Rotary converting apparatus and method for laminated products and packaging

A method of producing a series of thin-film electrochemical unit cells, comprising:

• moving a cathode web comprising a cathode layered structure at a first speed;
• rotatably cutting the cathode web at a second speed to produce a series of cathode sheets;
• rotatably laminating each of the cathode sheets moving at the second speed to an anode web comprising an anode layered structure moving at a third speed to produce a laminated unit cell having a space between adjacent cathode sheets;
• and
• cutting the laminated anode web within the space between adjacent cathode sheets to produce a series of unit cell sheets.

A method of producing a series of thin-film electrochemical unit cells, comprising,

• cutting a web comprising a cathode layered structure at a first speed into a series of cathode layered structures using a patterned rotary die;
• laminating each of the cathode layered structures to a web comprising an anode layered structure moving at a second speed equal to or greater than the first speed to produce a laminated unit cell having a space between adjacent cathode layered structures;
• discarding waste cathode web material resulting from patterned rotary die cutting;
• and
• cutting the laminated anode web within the space between adjacent cathode sheets to produce a series of unit cell sheets.