Abstract:
A method and apparatus for producing shaped articles from a web material is disclosed. The apparatus generally includes a rotary cutting roller, preferably including indicia on an end surface, and an anvil roller operating in cooperating rotational movement with the rotary cutting roller. The apparatus die cuts web material into predetermined shapes. The apparatus further includes at least one sensor for detecting rotational movement of the rotary cutting die by way of the indicia on the end surface of the rotary cutting roller. The information from the at least one sensor and an encoder is processed and translated to drive means to thereby corrects variation in web alignment relative to the rotary cutting roller. The adjustment of the rotary cutting roller of the present invention allows the rotary cutting roller to cut within a high degree of accuracy and precision.

Description:
RELATED APPLICATION 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 10/902,499, filed 29 Jul. 2004, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/490,833, filed 29 Jul. 2003, and entitled “Method and Apparatus for Die Cutting a Web.” 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a method and an apparatus for die cutting web material into shaped articles, and more particularly to an apparatus that precisely aligns a cutting die relative to the web material to facilitate precise cuts. 
         [0003]    In the past, web material including preprinted web material, such as label stock has been laminated and die cut using tools with tolerances of no less than an eighth of an inch. While this level of accuracy is acceptable in certain applications, when relatively small labels or labels having a detailed peripheral edge configuration are desired, a greater degree of cutting accuracy is often desired. Certain tools have used a variety of sensing means configured to read indicia to thereby correctly register the die cuts. While such tools may attain a certain degree of accuracy, the present invention seeks to provide a tool capable of die cutting and laminating a web material with greater cut accuracy while further providing economy of design. 
       SUMMARY OF THE INVENTION 
       [0004]    Briefly, to achieve the desired objects of the instant invention, and in accordance with a preferred embodiment thereof, disclosed herein is an apparatus and method for laminating and die cutting web material. Examples of such web materials may include, but are not limited to blank or printed matter such as labels, gaskets, seals, films, cardboard, and other sheet goods. Users of the apparatus may also choose to die cut web materials without having been previously laminated. Additionally, this invention may be used in conjunction with other tools as for instance a web-printing machine for printing web material on demand and a stacking and folding device (not shown) for preparation of finished product. A perforation die (not shown) may also be included as a feature of the apparatus. 
         [0005]    In a preferred embodiment of the present invention, the apparatus includes means for receiving spooled web material, means for receiving laminating material, a rotary cutting die or roller, an anvil roller in cooperating rotational movement with the rotary cutting roller, drive means, at least one idler roller to support the web material preceding a nip between the rotary cutting roller and the anvil roller, an encoder for detecting rotational movement of the anvil roller, at least one end sensor and at least one web sensor, the end sensor detecting at least one indicia on an end surface of the rotary cutting roller, the web sensor for detecting web indicia on the web material, a processor for receiving information from the sensors and encoder and translating the information to the drive means, wherein the drive means preferably includes but is not limited to a stepper motor connected to a differential drive unit, the differential drive unit being connected to the anvil roller, and gearing or other conventional drive means for driving the rotary cutting roller, to thereby correct variation in web alignment relative to the rotary cutting roller. The processor is capable of communicating to the stepper motor, thereby changing the rotational speed of the anvil roller and rotary cutting roller relative the web material to better align predetermined die cutting configurations on the web material. Further, the present invention is adapted to die cut within a high degree of accuracy and precision. 
         [0006]    The present invention preferably includes a label supply spindle. The label supply spindle receives spooled, web material for feed into the device of the present invention along the web material path. Alternatively, the present invention may include a web feed assembly adapted to receive preprinted web material from a printing device or other conventional web supply means. 
         [0007]    As the web material is unwound from the label supply spindle and following the web material path, or alternatively, supplied by the web feed assembly, it is directed toward a laminating web which is preferably carried on a laminating web supply roll spindle. 
         [0008]    The preferred web material to be used in accordance with the present invention is preferably a continuously spooled sheet of a suitable label material that may be carried on a releasable liner material, and having a first side and a second side. The web material may be preprinted or may contain no printing, and supplied in a spindled roll, or may be printed at need by an optionally attached printing system. Further, the web material preferably includes preapplied, longitudinally spaced datum or web indicia marks to be read by the web sensor. The laminating material to be used in accordance with the present invention is preferably a continuously spooled transparent, protective web having an adhesive coated side, although it is within the spirit of this invention to use other types of laminating material such as colored, metallic, or other conventional protective web materials. Alternatively, laminating material may not be used. The laminating material may further include a lamination backing material, if desired. In instances wherein the laminating material is provided with backing material, the apparatus of the present invention may further be supplied with a lamination backing material take-up spindle for receiving backing material after the laminating material has been separated from the backing material. 
         [0009]    A method according to the present invention preferably includes the steps of providing a sheet of web material having a first, preprinted side and an oppositely disposed second side along a web material path. One of the first side and the second side of the web material is preferably provided with at least one web indicia. A web sensor is preferably provided for sensing the at least one web indicia mark on the web material. 
         [0010]    Next, a rotary cutting roller is provided having a first end surface, a second end surface, and a circumferential surface with at least one indicia on the first end surface and at least one cutting knife on the circumferential surface, the cutting knife corresponding to a predetermined die cutting configuration. The cutting knife extends radially from the circumferential surface to a predetermined height. The rotary cutting roller operates in cooperating rotational movement with an anvil roller. An end sensor is provided for sensing the at least one indicia on the first end surface of the rotary cutting roller. An encoder is also provided for sensing anvil roller rotational movement. The web material is then moved toward a nip between the rotary cutting roller and anvil roller whereby a predetermined die cutting configuration is cut in the laminated web material. A processor receives and processes data from the web sensor, the end sensor, and the encoder and adjusts the rotational movement of the rotary cutting roller to ensure proper placement of the predetermined die cutting configurations. 
         [0011]    Additionally, an overdriven lower tension roller and an upper nip roller are preferably provided for receiving the cut web material. The overdriven lower tension roller and the upper nip roller provide a continuous tension on the web material between the overdriven lower tension roller and the upper nip roller and the rotary cutting roller and anvil roller. A take-up spindle may then be provided for receiving a take-up spool, where the take-up spool is arranged to receive cut web material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a side representation of an apparatus according to the present invention and showing web travel therethrough. 
           [0013]      FIG. 1A  is a view similar to that of  FIG. 1 , but showing an alternative rotary cutting roller, having a slightly larger diameter than that illustrated in  FIG. 1 . 
           [0014]      FIG. 1B  is a fragmentary representation of an apparatus similar to that of  FIGS. 1 and 1A , but showing an alternative overdriven lower tension roller, having a slightly larger diameter than that illustrated in  FIGS. 1 and 1A . 
           [0015]      FIG. 2  is a schematic view illustrating the general relationship of the rotary cutting roller, anvil roller, sensing devices, and rotary cutting roller driving means. 
           [0016]      FIG. 3  is a perspective view of a rotary cutting roller and, anvil roller with sensors and encoder according to the present invention. 
           [0017]      FIGS. 4A-4C  are perspective views of rotary cutting rollers according to the present invention and showing indicia on a first end surface thereof. 
           [0018]      FIG. 5  is a fragmentary end view of the apparatus of the present invention and showing cut, laminated web material in relation to the upper nip roller and overdriven lower tension roller. 
           [0019]      FIG. 6  is a sectional view of the overdriven lower tension roller shown in  FIG. 5 , and taken along lines  6 - 6  thereof. 
           [0020]      FIG. 7A  is a partial side plan view of the preferred web material as shown in  FIG. 9 . 
           [0021]      FIG. 7B  is a partial side plan view of the web material of  FIG. 7A , including a laminating layer, as shown in  FIG. 9 . 
           [0022]      FIG. 7C  is a partial side plan view of the laminated web material of  FIG. 7B , showing the excess laminating material and web material removed after the die cutting process, as shown in  FIG. 10 . 
           [0023]      FIG. 7D  is a partial side plan view of the excess laminating material and web material of  FIG. 7B , as shown in  FIG. 10 . 
           [0024]      FIG. 8A  is a side view of an alternative web feed assembly, showing the upper and lower rocker rollers in a first predetermined position. 
           [0025]      FIG. 8B  is a side view of the alternative web feed assembly of  FIG. 8A  showing the upper and lower rocker rollers in a second predetermined position. 
           [0026]      FIG. 9  is a side view of the infeed and laminating assembly of the apparatus of  FIG. 1 . 
           [0027]      FIG. 10  is a detailed side view of the rotary cutting assembly of the apparatus of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention. 
         [0029]    Turning now to the drawings, in which like reference numerals refer to corresponding elements throughout the views, attention is first directed to  FIG. 1  illustrating a side plan view of the apparatus  10  with the control panel (not shown) removed so that the various components of the apparatus  10  may be better seen. 
         [0030]    The apparatus  10  preferably includes a web feed spindle  20  for carrying spooled, continuous, preprinted web material  22  of the type to be used with the present invention, and a laminating spindle  24  for receiving spooled laminating material  26  of the type to be used with the present invention. As may be seen particularly in  FIG. 1 , a stepper motor  94  is preferably arranged to provide power to differential drive  16  (shown in phantom in these views). Gearboxes  15 ,  17  are engaged to the differential drive  16  by way of shaft  19  (shown in phantom). A drive motor  14  is preferably arranged to provide power to drive belt  18  (shown in phantom), which engages shaft  19 . 
         [0031]    As best seen in  FIGS. 7A through 7D , web material  22 , is generally described as preferably having a first side  25  and an oppositely disposed second side  27 . The web material  22  preferably includes a releasable liner material  21  located adjacent the second side  27 . Web material  22  preferably includes an adhesive (not shown) on the second side  27 . It is to be understood that web material  22  does not require the releasable liner material  21 . Web material  22  preferably is adapted to include preapplied longitudinally spaced web indicia  12 . The web feed spindle  20  is arranged to facilitate web material  22  feed into the apparatus  10 . 
         [0032]    Referring to  FIGS. 8A and 8B , alternatively, the apparatus  10  may include a web feed assembly  80 . The web feed assembly  80  preferably includes a clutched roller  82  and a wrap idler  84 , and allows the apparatus  10  to receive preprinted web material  22  from a printer  90  or other conventional web supply means. The web feed assembly  80  further preferably includes an upper rocker roller  86  and a lower rocker roller  88  adapted to shut off the apparatus  10  when the printer  90  or other web supply means stops providing preprinted web material  22 . As can be seen in  FIG. 8B , the upper and lower rocker rollers  86 ,  88  may rotate in the direction shown to a predetermined position when web material  22  no longer provides sufficient tension to maintain the upper and lower rocker rollers  86 ,  88  in a first predetermined position as seen in  FIG. 8A . When the upper and lower rocker rollers  86 ,  88  rotate, a switch (not shown) may be activated to remove power to the apparatus  10 . 
         [0033]    Referring to  FIG. 1 , the laminating material may include a backing material  28 , with backing material take-up spindle  30  being arranged to receive and wind up backing material  28  once the laminating material has been removed. Alternatively, the laminating material  26  may be an adhesive-backed material without backing material. 
         [0034]    As further seen in the Figures and particularly  FIGS. 2 and 3 , the present invention further includes a novel rotary cutting assembly  31 . The rotary cutting assembly  31  is adapted to receive laminated web material  22   a  for die cutting. As seen, the cutting assembly  31  preferably includes a rotary cutting roller  38  having at least one cutting knife or edge  40  located on its circumferential surface  39 . The cutting knife  40  has a predetermined die cutting configuration corresponding to the cut desired. The cutting knife  40  extends radially from the circumferential surface to a predetermined height H (see  FIG. 7C ), allowing the cutting knife  40  to cut a range of layers of the web material  22 , in a variety of applications, ranging from all the web layers to none of the web layers. It is to be noted that any number or shape of cutting knifes  40  may be used, including open ended, such as a line or zig-zag pattern, or closed configurations as seen for example in  FIGS. 4A-4C . As may be further seen in FIGS.  3  and  4 A- 4 C, the rotary cutting roller  38  preferably includes a central shaft  42  and a first end surface  44   a  and a second end surface  44   b . First end surface  44   a  preferably includes at least one indicia  46 . Indicia  46  may be engraved or attached on first end surface  44   a  or alternatively, may be printed on paper or other suitable material and affixed to first end surface  44   a  as seen in  FIG. 4B . The preferred method of applying indicia  46  to the first end surface  44   a  is engraving to minimize the tendency of alternative applications to shift or fall off over time. As seen particularly in  FIG. 4A-4C , the number and placement of indicia  46  may correspond to the number and placement of repeat cutting knifes  40 . For example,  FIG. 4B  illustrates a rotary cutting roller  38  having four repeat rows of cutting knifes  40 , with four indicia marks  46  corresponding to a first edge  47  of each row, although it is to be understood that the indicia  46  may correspond to any predetermined location of the rotary cutting roller  38 . 
         [0035]    As seen in  FIGS. 2 and 3 , the rotary cutting assembly  31  preferably further includes an end sensor  34 . The end sensor  34  is adapted to detect the indicia pattern  46  on the preferred first end surface  44   a  as the rotary cutting roller  38  rotates on shaft  42 . This arrangement is preferred over known arrangements, which are typically arranged to detect markings on circumferential surfaces. Sensors in known arrangements must be moved relative to every cutting roller diameter. The present novel arrangement allows the end sensor  34  to be fixed and able to read indicia  46  on rotary cutting roller  38  regardless of the diameter of rotary cutting roller  38 . As can be seen in  FIG. 1 , and by way of non-limiting example, a rotary cutting roller  38 ′ is shown in dashed lines, with a diameter greater than that of rotary cutting roller  38 . The positioning of end sensor  34  is unaffected by the change in diameter from rotary cutting roller  38  to rotary cutting roller  38 ′. End sensor  34  remains in position to detect the indicia  46  on end surface  44   a  as the rotary cutting roller  38  or  38 ′ rotates on shaft  42 . 
         [0036]    As may be seen particularly in the view of  FIG. 3 , the rotary cutting assembly  31  further preferably includes a web indicia sensor  32 , which is adapted to detect web indicia  12  on the web material  22   a  as it advances toward the rotary cutting roller  38 . The rotary cutting assembly  31  further includes an anvil roller  48  in cooperating rotational movement with the rotary cutting roller  38 . The rotary cutting roller  38  and the anvil roller  48  being in rotational contact to provide a nip  50  to receive laminated web material  22   a . The rotary cutting roller  38  and anvil roller  48  rotate in opposite directions such that the web material  22   a  is drawn into the nip  50  upon contact with the rotary cutting roller  38 . Preferably, the rotary cutting roller  38  is configured to substantially the height needed to cut the web material  22   a  without cutting the releasable liner material  21  (see  FIG. 7A through 7D  and  FIG. 10 ), although it is to be understood that the cutting knife  40  may be of any predetermined height H necessary to cut as many layers of a web material as required by the user. 
         [0037]    As may be further seen in  FIGS. 2 and 3 , the rotary cutting assembly  31  further preferably includes an encoder  52 . Encoder  52  is coupled to the anvil roller  48  and detects incremental rotational movement of the anvil roller  48 . The encoder  52 , along with web sensor  32  and end sensor  34  are further in communicative arrangement with processor  54  (see schematic view of  FIG. 2 ). The processor  54  is preferably in communication with the stepper motor  94 . The stepper motor  94  allows adjustment in rotational speed of the anvil roller  48  and rotary cutting roller  38  thereby maintaining alignment of the rotary cutting roller  38  relative to the web material  22   a  to be cut. 
         [0038]    As seen in  FIG. 1 , the apparatus  10  of the present invention further preferably includes an infeed and laminating assembly  60  for applying the laminating material  26  to the preprinted web  22 . As seen, the infeed and laminating assembly  60  preferably includes a drive roller  62  and a pressure roller  64 . The infeed and laminating assembly  60  further may include drive means such as a gear box  15  or other conventional means for controlling rotational movement of the drive roller  62 , along with a tension roller  65  adapted to maintain tension on the preprinted web material  22  prior to applying the laminating material  26 . Preceding the tension roller  65  may be a guide roller  72  to guide the web material  22  into the infeed and laminating assembly  60 . 
         [0039]    As seen in  FIGS. 1 and 5 , the apparatus  10  of the present invention further preferably includes a take-up assembly  55  for taking up cut web material  22   b  and maintaining proper tension of the web material  22   b  throughout its travel from the rotary cutting assembly  31 . The take-up assembly  55  preferably includes a take-up spindle  56  for receiving spooled cut web material  22   b , an overdriven lower tension roller  58 , an, upper nip roller  59 , and drive means such as a gearbox  17  or other conventional means for controlling rotational movement of the overdriven lower tension roller  58 . An idler roller  70  may support the web material  22   b  preceding a nip  74  between the overdriven lower tension roller  58  and the upper nip roller  59 . Preceding the take-up spindle  56  may be a guide roller  72  to guide the web material  22   b  onto the take-up spindle  56 . Alternatively, laminated and cut web material  22   b  may be fed into a folding and stacking apparatus (not shown) or other conventional post laminating and cutting operation. The tension roller  58  is preferably of a larger diameter than the anvil roller  48  thereby creating proper tensioning of the cut web material  22   b  between the anvil roller  48  and the tension roller  58 . The overdriven lower tension roller  58  is further adapted to slip a predetermined amount with every revolution. As seen particularly in  FIG. 6 , rotational slippage of the tension roller  58  is controlled due to end pressure exerted by spring biasing means  66 , wherein the spring biasing means  66  is preferably a helical spring. The tension roller  58  is further provided with a shaft  62  having a sleeve  68  circumjacent to the shaft  62 , the shaft being supported by bearings  79 . The tension roller  58  preferably includes laterally spaced oppositely disposed end caps  69  mating with respective ends of the sleeve  68 , with oil washers  76  positioned therebetween. End caps  69  may be secured by way of conventional means such as the set screws  75  shown, and positioned within at least one key way  77 . A bushing  78  may also be positioned between the sleeve  68  and the shaft  62 . 
         [0040]    As seen in  FIGS. 1 and 7A  through  7 D, spooled web material  22  may be threaded through the apparatus  10  prior to commencement of the laminating and cutting processes. The preprinted web material  22  is positioned in the apparatus  10  such that it is guided by guide roller  72  and tension roller  65  into nip  61  formed between drive roller  62  and pressure roller  64 , wherein if desired laminating material  26  may be applied to the web material  22 . Thereafter, the laminating material  26  having been applied to the web material  22 , the laminated web material  22   a  continues past idler roller  70  and sensor  32  and into nip  50 . The nip  50  is preferably provided by the anvil roller  48  and rotary cutting roller  38 . As mentioned previously, the anvil roller  48  is preferably driven by differential drive motor  16  by way of stepper motor  94 . The anvil roller  48  and rotary cutting roller  38  are designed to pull the laminated web material  22   a  through the nip  50  for cutting. Excess laminated web material  22   c  continues past guide roller  72  and is preferably received onto a take-up spindle  29 . Laminated and cut web material  22   b  proceeds towards take-up assembly  55  and continues past idler roller  70  and into nip  74 . The nip  74  is preferably provided by the overdriven lower tension roller  58  and upper nip roller  59 . Laminated and cut web material  22   b  preferably continues through nip  74  and past guide roller  72 , and may be received on take up spindle  56 . 
         [0041]    Referring to  FIGS. 8A and 8B , alternatively, the preprinted web material  22  may be positioned in the apparatus  10  such that it is first positioned in the web feed assembly  80 . As may be seen particularly in  FIG. 8A , web material  22  may be supplied by a printer  90  or other conventional web producing means. The preprinted web material  22  may be guided by guide roller  72  and idler roller  70  of the web feed assembly  80 . The web material  22  may then be guided by upper rocker roller  86  and lower rocker roller  88 . Preferably, the web material  22  is next fed between a wrap idler  84  and a clutched roller  82  in order to supply properly tensioned web material  22  to the apparatus  10 . 
         [0042]    The upper rocker roller  86  and the lower rocker roller  88  preferably function as a power switch to apparatus  10 . When web material  22  is present within the web feed assembly  80 , as seen in  FIG. 8A , the upper and lower rocker rollers  86 ,  88  are maintained in a predetermined position as shown, and power may be allowed to the apparatus  10 . When web material  22  is no longer supplied to the web feed assembly  80  and tension from web material  22  is no longer applied to the upper and lower roller rockers  86 ,  88 , the roller rockers  86 ,  88  may rotate and take on a position as shown in  FIG. 8B . In this position, power may be disconnected to the apparatus  10  by way of a switch (not shown). 
         [0043]    Referring to  FIGS. 1 and 3 , as earlier mentioned, the laminated web material  22   a  is pulled through the apparatus  10  and past web sensor  32 . The web material  22   a  preferably includes web indicia  12 . The web sensor  32  is arranged to detect the web indicia  12  so that the apparatus  10  may determine presence and incremental movement of the laminated web material  22   a  as it advances toward the nip  50 . Additionally, end sensor  34  determines the rotational speed of the rotary cutting roller  38  to thereby allow precise cut alignment. As seen in  FIG. 2 , in order to achieve precision cuts, the web sensor  32  and the end sensor  34 , along with the encoder  52 , are preferably connected to the processor  54 , which adjusts the speed of the rotary cutting roller  38  and anvil roller  48  via stepper motor  94  connected to the differential drive unit  16 . 
         [0044]    Additionally, the present invention may be described as a method for die cutting and laminating. The steps of the method of die cutting and laminating according to the present invention are generally described. Referring generally to the Figures, and specifically to  FIGS. 3 and 9 , a web material  22  having a first preprinted side  25  and an oppositely disposed second side  27  is provided to the apparatus  10  along a web material path and toward previously described infeed and laminating assembly  60 . One of the first side  25  and the second side  27  of the web material  22  may be provided with at least one web indicia  12 . A drive roller  62  and pressure roller  64  are provided and operate in cooperating rotational movement, the drive roller  62  preferably being driven by a gear box  15  for controlling rotational movement. A tension roller  65  is positioned for tensioning web material  22  preceding a nip  61  formed between the drive roller  62  and pressure roller  64 . A laminating spindle  24  is provided for receiving spooled laminating material  26  of the type to be used with the present invention. A laminating material  26  preferably is next provided to the nip  61  formed between the drive roller  62  and pressure roller  64 . The laminating material  26  is preferably provided having an adhesive coated side. The adhesive coated side of the laminating material  26  is applied to the first side  25  of the web material  22  whereby a laminated web material  22   a  is formed. 
         [0045]    Referring to  FIGS. 1 and 3 , a web sensor  32  is provided for sensing the at least one web indicia  12  on the web material  22   a . The laminated web material  22   a  is then moved past the web sensor  32 . Next, a rotary cutting roller  38  is provided having a first end surface  44   a , a second end surface  44   b , and a circumferential surface  39 , with at least one indicia  46  on the first end surface  44   a  and at least one cutting knife  40  on the circumferential surface  39 , corresponding to a predetermined die cut configuration. The rotary cutting roller  38  operates in cooperating rotational movement with an anvil roller  48 . An end sensor  34  is preferably provided for sensing the at least one indicia  46  on the first end surface  44   a  of the rotary cutting roller  38 . An encoder  52  is also preferably provided for sensing anvil roller  48  rotational movement. The web material  22   a  is then moved toward a nip  50  between the rotary cutting roller  38  and anvil roller  48  whereby a die cutting configuration is cut in the laminated web material  22   b . The anvil roller  48  is preferably provided with a differential drive unit  16  controlled by a stepper motor  94 , and further including a drive means such as a belt, shaft, or gear  36  for interfacing with the rotary cutting roller  38 . The rotary cutting roller  38  is also further provided with a drive means such as a belt, shaft, or gear  37  for interfacing with the anvil roller gear  36 . Referring to  FIG. 2 , a processor  54  is provided to receive and process data from the web sensor  32 , the end sensor  34 , and the encoder  52 , the processor  54  being in communicative arrangement with the stepper motor  94 , whereby the stepper motor  94  drives the differential drive unit  16  and is adapted to adjust the rotational movement of the anvil roller  48  and preferably the rotary cutting roller  38  to ensure proper placement of the predetermined die cutting configurations. A waste take-up spindle  29  is preferably provided for receiving laminated web material waste  22   c  after cutting (see  FIG. 1 ). 
         [0046]    Still referring to  FIG. 1 , an overdriven lower tension roller  58  and an upper nip roller  59  may be provided, the overdriven lower tension roller  58  and the upper nip roller  59  providing a nip  74  for receiving the cut, laminated web material  22   b . The cut, laminated web material  22   b  is moved into the nip  74  formed between the overdriven lower tension roller  58  and the upper nip roller  59  whereby the overdriven lower tension roller  58  and the upper nip roller  59  provide a continuous tension on the web material  22   b  between the overdriven lower tension roller  58  and the upper nip roller  59  and the rotary cutting roller  38  and anvil roller  39 . A take-up spindle  56  may then be provided for receiving a take-up spool, where the take-up spool is arranged to receive cut web material  22   b.    
         [0047]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.