Patent ID: 7850884

Claim:
A method of forming a compacted disk, comprising the steps of: a) inserting a mixture of material into a cavity running through a die casing, b) positioning a first plunger in alignment with said cavity so that said first plunger may engage said mixture of material when said first plunger is moved downwardly into said cavity, c) positioning a second plunger in alignment with said cavity so that said second plunger may engage said mixture of material when said second plunger is moved upwardly into said cavity, d) positioning a flexible polymeric sleeve circumferentially around at least a portion of the outer surface of said first plunger so that said sleeve lies flush against at least a portion of the outer surface of said plunger, thereby hugging the outer surface of said plunger, e) moving said first plunger downwardly into said cavity so that said mixture of material is compacted against a portion of said second plunger thereby forming a compacted disk, wherein as said first plunger moves downwardly into said cavity to compact said mixture of material, a major portion of said polymeric sleeve flexes outwardly to bulge away from the outer surface of said first plunger, f) ejecting said compacted disk from said cavity by moving said first and second plungers upwardly within said cavity, wherein as said first plunger moves upwardly said sleeve reflexes to lie flush against the outer surface of said first plunger thereby hugging the outer surface of said first plunger, wherein said compacted disk contacts at least a portion of said reflexed sleeve as said compacted disk is being ejected from said cavity, and wherein said contact between said compacted disk and said reflexed sleeve prevents a web of flashed material from forming and attaching to said compacted disk as the disk is being ejected from the cavity.