Method and apparatus for die cutting and making laminate articles

• US 20050016343A1
• Filed: 08/27/2004
• Published: 01/27/2005
• Est. Priority Date: 04/28/1998
• Status: Abandoned Application

• Current Assignee: John Robert Manley, Steven Kenneth Frendle
• Original Assignee: John Robert Manley, Steven Kenneth Frendle
• Inventors: Frendle, Steven Kenneth, Manley, John Robert
• Application Number:
  US10/927,189
• Publication Number:
  US 20050016343A1
• Time in Patent Office: Days
• US Class Current: 83/13
• CPC Class Codes: B26D 2007/0068 Trimming and removing web edges
• CPC Class Codes: B26D 3/085 On sheet material
• CPC Class Codes: B26D 7/088 by cleaning or lubricating sterilizing B26D1/00
• CPC Class Codes: B26D 7/18 Means for removing cut-out material or waste
• CPC Class Codes: B26F 1/384 using rotating drums
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• CPC Class Codes: B32B 38/04 Punching, slitting or perforating
• CPC Class Codes: B32B 38/10 Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: Y10T 156/1074 Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web
• CPC Class Codes: Y10T 156/1085 One web only
• CPC Class Codes: Y10T 156/1326 Severing means or member secured thereto also bonds
• CPC Class Codes: Y10T 156/1335 Cutter also delivers cut piece
• CPC Class Codes: Y10T 83/04 Processes
• CPC Class Codes: Y10T 83/364 By fluid blast and/or suction

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.

Claims

1-40. -40 canceled.

41. A method for laminating a primary web material and a secondary web material comprising the steps of:

(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.

42. The method of claim 41, wherein the step of feeding the primary web material comprises conveying the primary web material on a vacuum belt.

43. The method of claim 41, wherein the step of conveying the final product away comprises conveying the final product away on a vacuum belt.

44. The method of claim 41, wherein the step of removing the secondary web flash comprises conveying the secondary web flash on a belt.

45. The method of claim 41, wherein the step of removing the secondary web flash comprises vacuuming the secondary web flash off of the first anvil roller.

46. The method of claim 41, wherein the step of removing the primary web flash comprises conveying the primary web flash on a belt.

47. The method of claim 41, wherein the step of removing the secondary web flash further comprises applying lubricant to the rotary die to ease removal of the secondary web flash from the rotary die.

48. The method of claim 41, wherein the step of removing the primary web flash further comprises applying lubricant to the rotary die to ease removal of the primary web flash from the rotary die.

49. The method of claim 41, wherein the step of adhering the secondary web product to the rotary die comprises applying a vacuum through the rotary die.

50. The method of claim 41, wherein the step of adhering the web product to the rotary die comprises applying temporary adhesive to the rotary die.

51. The method of claim 41, wherein the step of cutting the primary web material further comprises pressing the secondary web product onto the primary web product using foam of the rotary die.

52. The method of claim 41, wherein the rotary die, the first anvil roller, and the second anvil roller are mounted as a first assembly on a lifting mechanism, wherein a second assembly including a second rotary die, a third anvil roller, and a fourth anvil roller is mounted on a second lifting mechanism in a raised position, and wherein the method further comprises the steps of:

(k) lifting the first assembly out of service;

(l) lowering the second assembly; and

(m) repeating steps (a) through (j) using the second assembly.

53. The method of claim 41, wherein the primary web material comprises at least one member selected from the group consisting of a mastic, a polyethylene, a polyester, and a metal foil, and wherein the secondary web material comprises at least one member selected from the group consisting of a mastic, a polyethylene, a polyester, and a metal foil.

54. A method for changing a shaping or lamination process comprising:

(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.