Registered lamination of webs using laser cutting

A method of generating a multi-layered product using a web lamination machine, the machine including a position detection device, first and second nip rollers, and a modifying device, the method comprising:

• feeding a continuous sheet of a first layer to the first nip roller, the first layer including at least one component positioned thereon;
• detecting the position of the component to determine a position of the component relative to the first nip roller;
• feeding a continuous sheet of a second layer to the second nip roller, the first and second nip rollers directing the first and second layers into engagement with each other to form a continuous sheet of multi-layered product;
• and
• forming an aperture in the second layer based on the determined position of the component such that the component is exposed within the aperture in the multi-layered product.

A method of generating a multi-layered product using a web lamination machine, the machine including a position detection device, first and second nip rollers, and an altering device, the method comprising:

• feeding a continuous sheet of a first layer to the first nip roller, the first layer including a predetermined pattern;
• detecting the position of at least a portion of the predetermined pattern with the position detection device to determine a characteristic of the portion of the predetermined pattern;
• feeding a continuous sheet of a second layer to the second nip roller, the first and second nip rollers directing the first and second layers into engagement with each other to form a continuous sheet of multi-layered product;
• and
• altering the second layer with the altering device prior to the second layer being fed to the second nip roller based on the determined characteristic of the portion of the predetermined pattern.

A system for generating a multi-layered circuit assembly, the system comprising:

• a first roll support configured to support a continuous roll of webbing, the webbing having at least one circuit component positioned thereon;
• a second roll support configured to support a continuous roll of laminate layer;
• first and second nip rollers configured to direct the webbing and laminate layers, respectively, into engagement with each other to form a continuous sheet of multi-layered product
• a position detection device positioned between the first roll support and the first nip roller, the position detection device being arranged and configured to monitor a position of the at least one circuit component relative to the first nip roller;
• and
• a modifying device positioned between the second roll support and the second nip roller, the modifying device being arranged and configured to modify the laminate layer based on the monitored position of the circuit component.