Die cutter blanket

A die cutter blanket for use with an anvil having an axially extending channel of a given transverse width dimension in the surface thereof comprising:

• a plastic sheet member having an outer work surface and opposing longitudinal edges forming a first layer exhibiting edge curl at the longitudinal edges and having first and second ends terminating in first and second transverse edges;
• a second layer of different plastic sheet material than the first layer having a different greater rate of shrinkage during curing than the first layer and molded to the first layer to minimize the edge curl during the curing of the second layer;
• interengaging locking structures molded one piece and integral with the first and second layers at the ends of the first and second layers for securing the ends together and for securing the blanket to the anvil, the locking structures being located spaced from the outer work surface.

A method of making a die cutter blanket having opposing ends comprising:

• molding a first layer of urethane material of a first shrinkage value and having an outer peripheral work surface;
• molding a second layer;
• molding the first and second layers together during one of the above molding steps, the first layer having a second shrinkage value smaller than the first value, the second layer being harder than the first layer, the difference in shrinkage value for minimizing edge curl in the layers, at least one of the molding and forming steps for molding an interlocking system at and to the opposing ends for locking the opposing ends together, the interlocking system being molded one piece with at least one of said first and second layers and spaced from the outer work surface of the blanket.