3D foam sticker production process and equipment

Abstract

This invention provides a 3D foam sticker production process: PVC film, PVC foam, and PET film are continuously supplied; the PVC film and PET film are respectively adhered to the top and bottom surfaces of the PVC foam to form a continuous composite sheet; the composite sheet is introduced into a flexographic printing machine and a full-rotation multi-color printing machine to print graphic units; the composite sheet is molded and welded along the outline and preset lines of the graphic units, resulting in a three-dimensional relief effect, forming sticker units corresponding to the graphic units; die-cutting separates the sticker units from the composite sheet, obtaining the finished 3D foam sticker. This invention also provides a 3D foam sticker production equipment, which includes a feeding unit, a composite unit, a printing unit, a die-cutting unit, and a waste collection unit connected in sequence to form a production line; the die-cutting unit uses a cutting roller and an ultrasonic welding head to die-cut the composite sheet, causing the sticker units to separate from the composite sheet.

Description

Technical Field

[0001] This invention relates to the field of toy stickers, specifically to the production process and equipment for 3D foam stickers. Background Technology

[0002] 3D foam stickers are a type of toy sticker. They are typically made from a composite sheet material consisting of a PVC film as the top layer, PVC foam as the middle layer, and a PET film as the bottom layer. Graphic units are printed on the PVC film, and then the composite sheet is molded and fused along the edges and pre-set lines of the graphic units in the thickness direction, resulting in a three-dimensional relief effect. Finally, the 3D foam sticker with a 3D effect is obtained through die-cutting.

[0003] In the existing technology, the composite sheet is mostly obtained as a single sheet with limited size. It needs to be produced one sheet at a time in advance, and each sheet needs to be printed with graphic units, welded to form creasing, and die-cut. The production efficiency needs to be improved, and the precision control of graphic unit printing, welding to form creasing, and die-cutting is increased. Summary of the Invention

[0004] The present invention aims to provide a 3D foam sticker production process to overcome the above-mentioned deficiencies of the prior art, and the technical solution is as follows.

[0005] The production process of 3D foam stickers involves the following steps:

[0006] S1. PVC film, PVC foam and PET film are continuously supplied by feeding material rolls;

[0007] S2. Apply adhesive to the bottom surface of the PVC film and the top surface of the PET film using an adhesive roller;

[0008] S3. Adhere the PVC film and PET film coated with glue to the top and bottom surfaces of the PVC foam respectively to form a continuous composite sheet.

[0009] S4. Introduce the composite sheet into a unit-type flexographic printing press and a full-rotation multicolor printing press for inline printing, thereby printing graphic units on the top surface of the PVC film in the composite sheet.

[0010] S5. The composite sheet is molded and welded in the thickness direction along the outline of the graphic unit and the preset lines in the graphic unit, so that the graphic unit presents a three-dimensional relief effect, thereby forming a sticker unit corresponding to the graphic unit on the composite sheet.

[0011] S6. Die-cut the composite sheet with sticker units to separate the sticker units from the composite sheet and obtain the finished 3D foam sticker.

[0012] S7. The composite sheet with separated sticker units is wound up using a waste roll method.

[0013] Optionally, the bottom surface of the PET film has an adhesive backing and is covered with a release film.

[0014] Preferably, in step S5, the bottom surface of the composite sheet is supported by an ultrasonic welding head and upward ultrasonic waves are applied. The composite sheet is then rolled from the top surface using a blade roller in conjunction with the ultrasonic welding head, causing the composite sheet to be ultrasonically welded along the contour of the graphic unit and the preset lines in the graphic unit.

[0015] Preferably, in step S6, the composite sheet is die-cut using ultrasonic die-cutting.

[0016] Preferably, steps S5 and S6 share the ultrasonic welding head and the cutting roller to be performed simultaneously. Furthermore, the cutting roller has a first cutting edge corresponding to the outline of the graphic unit and the preset lines within the graphic unit, and a second cutting edge corresponding to the outline of the finished 3D foam sticker. When the cutting roller, in conjunction with the ultrasonic welding head, rolls the composite sheet, the first cutting edge only penetrates downwards through the PVC film and PVC foam of the composite sheet, while the second cutting edge completely penetrates the composite sheet.

[0017] In order to realize the above-mentioned 3D foam sticker production process, the present invention also provides a 3D foam sticker production equipment, which includes a feeding unit, a composite unit, a printing unit, a die-cutting unit and a waste collection unit connected in sequence to form a production line.

[0018] The feeding unit includes synchronously unwinding PVC film feeding rolls, PVC foam feeding rolls, and PET film feeding rolls;

[0019] The composite unit includes an upper guide roller that continuously feeds PVC film strips from a PVC film feed roll, a middle guide roller that continuously feeds PVC foam strips from a PVC foam feed roll, and a lower guide roller that continuously feeds PET film strips from a PET film feed roll. It also includes an upper coating roller that coats the bottom surface of the PVC film strip with adhesive, a lower coating roller that coats the top surface of the PET film strip with adhesive, and a pair of counter-pressure rollers that press the PVC film strip, PVC foam strip, and PET film strip together from top to bottom and then pressed together by the counter-pressure rollers to form a composite sheet that is continuously fed into the printing unit.

[0020] The printing unit is an inline printing device consisting of a unit-type flexographic printing press and a full-rotation multicolor printing press connected in sequence. It is used to print graphic units on the top surface of the PVC film in the composite sheet and send them to the die-cutting unit.

[0021] The die-cutting unit includes a traction mechanism and a die-cutting mechanism. The traction mechanism is used to continuously pull the composite sheet from the printing unit to the die-cutting mechanism. The die-cutting mechanism includes a blade roller and an ultrasonic welding head arranged above and below the composite sheet. The ultrasonic welding head supports the bottom surface of the composite sheet and applies upward ultrasonic waves. The blade roller and the ultrasonic welding head roll the composite sheet, causing the composite sheet to be ultrasonically welded along the outline of the graphic unit and the preset lines in the graphic unit. At the same time, the blade roller and the ultrasonic welding head die-cut the composite sheet, causing the sticker unit to separate from the composite sheet.

[0022] The waste collection unit includes a waste collection reel that is synchronously driven with the traction mechanism. The composite sheet is wound onto the waste collection reel after passing through the die-cutting unit.

[0023] Preferably, the traction mechanism includes two pairs of rubber rollers arranged on both sides of the die-cutting mechanism. The axial direction of the rubber rollers is parallel to that of the cutter roller, and each pair of rubber rollers forms a circular-to-circular fit. The composite sheet is inserted between one pair of rubber rollers and then pulled through the lower edge of the cutter roller to the other pair of rubber rollers before exiting into the waste collection unit.

[0024] Preferably, the cutter roller has a first cut corresponding to the outline of the graphic unit and the preset lines in the graphic unit, and a second cut corresponding to the outline of the finished 3D foam sticker; when the cutter roller is used in conjunction with the ultrasonic welding head to roll the composite sheet, the first cut only penetrates downwards through the PVC film and PVC foam of the composite sheet, while the second cut completely penetrates the composite sheet.

[0025] Preferably, the die-cutting unit further includes a support, with both ends of the rubber roller and both ends of the cutter roller rotatably mounted on the support; wherein, both ends of the cutter roller are provided with rotatably mounted bearing seats, and the support has a guide groove for providing vertical sliding stroke for the bearing seats, the lower end of the guide groove has a spring assembly for upward elastic support of the bearing seats, the upper end of the guide groove is threaded with a vertically arranged lifting adjustment screw, the lower end of the lifting adjustment screw has a rotatably mounted pressure block, the pressure block slides vertically within the guide groove, and when the lifting adjustment screw moves downward, it presses down on the bearing seats through the pressure block.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows: the composite sheet is produced online by means of in-line processing, printing, die-cutting and waste removal, so that the composite sheet can be continuously formed, continuously printed and continuously die-cut, reducing the frequency of precision adjustment of production equipment, and greatly improving the accuracy and production efficiency of graphic unit printing, welding to form indentations and die-cutting.

[0027] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0028] Figure 1This is a schematic diagram of the structure of the 3D foam sticker production equipment involved in this invention.

[0029] Figure 2 This is a schematic diagram illustrating the working principle of the pressure roller in the 3D foam sticker production equipment involved in this invention.

[0030] Figure 3 This is a schematic diagram illustrating the working principle of the die-cutting unit in the 3D foam sticker production equipment involved in this invention.

[0031] Figure 4 This is a schematic diagram of a cutting roller in the 3D foam sticker production equipment involved in this invention.

[0032] Figure 5 This is a schematic diagram of another structure of the cutter roller in the 3D foam sticker production equipment of the present invention. Detailed Implementation

[0033] In one embodiment, the present invention provides a 3D stereoscopic foam sticker manufacturing process, which comprises the following steps:

[0034] S1. PVC film, PVC foam and PET film are continuously supplied by feeding material rolls;

[0035] S2. Apply adhesive to the bottom surface of the PVC film and the top surface of the PET film using an adhesive roller;

[0036] S3. Adhere the PVC film and PET film coated with glue to the top and bottom surfaces of the PVC foam respectively to form a continuous composite sheet.

[0037] S4. Introduce the composite sheet into a unit-type flexographic printing press and a full-rotation multicolor printing press for inline printing, thereby printing graphic units on the top surface of the PVC film in the composite sheet.

[0038] S5. The composite sheet is molded and welded in the thickness direction along the outline of the graphic unit and the preset lines in the graphic unit, so that the graphic unit presents a three-dimensional relief effect, thereby forming a sticker unit corresponding to the graphic unit on the composite sheet.

[0039] S6. Die-cut the composite sheet with sticker units to separate the sticker units from the composite sheet and obtain the finished 3D foam sticker.

[0040] S7. The composite sheet with separated sticker units is wound up using a waste roll method.

[0041] In the above embodiments, the composite sheet is produced, printed, die-cut, and waste is removed online using an inline processing method. The composite sheet can be continuously formed, printed, and die-cut, which reduces the frequency of precision adjustment of production equipment. The accuracy of graphic unit printing, welding to form indentations, and die-cutting, as well as the production efficiency, are greatly improved.

[0042] In the above embodiments, optionally, the bottom surface of the PET film has adhesive backing and is covered with a release film, so that the finished 3D foam sticker also has adhesive backing, and can be directly pasted by peeling off the release film.

[0043] The above embodiment can be further improved as follows: In step S5, the bottom surface of the composite sheet is supported by an ultrasonic welding head and upward ultrasonic waves are applied. From the top surface of the composite sheet, a roller in conjunction with the ultrasonic welding head rolls the composite sheet, causing the composite sheet to be ultrasonically welded along the contour of the graphic unit and the preset lines within the graphic unit. In contrast, existing technologies often use high-frequency welding for welding. The above embodiment improves upon this by using ultrasonic welding, which is faster, stronger, and has better sealing properties. It is also less expensive, does not damage the workpiece, and the entire process is very stable. Process parameters can be tracked and monitored through a software system.

[0044] Furthermore, in step S6, the composite sheet is also die-cut using ultrasonic die-cutting.

[0045] In the further improved embodiment described above, since steps S5 and S6 share the ultrasonic welding head and the cutting roller, steps S5 and S6 can be performed simultaneously, further improving production efficiency. Specifically, the cutting roller has a first cutting edge corresponding to the outline of the graphic unit and the preset lines within the graphic unit, and a second cutting edge corresponding to the outline of the finished 3D foam sticker. When the cutting roller, in conjunction with the ultrasonic welding head, rolls the composite sheet, the first cutting edge only penetrates downwards through the PVC film and PVC foam of the composite sheet, while the second cutting edge completely penetrates the composite sheet.

[0046] like Figures 1 to 3 As shown, in order to realize the above-mentioned 3D foam sticker production process, the present invention also provides a 3D foam sticker production equipment, which includes a feeding unit 1, a composite unit 2, a printing unit 3, a die-cutting unit 4, and a waste collection unit 5 connected in sequence to form a production line.

[0047] The feeding unit 1 includes a synchronously unwinding PVC film feeding roll 11, a PVC foam feeding roll 12, and a PET film feeding roll 13;

[0048] The composite unit 2 includes an upper guide roller 21 that continuously feeds PVC film strip 61 from PVC film unloading roll 11, a middle guide roller 22 that continuously feeds PVC foam strip 62 from PVC foam unloading roll 12, and a lower guide roller 23 that continuously feeds PET film strip 63 from PET film unloading roll 13. It also includes an upper coating roller 24 that coats the bottom surface of PVC film strip 61 with adhesive, a lower coating roller 25 that coats the top surface of PET film strip 63 with adhesive, and a pair of counter-pressure rollers 26 that press and match in a circular motion. The PVC film strip 61, PVC foam strip 62, and PET film strip 63 are stacked from top to bottom and pressed together by the counter-pressure rollers 26 to form a composite sheet 6 that is continuously fed into the printing unit 3.

[0049] The printing unit 3 is an inline printing device consisting of a unit-type flexographic printing machine 31 and a full-rotation multicolor printing machine 32 connected in sequence. It is used to print graphic units on the top surface of the PVC film in the composite sheet 6 and send them to the die-cutting unit 4.

[0050] The die-cutting unit 4 includes a traction mechanism 41 and a die-cutting mechanism 42. The traction mechanism 41 is used to continuously pull the composite sheet 6 from the printing unit 3 to the die-cutting mechanism 42. The die-cutting mechanism 42 includes a blade roller 421 and an ultrasonic welding head 422 arranged above and below the composite sheet 6. The ultrasonic welding head 422 supports the bottom surface of the composite sheet 6 and applies upward ultrasonic waves. The blade roller 421 and the ultrasonic welding head 422 roll the composite sheet 6, causing the composite sheet 6 to be ultrasonically welded along the outline of the graphic unit and the preset lines in the graphic unit. At the same time, the blade roller 421 and the ultrasonic welding head 422 die-cut the composite sheet 6, causing the sticker unit to separate from the composite sheet 6.

[0051] The waste collection unit 5 includes a waste collection reel 51 that is synchronously driven with the traction mechanism 41. The composite sheet 6 is wound around the waste collection reel 51 after passing through the die-cutting unit 4.

[0052] In the above embodiments, the 3D foam sticker production equipment of the present invention can be synchronously driven by the motor servo system in an inline printing equipment consisting of a unit-type flexographic printing machine 31 and a full-rotation multi-color printing machine 32, through gear, belt, or chain external transmission. This drives the PVC film unloading roll 11, PVC foam unloading roll 12, PET film unloading roll 13, upper guide roller 21, middle guide roller 22, lower guide roller 23, upper glue coating roller 24, lower glue coating roller 25, pressure roller 26, traction mechanism 41, and waste roll 51. Since the above-described synchronous drive structure via gear, belt, or chain external transmission is not an improvement of the present invention and can be directly implemented according to conventional settings in the art, it will not be described in detail further.

[0053] In the above embodiments, such as Figure 3As shown, after the composite sheet 6 passes through the die-cutting unit 4, the sticker unit remains on the same conveying plane as the composite sheet 6, so the sticker unit will continue to be pulled forward along with the composite sheet 6. Therefore, as... Figure 1 As shown, a guide roller 52 can be installed between the die-cutting unit and the waste collection unit for the composite sheet 6. The composite sheet 6 is drawn upwards along the lower edge of the guide roller 52 to the waste collection reel 51. When the composite sheet 6 passes the guide roller, the sticker unit will completely detach from the composite sheet 6, and the detached sticker unit can be collected as a finished 3D foam sticker. Furthermore, a sorting belt or sorting table can be installed below the guide roller to receive the finished 3D foam sticker.

[0054] like Figure 3 As shown, the above embodiment can be further implemented as follows: the traction mechanism 41 includes two pairs of rubber rollers arranged on both sides of the die-cutting mechanism 42. The axial direction of the rubber rollers is parallel to that of the cutter roller 421, and each pair of rubber rollers forms a circular-to-circular fit. The composite sheet 6 passes through the first pair of rubber rollers 411, and is then pulled through the lower edge of the cutter roller 421 to the second pair of rubber rollers 412 before exiting into the waste collection unit 5. The second pair of rubber rollers 412 actively rotates to pull the composite sheet 6, while the first pair of rubber rollers 411 passively rotates with the pull of the composite sheet 6, thereby keeping the composite sheet 6 between the two pairs of rubber rollers 411 taut, facilitating the operation of the die-cutting mechanism 42.

[0055] like Figure 4 As shown, the die-cutting roller 421 has a first cutting edge 423 corresponding to the outline of the graphic unit and the preset lines in the graphic unit, and a second cutting edge 424 corresponding to the outline of the finished 3D foam sticker. When the die-cutting roller 421, in conjunction with the ultrasonic welding head 422, rolls the composite sheet 6, the first cutting edge 423 does not penetrate the PET film of the composite sheet 6 downwards, while the second cutting edge 424 completely penetrates the composite sheet 6. This die-cutting method will cause the die-cut 3D foam sticker to completely detach from the composite sheet 6, which is suitable for obtaining multiple 3D foam stickers that are separated from each other and correspond one-to-one with the graphic unit.

[0056] Furthermore, for cases where the bottom surface of the PET film has adhesive backing and is covered with a release film, the die-cutting method can be further configured as follows: when the die roller 421 and the ultrasonic welding head 422 roll the composite sheet 6, the first cutting edge 423 only penetrates downwards through the PVC film and PVC foam of the composite sheet 6, and the second cutting edge 424 only penetrates downwards through the PVC film, PVC foam, and PET film of the composite sheet 6. This die-cutting method will cause the multiple 3D foam stickers produced by die-cutting to remain on the release film. The waste collection unit only winds up the composite sheet 6 after the release film has been peeled off, and the release film can be cut into plates later to obtain multiple 3D foam stickers arranged in a whole plate.

[0057] Furthermore, in order to obtain multiple 3D foam stickers arranged in a single sheet by cutting the release film into multiple sections, it can be further configured as follows: Figure 5 As shown, the cutting roller 421 also has a third cutting edge 425 corresponding to the size of the preset plate. When the cutting roller 421 and the ultrasonic welding head 422 roll the composite sheet 6, the first cutting edge 423 only penetrates downward through the PVC film and PVC foam of the composite sheet 6, the second cutting edge 424 only penetrates downward through the PVC film, PVC foam and PET film of the composite sheet 6, and the third cutting edge 425 completely penetrates the composite sheet 6. Each rotation of the cutting roller 421 will die-cut out a whole plate of multiple 3D foam stickers arranged on the release film.

[0058] Furthermore, such as Figure 3 As shown, the die-cutting unit 4 includes a support 40, with both ends of the rubber roller 411 and both ends of the cutter roller 421 rotatably fitted onto the support 40. Each end of the cutter roller 421 has a rotatably fitted bearing seat 401. The support 40 has a guide groove 402 providing a vertical sliding stroke for the bearing seats 401. The lower end of the guide groove 402 has a spring assembly 403 that elastically supports the bearing seats 401 upwards. The upper end of the guide groove 402 is threaded with a vertically arranged lifting adjustment screw 404. The lower end of the lifting adjustment screw 404 has a rotatably fitted pressure block 405, which slides vertically within the guide groove 402. When the lifting adjustment screw 404 moves downwards, it presses against the bearing seats 401 downwards through the pressure block 405. This arrangement is used to adjust the fit clearance between the cutter roller 421 and the ultrasonic welding head 422 to accommodate composite sheets 6 of different thicknesses. Furthermore, for composite sheets 6 of different thicknesses, a matching cutter roller needs to be replaced. After replacing the cutting roller, when testing the die-cutting mechanism 42, the cutting roller 421, in conjunction with the ultrasonic welding head 422, rolls the composite sheet 6. By adjusting the fitting gap between the cutting roller 421 and the ultrasonic welding head 422, the penetration depth of the first cutting edge 423, the second cutting edge 424, and the third cutting edge 425 can be ensured.

[0059] For those skilled in the art, the scope of protection of this invention is not limited to the details of the above exemplary embodiments. Without departing from the spirit or essential characteristics of this invention, all equivalent and varied implementations made by those skilled in the art based on the elements of this invention should be included within this invention.

Claims

1. 3D stereoscopic foam sticker production process, characterized in that, The following steps are used: S1. PVC film, PVC foam and PET film are continuously supplied by feeding material rolls; S2. Apply adhesive to the bottom surface of the PVC film and the top surface of the PET film using an adhesive roller; S3. Adhere the PVC film and PET film coated with glue to the top and bottom surfaces of the PVC foam respectively to form a continuous composite sheet. S4. Introduce the composite sheet into a unit-type flexographic printing press and a full-rotation multicolor printing press for inline printing, thereby printing graphic units on the top surface of the PVC film in the composite sheet. S5. The composite sheet is molded and welded in the thickness direction along the outline of the graphic unit and the preset lines in the graphic unit. The bottom surface of the composite sheet is supported by an ultrasonic welding head and upward ultrasonic waves are applied. At the same time, the top surface of the composite sheet is rolled with a knife roller in conjunction with the ultrasonic welding head, so that the composite sheet is ultrasonically welded along the outline of the graphic unit and the preset lines in the graphic unit, resulting in a three-dimensional relief effect of the graphic unit, thereby forming a sticker unit corresponding to the graphic unit on the composite sheet. S6. The composite sheet is die-cut using ultrasonic die-cutting. The composite sheet with sticker units is die-cut, causing the sticker units to separate from the composite sheet, and the finished 3D foam sticker is obtained. S7. The composite sheet with the separated sticker units is wound up using a waste roll method; In this process, steps S5 and S6 share the ultrasonic welding head and the cutter roller to be performed simultaneously. The cutter roller has a first cut corresponding to the outline of the graphic unit and the preset lines in the graphic unit, and a second cut corresponding to the outline of the finished 3D foam sticker. When the cutter roller and the ultrasonic welding head roll the composite sheet, the first cut only penetrates downwards through the PVC film and PVC foam of the composite sheet, while the second cut completely penetrates the composite sheet.

2. The 3D stereoscopic foam sticker production process according to claim 1, characterized in that, The bottom surface of the PET film has an adhesive backing and is covered with a release film.

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