A system for manufacturing a copper foil die-cut product and a method for manufacturing the same

Abstract

The application relates to a copper foil die-cut product manufacturing system and a manufacturing method thereof, which comprises a first protective film unwinding roller, a double-sided adhesive raw material unwinding roller, a cover film unwinding roller, a first die-cut mechanism, a cover film waste winding roller, a Mylar unwinding roller, a Mylar winding roller, a copper foil unwinding roller, a first winding roller, a second die-cut mechanism, a second protective film unwinding roller, a second winding roller, a third die-cut mechanism, a waste discharge roller, a third protective film unwinding roller, a finished product winding roller and a plurality of laminating mechanisms. The C-shaped knife line is arranged in the punch die, a pair of C-shaped holes can be punched when punching, the C-shaped hole is behind the discharge direction during product manufacturing, the C-shaped hole is punched first, then positioning sleeve punching is carried out, the positioning effect is achieved, the accurate positioning of the material belt during punching is effectively ensured, the die-cut joint is aligned, and the glue pulling problem is avoided.

Description

Technical Field

[0001] This invention relates to the field of die-cutting technology, specifically to a manufacturing system and method for copper foil die-cutting products. Background Technology

[0002] Copper foil possesses low surface oxygen properties, allowing it to adhere to various substrates such as metals and insulating materials. It has a wide operating temperature range and is primarily used for electromagnetic shielding and antistatic purposes. Placing conductive copper foil on a substrate, combined with a metal substrate, provides excellent conductivity and electromagnetic shielding. It can be categorized as self-adhesive copper foil, double-sided conductive copper foil, and single-sided conductive copper foil. Electronic-grade copper foil (purity ≥ 99.7%, thickness 5µm-105µm) is one of the fundamental materials of the electronics industry. With the rapid development of the electronics and information industry, the use of electronic-grade copper foil is increasing. The product is widely used in industrial calculators, communication equipment, QA equipment, lithium-ion batteries, consumer televisions, VCRs, CD players, copiers, telephones, air conditioners, automotive electronic components, game consoles, etc. The demand for electronic-grade copper foil, especially high-performance electronic-grade copper foil, is increasing both domestically and internationally.

[0003] The double-sided adhesive for copper foil products is a substrate-free double-sided adhesive: it is directly coated and pressed from acrylic adhesive. The tape is transparent, and the common thickness is 0.06-0.13MM. It has excellent adhesion and waterproof performance, good processability, good temperature resistance, good dimensional stability, thermal stability, and chemical stability. It also has good initial tack and holding power. However, the disadvantage of substrate-free double-sided adhesive is that it is glue, which is easy to pull off, leading to product scrap.

[0004] The current manufacturing method for copper foil die-cutting products involves using a 2mm etching blade and small-hole alignment technology (small-hole alignment die-cutting machines have a unique automatic correction function, enabling precise alignment and punching of empty holes). This method typically involves two or more alignment machines working in conjunction with a waste removal machine and a slicing machine. However, due to uneven blade joints and the fact that the products are made with double-sided adhesive without a substrate, adhesive pulling occurs at the blade joints during waste removal, resulting in either no adhesive or excessive adhesive in the adhesive areas of the products. This leads to a high defect rate and fails to meet actual production requirements. Summary of the Invention

[0005] The purpose of this invention is to solve the problem of adhesive stretching in the preparation of existing copper foil die-cut products, and to provide a manufacturing system and method for copper foil die-cut products.

[0006] The objective of this invention is achieved through the following technical solution: A copper foil die-cutting product manufacturing system, for producing copper foil die-cutting products, includes a first die-cutting unit, a second die-cutting unit, and a third die-cutting unit, wherein: The first die-cutting unit includes: The first protective film unwinding roller is used to release the protective film. The double-sided adhesive raw material unwinding roller is located downstream of the first protective film unwinding roller along the material belt movement direction, and is used to release the double-sided adhesive raw material and adhere it to the upper part of the protective film. The cover film unwinding roller is located downstream of the double-sided adhesive raw material unwinding roller along the material belt movement direction, and is used to release the cover film and adhere it to the upper part of the double-sided adhesive raw material; The first die-cutting mechanism is used to die-cut the strips of the laminated protective film, double-sided adhesive material and cover film, and to punch out the tear handle and edge outline of the copper foil die-cut product. The cover film waste take-up roller is located downstream of the first die-cutting mechanism along the material belt movement direction, and is used to take up the cover film and remove waste from the waste discharge area; The Mylar unwinding roller is located downstream of the film waste winding roller along the direction of material belt movement, and is used to release Mylar and adhere it to the upper part of the material belt; Mylar take-up roll, located downstream of the Mylar unwind roll along the direction of material belt movement, is used to take up the Mylar and remove any remaining waste material; The copper foil unwinding roller is located downstream of the Mylar take-up roller along the direction of material strip movement, and is used to release the copper foil and adhere it to the surface of the material strip after waste discharge; The first take-up roller is located downstream of the copper foil unwinding roller along the direction of material strip movement and is used to take up the semi-finished material strip obtained by the first die-cutting unit. The second die-cutting unit includes: The second die-cutting mechanism is used to punch the semi-finished strip obtained by the first die-cutting unit and make marking marks on the copper foil. The second protective film unwinding roller is located downstream of the second die-cutting mechanism along the direction of material strip movement. It is used to release the protective film and attach it to the upper part of the copper foil according to the marking. The second take-up roller is located downstream of the second protective film unwinding roller along the material strip movement direction, and is used to take up the semi-finished material strip obtained by the second die-cutting unit; The third die-cutting unit includes: The third die-cutting mechanism is used to punch the semi-finished strip obtained from the second die-cutting unit to punch out the outer contour line of the copper foil die-cut product; The waste discharge roller is located downstream of the third die-cutting mechanism along the material belt movement direction and is used to discharge the waste material of the product outer frame; The third protective film unwinding roller is located downstream of the waste discharge roller along the material belt movement direction, and is used to release the protective film and adhere it to the upper part of the material belt; Finished winding rollers are used to wind up copper foil die-cut products; and Several bonding mechanisms are arranged between each unwinding roller and each take-up roller to bond the various strips together.

[0007] As a preferred technical solution, the first die-cutting mechanism includes a first upper die-cutting unit and a first lower die-cutting unit corresponding to the first upper die-cutting unit. The first upper die-cutting unit includes an aluminum plate and a blade plate. The blade plate is provided with guide posts and a first die-cutting tool. The first lower die-cutting unit includes a lower die plate, which is provided with positioning holes that match the guide pillars.

[0008] As a preferred technical solution, the first die-cutting tool includes: A pair of C-shaped wire cutters are used to punch out C-shaped holes; A pair of round hole punches are used to punch out round holes; A tear-off cutter is used to cut the outer contour of the tear line on copper foil products. A cutting blade is used to cut the edge contours of copper foil products.

[0009] As a preferred technical solution, the distance between the C-shaped hole and the round hole is the length and spacing of the product.

[0010] As a preferred technical solution, the second die-cutting mechanism includes a second upper die-cutting unit and a second lower die-cutting unit corresponding to the second upper die-cutting unit. The second upper die-cutting unit includes a blade plate, and the blade plate is provided with a second die-cutting tool, which includes a pair of marking line cutters.

[0011] As a preferred technical solution, the third die-cutting mechanism includes a third upper die-cutting unit and a third lower die-cutting unit corresponding to the third upper die-cutting unit. The third upper die-cutting unit includes a blade plate, and the blade plate is provided with a third die-cutting tool. The third die-cutting tool includes a product outer contour line cutter, and the blade edge contour matches the shape of the product contour line.

[0012] As a preferred technical solution, the bonding mechanism consists of a pair of rotating rollers.

[0013] As a preferred technical solution, the die-cutting system is also equipped with several auxiliary rollers.

[0014] As a preferred technical solution, the copper foil die-cut product includes a copper foil layer, a double-sided adhesive layer, and multiple protective films.

[0015] A method for manufacturing copper foil die-cut products, using the aforementioned system, specifically includes the following steps: (1) Place the adhesive side of the protective film in the center onto the original paper side of the double-sided adhesive; (2) Center the release surface of the cover film onto the adhesive side of the double-sided tape; (3) Perform a punching cut to cut out the outline of the tear handle and edge of the copper foil die-cut product; (4) Covering the waste in the waste discharge area with a membrane; (5) Adhere the Mylar waste adhesive and the remaining cover film; (6) Center any side of the copper foil onto the adhesive side of the double-sided tape; (7) Perform a second punching to make a marking mark on the copper foil; (8) Apply the two protective films to the copper foil in two separate steps along the marking lines of the die-cut markings; (9) Perform three punching cuts to punch out the outer outline of the copper foil die-cut product; (10) Remove the outer frame waste, but not the raw paper; (11) Apply the protective film to the copper foil; (12) Roll up the slices.

[0016] This invention addresses the problem of adhesive pulling during the preparation of copper foil die-cut products. Through dedicated research, the inventors discovered that the main cause of adhesive pulling in copper foil die-cut products is uneven die-cutting edges. Since the product is a substrate-free double-sided adhesive, adhesive pulling occurs at the die-cutting edges during waste removal, resulting in either no adhesive or excessive adhesive in the adhesive area. Furthermore, the die cannot properly separate the cutting line, leading to a small cutting line position and insufficient padding foam. This causes compression of the adhesive area during manufacturing, making waste removal difficult and affecting product quality.

[0017] This invention solves the technical problem by improving the product die-cutting system and process, especially the single-punch die-cutting mechanism. The invention sets two C-shaped cutter lines in the single-punch die, which can cut a pair of C-shaped holes during punching. During product manufacturing, the C-shaped holes are located after the material exits. The C-shaped holes are punched first, followed by a positioning punch, which effectively positions the material strip, ensuring precise positioning during punching. This guarantees the alignment of the die-cutting edges and avoids glue pulling problems.

[0018] This manufacturing method reduces defects caused by uneven joints at the blade edges, decreasing by approximately 20% in terms of excess glue. It also solves the problem of insufficient padding foam due to the absence of a jump cutter or overly dense blade lines, reducing defects by about 10%. Furthermore, this method eliminates the need for manual repairs of excess glue, reducing defects caused by repairs by 5% and lowering production costs. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the copper foil product of the present invention; Figure 2 This is a schematic diagram of the first die-cutting mechanism; Figure 3 This is a schematic diagram of the second die-cutting mechanism; Figure 4 This is a schematic diagram of the third die-cutting mechanism; Figure 5a This is a schematic diagram of the die-cutting tool of the original first die-cutting mechanism; Figure 5b This is a schematic diagram of the die-cutting tool of the first die-cutting mechanism of the present invention; Figure 6 This is a schematic diagram of the die-cutting tool of the second die-cutting mechanism of the present invention; Figure 7 This is a schematic diagram of the die-cutting tool of the third die-cutting mechanism of the present invention; Figure 8 , 9 This is a schematic diagram of the structure of the first die-cutting mechanism of the present invention; Figure 10 This is a schematic diagram of the die-cutting strip of the first die-cutting mechanism of the present invention; Figure 11 This is a schematic diagram of the material strip processing process of the present invention. Detailed Implementation

[0020] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0021] Figure 1 The copper foil die-cut product of the present invention includes a copper foil layer, a double-sided adhesive layer and multiple protective films, and is manufactured using a die-cutting process. Figure 5a This is a schematic diagram of the die-cutting tool of the original first die-cutting mechanism. The punching hole penetrates the positioning hole, and the waste material from the round hole is left in the waste trough of the machine through the lower plate. Due to the poor connection of the blade edge, the product's cutting lines must be together and cannot be adjusted. When the material moves, the die-cutting will cause the material to shift. For copper foil die-cutting products, the problem of glue pulling is more serious, which affects the product quality.

[0022] To solve this technical problem, the present invention provides a manufacturing system for copper foil die-cut products, comprising a first die-cutting unit, a second die-cutting unit, and a third die-cutting unit, wherein: like Figure 2 The first die-cutting unit includes: First protective film unwinding roller 1, used to release the protective film; The double-sided adhesive raw material unwinding roller 2 is located downstream of the first protective film unwinding roller 1 along the material belt moving direction, and is used to release the double-sided adhesive raw material and adhere it to the upper part of the protective film. The cover film unwinding roller 3 is located downstream of the double-sided adhesive raw material unwinding roller 2 along the material belt moving direction, and is used to release the cover film and adhere it to the upper part of the double-sided adhesive raw material. The first die-cutting mechanism 4 is used to die-cut the strips of the laminated protective film, double-sided adhesive material and cover film, and punch out the tear handle and edge outline of the copper foil die-cut product. The cover film waste take-up roller 5 is located downstream of the first die-cutting mechanism 4 along the material belt moving direction, and is used to take up the cover film and remove waste from the waste discharge area; Mylar unwinding roller 6 is located downstream of the cover film waste winding roller 5 along the direction of material belt movement, and is used to release Mylar and adhere it to the upper part of the material belt; Mylar take-up roller 7 is located downstream of Mylar unwind roller 6 along the direction of material belt movement, and is used to take up Mylar and remove the remaining waste material; The copper foil unwinding roller 8 is located downstream of the Mylar take-up roller 7 along the direction of material strip movement. It is used to release the copper foil and adhere it to the surface of the material strip after waste discharge. The first take-up roller 9 is located downstream of the copper foil unwinding roller 8 along the direction of material strip movement, and is used to take up the semi-finished material strip obtained from the first die-cutting unit. like Figure 3 The second die-cutting unit includes: The second die-cutting mechanism 10 is used to punch the semi-finished strip obtained from the first die-cutting unit and make marking marks on the copper foil. The second protective film unwinding roller 11 is located downstream of the second die-cutting mechanism 10 along the material belt moving direction. It is used to release the protective film and attach it to the upper part of the copper foil according to the marking knife print. The second take-up roller 12 is located downstream of the second protective film unwinding roller 11 along the material strip moving direction, and is used to take up the semi-finished material strip obtained by the second die-cutting unit. like Figure 4 The third die-cutting unit includes: The third die-cutting mechanism 13 is used to punch the semi-finished strip obtained from the second die-cutting unit to punch out the outer contour line of the copper foil die-cut product. Waste discharge roller 14 is located downstream of the third die-cutting mechanism 13 along the material belt moving direction and is used to discharge waste material from the outer frame of the product. The third protective film unwinding roller 15 is located downstream of the waste discharge roller 14 along the material belt moving direction, and is used to release the protective film and adhere it to the upper part of the material belt. Finished winding roller 16, used for winding the prepared copper foil die-cut products; and Several bonding mechanisms, each consisting of a pair of rotating rollers, are positioned between the unwinding and rewinding rollers to bond the various strips together.

[0023] like Figure 5b , Figure 8 , Figure 9 The first die-cutting mechanism 4 includes a first upper die-cutting unit and a first lower die-cutting unit corresponding to the first upper die-cutting unit. Figure 8In the diagram, A1 is the upper machine platform, A2 is the lower machine platform, A3 is the universal upper template, B2 is the universal lower template, C1 is the upper mold plate, and C2 is the lower mold plate. The first upper die-cutting unit includes an aluminum plate 405 and a cutting plate. The cutting plate is equipped with guide pillars 402 and a first die-cutting tool. The first lower die-cutting unit includes a lower mold plate, which has positioning holes 404 that match the guide pillars. The first die-cutting tool includes: a pair of C-shaped wire cutters 401 for punching C-shaped holes; a pair of round hole wire cutters 403 for punching round holes; a tearing wire cutter b for punching the outer contour of the tear line on the copper foil product; and a cutting wire cutter a for punching the edge contour of the copper foil product. The distance between the C-shaped holes and the round holes represents the length and spacing of the product.

[0024] The second die-cutting mechanism 10 includes a second upper die-cutting unit and a corresponding second lower die-cutting unit. The second upper die-cutting unit includes a blade plate with a second die-cutting tool, which includes a pair of marking line cutters c. The third die-cutting mechanism 13 includes a third upper die-cutting unit and a corresponding third lower die-cutting unit. The third upper die-cutting unit includes a blade plate with a third die-cutting tool, which includes product outer contour line cutters d and e, the blade edge contour matching the shape of the product contour line.

[0025] A method for manufacturing copper foil die-cut products specifically includes the following steps. Figure 10 , 11 This is a schematic diagram of the die-cutting mechanism for the material strip of the present invention and a schematic diagram of the material strip processing process: 1. Center the adhesive side of the protective film onto the original paper side of the double-sided adhesive; 2. Center the release liner of the cover film onto the adhesive side of the double-sided tape; 3. Perform a punching cut to cut out the tear strip and edge outline of the copper foil die-cut product; 4. Remove the covering membrane from the waste disposal area; 5. Adhere the Mylar waste adhesive and the remaining cover film; 6. Center any side of the copper foil and attach it to the adhesive side of the double-sided tape; 7. Perform a second punching to make a marking mark on the copper foil; 8. Apply the two protective films to the copper foil in two separate applications, following the marking lines of the die-cut markings. 9. Perform three punching cuts to cut out the outer outline of the copper foil die-cut product; 10. Remove waste from the outer frame, but not from the raw paper; 11. Apply the protective film to the copper foil; 12. Roll up and slice.

[0026] This invention features two C-shaped cutting lines in a punch die, which can punch out a pair of C-shaped holes during punching. When the product is manufactured, the C-shaped holes are located behind the material exit direction. The C-shaped holes are punched first, and then the positioning sleeve is punched to achieve a positioning function. This effectively ensures the precise positioning of the strip during punching, ensures the alignment of the die-cutting blades, and avoids the problem of glue pulling.

[0027] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A system for manufacturing copper foil die-cut products, characterized in that, It includes a first die-cutting unit, a second die-cutting unit, and a third die-cutting unit, wherein: The first die-cutting unit includes: The first protective film unwinding roller (1) is used to release the protective film; The double-sided adhesive raw material unwinding roller (2) is located downstream of the first protective film unwinding roller (1) along the material belt moving direction, and is used to release the double-sided adhesive raw material and adhere it to the upper part of the protective film; The cover film unwinding roller (3) is located downstream of the double-sided adhesive raw material unwinding roller (2) along the material belt moving direction, and is used to release the cover film and adhere it to the upper part of the double-sided adhesive raw material; The first die-cutting mechanism (4) is used to die-cut the strips of the laminated protective film, double-sided adhesive material and cover film, and punch out the tear handle and edge outline of the copper foil die-cut product. The cover film waste take-up roller (5) is located downstream of the first die-cutting mechanism (4) along the material belt moving direction, and is used to take up the cover film and remove the waste from the waste discharge area; Mylar unwinding roller (6) is located downstream of the cover film waste winding roller (5) along the direction of material belt movement, and is used to release Mylar and adhere it to the upper part of the material belt; Mylar take-up roller (7), located downstream of the Mylar unwind roller (6) along the direction of material belt movement, is used to take up Mylar and remove the remaining waste material; The copper foil unwinding roller (8) is located downstream of the Mylar take-up roller (7) along the direction of material strip movement, and is used to release the copper foil and adhere it to the surface of the material strip after waste discharge; The first take-up roller (9) is located downstream of the copper foil unwinding roller (8) along the material strip moving direction, and is used to take up the semi-finished material strip obtained by the first die-cutting unit. The second die-cutting unit includes: The second die-cutting mechanism (10) is used to punch the semi-finished strip obtained by the first die-cutting unit and make marking marks on the copper foil; The second protective film unwinding roller (11) is located downstream of the second die-cutting mechanism (10) along the material belt moving direction, and is used to release the protective film and attach it to the upper part of the copper foil according to the marking knife mark; The second take-up roller (12) is located downstream of the second protective film unwinding roller (11) along the material strip moving direction, and is used to take up the semi-finished material strip obtained by the second die-cutting unit; The third die-cutting unit includes: The third die-cutting mechanism (13) is used to punch the semi-finished strip obtained by the second die-cutting unit to punch out the outer contour line of the copper foil die-cut product. Waste discharge roller (14) is located downstream of the third die-cutting mechanism (13) along the material belt moving direction and is used to discharge waste material from the outer frame of the product; The third protective film unwinding roller (15) is located downstream of the waste discharge roller (14) along the direction of material belt movement, and is used to release the protective film and adhere it to the upper part of the material belt; Finished winding roller (16), used to wind up the copper foil die-cut products obtained; and Several bonding mechanisms are arranged between each unwinding roller and each take-up roller to bond the various strips together.

2. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The first die-cutting mechanism (4) includes a first upper die-cutting unit and a first lower die-cutting unit corresponding to the first upper die-cutting unit. The first upper die-cutting unit includes an aluminum plate (405) and a blade plate. The blade plate is provided with a guide post (402) and a first die-cutting tool. The first lower die-cutting unit includes a lower die plate, which is provided with positioning holes (404) that match the guide post.

3. The copper foil die-cutting product manufacturing system according to claim 2, characterized in that, The first die-cutting tool includes: A pair of C-shaped wire cutters (401) are used to punch out C-shaped holes; A pair of round hole cutting knives (403) are used to punch out round holes; A tear-off cutter is used to cut the outer contour of the tear line on copper foil products. A cutting blade is used to cut the edge contours of copper foil products.

4. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The second die-cutting mechanism (10) includes a second upper die-cutting unit and a second lower die-cutting unit corresponding to the second upper die-cutting unit. The second upper die-cutting unit includes a blade plate, and the blade plate is provided with a second die-cutting tool. The second die-cutting tool includes a pair of marking knife line tools.

5. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The third die-cutting mechanism (13) includes a third upper die-cutting unit and a third lower die-cutting unit corresponding to the third upper die-cutting unit. The third upper die-cutting unit includes a blade plate, and the blade plate is provided with a third die-cutting tool. The third die-cutting tool includes a product outer contour line cutter, and the blade edge contour matches the shape of the product contour line.

6. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The bonding mechanism consists of a pair of rotating rollers.

7. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The manufacturing system is also equipped with several auxiliary rollers.

8. The copper foil die-cutting product manufacturing system according to claim 1, characterized in that, The copper foil die-cut product includes a copper foil layer, a double-sided adhesive layer, and multiple protective films.

9. A method for manufacturing copper foil die-cut products, characterized in that, The system described in any one of claims 1-7 is used for fabrication, specifically including the following steps: (1) Place the adhesive side of the protective film in the center onto the original paper side of the double-sided adhesive; (2) Center the release surface of the cover film onto the adhesive side of the double-sided tape; (3) Perform a punching cut to cut out the outline of the tear handle and edge of the copper foil die-cut product; (4) Remove the waste film covering from the waste discharge area; (5) Apply Mylar, remove waste adhesive and remove excess cover film; (6) Center any side of the copper foil onto the adhesive side of the double-sided tape; (7) Perform a second punching to punch out the marking knife marks on the copper foil; (8) Apply the two protective films to the copper foil in two separate steps along the marking lines of the die-cut markings; (9) Perform three punching cuts to punch out the outer outline of the copper foil die-cut product; (10) Remove the outer frame waste, but not the raw paper; (11) Apply the protective film to the copper foil; (12) Roll up the slices.

Images