Knife-mark-free die cutting processing technology for foam product

Abstract

The invention relates to a non-knife-mark die cutting processing technology of a foam product, which comprises the following steps: A1, attaching a release film to a first protective film, attaching a double-faced adhesive tape to the release film, removing double-faced adhesive tape paper of the double-faced adhesive tape, and attaching an auxiliary release film to the upper part of the double-faced adhesive tape to form a primary material belt; a2, the first-stage material belt is subjected to first-stage punching die cutting in a first-stage punching die cutting machine, and inner frame waste is discharged; a3, the first protective film and the release film attached to the first protective film are discharged, the material belt release film is attached to the double-faced adhesive tape, then the second protective film is attached to the material belt release film, the base-material-free foam attached to the base-material-free double-faced adhesive tape is attached to the auxiliary material release film, and a second-stage material belt is formed; a4, the second-stage material belt is subjected to second-stage die cutting on a second-stage die cutting machine, and a foam die cutting piece finished product is formed; and A5, the foam die cutting piece finished product is rolled. Compared with the prior art, the method is beneficial to reducing the deformation quantity of foam products and improving the yield of the foam products.

Description

Technical Field

[0001] The present invention relates to the technical field of die-cutting, and particularly to a knife-free die-cutting process for foam products. Background Art

[0002] Foam is a material obtained by foaming plastic particles, simply referred to as foam. Foams are divided into polyurethane (PU) foam, anti-static foam, conductive foam, pearl cotton (EPE), anti-static EPE, chloroprene rubber (CR), ethylene-vinyl acetate copolymer (EVA), cross-linked polyethylene (PE), styrene-butadiene rubber (SBR), ethylene propylene diene monomer (EPDM), etc. Foam has a series of characteristics such as elasticity, light weight, fast pressure-sensitive fixation, easy use, flexible bending, ultra-thin volume, and reliable performance.

[0003] Foams can be divided into foams with a substrate and foams without a substrate. Foams with a substrate are based on materials such as cotton paper, PET, PVC film, non-woven fabric, foam, acrylic, film, etc. Currently, some foams without a substrate have a substrate on one side and no substrate on the other side, and some foams without a substrate have no substrate on both sides. For a foam without a substrate, after a double-sided tape is adhered to one side, if a knife-imprint die-cutting method is used for the foam product, it is not easy to peel off, and poor peeling is likely to occur. Generally, a protective film needs to be adhered to the other side to remove the bottom film with knife marks, and then a release film is adhered again to form a knife-free imprint method. However, due to the soft material of the foam without a substrate on the market currently, it is easy to deform during the re-adhesion process, resulting in dimensional defects. For a box-shaped foam without a PET substrate, traditional die-cutting methods such as Figures 1 to 5 As shown, the foam product needs to be re-adhered and reverse-cut, and it is easy to pull and deform the foam during the process, causing dimensional changes. Summary of the Invention

[0004] The purpose of the present invention is to overcome the above-mentioned defects existing in the prior art and provide a knife-free die-cutting process for foam products, which is beneficial to reducing the deformation amount of foam products and improving the yield rate of foam products.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A knife-free die-cutting process for foam products includes the following steps:

[0007] A1. Adhere a release film to a first protective film, adhere a double-sided tape to the release film, remove the double-sided tape paper of the double-sided tape, and adhere an auxiliary release film above the double-sided tape to form a first-level tape;

[0008] A2. Perform first-stage die-cutting on the release film along a first-stage contour line in a first-stage die-cutting machine, and discharge the inner frame waste. The first-stage contour line includes a first group of square frames connected in a row by a first straight line and a second group of square frames connected in a row by a second straight line. The first group of square frames and the second group of square frames are parallel to each other vertically.

[0009] A3. Discharge the first protective film and the attached release film, attach the tape release film to the double-sided tape, then attach the second protective film to the tape release film, and attach the non-substrate foam with the non-substrate double-sided tape attached thereto to the auxiliary release film to form a second-stage tape.

[0010] A4. Perform second-stage die-cutting on the auxiliary release film and the tape release film along a second-stage contour line in a second-stage die-cutting machine to form a finished foam die-cut part. First, discharge the contour waste of the non-substrate foam with the non-substrate double-sided tape attached thereto. Then, sequentially pull out the middle waste and the side waste of the auxiliary release film and the double-sided tape. Finally, discharge the side waste of the second protective film and the tape release film. The second-stage contour line includes a third group of square frames and a fourth group of square frames distributed in a row on the auxiliary release film. The third group of square frames and the fourth group of square frames are parallel to each other vertically. The first group of square frames is located inside the third group of square frames, and the second group of square frames is located inside the fourth group of square frames.

[0011] A5. Wind up the finished foam die-cut part.

[0012] Further, in step A1, the non-release surface of the release film faces upward, so that the release film is completely adhered to the first protective film.

[0013] Further, in step A1, the thickness of the auxiliary release film is 0.036 - 0.05T. Since the processing process is to discharge the inner frame waste between the release film, the double-sided tape, and the auxiliary release film, and then attach the non-substrate foam with the non-substrate double-sided tape attached thereto to the auxiliary release film. However, the non-substrate foam with the non-substrate double-sided tape attached thereto at the perforated position of the auxiliary release film is attached to the tape release film, with a certain height difference.

[0014] If the height difference is too large, it will affect the size of the foam die-cut part product. If the height difference is too small, it is easily cut through during the second-stage die-cutting.

[0015] Further, in step A2, the first group of square frames and the second group of square frames are parallel to the tape conveying direction.

[0016] Further, in step A2, the first group of square frames and the second group of square frames are of the same size and shape.

[0017] Furthermore, the non-release surface of the auxiliary material release film is adhered to the substrate-free double-sided adhesive and cannot be separated after being adhered.

[0018] Furthermore, in step A3, the size of the third frame group is larger than that of the first frame group, with a single side larger by 0.1 to 0.3 mm; the size of the fourth frame group is larger than that of the second frame group, with a single side larger by 0.1 to 0.3 mm. If the size of the third frame group and the fourth frame group is too small, it will be troublesome to match the first punch with the second punch, and if the match is off, the punching will cut onto the release film of the material strip; if the size of the third frame group and the fourth frame group is too large, it is easy to pull up the foam die-cut product when pulling out the waste, and pull the foam die-cut product out of place.

[0019] Further, in step A3, the third frame group and the fourth frame group are the same in size and shape.

[0020] Furthermore, in step A3, a second die-cutting is performed on the auxiliary material release film along the third frame group and the fourth frame group.

[0021] Furthermore, in step A2, the contour line further includes:

[0022] a first upper border line located above the first frame group;

[0023] a first bottom border line located below the second frame group;

[0024] And first positioning holes are located on both sides of the first upper frame line and the first lower frame line.

[0025] Furthermore, in step A3, the second stroke contour line further includes:

[0026] A second upper border line at the same position as the first upper border line;

[0027] A second lower border line at the same position as the first lower border line;

[0028] A second positioning hole at the same position as the first positioning hole;

[0029] Perform a second punching and die-cutting on the material strip release film along the second upper frame line, the second lower frame line and the second positioning hole.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] (1) During the die-cutting process, the auxiliary release film is always adhered to the non-substrate foam that is well adhered with the non-substrate double-sided tape, used to adhere the non-substrate double-sided tape on the non-substrate foam, making it in a way without knife marks. At the same time, the non-substrate foam is not easily deformed, and the product is easy to peel off. The auxiliary release film is always adhered to the non-substrate foam that is well adhered with the non-substrate double-sided tape, and can be directly die-cut without the need for post-die-cutting transfer and reverse cutting, reducing the deformation amount of the foam and making its size more accurate, which is beneficial to improving the product yield.

[0032] (2) During the die-cutting process, the squares in the first square group and the second square group are all connected by straight lines. The outer shape of the square foam product is irregular. Directly pulling and discharging waste from the auxiliary release film and the double-sided tape is likely to cause tearing of the foam die-cut part product and make it deformed. However, in this processing technology, during the first-stage die-cutting, the release film is die-cut along the first-stage contour line. After die-cutting, the auxiliary release film layer, double-sided tape, and release film can be divided into the middle part and the two side parts, which is beneficial to the discharge of waste after the second-stage die-cutting. Description of the Drawings

[0033] Figure 1 is a schematic diagram of the traditional die-cutting processing technology;

[0034] Figure 2 is a schematic diagram of the first-stage die-cutting of the traditional die-cutting processing technology;

[0035] Figure 3 is a schematic diagram of the structural hierarchy of the first-stage die-cutting of the traditional die-cutting processing technology;

[0036] Figure 4 is a schematic diagram of the second-stage die-cutting of the traditional die-cutting processing technology;

[0037] Figure 5 is a schematic diagram of the structural hierarchy of the second-stage die-cutting of the traditional die-cutting processing technology;

[0038] Figure 6 is a schematic diagram of the die-cutting processing technology shown in Embodiment 1;

[0039] Figure 7 is a schematic diagram of the first-stage die-cutting shown in Embodiment 1;

[0040] Figure 8 is a schematic diagram of the structural hierarchy of the first-stage die-cutting shown in Embodiment 1;

[0041] Figure 9 is a schematic diagram of the strip after the first-stage die-cutting shown in Embodiment 1;

[0042] Figure 10 is a schematic diagram of the second-stage die-cutting of the die-cutting processing technology shown in Embodiment 1;

[0043] Figure 11Schematic diagram of the hierarchical structure of the two-step die-cutting structure for the die-cutting process shown in Embodiment 1;

[0044] Figure 12 Schematic diagram of the strip after two-step die-cutting shown in Embodiment 1.

[0045] Description of the markings in the figure:

[0046] 1 - First protective film, 2 - Release film, 3 - Double-sided adhesive, 31 - Double-sided adhesive base paper, 4 - Auxiliary release film, 5 - Strip release film, 6 - Second protective film, 7 - Double-sided adhesive without substrate, 8 - Foam without substrate, 9 - First-step die-cutting machine, 10 - Second-step die-cutting machine, 11 - Inner frame waste, 12 - Outline waste, 13 - Middle waste, 14 - Waste on both sides, 15 - Edge waste, 16 - Foam die-cut part product, 17 - First-step die-cutting outline, 171 - First straight line, 172 - First set of squares, 173 - Second straight line, 174 - Second set of squares, 175 - First upper border line, 176 - First lower border line, 177 - First positioning hole, 18 - Second-step die-cutting outline, 181 - Third set of squares, 182 - Fourth set of squares, 183 - Second upper border line, 184 - Second lower border line, 185 - Second positioning hole, 19 - Edge material of the strip release film Detailed implementation mode

[0047] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented on the premise of the technical solution of the present invention, and the detailed implementation mode and specific operation process are given. However, the protection scope of the present invention is not limited to the following embodiments. Based on the given embodiments, all other embodiments obtained by those of ordinary skill in the art without making creative efforts fall within the scope of protection of this application.

[0048] Embodiment 1

[0049] A knife-free die-cutting process for a foam product, as Figure 6 shown, includes the following steps:

[0050] A1. Attach the release film 2 to the first protective film 1, attach the double-sided adhesive 3 to the release film 1, remove the double-sided adhesive tape paper 31 of the double-sided adhesive 3, and attach the auxiliary release film 4 above the double-sided adhesive 3 to form a primary strip;

[0051] A2. Perform first-step die-cutting on the release film 2 along the first-step die-cutting outline 17 in the first-step die-cutting machine 9, and discharge the inner frame waste 11. The first-step die-cutting outline 12 includes a first set of squares 172 connected in rows by the first straight line 171 and a second set of squares 174 connected in rows by the second straight line 173. The first set of squares 172 and the second set of squares 174 are parallel up and down, as Figures 7 to 9 shown;

[0052] A3. Remove the first protective film 1 and the attached release film 2, attach the tape release film 5 to the double-sided tape 3, then attach the second protective film 6 to the tape release film 5, and attach the non-substrate foam 8 with the non-substrate double-sided tape 7 attached thereto to the auxiliary release film 4 to form a secondary tape;

[0053] A4. Perform second-stage die-cutting on the auxiliary release film 4 and the tape release film 5 along the second-stage contour line 18 on the second-stage die-cutting machine 10 to form a finished foam die-cut part 16. First, remove the contour waste 12 of the non-substrate foam 8 with the non-substrate double-sided tape 7 attached thereto, then sequentially pull out the middle waste 13 and the side wastes 14 of the auxiliary release film 4 and the double-sided tape 3, and finally remove the side wastes 15 of the second protective film 6 and the tape release film 5. The second-stage contour line 18 includes a third square frame group 181 and a fourth square frame group 182 arranged in rows on the auxiliary release film 5. The third square frame group 181 and the fourth square frame group 182 are parallel up and down. The first square frame group 172 is located inside the third square frame group 181, and the second square frame group 174 is located inside the fourth square frame group 182, as Figures 10 to 12 shown;

[0054] A5. Wind up the finished foam die-cut part.

[0055] In this embodiment, in step A1, the non-release surface of the release film 2 faces upward, so that the release film 2 is completely attached to the first protective film 1.

[0056] In this embodiment, the thickness of the double-sided tape is 0.03T.

[0057] In this embodiment, in step A1, the thickness of the auxiliary release film 4 is 0.036T. Since the processing process is to remove the inner frame waste 11 between the release film 2, the double-sided tape 3 and the auxiliary release film 4, and then attach the non-substrate foam 8 with the non-substrate double-sided tape 7 attached thereto to the auxiliary release film 4. However, the non-substrate foam 8 with the non-substrate double-sided tape 7 attached thereto at the perforated position of the auxiliary release film 4 is attached to the tape release film 5, having a certain height difference.

[0058] If the height difference is too large, it will affect the size of the foam die-cut part product 16. If the height difference is too small, it is easily cut through during the second-stage die-cutting.

[0059] In this embodiment, the thickness of the non-substrate foam 8 is 2 mm.

[0060] In this embodiment, in step A2, the first square frame group 172 and the second square frame group 174 are parallel to the tape conveying direction.

[0061] In this embodiment, in step A2, the first frame group 172 and the second frame group 174 are the same in size and shape.

[0062] In this embodiment, the non-release surface of the auxiliary material release film 4 is adhered to the substrate-free double-sided adhesive tape 7 and cannot be separated after being adhered.

[0063] In this embodiment, in step A3, the size of the third frame group 181 is larger than the first frame group 172, and is 0.1mm larger on one side; the size of the fourth frame group 182 is larger than the second frame group 174, and is 0.1mm larger on one side. If the size of the third frame group 181 and the fourth frame group 182 is too small, it will be troublesome to match the first punch with the second punch, and if the match is off, the material strip release film 5 will be punched. If the size of the third frame group 181 and the fourth frame group 182 is too large, it is easy to pull up the foam die-cut product 16 when pulling out the waste, and pull the foam die-cut product 16 out of place.

[0064] In this embodiment, in step A3, the third frame group 181 and the fourth frame group 182 are the same in size and shape.

[0065] In this embodiment, in step A3 , a second die-cutting is performed on the auxiliary material release film 4 along the third frame group 181 and the fourth frame group 182 .

[0066] In this embodiment, in step A2, the punching contour line 12 further includes:

[0067] A first upper frame line 175 located above the first frame group 172;

[0068] a first lower border line 176 located below the second frame group 174;

[0069] And first positioning holes 177 located on both sides of the first upper frame line 175 and the first lower frame line 176 .

[0070] In this embodiment, in step A3, the second stroke contour line 18 further includes:

[0071] A second upper frame line 183 located at the same position as the first upper frame line 175;

[0072] A second lower border line 184 located at the same position as the first lower border line 176;

[0073] A second positioning hole 185 located at the same position as the first positioning hole 177;

[0074] A second punching and die-cutting is performed on the material strip release film 5 along the second upper frame line 183 , the second lower frame line 184 and the second positioning hole 185 .

[0075] Example 2

[0076] Compared with Example 1, most of them are the same, except that the thickness of the auxiliary material release film 4 is 0.05T; the size of the third frame group 181 is larger than the first frame group 172, and is 0.3mm larger on one side; the size of the fourth frame group 182 is larger than the second frame group 174, and is 0.3mm larger on one side.

[0077] Example 3

[0078] Compared with Example 1, most of them are the same, except that the thickness of the auxiliary material release film 4 is 0.042T; the size of the third frame group 181 is larger than the first frame group 172, and is 0.2mm larger on one side; the size of the fourth frame group 182 is larger than the second frame group 174, and is 0.2mm larger on one side.

[0079] Although the present invention has been described in detail above by means of general description, specific implementation methods and tests, it is obvious to those skilled in the art that some modifications or improvements may be made to the present invention. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of protection claimed by the present invention.

Claims

1. A non-knife-imprint die-cutting process for a foam product, characterized in that, It includes the following steps: A1. Bond the release film (2) onto the first protective film (1), bond the double-sided tape (3) onto the release film (1), remove the double-sided tape paper (31) of the double-sided tape (3), and bond the auxiliary release film (4) above the double-sided tape (3) to form a primary strip; A2. Perform a first-stage die-cutting on the release film (2) along the first-stage die-cutting contour line (17) in a first-stage die-cutting machine (9), and discharge the inner frame waste (11). The first-stage die-cutting contour line (12) includes a first set of square frames (172) connected in rows by the first straight line (171) and a second set of square frames (174) connected in rows by the second straight line (173). The first set of square frames (172) and the second set of square frames (174) are parallel to each other vertically; A3. Discharge the first protective film (1) and the release film (2) adhered thereto, bond the strip release film (5) onto the double-sided tape (3), then bond the second protective film (6) to the strip release film (5), and bond the non-woven foam (8) with the non-woven double-sided tape (7) adhered thereto onto the auxiliary release film (4) to form a secondary strip; A4. Perform a second-stage die-cutting on the auxiliary release film (4) and the strip release film (5) along the second-stage die-cutting contour line (18) on the second-stage die-cutting machine (10) to form the finished foam die-cut parts (16). First, discharge the contour waste (12) of the non-woven foam (8) with the non-woven double-sided tape (7) adhered thereto, then sequentially pull out the middle waste (13) and the side waste (14) of the auxiliary release film (4) and the double-sided tape (3), and finally discharge the edge waste (15) of the second protective film (6) and the strip release film (5). The second-stage die-cutting contour line (18) includes a third set of square frames (181) and a fourth set of square frames (182) distributed in rows on the auxiliary release film (5). The third set of square frames (181) and the fourth set of square frames (182) are parallel to each other vertically. The first set of square frames (172) is located inside the third set of square frames (181), and the second set of square frames (174) is located inside the fourth set of square frames (182); A5. Wind up the finished foam die-cut parts.

2. The knife-free die-cutting process for a foam product according to claim 1, characterized in that, In step A1, the thickness of the auxiliary release film (4) is 0.036 - 0.05T.

3. The die-cutting process without knife marks for a foam product according to claim 1, characterized in that, In step A2, the first set of square frames (172) and the second set of square frames (174) are parallel to the strip conveying direction.

4. The die-cutting process without knife marks for a foam product according to claim 3, characterized in that, In step A2, the first set of square frames (172) and the second set of square frames (174) are of the same size and shape.

5. The non-knife die-cutting process for a foam product according to claim 1, characterized in that, In step A1, the non-release surface of the auxiliary release film (4) is bonded to the non-woven double-sided tape (7), and they cannot be separated after bonding.

6. The die-cutting process without knife marks for a foam product according to claim 1, characterized in that, In step A3, the size of the third set of square frames (181) is larger than that of the first set of square frames (172), with a unilateral increase of 0.1 - 0.3 mm; the size of the fourth set of square frames (182) is larger than that of the second set of square frames (174), with a unilateral increase of 0.1 - 0.3 mm.

7. A non-knife die-cutting process for a foam product according to claim 1, characterized in that, In step A3, the third set of square frames (181) and the fourth set of square frames (182) are of the same size and shape.

8. A non-knife die-cutting process for a foam product according to claim 1, characterized in that, In step A3, perform second-stage die cutting on the auxiliary release film (4) along the third square frame group (181) and the fourth square frame group (182).

9. The non-knife die-cutting processing technology of a foam product according to claim 1, characterized in that, In step A2, the first-stage contour line (12) further includes: A first upper border line (175) located above the first square frame group (172); A first lower border line (176) located below the second square frame group (174); And first positioning holes (177) located on both sides of the first upper border line (175) and the first lower border line (176).

10. The die-cutting process without knife marks for a foam product according to claim 9, characterized in that, In step A3, the second-stage contour line (18) further includes: A second upper border line (183) having the same position as the first upper border line (175); A second lower border line (184) having the same position as the first lower border line (176); A second positioning hole (185) having the same position as the first positioning hole (177); Perform second-stage die cutting on the strip release film (5) along the second upper border line (183), the second lower border line (184), and the second positioning hole (185).

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