Cushioned foam slitting and lamination processes and sticker products

Abstract

The application discloses a cushion foam slitting and compounding process and a sticker product, and belongs to the technical field of die cutting. The cushion foam slitting and compounding process comprises the following steps: providing cushion foam raw materials and bottom supporting films; performing compounding treatment and cutting and slitting treatment on the cushion foam raw materials and the bottom supporting films to obtain a first combined material belt; the cutting depth of the cutting and slitting treatment is matched with the thickness of the cushion foam raw materials, so that the cushion foam raw materials are cut into a plurality of strip-shaped cushion foams; performing whole-page winding treatment on the first combined material belt to obtain a first product; performing separation treatment on the first product to obtain the strip-shaped cushion foams; providing release films and strip-shaped adhesive films; the number of the strip-shaped adhesive films is matched with that of the strip-shaped cushion foams; performing compounding treatment on the release films, the strip-shaped adhesive films and the strip-shaped cushion foams to obtain a second product; and the strip-shaped adhesive films are located between the strip-shaped cushion foams and the release films. The application can reduce the frequency of abnormal processing, improve processing efficiency and save materials.

Description

Technical Field

[0001] This application relates to the field of die-cutting technology, and in particular to a process for slitting and laminating raised foam and a sticker product. Background Technology

[0002] Existing sticker products typically incorporate thicker foam padding between the adhesive and release surfaces. This foam absorbs the winding tension of the sticker, resolving the issue of separation between the adhesive and release surfaces. Current foam slitting and lamination processes usually involve laminating the foam, double-sided adhesive, and adhesive paper, then cutting it into narrow strips. Each strip is then wound up using several cores with baffles on both sides. Next, the strips are removed as needed, the adhesive paper is peeled off to expose the adhesive surface, and then it is laminated with the release surface to obtain the final sticker product. Existing processes require a low-adhesion backing film for the cutting blades. Winding the narrow strips requires 15 to 20 sets of cores with baffles on both sides, and the winding process is prone to bursting and material flipping. Furthermore, peeling off the adhesive paper can easily cause the strips to break. Therefore, reducing the frequency of processing abnormalities, improving processing efficiency, and saving materials are urgent technical problems that need to be solved. Summary of the Invention

[0003] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes a process for slitting and laminating raised foam, which can reduce the frequency of abnormalities during processing, improve processing efficiency, and save materials.

[0004] To achieve the above objectives, this application adopts the following technical solution:

[0005] This application provides a process for slitting and laminating raised foam, including:

[0006] Provide raised foam materials and base film;

[0007] The raised foam material and the base film are subjected to composite processing and cutting and slitting processing to obtain a first composite material strip; wherein, the cutting depth of the cutting and slitting processing is matched with the thickness of the raised foam material so that the raised foam material is cut into several strips of raised foam.

[0008] The first composite strip is wound up in its entirety to obtain the first product;

[0009] The first product is separated to obtain strip-shaped raised foam;

[0010] A release film and strip adhesive film are provided; wherein the number of strip adhesive films is matched with the number of strip-shaped padding foams;

[0011] The release film, the strip adhesive film, and the strip-shaped raised foam are composited to obtain a second product; wherein the strip adhesive film is located between the strip-shaped raised foam and the release film.

[0012] The high-density foam slitting and laminating process according to the first aspect of this application has at least the following beneficial effects: By cutting only the raw material of the raised foam and using a backing film liner, materials are saved. By winding the first composite strip in one sheet, the materials and time required for winding are saved. Simultaneously, the first product after whole-sheet winding is wider, reducing the risk of bursting and material flipping, and reducing the frequency of anomalies. By separating the first product to obtain strip-shaped raised foam, and then laminating it with release film and strip-shaped adhesive film, the frequency of anomalies is reduced and the laminating efficiency is improved. Compared with the prior art, the embodiments of this application can reduce the frequency of anomalies during processing, improve processing efficiency, and save materials. Therefore, the embodiments of this application solve the technical problem of how to reduce the frequency of anomalies during processing, improve processing efficiency, and save materials.

[0013] According to some embodiments of the first aspect of this application, the raised foam slitting and composite equipment includes a pressing and cutting device, the pressing and cutting device includes a pressing station and a cutting station, the pressing station is provided with pressing rollers, and the cutting station is provided with a slitting knife;

[0014] The process of compounding and slitting the raised foam material and the base film to obtain a first composite strip includes:

[0015] The raised foam material and the base film are transported to the pressing station, and the pressing rollers are controlled to press the raised foam material and the base film together to obtain a second composite strip, wherein the raised foam material is located above the base film.

[0016] The second composite strip is transported to the cutting station, and the slitting knife is controlled to cut the raised foam material to obtain the first composite strip.

[0017] According to some embodiments of the first aspect of this application, the step of performing a full-sheet winding process on the first composite strip to obtain the first product includes:

[0018] Provides winding cores;

[0019] The first product is obtained by winding the first composite strip using the core, wherein the whole-sheet winding is performed when the strip-shaped padding foam and the bottom film are in a composite state.

[0020] According to some embodiments of the first aspect of this application, the separation process of the first product to obtain strip-shaped raised foam includes:

[0021] The first product is separated to obtain the strip-shaped raised foam and the third composite material strip, wherein the strip-shaped raised foam is separated from the first product at intervals, and the third composite material strip includes the bottom support film and the remaining strip-shaped raised foam.

[0022] The third composite strip is wound up to obtain the third product.

[0023] According to some embodiments of the first aspect of this application, after the step of winding the third composite strip to obtain the third product, the method further includes:

[0024] The third product is separated to obtain the strip-shaped raised foam and waste tape;

[0025] A new release film and a new strip adhesive film are provided; wherein the new strip adhesive film is matched in quantity with the strip-shaped padding foam;

[0026] The new release film, the new strip adhesive film, and the strip-shaped raised foam are laminated together to obtain the second product; wherein the new strip adhesive film is located between the strip-shaped raised foam and the new release film;

[0027] The waste belt is then discharged.

[0028] According to some embodiments of the first aspect of this application, the composite treatment of the release film, the strip adhesive film, and the strip-shaped raised foam to obtain a second product includes:

[0029] The strip-shaped adhesive film and the strip-shaped raised foam are composited to obtain several first composite strips;

[0030] The release film and several of the first composite strips are composited to obtain a second composite strip;

[0031] The second composite strip is wound up to obtain the second product.

[0032] According to some embodiments of the first aspect of this application, the spacing between a plurality of the first composite strips on the second composite strip is equal.

[0033] According to some embodiments of the first aspect of this application, the width of the raised foam material matches the width of the base film.

[0034] According to some embodiments of the first aspect of this application, the width of the strip-shaped padding foam matches the width of the strip-shaped adhesive film.

[0035] The present application will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0036] Figure 1 A flowchart illustrating one embodiment of the raised foam slitting and laminating process of this application;

[0037] Figure 2 for Figure 1 The flowchart of step S120 in the middle;

[0038] Figure 3 for Figure 1 The flowchart of step S130 in the process;

[0039] Figure 4 for Figure 1 The flowchart of step S140 in the middle;

[0040] Figure 5 for Figure 1 The flowchart for step S160 in the process. Detailed Implementation

[0041] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0042] In the description of this application, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0043] The embodiments of this application will be further described below with reference to the accompanying drawings.

[0044] Reference Figure 1 As shown, this application provides a process for slitting and laminating raised foam, applied to equipment for slitting and laminating raised foam. The process includes, but is not limited to, steps S110, S120, S130, S140, S150, and S160:

[0045] Step S110: Provide the raised foam material and the base film;

[0046] Step S120: The raised foam material and the base film are compounded and cut into strips to obtain the first composite material strip; wherein, the cutting depth of the cutting and slitting process is matched with the thickness of the raised foam material so that the raised foam material is cut into several strips of raised foam.

[0047] Step S130: The first composite strip is wound up in a single sheet to obtain the first product;

[0048] Step S140: Separate the first product to obtain strip-shaped raised foam;

[0049] Step S150: Provide release film and strip adhesive film; wherein the number of strip adhesive films matches the number of strip-shaped padding foam;

[0050] Step S160: The release film, strip adhesive film and strip-shaped raised foam are compounded to obtain the second product; wherein the strip adhesive film is located between the strip-shaped raised foam and the release film.

[0051] Steps S110, S120, S130, S140, S150, and S160 shown in this embodiment save materials by cutting only the raised foam material and using a backing film liner. By winding the first composite strip into a single sheet, both the material and time required for winding are saved. Simultaneously, the wider first product after full-sheet winding reduces the risk of bursting and material flipping, thus reducing the frequency of anomalies. Separating the first product to obtain strip-shaped raised foam, which is then laminated with release film and strip-shaped adhesive film, reduces the frequency of anomalies and improves lamination efficiency. Compared with existing technologies, this embodiment reduces the frequency of processing anomalies, improves processing efficiency, and saves materials.

[0052] It is understood that the raised foam slitting and laminating equipment includes a pressing and cutting device, which includes a pressing station and a cutting station. The pressing station is equipped with pressing rollers, and the cutting station is equipped with a slitting knife. (Refer to...) Figure 1 , 2 As shown, step S120 also includes, but is not limited to, steps S210 and S220:

[0053] Step S210: Transport the raised foam material and the bottom support film to the pressing station, control the pressing rollers to press the raised foam material and the bottom support film to obtain the second composite strip, wherein the raised foam material is located above the bottom support film.

[0054] Step S220: Transport the second composite strip to the cutting station, control the slitting knife to cut the raised foam material, and obtain the first composite strip.

[0055] Steps S210 and S220, as illustrated in the embodiments of this application, involve pressing the raised foam material and the base film together to ensure a tight bond between them, providing higher quality raw materials for subsequent processing. The use of a slitting knife to precisely cut the raised foam material ensures cutting depth and accuracy, reduces material waste, and improves production efficiency.

[0056] In some embodiments, the raised foam material and the backing film are transported to the lamination station. Here, lamination rollers precisely press the two together. The lamination rollers, by adjusting pressure and speed control, ensure a tight bond between the raised foam material and the backing film. To guarantee a good lamination effect, the raised foam material is always positioned above the backing film, ensuring a strong and uniform connection between the foam and the film. The lamination rollers are adjusted according to the thickness and characteristics of the material to ensure no damage is caused. During the lamination process, temperature and pressure parameters are also optimized and adjusted according to the requirements of different materials. By precisely controlling the lamination force, a good lamination effect between the raised foam material and the backing film is ensured, avoiding bubbles, wrinkles, or unevenness, providing a stable foundation for subsequent cutting and processing. Next, the second composite strip, which has been lamination completed, is transported to the cutting station. The cutting station is equipped with a precise slitting knife, capable of finely cutting the raised foam material according to the set cutting depth and spacing. The cutting tool depth is perfectly matched to the thickness of the raised foam material, ensuring accurate cutting dimensions for each strip of raised foam. During the cutting process, the cutting speed and angle are precisely controlled to prevent burrs or breakage, while maintaining the material's flatness and ensuring smooth subsequent processing. After cutting, the strips of raised foam in the first assembly strip are neatly arranged.

[0057] Understandably, referring to Figure 1 , 3 As shown, step S130 also includes, but is not limited to, steps S310 and S320:

[0058] Step S310: Provide the core;

[0059] Step S320: Use a core to wind up the first composite strip to obtain the first product. The whole-sheet winding is performed while the strip-shaped padding foam and the backing film are in a composite state.

[0060] Steps S310 and S320, as illustrated in this embodiment, utilize a full-plate winding process. The first product after full-plate winding is wider, reducing the risk of bursting and material flipping, and decreasing the frequency of anomalies. First, a core is provided to prepare for subsequent full-plate winding. The core is then used to wind the first composite strip in a composite state of strip-shaped padded foam and backing film. This process ensures that the material is neatly and compactly wound, avoiding wrinkles and unevenness, reducing material damage and waste, and also providing standardized raw materials for subsequent separation processing.

[0061] In some embodiments, the foam slitting and laminating equipment includes a winding station. Before starting full-sheet winding, a core suitable for the current production process must first be provided. The size and material of the core must be appropriately selected based on the length and width of the first composite strip and the characteristics of the composite material. Generally, the core is made of robust metal or high-strength plastic material to ensure that it will not deform due to changes in internal and external pressure during winding. Simultaneously, the diameter and length of the core should be compatible with the winding drum on the pressing and cutting equipment to ensure smooth completion of the entire winding process. During winding, to ensure tight winding of the material, the winding station is equipped with an automatic tension control device that monitors and adjusts the material tension on the core in real time. This prevents the material from being too loose or too tight, avoiding winding problems caused by uneven tension. The control system automatically adjusts the winding speed according to the material thickness, width, and tension requirements to ensure uniform winding and avoid curling or air bubbles. Furthermore, the winding station is also equipped with an automatic detection system that monitors the quality of the first composite strip in real time during the winding process, ensuring that each roll of product meets standards. If defects are found in the material, such as cracks, bubbles, or uneven seams, the system will immediately stop winding and issue an alarm to prompt the operator to check and repair the problem, thereby improving the quality of the final product.

[0062] Understandably, referring to Figure 1 , 4 As shown, step S140 also includes, but is not limited to, steps S410 and S420:

[0063] Step S410: Separate the first product to obtain strip-shaped raised foam and a third composite material strip, wherein the strip-shaped raised foam is separated from the first product at intervals, and the third composite material strip includes a backing film and the remaining strip-shaped raised foam.

[0064] Step S420: The third composite strip is wound up to obtain the third product.

[0065] Steps S410 and S420, as illustrated in this embodiment, firstly, the first product is separated to separate the strip-shaped raised foam spacers from the first product, forming strip-shaped raised foam and a third composite strip. The third composite strip includes a backing film and the remaining strip-shaped raised foam. The strip-shaped raised foam spacers are separated from the first product as needed, and the remaining strip-shaped raised foam can be used later, saving material. Next, the third composite strip is wound up to obtain the third product, providing a convenient product form for later use and reducing unnecessary material loss.

[0066] In some embodiments, the foam slitting and laminating equipment includes a separation station. First, a first product is fed to the separation station. The first product is a composite material after being wound into a single sheet, in which strips of foam padding and the backing film are tightly bonded. At this point, the separation station is equipped with a precise separation device capable of effectively separating the strips of foam padding from the backing film. The separation process, by adjusting the spacing and separation pressure, separates the strips of foam padding from the first product one by one. Specifically, the equipment utilizes a robotic arm or automated device to precisely separate the strips of foam padding from the backing film along the seam line of the composite material. During the separation process, the strips of foam padding maintain their integrity, ensuring that they do not break or deform.

[0067] Understandably, referring to Figure 1 , 4 As shown, after step S420, there are also steps S430, S440, S450, and S460:

[0068] Step S430: Separate the third product to obtain strip-shaped raised foam and waste tape;

[0069] Step S440: Provide a new release film and a new strip adhesive film; wherein the number of the new strip adhesive film matches the number of strip-shaped padding foam;

[0070] Step S450: The new release film, the new strip adhesive film, and the strip-shaped raised foam are laminated to obtain the second product; wherein the new strip adhesive film is located between the strip-shaped raised foam and the new release film;

[0071] Step S460: Discharge the waste belt.

[0072] Steps S430, S440, S450, and S460, as illustrated in this embodiment, firstly, separate the third product, successfully separating the strip-shaped raised foam from the waste strip, thereby ensuring the integrity of the strip-shaped raised foam and isolating the waste strip for convenient subsequent processing. This step allows the third product to be utilized, saving materials. Next, new release film and new strip-shaped adhesive film are provided, ensuring that the quantity of the new strip-shaped adhesive film matches the quantity of the new strip-shaped raised foam, avoiding material waste and improving the accuracy and efficiency of the lamination process.

[0073] In some embodiments, the raised foam slitting and laminating equipment is equipped with a recycling station. The recycling station can automatically collect waste belts for subsequent waste treatment, effectively maintaining the cleanliness of the production line, reducing the accumulation of ineffective materials, and ensuring an efficient and environmentally friendly production environment.

[0074] Understandably, referring to Figure 1 , 5 As shown, step S160 also includes, but is not limited to, steps S510, S520, and S530:

[0075] Step S510: The strip-shaped adhesive film and the strip-shaped raised foam are composited to obtain several first composite strips;

[0076] Step S520: The release film and several first composite strips are laminated to obtain a second composite strip;

[0077] Step S530: The second composite strip is wound up to obtain the second product.

[0078] Steps S510, S520, and S530, as illustrated in the embodiments of this application, optimize material bonding and subsequent product manufacturing through precise lamination and winding processes. First, the strip-shaped adhesive film and the strip-shaped raised foam are laminated to obtain several first composite strips. This step ensures a tight bond between the strip-shaped adhesive film and the strip-shaped raised foam, providing a high-quality base material for subsequent lamination. Next, a release film and several first composite strips are laminated to obtain a second composite strip. This lamination process tightly bonds the release film to the composite material, ensuring strong adhesion between the three layers and improving the overall performance and stability of the product.

[0079] In some embodiments, strip-shaped adhesive film and strip-shaped raised foam are first laminated. The purpose of this process is to tightly bond the strip-shaped adhesive film and the strip-shaped raised foam to form several first composite strips. During the lamination process, the raised foam slitting and lamination equipment controls pressure, temperature, and time to ensure a stronger and more uniform bond between the strip-shaped adhesive film and the raised foam. The control system ensures consistent spacing and bonding quality between each strip-shaped adhesive film and strip-shaped raised foam, thereby guaranteeing the stability and reliability of the composite strips.

[0080] Understandably, the spacing between several first composite strips on the second composite strip is equal. Equal spacing between the first composite strips allows them to uniformly support the release film, reducing the risk of deformation due to uneven stress.

[0081] Understandably, the width of the raised foam material is matched with the width of the backing film, reducing material waste.

[0082] Understandably, the width of the strip-shaped padding foam matches the width of the strip-shaped adhesive film, reducing material waste.

[0083] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

Claims

1. A process for slitting and laminating raised foam, characterized in that, The application is applied to a cushioning foam slitting and compounding device, which comprises a pressing and cutting device, the pressing and cutting device comprises a pressing station and a cutting station, the pressing station is provided with a pressing roller, and the cutting station is provided with a slitting cutter; the cushioning foam slitting and compounding process comprises: a cushioning foam raw material and a bottom film are provided; the cushioning foam raw material and the bottom film are subjected to compounding treatment and cutting and slitting treatment to obtain a first combined material belt; wherein the cutting depth of the cutting and slitting treatment matches the thickness of the cushioning foam raw material, so that the cushioning foam raw material is cut into a plurality of strip-shaped cushioning foams; the first combined material belt is subjected to whole-page winding treatment to obtain a first product; the first product is subjected to separation treatment to obtain a strip-shaped cushioning foam; a release film and a strip-shaped adhesive film are provided; wherein the number of the strip-shaped adhesive film matches that of the strip-shaped cushioning foam; the release film, the strip-shaped adhesive film and the strip-shaped cushioning foam are subjected to compounding treatment to obtain a second product; wherein the strip-shaped adhesive film is located between the strip-shaped cushioning foam and the release film; wherein the compounding treatment and cutting and slitting treatment of the cushioning foam raw material and the bottom film to obtain a first combined material belt comprises: the cushioning foam raw material and the bottom film are transported to the pressing station, and the pressing roller is controlled to press the cushioning foam raw material and the bottom film to obtain a second combined material belt, wherein the cushioning foam raw material is located above the bottom film; the second combined material belt is transported to the cutting station, and the slitting cutter is controlled to cut the cushioning foam raw material to obtain the first combined material belt; wherein the whole-page winding treatment of the first combined material belt to obtain a first product comprises: a winding core is provided; the first combined material belt is wound on the winding core to obtain a first product, wherein the winding is carried out when the strip-shaped cushioning foam and the bottom film are in a compounded state; wherein the separation treatment of the first product to obtain a strip-shaped cushioning foam comprises: the first product is subjected to separation treatment to obtain the strip-shaped cushioning foam and a third combined material belt, wherein the strip-shaped cushioning foam is separated from the first product at intervals, and the third combined material belt comprises the bottom film and the remaining strip-shaped cushioning foam; the third combined material belt is wound to obtain a third product; wherein the compounding treatment of the release film, the strip-shaped adhesive film and the strip-shaped cushioning foam to obtain a second product comprises: the strip-shaped adhesive film and the strip-shaped cushioning foam are subjected to compounding treatment to obtain a plurality of first compounded material belts; the release film and the plurality of first compounded material belts are subjected to compounding treatment to obtain a second compounded material belt; the second compounded material belt is subjected to winding treatment to obtain a second product; wherein after the winding of the third combined material belt to obtain a third product, the method further comprises: the third product is subjected to separation treatment to obtain the strip-shaped cushioning foam and a waste material belt; The new release film and the new strip-shaped adhesive film are provided; The new release film, the new strip-shaped adhesive film and the strip-shaped cushioning foam are compounded to obtain the second product; wherein the new strip-shaped adhesive film is located between the strip-shaped cushioning foam and the new release film; The waste strip is discharged.

2. The process of claim 1, wherein, The intervals of the first compound strip on the second compound strip are equal.

3. The process of claim 1, wherein the foam is a polyurethane foam. The width of the cushioning foam raw material matches the width of the bottom supporting film.

4. The process of claim 1, wherein the foam is a polyurethane foam. The width of the strip-shaped cushioning foam matches the width of the strip-shaped adhesive film.

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