A double-mode misregistration asynchronous die-cutting system and process method

Abstract

The application discloses a double-mode misaligned layout asynchronous die-cutting system and a process method, which comprises a feeding process module, an asynchronous process module, a sequential bonding process module and a forming process module, the asynchronous process module comprises workstations No. 1-5, the sequential bonding process module comprises workstations No. 6-14, the forming process module comprises workstations No. 15-18, and the workstations internally comprise rubber rollers, knife rollers, concave rollers and steel rollers. Compared with single-mode layout, double-mode or even multi-mode layout can significantly increase the production capacity per unit time, and compared with double-mode aligned layout, double-mode misaligned layout does not affect the production capacity, therefore, double-mode or multi-mode layout is one of effective measures to realize the increase of production capacity, and compared with double-mode aligned layout, double-mode misaligned layout can efficiently utilize materials whether asynchronous die-cutting is performed or not, and especially, the loss of expensive materials is reduced.

Description

Technical Field

[0001] This invention relates to the field of die-cutting technology, specifically to a dual-die staggered layout asynchronous die-cutting system and process. Background Technology

[0002] Die-cutting plays a vital role in the consumer electronics industry. As consumer electronics devices such as laptops and tablets become thinner and lighter with simpler designs, they are increasingly becoming multi-unit integrated. Therefore, achieving an economical and high-precision processing model is the primary task of die-cutting.

[0003] Dual-die layout die-cutting is a process that can form two centrally symmetrical products in one die-cutting operation. It is generally used for die-cutting long and narrow products. Compared with single-die layout die-cutting, this process can significantly increase production capacity. Moreover, the two products are closely related, which greatly facilitates the die-cutting personnel's control over the product's appearance, size and other characteristics. However, when the products are processed in an aligned layout, it inevitably increases the waste of some expensive materials.

[0004] Chinese patent CN109748134B proposes to transfer materials that need to be saved to the main material strip in an asynchronous manner. The asynchronous size of the material (theoretically equal to the material bonding length) can be adaptively adjusted according to actual needs in order to reduce waste area. This is called asynchronous die-cutting process. Asynchronous die-cutting largely avoids material waste. However, this asynchronous die-cutting method is to some extent affected by the die-cutting layout method.

[0005] To maximize material utilization in asynchronous die-cutting, this process proposes a dual-mold staggered layout asynchronous die-cutting method. This method involves staggering the product layout in two molds, causing the upper and lower pieces to be misaligned in the axial direction. On the one hand, the dual-mold layout maintains high production capacity; on the other hand, the staggered layout changes the expensive material from the central symmetry of the aligned layout to the axial symmetry, which theoretically further shortens the asynchronous material distance and provides a more "material-saving" approach to asynchronous die-cutting.

[0006] Chinese patent CN209207694U proposes combining two or more products on a single circular die using the characteristics of a circular die, while simultaneously arranging multiple identical dies evenly within one cycle of the circular die. This is suitable for products with simple structures and high material utilization, but for products with complex structures and containing valuable materials, it is no different from the traditional double-die alignment and layout die-cutting process, and the material loss problem remains unresolved.

[0007] Therefore, it is essential to design a practical dual-mode misaligned layout asynchronous die-cutting system and process. Summary of the Invention

[0008] The purpose of this invention is to provide a dual-mode misaligned layout asynchronous die-cutting system and process method to solve the problems mentioned in the background art.

[0009] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a dual-mold staggered layout asynchronous die-cutting system, including a feeding process module, an asynchronous process module, a sequential bonding process module and a forming process module.

[0010] The asynchronous process module includes workstations one to five, the sequential bonding process module includes workstations six to fourteen, and the forming process module includes workstations fifteen to eighteen.

[0011] According to the above technical solution, the workstation number includes a rubber roller, a knife roller, a concave roller, and a steel roller.

[0012] According to the above technical solution, the feeding process module includes a silicone protective film, an infrared guide, and a bottom support film. The silicone protective film enters the asynchronous process module through the infrared guide and is discharged by the steel roller at station number one. The silicone protective film forms a die-cutting main material strip with uniform tension and near flatness through the action of the infrared guide.

[0013] According to the above technical solution, the asynchronous process module includes an asynchronous transfer knife, an asynchronous material backing film, and an asynchronous material. The main material strip enters the bottom of the asynchronous transfer knife after passing through station number one and the second adhesive strip composite material two. The asynchronous material backing film and the asynchronous material pass through the bottom of the adhesive roller, through the bottom of the knife roller, and then enter the bottom of the asynchronous transfer knife. The asynchronous material backing film and the asynchronous material are positioned above the main material strip. After being cut by the asynchronous transfer knife, they pass through station numbers three, four, and five in sequence to complete the asynchronous process module and obtain the asynchronous layer. In the asynchronous process module, two or more knife rollers need to cooperate to complete the die-cutting of expensive materials. After the first knife roller roughly cuts, the material is transferred to the main material strip by the asynchronous feeding roller group through the asynchronous transfer knife. Then, based on the second knife roller, a higher precision trimming is achieved, thereby obtaining the asynchronous layer.

[0014] According to the above technical solution, the sequential bonding process module includes a first adhesive strip composite material, insulating PET, a second adhesive strip composite material, foil, and a silicone film removal layer. The asynchronous layer enters station number six, where the first adhesive strip composite material is bonded to the top of the asynchronous layer by a roller. The bonded asynchronous layer then enters station number seven, where excess first adhesive strip composite material is removed by a cutting roller. It then enters station number eight, where the insulating PET is simultaneously conveyed to station number eight and bonded to the top of the asynchronous layer by a roller. The asynchronous layer, with the first adhesive strip composite material and insulating PET bonded sequentially, enters station number nine, where excess material is removed by a cutting roller. The asynchronous layer then sequentially enters stations ten, eleven, and twelve, where the second adhesive strip composite material passes through station number nine. Station 12 performs front-side adhesive application, then proceeds to station 11 for cutting, and then to station 10 for back-side adhesive application. At station 10, the foil is bonded using steel rollers, with the unbonded portion at the bottom moved by concave rollers to avoid affecting the bottom adhesive application. The foil, after being bonded by the steel rollers, enters the top of the adhesive roller for adhesive application, then proceeds to station 13. The asynchronous layer, after adding the second adhesive strip composite material, enters station 13, where the foil and asynchronous layer are processed by the pressing of the steel rollers. At station 14, the silicone film is removed by the discharge blade, and then the foil enters the molding module. At stations 6 to 14, the first adhesive strip composite material, insulating PET, the second adhesive strip composite material, and the foil are bonded sequentially, resulting in an adhesive strip layer, a PET layer, an adhesive strip layer, and a foil layer.

[0015] According to the above technical solution, the molding process module includes a release film and outer frame waste. The release film enters station number sixteen and is cut by the top of the cutting roller. Then it enters station number fifteen and is bonded to the bottom of the steel roller and the bottom of the asynchronous layer that has entered station number fifteen. The asynchronous layer, after being bonded to the release film, enters station number seventeen and is cut by the cutting roller. Then, between stations seventeen and eighteen, the outer frame waste is removed by the discharge blade. Finally, it enters station number eighteen and is processed by the rubber roller to complete the production of the finished material. Then, by peeling off the main material strip at stations fifteen to sixteen, the materials of each layer are transferred to the release film, and the final product is obtained.

[0016] According to the above technical solution, the finished material consists of a foil layer, a second adhesive strip layer, a PET layer, a first adhesive strip layer, an asynchronous layer, and a release film layer from top to bottom.

[0017] According to the above technical solution, different cutting lines are processed on the cutting roller according to the product's appearance contour. The spacing between the cutting lines is not greater than the axial dimension of the cutting roller, so that the material on the strip is broken by the shearing of the cutting lines when it passes through the cutting roller, thus obtaining the material's contour. The next process after the cutting roller is to set a rubber roller, through which the different materials behind the cutting lines of the cutting roller are firmly bonded together in sequence to obtain a product made of stacked materials.

[0018] According to the above technical solution, the cutter roller is provided with staggered cutter lines, and the asynchronous die-cutting process of the material is realized through the double cutter line design.

[0019] A process method for a dual-mold staggered layout asynchronous die-cutting system includes the following steps: a silicone protective film is used to form a die-cutting main material strip with uniform tension and near flatness through an infrared correction device; in the asynchronous process module, two or more cutting rollers are usually required to cooperate to complete the die-cutting of expensive materials. After the first cutting roller roughly cuts the material, it is transferred to the main material strip by an asynchronous feeding roller group through an asynchronous transfer knife. Then, a second cutting roller is used to achieve higher precision trimming, thereby obtaining an asynchronous layer; in the sequential bonding process module, the first adhesive strip composite material, insulating PET, the second adhesive strip composite material, and foil are sequentially bonded, that is, the first adhesive strip layer, the PET layer, the second adhesive strip layer, and the foil layer are obtained in sequence; then, in the forming process module, the main material strip is peeled off and the materials of each layer are transferred to the release film to finally obtain the product.

[0020] Compared with the prior art, the beneficial effects achieved by the present invention are: Compared to single-mode layout, dual-mode or even multi-mode layout can significantly increase the production capacity per unit time. Compared to dual-mode aligned layout, dual-mode misaligned layout does not affect the production capacity. Therefore, dual-mode or multi-mode layout is one of the effective measures to increase production capacity.

[0021] This invention employs a dual-mold staggered layout for products, causing the upper and lower product pieces to be misaligned in the axial direction. On the one hand, the dual-mold layout maintains high production capacity, and on the other hand, the staggered layout transforms the central symmetry of expensive materials from that of aligned layout to axial symmetry, further shortening the distance between asynchronous materials and providing a more material-saving approach for asynchronous die-cutting.

[0022] Compared to dual-mode aligned layout, this invention can make efficient use of materials, especially reducing the waste of expensive materials, regardless of whether asynchronous die-cutting is performed.

[0023] In this invention, the asynchronous process module is not limited to the installation station in this case. It varies from product to product, and the process is highly flexible. Combined with dual-mode or even multi-mode staggered layout, it can effectively increase production capacity and reduce losses. Attached Figure Description

[0024] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0025] In the attached diagram: Figure 1 This is a schematic diagram of the process flow of the present invention; Figure 2 This is a schematic diagram of the production materials layered according to the present invention.

[0026] In the diagram: 1. Base film; 2. Asynchronous material base film; 3. Asynchronous material; 4. Silicone protective film; 5. Infrared correction device; 6. Asynchronous transfer knife; 7. First adhesive strip composite material; 8. Insulating PET; 9. Adhesive roller; 10. Knife roller; 11. Concave roller; 12. Steel roller; 13. Station number; 14. Second adhesive strip composite material; 15. Foil material; 16. Remove silicone film; 17. Release film; 18. Outer frame waste. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Please see Figure 1-2 The present invention provides the following technical solution: a dual-mold staggered layout asynchronous die-cutting process, including a feeding process module, an asynchronous process module, a sequential bonding process module and a forming process module.

[0029] The asynchronous process module includes station numbers 131 to 135, the sequential bonding process module includes station numbers 136 to 14, and the forming process module includes station numbers 1315 to 18. Station number 13 includes a rubber roller 9, a cutter roller 10, a concave roller 11, and a steel roller 12. Different cut lines are processed on the cutter roller 10 according to the product's appearance contour. The distance between the cut lines is not greater than the axial dimension of the cutter roller 10, so that the material on the strip is broken by the shearing of the cut lines when it passes through the cutter roller 10, thus obtaining the material's contour. The next process after the cutter roller 10 is set with a rubber roller 9. The rubber roller 9 firmly bonds the different materials behind the cut lines of the cutter roller 10 in sequence to obtain a product made of stacked materials. The cutter roller 10 has staggered cut lines. Through the double cutter line design, the asynchronous die-cutting process of the material is realized.

[0030] The feeding process module includes a silicone protective film 4, an infrared guide 5, and a bottom support film 1. The silicone protective film 4 enters the asynchronous process module through the infrared guide 5. The bottom support film 1 is discharged through the steel roller 12 at station number 13. The silicone protective film 4 forms a die-cutting main material strip with uniform tension and near flatness through the action of the infrared guide 5.

[0031] The asynchronous process module includes an asynchronous transfer knife 6, an asynchronous material support film 2, and an asynchronous material 3. The main material strip passes through station 13-1 and the second adhesive strip composite material 14-2 before entering the bottom of the asynchronous transfer knife 6. The asynchronous material support film 2 and the asynchronous material 3 pass through the bottom of the adhesive roller 9, through the bottom of the knife roller 10, and then enter the bottom of the asynchronous transfer knife 6. The asynchronous material support film 2 and the asynchronous material 3 are positioned above the main material strip. After being cut by the asynchronous transfer knife 6, they pass through station 13-3, 4, and 5 in sequence to complete the asynchronous process module and obtain the asynchronous layer. In the asynchronous process module, two or more knife rollers need to work together to complete the die cutting of expensive materials. After the first knife roller roughly cuts the material, it is transferred to the main material strip by the asynchronous feeding roller group through the asynchronous transfer knife. Then, based on the second knife roller, a higher precision trimming is achieved, thereby obtaining the asynchronous layer.

[0032] The sequential bonding process module includes a first adhesive strip composite material 7, insulating PET 8, a second adhesive strip composite material 14, foil 15, and a silicone film removal device 16. The asynchronous layer enters station 136, where the first adhesive strip composite material 7 is bonded to the top of the asynchronous layer by the action of the adhesive roller 9. The bonded asynchronous layer then enters station 137, where excess first adhesive strip composite material 7 is removed by the cutting roller 10. It then enters station 138, while the insulating PET 8 is simultaneously conveyed to station 138. The insulating PET 8 is bonded to the top of the asynchronous layer by the action of the adhesive roller 9. The asynchronous layer with the first adhesive strip composite material 7 and insulating PET 8 bonded sequentially enters station 139, where excess material is removed by the cutting roller 10. The asynchronous layer then sequentially enters stations 1310, 1311, and 1312. The second adhesive strip composite material 14 is processed at station 1312. The front side is coated with adhesive, then it enters station 13 eleven for cutting, and then enters station 13 ten for back side adhesive. In station 13 ten, it is bonded by steel roller 12. The unbonded part at the bottom is moved by concave roller 11 to avoid affecting the bottom adhesive. The foil 15 is bonded to the top of the glue roller 9 by the action of steel roller 12, and then enters station 13 thirteen. The asynchronous layer after adding the second adhesive strip composite material 14 enters station 13 thirteen. The foil 15 and the asynchronous layer are processed by the pressing of steel roller 12. After entering station 13 fourteen, the silicone film 16 is removed by the discharge blade, and then it enters the molding process module. The first adhesive strip composite material 7, insulating PET 8, second adhesive strip composite material 14 and foil 15 are bonded sequentially in stations six to fourteen of station 13, that is, the adhesive strip layer, PET layer, adhesive strip layer and foil layer are obtained in sequence.

[0033] The molding process module includes a release film 17 and outer frame waste 18. The release film 17 enters station 13-sixteen and is cut by the top of the cutting roller 10. Then it enters station 13-fifteen and is bonded to the bottom of the steel roller 12 with the bottom of the asynchronous layer that has entered station 13-fifteen. The asynchronous layer, after being bonded with the release film 17, enters station 13-seventeen and is cut by the cutting roller 10. Then, between station 13-seventeen and eighteen, the outer frame waste 18 is removed by the discharge blade. Finally, it enters station 13-eighteen and is processed by the rubber roller 9 to complete the production of the finished material. Then, by peeling off the main material strip at stations 13-fifteen to sixteen, the materials of each layer are transferred to the release film, and the final product is obtained.

[0034] The finished material consists of, from top to bottom, a foil layer, a second adhesive strip layer, a PET layer, a first adhesive strip layer, an asynchronous layer, and a release film layer.

[0035] When in use, the silicone protective film forms a nearly flat die-cut main material strip with uniform tension through an infrared correction device. In the asynchronous process module, two or more cutting rollers are usually required to cooperate to complete the die-cutting of expensive materials. After the first cutting roller roughly cuts the material, it is transferred to the main material strip by the asynchronous feeding roller group through the asynchronous transfer knife. Then, the second cutting roller achieves higher precision trimming, thus obtaining the asynchronous layer. In the sequential bonding process module, the first adhesive strip composite material, insulating PET, the second adhesive strip composite material, and the foil are bonded sequentially, that is, the first adhesive strip layer, the PET layer, the second adhesive strip layer, and the foil layer are obtained in sequence. Then, in the molding process module, the main material strip is peeled off and the materials of each layer are transferred to the release film to finally obtain the product.

[0036] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0037] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A dual-mode misaligned layout asynchronous die-cutting system, characterized in that: It includes a feeding process module, an asynchronous process module, a sequential bonding process module, and a forming process module; The asynchronous process module includes station numbers (13) one to five, the sequential bonding process module includes station numbers (13) six to fourteen, the forming process module includes station numbers (13) fifteen to eighteen, and the station number (13) includes a rubber roller (9), a knife roller (10), a concave roller (11), and a steel roller (12). The feeding process module includes a silicone protective film (4), an infrared guide (5), and a bottom support film (1). The silicone protective film (4) enters the asynchronous process module through the infrared guide (5), and the bottom support film (1) is discharged by the steel roller (12) at station number (13). The silicone protective film (4) forms a die-cutting main material strip with uniform tension and near flatness through the action of the infrared guide (5). The asynchronous process module includes an asynchronous transfer knife (6), an asynchronous material support film (2), and an asynchronous material (3). The main material strip enters the bottom of the asynchronous transfer knife (6) after passing through station number (13) 1 and station number (13) 2. The asynchronous material support film (2) and the asynchronous material (3) pass through the bottom of the rubber roller (9), pass through the bottom of the knife roller (10), and enter the bottom of the asynchronous transfer knife (6). The asynchronous material support film (2) and the asynchronous material (3) are set above the main material strip. After being cut by the asynchronous transfer knife (6), they pass through station number (13) 3, 4, and 5 in sequence to complete the asynchronous process module and obtain the asynchronous layer. The sequential bonding process module includes a first adhesive strip composite material (7), insulating PET (8), a second adhesive strip composite material (14), foil (15), and a silicone film removal device (16). The asynchronous layer enters station number (13) six. The first adhesive strip composite material (7) is bonded to the top of the asynchronous layer by the action of the adhesive roller (9). Then, the bonded asynchronous layer enters station number (13) seven. The excess first adhesive strip composite material (7) is removed by the cutting roller (10). Then, it enters station number (13) eight. At the same time, the insulating PET (8) is transported to station number (13) eight. By the action of the adhesive roller (9), the insulating PET (8) is bonded to the top of the asynchronous layer. The asynchronous layer with the first adhesive strip composite material (7) and the insulating PET (8) bonded in sequence enters station number (13) nine. The excess material is removed by the cutting roller (10). Then, the asynchronous layer enters station number (13) nine. The second adhesive strip composite material (14) enters station number (13) 10, 11, and 12. The second adhesive strip composite material (14) is coated with adhesive on the front side through station number (13) 12, and then cut in station number (13) 11. It is coated with adhesive on the back side through station number (13) 10. It is bonded by steel roller (12) in station number (13) 10. The unbonded part at the bottom is moved by concave roller (11) to avoid affecting the bottom coating. The foil material (15) is coated with adhesive on the top of the adhesive roller (9) through the action of steel roller (12), and then enters station number (13) 13. The asynchronous layer after adding the second adhesive strip composite material (14) enters station number (13) 13. The foil material (15) and the asynchronous layer are processed by the pressing of steel roller (12). After entering station number (13) 14, the silicone film (16) is removed by the discharge blade, and then it enters the molding process module.

2. The dual-mode misaligned layout asynchronous die-cutting system according to claim 1, characterized in that: The molding process module includes a release film (17) and outer frame waste (18). The release film (17) enters station number (13) sixteen and is cut by the top of the cutter roller (10). Then it enters station number (13) fifteen and is bonded to the bottom of the steel roller (12) and the bottom of the asynchronous layer that has entered station number (13) fifteen. The asynchronous layer after being bonded with the release film (17) enters station number (13) seventeen and is cut by the cutter roller (10). Then, the outer frame waste (18) is removed by the discharge blade between station number (13) seventeen and eighteen. Finally, it enters station number (13) eighteen and is processed by the rubber roller (9) to complete the production of the finished material.

3. The dual-mode misaligned layout asynchronous die-cutting system according to claim 2, characterized in that: The finished material consists of, from top to bottom, a foil layer, a second adhesive strip layer, a PET layer, a first adhesive strip layer, an asynchronous layer, and a release film layer.

4. The dual-mode misaligned layout asynchronous die-cutting system according to claim 3, characterized in that: Different cutting lines are processed on the cutting roller (10) according to the product's appearance outline. The spacing between the cutting lines is not greater than the axial dimension of the cutting roller (10), so that the material on the strip is broken by the shearing of the cutting lines when it passes through the cutting roller (10), and the outline of the material is obtained. The next process of the cutting roller (10) is to set a rubber roller (9), and the different materials behind the cutting lines of the cutting roller (10) are firmly bonded together in sequence through the rubber roller (9) to obtain a product made of stacked materials.

5. The dual-mode misaligned layout asynchronous die-cutting system according to claim 4, characterized in that: The cutter roller (10) has staggered cutter lines, and the asynchronous die-cutting process of the material is realized through the design of double cutter lines.

6. A process method for a dual-mode misaligned layout asynchronous die-cutting system according to any one of claims 1-5, characterized in that: Includes the following steps: Step 1: The silicone protective film is used by an infrared correction device to form a die-cutting main material strip with uniform tension and near flatness; Step 2: In the asynchronous process module, two or more cutting rollers are usually required to work together to complete the die cutting of expensive materials. After the first cutting roller roughly cuts the material, it is transferred to the main material belt by the asynchronous feeding roller group through the asynchronous transfer knife. Then, the second cutting roller is used to achieve higher precision trimming, thereby obtaining the asynchronous layer. Step 3: In the sequential bonding process module, the first adhesive strip composite material, the insulating PET, the second adhesive strip composite material, and the foil are bonded sequentially to obtain the first adhesive strip layer, the PET layer, the second adhesive strip layer, and the foil layer. Step 4: Subsequently, in the molding process module, the main material strip is peeled off to transfer the materials of each layer onto the release film, and finally the product is obtained.

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