Flat continuous wound adhesive tape dispenser and method of manufacture

Abstract

A flat tape dispenser of a continuous length of pressure-sensitive-adhesive (PSA) tape is wound around a flat panel core producing a more compact, more convenient and easier to carry PSA tape dispenser. The tape utilizes an easy-tear feature. The flat tape dispenser is manufactured by winding the PSA tape on a round shaft of Teflon or a shaft covered by a release liner or release coating. The fully wound PSA tape is removed from the shaft, a flat panel core is inserted and the roll is flattened so the inside seals against the core. Alternatively, the PSA tape is wound on a deformable core and then flattened to its final shape.

What is claimed is:  
     
         1 . A tape dispenser for pressure-sensitive-adhesive (PSA) tape, comprising: 
 a flat core; and    a length of said PSA tape under 100 meters in length wound around said flat core;    whereby a flat pad of continuous tape that can be conveniently carried is produced.    
     
     
         2 . The tape dispenser of  claim 1  wherein said flat core is up to two inches wide, up to 5 inches long and up to 3 mm thick.  
     
     
         3 . The tape dispenser of  claim 2  wherein said PSA tape is between 0.001 and 0.005 inches thick.  
     
     
         4 . The tape dispenser of  claim 1  wherein said flat core is the same width as the tape and is 1 to 10 mm thick.  
     
     
         5 . The tape dispenser of  claim 1  wherein the flat core is 3 to 5 mm thick.  
     
     
         6 . The tape dispenser of  claim 1  wherein the flat core has designs or advertisements thereon that is seen through the clear PSA tape wound around it.  
     
     
         7 . The tape dispenser of  claim 1  wherein the PSA tape utilizes an easy-tear feature that allows any length of tape to be separated from the dispenser pad by hand, without a cutting edge.  
     
     
         8 . A method of manufacturing a tape dispenser of continuous pressure-sensitive-adhesive tape, the steps of the method comprising: 
 winding a continuous length of said tape on a cylinder coated with a release material to a desired roll;    removing the wound roll of tape from the cylinder, wherein the roll of tape is without a core at its center;    flattening the coreless roll of tape without completely collapsing the space in the center of the roll;    inserting a substantially flat core into the center; and    flattening the tape again so that the center seals against the flat core;    whereby a flat tape dispenser of continuous tape results.    
     
     
         9 . The method of  claim 8  wherein the release material on the cylinder is a release liner.  
     
     
         10 . The method of  claim 8  wherein the cylinder is made of Teflon material.  
     
     
         11 . The method of  claim 8  wherein the substantially flat core is the same width as the tape and between 1 to 10 mm thick.  
     
     
         12 . The method of  claim 8  wherein the substantially flat core is the same width as the tape and between 3 to 5 mm thick.  
     
     
         13 . The method of  claim 8  wherein the continuous length of tape is about 0.003 inches thick.  
     
     
         14 . The method of  claim 8  wherein the continuous length of tape is up to 2 inches wide and up to 100 meters in length.  
     
     
         15 . The method of  claim 8  wherein the substantially flat core is up to two inches wide, up to five inches long and about 3 mm thick.  
     
     
         16 . The method of  claim 9  wherein the release liner is removed from the center of the roll before the tape roll is flattened.  
     
     
         17 . The method of  claim 8  wherein the substantially flat core has designs or advertising on both sides which show through the tape after being flattened.  
     
     
         18 . The method of  claim 8  wherein the cylinder is between one inch and three inches in diameter.  
     
     
         19 . A method of manufacturing a tape dispenser of continuous pressure-sensitive-adhesive tape, the steps of the method comprising: 
 winding a continuous length of said tape on a deformable core;    placing an adhesive on the internal surfaces of the deformable core; and    flattening the tape so that the internal surfaces of the core seals against themselves causing a flat tape dispenser of continuous tape.    
     
     
         20 . The method of  claim 19  wherein the deformable core is corrugated.  
     
     
         21 . The method of  claim 19  wherein the deformable core is made of thin film plastic.  
     
     
         22 . The method of  claim 19  wherein the deformable core is between 1 to 10 mm thick.  
     
     
         23 . The method of  claim 19  wherein the deformable core is between 3 to 5 mm thick.  
     
     
         24 . The method of  claim 19  wherein the tape is about 0.003 inches thick.  
     
     
         25 . The method of  claim 19  wherein the tape is up to 2 inches wide and up to 100 meters in length.  
     
     
         26 . The method of  claim 19  wherein the core is between one inch and three inches in diameter.