Process method for improving foam die cutting layering problem in foam rubber industry
By adjusting the die-cutting blade height and initial cutting depth, and optimizing the foam die-cutting process using a material pulling and bottom film and a molding mechanism, the problem of uneven product end faces after foam die-cutting was solved, improving die-cutting quality and reducing economic losses.
Patent Information
- Application Number
- CN202511871629.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-12
- Publication Date
- 2026-03-06
AI Technical Summary
During the foam die-cutting process, unevenness can easily occur on the product end face, leading to a decrease in die-cutting quality and economic losses.
By adjusting the height of the die-cutting blade and the initial cutting depth, the product is skipped using a material-pulling support film. During the application process, attention is paid to the flatness of the material and the inspection of foreign objects. Combined with the optimization of the molding and die-cutting mechanisms, the product end face is ensured to be flat.
This solved the problem of uneven product end faces after foam die-cutting, reduced economic losses, and improved die-cutting quality.
Smart Images
Figure CN121608241A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of foam die-cutting technology, and in particular to a process method for improving the delamination problem in foam die-cutting in the foam adhesive industry. Background Technology
[0002] Foam die-cutting is a method of cutting foam materials (such as sponges, foam plastics, etc.) into the required shape through a die-cutting process. This method is commonly used to make packaging materials, filling materials, sound insulation materials, etc.
[0003] The process of die-cutting foam typically includes the following steps: Mold design: Design a suitable mold based on the required shape and size; Mold making: Using appropriate materials (such as wood, plastic, etc.) to make the designed mold; Prepare the foam: Select the appropriate foam material according to the required thickness and density, and cut it into the appropriate size; Die-cutting: Place the prepared mold on the foam material, and use a die-cutting machine or hand cutting tool to cut the foam out according to the shape of the mold; Finishing and cleaning: Finish and clean the cut foam to ensure its quality and appearance.
[0004] Regarding the aforementioned technologies, the inventors believe that the following defects exist: during the die-cutting and delamination of foam, unevenness and other quality defects are easily produced on the end faces of the slit products, which reduces the die-cutting quality of the die-cutting equipment and causes economic losses. Therefore, a process method to improve the foam die-cutting delamination problem in the foam adhesive industry is proposed. Summary of the Invention
[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a process method to improve the delamination problem in foam die-cutting in the foam adhesive industry, solving the problem of uneven product end faces after foam die-cutting and reducing economic losses.
[0006] (II) Technical Solution This invention employs the following technical solution: a process method to improve the delamination problem in foam die-cutting in the foam adhesive industry, comprising the following steps: S1. Prepare the materials and adjust the height of the die-cutting blade and the initial cutting depth; S2. Adjust the pressure of the die-cutting blade and transfer the product to the bottom support film after the cut. S3. Inspect the products after die-cutting; S4. After testing, the products are divided and sorted.
[0007] Preferably, in step S1, the materials are prepared, namely, the production drawings, process sheets, die-cutting molds and auxiliary materials corresponding to the product are prepared, and items unrelated to this production are cleared from the machine. The height of the die-cutting blade is adjusted to 23.8 mm, the initial cutting depth of the die-cutting blade is 23.72-23.76 mm, and the pressure is adjusted by 0.01 mm each time, with the standard being that there are no visible knife marks when the foam main material is cut into the white film.
[0008] Preferably, during the reverse cutting process in step S1, the cut sheet is laid flat on the table, the release film on one end of the foam adhesive side is peeled off, and a 220mm wide release film is attached to the material adhesive side along the edge to restore the surface release film.
[0009] Preferably, in step S2, after adjusting the die-cutting blade pressure, the prepared material is laid flat on the feeding base film, horizontally parallel to the die-cutting blade and not tilted. Each die-cut defective product is limited to a maximum of 4 pieces, and both sides are stretched flat during attachment. The material cannot be bent and there should be no air bubbles after attachment. At the same time, check that there are no foreign objects adsorbed on both sides of the material. The product is transferred to the pulling base film by the die-cutting blade. When adjusting the pulling size, the material before completion and the splicing joint material are placed separately. At the end of the order, the width of 5 pieces before and after the joint is fully inspected. Good products that conform to the drawings flow into the next process.
[0010] Preferably, in step S3, the first product produced is fully measured according to the drawings, and reported to the quality inspector for mutual inspection. An inspection form is filled out, and the product drawings are the sole standard for inspecting the product dimensions. During the reverse cutting process, the waste material at the white handle end of the die-cut product is removed, and the die-cutting condition of the white film end is checked. The product and waste material should not be stuck together, and there should be no die-cutting marks on the white film. After the first product is confirmed, the cutting status is confirmed to be qualified in sequence at 100-200-500-1000 times before production continues. The equipment should randomly inspect no less than 5 pieces every 1000 die-cuts. For the product release film delamination inspection of water-absorbing materials, the method is as follows: take the edge of the sheet, attach the PET strand to the plane for 20CM, and pull up the other end to the plane at 75°-85° for 15 seconds. The standard for qualification is that the white film at the surface bend does not delaminate. No less than 3 pieces are inspected for each batch, and the test results are noted on the inspection and packaging record.
[0011] Preferably, in step S4, the die-cut products are brought together with the backing film and divided into sheets of 40 pieces each. Any remaining pieces are spliced together. The splicing method is to overlap the backing film so that the edges of the two products are aligned and parallel. During production, the die must be cleaned every 2000 pieces. When cleaning the die, it is forbidden to use mold release agents or other oily reagents. Use volatile substances, such as alcohol, sprayed on a lint-free cloth and wiped clean.
[0012] Preferably, step S1 includes several sets of aligned die-cutting seats and a molding mechanism disposed inside the die-cutting seats. The molding mechanism can mold the layered product. A die-cutting mechanism is disposed on one side of the molding mechanism to die-cut the product. A guide component is detachably installed on the die-cutting seat.
[0013] Preferably, the molding mechanism includes three sets of molding rollers arranged from top to bottom inside the die-cutting seat, two sets of first connecting blocks movably arranged on the molding rollers, and a second connecting block fixedly arranged below the first connecting blocks. The upper end of the die-cutting seat has a groove, and the first connecting block is movably arranged in the groove. One end of each set of molding rollers is rotatably connected to the inner side of the first connecting block and the inner side of the second connecting block, respectively. A support block is detachably fixed to the upper end of the die-cutting seat. An adjustment block for adjusting the first connecting block and a screw for squeezing and moving the adjustment block are provided on the support block. The adjustment block can control the first connecting block to move in the groove. A screw block corresponding to the screw is provided at the upper end of the support block. The top end of the screw passes through the screw block and is provided with a handle block. The handle block can control the screw to rotate on the screw block.
[0014] Preferably, the die-cutting mechanism includes two sets of first die-cutting rollers rotatably mounted inside the die-cutting base and a die-cutting cutter disposed above the first die-cutting rollers. The die-cutting cutter can cooperate with the first die-cutting rollers to die-cut the layered product. The die-cutting mechanism also includes a second die-cutting roller disposed on one side of the first die-cutting roller and a die-cutting plate disposed corresponding to the second die-cutting roller. The die-cutting cutter is disposed between the die-cutting roller and the second die-cutting roller. Several sets of mounting grooves are equally spaced from top to bottom on both sides of the outer surface of the die-cutting base. The die-cutting mechanism also includes a mounting rod detachably fixed to the mounting groove and a connecting member rotatably disposed at one end of the mounting rod. A mounting block detachably fixed to the die-cutting plate is vertically fixed to the inner side of the connecting member.
[0015] Preferably, the guiding assembly includes a guide roller and a rotating rod rotatably disposed with the guide roller, one end of the rotating rod being fixed or detached perpendicularly to the connecting member.
[0016] (III) Beneficial Effects Compared with existing technologies, this invention provides a process method to improve the problem of foam die-cutting delamination in the foam adhesive industry, and has the following beneficial effects: This process method for improving the delamination problem in foam die-cutting in the foam adhesive industry involves preparing production drawings, process sheets, die-cutting molds, and auxiliary materials corresponding to the product, adjusting the height and initial cutting depth of the die-cutting blade, adjusting the pressure of the die-cutting blade, transferring the product to the backing film during the jump cut, ensuring that both sides are flat during the application, and that the material is not bent and there are no air bubbles after application. At the same time, it is important to check that there are no foreign objects adsorbed on both sides of the material. This method solves the problem of uneven product end faces after foam die-cutting and reduces economic losses. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention.
[0018] Figure 2 This is a partial structural diagram of the molding mechanism in this invention.
[0019] Figure 3 This is a partial structural diagram of the die-cutting mechanism in this invention.
[0020] Figure 4 This is a partial structural diagram of the die-cutting seat and guide roller in this invention.
[0021] In the diagram: 1. Die-cutting base; 2. Die-cutting roller; 3. First connecting block; 4. Second connecting block; 5. Groove; 6. Support block; 7. Adjusting block; 8. Screw; 9. Screw block; 10. Handle block; 11. First die-cutting roller; 12. Die-cutting cutter; 13. Second die-cutting roller; 14. Die-cutting plate; 15. Mounting groove; 16. Mounting rod; 17. Connector; 18. Mounting block; 19. Guide roller; 20. Rotating rod. Detailed Implementation
[0022] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.
[0023] Example 1: Please refer to Figures 1-4 The process method for improving the delamination problem in foam die-cutting in the foam adhesive industry, as described in this embodiment, includes the following steps: S1. Prepare the materials and adjust the height of the die-cutting blade and the initial cutting depth; S2. Adjust the pressure of the die-cutting blade and transfer the product to the bottom support film after the cut. S3. Inspect the products after die-cutting; S4. After testing, the products are divided and sorted.
[0024] In step S1, prepare the materials, namely the production drawings, process sheets, die-cutting molds, and auxiliary materials corresponding to the product. Clean up any items on the machine that are not related to this production. Adjust the height of the die-cutting blade to 23.8 mm and the initial cutting depth of the die-cutting blade to 23.72-23.76 mm. Adjust the pressure by 0.01 mm each time, with the standard being that there are no visible knife marks when the foam material is cut into the white film.
[0025] When performing the reverse cutting process in step S1, lay the cut sheet flat on the table, peel off the release film on one end of the foam adhesive side, and use a 220mm wide release film to attach it to the material adhesive side along the edge, and restore the surface release film.
[0026] In step S2, adjust the die-cutting blade pressure, lay the prepared material flat on the feeding tray film, horizontally parallel to the die-cutting blade and not tilted. Each die-cut defective product is limited to a maximum of 4 pieces, and both sides should be flat when attaching. The material should not be bent and there should be no air bubbles after attachment. At the same time, check that there are no foreign objects adsorbed on both sides of the material. After the die-cutting blade passes through, the product is transferred to the feeding tray film. When adjusting the feeding size, the material before completion and the splicing joint material are placed separately. At the end of the order, the width of 5 pieces before and after the joint is fully inspected. Good products that conform to the drawings flow into the next process.
[0027] In step S3, after the first product is produced, its dimensions are measured according to the drawings and submitted to the quality inspector for mutual inspection. An inspection form is filled out. The product drawings are the sole standard for inspecting the product dimensions. During the reverse cutting process, the waste material at the white handle end of the die-cut product is removed, and the die-cutting condition of the white film end is checked. There should be no adhesion between the product and the waste material, and there should be no die-cutting marks on the white film. After the first product is confirmed, the cutting status is checked sequentially at 100-200-500-1000 times before production continues. The equipment should randomly inspect no less than 5 pieces every 1000 die-cuts. For the product release film delamination inspection of water-absorbing materials, the method is as follows: take the edge of the sheet, attach the PET strand to the plane for 20CM, and pull up the other end to the plane at 75°-85° for 15 seconds. The standard for acceptance is that the white film at the surface bend does not delaminate. No less than 3 pieces are inspected for each batch, and the test results are noted on the inspection and packaging record.
[0028] In step S4, the die-cut products are placed together with the backing film and divided into sheets of 40 pieces each. Any remaining pieces are then joined together. The joining method is to overlap the backing film so that the edges of the two products are aligned and parallel. During production, the die must be cleaned every 2000 pieces. When cleaning the die, do not use mold release agents or other oily reagents. Use volatile substances, such as alcohol, sprayed onto a lint-free cloth and wiped clean.
[0029] Step S1 includes several sets of aligned die-cutting seats 1 and a molding mechanism located inside the die-cutting seats 1. The molding mechanism can mold the layered product. A die-cutting mechanism is provided on one side of the molding mechanism to die-cut the product. A guide component can be detachably installed on the die-cutting seat 1.
[0030] The molding mechanism includes three sets of molding rollers 2 arranged from top to bottom inside the die-cutting base 1, two sets of first connecting blocks 3 movably arranged on the molding rollers 2, and a second connecting block 4 fixedly arranged below the first connecting block 3. The upper end of the die-cutting base 1 is provided with a groove 5, and the first connecting block 3 is movably arranged in the groove 5. One end of several sets of molding rollers 2 is rotatably connected to the inner side of the first connecting block 3 and the inner side of the second connecting block 4, respectively. The upper end of the die-cutting base 1 is detachably fixed with a support block 6. The support block 6 is provided with an adjustment block 7 for adjusting the first connecting block 3 and a screw 8 for squeezing and moving the adjustment block 7. The adjustment block 7 can control the first connecting block 3 to move in the groove 5. The upper end of the support block 6 is provided with a screw block 9 corresponding to the screw 8. The top end of the screw 8 passes through the screw block 9 and is provided with a handle block 10. The handle block 10 can control the screw 8 to rotate on the screw block 9.
[0031] The die-cutting mechanism includes two sets of first die-cutting rollers 11 rotatably mounted inside the die-cutting base 1 and a die-cutting cutter 12 disposed above the first die-cutting rollers 11. The die-cutting cutter 12 can cooperate with the first die-cutting rollers 11 to die-cut the layered product. The die-cutting mechanism also includes a second die-cutting roller 13 disposed on one side of the first die-cutting rollers 11 and a die-cutting plate 14 disposed corresponding to the second die-cutting rollers 13. The die-cutting cutter 12 is disposed between the die-cutting rollers 2 and the second die-cutting rollers 13. Several sets of mounting grooves 15 are equally spaced from top to bottom on both sides of the outer surface of the die-cutting base 1. The die-cutting mechanism also includes a mounting rod 16 detachably fixed to the mounting grooves 15 and a connector 17 rotatably disposed at one end of the mounting rod 16. A mounting block 18 detachably fixed to the die-cutting plate 14 is vertically fixed to the inner side of the connector 17.
[0032] The guiding assembly includes a guide roller 19 and a rotating rod 20 rotatably disposed with the guide roller 19. One end of the rotating rod 20 is fixed or detached perpendicularly to the connector 17.
[0033] This process method for improving the delamination problem in foam die-cutting in the foam adhesive industry involves preparing production drawings, process sheets, die-cutting molds, and auxiliary materials corresponding to the product, adjusting the height and initial cutting depth of the die-cutting blade, adjusting the pressure of the die-cutting blade, transferring the product to the backing film during the jump cut, ensuring that both sides are flat during the application, and that the material is not bent and there are no air bubbles after application. At the same time, it is important to check that there are no foreign objects adsorbed on both sides of the material. This method solves the problem of uneven product end faces after foam die-cutting and reduces economic losses.
[0034] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.
Claims
1. A process for improving the problem of foam die cutting delamination in the foam tape industry, characterized by, It comprises the following steps: S1, prepare materials, and adjust the height and initial cutting depth of the die cutter; S2, debug the die cutter pressure, and transfer the product jump cutting to the material pulling bottom film; S3, detect the product after die cutting; S4, segment and arrange the product after detection.
2. The process for improving the foam die cutting layering problem in the foam gum industry as claimed in claim 1, wherein, In S1, prepare production drawings, process sheets, cutting dies and auxiliary materials corresponding to the product, clean the machine table of unrelated items for this production, adjust the height of the die cutter to 23.8mm, the initial cutting depth of the die cutter to 23.72-23.76, and adjust the pressure by 0.01 each time, with the standard being that there are no visible knife marks on the foam main material cutting white film.
3. The process for improving the foam die cutting layering problem in the foam tape industry as claimed in claim 2, wherein, In S1, when performing reverse cutting process, place the cut sheet on the table, remove the release film from one end of the foam adhesive surface, and use a 220mm wide release film to attach it to the edge of the material adhesive surface, and restore the surface release film.
4. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 3, wherein, In S2, place the prepared material on the material pulling bottom film, and make sure that the transverse direction is parallel to the die cutter and cannot be inclined. The maximum number of defective products per sheet is 4PCS, and the edges should be stretched flat after attachment. The material cannot be bent after attachment and cannot have air bubbles. At the same time, check that there are no foreign objects on both sides of the material. After cutting by the die cutter, the product is transferred to the material pulling bottom film. When adjusting the material pulling size, place the material before adjustment and the splicing joint material separately. When the order is completed, check the joint for 5 widths before and after, and the good product that meets the drawing is sent to the next process.
5. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 4, wherein, In S3, the first product is produced, the product size is measured according to the drawing, and the quality inspector is reported for mutual inspection. Fill in the detection sheet. The product drawing is the only basis for checking the product size; When reverse cutting process is performed, remove the waste material from the white handle end of the die-cut product, and check the die-cutting condition of the white film end. The product and waste material cannot be connected, and there cannot be die marks on the white film. After confirming the first product, continue production after confirming that the cutting state is qualified. The equipment is checked every 1000 times of die cutting, and no less than 5 strips are checked. The product of the accumulated water material is inspected by layering the release film. Method: Take the edge material, attach the PET strand to the plane for 20CM, and pull the other end at an angle of 75°-85° to the plane for 15 seconds. The standard for layering is that the white film at the bending point is not layered. Check at least 3 batches each time, and record the test results on the inspection package record.
6. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 5, wherein, In S4, the die-cut product is placed together with the material pulling bottom film, and is divided into 40PCS per sheet. The splicing method is to overlap the bottom film and align the two products parallel to the splicing edge. The die cutter must be cleaned every 2000PCS during production. Cleaning the die cutter is prohibited from using release agents and other oily reagents. Volatile substances such as alcohol can be used to clean the die cutter by spraying them on a clean cloth.
7. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 6 wherein, 8. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 7, wherein, The die-cutting mechanism comprises three groups of die-cutting rollers (2) arranged from top to bottom inside a die-cutting seat (1), two groups of first connecting blocks (3) movably arranged on the die-cutting rollers (2), and second connecting blocks (4) fixedly arranged below the first connecting blocks (3); the upper end of the die-cuting seat (1) is provided with a groove (5), the first connecting blocks (3) are movably arranged in the groove (5), and one end of each group of the die-cutting rollers (2) is rotatably connected to the inner side surface of the first connecting blocks (3) and the inner side surface of the second connecting blocks (4); The upper end of the die-cutting seat (1) is detachably fixed with a supporting block (6), the supporting block (6) is provided with an adjusting block (7) for adjusting the first connecting blocks (3) and a screw rod (8) for extruding and moving the adjusting block (7), the upper end of the supporting block (6) is provided with a screw block (9) corresponding to the screw rod (8), the top end of the screw rod (8) penetrates through the screw block (9) and is provided with a handle block (10).
9. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 8, wherein, The die-cutting mechanism comprises two groups of first die-cutting rollers (11) rotatably installed inside the die-cutting seat (1) and a die-cutting tool (12) arranged above the first die-cutting rollers (11), the die-cutting mechanism further comprises a second die-cutting roller (13) arranged on one side of the first die-cutting rollers (11) and a die-cutting plate (14) arranged corresponding to the second die-cutting roller (13), and the die-cutting tool (12) is arranged between the die-cutting rollers (2) and the second die-cutting roller (13); The outer surface of the die-cutting seat (1) is provided with a plurality of groups of installation grooves (15) at equal intervals from top to bottom on both sides; The die-cutting mechanism further comprises an installation rod (16) detachably fixed with the installation grooves (15) and a connecting piece (17) rotatably arranged at one end of the installation rod (16), and the inner side of the connecting piece (17) is perpendicularly fixed with an installation block (18) detachably fixed with the die-cutting plate (14).
10. The process for improving the problem of foam die cutting layering in the foam gum industry as claimed in claim 9, wherein, The guide assembly comprises a guide roller (19) and a rotating rod (20) rotatably arranged with the guide roller (19), and one end of the rotating rod (20) is perpendicularly fixed or detachable with the connecting piece (17).