US 6,786,995 B2Granted

Method and apparatus for die cutting and making laminate articles

AssigneeDenovus LLC

InventorsSteven Kenneth Frendle, John Robert Manley

Life of this patent

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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.

Claims23

Dependent claims

A method for shaping web materials comprising the steps of:

(a) feeding a web material between a rotary die and an anvil roller, wherein the rotary die and the anvil roller are rotating in opposite directions;
(b) cutting the web material with the rotary die into a web product and a web flash;
(c) conveying the web product away from the anvil roller;
(d) removing the web flash for recycling;
(e) adhering the web product to the rotary die;
(f) rotating the web product around the rotary die to the bottom of the rotary die;
(g) feeding a 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;
(h) joining the web product and the primary web material at a location between the rotary die and the second anvil roller;
(i) 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 web product and is attached to the web product to form a final product;
(j) conveying the final product away from the rotary die and the second anvil roller;
and
(k) removing the primary web flash for recycling.

9 more elements

Dependencies are inferred from the claim text.

Facts

Application: 09/874,266Filed 6 Jun 2001 · division
Priority: 28 Apr 1998
Published: US 2001/0023740 A127 Sep 2001
Granted: 7 Sep 2004
Term ends: Not estimatedThe source records don’t support an estimate.

Classification21 codes

B32B 38/04
Ancillary operations in connection with laminating processes: punching, slitting or perforating
B26D 3/085
Making a superficial cut in the surface of the work without removal of material, e.g. scoring, incising: on sheet material
B26D 7/088
Means for treating work or cutting member to facilitate cutting: by cleaning or lubricating
B26D 7/18
Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting: means for removing…

Family

Application60/083,290Us provisional application · filed 28 Apr 1998
Application09/300,387Parent of this division · filed 27 Apr 1999
US 2001/0023740 A1Pre-grant publication · published 27 Sep 2001
US 6,253,819 B1Parent of this division
US 6,786,995 B2This patent

From the US filing history. Foreign family members aren’t listed.