A punching method and punching device for square frame type foam products

Abstract

The present invention relates to a punching method for a square frame type foam product, comprising the following steps: using a primary punching tool to cut the foam raw material into N strips of foam intermediate products whose width meets the product requirements, rolling up the strips of foam intermediate products to obtain intermediate product rolls; installing N intermediate product rolls on the unwinding roller of a laminating machine, and setting the intervals between each intermediate product roll at an equal interval of L; using a laminating machine to laminate each strip of foam intermediate product onto a material strip release film; using a secondary punching tool to process a long strip structure extending along the width direction of the material strip on the continuous strip of foam intermediate products, removing waste at the position of the long strip structure, and obtaining a square frame type foam product arranged in a matrix shape. Compared with the prior art, the present invention has the advantages of convenient operation, high processing accuracy, and saving foam.

Description

Technical Field

[0001] The invention relates to the field of die-cutting technology, and in particular to a die-cutting method and a die-cutting device for a square frame type foam product. Background Art

[0002] Foam products mainly play a cushioning role. In electronic products, there are usually foam die-cut parts, but the price of foam is relatively expensive, usually several hundred yuan per square meter, and the requirements for the products made are also very high, generally with a tolerance of ±0.1MM. Figure 1 The foam product in the box shown is 7*3 in size with a tolerance of ±0.1MM. For the processing of square foam products, the following methods are usually used: Figure 2 The knife die shown has a rectangular frame-shaped knife line that matches the contour of the foam product. As can be seen from the two figures above, the total width of the knife die is 23MM. When making it, we need to give the width of the foam and glue to 31MM, and there should be a 4MM margin on each edge. Because this margin is too small, there will be tolerances when fitting and cutting materials, and there may be a shortage of materials. If the margin is too small, there will be a risk of breakage when arranging the contour waste. However, if a larger margin is maintained, the larger the waste area, the more material cost will be wasted because the price of foam is relatively expensive. If you want to save material costs, you need to find a way to reduce the waste area, but at the same time ensure that the product tolerance meets the requirements. Summary of the invention

[0003] The purpose of the present invention is to provide a punching method and a punching device for a square frame type foam product in order to overcome the defect of foam waste in the above-mentioned prior art.

[0004] The purpose of the present invention can be achieved by the following technical solutions:

[0005] A punching method for a square frame type foam product comprises the following steps:

[0006] (S-1) laminating the foam raw material, the double-sided adhesive tape, the auxiliary release film, and the auxiliary protective film in sequence, using a single punching tool to punch the material strip from one side of the foam raw material, punching the blade to the auxiliary release film, and dividing the foam raw material into N strips of foam intermediate products with a width that meets product requirements, the strip of foam intermediate products comprising a foam layer, a double-sided adhesive layer, and an auxiliary release film layer; discharging waste, and rolling up each strip of foam intermediate product to obtain an intermediate product roll;

[0007] (S-2) Installing the obtained N intermediate product rolls onto a discharge roller, and equidistantly spacing the intermediate product rolls at a spacing of L; using the above-mentioned foam raw material to make N-1 strips of partition foam with a width of L, wrapping a layer of partition foam on the laminating roller of a laminating machine, and the spacing of the partition foam is the width of the strip-shaped foam intermediate product, and the two sides of each partition foam are the placement positions of the strip-shaped foam intermediate product; each strip-shaped foam intermediate product is discharged from the discharge roller, and is laminated on the material strip release film through the placement positions of the strip-shaped foam intermediate product of the laminating roller;

[0008] (S-3) A secondary punching tool is used to punch out the material strip from one side of the foam raw material, and the blade punches to the double-sided adhesive layer. A long strip structure extending along the width direction of the material strip is processed on the continuous strip foam intermediate product, and waste materials at the position of the long strip structure are removed to obtain a square-type foam product arranged in a matrix shape.

[0009] The working principle of the present invention is:

[0010] First, the whole piece of foam raw material is cut into strips of foam intermediate products with the same width as the final foam product through a primary punching tool, and then the strips of foam intermediate products are bonded to the material belt release film through special unloading rollers and bonding rollers, and then the strips of foam intermediate products are cut through a secondary punching tool. Along the feeding direction of the foam raw material, only the foam at the edge of the foam raw material belongs to the punching waste, which greatly reduces the foam waste and saves raw materials. At the same time, the edges of the punching waste on both sides are straight lines, and the punching waste on both sides is easier to discharge, so the width of the punching waste on both sides can be smaller, which is also conducive to reducing foam waste.

[0011] The difficulty of the two punching is how to ensure the processing accuracy of the product. When cutting the foam, the present invention adopts a slitting machine instead of a stripping machine or a slitting machine, which is conducive to ensuring that the width of the product meets the requirements; during the second punching, it is only necessary to ensure that the strip foam intermediate product is bonded along the feeding direction of the material belt. The use of a bonding roller with a separated foam can ensure that the product is bonded to the material belt release film along the feeding direction of the material belt. During the second punching, as long as the secondary punching tool is accurately positioned, the product that meets the requirements can be accurately processed.

[0012] Therefore, the method of the present invention not only ensures the processing accuracy of the product, but also greatly reduces foam waste, saves raw materials and improves economic benefits.

[0013] Furthermore, in step (S-1), the primary punching tool continuously punches on the material strip to obtain a strip-shaped foam intermediate product, and the patterns obtained by two adjacent punchings are connected end to end.

[0014] Furthermore, in step (S-1), the material between the outermost dividing line and the edge of the foam raw material close to the dividing line obtained by punching on the material strip is the punching waste, and the width of the punching waste is 2.5 to 3 mm.

[0015] In the present invention, the punched waste is in strip shape, which is easy to discharge, so the width can be less than 3 mm.

[0016] Furthermore, in step (S-2), L is 1.5 to 2.5 mm, preferably 2.0 mm.

[0017] A punching device for a frame-type foam product comprises a primary punching tool, an edge waste winding roller, a strip foam intermediate product winding roller, an auxiliary protective film winding roller, a laminating machine, a discharge roller, and a secondary punching tool which are arranged in sequence; the primary punching tool is provided with a linear cutting line for dividing the foam raw material into N strip foam intermediate products with a width that meets product requirements, a first positioning hole line and a first positioning pin arranged on both sides of the linear cutting line; the secondary punching tool is provided with a long strip line for dividing the strip foam intermediate product into a single frame-type foam product, a second positioning hole line and a second positioning pin arranged on both sides of the long strip line.

[0018] Furthermore, the long strip knife line is a rectangular frame structure.

[0019] Furthermore, the long strip knife line of the secondary punching tool is a self-priming knife die, and during the punching process, the waste obtained by punching the long strip knife line is sucked into the knife cavity of the secondary punching tool.

[0020] By using a self-priming die, the discontinuous strip-shaped die-cutting waste produced by punching is easily discharged, which is beneficial to improving processing efficiency. The self-priming die is an existing structure and does not belong to the invention point of the present invention, so it will not be described in detail here.

[0021] Furthermore, the first positioning hole cut line and the first positioning pin are each provided with one, and a connecting line of the first positioning hole cut line and the first positioning pin is along the feeding direction of the material strip.

[0022] Furthermore, the second positioning hole cut line is provided with one, the second positioning pins are provided with two, and the connecting line of the second positioning hole cut line and the second positioning pins is along the feeding direction of the material strip.

[0023] Furthermore, the first positioning hole cut line and the second positioning hole cut line are both C-shaped hole cut lines. With the C-shaped hole cut line, the punching waste in the first positioning hole cut line remains connected to the material strip body, so there is no need to discharge the waste, which is conducive to improving processing efficiency.

[0024] Compared with the prior art, the present invention has the following advantages:

[0025] (1) The present invention changes the punching process and greatly reduces the consumption of foam raw materials when processing the same number of products, which is conducive to improving economic benefits;

[0026] (2) When processing the same product, the width of the foam tape is 3mm when the old process is used, while the process of the present invention only requires 21mm, saving 10mm. For example, if the number of products is 1KK, the old process requires about 56 square meters of foam and double-sided tape, while the new process requires about 38 square meters of foam and double-sided tape; based on the single-sided price of 150 yuan for foam and double-sided tape, the foam and double-sided tape can be saved by about 2,700 yuan, and the additional auxiliary materials and labor costs generated when punching and cutting the foam adhesive do not exceed 800 yuan, that is, the comprehensive calculation can save about 20% of the cost;

[0027] (3) The method of the present invention is particularly suitable for expensive foam materials, such as conductive foam, which has a unit price of about RMB 500 per square meter or more, and the cost savings will be even higher. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a structural schematic diagram of a square-type foam product;

[0029] Figure 2 It is a schematic diagram of the structure of the material strip obtained by punching in the prior art;

[0030] Figure 3 A schematic diagram of the punching levels of a punching tool in the prior art;

[0031] Figure 4 It is a schematic diagram of the structure of the device for processing strip-shaped foam intermediate products in the present invention;

[0032] Figure 5 It is a structural schematic diagram of the device for processing a square frame type foam product in the present invention;

[0033] Figure 6 It is a structural schematic diagram of a punching tool;

[0034] Figure 7 It is a schematic diagram of the punching layers of a punching tool;

[0035] Figure 8 It is a schematic diagram of the structure of the material strip obtained by punching once;

[0036] Fig. 9 It is a structural schematic diagram of the secondary punching tool;

[0037] Fig.10 It is a schematic diagram of the punching level of the secondary punching tool;

[0038] Fig.11 It is a schematic diagram of the structure of the material strip obtained by secondary punching;

[0039] Fig.12 It is a structural schematic diagram of the unwinding roller;

[0040] Fig.13 It is a structural schematic diagram of the laminating roller;

[0041] In the figure, 1 is a square-type foam product, 2 is a foam raw material, 3 is a double-sided adhesive tape, 4 is a material strip release film, 5 is an auxiliary protective film, 6 is the edge position of the foam raw material, 7 is a first frame, 8 is a punching material strip, 9 is a primary punching tool, 901 is a linear dividing knife line, 902 is a first positioning hole knife line, 903 is a first positioning pin, 10 is an edge waste winding roller, 11 is a first part of a strip foam intermediate product, 12 is a second part of a strip foam intermediate product, 13 is an auxiliary protective film winding roller, 14 is the second frame, 15 is the strip foam intermediate product, 16 is the unwinding roller, 17 is the laminating machine, 18 is the laminating roller, 19 is the secondary punching tool, 1901 is the long strip knife line, 1902 is the second positioning hole knife line, 1903 is the second positioning pin, 20 is the product material strip winding roller, 21 is the intermediate product roll, 22 is the partition foam, 23 is the auxiliary release film, a is the distance between the edge of the outermost foam product and the edge of the foam raw material, b is the width of the punching waste, and c is the spacing between each intermediate product roll. DETAILED DESCRIPTION

[0042] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several variations and improvements may be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0043] Comparative Example

[0044] A punching method for a square frame type foam product, which is mainly used for processing various frame-shaped foam products, such as Figure 1 As shown, the size of the square-type foam product 1 is 7MM*3MM, and the tolerance is ±0.1MM.

[0045] In the prior art, a punching knife matching the outline of the square-shaped foam product 1 is used to sequentially attach the foam raw material 2, the double-sided adhesive tape 3 and the material release film 4, and the punching knife is used for punching. Figure 3 As shown, the punched strip is Figure 2As shown. The total width of the die cutter is 23MM. When making it, we need to give the width of the foam and glue to 31MM, and the two edges should have a margin of 4MM, that is, the distance a between the edge of the outermost foam product and the edge of the foam raw material is 4MM. If the margin is too small, there will be tolerances when fitting and cutting materials, and there may be a shortage of materials. If the margin is too small, there will be a risk of breakage when arranging the contour waste. Since the price of foam is relatively expensive, the larger the waste area, the more material cost is wasted. If you want to save material costs, you need to find a way to reduce the waste area.

[0046] Example

[0047] A punching device and a punching method for a square frame type foam product, comprising the following steps:

[0048] S-1: The foam raw material 2, the double-sided adhesive tape 3, the auxiliary release film 23, and the auxiliary protective film 5 are sequentially attached, and a punching tool 9 is used to punch the material strip from one side of the foam raw material 2. The punching mode of the punching tool 9 is continuous punching. The patterns obtained by two adjacent punchings are connected end to end. The blade punches to the auxiliary release film 23, and the foam raw material 2 is divided into 5 strips of foam intermediate products 15 with a width that meets the product requirements. The structure of the punching tool 9 is as follows: Figure 6 As shown, the punching level is Figure 7 As shown, the obtained strip structure is as follows Figure 8 As shown in FIG. 1 , the material between the outermost dividing line obtained by punching on the material strip and the edge of the foam raw material 2 close to the dividing line is the punching waste, such as Figure 8 As shown by the edge position 6 of the middle foam raw material and the dividing line of the outermost layer, the width b of the punched waste in this embodiment is 3 mm, and the strip foam intermediate product 15 finally obtained includes foam material, double-sided adhesive and auxiliary release film; after the waste is discharged, each strip foam intermediate product 15 is rolled up to obtain an intermediate product roll 21;

[0049] After one-step punching, the width of the waste material is only 3MM. The width of the product is 3MM, so the distance between the knife lines is also 3MM. One punch and one set or two sets are used, that is, one positioning hole is followed by one or two positioning pins to position the hole, ensuring that the 3MM-wide straight strip punched out has no obvious steps and can meet the product's dimensional tolerance of ±0.1MM. Remove the auxiliary protective film, and roll up the 3MM-wide strip separately for bonding before the next step of punching.

[0050] The device used in this step is as follows Figure 4As shown, it includes a first frame 7, a primary punching cutter 9 arranged on the first frame 7, a waste discharge roller 10, a strip foam intermediate product winding roller, and an auxiliary protective film winding roller 13, wherein the strip foam intermediate product winding roller includes a first portion of strip foam intermediate products 11 and a second portion of strip foam intermediate products 12, the first portion of strip foam intermediate products 11 is two rolls of 3MM width strip foam intermediate products located at even positions, and the second portion of strip foam intermediate products 12 is three rolls of 3MM width strip foam intermediate products located at odd positions, that is, the strip material strips of the first portion of strip foam intermediate products 11 and the second portion of strip foam intermediate products 12 are spaced apart from each other. Figure 6 As shown, the primary punching tool 9 is provided with a linear cutting line 901 for cutting the foam raw material 2 into N strips of foam intermediate products whose width meets the product requirements, a first positioning hole cutting line 902 and a first positioning pin 903 provided on both sides of the linear cutting line 901, one first positioning hole cutting line 902 and one first positioning pin 903 are provided respectively, and the connecting line of the first positioning hole cutting line 902 and the first positioning pin 903 is along the feeding direction of the material strip.

[0051] S-2: The obtained N intermediate product rolls 21 are installed on the discharge roller 16 of the laminating machine 17, and the intermediate product rolls 21 are arranged at equal intervals of L, and the distance L is generally 2.0 mm; the above-mentioned foam raw material 2 is used to make 4 partition foams 22 with a width of 2 mm, and a layer of partition foam 22 is wrapped on the laminating roller 18 of the laminating machine 17, and the spacing of the partition foams 22 is the width of the strip-shaped foam intermediate product 15, and the two sides of each partition foam 22 are the placement positions of the strip-shaped foam intermediate product; each strip-shaped foam intermediate product 15 is discharged from the discharge roller 16, the auxiliary release film is torn off, and then it is laminated on the material belt release film 4 through the placement position of the strip-shaped foam intermediate product of the laminating roller 18;

[0052] S-3: Use a secondary punching tool 19 to punch the material strip from one side of the foam raw material 2, and punch the double-sided adhesive layer with the blade to process a long strip structure extending along the width direction of the material strip on the continuous strip foam intermediate product. The structure of the secondary punching tool 19 is as follows: Fig. 9 As shown, the punching level is Fig.10 As shown, the obtained strip structure is as follows Fig.11 As shown, after excluding the waste at the position of the long strip structure, a square-type foam product 1 arranged in a matrix shape is obtained. The obtained foam product 1 is located on the material strip release film 4 to form a roll product, which can be rolled up by the product material strip winding roller 20.

[0053] The apparatus used in step S-2 and step S-3 is as follows Figure 5As shown, the second frame 14 and the laminating machine 17, the unloading roller 16 and the secondary punching tool 19 are provided on the second frame 14. In order to ensure the laminating accuracy, the structure of the unloading roller 16 is as follows Fig.12 As shown, five intermediate product coils 21 are mounted on the unwinding roller 16, and the spacing c between each intermediate product coil is 2MM. The laminating machine 17 is a pressure roller laminating machine, wherein the structure of the laminating roller 18 is as shown in FIG. Fig.13 As shown, the bonding roller 18 has four partition foams 22 with a width of 2 mm. The interval positions between the partition foams 22 and the side positions of the partition foams 22 on both sides are all placement positions for the strip foam intermediate product. During bonding, the strip foam intermediate product 15 is stuck into the placement position, which is beneficial for the thickness of the partition foams 22 on both sides to limit the direction of the strip foam intermediate product 15 and ensure the bonding direction.

[0054] The secondary punching tool 19 has a structure as follows: Fig. 9 As shown, the secondary punching tool 19 is provided with a long strip knife line 1901 for cutting the strip foam intermediate product into a single frame type foam product 1, a second positioning hole knife line 1902 and a second positioning pin 1903 arranged on both sides of the long strip knife line 1901; the long strip knife line 1901 is a rectangular structure, the second positioning hole knife line 1902 is provided with one, the second positioning pin 1903 is provided with two, and the connecting line of the second positioning hole knife line 1902 and the second positioning pin 1903 is along the feeding direction of the material belt. The long strip knife line 1902 of the secondary punching tool 19 is a self-absorbent knife die. During the punching process, the waste obtained by punching the long strip knife line 1902 is sucked into the knife cavity of the secondary punching tool. The first positioning hole knife line 902 and the second positioning hole knife line 1902 are both C-shaped hole knife lines.

[0055] Compared with the existing process, the process of this embodiment adds a step to repair the width of the foam with glue on the punching machine. For the same number of products, the old process requires a width of 31MM, while the new process only requires 21MM, saving 10MM. Taking this product quantity 1KK as an example, the old process requires the use of about 56 square meters of foam and double-sided tape, and the new process requires the use of about 38 square meters of foam and double-sided tape; based on the single-sided price of 150 yuan for foam and double-sided tape, the foam and double-sided tape can be saved by about 2,700 yuan. The labor costs for the added auxiliary materials and the punching and cutting of the foam adhesive do not exceed 800 yuan, which can save about 20% of the cost. This process can also be used for other foam materials of the same type, such as conductive foam, which has a unit price of about 500 yuan / square meter, and the cost savings will be higher.

[0056] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art may make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A punching method for a square frame type foam product, characterized in that: The punching method is implemented by a punching device, wherein the punching device, The invention comprises a primary punching tool (9), an edge waste winding roller (10), a strip foam intermediate product winding roller, an auxiliary protective film winding roller (13), a laminating machine (17), a material unwinding roller (16), and a secondary punching tool (19) which are arranged in sequence; the primary punching tool (9) is provided with a linear cutting line (901) for cutting the foam raw material (2) into N strip foam intermediate products whose width meets product requirements, a first positioning hole cutting line (902) and a first positioning pin (903) arranged on both sides of the linear cutting line (901); the secondary punching tool (19) is provided with a long strip cutting line (1901) for cutting the strip foam intermediate product into a single frame type foam product (1), a second positioning hole cutting line (1902) and a second positioning pin (1903) arranged on both sides of the long strip cutting line (1901); The punching method comprises the following steps: S-1: laminating the foam raw material (2), the double-sided adhesive tape (3), the auxiliary release film (23), and the auxiliary protective film (5) in sequence, using a single punching tool (9) to punch the material strip from one side of the foam raw material (2), with the blade punching to the auxiliary release film (23), and dividing the foam raw material (2) into N strips of foam intermediate products (15) with a width that meets product requirements, the strips of foam intermediate products (15) comprising foam material, double-sided adhesive tape, and the auxiliary release film; discharging waste, and rolling up each strip of foam intermediate product (15) to obtain an intermediate product roll (21); S-2: The obtained N intermediate product rolls (21) are mounted on a discharge roller (16), and the intermediate product rolls (21) are arranged at equal intervals of L; the foam raw material (2) is used to make N-1 strips of partition foam (22) with a width of L, and a layer of partition foam (22) is wrapped on a laminating roller (18) of a laminating machine (17), and the spacing of the partition foam (22) is the width of the strip-shaped foam intermediate product (15), and the two sides of each partition foam (22) are the placement positions of the strip-shaped foam intermediate product; each strip-shaped foam intermediate product (15) is discharged from the discharge roller (16), the auxiliary release film is torn off, and then the strip-shaped foam intermediate product (15) is laminated on the material strip release film (4) through the placement position of the strip-shaped foam intermediate product of the laminating roller (18); S-3: A secondary punching tool (19) is used to punch a material strip from one side of the foam raw material (2), and the blade punches to the double-sided adhesive layer, and a long strip structure extending along the width direction of the material strip is processed on the continuous strip foam intermediate product, and waste materials at the position of the long strip structure are removed to obtain a square frame type foam product (1) arranged in a matrix shape.

2. A punching method for a square frame type foam product according to claim 1, characterized in that: In step S-1, the primary punching tool (9) continuously punches on the material strip to obtain a strip-shaped foam intermediate product, and the patterns obtained by two adjacent punching operations are connected end to end.

3. A punching method for a square frame type foam product according to claim 1, characterized in that: In step S-1, the material between the outermost dividing line and the edge of the foam raw material (2) close to the dividing line obtained by punching on the material strip is the punching waste, and the width of the punching waste is 2.5-3 mm.

4. A punching method for a square frame type foam product according to claim 1, characterized in that: In step S-2, L is 1.5~2.5mm.

5. A punching method for a square frame type foam product according to claim 1, characterized in that: The long knife line (1901) is a rectangular frame structure.

6. A punching method for a square frame type foam product according to claim 1, characterized in that: The long strip-shaped knife line (1901) of the secondary punching tool (19) is a self-priming knife die, and during the punching process, the waste material punched by the long strip-shaped knife line (1901) is sucked into the knife cavity of the secondary punching tool (19).

7. A punching method for a square frame type foam product according to claim 1, characterized in that: The first positioning hole cut line (902) and the first positioning pin (903) are each provided with one, and a line connecting the first positioning hole cut line (902) and the first positioning pin (903) is along the material feed direction.

8. A punching method for a square frame type foam product according to claim 1, characterized in that: The second positioning hole cut line (1902) is provided with one, the second positioning pins (1903) are provided with two, and the connecting line of the second positioning hole cut line (1902) and the second positioning pins (1903) is along the feeding direction of the material strip.

9. A punching method for a square frame type foam product according to claim 1, characterized in that: The first positioning hole cut line (902) and the second positioning hole cut line (1902) are both C-shaped hole cut lines.

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