US3018212A - Thermoplastic bonding and coating - Google Patents

Thermoplastic bonding and coating Download PDF

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US3018212A
US3018212A US749274A US74927458A US3018212A US 3018212 A US3018212 A US 3018212A US 749274 A US749274 A US 749274A US 74927458 A US74927458 A US 74927458A US 3018212 A US3018212 A US 3018212A
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sheet material
web
bead
skirt
edge
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Hyman G Chinn
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Union Carbide Corp
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Union Carbide Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40—Applying molten plastics, e.g. hot melt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/524—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7888—Means for handling of moving sheets or webs
    • B29C65/7894—Means for handling of moving sheets or webs of continuously moving sheets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4329—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms the joint lines being transversal but non-orthogonal with respect to the axis of said tubular articles, i.e. being oblique
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/49—Internally supporting the, e.g. tubular, article during joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72321—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7232—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer
    • B29C66/72327—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a non-plastics layer consisting of natural products or their composites, not provided for in B29C66/72321 - B29C66/72324
    • B29C66/72328—Paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer

Definitions

  • thermoplastic coatings over both the surface and the edges of sheet material have heretofore been generally unsatisfactory and diflicult to obtain.
  • continuous thermoplastic coatings have been impossible to obtain. Coating the flat expanse of sheet material faces is easily accomplished, but the edges of the sheet material Web cannot be successfully coated with thermoplastic by any of the presently known coating techniques.
  • bonds employed to join or seal webs of sheet material
  • a butt-joint or edgeto-edge bond and a lap joint or edge margin-over-edge margin bond wherein the portion of sheet material immediately adjacent to the edge, or edge margin, is lapped over the corresponding portion of the sheet material web.
  • a web of sheet material is folded lengthwise and the opposite edge margins are brought into contact with one another and bonded with a suitable adhesive.
  • a suitable adhesive there is a seam running the entire length of the bag. If the bag is fabricated from sheet material coated on the inner side, a continuous thermoplastic lining would be obtained if a suitable bond were made between the edges.
  • a lap joint is employed because it affords greater strength than butt joint bonds, and in many applications the extra bulk at the seam which invariably accompanies lap joints is not harmful. Whether bulky or not, the lap joint exposes an edge of the web inside the container which, if uncoated, breaks the continuity of the thermoplastic lining and defeats the purpose of the coating. Bags with discontinuous-linings are prone to unsightly staining and physical weakening due to seepage of the contents. Because a butt joint generally lacks the necessary strength for most bag making and similar applications, it is not so widely used, although with such a joint adjacent, un-
  • Patented Jan. 23, 1962 coated edges are coextensive and are thus not exposed to the container contents and a bond of less bulk is obtained.
  • a bag with a long seam is only one of the many types of containers in which the problem of exposed uncoated edges arises.
  • Others are spiral wound containers and convolute containers which offer greater rigidity and strength but are subject to the same limitations as bags with regard to liquid and semi-liquid goods. Also, in these containers, the bulk of a lap joint can become a serious drawback.
  • the method of my invention utilizes one and preferably two extruders.
  • the first extruder places a bead of resin upon a travelling web of sheet material near the edge.
  • the head after flattening adheres firmly'to the sheet material and is sufficiently solidified to extend outwardly without outside support as a skirt.
  • the second extruder places a head of hot resin between said skirt and a second web edge margin andsaid skirt and edge margin are then pressed against the hot bead and become firmly bonded together thereby. Additionally, in .those instances in which the two web edges are aligned in substantially abutting relation, some of theresin from the second extruder may be squeezed between said edges and form a bond therebetween as well.
  • the bond when formed, possesses the valuable attributes of both an overlap seal and a butt joint seal and also avoids the disadvantages of both.
  • the bond possesses great strength, is uniform, does not leak, does not expose an uncoated surface, is easily .applied, is not bulky, and is universally adaptable. "This combination of qualities has not'been attained before.
  • the joint produced by the method of my invention is ideal in containers which are to package liquid, semi-liquid, and/or chemically active goods.
  • the method is extremely versatile in that the extruded head can be any thermoplastic composition and can be applied to virtually any web of sheet material, regardless of thickness, whether single or multi-ply, e.g., paper, metal foil, coated paper, and laminates.
  • the width and thickness of both the portion of the flattened bead adhering to the web and the portion protruding outwardly from the web, i.e., the skirt, can be exactly controlled during the process.
  • FIGURE 1 is a diagrammatic isometric View of the apparatus according to and for carrying out the method of the preferred embodiment of the present invention
  • FIGURE 2 is a section taken along the line 22 of FIGURE 1,
  • FIGURE 3 is a pictorial view of the preferred embodiment of a product of the method of my invention.
  • FIGURE 4 is a section taken along the line 44 of FIGURE 3. V
  • FIGURE 1 The method of my invention as particularly adapted to the formation of spiral wound containers is shown in FIGURE 1. From a consideration of the figure, it will be seen that sheet material is withdrawn from a supply roll 12 at a constant rate along a predetermined path. An extruder, not shown, with nozzle 14 is positioned above the travelling web of sheet material 10 so as to be approximately M; inch from the edge of the sheet material 10. A bead of molten resin 16 is forced from the nozzle 14 onto the sheet material 10 which advances with the resin bead 16 through the nip of a pair of pinch rolls 18.
  • the pinch rolls 18 serve to flatten the resin bead 16, causing it to adhere to the sheet material 10 and to extend outwardly from the sheet material '10 in a self-supporting manner as a skirt 20.
  • the relation of the skirt 20 and the sheet material 10 is best shown in FIGURE 2.
  • the sheet material 10 with skirt 20 is wound around fixed mandrel 22.
  • a paraffin-waxed paper slip sheet 24 is wound simultaneously with and slightly ahead of the sheet material 10 to ensure easy removal of the tube formed.
  • a second extruder or sealer with nozzle 26 places adhesive bead 28 on the skirt 20 of sheet material 10. Winding of sheet material 10 about the mandrel 22 is accomplished in a manner which places edge margin 34 adjacent to edge margin 36.
  • edge margins 34 and 36 are in abutting relation, however, it is within the scope of my invention for edge margins 34 and 36 to be in overlapping relation.
  • skirt 20 margin 36 of sheet material 10 in overlapping relation with skirt 20.
  • the nozzle 26 places a bead of adhesive between skint 20 and the next turn of sheet material 10.
  • the pressure induced by the winding action forces edge margin 36 against skirt 20 to form a bond such as shown in FIGURE 4.
  • the bond hardens and the spiral wound container is cut as withdrawn from the mandrel and appears in FIGURE 3.
  • a method of forming a strong, moisture-proof bond comprising the steps of placing a head of thermoplastic melt onto the edge margin of a sheet material Web, flattening the bead causing a portion of the head to adhere to said edge margin and another portion of the head to extend outwardly from said edge margin as a skirt, placing a second sheet material web in contact with the skirted sheet material web, and supplying thermoplastic melt between the skirt and the adjacent second web forming a bond.
  • a method of forming spiral wound containers com prising the steps of placing on one edge margin of a sheet material web a bead of thermoplastic melt, flattening the bead causing a portion to extend outwardly from said edge margin as a skirt, wrapping the skirted web around a mandrel, placing the edges of successive turns of said web in abutting relation, and placing a head of adhesive between the skirt and the adjacent edge margin of the web to form a joint between successive turns of sheet material web.
  • a method of forming spiral wound containers comprising the steps of placing on one edge margin of a sheet material web a bead of thermoplastic melt, flattening the bead causing a portion to extend outwardly from said edge margin as a skirt, wrapping the skirted web around a mandrel, placing the edges of successive turns of said web in abutting relation, and placing a head of thermoplastic adhesive between the skirt and the adjacent edge margin of the web to form a joint between successive turns of sheet material web.
  • a method of forming a skirted sheet material web which comprises the steps of placing a bead of thermoplastic melt on the surface of a sheet material Web near the edge of said web, and by application of pressure fiattening said bead, causing a portion of the head to adhere to the web surface and another portion to extend out wardly past the said edge of the web as a self-supporting skirt.

Description

Jan. 23, 1962 H. G. CHlNN 3,018,212
THERMOPLASTIC BONDING AND COATING Filed July 17, 1958 INVENTOR 40 HYMAN o. CHINN Y r 34 14. BY M 1.5%
A T TORNE Y United States PatentOfiice 3,018,212 THERMOPLASTIC BONDING AND COATING Hyman Chinn, Somerville, NJ., assignor to Union Carbide Corporation, a corporation of New York Filed July 17, 1958, Ser. No. 749,274 4 Claims. (Cl. 156-195) This invention relates to thermoplastic edged webs and thermoplastic lined containers and a method for their manufacture.
Continuous thermoplastic coatings over both the surface and the edges of sheet material have heretofore been generally unsatisfactory and diflicult to obtain. In certain instances, as when the sheet material has been fabIicated into a container, continuous thermoplastic coatings have been impossible to obtain. Coating the flat expanse of sheet material faces is easily accomplished, but the edges of the sheet material Web cannot be successfully coated with thermoplastic by any of the presently known coating techniques.
, The presence of a discontinuity in a coating such as is created by an uncoated and exposed sheet material edge almost completely nullifies the advantages realized from coating the sheet material faces. Uncoated sheet material edges are a point, in an othervn'se completely coated container, at which leakage can develop, if the packaged contents are liquid or even semi-liquid. In addition, contamination of the contents by the elution of chemicals from the sheet material is a distinct possibility. Thus the presence of even one uncoated edge interrupts the inert, chemically resistant, moisture and vapor impermeable barrier which resin coatings, when continuous, provide.
Inaccessibility of the edges, particularly after the sheet material has been fabricated into a container, and coincidence of a sheet material edge with a container edge preclude use of spray coating techniques which are awkward, time consuming, and unreliable in these applications. Further, with thermoplastic resins, such as polyethylene, a problem of adhesion to nonmetallic subtrates arises, rendering spray-coating techniques even less desirable. In other applications, such as coating of sharpedged webs with plastic to prevent their cutting, a convenient, widely adaptable method is not known. Dip coating techniques such as are used with wax coatings are not practicable with thermoplastics,
There are two general types of bonds employed to join or seal webs of sheet material, a butt-joint or edgeto-edge bond, and a lap joint or edge margin-over-edge margin bond wherein the portion of sheet material immediately adjacent to the edge, or edge margin, is lapped over the corresponding portion of the sheet material web. In the fabrication of a paper bag, for example, a web of sheet material is folded lengthwise and the opposite edge margins are brought into contact with one another and bonded with a suitable adhesive. Thus there is a seam running the entire length of the bag. If the bag is fabricated from sheet material coated on the inner side, a continuous thermoplastic lining would be obtained if a suitable bond were made between the edges. Generally a lap joint is employed because it affords greater strength than butt joint bonds, and in many applications the extra bulk at the seam which invariably accompanies lap joints is not harmful. Whether bulky or not, the lap joint exposes an edge of the web inside the container which, if uncoated, breaks the continuity of the thermoplastic lining and defeats the purpose of the coating. Bags with discontinuous-linings are prone to unsightly staining and physical weakening due to seepage of the contents. Because a butt joint generally lacks the necessary strength for most bag making and similar applications, it is not so widely used, although with such a joint adjacent, un-
Patented Jan. 23, 1962 coated edges are coextensive and are thus not exposed to the container contents and a bond of less bulk is obtained.
A bag with a long seam is only one of the many types of containers in which the problem of exposed uncoated edges arises. Others are spiral wound containers and convolute containers which offer greater rigidity and strength but are subject to the same limitations as bags with regard to liquid and semi-liquid goods. Also, in these containers, the bulk of a lap joint can become a serious drawback.
It is an object, therefore, of my invention to provide a method for forming a bond between webs of sheet material which possesses the advantages but not the drawbacks of both the butt joint and the lap joint.
This and other objects are accomplished in accordance with my invention by extruding a bead of a thermoplastic onto the edge margin of a web of sheet material and flattening the extruded bead, as by a pair of pinch rolls, so that a portion of the flattened bead adheres to the web edge margin of the sheet material and the remainder of the flattened bead extends outwardly from the web edge margin as a skirt. Thereafter the sheet material can be fabricated into a container by placing a skirted sheet material edge adjacent to asecond sheet material edge in such manner that the skirt of said skirted sheet material edge overlaps the edge margin of said second sheet material edge and placing adhesive therebetween and simultaneously pressing said skirt and said edge margin against said adhesive to form a joint therebetween.
The method of my invention utilizes one and preferably two extruders. The first extruder places a bead of resin upon a travelling web of sheet material near the edge. The head after flattening adheres firmly'to the sheet material and is sufficiently solidified to extend outwardly without outside support as a skirt. The second extruder places a head of hot resin between said skirt and a second web edge margin andsaid skirt and edge margin are then pressed against the hot bead and become firmly bonded together thereby. Additionally, in .those instances in which the two web edges are aligned in substantially abutting relation, some of theresin from the second extruder may be squeezed between said edges and form a bond therebetween as well. The bond, when formed, possesses the valuable attributes of both an overlap seal and a butt joint seal and also avoids the disadvantages of both. The bond possesses great strength, is uniform, does not leak, does not expose an uncoated surface, is easily .applied, is not bulky, and is universally adaptable. "This combination of qualities has not'been attained before. The joint produced by the method of my invention is ideal in containers which are to package liquid, semi-liquid, and/or chemically active goods.
The method is extremely versatile in that the extruded head can be any thermoplastic composition and can be applied to virtually any web of sheet material, regardless of thickness, whether single or multi-ply, e.g., paper, metal foil, coated paper, and laminates. The width and thickness of both the portion of the flattened bead adhering to the web and the portion protruding outwardly from the web, i.e., the skirt, can be exactly controlled during the process.
Additional advantages will become apparent from a consideration of the detailed description below of one embodiment of the invention which is described in conjunction with the attached drawings in which:
FIGURE 1 is a diagrammatic isometric View of the apparatus according to and for carrying out the method of the preferred embodiment of the present invention,
FIGURE 2 is a section taken along the line 22 of FIGURE 1,
FIGURE 3 is a pictorial view of the preferred embodiment of a product of the method of my invention, and
FIGURE 4 is a section taken along the line 44 of FIGURE 3. V
The method of my invention as particularly adapted to the formation of spiral wound containers is shown in FIGURE 1. From a consideration of the figure, it will be seen that sheet material is withdrawn from a supply roll 12 at a constant rate along a predetermined path. An extruder, not shown, with nozzle 14 is positioned above the travelling web of sheet material 10 so as to be approximately M; inch from the edge of the sheet material 10. A bead of molten resin 16 is forced from the nozzle 14 onto the sheet material 10 which advances with the resin bead 16 through the nip of a pair of pinch rolls 18. The pinch rolls 18 serve to flatten the resin bead 16, causing it to adhere to the sheet material 10 and to extend outwardly from the sheet material '10 in a self-supporting manner as a skirt 20. The relation of the skirt 20 and the sheet material 10 is best shown in FIGURE 2.
In order to form a spiral wound container such as shown in FIGURE-3, the sheet material 10 with skirt 20 is wound around fixed mandrel 22. A paraffin-waxed paper slip sheet 24 is wound simultaneously with and slightly ahead of the sheet material 10 to ensure easy removal of the tube formed. A second extruder or sealer with nozzle 26 places adhesive bead 28 on the skirt 20 of sheet material 10. Winding of sheet material 10 about the mandrel 22 is accomplished in a manner which places edge margin 34 adjacent to edge margin 36. In the specific embodiment shown, the edges of the respective edge margins 34 and 36 are in abutting relation, however, it is within the scope of my invention for edge margins 34 and 36 to be in overlapping relation. In
' FIGURE 1, as the sheet material 10 is wound, skirt 20 margin 36 of sheet material 10 in overlapping relation with skirt 20. The nozzle 26 places a bead of adhesive between skint 20 and the next turn of sheet material 10. The pressure induced by the winding action forces edge margin 36 against skirt 20 to form a bond such as shown in FIGURE 4. The bond hardens and the spiral wound container is cut as withdrawn from the mandrel and appears in FIGURE 3.
Various modifications such as formation of two skirts simultaneously and alternate embodiments of our invention such as bag and convolute wound container manufacture are obvious to those skilled in the art.
The scope of my invention, therefore, is not limited except as defined in the appended claims.
What is claimed is:
1. A method of forming a strong, moisture-proof bond comprising the steps of placing a head of thermoplastic melt onto the edge margin of a sheet material Web, flattening the bead causing a portion of the head to adhere to said edge margin and another portion of the head to extend outwardly from said edge margin as a skirt, placing a second sheet material web in contact with the skirted sheet material web, and supplying thermoplastic melt between the skirt and the adjacent second web forming a bond.
2. A method of forming spiral wound containers com prising the steps of placing on one edge margin of a sheet material web a bead of thermoplastic melt, flattening the bead causing a portion to extend outwardly from said edge margin as a skirt, wrapping the skirted web around a mandrel, placing the edges of successive turns of said web in abutting relation, and placing a head of adhesive between the skirt and the adjacent edge margin of the web to form a joint between successive turns of sheet material web.
3. A method of forming spiral wound containers comprising the steps of placing on one edge margin of a sheet material web a bead of thermoplastic melt, flattening the bead causing a portion to extend outwardly from said edge margin as a skirt, wrapping the skirted web around a mandrel, placing the edges of successive turns of said web in abutting relation, and placing a head of thermoplastic adhesive between the skirt and the adjacent edge margin of the web to form a joint between successive turns of sheet material web.
4. A method of forming a skirted sheet material web which comprises the steps of placing a bead of thermoplastic melt on the surface of a sheet material Web near the edge of said web, and by application of pressure fiattening said bead, causing a portion of the head to adhere to the web surface and another portion to extend out wardly past the said edge of the web as a self-supporting skirt.
References Cited in the file of this patent UNITED STATES PATENTS 1,317,665 Orr Sept. 30, 1919 1,704,991 Ricks Mar. 12, 1929 2,037,675 Boothby Apr. 14, 1936 2,349,730 Horming May 23, 1944 2,539,450 Magill Jan. 30, 1951 2,623,444 Maier Dec. 30, 1952 2,659,958 Johnson Nov. 24, 1953 2,677,633 Gross May 4, 1954 2,874,752 Brey Feb. 24, 1959

Claims (1)

  1. 2. A METHOD OF FORMING SPIRAL WOUND CONTAINERS COMPRISING THE STEPS OF PLACING ON ONE EDGE MARGIN OF A SHEET MATERIAL WEB A BEAD OF THERMOPLASTIC MELT, FLATTENING THE BEAD CAUSING A PORTION TO EXTEND OUTWARDLY FROM SAID EDGE MARGIN AS A SKIRT, WRAPPING THE SKIRTED WEB AROUND A MANDREL, PLACING THE EDGES OF SUCCESSIVE TURNS OF SAID WEB IN ABUTTING RELATION, AND PLACING A BEAD OF ADHESIVE BETWEEN THE SKIRT AND THE ADJACENT EDGE MARGIN
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Cited By (22)

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US3089630A (en) * 1961-08-17 1963-05-14 Superpack Vending Curacao N A Cylindrical package
US3178087A (en) * 1962-01-18 1965-04-13 Cleveland Container Co Container
US3195427A (en) * 1961-09-15 1965-07-20 Metal Box Co Ltd Method of manufacturing containers
US3242025A (en) * 1963-02-13 1966-03-22 Wilco Machine Works Inc Method of connecting together a plurality of wood veneer pieces
US3300355A (en) * 1963-06-20 1967-01-24 William E Adams Method of making irregularly shaped hollow plastic bodies
US3338270A (en) * 1965-05-03 1967-08-29 Denenberg Maurice Laminated tubing
US3381594A (en) * 1965-05-27 1968-05-07 R C Can Co Liquid package and process for producing the same
US3385179A (en) * 1965-06-01 1968-05-28 Owens Illinois Inc Cylindrical article and method and apparatus for the production thereof
US3399095A (en) * 1964-05-29 1968-08-27 Owens Illinois Inc Method and apparatus for producing containers of tubular foam laminates
US3406614A (en) * 1965-06-09 1968-10-22 Reynolds Metals Co Tubular member and method for making the same and container made therefrom
US3769130A (en) * 1969-02-17 1973-10-30 J Jones Process for manufacturing sheet binders
US3770556A (en) * 1970-08-07 1973-11-06 Reychem Corp Wraparound closure sleeve
US3934043A (en) * 1973-03-23 1976-01-20 Franz Haas Process for manufacturing hollow pastries
US3944126A (en) * 1974-10-02 1976-03-16 Phillips Petroleum Company Container
US4540391A (en) * 1982-12-06 1985-09-10 International Paper Company Method and apparatus for skiving and hemming
US5586963A (en) * 1994-06-27 1996-12-24 Sonoco Products Company Single-ply paperboard tube and method of forming same
US6159134A (en) * 1999-05-04 2000-12-12 Sekar; Chandra Methods for manufacturing a paint roller with integrated core and cover
US6324717B1 (en) 1999-11-29 2001-12-04 Chandra Sekar Paint roller with finished edge and method for making same
US6539999B2 (en) 2001-02-19 2003-04-01 Newell Operating Company Apparatus and method for making variable paint roller covers
US20050129884A1 (en) * 2003-06-30 2005-06-16 The Procter & Gamble Company Spiral wound tubes, method and apparatus for forming the same
US20090320999A1 (en) * 2008-06-26 2009-12-31 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate
US20090321007A1 (en) * 2008-06-26 2009-12-31 Chandra Sekar Methods for manufacturing a paint roller with perforated substrate

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US1317665A (en) * 1919-09-30 Clifford
US1704991A (en) * 1926-06-11 1929-03-12 United Shoe Machinery Corp Shoe stiffener and method of making the same
US2037675A (en) * 1933-01-10 1936-04-14 Boothby Fibre Can Company Collapsible paper can
US2349730A (en) * 1941-01-21 1944-05-23 Oswego Falls Corp Tubular container
US2539450A (en) * 1946-11-21 1951-01-30 American Can Co Method of producing fiber tubing
US2623444A (en) * 1952-12-30 Method of making lined lapped seam fiber containers
US2659958A (en) * 1952-05-09 1953-11-24 Johnson Henry Fourdrinier wire having reinforced coated marginal portions
US2677633A (en) * 1950-08-07 1954-05-04 Rohr Aircraft Corp Processes for sealing the seams and joints of structures fabricated of nonporous materials
US2874752A (en) * 1958-02-17 1959-02-24 Firestone Tire & Rubber Co Preparation of coated fabric material

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Publication number Priority date Publication date Assignee Title
US1317665A (en) * 1919-09-30 Clifford
US2623444A (en) * 1952-12-30 Method of making lined lapped seam fiber containers
US1704991A (en) * 1926-06-11 1929-03-12 United Shoe Machinery Corp Shoe stiffener and method of making the same
US2037675A (en) * 1933-01-10 1936-04-14 Boothby Fibre Can Company Collapsible paper can
US2349730A (en) * 1941-01-21 1944-05-23 Oswego Falls Corp Tubular container
US2539450A (en) * 1946-11-21 1951-01-30 American Can Co Method of producing fiber tubing
US2677633A (en) * 1950-08-07 1954-05-04 Rohr Aircraft Corp Processes for sealing the seams and joints of structures fabricated of nonporous materials
US2659958A (en) * 1952-05-09 1953-11-24 Johnson Henry Fourdrinier wire having reinforced coated marginal portions
US2874752A (en) * 1958-02-17 1959-02-24 Firestone Tire & Rubber Co Preparation of coated fabric material

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3089630A (en) * 1961-08-17 1963-05-14 Superpack Vending Curacao N A Cylindrical package
US3195427A (en) * 1961-09-15 1965-07-20 Metal Box Co Ltd Method of manufacturing containers
US3178087A (en) * 1962-01-18 1965-04-13 Cleveland Container Co Container
US3242025A (en) * 1963-02-13 1966-03-22 Wilco Machine Works Inc Method of connecting together a plurality of wood veneer pieces
US3300355A (en) * 1963-06-20 1967-01-24 William E Adams Method of making irregularly shaped hollow plastic bodies
US3399095A (en) * 1964-05-29 1968-08-27 Owens Illinois Inc Method and apparatus for producing containers of tubular foam laminates
US3338270A (en) * 1965-05-03 1967-08-29 Denenberg Maurice Laminated tubing
US3381594A (en) * 1965-05-27 1968-05-07 R C Can Co Liquid package and process for producing the same
US3385179A (en) * 1965-06-01 1968-05-28 Owens Illinois Inc Cylindrical article and method and apparatus for the production thereof
US3406614A (en) * 1965-06-09 1968-10-22 Reynolds Metals Co Tubular member and method for making the same and container made therefrom
US3769130A (en) * 1969-02-17 1973-10-30 J Jones Process for manufacturing sheet binders
US3770556A (en) * 1970-08-07 1973-11-06 Reychem Corp Wraparound closure sleeve
US3934043A (en) * 1973-03-23 1976-01-20 Franz Haas Process for manufacturing hollow pastries
US3944126A (en) * 1974-10-02 1976-03-16 Phillips Petroleum Company Container
US4540391A (en) * 1982-12-06 1985-09-10 International Paper Company Method and apparatus for skiving and hemming
US5586963A (en) * 1994-06-27 1996-12-24 Sonoco Products Company Single-ply paperboard tube and method of forming same
US6159134A (en) * 1999-05-04 2000-12-12 Sekar; Chandra Methods for manufacturing a paint roller with integrated core and cover
US6324717B1 (en) 1999-11-29 2001-12-04 Chandra Sekar Paint roller with finished edge and method for making same
US6539999B2 (en) 2001-02-19 2003-04-01 Newell Operating Company Apparatus and method for making variable paint roller covers
US20050129884A1 (en) * 2003-06-30 2005-06-16 The Procter & Gamble Company Spiral wound tubes, method and apparatus for forming the same
US20090320999A1 (en) * 2008-06-26 2009-12-31 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate
US20090321007A1 (en) * 2008-06-26 2009-12-31 Chandra Sekar Methods for manufacturing a paint roller with perforated substrate
US7736455B2 (en) 2008-06-26 2010-06-15 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate
US7846283B2 (en) 2008-06-26 2010-12-07 Chandra Sekar Methods for manufacturing a paint roller with perforated substrate
US20110005664A1 (en) * 2008-06-26 2011-01-13 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate
US8257534B2 (en) 2008-06-26 2012-09-04 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate
USRE46070E1 (en) 2008-06-26 2016-07-19 Chandra Sekar Methods for manufacturing a paint roller with grooved substrate

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