CN110856289A - Flexible heating film and die cutting processing method and equipment thereof - Google Patents
Flexible heating film and die cutting processing method and equipment thereof Download PDFInfo
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- CN110856289A CN110856289A CN201810952567.7A CN201810952567A CN110856289A CN 110856289 A CN110856289 A CN 110856289A CN 201810952567 A CN201810952567 A CN 201810952567A CN 110856289 A CN110856289 A CN 110856289A
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
- H05B3/34—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater flexible, e.g. heating nets or webs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
- B29C65/741—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area characterised by the relationships between the joining step and the severing step
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/45—Joining of substantially the whole surface of the articles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
- H05B2203/009—Heaters using conductive material in contact with opposing surfaces of the resistive element or resistive layer
- H05B2203/01—Heaters comprising a particular structure with multiple layers
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Surface Heating Bodies (AREA)
- Resistance Heating (AREA)
Abstract
The invention discloses a flexible heating film and a die cutting processing method and device thereof. The flexible heating film comprises: the first insulating layer, the second insulating layer and the patterned metal electrode packaged between the first insulating layer and the second insulating layer; or, the flexible heating film comprises a first insulating layer, a second insulating layer, and a carbon film and a patterned metal electrode which are packaged between the first insulating layer and the second insulating layer, wherein the carbon film is in ohmic contact with the patterned metal electrode. Compared with the etching resistance wire heating film, the flexible heating film provided by the embodiment of the invention has obvious advantages in the aspects of line width precision and size, and the batch production of the heating film can be realized without a complex etching process, so that the problems of pollution and high cost caused by etching can be avoided; the embodiment of the invention also provides a die cutting processing method of the flexible heating film, which can realize the roll-to-sheet continuous production of the flexible heating sheet, does not need manual operation in the whole process and has high automation degree.
Description
Technical Field
The invention particularly relates to a flexible heating film and a die cutting processing method and device thereof, belonging to the technical field of processing and manufacturing.
Background
The flexible heating film is a flexible heating material, and can be generally divided into Polyimide (PI) heating films, silicon rubber heating films, Polyester (PET) heating films and the like according to the material difference of insulating materials; the heating materials may be classified into a wire heating film, an etched metal sheet heating film, a resistance paste heating film, a carbon film (generally, carbon crystal, graphene, carbon nanotube) heating film, and the like. The flexible heating film has the advantages of being light, thin, soft, convenient to install, high in heating speed and the like, and is widely applied to the fields of equipment, pipelines, medical appliances, automobiles, power batteries, intelligent wearing and the like.
The traditional manufacturing process of the flexible heating film is sheet-to-sheet production, namely, raw materials used by the heating film are cut into sheets, and the sheets are manufactured into finished products through a plurality of procedures such as punching, aligning, wiring, laminating, pressing, punching and the like, so that the production process is complex, and the efficiency and the yield are low; in addition, most of flexible heating films mostly relate to etching processes, namely, metal foils are etched into required circuits through processes of dry film pressing, exposure, development, etching, cleaning and the like, and the processes are complex and are not environment-friendly. The existing roll-to-roll etching process can improve the production efficiency to a certain extent, but a plurality of manual working procedures are still needed to finish the manufacture of the heating film after etching, the yield cannot be ensured, and the problem of environmental pollution cannot be solved.
At present, the demand of various industries on flexible heating films is increasing day by day, for example, the market demand of light weight of new energy automobiles must require light and thin heating materials; flexible wearing products are becoming the next fashion trend, and products such as heating clothes, heating kneecaps and the like are more and more favored by consumers. Therefore, development of a flexible heating film and a manufacturing method that can be scaled and environmentally friendly is urgently needed.
Disclosure of Invention
The invention mainly aims to provide a flexible heating film and a die cutting processing method and equipment thereof, so as to overcome the defects of the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention comprises the following steps:
an embodiment of the present invention provides a flexible heating film, including: the first insulating layer, the second insulating layer and the patterned metal electrode packaged between the first insulating layer and the second insulating layer;
or, the flexible heating film comprises a first insulating layer, a second insulating layer, and a carbon film and a patterned metal electrode which are packaged between the first insulating layer and the second insulating layer, wherein the carbon film is in ohmic contact with the patterned metal electrode.
The embodiment of the invention also provides roll-to-sheet continuous production equipment which is used for preparing the flexible heating film and comprises a circular knife die-cutting machine, a first die-cutting mechanism, a second die-cutting mechanism, a first compound mechanism, a third die-cutting mechanism and a second compound mechanism, wherein the first die-cutting mechanism, the second die-cutting mechanism, the first compound mechanism, the third die-cutting mechanism and the second compound mechanism are arranged on the circular knife die-cutting machine;
the first compound mechanism is at least used for arranging the patterned metal electrode and the first insulating layer in a laminated mode, the third die-cutting mechanism is at least used for carrying out die cutting on the second insulating film to form the second insulating layer, and the second compound mechanism is at least used for combining the first insulating layer and the second insulating layer, so that the patterned metal electrode is packaged between the first insulating layer and the second insulating layer to form the flexible heating film.
The embodiment of the invention also provides a die cutting processing method of the flexible heating film, which comprises the following steps:
providing the roll-to-sheet continuous production equipment,
the method comprises the steps of carrying out die cutting treatment on a metal electrode by adopting a metal electrode die cutting die to form a patterned metal electrode, separating redundant metal electrodes from the patterned metal electrode by adopting an electrode waste removing cutting die, carrying out die cutting treatment on a first insulating film by adopting a first insulating film die cutting die to form a first insulating layer, carrying out die cutting treatment on a second insulating film by adopting a second insulating film die cutting die to form a second insulating layer, enabling the patterned metal electrode and the first insulating layer to be laminated through a composite roller, enabling the first insulating layer and the second insulating layer to be combined into an integrated structure through a heating composite roller, packaging the patterned metal electrode between the first insulating layer and the second insulating layer, and further forming the flexible heating film.
Compared with the prior art, the flexible heating film etching resistance wire heating film provided by the embodiment of the invention has the advantages that the precision and the product size are mainly determined by the processing precision of the cutting die, the diameter and the width of the cutting die, and different from the etching resistance wire process, the processing precision and the size are limited by the size of the silk screen plate and the etching process, so that the process has obvious advantages in the aspects of line width precision and size, the batch production of the heating film can be realized without a complex etching process, and the problems of pollution and high cost caused by etching can be avoided; the embodiment of the invention also provides a die cutting processing method of the flexible heating film, the method can realize the roll-to-sheet continuous production of the flexible heating sheet, the whole process does not need manual operation, and the automation degree is high.
Drawings
FIG. 1 is a schematic diagram of a resistance wire heating film in an exemplary embodiment of the invention;
FIG. 2 is a schematic diagram of a carbon film heating film according to an exemplary embodiment of the present invention;
FIG. 3 is a photograph of a carbon film heating film in an exemplary embodiment of the invention;
FIG. 4 is a photograph of a resistance wire heating film in an exemplary embodiment of the invention;
FIG. 5 is a schematic diagram of a roll-to-sheet continuous manufacturing apparatus in accordance with an exemplary embodiment of the present invention;
fig. 6 is a schematic diagram of a die-cutting process for a flexible heating film according to an exemplary embodiment of the present invention.
Detailed Description
In view of the deficiencies in the prior art, the inventors of the present invention have made extensive studies and extensive practices to provide technical solutions of the present invention. The technical solution, its implementation and principles, etc. will be further explained as follows.
An embodiment of the present invention provides a flexible heating film, including: the first insulating layer, the second insulating layer and the patterned metal electrode packaged between the first insulating layer and the second insulating layer;
or, the flexible heating film comprises a first insulating layer, a second insulating layer, and a carbon film and a patterned metal electrode which are packaged between the first insulating layer and the second insulating layer, wherein the carbon film is in ohmic contact with the patterned metal electrode.
Further, the patterned metal electrode includes any one of a patterned metal copper foil, an aluminum foil, a nickel-plated copper foil, and a flexible copper foil base material, or an adhesive tape formed of any one of a metal copper foil, an aluminum foil, a nickel-plated copper foil, and a flexible copper foil base material, but is not limited thereto.
Preferably, the thickness of the patterned metal electrode is 5-100 μm.
Further, the first insulating layer and the second insulating layer include any one of a polyimide film, a polyimide cover film, a polyester cover film, a silicone rubber, a semi-vulcanized silicone rubber, a non-woven fabric, and a thermal lining cloth, but are not limited thereto.
Preferably, the first insulating layer and the second insulating layer each have a thickness of 10 to 1000 μm.
Further, the first insulating layer and the second insulating layer are integrally provided.
Further, the carbon film comprises an insulating material layer and carbon crystals, graphene or carbon nanotubes which are formed on the insulating material layer in any one of silk-screen printing and coating modes.
Preferably, the insulating material layer includes a PI insulating material layer, but is not limited thereto.
Furthermore, a conductive adhesive film is adhered to the surface of one side of the patterned metal electrode, which is opposite to the carbon film.
Preferably, the conductive adhesive film is mainly used for connecting a plurality of conductors in the vertical direction, the surface resistance is 30-500 m Ω/sq, and the material of the conductive adhesive film comprises an epoxy resin thermosetting resin film containing conductive particles, such as Tuoda CBF300 or a substitute thereof.
Preferably, the thickness of the conductive adhesive film is 30-50 um.
The embodiment of the invention also provides roll-to-sheet continuous production equipment which is used for preparing the flexible heating film and comprises a circular knife die-cutting machine, a first die-cutting mechanism, a second die-cutting mechanism, a first compound mechanism, a third die-cutting mechanism and a second compound mechanism, wherein the first die-cutting mechanism, the second die-cutting mechanism, the first compound mechanism, the third die-cutting mechanism and the second compound mechanism are arranged on the circular knife die-cutting machine;
the first compound mechanism is at least used for arranging the patterned metal electrode and the first insulating layer in a laminated mode, the third die-cutting mechanism is at least used for carrying out die cutting on the second insulating film to form the second insulating layer, and the second compound mechanism is at least used for combining the first insulating layer and the second insulating layer, so that the patterned metal electrode is packaged between the first insulating layer and the second insulating layer to form the flexible heating film.
Further, the first die-cutting mechanism comprises a metal electrode die-cutting die for die-cutting the metal electrode and an electrode waste-removing cutting die for separating waste materials generated by die-cutting; the second die-cutting mechanism comprises a first insulating film die-cutting die for die-cutting the first insulating film; the third die cutting mechanism comprises a second insulating film die cutting cutter die for die cutting of a second insulating film; the first compound mechanism comprises a compound roller; the second compounding mechanism includes a heated compounding roller.
In some more specific embodiments, the roll-to-sheet continuous production apparatus further comprises a fourth die-cutting mechanism disposed between the first combining mechanism and the third die-cutting mechanism, and at least used for die-cutting the carbon film.
Preferably, the fourth die-cutting mechanism includes a carbon film die-cutting die and a carbon film waste extracting die.
Preferably, the carbon film die cutting die comprises a carbon film profile cutting die and a carbon film hole opening cutting die.
In some more specific embodiments, the roll-to-sheet continuous production apparatus further comprises a contour cutting die for forming the flexible heating film into a target shape.
Further, the metal electrode die-cutting die, the first insulating film die-cutting die, the second insulating film die-cutting die and the carbon film die-cutting die are all circular knife dies.
Furthermore, the wire precision of the circular knife mould is +/-10 microns.
Preferably, the line width of the metal electrode die-cutting die is more than or equal to 1 mm.
The embodiment of the invention also provides a die cutting processing method of the flexible heating film, which comprises the following steps:
providing the roll-to-sheet continuous production equipment,
the method comprises the steps of carrying out die cutting treatment on a metal electrode by adopting a metal electrode die cutting die to form a patterned metal electrode, separating redundant metal electrodes from the patterned metal electrode by adopting an electrode waste removing cutting die, carrying out die cutting treatment on a first insulating film by adopting a first insulating film die cutting die to form a first insulating layer, carrying out die cutting treatment on a second insulating film by adopting a second insulating film die cutting die to form a second insulating layer, enabling the patterned metal electrode and the first insulating layer to be laminated through a composite roller, enabling the first insulating layer and the second insulating layer to be combined into an integrated structure through a heating composite roller, packaging the patterned metal electrode between the first insulating layer and the second insulating layer, and further forming the flexible heating film.
In some more specific embodiments, the die-cutting process further comprises: and carrying out die cutting treatment on the carbon film by adopting a carbon film die cutting die, separating redundant carbon film by adopting a carbon film waste extracting die, and enabling the die-cut carbon film to form ohmic contact with the patterned metal electrode.
Further, the carbon film comprises an insulating material layer and carbon crystals, graphene or carbon nanotubes which are formed on the insulating material layer in any one of silk-screen printing and coating modes.
Preferably, the insulating material layer includes a PI insulating material layer, but is not limited thereto.
Furthermore, a conductive adhesive film is adhered to the surface of one side of the patterned metal electrode, which is opposite to the carbon film.
Preferably, the conductive adhesive film is mainly used for connecting a plurality of conductors in the vertical direction, the surface resistance is 30-500 m Ω/sq, and the material of the conductive adhesive film comprises an epoxy resin thermosetting resin film containing conductive particles, such as Tuoda CBF300 or a substitute thereof.
Preferably, the thickness of the conductive adhesive film is 30-50 um.
Furthermore, the heating temperature of the heating composite roller is 80-150 ℃, and the attaching pressure is 1-20 kg.
Further, the die-cut line width precision of the patterned metal electrode is less than +/-10 mu m.
Preferably, the die cutting line width precision of the resistance wire is less than +/-10 um.
Further, the die cutting processing method further comprises the following steps: the resistance of the carbon film is adjusted by at least either punching or coating a pattern.
The technical solution, its implementation and principles, etc. will be further explained with reference to the drawings and the embodiments
Referring to fig. 1, in some specific embodiments, a flexible heating film may be a resistance wire heating film, the resistance wire heating film is mainly composed of a patterned metal electrode (i.e., a resistance wire electrode) 4 and an upper cover film 1 and a lower cover film 5 (i.e., a first insulating layer and a second insulating layer) disposed at two sides of the electrode, the upper cover film 1 and the lower cover film 5 are an integrated structure, and the patterned metal electrode 4 is encapsulated between the upper cover film 1 and the lower cover film 5.
Referring to fig. 2, in another more specific embodiment, a flexible heating film may also be a carbon film heating film, which mainly comprises a carbon film 2, a patterned metal electrode 4 in ohmic contact with the carbon film, a conductive adhesive film 3 disposed between the carbon film 2 and the patterned metal electrode 4, and an upper cover film 1 and a lower cover film 5 (i.e., a first insulating layer and a second insulating layer) disposed on both sides of the carbon film/metal electrode.
Further, the carbon film may be a carbon crystal, graphene, or carbon nanotube formed on the PI insulating material layer by any one of screen printing and coating.
Furthermore, the carbon film can adjust the resistance through processes of punching, pattern coating and the like.
In order to ensure ohmic contact between the carbon film and the metal electrode, it is particularly preferable that the surface of the metal electrode (i.e., the bonding surface where the carbon film and the metal electrode are oppositely arranged) is adhered with a conductive adhesive film.
Preferably, the die-cutting line width precision of the patterned metal electrode is less than +/-10 um.
The patterned metal electrode includes any one of patterned copper foil, aluminum foil, nickel-plated copper foil, and soft copper foil base material, or an adhesive tape formed of any one of copper foil, aluminum foil, nickel-plated copper foil, and soft copper foil base material, but is not limited thereto;
furthermore, the thickness of the patterned metal electrode is determined by the product design, and is generally 5-100 um.
Specifically, the processing technology of the patterned metal electrode is a circular knife rolling and sheet-to-sheet die cutting technology.
Specifically, the insulating film includes an upper cover film (i.e., a first insulating layer) and a lower cover film (i.e., a second insulating layer), and the insulating film includes a Polyimide (PI) film, a PI cover film, a (polyester) PET film, a PET cover film, a silicone rubber, a semi-vulcanized silicone rubber, a non-woven fabric, a thermal liner, and the like, but is not limited thereto.
Further, the thickness of the upper cover film and the thickness of the lower cover film are both 10-1000 um;
further, the PI covering film, the PET covering film, the semi-vulcanized silicone rubber and the thermal lining cloth soften in the rubber layer at 80-200 ℃, and the purpose of bonding can be achieved.
Compared with the resistance wire heating film and the etching resistance wire heating film, the resistance wire heating film provided by the embodiment of the invention has obvious advantages in the aspects of line width precision and size, and the batch production of the heating film can be realized without a complex etching process, so that the problems of pollution and high cost caused by etching can be avoided.
Referring to fig. 5, a die-cutting processing method of a flexible heating film according to an embodiment of the present invention is performed on a roll-to-roll continuous production apparatus, which includes a circular knife die-cutting machine, customized circular knife dies (including a patterned metal electrode die-cutting die, an electrode waste extracting die, an upper/lower insulating layer die-cutting die (i.e., a first insulating layer die-cutting die, a second insulating layer die-cutting die), and a finished product profile die-cutting die), and a heating composite roll.
Specifically, the roll-to-sheet continuous production equipment for manufacturing the resistance wire heating film comprises a circular knife die-cutting machine, a first die-cutting mechanism 10, a second die-cutting mechanism 11, a first compound mechanism 12, a third die-cutting mechanism 13, a second compound mechanism 14 and a finished product appearance processing mechanism 15, wherein the first die-cutting mechanism, the second die-cutting mechanism 11, the first compound mechanism 12, the third die-cutting mechanism 13, the second compound mechanism 14 and the finished product appearance processing mechanism 15 are installed on.
More specifically, the first die-cutting mechanism 10 includes an electrode discharging roller 101 for discharging the electrode material, a patterned metal electrode die-cutting die 102 disposed along the advancing direction of the electrode material, an electrode waste extracting cutting die 102 disposed along the advancing direction of the electrode material, and an electrode waste roller 103 for collecting the waste electrode material; the second die-cutting mechanism 11 includes a first insulating film discharging roller 105 for discharging the first insulating film, a first insulating film die-cutting die (not shown in the figure) disposed along the traveling direction of the first insulating film, the first combining mechanism 12 includes two oppositely disposed combining rollers 106, the third die-cutting mechanism 12 includes a second insulating film discharging roller 107 for discharging the second insulating film, a second insulating film die-cutting die 108 disposed along the traveling direction of the second insulating film, the second combining mechanism 14 includes two oppositely disposed heating combining rollers 109 for heating and bonding the first insulating layer and the second insulating layer to encapsulate the patterned metal electrode between the first insulating layer and the second insulating layer to form a resistance wire heating film, and the finished product shape processing mechanism 15 includes a finished product shape cutting die 110 disposed along the traveling direction of the resistance wire heating film.
Specifically, the roll-to-sheet continuous production equipment for manufacturing the carbon film heating film comprises a circular knife die-cutting machine, and a first die-cutting mechanism 10, a second die-cutting mechanism 11, a fourth die-cutting mechanism 16, a first compound mechanism 12, a third die-cutting mechanism 13, a second compound mechanism 14 and a finished product appearance processing mechanism 15 which are arranged on the circular knife die-cutting machine.
More specifically, the first die-cutting mechanism 10 includes an electrode discharging roller 101 for discharging the electrode material, a patterned metal electrode die-cutting die 102 disposed along the advancing direction of the electrode material, an electrode waste extracting cutting die 102 disposed along the advancing direction of the electrode material, and an electrode waste roller 103 for collecting the waste electrode material; the second die-cutting mechanism 11 includes a first insulating film discharging roller 105 for discharging the first insulating film, a first insulating film die-cutting die (not shown in the figure) provided along the traveling direction of the first insulating film, and the fourth die-cutting mechanism 16 includes a carbon film discharging roller 111 for discharging a carbon film, a carbon film die-cutting die 113 provided along the traveling direction of the carbon film, a carbon film removing cutting die (not shown in the figure), a carbon film waste roller 112 for collecting the waste carbon film; the first compound mechanism 12 includes two compound rollers 106 arranged oppositely, the third die-cutting mechanism 12 includes a second insulating film discharging roller 107 for discharging the second insulating film, a second insulating film die-cutting die 108 arranged along the advancing direction of the second insulating film, the second compound mechanism 14 includes two oppositely arranged heating compound rollers 109 for heating and combining the first insulating layer and the second insulating layer so as to package the patterned metal electrode and the carbon film between the first insulating layer and the second insulating layer to form a resistance wire heating film, and the finished product shape processing mechanism 15 includes a finished product shape cutting die 110 arranged along the advancing direction of the resistance wire heating film.
Furthermore, in order to ensure continuous and stable production, various bottom films and waste extracting films are required to be used in the process; the plastic film carrier film and the waste extracting film are PET silica gel protective films, PET acrylic protective films, PE protective films and the like.
Furthermore, the stripping force of the stripping film and the backing film is determined by the process, the stripping force is generally in the range of 1-50 kgf, and the stripping force of the stripping film is greater than that of the backing film.
Furthermore, the number of stations of the circular knife die-cutting machine (each station is a functional area, which can include a die-cutting die, a profile die, a material roller and the like) is determined by the length of a product and the type of the product, and the preferred 8-20 stations are selected.
Further, the production speed of the flexible heating film is 20-100 pcs/min.
Furthermore, the width of the circular knife die-cutting machine is determined by the width of a product, a standard circular knife machine with the width of 250mm is used for the product with the width of less than or equal to 250mm, and nonstandard equipment can be customized for the product with the width of more than 250mm according to the product time and the width; generally, the circular knife machine can produce any product with the width less than or equal to the width of the circular knife machine.
Further, the customized circular knife mold generally comprises: the device comprises a patterned metal electrode die-cutting die, an electrode waste extracting cutting die, an upper/lower insulating layer die-cutting die (namely a first insulating layer die-cutting die and a second insulating layer film die-cutting die) and a finished product appearance cutting die.
Further, the circular knife mold is adjusted according to the size and the shape of the heating film.
Furthermore, the circular knife mold is generally made of stainless steel and is annealed, the surface hardness is more than or equal to 60 degrees, and the service life is more than or equal to 10000 h.
Further, the knife line precision of circular knife mould is 10 um.
Furthermore, the line width of the patterned metal electrode die-cutting die is more than or equal to 1 mm.
In particular, a carbon film die cutting die is required to be added for carbon film heating film (carbon crystal, graphene, carbon nanotube, etc.) products.
Furthermore, the carbon film die cutting die comprises a carbon film profile cutting die and a carbon film hole opening cutting die.
Further, the heating composite roller is at least used for bonding the upper cover film and the lower cover film into an integral structure through the heating roller.
Furthermore, the heating temperature of the heating composite roller is 80-150 ℃, and the bonding pressure is 1-20 kg;
furthermore, after the flexible heating film is subjected to multi-station circular knife die cutting machine, heating roller laminating and sheet-to-sheet slicing, the sheet can be pressed by a press transfer machine or a quick press to obtain a finished product of the flexible heating film.
Furthermore, the pressing temperature of the pressure transfer machine or the quick pressing machine is 130-200 ℃, and the pressure is 50-200 kg.
The embodiment of the invention also provides a die cutting processing method of the flexible heating film, which can realize the roll-to-sheet continuous production of the flexible heating sheet, does not need manual operation in the whole process and has high automation degree.
Referring to fig. 6, a die cutting method for a flexible heating film includes:
providing the roll-to-sheet continuous production equipment,
the method comprises the steps of carrying out die cutting treatment on a metal electrode by using a metal electrode die cutting die to form a patterned metal electrode, separating redundant metal electrodes from the patterned metal electrode by using an electrode waste removing cutting die, carrying out die cutting treatment on a first insulating film by using a first insulating film die cutting die to form a first insulating layer, carrying out die cutting treatment on a second insulating film by using a second insulating film die cutting die to form a second insulating layer, enabling the patterned metal electrode and the first insulating layer to be laminated through a composite roller, enabling the first insulating layer and the second insulating layer to be combined into an integrated structure through a heating composite roller, packaging the patterned metal electrode between the first insulating layer and the second insulating layer, further forming the flexible heating film, and preparing a picture of the formed resistance wire heating film as shown in figure 4.
In some more specific embodiments, the die-cutting process further comprises: performing die cutting treatment on the carbon film by adopting a carbon film die cutting die, separating redundant carbon film by adopting a carbon film waste extracting die, and enabling the die-cut carbon film to form ohmic contact with the patterned metal electrode; a photograph of the resulting carbon film heating film was prepared as shown in fig. 3.
The method provided by the invention simultaneously die-cuts the upper cover film, the metal electrode, the carbon film and the lower cover film by using a multi-station circular cutter machine and a plurality of sets of circular cutter dies specially customized according to the product size, and synchronously completes heating lamination and appearance die cutting; the method provided by the invention has high automation degree, greatly improves the productivity, avoids foreign matter pollution in the heating film, greatly improves the yield, and can manufacture the flexible heating film in a large scale.
Example 1
Die cutting of the flexible resistance wire heating film:
1. selecting materials according to design requirements: the upper/lower cover films are both 100um PI cover films, and PET silica gel support films with 3gf peeling force are compounded; the electrode (metal electrode) uses a PET silica gel carrier film with 18um copper foil compounded with 3gf stripping force;
2. opening a cutting die according to design drawings: the patterned metal electrode die-cutting die, the electrode waste extracting cutting die, the upper/lower cover film die-cutting die and the finished product appearance cutting die are arranged on a circular cutting machine;
3. die cutting and processing: the material is subjected to die cutting by round knives to fix the size, is attached at 120 ℃ by a heating roller, and is subjected to die cutting by a profile knife die to form a finished product structure, wherein the die cutting speed is 10 m/min;
4. die cutting results: the external dimensions and the internal resistance of the heating film were measured, and the design value of the internal resistance for heating was 2.60 Ω, and the actual measurement value was 2.61 Ω.
Example 2
Die cutting of the flexible carbon film heating film:
1. selecting materials according to design requirements: the upper cover film is a 100um PI cover film, the lower cover film is a 50um PI cover film, and PET silica gel support film with 3gf peeling force is compounded; the electrode uses a PET silica gel carrier film with 18um copper foil compounded with 3gf stripping force; the carbon film uses a carbon nano tube conductive film which meets the composite design requirement;
2. opening a cutting die according to design drawings: the patterned metal electrode die-cutting die, the electrode waste extracting cutting die, the carbon film die-cutting die, the upper/lower cover film die-cutting die and the finished product appearance cutting die are arranged on a circular cutting machine;
3. die cutting and processing: the material is subjected to die cutting by each circular knife to fix the size, is attached at 120 ℃ by a heating roller, and is subjected to die cutting by an appearance knife die to form a finished product structure, wherein the die cutting speed is 8 m/min;
4. die cutting results: the external dimensions and the internal resistance of the heating film were measured, and the designed value of the internal resistance for heating was 7.55 Ω, and the actual measured value was 7.51 Ω.
Example 3
And (3) die cutting of the intelligent garment heating film:
1. selecting materials according to design requirements: the upper/lower cover films are both made of 100um hot lining cloth and compounded with a PET silica gel supporting film with 3gf peeling force; the electrode uses a PET silica gel carrier film with 18um copper foil compounded with 3gf stripping force; the carbon film uses a carbon nano tube conductive film which meets the composite design requirement;
2. opening a cutting die according to design drawings: the patterned metal electrode die-cutting die, the electrode waste extracting cutting die, the carbon film die-cutting die, the upper/lower cover film die-cutting die and the finished product appearance cutting die are arranged on a circular cutting machine;
3. die cutting and processing: the material is subjected to die cutting by each circular knife to fix the size, is attached at 120 ℃ by a heating roller, and is subjected to die cutting by an appearance knife die to form a finished product structure, wherein the die cutting speed is 8 m/min;
4. die cutting results: the external dimensions and the internal resistance of the heating film were measured, and the design value of the internal resistance for heating was 1.70 Ω, and the actual measurement value was 2.71 Ω.
Compared with the prior art, the flexible heating film provided by the embodiment of the invention has obvious advantages in the aspects of line width precision and size compared with an etching resistance wire heating film, and the batch production of the heating film can be realized without a complex etching process, so that the problems of pollution and high cost caused by etching can be avoided; the embodiment of the invention also provides a die cutting processing method of the flexible heating film, which can realize the roll-to-sheet continuous production of the flexible heating sheet, does not need manual operation in the whole process and has high automation degree.
It should be understood that the above-mentioned embodiments are merely illustrative of the technical concepts and features of the present invention, which are intended to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and therefore, the protection scope of the present invention is not limited thereby. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (10)
1. A flexible heating film, characterized by comprising: the first insulating layer, the second insulating layer and the patterned metal electrode packaged between the first insulating layer and the second insulating layer;
or, the flexible heating film comprises a first insulating layer, a second insulating layer, and a carbon film and a patterned metal electrode which are packaged between the first insulating layer and the second insulating layer, wherein the carbon film is in ohmic contact with the patterned metal electrode.
2. The flexible heating film according to claim 1, wherein: the patterned metal electrode comprises any one of a patterned copper foil, an aluminum foil, a nickel-plated copper foil and a flexible copper foil base material or an adhesive tape formed by any one of a copper foil, an aluminum foil, a nickel-plated copper foil and a flexible copper foil base material; preferably, the thickness of the patterned metal electrode is 5-100 μm; and/or the first insulating layer and the second insulating layer comprise any one of a polyimide film, a polyimide cover film, a polyester cover film, silica gel, semi-vulcanized silicone rubber, non-woven fabric and thermal lining cloth; preferably, the thickness of the first insulating layer and the second insulating layer is 10-1000 μm; preferably, the first insulating layer and the second insulating layer are integrally provided; and/or the carbon film comprises an insulating material layer and carbon crystals, graphene or carbon nanotubes which are formed on the insulating material layer in any one of silk-screen printing and coating modes; and/or the surface of one side of the patterned metal electrode, which is opposite to the carbon film, is adhered with a conductive adhesive film; preferably, the material of the conductive adhesive film comprises an epoxy resin thermosetting resin film containing conductive particles; preferably, the thickness of the conductive adhesive film is 30-50 um.
3. Roll-to-sheet continuous production equipment for preparing the flexible heating film according to any one of claims 1 to 2, wherein the roll-to-sheet continuous production equipment comprises a circular knife die-cutting machine and a first die-cutting mechanism, a second die-cutting mechanism, a first compound mechanism, a third die-cutting mechanism and a second compound mechanism which are arranged on the circular knife die-cutting machine;
the first die cutting mechanism is at least used for die cutting of the metal electrode to form a patterned metal electrode, the second die cutting mechanism is at least used for die cutting of the first insulating film to form a first insulating layer, the first composite mechanism is at least used for laminating the patterned metal electrode and the first insulating layer, the third die cutting mechanism is at least used for die cutting of the second insulating film to form a second insulating layer, and the second composite mechanism is at least used for combining the first insulating layer and the second insulating layer to package the patterned metal electrode between the first insulating layer and the second insulating layer to form the flexible heating film.
4. The roll-to-roll continuous production apparatus according to claim 3, characterized in that: the first die-cutting mechanism comprises a metal electrode die-cutting die for die-cutting the metal electrode and an electrode waste-extracting cutting die for separating waste materials generated by die-cutting; the second die-cutting mechanism comprises a first insulating film die-cutting die for die-cutting the first insulating film; the third die cutting mechanism comprises a second insulating film die cutting cutter die for die cutting of a second insulating film; the first compound mechanism comprises a compound roller; the second compounding mechanism includes a heated compounding roller.
5. The roll-to-roll continuous production apparatus according to claim 3, further comprising a fourth die-cutting mechanism provided between the first combining mechanism and the third die-cutting mechanism and at least for die-cutting the carbon film; preferably, the fourth die-cutting mechanism comprises a carbon film die-cutting die and a carbon film waste extracting cutting die; preferably, the carbon film die cutting die comprises a carbon film appearance die and a carbon film hole opening die; and/or the roll-to-sheet continuous production equipment further comprises a profile cutting die for forming the flexible heating film into a target shape.
6. The roll-to-roll continuous production apparatus according to claim 5, characterized in that: the metal electrode die-cutting die, the first insulating film die-cutting die, the second insulating film die-cutting die and the carbon film die-cutting die are all circular knife dies; and/or the wire precision of the circular knife mould is +/-10 mu m; preferably, the line width of the metal electrode die-cutting die is more than or equal to 1 mm.
7. A die cutting processing method of a flexible heating film is characterized by comprising the following steps:
providing a roll-to-roll continuous production apparatus according to any one of claims 3 to 6,
the method comprises the steps of carrying out die cutting treatment on a metal electrode by adopting a metal electrode die cutting die to form a patterned metal electrode, separating redundant metal electrodes from the patterned metal electrode by adopting an electrode waste removing cutting die, carrying out die cutting treatment on a first insulating film by adopting a first insulating film die cutting die to form a first insulating layer, carrying out die cutting treatment on a second insulating film by adopting a second insulating film die cutting die to form a second insulating layer, enabling the patterned metal electrode and the first insulating layer to be laminated through a composite roller, enabling the first insulating layer and the second insulating layer to be combined into an integrated structure through a heating composite roller, packaging the patterned metal electrode between the first insulating layer and the second insulating layer, and further forming the flexible heating film.
8. The die cutting process of claim 7, further comprising: performing die cutting treatment on the carbon film by adopting a carbon film die cutting die, separating redundant carbon film by adopting a carbon film waste extracting die, and enabling the die-cut carbon film to form ohmic contact with the patterned metal electrode; and/or the carbon film comprises an insulating material layer and carbon crystals, graphene or carbon nanotubes which are formed on the insulating material layer in any one of silk-screen printing and coating modes; and/or the surface of one side of the patterned metal electrode, which is opposite to the carbon film, is adhered with a conductive adhesive film; preferably, the material of the conductive adhesive film comprises an epoxy resin thermosetting resin film containing conductive particles; preferably, the thickness of the conductive adhesive film is 30-50 um.
9. The die cutting process of claim 7, wherein: the heating temperature of the heating composite roller is 80-150 ℃, and the bonding pressure is 1-20 kg; and/or the die-cut line width precision of the patterned metal electrode is less than +/-10 mu m.
10. The die cutting process of claim 8, further comprising: the resistance of the carbon film is adjusted by at least either punching or coating a pattern.
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| CN113442231A (en) * | 2020-03-25 | 2021-09-28 | 昊佰电子科技（上海）有限公司 | Hot punching and cutting hardware die |
| CN113968063A (en) * | 2021-10-13 | 2022-01-25 | 赛柯赛斯新能源科技(苏州)有限公司 | Heating sheet, processing equipment and processing method |
| CN114434811A (en) * | 2022-01-12 | 2022-05-06 | 广西安鑫新材料科技有限公司 | Manufacturing method of electrothermal film based on circular knife die cutting equipment |
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| CN117202485B (en) * | 2023-09-20 | 2024-04-02 | 赛维精密科技(广东)有限公司 | FPCB circuit board, combined die-cutting production process and production equipment |
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