An antibacterial type PET bottle body material modification and pressing structure optimization system

Abstract

The application relates to the technical field of PET bottle body processing, in particular to an antibacterial PET bottle body material modification and pressing structure optimization system, which comprises a material modification unit, a structure forming unit, a pressing performance test unit, an intelligent regulation and control unit and a data storage and analysis unit; the material modification unit adopts a sectional screw extrusion and precise antibacterial agent feeding, realizes uniform mixing of PET, nano-silver and zinc oxide composite antibacterial agent, and guarantees the densification of a melt through vacuum exhaust; the structure forming unit forms a high-performance pressing structure through a pressing core with a stress dispersion groove and precise cooling; the test unit completes pressing mechanical and fatigue performance detection; the intelligent regulation and control unit plans parameters of all units, and the data storage and analysis unit realizes whole-process data recording and process optimization. The technical scheme has high integration degree, automatic and precise, and is suitable for food and daily chemical PET bottle body production.

Description

Technical Field

[0001] This invention relates to the field of PET bottle processing technology, specifically to a system for modifying antibacterial PET bottle materials and optimizing their pressing structure. Background Technology

[0002] PET bottles are widely used in food, daily chemical and other packaging fields due to their advantages of being lightweight, transparent and easy to form. The market has increasingly higher requirements for their antibacterial properties and the reliability of their pressing structure. However, the existing PET bottle production technologies have many defects and are difficult to meet the high-quality requirements.

[0003] In the material modification process, screw extrusion is mostly a single-stage structure, resulting in uneven mixing of PET resin and antibacterial agent. Furthermore, the antibacterial agent is not accurately metered, which easily leads to ratio deviations. At the same time, bubbles are easily generated during the melting process, resulting in unstable antibacterial effect and decreased mechanical properties of the modified material. During structural molding, the bottle pressing structure core design is simple and lacks a stress dispersion structure. After molding, the pressing part is prone to permanent deformation. In addition, the mold cooling water channel is unevenly distributed and the temperature control accuracy is low, making the bottle prone to warping and affecting the molding quality.

[0004] Pressing performance tests are mostly single-index tests, lacking fatigue tests that match actual usage scenarios, and the test data cannot be fed back to the production process in real time; each production unit is independent of each other, there is no unified intelligent control system, process parameter adjustments rely on manual experience, the coordination between material modification and structural forming is poor, and there is a lack of full-process data storage and analysis capabilities, production parameters are not traceable, and it is difficult to achieve process optimization. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this invention provides a system for modifying antibacterial PET bottle materials and optimizing the pressing structure.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the present invention provides the following technical solution: An antibacterial PET bottle material modification and pressing structure optimization system of the present invention includes a material modification unit, a structure forming unit, and a pressing performance testing unit; the material modification unit includes a screw extruder, an antibacterial agent metering and feeding device, a melt mixing chamber, and a vacuum exhaust device; the screw extruder includes a feeding section and a melt mixing section; the antibacterial agent metering and feeding device is connected to the feed inlet of the melt section of the screw extruder via a variable frequency screw feeder; the vacuum exhaust device is connected to the top of the melt mixing chamber via a pipe. The structure forming unit includes an injection molding machine, a bottle mold, and a cooling circulation system. The bottle mold includes a cavity and a core, with the core embedded in the cavity. The cooling circulation system includes cooling water channels and a temperature controller, with the cooling water channels evenly distributed inside the cavity. The pressing performance testing unit includes a servo press, a pressing structure core, a displacement sensor, a pressure sensor, and a fatigue testing module. The pressing structure core is mounted on the press head of the servo press. The displacement sensor is embedded in the top of the press head, and the pressure sensor is embedded in the bottom of the pressing structure core.

[0009] Preferably, the feeding end and the melting and mixing section are connected via a feed pipe, which is equipped with an electric valve. A horizontal screw extruder is rotatably mounted inside the feeding end, and a vertical screw extruder is rotatably mounted inside the melting and mixing section. A drive motor is installed at one end of the feeding end and at the top of the melting and mixing section, and the two drive motors are respectively connected to the horizontal screw extruder and the vertical screw extruder via couplings.

[0010] More preferably, the bottom of the melting and mixing section has a conical structure, and a discharge pipe is provided at the bottom of the bottom of the melting and mixing section, and an electromagnetic discharge valve is configured on the discharge pipe.

[0011] Preferably, the melting and mixing section is provided with a heating chamber, the heating chamber is provided with a heating tube, a temperature controller is fixedly installed on the outer wall of the melting and mixing section, the temperature controller is electrically connected to the heating tube, the melting and mixing section has a built-in temperature sensor, and the temperature sensor is electrically connected to the temperature controller.

[0012] Preferably, the antibacterial agent metering and feeding device includes a silo, a variable frequency screw feeder, and a level gauge. The inner wall of the silo is provided with an anti-stick coating, the variable frequency screw feeder is located inside the silo, and the level gauge is an ultrasonic level gauge.

[0013] More preferably, the pressing structure core is provided with a plurality of arc-shaped pressing protrusions, and the arc-shaped pressing protrusions are provided with stress dispersion grooves, the stress dispersion grooves being annular grooves.

[0014] Preferably, the antibacterial agent in the antibacterial agent metering and feeding device is a composite antibacterial agent of nano-silver and zinc oxide, and the mixing mass ratio of the antibacterial agent to PET resin is 0.5%-2.0%.

[0015] Preferably, the cooling water channel of the cooling circulation system is equipped with a circulating water pump, and the temperature controller acquires the mold temperature through a platinum resistance temperature sensor.

[0016] Further preferably, the system also includes an intelligent control unit and a data storage and analysis unit. The intelligent control unit includes a PLC controller, a touch screen display, a frequency converter driver, and a flow controller. The PLC controller is electrically connected to the data storage and analysis unit, the screw extruder, the antibacterial agent metering and feeding device, the injection molding machine, the cooling circulation system, the servo press, the displacement sensor, the pressure sensor, and the fatigue testing module. The touch screen display communicates bidirectionally with the PLC controller. The PLC controller is electrically connected to the screw extruder and the injection molding machine via the frequency converter driver. The flow controller is configured on the antibacterial agent feeding device and the cooling water channel. The data storage and analysis unit includes a data acquisition card, a solid-state drive, and analysis software.

[0017] (III) Beneficial Effects

[0018] Compared with the prior art, the present invention provides an antibacterial PET bottle material modification and pressing structure optimization system, which has the following beneficial effects:

[0019] The material modification unit of this technical solution uses a screw extruder and a variable frequency screw feeder for precise metering and feeding, ensuring uniform dispersion of nano-silver and zinc oxide composite antibacterial agents in PET resin and avoiding agglomeration; the melting and mixing chamber is equipped with a heating tube and a temperature controller to monitor and adjust the temperature in real time, ensuring that the materials are fully melted and mixed; the vacuum exhaust device effectively removes volatile impurities, improving the purity and antibacterial effect of the finished product.

[0020] The structural molding unit is equipped with an injection molding machine and a high-precision bottle mold. The core is embedded inside the cavity, and the cooling water channels are evenly distributed. Combined with a temperature controller and a circulating water pump, it can achieve rapid and uniform cooling and reduce product shrinkage and deformation. The arc-shaped pressing boss and stress dispersion groove design enhance the fatigue resistance of the pressing part and extend its service life.

[0021] The pressing performance testing unit integrates a servo press, displacement sensor, pressure sensor, and fatigue testing module, which can simulate actual usage conditions to conduct multi-dimensional mechanical evaluation of the bottle; the intelligent control unit integrates a PLC controller, touch screen, and data storage and analysis unit, supporting formula preset, automatic operation, data acquisition, and real-time feedback, greatly reducing human error and improving product quality consistency.

[0022] Each functional unit is independently configured and has standardized interfaces, which facilitates installation, debugging and troubleshooting; key components such as screw extrusion paddles and pressing structure cores are made of wear-resistant materials to extend their service life; the anti-stick coating and electromagnetic unloading valve design reduce material residue and facilitate cleaning and maintenance.

[0023] In summary, this technical solution, through a series of innovative designs, achieves efficient dispersion of antibacterial agents, optimized pressing structure, integrated molding and cooling, and intelligent control throughout the entire process. This not only significantly improves the antibacterial properties and mechanical strength of PET bottles but also substantially increases production efficiency and product yield, demonstrating broad application prospects and significant technological advantages. It is particularly suitable for the high-performance antibacterial packaging material needs in the food and beverage, and pharmaceutical packaging industries. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the material modification unit structure of the present invention;

[0025] Figure 2 This is a schematic diagram of the cross-sectional structure of the material modification unit of the present invention;

[0026] Figure 3 This is a schematic diagram of the structural forming unit of the present invention;

[0027] Figure 4 This is a schematic diagram of the pressing performance testing unit structure of the present invention;

[0028] Figure 5 This is a schematic diagram of the connection architecture between the PLC controller and various electrical components of the present invention;

[0029] In the diagram: 1. Feeding section; 2. Melting and mixing section; 3. Hopper; 4. Vacuum exhaust device; 5. Feed pipe; 6. Temperature sensor; 7. Electric valve; 8. Temperature controller; 9. Variable frequency screw feeder; 10. Level gauge; 11. Discharge pipe; 12. Electromagnetic discharge valve; 13. Heating element; 14. Horizontal screw extruder; 15. Vertical screw extruder; 16. Drive motor; 17. Injection molding machine; 18. Bottle mold; 19. Cooling water channel; 20. Circulating water pump; 21. Servo press; 22. Pressing structure core; 23. Arc-shaped pressing boss; 24. Displacement sensor. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Please see Figure 1-5This invention discloses an antibacterial PET bottle material modification and pressing structure optimization system, comprising a material modification unit, a structure forming unit, and a pressing performance testing unit. The material modification unit includes a screw extruder, an antibacterial agent metering and feeding device, a melt mixing chamber, and a vacuum exhaust device 4. The screw extruder includes a feeding section 1 and a melt mixing section 2. The antibacterial agent metering and feeding device is connected to the melt section inlet of the screw extruder via a variable frequency screw feeder 9. The vacuum exhaust device 4 is connected to the top of the melt mixing chamber via a pipe. The structure forming unit includes an injection molding machine 17 and a bottle... The bottle body mold 18 includes a cavity and a core, with the core embedded in the cavity. The cooling circulation system includes cooling channels 19 and a temperature controller, with the cooling channels 19 evenly distributed inside the cavity. The pressing performance testing unit includes a servo press 21, a pressing structure core 22, a displacement sensor 24, a pressure sensor, and a fatigue testing module. The pressing structure core 22 is mounted on the press head of the servo press 21. The displacement sensor 24 is embedded in the top of the press head, and the pressure sensor is embedded in the bottom of the pressing structure core 22.

[0032] The material modification unit of this technical solution achieves precise proportioning and efficient melt mixing of PET resin and nano-silver / zinc oxide composite antibacterial agent through the synergy of a screw extruder and an antibacterial agent metering and feeding device. A vacuum exhaust device 4 ensures the density of the modified melt. The structural molding unit utilizes an injection molding machine 17 and a bottle mold 18 with a dedicated core to mold the modified PET melt into a bottle with an optimized pressing structure. A cooling circulation system precisely controls the temperature to ensure molding accuracy. The pressing performance testing unit uses a servo press 21, a pressing structure core 22, and high-precision sensors to test the mechanical properties and fatigue life of the bottle's pressing structure, obtaining accurate performance data. The intelligent control unit, with a PLC controller at its core, coordinates the adjustment of parameters in each unit and optimizes the modification and molding processes in real time based on test data. The data storage and analysis unit records all process parameters and performance data and generates optimization suggestions through analysis software, enabling continuous process improvement. The coordinated operation of each unit addresses the pain points of insufficient antibacterial properties in traditional PET bottles, easy deformation of the pressing structure, and poor synergy between materials and structural processes, achieving simultaneous improvement in both antibacterial and pressing performance.

[0033] The material modification unit serves as the preparation carrier for antibacterial PET melt. PET resin is fed into the feed port of the screw extruder feeding section 1 and transported to the melt mixing section 2 via the guide pipe 5. The antibacterial agent metering and feeding device accurately feeds the antibacterial agent into the melt mixing section 2 through the frequency conversion screw feeder 9, and mixes it thoroughly with the molten PET resin. The heating structure of the melt mixing chamber maintains the optimal mixing temperature of the melt. The vacuum exhaust device 4 removes bubbles and volatiles generated during the mixing process. The modified PET melt is transported to the structural molding unit via the discharge pipe 11, providing a homogeneous, antibacterial, and dense raw material base for bottle molding.

[0034] The feeding end is equipped with a horizontal screw extruder 14, and the melt mixing section 2 is equipped with a vertical screw extruder 15, both driven by an independent drive motor 16. The horizontal screw realizes the quantitative delivery of PET resin, and the vertical screw increases the shear mixing area between the melt and the antibacterial agent, making the antibacterial agent more evenly dispersed in the PET matrix. The feeding section 1 and the melt mixing section 2 are connected by five guide pipes with electric valves 7. The electric valves 7 can precisely control the feeding speed and timing to avoid raw material accumulation or interruption, and adapt to the modification requirements of different ratios.

[0035] The bottom of the melt mixing section 2 has a conical structure, which allows the molten material to converge towards the discharge pipe 11 under the action of gravity and screw shear force, with no material residue, ensuring the uniformity of each discharge; the electromagnetic discharge valve 12 on the discharge pipe 11 is precisely controlled by the PLC controller to realize the quantitative and intermittent delivery of the modified melt, which is precisely matched with the injection rhythm of the injection molding machine 17 to avoid melt waste.

[0036] The melting and mixing section 2 is equipped with a heating chamber and a heating tube 13. The external wall temperature controller 8 and the built-in temperature sensor 6 form a closed-loop control. The temperature sensor 6 collects the melt temperature in real time and feeds it back to the temperature controller 8. When the temperature deviates from the set value, the temperature controller 8 automatically adjusts the power of the heating tube 13 to ensure that the temperature in the melting and mixing section 2 is stable, avoiding excessive temperature that could lead to degradation of PET resin or failure of antibacterial agent, and excessive temperature that could lead to uneven mixing.

[0037] The inner wall of the hopper 3 of the antibacterial agent metering and feeding device is coated with an anti-stick coating, preferably polytetrafluoroethylene coating, to prevent antibacterial agent powder from sticking to the hopper 3 and ensure smooth feeding; the variable frequency screw feeder 9 can adjust the speed through frequency conversion to achieve precise control of the amount of antibacterial agent fed; the ultrasonic level gauge 10 monitors the remaining amount of antibacterial agent in the hopper 3 in real time, and triggers a replenishment reminder when the level is lower than the preset value to avoid feeding interruption; the antibacterial agent is a nano silver / zinc oxide composite antibacterial agent, which is mixed with PET resin at a mass ratio of 0.5%-2.0%, taking into account both the antibacterial effect and the mechanical properties of PET material. The composite antibacterial agent can produce a synergistic antibacterial effect, and the antibacterial rate is much higher than that of a single antibacterial agent.

[0038] The vacuum exhaust device 4 is usually a vacuum suction pump, which is connected to the top of the melt mixing chamber through a pipe. When working, it draws the chamber to a slightly negative pressure state, effectively removing air bubbles and low molecular weight volatiles generated during the mixing of PET resin melt and antibacterial agent. This avoids defects such as pores and shrinkage marks in the bottle after the modified melt is formed, and improves the density and mechanical properties of the bottle.

[0039] Employing a segmented screw extrusion and independent drive design, it breaks through the limitations of uneven mixing in traditional single-screw extruders, achieving precise control over raw material delivery and melt mixing. A closed-loop temperature control and vacuum exhaust structure ensures the quality stability of the modified melt, preventing antibacterial agent failure and material degradation. A precise antibacterial agent dosing structure achieves the optimal ratio of composite antibacterial agent to PET resin, ensuring antibacterial performance without affecting the moldability and mechanical properties of the PET material, laying the material foundation for subsequent pressing structure molding.

[0040] The structural molding unit is the execution unit that transforms modified PET melt into a bottle with an optimized pressing structure. The injection molding machine 17 injects the modified PET melt delivered by the material modification unit into the cavity of the bottle mold 18 under high pressure. The core and the cavity cooperate to form the overall outline of the bottle. The pressing structure core 22 forms the pressing part of the bottle. The cooling circulation system precisely controls the temperature of the mold through the cooling water channel 19 inside the cavity, so that the molten modified PET melt cools and solidifies quickly and evenly. After demolding, a PET bottle with antibacterial properties is obtained. Its pressing structure and core are precisely matched, and it has good mechanical properties.

[0041] The arc-shaped protrusion and annular stress dispersion groove of the pressing structure core 22: The arc-shaped pressing protrusion 23 on the pressing structure core 22 is adapted to the force arc of human pressing operation, so that the force is evenly distributed during pressing and avoids local stress concentration; the annular stress dispersion groove can disperse the circumferential stress generated during pressing, prevent the pressing part of the bottle from cracking or permanent deformation due to repeated pressing, and improve the fatigue life of the pressing structure; the mechanical properties of this core structure and the modified PET material work together to achieve a dual improvement of structural optimization and material modification.

[0042] The cooling circulation system features a precise temperature control structure: cooling water channels 19 are evenly distributed inside the cavity to ensure consistent cooling rates in all parts of the mold, preventing warping and deformation of the bottle due to uneven cooling; the circulating water pump 20 on the cooling water channel 19 has its speed controlled by a flow controller to regulate the cooling water flow rate; the temperature controller collects the mold temperature in real time through a platinum resistance temperature sensor 6, and when the mold temperature deviates from the set value, the PLC controller adjusts the cooling water flow rate through the flow controller to achieve precise control of the mold temperature, ensuring the molding accuracy and dimensional stability of the bottle.

[0043] The design of the special pressing structure core 22 is specifically designed to solve the problems of stress concentration and easy deformation of traditional bottle pressing structures. In conjunction with antibacterial modified PET material, it achieves a fundamental improvement in pressing performance. The evenly distributed cooling water channels 19 and the closed-loop temperature-controlled cooling circulation system ensure rapid and uniform cooling of the bottle, avoid molding defects, improve the bottle molding qualification rate, and meet the needs of large-scale production.

[0044] The pressing performance testing unit is the core unit for testing the mechanical properties and fatigue life of the bottle's pressing structure. The pressing head of the servo press 21 is equipped with the pressing structure core 22 to simulate the actual pressing operation of the human body. The displacement sensor 24 is embedded in the top of the pressing head to collect pressing stroke data in real time, and the pressure sensor is embedded in the bottom of the pressing structure core 22 to collect pressing force data in real time. The fatigue test module controls the servo press 21 to perform cyclic pressing according to preset parameters to simulate the long-term use scenario of the bottle and test the fatigue life and elastic recovery rate of the pressing structure. The test data is transmitted to the intelligent control unit and the data storage and analysis unit in real time to provide data support for process optimization.

[0045] The pressure head is equipped with a pressing structure core 22 to ensure that the test scenario is highly consistent with the actual use scenario, and the test data is more reliable. The high-precision displacement sensor 24 and the pressure sensor realize the synchronous and accurate acquisition of pressing force and displacement data, which can intuitively reflect the mechanical performance of the pressing structure. The fatigue test module simulates long-term use conditions to detect the durability of the pressing structure, avoid early failure in actual use of the product, and ensure product quality.

[0046] The intelligent control unit, with a PLC controller at its core, serves as the control center of the entire system. It is electrically connected to the material modification unit, structural molding unit, pressing performance testing unit, and data storage and analysis unit, enabling coordinated operation among these units. The touch screen is the human-machine interface, supporting the preset of process parameters, real-time status display, and the issuance of operation commands. The frequency converter adjusts the speed of each drive motor 16 of the screw extruder and the injection molding machine 17, achieving precise control of feeding, mixing, and injection speeds. Flow controllers are configured on the antibacterial agent metering and feeding device and the cooling water channel 19, respectively, to precisely control the amount of antibacterial agent fed and the cooling water flow rate. Based on feedback data from the pressing performance testing unit, the PLC controller automatically adjusts the modification and molding process parameters, achieving closed-loop optimization of the process.

[0047] The centralized control of the PLC controller enables the linkage and coordination of each unit, breaking the limitations of the traditional independent operation of each process and realizing the process coordination of material modification and structural forming; the frequency converter and flow controller enable precise and stepless adjustment of process parameters, adapting to the production of PET bottles with different specifications and performance requirements; the visual operation of the touch screen reduces the difficulty of manual operation, allowing equipment operation to be completed without professional technicians, thus improving production efficiency.

[0048] The data storage and analysis unit is the data storage and analysis center of the entire system. The data acquisition card collects process parameters of each unit in real time, such as antibacterial agent dosage, melting temperature, injection pressure, cooling temperature, etc., as well as performance test data, such as pressing pressure, pressing stroke, fatigue life, etc., and stores the data to solid-state drives. The analysis software processes and analyzes the stored data, generates visual charts such as pressing pressure-displacement curves and fatigue life curves, and automatically generates process optimization suggestions based on the correlation between performance data and process parameters, providing data support for subsequent production and process improvement.

[0049] The data acquisition card enables real-time and synchronous acquisition of data throughout the entire process, ensuring data integrity and accuracy; the large-capacity solid-state drive enables long-term data storage, supports full traceability of the production process, and facilitates the investigation of quality issues; the analysis software uses data mining to perform correlation analysis between process parameters and product performance, automatically generates optimization suggestions, transforms experience-based production into data-driven production, shortens the R&D cycle, and improves product qualification rate.

[0050] This technical solution is based on mature polymer material modification, injection molding, electromechanical control, and data processing technologies. The core components are all industrially standardized products, with a simple and rational structural design. The connection and control logic of each unit is clear, and there are no technical barriers. Those skilled in the relevant technical field can directly implement it based on the contents of the instruction manual. Specifically, this is reflected in the following aspects:

[0051] Structure and processing components: The screw extruder and injection molding machine 17 are standardized equipment in the field of plastic processing and can be directly selected according to production needs; the bottle mold 18 and the pressing structure core 22 can be formed by CNC machining of H13 hot work die steel; the cooling water channel 19 can be processed by drilling and polishing to ensure uniform distribution; the horizontal / vertical screw extrusion paddle 15 is a standardized screw component and the pitch and shearing gap can be customized according to mixing needs.

[0052] Metering and feeding components: The variable frequency screw feeder 9, ultrasonic level gauge 10, and electromagnetic unloading valve 12 are all standardized products in the field of industrial automation, and the metering accuracy can meet the requirements of antibacterial agent ratio of 0.5%-2.0%; the anti-stick coating of the hopper 3 can be achieved by spraying polytetrafluoroethylene, which is a mature process with controllable cost.

[0053] Temperature control and cooling components: Heating tube 13, temperature controller 8, temperature sensor 6, and circulating water pump 20 are all standardized products in the field of temperature control, which can realize closed-loop temperature control between the melting and mixing section 2 and the mold, with a temperature control accuracy of ±1℃; the pipes and joints of the cooling water channel 19 are general-purpose plumbing components, which are convenient to purchase and easy to assemble.

[0054] Testing and sensing components: The servo press 21, displacement sensor 24, pressure sensor, and fatigue testing module are all standardized equipment in the field of mechanical performance testing, and their accuracy can meet the requirements of pressing performance testing; the press head can be CNC machined according to the shape of the pressing structure core 22 to ensure precise fit with the test part.

[0055] Control and data components: PLC controllers, such as Siemens S7-1200 / 1500 series, touch screens, frequency converters, and flow controllers are all mainstream products in the field of industrial automation, with strong interface compatibility and low programming and debugging difficulty; data acquisition cards, solid-state drives, and analysis software can be secondary developed based on MATLAB / Excel, and are all mature products in the field of computer data processing, which can be directly selected and adapted.

[0056] Materials and antibacterial agents: PET resin is a general-purpose plastic and is easy to purchase; nano silver / zinc oxide composite antibacterial agent is a commercial product, with particle sizes of 50-100nm that can be purchased directly, and a mass ratio of 0.5%-2.0% can be accurately achieved through a metering and feeding device without changing the conventional processing technology of PET resin.

[0057] Installation process

[0058] Step 1, Material Modification Unit Assembly: Connect the feeding section 1 and the melting and mixing section 2 through the feed pipe 5, and install the electric valve 7; install the horizontal / vertical screw extruder 15 and drive motor 16 in the feeding section 1 and the melting and mixing section 2 respectively, and connect them through the coupling; install the heating tube 13, temperature sensor 6 and temperature controller 8 in the melting and mixing section 2, and connect the circuit; connect the frequency conversion screw feeder 9 of the antibacterial agent metering and feeding device to the feed inlet of the melting and mixing section 2, and install the hopper 3 and ultrasonic level gauge 10; connect the vacuum exhaust device 4 to the top of the melting and mixing chamber through the pipe, and install the discharge pipe 11 and electromagnetic discharge valve 12.

[0059] The second step is the assembly of the structural molding unit: the pressing structural core 22 is embedded into the cavity of the bottle mold 18 to complete the mold assembly; cooling water channels 19 are processed inside the mold cavity, and the circulating water pump 20, temperature controller and platinum resistance temperature sensor 6 of the cooling circulation system are connected; the mold is installed into the mold closing mechanism of the injection molding machine 17, and the feed port of the injection molding machine 17 is connected to the discharge pipe 11 of the material modification unit.

[0060] The third step is to assemble the test unit: fix the servo press 21 on the test platform, install the pressure head that is compatible with the pressing structure core 22, and embed the displacement sensor 24 on the top of the pressure head; assemble the pressing structure core 22 into the pressure head, and embed the pressure sensor at its bottom; connect the servo press 21 to the fatigue test module to complete the circuit and signal line connection.

[0061] Step 4, control and data unit assembly: Electrically connect the PLC controller to the actuators, sensors, and test modules of each unit; connect the touch screen, frequency converter, flow controller, and PLC controller; connect the data acquisition card to each sensor and test module; connect the solid-state drive and analysis software; and complete the wiring of the entire system.

[0062] Detailed workflow:

[0063] Step 1: Parameter Preset

[0064] Operators select the production mode via the touch screen and enter the parameter setting interface. Based on the bottle specifications and performance requirements, they preset material modification parameters, such as PET resin feeding speed, the mass ratio of antibacterial agent to PET resin (0.5%-2.0%), the temperature of the melt mixing section 2, the vacuum degree of the vacuum exhaust device 4, the discharge speed, and structural molding parameters, such as injection pressure / speed / holding time of the injection molding machine 17, mold cooling temperature, cooling water flow rate, and performance testing parameters, such as pressing stroke, pressing pressure threshold, number of pressing cycles, and fatigue life qualification standard.

[0065] Check the status of each unit: ensure that there is enough PET resin and antibacterial agent in the hopper 3 of the material modification unit, and that the vacuum exhaust device 4 and heating tube 13 are operating normally; ensure that the mold of the structure forming unit is installed in place, and that the cooling circulation system has water and no leaks; ensure that the sensor and servo press 21 of the pressing performance testing unit are calibrated; ensure that the solid-state drive of the data storage and analysis unit has sufficient storage space and that the analysis software is operating normally.

[0066] The system power is turned on, the PLC controller initializes each unit, sends preset parameters to each actuator, and each unit is reset to its initial state, waiting for production instructions.

[0067] Step 2: Material Modification

[0068] Raw material conveying: The PLC controller controls the start of the drive motor 16 of the screw extruder feeding section 1, the horizontal screw extrusion paddle 14 rotates, and quantitatively conveys PET resin to the feed pipe 5. The electric valve 7 opens at the preset speed, and the PET resin enters the melt mixing section 2.

[0069] Antibacterial agent feeding: The PLC controller controls the variable frequency screw feeder 9 of the antibacterial agent metering and feeding device to start at the preset speed, accurately feeding the nano silver / zinc oxide composite antibacterial agent in the silo 3 into the melting and mixing section 2, and mixing it synchronously with the PET resin. The ultrasonic level gauge 10 monitors the remaining amount of antibacterial agent in the silo 3 in real time, and triggers a replenishment reminder when it is lower than the preset value.

[0070] Melting and mixing: The drive motor 16 of the melting and mixing section 2 is started, and the vertical screw extruder 15 rotates at high speed to shear and mix the PET resin and antibacterial agent; the temperature controller 8 adjusts the power of the heating tube 13 according to the feedback data of the temperature sensor 6 to maintain the temperature stability in the melting and mixing section 2, ensuring that the PET resin is completely melted and the antibacterial agent does not become ineffective; the vacuum exhaust device 4 is started to remove air bubbles and volatiles in the melting and mixing chamber to ensure the density of the melt;

[0071] Melt delivery: The modified antibacterial PET melt is pushed by the vertical screw extruder 15 and extruded into the conical structure at the bottom of the melt mixing section 2. It can be extruded through the pipeline to the injection molding machine 17. The PLC controller controls the electromagnetic unloading valve 12 to open intermittently according to the injection rhythm of the injection molding machine 17, and quantitatively delivers the modified melt to the barrel of the injection molding machine 17 to complete the material modification.

[0072] Step 3: Structural Forming

[0073] Melt injection: After receiving the modified melt, the injection molding machine 17 heats the barrel to maintain the melt temperature. The PLC controller controls the injection molding machine 17 to inject the modified PET melt into the cavity of the bottle mold 18 at a preset injection pressure and speed. The melt fills the space between the cavity and the core to form the overall outline of the bottle.

[0074] Holding pressure and shaping: After the melt is filled, the injection molding machine 17 holds pressure according to the preset holding pressure and holding time to make up for the volume loss caused by the cooling and shrinkage of the melt and avoid defects such as shrinkage marks and dents in the bottle;

[0075] Precise cooling: The cooling circulation system starts synchronously, and the circulating water pump 20 delivers cooling water to the cooling water channel 19 inside the cavity to cool the mold; the temperature controller collects the mold temperature in real time through the platinum resistance temperature sensor 6. If the temperature deviates from the preset value, the PLC controller adjusts the cooling water flow rate through the flow controller to ensure that the cooling rate of each part of the mold is consistent.

[0076] Demolding and part removal: After the bottle body cools and solidifies, the PLC controller controls the mold closing mechanism of the injection molding machine 17 to open the mold. The ejection mechanism of the injection molding machine 17, which is conventionally configured, ejects the bottle body from the mold. The operator or robot arm then transfers the bottle body to the pressing performance test unit to complete the structural forming.

[0077] Step 4: Performance Testing

[0078] The molded antibacterial PET bottle is placed on the testing platform, and the pressing part of the bottle is precisely aligned with the pressing structure core 22 of the servo press 21 to complete the positioning.

[0079] Mechanical performance test: The PLC controller controls the servo press 21 to start, and the press head presses the bottle body pressing structure downward at a preset speed. The displacement sensor 24 collects the pressing stroke data in real time, and the pressure sensor collects the pressing force data in real time. The data is transmitted to the data storage and analysis unit through the data acquisition card to generate the pressing force-displacement curve and analyze the mechanical properties of the pressing structure such as elastic recovery rate and pressing stiffness.

[0080] Fatigue life test: After the mechanical performance test is qualified, the fatigue test module is started and the servo press 21 is controlled to perform cyclic pressing according to preset parameters to simulate the long-term use scenario of the bottle until the preset number of cyclic pressing is reached or the pressing structure fails. The fatigue life of the pressing structure is recorded.

[0081] Result determination: The PLC controller compares the test data with the preset pass standard to automatically determine whether the bottle pressing performance is qualified. Qualified bottles are transferred to the next process, while unqualified bottles are marked and recycled for reprocessing. The test data is transmitted to the intelligent control unit and data storage and analysis unit in real time.

[0082] Step 5: Intelligent Optimization

[0083] Data reception and analysis: The analysis software of the data storage and analysis unit receives performance test data and process parameters throughout the entire process, processes and analyzes the data, explores the correlation between process parameters and product performance, and generates visual charts such as pressure-displacement curves and fatigue life curves.

[0084] Process parameter optimization: If test data shows that the bottle's pressing performance does not meet the standards, such as low elastic recovery rate and short fatigue life, the analysis software will automatically generate process optimization suggestions based on the data correlation, such as adjusting the antibacterial agent ratio, increasing the melt mixing temperature, optimizing the injection pressure, and adjusting the cooling temperature.

[0085] Automatic parameter adjustment: The PLC controller receives optimization suggestions from the analysis software and automatically adjusts the process parameters of each unit, such as adjusting the feeding speed of the antibacterial agent metering and feeding device, the melt mixing speed of the screw extruder, and the injection pressure of the injection molding machine 17 through the frequency converter driver, and adjusting the cooling water flow rate through the flow controller.

[0086] Secondary trial production and verification: Repeat steps 2-4 according to the optimized process parameters to conduct secondary trial production and performance testing until the antibacterial performance and pressing performance of the bottle reach the preset standards and the optimal process parameters are locked.

[0087] Step 6: Data Storage

[0088] The solid-state drive of the data storage and analysis unit stores the process parameters of the entire process in real time, such as the amount of antibacterial agent added, melting temperature, injection pressure, cooling temperature, etc., equipment operating parameters, motor speed, water pump flow, servo press 21 operating parameters, performance test data, pressing pressure, pressing stroke, fatigue life, elastic recovery rate, etc., and product qualification status.

[0089] The analysis software categorizes the stored data by production batch and supports queries based on batch, time, parameters, and other conditions, facilitating full traceability of the production process. If quality issues arise later, the cause can be quickly identified.

[0090] Operators can export data to Excel, PDF, and other formats via a touch screen or external terminal for use in process documentation and quality inspection report generation.

[0091] Step 7: Mass Production

[0092] Once the optimal process parameters are locked, the PLC controller saves them as a standard production process plan. The operator initiates the batch production command, and the system runs automatically according to the standard process plan. All units work together to achieve large-scale and standardized production of antibacterial PET bottles.

[0093] During the production process, various sensors collect data in real time, and the PLC controller monitors the process parameters in real time. If parameter drift occurs, it will automatically make fine adjustments to ensure the consistency of product performance.

[0094] Samples of bottles produced in batches are tested at a preset frequency. The test data are compared with the test data of the standard process plan to verify the stability of the process. If deviations occur, the process parameters are optimized in a timely manner.

[0095] Step 8: Shutdown and Maintenance

[0096] After mass production is completed, the operator issues a stop command through the touch screen, and the PLC controller controls each unit to stop running in sequence and shuts off the system power.

[0097] Clean the material modification unit: clean the residual materials in the feeding section 1 and the melting and mixing section 2, clean the hopper 3 and the variable frequency screw feeder 9, check the filter element of the vacuum exhaust device 4 and replace it in time.

[0098] Maintenance of the structural forming unit: Clean the residual melt inside the bottle mold 18, perform rust prevention treatment on the mold, check the sealing performance of the cooling water channel 19, and replace the aged sealing gasket.

[0099] Calibrate the test unit: Recalibrate the displacement sensor 24 and pressure sensor, check the wear of the pressing structure core 22 of the servo press 21, and replace it in time;

[0100] Perform maintenance on the control and data units: back up production data on the solid-state drive, clear the cache of the analysis software, check the connections of circuits and signal lines, and ensure the equipment operates normally next time.

[0101] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A system for modifying and optimizing the pressing structure of antibacterial PET bottle material, characterized in that, The system includes a material modification unit, a structural forming unit, and a pressing performance testing unit. The material modification unit includes a screw extruder, an antibacterial agent metering and feeding device, a melt mixing chamber, and a vacuum exhaust device (4). The screw extruder includes a feeding section (1) and a melt mixing section (2). The antibacterial agent metering and feeding device is connected to the feed inlet of the melt section of the screw extruder via a variable frequency screw feeder (9). The vacuum exhaust device (4) is connected to the top of the melt mixing chamber via a pipe. The structural forming unit includes an injection molding machine (17), a bottle mold (18), and a cooling circulation system. The tool (18) includes a cavity and a core, the core being embedded in the cavity. The cooling circulation system includes a cooling water channel (19) and a temperature controller, the cooling water channel (19) being evenly distributed inside the cavity. The pressing performance testing unit includes a servo press (21), a pressing structure core (22), a displacement sensor (24), a pressure sensor, and a fatigue testing module. The pressing structure core (22) is mounted on the press head of the servo press (21). The displacement sensor (24) is embedded in the top of the press head, and the pressure sensor is embedded in the bottom of the pressing structure core (22).

2. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The feeding end is connected to the melting and mixing section (2) through the guide pipe (5). An electric valve (7) is provided on the guide pipe (5). A horizontal screw extruder (14) is rotatably installed in the feeding end. A vertical screw extruder (15) is rotatably installed in the melting and mixing section (2). A drive motor (16) is provided at one end of the feeding end and at the top of the melting and mixing section (2). The two drive motors (16) are connected to the horizontal screw extruder (14) and the vertical screw extruder (15) respectively through a coupling.

3. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The bottom of the melting and mixing section (2) is a conical structure, and a discharge pipe (11) is provided at the bottom of the bottom of the melting and mixing section (2). An electromagnetic discharge valve (12) is configured on the discharge pipe (11).

4. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The melting and mixing section (2) is provided with a heating chamber, and a heating tube (13) is provided in the heating chamber. A temperature controller (8) is fixedly installed on the outer wall of the melting and mixing section (2). The temperature controller (8) is electrically connected to the heating tube (13). The melting and mixing section (2) has a built-in temperature sensor (6), and the temperature sensor (6) is electrically connected to the temperature controller (8).

5. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The antibacterial agent metering and feeding device includes a silo (3), a variable frequency screw feeder (9) and a level gauge (10). The inner wall of the silo (3) is provided with an anti-stick coating. The variable frequency screw feeder (9) is located inside the silo (3). The level gauge (10) is an ultrasonic level gauge (10).

6. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The pressing structure core (22) is provided with a number of arc-shaped pressing bosses (23), and the arc-shaped pressing bosses (23) are provided with stress dispersion grooves, which are annular grooves.

7. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The antibacterial agent in the metering and feeding device is a composite antibacterial agent of nano-silver and zinc oxide, and the mixing mass ratio of the antibacterial agent to PET resin is 0.5%-2.0%.

8. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, The cooling water channel (19) of the cooling circulation system is equipped with a circulating water pump (20), and the temperature controller collects the mold temperature through a platinum resistance temperature sensor (6).

9. The antibacterial PET bottle material modification and pressing structure optimization system according to claim 1, characterized in that, It also includes an intelligent control unit and a data storage and analysis unit. The intelligent control unit includes a PLC controller, a touch screen, a frequency converter, and a flow controller. The PLC controller is electrically connected to the data storage and analysis unit, the screw extruder, the antibacterial agent metering and feeding device, the injection molding machine (17), the cooling circulation system, the servo press (21), the displacement sensor (24), the pressure sensor, and the fatigue testing module. The touch screen communicates bidirectionally with the PLC controller. The PLC controller is electrically connected to the screw extruder and the injection molding machine (17) through the frequency converter. The flow controller is configured on the antibacterial agent feeding device and the cooling water channel (19). The data storage and analysis unit includes a data acquisition card, a solid-state drive, and analysis software.

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