Microprismatic retroreflective material and method of making same

Abstract

The present application relates to the field of reflective material production, and more particularly to a micro-prism reflective material, comprising a composite layer, which comprises, from top to bottom, a protective transparent layer, an intermediate reflective layer, an adhesive layer and a release paper layer, the adhesive layer connecting the intermediate reflective layer and the release paper layer, the intermediate reflective layer being provided with positioning holes, and the adhesive layer being bonded to the protective transparent layer through the positioning holes, which solves the technical problem of the attenuation of the reflective intensity of the existing reflective film due to the influence of the environment and the service life, and simultaneously proposes a production method of the micro-prism reflective material.

Description

Technical Field

[0001] This invention relates to the field of reflective material production, and in particular to a microprism reflective material and its production method. Background Technology

[0002] The retroreflective principle of microprism reflective films differs from that of engineering-grade (lens-embedded) and high-intensity (lens-sealed) reflective films. Engineering-grade and high-intensity reflective films utilize the reflection principle of glass beads, while microprism reflective films employ the refraction and reflection of microprisms. Based on their retroreflective characteristics and structure, representative microprism reflective films can be broadly categorized into four types: truncated prisms emphasizing long-distance visibility, truncated prisms emphasizing close-range, large-angle readability, full prisms balancing both long-distance and close-range performance, and novel prism-type reflective films combining these prism technologies with new material technologies. These are new reflective materials that have emerged in recent years to meet the diverse needs of various application levels.

[0003] In recent years, while the structure of prism-type reflective films has remained largely unchanged, innovation has shifted more towards achieving richer light control effects and diverse material properties through different material processing technologies. This results in varying retroreflective capabilities and flexibility to meet diverse needs. Reflective films commonly referred to in the market as "super-strong," "extra-strong," or prism-type engineering-grade reflective films represent these new forms. While these reflective films share a similar truncated prism structure, their material processing techniques differ, resulting in varying reflective effects, superior weather resistance, and processing adaptability to meet diverse application requirements.

[0004] Chinese patent application number 201710361806.7 discloses a microprism-type reflective film and its manufacturing method. The reflective film comprises, from bottom to top, an air layer, a prism layer, an intermediate functional layer, and a functional surface layer. The manufacturing method includes the following steps: a) drying and preheating the prism film, the intermediate functional layer film, and the functional surface layer film respectively; b) heating the prism layer film after drying and preheating in step a with an elastic mirror steel roller and then molding it into a mold belt to replicate the microprism structure; c) heating the intermediate functional layer film and the functional surface layer film after drying and preheating in step a with an elastic mirror steel roller and then molding them together into the mold belt, and then thermally bonding them with the prism layer film after step b, thus replicating the microprism structure a second time; d) cooling and peeling the film on the mold belt after step c, and then welding it to a white reflective film. The reflective film and its manufacturing method can combine 2-3 different materials, making production flexible and improving product performance. When the aforementioned microprism reflective film and existing microprism reflective films are used in traffic situations, their brightness is easily reduced by time and environmental factors, making it impossible for people to read the sign content within the reading distance, or requiring more time to read it. Summary of the Invention

[0005] Therefore, in response to the above problems, this invention proposes a microprism reflective material, which solves the technical problem of the reduction in reflective intensity of existing reflective films due to environmental factors and usage time. At the same time, it also proposes a production method for this microprism reflective material.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a microprism reflective material, comprising a composite layer, wherein the composite layer comprises, from top to bottom, a protective transparent layer, an intermediate reflective layer, an adhesive layer and a release paper layer, the adhesive layer connecting the intermediate reflective layer and the release paper layer, the intermediate reflective layer having a positioning hole, and the adhesive layer being bonded to the protective transparent layer through the positioning hole.

[0007] Furthermore, the protective transparent layer, the intermediate reflective layer, and the adhesive layer are reinforced and connected by hot pressing.

[0008] Furthermore, a microprism reflective structure is provided on the intermediate reflective layer, and the microprism reflective structure is a square pyramid structure.

[0009] A method for producing a microprism reflective material includes the following steps:

[0010] 1) Material preparation; prepare the protective transparent layer roller, adhesive layer roller and release paper layer roller, and place them on the frame respectively;

[0011] 2) Prepare the intermediate reflective layer;

[0012] a. To prepare the forming roller, the reflective film mold material is first cut to the required size using a metal cutting device. The edges of the cut reflective film mold are then trimmed again using the metal cutting device to ensure the smoothness of the edges. The cut reflective film molds are then joined end to end and welded together using a metal welding device to form a cylindrical shape. The cylindrical reflective film mold is then fitted onto the roller to form the forming roller.

[0013] b. The raw material film is introduced into the forming roller and heated and formed by the heating roller. The raw material film after passing through the forming roller has a micro-prism structure.

[0014] c. Introduce the raw material film from step b onto the cooling roller for cooling. Cooling is divided into primary cooling and secondary cooling. During primary cooling, the cooling roller is kept at a constant temperature of 20-25 degrees Celsius. After primary cooling, the film is left at room temperature for 0.5-1 hour before secondary cooling. During secondary cooling, the cooling roller is kept at a constant temperature of 10-15 degrees Celsius.

[0015] d. After cooling, the intermediate reflective layer is obtained, and it is perforated by a needle roller;

[0016] 3) Surface layer lamination: The adhesive layer is preheated to make both the upper and lower surfaces of the adhesive layer sticky. The protective transparent layer, the intermediate reflective layer, the adhesive layer and the release paper layer are then introduced into the heated lamination roller for surface layer lamination.

[0017] 4) Pressure bonding; The bonded composite layer is introduced into a pressure roller for pressure bonding.

[0018] Furthermore, in step a of step 2), the reflective film mold undergoes two welding operations during the head and tail welding process using a metal welding device: the initial welding and the secondary reinforcement welding.

[0019] Furthermore, the metal welding device includes a frame, a worktable fixedly mounted on the frame, and a laser welding device. The worktable has a rectangular structure, and a working groove is provided on the upper surface of the worktable. The working groove is arranged along the width direction of the worktable and extends through the worktable in the width direction. The working groove includes a bottom surface and two oppositely arranged side surfaces. A rotating mechanism is provided in the working groove. The rotating mechanism includes a driving shaft, a driven shaft, and a placement plate. The driving shaft and the driven shaft pass through the placement plate and are mounted on the two sides of the working groove. The driving shaft rotates along its own axis by a rotary motor. An electromagnetic adsorption device is integrated in the placement plate. The frame is equipped with a movable guide rail, which is arranged along the length of the worktable. A first driving device is arranged on the movable guide rail, and the laser welding device is arranged on the first driving device. Under the drive of the first driving device, the laser welding device reciprocates on the movable guide rail. The laser welding device includes an electric telescopic shaft, a laser welding box, a laser welding gun, and a positioning robotic arm. The electric telescopic shaft connects the first driving device and the laser welding box. The laser welding box can reciprocate along the width of the welding worktable through the electric telescopic shaft. The laser welding gun is arranged on the bottom surface of the laser welding box, and a positioning laser head is arranged on the bottom surface of the laser welding box.

[0020] Furthermore, the working groove is provided with a main rotating hole and a secondary rotating hole on its side. The secondary rotating holes are symmetrically arranged on both sides of the main rotating hole. The secondary rotating holes are semi-circular arc-shaped. The active rotating shaft is inserted into the main rotating hole, and the driven rotating shaft is inserted into the secondary rotating hole.

[0021] Furthermore, a composite vibration motor is integrated within the shelf, and the vibration mode of the composite vibration motor is linear vibration.

[0022] Furthermore, the composite vibration motor enables the placement plate to vibrate back and forth on the horizontal plane along the length of the worktable or along the width of the worktable. When it vibrates back and forth along the length of the worktable, its vibration frequency is 8-12 times / second, and the vibration range is 0.8-1.2mm back and forth from the initial position. When it vibrates back and forth along the width of the worktable, its vibration frequency is 3-5 times / second, and the vibration range is 1-3mm back and forth from the initial position.

[0023] Furthermore, the positioning robotic arm is disposed on the side of the laser welding box, and the positioning robotic arm includes an arm body and a fixing plate disposed at the free end of the arm body.

[0024] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0025] 1. Compared with existing microprism reflective films, the microprism reflective film proposed in this invention perforates the intermediate reflective layer. The purpose of perforation is to ensure that the adhesive on the adhesive layer can directly contact and bond with the transparent protective layer during the bonding and lamination process of the surface layers. This treatment has two advantages: First, by bonding the transparent protective layer and the adhesive layer together, the intermediate reflective layer is sandwiched between the two, which can protect the intermediate reflective layer and thus improve its service life; Second, the pre-bonding of the transparent protective layer and the adhesive layer ensures that the surface layers will not slip during the subsequent hot-pressing and lamination process, and that the surface layers can be connected more tightly.

[0026] 2. In step c, the raw material film is introduced into the cooling roller for secondary cooling. The advantage of this is that the raw material film, after being formed by the forming roller and the heating roller, already has a microprism structure on its surface. At this time, the microprism structure is at a high temperature and is extremely unstable. After the first cooling operation, the microprism structure layer can be fixed on the raw material film. The cooling roller in the first cooling operation maintains a constant temperature of 20-25 degrees Celsius. However, the raw material film does not yet have bending properties, that is, it cannot be wound up. When it bends, the surface microprism structure will still be damaged. The conventional treatment method is to place it at room temperature for more than 24 hours to stabilize the microprism structure on the raw material film. However, this invention performs secondary cooling. Before the secondary cooling, it is placed at room temperature for 0.5-1 hour to slightly increase its own temperature. Then, the secondary cooling roller maintains a constant temperature of 10-15 degrees Celsius. After the secondary cooling, the raw material film has the ability to be wound up, and its surface microprism structure is in a stable state. Compared with the conventional method, it saves the overall process time and improves work efficiency.

[0027] 3. After cooling in step d, the intermediate reflective layer is obtained. It is then perforated by a needle roller. The purpose of this is to ensure that the intermediate reflective layer is stable after cooling and to avoid damage to the microprism structure on its surface caused by vibration during the perforation process.

[0028] 4. In the preparation process of the forming roller, the reflective film mold is the most important step, as it is a key component in the preparation of the intermediate reflective layer. The quality of the intermediate reflective layer directly determines the reflective performance of the finished reflective film. The reflective film mold needs to ensure that the weld seams at the beginning and end are flat to ensure that it is flat and seamless when fitted onto the forming roller. Therefore, the metal welding device used in this invention is necessary. Existing metal welding devices usually involve assembling the metal parts to be welded into one piece, forming a welding line between them, and then the operator manually controls the laser welding gun with a joystick to perform the welding. The disadvantages of this method are that the welding process requires a high level of operator skill, and the welding accuracy is difficult to guarantee. At the same time, the welding process must be smooth and stable; if the time spent at the same point is too long, it will lead to weld seams. Unsightly or even failed welding is a problem. This invention first establishes a work slot on the workbench, within which a shelf is placed to hold the metal parts to be welded. When placing the metal parts, the shelf's tilt angle can be adjusted to tilt towards the operator. The metal parts are then pre-assembled manually. During assembly, an electromagnetic adsorption device is activated to fix the metal parts to the shelf, preventing displacement. During welding, pre-marking points on the weld seam, followed by a laser welding gun along the marked path, is conducted. Simultaneously, a positioning robotic arm provides downward pressure to the metal parts, ensuring no shaking during welding and guaranteeing a high welding success rate.

[0029] 5. The active and driven shafts are mounted in the working slot and pass through the placement plate. During rotation, the active shaft provides the main rotational driving force, while the two driven shafts provide auxiliary rotation. The driven shafts are located on both sides of the active shaft to prevent the placement plate from tilting under pressure when the metal part to be welded is placed on it. The driven shafts provide stability assistance for the placement and rotation of the placement plate. The secondary rotation hole is semi-circular, which restricts the movement trajectory of the driven shaft, thus ensuring that when the placement plate tilts, the driven shaft is exactly at the beginning and end of the secondary rotation hole, thereby ensuring the stability of the placement process.

[0030] 6. The storage panel is equipped with a composite vibration motor. The composite vibration motor consists of two identical vibration motors installed on the vibrating machine body. Its vibration mode is linear vibration, that is, the vibration trajectory of the vibrating body is a straight line on the horizontal plane.

[0031] 7. The composite vibration motor includes two vibration modes: one mode allows the placement plate to vibrate back and forth along the length of the worktable on a horizontal plane, and the other mode allows the placement plate to vibrate back and forth along the width of the worktable on a horizontal plane. These two different vibration modes are designed to coordinate two laser welding operations. When vibrating back and forth along the length of the welding worktable, the vibration frequency is 8-12 times / second, and the vibration range is 0.8-1.2mm from the initial position. In existing welding processes, the placement plate is assumed to be stationary when the laser welding gun performs welding operations along a preset trajectory. In this case, the laser welding gun's welding trajectory forms the weld seam, but errors during welding cannot be avoided. The usual solution is to manually adjust the laser welding gun after observing the deviation, but this carries the risk of damaging the original weld seam during the repair process. However, with this invention, during the first welding operation, the laser welding gun performs welding operations along a pre-marked path, while the placement plate vibrates back and forth along the length of the worktable. The back-and-forth vibration in the direction corresponding to the left and right of the welding line ensures that the weld formed after the initial welding is S-shaped and wrapped around the welding line. When it vibrates back and forth along the width of the worktable, its vibration frequency is 3-5 times / second, and the vibration range is 1-3mm back and forth from the initial position. The purpose of this vibration is to meet the requirements of the secondary welding operation. After the first welding, the weld is wrapped in an S-shape around the welding line. As the initial welding, its function is to initially fix the two metal parts to be welded, and at the same time, to lay the groundwork for the second welding operation. The secondary welding process is... The worktable vibrates back and forth along its width, with the vibration direction being the length of the welding line. The laser welding gun welds in the opposite direction of the preset welding path. With the worktable vibrating back and forth along the welding line, the laser welding gun can repeatedly weld the welding line per unit time and unit distance. It can also melt the weld formed after the first welding operation to form a new weld. The new weld is wider than the original welding line and completely covers the welding line. At the same time, it completely covers the S-shaped weld formed in the first welding, achieving both aesthetics and stability.

[0032] 8. The positioning robotic arm includes an arm body and a fixed plate disposed at the free end of the arm body. The arm body has six degrees of freedom and can move freely in three-dimensional space. The fixed plate at the free end of the arm body is used to cooperate with a placement plate with electromagnetic attraction function to provide downward pressure from the vertical direction, providing a better clamping effect for the metal parts to be welded. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the layered structure of the microprism reflective material in this invention;

[0034] Figure 2This is a cross-sectional view of the layered structure of the microprism reflective material in this invention;

[0035] Figure 3 This is a top view of the intermediate reflective layer of the microprism reflective material in this invention;

[0036] Figure 4 This is a three-dimensional structural diagram of the metal welding device in this invention;

[0037] Figure 5 This is a schematic diagram of the front structure of the metal welding device in this invention;

[0038] Figure 6 yes Figure 5 Enlarged view of point A in the middle;

[0039] Figure 7 This is a three-dimensional structural diagram of the workbench in the metal welding device of the present invention;

[0040] Figure 8 This is a schematic diagram of the internal structure of the workbench in the metal welding device of the present invention;

[0041] Figure 9 This is a top view of the workbench in the metal welding device of the present invention.

[0042] Figure 10 This is a schematic diagram of the bottom surface structure of the fixing plate in this invention;

[0043] Figure 11 This is a schematic diagram of the first welding trajectory of the reflective film mold in this invention;

[0044] Figure 12 This is a schematic diagram of the second welding trajectory of the reflective film mold in this invention. Detailed Implementation

[0045] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0046] refer to Figures 1 to 12 This embodiment proposes a microprism reflective material, including a composite layer 1. The composite layer 1 includes, from top to bottom, a protective transparent layer 11, an intermediate reflective layer 12, an adhesive layer 13, and a release paper layer 14. The adhesive layer 13 connects the intermediate reflective layer 12 and the release paper layer 14. The intermediate reflective layer 12 is provided with a positioning hole 121. The adhesive layer 13 is bonded to the protective transparent layer 11 through the positioning hole 121. The protective transparent layer 11, the intermediate reflective layer 12, and the adhesive layer 13 are reinforced and connected by hot pressing. The intermediate reflective layer 12 is provided with a microprism reflective structure 122. The microprism reflective structure is a four-sided pyramid structure. The microprism reflective structure 122 is formed on the intermediate reflective layer 12 by direct hot pressing through a reflective film mold.

[0047] This embodiment also proposes a method for preparing the above-mentioned microprism reflective material, including the following steps:

[0048] 1) Material preparation; prepare the protective transparent layer roller, adhesive layer roller and release paper layer roller, and place them on the frame respectively;

[0049] 2) Prepare the intermediate reflective layer 12;

[0050] a. To prepare the forming roller, the reflective film mold material is first cut to the required size using a metal cutting device. The edges of the cut reflective film mold are then trimmed again using the metal cutting device to ensure the smoothness of the edges. The cut reflective film molds are then joined end to end and welded together using a metal welding device to form a cylindrical shape. The cylindrical reflective film mold is then fitted onto the roller to form the forming roller.

[0051] b. The raw material film is introduced into the forming roller and heated and formed by the heating roller. The raw material film after passing through the forming roller has a micro-prism structure.

[0052] c. Introduce the raw material film from step b onto the cooling roller for cooling. Cooling is divided into primary cooling and secondary cooling. During primary cooling, the cooling roller is kept at a constant temperature of 20-25 degrees Celsius. After primary cooling, the film is left at room temperature for 0.5-1 hour before secondary cooling. During secondary cooling, the cooling roller is kept at a constant temperature of 10-15 degrees Celsius.

[0053] d. After cooling, the intermediate reflective layer is obtained, and it is perforated by a needle roller;

[0054] 3) Surface layer lamination: The adhesive layer is preheated to make both the upper and lower surfaces of the adhesive layer sticky. The protective transparent layer 11, the intermediate reflective layer 12, the adhesive layer 13 and the release paper layer 14 are introduced into the heated lamination roller for surface layer lamination.

[0055] 4) Pressure bonding; The bonded composite layer is introduced into a pressure roller for pressure bonding.

[0056] In the above method, step a of step 2) involves two welding operations during the head and tail welding of the reflective film mold using a metal welding device: the initial welding and the secondary reinforcement welding.

[0057] The aforementioned metal welding apparatus includes a frame 2, a worktable 3 fixedly mounted on the frame 2, and a laser welding device 4;

[0058] A worktable 3 is a cuboid structure, defined by two sides along its length direction X as long sides and two sides along its width direction Y as wide sides. A working groove 31 is provided on the upper surface of the worktable 3, extending along and through the worktable 3 in the width direction Y. The working groove 31 includes a bottom surface 311 and two oppositely arranged side surfaces 312. A rotating mechanism is provided within the working groove 31, comprising a driving shaft 8, a driven shaft 9, and... The storage plate 51 has an active rotating shaft 8 and a driven rotating shaft 9 that pass through it and are mounted on both sides 312 of the working groove 31. The active rotating shaft 8 rotates along its own axis via a rotary motor. An electromagnetic adsorption device is integrated inside the storage plate 51. The active rotating shaft 8 and the driven rotating shaft 9 are fixedly connected to the storage plate 51. The rotation of the active rotating shaft 8 drives the storage plate 51 to rotate. The rotary motor and the electromagnetic adsorption device built into the storage plate 51 are known components and will not be described in detail here.

[0059] The laser welding device 4 includes a movable guide rail 6 mounted on the frame 2, which is arranged along the length X of the worktable 3. A first driving device 7, which is a drive motor, is mounted on the movable guide rail 6. The laser welding device 4 is mounted on the first driving device 7 and reciprocates on the movable guide rail 6 under the drive of the first driving device 7. The laser welding device 4 includes an electric telescopic shaft 41, a laser welding box 42, a laser welding gun 43, and a positioning robotic arm 44. The electric telescopic shaft 41 is connected to the first... The drive device 7 and the laser welding box 42 are connected by the electric telescopic shaft 41. The laser welding box 42 can reciprocate along the width direction Y of the worktable 3. The laser welding gun 43 is disposed on the lower bottom surface of the laser welding box 42. A laser positioning head 45 is disposed on the lower bottom surface of the laser welding box 42. The laser positioning head 45 and the laser welding gun 43 are focused on the same point, which is used to provide dot positioning for the welding path. The side 312 of the working groove 31 is provided with a main rotation hole 32 and a secondary rotation hole 33. There are two secondary rotation holes 33. The auxiliary rotating hole 33 is semi-circular and is located on both sides of the main rotating hole 32. The driving rotating shaft 8 is inserted into the main rotating hole 32, and the driven rotating shaft 9 is inserted into the auxiliary rotating hole 33. A composite vibration motor is integrated into the shelf 51. The vibration mode of the composite vibration motor is linear vibration. The composite vibration motor is not shown in the figure. The composite vibration motor can make the shelf 51 vibrate back and forth along the length direction X of the worktable 3 or along the width direction Y of the worktable 3 on the horizontal plane. When the worktable 3 vibrates back and forth along its length direction X, its vibration frequency is 8-12 times / second, and the vibration range is 0.8-1.2mm back and forth from the initial position. When it vibrates back and forth along the width direction Y of the worktable 3, its vibration frequency is 3-5 times / second, and the vibration range is 1-3mm back and forth from the initial position. The above descriptions are of its working parameter ranges. In this embodiment, the specific parameters are set as follows: when it vibrates back and forth along the length direction X of the worktable 3, its vibration frequency is 8 times / second, and the vibration range is 0.8mm back and forth from the initial position.The positioning robotic arm 44 is located on the side of the laser welding box 42. It has a vibration frequency of 3 times per second when vibrating back and forth along the width direction Y of the worktable 3. The vibration range is 1 mm from the initial position. The positioning robotic arm 44 includes an arm body 441 and a fixed plate 442 located at the free end of the arm body 441. The fixed plate 442 is a hollow rectangular ring structure. Ball bearings 4421 are provided on the lower surface of the fixed plate 442 to ensure that the fixed plate 442 is simultaneously attracted when the electromagnet attracts the metal plate C. The attracted fixed plate 442 provides downward pressure on the metal plate C in the vertical direction, ensuring that it does not shake during welding. The ball bearings 4421 reduce the horizontal friction force on the fixed plate 442 when it moves with the laser welding gun 43.

[0060] The method of using the aforementioned metal welding device is also proposed, including the following steps:

[0061] 1) Place the parts to be welded; when the electromagnet is energized, place the two metal plates C, which have been trimmed by the cutting device, on the shelf 51 on the workbench 3. After placement, control the tilt angle of the shelf 51 to tilt it towards the operator's side, so that the operator can visually calibrate the connection between the two metal plates C for the first time. After the first calibration, the shelf 51 returns to a horizontal state.

[0062] 2) Laser pre-positioning; after the edges of the two metal plates C are joined together, a welding line is formed. The operator controls the laser positioning head 45 on the laser welding device 4 to make dots on the welding line through the computer. The working path of the laser welding gun 43 is a straight line movement between two adjacent laser positioning points.

[0063] 3) Initial welding operation; the composite vibration motor built into the placement plate 51 is started, causing it to vibrate back and forth along the length direction X of the worktable 3, and then the laser welding gun 43 performs welding operations along the preset welding path. After the initial welding, the weld seam is a small-pitch wavy pattern placed on the welding line (e.g., Figure 11 (as shown);

[0064] 4) Secondary welding operation; keeping the position of the laser welding gun 43 unchanged, start the composite vibration motor built into the placement plate 51, causing it to vibrate back and forth along the width direction Y of the worktable 3. Further, the laser welding gun 43 begins to work, its working path being the reverse of the path formed after pre-positioning. The weld seam overlaps with the welding line and completely covers the weld seam formed in the initial welding (e.g., ...). Figure 12 (as shown);

[0065] 5) When the electromagnet is de-energized, the welding of metal plate C is completed.

[0066] In the implementation of the above method, in step 3), the laser welding gun 43 moves at a speed of 8 mm / s when welding along the preset welding path, and in step 4), the laser welding gun 33 moves at a speed of 3 mm / s when welding in the opposite direction of the welding path. This moving speed is to match the vibration frequency of the composite vibration motor. When the frequency of the composite vibration motor is adjusted, the moving speed of the laser welding gun 33 can also be adaptively adjusted to meet the welding accuracy requirements. Specifically, in step 3), the laser welding gun moves at a speed of 8 mm-12 mm / s when welding along the preset welding path, and in step 4), the laser welding gun moves at a speed of 3 mm-5 mm / s when welding in the opposite direction of the welding path.

[0067] The fixing plate is a hollow rectangular ring structure. Ball bearings are provided on the lower surface of the fixing plate. The ball bearings can reduce the contact area between the fixing plate and the metal part to be welded, as well as the friction between them, thereby ensuring that it does not affect the vibration.

[0068] During the welding process, the metal parts are fixed to the placement plate by electromagnets. The magnetic attraction of the placement plate can be controlled by adjusting the current flowing through the electromagnets. Before laser welding, pre-marking is done manually on the welding line to provide a path for the laser welding gun. The working path of the laser welding gun is a straight line between two adjacent laser positioning points. The more positioning points there are, the higher the overlap between the laser welding gun and the welding line, resulting in more precise welding.

[0069] During the welding operation, the initial welding operation is carried out first. During the initial welding, the plate is vibrated back and forth along the length of the worktable 3. The length of the worktable is the width of the welding line. After welding with the laser welding gun, a small-pitch wavy (S-shaped) pattern is formed. The initial welding is a pre-welding, which pre-fixes the two metal plates. At the same time, the weld formed can provide a foundation for the second welding.

[0070] During the secondary welding operation, the laser welding gun is kept in the same position, and the placement plate vibrates back and forth along the width of the worktable 3, which is the length direction of the welding line. This, combined with the laser welding gun, ensures back-and-forth welding operations per unit time and unit distance. The back-and-forth welding process improves the welding completion rate and makes the finished product more stable. Furthermore, it widens the weld seam, allowing the secondary weld seam to completely cover the S-shaped weld seam formed in the first welding, resulting in a more aesthetically pleasing finished product.

[0071] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0072] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0073] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0074] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0075] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A method for using a microprism reflective material, the microprism reflective material comprising a composite layer, the composite layer comprising, from top to bottom, a protective transparent layer, an intermediate reflective layer, an adhesive layer, and a release paper layer, the adhesive layer connecting the intermediate reflective layer and the release paper layer, the intermediate reflective layer having a positioning hole, the adhesive layer being bonded to the protective transparent layer through the positioning hole, the protective transparent layer, the intermediate reflective layer, and the adhesive layer being reinforced by hot pressing, the intermediate reflective layer having a microprism reflective structure, the microprism reflective structure being a square pyramid structure; Its features are: Includes the following steps: 1) Material preparation; prepare the protective transparent layer roller, adhesive layer roller and release paper layer roller, and place them on the frame respectively; 2) Prepare the intermediate reflective layer; a. To prepare the forming roller, the reflective film mold material is first cut to the required size using a metal cutting device. The edges of the cut reflective film mold are then trimmed again using the metal cutting device to ensure the smoothness of the edges. The cut reflective film molds are then joined end to end and welded together using a metal welding device to form a cylindrical shape. The cylindrical reflective film mold is then fitted onto the roller to form the forming roller. b. The raw material film is introduced into the forming roller and heated and formed by the heating roller. The raw material film after passing through the forming roller has a micro-prism structure. c. Introduce the raw material film from step b onto the cooling roller for cooling. Cooling is divided into primary cooling and secondary cooling. During primary cooling, the cooling roller is kept at a constant temperature of 20-25 degrees Celsius. After primary cooling, the film is left at room temperature for 0.5-1 hour before secondary cooling. During secondary cooling, the cooling roller is kept at a constant temperature of 10-15 degrees Celsius. d. After cooling, the intermediate reflective layer is obtained, and it is perforated by a needle roller; 3) Surface layer lamination: The adhesive layer is preheated to make both the upper and lower surfaces of the adhesive layer sticky. The protective transparent layer, the intermediate reflective layer, the adhesive layer and the release paper layer are then introduced into the heated lamination roller for surface layer lamination. 4) Pressure lamination; The laminated layer is introduced into a pressure roller for pressure lamination; In step 2), step a) involves two welding operations during the head and tail welding of the reflective film mold using a metal welding device: the initial welding and the secondary reinforcement welding. The metal welding device includes a frame, a worktable fixedly mounted on the frame, and a laser welding device. The worktable has a rectangular structure, and a working groove is provided on the upper surface of the worktable. The working groove is arranged along the width direction of the worktable and extends through the worktable in that direction. The working groove includes a bottom surface and two oppositely arranged side surfaces. A rotating mechanism is provided inside the working groove. The rotating mechanism includes a driving shaft, a driven shaft, and a placement plate. The driving shaft and the driven shaft pass through the placement plate and are mounted on the two sides of the working groove. The driving shaft rotates along its own axis via a rotary motor. An electromagnetic adsorption device is integrated inside the placement plate. The machine frame is equipped with a movable guide rail, which is arranged along the length of the worktable. A first driving device is arranged on the movable guide rail, and the laser welding device is arranged on the first driving device. Under the drive of the first driving device, the laser welding device reciprocates on the movable guide rail. The laser welding device includes an electric telescopic shaft, a laser welding box, a laser welding gun, and a positioning robotic arm. The electric telescopic shaft connects the first driving device and the laser welding box. The laser welding box can reciprocate along the width of the worktable through the electric telescopic shaft. The laser welding gun is arranged on the bottom surface of the laser welding box, and a positioning laser head is arranged on the bottom surface of the laser welding box. The working groove has a main rotating hole and a secondary rotating hole on its side. The secondary rotating holes are symmetrically arranged on both sides of the main rotating hole. The secondary rotating holes are semi-circular arc-shaped. The active rotating shaft is inserted into the main rotating hole, and the driven rotating shaft is inserted into the secondary rotating hole.

2. The method for producing a microprism reflective material according to claim 1, characterized in that: The shelf is equipped with a composite vibration motor, which vibrates in a linear manner.

3. The method for producing a microprism reflective material according to claim 2, characterized in that: The composite vibration motor enables the shelf to vibrate back and forth on the horizontal plane along the length of the worktable or along the width of the worktable. When it vibrates back and forth along the length of the worktable, its vibration frequency is 8-12 times / second, and the vibration range is 0.8-1.2mm back and forth from the initial position. When it vibrates back and forth along the width of the worktable, its vibration frequency is 3-5 times / second, and the vibration range is 1-3mm back and forth from the initial position.

4. The method for producing a microprism reflective material according to claim 3, characterized in that: The positioning robotic arm is disposed on the side of the laser welding box, and the positioning robotic arm includes an arm body and a fixing plate disposed at the free end of the arm body.

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