Ultra-thin optical adhesive laser and circular knife cooperation die cutting device and method

Abstract

The application provides a laser and circular knife cooperating die cutting device and method for ultrathin optical glue, relates to the technical field of ultrathin optical glue, and the device comprises a unwinding mechanism; a laser die cutting unit arranged downstream of the unwinding mechanism and used for performing inner shape and contour cutting on the ultrathin optical glue and forming a positioning mark in a waste area; a circular knife die cutting unit arranged downstream of the laser die cutting unit and used for performing outer shape cutting on the ultrathin optical glue which has completed the inner shape cutting; a visual positioning mechanism arranged between the laser die cutting unit and the circular knife die cutting unit and used for shooting the positioning mark and calculating the deviation between the actual position and the theoretical position of the positioning mark; and a controller configured to receive the position deviation detected by the visual positioning mechanism, generate a phase compensation instruction based on the position deviation, and dynamically adjust the rotation phase of a circular knife servo motor in the circular knife die cutting unit, so that the circular knife die cutting unit and the laser die cutting unit can accurately cut the pattern of the ultrathin optical glue during continuous movement of the ultrathin optical glue.

Description

Technical Field

[0001] This application relates to the field of ultrathin optical adhesive technology, specifically to a laser and rotary knife combined die-cutting device and method for ultrathin optical adhesive. Background Technology

[0002] As consumer electronics products become thinner and more precise, the thickness of ultra-thin optical adhesives (OCAs) has been reduced to 25 micrometers or even less. Against this backdrop, both single laser die-cutting and rotary die-cutting technologies face bottlenecks: while laser die-cutting offers high precision and can process complex internal shapes, its processing efficiency is insufficient for large-scale continuous production; while rotary die-cutting is highly efficient, its mechanical contact processing can easily cause stress deformation when cutting ultra-thin materials and it is difficult to handle fine internal holes.

[0003] To address this, the industry has developed a combined solution that physically connects laser die-cutting units and rotary die-cutting units, hoping to combine the advantages of both. However, this simple combination fails to solve a fundamental technical problem: during the continuous high-speed movement of materials, the physical distance between the laser station and the rotary die station causes stretching, deformation, and cumulative positioning errors in the material. Because the two modules operate independently and lack real-time collaborative correction, the rotary die cannot accurately align with the laser-cut pattern for precise cutting, resulting in misalignment of the final product contour and low yield. Achieving real-time, precise alignment between the laser and the rotary die during high-speed operation has become the core obstacle hindering the practical application of this technology. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, this application aims to provide a laser and rotary knife combined die-cutting device and method for ultra-thin optical adhesive.

[0005] In a first aspect, this application proposes a laser and rotary die-cutting device for ultra-thin optical adhesive, comprising: An unwinding mechanism is used to supply ultra-thin optical film and control its tension; A laser die-cutting unit, located downstream of the unwinding mechanism, is used to cut the inner shape and contour of the ultra-thin optical adhesive and to form alignment marks in the waste area. A circular die-cutting unit is located downstream of the laser die-cutting unit and is used to perform external die-cutting on the ultra-thin optical adhesive that has already undergone internal cutting. A visual alignment mechanism is located between the laser die-cutting unit and the rotary die-cutting unit, used to capture the alignment mark and calculate the deviation between its actual position and theoretical position; The controller is electrically connected to the laser die-cutting unit, the rotary die-cutting unit, and the vision alignment system, respectively. The controller is configured as follows: Receive the position deviation detected by the visual alignment mechanism, and generate a phase compensation command based on the position deviation; According to the phase compensation command, the rotation phase of the circular knife servo motor in the circular knife die-cutting unit is dynamically adjusted to achieve precise overlay cutting of the cutting pattern between the circular knife die-cutting unit and the laser die-cutting unit during the continuous travel of the ultra-thin optical adhesive.

[0006] According to the technical solution provided in the embodiments of this application, it also includes an integrated waste removal mechanism electrically connected to the controller. The integrated waste removal mechanism includes a laser waste removal sub-mechanism and a circular knife waste removal sub-mechanism, which are used to remove the dust generated by laser cutting and collect the edge waste generated by circular knife cutting, respectively.

[0007] According to the technical solution provided in the embodiments of this application, the laser die-cutting unit and the circular die-cutting unit are fixed together on an integrated base; the integrated base is a cast iron base with high shock absorption performance and high rigidity, and the bottom of the housing of the laser die-cutting unit and the mounting base of the circular die-cutting unit are provided with positioning keys, and are locked and fixed to the integrated base by prestressed bolts passing through the T-slot.

[0008] According to the technical solution provided in the embodiments of this application, the laser waste removal sub-mechanism includes at least one dust suction port, which is located downstream of the cutting point of the laser die-cutting unit; the internal channel of the dust suction port is constructed as a Venturi nozzle structure, and its outlet end is flat and tapered to form a local high-speed negative pressure zone near the cutting point.

[0009] According to the technical solution provided in the embodiments of this application, the circular knife waste removal sub-mechanism includes at least one peeling plate, which is located downstream of the cutting point of the circular knife die-cutting unit; the peeling plate is made of engineering plastic with a low coefficient of friction, and its guide blade for guiding the waste strip has an eagle-beak-shaped arc transition shape.

[0010] According to the technical solution provided in the embodiments of this application, the arc transition area of ​​the guide blade edge is composed of at least one guide slope, and the angle between the guide slope and the stripping direction of the waste strip is 15° to 30°; the final thickness of the working end of the guide blade edge is 0.05mm to 0.15mm.

[0011] Secondly, this application proposes a laser and rotary die-cutting method for ultra-thin optical adhesive, based on the laser and rotary die-cutting apparatus for ultra-thin optical adhesive as described above, including the following steps: We supply ultra-thin optical film rolls and control their tension to remain constant during transport. According to the preset pattern, the inner shape and outline of the ultra-thin optical adhesive in the continuous movement state are cut, and alignment marks are formed in the waste area. The alignment mark is photographed, and the deviation between its actual position and the preset theoretical position is calculated; The deviation is received, a corresponding phase compensation command is generated, and the circular knife servo motor is driven to adjust its rotation phase. Based on the adjusted phase, during the continuous travel of the ultra-thin optical adhesive, the portion that has completed the inner shape cutting is then subjected to outer shape cutting.

[0012] According to the technical solution provided in the embodiments of this application, generating the corresponding phase compensation command includes the following steps: Receive the current linear velocity of the material fed back by the encoder and read the preset system processing delay; The deviation is subjected to proportional, integral, and differential operations to obtain the feedback compensation component; Based on the current linear velocity and the system processing delay, a predicted displacement compensation component is calculated, and the predicted displacement compensation component is equal to the product of the current linear velocity and the system processing delay; The feedback compensation component is superimposed with the predicted displacement compensation component to generate the phase compensation command.

[0013] According to the technical solution provided in the embodiments of this application, after capturing the alignment mark and calculating the deviation between its actual position and the preset theoretical position, and before generating the corresponding phase compensation command, the following steps are further included: The deviation is compared with the pre-stored phase compensation capability range of the circular tool servo system; The generation of the corresponding phase compensation command includes the following steps: If the deviation falls within the phase compensation capability range, a first type of instruction is generated, which only includes driving the circular knife servo motor to perform phase adjustment. If the deviation exceeds the phase compensation capability range, a second type of instruction is generated. The second type of instruction includes: driving the circular knife servo motor to perform phase adjustment within the maximum capability range, and synchronously adjusting the cutting path parameters of the laser die-cutting unit for the next die-cutting unit graphic, so as to perform visual graphic pre-compensation for the deviation exceeding the limit.

[0014] According to the technical solution provided in the embodiments of this application, the inner shape and contour cutting of the ultrathin optical adhesive in a continuously moving state according to a preset pattern is performed based on a pre-deformation compensated laser cutting path; the method for obtaining the pre-deformation compensated laser cutting path includes: Based on a pre-established contact-deformation coupling model associated with current material properties, circular cutter parameters, and process parameters, the predicted contact deformation amount that the circular cutter will produce on the material when performing outlining cutting is calculated. Based on the predicted contact deformation, the preset shape is subjected to reverse geometric compensation to generate the pre-deformation compensated laser cutting path; so that the inner shape cut by the laser according to the compensated path, after being deformed and recovered by the contact deformation of the circular blade outer shape, achieves a preset matching accuracy with the theoretical design contour.

[0015] Compared with the prior art, the beneficial effects of this application are as follows: I. Achieved ultra-high precision nesting in high-speed continuous production: A vision alignment mechanism detects deviations in real time, and the controller drives the circular blade servo motor to dynamically adjust its phase, achieving flight alignment. This ensures that the circular blade cutting line accurately matches the actual position of the laser-cut graphic. This completely eliminates the problem of inaccurate nesting caused by material transfer deformation and cumulative errors, achieving nesting accuracy of ±0.05mm or even higher in high-speed production with uninterrupted material flow.

[0016] Second, it achieves a true balance between precision and efficiency: This device retains the efficiency advantages of continuous high-speed operation in rotary die-cutting, while simultaneously providing it with cutting precision comparable to laser processing through real-time closed-loop compensation. It is not a simple superposition of two technologies, but rather a systematic improvement achieved through coordinated control, enabling high efficiency and high precision to be realized simultaneously on a single production line.

[0017] Third, it reduces the reliance on the extreme precision of the mechanical transmission system: Traditional mechanical positioning methods require extremely high machining and installation precision to reduce cumulative errors. This invention corrects physical deviations in hardware through intelligent software compensation, reducing the absolute precision requirements of mechanical systems such as guide rails and rollers, improving the system's fault tolerance and stability, and also reducing manufacturing and debugging costs. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the laser and rotary knife combined die-cutting device for ultra-thin optical adhesive provided in the embodiments of this application; Figure 2 A flowchart illustrating the steps of a laser and rotary die-cutting method for ultrathin optical adhesive provided in this application embodiment. Detailed Implementation

[0019] The present application will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0020] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0021] Example 1 As mentioned in the background section, in view of the problems in the prior art, this application proposes a laser and rotary knife combined die-cutting device for ultrathin optical adhesive, such as... Figure 1 As shown, it includes: An unwinding mechanism is used to supply ultra-thin optical film and control its tension; A laser die-cutting unit, located downstream of the unwinding mechanism, is used to cut the inner shape and contour of the ultra-thin optical adhesive and to form alignment marks in the waste area. A circular die-cutting unit is located downstream of the laser die-cutting unit and is used to perform external die-cutting on the ultra-thin optical adhesive that has already undergone internal cutting. A visual alignment mechanism is located between the laser die-cutting unit and the rotary die-cutting unit, used to capture the alignment mark and calculate the deviation between its actual position and theoretical position; The controller is electrically connected to the laser die-cutting unit, the rotary die-cutting unit, and the vision alignment system, respectively. The controller is configured as follows: Receive the position deviation detected by the visual alignment mechanism, and generate a phase compensation command based on the position deviation; According to the phase compensation command, the rotation phase of the circular knife servo motor in the circular knife die-cutting unit is dynamically adjusted to achieve precise overlay cutting of the cutting pattern between the circular knife die-cutting unit and the laser die-cutting unit during the continuous travel of the ultra-thin optical adhesive.

[0022] Specifically, ultra-thin optical film refers to transparent optical adhesives (OCAs) typically with a thickness between 15 and 50 micrometers, used for bonding consumer electronics display modules. They are usually supplied in roll-to-roll form and include an adhesive layer and a release film. Laser die-cutting unit: refers to a module that uses a non-contact high-energy laser beam for cutting. Preferably, an ultraviolet (UV) laser (e.g., 355nm wavelength) is used due to its cold-working characteristics and small heat-affected zone. This unit includes at least a laser generator, a galvanometer scanning system (for controlling beam deflection), and a focusing lens. Its function is to perform high-precision internal and contour cutting, such as cutting internal air vents, irregular holes, and fine wiring grooves, and forming crosshairs, circles, or specific geometric "alignment marks" in the outer "waste area." Circular die-cutting unit: refers to a module that uses a physical contact rotating die for punching. Its core is a precision circular die roller, the die shape of which matches the final product shape. The circular die roller is driven by a high-precision servo motor, enabling precise control of the rotation phase. Its function is to efficiently complete the "outline cutting" of products, i.e., blanking. The vision alignment mechanism is the "eye" that achieves precise alignment. It typically includes at least one high-resolution industrial CCD camera, a telecentric lens (to eliminate perspective errors), and a high-brightness, uniform LED lighting system. Its installation position ensures that the laser-cut "alignment marks" can be clearly captured as the material passes by. The controller usually consists of an industrial computer (IPC) and a dedicated multi-axis motion control card. The motion control card is responsible for high real-time servo control, encoder signal processing, and hardware triggering. The core configuration of the controller is to run a set of collaborative control software that receives deviation data from the vision system, executes specific control algorithms, and outputs high-precision phase compensation commands.

[0023] Implementation steps: During operation, the ultra-thin optical film roll is drawn from the unwinding mechanism and, after being kept under constant tension by the tension control system, enters the laser die-cutting area. The laser die-cutting unit, based on a pre-imported CAD drawing file, uses a galvanometer to control the laser focus and scan the material surface at high speed, completing the cutting of the preset inner shape and contour, and simultaneously etching alignment marks in the waste area around the shape. The cut material continues to be conveyed forward. When the alignment mark moves directly below the visual alignment mechanism, the controller sends a trigger signal, and the CCD camera instantly captures an image. The image processing software analyzes the image in real time, using algorithms such as template matching and sub-pixel edge detection to accurately calculate the actual coordinates (X_actual, Y_actual) and angle (θ_actual) of the center point of the alignment mark, and compares them with the theoretical coordinates (X_theory, Y_theory, θ_theory) stored in the controller to obtain the positional deviation (Δx, Δy, Δθ). These deviation data are immediately sent to the controller. The co-control algorithm within the controller (e.g., a PID algorithm incorporating feedforward prediction) calculates the required phase adjustment (ΔΦ) of the rotary cutter servo motor to compensate for the deviation, based on the deviation, the material's current linear velocity (feedback from a high-resolution encoder mounted on the main drive roller), and the system's inherent processing delay. This phase compensation command is sent to the rotary cutter servo driver via a high-speed fieldbus (such as EtherCAT). The driver drives the rotary cutter servo motor to dynamically fine-tune its current phase (i.e., advance or lag by a small angle) while it rotates continuously. When the material, carrying the laser-cut pattern, arrives at the rotary cutter die-cutting station, the rotary cutter cuts precisely with the adjusted phase, and its blade trajectory accurately coincides with the edge of the existing laser-cut pattern, thus achieving "flying alignment" and "precise overlay cutting" without interrupting the material's movement.

[0024] This device achieves high-precision laser-grade die-cutting while ensuring efficient continuous production of circular die-cutting. It eliminates the misalignment of internal and external patterns caused by material stretching, deformation, and cumulative errors in transmission between workstations, achieving a die-cutting accuracy of ±0.05mm or even higher, significantly improving product yield. Simultaneously, this solution reduces the stringent requirements for the absolute precision of the mechanical transmission system, correcting "hardware physical deviations" through "software intelligent compensation," thus improving system cost-effectiveness and stability. Its core principle is "phase-synchronous dynamic compensation based on real-time feedback." The system constructs a closed-loop control circuit: using the laser-cut pattern as a reference, a vision sensor detects the actual position of this reference after transmission in real time, converting the position error into an adjustment amount for the time reference (phase) of the circular die's rotational movement. Adjusting the circular die's phase is equivalent to spatially shifting the starting point of its cutting contour, thereby realigning it with the moving laser pattern. Essentially, this is a servo synchronous control technology that maps spatial position errors to phase differences on the time axis and corrects them in real time.

[0025] In a preferred embodiment, the system further includes an integrated waste removal mechanism electrically connected to the controller. The integrated waste removal mechanism includes a laser waste removal sub-mechanism and a circular blade waste removal sub-mechanism, which are used to remove the dust generated by laser cutting and collect the edge waste generated by circular blade cutting, respectively.

[0026] Specifically, the integrated waste removal mechanism refers to a composite system that is deeply integrated in physical layout and control logic, jointly serving the goal of removing all processing waste. Its integration is mainly reflected in: a compact and integrated spatial layout to avoid interference; and coordinated power and control, uniformly scheduled by a single controller according to the processing cycle. The laser waste removal sub-mechanism is specifically designed for micron-sized waste such as powder and fumes generated by laser cutting. It mainly includes a centrifugal fan that generates negative pressure, connecting pipes, a high-efficiency filter (such as HEPA), and the most critical working end—the dust extraction port. The circular blade waste removal sub-mechanism is specifically designed for frame-shaped and sheet-like solid waste generated by circular blade punching. It mainly includes a peeling plate for peeling the waste from the base film, and a drive take-up roller or traction device for collecting the peeled waste.

[0027] Implementation Steps: During device operation, the integrated waste removal mechanism starts synchronously with the processing actions. For laser waste removal, the controller starts the high-pressure centrifugal fan simultaneously with laser cutting. The strong negative pressure generated by the fan is conducted through pipes to the dust suction port installed downstream of the laser cutting point (on the material outlet side adjacent to the focal point). The dust suction port is typically designed to be flat, with its opening directly facing and close to (approximately 1-3 mm away from) the material surface. The hot dust and fumes generated by laser cutting are sucked into the dust suction port the instant they are generated, and then enter a multi-stage filtration system through pipes. The purified air is discharged, and the dust is collected. For circular blade waste removal, after the circular blade completes the punching, the product (attached to the base film) separates from the edge waste and continues to move forward. The peeling plate is precisely positioned on the path of the waste strip, and its tip gently "prys" into the gap between the waste and the base film at a certain angle ("angle of attack"). As the material moves forward, the waste strip is smoothly peeled off from the base film by the peeling plate and guided to a waste collection roller driven by an independent servo motor. The collection roller typically operates in torque control mode, pulling the waste strip with a constant, low tension (e.g., 2-5N) to ensure smooth winding without breakage. The controller coordinates the operation of the two sub-mechanisms; for example, when the circular knife waste discharge is detected to be activated, the power of the laser waste discharge fan can be appropriately increased to handle any slight dust that may be stirred up.

[0028] This implementation method completely solves the waste management problem in hybrid die-cutting processes, achieving continuous cleanliness of the production interface. Laser waste removal prevents dust from contaminating material surfaces, optical lenses, or the inside of the equipment; circular blade waste removal reliably removes edge waste, preventing its accumulation and entanglement that could lead to downtime. Working together, these two methods significantly reduce unplanned downtime during production, improving overall equipment efficiency (OEE) and product cleanliness.

[0029] In a preferred embodiment, the laser die-cutting unit and the rotary die-cutting unit are fixed together on an integrated base; the integrated base is a cast iron base with high shock absorption performance and high rigidity, and the bottom of the housing of the laser die-cutting unit and the mounting base of the rotary die-cutting unit are provided with positioning keys, and are locked and fixed to the integrated base by prestressed bolts passing through the T-slot.

[0030] Specifically, an integrated base refers to a single, integral mechanical component that serves as the mounting foundation for both laser die-cutting and rotary die-cutting units. It is not a platform assembled from multiple parts, but rather a large base considered as a whole during the design phase, cast or machined in a single operation. High vibration damping and high rigidity cast iron base: The preferred material is high-strength gray cast iron (such as HT300). The graphite flakes within gray cast iron effectively dampen vibrations, providing excellent vibration damping performance. "High rigidity" refers to the base's minimal deformation under working loads (such as motor start-stop torque and material tension), ensured through optimized rib structure design and sufficient cross-sectional dimensions. Positioning keys: These are protrusions (keys) located at the bottom of the module housing or mounting base, engaging with corresponding grooves (keyways) on the base. Their function is to provide coarse positioning, restricting the module's freedom of movement in the horizontal plane except in one direction, enabling rapid and repeatable initial installation alignment. T-slots are long, narrow grooves with an inverted T-shaped cross-section machined into the base. After the prestressed bolt passes through the module mounting hole, its head is engaged in the T-slot. When tightened, the bolt generates a strong preload, firmly "pressing" the module onto the base plane. This "prestress" not only resists working loads but also eliminates microscopic gaps between the mating surfaces, improving connection rigidity.

[0031] Implementation Steps: During manufacturing and assembly, the integrated cast iron base is first structurally optimized using finite element analysis (FEA) to ensure that the deformation of key mounting surfaces is less than 10 micrometers under simulated maximum working load. After casting, the base undergoes thorough aging treatment to eliminate internal stress. Then, its upper surface (mounting plane) and key locating keyways and T-slots are precision milled and ground to ensure flatness, straightness, and slot position accuracy. When installing the laser die-cutting unit and the rotary die-cutting unit, the locating keys at the bottom of each unit are aligned with the corresponding keyways on the base and placed down. At this point, the relative positions of the two modules are roughly determined within sub-millimeter accuracy. Then, high-strength bolts are passed through the mounting flanges of each module and screwed downwards into the T-nuts pre-embedded in the T-slots. Using a torque wrench or hydraulic tensioner, these bolts are tightened step-by-step according to the specified sequence and torque values ​​to generate uniform and sufficient prestress. This pre-tightening force ensures a tight fit between the module mounting surface and the base mounting surface, forming a highly rigid mechanical connection. In this way, the relative position between the optical center of the laser scanning galvanometer and the rotation center of the circular cutter roller is mechanically locked in an extremely stable manner. Its micron-level stability does not depend on cumbersome on-site debugging and can resist temperature rise changes and vibration interference during long-term operation.

[0032] This structural design fundamentally ensures a long-term, stable microscopic geometric relationship between the two core modules: the laser and the circular blade. It minimizes the "Abbe error" and "thermal deformation asynchrony error" that may occur when docking two independent platforms in traditional solutions. Due to the unified and stable reference, the system has high initial alignment accuracy, short debugging time, and the cutting accuracy will not drift under long-term high-speed operation or ambient temperature fluctuations, resulting in low maintenance costs.

[0033] In a preferred embodiment, the laser waste removal sub-mechanism includes at least one dust suction port, which is located downstream of the cutting point of the laser die-cutting unit; the internal channel of the dust suction port is constructed as a Venturi nozzle structure, and its outlet end is flat and tapered to form a local high-speed negative pressure zone near the cutting point.

[0034] Specifically, the Venturi nozzle structure refers to a specific shape of the airflow channel inside the suction port. Its characteristic is the presence of a "throat" with a minimum cross-sectional area in the center of the channel. According to Bernoulli's principle in fluid mechanics, when the airflow (provided by an external fan) passes through the throat, the velocity increases sharply, causing a significant decrease in static pressure at that point, thus creating a strong local negative pressure (suction) in the throat and its downstream outlet area. The flat, tapering outlet end describes the shape of the working end of the suction port relative to the material. "Flat" indicates that the outlet cross-section is a long rectangle, wider in the width direction to cover the laser scanning range, and thinner in the height direction to fit close to the material. "Cut-off" means that the cross-section gradually narrows from the internal channel towards the outlet; this shape helps to accelerate the airflow and direct it to a concentrated area.

[0035] Implementation Steps: The suction port is typically precision-machined from high-temperature resistant, anti-static metals (such as aluminum alloys) or engineering plastics (such as PEEK). Its installation position requires fine adjustment, ensuring the long side of its flat outlet is parallel to the material surface, and the distance from the material is usually maintained within an adjustable range of 1 to 3 millimeters, ensuring it doesn't touch the material while effectively covering the suction field. The suction port is connected to the high-pressure centrifugal fan and dust collection system via a flexible hose. When the system is operating, the fan starts, generating a high-speed airflow inside the suction port. Due to the Venturi structure, the airflow is accelerated as it passes through the throat, forming a high-speed, low-pressure jet at the outlet. This high-speed airflow, closely adhering to the material surface, creates a strong localized negative pressure zone around the cutting point (similar to a miniature "wind tunnel"). The dust generated from laser cutting of ultra-thin OCA is typically in the micrometer range in size, extremely lightweight, and prone to static electricity. The moment they are vaporized or molten and ejected from the material, they are captured by this directional, powerful suction field and rapidly drawn into the internal channel of the suction port along with the airflow, entering the waste discharge pipe system. The flat, tapering outlet design makes this powerful suction field more evenly distributed along the width of the material (the long side of the suction port), ensuring that the cut area within the scanning range is effectively cleaned.

[0036] This embodiment features a specially designed suction port that achieves near 100% instant removal efficiency for micron-sized laser-cut dust. It effectively solves the problem of dust residue caused by electrostatic adsorption of materials, preventing dust from falling onto material surfaces and causing appearance defects, or contaminating subsequent critical components such as the vision alignment lens and the circular blade, thus ensuring product cleanliness and long-term stable operation of the equipment. Compared to ordinary circular tube suction ports, its suction efficiency is several times higher.

[0037] In a preferred embodiment, the circular blade waste removal mechanism includes at least one stripping plate located downstream of the cutting point of the circular blade die-cutting unit; the stripping plate is made of engineering plastic with a low coefficient of friction, and its guide blade for guiding the waste strip has an eagle-beak-shaped arc transition shape.

[0038] Specifically, the stripper plate is the core guiding component in the circular blade waste removal system, responsible for separating the punched edge waste from the supporting base film and guiding it to the collection path. It is not a simple baffle, but a functional element with precise geometry and specific physical properties. Low-friction engineering plastics: This refers to the material category used to manufacture the stripper plate, requiring low surface energy, high wear resistance, good dimensional stability, and a certain degree of toughness. A preferred embodiment is polyetheretherketone (PEEK), which possesses an extremely low coefficient of friction (approximately 0.2-0.3 against dry steel), high strength, high heat resistance (long-term operating temperature >250℃), and excellent creep resistance, maintaining the precision of the cutting edge shape over a long period. Eagle-beak-like rounded transition shape: This is a figurative description of the three-dimensional geometry of the guiding cutting edge. It refers to the cutting edge not being a sharp right angle or point, but rather a rounded tip profile formed by one or more curved surfaces smoothly transitioning into an eagle-beak-like shape. This shape avoids stress concentration, allowing the waste strip to undergo a gradual bending and stress-increasing "guided" process during stripping, rather than being "hardly scraped" or "suddenly torn".

[0039] Implementation steps: The peeling plate is mounted downstream of the rotary die-cutting unit via a precision adjusting bracket, adjacent to the tangent exit of the rotary die roller and the bottom roller. Its mounting position and angle (“angle of attack”) must be finely adjustable. During installation, the peeling plate's guide blade, with its “eagle-beak-like arc transition shape,” is precisely aligned and gently “embedded” into the boundary gap between the waste strip (already cut by the rotary die but still attached to the bottom film) and the product (remaining on the bottom film and continuing to advance). A very small gap (approximately 0.05-0.1 mm) is maintained between the tip of the blade and the bottom film surface to ensure no scratches are made. As the material continues to advance, the waste strip is pulled forward, its leading edge first contacting the guide curve of the peeling plate's blade. Under the combined action of the material's forward force and the pull of the waste collection roller, the waste strip is gradually and smoothly “pried up” along the arc surface of the blade, thus separating from the bottom film. Due to the extremely low coefficient of friction of PEEK material, the sliding friction between the scrap strip and the stripping plate is minimal, reducing stripping resistance and lateral stretching of the scrap strip. The stripped scrap strip is guided to a servo-motor driven scrap collection roller and wound up under constant tension. The entire stripping process is continuous and smooth.

[0040] This implementation utilizes a specially designed peeling plate, which significantly improves the success rate and stability of peeling highly viscous, ultra-thin OCA waste, virtually eliminating waste breakage and stringing. This ensures the continuity of the waste removal process, avoids unplanned downtime caused by waste breakage and entanglement, and greatly improves the overall equipment efficiency (OEE). Simultaneously, the smooth peeling action reduces the risk of damage to the base film and disturbance to the product adhesive layer.

[0041] In a preferred embodiment, the arc transition region of the guide blade edge is formed by at least one guide bevel, the angle between the guide bevel and the stripping direction of the waste strip is 15° to 30°, and the final thickness of the working end of the guide blade edge is 0.05mm to 0.15mm.

[0042] Specifically, the guide bevel: the basic geometric element constituting the "arc transition area". It typically refers to one or more planes or micro-curved surfaces formed by precision grinding, which connect at specific angles to form a smooth guide profile. At least one bevel is required, and in practice, it may be formed by smoothly connecting 2-3 bevels at different angles. Angle of 15° to 30°: refers to the acute angle between the guide bevel and the "waste strip peeling direction". The peeling direction is usually approximated to the tangential direction of material transport. This angle range is an optimized range verified through extensive experimentation. An angle less than 15° may result in an overly gentle guide, insufficient peeling force, and incomplete peeling; an angle greater than 30° may result in an overly steep guide, tending towards "hard scraping", increasing the risk of stress concentration. Final thickness of the working end of the guide cutting edge: 0.05mm to 0.15mm: refers to the physical thickness of the tip of the cutting edge after all bevel grinding and final finishing. This is a crucial dimension. "Final thickness" emphasizes the finished product size after all machining is completed, not the material blank thickness.

[0043] Implementation Steps: When manufacturing this stripping plate, PEEK bars or sheets are first selected as the blank. Initial shaping is achieved through CNC precision milling, followed by the crucial edge fine grinding process. Using a high-precision universal tool grinder or optical profile grinder, the operator first grinds the main guide bevel at a design angle of 15° to 30° (e.g., 20°). Typically, two intersecting bevels (one main guide surface and one auxiliary transition surface) are ground to create a more optimized rounded transition effect, ensuring their intersection (i.e., the desired cutting edge) is as smooth as possible. After forming the basic profile, final edge "thinning" and "fine grinding" are performed. Using extremely fine-grit diamond wheels or oilstones, while maintaining the guide angle, the thickness of the very tip of the cutting edge (approximately 0.5-1 mm in length) is gradually ground to between 0.05 mm and 0.15 mm (e.g., a target value of 0.1 mm). This process requires extremely high skill and inspection methods (such as tool microscopes and profilometers) to monitor the angle and thickness in real time. After grinding, the contact area of ​​the cutting edge may be mirror-polished or coated with Teflon (PTFE) to further reduce the coefficient of friction. During assembly, a dial indicator or laser displacement sensor is used to precisely adjust the position of the peeling plate, ensuring that the theoretical angle between its guide bevel and the material peeling direction is within the set value of 15°-30°, while ensuring that the gap between the cutting edge tip and the base film meets the requirements.

[0044] Example 2 Based on Example 1, this example proposes a laser and rotary die-cutting method for ultrathin optical adhesives, using a laser and rotary die-cutting apparatus for ultrathin optical adhesives as described above. Figure 2 As shown, it includes the following steps: S1. Supply ultra-thin optical film and control its tension to be constant during transportation; S2. According to the preset pattern, the inner shape and outline of the ultra-thin optical adhesive in the continuous movement state are cut, and alignment marks are formed in the waste area. S3. Take a picture of the alignment mark and calculate the deviation between its actual position and the preset theoretical position; S4. Receive the deviation, generate a corresponding phase compensation command, and drive the circular knife servo motor to adjust its rotation phase; S5. Based on the adjusted phase, during the continuous travel of the ultra-thin optical adhesive, the portion that has completed the inner shape cutting is then outer-shaped.

[0045] Specifically, this method begins with the operator setting process parameters (material type, thickness, pattern, tension setting, speed, etc.) on the HMI and starting production. The system first performs initialization: the tension control system establishes the preset tension, and each servo drive is powered on and enabled. Subsequently, the main drive roller servo motor starts, and the traction material begins to move continuously. Once the material is running stably, the laser die-cutting unit starts. In the laser cutting step, the galvanometer scanning system, according to the pre-programmed pattern path, controls the laser focus to perform high-speed scanning on the moving material surface, ablating and cutting out the product's internal shape (such as holes, grooves) and main contour lines, and simultaneously engraving alignment marks in the waste area. The material, carrying the just-cut pattern, continues to move forward. When the alignment mark moves to the center area of ​​the vision camera's field of view, it is triggered by the synchronous pulse of the rotary encoder or the controller's internal timer to capture an image. The image captured by the camera is transmitted to the image processor for real-time analysis. The algorithm calculates the X, Y coordinates and rotation angle of the mark center and compares them with the stored theoretical values ​​to obtain Δx, Δy, and Δθ. These deviation data are immediately sent to the controller's motion control module. The algorithmic logic within the controller (e.g., a PID controller incorporating feedforward) receives the deviation and, combined with the real-time linear velocity feedback from the encoder, generates a specific phase compensation command (e.g., advancing the circular cutter phase by 1000 pulses). This command is sent to the circular cutter servo driver via a high-speed bus. The driver drives the circular cutter servo motor, enabling it to dynamically adjust the phase within milliseconds. Almost simultaneously, the material area with the laser-cut pattern moves precisely under the circular cutter roller. The circular cutter, with its adjusted phase, performs a rotating cut, its die trajectory precisely falling along the outer edge of the laser-pre-cut contour, completing the outline cutting and separating the product from the material strip. Throughout the process, an integrated waste removal mechanism works synchronously to remove laser dust and collect the waste edges from the circular cutter.

[0046] This method successfully integrates the ultra-high precision and flexibility of laser processing with the high efficiency and easy waste removal of rotary die-cutting on a continuous production line. It produces die-cut products with perfect alignment of inner and outer contours, high edge quality, and a fast production cycle. Through real-time closed-loop control, the method compensates for dynamic errors in production, making it possible to achieve a cutting accuracy of ±0.05mm at high speeds (e.g., 60m / min), significantly improving product yield and production efficiency. The underlying principle of this method is "time-axis motion resynchronization based on real-time spatial information feedback." It transforms a spatial positioning problem (alignment of the laser pattern and the rotary die pattern) into a time synchronization problem (synchronization of the rotary die rotation phase and the material position signal). The vision system provides spatial error feedback. The controller, acting as a "synchronizer," compensates for the positional shift of the material during spatial transport by adjusting the phase of the rotary die rotation on the time axis (i.e., time offset). This is a typical application of "electronic axis" or "virtual spindle" synchronization technology in complex processes, realizing the integration of two mechanically separate processing tools into a coordinated whole at the motion control level.

[0047] In a preferred embodiment, generating the corresponding phase compensation command includes the following steps: Receive the current linear velocity of the material fed back by the encoder and read the preset system processing delay; The deviation is subjected to proportional, integral, and differential operations to obtain the feedback compensation component; Based on the current linear velocity and the system processing delay, a predicted displacement compensation component is calculated, and the predicted displacement compensation component is equal to the product of the current linear velocity and the system processing delay; The feedback compensation component is superimposed with the predicted displacement compensation component to generate the phase compensation command.

[0048] Specifically, the current linear velocity (V) of the material fed back by the encoder refers to the instantaneous movement velocity of the material measured and calculated in real time by a high-resolution rotary encoder installed on the main drive roller or other driven rollers. This is a key input for feedforward compensation. V = (encoder pulse frequency / number of pulses per revolution) × π × roller diameter. The preset system processing delay (T_d) refers to the total time spent from the completion of the visual camera exposure to the start of the circular knife servo motor executing the compensation command (including image transmission, processing, controller calculation, command issuance, and driver response). This time can be accurately determined in advance through system identification experiments and stored in the controller as a constant or a parameter that varies slightly with speed. The feedback compensation component refers to the control output calculated by the classic PID (proportional-integral-derivative) controller in the control algorithm based on the current deviation (Δx, Δy, Δθ). It is a response to and correction of the error that has "already occurred." The proportional (P) term provides a fast response, the integral (I) term eliminates steady-state error, and the derivative (D) term predicts the error change trend and suppresses overshoot. Predictive displacement compensation component: This refers to the control output portion calculated by the feedforward controller based on the predictive model. Its core model is: Predicted displacement = Current linear velocity × System processing delay. It predicts the distance the material will continue to move during the system's "thinking" and "responding" time (T_d), thus injecting this future displacement as a compensation value into the control command in advance.

[0049] Implementation Steps: A dedicated phase compensation command generation module is implemented in the controller software. This module executes the following steps within each control cycle (e.g., 1ms): First, it receives deviation data packets (Δx, Δy, Δθ) from the vision system, simultaneously reads the current linear velocity V of the material updated in real-time by the encoder module from the high-speed bus, and retrieves a preset T_d value from the parameter table (e.g., T_d = 5ms). Then, the algorithm performs two calculations in parallel: one enters the feedback control loop, performing PID calculations on the X component of the deviation (mainly affecting the phase) Δx: P_out = Kp × Δx; I_out = Ki × Σ(Δx × dt); D_out = Kd × (Δx - last_Δx) / dt. The three are summed to obtain the feedback compensation component. The other enters the feedforward prediction loop, performing a multiplication operation: S_ff = V × T_d. This S_ff is the predicted displacement compensation component, representing the distance the material will travel in the future time interval T_d starting from this moment. Then, the algorithm superimposes these two components: S_total = S_fb + S_ff. Finally, based on the kinematic relationship, the total displacement S_total that needs to be compensated is converted into the phase angle increment ΔΦ that the circular cutter servo motor needs to adjust (e.g., ΔΦ = (S_total / circular cutter circumference) × 360°), and this ΔΦ is encapsulated into a specific pulse command or position command, which is sent to the circular cutter servo driver as a phase compensation command via a bus such as EtherCAT.

[0050] This algorithm effectively overcomes the lag compensation problem caused by visual processing and system response delays, achieving truly real-time and accurate alignment. It ensures that the compensation command is based not on the position captured in the past, but on the predicted position at the future cutting moment, thus significantly improving overlay accuracy at high speeds. Compared to pure PID control, this composite control strategy reduces following errors by approximately 60%-80%, exhibiting more stable performance, especially under conditions of speed changes or acceleration / deceleration.

[0051] In a preferred embodiment, after capturing the alignment mark and calculating the deviation between its actual position and the preset theoretical position, and before generating the corresponding phase compensation command, the following steps are further included: The deviation is compared with the pre-stored phase compensation capability range of the circular tool servo system; The generation of the corresponding phase compensation command includes the following steps: If the deviation falls within the phase compensation capability range, a first type of instruction is generated, which only includes driving the circular knife servo motor to perform phase adjustment. If the deviation exceeds the phase compensation capability range, a second type of instruction is generated. The second type of instruction includes: driving the circular knife servo motor to perform phase adjustment within the maximum capability range, and synchronously adjusting the cutting path parameters of the laser die-cutting unit for the next die-cutting unit graphic, so as to perform visual graphic pre-compensation for the deviation exceeding the limit.

[0052] Specifically, the phase compensation capability range of the circular cutter servo system is a preset system performance boundary parameter. It defines the maximum positional deviation that the circular cutter servo motor can effectively compensate for by dynamically adjusting its rotational phase within a single processing cycle (between two adjacent die-cutting units) at the current material running speed. This range is typically calculated and experimentally calibrated using the servo motor's maximum acceleration, torque, and the mechanical system's response bandwidth, and stored in the controller. For example, for a specific configuration, this range might be set as Δx_max = ±0.2mm, Δθ_max = ±0.3°. The first type of instruction refers to the regular instructions generated by the controller when the detected deviation is within the single-stage compensation capability of the circular cutter. These instructions only contain commands to drive the circular cutter servo motor to perform the corresponding phase adjustment; this is the most commonly used and efficient operating mode of the system. The second type of instruction refers to the emergency coordination instructions generated by the controller when the detected deviation exceeds the single-stage compensation capability of the circular cutter. Its content comprises two parts: 1) instructing the circular cutter servo motor to compensate within its maximum capacity (i.e., "making the best effort"); 2) synchronously instructing the laser die-cutting unit to adjust the cutting path parameters of the next die-cutting unit graphic to be cut (the next one, not the one currently showing deviation), in order to perform "visual graphic pre-compensation" for the "excessive deviation" that the circular cutter cannot compensate for. Visual graphic pre-compensation: This is a software-level geometric correction. It does not move materials or tools in physical space, but rather modifies the coordinate data of the cutting graphic to be sent to the laser galvanometer, causing it to undergo slight translation, rotation, or deformation. This allows the laser-cut graphic to "adapt" or "offset" the existing residual error that the circular cutter cannot completely correct in the next cutting cycle, creating alignment conditions for the next circular cutter overlay cut.

[0053] Implementation steps description: After the method executes to visual alignment and calculates the deviation (Δx, Δy, Δθ), the controller does not immediately generate instructions, but first executes a decision step: it compares the absolute values ​​of Δx and Δθ with the "phase compensation capability range" (Δx_max, Δθ_max) at the corresponding speed in the pre-stored database.

[0054] Scenario 1 (deviation within range): If |Δx| ≤ Δx_max and |Δθ| ≤ Δθ_max, the controller determines it to be a normal case. It calls the standard algorithm (as described above) to generate a first-type instruction, which only contains the circular knife phase adjustment amount for the current deviation, and sends it to the circular knife servo driver for execution. The laser die-cutting unit then continues to cut the next unit according to the original pattern.

[0055] Scenario 2 (Deviation Out of Range): If |Δx|>Δx_max or |Δθ|>Δθ_max, the controller determines it as an abnormal situation. First, it generates a "saturated" circular blade phase command, instructing the circular blade servo motor to adjust to the maximum allowable compensation amount (e.g., +Δx_max or -Δx_max). Simultaneously, the controller calculates the compensation amount for the laser pattern. This compensation amount is for the "next" die-cutting unit. The calculation formula is: Laser pattern compensation amount = Current total detected deviation - Circular blade maximum compensation amount. For example, if Δx = +0.3mm is detected, and the circular blade can compensate up to +0.2mm, then the laser pattern needs a -0.1mm translational pre-compensation in the X direction. The controller immediately modifies the processing queue of the next die-cutting unit pattern in memory, applying the calculated translational and / or rotational compensation amounts to all coordinate points of that pattern. Subsequently, the current circular blade performs overcutting on the current pattern after maximum compensation (there may still be slight residual errors), while the laser head cuts the next pattern according to the corrected new path. When the next graphic moves to the rotary cutter station, since the laser has already pre-compensated it, the rotary cutter only needs to perform regular or minor compensation to achieve precise cutting, thus "pulling" the system back from a large deviation state to a normal accuracy track without stopping the machine.

[0056] This method significantly enhances the resilience and continuity of the production system in the face of unexpected anomalies. It avoids the inevitable emergency shutdowns or batches of scrap caused by large, accidental deviations (such as instantaneous material slippage or localized foreign objects). Through a relay approach of "circular blade striving to compensate for the current situation + laser pre-compensating for the next situation," the system can smoothly absorb and digest abnormal shocks, maintaining the continuous operation of the production line. This is of great significance for ensuring the overall yield and efficiency of high-value material production.

[0057] In a preferred embodiment, the inner shape and contour cutting of the ultrathin optical adhesive in a continuously moving state according to a preset pattern is performed based on a pre-deformation compensated laser cutting path; the method for obtaining the pre-deformation compensated laser cutting path includes: Based on a pre-established contact-deformation coupling model associated with current material properties, circular cutter parameters, and process parameters, the predicted contact deformation amount that the circular cutter will produce on the material when performing outlining cutting is calculated. Based on the predicted contact deformation, the preset shape is subjected to reverse geometric compensation to generate the pre-deformation compensated laser cutting path; so that the inner shape cut by the laser according to the compensated path, after being deformed and recovered by the contact deformation of the circular blade outer shape, achieves a preset matching accuracy with the theoretical design contour.

[0058] Specifically, the pre-deformation compensated laser cutting path: This is the digital path followed by the laser die-cutting unit during actual cutting. It is not the original design drawing of the product ("preset drawing"), but a version of the original drawing after specific geometric corrections. The purpose of this correction is to pre-counteract the material deformation introduced by subsequent circular die cutting, so that the final product contour returns to the design shape. Contact-deformation coupling model: This is a mathematical or data model used to predict material deformation caused by mechanical contact. The model takes material properties (such as the thickness of OCA adhesive, viscoelastic modulus, and base film type), circular die parameters (such as blade angle, pressure, and circular die roller diameter), and process parameters (such as cutting speed and material tension) as input variables. Through theoretical formulas (such as contact mechanics formulas based on elasticity or viscoelasticity) or machine learning models based on large amounts of experimental data (such as neural networks), it outputs the predicted amount of contact deformation generated in the material near the cutting point. This deformation is typically a vector field describing the direction and magnitude of compression, stretching, or shearing of the material at different locations. Predicted contact deformation: This refers to the amount of localized, instantaneous shape change in the material (especially the flexible OCA adhesive layer) caused by the physical compression and friction between the blade and the material at the moment the circular cutter edge presses down and cuts, as calculated by the model. This deformation does not completely disappear after cutting due to the elastic or viscoelastic recovery of the material; a portion remains, causing the actual position of the final cut edge to deviate from the theoretical position. Reverse geometric compensation: This is a graphic processing procedure. Based on the calculated predicted deformation field, the original "preset graphic" undergoes a reverse, equal-amount, but opposite-direction geometric adjustment. For example, if the model predicts that the circular cutter contact will cause an edge to be compressed outward by 0.02mm, then when generating the laser path, the coordinates of this edge are contracted inward by 0.02mm. Thus, when the circular cutter actually cuts, its compression deformation precisely "pushes" this contracted edge back to the theoretically designed position.

[0059] Implementation Steps: This method begins in the process development phase. First, a contact-deformation coupling model needs to be established for a specific material series and circular die configuration through experiments and theoretical analysis. This includes designing a series of tests, performing punching with different parameters, and using a high-precision 3D scanner or laser displacement sensor to measure the microscopic geometry of the product edge after punching, comparing it with the theoretical edge to obtain deformation data. These data are then used to train or fit model parameters and embed them into the control system. Before producing a new product, the operator selects the corresponding material and circular die number on the HMI. When production starts, the control system automatically calls the corresponding contact-deformation coupling model. The model, combined with the current process parameters (from the recipe), calculates the predicted contact deformation amount for each contour of the current graphic in real time. Subsequently, the graphics processing engine performs fully automatic, pixel-level / vector-level reverse geometric compensation calculations on the original CAD design graphic (preset graphic) based on this deformation distribution map, generating a corrected digital graphic, i.e., a pre-deformation compensated laser cutting path. This new path is then sent to the laser galvanometer control system. The subsequent processing continues as usual: the laser cuts along this "deformed" path. When the laser-cut, pre-compensated shape reaches the rotary cutter station, the rotary cutter performs contour cutting. At the moment of contact and cutting by the rotary cutter, the material undergoes the physical deformation predicted by the model. Crucially, this deformation effect is the opposite of the geometric compensation pre-applied by the laser. Therefore, after cutting is complete and the deformed material recovers, the final product contour closely matches the initial design (preset shape), achieving the preset matching accuracy (e.g., edge position error <5μm).

[0060] This method elevates the precision of die cutting to a new limit determined by materials mechanics and process physics. It addresses a systemic error source that traditional methods cannot reach—material deformation caused by the process itself. Its effect is particularly significant for ultra-thin, flexible, and easily deformable optical adhesives, completely eliminating contour "collapse," "bulging," or localized deformation caused by circular die extrusion, resulting in near-perfect edge straightness and contour accuracy—crucial for the performance and appearance of high-end optical devices.

[0061] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. The above descriptions are only preferred embodiments of this application. It should be noted that due to the limitations of written expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of this invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other situations without modification, should all be considered within the scope of protection of this application.

Claims

1. A laser and rotary die-cutting method for ultrathin optical adhesive, characterized in that, This is achieved using a laser and rotary die-cutting device based on ultra-thin optical adhesive. The device includes: An unwinding mechanism is used to supply ultra-thin optical film and control its tension; A laser die-cutting unit, located downstream of the unwinding mechanism, is used to cut the inner shape and contour of the ultra-thin optical adhesive and to form alignment marks in the waste area. A circular die-cutting unit is located downstream of the laser die-cutting unit and is used to perform external die-cutting on the ultra-thin optical adhesive that has already undergone internal cutting. A visual alignment mechanism is located between the laser die-cutting unit and the rotary die-cutting unit, used to capture the alignment mark and calculate the deviation between its actual position and theoretical position; The controller is electrically connected to the laser die-cutting unit, the rotary die-cutting unit, and the vision alignment system, respectively. The controller is configured as follows: Receive the position deviation detected by the visual alignment mechanism, and generate a phase compensation command based on the position deviation; According to the phase compensation command, the rotation phase of the circular knife servo motor in the circular knife die-cutting unit is dynamically adjusted so as to achieve precise overlay cutting of the cutting pattern between the circular knife die-cutting unit and the laser die-cutting unit during the continuous travel of the ultra-thin optical adhesive; The method includes the following steps: We supply ultra-thin optical film rolls and control their tension to remain constant during transport. According to the preset pattern, the inner shape and outline of the ultra-thin optical adhesive in the continuous movement state are cut, and alignment marks are formed in the waste area. The alignment mark is photographed, and the deviation between its actual position and the preset theoretical position is calculated; The deviation is received, a corresponding phase compensation command is generated, and the circular knife servo motor is driven to adjust its rotation phase. Based on the adjusted phase, during the continuous travel of the ultra-thin optical adhesive, the portion that has completed the inner shape cutting is subjected to outer shape cutting. After capturing the alignment mark and calculating the deviation between its actual position and the preset theoretical position, and before generating the corresponding phase compensation command, the following steps are also included: The deviation is compared with the pre-stored phase compensation capability range of the circular tool servo system; The generation of the corresponding phase compensation command includes the following steps: If the deviation falls within the phase compensation capability range, a first type of instruction is generated, which only includes driving the circular knife servo motor to perform phase adjustment. If the deviation exceeds the phase compensation capability range, a second type of instruction is generated. The second type of instruction includes: driving the circular knife servo motor to perform phase adjustment within the maximum capability range, and synchronously adjusting the cutting path parameters of the laser die-cutting unit for the next die-cutting unit graphic, so as to perform visual graphic pre-compensation for the deviation exceeding the limit.

2. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 1, characterized in that: The laser and rotary blade die-cutting device based on ultra-thin optical adhesive is used. The device also includes an integrated waste removal mechanism electrically connected to the controller. The integrated waste removal mechanism includes a laser waste removal sub-mechanism and a rotary blade waste removal sub-mechanism, which are used to remove the dust generated by laser cutting and collect the edge waste generated by rotary blade cutting, respectively.

3. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 1, characterized in that: The laser and rotary die-cutting device based on ultra-thin optical adhesive is used. The device also includes: the laser die-cutting unit and the rotary die-cutting unit are fixed together on an integrated base; the integrated base is a cast iron base with high shock absorption and high rigidity. The bottom of the housing of the laser die-cutting unit and the mounting base of the rotary die-cutting unit are provided with positioning keys, and are locked and fixed to the integrated base by prestressed bolts passing through the T-slots.

4. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 2, characterized in that: The laser and circular knife die-cutting device based on ultra-thin optical adhesive is further included in the following: the laser waste removal sub-mechanism includes at least one dust suction port, which is located downstream of the cutting point of the laser die-cutting unit; the internal channel of the dust suction port is constructed as a Venturi nozzle structure, and its outlet end is flat and tapered to form a local high-speed negative pressure zone near the cutting point.

5. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 2, characterized in that: The laser and circular blade die-cutting device based on ultra-thin optical adhesive is further comprising: the circular blade waste removal mechanism includes at least one peeling plate, which is located downstream of the cutting point of the circular blade die-cutting unit; the peeling plate is made of engineering plastic with a low coefficient of friction, and its guide blade for guiding the waste strip has an eagle-beak-shaped arc transition shape.

6. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 5, characterized in that: The laser and circular blade die-cutting device based on ultra-thin optical adhesive is used. The device also includes: the arc transition area of ​​the guide blade is composed of at least one guide bevel, the angle between the guide bevel and the stripping direction of the waste strip is 15° to 30°; the final thickness of the working end of the guide blade is 0.05mm to 0.15mm.

7. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 1, characterized in that: The generation of the corresponding phase compensation command includes the following steps: Receive the current linear velocity of the material fed back by the encoder and read the preset system processing delay; The deviation is subjected to proportional, integral, and differential operations to obtain the feedback compensation component; Based on the current linear velocity and the system processing delay, a predicted displacement compensation component is calculated, and the predicted displacement compensation component is equal to the product of the current linear velocity and the system processing delay; The feedback compensation component is superimposed with the predicted displacement compensation component to generate the phase compensation command.

8. The laser and rotary die-cutting method for ultrathin optical adhesive according to claim 7, characterized in that: The process of cutting the inner shape and contour of the ultrathin optical adhesive in a continuously moving state according to a preset pattern is performed based on a laser cutting path that has undergone pre-deformation compensation. The method for obtaining the pre-deformation compensated laser cutting path includes: Based on a pre-established contact-deformation coupling model associated with current material properties, circular cutter parameters, and process parameters, the predicted contact deformation amount that the circular cutter will produce on the material when performing outlining cutting is calculated. Based on the predicted contact deformation, the preset shape is subjected to reverse geometric compensation to generate the pre-deformation compensated laser cutting path; so that the inner shape cut by the laser according to the compensated path, after being deformed and recovered by the contact deformation of the circular blade outer shape, achieves a preset matching accuracy with the theoretical design contour.

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