Splicing apparatus and method

Abstract

An apparatus and method for splicing tapes dispensed from a tape dispenser. According to one embodiment, a first, running or unwinding roll of tape is provided with a first splicing element secured to its trailing end portion. A second, stationary or standby roll of tape is provided with a second splicing element secured to its leading end portion. The second splicing element comprises a body made of a self-supporting material and formed with at least one aperture sized to receive the tape from the first roll. While tape is being dispensed from the first roll, the running tape is inserted into the aperture of the second splicing element. When the first roll of tape becomes depleted, the first splicing element engages the second splicing element, thereby splicing the leading end portion of the second tape roll to the trailing end portion of the first tape roll.

1 . An apparatus comprising: 
 a first, running spool of tape having a trailing end portion and a first splicing element secured to the trailing end portion;    a second, stand-by spool of tape having a leading end portion and a second splicing element secured to the leading end portion; and    wherein the second splicing element is made of a self-supporting material and has at least one aperture sized to receive the tape from the first spool and a peripheral portion bounding at least a portion of the aperture, whereby the tape being dispensed from the first spool can be introduced into the aperture by inserting the tape through a gap in the peripheral portion;    wherein when the tape from the first spool is inserted in the aperture and the first spool becomes depleted of tape, the first splicing element engages the second splicing element so as to splice the tape from the first spool to the tape from the second spool.    
   
   
       2 . The apparatus of  claim 1 , wherein the first splicing element extends transversely across the tape of the first spool and has a length longer than the length of the aperture in the second splicing element.  
   
   
       3 . The apparatus of  claim 1 , wherein the second splicing element is a wire having a substantially closed geometric shape.  
   
   
       4 . The apparatus of  claim 1 , wherein the gap in the peripheral portion is a permanent gap extending from an inner peripheral edge bounding the aperture to an outer peripheral edge of the second splicing element.  
   
   
       5 . The apparatus of  claim 1 , wherein the second splicing element comprises at least one slit extending from an inner peripheral edge bounding the aperture to an outer peripheral edge of the second splicing element, whereby the gap in the peripheral portion is formed between the opposing edges of the slit by bending part of the peripheral portion.  
   
   
       6 . The apparatus of  claim 1 , wherein: 
 the second splicing element comprises a first body portion and a second body portion foldably coupled to each other along a folding axis, allowing the first and second body portions to be folded closed and opened relative to each other;    the at least one aperture comprises a first aperture in the first body portion and a second aperture in the second body portion;    the first body portion comprises a first bendable tab portion bounding at least a portion of the first aperture which can be bent to create an opening in the first body portion through which the tape from the first spool can be inserted into the first aperture;    the second body portion comprises a second bendable tab portion bounding at least a portion of the second aperture which can be bent to create an opening in the second body portion through which the tape from the first spool can be inserted into the second aperture; and    wherein when the tape from the first spool is inserted into the first and second apertures and the first and second body portions are folded closed, the first and second apertures align with each other to allow the tape from the first spool to pass through the second splicing element but not the first splicing element.    
   
   
       7 . The apparatus of  claim 6 , wherein the second splicing element comprises an adhesive on one or both of the first and second body portions to adhesively secure the body portions to each other when the body portions are folded closed.  
   
   
       8 . The apparatus of  claim 6 , wherein: 
 the first body portion is formed with a first slit extending from an inner peripheral edge of the first aperture to an outer peripheral edge of the first body portion; and    the second body portion is formed with a second slit extending from an inner peripheral edge of the second aperture to an outer peripheral edge of the second body portion.    
   
   
       9 . The apparatus of  claim 8 , wherein the first and second slits intersect the outer peripheral edges of the first and second body portions on opposite sides of the second splicing element.  
   
   
       10 . The apparatus of  claim 1 , wherein the second splicing element is made of a flexible, resilient material.  
   
   
       11 . The apparatus of  claim 10 , wherein the second splicing element is made of plastic.  
   
   
       12 . The apparatus of  claim 6 , wherein: 
 the first body portion comprises a third aperture;    the second body portion comprises a fourth aperture; and    wherein the leading end portion of the second tape forms a loop extending through the third and fourth apertures.    
   
   
       13 . The apparatus of  claim 1 , wherein the leading end portion of the second tape comprises a loop extending through another aperture in the second splicing element.  
   
   
       14 . The apparatus of  claim 1 , wherein: 
 the second splicing element comprises a generally flat, first body portion and a generally flat, second body portion pivotally coupled to each other at a pivot axis, allowing the first and second body portions to be pivoted between closed and open positions relative to each other in mutually parallel planes;    the at least one aperture comprises a first aperture in the first body portion and a second aperture in the second body portion;    the first body portion comprises a first bendable tab portion bounding at least a portion of the first aperture which can be bent to create an opening in the first body portion through which the tape from the first spool can be inserted into the first aperture;    the second body portion comprises a second bendable tab portion bounding at least a portion of the second aperture which can be bent to create an opening in the second body portion through which the tape from the first spool can be inserted into the second aperture; and    wherein when the tape from the first spool is inserted into the first and second apertures and the first and second body portions are pivoted to the closed position, the first and second apertures align with each other to allow the tape from the first spool to pass through the second splicing element but not the first splicing element.    
   
   
       15 . A method of splicing a first, running tape to a second, stand-by tape, the method comprising: 
 securing a first splicing element to a trailing end portion of the first tape;    securing a second splicing element to a leading end portion of the second tape, the second splicing element having at least one opening sized to receive the first tape, the second splicing element being made of a self-supporting material; and    inserting the first tape into the opening of the second splicing element, such that the first tape can pass through the opening and the first splicing element can engage the second splicing element to splice the first tape to the second tape.    
   
   
       16 . The method of  claim 15 , wherein inserting the first tape into the opening comprises forming a gap in a peripheral portion of the second splicing element bounding the opening, inserting the first tape into the opening via the gap, and closing the gap.  
   
   
       17 . The method of  claim 15 , wherein the first splicing element comprises a wire having two overlapping end portions.  
   
   
       18 . The method of  claim 15 , wherein: 
 the second splicing element comprises a generally flat body, a slit extending from the opening to an outer peripheral edge of the body, and a bendable tab portion at least partially bounding the opening; and    inserting the first tape into the opening comprises bending the tab portion so as to create a gap between the opposing edges of the slit, and inserting the first tape through the gap and into the opening.    
   
   
       19 . The method of  claim 15 , wherein: 
 the second splicing element comprises a first body portion and a second body portion foldably coupled to each other along a folding axis, allowing the first and second body portions to be folded closed and opened relative to each other;    the at least one opening comprises a first opening in the first body portion and a second opening in the second body portion;    the first body portion has a first slit extending from the first opening to an outer peripheral edge of the first body portion;    the second body portion has a second slit extending from the second opening to an outer peripheral edge of the second body portion; and    inserting the first tape into the opening comprises inserting the first tape through the first slit and into the first opening, inserting the first tape through the second slit and into the second opening and folding the first and second body portions to a closed position.    
   
   
       20 . The method of  claim 19 , further comprising adhesively securing the first body portion to the second body portion.  
   
   
       21 . The method of  claim 15 , wherein securing the second splicing element to the leading end portion of the second tape comprises inserting the leading end portion of the second tape through another opening in the second splicing element and folding back and adhering the leading end portion onto itself so as to form a loop.  
   
   
       22 . The method of  claim 15 , wherein the second splicing element is received between two spaced-apart leg portions of the first splicing element when the first splicing element engages the second splicing element.  
   
   
       23 . The method of  claim 15 , wherein the second tape is supplied from a stationary roll of tape that begins rotating from a stationary position after the first splicing element engages the second splicing element.  
   
   
       24 . The method of  claim 15 , further comprising dispensing the first tape from a first tape roll at a rate of at least 1,100 feet per minute and, after the first tape is spliced to the second tape, dispensing the second tape from a second tape roll at a rate of at least 1,100 feet per minute.  
   
   
       25 . The method of  claim 15 , further comprising dispensing the first tape from a first tape roll at a rate of at least 1,400 feet per minute and, after the first tape is spliced to the second tape, dispensing the second tape from a second tape roll at a rate of at least 1,400 feet per minute.  
   
   
       26 . A splicing element for use in splicing a first, running tape being dispensed from a tape dispensing device to a second, standby tape, the splicing element comprising a self-supporting body formed with at least one aperture sized to receive the first tape, and a peripheral portion bounding at least a portion of the aperture, whereby the first tape can be introduced into the aperture by inserting the first tape through an opening in the peripheral portion while the first tape is being dispensed by the dispensing device.  
   
   
       27 . The splicing element of  claim 26 , wherein the body is formed with at least one slot sized to receive the second tape and spaced from the aperture.  
   
   
       28 . The splicing element of  claim 27 , wherein: 
 the body comprises a first body portion and a second body portion foldably coupled to each other along a folding axis, allowing the first and second body portions to be folded closed and opened relative to each other;    the at least one aperture comprises a first aperture in the first body portion and a second aperture in the second body portion;    the at least one slot comprises a first slot in the first body portion and a second slot in the second body portion, whereby a leading end portion of the second tape can be secured to the splicing element by forming a loop of tape extending through the first and second slots;    whereby the first tape can be introduced into the first aperture via an opening in the first body portion and into the second aperture via an opening in the second body portion while the first tape is being dispenses by the dispensing device.    
   
   
       29 . The splicing element of  claim 28  wherein: 
 the first body portion comprises a bendable tab portion at least partially bounding the first aperture and a slit extending from the first aperture to an outer peripheral edge of the first body portion such that the opening in the first body portion can be formed by bending the tab portion; and    the second body portion comprises a bendable tab portion at least partially bounding the second aperture and a slit extending from the second aperture to an outer peripheral edge of the second body portion such that the opening in the second body portion can be formed by bending the tab portion.    
   
   
       30 . The splicing element of  claim 28  further comprising an adhesive that adhesively secures the first and second body portions to each other when the body portions are folded closed.  
   
   
       31 . The splicing element of  claim 26 , wherein the opening in the body is a permanent opening extending from the at least one aperture to an outer peripheral edge of the body.  
   
   
       32 . The splicing element of  claim 31 , wherein the permanent opening extends diagonally from the at least one aperture to the outer peripheral edge of the body.  
   
   
       33 . The splicing element of  claim 31 , wherein the body is generally rectangular with rounded comers.  
   
   
       34 . A roll of tape comprising: 
 a trailing end portion;    a leading end portion;    a first splicing element secured to the trailing end portion; and    a second splicing element secured to the leading end portion, the second splicing element comprising a self-supporting body formed with at least one aperture sized to receive a running tape dispensed from another tape roll, and a peripheral portion bounding at least a portion of the aperture, whereby the running tape can be introduced into the aperture by inserting the running tape through an opening in the peripheral portion.    
   
   
       35 . The roll of tape according to  claim 34 , wherein the first and second splicing elements have the same shape.