ABA Three-Layer Co-Extrusion Casting Tester
Solving Three Core Challenges in PET Material R&D Against the backdrop of escalating performance requirements for PET films in optical display, new energy, and high-end packaging, a leading materials enterprise faced a triple dilemma: difficulty in functional compounding, challenges in cost control, and obstacles in mass production conversion. After introducing the ABA Three-Layer Co-Extrusion Casting Tester fromPOTOP Co., Ltd., the company achieved technological breakthroughs in just 3 months.
The specific outcomes of the case are as follows:
Breakthrough in Functional Compounding: Unlocking "Customizable Properties" of PET Films for High-End Scenarios：
Core Pain Point: The enterprise needed to develop highly transparent, antistatic PET films for foldable screens, requiring a light transmittance of ≥92%, surface resistance of 10⁸–10¹⁰ Ω, and folding resistance at a bending radius of 0.01 mm.
Equipment Solution: Leveraging the ABA three-layer structure, nano-antistatic masterbatch was added to the A-side skin layers, while the B-layer used modified PET substrate to ensure mechanical performance. A precision extruder with an L/D ratio of 35:1 enabled uniform plasticization of raw materials, and temperature control accuracy of ±1℃ prevented thermal degradation of the material.
Implementation Results: The film achieved a light transmittance of 93.2% and a haze of 0.6%. After 400,000 cycles of 180° folding, the brightness attenuation was less than 4%, far exceeding industry averages. It successfully passed the supply chain certification of a renowned smartphone manufacturer, filling the domestic technical gap in PET films for flexible displays.
II. Cost Optimization: Efficient Reuse of Recycled Materials, Maintaining Performance While Reducing Costs
Core Pain Point: PET raw material costs accounted for over 68% of production costs, directly impacting profit margins. However, adding recycled materials often led to reduced mechanical properties and increased appearance defects in films.
Equipment Solution: Through flexible adjustment of the layer thickness ratio from 1:2 to 1:5, 30% recycled material was precisely blended in the B-layer. A high-vacuum venting system controlled the moisture content of PET chips below 30 ppm, avoiding hydrolytic bubbles.
Implementation Results: Raw material costs were reduced by 18%, while the film’s tensile strength remained above 200 MPa and elongation at break exceeded 200%. The first-pass yield of finished products increased from 88% to 95.7%, saving over 2 million yuan in annual raw material costs.
III. R&D-to-Production Transition: Shortening Cycle by 40%, Accelerating Industrialization
Core Pain Point: Traditional equipment produced R&D data disconnected from industrial production lines, making it difficult to replicate process parameters during pilot testing. This resulted in R&D cycles of 8–12 months, missing market windows.
Equipment Solution: A modular co-extrusion die and traction winding system were adopted to simulate the entire industrial production process. An online thickness measurement system captured thickness variations in the range of 0.5–2 mm in real time, and data was synchronized to the MES system to form a process database.
Implementation Results: The R&D cycle for PET films for photovoltaic backsheets was shortened from 10 months to 5.8 months, with a process parameter reuse rate of 92%. The performance deviation between pilot samples and mass-produced products was less than 3%, enabling the enterprise to quickly seize market opportunities driven by the increasing penetration of double-glass modules.
Case Summary: Empowering PET Material Industry Upgrading through Equipment Innovation
The ABA Three-Layer Co-Extrusion Casting Tester from Guangzhou POTOP perfectly addresses core pain points in PET material R&D through structural optimization, precise control, and industrial-grade simulation capabilities. Whether in the technological breakthrough of high-end functional films, cost optimization under green production, or the efficient transition from R&D to mass production, the equipment demonstrates strong scenario adaptability. Currently, it is widely used in university laboratories and R&D centers of materials enterprises, driving the continuous improvement of the domesticization rate of optical-grade PET films in China and becoming a core equipment support for PET material innovation.
