Method and apparatus for die cutting and making laminate articles
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Abstract
A method and apparatus that produces shaped and laminate articles and recovers the excess material or flash as a part of the manufacturing process. The apparatus uses a combination of rotary die and anvil roller assemblies in successive multiple stations to cut and separate each raw material into final product portions and recyclable flash portions as each raw material enters the apparatus. The apparatus separately reclaims each raw material flash portion and delivers the flash of each material in a recyclable form to an auxiliary recycling operation. In recovering the flash, the apparatus does not adversely affect the speed or quality of production of the final shaped or laminated product. To ease removal of the flash, the apparatus applies lubricant to the blades of the rotary die. To avoid damage to web material, the apparatus uses vacuum belts to convey the web material and web product through the apparatus.
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Citations
54 Claims
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1-40. -40 canceled.
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41. A method for laminating a primary web material and a secondary web material comprising the steps of:
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(a) feeding the secondary web material between a rotary die and a first anvil roller, wherein the rotary die and the first anvil roller are rotating in opposite directions;
(b) cutting the secondary web material with the rotary die into a secondary web product and a secondary web flash;
(c) removing the secondary web flash for recycling;
(d) adhering the secondary web product to the rotary die;
(e) rotating the secondary web product around the rotary die to the bottom of the rotary die;
(f) feeding the primary web material between the rotary die and a second anvil roller, wherein the rotary die and the second anvil roller are rotating in opposite directions;
(g) joining the secondary web product and the primary web material at a location between the rotary die and the second anvil roller;
(h) cutting the primary web material with the rotary die into a primary web product and a primary web flash, wherein the primary web product is equal in size and shape to the secondary web product and is attached to the secondary web product to form a final product;
(i) conveying the final product away from the rotary die and the second anvil roller; and
(j) removing the primary web flash for recycling. - View Dependent Claims (42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53)
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54. A method for changing a shaping or lamination process comprising:
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(a) arranging a plurality of die and anvil roller assemblies in succession along a production line;
(b) mounting the plurality of die and anvil roller assemblies on a plurality of lifting mechanisms;
(c) engaging a first portion of the plurality of die and anvil roller assemblies in production;
(d) lifting a second portion of the plurality of die and anvil roller assemblies out of service; and
(e) simultaneously raising the first portion of the plurality of die and anvil roller assemblies and lowering the second portion of the plurality of die and anvil roller assemblies.
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Specification