Die cutting material utilization rate improving structure and process method based on asynchronous attachment

Abstract

The invention discloses a die cutting material utilization rate improving structure based on asynchronous attachment and a process method. The die cutting material utilization rate improving structure comprises a base layer, a composite function layer and a shielding layer. The base layer is an antistatic single-sided adhesive tape, and the composite functional layer is precisely fixed on the adhesive surface of the base layer in an asynchronous fitting manner; aiming at a product with a multi-layer composite structure including an antistatic protective film, a copper foil adhesive tape, foam, grid exhaust glue and the like, through accurate asynchronous lamination control and performance parameter matching (such as antistatic performance, stripping force, thickness and the like) of each layer of material, the utilization rate is improved, meanwhile, the synergistic effect of each functional layer is ensured, and the product quality is improved. And the comprehensive properties such as antistatic property, viscosity and peel strength of the product are ensured to reach the standard.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of die cutting processing, and particularly relates to a die cutting material utilization rate improving structure and process method based on asynchronous lamination. BACKGROUND

[0002] With the rapid development of the intelligent display industry, the iteration speed of terminal products continues to accelerate, and the industry competition is becoming increasingly fierce. Under this background, cost control has become one of the core competencies of enterprises, which not only needs to meet the stringent requirements of customers on product performance and precision, but also needs to achieve cost reduction and efficiency improvement through technological innovation.

[0003] In the field of die cutting processing, the traditional die cutting process generally adopts synchronous lamination, that is, the material usage and the product quantity maintain a 1:1 corresponding relationship. Limited by the fixed requirements of customers on product layout size and precision, a certain spacing must be reserved between products to avoid processing interference, and the material corresponding to this part of the spacing cannot be converted into effective products, resulting in a large amount of material waste. Especially for die cutting products containing multi-layer composite structures such as foam, grid exhaust glue, and original grid release film, the original grid release film is a key component for supporting the grid pattern and ensuring the exhaust performance, and the customer explicitly requires that the grid pattern should not be torn or damaged, otherwise it will directly affect the exhaust effect and use performance of the product, which further limits the optimization space of the traditional process for the material spacing, resulting in a long-term low level of material utilization, which not only increases the production cost of enterprises, but also contradicts the current industry's advocacy of saving and environmental protection and sustainable development. SUMMARY

[0004] In order to overcome the shortcomings of the prior art, one of the purposes of the present application is to provide a die cutting material utilization rate improving structure and process method based on asynchronous lamination.

[0005] One of the purposes of the present application is achieved by adopting the following technical solutions: A die cutting material utilization rate improving structure based on asynchronous lamination, comprising a base layer, a composite functional layer, and a shielding layer; the base layer is an antistatic single-sided adhesive tape, the composite functional layer is precisely fixed to the adhesive surface of the base layer by asynchronous lamination, the shielding layer is an antistatic release film, the shielding layer is laminated to the adhesive surface of the base layer and shields the exposed adhesive surface of the base layer which is not covered by the composite functional layer, so that the base layer and the shielding layer form a carrier tape together; the composite functional layer comprises a copper foil adhesive tape, foam, grid exhaust glue, and grid release film which are laminated in sequence, the grid release film is an original grid release film and has not been torn, and the composite functional layer is a sheet structure with a size of 1.3-1.5mm larger than the product body after cutting.

[0006] Further, the antistatic single-sided adhesive tape has an electrostatic resistance of ≤10^11Ω, a peel force of ≥1200gf / inch, and a thickness of 0.12mm.

[0007] Further, the grid exhaust glue has a peel strength of >1000 gf / inch, a surface impedance of 10^5-10^9 Ω, and a thickness of 0.042 mm.

[0008] Further, the foam has a peel strength of >1000 gf / inch, a surface impedance of 10^11-10^13 Ω, and a thickness of 0.12 mm.

[0009] Further, the original grid release film has a thickness of 0.130 mm.

[0010] Further, the protection film with antistatic is compounded on the surface of the copper foil tape away from the foam, and is attached to the surface of the copper foil; the protection film has an electrostatic resistance of 1.0*10^5-1.0*10^11 Ω, a viscosity of 3-10 gf / inch, and a thickness of 0.085 mm.

[0011] Further, the release film with antistatic is cut by die cutting to remove the middle excess waste, and only covers the exposed adhesive surface of the base layer.

[0012] A die cutting material utilization improvement process based on asynchronous attachment, comprising the following steps: a. The copper foil tape, foam, grid exhaust glue, and original grid release film are compounded in sequence to form a composite functional layer, the composite functional layer is cut into a piece of material 1.3-1.5 mm larger than the product body by using a mold, and the cut piece of material is accurately attached to the adhesive surface of the single-sided tape with antistatic according to the designed step distance by the asynchronous attachment function; b. The release film with antistatic is cut by die cutting to remove the middle excess waste, and the cut release film is attached to the adhesive surface of the single-sided tape with antistatic to cover the exposed adhesive surface of the single-sided tape with antistatic, so that the single-sided tape with antistatic and the release film form a carrier tape together; c. The composite functional layer attached to the single-sided tape with antistatic in step a is punched to form an outer shape and a hole, and the excess waste is removed; d. The protection film with antistatic is cut to a shape, and the protection film is compounded on the surface of the copper foil tape away from the foam to complete the product processing; In steps a to d, the original grid release film is not torn to improve material utilization.

[0013] Further, The designed step distance in step a is set according to the product layout requirements to reduce the material waste between products.

[0014] The cutting shape of the release film in step b is matched with the exposed adhesive surface shape of the single-sided antistatic adhesive tape, the static resistance of the single-sided antistatic adhesive tape is less than or equal to 10^11 ohm, the peeling force is greater than or equal to 1200 gf / inch, and the thickness is 0.12 mm; the peeling force of the grid exhaust adhesive is greater than 1000 gf / inch, the surface impedance is 10^5-10^9 ohm, and the thickness is 0.042 mm; and the peeling force of the foam is greater than 1000 gf / inch, the surface impedance is 10^11-10^13 ohm, and the thickness is 0.12 mm.

[0015] Compared with the prior art, the present application has the following advantages: 1. The present application breaks the limitation of traditional synchronous bonding 1:1 dosage through asynchronous bonding technology. After cutting the composite functional layer into a specific size of sheet material, it is accurately bonded to the adhesive surface of the base layer according to the designed step distance. The layout gap can be optimized according to the actual product demand, which greatly reduces the waste of invalid spacing material between products, effectively improves the utilization rate of core materials such as copper foil adhesive tape, foam, grid exhaust adhesive, release film, etc., and reduces the material consumption per unit product.

[0016] 2. While improving the material utilization rate, the integrity of the original grid release film is strictly preserved, and the grid pattern is not torn or damaged in any way. This ensures that the exhaust effect of the grid exhaust adhesive is not affected, maintains the air permeability and stability of the product during use, and fully meets the core requirements of customers for product performance.

[0017] 3. By reducing material waste, the enterprise's raw material procurement cost is directly reduced, and the production benefit is improved. At the same time, the improvement of material utilization reduces the amount of waste generated, which meets the national advocacy of resource saving and green production concept, and provides technical support and new energy for the sustainable development of the die-cutting industry.

[0018] 4. The present application forms a complete carrier tape with the shielding layer and the base layer, effectively shielding the exposed adhesive surface of the base layer, avoiding contamination or adhesion of the adhesive surface during processing, and improving the stability of die-cutting processing and product yield. At the same time, the process step design of step-by-step cutting and bonding adapts to the processing capacity of existing die-cutting equipment, facilitating rapid technical transformation and large-scale production of enterprises.

[0019] 5. For products containing an antistatic protective film, a copper foil adhesive tape, a foam, a grid exhaust adhesive and other multi-layer composite structures, the present application controls the precise asynchronous bonding and matches the performance parameters of each layer of material (such as antistatic performance, peeling force, thickness, etc.), while improving the utilization rate, ensuring the synergistic effect of each functional layer, and ensuring that the comprehensive performance of the product such as antistatic, adhesion, and peel strength meets the standards.

[0020] The above description is only a summary of the technical solutions of the present application, in order to enable the technical means of the present application to be more clearly understood, and to be implemented in accordance with the content of the specification, and in order to enable the above and other purposes, features and advantages of the present application to be more apparent and easy to understand, the following preferred embodiments are described in detail below, and the accompanying drawings are described as follows. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 It is a schematic diagram of the protective film structure of the present embodiment; Figure 2 It is a schematic diagram of the protective film structure of the present embodiment; Figure 3 It is a schematic diagram of the protective film structure of the present embodiment; Figure 4 It is a process flow chart of the present application.

[0022] Reference numerals in the figure: 01, protective film with antistatic; 02, copper foil tape; 03, foam; 04, grid exhaust adhesive; 05, grid release film; 06, antistatic release film; 07, single-sided tape with antistatic. DETAILED DESCRIPTION

[0023] In the following, the present application will be further described in conjunction with the drawings and specific embodiments, and it should be noted that the following described embodiments or technical features can be combined in any manner to form new embodiments without conflict.

[0024] It should be noted that when a component is referred to as "fixed to" another component, it can be directly on the other component or there can be a middle component. When a component is referred to as "connected to" another component, it can be directly connected to the other component or there can be a middle component. When a component is referred to as "disposed on" another component, it can be directly disposed on the other component or there can be a middle component. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0025] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application belongs. The terminology used in the description of the present application herein is only for the purpose of describing specific embodiments and is not intended to limit the present application. The term "and / or" used herein includes any and all combinations of one or more of the associated listed items. EMBODIMENT

[0026] The present embodiment discloses a specific application of a die-cutting material utilization rate improvement structure and process method based on asynchronous lamination, which is suitable for processing die-cutting components with antistatic and exhaust functions in intelligent display devices. The following will be described in conjunction with specific material parameters and process details.

[0027] I. Material Preparation The materials and parameters used in this embodiment are as follows: 1. With antistatic protective film 01: Static resistance value 1.0×10 5 ~1.0×10¹¹Ω, viscosity 5gf / inch, thickness 0.085mm, material is PET substrate; 2. Copper foil tape 02: 0.03mm thick, made of rolled copper foil, with conductive adhesive on the surface; 3. Foam 03: Thickness 0.12mm, peel force 1200gf / inch, surface resistance 10¹²Ω, material is conductive PU foam; 4. Mesh Venting Adhesive 04: Thickness 0.042mm, Peel Strength 1100gf / inch, Surface Resistance 10 7 Ω, mesh density 30 mesh; 5. Original mesh release film 05: 0.130mm thick, PET substrate, surface mesh pattern is a pre-set exhaust channel, customer requirements do not allow it to be torn or damaged; 6. Release film with antistatic properties 06: thickness 0.05mm, static resistance 1.0×10⁻⁶ 9 Ω, release force 50gf / inch; 7. Antistatic single-sided tape 07: thickness 0.12mm, static resistance value 5×10¹ 0 Ω, peel strength 1500gf / inch, substrate is PET, adhesive layer is acrylic pressure-sensitive adhesive.

[0028] II. Specific Process Steps Step a: Fabrication and asynchronous bonding of composite functional layers 1. Composite functional layer forming: Using a roller lamination equipment, copper foil tape 02, foam 03, mesh exhaust adhesive 04, and original mesh release film 05 are laminated in sequence. The lamination pressure is set to 0.3MPa and the temperature is 40℃ to ensure that each layer is tightly bonded without air bubbles. 2. Sheet Cutting: After the composite functional layer has cured for 2 hours, it is cut into sheets using a precision flat die. In this embodiment, the product body is designed to be 50mm × 30mm, so the sheet cutting size is 51.5mm × 31.5mm (1.5mm larger than the product body), and the cutting accuracy is controlled within ±0.05mm; 3. Asynchronous lamination: use a die-cutting machine with asynchronous lamination function (model: MQ-AS300) to accurately laminate the cut piece to the adhesive surface of the single-sided tape 07 according to the designed step distance. The horizontal step distance is set to 32mm (the traditional synchronous lamination step distance is 35mm), and the vertical step distance is set to 52mm (the traditional synchronous lamination step distance is 55mm), which reduces material waste by reducing the gap between products.

[0029] Step b: carrier tape formation 1. Release film cutting: use a laser die-cutting machine to cut the antistatic release film 06. According to the shape of the exposed adhesive surface on the single-sided tape 07 (in the form of "grid gap"), exclude the middle excess waste, and retain the shielding area matching the exposed adhesive surface; 2. Shielding lamination: transfer and laminate the cut release film 06 to the adhesive surface of the single-sided tape 07 by vacuum suction, ensuring that the shielding area completely covers the exposed adhesive surface, so that the single-sided tape 07 and the release film 06 form a complete carrier tape together, avoiding contamination of the adhesive surface or adhesion during processing.

[0030] Step c: composite functional layer shape processing Use a die-cutting mold to process the shape and holes of the composite functional layer laminated on the single-sided tape 07: Die-cut the product shape to 50mm x 30mm (consistent with the product body size), excluding the excess waste (1.5mm wide ring) at the edge of the piece; Simultaneously punch two positioning holes with a diameter of 2mm (hole center distance from edge 5mm), ensuring hole accuracy ±0.1mm, and removing the waste inside and around the holes by negative pressure suction after punching.

[0031] Step d: protective film compounding 1. Protective film cutting: according to the surface size of the copper foil tape 02 (50mm x 30mm), use a round knife mold to cut the antistatic protective film 01 into the corresponding shape, with no burrs on the cutting edge; 2. Compound fixation: compound the protective film 01 to the side surface of the copper foil tape 02 away from the foam 03 by hot pressing, with a compounding temperature of 50℃ and a pressure of 0.2MPa, to ensure that the protective film does not lift or bubble. Implementation effect

[0032] After processing by the above process, the product completely retains the integrity of the original grid release film 05, the grid pattern is not damaged, and the grid exhaust adhesive 04 meets the exhaust standard (exhaust rate ≥5mL / s). At the same time, due to the use of asynchronous lamination optimization step distance, the material utilization rate is improved from 62% of traditional synchronous lamination to 86%, the unit product material consumption is reduced by 38%, and the performance parameters (antistatic, peel force, thickness, etc.) of each layer of material meet the design requirements. Embodiment

[0033] The die-cut material utilization rate improving structure based on asynchronous bonding of the embodiment comprises a base layer, a composite functional layer and a shielding layer; the base layer is an antistatic single-sided tape, the composite functional layer is precisely fixed to the adhesive surface of the base layer through asynchronous bonding, the shielding layer is an antistatic release film, the shielding layer is bonded to the adhesive surface of the base layer and shields the exposed adhesive surface of the base layer that is not covered by the composite functional layer, so that the base layer and the shielding layer jointly form a carrier tape; the composite functional layer comprises a copper foil tape, foam, grid exhaust glue and a grid release film that are sequentially compounded, the grid release film is an original grid release film and is not torn, the composite functional layer is a sheet structure with a size of 1.3-1.5 mm larger than the product body after cutting, the static resistance of the antistatic single-sided tape is ≤10<11> Ω, the peel force is ≥1200 gf / inch, the thickness is 0.12 mm, the peel force of the grid exhaust glue is >1000 gf / inch, the surface impedance is 10<5>-10<9> Ω, the thickness is 0.042 mm, the peel force of the foam is >1000 gf / inch, the surface impedance is 10<11>-10<13> Ω, the thickness is 0.12 mm, the thickness of the original grid release film is 0.130 mm, and the antistatic protective film is further included, which is compounded to the side surface of the copper foil tape away from the foam; the static resistance of the protective film is 1.0×10<5>-1.0×10<11> Ω, the adhesion is 3-10 gf / inch, and the thickness is 0.085 mm; the antistatic release film excludes the middle excess waste after die cutting and only shields the exposed adhesive surface of the base layer.

[0034] The die-cut material utilization rate improving process method based on asynchronous bonding of the embodiment comprises the following steps: a. sequentially compounding a copper foil tape, foam, grid exhaust glue and an original grid release film to form a composite functional layer, cutting the composite functional layer into a sheet with a size of 1.3-1.5 mm larger than the product body using a mold, and precisely bonding the cut sheet to the adhesive surface of an antistatic single-sided tape according to a designed step distance through asynchronous bonding; b. cutting the shape of an antistatic release film and excluding the middle excess waste, bonding the cut release film to the adhesive surface of the antistatic single-sided tape, shielding the exposed adhesive surface of the antistatic single-sided tape, and making the antistatic single-sided tape and the release film jointly form a carrier tape; c. punching the outer shape and holes of the composite functional layer bonded to the antistatic single-sided tape in step a and excluding the excess waste; d. cutting the shape of an antistatic protective film, compounding the protective film to the side surface of the copper foil tape away from the foam, and completing the product processing; In steps a to d, the original grid release film is not torn to improve the material utilization rate.

[0035] The step distance in step a is set according to product layout requirements, so as to reduce the waste of product gap materials.

[0036] The cutting shape of the release film in step b is matched with the exposed adhesive surface shape of the single-sided adhesive tape with antistatic property, the static resistance of the single-sided adhesive tape with antistatic property is less than or equal to 10^11 Ω, the peeling force is greater than or equal to 1200 gf / inch, and the thickness is 0.12 mm; the peeling force of the grid exhaust adhesive is greater than 1000 gf / inch, the surface impedance is 10^5-10^9 Ω, and the thickness is 0.042 mm; the peeling force of the foam is greater than 1000 gf / inch, the surface impedance is 10^11-10^13 Ω, and the thickness is 0.12 mm.

[0037] The above embodiments are only preferred embodiments of the present application, and cannot be used to limit the protection scope of the present application. Any non-essential changes and replacements made by those skilled in the art on the basis of the present application shall fall within the protection scope of the present application.

Claims

1. A structure for improving the utilization rate of die-cutting materials based on asynchronous bonding, characterized in that, The product comprises a base layer, a composite functional layer, and a shielding layer. The base layer is a single-sided adhesive tape with antistatic properties. The composite functional layer is precisely fixed to the adhesive surface of the base layer via asynchronous bonding. The shielding layer is a release film with antistatic properties. The shielding layer is bonded to the adhesive surface of the base layer and shields any exposed adhesive surfaces on the base layer not covered by the composite functional layer, so that the base layer and the shielding layer together form a carrier tape. The composite functional layer comprises copper foil tape, foam, mesh exhaust adhesive, and mesh release film sequentially bonded together. The mesh release film is an original mesh release film that has not been torn. The composite functional layer is a sheet structure whose dimensions are 1.3~1.5mm larger than the product body after cutting.

2. The structure according to claim 1, characterized in that, The single-sided adhesive tape with antistatic properties has a static resistance value ≤10^11Ω, a peel strength ≥1200gf / inch, and a thickness of 0.12mm.

3. The structure according to claim 1, characterized in that, The mesh venting adhesive has a peel strength >1000gf / inch, a surface resistance of 10^5-10^9Ω, and a thickness of 0.042mm.

4. The structure according to claim 1, characterized in that, The foam has a peel strength >1000gf / inch, a surface impedance of 10^11-10^13Ω, and a thickness of 0.12mm.

5. The structure according to claim 1, characterized in that, The original mesh release film has a thickness of 0.130 mm.

6. The structure according to claim 1, characterized in that, It also includes an antistatic protective film, which is laminated to the surface of the copper foil tape away from the foam and adhered to the surface of the copper foil; the static resistance of the protective film is 1.0×10^5~1.0×10^11Ω, the adhesion is 3-10gf / inch, and the thickness is 0.085mm.

7. The structure according to claim 1, characterized in that, The antistatic release film is die-cut to remove excess waste material, leaving only the exposed adhesive surface of the base layer.

8. A process method for improving the utilization rate of die-cutting materials based on asynchronous bonding, characterized in that, Includes the following steps: a. Copper foil tape, foam, mesh exhaust adhesive and original mesh release film are sequentially laminated to form a composite functional layer. The composite functional layer is cut into sheets 1.3~1.5mm larger than the product body using a mold. The cut sheets are then precisely laminated to the adhesive side of the antistatic single-sided tape according to the designed pitch using an asynchronous lamination function. b. Cut the antistatic release film into shape by die-cutting and remove excess waste material in the middle. Then, attach the cut release film to the adhesive side of the antistatic single-sided tape, and cover the exposed adhesive side of the antistatic single-sided tape, so that the antistatic single-sided tape and the release film together form a carrier tape. c. The composite functional layer attached to the antistatic single-sided tape in step a is punched to form its shape and holes, and excess waste is removed. d. Cut the antistatic protective film of the tape into shape, and laminate the protective film onto the surface of the copper foil tape away from the foam to complete the product processing; In steps a to d, the original mesh release film is left untorn to improve material utilization.

9. The process method according to claim 8, characterized in that, The design step distance described in step a is set according to the product layout requirements in order to reduce material waste between products.

10. The process method according to claim 8, characterized in that, In step b, the cut shape of the release film is adapted to the shape of the exposed adhesive surface of the antistatic single-sided tape. The antistatic single-sided tape has a static resistance value ≤ 10^11 Ω, a peel force ≥ 1200 gf / inch, and a thickness of 0.12 mm; the mesh exhaust adhesive has a peel force > 1000 gf / inch, a surface resistance of 10^5-10^9 Ω, and a thickness of 0.042 mm; the foam has a peel force > 1000 gf / inch, a surface resistance of 10^11-10^13 Ω, and a thickness of 0.12 mm.

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