.
The web material 26 is also advanced over idler roller 44, and then over idler rollers
45 and 46. The non-adhesive surface ofthe web material 26 engages idler roller 45, while
the adhesive surface ofthe web material 26 engages idler rollers 44 and 46, both of which
are release-coated idler rollers. The adhesive side of the web material 26 then engages main
drive roller 47 (which is also a release-coated roller). The main drive roller 47 provides the
primary traction or pulling force for advancing the web material 26 from the supply roll 25
through the tape roll winding apparatus 20.
From the main drive roller 47, the web material 26 continues on to a driven and
grooved anvil roller 48 (with its non-adhesive side toward the roller 48), and a slitting
station 49 thereon. The web material 26 iS then slit by a plurality of laterally disposed and
spaced knives acting in cooperation with the grooved anvil roller 48 to form a plurality of
l~n~hlr1in~11y ~ , tape strips 50 and 51 of web material (see FIG. 1). F.xl~n.1il-g
laterally, alternate tape strips 50 and 51 are directed either to a first upper tape winding
station 52 or to a second lower tape winding station 53, l e~e.~ ely.
At each willding station, the advancing tape strips are wound about a winding
mandrel. Thus, a plurality oftape rolls are formed .c;.. ~ eo~lsly on the same winding
mandrel. In the upper winding station 52, initial winding of the innerrnost wrap of each
tape strip 50 on a willdillg mandrel 55 iS f~ it~t~d by a cut-offand winding assembly which
has an upper enveloper assembly 56 and an upper lay-on roller and knife assembly 57.
Likewise, initial willding the innermost wrap of each tape strip 51 about a winding mandrel
60 in the lower winding station 53 iS f~cilit~ted by a cut-offand winding assembly which
has a lower enveloper assembly 61 and a lower lay-on roller and knife a~st;~ ly 62. The
enveloper and knife as~l.lblies at each -winding station are mounted to selectively pivot
toward and away from their respective winding mandrels. The winding mandrel 55 iS
- 30 m~ ~-nted at its ends in a rotating upper turret assembly 65. The upper turret assembly 65
has opposed chucks for çng~ ing each end ofthe winding mandrel 55 and rotatably driving
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the winding mandrel 55 when it has been advanced to the upper winding station 52. Five
positions or stations are defined about the upper turret assel,~ly 65, through which the
winding mandrel 55 cycles during tape roll production, inc~ a winding mandrel loading
position A, ready position B, winding position C (upper winding station 52), transfer
position D and Imlo~-ling position E. Likewise, a lower turret asse~ ly 70 is provided with
opposed chucks for ~ll~g;~ each end ofthe second WUldUlg mandrel 60 and rotatably
driving the winding mandrel 60 when it has been advanced to lower winding station 53.
The lower turret as~",l)ly 70 also has five positions or stations defned for movement of
the winding mandrel 60 Llle-~Lll,(,.lgh, in~.l.ltling a winding mandrel loading position A,
ready position B, winding position C (lower winding station 53), transfer position D and
, Inlo~rllir~ position E.
A~er a plurality oftape strips have been ~imlllt~np~ou~ly wound about their
;Li~e ~,,,du,g mandrel to a desired tape roll length, each tape strip is severed and the
winding of tape rolls is completed on one winding mandrel while the winding of a new set
of tape rolls begins about a new v~uldillg mandrel in each w,n.l",g station. This severing is
achieved while the enveloper and k~mfe ~ are advanced against a winding mandrel
in its winding station. Each winding mandrel carrying completP.ly wound tape rolls is then
removed from its respective turret asse,lll,ly, and the tape rolls thereon are removed from
the winding mandrel.
As described below, this invention pl t;S~"l~ a unique apparatus and method for
forming those tape rolls without the use of separate tape roll cores. The tape rolls are
wound directly on the winding ",~d,~,ls. To f~ t~te this, each circ~l,-,rer~..,Lial se~rnPnt of
the winding mandrel that is aligned to accept an advancing tape strip has a tape ~ gitlg
surface that, in a radial o,il;"L~Lion, is co",~ess;l,le yet s lffi~iently stiffto support the tape
25 as it is successively wound about the winding mandrel to form a tape rolL Each
circll"~;le"Lial segl"e,lL is also independently rotatable about the axis ofthe winding
mandrel, with such rotation controlled by a clutch ~ r.l~ In addition, the winding of
coreless tape rolls is ~nh~n~ed by utilization of a portion ofthe liner/tab which had been
applied to the web material at the liner/tab applic~tinn station. That liner/tab portion is
3 0 aligned to form the innermost wrap of each tape roll, thereby m~.cking the adhesive of the
web material at its innermost wrap from the tape ~ong~ging surface on the circu"~ lLial
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_9 _
seg,..~ ofthe winding mandrel. The tape ~ ng surface is sllffi~iPntly pliant to permit
ready axial removal ofthe cc, , 1~ ~d tape rolls offofthe winding mandrel.
A coreless roll of pressure sensitive adhesive tape 15 as forrned by the presentinventive process is illustrated in FIG. 2. This tape roll 15 is formed from a single tape strip
of web material 26 whose width was defined at the slitting station 49. The tape roll 15 has
no separate core. Starting with its leading or inner edge 71, the inner nost wrap 72 oftape
strip is covered on its adhesive (inner) side by an extent ofthe liner/tab which had been
applied to the web m~t~ri~l 26 at the liner/tab ~plic~liQn station 35, thus forming a liner 73
for the tape roll 15. At its trailing or ouL~ll"osL edge 74, a tape tab portion 75 oftape strip
is defined that has its adhesive masked. The adhesive is masked by a segment 76 of a
liner/tab that was applied to the web material 26 at tab ap~ .n station 35. The
rem~intlPr ofthat particular liner/tab forrned the liner for a sl-bsçqll~ntly forrned tape roll in
the tape roll wi~di~g apparatus 20. Likewise, a se~ of the liner/tab which defined the
liner 73 oftape roll 15 forrned the tab portion ~dj~ nt the trailing edge of a previously
wound tape roD in the tape roll winding apparatus 20. PlGrt;lal~ly~ the liner/tab is provided
with visuaUy pt;lcel,lil,le indicia 77 on one or both sides thereof; and the indicia 77 is visible
upon ro""a~ of a ~ tape roll 15 (both on tape tab portion 75 and ~Illlt;llllo~
wrap 72).
Specific details ~~ga-di.,g the coreless adhesive tape roll winding process and
20 apparatus ofthe present invention are described below. It is co~ ed that the
invention will take alternative forms and formats, some of which are specificaDy noted. For
~mpl~, the tape roll winding apparatus 20 illustrated in FIG. 1 advances the web material
26 with its adhesive surface facing generally upwardly. It is understood that in some
a~,rli~ io--.~ it may be desirable to align the web material 26 so that for the most part, its
Z5 surface bearing the adhesive faces generally downwardly. The ~ic~ losed orientation is not
meant to be limiting, but merely illustrative~ Numerous other modifications and
embodiments of the inventive apparatus and process fall within the scope and spirit of the
principles of this invention, and can be devised by those skiDed in the art.
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,
Liner/Tab Applicator
FIGS. 3-5 illustrate the liner/tab application station 35 in greater detail. As seen in
FIG.3, a supply roll 80 of liner/tab material is ~oLal~ly supported on a spindle 81 ~ rf~.nt
one side edge ofthe travel path ofthe web material. In FIGS. 4a and 4b, supply roll 80 has
been removed from spindle 81 to permit illustration of other colllpu~ s of the liner/tab
a~plicalor 37.
In FIG. 3, idler rollers 31 and 32 are seen, as I uL~ y S~ppùl led at their ends by
frame panels 82 and 84 (the web material 26 is not shown in FIG. 3, for clarity). The
spindle 81 is . uL~Lably supported on a central frame bar 86 which extends laterally over the
travel path ofthe web material. The central frame bar 86 has a pair of duwllw~dly
,l;llg supports 87 ~ nt its lateral end portions (see FIGS. 3 and 5a) which are
oL~ ly mollntf-d relative to the frame panels 82 and 84 along a comm-)n lateral pivot axis
88. Other operative cû~ onellLs ofthe liner/tab a~",lic~ol 37 are also ~,upl)olLed by the
central frame bar 86. As seen in FIGS. 4a and 4b, an air brake 89 is mounted on the spindle
81 to provide rotatiûn ~r~ and thereby prevent loose outer wu~dil.gs of liner/tab
material 90 from forming as rotation ofthe supply roll 80 is suddenly started and stopped.
In ~-ltlitirm, side spool screens or panels (not shown) may also be provided to .-.~;.,l;.;,l the
liner/tab material 90 in proper ~li~""~"l on the supply roll 80;
The supply roll 80 supplies liner/tab material 90 to a feed asse---bly 92, a cutting
assembly 94 and a belt feed asseml,ly 96. The liner/tab material 90 is drawn from the
supply roll 80 and fed laterally relative to the travel path of the web material 26 (facing its
pressure sensitive adhesive side) by the feed asse...l ly 92. The feed assenll,ly 92 includes
driven rubber-coated roller 98 and steel back-up idler roller 100, both of which are
l.~t~L~bly supported upon a roller support 102 mol-nt~d to the central frame bar 86. A drive
2S motor 104 c,l)e.~Les via a gearbox 106 (see FIGS. 3, 4a and 4b) to drive chain sprocket
108. Chain 110 engages driven sprocket 108 and, in turn, Ll~u~s--li~s power to chain
sprocket 112, which is coupled via clutch 113 to a shaft 114 of driven roller 98. Activation
of motor 104 thus causes drive roller 98 (when clutch 113 is ~n~ged) to advance liner/tab
material 90 through the nip between rollers 98 and 100, and to feed the liner/tab material 90
laterally across the cutting station 94 and into the belt feed asse lll)ly 96.
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The cutting asse",l,ly 94 has a liner/tab Imife 116 knife actuator 118 and cutting
support table 120, all of which are supported from central frame bar 86 by knife support
122 ~see FIG. 3). Normally the liner/tab knife 116 is ~ ed or spaced above the knife
support table 120 sllfficipntly to allow liner/tab material 90 to pass Lh~ Lwe~. Upon
act*ation ofthe knife actuator 118 the liner/tab hlife 116 is driven down through liner/tab
material 90 which is suppo,Led for cutting by cutting support table 120. The cutting
support table 120 has a groove aligned under the liner/tab knife 116 for ptlll~LLulg over
travel ofthe cutting knife 116 and to ensure con".'ote cutting ofthe liner/tab material 90.
The cutting a~st~ ly 94 thus severs the liner/tab material 90 into discrete liner/tab
se.~mPnt~ 123 for appli~ n to the web material 26.
The belt feed assembly 96 includes two lateraUy extending endless belts 124 and
126 which are aligned to have a l~n~ihl-lin~l lateral belt run wherein the belts 124 and 126
have contiguous and opposed outer faces. Upper belt 124 is supported at its ends by belt
rollers 128 and 130. Lower belt 126 is sul".u, led at its ends by belt rollers 132 and 134.
The inner surface of each endless belt is grooved lengthwise and the circu,l~,el.Lal
surfaces of the belt rollers have mating grooves and ridges to ensure that the belts stay in
proper ~li~ ., . .~.. .I during ope, aliOll. The belt feed as~;ml,ly 96 is also driven by motor 104.
Power is provided via the gearbox 106 to a chain sprocket 136 and then through chain 138
to chain sprocket 140. Chain sprocket 140 is in turn coupled to belt roller 132 to rotate
roller 132 and drive belt 126 mounted thereon. Con~eql-ently belt 124 which contacts belt
126 along their conti.~lo~s outer faces is driven as well.
Belt roUers 132 and 134 for lower endless belt 126 are rotatably supported on
lower plate structure 142 (FIGS. 5a and 5b), which is in turn mollntP~l to bracket 144
secured to central ~ame bar 86. Belt rollers 128 and 130 for upper endless belt 124 are
~ ly supported upon upper plate structure 146 which in turn is pivotaUy mounted as
at lateral pivot axis 148 to a plurality of up~ l;"g ear members 150, which in turn are
secured to the bracket 144. Thus the endless belts and their su~,l,ol L;llg structure are all
su~u~3Ollt;d by central frame bar 86, and when the central frarne bar 86 is pivoted about its
lateral pivût axis 88 the belt feed assen,l,ly 96 travels with it.
- 30 As seen in FIG. 5a, endless belts 124 and 126 are aligned with opposed facing outer
sur~aces 152 and 154. These surfaces are adapted to engage and entrain the liner/tab
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material 90 therebet~,veen, as it is readied for application to the web material 26. The upper
and lower plate structures 146 and 142 also have opposed facing surfaces 158 and 160
which are aligned to retain the liner/tab se~ 123 Ihe,~Lw~ l. The opposing facing
surfaces 158 and 160 of the upper and lower plate structures 146 and 142 are spaced apart
5 sl-ffir,i~nt to allow passage of the liner/tab material 90 thel ebe~een. As seen in FIGS. 5a
and 5b, the facing surfaces 158 and 160 ofthe upper and lower plate structures 146 and
142 are l~cessed to acco"~"odate the endless belts 124 and 126, as at recesses 166 and
167. The upper and lower plate structures 146 and 142 extend laterally across the travel
path ofthe advancing web material 26 to a width at least the extent ofthe width of idler
back-up roller 32. The upper and lower plate structures 146 and 142 are dp~i~npd to
separate. The upper plate structure 146 can pivot (as in-iie~tPd by arrow 168)) about pivot
axis 148, and thereby permit separation ofthe opposed facing outer surfaces 152 and 154
of endless belts 124 and 126. A plurality of laterally disposed spring f ~ 'i 169 are
positioned between the upper and lower plate structures 146 and 142 to counteract the
weight of upperplate structure 146 during such separation.
Lay-on rollers 170 are . o~ly ~uppo, led on a plurality of ears 172 which are
molmted to the upper plate structure 146. The lay-on rollers 170 are thus also pivotally
molmted about pivot axis 148 relative to the central frarne bar 86. The lay-on rollers 170
are axially aligned laterally across the travel path ofthe advancing web material 26, and
~,~lged to define a roller nip with idler back-up roller 32 for deposition ofthe liner/tab
se~ 123 on the advancing web material 26 (see FIG. 5b).
As mentioned, the central frame bar 86 and all components molmted thereto are
pivotally supported relative to the frame panels 82 and 84 about pivot axis 88. This
pivoting action (referenced by arrow 174) is attained by means of a three-position, double-
acting pnP~lm~tic cylinder 176 having its cylinder portion 178 rnounted to the fiarne panel
84 by suitable means, such as mount braclcet 180. An extensible piston rod 182 ofthe
cylinder 176 is pivotally col~ec~ed at its outer end (as at pivot axis 183) to an arm structure
184 which, in turn, is mounted to one of the supports 87 for the central frame bar 86.
Linear extension ofthe piston rod 182 relative to the cylinder portion 178 thus causes the
central frame bar 86 and co"lpone.l~s supported thereby to pivot about pivot axis 88
(cloch,vise as viewed in FIGS. 4a and 4b, or countercloclcwise as viewed in FIGS. 5a and
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5b). When the piston rod 182 is in its most extended position (not shown), the liner/tab
applicator 37 is pivoted away from the web path to allow ~ nmPnt ofthe web material on
~ the web path.
Im operation, the liner/tab application sta~ion 35 applies a liner/tab segrnent 123
5 during adv~n~Pment of the web material 26 along its travel path. Each liner/tab sC~nPnt
123 is aligned for lateral pl~P.mP.nt on the web material 26 as follows. Driven roller 98 and
belt roller 132 are rotated by activation ofthe motor 104. The feed a~se --l,ly 92 thus pulls
liner/tab m~P.ri~l 90 from the supply roll 80, past the cutting assembly 94 and into the belt
feed assembly 96. A leading edge of the liner/tab se~rnpn1 123 is Png~ged by the opposed
outer surfaces 152 and 154 ofthe upper and lower endless belts 124 and 126 and liner/tab
segment 123 is then camed laterally across the travel path ofthe web material 26. When
the leading edge ofthe liner/tab se~..,,..l 123 is dl~ected by an optical sensor 186, the knife
actuator 118 is sipn~lPd to drive the liner/tab knifie 116 toward the cutting support table 120
and thus cut and defne a trailing edge ofthe liner/tab se~..~.l 123, while also thereby
defining a leading edge ofthe liner/tab material 90 that will form the next liner/tab se~ nt
Sim--lt~nPously, the clutch 113 is ~lic~ng~g~pd to stop rotation ofthe driven roller 98 and
hence stop the advance ofthe leading edge ofthe liner/tab material 90 at the cutting
assembly 94. The belt feed assellll,ly 96 continues to operate, and continues to laterally
advance the liner/tab segment 123 until its leading edge is detected by a second optical
sensor 188. Upon detection ofthe leading edge by sensor 188, the motor 104 is
deactivated to stop the belt feed assel,~ly 96. The endless belts 124 and 126 thus hold the
liner/tab se~rnP.nt 123 in position for applir~tion to the pressure sensitive adhesive side of
the advancing web m~teri~l 26.
The formation and positioning of a liner/tab segment 123 occurs while the liner/tab
applicator 37 is in a ready or run position, as illustrated in FIGS. 4a and 5a. In this position,
the rod 182 ofthe cylinder 176 is P.xtçn-led to pivot the central frame bar 86 and the
components thereon about pivot axis 88 s -ffiri~-nt to space the liner/tab segment 123 a
short distance away from the advancing web material 26, as best seen in FIG. 5a. A leading
Iateral section 190 ofthe liner/tab segment 123 is, however, exposed below lay-on rollers
170 and aligned to engage the adhesive surface 27 ofthe advancing web material 26. This
Png~gPm~Pnt occurs when the cylinder 176 is activated to retract its rod 182 and pivot the
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central frame bar 86 and coln~)on~ll~ thereon to move the liner/tab applicator 37 to an
applicator position, as shown in FIGS. 4b and 5b. In this position, the leading lateral
section 190 of the linerltab segrnent 123 engages the web material 26 and adheres thereto.
The lay-on rollers 170 press and roll the liner/tab se~-lP"~ 123 against the web material 26
as it is pulled out ofthe liner/tab applicator 37. A slight illLelrt;l~llce is provided between
idler back-up roller 32 and lay-on rollers 170, which is ~ccommotl~tp~ by the pivoting
about pivot axis 148 ofthe upper plate structure 146 and away from the lower plate
structure 142 (see FIG. 5b). As mPnti~nPtl, this movement and support ofthe upper plate
structure 146 is f~-ilit~ted by the springs 169 between the upper and lower plate structures
] 0 146 and 142. This also separates the opposed outer surfaces 152 and 154 ofthe endless
belts 124 and 126, thereby releasing the liner/tab se~..~..l 123 for its wilhdl~al from the
liner/tab applicator 37.
A~er the second sensor 188 detects the absence of liner/tab material between theendless belts 124 and 126, the cylinder 176 is activated to extend rod 182 and return the
:L S central frame bar 86 and ~Ill~.on~ thereon to the ready or run position illustrated in
~IGS. 4a and Sa. The cylinder 176 is not activated to extend rod 182 solely in response to
the cletectinn of the absence of liner/tab material by the second sensor 188, however. The
activation of cylinder 176 is also dependent upon cc~ elion of a predetermined time delay
in the circuit for retraction of rod 182 which initiated the a~plic~llion ofthe liner/tab
se~mPnt 123 on the advancing web material 26. After the time delay and "no liner tab
material" signal from the second sensor 188, the motor 104 is also activated and clutch 113
P~gPd to initiate the steps nPcP~ry to position a next liner/tab se~.~ in position for
lateral application to the advancing web material 26.
The liner/tab applicator 37 ofthe present invention thus provides an efflcient supply
and delivery scheme for applying a mask onto an adhesive bearing side of a moving web.
In this regard, the inventive liner/tab application scheme, although illustrated in connection
with the formation of coreless pressure sensitive adhesive tape rolls, can also be used in
connection with the formation oftape rolls having cores.
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Web Slitting Sfation
During operation of the tape roll winding apparatus 20, the web material 26 withliner/tab segl~elll 123 adhered thereto travels from the liner/tab appli-;alion station 35 to the
first lateral edge slitting station 43. At the first slitting station 43, a pair of knives disposed
5 ~ ent the lateral edges ofthe advancing web material 26 cut edge strips offofthe web
material 26 (and liner/tab sef~mf~nf 123 thereon) to define a precise width for the web
material 26 for further proc~ As m~nti-)ne(l, the rnaterial trimm~A from the webmaterial 26 is collected by a suitable cc llection merl~ .., 43b. As the web material 26
passes the main drive roller 47, its progress is tracked by a length encoder 202 coupled to
]: O the main drive roller 47. The length encoder 202 thus provides data as to the extent of web
material 26 that has advanced along its travel path.
From the main drive roller 47, the web material is advanced to the anvil roller 48,
which has a plurality of circul,~e,enLial grooves ~" le~ side-by-side along the width
thereof. The main drive roller 47 and anvil roller 48 are both driven by a common drive
motor (not shown), as is conventional in tape slitting and v~ dillg m~chin.?s ofthis type.
The main drive roller 47 is driven to define line speed for the advancing web material, while
the anvil roller 48 is driven slightly faster than drive roller 47.
While on the anvil roller 48, the web material 26 passes through the slitting station
49, which ope,~l~s in coope;,~lion with the grooved anvil roller 48. The slitting station 49
influde.c a plurality of knives 203 laterally disposed across the width ofthe material web 26
travel path. Each knife 203 extends in part into one ofthe circu",rt;lcl,~ial grooves on the
anvil roller 48. Thus, as the web material 26 advances through the slitting station 49, each
lmife 203 cuts the web material longitll-lin~lly into a plurality oftape strips 50 and 51 (FIG.
6). The lateral space between atlj~ nt knives 203 defines the ~,vidth ofthe tape strips cut
thereby, and p,~r~,~ly, the knives 203 are equally spaced apart.
As the tape strips 50 and 51 are slit in the slitting station 49, the liner/tab se~m~,nt
123 ~xtt~,n~lin~ laterally across the web material 26 is also slit as it passes the knives 203.
Thus, a liner/tab strip 204 is formed (as adhered to each tape strip S0), and a liner/tab strip
205 is formed (as adhered to each tape strip 51) (see FIG. 13). From the anvil roller 48, the
3() tape strips 50 and 51 are then directed to the upper and lower turret assemblies 65 and 70.
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Alternate tape strips are directed to the ~llcl"a~ e turret asscllll~lies, as is typical in a tape
slitter m~rhin~,
Coreless Tape Roll Winding
1. TurretAssemblies
'i From the anvil roller 48, the tape strips 50 are directed to the first winding station
52 in the upper turret assembly 65. A wil~dil~g mandrel 55a is L~ bly driven in the first
winding station 52, and the tape strips 50 are wound thereon, as seen in FIG. 6. Likewise,
the tape strips 51 are directed ~om the anvil roller 48 to be wound upon a winding mandrel
60a r.~laL~bly driven in the second winding station 53 of lower turret assembly 70. Thus,
I() the tape strips 50 and 51 are eiml-lt~n~ously wound on separately rotating winding
mandrels in their ~ c~ec~ e turret ~wl~ lies to for n tape rolls 15 thereon.
The turret assemblies are ~rcl~Lbly ar~ ted turret ~e~ oc, which are ofthe
type which is conventional in the pressure-sensitive adhesive tape m~mlf~ct~lring industry.
A suitable articlll~ted turret assc",l,ly is the KampfRSA-450 turret of Jagenburg GmbH,
15 Germany. In the articulated turret ~S~ ic~ die~losed herein, each turret assembly
consists of a pair of spaced turret heads 64 and 69 (only one of which is shown in the
drawings for each turret assembly) belwcell which the winding mandrels 55 and 60 are
supported and molmted for rotation, respectively. Conventionally, the turret a~c"lblies
contain drives (not shown) for indexing the turret heads, i.e., rotating them to transport the
2() windillg mandrels among di~clclll positions about each turret assembly. Each turret
assembly has two or more pairs of winding mandrel chucks, and each pair of chucks can
independently engage and inrleplon-iently rotatably drive a winding mandrel. It is also
c~ ed that a fixed turret asscl~ ly can be used for the present invention~ such as the
RS240 turret of Ghezi & Annoni SpA, Italy.
A winding mandrel is position~d for use on its turret assembly by means of loading
ramp 206. In artic~ ted turret assemblies such as those illustrated and co,l~el"~lated for
use in connection with the present invention, each separate pair of winding mandrel chucks
on a turret as~cl~ll)ly has a separate drive motor to independently index those chucks about
their positions on the turret assembly. A pair of empty chucks engage the ends of the
winding mandrel at position A (offof the loading rarnp 206). Those chucks are then
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advanced to position B, placing the winding mandrel in a ready position for tape winding.
The chucks are then further advanced to position C for engagement and winding of tape
strips thereon. Once winding is nearly co~ E~efl that pair of chucks is then indexed to
position D to finish the winding process for the winding mandrel therebetween. Finally, the
5 chucks are advanced to position E, where the chucks release the winding mandrel, thereby
allowing it to exit its turret a~se~ ly via l-nlo~-lin~ ramp 208. While the relative positions
ofthe winding mandrel stations about the turret assemblies 65 and 70 differ, their functional
aspects are the same, moving through win~ g mandrel loading position A, winding
mandrel ready position B, winding mandrel winding position C (the winding stations),
10 winding mandrel transfer position D and winding mandrel l-nl~ ~l1in~ position E. All ofthe
winding mandrels in their Ic;~e~;~ive chucks may be driven by one drive motor through a
plurality of clutch means, or by separate independently controlled drive motors, one for
each pair of winding mandrel chucks (these drive motors are not shown).
2. WindingMandrel
The unique structure of a caliper cu-l~p~n~ ion winding mandrel ofthe present
invention is illustrated in FIGS. 7-12. For exarnple, a winding mandrel 55 has a central
cylindrical shaf~ 210 with ends 212 and 214. At least one end (such as end 212) has a
chuck eng.qging end portion 216, which is forrned to mate with a chuck 218 having a
similarly shaped recess or mating portion 220 thereon. The end portion 216 may be
squared off(as illustrated in FIG. 8), or it may have other lo~iunal mating structures such
as keyed portions or a tapered cone that operates in conjunction with a mating shape on the
chuck. Adjacent the other end 214 ofthe cylindrical shaft 210, a chuck 222 also engages
the shaft 210. The chucks 218 and 222 are selectively movable axially away from the shaft
210 to permit its loading and unloading on the upper turret assembly 65. When f~n~g
2;5 as seen in F~G. 7, however, the chucks 218 and 222 ~Ill~Li~ely engage the cylindrical
shafl 210 for coupled rotation therewith.
~ An end stop sleeve 224 is secured to the cylindrical shafl 210 ~ 9(c~nt one end
thereof: In one embodiment, the end stop sleeve 224 is fixedly secured to the cylindrical
shaft 210 by means of pin 226, thereby limiting it from axial or lolalional movement relative
to the sha~ 210. Alternatively, the position ofthe end stop sleeve 224 is variable along the
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:,
cylindrical shaft 210. A cO.,~ Oll spring 228 is mounted about the shaft 210 a~ cent
the end stop sleeve 224 and abuts an annular face end 230 of end stop sleeve 224, as seen
in FlGS. 7 and 8. A plurality of alternating spacer tubes 232 and core tubes 234 are aligned
along the length of the cylindrical shaft 210. One of the spacer tubes 232 is positioned
~-1jac~nt the CUIII~JI e~sion spring 228, with an annular face end 236 thereof ~h- ltting the
co.l.~-.t;ssion spring 228. Each spacer tube 232 has an inner ~Ji~ rk;l slightly larger than
the outer ~ lel~ ofthe cylindrical shaft 210. As best seen in FIG. 9, each spacer tube
232 is aligned over a pin 238 e7~ten-1in~ through a bore 239 in the cylindrical shaft 210.
Each spacer tube 232 has an axial groove 240 along its inner surface which receives a head
242 ofthe pin 238 therein. Thus, the spacer tubes 232 can move axially relative to the shaft
210, but the pin 238 prevents rotational movement of the spacer tube 232 with respect to
the shaft 210.
A core tube 234 is aligned on the shaf'c 210 bc;lween each pair of ~t1jae~.nt spacer
tubes 232, as seen in FIGS. 7 and 8, and is adapted for reusable use in forming coreless
tape rolls thereon. Each core tube 234 is formed from a cylindrical sleeve 244 (see FIGS.
7, 10 and 11). Plc;rel~ly7 the sleeve 244 is formed from a low-friction, durable m~t~ri~l
such as DELR~TM material, available from E. I. du Pont de Nemours and Company, Inc.,
of Wil~ , Dclaw~ue. The inner d~ ofthe sleeve 244 is slightly larger than the
outer fli~metP.r of cylindrical shaft 210. The sleeve 244 is thus free to move axially and
rotatably relative to the shaft 210, c~ ed only by means ofthe spacer tubes 232.A radially colnples~il,le material layer 246 is mounted about the circumference of
each sleeve 244. Pler~;;l~ly, the material layer 246 is formed from SCOTCE~ATETMhook material having a pressure sensitive adhesive ba~L-in~, m~nl -f~ -red by Minnesota
Mining and ~m-f~ring Company of St. Paul, MinllesoL~I, and idPntifiçd by Part No. 70-
0704-2795-3. As illustrated in F~G. 8, such material is pl ~;;rt;l~bly spirally wound about and
af~ixed to the exterior circul-lÇ~e,-~ial surface of sleeve 244 by its adhesive ba~kin~ This
SCOTCHMATE~M material is de&ed by a base layer or fabric 247 which supports a
plurality of up~ stems 248. Each stem is formed as a small polymer filament which
extends generally outwardly from the winding mandrel shaft 210 and has a hook portion at
an outermost end thereof. While the radial orientation ofthe stems 248 is not as uniform as
illustrated in ~IGS. 7, 8 and 12, the outermost ends ofthe stems 248 ofthe coln~ le
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material layer 246 are generally equal in height, and serve to define a low surface area outer
wl(;ulllr~ ce ofthe core tubes 234. It is about this outer circunlrt;~ ce that the tape strips
are applied and wound, and when the innermost wrap of each tape strip is ti~htP.n~d
thereon, the comples~il,'~ material layer 246 provides enough friction so there is very little
5 or no slippage between the tape strips and the stems 248 during w~lulll-g. The tape strips
are applied directly onto the coll~ e material layer 246. When tape rolls are forrned
by the inventive method, as further .lic~-~.cPd below, it is ~lc:rtldlJly not the adhesive on the
tape strips 50 (or 51) which engages the c~ e~ ,il le matelial layer 246, but rather their
I~spe.;live liner/tab strips 204 (or 205) which engage the Coln~ ib!c material layer 246
10 and define an innermost wrap 72 of a tape roll 15 wound thereabout. As such, the
innermost wrap 72 forms the liner 73 for the tape roll 15 (see FIG. 2).
As mentioned, the spacer tubes 232 and core tubes 234 alternate in the above-
described manner along the central cylindncal shaft 210. At the other end 214 ofthe
winding mandrel shaft 210, a second end stop sleeve 250 is secured over the shafl 210 and
is secured thereto by pin 252. As seen in FIG. 7, an inner annular end face 254 of stop
sleeve 250 abuts an annular end face 256 of an a~ cent core tube 234. The end stops 224
and 250 are positioned on the Willdillg mandrel shaf~ 210 to place the coln~ ion spring
228 in CC~nl~n t~ ;OII, thereby placing an axial colll~ ll force against the spacer and core
tubes 232 and 234. Thus, the core tubes 234, while free to rotate about the shaP[210, are
20 retarded from completely free rotation by this all~, .~, ..~. .l The amount of rotation
inhibition is a function of a number of variables, in~ 1ing force exerted by co~ es~ion
spring 228, and serves to define a con~t~nt torque during tape winding.
As seen in FIG. 7, each core tube 234 is wide enough to accept a tape strip for
forming tape roll 15. The spacing between core tubes 234 is determined by the width of
25 the spacer tubes 232. However, because alternative tape strips are fed to the winding
mandrel 55 from the anvil roller 48, the spacing between the edges of ~ cpnt tape strips
coming to winding mandrel 55 is pler~ bly the same as the width of each tape strip (when
the knives 203 are equally spaced apart).
The winding mandrel illustrated in FIGS. 7-12 is a winding mandrel 55 for use in30 the upper turret a~sel~ ly 65. As mentioned, the tape strips 51 being wound on the
winding mandrel 60 in lower turret assembly 70 alternate (in lateral relation) with the tape
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strips 50 being wound at the same time on the winding mandrel 55 in upper turret ass~ml~ly
65. Wlth this in mind, it is understood that the winding n,al.d,~,ls used in the upper turret
assembly 65 are functionaUy the same as the winding lllandl~ls used in the lower turret
assembly 70, except that the intervals ofthe spacer tubes and the core tubes is reversed
along the lateral widths ofthe respective winding mandrels.
It is possible to m~mlf~ lre tape rolls of di~elt~ widths using the same windingmandrel (even at the same time). Such widths would be mlllt~ s ofthe smallest possible
width (one tape roll per core tube). Thus, a tape roll could be formed on the winding
mandrel that spanned two core tubes and a spacer tube tllel~t;L~veen (or three core tubes
and the two spacer tubes therebetween, etc.) by revising the lateral spacing of knives 203 in
the slitting station 49. Alternatively, di~t;le;lll willdill~ mandrels having .li~l~nl widths
.e., spacing) oftheir aligned spacer tubes and core tubes can be used with correspondingly
d~ knife spacings in the slitting station 49.
Each win&g mandrel thus selves as an axial base for tape winding. As a tape strip
is advanced about the winding mandrel, it engages the colllples~le material layer 246.
Specifically, when the tape is wound with its adhesive side facing the winding mandrel
winding axis, the liner 73 (see FIGS. 2 and 11) engages the outermost ends ofthe stems
248, since the liner 73 defines the innermost wrap 72 of each tape roll 15. Collectively~ the
sterns 248 are stiffenough not to flatten as the innernnost wrap 72 is placed thereon, but
resilient enough to slightly bend and provide an overall ~ reduction (radial
coll",~ sion) as the innermost wrap 72 is ti~htPn~pd (i.e., cinched) about the core tube 234
and then held in place by the ~rlhP~ion of the further wraps of the tape strip thereabout.
The stems 248 bend and allow a generally uniform con""~;ssion about the core tube 234,
thereby defining the inner diameter for each tape roll 15. The bending and co",p,t;s~ion of
the stems 248 is illustrated in FIG. 12. A seglllc;lll 257 of stems 248 under the innermost
wrap 72 of atape roll 15 is shown bent in conl~.~ssion about sha~ 210. A section 258 of
stems 248 on the same core tube 234 is shown uncomplessed, where there is no tape
wound thereabout.
It is cont~mrl~ted that other materials will also be suitable to define the
co"~le~il.lc and resilient material on the winding mandrel. Such m~t~.n~l.c may include,
for example, a bristle structure such as BRUSHLONTM material of Minnesota Mining and
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.
~ mlf~ ring Company of St. Paul, Minnesota, or a loopy material having the desired
re~ilience and co~l~p~es~ y characteristics. Other m~tPri~lc suitable for this purpose
would include steel leaf springs, a plurality of spring-loaded devices such as VLIERTM pins
(m~n~ red by Vlier Fn~ g, Burbank, C~liforni~), steel VELCROTM material
5 (m~mlfi~rtl lred by Velcro USA, Inc., ~nrhestP.r, New lF~ .xl .;l e), a lubricous foam
material, or some Png3nePred composite of the above-mentionecl m~tf~,ri~l~, which is a non-
exclusive list. Any such material is suitable, so long as it provides the desired radial
co~ wibility, yet is stiffenough to .",.i.~l~;.. the tape material wound thereabout for
defining its inner tli~m~ter and is low friction enough to permit ready axial removal of a
10 cormr'eted tape roll from the winding mandrel. The matenal is also sufficiently resilient to
resume its original form after being con~l~ssed during the tape winding process.P-t;rel~bly, the tensioner clutch mP~h~ni~m for controUing the rate of rotation of
core tubes (i.e., torque on the tape being wound) across a winding mandrel can be
controUed by varying the cc,~ ion of spring 228. To doso, the end stop collar 224 can
15 be selectively fixed at ~dj~-st~ble po~iLiolls along the shaft 210 (such as by cooperative
threading between the coUar 224 and shaft 210) or spacer shims can be added between the
end stop collar 224 and spring 228 to vary the coll~le~;on placed on the spring 228.
Alternatively, instead of the spring 228, axial clutch pressure may be exerted upon the
spacer tubes 232 by a yoke (s~po, led ~dj~c~nt the turret assembly) which through
:20 operation of a suitable activator, is moved to engage a radially disposed face (such as face
236) ofthe outermost spacer tube on a winding mlandrel and applies axial pressure thereto
as the winding mandrel is rotated.
Another alternative winding mandrel tension construction has co,l,l"c;ssiblc springs
nt each end ofthe winding mandrel (within fixed end stops on the winding mandrel25 shaft). A third fixed stop is secured to the shaft ~dj~c~nt its rnidpoint, and thus aUows the
separate definition of axial co--lp~ ion (and torque) for each half of the winding mandrel
by the two separately co~ -e~ed springs.
It is also conf~mrl~ted that a merh~n ~~lly operable winding mandrel may also
function in the process and apparatus ofthe present invention. For ~x~mrle7 a diametrically
30 collapsible/l-~r~n-l~hle winding mandrel or button bar wiU suffice, so long as it provides
caliper compensation (independent rotation capability for each tape roll being wound) and
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means for support of the tape while wound and for permitting ready removal of a
completed tape roll from the winding mandrel.
3. Cut-Of~and WindingAssemblies
The initiation of coreless winding on a winding mandrel and the severing oftapesS bc~wcen sllecç.eeive winding mandrels in each turret assembly is f~ it~t~d by a tape cut-off
and winding assell-l,ly that includes a pair of cooperative ~ mhli~o5 which pivot into
en~p~ c~ with the w l,-li lg mandrel in its winding station. Thus, it is i~ c~ re that the
turret ~enllbly provide relatively precise po~itinning ofthe winding mandrel in the v~ ,g
station so that it is properly aligned for interaction with the tape cut-offand winding
lCI assembly. As seen in FIGS. 6 and 13, for the willdillg station 52 ofthe upper turret
assembly 65, the cut-offand winding asse~ ly is defined by the upper enveloper assembly
56 and the upper lay-on roller and knife assembly 57. The upper enveloper assembly 56
inrl.ldes an enveloper frame 264 supported by an arm 266 which is pivotally mounted along
a lateral pivot axis 268. The upper kni~e assembly 57 has a knife frame 270 supported by
an arm 272, which is also aligned for pivoting along lateral pivotal axis 268. Likewise, the
winding station 53 ofthe lower turret assembly 70 has a cut-offand winding assembly
defined by the lower enveloper assembly 61 and a lower lay-on roller and knife assembly
62. The lower enveloper ~sell~l)ly 61 has an enveloper frame 278 supported by an arm
280 which is pivotally molmted along a lateral pivot axis 282. The lower knife assembly 62
has a knife frame 284 supported by an arm 286 which is also pivotaDy mounted along
lateral pivot axis 282.
RPf~mnE again to the turret assenlblies ~FIGS. 6 and 13), the Wl~yJpillg oftape
strips about a winding mandrel begins in its respective winding station, and the bulk ofthe
winding also takes place in that winding station. When the winding of tape strips 50 upon
Willdil-g mandrel 55a is nearly colll~ e in the winding mandrel winding station 52 Cposition
C), an empty winding mandrel 55b is advanced by the upper turret assembly 65 into ready
position B (see FIG. 6). Likewise, the winding mandrel 60a is .eiml~lt~neously winding tape
strips 51 in its winding station 53 Cposition C) ofthe lower turret assembly 70. When the
wi~ g on winding mandrel 60a is nearly co , 'et~, an empty winding mandrel 60b is
advanced to its ready position B.
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The enveloper and knife assemblies extend laterally to engage the winding mandrel
and tape strips wound thereon in each winding station During wil~L,g (as illustrated in
FIG 6), the enveloper and knife ass~lnblics are pivoted away from their l~;sl ecli~e winding
mandrels to permit the inrlPYing of empty winding ~ dr~,ls about the turret acsPmhlip~
5 specifically (from position A to position B) However, when winding is nearly c ~ e
upon a winding mandrel (such as for winding Illalldl~ ls 55a and 60a in F~G 6), the turret
assembly chucks in position C are indexed and winding l"~dl~ls 55a and 60a are moved to
position D on their respective turret asse..ll,lics (as seen in FIG 13) While the winding
mandrels 55a and 60a in position D contin~le to rotate and wind tape strips thereon, empty
10 winding mandrels 55b and 60b are moved from position B on each turret asseml,ly into the
winding stations (position C) for Pn~ with the advancing tape strips This winding
mandrel advance seq~Pm~e is shown in FIGS 6 and 13 As this winding mandrel inflPYin~
occurs, the enveloper and knife ~e~ li~ . are pivoted toward each empty windil~ mandrel
in its winding station This pivoting is begun as a function of the amount of web matenal
15 26 that has been advanced, as ~--ol-.Lol~d by the length encoder 202
In FIG 13, the enveloper ~"II,lies are shown to have advanced sl m~ y to
engage the tape strips advancing from the anvil roller 48 to the winding tape rolls on
winding mandrels 55a and 60a, and the knife a~e.l.blies are ready to envelop the winding
mandrel and advancing tape strips when the ~ ,.ce of a liner/tab strip on the advancing
20 tape strips is detected This is accomrli~h~d by means of optical sensors, such as sensors
288 and 290 mounted on the enveloper asse nl,lics 56 and 61, respectively Thus, for
~Y S~ e; when a leading edge of the liner/tab strip 204 is detçcted by the sensor 288, the
upper enveloper and Imife ~emhlies 56 and 57 are pivoted together to fully envelope the
empty winding mandrel 55b and at1ja~nt portions of advancing strips 50 The sensor 290
25 operates in a similar manner to detect a leading edge ofthe liner/tab strip 205 for l-i~ge i..g
the final pivoting together ofthe lower enveloper and knife ~sPmhlies 61 and 62
The sequence of tape cut-offand winding about a winding mandrel is illustrated
~pecific~lly in FIGS 14a-141 These figures and this discussion illustrate the upper
enveloper and knife assemblies 56 and 57 and their operation Other than orientation, the
iO operation ofthe lower enveloper and knife assemblies 61 and 62 functionally is the same, as
is the construction of those assemblies
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The upper enveloper assembly 56 has a strand feed roller 292 and a cinch roller 294
~FIG. 14a). The circ~ llLial surface ofthe strand feed roller 292 is defined by a
plurality of laterally spaced apart silicone rubber O-rings 296. Likewise, the circ~ ial
surface ofthe cinch roller 294 is defined by a plurality of laterally spaced apart silicone
rubber O-rings 298. The strand feed and cinch rollers 292 and 294 are lo~al~l)ly supported
from the enveloper frarne 264 and are driven to rotate in an oppo~"le direction from the
rotation ofthe w~~ lg mandrel 55b. The strand feed and cinch rollers on each enveloper
assembly are, o~ly driven by a coll~ on motor (not shown) which is carried by the
enveloper frame 264. As illustrated in FIGS. 14a and 15, a plurality of strand guide fingers
300 are laterally spaced across the upper enveloper assembly 56. Each strand guide finger
300 extends between ~ c~.nt O-rings 296 on the strand feed roller 292, and likewise
between ~ c~nt O-rings 298 on the cinch roller 294. Each strand feed guide 300 is
mounted at its base 302 to the enveloper frame 264, and has a first bridge por~ion 303
between its base 302 and the strand feed roller 292, and a second bridge portion 304
between the strand feed roller 292 and cinch roller 294 (see ~IG. 15). Each strand feed
guide 300 then has a distal finger portion 306 ~ .I;..g generally outwardly from the cinch
roller 294. The distal pollions ofthe strand feed guide 300 are shaped to envelop the
empty winding ~ d-t;l 55b, as illustrated in Figure 14b.
A tail-winder asse~llll)ly 308 is also carried upon the enveloper assembly 56. The
tail-winder a~ell,l~ly 308 includes an arm 310 pivotally mounted to the enveloper frame
264 at pivot axis 312. An upper end of arm 310 is pivotally crnnected to a linear actuator
314, such as a pnel lm~tic cylinder which is pivotally mounter at its cylinder end to a support
316 fixed to the enveloper ~ame 264. An ~ Alell~;l,le rod 318 of the actuator 314 is
~.xt.~.nfled and pivotaUy coupled to an upper end ofthe arm 310 ofthe tail-winder assembly
308. At its lower end, the arrn 310 has a laterally ~ .I,u~ anchor plate 320 which is
adapted to engage the tape strips ~0. Lay-down rollers 322 are also pivotaUy mollntecl to
the arm 310 ~ nt its lower end, by a plurality of ~u~po.l~ 324.
The upper lay-on roller and knife as~e.nl,ly ~7 in~ e first and second lay-on idler
rollers 326 and 328, which extend laterally across the tape strip travel path and are release r
coated. The second lay-on idler rollers 328 are lot~l~ly mounted to knife frame 270 by
supports 330. The first lay-on idler rollers 326 are ~ l~ly supported by support arms
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332, which are pivotally mounted to supports 330 as at laterai pivot axis 334. The support
arms 332 and first lay-on idler rollers 326 are biased away from the knife frame 270 by
suitable bias means such as springs 336.
A lateraUy extending tape knife blade 338iS mounted to the knife frame 270
~dj~ctont the first lay-on idler rollers 326. A laterally ~ g tape tuck plate 340 is
mounted ;~dj~c~nt the tape knife blade 338, between the tape knife blade 338 and first lay-
on idler rollers 326. A laterally ~Y~ g tape pinning bar 342is also supported by the
Imife frame 270 a~ c~nt the tape knife blade 338. The tape pinning bar 342 is biased away
from the knife frame 270 by suitable bias means such as springs 344.
4 Cut-O~and WindingOperations
FIG. 13 illu~Llales the upper enveloper and knife as~ lies 56 and 57 ;~ PIy
pnor to their compl C~te enveloplll~llL of the empty winding mandrel S5b. This I ~laliol~l~ is
also shown in greater detail in ~IG. 14b . During the operation of the cut-off and winding
assembly, a plurality oftape strips can be siml~lt~neQll~ly processed in relation to a single
].5 winding mandrel. For clarity of illustration, however, the following ~liscllc~ n will relate to
the processing of a single tape strip.
Upon detectiQn of a leading edge 350 of the liner/tab strip 204, the enveloper and
knife ~emhlies 56 and 57 are pivoted together about the empty winding mandrel 55b, as
illustrated in the .ceqllPnce of FIGS. 14a-14e. In 14a, the enveloper assembly 56 and knife
assembly 57 are shown approaching the empty winding mandrel 55b, which lllO~ ;Iycontacts the advancing tape strip 50. In FIG. 14b, the enveloper assembly 56 is shown
contacting the rotating empty winding mandrel 55b, with its lay-down roller 322 (which is
release coated) ~ ging the advancing tape strip 50 to push it away from the winding
mandrel 55b. This prevents the adhesive on the tape strip 50 from llnn~c~ rily running
over the c~l~.p~ es~iblc material layer 246 on the winding mandrel 55b. In FIG. 14c, the
enveloper assembly 56 and knife assembly 57 are shown first contacting tape strip 50 for
tape cufflng. Specifically, the adhesive side 27 ofthe tape sbip 50 has contacted and
adhered to the anchor plate 320 ofthe arm 310 on enveloper assembly 56, and the tape
~ strip 50 is contacted on its opposite side by the tape pinning bar 342 ofthe knife assembly
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57. At the same time, the first lay-on idler roller 326 engages the tape strip 50 opposite the
rotating willdin~ mandrel 55b.
As the enveloper and knife a~ l)lies 56 and 57 contim-e to merge together about
the winding mandrel 55b, the springs 336 and 344 exert pressure against the first lay-on
S idler roller 326 and tape pinning bar 342, ~t;s,oe~ ely. This secures a se~rnent 352 ofthe
tape strip 50 therebetween for cutting. As seen in FLGS. 14c and 14d, the tape strip
~e~..~ 352 (bearing a leading part ofthe liner/tab se~ 204 thereon) is held in tension
as the tape knife blade 338 engages it. As seen in FIG. 14e, when the enveloper assembly
and knife assembly 56 and 57 are fully coupled to envelop the wl~ldi~lg mandrel 55b, the
tape knife blade 338 has severed the 9~ -1 352 ofthe tape strip 50. The springs 336 are
in eo~ s;oll, urging the first lay-on idler rollers 326 against the wi..d~.g mandrel 55b.
The springs 344 are also in .i~lllplt;ssion, urging the tape pinning bar 342 against the anchor
plate 320. The tape strip 50 is now defined as two tape strips 50a and SOb (FIG. 14e),
where tape strip 50a is alînost fully wound about winding mandrel 55a, and tape strip 50b is
just beginni~ to be wound about winding mandrel S5b.
During this severing process, the anchor plate 320 and tape pinning bar 342
cooperate to secure an adhesive bearing portion ofthe tape strip 50a just ahead ofthe
liner/tab strip 204. Thus, when the tape knife blade 338 severs the liner/tab strip 204, it
defines, on the one hand, a se~ 76 ofthe liner/tab strip 204 at the trailing end ofthe
tape strip 50a which is being wound onto the winding mandrel 55a. Referring again to
FIG. 2, this se~ 76 masks the adhesive at the trailing end ofthe tape strip, thereby
defining a tape tab portion 75. The rPrn~in~1~r of the liner/tab strip 204 is wound about the
winding mandrel 55b to form the innerrnost wrap 72 of a next tape roll 15 to be formed,
and con~titut.?s its liner 73 ~ G. 2). Further, the cutting defines the leading edge 71 ofthe
innPrmost wrap 72 that will be defined by the liner 73, which is being directed about the
winding mandrel 55b.
At all times while the tape strip 50a is held between the anchor plate 320 and tape
pinning bar 342 (e.g., FIGS. 14c-14h), the first winding mandrel 55a continlle~ to rotate,
thereby placing the tape strip 50a between the tape roll 15 and the enveloper and knife
assemblies 56 and 57 in tension. The winding mandrel 55a in FIGS. 14a-14k is in position
D on the upper turret assembly 65, and while the winding mandrel sha~c 210 ofthe winding
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mandrel 55a in this position contin~ S to rotate, the core tube 234 about which the tape roll
15 is wound slips rotatably on the shaPL 210 ofthe winding mandrel 55a to hold the tape
roll 15 in the position illustrated by Figures 14c-14h.
The actual winding of the innermost wrap of a tape roll about winding mandrel 55b
is illustrated in the seq~l~nce of FIGS. 14d-14g. As seen in FIG. 14e, the tape tuck plate
340 urges the just-severed leading end of the next tape roll to be formed (edge 71)
,v~dly toward the nip defined by the winding mandrel 55b and the O-rings 296 on the
strand feed roller 292. The first bridge portion 303 ofthe strand feed guide 300 also aids in
directing that leading end into that nip. In FIG. 14f, the leading edge 71 is seen in the nip
between the winding mandrel 55b and O-rings 296 of strand feed roller 292. The second
bridge portion 304 of the strand feed guide 300 aids in feeding the leading edge 71 into the
nip between the wil~dil~ mandrel 55b and O-rings 298 ofthe cinch roller 294. In ~G. 14g,
the leading edge 71 has now passed through the nip between the winding mandrel 55b and
the O-rings 298 of the cinch roller 294. The distal finger portion 306 of the strand feed
guide 300 aids in guiding the leading edge 71 into an underlying l~la~iu~ u to the trailing
portion of the innermost wrap (liner 73) and the adhesive side of the tape strip 50b
following it. The second lay-on roller 328 is aligned to urge the tape strip 50b into the
largest possible contact arc about the winding rnandrel 55b, thereby defining the overlap of
advancing tape strip 50b onto the innermost wrap as close as possible to the distal finger
portion 306. Finally, in FIC~. 14h, the leading edge 71 is seen as now over wrapped by the
trailing end of the ilulel most wrap (formed by the liner 73). As the winding continues, the
adhesive side 27 of the tape strip 50b contacts the liner 73 and is urged against it by the first
lay-on idler roller 326 (which~ ~lthough it has been pushed toward the knife frame 270,
cQntin~-es to be fiFeely r~f~le~ to adhere ~ereto and secure the innermost wrap
about the wi-~di~lg mandrel 55b.
To f~r~ilit~te the feeding of the leading end 71 of the liner 73 about the winding
mandrel 55b and into the path defined by the strand feed guide 300 thereabout, in one
alternative the first lay-on idler rollers 326 are driven at a rate faster than line speed and
faster than the rate of rotation ofthe winding mandrel 55b. This tends to direct the leading
3 0 end 71 away from the driven lay-on rollers 326 and up toward the travel path defined by
the strand feed guide 3 00 about the rotating winding mandrel 55b.
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The strand feed and cinch rollers 292 and 294 are driven to rotate at a much faster
;umr~ ial speed than the line speed and rate of rotation of winding mandrel 55b.Thus, when the liner 73 engages the strand feed and cinch rollers 292 and 294, it is forced
under increased tension into the nip between those rollers and the winding mandrel 55b and
'; pulled relative to the line speed ofthe tape strip 50b. The increased rate of rotation of.the
strand feed and cinch rollers 292 and 294 also tends to direct the leading end 71 away from
the strand feed and cinch rollers 292 and 294, about the winding mandrel 55b and under the
trailing edge ofthe liner 73. The strand feed roller 292 is driven via a one-way clutch to
allow over-rotation caused by the cinch roller 294
The increased tension placed on the innermost wrap (liner 73) as it is wound about
the core tube 234 co~ sses the rnaterial layer 246 (via bending of stems 248, as seen in
~IGS. 11 and 12), thereby defining the inner di~metpr ofthe ,mlellllo~L wrap. The material
layer 246 is con~,es~il,le under shear applied ~ Ily to its outer surrace (stems 248)
by the innermost wrap of tape as it is wound about the winding mandrel 55b in tension.
15 The innermost wrap is thus pulled or cinched in tension about the winding mandrel 55b to a
desired position, and this tension is held and ~ ed when the adhesive on the tape strip
50b is wrapped about and secures the innermost wrap in place (~,t;re,~ly, the length ofthe
liner 73 is slightly longer than the circumference of ~he cinched innermost wrap). The
action ofthe strand feed rollers 292 and cinch rollers 294 and the w..,d",g mandrel 55b
2() cause the innP.rmost wrap to tighten about the winding mandrel 55b for a short time. As
soon as the adhesive 27 on the advancing tape strip 50b contacts the wound liner 73, the
increased pulling ceases, forming an inLt;lr~lt;"ce fit oftape strip 50b around the winding
mandrel 5'ib. The core tube 234 may luL~l~ly slip relative to the winding mandrel shaflc
210 during this process. The end result is a relatively tightly wound innermost wrap of the
2'i tape strip, and specifically the leading portion ofthe tape strip covered by liner/tab material
(liner 73), with successive windings of adhesive-bearing tape strip thereon. During further
proceCci~lg, the tape roll 15 does not slip rotatably relative to the core tube 234, but the
core tube 234 may slip rotatably relative to the winding mandrel shaft 210 (and indeed, is
designed to do so).
After the initial wrap oftape strip 50b around the winding mandrel 55b is
completed (FIG. 14h), the enveloper assembly 56 and knife assembly 57 pivot about pivot
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axis 268 to separate and ~ P.ng~ from the winding mandrel 55b. As seen in FIG. 14i,
once the enveloper and knife assell-blies 56 and 57 are s~mcie~ y separated to ~ii.s.on~e
the anchor plate 320 and tape pinning bar 342, the tension placed on the tape strip SOa by
rotation of wil~L~, rnandrel 55a pulls on the arm 310. The arm 310 is free to pivot about
pivot axis 312, and thus pivots toward winding mandrel SSa, while rod 318 retracts into
cylinder 314. The tape strip 50a leading to winding mandrel 55a remains adhered to the
anchor plate 320 initially, as illustrated in FIG. 14i. The winding mandrel 55a continues to
rotate, and because the tape strip 50a is no longer held to the enveloper a,~ell-l~ly 56, the
rP.m~in-l~r oftape strip 50a starts winding onto tape roll lS on wil~d~ mandrel 55a and
pulling arm 310 toward winding mandrel 55a. Thus, the rotational slippage of core tube
234 under the tape roll 15 on winding mandrel 55a slows as the tape roll 15 on the winding
mandrel 55a again begins to rotate with the winding mandrel 55a. Eventually, the angular
orient~tion ofthe anchor plate 320 and rrl~ strand oftape strip SOa causes the
adhesive side 27 of the tape strip 50 to peel off of the anchor plate 320, as illustrated in
~IG. 14j. Finall,v, the alm 310 is pulled to a position wherein the lay-down roller 322
engages the outer circulllrelt;ll~ial su face ofthe tape roll 15 as it rotates, thereby wiping or
rolling over the oule~ os~ layer thereof (FIG. 14k). The cylinder 314 holds it in this
position momt~.nt~rily and is then actu~t~1 to extend rod 318 and pivot arm 310 back in
place on the enveloper frame 264. The enveloper assembly 56 may dwell mom~nt~rily on
'20 the winding mandrel 55b as the alm 310 is pivoted out and back (as shown), or the arm
310 may move during the pivoting away ofthe em~eloper assembly 56 from the winding
mandrel 55b.
The enveloper and knife assel..~ .56 and 57 continue pivoting away from
winding mandrel SSb until fully retracted from the winding mandrel path defined by the
25 upper turret asst; l-l)ly 65. At the same time, the rate of rotation of the winding mandrel
SSb is accelerated to achieve rapid winding ofthe tape strips 50b thereon. The winding
mandrel 55b is rotated at a rate faster than the line speed ofthe advancing web material 26.
Thus, winding mandrel rotation places the tape strip 55b under tension during winding,
although less tension than placed on the tape strip 55b by the enveloper assembly 56 during
30 initial wrap v\/indil-~. The torque applied to each ofthe caliper compensating core tubes
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234 is COll~ llll, as moderated by the force of con~ ssion spring 228 on the independently
.,~le core tubes 234.
FIG. 141 illustrates a winding mandrel stabilizing assembly 354 which is carried on
the upper knife assembly 57. The winding mandrel ~ a~ l,ly 354 is not shown in
5 the other drawing figures for clarity. The winding mandrel stabilizer assembly 354 includes
a ~L~ l finger 355 which is pivotally mounted, as at lateral pivot axis 356, to the knife
assembly 57. At its lower end 357, the ~ r finger 355 is pivotally coupled to an
extensible rod 358 of a linear actuator 359. The linear actuator 359 has a cylinder portion
360 which is in turn pivotally mounted to the knife frame 270 by a support 361. An upper
end 362 ofthe stabilizer finger 355 is formed with a socket 363 adapted to engage one of
the spacer tubes 232, ~I~;r~.~ly ~ c~nt the midpoint ofthe rotating winding mandrel 55b.
The lateral width ofthe .~1~1.;1;,~. finger 355 is less than a width ofthe tape strips 50b being
wound upon the willd~lg mandrel 55b, which allows the sl~hil;,.~.r finger 355 to extend
between ~ eP.nt tape strips 50b being wound on the winding mandrel 55b. One or more
15 ~L~ili~el fingers 355 may be provided along the winding mandrel, depending on the width
and rotational rigidity ofthe winding mandrel.
At the desired high rate of rotation for winding mandrel 55b during tape winding,
the ~ r finger 355 acts to prevent undesired oscillation ofthe rotating v~ ding
mandrel 55b between its chucks. The actuator 359 is normally positioned with its arm
20 retracted, so the ~L~ finger 355 ~ m~s a position such as shown in ph~ntcm in FIG.
141. Upon wi~ wal ofthe upper enveloper asst;"-l~ly 56 from ~cljac~nt the winding
mandrel 55b (after the innermost wrap has been formed and secured), the linear actuator
359 is activated to extend rod 358 and thus pivot the stabilizer finger 355 into çng~g~...l?..
with the rotating winding mandrel 55b, as seen in FIG. 141. When a tape roll 15 is nearly
25 compl~tPIy wound on winding mandrel 55b (an "in-process" tape roll)~ and the winding
mandrel 55b is indexed to its next position D on the upper turret assembly 65, the stabilizer
finger 355 is withdrawn to allow the intlf~xing of an empty winding mandrel from its ready
position B into the winding position C.
During winding ofthe tape strip on winding mandrel 55b, the tape winding and
30 cutting components resume the relative ori~nt~tinn illustrated in FIG. 6. After the
enveloper assembly 56 has returned to its position illustrated in FIG. 6, an empty winding
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mandrel in position A is then indexed to the ready position B to begin the sequ~n~e anew.
The strand feed and cinch rollers are not driven when the enveloper assembly 56 is in its
ready position of FIG. 6. However, as soon as the enveloper assembly 56 begins pivoting
toward the winding mandrel 55b, the drive motor borne thereon for the strand feed and
5 cinch rollers is activated. Likewise, that motor is deactivated as soon as the enveloper
assembly starts pivoting away ~om the winding rnandrel 55b.
The winding mandrel 55a, now bearing a plurality of c~ X tape rolls 15, is no
longer rotatably driven, and its chucks are indexed from transfer position D to unload
position E on the upper turret of assembly 65. After a winding mandrel has been removed
10 from the chucks of its turret assel,ll)ly, with completed tape rolls 15 thereon, the tape rolls
are extracted from the winding mandrel by sliding them axially along the winding mandrel
(as in directions of arrows 365 in FIG. 12). The pliant stems 248 bend to permit axial
movement ofthe tape roll 15 relative to the v~ind~ , mandrel shaft 210, and then aPcer the
tape roll 15 has passed, the stems resume their original l-rst~n~inf~ position (as illustrated by
section 258 of stems 248 in FIG. 12).
The seq~ nce of events illustrated in FIGS. 14a-141 happens quite quickly. The
advance of the tape strip 50 is not stopped to perform the cutting and initial winding
operations illustrated in FIGS. 14a-141. The advance ofthe tape strip S0 is slowed to a
speed lower than its winding speed, but it is not n~ce.~.s~ry to completely stop and then
20 restaIt the tape strip advance.
Process Control
As described above, there are numerous motors and actuators which must be
precisely controlled to achieve the desired coreless tape roll winding. System control is
p~rc;l~ly achieved through use of a microprocessor, which is operatively coupled to the
25 various motors to control their actuation and speeds, and to the various activators to
control their manipulation. For example, in the tab applicator 37, the processor will actuate
- the motor 104 based upon signals received from the optical sensors 186 and 188.
Likewise, the lmife actuator 118 in the tab applicator 37 is activated based upon signals
received from the processor by the optical sensors 186, 188, as is the clutch 113, and also
30 the operation of hydraulic cylinder 176. Similarly, the processor conkols the motor for
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advancing the web material through the apparatus, the motors for the turret a~st;lllblies, the
motors for rotating the winding mandrels and the motors on the enveloper ~emhliP~ In
addition to the sensors and length encoder mentioned, it will be understood by those skilled
in the art that further sensors may be provided as is typical to control the operation and
coordination of such assemb!ies in a system of this type and complexity.
rnple
In one embodiment ofthe present invention, a supply roll of web material is
provided with a nominal width of 60 inches. The tape is formed from a starting supply roll
material of box sealing tape, TARTAN brand No. 371, having a 1' -L-n~o.e~ of .002 inch,
m~nllf~-red by Mill"esuL~ Mining and ~mlf~ctllnnp Company of St. PauL Minnesota.After processing through an apparatus such as illustrated herein, 31 tape rolls are formed,
and each finished tape roll is 48 mm wide and bears apl)loxi~ ely 100 meters oftape. The
finished tape roll has an irmeml~ P~ of 25 mm and an outer ~ ."~ of about 3.25
inches. The line speed for tape winding (e.g., FIG. 6) may be, for ~ , 500 feet per
minute, with a slowdown for cut-offand the start of winding at about 3 feet per rninute.
During willdillg, the wind~g mandrel is rotated at a 5-10% faster rate than the web material
advance speed. In addition, the WUIdi1lg mandrel rotation rate during winding varies
depel~dil~g upon the outer ~ ofthe tape roll wound on the winding mandrel, as
controlled by the processor, in order to slightly exceed the web speed. That ~ mP~ter is
Z0 deplo.n-l~nt upon the i'3: '~n~ ofthe web material and the tension placed thereon during
Wuldil~g~ Initial web tension (at the start ofthe winding seq~çn(~e for a tape roll) is 2/3 to
3/4 Ib/lineal inch width, and the tape rolls are wound in a cun~ torque mode on the
wuldll~ mandrel. In this ~ullpl-, the core tubes on the winding mandrels were covered
with SCOTCHMATETM pressure sensitive backing hook m~tçri~l, m~nllfi.~lred by
2 5 Mill,lesu~ Mining and l~m-f~ lring Company of St. PauL Minnesot~ Part No. 70-0704-
2795-3, and each DEIRINTM core tube had an outer t1i, met~.r of .875 inches. The strand
feed and cinch rollers were rotated, during winding ofthe innermost wrap, at 3-5 times the
web m~tçri~l advance speed. In making the tape rolls of this; , ' -, the tape has a single
adhesive side and is wound with its adhesive side facing the winding mandrel axis. A paper
3 0 liner/tab having a thickness of .003 inch and a length along the travel path of the web
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material of 3.75 inches is provided. Once severed, app~ Al~ly 3.25 inches ofthe
liner/tab defines the liner for the tape roll, while the rP.m~in~iP.r ofthe liner/tab defines the
tape tab portion at the outermost end of a previously formed tape roll.
Although the present invention has been described with reference to p~c:r~llt d
5 embollimPntc, workers skilled in the art will recogr~ize that changes may be made in form
and detail without del~allill~, from the spirit and scope ofthe invention. Thus, the scope of
the present invention should not be limited to the apparatus and procedures described
herein, but rather by the apparatus and mPthorl.c described by the l~n~l~ge ofthe claims,
and their equivalents.
For ~nple, the colllpl ~s~iblc and pliant material layer on the core tubes of the
winding mandrel may also be used to ~ilit~te the r~lll,alion of a coreless roll of pressure
sensitive adhesive tape using a level wind--l~ technique, rather than a cono~,.l.ic -winding
te~hr:qlle. In this in~ne.~, the adhesive liner on the tape strip being wound is sufficiently
long to mask adhesive on the first pass ofthe level winding process, which defines the
15 innerrnost spiral wrap on the tape roll ~ ly formed thereby.
It is also conte~ d that tape rolls be formed with no tape tab portion. In this
instance, the cut-offand winding assembly is controlled to sever the advancing tape strip at
the leading lateral edge ofthe liner/tab, thereby placing no liner/tab material on the trailing
edge ofthe severed tape strip which is u~ y wound as the outermost wrap and edge of
20 a finished tape roll. Thus, all ofthe liner/tab is used to form the liner ofthe tape roll being
wound on the w~1d-l-g mandrel.
In another embodiment, a small lateral strip ofthe leading edge of a tape roll being
wound on the wil~ding mandrel is bent back upon itself as it is wound around the winding
mandrel. As that bent-over lateral strip is wound about the winding mandrel, it then first
'75 engages the adhesive ofthe advancing tape strip. Thus, the leading edge itselfis not
exposed, but rather sandwiched and secured between the first and second innermost wraps
ofthe tape roll being formed. This arrangement thus reduces the possibility that an
unde.l~ ....g portion ofthe leading edge is unadhered and thus prone to catch and become
inadvertently peeled from the tape roll.
Although tli~cll~sed primarily above in the context of pressure sensitive tape having
adhesive on one side thereof, with the adhesive being wound on the inner side of the tape
CA 02221182 1997-11-13
Wo 96/40578 PCT/US96/07~165
--34--
windings, it is contç~ ed that the inventions defined herein are applicable to form
coreless rolls oftape wound in an opposite configuration (with the adhesive side facing
out), as well as to form coreless rolls of pressure sensitive adhesive tape transfer materials
and doubl~nided pressure adhesive tape. It is understood that the willdillg of coreless tape
5 rolls with the adhesive side facing away from the winding ~ ldl~;l Willding axis will result
in some diJr~ Itllt process considerations. For in~t~nt.~; when a liner is provided which
masks the adhesive on the innermost wrap of such tape, the adhesive on the tape will not
engage sl1cc.ç~ive windings thereof until the initi~ti-)n of the third wrap of tape about the
winding mandrel. Thus, it will be nec~ ..y to ~ the ~ ltased tension on the tape as
10 it is wound for two initial wraps about the winding mandrel in order to cinch the tape about
the winding mandrel using its own adhesive. In that regard, the roller and O-rings on the
cut-off and winding a~ellll,ly must n~ce~. ily be release coated or formed of a suitable
material (i.e., silicone rubber) because they will be contacting the adhesive bearing side of
the tape. Because the adhesive is on an opposite side of the tape, the tail-winder assembly
15 308 must be recc-nfi~-red, since there would be no ~lh~ion ofthe severed tape to the
anchor plate, but rather to the pinning bar 342. Further, because the o~lt~rmost wrap of a
finished tape roll would have its adhesive on its outer surface, the length ofthe liner/tab
may be e~ntled so that the se~ thereofwhich previously formed the tape tab portion
is long enough to extend about the entire outermost wrap of the finished tape roll, thereby
20 m~king exposed adhesive thereon. Pressure sensitive adhesive tape wound with its
adhesive side out requires no liner on the innermost wrap to prevent adhesive from
~.ng~ging the winding mandrel, since the non-adhesive side of the tape faces the winding
mandrel. Thus, it is c~ ..pl~led that no liner be provided for the innermost wrap, in
which in~t~nce the adhesion by wrapping about the winding mandrel would begin with the
25 second wrap. If a liner/tab is provided, the liner/tab may be severed at its trailing lateral
edge by the cut-offand windil~ ass~ ly and serve only to mask the outermost wrap of a
finished tape roll, rather than as a liner for an innermost wrap.
