Manufacturing method for flat cutter die cutting double-faced adhesive tape interlayer gauze structure product

Abstract

The invention discloses a method for manufacturing a flat cutter die-cut double-faced adhesive tape interlayer gauze structure product, which comprises the following steps of: S1, material preparation: sequentially laminating a first double-faced adhesive tape material belt and a first cover film material belt on a bottom film material belt with a positioning hole to form a first punched base material; s2, primary punching die cutting is conducted, specifically, a plurality of first hole bodies are formed in the primary punching base material in a die cutting mode through matched positioning of positioning needles and positioning holes; s3, primary waste discharge; s4, composite fitting is conducted, specifically, a gauze material belt, a double-faced release film material belt, a second double-faced adhesive tape material belt and a second cover film material belt are sequentially fitted, and a secondary punching base material is formed; s5, secondary die cutting is conducted, specifically, positioning is conducted again through cooperation of the positioning pins and the positioning holes, and under protection of the cushion cutter of the double-face release film material belt, a second hole body corresponding to the first hole body in position is formed through die cutting; and S6, secondary waste discharging and rolling are conducted, and a finished product material belt is obtained. According to the invention, the problems of low efficiency, poor precision and high cost caused by dependence on manual opposite pasting in the traditional process are solved.

Description

Technical Field

[0001] This invention relates to the field of planar die-cutting technology, and in particular to a method for manufacturing double-sided adhesive interlayer mesh structure products using a flat die-cutting tool. Background Technology

[0002] Flatbed die-cutting technology is widely used in electronics, automotive, and medical fields to precisely cut various composite materials such as films, tapes, foams, and meshes into die-cut products of specific shapes. Among them, double-sided adhesive sandwich mesh structure products are in increasing demand in consumer electronics, acoustic devices, and smart wearable devices due to their unique breathability, cushioning, adhesion, and electromagnetic shielding properties.

[0003] Traditional manufacturing processes for double-sided adhesive sandwich mesh structures typically combine step-by-step die-cutting with manual bonding. Specifically, the double-sided adhesive layer and the mesh layer are first die-cut separately, then the mesh layer is aligned and bonded to the designated area of ​​the double-sided adhesive layer using manual labor or simple jigs. This design, however, features perforations in both layers of double-sided adhesive. This process has the following significant drawbacks:

[0004] Low production efficiency and high cost: The manual pasting process relies heavily on the operator's skill level, resulting in slow production speed, high labor costs, and difficulty in achieving large-scale continuous production.

[0005] Poor product precision and consistency: Manual alignment inevitably produces deviations, resulting in misalignment of the holes in the two layers of double-sided adhesive after bonding. Inaccurate alignment affects the final dimensional accuracy and functional consistency of the product, making it difficult to guarantee the yield rate.

[0006] The process is complex and relies on specialized fixtures: To achieve initial alignment, it is often necessary to design and manufacture specialized positioning fixtures, which increases the initial development costs and the complexity of the production process.

[0007] Material loss is significant: During the step-by-step die-cutting and transfer process, the material is prone to wrinkles, contamination or damage, and there are many waste separation steps, so the overall material utilization rate needs to be improved.

[0008] Therefore, the industry urgently needs a flat die-cutting process that can simplify the production process, reduce manual intervention, improve bonding accuracy and production efficiency, and reduce overall costs, for the high-quality and highly consistent manufacture of double-sided adhesive sandwich mesh structure products. Summary of the Invention

[0009] The purpose of this invention is to provide a method for manufacturing double-sided adhesive sandwich mesh structure products using a flat die-cutting tool to solve the problems mentioned in the background art.

[0010] To achieve the above objectives, the present invention provides the following technical solution:

[0011] A method for manufacturing a double-sided adhesive sandwich mesh structure product using a flat die-cutting tool includes the following steps:

[0012] S1. Material preparation: The first double-sided adhesive tape and the first cover film tape are sequentially bonded to the top of the bottom film tape. The bottom film tape has two rows of positioning holes distributed front and back. The bonded tape is a punching substrate.

[0013] S2, One-punch die cutting: The one-punch die cutting machine performs die cutting and punching on the one-punch substrate. During the punching process, the one-punch die cutting machine positions itself by cooperating with the positioning holes on the bottom film strip through the first positioning pin, and die cutting out multiple first holes on the one-punch substrate.

[0014] S3, First waste removal: Remove the waste from the strip after the first die-cutting, remove the waste from the first cover strip, and obtain the first die-cut semi-finished product;

[0015] S4. Composite lamination: On the top of the first-cut semi-finished product, a mesh strip, a double-sided release film strip, a second double-sided adhesive strip, and a second cover film strip are sequentially laminated. The first double-sided adhesive strip and the second double-sided adhesive strip are bonded on one side of their width direction, while the mesh strip and the double-sided release film strip extend from the other side of their width direction. The laminated strip is the second-cut substrate.

[0016] S5. Secondary die-cutting: The secondary die-cutting machine performs die-cutting and punching on the secondary substrate. The double-sided release film strip acts as a backing knife in this die-cutting process. During the punching process, the secondary die-cutting machine positions itself by cooperating with the positioning holes on the bottom film strip through the second positioning pin. Multiple second holes are die-cut on the second cover film strip and the second double-sided adhesive strip.

[0017] S6. Secondary waste removal and winding: The double-sided release film strip is pulled out from the side, and the waste of the second cover film strip is removed from the top, resulting in a finished strip consisting of a bottom film strip, a first double-sided adhesive strip, a mesh strip, and a second double-sided fabric strip from bottom to top. The finished strip is then wound up.

[0018] In a further description of the present invention, in step S5, the position, specifications, and number of the second holes processed by the secondary die-cutting machine on the two-punch substrate are the same as those of the first holes.

[0019] In a further description of the present invention, in steps S3 and S5, the waste material at the die-cutting hole is sucked out by the die of the first-punch die-cutting machine and the second-punch die-cutting machine through the circular hole suction waste.

[0020] In a further description of the present invention, in step S4, the first double-sided adhesive tape and the second double-sided adhesive tape are bonded and fixed to the rear side, and the mesh tape and the double-sided release film tape extend from the front side of the first double-sided adhesive tape and the second double-sided adhesive tape; in step S6, the double-sided release film tape is pulled away from the front side.

[0021] As further described in this invention, steps S1-S6 achieve fully automated production and manufacturing through an automated production line.

[0022] The beneficial effects of this invention are as follows:

[0023] By precisely matching the positioning holes on the base film strip with the positioning pins of the die-cutting machine, the positional height of the first and second punched parts is ensured to be consistent during the two die-cutting processes, achieving accurate alignment of the holes in the two layers of double-sided adhesive. This method systematically avoids alignment deviations caused by manual operation, ensuring that each die-cut product has extremely high dimensional accuracy and functional consistency, thereby significantly improving product yield.

[0024] This process simplifies the operation steps, reduces the design and reliance on dedicated positioning fixtures, and lowers the initial development and fixture costs.

[0025] In the secondary die-cutting step (S5), a double-sided release film strip is creatively used as a "shield" layer to protect the underlying mesh and other materials from damage during the die-cutting process, ensuring die-cutting quality. Subsequently, the release film can be easily removed from the side (S6), fulfilling its functional purpose while facilitating waste removal. This design cleverly solves the problem of protecting and separating multi-layer composite materials in precision die-cutting, enhancing the reliability and stability of the process.

[0026] Because this process involves machining the first hole in the first double-sided adhesive tape, and then attaching one side of the second double-sided adhesive tape to the first double-sided adhesive tape to achieve positioning between the two tapes, and then machining the second hole on the second double-sided adhesive tape, the positional accuracy between the first and second holes is extremely high. This avoids the errors caused by molding first and then attaching, and significantly improves the quality of the product. Attached Figure Description

[0027] Figure 1 This is a diagram showing the die-cutting state of the present invention;

[0028] Figure 2 This is a diagram showing the state of the two-punch film cutting process of the present invention;

[0029] Figure 3 This is a schematic diagram of the present invention for removing the mesh strip;

[0030] Figure 4 This is a top view of the bonding position of the material strip in this invention;

[0031] Figure 5 This is a schematic diagram of the automated production line structure of the present invention. Detailed Implementation

[0032] The present invention will be further described below with reference to the accompanying drawings:

[0033] like Figure 1-5 As shown, a method for manufacturing a double-sided adhesive sandwich mesh structure product using a flat die-cutting tool includes the following steps:

[0034] S1. Material preparation: The first double-sided adhesive tape 2 and the first cover film tape 3 are sequentially attached to the top of the bottom film tape 1. The bottom film tape 1 has two rows of positioning holes 11 distributed in the front and back. The attached tape is a die-cutting substrate. The first cover film tape 3 is used to cover the upper surface of the first double-sided adhesive tape 2 to prepare for die-cutting.

[0035] S2. One-punch die cutting: The one-punch die cutting machine 10 performs die cutting and punching on the one-punch substrate. During the punching process, the one-punch die cutting machine 10 is positioned by cooperating with the positioning hole 11 on the bottom film strip 1 through the first positioning pin, and multiple first holes 11 are die-cut on the one-punch substrate. The die of the one-punch die cutting machine 10 performs full-cut die cutting on the one-punch substrate. After die cutting, the die cutting waste of the first holes 11 is sucked out and discharged by the adsorption of the round hole on the die.

[0036] S3, First waste removal: Remove the waste from the strip after the first die-cutting, remove the waste from the first cover strip 3, and obtain the first die-cut semi-finished product;

[0037] S4. Composite Lamination: Mesh tape 4, double-sided release film tape 5, second double-sided adhesive tape 6, and second cover film tape 7 are sequentially laminated onto the top of the semi-finished product. The first double-sided adhesive tape 2 and the second double-sided adhesive tape 6 are bonded on one side of their width direction, while the mesh tape 4 and the double-sided release film tape 5 extend from the other side of their width direction. The laminated tapes form the substrate for the second-stage die-cutting process. In this design, the rear sides of the first double-sided adhesive tape 2 and the second double-sided adhesive tape 6 are bonded and fixed. The mesh tape 4 and the double-sided release film tape 5 extend from the other side of their width direction. Release film strip 5 extends from the front side of the first double-sided adhesive strip 2 and the second double-sided adhesive strip 6; in step S6, the double-sided release film strip 5 is pulled out from the front side; the first double-sided adhesive strip 2 and the second double-sided adhesive strip 6 are bonded to the rear side for positioning, to avoid displacement after punching the second double-sided adhesive strip 6, and to improve accuracy. The mesh strip 4 and the double-sided release film strip 5 extend from the front side of the first double-sided adhesive strip 2 and the second double-sided adhesive strip 6, which lays the foundation for the peeling of the double-sided release film material, so that the double-sided release film strip 5 can be pulled out from the front side in the future.

[0038] S5. Secondary Die-cutting: The secondary die-cutting machine 20 performs die-cutting and punching on the secondary substrate. The double-sided release film strip 5 acts as a backing material during the die-cutting process. During the punching process, the secondary die-cutting machine uses the second positioning pin to cooperate with the positioning hole 11 on the bottom film strip 1 to improve the alignment accuracy. Multiple second holes 61 are die-cut on the second cover film strip 7 and the second double-sided adhesive strip 6. The waste material of the die-cut second holes 61 is discharged through the round hole on the die. The position, specifications and quantity of the second holes 61 die-cut by the secondary die-cutting machine on the secondary substrate are the same as those of the first holes 11. This setting can ensure that the position and height of the processed first holes 11 and second holes 61 are uniform. The double-sided release film strip 5 acts as a backing material during the die-cutting process, preventing the double-sided release film from being broken. It also provides protection for the mesh strip 4, avoiding the breakage of the mesh strip 4 during the die-cutting process.

[0039] S6. Secondary waste removal and winding: The double-sided release film material strip 5 is pulled out from the side, and the waste of the second cover film material strip 7 is removed from the top, resulting in a finished material strip consisting of bottom film material strip 1, first double-sided adhesive material strip 2, mesh material strip 4 and second double-sided fabric material strip from bottom to top. The finished material strip is then wound up. After the waste of the double-sided release film material strip 5 and the second cover film material strip 7 is removed, the first double-sided adhesive material strip 2 and the second double-sided adhesive material strip 6 can be tightly attached to the mesh material strip 4 during subsequent transportation and winding.

[0040] Steps S1-S6 of this design achieve fully automated production through an automated production line. Production is carried out automatically in one go. The bonding and winding of each strip can be achieved by feeding and taking up rollers, eliminating the need for repeated alignment and manual intervention, which greatly improves production efficiency and processing accuracy.

[0041] The finished roll material processed in this design will be die-cut according to actual needs. The desired product shape can be die-cut from the finished roll material. The die-cut product consists of a bottom film layer, a first double-sided adhesive layer, a mesh layer and a second double-sided adhesive layer distributed from bottom to top. Usually, a finished product is formed on the outer periphery of each hole (first hole 11, second hole 61).

[0042] The above description is not intended to limit the scope of the present invention. Any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for manufacturing a double-sided adhesive sandwich mesh structure product using a flat die-cutting tool, characterized in that: Includes the following steps: S1. Material Preparation: The first double-sided adhesive tape and the first cover film tape are sequentially bonded to the top of the bottom film tape. The bottom film tape has two rows of positioning holes distributed front and back. The bonded tape is a punched substrate. S2. Punch Cutting: The punched substrate is die-cut using a punch cutting machine. During the punching process, the punch cutting machine uses a first positioning pin to engage with the positioning holes on the bottom film tape for positioning, die-cutting multiple first holes into the punched substrate. S3. First Waste Removal: The punched tape is removed to remove the waste from the first cover film tape, resulting in a punched semi-finished product. S4. Composite Bonding: A mesh tape, a double-sided release film tape, a second double-sided adhesive tape, and a second cover film tape are sequentially bonded to the top of the punched semi-finished product. The width direction of the first double-sided adhesive tape and the second double-sided adhesive tape... One side is bonded, and the mesh tape and double-sided release film tape extend from the other side of the width direction of the first double-sided adhesive tape and the second double-sided adhesive tape. The composite tape is a two-punch substrate; S5, secondary die-cutting: the two-punch substrate is die-cut and punched by a two-punch die-cutting machine. The double-sided release film tape acts as a backing knife in this die-cutting process. During the punching process, the secondary die-cutting machine is positioned by the second positioning pin cooperating with the positioning hole on the bottom film tape. Multiple second holes are die-cut on the second cover film tape and the second double-sided adhesive tape; S6, secondary waste removal and winding: the double-sided release film tape is pulled out from the side, and the waste of the second cover film tape is removed from the top to obtain the finished tape, which consists of the bottom film tape, the first double-sided adhesive tape, the mesh tape and the second double-sided adhesive tape from bottom to top. The finished tape is then wound up.

2. The method for manufacturing a double-sided adhesive sandwich mesh structure product by die-cutting with a flat blade according to claim 1, characterized in that: In step S5, the position, specifications, and number of the second holes processed by the secondary die-cutting machine on the two-punch substrate are the same as those of the first holes.

3. The method for manufacturing a double-sided adhesive sandwich mesh structure product by die-cutting with a flat blade according to claim 1, characterized in that: In steps S3 and S5, the waste material at the die-cutting hole is sucked out by the die of the first-punch die-cutting machine and the second-punch die-cutting machine through the round hole suction.

4. The method for manufacturing a double-sided adhesive sandwich mesh structure product by die-cutting with a flat blade according to claim 1, characterized in that: In step S4, the first double-sided adhesive tape and the second double-sided adhesive tape are bonded and fixed at the rear side, and the mesh tape and the double-sided release film tape extend from the front side of the first double-sided adhesive tape and the second double-sided adhesive tape; in step S6, the double-sided release film tape is pulled away from the front side.

5. The method for manufacturing a double-sided adhesive sandwich mesh structure product by die-cutting with a flat blade according to claim 1, characterized in that: Steps S1-S6 achieve fully automated production through automated production lines.

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