Ultra-thin films, composite films, metal films – the wide applicability of film slitting machines

As the core equipment of material processing, the design of film slitting machine needs to take into account material characteristics, process requirements and production efficiency. The following analyzes how it can efficiently adapt to different materials such as ultra-thin films, composite films, and metal films from three aspects: technical principles, equipment structures, and application cases.

1. Technical principle: three core challenges of flexible material slitting

1. Material thickness differences

• Ultra-thin films (e.g., BOPET, thickness 3-12 μm) are prone to wrinkles and breakage, and need to be controlled by low tension;

• Metal films (e.g. aluminum foil, thickness 10-50μm) are prone to scratches and require high-rigidity blades;

• Composite film (e.g. PET/AL/PE, thickness 50-200μm) needs to be cut in layers without sticking.

2. Physical property differences

• Ultra-thin film: high elasticity, low tensile strength;

• Metallic film: high hardness, low ductility;

• Composite membranes: The multi-layer structure results in different shrinkage rates for each layer.

3. Differences in process requirements

• Ultra-thin film: slitting accuracy ± 0.1mm;

• Metal film: anti-static and anti-oxidation treatment is required;

• Composite film: multiple layers need to be cut simultaneously and the edges must be aligned.

2. Equipment structure: modular design to achieve "one machine for multiple purposes"

3. Application case: slitting solutions for different materials

1. Ultra-thin film (e.g. lithium battery separator)

• Challenge: 5 μm thickness, low tensile strength, easy breakage.

•Solution:

◦ Air bearing slitting knife set is used to reduce cutting resistance;

◦ The tension fluctuation is controlled within ±0.5N to avoid wrinkles;

◦ The winding speed ≤50m/min to prevent the deformation of the coil.

• Effect: 30% increase in slitting efficiency and ≤0.2% scrap rate.

2. Composite film (e.g. food packaging film)

• Challenge: PET/AL/PE three-layer structure, each layer shrinkage is different.

•Solution:

◦ Using synchronous layering blades, each layer is driven independently;

◦ Tension segmentation control to compensate for the difference in shrinkage of each layer;

◦ Layer isolation paper is used during winding to prevent adhesion.

• Effect: Edge alignment accuracy ±0.1mm, customer complaint rate reduced by 50%.

3. Metal film (e.g. capacitor aluminum foil)

• Challenge: 12μm thickness, high hardness, easy to scratch.

•Solution:

◦ The blade material is made of high-speed steel + titanium plating to improve wear resistance;

◦ The winding shaft is covered with soft rubber to reduce contact damage;

◦ Add a dust removal module before anti-oxidation coating to reduce particle pollution.

• Results: Scratch rate ≤ 0.1%, customer return rate reduced by 40%.

Fourth, the comparison of technical parameters: the slitting efficiency of different materials

5. Summary

The wide applicability of the film slitting machine is due to its modular design and precise control technology:

• Tension control: adapt to the tensile strength of different materials;

• Slitting knife set: to meet the cutting needs of different materials;

• Winding system: prevent coil deformation and interlayer adhesion;

• Dust removal/anti-static: reduce the risk of particle contamination and oxidation.

Recommended Solution:

• If you need high-precision slitting of ultra-thin film, air bearing slitting machine is recommended;

• If you need to cut metal film with high rigidity, titanium-plated high-speed steel blades are recommended;

• If you need to cut the composite film in layers, it is recommended to synchronize the layering knife set.

Through the precise matching of technical parameters, the film slitting machine can realize the efficient slitting of ultra-thin film, composite film and metal film to meet the production needs of different industries.