Single-pass, in-line process for manufacturing multi-part articles

• US 20040211510A1
• Filed: 05/26/2004
• Published: 10/28/2004
• Est. Priority Date: 12/06/2002
• Status: Active Grant

• Current Assignee: Quality Assured Enterprises Incorporated
• Original Assignee: Quality Assured Enterprises Incorporated
• Inventors: Franko, Joseph D. Sr.
• Granted Patent: US 7,172,670 B2
• Time in Patent Office: Days
• US Class Current: 156/252
• CPC Class Codes: B31D 1/021 Making adhesive labels having a multilayered structure, e.g. provided on carrier webs
• CPC Class Codes: B31D 1/026 Cutting or perforating B31D1/022 takes precedence
• CPC Class Codes: G06K 19/07718 the record carrier being manufactured in a continuous process, e.g. using endless rolls
• CPC Class Codes: G09F 3/0289 Pull- or fold-out labels
• CPC Class Codes: Y10T 156/1056 Perforating lamina
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1082 Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1085 One web only
• CPC Class Codes: Y10T 156/1309 and securing separate part over hole or aperture
• CPC Class Codes: Y10T 156/1322 Severing before bonding or assembling of parts
• CPC Class Codes: Y10T 156/133 Delivering cut part to indefinite or running length web

Abstract

A single-pass, in-line process for creating multi-part articles by combining primary substrates in a first continuous web with discrete elements from a second continuous web which includes pre-cutting the second web to define, but not separate, discrete element portions and a waste portion, with the web remaining intact, joining the first and second webs in aligned relation in a manner which causes selected portions of the discrete element portions to adhere to selected portions of the primary substrates in the first web in a predetermined aligned registration to form multi-part articles and removing the waste portion of the second web from the combined web.

Claims

1. A single-pass, in-line process for creating multi-part articles by combining primary substrates in a first continuous web with discrete elements from a second continuous web, comprising steps of:

(a) providing a first web which defines primary substrates, said first web having a front surface and a back surface;

(b) providing a second web which defines a discrete element source material, said second web having a front surface and a back surface;

(c) pre-cutting said second web to define, but not separate, discrete element portions and a waste portion, said second web remaining intact;

(d) joining said first and said second webs in aligned relation in a manner which causes selected portions of said discrete element portions to adhere to selected portions of said primary substrates in said first web in a predetermined aligned registration to form multi-part articles; and

(e) removing said waste portion of said second web from said combined web.

2. A process as in claim 1 comprising the step of final cutting said combined web to define final multi-part articles.

3. A process as in claim 1 wherein said first and said second webs are joined using an adhesive applied on a selected one of said first and said second webs, in a position corresponding to selected portions of said discrete element portions in said second web.

4. A process as in claim 2 wherein said first and said second webs are joined using an adhesive applied on a selected one of said first and said second webs, in a position corresponding to selected portions of said discrete element portions in said second web.

5. A process as in claim 1 wherein said waste portion of said second web is removed by continuous stripping.

6. A process as in claim 2 wherein said waste portion of said second web is removed by continuous stripping.

7. A process as in claim 3 wherein said waste portion of said second web is removed by continuous stripping.

8. A process as in claim 4 wherein said waste portion of said second web is removed by continuous stripping.

9. A process as in claim 1 wherein said first web is of a multi-ply construction.

10. A process as in claim 2 wherein said first web is of a multi-ply construction.

11. A process as in claim 2 wherein said final cutting step defines but does not separate said primary substrates from said first web and including the step of winding said first web on a roll for finished articles.

12. A process as in claim 2 wherein said final cutting step separates said primary substrates from said combined web, and including the step of stacking finished multi-part articles.

13. A process as in claim 1 wherein said discrete elements are smaller than said primary substrates.

14. A process as in claim 4 wherein said discrete elements are smaller than said primary substrates.

15. A process as in claim 1 including the step of pre-cutting said first web.

16. A process as in claim 1 including the step of pre-cutting said first web to create window openings in said primary substrates prior to joining said first and said second webs.

17. A process as in claim 1 including the step of applying graphics to selected portions of one or more of said surfaces of said first and said second webs prior to joining said first and said second webs.

18. A process as in claim 1 further comprising the step of laminating a third web over said combined web after the removal of said waste portion of said second web from said combined web.

19. A process as in claim 1 wherein said discrete elements carry an additional adhered article.

20. A single-pass, in-line process for manufacturing discrete elements combined with primary substrates, including steps of:

(a) providing a first web which defines primary substrates, said first web having a front surface and a back surface;

(b) providing a second web which defines a discrete element source material, said second web having a front surface and a back surface;

(c) cutting said second web to define discrete element portions and a waste portion;

(d) providing adhesive on a selected one of said first and second webs, in a position corresponding to selected areas of said discrete element portions in said second web;

(e) joining said first and second webs in aligned relation by said adhesive, to create a combined web;

(f) removing said waste portion from said second web as a waste matrix from said combined web, thereby combining discrete elements with said primary substrates; and

(g) cutting said combined web to define a final combination configuration.

21. A process as in claim 20, further comprising the step of laminating a third web over said combined web carrying said discrete elements.

22. The process of claim 20, wherein graphics are applied to selected portions of said front and back surfaces of said first and second webs prior to said step of joining said first and second webs.

23. A method of producing a plurality of multi-part articles from a plurality of continuous webs in a single-pass, in-line process in which discrete elements cut-out from one web are combined with defined parts from another web, comprising steps of:

(a) pre-cutting at least one web to define, but not separate, discrete elements, and to define a waste portion, the web remaining intact;

(b) joining webs in predetermined aligned registration, at least one of which is subjected to step (a); and

(c) removing said waste portion created in step (b).

24. A multi-part article made using the process of claim 23.

25. A multi-part article as in claim 24 wherein said first web is of a multi-ply construction.

26. A multi-part article as in claim 24 wherein said primary substrate is provided with a window opening covered by one of said discrete elements.

27. A multi-part article as in claim 24 including printed graphics on one or more selected surfaces thereof.

28. A multi-part article as in claim 24 contained on a roll of such articles.

29. A multi-part article as in claim 24 contained in a stack of such articles.

30. A multi-part article as in claim 24 including a laminate overlayer.

31. A multi-part article as in claim 26 wherein said article comprises a windowed golf ball container.

32. A multi-part article as in claim 24 wherein said article is a container in knock-down form.

33. A multi-part article as in claim 26 including printed graphics on one or more selected surfaces thereof.