Preparation process of Taika skin-friendly film

Abstract

The invention discloses a preparation process of a skin-friendly thin film of a special skin drawing. The process comprises the steps of preparation of a gauze braided fabric, shaping of the braided fabric, fixing of a frame, accurate alignment, alignment calibration, primary polymer permeation, silk screen sleeve printing, curing forming, multi-round circulation and forming of a skin-friendly layer. The base layer is prepared from a modified polydimethylsiloxane elastic polymer, the skin-friendly layer is formed by a special modified polydimethylsiloxane superelastic polymer, and functions and skin-friendly performance are both considered; and by combining multi-machine-head silk-screen printing, multi-temperature-section curing and multi-round process circulation, customization of the number of layers, the thickness and the function of the thin film is achieved. The method has the advantages of whole-course numerical control automation, stable production, high efficiency, low cost, suitability for industrial batch production, stable film structure, long service life and good use experience.

Description

Technical Field

[0001] This invention belongs to the field of thin film forming technology and relates to a preparation process of a Tefula skin-friendly film. Background Technology

[0002] As people's demands for product user experience continue to rise, skin-friendly films are increasingly widely used in daily necessities, medical devices, electronic products, and other fields. Tefula skin-friendly film, as a new type of film with excellent skin-friendly feel, good breathability, and stability, relies heavily on the precision and controllability of its manufacturing process to determine product quality.

[0003] Existing processes for preparing skin-friendly films often suffer from problems such as uneven shaping of the mesh fabric, weak frame fixation, uneven polymer penetration, low printing registration accuracy, and poor curing effect. This results in films with uneven thickness, poor skin-friendliness, and insufficient functional stability, making it difficult to meet the demands of high-end applications. Furthermore, existing processes often employ a single polymer coating, lacking a layered design, failing to balance functionality and skin-friendliness, and exhibiting poor process cycle controllability, hindering stable mass production. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A process for preparing a Tefula skin-friendly film includes the following steps: Step 1: Preparation of mesh fabric: Different mesh sizes and opening ratios of wire mesh and steel mesh are selected as weaving materials. The mesh size of low-mesh mesh is 50-180 mesh, and the mesh size of high-mesh mesh is 200-3000 mesh. Through weaving process, breathable woven fabrics with different thicknesses of mesh structure are prepared according to requirements to ensure the breathability and structural stability of the woven fabric, laying the foundation for subsequent polymer infiltration and film forming.

[0005] Step 2: Shaping the knitted fabric: The mesh fabric prepared in step 1 is subjected to a fixing and shaping process. The fixing process forms the fabric into a sheet-like object with a specific hole shape. The hole shape can be selected from one or more of square, rhombus, arc, circle, trapezoid, and triangle according to the application requirements to ensure that the sheet-like fabric has a regular structure, which facilitates subsequent frame fixing and polymer penetration.

[0006] Step 3: Frame fixing: First, the sheet-like woven fabric obtained in step 2 is placed in a CNC tension expansion stretching machine for flattening and shaping. The shaping tension is adjustable from 10 to 200 pounds, and can be flexibly adjusted according to the thickness and material of the woven fabric to ensure that the surface of the sheet-like woven fabric is flat and wrinkle-free with uniform tension. Then, frame structure components of preset specifications are selected. The frame material can be one or more of aluminum, aluminum alloy, and steel, and the shape can be one or more of square, round, and oval. The specifications include one or more of 20mm wide × 35mm high × 1mm thick, 20mm wide × 40mm high × 1.5mm thick, 25mm wide × 45mm high × 2mm thick, and 25mm wide × 50mm high × 2mm thick. Through a series of processes such as alignment, fixing, edge locking, edge grinding, bonding, and welding, the sheet-like woven fabric is firmly fixed to the surface and bottom of the frame structure to ensure a firm connection between the woven fabric and the frame, and to avoid problems such as displacement or loosening in subsequent processes.

[0007] Step 4, Precise Alignment: Using bidirectional CNC clamps, the frame with the woven fabric fixed in step 3 is fixed in a horizontal position. By precisely adjusting the CNC screws, the frame and the woven fabric mesh can be made to move smoothly. Then, with the downward pressing action of the upper and lower interactive platform, the up, down, left and right positions of the woven fabric mesh are adjusted in a smooth and orderly rhythm to ensure that it reaches the optimal horizontal state, providing a precise benchmark for subsequent alignment calibration and polymer infiltration.

[0008] Step 5, Alignment and Calibration: The four-station capture and positioning system and alignment system of the lower pressing plate are adjusted to enable the alignment system to accurately identify the position of the upper pressing woven mesh, achieving precise correspondence between the lower pressing plate and the woven mesh, and controlling the alignment error within a preset range. An infrared sensing device is used to detect each corner of the woven mesh in real time. Based on the detection results, the balance of the mesh and the force of each corner are adjusted. At the same time, by controlling the offset and trace elements, the operation trajectory of the entire device is precisely controlled to ensure the accuracy of subsequent processes.

[0009] Step 6, Initial Polymer Infiltration: Modified polydimethylsiloxane-elastic polymer is selected as the permeation raw material and formulated into a layered liquid polymer in the flow space. The liquid polymer is poured into a fixed woven mesh frame, and one or more rubber pressing devices of U-shape, V-shape, and O-shape with a hardness of 20-99 are used to evenly apply the liquid polymer to the surface of the lower pressure plate. With the pressure of the pressing device, the liquid polymer flows smoothly and evenly to the surface of the application item below through the vent holes of the woven fabric. After the application is completed, the upper pressure plate is lifted using a flexible touch sensor, and the liquid polymer flows naturally and leveled on the surface of the application item, slowly forming the first film.

[0010] Step 7, screen printing: The application item is unloaded and its surface is protected by a flexible touch sensor to prevent damage. The item is then smoothly moved to the next fixed platform by an automatic device. A screen printing machine with 4 to 60 heads is used to perform 1 to 300 registration prints according to the functional requirements of the application item. During the printing process, one or more processes such as 1 to 300 layer superposition, misalignment, fixed point, local, thickness, segmentation, cracking, frosting, smoothness, and anti-slip can be used to customize the film function.

[0011] Step 8: Curing and shaping: A continuous and stable operating device is used to smoothly transport the application items printed in step 7 to the curing area. This area is equipped with 10-200 intelligent heating corrugated heating tubes, which can achieve direct heating. The application items are placed in an oven with a temperature of 10-600℃, and liquid polymer film curing and molding process is carried out 1-300 times according to the number of printing layers and polymer characteristics to ensure that each layer of film can be fully cured, thereby improving the structural stability and wear resistance of the film.

[0012] Step 9, Multiple rounds of iteration: Repeat steps 5-8 for alignment calibration, polymer infiltration, screen printing, and curing, with 2-100 cycles. Through multiple cycles, the number of film layers is continuously increased and the film performance is optimized to achieve the best function and effect on the surface of the applied item, meeting the needs of different application scenarios.

[0013] Step 10: Skin-friendly layer formation: A specially modified polydimethylsiloxane-superelastic polymer was selected as the raw material for the final skin-friendly layer and formulated into a liquid polymer with a skin-friendly feel in the flow space. The permeation process in step 6 was repeated. The liquid polymer was evenly applied to the lower pressure plate through the fixed woven mesh frame and a rubber pushing device, so that it flowed smoothly to the surface of the application item through the vent holes of the woven fabric. The upper pressure plate was lifted, and the liquid polymer slowly flowed and solidified to form the last skin-friendly film, thus completing the preparation of the Tefula skin-friendly film.

[0014] The beneficial effects of the present invention are as follows: By selecting wire mesh and steel mesh weaving structures with different mesh counts and opening degrees, and combining them with CNC tension flattening and shaping and multi-process frame fixing, the present invention effectively solves the problems of irregular shaping of woven fabrics and loose frames, and provides a precise benchmark for subsequent processes. Simultaneously, bidirectional alignment numerical control clamps, a four-station positioning system, and infrared sensing calibration are used to achieve precise alignment between the mesh and the application item, significantly improving the film preparation accuracy and avoiding defects such as uneven thickness and loose bonding. In terms of film formation, a layered polymer permeation design is adopted, using modified polydimethylsiloxane. Elastic polymers form the base film, and specially modified polydimethylsiloxane The skin-friendly layer is constructed from a super-elastic polymer, balancing the film's functionality with its skin-friendliness for an optimized user experience. Combined with multi-head screen printing, multi-temperature zone curing, and multiple process cycles, the number, thickness, and function of the film layers can be flexibly adjusted to achieve customized production. At the same time, it ensures that the film is fully cured, improving structural stability and service life. The entire process is fully CNC-controlled and automated, offering strong controllability and high production efficiency. It can achieve stable mass production, reduce labor costs, and has value for large-scale industrial applications. Detailed Implementation

[0015] The technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. It should be understood that this application is not limited to the exemplary embodiments disclosed herein. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0016] Example 1: A preparation process for a skin-friendly film called Tefula includes the following steps: Step 1: Preparation of mesh fabric: Select low mesh wire mesh with an opening of 0.1mm, an opening rate of 50%, and a mesh count of 100 mesh, and high mesh steel mesh with a mesh count of 1000 mesh to weave into a breathable mesh structure with a thickness of 0.5mm.

[0017] Step 2, shaping the woven fabric: The above-mentioned mesh woven fabric is shaped and fixed to form a sheet-like object with square holes measuring 0.5mm × 0.5mm.

[0018] Step 3, Frame Fixing: Place the sheet-like woven fabric into a CNC tension expansion stretching machine, adjust the tension to 50 pounds, and flatten and shape it; select a square aluminum alloy frame with specifications of 20mm width × 40mm height × 1.5mm thickness, and fix the sheet-like woven fabric to the surface and bottom of the frame through alignment, fixing, edge locking, edge grinding, bonding, and welding processes.

[0019] Step 4, Precise Alignment: Use bidirectional alignment CNC clamps to fix the frame in a horizontal position, adjust it with CNC screws to achieve smooth operation, and adjust it to the optimal horizontal position with the help of the downward rhythm of the upper and lower interactive platform.

[0020] Step 5, Alignment and Calibration: Adjust the four-position capture positioning and alignment system of the lower pressure plate to correspond to the upper pressure woven mesh, so that the alignment error is controlled within 0.01mm; use an infrared sensing device to detect each corner point, adjust the balance and the force at each point, and control the operating trajectory through offset and trace elements to complete the calibration.

[0021] Step 6, Initial Polymer Infiltration: Select modified polydimethylsiloxane-elastic polymer and prepare it into a liquid state; through the woven mesh in the frame, use a U-shaped rubber pushing device with a hardness of 50 to evenly apply the liquid polymer to the lower pressure plate, allowing it to flow through the vent holes to the surface of the application item, then lift the upper pressure plate to form the first film.

[0022] Step 7, screen printing: Loosen the application material, use a 16-head screen printing machine to move the application material to the fixed table, and perform 50 registration printings, using 50 layers of superposition and frosting process.

[0023] Step 8, Curing and Molding: Using a continuous operation device, the application material is sent to the direct environment of 50 intelligent heating corrugated heating tubes and cured and molded 50 times in an oven at a temperature of 200℃.

[0024] Step 9, Multiple cycles: Repeat steps 5-8 for 10 cycles to ensure the film performance meets the requirements.

[0025] Step 10, Final Skin-Friendly Layer Formation: Select a specially modified polydimethylsiloxane-superelastic polymer, prepare it into a skin-friendly liquid polymer, repeat the permeation process of step 6, form the final skin-friendly film, and complete the preparation.

[0026] Example 2: A preparation process for a skin-friendly film called Tefula includes the following steps: Step 1: Preparation of mesh fabric: Select a low-mesh steel mesh with an opening of 0.05mm, an opening rate of 60%, and a mesh count of 180 and a high-mesh wire mesh with a mesh count of 3000 to weave a breathable mesh structure with a thickness of 0.3mm.

[0027] Step 2, shaping the woven fabric: The above-mentioned mesh woven fabric is shaped and fixed to form a sheet-like object with circular eyelets of 0.3mm in diameter.

[0028] Step 3, Frame Fixing: Place the sheet-like woven fabric into a CNC tension expansion stretching machine, adjust the tension to 100 pounds, and flatten and shape it; select a round steel frame with specifications of 25mm width × 50mm height × 2mm thickness, and fix the sheet-like woven fabric to the surface and bottom of the frame through alignment, fixing, edge locking, edge grinding, bonding, and welding processes.

[0029] Step 4, Precise Alignment: Use bidirectional alignment CNC clamps to fix the frame in a horizontal position, adjust it with CNC screws to achieve smooth operation, and adjust it to the optimal horizontal position with the help of the downward rhythm of the upper and lower interactive platform.

[0030] Step 5, Alignment and Calibration: Adjust the four-position capture positioning and alignment system of the lower pressure plate to correspond to the upper pressure woven mesh, so that the alignment error is controlled within 0.005mm; use an infrared sensing device to detect each corner point, adjust the balance and the force at each point, and control the operation trajectory through offset and trace elements to complete the calibration.

[0031] Step 6, Initial Polymer Infiltration: Select modified polydimethylsiloxane-elastic polymer and prepare it into a liquid state; through the woven mesh in the frame, use a V-shaped rubber pushing device with a hardness of 80 to evenly apply the liquid polymer to the lower pressure plate, allowing it to flow through the vent holes to the surface of the application item, then lift the upper pressure plate to form the first film.

[0032] Step 7, screen printing: Loosen the application material, use a 40-head screen printing machine to move the application material to the fixed table, and perform 200 registration printings, using 200 layers of overlapping, smooth and anti-slip treatment.

[0033] Step 8, Curing and Molding: Using a continuous operation device, the application material is sent to a direct environment of 150 intelligent heating corrugated heating tubes and cured and molded 200 times in an oven at a temperature of 400℃.

[0034] Step 9, Multiple cycles: Repeat steps 5-8 for 50 cycles to ensure the film performance meets the requirements.

[0035] Step 10, Final Skin-Friendly Layer Formation: Select a specially modified polydimethylsiloxane-superelastic polymer, prepare it into a skin-friendly liquid polymer, repeat the permeation process of step 6, form the final skin-friendly film, and complete the preparation.

[0036] It should also be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0037] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A preparation process for a Tefula skin-friendly film, characterized in that, Includes the following steps: Step 1, Preparation of mesh fabric: Select wire mesh and steel mesh with different opening degree and opening rate, and with low mesh number of 50-180 mesh and high mesh number of 200-3000 mesh to weave into breathable mesh structures of different thicknesses; Step 2, shaping the woven fabric: The woven fabric prepared in Step 1 is shaped and fixed to form a sheet-like object with at least one of the following shapes: square, rhombus, arc, circle, trapezoid, and triangle. Step 3, Frame Fixing: The sheet-like woven fabric obtained in Step 2 is flattened and shaped using a CNC tension expansion stretching machine with a shaping tension of 10-200 pounds. Then, frame structure components with at least one of the following specifications—20mm wide × 35mm high × 1mm thick, 20mm wide × 40mm high × 1.5mm thick, 25mm wide × 45mm high × 2mm thick, and 25mm wide × 50mm high × 2mm thick—are selected. The shapes are at least one of square, round, and oval, and the materials are at least one of aluminum, aluminum alloy, and steel. The sheet-like woven fabric is fixed to the surface and bottom of the frame structure through alignment, fixing, edge locking, edge grinding, bonding, and welding processes. Step 4, Precise alignment: Use the bidirectional alignment CNC clamps to fix the woven mesh sheet fixed in step 3 in a horizontal position, achieve smooth operation through CNC screws, and then adjust to the optimal horizontal position with the help of the downward rhythm of the upper and lower interactive platform. Step 5, Alignment and Calibration: Adjust the four-position capture positioning and alignment system of the lower pressure plate to correspond with the upper pressure woven mesh to make the error reach the preset standard; use an infrared sensing device to detect each corner point, adjust the balance and the force at each point, and control the operation trajectory through offset and trace elements to complete the precise calibration. Step 6, First Polymer Infiltration: A modified polydimethylsiloxane-elastic polymer is used for the first infiltration to form a liquid polymer. Through the woven mesh frame fixed in Step 3, at least one rubber pushing device of U-shape, V-shape, and O-shape with a hardness of 20-99 is used to evenly apply the liquid polymer to the lower pressure plate, allowing it to flow smoothly through the vent holes of the woven fabric to the surface of the application item. The upper pressure plate is then lifted to form the first film. Step 7, screen printing: Release the application material using a flexible touch sensor, and use a 4-60 head screen printing machine to smoothly move the application material to a fixed table for 1-300 registration printings. The process involves at least one of the following techniques: layering, misalignment, fixed point, local, thickness, segmentation, cracking, frosting, smoothness, and anti-slip. Step 8, Curing and Molding: Using a continuous and stable operating device, the application material processed in Step 7 is sent to a direct environment of 10-200 intelligent heating corrugated heating tubes, and cured into a liquid polymer film 1-300 times in an oven at a temperature of 10-600℃. Step 9, Multiple cycles: Repeat steps 5-8, 2-100 times, until the optimal function and effect required by the application are achieved; Step 10: Skin-friendly layer formation: A special modified polydimethylsiloxane-superelastic polymer is used for the final permeation and absorption to form a liquid polymer with a skin-friendly feel; repeat the pushing, spreading, and permeation process of step 6, lift the upper platen to form the final skin-friendly film, and complete the preparation of the Tefula skin-friendly film.

2. In the preparation process of the Tefula skin-friendly film according to claim 1, the flattening and shaping in step 3 is carried out by a CNC tension expansion stretching machine, and the tension can be continuously adjusted in the range of 10-200 pounds to ensure that the surface of the sheet woven material is flat and wrinkle-free.

3. In the preparation process of the Tefula skin-friendly film according to claim 1, the infrared sensing device in step 5 can detect the balance and strength of each corner of the woven mesh in real time, and minimize the alignment error through offset compensation and trace element control.

4. In the preparation process of the Tefula skin-friendly film according to claim 1, the hardness of the rubber pressing device in steps 6 and 10 can be adjusted within the range of 20-99 according to the polymer viscosity and the pore size of the woven fabric to ensure uniform polymer penetration.

5. In the preparation process of the Tefula skin-friendly film according to claim 1, the number of screen printing heads in step 7 can be selected between 4 and 60 heads according to the printing accuracy and efficiency requirements, and the number of registration printing times and the number of superimposed layers can be flexibly adjusted according to the functional requirements of the application.

6. In the preparation process of the Tefula skin-friendly film according to claim 1, the oven temperature in step 8 can be adjusted in segments within the range of 10-600℃, and the number of curing times matches the number of printing layers in step 7 to ensure that each film layer can be fully cured.

Images