The following are specific case study results:
I. Functional Breakthrough: Unlocking the "Customized Attributes" of PET Film to Adapt to High-End Scenarios
- - Core Pain Point: The need to develop a high-transmittance, antistatic PET film for foldable screens, requiring a light transmittance ≥92%, surface resistivity of 10⁸-10¹⁰Ω, and anti-folding performance at a bending radius of 0.01mm.
- - Equipment Solution: Utilizing an ABA three-layer structure design, the A layer incorporates nano-antistatic masterbatch, while the B layer uses a modified PET substrate to ensure mechanical properties. A precision extruder with a 35:1 aspect ratio is used to achieve uniform plasticization of the raw materials, and temperature control accuracy is ±1℃ to prevent thermal degradation of the material.
- - Implementation Results: The film achieves a light transmittance of 93.2% and a haze of 0.6%. After 400,000 180° folds, the brightness decay is <4%, far exceeding the industry average. It has successfully passed the supply chain certification of a well-known mobile phone manufacturer, filling the technological gap in domestic PET film for flexible displays.
II. Cost Optimization Implementation: Efficient Reuse of Recycled Materials, Reducing Costs While Maintaining Performance
- - Core Pain Point: PET raw material costs account for over 68% of production costs, directly impacting product profit margins. However, adding recycled materials easily leads to a decline in film mechanical properties and an increase in appearance defects.
- - Equipment Solution: By flexibly adjusting the layer thickness ratio from 1:2 to 1:5, 30% recycled material is precisely proportioned in the B layer. Combined with a high-vacuum degassing system, the moisture content of PET chips is controlled below 30ppm, avoiding the generation of hydrolytic bubbles.
- - Implementation Results: Raw material costs are reduced by 18%, while film tensile strength remains above 200MPa, elongation at break is >200%, and the first-pass yield of finished products increases from 88% to 95.7%, resulting in annual raw material cost savings exceeding 2 million yuan.
III. R&D and Mass Production Integration: Shortening the Cycle by 40%, Accelerating Technology Industrialization
- - Core Pain Point: The disconnect between traditional equipment R&D data and industrial production lines, and the difficulty in replicating process parameters during the pilot-scale stage, leads to R&D cycles of 8-12 months, missing market opportunities.
- - Equipment Solution: The system adopts a modular co-extrusion die and traction winding system to simulate the entire industrial mass production process. The online thickness measurement system captures thickness changes in the range of 0.5-2mm in real time, and the data is synchronized to the MES system to form a process database.
- - Implementation Results: The R&D cycle for PET film used in photovoltaic backsheets has been shortened from 10 months to 5.8 months, the reuse rate of process parameters has reached 92%, and the performance deviation between pilot samples and mass-produced products is less than 3%, helping companies to quickly seize the market demand brought about by the increased penetration rate of double-glass modules.
Case Summary: Empowering the Upgrading of the PET Material Industry with Equipment Innovation
POTOP ABA three-layer co-extrusion casting test machine, through structural optimization, precise control, and industrial-grade simulation capabilities, perfectly solves the core pain points in PET material R&D. Whether it's technological breakthroughs in high-end functional films, cost optimization under green production, or efficient integration of R&D and mass production, this equipment demonstrates strong adaptability to various scenarios. Currently, this equipment is widely used in university laboratories and material enterprise R&D centers, continuously promoting the localization rate of optical-grade PET films in China and becoming a core equipment support for PET material innovation.
