Production method and system for diaphragm for laminating special-shaped structural shell
The UV curing and bridging varnish process for shell diaphragms addresses environmental and cost issues, achieving stable and high-quality diaphragm production by precise texture transfer and intelligent parameter control.
Patent Information
- Application Number
- CN202411346681.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-26
- Publication Date
- 2024-12-20
- Estimated Expiration
- 2044-09-26
AI Technical Summary
The production process of shell diaphragms for electronic devices and automotive parts is environmentally unfriendly, costly, and results in unstable product quality due to volatile organic compounds, material waste, and uneven coating thickness.
A method involving UV curing coatings and bridging varnishes is used to transfer textures onto film substrates, ensuring precise and efficient transfer of both basic and fine textures, while utilizing an intelligent database for parameter configuration based on substrate type.
This method reduces environmental impact, lowers production costs, and enhances the stability and appearance quality of the diaphragms by minimizing VOC emissions and material waste, and ensuring consistent texture transfer.
Smart Images
Figure CN118876622B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical fields of housings or structural parts of electrical equipment, digital industrial production processes of housing diaphragms, curing coatings, and more particularly to a production method and system for diaphragms used for bonding to housings with special-shaped structures. Background Art
[0002] In the shell appearance design and production of electronic devices such as mobile phones and tablets and automotive interior parts, in order to meet consumers' demand for shell appearance, the shell is usually designed to be transparent and combined with a shell diaphragm with decorative effects to enhance the aesthetics of the device. In the prior art, the decorative effect of the shell diaphragm is mainly formed by printing and spraying processes, and the decorative effect required by the spray design is printed on the diaphragm substrate. The printing and spraying process will produce volatile organic compounds, which are not only harmful to the environment but also affect the health of workers. In order to control the emission of volatile organic compounds, enterprises need to install exhaust gas treatment equipment, which will increase production costs. During the spraying process, especially when coating special-shaped structures, a high amount of material waste will be caused. The excess paint produced by spraying is usually difficult to recycle and reuse, resulting in an increase in the amount of material used and the cost. The coating thickness may also be uneven in different areas, resulting in unstable product quality. Moreover, if the equipment or environmental parameters are improperly controlled during the spraying process (such as spraying pressure, nozzle status), it may cause color consistency problems and affect the appearance quality of the product.
[0003] In summary, in the prior art, the production process of the shell diaphragm has technical problems such as being environmentally unfriendly, high cost, and unstable product appearance quality. Summary of the invention
[0004] In view of the deficiencies in the above-mentioned prior art, the present invention provides a method and system for producing diaphragms for bonding to special-shaped structure shells, so as to produce environmentally friendly and healthy shell diaphragms, reduce the production cost of shell diaphragms, and improve the stability of the appearance quality of shell diaphragms.
[0005] In a first aspect, the present invention provides a method for producing a membrane for laminating a housing with a special-shaped structure, comprising:
[0006] Configuring the type of the film substrate, and configuring the printing process parameters for the different types of the film substrate, wherein the printing process parameters include basic texture printing process parameters and fine texture printing process parameters;
[0007] Spraying a first UV curing coating between the specific type of the film substrate and the basic texture master mold, light curing the first UV curing coating according to the basic texture printing process parameters corresponding to the specific type of the film substrate, so that the basic texture of the basic texture master mold is transferred to the specific type of the film substrate through the first UV curing coating, and printing a first bridging varnish on the film substrate after the basic texture is transferred, and thermally curing the first bridging varnish to obtain a basic texture film;
[0008] A second UV curing coating is sprayed between the basic texture film and the fine texture master mold, and the second UV curing coating is photocured according to the fine texture printing process parameters corresponding to the specific type of the film substrate, so that the fine texture of the fine texture master mold is transferred to the basic texture film through the second UV curing coating, and a second bridging varnish is printed on the basic texture film after the fine texture is transferred, and the second bridging varnish is thermally cured to obtain a fine texture film, and the film base color printing and laminating glue printing are performed.
[0009] In a second aspect, the present invention provides a production system for a membrane for bonding a special-shaped structure housing, comprising:
[0010] Controlling the host computer to run the above-mentioned production method of the diaphragm for laminating a housing with a special-shaped structure;
[0011] a roll-to-roll transfer machine, communicating with the control host, for transferring the base texture and the fine texture under the control of the control host;
[0012] The roll-to-roll printing machine communicates with the control host and is used for printing the first bridge varnish and the second bridge varnish under the control of the control host.
[0013] Compared with the prior art, the present invention has the following beneficial effects:
[0014] The present invention provides a production method and system for a membrane for bonding a special-shaped structural shell. The method comprises configuring the type of a membrane substrate and configuring printing process parameters for different types of the membrane substrate, wherein the printing process parameters include basic texture printing process parameters and fine texture printing process parameters. A first UV curing coating is sprayed between the membrane substrate of a specific type and a basic texture master mold. The first UV curing coating is photocured according to the basic texture printing process parameters corresponding to the membrane substrate of a specific type, so that the basic texture of the basic texture master mold is transferred to the membrane substrate of a specific type through the first UV curing coating. A first bridging varnish is printed on the membrane substrate after the basic texture is transferred. The first bridging varnish is thermally cured to obtain a basic texture membrane, a second UV curing coating is sprayed between the basic texture membrane and the fine texture master mold, and the second UV curing coating is photocured according to the fine texture printing process parameters corresponding to the specific type of the membrane substrate, so that the fine texture of the fine texture master mold is transferred to the basic texture membrane through the second UV curing coating, and the second bridging varnish is printed on the basic texture membrane after the fine texture is transferred, and the second bridging varnish is thermally cured to obtain a fine texture membrane, and membrane base color printing and laminating glue printing are performed, thereby producing environmentally friendly and healthy shell membranes, reducing the production cost of shell membranes, and improving the stability of the appearance quality of shell membranes. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their description are used to explain the present invention and do not constitute an improper limitation of the present invention. Some specific embodiments of the present invention will be described in detail in an exemplary and non-restrictive manner with reference to the drawings. The same reference numerals in the drawings indicate the same or similar components or parts. It should be understood by those skilled in the art that these drawings are not necessarily drawn to scale. In the drawings:
[0016] Figure 1 It is a schematic flow chart of a method for producing a diaphragm for laminating a housing with a special-shaped structure according to an embodiment of the present invention;
[0017] Figure 2 This is a schematic diagram of the structure of a housing diaphragm according to an embodiment of the present invention;
[0018] Figure 3 It is a schematic diagram of the architecture of a production system for a membrane for bonding a special-shaped structure shell according to an embodiment of the present invention.
[0019] Description of reference numerals: 1. feeding roller; 2. pressing roller; 3. membrane substrate; 4. mother mold; DETAILED DESCRIPTION
[0020] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiment of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiment of the present invention. Obviously, the described embodiment is only an embodiment of a part of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work should fall within the scope of protection of the present invention.
[0021] Embodiment 1
[0022] See also Figure 1-Figure 3 This embodiment provides a method for producing a membrane for bonding a special-shaped structural shell, including step S101, step S102 and step S103.
[0023] S101, configuring the type of film substrate, and configuring printing process parameters for different types of the film substrate, wherein the printing process parameters include basic texture printing process parameters and fine texture printing process parameters;
[0024] S102, spraying a first UV curing coating between the specific type of the film substrate and the basic texture master mold, and light curing the first UV curing coating according to the basic texture printing process parameters corresponding to the specific type of the film substrate, so that the basic texture of the basic texture master mold is transferred to the specific type of the film substrate through the first UV curing coating, and printing a first bridging varnish on the film substrate after the basic texture is transferred, and thermally curing the first bridging varnish to obtain a basic texture film;
[0025] S103, spraying a second UV curing coating between the basic texture film and the fine texture master mold, and light-curing the second UV curing coating according to the fine texture printing process parameters corresponding to the specific type of the film substrate, so that the fine texture of the fine texture master mold is transferred to the basic texture film through the second UV curing coating, and printing a second bridging varnish on the basic texture film after the fine texture is transferred, thermally curing the second bridging varnish to obtain a fine texture film, and performing film base color printing and laminating glue printing.
[0026] It should be noted that different substrates exhibit different characteristics (such as thermal expansion coefficient, surface smoothness, etc.) during processing. In step S101, before starting production, by configuring the type of film substrate and the printing process parameters required for different substrates (including printing process parameters for basic texture and fine texture), the stability of the printing effect can be ensured, material waste and defective products can be reduced, and cost control can be achieved. In step S102, when the basic texture is transferred on the film substrate, the first UV curing coating is sprayed, and the basic texture printing process parameters adapted to the specific type of substrate are photocured, so that the basic texture on the basic texture master mold is accurately transferred to the film substrate through the first UV curing coating. After the basic texture is transferred to the film substrate, the first bridge varnish is printed and thermally cured. After the first bridge varnish is cured, it can not only provide a stable base layer for the subsequent transfer of fine textures, but also enhance the mechanical properties and surface hardness of the film. It should be noted that UV curing coatings are usually composed of low molecular weight resins, reactive diluents, photoinitiators, and additives. Compared with traditional solvent-based coatings, UV-curing coatings contain almost no or only a very small amount of volatile organic solvents. During the construction and curing process, there is almost no solvent volatilization, which can significantly reduce the emission of volatile organic compounds (VOCs). Under UV light, the photoinitiator absorbs light energy and decomposes to produce free radicals or cations. These free radicals or cations initiate the chain polymerization reaction of the resin in the coating, cross-linking the resin molecules into a solid film. The entire curing process does not rely on the volatilization of the solvent to form a film, but directly initiates the polymerization reaction under light by the photoinitiator, so a large amount of volatile substances will not be produced. Moreover, the curing time of UV-curing coatings is extremely short, usually a few seconds to tens of seconds to complete the curing process. Compared with traditional coatings, UV-curing coatings significantly reduce energy consumption. It is understandable that the bridging varnish is usually a resin or prepolymer containing multiple functional groups, which can form a three-dimensional network structure after curing, which can not only enhance the mechanical properties and surface hardness of the film, but also make the film surface more uniform, stable and flat, effectively supporting the subsequent fine texture transfer, and avoiding texture distortion or transfer defects caused by uneven or unstable film surface. Among them, the cured bridging varnish layer can fill the tiny depressions or unevenness that may exist in the base texture film, making the surface smoother, which is conducive to the precise transfer of fine textures. In addition, the cured varnish layer provides a high-adhesion surface, which is conducive to the firm adhesion of the fine texture transfer material on the film surface, thereby ensuring the consistency and integrity of the transfer effect.
[0027] It should also be noted that when transferring fine textures onto the base texture film, similarly, the pattern on the fine texture master mold is transferred to the base texture film by spraying a second UV curing coating and performing light curing according to the fine texture printing process parameters. This process can further enrich the surface texture and visual effect of the film. At the same time, the printing and thermal curing of the second bridging varnish can not only protect the fine texture layer and enhance the scratch resistance and wear resistance of the film, but also provide a surface suitable for base color printing and laminating adhesive printing. Among them, the use of fine texture transfer can enhance the complexity of the product's appearance and market appeal, while the use of UV curing technology can reduce the negative impact on the environment, reduce energy consumption, and reduce the cost of waste disposal.
[0028] It should be noted that in this embodiment, by configuring the type of diaphragm substrate and configuring the printing process parameters for different types of diaphragm substrates, the printing process parameters include basic texture printing process parameters and fine texture printing process parameters, so that an intelligent database containing different diaphragm substrate types and their corresponding process parameters can be established. Different diaphragm types correspond to different parameter configurations. By identifying the substrate type, the corresponding process parameters are quickly called for production control. After identifying the type of diaphragm substrate, the printing process parameters of the basic texture and fine texture that match it are automatically called to realize information-based and intelligent production control, ensure the accuracy and consistency of parameters, reduce debugging time, and improve production efficiency.
[0029] It is also important to note that base textures usually involve coarser or macro textures, such as larger patterns, geometric shapes, or deeper bumps. These textures provide the main visual and tactile effects for the entire film and are the basis of the surface texture. Fine textures involve finer texture details, such as tiny lines, texture particles, or very detailed patterns. These textures are usually superimposed on the base texture to increase the complexity and sophistication of the surface texture. Because base textures and fine textures have significant differences in size, depth, and optical effect requirements, different printing process parameters are required to ensure that each layer of texture can be accurately and clearly transferred to the film. In addition, because base textures are usually rough, the required UV-curable coatings have higher viscosity and stronger fluidity to accommodate larger areas of coverage and deeper texture transfer. This requires that the parameters of the light curing process, such as light intensity, curing time, etc., need to be optimized for these characteristics. Fine textures require higher precision and finer coatings, so UV-curable coatings with lower viscosity and better fluidity are required to ensure that the fine parts of the fine texture can be accurately filled. At the same time, more sophisticated control parameters are required during the photocuring process to prevent blurring of textures or loss of details. In addition, different film substrates respond differently to these materials, so the configuration of printing process parameters needs to consider the characteristics of the substrate and the compatibility of the materials to ensure that both basic and fine textures can obtain ideal transfer effects. Based on this, this embodiment proposes some further preferred embodiments, in which the first UV curing coating has higher viscosity and stronger fluidity than the second UV curing coating.
[0030] It should also be noted that, in this embodiment, the special-shaped structural housing may include housings of electrical devices such as mobile phones and tablet computers, and housings of automotive interior decoration parts.
[0031] In some specific embodiments, see Figure 2 , spraying a first UV curing coating between the specific type of the film substrate and the basic texture master mold, including: controlling the feed roller 1 of the roll-to-roll transfer machine to drive the specific type of the film substrate 3 to move to the bottom of the pressure roller 2 of the roll-to-roll transfer machine and contact the basic texture master mold covered on the pressure roller of the roll-to-roll transfer machine, and the basic texture is formed on the master mold 4; controlling the curing coating nozzle of the roll-to-roll transfer machine to spray the first UV curing coating to the contact gap between the master mold and the film. Spraying a second UV curing coating between the basic texture film and the fine texture master mold includes: controlling the feed roller of the roll-to-roll transfer machine to drive the basic texture film to move to the bottom of the pressure roller of the roll-to-roll transfer machine and contact the fine texture master mold covered on the pressure roller of the roll-to-roll transfer machine; and spraying the second UV curing coating to the contact gap between the master mold and the film.
[0032] In some preferred embodiments, the basic texture printing process parameters include a first light curing time and a first light curing energy for light curing the first UV curing coating, and the fine texture printing process parameters include a second light curing time and a second light curing energy for light curing the second UV curing coating, the first light curing time is longer than the second light curing time, and the first light curing energy is higher than the second light curing energy. Exemplarily, the first light curing time is 5 seconds, the first light curing energy is 1000mJ / cm², the second light curing time is 4 seconds, and the second light curing energy is 500mJ / cm².
[0033] It should be noted that the base texture is usually rough or deep, so a longer light curing time and higher light curing energy are required to ensure that the UV curing paint can fully cure and fill the depth of the texture. Fine textures are usually delicate, with shallow texture depth, and need to show fine patterns and tiny details. Therefore, using a shorter light curing time and a lower light curing energy can avoid over-curing and ensure that the paint does not flow too much, thereby maintaining the clarity and accuracy of the fine texture. In addition, since the base texture usually involves a large surface area and deeper bumps, the first UV curing paint requires a higher viscosity and stronger adhesion, so a higher light curing energy and a longer curing time are required to ensure that the paint can be fully cured and form a solid base layer. The second UV curing paint is a paint for fine textures, which needs to have a lower viscosity and better fluidity to adapt to fine texture features. Lower light curing energy and shorter curing time can avoid excessive flow of the paint during the curing process, ensure clear transfer of fine textures, and reduce excessive material accumulation.
[0034] In some preferred embodiments, the basic texture printing process parameters include a first heat curing time and a first heat curing temperature for heat curing the first bridge varnish, and the fine texture printing process parameters include a second heat curing time and a second heat curing temperature for heat curing the second bridge varnish, the first heat curing time is shorter than the second heat curing time, and the first heat curing temperature is equal to the second heat curing temperature. Exemplarily, the first heat curing time is 20 minutes, the second heat curing time is 90 minutes; the first heat curing temperature and the second heat curing temperature are both 80°C. It should be noted that the main function of the bridge varnish of the basic texture layer is to provide a stable bottom layer and enhance the mechanical properties and surface hardness of the film. Since the basic texture is relatively rough, the required bridge varnish layer is usually thicker, so a shorter heat curing time (20 minutes) can quickly achieve curing in a shorter time while ensuring its strength and hardness. The bridge varnish of the fine texture layer needs to not only protect the fine surface texture, but also ensure that the details of the texture are clear. Due to the complexity and richness of the fine texture, a longer heat curing time (90 minutes) is required to ensure that the bridge varnish can be gradually and evenly cured at a lower temperature to avoid texture deformation or detail loss caused by too fast curing. In addition, setting the same heat curing temperature (80°C) helps simplify process control and avoid unstable quality caused by temperature fluctuations. By adjusting the curing time instead of the curing temperature, the curing process can be controlled more accurately, so that the basic texture and fine texture can complete different curing tasks at the same temperature, ensuring the stability and consistency of the production process.
[0035] In some preferred embodiments, the different types of film substrates include PET type film substrates, PO type film substrates, ABS type film substrates and PETG type film substrates. When the film substrate is a PET type film substrate, the first light curing energy includes 700-1000 mJ / cm², the second light curing energy includes 500-600 mJ / cm², the first light curing time includes 15-20 seconds, and the second light curing time includes 10-15 seconds; when the film substrate is a PO type film substrate, the first light curing energy includes 750-850 mJ / cm², the second light curing energy includes 550-650 mJ / cm², the first light curing time includes 18-22 seconds, and the second light curing time includes 12-17 seconds; when the film substrate is an ABS type film substrate, the first light curing energy includes 600-700 mJ / cm², the second light curing energy includes 400-500 mJ / cm², the first light curing time includes 12-16 seconds, and the second light curing time includes 8-12 seconds; when the film substrate is a PETG type film substrate, the first light curing energy includes 700-800 mJ / cm², the second light curing energy includes 500-600 mJ / cm², the first light curing time includes 14-18 seconds, and the second light curing time includes 10-14 seconds. It should be noted that PET (polyethylene terephthalate) has good mechanical strength, thermal stability and chemical resistance, but it is highly sensitive to the UV curing process. In order to avoid deformation of the substrate or degradation of surface properties caused by over-curing, medium to high light curing energy (700-1000 mJ / cm²) and relatively long light curing time (15-20 seconds, 10-15 seconds) are required to ensure uniform curing of the coating. PO (polyolefin) generally has good flexibility and chemical resistance, but its absorption rate of UV light is low, so higher light curing energy (750-850 mJ / cm², 550-650 mJ / cm²) and slightly longer light curing time (18-22 seconds, 12-17 seconds) are required to ensure sufficient curing of the material surface coating. ABS (Acrylonitrile Butadiene Styrene) is tougher, but its heat and UV resistance are not as good as other materials. To avoid over-curing that causes embrittlement of the substrate or surface cracking, set a lower light curing energy (600-700 mJ / cm², 400-500 mJ / cm²) and a shorter light curing time (12-16 seconds, 8-12 seconds) to accommodate its lower heat resistance and higher light curing sensitivity. PETG (Polyethylene Terephthalate Glycol Copolymer) is similar to PET, but has better processability and flexibility.In order to maintain its excellent physical properties while ensuring good coating adhesion and surface quality, a medium light curing energy (700-800 mJ / cm², 500-600 mJ / cm²) and a relatively moderate light curing time (14-18 seconds, 10-14 seconds) are set. It is understandable that different substrates absorb UV light at different efficiencies. Substrates with higher absorption rates (such as ABS) require lower light curing energy to avoid over-curing, while substrates with lower absorption rates (such as PO) require higher light curing energy to ensure sufficient curing of the coating. In addition, light curing time is closely related to energy. Too short a time may lead to incomplete curing and affect coating performance; too long a time may cause overexposure of the material, causing thermal stress or deformation. Therefore, the combination of time and energy needs to be optimized according to the curing response characteristics of the substrate. The setting of light curing energy and time needs to ensure sufficient adhesion between the coating and the substrate. Especially for harder substrates such as PET and ABS, proper control of light curing energy is crucial to avoid adhesion loss due to over-curing. High photocuring energy can usually improve the surface hardness of the coating, but for flexible substrates such as PO and PETG, too high hardness may affect its flexibility. Therefore, the photocuring energy needs to be controlled within an appropriate range to achieve a balance between hardness and flexibility.
[0036] In some further preferred embodiments, when the film substrate is a PET type film substrate, the first thermal curing time is 10-20 minutes, preferably 15 minutes; the first thermal curing temperature is 70-90°C, preferably 80°C; the second thermal curing time is 45-75 minutes, preferably 60 minutes; the second thermal curing temperature is 70-90°C, preferably 80°C; when the film substrate is a PO type film substrate, the first thermal curing time is 15-25 minutes, preferably 20 minutes; the first thermal curing temperature is 75-95°C, preferably 85°C; the second thermal curing time is 60-90 minutes, preferably 75 minutes; the second thermal curing temperature is 75-95°C, preferably 85°C; when the film substrate is an ABS type film substrate, the first thermal curing time is 8-18 minutes, preferably 12 minutes; the first thermal curing temperature is 65-80°C, preferably 75°C; the second thermal curing time is 30-60 minutes, preferably 45 minutes; the second heat curing temperature is 65-80°C, preferably 75°C; when the film substrate is a PETG type film substrate, the first heat curing time is 12-20 minutes, preferably 16 minutes; the first heat curing temperature is 70-85°C, preferably 80°C; the second heat curing time is 40-70 minutes, preferably 55 minutes; the second heat curing temperature is 70-85°C, preferably 80°C. It should be noted that PET has high thermal stability and can maintain stable performance for a long time. The heat curing time is preferably set to a first heat curing time of 15 minutes and a second heat curing time of 60 minutes to ensure that uniform curing can be achieved in different levels of curing without damaging the material properties. The PO substrate has better flexibility, but requires higher temperatures and longer times to ensure uniform curing. The heat curing time is preferably set to a first heat curing time of 20 minutes and a second heat curing time of 75 minutes, which can ensure that the coating does not deform or lose details during the entire curing process. ABS material is sensitive to heat, and the shorter curing time is to avoid embrittlement. The heat curing time is preferably set to 12 minutes for the first heat curing time and 45 minutes for the second heat curing time to achieve good coating adhesion while maintaining the toughness of the material. PETG material is suitable for medium time and temperature heat curing, and the heat curing time is preferably set to 16 minutes for the first heat curing time and 55 minutes for the second heat curing time to ensure delicate texture and coating performance while maintaining the physical properties of the material.
[0037] It should also be noted that PET materials have good thermal stability and can withstand relatively high temperatures without significant deformation or performance degradation. The heat curing temperature range of 70-90℃ can fully activate the cross-linking reaction of the bridging varnish while maintaining the physical properties of the PET substrate. In this temperature range, the coating material can form a strong chemical bond with the surface of the PET substrate to improve adhesion. The preferred value of 80℃ provides a good balance, allowing the coating to fully cure while avoiding degradation of the substrate due to overheating. Higher heat curing temperatures help to increase the surface hardness of the coating and enhance the scratch resistance and wear resistance of the film, while 80℃ can achieve a good balance between hardness and flexibility. In addition, PO materials are relatively soft and have a high coefficient of thermal expansion, requiring higher temperatures (75-95℃) to ensure uniform curing of the coating and avoid incomplete curing. The preferred value of 85℃ can reduce the risk of thermal deformation of the substrate while ensuring the integrity of the coating. Higher curing energy can promote uniform spreading and curing of the coating on the surface of the PO substrate, preventing surface defects or uneven coating. This temperature range also helps maintain a stable curing effect during the production process, especially in continuous production lines, to ensure consistent product quality. ABS materials are sensitive to temperature changes, and higher temperatures may cause embrittlement of the material, so the lower temperature range of 65-80°C can avoid thermal damage to the substrate during the curing process. The preferred value of 75°C can ensure moderate curing of the coating while avoiding embrittlement or cracking of the ABS substrate. In this temperature range, it can ensure that the bridging varnish forms a strong bond with the surface of the ABS substrate, enhance adhesion, and prevent coating peeling. The lower heat curing temperature can also maintain the flexibility of ABS, which is suitable for applications that require use under large deformation conditions. In addition, PETG material is similar to PET, but it has better processability and flexibility. The heat curing temperature range of 70-85°C ensures sufficient curing of the bridging varnish without affecting the physical properties of the substrate. The preferred value of 80°C can effectively improve the hardness and durability of the coating while maintaining the flexibility of the substrate. In this temperature range, the coating material can evenly cover the surface of the PETG substrate to avoid uneven coating or sagging.
[0038] In some further preferred embodiments, after obtaining the fine texture film, the fine texture film is imaged to obtain a fine texture film image, and the surface appearance defects of the fine texture film in the fine texture film image are analyzed, and when the fine texture film does not have surface appearance defects in the laminated product image, the fine texture film without surface appearance defects is printed with film base color and laminated glue, and when the fine texture film has surface appearance defects in the laminated product image, the basic texture printing process parameters and the fine texture printing process parameters are adjusted. It should be noted that by image capturing the fine texture film and obtaining the surface appearance image of the fine texture film, tiny surface appearance defects such as scratches, dents, texture fractures or unevenness can be accurately detected, thereby improving the efficiency and accuracy of quality control. Once the surface appearance defects are detected, the corresponding basic texture and fine texture printing process parameters are automatically fed back and adjusted to ensure that the process parameters can be optimized in real time according to the actual situation during the production process, thereby improving the intelligent level of production. At the same time, through the image analysis of the fine texture film, potential production problems can be discovered at an early stage, thereby avoiding material waste in subsequent processing.
[0039] Embodiment 2
[0040] See also Figure 1-3 This embodiment provides a production system for a membrane for bonding a special-shaped structure housing, including:
[0041] Controlling the host to run the method for producing a membrane for laminating a housing with a special-shaped structure as described in any of the above embodiments;
[0042] a roll-to-roll transfer machine, communicating with the control host, for transferring the base texture and the fine texture under the control of the control host;
[0043] The roll-to-roll printing machine communicates with the control host and is used for printing the first bridge varnish and the second bridge varnish under the control of the control host.
[0044] It should be noted that, in this embodiment, by configuring the type of the film substrate and configuring the printing process parameters for the different types of the film substrate, the printing process parameters include the basic texture printing process parameters and the fine texture printing process parameters, spraying the first UV curing coating between the specific type of the film substrate and the basic texture master mold, and photocuring the first UV curing coating according to the basic texture printing process parameters corresponding to the specific type of the film substrate, so that the basic texture of the basic texture master mold is transferred to the specific type of the film substrate through the first UV curing coating, and printing the first bridging varnish on the film substrate after the basic texture is transferred, and thermally curing the first bridging varnish. A bridge varnish is applied to obtain a basic texture membrane, a second UV curing coating is sprayed between the basic texture membrane and the fine texture master mold, and the second UV curing coating is photocured according to the fine texture printing process parameters corresponding to the specific type of the membrane substrate, so that the fine texture of the fine texture master mold is transferred to the basic texture membrane through the second UV curing coating, and a second bridge varnish is printed on the basic texture membrane after the fine texture is transferred, and the second bridge varnish is thermally cured to obtain a fine texture membrane, and membrane base color printing and laminating glue printing are performed, thereby producing an environmentally friendly and healthy shell membrane, reducing the production cost of the shell membrane, and improving the stability of the appearance quality of the shell membrane.
[0045] It should be noted that in this embodiment, by configuring the type of diaphragm substrate and configuring the printing process parameters for different types of diaphragm substrates, the printing process parameters include basic texture printing process parameters and fine texture printing process parameters, so that an intelligent database containing different diaphragm substrate types and their corresponding process parameters can be established. Different diaphragm types correspond to different parameter configurations. By identifying the substrate type, the corresponding process parameters are quickly called for production control. After identifying the type of diaphragm substrate, the printing process parameters of the basic texture and fine texture that match it are automatically called to realize information-based and intelligent production control, ensure the accuracy and consistency of parameters, reduce debugging time, and improve production efficiency.
[0046] It is also important to note that base textures usually involve coarser or macro textures, such as larger patterns, geometric shapes, or deeper bumps. These textures provide the main visual and tactile effects for the entire film and are the basis of the surface texture. Fine textures involve finer texture details, such as tiny lines, texture particles, or very detailed patterns. These textures are usually superimposed on the base texture to increase the complexity and sophistication of the surface texture. Because base textures and fine textures have significant differences in size, depth, and optical effect requirements, different printing process parameters are required to ensure that each layer of texture can be accurately and clearly transferred to the film. In addition, because base textures are usually rough, the required UV-curable coatings have higher viscosity and stronger fluidity to accommodate larger areas of coverage and deeper texture transfer. This requires that the parameters of the light curing process, such as light intensity, curing time, etc., need to be optimized for these characteristics. Fine textures require higher precision and finer coatings, so UV-curable coatings with lower viscosity and better fluidity are required to ensure that the fine parts of the fine texture can be accurately filled.
[0047] It should be pointed out that the above embodiments are only preferred specific implementation modes of the present invention, and the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by any technician familiar with the technical field within the technical scope disclosed by the present invention should be covered within the protection scope of the present invention. The protection scope of the present invention should be based on the protection scope of the claims.
Claims
1. A method for producing a diaphragm for laminating a special-shaped structural shell, characterized in that: include: Configuring the type of the film substrate, and configuring the printing process parameters for the different types of the film substrate, wherein the printing process parameters include basic texture printing process parameters and fine texture printing process parameters; Spraying a first UV curing coating between the specific type of the film substrate and the basic texture master mold, light curing the first UV curing coating according to the basic texture printing process parameters corresponding to the specific type of the film substrate, so that the basic texture of the basic texture master mold is transferred to the specific type of the film substrate through the first UV curing coating, and printing a first bridging varnish on the film substrate after the basic texture is transferred, and thermally curing the first bridging varnish to obtain a basic texture film; A second UV curing coating is sprayed between the basic texture film and the fine texture master mold, and the second UV curing coating is photocured according to the fine texture printing process parameters corresponding to the specific type of the film substrate, so that the fine texture of the fine texture master mold is transferred to the basic texture film through the second UV curing coating, and a second bridging varnish is printed on the basic texture film after the fine texture is transferred, and the second bridging varnish is thermally cured to obtain a fine texture film, and the film base color printing and laminating glue printing are performed; the first UV curing coating is sprayed between the specific type of the film substrate and the basic texture master mold, including: controlling the feeding roller of the roll-to-roll transfer machine to drive the specific type of the film substrate to move to the bottom of the pressure roller of the roll-to-roll transfer machine to contact the basic texture master mold covered on the pressure roller of the roll-to-roll transfer machine; controlling the curing coating nozzle of the roll-to-roll transfer machine to spray the first UV curing coating into the contact gap between the master mold and the film; The method comprises: controlling a feed roller of a roll-to-roll transfer machine to drive the basic texture film sheet to move to the bottom of a pressure roller of the roll-to-roll transfer machine and contact the fine texture master mold covered on the pressure roller of the roll-to-roll transfer machine; controlling a curing coating nozzle of the roll-to-roll transfer machine to spray the second UV curing coating to the contact gap between the master mold and the film sheet; the basic texture printing process parameters comprise a first light curing time and a first light curing energy for light curing the first UV curing coating, and the fine texture printing process parameters comprise a second light curing time and a second light curing energy for light curing the second UV curing coating, the first light curing time being longer than the second light curing time, and the first light curing energy being higher than the second light curing energy; the first light curing time is 5 seconds, the first light curing energy is 1000mJ / cm², the second light curing time is 4 seconds, and the second light curing energy is 500mJ / cm².
2. The method for producing a membrane for bonding a special-shaped structure shell according to claim 1, characterized in that: The basic texture printing process parameters include a first thermal curing time and a first thermal curing temperature for thermal curing the first bridging varnish, and the fine texture printing process parameters include a second thermal curing time and a second thermal curing temperature for thermal curing the second bridging varnish, wherein the first thermal curing time is shorter than the second thermal curing time, and the first thermal curing temperature is equal to the second thermal curing temperature.
3. The method for producing a membrane for bonding a special-shaped structure housing according to claim 2, characterized in that: The first thermal curing time is 20 minutes, the second thermal curing time is 90 minutes; the first thermal curing temperature and the second thermal curing temperature are both 80°C.
4. The method for producing a membrane for bonding a special-shaped structure housing according to claim 1, characterized in that: Different types of the film substrates include PET type film substrates, PO type film substrates, ABS type film substrates and PETG type film substrates.
5. The method for producing a membrane for bonding a special-shaped structure housing according to claim 4, characterized in that: When the film substrate is a PET type film substrate, the first light curing energy includes 700-1000 mJ / cm², the second light curing energy includes 500-600 mJ / cm², the first light curing time includes 15-20 seconds, and the second light curing time includes 10-15 seconds; when the film substrate is a PO type film substrate, the first light curing energy includes 750-850 mJ / cm², the second light curing energy includes 550-650 mJ / cm², the first light curing time includes 18-22 seconds, and the second light curing time includes 12-17 seconds; when the film substrate is an ABS type film substrate, the first light curing energy includes 600-700 mJ / cm², the second light curing energy includes 400-500 mJ / cm², the first light curing time includes 12-16 seconds, and the second light curing time includes 8-12 seconds; when the film substrate is a PETG type film substrate, the first light curing energy includes 700-800 mJ / cm², the second light curing energy includes 500-600 mJ / cm², the first light curing time includes 14-18 seconds, and the second light curing time includes 10-14 seconds.
6. A production system for membranes used for bonding special-shaped structural shells, characterized in that: include: Controlling the host computer to run the method for producing a membrane for laminating a special-shaped structural shell according to any one of claims 1 to 5; a roll-to-roll transfer machine, communicating with the control host, for transferring the base texture and the fine texture under the control of the control host; The roll-to-roll printing machine communicates with the control host and is used for printing the first bridge varnish and the second bridge varnish under the control of the control host.