Method and apparatus for die cutting and making laminate articles

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.

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,...

AI Technical Summary

Benefits of technology

[0013] The present invention provides a method and apparatus for die cutting and making shaped and laminated articles in a process that efficiently recovers unused recyclable flash material without adversely impacting production speed or quality. The present invention reduces material waste in the shaping of a web of material or the laminating of at least two films, layers or web stock and also permits changing or modifying the product being produced without stopping production.

[0018] Like the shaping configuration, in the lamination configuration, a lubricant system improves flash removal by applying lubricant directly to the blades of the rotary die before the die contacts the secondary web material or primary web material. Additionally, the first and second anvil rollers can be either stepped or regular to produce the desired cut and the flash removal mechanism can be tailored to meet recycling requirements, e.g., conveyed, vacuumed, or rewound.

[0021] It is another object of the present invention to deliver a web material to a rotary die without contacting or handling the top of the web material so as to reduce the possibility of damaging the web material.

[0023] It is another object of the present invention to provide a lubrication system for a die cutting apparatus that minimizes wasted lubricant and reduces degradation of the web material from over-saturation.

Problems solved by technology

The typical apparatus do not recover the flash in a systematic manner that facilitates recycling.

Thus, much of the unused raw material is thrown away and wasted.

Laminate products present additional obstacles to recycling.

Even if an apparatus recovers the flash from a laminate product, often the multiple layers of varying materials are inseparable and incompatible with recycling operations.

Thus, if the apparatus collects the laminate flash at the end of the manufacturing process, the flash cannot be recycled.

In addition to inadequate flash removal, the rotary die apparatus known in the art present three other significant drawbacks.

First, conventional apparatus typically use individual rotary processing stations.

Therefore, when the machines must be re-tooled to accommodate new products, the single individual station must be taken out of service for extended periods of time.

The prior art apparatus do not provide means to quickly change shaping or laminating functions without curtailing production.

Second, conventional rotary die apparatus regulate web tension with nip or pinch rollers.

Often, the pinching action of these rollers damages the web material and diminishes the quality of the final product.

The prior art apparatus do not provide means to consistently convey the web material without excessive, deleterious handling.

Such a method uses excessive amounts of lubricant and degrades the quality of the web material because of over-saturation.

The prior art apparatus do not provide means to apply minimal amounts of lubricant to the specific locations at which lubrication is needed for effective flash removal.

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