Method and apparatus for die cutting and making laminate articles

US20050016343A1Inactive Publication Date: 2005-01-27FRENDLE STEVEN KENNETH +1
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Patent Information

Authority / Receiving Office
US · United States
Current Assignee / Owner
Publication Date
2005-01-27
Estimated Expiration
Not applicable · inactive patent

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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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Description

[0001] The present application claims priority from the filing date of the provisional patent application Ser. No. 60 / 083,290 filed Apr. 28, 1998, entitled “Method and Apparatus for Die Cutting and Making Laminate Articles.”BACKGROUND

[0002] 1. Field of the Invention

[0003] The present invention relates to a method and an apparatus for making shaped and laminate articles, and more particularly, to an apparatus that recovers excess material or flash for recycling as a part of the shaping and laminating process.

[0004] 2. Background of the Invention

[0005] Rotary dies and methods of using such dies are conventionally used in this art to produce shaped and laminated articles of continuous lengths or discrete shapes. Examples of such articles include seals and gaskets, expandable articles for automotive uses, diapers, edible items such as cereal, printed matter such as labels and cardboard boxes, and other sheet goods.

[0006] U.S. Pat. Nos. 4,427,481; 5,266,133; 5,373,027; 5,678,826; 5,...

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Embodiment Construction

[0036] Referring to the drawings, the present invention comprises an apparatus and a method for forming a shaped or laminate product, using at least one rotary die, at least one anvil roller and at least one support or drive roller. FIGS. 1a-1d illustrate the preferred embodiment of the present invention as a part of a larger, manufacturing apparatus. The present invention processes web material in two configurations: shaping and lamination. FIG. 2 depicts the preferred embodiment of the present invention in the shaping configuration. FIGS. 3-4 show the preferred embodiment of the present invention in the lamination configuration. In each configuration, as the process materials are cut, excess material known as flash is recovered for recycling.

[0037]FIG. 2 shows the die cutting apparatus configured to produce shaped products, in which primary web material 202, in sheet or web form, enters the apparatus between rotary die 201 and anvil roller 203, at which point rotary die 201 cuts ...