Method for and devices used in covering a roll core with a resin infused fiber reinforced adhesive under layer and a polymeric top layer, the method including the use of an improved mold tape

Abstract

The invention includes a method for producing a covered roll having a reinforcement fiber mat under layer infused with low viscosity thermoset resin and a smooth high temperature, high performance polymeric outer layer. The mat is formed of a plurality of layers, each layer having a leading edge that abuts a following edge when wrapped over the roll core, each subsequent layer being affixed to the previous layer along a seam, the seams being spaced apart angularly from one another to prevent irregularities over the surface of the resulting roll core. One or more layers of the dry reinforcement fiber mat may be formed of a two-ply construction, the first ply having fibers arranged in a random pattern, the second ply having aligned fibers oriented either parallel or perpendicular to the roll core central axis. The invention also includes an improved mold tape assembly for use in applying a polymeric cover over a roll core and an inventive apparatus for fabricating the mold tape assembly. The mold tape assembly is formed of at least two ribbons that are arranged in a substantially parallel and partially overlapping orientation, the ribbons being spot welded together at a predetermined radius of curvature. The apparatus for fabricating the mold tape assembly further includes an inventive device for aligning the ribbons prior to welding and an inventive curvature shoe for disposing the ribbons at a predetermined radius of curvature during welding.