Shen Hua: Special spring pads for cutting high-end film materials. They provide precise protection for the film, thereby enabling the quality upgrade of the film material industry.
The high-end film material die-cutting field (optical film, explosion-proof film, protective film, photovoltaic film, electronic film), the core demand focuses on seamless protection of the film, precise rebound, temperature resistance and solvent resistance, and no residual glue. The die plate spring pad, as the core consumable material for film die-cutting, directly determines the accuracy, surface integrity and product performance of the film die-cutting - it needs to be compatible with thin and lightweight materials such as films and composite films, provide uniform and gentle rebound support, avoid scratching the film surface and causing creases, and at the same time withstand solvents and high temperatures during the die-cutting process, eliminate residual glue and powder pollution of the film, and ensure that the optical performance and protective performance of the die-cut film materials are not affected. Shenhua has been deeply engaged in the die-cutting consumables field for 22 years, accurately grasping the core pain points of high-end film die-cutting, focusing on the specialized research and customization of film-specific die plate spring pads, with "precise protection of the film, stable weather resistance, no residual glue pollution" as the core, creating a high-end film material exclusive die plate spring pad solution, becoming the core supporting partner of many leading film material enterprises and electronic display enterprises, and enabling the quality upgrade of the film material industry.
Precise breakthrough, solving the core pain points of high-end film die-cutting
Shen Hua, while deeply engaged in the field of high-end film material die-cutting, discovered that the industry generally faces four core pain points. The requirements for the protective film performance and stability of the cutting tool plate spring pad are extremely high: First, the surfaces of high-end film materials (such as optical films and explosion-proof films) are sensitive. Traditional cutting tool plate spring pads have rough surfaces and uneven hardness, which can easily scratch the surface of the film material, cause scratches, and damage the optical performance and appearance of the film material; Second, the film materials are thin and easy to stretch. Traditional spring pads have uneven rebound, and during die-cutting, they are prone to cutting through failure, burrs, and film material stretching deformation, resulting in a high scrap rate of the finished products; Third, during die-cutting, oils and solvents are used. Traditional spring pads have poor resistance to solvents, which can easily swell, deform, and lose powder, contaminating the surface of the film material and affecting product quality; Fourth, the die-cutting accuracy of high-end film materials requires a micron-level precision. Traditional spring pads have large thickness tolerances and inaccurate positioning, which can easily cause die-cutting deviations and fail to meet the assembly requirements of high-end film materials.
Based on 22 years of accumulated experience in precision foam material research and die-cutting technology, Shenhua has established a specialized R&D team for high-end film material die-cutting plates and cushioning pads. They collaborate with film material enterprises and die-cutting equipment manufacturers to conduct joint research, aiming to overcome core technologies such as seamless protection of the film, precise shaping, resistance to solvents, and no residue of glue. Over the past 22 years, the technology has continuously evolved: In 2020, a dedicated die-cutting plate cushioning pad for film protection was launched, with its surface treated for ultra-smoothness, ensuring no scratches or contamination of the film material; in 2022, a solvent-resistant model was developed, capable of withstanding various die-cutting solvents without swelling or deformation; in 2023, the precision shaping process was optimized, with the thickness tolerance controlled within ±0.01mm, and the die-cutting accuracy reaching the micron level; in 2024, an anti-residue model was introduced, with its surface treated for anti-stick, ensuring no residue of glue, serving over 30 leading film material enterprises, and increasing the product yield to over 99.7%, while improving production efficiency by 40%.
Core product matrix, suitable for all scenarios of high-end membrane materials
Shenhua focuses on meeting the all-round demands of high-end membrane materials, and has developed three series of dedicated blade pad products. Each product has undergone rigorous tests for film protection, solvent resistance, and precision, ensuring the ultimate quality requirements for adhering to high-end membrane materials. "The membrane material dedicated blade pad of Shenhua, what we are most satisfied with is the film protection effect. It will not scratch the surface of the optical film at all, and it has high precision, no residual glue, and the edges of the cut products are smooth, significantly improving our product quality and market competitiveness," commented a production manager from a leading optical film enterprise.
Special knife pad for optical film: Focuses on achieving a seamless protective film, precise rebound, and no residual glue. It uses a high-rebound and dense polyurethane base material, with the surface treated by ultra-smooth micropores. It is soft and fine, without scratching or contaminating the surface of the optical film, and does not affect the light transmission and optical performance of the film material. The thickness ranges from 0.08mm to 1.0mm, with a thickness tolerance of ±0.01mm. Precise control of the die-cutting depth is achieved to prevent the film from being cut through or pierced. The elasticity is uniform and gentle, avoiding the stretching deformation of the film material, and is suitable for the precise die-cutting requirements of optical films for mobile phones, tablets, monitors, etc.
2. Special knife pad for explosion-proof film/protective film: Focuses on solvent resistance, long-lasting wear resistance, high-speed compatibility. It uses a solvent-resistant polyurethane composite base material, which can withstand various inks and solvents during die-cutting, without swelling, deformation, or powder shedding, thus avoiding contamination of the film surface. It is also resistant to wear and fatigue, with a rebound rate of 100% after 350,000 consecutive die-cuts without attenuation, suitable for batch production on high-speed die-cutting machines. The surface is treated with anti-stick treatment, leaving no residue of glue, and the die-cut edges are smooth without burrs, suitable for die-cutting requirements such as mobile phone explosion-proof films, car protection films, and household appliance protection films.
3. Special knife pad for photovoltaic film/electronic film: Centered on high temperature resistance, good weather resistance, and precise positioning, it uses special materials with high temperature and weather resistance. It can withstand the high-temperature environment during the production of photovoltaic films (-30℃~80℃), without cracking or softening. The precise forming process ensures precise positioning, with the cutting deviation controlled within ±0.01mm, suitable for cutting requirements of photovoltaic films, electronic insulation films, heat-conducting films, etc. It is resistant to aging and UV rays, with no degradation over a long period, ensuring the stable performance of the film material after cutting, and facilitating the upgrading of photovoltaic and electronic industries.
Specialized membrane material services, enabling quality upgrade
Based on 22 years of service experience, Shenhua has tailored a comprehensive service system for the high-end membrane material industry, which features "high precision, high requirements, and strong customization". This system encompasses the entire process from "demand research - scheme customization - precise prototyping - batch production - after-sales support". Before sales, a dedicated membrane material service team is established to deeply understand the material properties, die-cutting accuracy, solvent usage, and production requirements, and to provide customized and compatible solutions. Professional consultations on material selection, hardness adjustment, and process optimization are also offered. During sales, precise and rapid prototyping services are implemented, with sample delivery time reduced to 24 hours. Free on-machine testing is provided, and the results are used to rapidly iterate and optimize. After sales, a 7×24-hour technical response mechanism is established, with professional membrane material die-cutting engineers on hand to quickly resolve various issues related to installation, adaptation, and usage. Regular product usage follow-ups are conducted to assist customers in optimizing the die-cutting process and improving product quality.
In the future, Shenhua will further deepen the research and development of specialized knife plate and spring pad for high-end membrane materials, focusing on thinner, more precise and more weather-resistant directions. It will develop specialized products suitable for flexible membranes and photovoltaic membranes. It will also collaborate with membrane material enterprises to carry out joint innovation, intervening in the membrane design and die-cutting process research and development phases in advance, and creating an integrated die-cutting consumable solution. It will continuously provide high-quality and high-precision knife plate spring pad products to empower the high-end and intelligent upgrade of the membrane material industry.