Method for manufacturing discrete elements

Claim 1

A method for manufacturing discrete elements, said discrete elements carried by a carrier sheet and wherein the discrete elements manufactured by the method are arranged in substantial alignment on the carrier sheet, each discrete element to be manufactured having a predetermined periphery along which severing is to be performed, said discrete elements subsequently to be dispensed from the carrier sheet during movement of the carrier sheet in a predetermined direction of movement and the discrete elements each having leading and trailing edges relative to said direction of movvement of the carrier sheet, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along first and second paths of travel which are initially spaced from each other and thereafter are traveled with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed substantially in facing engagement; B. applying adhesive on one of said mating surfaces, prior to the carrier sheet and face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet, each of said zones being recessed from the entire periphery thereof; and C. severing the face sheet, while the carrier sheet and face sheet are disposed substantially in facing engagement, individually about the periphery of each of the discrete elements whereby no contact is made with the adhesive and the discrete elements are carried by said carrier sheet arranged in substantial alignment thereon with adhesive interposed between each discrete element and the carrier sheet and recessed from the periphery thereof.

Claim 2

A method for manufacturing discrete elements, said discrete elements carried by a carrier sheet and wherein the discrete elements manufactured by the method are arranged in substantial alignment on the carrier sheet, each discrete element to be manufactured having a predetermined periphery along which severing is to be performed, said discrete elements subsequently to be dispensed from the carrier sheet during movement of the carrier sheet in a predetermined direction of movement and the discrete elements each having leading and trailing edges relative to said direction of movvement of the carrier sheet, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along first and second paths of travel which are initially spaced from each other and thereafter are traveled with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed substantially in facing engagement; B. applying adhesive on one of said mating surfaces, prior to the carrier sheet and face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet, each of said zones being recessed from the entire periphery thereof; and C. severing the face sheet, while the carrier sheet and face sheet are disposed substantially in facing engagement, individually about the periphery of each of the discrete elements whereby no contact is made with the adhesive and the discrete elements are carried by said carrier sheet arranged in substantial alignment thereon with adhesive interposed between each discrete element and the carrier sheet and recessed from the periphery thereof.

Claim 3

A method for manufacturing discrete elements, each of said discrete elements in a manufactured form having predetermined lateral edges and leading and trailing edges together forming a periphery for each discrete element, carried by a carrier sheet, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along first and second paths of travel which are initially spaced from each other and thereafter are entrained with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed in substantially facing engagement; B. applying adhesive intermittently on one of said mating surfaces, prior to the carrier sheet and face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet, each of said zones being recessed from said lateral edges and from said leading and trailing edges of the discrete element to be manufactured so that each of said zones of adhesive is recessed from the entire periphery of the discrete element thereof to be manufactured; and C. severing the face sheet, while the carrier sheet and the face sheet are disposed substantially in facing engagement, along the lateral edges and leading and trailing edges of each discrete element to be manufactured and thus about the entire periphery of each discrete element and in spaced relation to the discrete zone of adhesive of each discrete element so as to prevent embedding of the adhesive in the carrier sheet as a result of severing and preventing migration of the adhesive over time beyond the periphery of each respective discrete element.

Claim 4

A method for manufacturing discrete elements, each of said discrete elements in a manufactured form having predetermined lateral edges and leading and trailing edges together forming a periphery for each discrete element, carried by a carrier sheet, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along first and second paths of travel which are initially spaced from each other and thereafter are entrained with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed in substantially facing engagement; B. applying adhesive intermittently on one of said mating surfaces, prior to the carrier sheet and face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet, each of said zones being recessed from said lateral edges and from said leading and trailing edges of the discrete element to be manufactured so that each of said zones of adhesive is recessed from the entire periphery of the discrete element thereof to be manufactured; and C. severing the face sheet, while the carrier sheet and the face sheet are disposed substantially in facing engagement, along the lateral edges and leading and trailing edges of each discrete element to be manufactured and thus about the entire periphery of each discrete element and in spaced relation to the discrete zone of adhesive of each discrete element so as to prevent embedding of the adhesive in the carrier sheet as a result of severing and preventing migration of the adhesive over time beyond the periphery of each respective discrete element.

Claim 5

A method for manufacturing discrete elements, said discrete elements carried by a carrier sheet, each of said discrete elements in a manufactured form having a predetermined periphery, said discrete elements subsequently to be dispensed from the carrier sheet during movement of the carrier sheet in a predetermined direction of movement, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along paths of travel wherein said sheets are first spaced from each other and are thereafter traveled with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed substantially in facing engagement; B. applying adhesive on one of said mating surface, prior to the carrier sheet and the face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet and recessed from the periphery of each of said discrete elements to be manufactured and said zones of the respective discrete elements to be manufactured being spaced from each other in said predetermined direction of movement; and C. severing the face sheet, while the carrier sheet and face sheet are disposed substantially in facing engagement, individually about the periphery of each of the discrete elements whereby the discrete elements are carried by said carrier sheet substantially without adhesive extending between adjacent discrete elements in said predetermined direction of movement of the carrier sheet.

Claim 6

A method for manufacturing discrete elements, said discrete elements carried by a carrier sheet, each of said discrete elements in a manufactured form having a predetermined periphery, said discrete elements subsequently to be dispensed from the carrier sheet during movement of the carrier sheet in a predetermined direction of movement, the method comprising: A. passing the carrier sheet and a face sheet from which said discrete elements are to be manufactured along paths of travel wherein said sheets are first spaced from each other and are thereafter traveled with each other with corresponding mating surfaces of the carrier sheet and the face sheet disposed substantially in facing engagement; B. applying adhesive on one of said mating surface, prior to the carrier sheet and the face sheet being disposed substantially in facing engagement, in discrete zones individual to the discrete elements to be manufactured from the face sheet and recessed from the periphery of each of said discrete elements to be manufactured and said zones of the respective discrete elements to be manufactured being spaced from each other in said predetermined direction of movement; and C. severing the face sheet, while the carrier sheet and face sheet are disposed substantially in facing engagement, individually about the periphery of each of the discrete elements whereby the discrete elements are carried by said carrier sheet substantially without adhesive extending between adjacent discrete elements in said predetermined direction of movement of the carrier sheet.

Claim 7

A method for manufacturing discrete elements from two sheets having longitudinal dimensions wherein the discrete elements manufactured by the method are carried by one of said two sheets and are dispensed therefrom during movement along a dispensing path of travel substantially in alignment with said longitudinal dimensions, the method comprising: A. applying adhesive on one of said two sheets in substantially intermittent successive zones of adhesive along the longitudinal dimension of the sheet wherein adjoining zones along said longitudinal dimension have portions spaced from each other along the longitudinal dimension of the sheet to form substantially adhesive free areas between said portions of adjoining zones of adhesive along said longitudinal dimension of the sheet; B. placing the two sheets in engagement in substantial longitudinal alignment so that the zones of adhesive resist separation of the two sheets; and C. severing one of the two sheets along courses substantially corrolated with said zones of adhesive to form the discrete elements, carried by the other of the two sheets, having edges substantially adjacent to said substantially adhesive free areas whereby the portions of the sheet about the discrete elements can be removed from about said discrete elements and from said other of the two sheets without substantial adhesive resistance.

Claim 8

A method for manufacturing discrete elements from two sheets having longitudinal dimensions wherein the discrete elements manufactured by the method are carried by one of said two sheets and are dispensed therefrom during movement along a dispensing path of travel substantially in alignment with said longitudinal dimensions, the method comprising: A. applying adhesive on one of said two sheets in substantially intermittent successive zones of adhesive along the longitudinal dimension of the sheet wherein adjoining zones along said longitudinal dimension have portions spaced from each other along the longitudinal dimension of the sheet to form substantially adhesive free areas between said portions of adjoining zones of adhesive along said longitudinal dimension of the sheet; B. placing the two sheets in engagement in substantial longitudinal alignment so that the zones of adhesive resist separation of the two sheets; and C. severing one of the two sheets along courses substantially corrolated with said zones of adhesive to form the discrete elements, carried by the other of the two sheets, having edges substantially adjacent to said substantially adhesive free areas whereby the portions of the sheet about the discrete elements can be removed from about said discrete elements and from said other of the two sheets without substantial adhesive resistance.