ADHESIVE INSULATION MATERIAL AND RELEASE PAPER ROLLS OF ADHESIVE INSULATION MATERIAL WHICH ARE STACKABLE AND NONADHERENT TO EACH OTHER

CROSS REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Application No. 62/170,000, filed June 2, 2015, which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a novel method and apparatus for preparing release paper rolls of adhesive insulation material and release paper rolls of adhesive insulation material which are stackable and non-adherent to each other.

2. Description of the Prior Art

Air conditioning and heating systems, generally referred to as Heating, Ventilating and Cooling (i.e., HVAC) systems, generally include a network of pathways for the treated air, which pathways are generally formed by a network of ducts, attached to each other.

The ducts are generally fastened together to form continuous airways. While the present day the attachment techniques for the ducts attempt to provide seals which are mechanically leakproof, the seams and spaces of the ductwork often need to be sealed by application of a suitable sealant material. In order to prevent leakage at the seams between ductwork sections, and at any junctions vulnerable to air leakage, a soft pliable and sticky adhesive material is used to seal the potential leaks. This material is generally referred to as duct seal, duct sealant, adhesive insulation material and the like. The material has a relatively soft and pliable consistency and is readily worked into open seams and crevices to prevent leaks.

Present day packaging of this type of duct sealant generally dispenses multiple parallel strips of the duct sealant onto a silicone release paper. Thereafter, the release paper is cut immediately below each side of the strip of duct sealant and the combined duct sealant and release paper is rolled into rolls of predetermined size. The rolls are then deposited into a shipping container.

Since the exposed sides of the duct sealant will generally contact each other, when packaging the rolls in a shipping container, it is generally necessary to place a sheet of paper between adjacent rolls to prevent the rolls from sticking to each other. The sheet of paper may be single coated or double side coated with silicone.

The present invention is directed to a method of preparing such release paper rolls by adhesive duct sealant which can be packaged in adjacent contracting relation without fear of the rolls becoming stuck to each other. In particular, each roll is provided with a marginal tab of release paper on at least one side of the duct sealant, which marginal tab prevents the roll of duct sealant from sticking to the next roll.

SUMMARY OF THE INVENTION

The present invention relates to a method and apparatus for preparing release paper rolls of adhesive duct sealant material which have a marginal tab of "excess" release paper on at least one side of the duct sealant, which marginal tab is bent upwardly to prevent the roll of duct sealant from sticking to the next roll when placed in a shipping container. This configuration avoids the need to place a sheet of paper (release type or other) between adjacent rolls in the shipping container to prevent the rolls from sticking to each other.

Accordingly, the added expanse of the additional sheets of release paper and the labor to place the sheets of release paper between adjacent rolls it thereby avoided. The invention also relates to the improved combined insulation material and release paper rolls which are produced on the apparatus and according to the method.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments are described hereinbelow with reference to the

drawings, wherein:

FIG. 1A is a schematic representation of the first stage of the method of preparing release paper rolls of adhesive insulation material (i.e., referred to as "Duct Seal" or the like ), and release paper rolls of adhesive insulation material which are stackable and nonadherent to each other, according to the invention;

FIG. IB is a schematic representation of the second stage of the method according to the invention, showing the steps of compressing the rolls together, and then depositing them into a container for shipment;

FIG. 2 is an elevational view, taken along lines 2-2 of FIG. 1A, showing the step of depositing the insulation material on the release paper;

FIG. 3 is an elevational view, taken along lines 3-3 of FIG. 1A, showing the initial cuts to create strips of release paper having the insulation material positioned thereon;

FIG. 4 is a plan view, taken along lines 4-4 ofFIG.3, viewing the cutter blades used to create the strips of release paper with a marginal portion adjacent each row of insulation material;

FIG. 5 is a partial cross- sectional view, taken along lines 5-5 of FIG. 1A, showing a "paddle wheel" type of rotating blades which make axially extending spaced slits in the marginal portions of the release paper to facilitate ease of rolling of the combined insulation material and release paper into "ready to use" rolls, with minimal wrinkling or crumpling of the release paper when portions adjacent the slits overlap each other;

FIG. 6 is a view taken along lines 6-6 of FIG. 5, partially in cross-section, and illustrating the axially extending spaced slits made in the marginal portions of the release paper adjacent respective adjacent strips of insulation material;

FIG. 7 is a partial cross- sectional view, taken along lines 7-7 of FIG. 1A, showing the tab folding guides used to fold the marginal portions of release paper gradually and upwardly until they become engaged in face-to-face relation with the side walls of the strip of insulation material as will be shown in FIG. 8;

FIG. 8 is a cross-sectional view, taken along lines 8-8 of FIG. 1A, showing the strips of insulation material having upwardly folded marginal tabs of the release paper which protect the respective side surfaces of the strips of insulation material when stacked together in a container;

FIG. 9 is a cross-sectional view, taken along lines 9-9 of FIG. 1A, showing three representative rolls of combined release paper and insulation material, said rolls positioned in lateral spaced relation before being "united" together in lateral face-to-face engaged relation for packing, as shown in FIG. IB;

FIG. 10 is an elevational view, taken along lines 10-10 of FIG. IB, showing a hydraulic system which includes a hydraulic cylinder and related linkage, which are arranged to "unite" the rolls of insulation material as shown in FIG. IB, into a compact arrangement for depositing into a packing container for shipment and ultimate use;

FIG. 11 is an elevational view, taken along lines 11-11 of FIG. IB, showing the rolls of insulation material in a united and compact mode, and being deposited into a packing container for shipment;

FIG. 12 is a cross-sectional view, taken along lines 12-12 of FIG. 11, showing the finished rolls of combined insulation material and release paper positioned in the packing container for shipment, and illustrating the release paper marginal tabs positioned between the respective rolls of insulation material, which marginal tabs prevent the rolls from adhering to each other until they are ultimately used in insulation systems;

FIG. 13 is a plan view of an alternative embodiment of the cutter system, which embodiment produces lateral "V -shaped" cuts in the marginal tab portions of release paper to better facilitate folding of the release paper with less wrinkling, when the combined insulation material and release paper is wrapped to form rolls, as shown in the previous FIGS.;

FIG. 14 is perspective view of a portion of three representative finished rolls of combined insulation material and release paper produced according to the invention, utilizing the "V-shaped" cutting system of FIG. 13;

FIG. 15 is a fragmentary plan view of yet another alternative embodiment of the cutter system of FIGS. 5 and 13, in which the system of providing lateral cuts in the release paper is eliminated, thereby facilitating rolling of the insulation material and release paper into rolls having the marginal tab portions of release paper positioned in an overlapping mode, with some portions being wrinkled or crumpled in overlapping folds; and

FIG. 16 is a perspective view, similar to FIG. 14, showing a portion of three representative rolls of insulation material produced according to the system of FIG. 15, i.e., without the use of lateral cutters, showing the marginal portions of release paper folded in overlapping relation.

Detailed Description of the Preferred Embodiments

Referring initially to FIG. 1A, there is shown a schematic representation of the first stage 10 of the method of preparing release paper rolls of adhesive insulation material that are stackable and non-adherent to each other, according to the present invention.

In FIG. 1A the advancement of the strips of duct sealant and release paper, before and after being combined, is provided by a system of distinct pairs of rollers 11, 13, 15, each roller of each pair being rotated in respectively opposite rotational directions as shown by the arrows in FIG. 1A. These pairs of rollers provide the forward momentum which advances the strips of insulation and release paper, as will be described

hereinbelow.

In FIG. 1A, the system 10 includes a roll 12 of insulation material, commonly referred to as "duct sealant", "duct seal", or the like. The duct sealant is a soft and pliable material generally used in Heating, Ventilation and Cooling (i.e., HVAC) systems, as well as by utilities to seal unwanted spaces and potential water leaks. The duct sealant has a "putty-like" consistency, which is capable of being molded by hand into any shape required to effect an air-tight and water-tight seal within an open space. This duct sealant has a soft "sticky" consistency similar to window putty or children's "Play-doh".

The roll 12 of insulation material includes a plurality of distinct axially spaced rolls 14 of the duct sealant material 16, and is mounted above a roll 18 which simultaneously dispenses release paper 20. Roll 12 deposits multiple parallel strips of the sealant material 16 onto the release paper 20 as it is fed into the system, as shown in FIG. 1A and FIG. 2.

As noted, and as shown in FIG. 2, the roll 12 is comprised of a plurality axially spaced rolls 14 of such duct sealant material, dispensing continuous strips 16 of the duct sealant material, which strips 16 are simultaneously deposited on the release paper 20 as each roll 14 of duct sealant unwinds in the counterclockwise direction, and as the roll 18 of release paper unwinds in the clockwise direction dispensing release paper 20, as shown in FIGS. 1A and 2.

The release paper 20 of roll 18 is comprised of a durable thin sheet of paper, suitably coated with release material such as silicone on one side, to promote temporary and releasable adherence of the insulation material to the coated side of the paper for storage purposes prior to use. Release paper having two coated sides can be used, as well.

In FIG. 2, the spaced strips 16 of insulation material are deposited on the release paper 20 as shown. Each strip 16 of duct sealant material is separated from the next adjacent strip 16 by spacer rollers 22, leaving a predetermined marginal "tab" portion 24 of release paper between each adjacent pair of spaced apart duct sealant strips 16. Referring now to FIG. 3, a system of rotating cutter blades 26 are positioned in spaced relation, to cut the release paper immediately adjacent side surface 28 of each strip of duct sealant, as shown. This cut leaves a free marginal strip (or tab) 30 of release paper attached to the release paper underneath the next adjacent strip of insulation material, such that the marginal tab 30 can subsequently be folded upwardly to meet the opposite adjacent side 32 of the next adjacent strip of duct sealant as shown and as will be described. It is important to note that each blade 26 is spaced and arranged to cut the release paper 20 immediately adjacent the same corresponding sides of adjacent strips 16 of duct sealant, so that each "left over," or "excess" marginal tab 30 of release paper is free to be folded upwardly in face-to-face relation with the side surface of the next opposing strip 16 of duct sealant, as shown in FIGS. 3 and 7.

The cutter blades 26 are seen in cross-section in FIG. 4 during their rotational movement, which cuts the release paper 20 immediately adjacent the side surface 28 of each respective strip 16 of duct sealant material. Referring again to FIG. 1A, after cutting the release paper 20 at station 3-3, as seen in FIGS. 3 and 4, the combined release paper and insulation material proceeds to the next station 5- 5 in which "paddle wheel"-type cutter 31 having rotating cutter blades 34, is operative to provide a series of longitudinally spaced lateral cuts 36 in the marginal tabs 30 of release paper between the strips 16 of insulation material. The operation of paddle wheel cutter blades 34 is best viewed in FIGS. 5 and 6, whereby the rotating cutter blades 34 provide laterally spaced axial cuts 36 in the marginal tabs 26 of release paper, positioned between adjacent strips 14 of insulation material.

The lateral cuts 36 in the marginal tabs 30 of release paper facilitate relative ease of rolling the combined insulation strip 16 and release paper 20 into convenient rolls by permitting the marginal tabs 30 of release paper to be wrapped into roll form without significant portions of the tab 30 of release paper being wrinkled or "crumpled". In particular, while portions of the release paper may neatly overlap adjacent portions, bulky wrinkles are avoided in this embodiment. However, it is noted that while such relatively bulky wrinkles may be avoided in this embodiment, in some instances, in an alternative embodiment to be described hereinbelow, wrinkling of the marginal tab portions may be permissible.

The next step in the procedure is to guide the marginal tabs 30 upwardly from the unfolded position shown in FIG. 3, to the upwardly folded positions shown in FIG. 8, until the marginal tabs 30 are fully folded upwardly and in face-to-face contact with the side surfaces of the strips 24 of the insulation material strips 14.

This folding procedure is accomplished at station 7-7 by tab folding guides 38, best shown in FIG. 1A and FIG. 7. Tab guides 38 are configured as curved metal or plastic guides which are engaged by the moving marginal tabs 30 of release paper whereby the release paper tabs 30 are gradually folded upwardly toward the side surfaces 28 of the strips 16 of insulation material, as the combined insulation material strip 16 and release paper 20 progresses forwardly toward the rolling station, while supported on support platen 40.

FIG. IB is a schematic representation of the second stage of the method according to the invention, showing the steps of compressing the rolls together by the hydraulic cylinder 46 and gripping linkage 48 to form a combined roll 43, and then lifting the combined roll 43 and transforming it to be deposited in shipping container 56. FIG. 8 is a cross-sectional view of three representative strips 16 of insulation material protected on the bottom by release paper 20 and on one side surface by a marginal tab 30 of release paper. As shown, marginal tabs 30 of release paper are folded upwardly sufficient to engage the respective alternate side surfaces 28 of the strips 16 of insulation material.

Referring to FIG. 9, there is shown a cross-sectional view taken along lines 9-9 of FIG. 1 A, of three representative rolls 42 of combined insulation material 16 and release paper 20, with one respective side surface 28 of each strip 16 of insulation material of each roll being protected by the upwardly folded marginal tab 30 of release paper. These rolls 42 may then be merged together for packaging, without the possibility of adjacent rolls becoming stuck to each other, due to the protective effect of the marginal tabs 30 of release paper on the respective alternate sides of the strips of insulation material.

Referring now to Fig. 10, there is illustrated a hydraulic system 44, including a hydraulic cylinder 46 and related "clamp-type" linkage 48 which is arranged to grip the rolls 42 of combined insulation material 16 and release paper 20, together to the relative positions shown in FIG. 11, i.e., ready for packaging in shipping container 50, shown in FIG. 11. The clamp-type linkage 48 includes extendable link 50 having attached at either end gripping plates 52, 54 which are movable axially as the hydraulic cylinder is actuated between the extended and the withdrawn positions. Thus, gripping plates 52, 54 are first movable outwardly and then inwardly toward the rolls 42 of combined insulation material 16 and release paper 20 until it "compresses" the rolls toward each other to form combined 43, whereby the axial dimension is reduced sufficiently to fit the combined rolls into a packing container 56 as shown in FIG. 11. The clamp-type linkage 48 includes extendable link 51 having attached at either end, gripping plates 52, 54, which are movable axially as the hydraulic cylinder is actuated between the extended and the withdrawn positions. Thus, gripping plates 52, 54, are first movable outwardly and then inwardly toward the rolls 42 of combined insulation material 16 and release paper 20 until it "compresses" the rolls 43 toward each other until the axial dimension is reduced sufficiently to fit the combined rolls into a packing container 56 as shown in FIG. 11.

FIG. 12 shows a cross-sectional view, taken along lines 12-12 of FIG. 11, of the finished rolls 42 of combined insulation material 16 and release paper 20 deposited into container 56 by gripping plates 52, 54 of the gripping linkage 48.

FIG. 13 illustrates an alternative embodiment of the invention whereby the system of providing straight axial cuts in the release paper is replaced by a "paddle-wheel" type system of V -shaped cutting blades 58 which provide V -shaped cuts 60 in spaced relation, similar to the device 34 of FIG. 1A, but modified to include V-shaped cutter blades 58 as shown.

This system facilitates folding the finished product, i.e., insulation strip 16 and release paper 20, more evenly, with less wrinkling or crumpling of the portions of release paper which become overlapped in the rolling procedure, as shown in FIG. 14. In particular, the V -shaped cuts result in removal of the "V -shaped" material, thereby permitting the marginal tabs of release paper to be rolled into roll form without significant wrinkling or crumpling.

FIG. 15 illustrates yet another alternative embodiment of the present invention, wherein the step of providing lateral cuts in the marginal tabs of the release paper is eliminated. Thus in this embodiment, the strips of combined insulation material 16 and release paper 20 may be wrapped into roll form, with the excess portions of the marginal tabs of release paper being wrinkled or crumpled as shown at 61 in FIG. 16, which in some instances may be permissible.

In this embodiment, however, the primary objective of the present invention is nevertheless satisfied, in that the side surfaces 28 of the rolled strips 16 of insulation material are protected from sticking to the next adjacent roll, as in the previous embodiments.

Furthermore, in this embodiment, wrinkling or crumpling may be tolerated, particularly where there are no constraints on the size of the shipping container which permits the combined stack of rolls of insulation material and release paper to be larger than the size of the shipping container used for the previous embodiments.

LIST OF REFERENCES j Q First Stage of the Method of Preparing Release Paper Rolls

¹⁰ System

11,13,15 System of Distinct Pairs of Rollers

12 Roll of Strips of Insulation Material ^ Axially Spaced Rolls of Insulation Sealant Material

¹⁶ Duct Sealant Strip

1 0

Roll of Release Paper

20 Release Paper

22 Spacer Rollers

24 Predetermined Marginal "tab" portion of release paper

²⁶ Rotating Cutter Blades

28 Side Surface of Strip of Insulation

30 Marginal Strip, or "Tab" of Release Paper

³¹ Paddle- Wheel Type Cutter

32 Opposite Adjacent Side of the Next Adjacent Strip of Duct Sealant 3 ⁴ Paddle Wheel Cutter Blades

³ ^ Laterally Spaced Axial Cuts

³ ^ Tab Folding Guides

^ Support Platen

42 Three Representative Rolls of Combined Insulation Material and Release Paper 4 ³ Combined Rolls 44 Hydraulic System

46 Hydraulic Cylinder

48 "Clamp- Type" Linkage

50 Shipping Container

51 Extendable Link

52,54 Gripping Plates

56 Shipping Container

58 V -shaped Cutting Blades

60 V -shaped Cuts

61 Excess Portions of the Marginal Tabs of Release Paper Wrinkled or

Crumpled