Patent Publication Number: US-2011059282-A1

Title: Adhesive Segment Indexing Method and Apparatus and Roll of Adhesive Segments for Use Therewith

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This patent application is a division of copending U.S. patent application Ser. No. 10/920,151, filed on Aug. 17, 2004, now U.S. Pat. No. 7,837,815, granted on Nov. 23, 2010, entitled “Adhesive Segment Indexing Method and Apparatus and Roll of Adhesive Segments for Use Therewith,” which patent application is assigned to the assignee of the present invention, which patent application in turn was a continuation-in-part of U.S. patent application Ser. No. 10/360,457, filed on Feb. 8, 2003, now abandoned, and a continuation-in-part of U.S. patent application Ser. No. 10/360,395, also filed on Feb. 8, 2003, also abandoned, both of which are continuations-in-part of U.S. patent application Ser. No. 10/125,012, filed on Apr. 18, 2002, now U.S. Pat. No. 6,686,016, granted on Feb. 3, 2004, and continuations-in-part of U.S. patent application Ser. No. 09/998,950, filed on Nov. 15, 2001, now U.S. Pat. No. 6,640,864, granted on Nov. 4, 2003. U.S. patent application Ser. No. 10/125,012, filed on Apr. 18, 2002, now U.S. Pat. No. 6,686,016, granted on Feb. 3, 2004, is itself a continuation of U.S. patent application Ser. No. 09/998,950, filed on Nov. 15, 2001, now U.S. Pat. No. 6,640,864, granted on Nov. 4, 2003, which is in turn a continuation of U.S. patent application Ser. No. 09/363,200, filed on Jul. 29, 1999, now U.S. Pat. No. 6,319,442, granted on Nov. 20, 2001, which is in turn a continuation-in-part of U.S. patent application Ser. No. 08/909,189, filed on Aug. 11, 1997, now U.S. Pat. No. 5,935,670, granted on Aug. 10, 2009, which in turn claimed the benefit of U.S. Provisional Patent Application No. 601036,896, filed on Feb. 6, 1997. All of the patents and patent applications mentioned in this paragraph are hereby incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains generally to pressure-sensitive adhesives and their application to desired surfaces, and, more specifically, to applicator systems and methods for use in combination with rolls of indexed carrier release tape having pressure-sensitive adhesive segments attached thereto which may be individually dispensed using such applicator systems and methods. 
     The term “adhesive” generically describes a class of “sticky” materials. Adhesives and adhesive applicators owe their innovation to the industrial revolution, which resulted in an explosion of technical and scientific breakthroughs. The breakthroughs of the industrial revolution included the introduction of new materials and ingredients for use in formulating market-specific and industry-specific adhesives. In creating novel adhesives, companies have diligently considered desirable qualities such as adhesive flexibility, toughness, minimum curing or setting time, and temperature and chemical resistance. Today, the technology and science of adhesives and apparatuses for their application is the foundation for a multi-billion dollar industry with over seven hundred companies competing for market share. More importantly, these companies strive to create and introduce novel adhesives as well as apparatuses and method for the simple, efficient, inexpensive, and safe application of adhesives. 
     One of the most significant adhesive technical breakthroughs of the past century has been the introduction of pressure-sensitive thermoplastic adhesives. Thermoplastic adhesives have excellent adhering qualities; they can be softened by heating and firmed by cooling. These characteristics help thermoplastic adhesives produce waterproof, resilient, and long-lasting flexible bonds. Thermoplastic adhesives have what is known as a “plastic memory” meaning that each time a thermoplastic adhesive is heated, it can be molded into any desired form. 
     Thermoplastic adhesives have significant applications in today&#39;s industry. For example, in the preparation of mass mailings, marketers often desire to attach a card, such as a credit card or the like, to a carrier document so that a consumer can peel the card easily from the carrier document. One method of making such an attachment involves the use of a pressure-sensitive, thermoplastic adhesive. For example, by using a heating container to melt the thermoplastic adhesive and a metering pump to dispense it during the printing or collating process, a portion of thermoplastic adhesive can be metered onto the carrier document and a credit card pressed against it. 
     In addition to the uses for thermoplastic adhesives described above, industry is now finding additional uses for them. For example, thermoplastic adhesives are routinely used and applied as small bond points to eliminate the use of mechanical fasteners, such as staples, screws, rivets, clips, snaps, nails, and stitching. Thermoplastic adhesives are also extensively used in the packaging and manufacture of cartons, boxes, and corrugated boards, bags, envelopes, disposable products (diapers and other paper products), cigarettes, labels, and stamps. In fact, today&#39;s demand for thermoplastic adhesives extends to very broad fields of use. 
     Increasingly, industry demands thermoplastic adhesive application at on-site locations from simple-to-use, efficient, and safe dispensing apparatuses. In providing thermoplastic adhesives for application to a surface, the previously known embodiments have contemplated all of the following thermoplastic adhesive carrying media and application methods: hot-melt “glue-gun” as adhesive dispensers; adhesive segment-laden carrier release tape for “by hand” adhesive application; use of a plunger-like dispensing system in combination with adhesive segment-laden carrier release tape; use of a cardboard box applicator system for use in combination with adhesive segment-laden carrier release tape; an electric automated dispensing system for use with adhesive segment-laden carrier release tape, which is activated by the pressing of a palm-sized push button; a hand-held mechanical adhesive segment applicator apparatus with a mechanical hand-operated trigger for advancing an adhesive segment-laden carrier release tape contained therein; and a stand for holding such a hand-held mechanical adhesive segment applicator with a powered system for activating the mechanical trigger automatically as a work piece is brought in contact with the adhesive segment applicator to apply an adhesive segment thereto. 
     Using a “glue gun” device is an inefficient, difficult, and at times unsafe method of applying thermoplastic adhesives to a desired surface. First, the cost of using this equipment is relatively high. The apparatus and method are also inefficient consumers of both energy and glue. Specifically, the costs of the operation of such a dispenser (electrical usage, wasted glue from droppings) for only short periods of time outweigh any other potential advantages which may be realized. Safety is also an issue. Glue-gun devices are potentially unsafe because they include a heat source to heat a quantifiable supply of adhesive material to its melting point. A major drawback of using such an instrument is that the hot, molten thermoplastic adhesive can burn untrained users, and can also melt the substrate the user is applying the glue to. Finally, application of thermoplastic adhesives from a glue-gun does not enable the thermoplastic adhesive to withstand cold temperatures or to cool to a smooth surface, but instead will typically leave “spider webs” in the dried adhesive. In short, glue-gun applicators of the prior art are inefficient, difficult, and unsafe. 
     Many of the shortcomings of the glue-gun applicators of the prior art were overcome by U.S. Pat. No. 5,935,670 to Downs (the “&#39;670 Patent), which patent is hereby incorporated herein by reference. The &#39;670 Patent discloses a method for presenting cold adhesive segments for application to a desired surface. The technology of the &#39;670 Patent focuses mainly on the manufacture of a clean, unaltered carrier release tape having first and second release surfaces with different coefficients of friction, and the application thereto of adhesive segments at periodic intervals. The adhesive segment-laden carrier release tape is then wound into a roll. This embodiment allows a user to apply the adhesive segments from the carrier release tape by hand. 
     Although the adhesive segment-laden carrier release tape taught in the &#39;670 Patent provides a highly innovative and commercially successful product, application of the adhesive segments from the release tape onto a work piece in an efficient manner remains a challenge. Specifically, the coiled adhesive segment-laden carrier release tape must be unrolled to present an adhesive segment for application. After the adhesive segment has been applied to the desired surface, the tape must be unrolled an additional distance to ready the next adhesive segment for application. Advancing the carrier release tape manually in this manner is time-consuming, and the “spent” carrier release tape must be either torn off and disposed of or left intact and in the way. Finally, dropping or unintentional uncoiling of the unused roll of adhesive segment-laden carrier release tape may also be a problem. 
     U.S. Pat. No. 6,319,442 to Downs (the “&#39;442 Patent”) which patent is hereby incorporated herein by reference, further evolves the previously known adhesive segment-laden carrier release tape of the &#39;670 Patent. Like the &#39;670 Patent, the &#39;442 Patent also contemplates a carrier release tape, which has first and second release surfaces with different coefficients of friction, and the application thereto of adhesive segments at periodic intervals. But, unlike the &#39;670 Patent, the &#39;442 Patent contemplates a thermoplastic adhesive carrier release tape having a transverse line of slits or perforations precut across its transverse width and between the adhesive segments. The precut tape of the &#39;442 Patent thus allows individual portions of the carrier release tape and associated thermoplastic adhesives to be removed from the roll for manual application to a desired surface. While such an embodiment remedies the &#39;670 Patent&#39;s problem of having a length of uncut spent carrier release tape, the carrier release tape of the &#39;442 Patent (as well as of the &#39;670 Patent) does not lend itself to use in combination with a more efficient dispenser for application of the adhesive segments. 
     While the &#39;670 and &#39;442 Patents focus primarily on the creation of adhesive segment-laden carrier release tape, they also contemplate the use of the adhesive segment-laden carrier release tape in combination with numerous dispenser apparatuses. First, a plunger-like applicator, as detailed within both the &#39;670 and &#39;442 Patents, proves manageable, but is essentially a manually operated device for applying adhesive segments to a work piece from an adhesive segment-laden carrier release tape. Another previously known thermoplastic adhesive applicator is the so-called box applicator. The box applicator encases a roll of adhesive segment-laden carrier release tape as disclosed within the &#39;670 and &#39;442 Patents. The carrier release tape is advanced from the box applicator by hand. Exposed adhesive segments must be pressed between the surface to be glued and the top of the cardboard box applicator to ensure adherence. This application process exposes unspent adhesive segments to dust and other debris, which may cause the adhesive segments to lose their adhesive tack and damage or soil the desired surface. Furthermore, the box applicator is an entirely manually operated device. 
     Not all previously known devices for applying thermoplastic adhesive from adhesive segment-laden carrier release tapes are entirely manual in operation. Previously known semi-automated methods dispose of the need to advance manually the carrier release tape. For example, the box applicator described above may be modified to include a motor for automatically advancing the adhesive segment-laden carrier release tape from the box either at a fixed rate, corresponding to the rate at which a worker may comfortably press a work piece against the adhesive segments as they are dispensed, or in response to the pressing of a push button to activate the motor to advance the adhesive segment-laden carrier release tape by a selected amount. 
     A more advanced mechanical adhesive segment applicator apparatus and method is described in U.S. patent application Ser. Nos. 10/360,395 and 10/360,457, filed on Feb. 8, 2003, and U.S. patent application Ser. No. 10/368,231, filed on Feb. 18, 2003, all of which are assigned to the assignee of the present application and the disclosures of which are incorporated herein by reference. These patent applications describe a hand held mechanical device for applying adhesive segments to a work piece from a carrier release tape having pressure-sensitive adhesive segments attached thereto. An indexing mechanism is provided on the carrier release tape to facilitate the dispensing of individual adhesive segments. The indexing mechanism consists of a plurality of patterned scores, cuts, or indentations located in the surface of the carrier release tape. The hand held adhesive segment applicator apparatus includes a mechanism for engaging the carrier release tape by the indexing mechanism to advance the tape to expose a new adhesive segment to be disposed therefrom each time a trigger mechanism on the applicator is manually actuated. The hand held adhesive segment applicator may be mounted on a stand that holds the applicator in a desired adjustable position. A pneumatic actuator may be provided to engage the trigger of the applicator to advance the carrier release tape to expose a new adhesive segment to be dispensed from the applicator automatically. The actuator may be activated by a trigger mechanism that is mounted near where the adhesive segment is dispensed from the applicator, to be engaged by a work piece as an adhesive segment is dispensed therefrom. Alternatively, the actuator may be activated by a hand or foot operated switch. 
     A limitation of previous systems and methods for applying thermoplastic adhesives to a work piece from an adhesive segment-laden carrier release tape is that operation of such systems and methods actually to apply the thermoplastic adhesive to a work piece is essentially manual. Even in systems that provide for the automatic or powered advancement of an adhesive segment-laden carrier release tape, the exposed adhesive segment must be applied to the work piece by either manually moving the applicator in contact with the work piece or manually moving the work piece in contact with the applicator. Such systems and methods for applying thermoplastic adhesives to work pieces from an adhesive segment-laden carrier release tape are thus not well suited to high speed high volume applications. 
     What is desired, therefore, is a system and method for the automatic application of thermoplastic adhesives to work pieces from an adhesive segment-laden carrier release tape for use in high-speed high-volume assembly line-like applications. Such an adhesive segment applicator should provide for assured automatic release of the adhesive segments from the carrier release tape onto a work piece. Such a system should also provide accurate indexing and advancement of the carrier release tape to ensure proper operation and positioning of the adhesive segment in the applicator device and on a work piece. 
     SUMMARY OF THE INVENTION 
     The present invention provides an automated system and method for applying thermoplastic adhesives to work pieces from a roll of adhesive segments applied to an adhesive segment-laden carrier release tape. The present invention may be implemented in a system that automatically advances the adhesive segment-laden carrier release tape to position an adhesive segment thereon in the apparatus for application thereof to a work piece. Accurate indexing and advancement of the adhesive segment-laden carrier release tape preferably is provided by optical indexing of the carrier release tape, e.g., by the optical detection of a transverse line or other index marking printed or otherwise provided on the adhesive segment carrier release along with the adhesive segments deposited thereon. The system may automatically apply the adhesive segment from the adhesive segment-laden carrier release tape onto a work piece by the use of an automatically actuated applicator head that contacts the surface of the adhesive segment-laden carrier release tape opposite the adhesive segment thereon to push the adhesive segment against the work piece to apply the adhesive segment to the work piece. In accordance with the present invention, the applicator head may include one or more sharp projections thereon that pierce through the carrier release tape, but not through the adhesive segment thereon, as the head presses the carrier release tape and adhesive segment against the work piece. It has been found that perforating the carrier release tape in this manner facilitates assured release of the adhesive segment from the carrier release tape and application of the adhesive segment to a work piece by the applicator head. Alternatively, the adhesive segment carrier release tape may be pre-perforated underneath each adhesive segment thereon, in which case the sharp projections need not be provided on the applicator head. 
     An automated adhesive segment indexing and applicator method and apparatus in accordance with the present invention employs a roll of adhesive segments provided on a differential carrier release strip or tape. A first surface of the carrier release tape has a coefficient of friction higher than the coefficient of friction of the second side of the carrier release tape, so that the first surface of the carrier release tape provides less release than does the second surface of the carrier release tape. Adhesive segments are deposited on the first, higher friction, surface of the carrier release tape, such that the adhesive segment-laden carrier release tape may be unwound with the adhesive segments remaining only on one surface of the carrier release tape. 
     In accordance with the present invention, the adhesive segment-laden carrier release tape includes optically detectable index markings thereon. Such index markings may include lines, e.g., black lines extending transversely across the carrier release tape, e.g., between the thermoplastic adhesive segments deposited thereon. Other optically detectable index markings may be printed on or otherwise applied to either one or both surfaces of the adhesive segment-laden carrier release tape. Such optically detectable markings may include physical perforations through the adhesive segment-laden carrier release tape. The index markings may be provided on the adhesive segment-laden carrier release tape as part of the process of depositing thermoplastic adhesive segments thereon, or may be provided by the manufacturer of the carrier release tape. In any case, the index markings must be accurately spaced along one or both surfaces of the differential release carrier release tape. During the application of the thermoplastic adhesive to the differential release carrier release tape the thermoplastic adhesive material is deposited thereon accurately in position relative to the index markings, e.g., by using optical detection of the index markings during the application process. 
     As will be discussed in more detail below, it has been found that, in an automatic adhesive segment applicator system in accordance with the present invention, an adhesive segment may be more assuredly removed from the adhesive segment-laden carrier release tape and applied to a work piece by an applicator head, if one or more holes or apertures are pierced through the adhesive segment-laden carrier release tape underneath the thermoplastic adhesive segments thereon. These perforations through the adhesive segment-laden carrier release tape may be formed during the process of forming a roll of adhesive segment-laden carrier release tape. This may be achieved, for example, by, after the thermoplastic adhesive segment has been applied onto the carrier release tape, and at least partially cooled, piercing the one or more perforations through the side of the carrier release tape opposite the adhesive segments. These perforations may be provided using an appropriate die, e.g., a rotary die with the appropriate sharp projections to pierce through the side of the carrier release tape opposite the adhesive segments and into, but preferably not through, the adhesive segment applied to the carrier release tape. As will be discussed in more detail below, such perforations through the carrier release tape may also be formed during the process of applying an adhesive segment from the tape onto a work piece by an adhesive segment applicator in accordance with the present invention. 
     An automatic adhesive segment applicator in accordance with the present invention preferably includes several components, all of which are mounted on a movable support structure. The components mounted on the movable support structure may include a supply spool, including a roll of adhesive segment-laden carrier release tape in accordance with the present invention, a tape guide, a take-up spool, a take-up spool drive motor, a tape clamp, an applicator head, pneumatic or other appropriate actuator mechanisms for the tape clamp and the applicator head, and an optical index detector. The applicator head may extend through a central aperture or bore formed through the tape guide and may have one or more sharp projections formed on the end thereof to pierce or otherwise provide perforations through the adhesive segment-laden carrier release tape on the side thereof opposite the adhesive segment during application thereof to a work piece to assure release of the adhesive segment from the release tape and application thereof to the work piece. The entire support structure on which these components are mounted, preferably is, in turn, mounted on a support base for movement with respect thereto toward and away from a work piece to which an adhesive segment from the adhesive segment-laden carrier release tape is to be applied. A pneumatic or other appropriate mechanism preferably is provided to move the support structure toward and away from the work piece by moving the support structure with respect to the support structure base. An appropriate controller preferably is provided to monitor and control system operation to apply automatically adhesive segments from the adhesive segment-laden carrier release tape onto a series of work pieces in a manner that assures release of the adhesive segments from the carrier release tape onto the work piece. 
     In operation, a roll of adhesive segment-laden carrier release tape, with optically detectable index markings formed thereon, as described above, is placed on the supply spool. The adhesive segment-laden carrier release tape is strung through the clamp and tape guide and onto the take-up spool. The take-up spool will accumulate the release tape after adhesive segments have been removed therefrom. The optical sensor is used to detect the index markings on the adhesive segment-laden carrier release tape to provide a signal to the system controller to indicate to the system controller the position of the tape, and, therefore, the position of the thermoplastic adhesive segments thereon, with respect to the tape guide and applicator head. Using this indexing information, the system controller may operate the motor driving the take-up spool to pull the adhesive segment-laden carrier release tape from the supply reel to position an adhesive segment on the release tape with respect to the applicator head for application thereby to a work piece. At this point, the one or more tape clamps may be closed and the entire support structure moved with respect to the support base to bring the thermoplastic adhesive segment adjacent to the work piece to which it is to be applied. The operation of the one or more tape clamps (e.g., either alone or in combination with pinch rollers) prevents undesirable movement of the release tape in the area of the adhesive segment to be applied to a work piece during the application process. The applicator head is then moved rapidly against the side of the adhesive segment-laden carrier release tape opposite the adhesive segment to push the adhesive segment against the surface of the work piece to which it is to be applied. Preferably the adhesive segment applicator head includes one or more sharp projections thereon which pierce through the surface of the adhesive segment-laden carrier release tape and into, but not through, the adhesive segment on the opposite side thereof. It is believed that the providing of these perforations through the release tape prevents air pressure between the adhesive segment and the release tape that might cause the adhesive segment not to be released from the tape onto the work piece in some cases as the applicator head is retracted. Preferably the extension and retraction of the applicator head to press the adhesive segment against the work piece, while providing perforations through the carrier release tape, may be performed twice in rapid succession to ensure release of the adhesive segment from the carrier release tape onto the work piece. After the adhesive segment is applied to the work piece in this manner the entire system support structure may be moved away from the work piece and the tape clamp released to allow free movement of the adhesive segment-laden carrier release tape supply spool. The controller may then operate the motor driving the take up spool to pull adhesive segment-laden carrier release tape from the supply spool to position the next adhesive segment on the carrier release tape in the proper position on the tape guide in front of the applicator head in preparation for the application thereof to the next work piece. The optical sensor is used to detect the index markings on the tape to provide feedback to the controller to ensure that the adhesive segment-laden carrier release tape is thus properly positioned for the next application. 
     This entire automatic application operation may be triggered manually by an operator, e.g., each time the operator presents a work piece to which a thermoplastic adhesive segment is to be applied by the device. Alternatively, the application operation, may be triggered automatically as part of an assembly line system, e.g., each time a work piece is detected to be in position for a thermoplastic adhesive segment to be applied thereto by the system. 
     Further objects, features, and advantages of the present invention will be apparent from the following detailed description thereof taken in conjunction with the accompanying drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       These and other advantages of the present invention are best understood with reference to the drawings, in which: 
         FIG. 1  is a schematic depiction of the manufacturing process for creating rolls of optically indexed adhesive segment-laden carrier release tape; 
         FIG. 2  is a perspective view of a section of a strip of the indexed adhesive segment-laden carrier release tape having optically detectable index marking lines extending transversely across the tape between thermoplastic adhesive segments thereon and an optical detector for detecting the index markings; 
         FIG. 3  is a figure similar to that of  FIG. 2  showing other exemplary index markings on the adhesive segment-laden carrier release tape that may be used in accordance with the present invention; 
         FIG. 4  is a detailed schematic cross sectional side view of an exemplary method for providing perforations through a surface of the adhesive segment carrier release tape opposite thermoplastic adhesive segments thereon during the manufacturing process thereof; 
         FIG. 5  is an isometric view of a roll of indexed adhesive segment-laden carrier release tape manufactured by the process illustrated in  FIG. 1 ; 
         FIG. 6  is a front plan view of an exemplary automated adhesive segment applicator apparatus in accordance with the present invention; 
         FIG. 7  is a side view of the exemplary automatic adhesive segment applicator apparatus of  FIG. 6  as taken along line  7 - 7  thereof; 
         FIG. 8  is a more detailed view of a tape guide, tape clamp, and applicator head of an exemplary adhesive segment applicator apparatus in accordance with the present invention as taken generally along line  8 - 8  of  FIG. 6 ; 
         FIG. 9  is a schematic block diagram of an exemplary control system for an automatic adhesive segment applicator apparatus in accordance with the present invention; 
         FIG. 10  is a flow chart diagram illustrating an exemplary method for applying a thermoplastic adhesive segment from an adhesive segment-laden carrier release tape onto a work piece using an adhesive segment indexing apparatus in accordance with the present invention; and 
         FIGS. 11-14  illustrate schematically a portion of an exemplary adhesive segment applicator apparatus in accordance with the present invention showing various positions thereof during use of the apparatus to apply an adhesive segment from an adhesive segment-laden carrier release tape onto a work piece. 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT 
     The present invention provides a system and method for applying automatically adhesive segments from an adhesive segment-laden carrier release tape onto a work piece or series of work pieces, in a rapid and effective manner. The present invention may employ optical index markings on the carrier release tape to assure accurate positioning of the carrier release tape within the apparatus. The system also employs an automatic applicator method that ensures full and sure release of adhesive segments from the carrier release tape onto a work piece during the application process. Both the structure and operation of an exemplary applicator apparatus and method in accordance with the present invention, as well as the optically indexed carrier release tape used therein, and the manufacturer of such an adhesive segment-laden carrier release tape will now be described in detail herein. 
     An exemplary process for manufacturing an adhesive segment-laden carrier release tape for use with an automatic adhesive segment applicator method and apparatus in accordance with the present invention will first be described with reference to  FIG. 1 . A system  20  for manufacturing an adhesive segment-laden carrier release tape in accordance with the present invention provides a back tensioned reel  22  holding a stock roll of differential release carrier release strip  24 , having a first surface  26  and a second surface  28  opposite the first surface. The carrier release strip  24  may be made of paper that has a silicone release material on the first  26  and second  28  surfaces. The first surface  26  of the carrier release strip  24  has a coefficient of friction higher than the coefficient of friction of the second surface  28  of the carrier release strip  24 , so that the first surface of the carrier release strip  26  provides less release than does the second surface of the carrier release strip  24 . 
     The carrier release strip  24  is dispensed from the tensioned reel  22  with the first surface  26  facing upward to move beneath a pair of thermoplastic glue metering nozzles  30  (only one of which is visible in  FIG. 1 ) supplied with thermoplastic adhesive by a metering pump (not shown) to dispense side-by-side adhesive segments  32  onto the first surface  26  as the first surface  26  moves past the nozzles  30 . Air jets  34  directed on the first surface  26  then cool the adhesive segments  32  which are also cooled by natural convection as the carrier strip  24  moves along. 
     A slitting knife  36  divides the carrier strip  24  into multiple strips, each of which are then wound into coils  40  on take-up reels  38  under controlled tensioning. Capstan and idler wheels may also be provided so that the tension on reels  38  may be controlled independently of the tension provided by the supply reel  22 . 
     The adhesive segments  32  are initially mounded high on the first surface  26  of the carrier strip  26 , but as they are wound about the reel  38 , each adhesive segment  32  is compressed beneath the second surface  28  of the carrier strip  24  of the next succeeding layer of the carrier strip  24  and the surface  26  of the layer of the carrier strip  24  on which it was deposited so as to flatten the adhesive segments into circular disks. Alternatively, a cooled drum having a non-stick surface may be used to flatten the adhesive segments  32  prior to winding on reel  38 . 
     The differential release properties of surfaces  26  and  28 , the fact that the adhesive segments  32  were initially applied in a hot state to surface  26  to cause better adherence, and the fact there is some cooling and hence “skinning over” of the adhesive segments  32  prior to winding on reel  38 , all ensure that the adhesive segments  32  remain adhered to the first surface  26  as the coil  40  is unwound. 
     It should be noted that although the adhesive segments  32  described and illustrated herein are generally circular in shape, the present invention may be applied to and employ adhesive segments on the carrier release tape which have any other generally two dimensional shape. The shape of the adhesive segments may determined in general by the shape or other characteristics of the thermoplastic glue metering nozzles  30  used to apply the thermoplastic adhesive to the carrier strip  24 . 
     In accordance with the present invention, the adhesive segment-laden carrier release tape  24  has a series of optically detectable index markings formed thereon. As will be described in more detail below, these optically detectable index markings are employed by an automatic adhesive segment applicator system in accordance with the present invention accurately to position adhesive segments for application by the applicator. As illustrated, for example, in  FIG. 2 , the optically detectable index markings may take the form of lines  42  formed on the carrier release tape  24  and extending transversely across the tape  24  between the adhesive segments  32  thereon. It should be understood that various different types of optically detectable index markings on the adhesive segment-laden carrier release tape  24  may be employed. For example, as illustrated in  FIG. 3 , printer registration marks  44  may be placed in regular positions along the carrier strip  24 . 
     Whatever index markings  42 ,  44  are employed, the index markings  42 ,  44  may be formed on either or both surfaces  26 ,  28  of the carrier release tape  24 . Besides being formed on one or both surfaces  26 ,  28  of the carrier release tape  24 , the index markings may also be formed as perforations or other cuts or holes formed into the carrier release tape  24  that may be detected by an optical detector. As also illustrated in  FIG. 3 , the optically detectable index markings  44  may be positioned on the surfaces  26 ,  28  of the carrier release tape  24  not only between the adhesive segments  32  thereon, but also at different positions on the surfaces  26 ,  28  of the tape  24  with respect to the adhesive segments  32 . For example, the adhesive segments  32  on the carrier release tape  24  may be made of a transparent thermoplastic material, in which case the index markings  44  may be positioned partially or entirely beneath the adhesive segments  32  on the carrier release tape  24  and still be detectable by an optical detector. 
     Preferably, the index markings  42 ,  44  may be pre-printed or otherwise formed on or in the carrier strip  24  before the adhesive segments  32  are deposited thereon. Alternatively, the index markings  42 ,  44  may be printed or otherwise formed on or in the carrier strip  24  as part of the process of or by the system  20  for depositing the adhesive segments  32  on the carrier strip  24 . In such a case, for example, a printer  46 , such as a laser printer or similar device, may be incorporated as part of the system  20  for creating the adhesive segment-laden carrier release tape, as illustrated in  FIG. 1 . In such a case, the printer  46 , or other device, is used to place the index markings  42  and  44  on one or both surfaces of the carrier release tape  24  before the adhesive segments  32  are deposited thereon. Note that if the index markings to be used are physical indentations, punctures, or perforations in or through the carrier tape  24 , a device other than the printer  46 , such as a rotary die with a plurality of die blades attached around its outer circumference, may be used to form the index markings in the carrier release tape  24 . In any case, whether printed or formed on the carrier release tape  24  by the manufacturer thereof or during the process of applying adhesive segments  32  to the carrier release tape  24 , the optically detectable index markings preferably are formed on the carrier release tape  24  in a uniformly spaced apart longitudinal progression along the length of the carrier release tape  24 . 
     During application of the adhesive segments  32  to the carrier release tape  24  it is important that the adhesive segments  32  be deposited on the carrier release tape  24  along the length of the carrier release tape  24  in a consistent relative position to the index markings formed on the carrier release tape  24 . In order to achieve this precise control for the depositing of the adhesive segments  32  on the carrier release tape  24  an optical sensor  48 , as illustrated in  FIG. 2 , or the like may be used to coordinate operation of the dispensing nozzles  30  so that the adhesive segments  32  are correctly placed with respect to the index markings on the carrier release tape  24 . 
     It should be noted that, in some cases, the adhesive segments  32  deposited on the carrier strip  24  may be detectable, or made detectable, by an optical detector. Therefore, the adhesive segments  32  may themselves be used as index markings. For example, thermoplastic adhesives used to form the adhesive segments  32  may be formulated for varying properties such as degrees of tack, etc. The thermoplastic adhesives  32  may also be formulated for optical detectability, e.g., by compounding the thermoplastic adhesive with colors or other optically detectable characteristics. For example, luminescence under ultra-violet is a natural characteristic of some thermoplastic adhesives and this fact may be used to employ adhesive segments  32  formed of such thermoplastic adhesives as index markings themselves. 
     Throughout the remainder of this patent application the index markings printed, or otherwise formed in or on the carrier release tape  24  will be referred to with reference to the exemplary line index markings  42  described and illustrated with reference to  FIG. 2 . However, it should be understood, that the term “index markings” and “optically detectable indices” and any similar terms as used throughout this application, including in the claims, also refers to other type of index markings, whether printed on or formed in the carrier release tape  24  including optical detectable adhesive segments  32  deposited on the carrier release tape  24 . 
     As will be discussed in more detail below, it has been found that for the application of adhesive segments  32  from an adhesive segment carrier release tape  24  onto a work piece using an automatic adhesive segment applicator in accordance with the present invention, release of the adhesive segment  32  from the carrier release tape  24  onto the work piece can better be assured if a portion of the carrier release tape  24  lying underneath or behind the adhesive segment  32  is punctured or perforated by one or more perforations. As will be described in more detail below, this perforating of the carrier release tape  24  behind an adhesive segment  32  may be performed by an automatic adhesive segment applicator in accordance with the present invention during the process of applying the adhesive segment  32  onto a work piece. Alternatively, one or more perforations may be formed in the carrier release tape  24  behind the adhesive segments  32  deposited thereon during the process of fabricating the adhesive segment-laden carrier release tape. For example, the adhesive segments  32  may be deposited upon a carrier release tape  24  in which such perforations have already been formed. However, since the adhesive segments  32  are deposited on the carrier release tape  24  in liquid form it is possible that the deposited liquid thermoplastic adhesive may seep through such preformed perforations in the carrier release tape  24  resulting in thermoplastic adhesive on both opposed surfaces  26  and  28  of the carrier release tape  24 . Obviously this is unacceptable. 
     Alternatively, and preferably, if perforations are to be made through the carrier release tape  24  behind the adhesive segments  32  deposited thereon, such perforations are preferably formed through the carrier release tape  24  after the thermoplastic adhesive segments  32  have been deposited thereon and, at least partially, cooled and solidified. An exemplary system and method for forming such perforations in the carrier release tape  24  is illustrated schematically at  50  in  FIGS. 1 and 4 . In this case, a rotary die  52  and corresponding rotary anvil member  54  cooperate to perforate the carrier release tape  24  behind each adhesive segment  32  deposited on the carrier release tape  24 . The rotary die  52  is typically drum-shaped with a plurality of blades or projections  56  formed around its outer circumference. The rotary anvil member  54  has corresponding recesses  58  formed therein. The carrier release tape  24  is effectively pinched between the rotary die  52  and the rotary anvil member  54 . As the carrier release tape  24  passes between the rotary die  52  and the rotary anvil member  54  the projections  56  on the rotary die punch one or more holes in the carrier release tape  24  through the surface  28  of the carrier release tape  24  opposite the surface  26  on which the adhesive segment  32  is deposited. The projections  56  formed on the rotary die  52  preferably are long enough to penetrate through the carrier release tape  24  without penetrating entirely through the adhesive segment  32  deposited thereon. The notched rotary anvil member  54  provides support for the carrier release tape  24  as the release tape  24  is punctured by the rotary die  52 . The recesses  58  on the rotating anvil member  54  are sized and shape such that, as the adhesive segment-laden carrier release tape  24  passes between the anvil member  54  and the rotary die  52 . The adhesive segments  32  on the carrier release tape  24  are positioned within the recesses  58  such that the anvil member  54  provides support to the carrier release tape  24  around the adhesive segments  32  without actually contacting or crushing the adhesive segments  32  on the carrier release tape  24 . It should be understood that although the embodiment illustrated and described herein shows perforating the carrier release tape  24  only at positions thereon which correspond to adhesive segments  32  deposited thereon, the perforations may, alternatively, be formed along the entire length of the carrier release tape  24 , so long as at least one such perforation is made in the carrier release tape  24  at each location at which an adhesive segment  32  is deposited thereon. 
     Referring now to  FIG. 5 , a tape roll  60  of the indexed adhesive segment-laden carrier release tape  24  is illustrated with a plurality of dispensable adhesive segments  32  contained thereon. It may be seen that the indexed adhesive segment-laden carrier release tape  24  is wound onto a hollow cylindrical core  62 , which may be, for example, made of cardboard, plastic, or the like. The inside of the core  62  has two identically-shaped orientation facilitating segments  64  and  66  mounted or formed therein. The orientation facilitating segments  64  and  66  will be used to facilitate the installation of the tape roll  60  onto a supply spool (to be discussed in detail below) in the proper orientation. Due to the presence and configuration of the orientation facilitating segments  64  and  66  on the inside of the core  62 , it will be impossible to place the tape roll  60  onto the supply spool backwards. 
     An automatic adhesive segment applicator apparatus  70  in accordance with the present invention will now be described in detail first with reference to  FIGS. 6 and 7 . The various components that form an automatic adhesive segment applicator apparatus  70  in accordance with the present invention are mounted on a movable support structure  72 . The movable support structure  72  may be implemented, for example, as a plate shaped structure made of steel, aluminum, or some other appropriate ridged and sturdy material. The support structure  72  is movably mounted with respect to a support structure base  74 . For example, the support structure  72  may be movably mounted via an appropriate mounting structure  76  to support rod bearings  78  that are fixedly attached to the support structure base  74 . A support structure actuation device  79 , such as, for example, a pneumatic air cylinder, or similar device is employed to move the support structure  72 , in this case, up and down on the support rod bearings  78  with respect to the support structure base  74 . 
     The main components of the automatic adhesive segment applicator apparatus  70  in accordance with the present invention that are mounted on the support structure  72  include a supply spool  80 , a tape guide  82 , a tape clamp  84 , an applicator head  86  (disposed within the tape guide  82  and illustrated in  FIG. 8 ), a spent tape take up spool  88  and an optical index marking detector  90 . Also attached to the support structure  72  are appropriate actuators including, e.g., an air cylinder actuator  92  for actuating the tape clamp  84 , an air cylinder actuator  94  for operating the applicator head  86 , and a motor  96  for driving the take up spool  88 . 
     The supply spool  80  may be mounted via an extension arm  98  to the support structure  72 . The extension arm  98  may be fixedly attached to the support structure  72  in any conventional and convenient manner. The supply spool  80  may be implemented in any conventional manner to support a tape roll  60  of indexed adhesive segment-laden carrier release tape  24 , as described above. The supply spool  80  preferably includes orientation facilitating segments  100  and  102  which are sized, shaped, and positioned to engage the corresponding orientation facilitating segments  64  and  66  on the tape roll  60  to ensure that the tape roll  60  can only be mounted on the supply spool  80  in the correct orientation, i.e., the orientation whereby the surface  26  of the carrier release tape  24  having adhesive segments  32  thereon is directed through the adhesive segment indexing applicator apparatus  70  for application to a work piece. The supply spool  80  preferably is implemented to allow rotation of the spool  80  such that the adhesive segment-laden carrier release tape  24  may be unwound from the tape roll  60  as tape is pulled from the roll  60  during normal operation of the adhesive segment applicator apparatus  70 . However, preferably enough resistance to rotation is provided, in any conventional manner, to prevent free rotation of the supply spool  80  in other situations, thereby to prevent unintended unwinding of the tape roll  60  mounted on the supply spool  80 . 
     The tape guide  82  is elongated, having two opposed elongated sides  104  and  106  along which the adhesive segment-laden carrier release tape  24  is strung during operation of the adhesive segment applicator  70 . The sides  104  and  106  of the tape guide  82  are preferably designed to facilitate such guiding of the carrier release tape  24  around the tape guide  82  past the applicator head  86 , which is disposed within the tape guide  82  and which, during operation, extends from an end  108  of the tape guide  82 . To facilitate such guidance of the carrier release tape  24  around the tape guide  82 , the sides  104  and  106  of the tape guide  82  may be provided with rails  110 , or other similar structures, which are spaced apart along the sides  104  and  106  of the tape guide  82  at a distance slightly larger than the width of the adhesive segment-laden carrier release tape  24 . Such rails  110  or other structures help to prevent the adhesive segment-laden carrier release tape  24  from slipping off the carrier guide  82  as the adhesive segment-laden carrier release tape  24  is moved through the adhesive segment applicator  70  during operation thereof. The transition  112  between the sides  104  and  106  and end  108  of the tape guide  82  preferably is rounded and smooth to facilitate movement of the adhesive segment-laden carrier release tape  24  around tape guide  82  without causing damage to the tape  24  or unintended peeling of the adhesive segments  32  therefrom. 
     The tape clamp  84  is designed to hold the adhesive segment-laden carrier release tape  24  tightly in position against the tape guide  82  during application of an adhesive segment  32  from the carrier release tape  24  onto a work piece. As illustrated in  FIG. 8 , the tape clamp  84  preferably includes projections  114  extending therefrom in the direction of a side  104  of the tape guide  82 . When the tape clamp  84  is moved in the direction of the tape guide  82 , by operation of the tape clamp actuator  92 , the tape clamp projections  114  pinch the adhesive segment-laden carrier release tape  24  between the projections  114  and the side  104  of the tape guide  82 , thereby preventing movement of the adhesive segment-laden carrier release tape  24 . The projections  114  are separated from each other by a distance such that a gap  116  is created between them such that when the clamp  84  is closed against the tape guide  82  the body of the clamp  84  other than the projections  114  remains spaced apart from the tape guide  82 , thereby to prevent the tape clamp  84  from contacting the adhesive segments  32  deposited on the adhesive segment-laden carrier release tape  24  passed in between the tape clamp  84  and the tape guide  82 . Note that the tape clamp actuator  92  may be implemented in any conventional manner, e.g., using a pneumatic air cylinder with pneumatic and/or spring return. 
     Note that during operation of the adhesive segment applicator  70  it is important that the adhesive segment-laden carrier release tape  24  be held firmly in position with respect to the applicator head  86  during operation of the applicator head  86  to apply an adhesive segment  32  onto a work piece. This may be achieved, for example, by providing a tape clamp  84  on both sides  104  and  106  of the tape guide  82 . Alternatively, a single tape clamp  84  may be employed, as illustrated in  FIG. 6 , wherein a pinch roller system  118  is provided on the opposite side of the tape guide  82  from the tape clamp  84 . A conventional pinch roller system  118  may be employed through which the spent carrier release tape  24 , with adhesive segments  32  removed therefrom, is strung and which allows movement of the carrier release tape in only one direction through the controller system  118  onto the take up spool  88 . 
     The applicator head  86  preferably is mounted for axial movement in a bore  120  formed through the tape guide  82  such that the applicator head  86  may be moved in and out of the tape guide  82  to extend from the bore  120  at the end  108  of the tape guide  82 . The size and shape of the applicator head  86  preferably corresponds generally to the size of the adhesive segments  32  that are to be applied to the work piece by the head  86 . The applicator head  86  preferably includes at least one, and preferably a plurality, of sharp projections  122  extending therefrom. As will be described in more detail below, during operation of the adhesive segment applicator  70  the applicator head actuator  94  is operated to move the applicator head  86  outward from the end of  108  of the tape guide, to contact the side  28  of the carrier release tape  24  opposite an adhesive segment  32  to press the adhesive segment  32  against a work piece to apply the adhesive segment  32  to the work piece. The projections  122  are sized, and the movement of the applicator head  82  is coordinated, to pierce through the carrier release tape  24  behind the adhesive segment  32 , preferably without piercing entirely through the adhesive segment  32  into the work piece upon which the adhesive segment  32  is being deposited. The forming of apertures through the release tape  24  in this manner during the application procedure facilitates release of the adhesive segment  32  from the carrier release tape  24  onto the work piece to provide assured application of the adhesive segment  32  to the work piece during the rapid automatic application of adhesive segments  32  to a work piece using the adhesive segment application  70  in accordance with the present invention. 
     The take up spool  88  may be implemented as a conventional rotatable spool onto which the carrier release tape  24  is wound after the adhesive segments  32  have been removed therefrom. The take up spool  88  may preferably be driven by a motor  96 , such as a stepper or servo motor. As illustrated, the take up spool motor  96  may be mounted on the support structure plate  72  on the side thereof opposite the take up spool  88 . A drive axle may extend from the motor  96  through the support structure  72  directly to engage and drive the pinch roller system  118 . A drive belt  126  connected between the pinch roller system  118  and the take up spool  88  couples the take up spool  88  to the motor  96 . In operation, the motor  96  is operated to rotated the pinch roller system  118  and take up spool  88  to pull the carrier release tape  24 , which is strung around the tape guide  82 , from the tape roll  60  mounted on the supply spool  80 . 
     In accordance with the present invention, an optical index marking detector  90  is employed to detect the index markings  42  formed on the adhesive segment-laden carrier release tape  24 . The optical detector  90  may be implemented in any conventional manner, and specifically is selected and implemented to detect the particular type of index marking formed on or in the carrier release tape  24 . The optical index marking detector  90  may be mounted in any appropriate and convenient place on the support structure  72  to detect the index markings  42 . 
     An exemplary control system  130  for an adhesive segment applicator in accordance with the present invention will now be described in more detail with reference to  FIG. 9 . The system controller  132  may be implemented in a conventional manner to perform the functions described herein. For example, the controller  132  may be implemented in whole or in part using a microprocessor or other programmable device and/or using in a combination of discreet digital and/or analog circuitry. The controller  132  may, but need not, be mounted to the adhesive segment applicator support structure  72 . 
     The optical index marking detector  90  operates as a tape position sensor which provides an input to the system controller  132  relative to the detected position of the index markings  42  on the carrier release tape  24 . The controller  132  processes the signal received from the tape position sensor  90  to determine, in a conventional manner, the position of the adhesive segment-laden carrier release tape  24 . Before controlling the applicator  70  to apply an adhesive segment  32  from the carrier release tape  24  onto a work piece, the controller  132  determines, based on the signal received from the tape position sensor  90 , whether the adhesive segment-laden carrier release tape  24  is positioned such that an adhesive segment  32  is positioned at the end  108  of the tape guide  82  to be applied to a work piece by the applicator head  86 . If an adhesive segment  32  is not in the desired position the controller  132  sends a control signal to the tape advance motor  96 , via an appropriate conventional motor controller  134 , to rotate the pinch roller system  118  and take up spool  88  to advance the adhesive segment-laden carrier release tape  24  from the supply roll  60  until the signal from the tape position sensor  90  indicates that an adhesive segment  32  is in the desired position. (Preferably a manual calibration input  136  is provided to provide an input to the controller  132  if it is determined by observation that the controller is not properly positioning in adhesive segment in the desired position for application to a work piece.) 
     Once the adhesive segment-laden carrier release tape  24  is positioned such that an adhesive segment  32  is positioned in an appropriate position at the end  108  of the tape guide  82 , the controller sends appropriate control signals to the support structure actuator  79 , the tape clamp actuator  92 , and the applicator head actuator  94  to control operation thereof in sequence automatically to apply the adhesive segment to a work piece, in a manner to be described in more detail below. This application process may be initiated manually, e.g., by a manual trigger  138  that provides a trigger signal to the controller  132 . The manual trigger  138  may be implemented, for example, as a hand or foot operated switch that provides a trigger signal to the controller to initiate the adhesive segment application process when an operator has positioned a work piece in a desired position or notes that a work piece is in the desired position for the application for an adhesive segment  32  thereto. Alternatively, the adhesive segment application process may be initiated automatically by a conveyor or other work piece related trigger system  140 . For example, such a work piece trigger  140  may provide a trigger signal to initiate the application of an adhesive segment  32  onto a work piece using a conventional system for detecting the presence of a work piece in the appropriate position relative to the adhesive segment applicator  70 . Such an automatic work piece trigger  140  may, particularly, be employed in an assembly line like setting. 
     As described previously, a support structure actuator  79 , tape clamp actuator  92 , and applicator head actuator  94  may be implemented using pneumatic air cylinder type actuators. In such a case, the control signals provided to operate such actuators are provided by the controller  132  to appropriate corresponding switching devices  142 ,  144 , and  146  to direct compressed air, from a compressed air supply  148 , to the appropriate air cylinder actuators  79 ,  92 , and  94  to operate the actuators at the desired time and in the desired manner. Note that preferably a single compressed air supply  148  may be used to provide operation of all of the air cylinder actuators  79 ,  92 , and  94  employed in the applicator apparatus  70 . 
     An exemplary process for operating an adhesive segment applicator system in accordance with the present invention to apply an adhesive segment  32  from an adhesive segment-laden carrier release tape  24  onto a work piece  152  now will be described with reference to the exemplary flow chart diagram of FIG.  10  and  FIGS. 11-14 .  FIGS. 11-14  illustrate, schematically, relative positions of the adhesive segment-laden carrier release tape  24 , tape guide  82 , tape clamp  84 , applicator head  86 , and work piece  152  at various points during the adhesive segment applicator operation. 
     The system controller  132  first employs the signal provided from the tape position sensor  90  to determine  154  the position of the tape  24  in the adhesive segment applicator apparatus  70 . Specifically, the controller employs the tape position sensor signal  90  to determine if the tape is in a position  156  such that an adhesive segment  32  is positioned at the end  108  of the tape guide  82 , in front of the opening of the bore  120  in which the applicator head  86  is positioned. If the adhesive segment-laden carrier release tape  24  is not in the desired position, the controller sends the appropriate signals to the tape advance motor  96  to advance the tape  158  until the signal from the tape position sensor  90  indicates that the tape is in the desired position. 
     The controller  132  then waits for a trigger signal  160 . As discussed above, the trigger signal may be provided manually by an operator or automatically by a work piece positioning or detection system when the work piece  152  is in the desired position for application of adhesive segment thereto. While the controller awaits for the trigger signal with the adhesive segment-laden carrier release tape positioned with an adhesive segment  32  ready for application to the work piece  152  the apparatus components are in the position illustrated in  FIG. 11 . 
     After receiving a trigger signal, indicating that a work piece is in position for an adhesive segment to be applied thereto, the controller  132  sends a signal to the tape clamp actuator  92  to actuate the tape clamp  84  thereby to clamp  162  the adhesive segment-laden carrier release tape  24  position such that the tape  24  in the area of the adhesive segment  32  to be applied to the work piece does not move. 
     With the tape clamped, the controller  132  sends a signal to the support structure actuator  79  to lower the support structure  72  to bring the adhesive segment  32  to be applied to the work piece  152  in contact with the work piece  152 . After clamping  162  the tape and lowering  164  the support structure  72  the apparatus is in the position illustrated in  FIG. 12 . 
     The controller  132  then provides a signal to the applicator head actuator  94  to lower  166  the actuator head  86  rapidly against the side of the carrier release tape  24  opposite the adhesive segment  32 . This operation, illustrated in  FIG. 13 , presses the adhesive segment  32  against the work piece  152 , thereby to apply the adhesive segment  32  onto the work piece  152 . Simultaneously, the sharp projections  122  provide one or more perforations through the release tape  24 , preferably without piercing through the adhesive segment  32  into the work piece  152 . The controller  132  may then send the appropriate signal to the applicator head actuator  94  to retract  168  the applicator head back into the tape guide  82 . It is believed that the piercing of holes or apertures through the release tape  24  behind the adhesive segment  32  prevents air pressure behind the adhesive segment  32  as the applicator head  86  is retracted from tending to pull adhesive segment  32  back off of the work piece  152  to which it has been applied. Thus, providing one or more perforations through the carrier release tape  24  behind the adhesive segment  32  assures removal of the adhesive segment  32  from the release tape  24  and complete application thereof to the work piece  152 . 
     Preferably the step of extending  166  and retracting  168  the applicator head  86  may be repeated  170  rapidly at least once for each adhesive segment  32  to be applied to a work piece. This further assures release of the adhesive segment  32  from the carrier release tape  24  onto the work piece  152 . 
     After the applicator head  86  has been operated to apply the adhesive segment  32  onto the work piece  152 , the controller  132  may send a control signal to the support structure actuator  79  to raise the support structure  72  back to its starting position and may send a signal to the tape clamp actuator  92  to release  174  the tape clamp  92  to allow movement of the adhesive segment-laden carrier release tape  24 . Having applied an adhesive segment  32  onto the work piece  152 , the controller  132  may then send a control signal to the tape advance motor  96  to advance the adhesive segment-laden carrier release tape  24  to position the next adhesive segment on the carrier release tape in the proper position for application to a work piece, as illustrated in  FIG. 14 . As discussed above, the, e.g., optical tape position sensor  90  may be employed to detect the index markings  42  on the carrier release tape  24  to ensure that the next adhesive segment  32  on the carrier release tape  24  is in the proper position. 
     It should be understood that the present invention is not limited to the particular exemplary applications and embodiments illustrated and described herein. In particular, although the exemplary adhesive segment applicator apparatus  70  illustrated and described herein moves in a generally vertical, up and down, direction with respect to a work piece  152  position below the applicator  70 , an adhesive segment applicator apparatus in accordance with the present invention may be positioned in any direction with respect to a work piece and oriented and operated with respect thereto to apply an adhesive segment from an adhesive segment carrier release tape onto the work piece in accordance with the present invention. 
     Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or alterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, variations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.