Assembling packaging
A tape dispensing unit (10), feeding tear tapes (12, 13), to a continuous portion of packaging material (14). The tear tape is applied to the packaging portions so that consumers may easily open the assembled packages. Tape is applied to packaging from a reel. A reserve reel also holding tape is provided. When the end of the tape on the reel in use is reached the tape dispensing unit splices together the end of the tape in use with the beginning of the reserve reel, so that tape is fed continuously to the packaging material.
The present invention relates to improvements in assembling packaging, especially packaging which incorporates a tape, such as a tear tape, to assist in the opening of a package.
In known systems, a sheet of packaging material which will form a plurality of packages is printed, before being cut into the requisite sized packages. If a tear tape is to be included in the finished package, this is usually applied after the printing step, but before the sheet is cut. Tear tape is usually supplied on self-wound reels, wherein one side of the tape is coated with pressure-sensitive adhesive, and the other side is coated with a release agent, such as silicon. Such a tape is disclosed in the applicant's own EP 0 121 371. Alternatively, if the tape is not self-wound, a release paper may be provided to prevent the tape from adhering to itself too strongly. Alternatively, an adhesive, such as hot melt adhesive, can be applied to one side of the tape, by a hot shoe, or similar device as a step of the application process.
The present invention is mainly concerned with the application of self-wound tear tape to packaging, where one side of the tape is coated with release agent and the other is coated with pressure-sensitive adhesive. This type of tape has advantages over the hot melt adhesive type in that: the tape can be applied more quickly, there is less likelihood of the adhesive contaminating other parts of the machinery, and no adhesive seeps out from under the tape after its application. Such seepage could, for example, cause problems when different packaging portions to which tapes are applied are stacked on top of each other, especially when the adhesive is still warm.
In known systems where tear tape is applied to packaging, tape is fed into the printing machine from a tape reel which may be motorised, depending upon the size and type of reel. The tape is then applied to the packaging as the packaging passes through the machine. When the reel of tape is empty, the machine must be stopped temporarily so that the reel can be changed. Obviously, this decreases productivity, not only because the printing has temporarily ceased, but also because upon restarting of the machine the distinct printing stages must again be brought into precise registration before the printing may be continued at normal speed.
EP 0358 477 discloses a toggle for attaching the trailing edge of a tape currently in use to the leading end of a reserve tape. The tape in use is supplied with a pin, which is disposed transversely to the axial extent of the tape. The reserve tape is provided with a loop, through which the tape in use (i.e. current tape) passes. When the pin attached to the tape in use contacts the loop, the reserve tape will be drawn into the machine. The portion of packaging incorporating this toggle will subsequently have to be located manually and discarded. This document discusses the fact that this toggle may cause the reserve tape to be fed into the machine upside down and that this could be a problem for tapes with one adhesive side. To address this problem the document discusses including a tail segment, where the portion of the tape in use that is attached to the reel is loosely attached (for example, with masking tape) to the portion of the in use tape having the pin. However, this arrangement involves complicated preparation of the tapes and is therefore undesirable.
U.S. Pat. No. 4,572,460 discloses a similar system in which the tape in use is provided with an aperture, and the reserve tape is supplied with a “mushroom-like” tab. There is no mention of any modification that would make this apparatus suitable for use with adhesive tape.
It would be advantageous to be able to supply tape continuously from a plurality of rolls of tape sequentially, without having to prepare the tapes, or having to attach anything thereto as with the prior art.
One aspect of the present invention provides a method of splicing tapes, having an adhesive coating, the method comprising the steps of:
driving a first tape supplied from a first tape supply reel past a splicing area, the splicing area including at least two rollers movable between a closed position in which contact is made with tape in the splicing area, and an open position in which contact is not made with any tape in the splicing area;
introducing a second tape from a second tape supply reel into the splicing area when the rollers are in the open position; and
pressing the first and second tapes together with the rollers, to cause the first and second tapes to adhere together, one on top of the other.
Preferably the method includes the steps of monitoring the amount of tape remaining on the first reel and moving the rollers in the splicing area into the closed position when the amount of tape remaining on the first reel falls to a predetermined level.
At least one of the first or second tapes should be coated with adhesive on one side.
Preferably the method further includes the step of cutting the first tape after the tapes have been joined.
Preferably the method further includes the step of moving the rollers to the open position.
The step of monitoring the amount of tape remaining on the first reel may be automated.
The step of moving the rollers to the closed position when the amount of tape remaining on the first reel falls to a predetermined level may be automated, and may be based on the automatic monitoring of the amount of tape remaining on the first reel.
The step of cutting the first tape may be automatic, and may be performed when a predetermined time has elapsed with the rollers in the closed position.
The step of monitoring the amount of tape on the first reel may comprise the steps of:
resting circumferentially on the reel an arm, one end of which is pivotally mounted on a rotary potentiometer, so that as tape is dispensed from the reel, and its diameter reduces, the arm is displaced pivotally;
monitoring the change in potential difference across the potentiometer;
using the said change in potential difference across the potentiometer to determine the amount of tape remaining on the reel.
Alternatively, the step of monitoring the amount of tape on the first reel may comprise the steps of:
resting circumferentially on the reel an arm, provided with a metal target, so that as tape is dispensed from the reel, and its diameter reduces, the arm is displaced;
providing an inductive sensor in the proximity of the metal target;
monitoring the load on the inductive sensor;
using the load on the inductive sensor to determine the amount of tape remaining on the reel.
According to another aspect of the present invention there is provided an apparatus for supplying a continuous length of adhesive tape from reels carrying discrete amounts of adhesive tape, the apparatus comprising:
a splicing unit, including a tape path for conveying tape, and at least two rollers, being movable between an open position in which the rollers do not come into contact with the tape path and a closed position in which the rollers contact the tape path to join together tapes from different reels in use.
There may be further provided first and second tape dispensers, for holding first and second reels of adhesive tape, respectively, wherein the splicing unit further includes at least one reserve tape retaining means, for retaining a leading edge of a tape from one of the first or second reels as a reserve reel.
The other of the first or second reels, as a currently-supplying reel, may be provided with an automatic monitoring system for monitoring the amount of tape held on the reel. The monitoring system may be connected to a control unit, which is arranged to move the rollers from the open position to the closed position when a signal from the monitoring system indicates that the amount of tape held on the currently-supplying reel has reached a predetermined low level.
The control unit may also control the reserve tape retainer, for allowing a tape held thereon to become released therefrom when the rollers move into the closed position.
The control unit may actuate a cutting mechanism, for cutting a tape from a spent reel when the rollers are in the closed position. The cutting may be activated a predetermined time after the rollers have been moved into the closed position.
The control unit may return the rollers into the open position a predetermined time after they moved into the closed position.
The monitoring unit may comprise:
an arm pivotally mounted on a portion of casing, for positioning circumferentially on a reel of tape, and a rotary potentiometer attached pivotally to one end of the arm, so that as the arm falls, the potential difference across the potentiometer will vary according to the position of the arm, for determining the amount of tape remaining on a reel.
Alternatively, the monitoring unit may comprise:
an arm having a metal target, pivotally mounted on a portion of casing, for positioning circumferentially on a reel of tape, and in the proximity of an inductive sensor, so that as the arm falls, a different loading on the inductive sensor is produced, for determining the amount of tape remaining on a reel.
A DC output may be produced by the monitoring unit which may then be input into a control unit.
According to another aspect of the invention there is provided tape splicing apparatus for splicing together tapes from different tape supply reels, the apparatus comprising:
a splicing station, having a first tape input path along which tape is arranged to pass from a first tape supply reel to a common tape output, and a second tape input path along which tape is arranged to pass from a second tape supply reel to the common tape output,
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- wherein the splicing station has at least a pair of nip rollers movable between a first, open configuration in which the rollers are spaced apart, and a second, closed configuration, in which the rollers come together to urge the tape portions from the first and second input paths into contact, one on top of the other;
wherein one of the first and second tape supply reels is arranged as a current reel and the other reel is arranged as a standby reel;
wherein the apparatus comprises means arranged in use to determine the quantity of tape remaining on the current reel and/or the estimated time remaining before the tape supply on the current reel is exhausted;
wherein, based upon said determination, the apparatus is arranged to move the nip rollers from the first position to the second position to cause the tapes to adhere to one another;
and wherein, the apparatus further provides cutting means, arranged to cut the tape from the current reel thereby to replace the current reel with the standby reel.
The present invention may include any combination of the features and/or limitations referred to herein, except such features as are mutually exclusive.
Preferred embodiments of the present invention will now be described with reference to the following drawings, in which:
Turning to
After a suitable time has elapsed the upper tape 12a is cut against an anvil 36, by a cutter 38a. The leading edge of the lower tape is now attached to the trailing edge of the upper tape 12a and the former is drawn out of the splicing machine. The reel dispensers are motorised since the new reel will have a large amount of inertia. This reduces the risk of the tape breaking under the tension caused by acceleration. Furthermore, each tape runs from its dispenser to an accumulator. The accumulator has the effect of accelerating the tape slightly before splicing occurs, and allows the length of the tape path to decrease slightly after splicing has occurred, to reduce the effect of the tension caused by the acceleration.
After the spent upper tape 12a is cut, the nip rollers are drawn apart again after a suitable time to ensure that the tapes are properly adhered together. The lower tape 12b is now fed onto the packaging material. Then, a new reel of tape will be fitted in place of the spent reel, and the leading edge of this tape drawn out and placed on the vacuum shoe 26a. A corresponding process will be carried out when the lower tape 12b currently in use runs out. Accordingly, this process can be carried out indefinitely without stopping the machine, which would lead to costly “down-time” and reduce productivity.
It may be necessary to slow the speed of the machinery when the tape is spliced, depending on the running speed of the machinery. Printing machines, which may use such dispensing units may run at about 4 m/s (800 ft/min), whereas currently splicing can only be performed at 2 m/s (400 ft/min). The motorised reel on the tape in use can be slowed to accommodate this change in speed; when the potentiometer senses that the tape on the reel is running low, i.e. the machine is about to perform splicing, the reel and therefore the tape can be driven at a lower speed. When the splicing action is completed the reel can again be driven at the usual speed.
Accordingly, the detection of the amount of tape remaining on the reel can be performed automatically, and this information can be used to perform the splicing of the tape in use to the reserve tape automatically. However, these functions could also be performed manually.
Claims
1. A method of splicing tapes having an adhesive coating, the method comprising the steps of:
- driving a first tape supplied from a first tape supply reel past a splicing area, the splicing area including at least two rollers movable between a closed position in which contact is made with tape in the splicing area, and an open position in which contact is not made with any tape in the splicing area;
- introducing a second tape from a second tape supply reel into the splicing area when the rollers are in the open position; and
- pressing the first and second tapes together with the rollers, to cause the first and second tapes to adhere together, one on top of the other.
2. A method of splicing tapes according to claim 1 including the steps of monitoring the amount of tape remaining on the first reel and moving the rollers in the splicing area into the closed position when the amount of tape remaining on the first reel falls to a predetermined level.
3. A method of splicing tapes according to claim 1 wherein at least one of the first or second tapes is coated with adhesive on one side.
4. A method of splicing tapes according to claim 1 the method further including the step of:
- cutting the first tape after the tapes have been joined.
5. A method of splicing tapes according to claim 1 the method further including the step of moving the rollers to the open position after the tapes have been joined.
6. A method of splicing tapes according to claim 2 wherein the step of monitoring the amount of tape remaining on the first reel is automated.
7. A method of splicing tapes according to claim 2 wherein the step of moving the rollers to the closed position when the amount of tape remaining on the first reel falls to a predetermined level is automated, and is based on the automatic monitoring of the amount of tape remaining on the first reel.
8. A method of splicing tapes according to claim 4 wherein the step of cutting the first tape is automatic, and is performed when a predetermined time has elapsed with the rollers in the closed position.
9. A method of splicing tapes according to claim 2 wherein the step of monitoring the amount of tape on the first reel comprises the steps of:
- resting circumferentially on the reel an arm, one end of which is pivotally mounted on a rotary potentiometer, so that as tape is dispensed from the reel, and its diameter reduces, the arm is displaced pivotally;
- monitoring the change in potential difference across the potentiometer;
- using the said change in potential difference across the potentiometer to determine the amount of tape remaining on the reel.
10. A method of splicing tapes according to claim 2 wherein the step of monitoring the amount of tape on the first reel comprises the steps of:
- resting circumferentially on the reel an arm, provided with a metal target, so that as tape is dispensed from the reel, and its diameter reduces, the arm is displaced;
- providing an inductive sensor in the proximity of the metal target;
- monitoring the load on the inductive sensor;
- using the load on the inductive sensor to determine the amount of tape remaining on the reel.
11. An apparatus for supplying a continuous length of adhesive tape from reels carrying discrete amounts of adhesive tape, the apparatus comprising:
- a splicing unit, including a tape path for conveying tape, and at least two rollers, being movable between an open position in which the rollers do not come into contact with the tape path and a closed position in which the rollers contact the tape path to join together tapes from different reels in use.
12. An apparatus for supplying a continuous length of adhesive tape according to claim 11 wherein there is further provided first and second tape dispensers, for holding first and second reels of adhesive tape, respectively, wherein the splicing unit further includes at least one reserve tape retaining means, for retaining a leading edge of a tape from one of the first or second reels as a reserve reel.
13. An apparatus for supplying a continuous length of adhesive tape according to claim 12 wherein the other of the first or second reels, as a currently-supplying reel, is provided with an automatic monitoring system for monitoring the amount of tape held on the reel.
14. An apparatus for supplying a continuous length of adhesive tape according to claim 13 wherein the monitoring system is connected to a control unit, which is arranged to move the rollers from the open position to the closed position when a signal from the monitoring system indicates that the amount of tape held on the currently-supplying reel has reached a predetermined low level.
15. An apparatus for supplying a continuous length of adhesive tape according to claim 14 wherein the control unit also controls the reserve tape retaining means, for allowing a tape held thereon to become released therefrom when the rollers move into the closed position.
16. An apparatus for supplying a continuous length of adhesive tape according to claim 14 wherein the control unit actuates a cutting mechanism, for cutting a tape from a currently-supplying reel when the rollers are in the closed position.
17. An apparatus for supplying a continuous length of adhesive tape according to claim 16 wherein the cutting is activated a predetermined time after the rollers have been moved into the closed position.
18. An apparatus for supplying a continuous length of adhesive tape according to claim 14 wherein the control unit may return the rollers into the open position a predetermined time after they moved into the closed position.
19. An apparatus for supplying a continuous length of adhesive tape according to claim 13 wherein the monitoring unit comprises:
- an arm pivotally mounted on a portion of casing, for positioning circumferentially on a reel of tape, and a rotary potentiometer attached pivotally to one end of the arm, so that as the arm falls, the potential difference across the potentiometer will vary according to the position of the arm, for determining the amount of tape remaining on a reel.
20. An apparatus for supplying a continuous length of adhesive tape according to claim 13 wherein, the monitoring unit comprises:
- an arm having a metal target, pivotally mounted on a portion of casing, for positioning circumferentially on a reel of tape, and in the proximity of an inductive sensor, so that as the arm falls, a different loading on the inductive sensor is produced, for determining the amount of tape remaining on a reel.
21. An apparatus for supplying a continuous length of adhesive tape according to claim 13 wherein a DC output is produced by the monitoring unit which may then be input into a control unit.
22. A tape splicing apparatus for splicing together tapes from different tape supply reels, the apparatus comprising:
- a splicing station, having a first tape input path along which tape is arranged to pass from a first tape supply reel to a common tape output, and a second tape input path along which tape is arranged to pass from a second tape supply reel to the common tape output, wherein the splicing station has at least a pair of nip rollers movable between a first, open configuration in which the rollers are spaced apart, and a second, closed configuration, in which the rollers come together to urge the tape portions from the first and second input paths into contact, one on top of the other;
- wherein one of the first and second tape supply reels is arranged as a current reel and the other reel is arranged as a standby reel;
- wherein the apparatus comprises means arranged in use to determine the quantity of tape remaining on the current reel and/or the estimated time remaining before the tape supply on the current reel is exhausted; and
- wherein, based upon said determination, the apparatus is arranged to move the nip rollers from the first position to the second position to cause the tapes to adhere to one another.
23. A tape splicing apparatus according to claim 22 wherein the apparatus further provides cutting means, arranged to cut the tape from the current reel thereby to replace the current reel with the standby reel.
Type: Application
Filed: Mar 8, 2006
Publication Date: Jul 20, 2006
Inventors: Gary Brooks (Alfreton), Michael Booth (Mansfield)
Application Number: 11/370,331
International Classification: B65H 19/00 (20060101);