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.

1 - 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.