METHOD AND APPARATUS FOR PREPARING TRANSFER TAPE CONSTRUCTS FOR PAPER WEB TURN-UP PROCESSES

Abstract

A cover-flap transfer tape construct and associated applicators for paper web turn-up are disclosed. A zone-coated substrate carried on a linered web includes a top-side central web-grabbing adhesive band bounded by uncoated edge zones, and underside edge mounting adhesive bands separated by an uncoated middle zone. An applicator forms an out-of-plane raised profile across a central portion of the tape while maintaining planar side bands, using cooperating forming members (convex crest and complementary cavity) and manual or motorized feed. The formed length is cut to yield a discrete tape construct with the raised profile over the central adhesive and side bands aligned with mounting adhesives. The tape construct promotes reliable interception and transfer of a moving paper web during turn-up.

Claims

1. A method of preparing a transfer tape construct for turning a paper web onto a web spool in a turn up process, the method comprising the steps of: a. providing a roll of prepared carrier paper including a zone-coated transfer tape substrate and a release layer on one or both of a top surface and a bottom surface of the zone-coated transfer tape substrate; b. threading a length of the prepared carrier paper into an applicator device having a first forming member with a raised profile portion and a second forming member with a complementary hollow profile portion, and positioning the length of the prepared carrier paper over the raised profile portion and under the complementary hollow profile portion; c. advancing the length of the prepared carrier paper through the applicator device while the first forming member and the second forming member define a forming gap that shapes the length of the prepared carrier paper into a raised profile across a central portion of the length of the prepared carrier paper while maintaining side bands of the length of the prepared carrier paper substantially planar; and d. cutting the length of the prepared carrier paper to obtain the transfer tape construct having the raised profile and the side bands.

2. The method of claim 1, wherein the zone-coated transfer tape substrate comprises on the top surface a longitudinal first adhesive zone bounded laterally by uncoated edge zones, and on the bottom surface a longitudinal second adhesive edge zone and a longitudinal third adhesive edge zone separated by an uncoated middle zone.

3. The method of claim 1, further comprising a first release layer on the top surface and a second release layer on the bottom surface of the zone-coated transfer tape substrate.

4. The method of claim 3, wherein the first release layer has a higher release value than the second release layer.

5. The method of claim 1, wherein the first forming member comprises a convex crest having a tapered crown height that decreases gradually from a front side to a back side of the applicator device.

6. The method of claim 5, wherein the second forming member comprises a concave cavity complementary to the convex crest.

7. The method of claim 1, wherein advancing the length of the prepared carrier paper comprises driving narrow feed rollers that contact only the side bands to push the length of the prepared carrier paper through the applicator device outwards while forming the raised profile across the central portion of the length of the prepared carrier paper.

8. The method of claim 1, wherein cutting the length of the prepared carrier paper is performed by a cutting blade traversing transversely across the length of the prepared carrier paper.

9. The method of claim 8, wherein the applicator device includes a push-button to activate the cutting blade.

10. The method of claim 8, wherein the applicator device includes a motor-actuated plunger that actuates the cutting blade.

11. The method of claim 1, wherein the raised profile portion and the complementary hollow profile portion are removably replaceable cartridges.

12. The method of claim 1, wherein the raised profile portion comprises a triangular crest shape.

13. The method of claim 1, wherein the raised profile portion comprises one of: a rectangular crest shape and a square crest shape.

14. The method of claim 1, wherein the raised profile portion comprises a rounded crest shape having a radius from about 5 mm to about 50 mm.

15. The method of claim 1, wherein the raised profile occupies a central portion of the transfer tape construct and the side bands flank the raised profile with lateral symmetry about a longitudinal centerline.

16. The method of claim 1, wherein advancing the length comprises manual pull using a grab bar located at an exit of the applicator device.

17. The method of claim 1, wherein the applicator device comprises a unified platform carrying the first forming member and a pivoting handle carrying the second forming member.

18. The method of claim 17, wherein the applicator device further comprises a roll holder mounted on the unified platform to hold the roll of the prepared carrier paper.

19. The method of claim 1, wherein the cutting step produces a discrete transfer tape construct having a length selected to be equal to or less than an intended spool shell width.

20. The method of claim 1, wherein the first forming member and the second forming member are secured together during forming by magnetic fasteners.

21. The method of claim 1, wherein the cutting of the length of the prepared carrier paper is performed automatically at a target length of the prepared carrier paper, wherein the target length is set by a detented rotary knob operatively coupled to a grab handle of the applicator device.

22. The method of claim 1, wherein the first forming member and the second forming member are secured together during forming by bayonet fasteners.

23. The method of claim 1, further comprising registration marks along the length of the prepared carrier paper to determine a desired dimension of the transfer tape construct before cutting the length of the prepared carrier paper.

24. The method of claim 2, wherein the raised profile of the transfer tape construct comprises the longitudinal first adhesive zone on its top surface, and the side bands of the transfer tape construct comprise the longitudinal second adhesive edge zone and the longitudinal third adhesive edge zone, respectively.

25. The method of claim 24, further comprising mounting the transfer tape construct onto an empty web spool by affixing the longitudinal second adhesive edge zone and the longitudinal third adhesive edge zone onto a shell of the empty web spool.

26. The method of claim 25, wherein mounting the transfer tape construct onto the empty web spool includes pressing the longitudinal second adhesive edge zone and the longitudinal third adhesive edge zone onto the shell with respective press members of the applicator device.

27. The method of claim 26, wherein the respective press members are operated by a motor.

28. The method of claim 25, wherein mounting the transfer tape construct onto the empty web spool includes pressing the longitudinal second adhesive edge zone and the longitudinal third adhesive edge zone onto the shell manually with fingers.

29. The method of claim 2, wherein each uncoated edge zone has a width from about 1 mm to about 10 mm.

30. The method of claim 2, wherein the longitudinal first adhesive zone has a width from about 10 mm to about 40 mm.

31. The method of claim 2, wherein each of the longitudinal second adhesive edge zone and the longitudinal third adhesive edge zone has a width from about 1 mm to about 10 mm.

32. The method of claim 2, wherein a ratio of a width of each uncoated edge zone to a width of the longitudinal first adhesive zone is from about 0.1 to about 0.5.

33. The method of claim 2, wherein a combined width of the uncoated edge zones is approximately equal to a width of the longitudinal first adhesive zone.

34. The method of claim 1, wherein the zone-coated transfer tape substrate comprises a calendered paper having a basis weight from about 80 g/m.sup.2 to about 180 g/m.sup.2.

35. The method of claim 1, wherein the zone-coated transfer tape substrate comprises a biaxially oriented polymer film having a thickness from about 25 m to about 75 m.

36. The method of claim 1, wherein the first forming member comprises a convex crest having a constant crown height from a front side to a back side of the applicator device.

37. An apparatus for preparing a transfer tape construct for turning a paper web onto a web spool in a turn-up process, the apparatus comprising: a roll of prepared carrier paper including a zone-coated transfer tape substrate and a release layer on one or both of a top surface and a bottom surface of the zone-coated transfer tape substrate; an applicator package having a first forming member with a raised-profile portion and a second forming member with a complementary hollow-profile portion, the first forming member and the second forming member being positionable to define a forming gap configured to shape a length of the prepared carrier paper into an out-of-plane raised profile across a central portion of the length while maintaining laterally spaced side bands of the length substantially planar; a feed assembly, configured to advance the length of the prepared carrier paper through the forming gap; and a cutter configured to traverse transversely across the length to cut the length and thereby provide a discrete transfer tape construct having the out-of-plane raised profile and the laterally spaced side bands.

38. The apparatus of claim 37, wherein the zone-coated transfer tape substrate comprises, on the top surface, a longitudinal first adhesive zone bounded laterally by uncoated edge zones, and, on the bottom surface, a longitudinal second adhesive edge zone and a longitudinal third adhesive edge zone separated by an uncoated middle zone.

39. The apparatus of claim 37, further comprising a first release layer on the top surface and a second release layer on the bottom surface of the zone-coated transfer tape substrate.

40. The apparatus of claim 37, wherein the first forming member comprises a convex crest having a tapered crown height that decreases from a front side to a back side of the applicator package.

41. The apparatus of claim 40, wherein the second forming member comprises a concave cavity complementary to the convex crest.

42. The apparatus of claim 37, wherein the feed assembly comprises narrow feed rollers positioned to contact only the laterally spaced side bands so as to advance the length through the applicator package while the central portion is formed into the out-of-plane raised profile.

43. The apparatus of claim 37, wherein the cutter comprises a cutting blade configured to traverse transversely across the length.

44. The apparatus of claim 43, further comprising a push-button actuator operatively coupled to the cutting blade.

45. The apparatus of claim 37, wherein the raised-profile portion and the complementary hollow-profile portion are removably replaceable cartridges.

46. The apparatus of claim 37, wherein the forming gap and the feed assembly are configured such that the raised profile occupies a central portion of the transfer tape construct, and the laterally spaced side bands flank the raised profile with lateral symmetry about a longitudinal centerline.

47. The apparatus of claim 37, wherein the apparatus comprises a unified platform carrying the first forming member and a pivoting handle carrying the second forming member.

48. The apparatus of claim 47, further comprising a roll holder mounted on the unified platform and configured to support the roll of the prepared carrier paper for a straight feed path into the forming gap.

49. The apparatus of claim 38, wherein a combined width of the uncoated edge zones is approximately equal to a width of the longitudinal first adhesive zone.

50. The apparatus of claim 38, wherein a width of the uncoated middle zone is approximately equal to the width of the longitudinal first adhesive zone.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is an illustration of a paper processing system where an Empty Web Spool has been set up for paper web transfer.

[0028] FIG. 1A is an enlarged view of an exemplary Cover Flap transfer tape construct for Turn-Up.

[0029] FIG. 2 is an illustration of a paper processing system where the Cover Flap transfer tape construct is approaching the Nip.

[0030] FIG. 2A is an enlarged view of an exemplary Cover Flap transfer tape construct as it approaches the Nip.

[0031] FIG. 3 is an illustration of a paper processing system where the Cover Flap transfer tape construct is compressed between the Empty Web Spool and the reel drum.

[0032] FIG. 3A is an enlarged view of an exemplary Cover Flap transfer tape or paper construct as it is compressed.

[0033] FIG. 4 is an illustration of a paper processing system where the Cover Flap of the Cover Flap transfer tape construct grabs the advancing paper web.

[0034] FIG. 4A is an exploded view of an exemplary Cover Flap transfer tape construct as it grabs the advancing paper web.

[0035] FIG. 5 is an illustration of a paper processing system where Turn-Up has occurred.

[0036] FIG. 5A is an exploded view of an exemplary paper processing system where Turn-Up has occurred.

[0037] FIGS. 6A-6F illustrates aspects of Transfer Tape construct processing.

[0038] FIGS. 7A and 7B are close-up illustrations of a Turn-Up construct.

[0039] FIGS. 8 and 8A illustrate an example with adhesive on a Cover Flap.

[0040] FIGS. 9 and 9A illustrate an example with adhesive on a Cover Flap.

[0041] FIGS. 10 and 10A illustrate an example with adhesive on a Cover Flap.

[0042] FIGS. 11 and 11A illustrate an example with adhesive on a Cover Flap.

[0043] FIGS. 12 and 12A illustrate an example with adhesive on a Cover Flap.

[0044] FIGS. 13 and 13A illustrate an example with adhesive on a Cover Flap.

[0045] FIGS. 14 and 14A illustrate an example with adhesive on a Cover Flap.

[0046] FIGS. 15 and 15A illustrate an example with adhesive on a Cover Flap.

[0047] FIGS. 16A-16C illustrate a cover-flap transfer tape construct, according to some embodiments of the present invention.

[0048] FIGS. 17A-17C illustrate an applicator device configured to form a raised profile in a cover-flap transfer tape construct, according to some embodiments of the present invention.

[0049] FIGS. 18-18A illustrate an applicator device having a motorized forming mechanism for creating a raised profile in a cover-flap transfer tape construct, according to some embodiments of the present invention.

[0050] FIG. 18B illustrates a mounted cover flap transfer tape with a formed cavity and hump structure, according to some embodiments of the present invention.

[0051] FIG. 18C illustrates a mounted cover flap transfer tape with a formed cavity and hump structure with the cover flap opened, according to some embodiments of the present invention.

[0052] FIGS. 19A-19C illustrate a unified applicator device configured to form a raised profile in a cover-flap transfer tape construct, according to some embodiments of the present invention.

[0053] FIG. 20 illustrates an apparatus configured to dispense, fold/crease, and apply a cover-flap transfer tape construct onto an empty web spool, according to some embodiments of the present invention.

[0054] FIG. 20A is an exemplary illustration of a paper processing system where Turn-Up has occurred.

[0055] FIG. 20B is an exploded view of an exemplary paper processing system where Turn-Up has occurred.

[0056] FIGS. 21A-21B illustrate a flowchart of exemplary method steps that may be implemented in some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0057] The present invention provides apparatus and methods for producing and attaching a Cover Flap Transfer Tape, which may be used in a paper web Turn-Up operation. The process facilitates a Turn-Up operation wherein a continuous paper web being rolled onto a Parent Web Roll (parent web spool) is severed and transferred to an Empty Web Spool when the Parent Web Spool nears a fully wound state. In operation, the transfer may occur without requiring the flow of the paper web to be temporarily altered or stopped (i.e., no planned slow-down or interruption of web motion).

[0058] In some embodiments, a cover-flap transfer tape construct is supplied as a continuous web on a roll with a carrier paper supporting a zone-coated substrate that carries a central, web-grabbing adhesive on a top face and two edge-mounting adhesive stripes on a bottom face. The upper release layer and lower release layer are engineered with different release values so that the lower release layer peels first during application, while the upper release layer remains in place until the moment of turn-up. Uncoated side zones on the top face and an uncoated middle zone on the bottom face extend the full length of each piece to promote controlled lift of the flap and to reduce adhesive contact with machine surfaces. The web-grabbing adhesive spans a central band, for example, 10-40 mm depending on grade, while each edge adhesive stripe spans, for example, 2-10 mm; these values scale proportionally with overall tape width.

[0059] In some embodiments, the tape-construct substrate is a calendered paper of 80-180 g/m.sup.2, a biaxially oriented polymer film of 25-75 m, or a composite laminate combining a stiff facing with a compliant core to achieve a selected bending modulus. The web-grabbing adhesive is an acrylic pressure-sensitive adhesive having high tack at line speed and controlled peel to the web back; the mounting stripes are high-shear pressure-sensitive adhesives tuned for strong bonding to steel, composite, or fiber-based cores. Primers or corona treatment may be applied only beneath the web-grabbing adhesive to stabilize anchorage of the adhesive to the substrate, while the uncoated zones are left untreated to lower surface friction. Registration marks printed along the carrier paper align the adhesive bands to form hardware and to spool datums during application.

[0060] In some embodiments, forming of the raised profile is performed with a dual-frame applicator, where a first frame structure carries a raised insert and a second frame structure carries a complementary cavity. The frames may be joined by magnets, bayonet fasteners, or spring toggles to define a stable forming gap. A push button actuates a cutter to separate a formed length. The device accepts the roll, and an operator draws the laminate through the forming channel by hand along the feed direction so that a profiled length exits with a crown and substantially planar side bands.

[0061] In some embodiments, the raised geometry is homogeneous along the machine direction, as in an applicator having a constant-section raised insert in which crown height remains substantially constant from entry to exit. Interchangeable cartridges supply alternative cross-sections, such as a triangular crest that produces a sharper apex or a rectangular-top crest that presents a wider plateau. The constant-section approach simplifies calibration across widths and supports a library of inserts matched to different web grades and winding diameters.

[0062] In some embodiments, forming and length control are automated. A powered feed assembly downstream of the forming channel employs a first motor and a second motor that drive rollers positioned to contact only the side bands of the profiled length, leaving the crown untouched. A controller accepts a setpoint from a length-selection knob (e.g., 50 mm, 75 mm, 100 mm), meters the advance to the target distance using encoder feedback, and then energizes a third motor to depress the push button that drives the cutter. The cut piece maintains the molded crown from exit through placement on the spool.

[0063] In some embodiments, the raised profile is formed in a unified device that integrates a platform with a fixed raised insert and a pivoting handle carrying a complementary insert. The handle pivots on uprights and carries an actuator button positioned for thumb actuation. A compact drive meters the profiled length to a nose for cutting. A removable roll holder mounts on the platform, staging the roll for a short, straight feed path into the forming throat. The inserts accept shims to adjust crown height without altering the pivot geometry.

[0064] In some embodiments, the applicator is outfitted with peel-assist subassemblies for liner management at the spool. First and second retractable arms extend toward the shell of the empty spool and carry crowned press rollers. Picks on the arms lift tails of the lower release layer along each side band and route the stripped liner into a waste path while the press rollers apply bonding pressure to activate the mounting adhesive stripes. A separate peel shoe on one arm lifts the upper release layer from the crown just before acceleration, presenting the web-grabbing adhesive to the approaching web. A gear or rack-and-pinion drive under control of motors sets approach distance, peel angle, and roller pressure.

[0065] In some embodiments, the transfer tape construct is cut before placement on the shell or surface; in other embodiments, the applicator feeds a still-attached profiled strip to the shell, the arms press and peel as described above, and the cutter severs the tail after anchorage, which aids alignment on narrow shells. Edge fences on the applicator nose and printed centerlines on the tape construct assist placement symmetry. A small, compliant shoe can support the crown during edge pressing so the raised geometry remains intact.

[0066] In some embodiments, the turn-up sequence is executed with a reel drum and nip. The empty spool accelerates to a surface speed matched to the moving web on the drum surface. Aerodynamic and centrifugal effects open the raised flap, so the crown adhesive crosses the nip plane and engages an approaching web segment, transitioning to a wrapped segment around the new spool. Continued rotation progresses to a controlled separation of the web from the full spool. The edge adhesive stripes remain bonded to the core and the crown adhesive becomes buried beneath subsequent wraps.

[0067] In some embodiments, geometry and chemistry are tailored to the paper grade. Crown height ranges from 1-3 mm for light tissue to 4-8 mm for heavier publication grades. The crown adhesive exhibits a 180 peel of 2-8 N/25 mm to the web back with shear creep exceeding 10,000 min at 1 kg/25 mm.sup.2, while the mounting stripes exhibit 10-25 N/25 mm peel to steel or composite cores. Micro-texture embossing in the uncoated zones promotes airflow beneath the flap during acceleration; shallow channels in the uncoated middle zone guide bending and stabilize lift. The edge adhesives may be segmented along the length to create tether intervals that manage lift while preserving anchorage.

[0068] In some embodiments, safety and maintainability are addressed by guarded cutters, disposable blade cassettes, non-stick wear liners on forming surfaces, and magnetically attached second frames that detach for cleaning. Replaceable cartridges for inserts permit rapid crown-shape changes; calibration marks etched on the frames record shim stacks and gap values for repeat setups. Electronics, when present, store recipes for length, feed speed, nip pressure, and crown height so operators can recall grade-specific settings.

[0069] In some embodiments, manufacturing of the laminate on the roll uses sequential slot-die coating of the bottom edge stripes of mounting adhesive, inversion of the web, central coating of the crown adhesive, lamination of release liners with selected release values, and final lamination to the carrier paper followed by slitting and winding. Registration marks and finger-lift features for the liners are printed in-line. Quality checks verify adhesive widths, liner-release values, and curl under controlled humidity before packaging.

[0070] In some embodiments, the apparatus and supplies are delivered as a kit that includes a hand applicator with two or more crest cartridges, a starter supply of transfer-tape rolls in several widths, spare blade cassettes, peel-assist tabs, and written settings for common spool diameters. The applicator footprint fits on existing winder decks; clamps or magnets hold the platform to a machine rail during use. A training card illustrates threading, forming, length selection, liner peeling, edge pressing, and proper crown orientation relative to the nip.

[0071] In some embodiments, the constructs and applicators are scaled for very wide or very narrow applications. For narrow cores, the crown width is reduced and the cutter stroke shortened; for wide tissue machines, the applicator accepts tape widths above 120 mm with dual-motor feeds that maintain even traction on both side bands. For humid environments, stainless frames and polymer bushings are used; for clean-room converting, low-outgassing materials are specified for frames, liners, and adhesives.

[0072] In some embodiments, sensors augment repeatability without complexity. A reflective sensor confirms arrival of a registration mark at the cut line; a small LED on the frame indicates length reached. A microswitch on the upper frame verifies full closure before a cut command is accepted. For motorized versions, a detented length knob communicates directly to a microcontroller that converts detent position to encoder counts, while a teach button captures any custom length based on live feed and stores it to non-volatile memory.

[0073] It is to be understood that the disclosure of the apparatus and methods in relation to a paper web Turn-Up operation is exemplary, and not meant to be limiting.

Glossary

[0074] Cover Flap: as referred to herein, means a physical layer positioned to mitigate exposure of an adhesive layer to environmental contaminants. During a Turn-Up, at least a portion of the Cover Flap moves to expose at least a portion of the adhesive layer that the Cover Flap previously protected from environmental contaminants.

[0075] Turn-Up: as used herein, means a process involving switching a paper web from a nearly completed parent or full web spool to an empty web spool. A Turn-up process may include severing a paper web from a rotating parent web roll nearing its capacity to hold paper, transferring the paper web to an empty web spool, and securing the paper web to the empty web spool.

[0076] Transfer Tape: as used herein, means a Transfer Tape, sometimes referred to as a turn-up tape, that refers to a substrate adapted for extending across a longitudinal cylindrical surface of one or both of an empty web spool and a paper bearing web spool. The transfer tape may include multiple layers.

[0077] Web Binding Adhesive: as used herein, means a web binding adhesive, sometimes referred to as web grabbing adhesive, that refers to an adhesive layer of a transfer tape that attaches the transfer tape to a paper web. During paper manufacture and/or processing, a paper web that is attached via web binding adhesive may be pulled to a spool to which a transfer tape is adhered.

[0078] Mounting adhesive: as used herein, means a mounting adhesive that refers to an adhesive used to bind transfer tape constructs together and/or used to hold a transfer tape construct to a web spool.

[0079] Pressure Sensitive Adhesive: as used herein, means a pressure sensitive adhesive refers to a non-reactive adhesive which creates a binding force when pressure is applied to attach the adhesive to a surface.

[0080] Nip: as used herein, means the area where a paper web or sheet is pressed between two rolls/spools.

[0081] Parent Web Roll: as used herein, means a parent web roll, which may be called an old spool, full spool, that refers to a web spool that is substantially nearing its capacity for holding paper web.

[0082] Empty Web Spool: as used herein, means an empty web spool, sometimes referred to as an empty reel, a new spool, or an empty spool, which may include a reel to which the paper web being reeled from a parent roll is transferred. The surface of an empty web spool is commonly used to adhere a transfer tape thereto.

[0083] Reel Drum: as used herein, means a reel drum that refers to a spool used to drive movement of a paper web; in some embodiments, a reel drum may impart rotational movement to a parent roll receiving a paper web in a reeling action.

[0084] With reference to the drawings, which are provided for descriptive and illustrative purposes which are not meant to be limiting as the scope of the invention, the invention, in various embodiments, in a broad and general sense, is an apparatus and a method for processing and applying a Cover Flap Transfer Tape Construct, which may be used in a paper web turn-up operation. The process may facilitate the turn up operation wherein a continuous paper web being rolled onto a first web spool is severed and transferred to an empty second web spool when the first web spool is fully wound. In the operation, the transfer may occur without requiring the flow of the paper web to be temporarily altered or stopped. It is to be understood that disclosure of the apparatus and method in relation to a paper web turn-up operation is an exemplary disclosure not meant to be limiting, as the Cover Flap Transfer Tape Construct, methods of its manufacture and associated applicators and methods of application may be suitable for use in different industrial applications.

[0085] The present invention provides improved methods and apparatus for utilizing a Cover Flap Transfer Tape Construct to sever and transfer a continuous paper web from one spool to another spool, such as, may be especially useful in transferring lightweight papers such as, tissue or newsprint Empty Web Spool. The Cover Flap Transfer Tape Construct may be applied to an Empty Web Spool Nip in a closed position such that the Cover Flap is temporarily adhered in a portion of its surface and opens during the run up in the speed of the spool to which it is attached due to both aerodynamic forces and to centrifugal force. In examples of the present application, the construct is produced so that when the cover flap opens, the adhesive layers open with the Cover Flap presenting the adhesive off of the surface of the spool. Thus, the adhesive layer is elevated to interact with the paper web.

[0086] The Cover Flap Transfer Tape Construct may be produced by assembling layers of structural materials, such as paper, along with layers of adhesive material, such as double stick adhesive tapes. Coatings of various kinds may be applied to the surfaces of the layers to alter the properties of the surface. A release layer may be performed by coating a portion of a surface, such as with a silicone coating, that renders the surface less adherent to an adhesive that may be attached to it. In a non-limiting example, if a portion of a surface of a structural layer is coated with a release coating, then an attached adhesive layer will form a strong bond with the uncoated portion and a weaker bond with the coated portion, such that when forces are applied, the adhesive will separate from the coated surface and lift up with the Cover Flap.

[0087] Referring to FIG. 1, a starting step of a paper Turn-Up process utilizing the concepts of the present specification is illustrated. In the first (starting) step, an operator has prepared the Cover Flap Transfer Tape Construct on an Empty Web Spool 103. The Empty Web Spool 103 may be used to take up the new paper web 100 as it is moved by the Reel Drum 101 in the direction as shown by the arrows. At the starting step, the Parent Web Roll 102 is approaching its capacity to take up the paper web 100. In the inset figure, FIG. 1A an enlarged view of the Empty Web Spool 103 is illustrated. On the surface of the Empty Web Spool 103 is the Cover Flap transfer paper or tape 111 which is held to the Empty Web Spool 103 with an adhesive layer 110.

[0088] Referring now to FIG. 2, the Empty Web Spool 103 approaches the Nip as it moves towards the reel drum 101. The paper web 100 is still carried over the Reel Drum surface 240 and remains associated with the Parent Web Roll 102. As displayed in FIG. 2A, the Cover Flap Transfer Tape Construct 210 sits on the surface of the Empty Web Spool 103. As the Empty Web Spool 103 approaches the Nip 220, it will contact the paper web 230, which is upon the reel drum surface 240, and be rotated as shown by the arrows. Rotation may be accomplished, for example, via an electric or air powered motor (not illustrated). In some examples, the motor described may bring the Empty Web Spool up to speed prior to it approaching the spool and closing the Nip. The rotary speed (rotations per minute) of the Empty Web Spool may be such that its surface speed equals that of the paper web and reel drum surface. During the run up to that speed, the Cover Flap of the Cover Flap Transfer Tape Construct may open up. The speed of the spool may create an apparent wind or aerodynamic force against the surface of the Cover Flap Transfer Tape Construct to open the flap. Additionally, as the spool rotational speed increases, the centrifugal force on the Cover Flap also increases to encourage it to open.

[0089] The rotation may bring the opened Cover Flap Transfer Tape Construct 210 into the Nip 220, which will put pressure onto the exposed adhesive surface. In some examples, the cover flap adhesive will approach the paper web when the Empty Web Spool is brought into close contact with the paper web on the reel drum. In some embodiments discussed herein, the adhesive remains attached to and lifts with the cover flap from the Transfer Tape Construct. As may be seen in the illustration, the fact that the adhesive is on the back of the Cover Flap brings the adhesive closer to the paper web.

[0090] In reference to FIGS. 3 and 3A, when the Cover Flap Transfer Tape Construct is in the Nip 320, the Cover Flap 311 may be pressed to adhere to the paper web 100 in the Nip 320. It may be noted that the proportions of the components in the figures may be exaggerated for clarity of illustration relative to the thickness or their size with respect to the spool.

[0091] Proceeding now to both FIGS. 4 and 4A, the paper web 400 adheres to the exposed adhesive as the reel drum 101 rotates and lifts the paper toward the Empty Web Spool 103. The Cover Flap Transfer Tape Construct region is rotating out of the Nip 320 as new paper from the paper web 230 advances on the reel drum surface 240. As discussed, the illustrations are exemplary and are provided to illustrate fundamental aspects of various embodiments. The scales of the illustrations are not intended to be limiting, such as for example, the relative dimensions of an adhesive layer when compared to paper thickness and spool dimensions.

[0092] As illustrated in FIGS. 5 and 5A, as the Empty Web Spool 103 continues to advance with the paper web 100 attached to the adhesive on the cover flap tape construct 500, it may eventually tear or burst the paper web 100 away from the last portion 510 of the paper web that is rolling onto the Parent Web Spool 102. This completes the turn up process. The Empty Web Spool (now web spool 102 becomes the Empty Web Spool) may be moved out of the region of the reel drum 101. As the Empty Web Spool (102) is moved out of the region, the Empty Web Spool 103 may continue to pick up paper from the paper web 100 and be moved into the location that the Parent Web Spool (102) had occupied before it was moved. In the embodiments discussed herein, the fact that the adhesive that the paper web 100 has attached to the back of the Cover Flap 500 is elevated above the spool surface may increase the energy involved in tearing the paper web 100, which may improve the efficacy.

[0093] The Cover Flap Transfer Paper or Tape Constructs include an arrangement of a zone-coated carrier paper and adhesive tape that can be adhered to a new spool. A function of a Cover Flap is to protect the adhesive that will eventually pick up and tear the paper web. The primary problem with applying adhesive tapes to a spool is that the dusty environment can blind the adhesive before it can be delivered to the nip to pick up the paper web. By integrating the Cover Flap, the turn-up adhesive remains protected from the environment and contamination until immediately prior to use. Various examples of Cover Flap Transfer Tape Constructs are described in the following sections.

[0094] However, the combination of multiple layers of adhesive tape, protective release liner, and/or carrier paper in assemblies or rolls, results in structures that resist being wound into a roll suitable for storage, distribution, and dispensing. The differential radii among the various layers may create issues such as differences in circumference and wrinkling, which can affect the performance of the system and may cause the system to delaminate.

[0095] As a solution, a dispenser system can be configured that performs part of the creation of the Transfer Tape Construct structure while dispensing and at the point of application to the spool face. Preformed materials may be dispensed from spools with the removal and discarding of unneeded materials during the application process.

[0096] For a Cover Flap Transfer Tape Construct, a dispensing solution may be achieved by applying a double-sided adhesive tape across the full width of the zone-coated carrier paper and winding the product into a roll. The packaged rolls of liner-backed substrate and adhesive may not be in the final configuration designed to perform the turn-up, and these final steps of the processing may be performed concurrently with the dispensing of the material and application to the spool in the paper mill.

[0097] In some examples, the zone coated carrier paper may be formed by treating a carrier paper with a silicone release material to the first face of the carrier paper in longitudinal stripes. When adhesive is applied to the zone coated carrier paper, it may permanently adhere to the uncoated stripes, while being impermanently or weakly adhered to the coated stripes. In some examples, the second face of the release liner has stripes in an order and placement opposite to those on the first face. In some examples, the adhesive and release liner are laminated together and wound into a roll. Again, the adhesive adheres permanently to the uncoated stripes of the second face of the release liner that has been laid upon the adhesive of the previous layer, wound into the roll. In some examples, when the outer-most layer of carrier paper is pulled away from the underlying layer, the adhesive separates into ribbons defined by the alternating coated and uncoated stripes.

[0098] In some examples, dispensing and completed processing may be accomplished by folding the carrier paper in half lengthwise. The outer face on one side of the folded ribbon presents adhesive that adheres the product to the face of the new spool. The product may be oriented with the edges pointing in the direction of spool rotation, while the fold is trailing. In examples without a remaining fold, the respective sides may be oriented in a similar manner.

[0099] An outer face of the folded carrier paper may not have adhesive on it. This side may face the paper web as the spool is set for the turn-up. The forward edge of the Cover Flap Transfer Tape Construct, as dispensed in this manner, may be caught in the air around the spinning spool and lift up and fold back, exposing the adhesive ribbon that had been protected by the folded carrier paper. In this manner, fresh adhesive may be presented to the paper web when the nip between the empty spool and the reel drum is closed. The paper web may adhere to the exposed adhesive and may follow the circumference of the empty spool. The change in direction ruptures the web in tension and the turn-up may be complete in a process as depicted in FIGS. 1-5.

[0100] An exemplary processing flow to form a Cover Flap Transfer Tape Construct may follow. Referring now to FIG. 6A, a carrier paper with zone coated release 610 may be received in a standard roll width. Double sided Adhesive Tape 611 may be laminated to the first surface of the carrier paper and may be kiss-cut (612, 613) at boundaries aligned with the edges of the coated stripes.

[0101] Referring now to FIG. 6B, a wide continuous sheet of double sided adhesive tape which has been laminated to the carrier paper, may be slit to a needed or desired width. Separate strips 620, 621 of the resulting tape material may be ribbon-wound. In the variations as are illustrated, no release paper is inserted between layers, so the exposed adhesive of the bottom layer is covered directly by the carrier paper of the next layer.

[0102] Referring now to FIG. 6C, the dispensing of the zone coated paper and laminated double sided adhesive tape causes ribbons of adhesive to adhere to the uncoated areas of the first surface 631 and transfers ribbons of adhesive 632, 633 to the uncoated areas of the second face of a layer pulled from the roll. The double sided adhesive tape may thereby separate into stripes along the kiss-cuts as illustrated.

[0103] Referring now to FIG. 6D, the composite tape strip 641 may be folded 642 in half. The strip may be twisted ninety degrees 650 to attach the strip 651 to the new spool 652 by the exposed adhesive. This may result in the strip being firmly adhered to the face of the spool, while the adhesive that will pick up the paper web is protected by the upper half of the folded strip. The open side of the folded strip is oriented to point in the direction of the spool rotation, and the fold acts as a hinge around which the upper half will turn when the air around the spinning spool lifts it.

[0104] Referring now to FIG. 6E, an applicator device or package 660 may contain the roll of prepared carrier paper and adhesive 661. The applicator package 660 may be equipped with mechanisms to perform the final processing and application steps to apply the product directly to the spool without manual intervention. The operator may press the leading end of the folded system against the spool and move the applicator package along the length of the spool before the spool is lifted into the primary arms. Thereafter, the applied Cover Flap Transfer Tape or Turn-up Construct may function to achieve Turn-Up without further operator action.

[0105] Proceeding to FIG. 6F, the carrier paper and adhesive may be folded lengthwise and twisted before being applied to the spool. FIG. 6F illustrates a creasing wire 670 in the folding mechanism of the dispenser applicator. In some examples, a wheel may be utilized. In some examples, the creasing wire or the wheel may have a non-stick coating to prevent fouling with adhesive, and non-stick coatings may be applied to the remainder of the folding mechanism.

[0106] Again, referring to FIG. 6F, a pressing wheel 671 may be used to firmly press the product to the spool. There may be numerous means to apply pressure to attach the Cover Flap Transfer Tape Construct to the surface, such as a wiper or similar apparatus that can apply pressure to the application. In some examples, a compressible polymer foam hub 672 may provide substantially constant friction and keep the construct well aligned. Other mechanisms may be used to keep the substantially constant friction. Some examples are provided below to illustrate different ways that the methods and apparatus may be used to create solutions for paper processing turn-up.

[0107] Referring to FIG. 7A, an illustration of a Cover Flap Transfer Tape Construct 7002 mounted on an Empty Web Spool 7001 is provided. The Cover Flap 7003 is illustrated in an original closed position. The spool may be turned in the direction indicated at arrow 7010. In some embodiments, spinning of the spool creates one or more of aerodynamic forces and centrifugal forces which act upon the Cover Flap 7003 to pull away from and increase in magnitude as the rotational velocity of the spool increases. Therefore, the spool may initially be rotating at a slower rate that maintains the Cover Flap 7003.

[0108] As the spool 7001 reaches a sufficient speed as it rotates in the direction of arrow 7010 the cover flap 7020 may detach from the tape construct and open. Referring to FIG. 7B the flap 7020 is shown in the open position, which exposes an adhesive layer 7021 on the underside of the Cover Flap, which interacts with the paper web 7022. As the paper web 7022 adheres to the adhesive layer 7021 attached to the Cover Flap 7020, the paper web 7022 may be pulled until the paper web 7022 severs 7030, the severing may include for example, tearing of the paper or other separation of fibers included in the paper web until there is no longer a contiguous sheet of paper web 7022.

[0109] As has been discussed generally in previous sections, and as can be seen in the illustrations, the rotational movement of the empty spool 7001 causes the flap 7020 to elevate off of the empty spool 7001 and bridge a gap between the empty spool 7001 and the paper web 7022 such that the adhesive 7021 adheres to the paper web 7022. However, prior to elevating off of the empty spool 7001, the adhesive 7021 is protected by the cover flap 7020 and is not exposed to airborne particles (such as for example, paper particles) and other air borne environmental contaminants in amounts sufficient to significantly impair the adhesive qualities of the adhesive 7021 until the empty spool 7001 spins up to speed. A desired spin up speed may be measured as rotations per minute of the empty spool. In some embodiments, the desired spin-up speed (in rotations per minute-RPM) may be based upon, such as within about 10% of the surface speed of a paper web 7022 that is traveling over a reel drum and spinning on a full spool (not shown in FIG. 7A or 7B).

[0110] In some embodiments, a release layer 7031 may be coated on a base of the Cover Flap Transfer Tape Construct 7002 to facilitate the adhesive layer 7021 on the cover flap 7020 separating from the release layer 7031.

[0111] In various embodiments of the present invention, alternate types of Cover Flap Transfer Tape Constructs that may be formed with the methods and apparatus as have been described. In the following sections, different examples are described and illustrated to highlight different features and functions that may be created.

[0112] Proceeding to FIG. 8, an exemplary Cover Flap Transfer Tape Construct 8000 according to some embodiments of the present invention is illustrated. In some embodiments, an adhesive layer 8002 is included under a cover flap 8001. The underlying adhesive layer 8002 is illustrated along with a base transfer tape substrate 8003, and a base adhesive layer 8004. In these embodiments, the dimensions of the cover flap 8001 create an overhang 8005 that extends beyond the adhesive layer 8002. In these examples, the Cover Flap 8001 and the base transfer tape substrate 8003 are about the same width and length (e.g., within one centimeter of each other).

[0113] To form the Cover Flap Transfer Tape Construct 8000, the Cover Flap adhesive 8002 is patterned or masked when applied to the Cover Flap Transfer Tape substrate 8001. Methods have been described for how to create the patterned layers of adhesive upon the tape substrate. Other means may also be used. Alternatively, the adhesive layer 8002 may be formed of a double sided adhesive tape with a dimensional width that is smaller than a width of the two substrate layers and the other base adhesive layer 8004.

[0114] Referring now to FIG. 8A, the Cover Flap Transfer Tape Construct 8000, is illustrated with a Cover Flap 8001 in an open position and an adhesive 8020 exposed to the environment (exposed adhesive 8020). The overhang 8005 feature may present a portion of the Cover Flap 8001 that extends beyond the adhesive 8002. During rotation of an empty spool to which the Cover Flap Transfer Tape Construct 8000 is attached, aerodynamic effects may be enhanced via circulation of air beneath the opening of the Cover Flap 8001 that is formed by the overhang 8005.

[0115] As is illustrated, in performing a turn up procedure, the Cover Flap 8001 opens, but still maintains an area of the Cover Flap (e.g., region 8005) that remains adhered to the rest of the transfer tape construct as it engages, adheres to, and pulls the paper web towards the Empty Web Spool. Accordingly, the region 8021 beginning at the edge of the Cover Flap may be configured to fixedly hold the Cover Flap even under the aerodynamic forces, the centrifugal forces, and under the forces related to attachment to the paper web. Maintaining the cover flap 8005 in a state of adherence to the transfer tape construct provides a safety benefit in not having the cover flap become a projectile due to its high speed of travel.

[0116] In some examples, the base Transfer Tape substrate 8003 may be treated with a release formulation, such as a silicone based formulation that renders a surface that has a reduced adhesion strength. Thus, when the Cover Flap layers, particularly the Cover Flap Adhesive Layer 8002 are assembled into the construct, there may be a portion of the Cover Flap that is fixedly attached. It may also be practical to treat the Cover Flap Adhesive Layer 8002 with a release formulation in the region of desired release.

[0117] Although the general method of forming the adhesive regions has been discussed previously in some alternative examples, a combination of double sided tapes cut to appropriate dimensions may be used in a process that allows for straightforward release formulation treatment. For example, a narrow double sided tape with high adherence may be used to form the adhered portion, and relatively wider double sided tape may pass with one of its faces passing over a treatment region where a release composition may be applied by spray treatment or other such means. The modified tape may then have a well adhered side and a less adhered side.

[0118] Referring to FIG. 9, another multilayered Transfer Tape Construct is illustrated. However, in this example, no overhang is present. The various layers have similar dimensions such as the Cover Flap Transfer Tape substrate 9001, the Cover Flap adhesive layer 9002, the base Transfer Tape substrate 9003, and the base adhesive layer 9004. As in the examples related to FIG. 8, a portion of the cover flap or underlying layers may need to be differentially treated to allow for a portion that releases and a portion that strongly adheres. Similar methods to achieve such a result may be applied to the examples of FIG. 9. When the Cover Flap opens as illustrated in FIG. 9A, the underlying adhesive 9020 is exposed.

[0119] Referring to FIG. 10, another example of a multilayer Cover Flap Transfer Tape Construct with an overhang 10010 is illustrated. The construct may be very similar to the examples illustrated in FIG. 8, but where the overhang 10010 does not overlap the base substrate and adhesive layers. The illustrated layers may include a Cover flap Transfer Tape substrate 10001, a Cover Flap adhesive layer 10002, a base Transfer Tape substrate 10003, and a base adhesive layer 10004. The design aspect that the overhang 10010 sits without any underlying structure over the spool that it is attached to may enhance the effect of aerodynamic forces on the Cover Flap. After the Cover Flap opens, a result may be as illustrated in FIG. 10A with exposed adhesive 10020.

[0120] Referring to FIG. 11, another variation of multilayer Cover Flap Transfer Tape Construct with an overhang 11010 is illustrated. In this example, the overhang has an adhesive layer under it as well. The layers include a Cover Flap Transfer Tape substrate 11001, a Cover Flap adhesive layer 11002, a base Transfer Tape substrate 11003, and a base adhesive layer 11004, exposed adhesive 11020 when the Cover Flap opens in FIG. 11A. The base transfer tape substrate 11003 may have a region that is either treated to enhance adhesive bonding or is conversely, a region of the substrate that is not treated. Thus, the Cover Flap remains adhered as it attaches the paper web as discussed previously. In some examples, the manufacture of the Cover Flap Transfer Tape Construct of FIG. 11 may be simplified by having commonality of the Cover Flap layers with each other and of the Base layers with each other.

[0121] Referring to FIG. 12, a multilayer Transfer Tape construct with an overhang 12010 where the overhang 12010 does not have an underlying adhesive layer but does have an overlying adhesive security layer 12011 is illustrated. The construct includes a Cover flap Transfer Tape substrate 12001, a Cover Flap adhesive layer 12002, a base Transfer Tape substrate 12003; and a base adhesive layer 12004. The base Transfer Tape substrate 12003 also has a separated attachment layer 12030 that joins the Cover Flap Transfer Tape substrate 12001 and the base Transfer Tape substrate 12003.

[0122] In previous sections, discussion has been made of the potential to form adhesive layers as composite layers of multiple tape dimensions. In the illustration of FIG. 12 the formation of the adhesive layer 12002 and the attachment layer 12030 may be formed in that manner from a set of different sized adhesive layers. As well, an additional layer of adhesive to form a security layer may be formed. As shown in FIG. 12A, when the top flap is opened during the spin up of a spool that the construct is attached to, the Cover Flap may open, exposing the underlayer of adhesive 12020. The top security layer 12011 may have numerous roles. In a first role, the added mass of the adhesive feature may enhance the effect of centrifugal force in opening the Cover Flap. In another role, in some examples, as the cover flap opens, it will tend to be forced by the aerodynamic forces to completely fold over onto the spool. When the security feature or layer interacts with the spool, it can hold the Cover Flap in a deployed position to maintain adhesive presentation.

[0123] Referring to FIG. 13, another example of a multilayer Transfer Tape construct with an overhang 13010 where the overhang does not have an underlying adhesive layer but does have an overlying adhesive security layer 13011 is provided. Much of the previous discussion applies to the example of FIG. 13. However, in this example, the Cover Flap layers overlap both sides of the Cover Flap Transfer Tape Construct. The layers may then be deformed such that the attachment overlap 13030 has its adhesive portion at the same level as the base Transfer Tape substrate adhesive. In general, the layers of the construct may be identified as a Cover Flap Transfer Tape substrate 13001, a Cover Flap adhesive layer 13002, a base Transfer Tape substrate 13003; and a base adhesive layer 13004. The Cover Flap substrate 13001 and Cover Flap adhesive layer 13002 are pre-creased and deformed to match the level of the bottom of the base adhesive layer 13004 in the attachment overlap 13030. In this construct, the attachment overlap 13030 directly attaches to the spool surface, making for a strong robust bond to hold when the Turn-up occurs. Again, in FIG. 13A, when the Cover Flap opens, the underlying adhesive 13020 is exposed.

[0124] Referring to FIG. 14, another example of a multilayer Cover Flap Transfer Tape Construct with an overhang 14010 where the overhang does not have an underlying adhesive layer but does have an overlying adhesive security layer 14011 is illustrated. The construct may have the following features: a Cover flap Transfer Tape substrate 14001, a Cover Flap adhesive layer 14002, a base Transfer Tape substrate 14003, and a base adhesive layer 14004. A distinguishing aspect of this example is that the Cover Flap Transfer Tape substrate and the base Transfer Tape substrate are a contiguous layer as may be formed by bending 14030 an initial piece into the two regions. This may result in a strong Cover Flap strength as a relatively large adhesive footprint is combined with material strength of the substrate layer. Referring to FIG. 14A, exposed adhesive 14020 is presented when the Cover Flap opens.

[0125] Referring to FIG. 15, another example of a multilayer Cover Flap Transfer Tape Construct with an overhang 15010 where the overhang does not have an underlying adhesive layer is illustrated. The example may include a Cover flap Transfer Tape substrate 15001, a Cover Flap adhesive layer 15002, a base Transfer Tape substrate 15003, and a base adhesive layer 15004. The differentiating factor for this example is that a hinge connection 15030 is created by folding and overlapping portion of the Cover Flap underneath the base adhesive layer. Cover Flap substrate 15001 and Cover Flap adhesive layer 15002 are deformed to receive a bent portion of the Cover Flap adhesive 15002 and the Cover Flap substrate 15001. The bonding of the two adhesive layers and the bending of the attached layers form a hinge joint 15030. When the Cover Flap opens during use, as illustrated in FIG. 15A, the underlying adhesive 15020 is exposed.

[0126] Referring now to FIGS. 16A-16C, a cover-flap transfer tape construct is illustrated in multiple views and stages of preparation and use. In FIG. 16A, a roll 1600 of a prepared carrier paper 1601 is shown presenting a continuous length of material configured for dispensing toward an applicator or directly toward an empty or new web spool. The carrier paper 1601 houses a zone-coated transfer tape substrate 1603 that may be factory-assembled with a first release layer 1602 on a top side and a second release layer 1604 on a bottom side. In supply and storage, the first release layer 1602 and the second release layer 1604 protect pressure-sensitive adhesive patterns (e.g., 1605, 1605A) disposed on the zone-coated transfer tape substrate 1603, and the carrier paper 1601 stabilizes the laminate against curling during winding on the roll 1600. The roll 1600 may be slit to widths correspondent to a desired cover-flap width, and the carrier paper 1601 may include printed registration marks or micro-perforations 1607 to cooperate with indexing sensors during dispensing from the roll 1600.

[0127] Turning to the layered perspective of FIG. 16B (left view), the carrier paper 1601 overlays the zone-coated transfer tape substrate 1603 with the first release layer 1602 and the second release layer 1604 disposed on opposing faces of the zone-coated transfer tape substrate 1603. In a peeled view in FIG. 16B (right), the first release layer 1602 is shown lifting away from the zone-coated transfer tape substrate 1603 to expose a first zone of adhesive 1605 disposed on a top surface (first surface) of the zone-coated transfer tape substrate 1603, while the second release layer 1604 may also be peeled off to reveal two laterally spaced second and third zones of adhesives 1605A disposed along opposite edge regions on a bottom surface (second surface) of the zone-coated transfer tape substrate 1603. The carrier paper 1601 in FIG. 16B may present a compliant yet dimensionally stable sheet that accommodates bending over guide radii during liner take-up without delaminating the first release layer 1602 from the zone-coated transfer tape substrate 1603 prematurely. The zone-coated transfer tape substrate 1603 may be a paper, polymer film, composite nonwoven, or laminate configured to act as a transfer tape construct during turn-up, with stiffness tuned so that, after deployment, a portion of the zone-coated transfer tape substrate 1603 lifts away from a web spool surface and exposes the first zone of adhesive 1605 to an approaching paper web.

[0128] FIG. 16C presents plan views that delineate the functional zoning. In the TOP VIEW of FIG. 16C (left), the first zone of adhesive 1605 occupies a central band extending lengthwise along the zone-coated transfer tape substrate 1603 and bounded on each lateral side by uncoated zones 1606 that remain free of adhesive for subsequent folding, handling, and aerodynamic opening of the first release layer 1602. The uncoated zones 1606 can function as hinge or stiffness-modulating margins, reduce contamination pickup, and provide visual alignment contrast against the first zone of adhesive 1605. In the BOTTOM VIEW of FIG. 16C (right), the second and third zones of adhesives 1605A are shown as longitudinal edge bands located along opposing sides of the underside of the zone-coated transfer tape substrate 1603, leaving an uncoated middle zone 1606A that extends the full length for sliding clearance and for receiving air flow during rotation. The dimensional relationship between the first zone of adhesive 1605, the uncoated side zones 1606, the second and third zones of adhesives 1605A, and the uncoated middle zone 1606A may be selected so that, when the zone-coated transfer tape substrate 1603 is applied to an empty or new web spool, the second and third zones of adhesives 1605A anchor the tape construct along the edges while the first zone of adhesive 1605 remains exposed on the top side for paper web capture. In some embodiments, the width of the uncoated middle zone 1606A may be approximately equal to the width of the first adhesive zone 1605, and the widths of the second and third zones of adhesives 1605A may be approximately equal to the widths of uncoated zones 1606.

[0129] In some modes of use, the first release layer 1602 and the second release layer 1604 are removed from the zone-coated transfer tape substrate 1603 immediately prior to application to an empty or new web spool. A user or an applicator device advances the carrier paper 1601 from the roll 1600 and separates the first release layer 1602 to expose the first zone of adhesive 1605 while also separating the second release layer 1604 to expose the second and third zones of adhesives 1605A. The zone-coated transfer tape substrate 1603 is then presented to an empty or new web spool so that the second and third zones of adhesives 1605A contact and bond to the web spool shell along edge-parallel tracks, thereby leaving the first zone of adhesive 1605 facing outward as an elevated, web-binding region. The uncoated middle zone 1606A between the second and third zones of adhesives 1605A permits the zone-coated transfer tape substrate 1603 to flex away from the web spool surface under aerodynamic or centrifugal influences during rotation; simultaneously the uncoated zones 1606 bordering the first zone of adhesive 1605 limit adhesive-to-hardware contact and contribute to a controlled opening behavior that presents the first zone of adhesive 1605 at a favorable angle for paper web interception.

[0130] The first zone of adhesive 1605 on the top surface of the zone-coated transfer tape substrate 1603 can be formulated as a web-binding pressure-sensitive adhesive with peel characteristics tailored to a target web grade. As examples, the first zone of adhesive 1605 may be an acrylic copolymer adhesive with a 180-degree peel of 2-8 N/25 mm to a tissue or newsprint back, a shear creep exceeding 10,000 minutes at 1 kg/25 mm.sup.2, and a tack window that allows immediate grab at line speed. The second and third zones of adhesives 1605A on the bottom surface of the zone-coated transfer tape substrate 1603 may be a mounting adhesive having a higher peel to the web spool shell, such as 10-25 N/25 mm, to maintain positional stability during run-up and through web severance. The uncoated zones 1606 on the top surface and the uncoated middle zone 1606A on the bottom surface can be corona-treated, primed, or left untreated to achieve desired friction and stiffness.

[0131] In some embodiments, each uncoated zone 1606 has a width of about 1-10 mm (millimetre), with the first zone of adhesive 1605 occupying the remaining central span on the top surface. Likewise, each of the second and third adhesive edge zones or bands 1605A on the bottom surface may be about 1-10 mm wide, with the uncoated middle zone 1606A occupying the remaining central span. The widths of the edge adhesives 1605A (longitudinal adhesive edge zones) may be substantially equal to the widths of the uncoated edge zones 1606 to simplify alignment and converting. In certain layouts, the combined widths of the two uncoated edge zones 1606 are approximately equal to the width of the central adhesive zone 1605; in another layout, the width of each uncoated zone 1606 is about one-quarter of the width of the central adhesive zone 1605. More generally, the width of each uncoated zone 1606 may be about 0.1-0.5 the width of the central adhesive zone 1605.

[0132] Manufacturing of the tape construct shown in FIGS. 16A-16C can be accomplished by sequential coating and lamination. A continuous web destined to form the zone-coated transfer tape substrate 1603 is unwound and the second and third zones of adhesives 1605A are applied as longitudinal edge stripes using slot-die heads fitted with mask inserts or using two narrow-slot dies that track the edges. After partial cure or dwell, the web is inverted and the first zone of adhesive 1605 is applied centrally using a slot-die or gravure station that leaves the uncoated zones 1606 at the lateral margins. The first release layer 1602 is laminated onto the first zone of adhesive 1605 and the second release layer 1604 is laminated onto the second and third zones of adhesives 1605A, where each liner is selected for a desired release value to permit controlled stripping at the point of application. The composite is then laminated to the carrier paper 1601, slit to the required width, and wound into the roll 1600. Registration marks on the carrier paper 1601 may be printed to cooperate with applicator vision or sensor systems and to align the start of each length with a spool seam or locator.

[0133] During application, the user indexes a length of the zone-coated transfer tape substrate 1603 and bonds the second and third zones of adhesives 1605A to the shell of a web spool. When the spool accelerates, air entrained by rotation accesses the uncoated middle zone 1606A and creates a lifting force that bends the zone-coated transfer tape substrate 1603 outward around the adhered edge anchors created by the second and third zones of adhesives 1605A. The uncoated zones 1606 bordering the first zone of adhesive 1605 behave as low-tack rails that reduce propensity for premature sticking to machine parts and also act as flexural hinges that guide the outward curvature. As the web approaches, the first zone of adhesive 1605 on the top surface of the zone-coated transfer tape substrate 1603 extends across the nip and engages the moving paper web. After contact, the developing wrap angle carries the paper web into a new roll and the first zone of adhesive 1605 is subsequently buried under the first few wraps while the second and third zones of adhesives 1605A maintain anchorage to the web spool beneath the wrap.

[0134] Various embodiments may tailor the geometry and chemistry of each element to match different products and line conditions. The roll 1600 may be supplied in discrete pads rather than continuous lengths; the carrier paper 1601 may be a polymeric film carrier to withstand humid environments; the first release layer 1602 may be a silicone of controlled release force between 10-60 g/25 mm to provide predictable liner peel; and the second release layer 1604 may be a polyethylene-coated paper sized to balance caliper for even winding on the roll 1600. The zone-coated transfer tape substrate 1603 may incorporate printed graphics that align the first zone of adhesive 1605 centrally, and the uncoated zones 1606 may carry micro-texture embossing that promotes airflow under the transfer tape during rotation. The second and third zones of adhesives 1605A can be segmented along the length to create tether regions alternating with low-adhesion regions, permitting controlled lift of the zone-coated transfer tape substrate 1603 while maintaining safety retention at the anchored edges. The uncoated middle zone 1606A may include perforations or shallow channels that further guide air ingress and influence the bending profile while the first zone of adhesive 1605 is presented toward the paper web.

[0135] Alternative material selections can expand the implementation window. The first zone of adhesive 1605 may be a rubber-resin PSA for low-temperature grab or a UV-curable hot-melt that is activated during application. The second and third zones of adhesives 1605A may be formulated with higher shear strength to resist peel during the onset of web pull. The zone-coated transfer tape substrate 1603 can be a fiber-reinforced paper that resists tearing when the web pulls away at transfer, preserving a clean underlying core. The carrier paper 1601 can be sized to accept water-based coatings without cockling during the dual-liner lamination of the first release layer 1602 and the second release layer 1604. The roll 1600 can be wrapped with a protective overwrap that is removed at the machine, and the outer tail of the carrier paper 1601 may be secured with a light removable tape to prevent telescoping during shipment.

[0136] In other embodiments related to FIG. 16C, the widths of the uncoated zones 1606 and the second and third zones of adhesives 1605A are proportioned so that, upon application, the outer edges bonded by the second and third zones of adhesives 1605A remain outside the future contact arc between the first zone of adhesive 1605 and the moving web, thereby reducing adhesive-to-web interference during transfer. The uncoated middle zone 1606A may be set wider than a calculated neutral axis width of the zone-coated transfer tape substrate 1603 so that bending occurs preferentially along the uncoated middle zone 1606A when the spool rotates, creating a predictable arc of the first zone of adhesive 1605 across the nip. A colored indicator printed along the uncoated zones 1606 can visually confirm correct orientation during installation, and indexing notches in the carrier paper 1601 can cooperate with a stop-pin on the applicator to fix the leading edge length for consistent performance from the roll 1600.

[0137] When an empty or new spool is prepared, the operator advances from the roll 1600, peels the first release layer 1602 to expose the first zone of adhesive 1605, peels the second release layer 1604 to expose the second and third zones of adhesives 1605A, and positions the zone-coated transfer tape substrate 1603 so that the second and third zones of adhesives 1605A adhere along two edge bands. After bonding, the first zone of adhesive 1605 remains outward-facing and ready for web engagement. During the turn-up event, the wrap builds, and the tension path causes the zone-coated transfer tape substrate 1603 to lay back against the spool while the first zone of adhesive 1605 transfers initial traction to the paper web. Subsequent layers bury the first zone of adhesive 1605 under the web wraps while the second and third zones of adhesives 1605A remain at the core interface.

[0138] Referring now to FIG. 17A, an applicator device 1700 configured to form a raised profile in a cover-flap transfer tape construct and to present the tape construct for application to an empty web spool is shown in exploded perspective. The applicator device 1700 includes a first forming member or first frame structure 1700A and a second forming member or second frame structure 1700B that are geometrically complementary so that the second frame structure 1700B nests with, or closes over, the first frame structure 1700A to define an operational channel for a prepared carrier paper 1601 dispensed from a roll 1600. The first frame structure 1700A presents a front side 1703 and a back side 1704, between which extend a first side frame 1705 and a second side frame 1706, each aligned longitudinally to provide rails that guide the prepared carrier paper 1601 along a straight or slightly curved path. Between the first side frame 1705 and the second side frame 1706 a third frame 1707 spans the length of the device and carries a raised profiled portion 1702 sized to impart a controlled out-of-plane curvature to the cover-flap laminate as it passes through. The raised profiled portion 1702 may be tapered crown on the third frame 1707, where the tapered crown or shape height of the raised profiled portion 1702 decreases gradually from the front side 1703 to the back side 1704. A fourth frame 1701 projects upward at the front side 1703 and carries an ergonomic grab bar or handle 1708 with an integrated push button 1709 that actuates a cutting blade 1710 arranged proximate to an egress edge of the front side 1703. One or more connection points 1711-1712 are provided on the first side frame 1705 and the second side frame 1706 to accept mating hardware from the second frame structure 1700B and to register the two halves with repeatable alignment during assembly and use.

[0139] The second frame structure 1700B is shaped to close over the first frame structure 1700A with complementary geometry. In particular, the second frame structure 1700B includes a complementary first side frame 1705A and a complementary second side frame 1706A that oppose the first side frame 1705 and the second side frame 1706 to form a slot or channel with defined gauge for the prepared carrier paper 1601. A hollow raised portion 1702A (e.g., concave cavity) is formed along the centerline of the second frame structure 1700B, dimensioned to cooperate with the raised profiled portion 1702 on the first frame structure 1700A (forming a die for preparing a raised profile tape construct); together the raised profiled portion 1702 and the hollow raised portion 1702A produce a controlled crest-and-cavity interface (die) that shapes the cover-flap transfer tape construct into a raised profile suited for aerodynamic opening and nip bridging. The second frame structure 1700B also carries complementary connection points 1711A-1712A positioned to mate with the connection points 1711-1712 on the first frame structure 1700A, thereby locating the two structures in a kinematically constrained manner.

[0140] In one arrangement, the connection points 1711-1712 and the complementary connection points 1711A-1712A are realized as quarter-turn bayonet studs with detent springs that engage with a 90-degree twist; in another arrangement, the connection points 1711-1712 and 1711A-1712A are magnetic couplers employing paired rare-earth magnets encapsulated in polymer pockets so that the second frame structure 1700B snaps onto the first frame structure 1700A without loose fasteners. A further arrangement provides snap-fit tongues on the complementary first side frame 1705A that latch into windowed receptacles on the first side frame 1705, while the complementary second side frame 1706A carries an over-center toggle that presses the second frame structure 1700B downward against compliant pads mounted along the third frame 1707. In each arrangement, fastening units 1713 and 1713A can be provided to augment or replace the connection points 1711-1712 and 1711A-1712A, for example, opposed-polarity magnets 1713, 1713A placed near the ends of the raised profiled portion 1702 and the hollow raised portion 1702A to maintain uniform gap height, or threaded inserts 1713, 1713A to accept captive thumb screws for environments that prefer purely mechanical retention. In some embodiments, the connection points 1711-1712 may be bayonet fasteners.

[0141] The first frame structure 1700A is engineered to guide, shape, and support the prepared carrier paper 1601 as it is pulled from the roll 1600. The first side frame 1705 and the second side frame 1706 can incorporate low-friction wear strips, such as PTFE or UHMW-PE, coextensive with the paper path to reduce drag and to keep the prepared carrier paper 1601 centered. The raised profiled portion 1702 on the third frame 1707 presents a smooth convex surface whose radius and crown height are selected to pre-form the cover-flap laminate into a gentle arch without wrinkling; crown height may vary along the length so that the arch initiates with a shallow ramp near the back side 1704 and reaches a maximum near the front side 1703, where the tape construct exits toward the spool. The fourth frame 1701 stands above the plane of the first side frame 1705 and the second side frame 1706 so that the grab bar or handle 1708 clears adjacent machine structures, and the push button 1709 triggers the cutting blade 1710 through a guarded slot such that an operator trims the prepared carrier paper 1601 to length after the laminate has been formed over the raised profiled portion 1702.

[0142] The second frame structure 1700B complements the shaping function by applying distributed pressure across the prepared carrier paper 1601 and by defining the upper boundary of the forming channel. The hollow raised portion 1702A is concave relative to the raised profiled portion 1702 and can be lined with an elastomeric skin to accommodate caliper variations in the prepared carrier paper 1601 and adhesive stack. Vent apertures near the apex of the hollow raised portion 1702A can be added to bleed trapped air as the second frame structure 1700B closes onto the first frame structure 1700A, thereby avoiding creases. In some embodiments, the complementary first side frame 1705A and the complementary second side frame 1706A carry longitudinal ribs that register with grooves formed on the first side frame 1705 and the second side frame 1706 to prevent lateral wander during high-speed manual pulls. The complementary connection points 1711A-1712A can integrate conductive pins that mate with receptacles at the connection points 1711-1712 to provide power or sensor signals to auxiliary modules mounted on the second frame structure 1700B, such as a small indicator LED that confirms closure or a microswitch that interlocks the cutting blade 1710.

[0143] In operation, a length from the roll 1600 feeds the prepared carrier paper 1601 into the channel formed by the first frame structure 1700A and the second frame structure 1700B. As the prepared carrier paper 1601 advances, the cover-flap transfer tape laminate seats over the raised profiled portion 1702 and under the hollow raised portion 1702A, acquiring a pre-arched profile that remains after the length is trimmed by the cutting blade 1710 actuated by the push button 1709 on the grab bar 1708. The operator grips the grab bar 1708, carries the applicator device 1700 toward the core location, and places the pre-arched length against the spool shell while referencing the front side 1703 against a machine datum. The connection points 1711-1712, 1711A-1712A and the fastening units 1713, 1713A hold the first frame structure 1700A and the second frame structure 1700B in a closed condition during this transfer so that the formed profile remains consistent from piece to piece. After adhesion of edge zones on the tape construct, the applicator device 1700 is lifted away and the formed transfer tape retains the raised geometry imparted by the raised profiled portion 1702 and the hollow raised portion 1702A.

[0144] Material choices for the first frame structure 1700A and the second frame structure 1700B may include anodized aluminum for rigidity and low mass, fiber-reinforced polymer for impact resistance, plastic, or stainless steel for wash-down environments; the raised profiled portion 1702 can be machined with a satin finish (Ra 0.4-1.6 m) to reduce adhesive pickup, while the hollow raised portion 1702A may be coated with a fluoropolymer to further discourage fouling. The grab bar or handle 1708 can be overmolded with an elastomer for grip, and the push button 1709 can be mechanically linked to a guarded guillotine-style cutting blade 1710 or to a rotary pizza-wheel cutter 1710 guided by a hardened track integrated into the fourth frame 1701. Optional catches near the front side 1703 retain the trimmed leading edge so that the formed piece remains indexed until the operator chooses to release it by depressing a local detent.

[0145] To support repeatable forming, gauge features may be added. The first side frame 1705 and the second side frame 1706 can include dial-in shims to set the gap to a chosen value according to tape caliper; corresponding shim pockets in the complementary first side frame 1705A and the complementary second side frame 1706A accept color-coded inserts that indicate the current setting. The connection points 1711-1712 and 1711A-1712A may be set on dowel-and-bore interfaces so that replacement second frame structures 1700B, for example, with different hollow raised portion 1702A profiles, swap in without recalibration. Fastening units 1713, 1713A can house quick-release plungers that unlock with a quarter-turn to speed changeover. A small datum notch on the first frame structure 1700A near the back side 1704 aligns with printed registration on the prepared carrier paper 1601 so that each cut length presents the same relative adhesive zoning when applied to the spool.

[0146] Cleaning and maintenance considerations can be addressed by removable liners and blade cassettes. The raised profiled portion 1702 may accept a sacrificial non-stick sleeve that slips off once contaminated; the hollow raised portion 1702A can accept a peel-off non-stick film that restores a fresh surface. The cutting blade 1710 can be part of a disposable cassette that snaps into a pocket in the fourth frame 1701, replacing both blade and guard in a single motion actuated by the push button 1709 for test cuts prior to production. Lubrication-free bushings embedded along the first side frame 1705 and the second side frame 1706 accommodate small rollers that present minimal contact area to the prepared carrier paper 1601, while still constraining the path as the roll 1600 is pulled.

[0147] In some embodiments, sensing and feedback elements are integrated. A reflective sensor adjacent the front side 1703 detects printed marks on the prepared carrier paper 1601 to signal the operator when the correct length has reached the cutting zone; the signal can be routed through the connection points 1711-1712, 1711A-1712A to a small indicator on the second frame structure 1700B. An optional spring-bias in the complementary first side frame 1705A and the complementary second side frame 1706A provides gentle preload onto the raised profiled portion 1702 so that caliper variation in the laminate is accommodated without marring. Where magnet-based fastening units 1713, 1713A are employed, pole orientation is selected to draw the second frame structure 1700B downward directly over the raised profiled portion 1702 and to resist shear as the prepared carrier paper 1601 is pulled forward, maintaining a stable forming gap from back side 1704 to front side 1703.

[0148] Referring now to FIG. 17B, the drawing presents the applicator device 1700 in a closed, operational condition in which the first frame structure 1700A and the second frame structure 1700B are coupled together to define a forming channel for the prepared carrier paper 1601 dispensed from the roll 1600. In this state, the raised profiled portion 1702 on the first frame structure 1700A cooperates with the hollow raised portion 1702A on the second frame structure 1700B to shape the material (e.g., the carrier paper 1601) as it advances through the device 1700. The coupling may be achieved at fastening units 1713 and 1713A and at connection points (e.g., 1711-1712 as shown in FIG. 17A) that register with complementary hardware on the second frame structure 1700B, thereby establishing a repeatable gap height and contour across the raised profiled portion 1702 and the hollow raised portion 1702A. With the two halves 1700A and 1700B mated, the front side 1703 presents a guarded cutting zone adjacent a cutting blade 1710, while the grab bar or handle 1708 supports a push button 1709 that actuates the cutting blade 1710 once a desired length has been formed.

[0149] In use, the carrier paper 1601 is placed, or threaded between the first frame structure 1700A and the second frame structure 1700B, laying over the raised profiled portion 1702 and beneath the hollow raised portion 1702A, and is then drawn or pulled forward by hand 1715 in the indicated direction 1716 under the grab bar or handle 1708 and past the front side 1703. The cooperating surfaces of the raised profiled portion 1702 and the hollow raised portion 1702A compress and guide the carrier paper 1601 so that a profiled carrier paper 1601A emerges from the channel with a defined raised profile 1721. The raised profile 1721 is accompanied by side bands 1722-1723 that remain substantially planar to provide edge stability while the middle or central region/portion is crowned by the contour of the raised profiled portion 1702. When the profiled carrier paper 1601A has advanced to a preset index length at the front side 1703, the operator depresses the push button 1709 to drive the cutting blade 1710 across the path and separate the profiled length, thereby producing a discrete tape construct 1601B while the hand 1715 maintains light forward traction in the direction 1716.

[0150] The shaping action imparted by the raised profiled portion 1702 and the hollow raised portion 1702A can be tuned for different laminate calipers and stiffness ranges by selecting the crown height, the longitudinal ramp of the raised profiled portion 1702, and the complementary cavity depth of the hollow raised portion 1702A. In one arrangement, the raised profiled portion 1702 exhibits a convex arc with a peak crown of 1-20 mm relative to the side frames on the first frame structure 1700A, while the hollow raised portion 1702A exhibits a matched concavity that maintains a constant forming gap 1724 to limit wrinkling of the carrier paper 1601 as it transitions into the profiled carrier paper 1601A. Low-friction liners along the contact surfaces of the raised profiled portion 1702 and the hollow raised portion 1702A may be provided to reduce drag during manual pull by the hand 1715. The fastening units 1713 and 1713A keep the second frame structure 1700B seated against the first frame structure 1700A so that the contour transferred to the profiled carrier paper 1601A is uniform along the length that is later trimmed by the cutting blade 1710.

[0151] After actuation of the push button 1709 and stroke of the cutting blade 1710, the separated tape construct 1601B carries the raised profile 1721 and the side bands 1722-1723 that stabilize placement against a core. The tape construct 1601B can be transported directly to a target core by the operator grasping the edges near the side bands 1722-1723, or the tape construct 1601B can be supported momentarily on a staging lip at the front side 1703 until transfer. The geometry of the raised profile 1721 is designed so that, when the tape construct 1601B is later affixed to a core, the central crown of the raised profile 1721 presents an elevated adhesive field toward an approaching paper web, while the side bands 1722-1723 lie flat and provide bonded anchorage zones. The fastening unit 1713 shown near the second frame structure 1700B may also function as a visual index that confirms closure prior to cutting via the cutting blade 1710, and the same fastening unit 1713 cooperates with a complementary feature 1713A on the first frame structure 1700A to maintain the designed gap during the forming step that creates the profiled carrier paper 1601A.

[0152] The tape construct 1601B can include one or more release layers on its upper and/or lower surfaces at the time it exits the device 1700. Prior to mounting on the target core 1725, these release layers are peeled to expose a first zone of adhesive 1605 on the crown of the raised profile 1721 and to expose second and third zones of adhesives 1605A along the underside edges corresponding to the side bands 1722-1723. The operator aligns the tape construct 1601B to the core 1725 and presses the underside edge zones carrying the second and third zones of adhesives 1605A to the shell of the core 1725, thereby anchoring the piece while leaving the first zone of adhesive 1605 exposed on the crown of the raised profile 1721. Once the core 1725 is accelerated, the crown defined by the raised profile 1721 presents the first zone of adhesive 1605 into the oncoming web path, while the side bands 1722-1723 remain bonded by the second and third zones of adhesives 1605A.

[0153] Alternative arrangements of the applicator device 1700 can augment the forming and cutting functions shown in FIG. 17B. The push button 1709 can be linked to a rotary cutting blade 1710 captured in a carriage that traverses across the front side 1703 for lighter cutting forces, or to a guillotine-style cutting blade 1710 guided in low-friction bushings for heavier calipers. The fastening units 1713 and 1713A can be realized as opposed-polarity magnets embedded in the second frame structure 1700B and the first frame structure 1700A so that closure is quick and the gap above the raised profiled portion 1702 is repeatable without threaded adjustments. A detented stop integrated into the second frame structure 1700B can index against printed marks on the carrier paper 1601 so that the profiled carrier paper 1601A is cut to uniform lengths via the cutting blade 1710, regardless of pull rate by the hand 1715 in the direction 1716.

[0154] The process indicated in FIG. 17B lends itself to several material and geometry variants for the raised profile 1721 and the side bands 1722-1723. In one embodiment, the raised profiled portion 1702 and the hollow raised portion 1702A are shaped to produce a symmetric crown that transitions with a cosine-like profile from the side bands 1722-1723 toward the apex of the raised profile 1721; in another embodiment, the raised profiled portion 1702 introduces a slight asymmetry so that the apex of the raised profile 1721 is offset toward the trailing side of the profile to bias the initial contact of the first zone of adhesive 1605. The side bands 1722-1723 may be embossed during forming to carry micro-ridges that facilitate air bleed when the tape construct 1601B is pressed onto the core 1725, and the crown forming the raised profile 1721 may be smoothed with a fluoropolymer skin on the hollow raised portion 1702A to reduce surface energy and discourage adhesive transfer during shaping.

[0155] Maintenance and handling aspects can also be integrated into the device 1700 as depicted in FIG. 17B. The cutting blade 1710 can be housed in a replaceable cassette that latches beneath the front side 1703 and is released by an internal catch linked to the push button 1709, allowing rapid swaps when the edge quality degrades. Wear strips on the raised profiled portion 1702 and on the hollow raised portion 1702A can be peel-and-stick PTFE films that are periodically renewed to keep friction low during the advance of the carrier paper 1601. The fastening units 1713 and 1713A can include small witness marks that align visually when the second frame structure 1700B is fully seated on the first frame structure 1700A, giving the operator an at-a-glance confirmation before forming another profiled carrier paper 1601A.

[0156] Referring now to FIG. 17C, an applicator device 1730 is presented in exploded perspective, the device 1730 being configured to form a raised profile in a cover-flap transfer tape construct while guiding a prepared carrier paper 1601 dispensed from a supply roll 1600. The applicator device 1730 is realized by coupling a first frame structure 1730A to a second frame structure 1730B so that the two structures define a forming channel through which the prepared carrier paper 1601 advances. The first frame structure 1730A carries a raised profiled portion 1732 that projects from a central span between lateral rails, and the second frame structure 1730B carries a complementary concavity aligned to the raised profiled portion 1732 such that, upon closure, a controlled gap is established along the length of the forming channel. The raised profiled portion 1732 shown in FIG. 17C exhibits a homogeneous or continuous crest, i.e., a substantially constant crown height and width, so that the formed profile imparted to the carrier paper 1601 presents a uniform hump from entry to exit, in contrast to the tapered crest geometry 1702 described in FIGS. 17A-17B above.

[0157] In operation, the prepared carrier paper 1601 is threaded across the first frame structure 1730A so that it seats over the raised profiled portion 1732, the second frame structure 1730B is coupled to the first frame structure 1730A to close the channel, and the material is then drawn forward to acquire the uniform raised profile imparted by the raised profiled portion 1732. The homogeneous crest of the raised profiled portion 1732 promotes an even arch height along the entire length of the formed piece, which is beneficial where the subsequent core-mount location demands a constant stand-off from the shell or where a uniform aerodynamic presentation of a web-binding adhesive zone is desired along the span. The first frame structure 1730A can integrate a leading guide lip and a trailing exit lip flanking the raised profiled portion 1732 to suppress wrinkling as the prepared carrier paper 1601 transitions onto and off of the crest; the second frame structure 1730B can be furnished with shallow chamfers around the complementary cavity to soften contact near the entry and exit and maintain a smooth draw.

[0158] The raised profiled portion 1732 is amenable to a variety of cross-sectional shapes that map directly to different performance envelopes of the finished tape construct. FIG. 17C includes shape icons 1732A to convey that the raised profiled portion 1732 can be furnished with alternative cross sections such as a triangular crest 1732A (schematically depicted as a triangle) or a rectangular/square crest 1732B (schematically depicted as a rectangle). A triangular crest 1732A concentrates elevation near a ridgeline and produces a crisp apex on the formed piece; this geometry is advantageous when a narrow, pronounced contact line is desired for the first contact of a web-binding adhesive zone. A rectangular crest 1732B yields a broad flat-topped hump, providing a plateau that carries adhesive across a wider span; this geometry is suited to wider webs or to conditions where a larger adhesive footprint is preferred. The homogeneous crest illustrated for the raised profiled portion 1732 may adopt any of these cross sections along its length without taper, and inserts can be interchanged to change the cross section while retaining the same first frame structure 1730A and second frame structure 1730B.

[0159] Mechanical coupling between the first frame structure 1730A (forming or framing member) and the second frame structure 1730B (forming or framing member) can be realized with quick-engage hardware that preserves a precise forming gap 1724 around the raised profiled portion 1732. In one arrangement, dowel pins seated in the first frame structure 1730A engage precision bores in the second frame structure 1730B to set lateral and longitudinal datum, while opposed spring plungers located adjacent the raised profiled portion 1732 preload the second frame structure 1730B downward to maintain uniform contact pressure across the carrier path. In another arrangement, embedded magnets located near the ends of the raised profiled portion 1732 and the complementary cavity of the second frame structure 1730B draw the two structures together with repeatable force; polymer shims at selected stations along the crest define the final gap height. Where rapid interchange of crest geometry is desired, the raised profiled portion 1732 can be fabricated as a removable cartridge that drops into a keyed pocket on the first frame structure 1730A and locks in place with a quarter-turn latch accessible from the exterior of the first frame structure 1730A.

[0160] Material choices for the applicator device 1730 are selected to balance rigidity, mass, and surface energy. The first frame structure 1730A and the second frame structure 1730B may be machined from anodized aluminum to hold tolerances across the raised profiled portion 1732, with low-friction liners, such as PTFE or UHMW-PE, bonded along the carrier path. The crest surface of the raised profiled portion 1732 can be electropolished or coated with a fluoropolymer to discourage adhesive pickup when the prepared carrier paper 1601 carries exposed zones. Where the device 1730 operates in wet or washdown environments, the first frame structure 1730A and the second frame structure 1730B may be stainless steel with a glass-bead finish, and the crest 1732 can be fitted with a removable elastomeric skin that backstops the paper without marring. The concavity formed in the second frame structure 1730B may include through-vents aligned above the apex of the raised profiled portion 1732 so that trapped air is relieved as the two structures close, limiting the risk of wrinkles during forming.

[0161] The constant-height crest of the raised profiled portion 1732 simplifies metrology and repeatability. A set of gauge blocks can be placed along the crest at calibration points so that the closed gap between the raised profiled portion 1732 and the complementary cavity of the second frame structure 1730B is verified before production runs. When forming thicker laminates or when a more pronounced hump is desired, thin spacers can be removed from beneath the raised profiled portion 1732 to increase crown height in discrete increments, while shims can be added to reduce the crown height when forming lightweight laminates. Scale marks etched along the side rails of the first frame structure 1730A provide a visual reference for the current crown setting and correspond to a setup sheet that maps crest height of 1732 to laminate caliper ranges for the prepared carrier paper 1601.

[0162] The homogeneous crest approach of FIG. 17C enables predictable downstream behavior of a tape construct formed over the raised profiled portion 1732. When such a construct is later mounted to a core, the uniform hump height generated by the raised profiled portion 1732 presents an adhesive zone at a consistent elevation around the circumference of the core, promoting even interception of a moving paper web. Where the adhesive zoning on the tape construct places a web-binding adhesive centrally and mounting adhesives along edge bands, the constant crest from the raised profiled portion 1732 harmonizes with the edge bands to set a stable stance against the shell. If an alternative presentation is desirable, such as biasing contact toward a leading or trailing edge, the cartridge form of the raised profiled portion 1732 allows quick substitution of a triangular crest 1732A or a rectangular crest 1732B to alter the contact mechanics while retaining the same first frame structure 1730A and second frame structure 1730B and the same roll 1600 and carrier paper 1601 supply geometry.

[0163] From a manufacturing standpoint, the first frame structure 1730A and the second frame structure 1730B of FIG. 17C lend themselves to modular assembly lines. The raised profiled portion 1732 can be milled as a constant-section extrusion and cut to length, lowering cost relative to individually machined tapered crests. The second frame structure 1730B can be produced with a matched radius broach that forms the complementary cavity in a single pass, assuring that the gap profile mirrors the crest of the raised profiled portion 1732. Where a triangular crest 1732A is specified, the first frame structure 1730A accepts an insert with a 60-120 degree included angle; where a rectangular crest 1732B is specified, the first frame structure 1730A accepts an insert with a flat-top width chosen to match an intended adhesive footprint on the completed tape construct.

[0164] Referring now to FIGS. 18-18A, the drawings depict an applicator device 1800 outfitted with a powered forming-and-feed system that produces a raised profile 1821 in a cover-flap transfer tape construct while metering and cutting discrete lengths from a prepared carrier paper 1601 unwound from a supply roll 1600. The device 1800 is shown with the first frame structure 1700A and the second frame structure 1700B coupled together by fastening units 1713 and 1713A so that a forming channel is established between a raised profiled portion 1702 on the first frame structure 1700A and a complementary hollow raised portion 1702A on the second frame structure 1700B. Downstream of the forming channel, a powered feed assembly includes a first motor 1801 that drives a first roller 1803 mounted on a first driven shaft 1803A, and a second motor 1802 that drives a second roller 1804 mounted on a second driven shaft 1804A. The narrow feed rollers 1803 and 1804 are positioned beneath the outlet of the forming channel adjacent the front side of the first frame structure 1700A near the guarded region of the cutting blade 1710, and together they establish a controllable nip that captures the profiled carrier paper 1601A as it exits the shaping zone.

[0165] During operation, the prepared carrier paper 1601 is threaded across the raised profiled portion 1702 and beneath the hollow raised portion 1702A so that it acquires the crowned geometry that defines the raised profile 1821. As the leading section of the profiled carrier paper 1601A reaches the powered feed assembly, the first motor 1801 and the second motor 1802 rotate the first roller 1803 and the second roller 1804 in the direction indicated by arrow 1811, drawing the profiled carrier paper 1601A forward while applying lateral stabilization at the side paper bands 1822-1823. The contact bands on the first roller 1803 and the second roller 1804 may be crowned elastomer rings aligned to the side paper bands 1822-1823 so the central raised profile 1821 remains free of compressive contact, preserving the formed arch established by the raised profiled portion 1702 and the hollow raised portion 1702A. The driven shafts 1803A and 1804A can be supported in low-friction bushings embedded in the first frame structure 1700A, with spring-preload or cam-adjusters that set nip pressure in a calibrated range so the feed is positive without leaving roller print on the profiled carrier paper 1601A.

[0166] The powered feed assembly allows precise metering of the profiled carrier paper 1601A length prior to severing. In the embodiment shown, a third motor or motor-actuated plunger 1805 actuates an integrated cutter mechanism by driving the push button 1709 to engage the cutting blade 1710 once a target length is advanced. A user-settable knob 1806 provides a length setpoint; the knob 1806 can be coupled to a rotary encoder whose counts map to an advancement distance so that, when the first motor 1801 and the second motor 1802 have driven the profiled carrier paper 1601A through the nip of the first roller 1803 and the second roller 1804 by the programmed distance, a control module energizes the third motor 1805. The third motor 1805 then depresses the push button 1709 through a linkage that strokes the cutting blade 1710 across the web path and separates a discrete piece that retains the raised profile 1821 and side paper bands 1822-1823. After the cut, the first motor 1801 and the second motor 1802 may index slightly to clear the severed tail from the cutting zone, preparing the device 1800 for the next cycle.

[0167] In some arrangements, the first motor 1801 and the second motor 1802 operate in closed-loop synchronization to prevent skew during feed. A master-follower scheme can be used in which the first motor 1801 speed is treated as master and the second motor 1802 follows with a fixed speed ratio, or both motors 1801, 1802 receive a common speed command from a controller that references an encoder mounted on one of the driven shafts 1803A or 1804A. The nip formed by the first roller 1803 and the second roller 1804 may be segmented into two narrow bands that coincide precisely with the side paper bands 1822-1823 so only the flat margins carry compressive load while the crown of the raised profile 1821 remains untouched. Where adhesive exposure is present on the crown, the first roller 1803 and the second roller 1804 can be clad with non-stick sleeves or relieved in the crown region to avoid contact with adhesive while feeding the profiled carrier paper 1601A.

[0168] In some embodiments, the fastening units 1713 and 1713A may be the batteries to power and control the motors (1801, 1802, 1805) within the applicator device 1800. In some embodiments, the batteries 1713 and 1713A may work only when they are aligned with each other when the first frame structure 1700A and the second frame structure 1700B are coupled together.

[0169] The cutting system driven by the third motor 1805 and the push button 1709 can be tailored to the laminate composition. The cutting blade 1710 may be a guillotine blade guided by linear bearings and returned by a spring so that the third motor 1805 applies force only during the downstroke; an alternate design equips the cutting blade 1710 as a rotary disc traversed by a short stroke linkage from the push button 1709 for lighter calipers. The knob 1806 (detented rotary knob) can include detents at common lengths (e.g., 2 in, 3 in, 4 in, 6 in, 8 in) and an indexed scale; an internal microcontroller maps the detent position to encoder counts so the first motor 1801 and the second motor 1802 stop at the programmed distance before the third motor 1805 is energized. An optional teach mode allows an operator to press the knob 1806 once a desired length is seen, capturing the count value as the new setpoint; subsequent cycles repeat to the same length without further adjustment.

[0170] FIG. 18A isolates the powered feed region to show how the first roller 1803 and the second roller 1804 act on the side paper bands 1822-1823 of the profiled carrier paper 1601A while maintaining the crown of the raised profile 1821. The path of the profiled carrier paper 1601A exiting the forming channel is guided by low-friction skids toward the nip created by the first roller 1803 and the second roller 1804, after which the profiled carrier paper 1601A advances in the direction of arrow 1811. Guide fences adjacent the side paper bands 1822-1823 keep lateral alignment until the cut produced by the cutting blade 1710 occurs; these fences can be adjusted laterally with micrometer screws to match different tape widths without re-machining the first frame structure 1700A or the second frame structure 1700B. The view in FIG. 18A also shows how minimal wrap on the first roller 1803 and the second roller 1804 reduces bending of the crown region so the raised profile 1821 holds its geometry from the raised profiled portion 1702 to the cut location.

[0171] Various enhancements improve reliability and throughput. A small optical sensor located ahead of the cutting blade 1710 detects printed registration marks on the carrier paper 1601 so the controller reconciles encoder counts with mark detection; where a mark is present, the third motor 1805 only actuates the push button 1709 when both the knob 1806 setpoint and the registration mark line up (e.g., 1607 as shown in FIG. 16A), giving length repeatability into the sub-millimeter range. A nip-open cam can be tied to the push button 1709 such that, during the cutting blade 1710 downstroke, the first roller 1803 lifts momentarily from the second roller 1804 to prevent drag lines, then re-closes as soon as the cut is complete. The first motor 1801, the second motor 1802, and the third motor 1805 can be low-voltage DC servos with integrated drivers mounted in a sealed compartment under the first frame structure 1700A, with a quick-disconnect harness so the powered module removes for cleaning without disturbing the fastening units 1713 and 1713A.

[0172] Material and surface selections are coordinated with adhesive handling. The first roller 1803 and the second roller 1804 may be coated with silicone-free, low-surface-energy sleeves to discourage pickup from exposed zones while still delivering adequate friction to advance the profiled carrier paper 1601A. The area around the cutting blade 1710 on the first frame structure 1700A can be lined with replaceable non-stick liners so any stray adhesive from the raised profile 1821 does not accumulate. Where high-humidity operation is expected, shafts 1803A and 1804A can be stainless steel; bearings near the first motor 1801 and the second motor 1802 may be polymer bushings rather than metal-to-metal designs, minimizing corrosion and simplifying maintenance.

[0173] In a representative cycle, the operator threads the prepared carrier paper 1601 through the forming channel defined by the raised profiled portion 1702 and the hollow raised portion 1702A while the first motor 1801 and the second motor 1802 jog the first roller 1803 and the second roller 1804 slowly. The knob 1806 is set to a target length, such as four inches, and the device 1800 advances the profiled carrier paper 1601A until encoder feedback indicates the programmed distance. The third motor 1805 then drives the push button 1709, the cutting blade 1710 severs the piece, and the discrete construct, bearing the raised profile 1821 and side paper bands 1822-1823, is ready for placement on a core. The forming geometry provided by the first frame structure 1700A and the second frame structure 1700B, the controlled feed delivered by the first roller 1803 and the second roller 1804, and the metered cutting driven by the third motor 1805 together provide consistent pieces that retain the intended crown through handling and subsequent mounting.

[0174] Referring now to FIG. 18B, a transfer tape construct 1832 is shown in a configuration where a raised profile or channel 1831 is formed within the laminate so that a cover flap 1833 is set at an elevated stance relative to adjacent regions. In the illustrated assembly, the construct 1832 is built upon a transfer tape substrate 1835 carried on a mounting-side pressure-sensitive adhesive 1834 for bonding to a spool or other support surface. Above the transfer tape substrate 1835, a zone-coated release-liner substrate 1837 with an associated release coating 1838 is arranged so that, after liner removal, selected adhesive fields are presented in a controlled manner. The geometry of the raised profile or channel 1831 deforms the laminate so that the cover flap 1833 rests over a shallow arch; a longitudinally extending uncoated or low-adhesion joining region (not separately numbered) is maintained along the flap hinge to keep the cover flap 1833 tethered as it opens under aerodynamic and/or centrifugal influence during rotation. The lower structure, comprising the transfer tape substrate 1835 and the mounting-side pressure-sensitive adhesive 1834, provides edge anchorage and a conformable base that accepts the molded contour of the raised profile or channel 1831 without buckling. When the assembly 1832 is installed on a spool, the raised profile or channel 1831 increases the projected area that interacts with the local airstream, promoting a clean lift of the cover flap 1833 and presenting the web-grabbing adhesive field borne on the underside of the flap at a height favorable for web interception. Elevation produced by the raised profile or channel 1831 also places the adhesive closer to an oncoming paper web, which in practice yields a firmer initial nip pressure and consistent traction as the paper web is captured.

[0175] Proceeding to FIG. 18C, the construct of FIG. 18B is depicted in an open raised-channel construct 1841 condition, where the cover flap 1833 has lifted from the underlying surface to expose a web-grabbing pressure-sensitive adhesive 1840 after removal of a release layer 1839. The release layer 1839 can be stripped manually at the time of application or displaced during machine acceleration once the flap 1833 begins to open. With the flap 1833 open, the raised profile or channel 1842 is visible beneath the crown region, and the geometry at location 1843 shows how the raised contour elevates the web-grabbing pressure-sensitive adhesive 1840 relative to adjacent side bands. This elevation establishes a protruding adhesive face that bridges toward an incoming paper web while the edge regions supported by the transfer tape substrate 1835 remain flat and bonded through the mounting-side pressure-sensitive adhesive 1834.

[0176] Referring now to FIG. 19A, a unified applicator device 1900 is shown that forms a raised profile in a cover-flap transfer tape construct and dispenses discrete, cut lengths ready for mounting to a web spool. The unified applicator device 1900 eliminates multi-piece upper/lower frames by integrating all forming and feed functions onto a single platform 1901. A raised profiled portion 1902 is machined or molded directly into the platform 1901 along a longitudinal centerline so that a carrier laminate drawn over the platform 1901 acquires a controlled, out-of-plane crown. At the forward region of the platform 1901, a pivoting handle assembly 1908 is mounted about a hinge carried on uprights 1904, the assembly 1908 moving along the arcuate path indicated by arrows to close toward or open away from the raised profiled portion 1902. The handle assembly 1908 incorporates a complementary profiled portion 1902A whose concavity is matched to the convexity of the raised profiled portion 1902 such that, when the handle 1908 is pressed downward, a precise forming gap 1910 is established across the laminate path, and when the handle 1908 is lifted, the path is open for threading and cleaning. A length set/actuate push button 1909 is located on the crown of the handle 1908 so the operator can trigger a cut while maintaining a secure grasp.

[0177] The raised profiled portion 1902 on the platform 1901 presents a smooth crest with a crown height chosen for the intended laminate caliper and desired hump elevation on the finished tape construct. In one arrangement, the crown height of the raised profiled portion 1902 is constant along its length to generate a homogeneous hump; in another arrangement, the raised profiled portion 1902 incorporates a progressive ramp where crown height increases toward the outlet so that forming strain is distributed gradually along the carrier path. The complementary profiled portion 1902A integrated into the handle 1908 is lined with a low-friction, low-surface-energy skin, such as PTFE film, to minimize drag on adhesive-bearing regions and to discourage fouling, while the raised profiled portion 1902 on the platform 1901 may be electropolished or coated with hard anodize for wear resistance. The hinge and bracket structure 1904 supports the handle 1908 at an angle that, when closed, produces a uniform gap over the raised profiled portion 1902 and, when open, presents adequate clearance for inserting a fresh lead from a supply roll staged adjacent the platform 1901.

[0178] Downstream of the forming region, compact feed motors 1903 and 1904 are mounted to the platform 1901 to advance a profiled carrier paper emerging from between the raised profiled portion 1902 and the complementary profiled portion 1902A. The motor 1903 drives a first feed element, such as a knurled or elastomer-sleeved roller, while the motor 1904 drives a cooperating element that forms a controllable nip, so the laminate is gripped primarily along flat edge bands rather than on the crowned region created by the raised profiled portion 1902. The motor 1903 and the motor 1904 operate in synchrony under a simple controller that accepts a target length and meters the advance accordingly; an internal encoder on the motor 1903 or on the motor 1904 provides feedback to arrest motion at the setpoint with sub-millimeter repeatability. The handle 1908 may incorporate spring preload so the complementary profiled portion 1902A exerts a light, uniform pressure across the laminate as it passes over the raised profiled portion 1902, promoting shape retention without embossing.

[0179] The push button 1909 on the handle 1908 interfaces with a guarded cutting mechanism located at the forward edge 1905 of the platform 1901. In one embodiment, depression of the push button 1909 actuates a guillotine blade that traverses transversely across the laminate path in a guided slot recessed into the platform 1901; a return spring lifts the blade to the safe position after the cut is completed. In another embodiment, the push button 1909 triggers a cam that drops a rotary disc blade through the path to perform a shear cut against a hardened anvil integrated into the platform 1901. The position of the cut relative to the outlet end of the raised profiled portion 1902 is chosen so the newly formed hump is not crushed during severing; a small hold-down shoe on the handle 1908 may momentarily stabilize the laminate at the complementary profiled portion 1902A while the cut occurs.

[0180] Threading and operation proceed as follows. A lead from a prepared carrier paper is placed on the platform 1901, aligned over the raised profiled portion 1902, and the handle 1908 is lowered so the complementary profiled portion 1902A establishes the forming gap 1910. The motors 1903 and 1904 jog forward to capture the lead in the feed nip and draw the laminate along the platform 1901, at which point the laminate acquires the raised profile generated by the raised profiled portion 1902. The operator selects a target length on a dial associated with the controller for the motors 1903 and 1904 and depresses the push button 1909 when prompted; the device 1900 executes a clean cut at the forward edge 1905, yielding a discrete piece that carries the intended hump and is ready to place on a core. The handle 1908 is lifted to release any trapped scrap, and the next cycle begins.

[0181] The unified architecture of the platform 1901 with the raised profiled portion 1902 and the handle 1908 with the complementary profiled portion 1902A lends itself to quick reconfiguration and maintenance. The complementary profiled portion 1902A may be a replaceable cartridge that slides into a keyed pocket on the handle 1908 so alternate crest shapes or crown heights are swapped in seconds; similarly, the raised profiled portion 1902 may accept thin shim plates on the platform 1901 to fine-tune gap height without adjusting the hinge geometry of the uprights 1904. The motors 1903 and 1904 are housed behind removable covers on the platform 1901 and connect via quick electrical couplers for service. A small mechanical stop at the forward edge 1905 (exit for Transfer Tape Construct in applicator device) can be flipped up to act as a datum for the leading edge of the laminate, allowing consistent registration before the motors 1903 and 1904 begin the metered feed.

[0182] Multiple embodiments extend functionality while staying within the geometry of FIG. 19A. The platform 1901 may integrate light-pipes or LEDs that illuminate the raised profiled portion 1902 and the complementary profiled portion 1902A to highlight adhesive zones during threading. The motors 1903 and 1904 may be paired with a low-cost microcontroller that offers presets for several standard lengths selectable by short presses on the push button 1909; a long press of the push button 1909 enters a teach mode where the operator advances to any desired mark and stores that length. In production environments, a small pneumatic cylinder can be added beneath the handle 1908 to automate closure and create a repeatable clamping force across the complementary profiled portion 1902A over the raised profiled portion 1902, while the motors 1903 and 1904 advance at a controlled acceleration profile that avoids disturbing the newly formed crown.

[0183] From a materials perspective, the platform 1901 and the uprights 1904 may be aluminum or stainless steel depending on environment; the raised profiled portion 1902 can be hard-anodized or coated with a fluoropolymer for non-stick performance; the complementary profiled portion 1902A on the handle 1908 can incorporate an elastomeric pad to accommodate caliper variation without marking the laminate. Low-friction bushings at the handle pivot on the uprights 1904 keep operation smooth even after extended use. Guards integrated at the forward edge 1905 shield the operator from the cutting zone, and the motors 1903 and 1904 are positioned such that heat does not transfer to adhesive-bearing regions passing over the raised profiled portion 1902.

[0184] Referring now to FIG. 19B, the unified applicator device 1900 is shown in a working configuration in which a prepared carrier paper 1601 is drawn from a supply roll 1600, guided along the platform 1901, and formed into a raised profile as it traverses beneath a pivoting handle assembly 1908. The handle assembly 1908 carries a complementary profiled portion 1902A that cooperates with a raised profiled portion formed in the platform 1901 (not labeled in this view but aligned beneath the complementary profiled portion 1902A) so that, as the prepared carrier paper 1601 passes through the throat, a controlled crown is imparted across the width of the prepared carrier paper 1601. The handle assembly 1908 pivots about uprights 1904 and is operated by an actuator button 1909 positioned for thumb reach, allowing an operator to close the handle assembly 1908 toward the platform 1901 with repeatable force and to open it when threading or clearing a length. Downstream, a compact drive module powered by motor 1903 meters the advance toward a front edge 1905, where the raised profiled carrier paper 1601A exits and is ready for severing into a discrete tape construct.

[0185] In this operating position, the geometry of the complementary profiled portion 1902A relative to the platform 1901 defines a forming gap 1910 that shapes the prepared carrier paper 1601 without wrinkling or embossing unintended regions. The complementary profiled portion 1902A can carry a low-friction facing that contacts only the neutral or non-adhesive bands of the prepared carrier paper 1601, while the crown region suspended over the raised profiled portion remains free to adopt the desired curvature. The actuator button 1909 on the handle assembly 1908 can be linked to a dwell cam that maintains the closed position for a brief interval during feed, after which the handle assembly 1908 reopens slightly to reduce drag as the motor 1903 indexes the raised profiled carrier paper 1601A forward. The uprights 1904 maintain the handle assembly 1908 at a clearance angle that provides visibility to the forming throat and progressive access to the length as it approaches the front edge 1905.

[0186] The supply roll 1600 is staged with its axis parallel to the feed direction so that the prepared carrier paper 1601 pays off with minimal twist before contacting the platform 1901. Edge guides formed into the platform 1901 register the prepared carrier paper 1601 laterally, and a shallow entry ramp leading into the forming throat centers the paper web over the raised profiled portion beneath the complementary profiled portion 1902A. As the prepared carrier paper 1601 slides under the handle assembly 1908, the crown height increases smoothly from the entry to the exit of the forming throat so that fiber strain in the prepared carrier paper 1601 is distributed along the length. The net result is a raised profiled carrier paper 1601A with a well-defined hump that aligns to the intended adhesive zoning when the tape construct is later cut at the front edge 1905.

[0187] The metering function provided by motor 1903 coordinates with the handle assembly 1908 to advance consistent lengths of the raised profiled carrier paper 1601A. In one arrangement, the motor 1903 drives a pair of narrow nip elements that engage the flat edge bands of the raised profiled carrier paper 1601A while leaving the crowned center portion free of compressive contact. An encoder integrated with motor 1903 reports incremental motion; a controller computes the distance from the forming throat to the front edge 1905 and arrests the feed when the leading edge of the raised profiled carrier paper 1601A reaches a programmed setpoint, e.g., 75 mm, 100 mm, or 150 mm, so that the cut length remains within a narrow tolerance. The actuator button 1909 can then be tapped to initiate a severing stroke (cutting mechanism not shown in this view), yielding a discrete piece that preserves the crown formed by the complementary profiled portion 1902A over the platform 1901.

[0188] In various embodiments, the surface finish of the platform 1901 and the complementary profiled portion 1902A is selected to manage friction and contamination. The platform 1901 may be anodized or treated with a fluoropolymer to reduce surface energy; the complementary profiled portion 1902A may carry a replaceable PTFE film or an elastomeric pad of controlled hardness to accommodate caliper variation in the prepared carrier paper 1601. The handle assembly 1908 can include internal springs that bias it upward so that, in the absence of operator input on the actuator button 1909, the complementary profiled portion 1902A releases the prepared carrier paper 1601 for threading. The uprights 1904 can house bushings or bearings that keep the pivot action smooth even after extended cycles, and the motor 1903 may be enclosed within a shield so dust does not settle on adhesive-bearing zones of the raised profiled carrier paper 1601A near the front edge 1905.

[0189] The configuration of FIG. 19B also lends itself to adjustable forming geometry. Shim plates under the raised region of the platform 1901 can be added or removed to increase or decrease crown height without changing the handle assembly 1908. Interchangeable inserts snap into the complementary profiled portion 1902A to alter cross-sectional shape, e.g., a soft-radius crest for delicate laminates or a flatter crest for wider adhesive footprints, while maintaining the same mounting to the uprights 1904. The motor 1903 may accept presets for common lengths and a manual jog mode to feed the raised profiled carrier paper 1601A a few millimeters at a time for fine positioning before a cut at the front edge 1905.

[0190] Once a section of the raised profiled carrier paper 1601A has been metered to the programmed length, the operator uses the actuator button 1909 to initiate cutting and lifts the handle assembly 1908 slightly to clear the throat for the next advance of the prepared carrier paper 1601 from the supply roll 1600. The discrete length maintains the arch imparted by the complementary profiled portion 1902A and the platform 1901 and is ready to be presented to a target core for bonding and paper web capture. Through the cooperation of the platform 1901, the complementary profiled portion 1902A, the handle assembly 1908 with actuator button 1909, the uprights 1904, the front edge 1905, and the metering motor 1903, the unified applicator device 1900 produces repeatable, raised-profile lengths from the prepared carrier paper 1601 with minimal setup and consistent geometry suited for subsequent turn-up operations.

[0191] Referring now to FIG. 19C, the unified applicator device 1900 is shown in a self-contained configuration that integrates a roll housing or holder 1911 on the platform 1901 so that a supply roll 1600 of prepared carrier paper 1601 is supported directly at the machine infeed. The platform 1901 carries the roll housing or holder 1911 near its rear region so the prepared carrier paper 1601 pays off along a shallow entry angle and transitions immediately onto the forming path that extends toward the handle assembly 1908. The roll housing or holder 1911 is fixedly or removably attached to the platform 1901; in one arrangement the roll housing or holder 1911 fastens with two socket-head screws into threaded inserts in the platform 1901, and in another arrangement the roll housing or holder 1911 employs a bayonet quarter-turn stud that locks into a keyhole in the platform 1901 for tool-free changeover. The geometry of the roll housing or holder 1911 aligns the axis of the roll 1600 parallel to the feed direction of the prepared carrier paper 1601, reducing edge wander and keeping the prepared carrier paper 1601 centered as it advances toward the forming throat.

[0192] The handle assembly 1908 again includes the complementary profiled portion 1902A which cooperates with the raised region formed on the platform 1901 to create the desired crown in the prepared carrier paper 1601. In the view of FIG. 19C, the handle assembly 1908 is positioned above uprights 1904 and carries an actuator button 1909 accessible to the operator during threading and metered feed. The front edge 1905 defines the exit of the forming zone and the approach to the cut location, while a compact drive module powered by motor 1903 meters the material forward so that a raised-profiled length 1601A is presented consistently for severing. The integration of the roll housing or holder 1911 on the same platform 1901 reduces setup steps and maintains alignment between the supply roll 1600, the forming throat under the complementary profiled portion 1902A, and the metering mechanism driven by motor 1903 at the front edge 1905.

[0193] In one embodiment, the roll housing or holder 1911 includes a removable spindle sized to the core of the roll 1600 and seated in low-friction bushings so the prepared carrier paper 1601 pays off smoothly under low torque. A light friction brake, such as a felt pad or adjustable spring collar, can be incorporated into the roll housing or holder 1911 to set unwind tension so the prepared carrier paper 1601 does not overrun when the handle assembly 1908 opens. Where rapid changeovers are favored, the roll housing or holder 1911 accepts a quick-release latch that lets the operator lift the empty core of the roll 1600 without disturbing the position of the roll housing or holder 1911 on the platform 1901. The entry path from the roll housing or holder 1911 to the forming region on the platform 1901 may include shallow guide fences or a replaceable PTFE entry shoe so the prepared carrier paper 1601 transitions cleanly into the gap beneath the complementary profiled portion 1902A.

[0194] The platform 1901 may include datum marks adjacent the roll housing or holder 1911 that reference the edge of the prepared carrier paper 1601; these marks help the operator keep the web centered before closing the handle assembly 1908. A small dancer arm integrated with the roll housing or holder 1911 can be added to accommodate short acceleration bursts from the motor 1903 at the front edge 1905, the dancer arm maintaining a short web loop between the roll 1600 and the forming throat so the prepared carrier paper 1601 remains flat across the raised region on the platform 1901. The actuator button 1909 on the handle assembly 1908 can be interlocked electrically with a sensor mounted on the roll housing or holder 1911 such that a cut command is accepted only when the prepared carrier paper 1601 is correctly threaded from the roll 1600 through the forming throat to the front edge 1905.

[0195] From a materials standpoint, the roll housing or holder 1911 may be machined aluminum with a hard-anodized spindle, or molded polymer with embedded metal sleeves where the spindle contacts, depending on environment. The platform 1901 provides threaded inserts that let the roll housing or holder 1911 be positioned at multiple stations to accommodate various roll 1600 diameters; a rearward station suits large diameter supply rolls 1600, while a forward station reduces reach for smaller rolls 1600. The handle assembly 1908 with the complementary profiled portion 1902A may include replaceable liners matched to the adhesive zoning on the prepared carrier paper 1601 so the crowned region avoids contact, and the motor 1903 is shielded so debris from the roll 1600 does not migrate toward the cutting zone near the front edge 1905. In operation, the arrangement shown, roll housing or holder 1911 feeding the prepared carrier paper 1601 along the platform 1901 under the complementary profiled portion 1902A, with length metered by motor 1903 and cut adjacent the front edge 1905, yields a discrete raised-profiled length 1601A that maintains its shape from the forming zone to the moment of application.

[0196] Referring now to FIG. 20, an apparatus 2000 is shown that dispenses, forms, exposes adhesives of, and applies a transfer tape construct 1601B onto an empty web spool 2020. The apparatus 2000 integrates functions described elsewhere into a single workstation having a frame platform 2001 that carries a raised profile portion 2002 along a longitudinal path and a cooperating handle assembly 2008 that carries a complementary profile portion 2002A. A prepared carrier paper 1601 is unwound from a supply roll 1600 and advanced across the raised profile portion 2002 while the handle assembly 2008 is closed, so the laminate passing between 2002 and 2002A is imparted with an out-of-plane crown. The push button 2009 on the handle assembly 2008 provides local actuation for forming and/or cutting operations as described below. The platform 2001 extends forward to a work region adjacent the empty web spool 2020, which is shown with a shell width 2015. A formed length can be sized shorter than, equal to, or slightly less than the shell width 2015 so that the finished transfer tape construct 1601B registers cleanly within the spool face without overhang.

[0197] In the illustrated configuration, propulsion of the laminate along the platform 2001 is achieved with powered feed elements driven by motors 2003 and 2004. The motors 2003, 2004 are mounted at opposing sides of the platform 2001 and may drive narrow nip rollers positioned to contact the flat edge bands of the laminate downstream of the forming throat between 2002 and 2002A, leaving the crowned center free of compressive contact. Motor control can be open-loop with timed moves or closed-loop using encoder feedback to meter a programmed length. When the prepared carrier paper 1601 has been formed into a profiled strip having a raised or hump region 2021, the feed advances that strip toward the web spool 2020 where the application and liner-removal sequence occurs. The apparatus 2000 may be operated by hand, with an operator guiding the emerging strip across the shell of the web spool 2020, or operation can be partially automated using extendable subsystems described next.

[0198] The apparatus 2000 includes a first retractable arm 2011 and a second retractable arm 2012 mounted near the front of the frame platform 2001 on opposite sides of the laminate path. Each retractable arm 2011, 2012 deploys toward and retracts from the shell of the web spool 2020 under power from the motors 2003, 2004 acting through a drive transmission 2016 (for example, a sector gear, rack-and-pinion, or belt-and-pulley). Stroke and velocity of each retractable arm 2011, 2012 may be independently set so that the arms approach the shell symmetrically or in a staggered timing sequence depending on the adhesive pattern and spool location. At their distal ends the retractable arms carry first and second pressing rollers 2013, 2014 (press members), respectively, which apply localized pressure to the side paper bands 2022, 2023 bordering the raised region 2021. The pressing rollers 2013, 2014 can include compliant sleeves or crowned profiles so that pressure is concentrated over the side paper bands 2022, 2023 without contacting the crown (e.g., 2021) carrying the web-grabbing adhesive.

[0199] A cutter may be integrated to create a discrete transfer tape construct 1601B. In one mode, the motors 2003, 2004 advance the profiled strip to the desired length and the push button 2009 triggers a blade traverse (the blade carriage is omitted in this view for clarity) that severs the strip into the finished transfer tape construct 1601B before application to the shell of the web spool 2020. In another mode, the profiled strip is placed against the shell and tacked by the side paper bands 2022, 2023 using the pressing rollers 2013, 2014 while still attached to the supply web, after which the cutter is actuated to separate the applied piece from the remainder of the web; this sequence can improve placement accuracy on narrow shells 2015.

[0200] The apparatus 2000 also supports removal of protective liners to expose both the web-grabbing and mounting adhesive zones. The prepared carrier paper 1601 shown in the inset view comprises a zone-coated transfer tape substrate 1603 protected by an upper release layer 1602 and a lower release layer 1604. The upper release layer 1602 covers the web-grabbing adhesive field located over the crown that becomes the raised region 2021, while the lower release layer 1604 covers mounting adhesive stripes on the underside aligned with the side paper bands 2022, 2023. During dispensing and forming, the liners 1602, 1604 remain in place so the laminate handles cleanly over 2002 and 2002A; immediately prior to application, one or both liners are peeled to expose the respective adhesive zones.

[0201] The first retractable arm 2011 and the second retractable arm 2012 are configured to assist liner removal. In one embodiment, the first retractable arm 2011 carries a small catch or pick ahead of the first pressing roller 2013 that engages a free end of the lower release layer 1604 along the first side paper band 2022. As the first retractable arm 2011 retracts, the pick lifts the lower release layer 1604 to an angle that exceeds its peel threshold, after which the first pressing roller 2013 guides the peeled liner around its circumference and into a discharge path that routes the spent liner away from the application zone. The second retractable arm 2012 mirrors this action along the second side paper band 2023, using the second pressing roller 2014 to guide the peeled portion of the lower release layer 1604 to a safe collection path. The two arms may peel the lower release layer 1604 in unison so both side bands 2022, 2023 expose mounting adhesives simultaneously, allowing the operator to press the strip onto the shell of the web spool 2020 with balanced tack on both sides.

[0202] In another arrangement, the first retractable arm 2011 is configured to lift a corner of the upper release layer 1602 at a tab adjacent the raised region 2021. A dedicated peel shoe on the first retractable arm 2011 moves upward and backward to separate the upper release layer 1602 from the crown; the shoe routes the upper release layer 1602 over a small idler to a waste guide while the second retractable arm 2012 simultaneously peels the lower release layer 1604 along the second side paper band 2023 using the second pressing roller 2014. This sequence exposes the web-grabbing adhesive on the crown and one or both mounting adhesive stripes beneath the side paper bands 2022, 2023 in a coordinated motion. Where manual removal is preferred, the arms 2011, 2012 retract to a standby position while the operator lifts 1602 and 1604 and then returns the arms to press the side paper bands 2022, 2023 via the rollers 2013, 2014.

[0203] The gear-drive transmission 2016 provides precise extension and retraction of the first retractable arm 2011 and the second retractable arm 2012. In one embodiment, 2016 is a pair of spur gears pinned to output shafts of the motors 2003, 2004, each meshing with a linear rack that forms the backbone of the respective arm. The stroke length is set by hard stops and sensed by limit switches or encoders so that the pressing rollers 2013, 2014 contact the shell of the web spool 2020 with a calibrated force and path. The same drive 2016 can be used to modulate the angle at which the pressing rollers 2013, 2014 approach the surface so that the lower release layer 1604 peels away at a controlled angle, e.g., 120-160 degrees relative to the tape plane, yielding stable, low-force release while the mounting adhesive beneath the side paper bands 2022, 2023 bonds to the shell.

[0204] During a representative application cycle, the motors 2003, 2004 advance the laminate across the raised profile portion 2002 beneath the complementary profile portion 2002A and feed a length that yields the target raised region 2021. The push button 2009 triggers a cut to form the transfer tape construct 1601B (alternatively, the cut is deferred until after tack-down). The first retractable arm 2011 and the second retractable arm 2012 peel the lower release layer 1604 as described to expose adhesives beneath the side paper bands 2022, 2023; the arms then press the side paper bands 2022, 2023 against the shell while the operator lightly supports the crown so that the raised region 2021 remains elevated. If desired, the first retractable arm 2011 peels the upper release layer 1602 to expose the web-grabbing adhesive on the crown immediately before the web spool 2020 is accelerated for a turn-up event. The result is the applied transfer tape construct 1601B shown at lower left, anchored by the side paper bands 2022, 2023 and presenting the elevated crown 2021 centrally across the shell width 2015.

[0205] Referring now to FIGS. 20A-20B, an exemplary paper turn-up and transfer sequence is depicted in which a full web spool 102, an empty web spool 103, and a reel drum 101 cooperate with a moving paper web 2031. The paper web 2031 is conveyed over a reel drum surface 2032 to a nip 2033 formed with the empty web spool 103, while the full web spool 102 supplies the paper web 2031 prior to transfer. In preparation, a transfer tape construct 1601B bearing an elevated adhesive field is affixed to the surface of the empty web spool 103 so that the raised region or profile (e.g., 2021 as shown in FIG. 20) is oriented toward the nip 2033. As the empty web spool 103 is brought to a surface speed substantially matching the paper web 2031, aerodynamic lift and centrifugal force act on the raised region of the transfer tape construct 1601B, presenting an outwardly facing adhesive area across the nip 2033 and reducing the gap to a small intercept distance relative to the paper web 2031A traveling on the reel drum surface 2032.

[0206] With the empty web spool 103 rotating and the paper web 2031 moving over the reel drum surface 2032, the exposed adhesive on the transfer tape construct 1601B engages the paper web 2031B at or just before the nip 2033. Contact initiates local adhesion and creates a traction point that begins to wrap the paper web 2031 around the circumference of the empty web spool 103. The geometry shown in FIG. 20B highlights that the elevated adhesive profile on the transfer tape construct 1601B effectively bridges the nip 2033, so the paper web 2031 does not need to penetrate deeply between the empty web spool 103 and the reel drum 101 to achieve initial grab. Once initial bonding occurs, the angular momentum of the empty web spool 103 advances the adhered portion of the paper web 2031 away from the nip 2033, and the wrap builds smoothly as the paper web 2031B transitions from the reel drum surface 2032 onto the circumference of the empty web spool 103.

[0207] Continued rotation of the full web spool 102, the reel drum 101, and the empty web spool 103 progresses the paper transfer process. Tension in the paper web 2031 increases between the full web spool 102 and the point of adhesion on the empty web spool 103; as the wrap on the empty web spool 103 grows, the path between the reel drum surface 2032 and the empty web spool 103 shortens, and the paper web 2031 peels from the reel drum surface 2032. The transfer tape construct 1601B maintains anchorage to the empty web spool 103 along non-elevated edge zones while the elevated adhesive region preserves adhesion to the paper web 2031 through the first few wraps, after which the adhesive becomes buried beneath subsequent layers. The progressive engagement illustrated in FIG. 20B from paper web 2031A to paper web 2031B yields a stable handoff at the nip 2033 without disturbing the web tension upstream of the reel drum 101.

[0208] As the empty web spool 103 accumulates wraps, differential tension created between the portion of the paper web 2031 still attached to the full web spool 102 and the portion newly wrapped on the empty web spool 103 produces a controlled severance event. The cut-over point is indicated by paper web segment 2031C, where the web separates near the nip 2033 or at a prepared notch, depending on machine setup and paper grade. After severance at 2031C, the full web spool 102 decelerates while the empty web spool 103 continues to wind as the new parent roll. Throughout this sequence, the transfer tape construct 1601B remains secured to the surface of the empty web spool 103, with its edge-bonded zones resisting lift and its elevated central adhesive zone now buried beneath the initial wraps to avoid later contact with downstream hardware.

[0209] Various embodiments of the transfer tape construct 1601B and its placement on the empty web spool 103 may be adopted to accommodate different grades and speeds. The elevated adhesive band on the transfer tape construct 1601B can be centered relative to the spool face or biased laterally to align with a preferred web edge; the width and height of the raised profile are selected so that, at the target surface speed of the empty web spool 103, the adhesive face approaches the paper web 2031 at a favorable incidence across the nip 2033. The timing of speed matching between the empty web spool 103 and the paper web 2031 can be coordinated with reel drum 101 torque so the intercept at paper web segment 2031A occurs during a narrow speed-difference window, promoting clean adhesion and an orderly progression to paper web segment 2031B and then to severance at 2031C. In all cases, the elements designated 102, 103, 101, 2031, 2031A, 2031B, 2031C, 2032, 2033, and 1601B cooperate to execute a reliable turn-up in which the raised, adhesive-bearing construct on the empty web spool captures the moving web, transfers it from the full web spool, and sustains winding as the new roll builds.

[0210] Referring now to FIGS. 21A-21B, a flowchart 2100 of exemplary method steps 2101-2115 is illustrated, for preparing, forming, exposing, and applying a cover-flap transfer tape construct to an empty web spool and then initiating web capture for paper turn-up process.

[0211] At step 2101, a roll (1600) of prepared carrier paper (1601) is provided in a condition ready for forming and application. The prepared carrier paper (1601) includes a zone-coated transfer tape substrate (1603) bearing distinct adhesive regions separated by uncoated zones and protected by one or more release layers (1602, 1604). In one embodiment, the top surface carries a web-grabbing pressure-sensitive adhesive (1605) shielded by the upper release layer (1602), while the underside carries two edge mounting adhesive stripes (1605A) shielded by the lower release layer (1604). The carrier backing may be paper, polymer film, or a paper/polymer laminate selected for flexural stiffness that supports curl-free winding on the roll (1600) during storage and transport. Rolls may be slit to widths matched to spool shell width, e.g., 50-120 mm, and may include printed registration marks or micro-perforations to cooperate with optical sensors or mechanical detents during downstream indexing. In some cases, the release layers are engineered with release values in the 10-60 g/25 mm range for predictable peel at application, and the adhesives are formulated, acrylic, rubber-resin, or UV-curable hot-melt, to provide immediate grab to the moving web and high shear to the core surface.

[0212] At step 2102, the prepared carrier paper (1601) is threaded into an applicator (e.g., 1700, 1800, 1900, 2000) so that it is positioned over a raised profile portion (e.g., 1702, 1732, 1902, 2002) and under a complementary profile portion (e.g., 1702A, 1732B, 1902A, 2002A). Threading may be manual, guiding the web along entry guides and across a low-friction ramp, or semi-automatic, using jog functions on powered feed rollers to draw the web into the forming throat. The operator references lateral fences or scribed datum lines, so the adhesive zoning aligns symmetrically to the crest of the forming insert; this alignment preserves equal width side bands for later anchoring on the spool. In one embodiment, the complementary insert is mounted to a pivoting handle that swings open to present a wide throat for threading; after the lead passes the crest, the handle lowers to a preset stop that fixes the forming gap (e.g., 1724, 1910). In another embodiment, an upper frame halves onto a lower frame with magnet pairs or quarter-turn fasteners, producing a repeatable gap without tools.

[0213] At step 2103, the forming members are closed or pivoted to define a controlled forming gap across the tape path. The gap height may be set by precision spacers, shim packs, or integral hard stops on the frame so that crown height of the formed profile matches a recipe. The closure may be latched with magnets, cam latches, or bayonet pins to hold the upper member against the lower member under the modest loads created during feed. In some embodiments, the upper member includes a compliant liner, PTFE, UHMW-PE, or an elastomer of Shore A 60-80, to accommodate caliper variation and to limit marking of the release layers during passage. Vent holes near the crest of the complementary insert relieve trapped air as the members close, reducing the chance of local wrinkling as the laminate conforms to the geometry.

[0214] At step 2104, the carrier paper (1601) advances through the forming gap by manual pull or motorized feed. Manual advance may use a grab bar to provide leverage while keeping fingers clear of the cut zone. Motorized advance may use paired narrow rollers driven by a servo motor (e.g., 1801, 1802, 1903) that contact only the flat edge bands of the laminate, avoiding compression of the crown region that will become the raised profile. Feed speed is selected to match operator ergonomics or an automated cycle time; for servo-driven systems, an encoder provides distance measurement, so the controller knows the exact amount of material that has passed the crest. In some embodiments, a reflective sensor reads printed marks on the carrier paper 1601 to refine the distance count, allowing the system to pause precisely with a mark located at the cut line.

[0215] At step 2105, the laminate acquires a raised profile or hump while flat side bands remain. The lower forming insert (e.g., 1702, 1732, 1902, 2002) presents a convex crest and the complementary insert (e.g., 1702A, 1732B, 1902A, 2002A) presents a matched concavity, so the laminate is shaped out-of-plane without sharp bending. Crown height may range from 1-8 mm and crest width from 6-40 mm, depending on grade and desired intercept behavior at the nip. The side bands, corresponding to uncoated top margins (1606) and bottom mounting stripes (1605A), remain planar, which later permits reliable anchoring to the spool. Variants include homogeneous crests of constant section (FIG. 17C) or progressive crests that ramp crown height toward the exit (FIG. 17A) to distribute strain along the length. Alternative cross-sections, rounded, triangular, or flat-topped, can be selected by swapping a cartridge insert to tailor the aerodynamic opening and adhesive presentation.

[0216] At step 2106, the formed strip is indexed to a target length using a knob/controller, a programmable setpoint, or a mechanical stop, the value based on spool shell width (2015), grade, or customer recipe. For electronic indexing, an encoder on the feed motor accumulates counts until the preset is reached; detents on a length knob may correspond to 50-, 75-, 100-, and 150-mm selections, with a teach mode that captures any custom length. For mechanical indexing, a retractable stop rises at the front edge; the operator pulls the formed strip until the leading edge contacts the stop. In either case, the raised profile apex is positioned relative to the length so that, when mounted to a given spool diameter, the crown presents at the desired angular location approaching the nip.

[0217] At step 2107, the formed length is cut to create a discrete piece. Actuation can occur via a push button on the handle or an electronic signal from the controller. Cutting hardware may be a guarded guillotine blade that traverses across the path in linear guides, a rotary disc that drops through the web against a hardened anvil, or a shearing scissor integrated into the front edge. The blade path is located just beyond the exit of the forming crest, so the crown is not compressed during severing. Some workflows defer cutting until after the piece is tacked to the spool; in that case the applicator feeds the formed strip directly to the shell, the side bands are pressed down, and the cutter then severs the tail at a clean angle. Disposable blade cassettes or field-sharpenable discs may be specified depending on maintenance practice.

[0218] At step 2108, the discrete transfer tape construct (1601B) with the raised profile is presented toward the application zone on the empty spool. The operator lifts the piece by the side bands, or a small staging lip holds the piece at the applicator's front edge for pick-off. Orientation marks printed along the side bands align to a datum on the spool stand so the piece lands centered. If the process includes immediate liner removal, the upper liner (1602) is peeled to present the web-grabbing adhesive (1605) on the crown, and the lower liner (1604) is peeled from the edge stripes to present the mounting adhesives (1605A); otherwise, liners are peeled at the spool using retractable arms and press rollers as described elsewhere. The piece is then pressed along the side bands to anchor to the shell, leaving the crowned adhesive outward and ready for web interception during spool acceleration and turn-up.

[0219] At step 2109, the upper release layer (1602) is peeled to expose the web-grabbing adhesive (1605) located on the crown of the raised profile. Peeling may be performed manually by lifting a starter tab formed by a short die-cut or kiss-cut at one end of the piece, or automatically using a peel shoe carried on a retractable arm that lifts the edge at a controlled angle, e.g., between about 120 and 160 relative to the plane of the tape, to obtain a smooth, low-force separation. The peel shoe can include a low-surface-energy face (PTFE, FEP, UHMW-PE) and a small radius guide so the liner (1602) transitions from tangential contact to a free path without tearing. On devices with sensors, a reflective mark printed on the liner (1602) confirms that the peel has reached the crown before the operator proceeds. In variants where the crown adhesive (1605) is sensitive to dust, a shield flips over the exposed area after peel and retracts automatically during placement on the spool.

[0220] At step 2110, the lower release layer (1604) is peeled along the side bands to expose the mounting adhesives (1605A) that will bond to the spool shell. A first retractable arm (2011) and a second retractable arm (2012) may carry picks that lift the liner (1604) near the edges and route the stripped material over crowned press rollers (2013, 2014) toward a waste chute or a powered take-up, keeping the removal paths away from the exposed crown adhesive (1605). The peel path is arranged so the liner (1604) departs at a constant angle and does not pull the tape off the applicator staging surface. For manual workflows, the operator grabs pre-formed finger lifts on the liner (1604) and pulls each edge back a set distance, leaving short tails that act as handles during alignment; once the piece is in position, the tails are pulled free and discarded. Alternative embodiments segment (1604) into two narrow edge liners so only one side is exposed at a time for staged anchoring on narrow cores.

[0221] At step 2111, the transfer tape construct (1601B) is aligned to the target empty or new spool (103/2020) using datums on the applicator and visual references on the tape. The applicator may present a nose plate with a machined straightedge and a pair of lateral gauges that match the shell width (2015), so the operator references both ends of the construct simultaneously. Printed arrows on the side bands indicate machine-direction orientation relative to the nip so the crown approaches the web at the intended angle. Where repeatability is desired across shifts, an index pin on the applicator locates into a notch on the spool arbor, fixing angular position of the crown. The distance from the crown apex to the spool face can be set by a simple ruler etched on the applicator nose or by a stop block that the operator touches off before placing the construct.

[0222] At step 2112, the side bands (2022, 2023) are pressed onto the spool shell to establish anchorage using the press rollers (2013, 2014) or, in manual arrangements, by finger pressure applied through a low-tack applicator card. The press rollers (2013, 2014) can be crowned slightly so peak pressure is centered on each band, and the contact patch does not wander toward the crown. Each roller may be mounted on a spring-loaded yoke that delivers a defined normal load, e.g., 30-80 N per band, sufficient to wet the mounting adhesive (1605A) into the shell surface. A short traverse along the band length removes trapped air; in some installations, a micro-texture on the roller cover vents air laterally. Once both bands are secured, the construct resists shear during spool acceleration while the crown remains free and elevated.

[0223] At step 2113, the spool is accelerated to a surface speed that matches the moving web at the nip formed with the reel drum (101) and path (2031). The machine control raises torque on the empty spool (103/2020) while the operator visually confirms that the crown faces upstream toward the incoming web. The aerodynamic shape of the raised profile creates a small, controllable opening force during rotation, with the uncoated middle zone on the underside acting as a hinge so the crown lifts without debonding the anchored side bands. On systems with servo coordination, the speed match window is narrow, e.g., within 2% of web speed, so the intercept occurs with minimal relative slip. If the process uses a staged peel, the last remnants of the lower liner tails are withdrawn during this acceleration so both bands are fully active before the interception.

[0224] At step 2114, the moving paper web (2031) is intercepted at the nip (2033) and initial adhesion to the raised profile is initiated. The elevated adhesive (1605) crosses the nip line first, contacting the approaching web at a point slightly ahead of the geometric line of centers. This geometry shortens the air gap and reduces turbulence between the adhesive and the web. As contact occurs, the crown begins to pull the leading area of the web away from the reel drum surface; the wrap of the web around the empty spool increases with each degree of rotation, while the mounting adhesives (1605A) keep the edges of the construct from creeping. For grades that benefit from a stronger first bite, the crown adhesive (1605) can be formulated with higher tack or micro-structured surface features to increase instantaneous contact area.

[0225] At step 2115, the paper web (2031) wraps around the empty web spool while the edge adhesives 1605A maintain core anchorage, and rotation continues until a controlled severance from the full spool occurs. The first few wraps bury the crown adhesive (1605), locking in the leading end and distributing tension across the band of paper. Upstream tension increases until the web separates at a designed notch, a pre-weakened stripe, or a natural break location designated as (2031C) in related figures. After severance, winding continues on the now-active spool while the full spool decelerates. The construct remains under the initial wraps; its edge bonds hold position, and the crown region transitions from an exposed interface to a subsurface layer that no longer contacts machine hardware. At the end of the cycle the applicator is ready to form and apply the next construct with the same parameter set or with a new set called from a stored recipe.

[0226] Particular embodiments of the subject matter have been described. Other embodiments are within the scope of the following claims. In some cases, the actions recited in the claims can be performed in a different order and still achieve desirable results. In addition, the processes depicted in the accompanying figures do not necessarily require the particular order show, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the claimed invention.

[0227] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word may is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words include, including, and includes mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.

[0228] The phrases at least one, one or more, and and/or are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B and C, at least one of A, B, or C, one or more of A, B, and C, one or more of A, B, or C and A, B, and/or C means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0229] The term a or an entity refers to one or more of that entity. As such, the terms a (or an), one or more and at least one can be used interchangeably herein. It is also to be noted the terms comprising, including, and having can be used interchangeably.

[0230] For clarity and to avoid redundancy in the drawings and description, the same reference numerals may be used in different figures to refer to the same or functionally analogous elements; such reuse is for reader convenience and does not, by itself, require that the elements be identical in every embodiment. Unless expressly stated otherwise, features, structures, operations, methods, and subassemblies illustrated or described with respect to any particular figure or embodiment may be used alone, combined together as a whole, or combined in part with features from other figures or embodiments to form additional embodiments. The figures are schematic and not necessarily to scale, and directional terms are used for ease of description rather than limitation.

[0231] Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in combination in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

[0232] As has been mentioned, the illustrations depict aspects of exemplary embodiments, and the relative scale of illustrated features may be exaggerated for depiction of various aspects. Accordingly, the scale of features illustrated is not intended to limit the scope of the elements of the various embodiments consistent with the present application.