Die cut window laminating device

A method of forming a moving web of laminated composite having window portions therein from a moving web of paper material and a moving web of film material having repeating sets of graphics thereon comprising the steps of:

• a. moving the paper web at a predetermined speed;
• b. moving the film web into touching parallel aligned relationship with the paper web at a speed equal to the speed of the paper web;
• c. at a position on the moving film web upstream from the point of initial parallel touching contact of the two webs, wetting the film web at target areas having a repeating predetermined size and shape within each set of repeating graphics to prevent adhesion of an adhesion agent thereto;
• d. at a position on the moving paper web upstream from the point of initial parallel touching contact of the two webs, cutting perforated window patterns on the moving paper web with identical shape and spacing as said wetted target areas on the moving film web;
• e. periodically adjusting the position at which said perforated window patterns are cut on the moving paper web to provide accurate registry of said perforated window patterns with said target areas at the point of parallel touching contact;
• f. coating at least one of the touching surfaces of the moving paper web and moving film web with an adhesive agent upstream of the point where the paper web and film web are brought into parallel touching contact;
• g. compressing the moving paper web and film web at the point of parallel touching contact to form a laminated composite;
• and
• h. removing chad portions from said perforated window patterns at a position downstream of the point of initial parallel touching contact of the two webs.

A method of forming a moving web of laminated composite having window portions therein from a moving web of paper material and a moving web of film material having repeating sets of graphics thereon and having target areas with a predetermined size, shape, and position within each repeating set of graphics, comprising the steps of:

• a. moving the paper web at a predetermined speed;
• b. moving the film web into touching parallel aligned relationship with the paper web at a speed equal to the speed of the paper web;
• c. at a position on the moving paper web upstream from the point of initial parallel touching contact of the two webs, cutting perforated window patterns on the moving paper web with identical shape and spacing as said target areas on the moving film web;
• d. periodically adjusting the position at which said perforated window patterns are cut on the moving paper web to provide accurate registry of said perforated window patterns with said target areas at the point of parallel touching contact;
• e. coating at least one of the touching surfaces of the moving paper web and moving film web with an adhesive agent upstream of the point where the paper web and film web are brought into parallel touching contact;
• f. compressing the moving paper web and film web at the point of parallel touching contact to form a laminated composite.

A device for forming a moving web of laminated composite material having window portions therein from a moving continuous web of plastic film material and a moving continuous web of paper material said film material and said paper material each having a lamination side to be laminated to an opposed surface of the other material and a non-lamination side for forming an exterior surface of the laminated composite, said apparatus comprising:

• a. paper supply means for providing a continuous web of paper to be laminated, said paper supply means defining the upstream end of said paper web;
• b. film supply means for providing a continuous web of film to be laminated, said film supply means defining the upstream end of said film web;
• c. rotating cutter means defining a cutter nip for repeatingly cutting spaced apart perforated window patterns in said paper web, and for engaging said paper web to control the advance thereof;
• d. adhesive supply means for applying adhesive material to at least one of said film web laminated surface and said paper web laminated surface;
• e. laminating nip means for engaging and moving said paper web and said film web in parallel aligned relationship at equal speeds and for laminating said paper web to said film web for forming a laminated composite;
• f. phasing means for providing accurate registry of said perforated window pattern portions of said paper web with predetermined, spaced apart, repeating target areas on said film web at said laminating nip means;
• g. composite transport means for continuously moving said composite web from said laminating nip means.

A device for forming a moving web of laminated composite material having window portions therein from a moving continuous web of plastic film material and a moving continuous web of paper material said film material and said paper material each having a lamination side to be laminated to an opposed surface of the other material and a non-lamination side for forming an exterior surface of the laminated composite, said apparatus comprising:

• a. paper supply means for providing a continuous web of paper to be laminated, said paper supply means defining the upstream end of said paper web;
• b. film supply means for providing a continuous web of film to be laminated, said film supply means defining the upstream end of said film web;
• c. rotating cutter means defining a cutter nip for repeatingly cutting spaced apart perforated window patterns in said paper web, and for engaging said paper web to control the advance thereof;
• d. adhesive supply means for applying adhesive material to at least one of said film web laminated surface and said paper web laminated surface;
• e. laminating nip means for engaging and moving said paper web and said film web in parallel aligned relationship at equal speeds and for laminating said paper web to said film web for forming a laminated composite;
• f. phasing means for providing accurate registry of said perforated window pattern portions of said paper web with predetermined, spaced apart, repeating target areas on said film web at said laminating nip means;
• g. composite transport means for continuously moving said composite web from said laminating nip means;
• wherein said phasing means comprises course phasing means for use at low speeds during system start-up operations for initially phasing said perforated window patterns with said target areas comprising:
• cutter nip opening means for controllingly opening said cutter nip for releasing said paper web from engagement from said cutter nip whereby said paper web is slippingly displaceable relative said cutter nip during an open state of said cutter nip;
• cutter means speed control means for controllingly varying the surface speed of said cutter means relative the surface speed of said laminating nip during a period when said cutter nip is in said open state whereby the relative position at which perforated window patterns are cut on said paper web are controllably shifted upstream or downstream thereon.

A device for forming a moving web of laminated composite material having window portions therein from a moving continuous web of plastic film material and a moving continuous web of paper material said film material and said paper material each having a lamination side to be laminated to an opposed surface of the other material and a non-lamination side for forming an exterior surface of the laminated composite, said apparatus comprising:

• a. paper supply means for providing a continuous web of paper to be laminated, said paper supply means defining the upstream end of said paper web;
• b. film supply means for providing a continuous web of film to be laminated, said film supply means defining the upstream end of said film web;
• c. rotating cutter means defining a cutter nip for repeatingly cutting spaced apart perforated window patterns in said paper web, and for engaging said paper web to control the advance thereof;
• d. adhesive supply means for applying adhesive material to at least one of said film web laminated surface and said paper web laminated surface;
• e. laminating nip means for engaging and moving said paper web and said film web in parallel aligned relationship at equal speeds and for laminating said paper web to said film web for forming a laminated composite;
• f. phasing means for providing accurate registry of said perforated window pattern portions of said paper web with predetermined, spaced apart, repeating target areas on said film web at said laminating nip means;
• g. composite transport means for continuously moving said composite web from said laminating nip means;
• wherein said phasing means comprises fine phasing means for use under normal speed operating condition for phasing said perforated window patterns with said target areas comprising:
• means for providing a first, controllably variable tension zone in said paper web immediately upstream of said cutter nip;
• means for providing a second tension zone of relatively constant tension between said cutter nip and said laminating nip means;
• whereby tension in said first tension zone is controllably variable relative to said tension in said second tension zone;
• whereby, during a forward phasing operation in which the tension in said second tension zone is increased above the tension in said second tension zone, relative shrinking occurs in said paper web upon passage thereof from said first tension zone to said second tension zone whereby a perforated window pattern cut in said paper web during said forward phasing operation is moved forwardly relative a perforated window pattern cut when the tensions in said first and second zones are equal;
• whereby during a rearward phasing operation in which the tension in said first tension zone is decreased below the tension in said second tension zone relative stretching occurs in said paper web upon passage thereof from said first tension zone to said second tension whereby a perforated window pattern cut in said paper web during said rearward phasing operating is moved rearwardly relative a perforated window pattern cut when the tension in said first tension zone and said second tension zone are equal.

A device for forming a moving web of laminated composite material having window portions therein from a moving continuous web of plastic film material and a moving continuous web of paper material said film material and said paper material each having a lamination side to be laminated to an opposed surface of the other material and a non-lamination side for forming an exterior surface of the laminated composite, said apparatus comprising:

• a. paper supply means for providing a continuous web of paper to be laminated, said paper supply means defining the upstream end of said paper web;
• b. film supply means for providing a continuous web of film to be laminated, said film supply means defining the upstream end of said film web;
• c. rotating cutter means defining a cutter nip for repeatingly cutting spaced apart perforated window patterns in said paper web, and for engaging said paper web to control the advance thereof;
• d. adhesive supply means for applying adhesive material to at least one of said film web laminated surface and said paper web laminated surface;
• e. laminating nip means for engaging and moving said paper web and said film web in parallel aligned relationship at equal speeds and for laminating said paper web to said film web for forming a laminated composite;
• f. phasing means for providing accurate registry of said perforated window pattern portions of said paper web with predetermined, spaced apart, repeating target areas on said film web at said laminating nip means;
• g. composite transport means for continuously moving said composite web from said laminating nip means;
• wherein said phasing means comprises course phasing means for use at low speeds during system start-up operations for initially phasing said perforated window patterns with said target areas comprising:
• cutter nip means for controllably opening said cutter nip for releasing said paper web from engagement from said cutter nip whereby said paper web is slippingly displaceable relative said cutter nip during an open state of said cutter nip;
• cutter means speed control means for controllingly varying the surface speed of said cutter means relative the surface speed of said laminating nip during a period when said cutter nip is in said open state whereby the relative position at which perforated window patterns are cut on said paper web are controllably shifted upstream or downstream thereon;
• and
• wherein said phasing means comprises fine phasing means for use under normal speed operating condition for phasing said perforated window patterns with said target means comprising:
• means for providing a first, controllably variable tension zone in said paper web immediately upstream of said cutter nip;
• means for providing a second tension zone of relatively constant tension between said cutter nip and said laminating nip means;
• whereby tension in said first tension zone is controllably variable relative to said tension in said second tension zone;
• whereby, during a phasing operation in which the tension in said second tension zone is increased above the tension in said second tension zone, relative shrinking occurs in said paper web upon passage thereof from said first tension zone to said second tension zone whereby a perforated window pattern cut in said paper web during said forward phasing operation is moved forwardly relative a perforated window pattern cut when the tensions in said first and second zones are equal;
• whereby during a rearward phasing operation in which the tension in said first tension zone is decreased below the tension in said second tension zone relative stretching occurs in said paper web upon passage thereof from said first tension zone to said second tension zone whereby a perforated window pattern cut in said paper web during said rearward phasing operating is moved rearwardly relative a perforated window pattern cut when the tension in said first tension zone and said second tension zone are equal.