Method and apparatus for die cutting and making laminate articles

• US 6,253,819 B1
• Filed: 04/27/1999
• Issued: 07/03/2001
• Est. Priority Date: 04/28/1998
• Status: Expired due to Fees

• Current Assignee: Henkel Corporation (Henkel AG & Co KGaA)
• Original Assignee: Denovus LLC
• Inventors: Frendle, Steven Kenneth, Manley, John Robert
• Primary Examiner(s): GRAY, LINDA LAMEY
• Application Number:
  US09/300,387
• Time in Patent Office: 798 Days
• Field of Search: 156/264, 156/265, 156/269, 156/270, 156/520, 156/267, 156/518, 283/70, 283/75, 283/94, 493/346
• US Class Current: 156/518
• 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. An apparatus for laminating a primary web material and a secondary web material comprising:

(a) a rotary die rotating in a first direction;

(b) a first anvil roller contacting the rotary die and rotating in a second direction opposite to the first direction, wherein the secondary web material enters the apparatus between the rotary die and the first anvil roller such that the rotary die cuts the secondary web material into a secondary web product and a secondary web flash, wherein the secondary web flash is removed for recycling, and wherein the secondary web product adheres to the rotary die and travels around the rotary die;

(c) a second anvil roller contacting the rotary die and rotating in the second direction, wherein the primary web material enters the apparatus between the rotary die and the second anvil roller, wherein the secondary web product travelling around the rotary die meets and adheres to the primary web material as the primary web material enters the apparatus between the rotary die and the second anvil roller, wherein the rotary die cuts the primary web material into a primary web product and a primary web flash, and wherein the primary web flash is removed for recycling and the primary web product that is attached to the secondary web product exits the apparatus;

(d) a primary web flash removal mechanism that removes the primary web flash from the apparatus; and

(e) a secondary web flash removal mechanism that removes the secondary web flash from the apparatus.

2. The apparatus of claim 1, wherein the primary web flash removal mechanism comprises a belt conveyor.

3. The apparatus of claim 1, wherein the secondary web flash removal mechanism comprises a belt conveyor.

4. The apparatus of claim 1, wherein the secondary web flash removal mechanism comprises a vacuum nozzle contacting the first anvil roller where the secondary web flash exits the rotary die and the first anvil roller.

5. The apparatus of claim 1, wherein the rotary die further contains a channel system through which a vacuum is drawn to adhere the secondary web product to the rotary die.

6. The apparatus of claim 1, wherein the rotary die further contains a channel system through which a coolant flows.

7. The apparatus of claim 1, further comprising an applicator that applies lubricant to the rotary die to ease removal of the primary web flash and the secondary web flash from the rotary die.

8. The apparatus of claim 1, further comprising an adhesive applicator that applies adhesive to the rotary die to temporarily adhere the secondary web product to the rotary die.

9. The apparatus of claim 1, further comprising:

(f) a first side nip roller contacting the first anvil roller on a first side; and

(g) a second side nip roller contacting the first anvil roller on a second side opposite to the first side.

10. The apparatus of claim 1, further comprising a control system that regulates the production speed, web tension, and web sheet height of the primary web material, the secondary web material, the primary web flash, the primary web product, the secondary web flash, and the secondary web product.

11. The apparatus of claim 1, wherein the rotary die contains a foam that presses the secondary web product onto the primary web product.

12. The apparatus of claim 1, wherein the first anvil roller is configured to produce a through-cut.

13. The apparatus of claim 1, wherein the first anvil roller is configured to produce a kiss-cut.

14. The apparatus of claim 1, wherein the second anvil roller is configured to produce a kiss-cut.

15. The apparatus of claim 1, wherein the second anvil roller is configured to produce a through-cut.

16. The apparatus of claim 1, further comprising a lifting mechanism on which the rotary die and the first anvil roller are mounted, said lifting mechanism being able to lift the rotary die and the first anvil roller out of service.

17. The apparatus of claim 1, further comprising:

(f) a first vacuum belt, adjacent to the rotary die and the second anvil roller, wherein the first vacuum belt delivers the primary web material to the apparatus; and

(g) a second vacuum belt, adjacent the rotary die and the second anvil roller, wherein the second vacuum belt conveys the primary web product away from the apparatus.

18. The apparatus of claim 1, wherein the primary web material comprises more than one layer and the first anvil roller is configured to produce a kiss-cut, wherein the rotary die cuts only one layer of the primary web material.

19. The apparatus claim 1, wherein the secondary web material comprises more than one layer and the second anvil roller is configured to produce a kiss-cut, wherein the rotary die cuts only one layer of the secondary web material.

20. The apparatus of claim 1, further comprising a plurality of die and anvil roller assemblies arranged in succession along a production line, each of the assemblies being mounted on lifting mechanisms,

wherein a first assembly of the plurality of assemblies is engaged in production and a second assembly of the plurality of assemblies is lifted out of service, and

wherein the first assembly is operable to be raised and the second assembly is operable to be lowered into production simultaneously.

21. The apparatus of claim 1, wherein (a) the rotary die and the first anvil roller are in longitudinal contact and are rotating in opposite directions, (b) the primary web material is cut by the rotary die into the primary web product and the primary web flash such that 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, and (c) the final product is conveyed away from the rotary die and the second anvil roller.

22. The apparatus of claim 21, wherein the primary web material is fed to the apparatus on a vacuum belt.

23. The apparatus of claim 21, wherein the final product is conveyed away from the apparatus on a vacuum belt.

24. The apparatus of claim 21, wherein the secondary web flash is removed by conveying the secondary web flash on a belt.

25. The apparatus of claim 21, wherein the secondary web flash is removed by vacuuming the secondary web flash off of the first anvil roller.

26. The apparatus of claim 21, wherein the primary web flash is removed by conveying the primary web flash on a belt.

27. The apparatus of claim 21, wherein the secondary web flash is removed by applying lubricant to the notary die to ease removal of the secondary web flash from the rotary die.

28. The apparatus of claim 21, wherein the primary web flash is removed by applying lubricant to the rotary die to ease removal of the primary web flash from the rotary die.

29. The apparatus of claim 21, wherein the secondary web product is adhered to the rotary die by applying a vacuum through the rotary die.