Termoplastiese elastomere (TPE), soms na verwys as termoplastiese rubbers (TPR), is 'n klas kopolimere of fisiese mengsels van polimere - tipies 'n plastiek en 'n rubber - wat die eienskappe van termoplaste en elastomere kombineer. Hierdie unieke kombinasie laat toe dat TPE's soos termoplastiek verwerk word (deur middel van ekstrusie, spuitgiet, blaasvorming, ens.) terwyl die elastisiteit en buigsaamheid van rubbers behou word. Anders as tradisionele gevulkaniseerde rubbers, TPE's kan verskeie kere gesmelt en herverwerk word sonder aansienlike verlies aan werkverrigting, maak hulle meer omgewingsvriendelik en koste-effektief. As die vraag na liggewig, buigsaam, en herwinbare materiale groei oor nywerhede soos die motor, elektries, konstruksie, en verbruikersgoedere, TPE's het al hoe meer gewild geword, dryf die ontwikkeling van gespesialiseerde masterbatch- en ekstrusietegnologieë aangepas by hul unieke verwerkingsvereistes.
Meesterbatch, as 'n sleutelmateriaal vir kleur en funksionele modifikasie van TPE's, speel 'n deurslaggewende rol in die verbetering van die werkverrigting en die uitbreiding van die toepassingsomvang van TPE-produkte. Die verwerking van TPE-meesterbatch vereis presiese beheer van vermenging, versprei, en temperatuur parameters, aangesien TPE's spesifieke viskositeit het, hitte weerstand, en elastisiteitskenmerke wat verskil van tradisionele plastiek. Dubbelskroef-ekstruders, met hul voortreflike meng- en verspreidingsvermoëns, presiese temperatuurbeheer, en aanpasbaarheid by uiteenlopende materiale, het die kernverwerkingstoerusting vir TPE-meesterbatch geword. Zhuoyue, 'n professionele vervaardiger van dubbelskroef-ekstruders, bied 'n volledige reeks gevorderde ekstrusie-oplossings wat spesifiek ontwerp is vir TPE-samestelling en masterbatch-verwerking, wat TPE/SBS/TPU/TPR/TPV en ander groot TPE-kategorieë dek, om aan die uiteenlopende behoeftes van vervaardigers in verskillende industrieë te voldoen.
1. Oorsig van termoplastiese elastomere (TPE): Kategorieë, Eienskappe en sleutelkenmerke
TPE's is 'n diverse familie van materiale, geklassifiseer in ses algemene kommersiële kategorieë gebaseer op hul chemiese samestelling en struktuur. Elke kategorie het unieke eienskappe, verwerking eienskappe, en toepassingsvelde, wat die vereistes vir meesterbatch-formulering en ekstrusietoerusting direk bepaal. Om die klassifikasie en eienskappe van TPE's te verstaan is die grondslag vir die optimalisering van masterbatch-verwerking en die keuse van geskikte dubbelskroef-ekstruders.
1.1 Ses algemene kommersiële kategorieë van TPE's
1.1.1 Styreenblokkopolimere (TPS, TPE-s).
TPS is die kategorie TPE's wat die meeste gebruik word, verantwoordelik vir 'n groot deel van die wêreldwye TPE-mark. Dit is saamgestel uit stireniese blokke (soos polistireen, PS) en elastomere blokke (soos polibutadieen, PB; poliisopreen, PI; of etileen-butileen, EB), verbind deur kovalente bindings. Die mees algemene tipes TPS sluit SBS in (Styrene-Butadienes-Stirene), SIS (Styreen-Isopreen-Stireen), SEBS (Styreen-etileen-butileen-stireen), en SEPS (Styreen-etileen-propileen-stireen).
Sleutel eienskappe van TPS sluit uitstekende buigsaamheid in, elastisiteit, en verwerkbaarheid. SEBS en SEPS, wat gehidrogeneerde weergawes van SBS en SIS is, het verbeterde hittebestandheid, weerbestandheid, en verouderingsweerstand, wat hulle geskik maak vir buitelug- en hoëtemperatuurtoepassings. TPS-materiaal word maklik gekleur en verander met meesterbatch, en hul verwerkingstemperatuur wissel van 150 ℃ tot 220 ℃, wat versoenbaar is met die meeste dubbelskroef-ekstruders. Algemene toepassings van TPS sluit in motorkomponente, drade en kabels, verbruikersgoedere, en mediese toestelle.
1.1.2 Termoplastiese poliolefien elastomere (TPO, TPE-o).
TPO is 'n fisiese mengsel van poliolefien (soos polipropileen, PP; of poliëtileen, PE) en elastomeer (soos etileen-propileen-dieen monomeer, EPDM). Dit kombineer die styfheid van poliolefiene met die elastisiteit van elastomere, en het uitstekende chemiese weerstand, weerbestandheid, en lae temperatuur buigsaamheid. TPO's is nie-giftig, reukloos, en herwinbaar, maak hulle ideaal vir toepassings wat omgewingsvriendelikheid vereis.
Die verwerkingstemperatuur van TPO wissel van 160 ℃ tot 230 ℃, en dit het goeie verenigbaarheid met verskeie meesterbatches (kleur meesterbatch, vlamvertragende meesterbatch, ens.). TPO's word wyd gebruik in motoronderdele buite (soos bufferbedekkings, fender voerings), boumateriaal (soos robbe, pakkings), en elektriese komponente. As gevolg van hul hoë poliolefieninhoud, TPO masterbatch-verwerking vereis ekstrueerders met goeie mengvermoë om eenvormige verspreiding van pigmente en bymiddels te verseker.
1.1.3 Termoplastiese Vulkanisate (BTW, TPE v).
TPV is 'n dinamies gevulkaniseerde mengsel van poliolefien (gewoonlik PP) en elastomeer (gewoonlik EPDM). Tydens verwerking, die elastomeerfase word in klein deeltjies gevulkaniseer en eenvormig in die poliolefienmatriks versprei, lei tot uitstekende elastisiteit, kompressie stel weerstand, en hittebestandheid. TPV's het beter meganiese eienskappe en dimensionele stabiliteit as tradisionele TPE's, en kan langtermyn blootstelling aan hoë temperatuur weerstaan (tot 150 ℃).
TPV-verwerking vereis presiese temperatuurbeheer en sterk skuifkrag om eenvormige vulkanisering en verspreiding te verseker. Die verwerkingstemperatuur wissel van 170 ℃ tot 240 ℃, en die materiaal het 'n hoë viskositeit tydens verwerking, wat hoë vereistes stel aan die wringkrag en slytasieweerstand van dubbelskroef-ekstruders. TPV's word wyd gebruik in motorseëls, slange, pakkings, en industriële komponente wat hoë werkverrigting en duursaamheid vereis.
1.1.4 Termoplastiese poliuretaan (TPU).
TPU is 'n blokkopolimeer wat uit harde segmente bestaan (diisosianaat en kettingverlenger) en sagte segmente (poliool). Dit het uitstekende elastisiteit, skuur weerstand, olie weerstand, en meganiese sterkte, en kan in hardheid van baie sag aangepas word (Kus A 30) tot baie hard (Kus D 85) deur die verhouding van harde en sagte segmente te verander.
TPU-verwerking is sensitief vir temperatuur en vog. Die verwerkingstemperatuur wissel van 180 ℃ tot 250 ℃, en die materiaal moet deeglik gedroog word voor verwerking (voginhoud ≤0.05%) om hidrolise en borrelvorming te vermy. TPU masterbatch processing requires extruders with precise temperature control and vacuum exhaust capabilities. TPU is widely used in wires and cables, automotive hoses, skoene, mediese kateters, en sporttoerusting.
1.1.5 Termoplastiese Copolyesters (TPC, TPE-E).
TPC is a block copolymer composed of polyester hard segments and polyether or polyester soft segments. Dit het uitstekende hittebestandheid, chemiese weerstand, en meganiese eienskappe, and can withstand high temperatures up to 150℃ for long periods. TPCs also have good flexibility and elasticity, making them suitable for high-performance applications.
The processing temperature of TPC ranges from 220℃ to 280℃, which is higher than other TPE categories. It has high viscosity during processing and requires extruders with high torque and precise temperature control. TPC masterbatch processing also requires special attention to the dispersion of pigments and additives to avoid affecting the material’s mechanical properties. TPCs are widely used in automotive components (such as air intake hoses, transmission seals), lugvaartonderdele, en industriële masjinerie.
1.1.6 Termoplastiese poliamiede (TPA, TPE-A).
TPA is a block copolymer composed of polyamide hard segments and polyether soft segments. It combines the high strength, slytasie weerstand, and chemical resistance of polyamides with the flexibility and elasticity of polyethers. TPA has excellent impact resistance and low temperature performance, and can be used in harsh environments.
The processing temperature of TPA ranges from 230℃ to 290℃, and it has high water absorption, requiring thorough drying before processing. TPA masterbatch processing requires extruders with high wear resistance (as gevolg van die hoë hardheid van poliamied) en presiese temperatuurbeheer om materiaaldegradasie te vermy. TPA word wyd gebruik in motorkomponente (soos ratte, laers), elektriese verbindings, en industriële slange.
1.2 Sleutel-eienskappe van TPE's wat Masterbatch-verwerking beïnvloed
TPE's het unieke eienskappe wat hulle van tradisionele plastiek onderskei, en hierdie eienskappe beïnvloed direk die formulering van meesterbatch en die keuse van ekstrusietoerusting. Die belangrikste eienskappe wat in ag geneem moet word by meesterbatch-verwerking is soos volg:
1.2.1 Elastisiteit en buigsaamheid.
TPE's het hoë elastisiteit en buigsaamheid, wat beteken dat die meesterbatch versoenbaar moet wees met die TPE-matriks om te verhoed dat die materiaal se elastiese werkverrigting verminder word. Die draer van die masterbatch moet goeie verenigbaarheid met die TPE hê, en die dispergeermiddel moet eenvormige verspreiding van pigmente verseker sonder om agglomerate te vorm wat streskonsentrasie kan veroorsaak en buigsaamheid kan verminder.
1.2.2 Hitteweerstand.
Verskillende TPE-kategorieë het verskillende hitteweerstand (verwerkingstemperatuur wissel van 150 ℃ tot 290 ℃). Masterbatch-pigmente en bymiddels moet hittebestandheid hê wat ooreenstem met die TPE-verwerkingstemperatuur om ontbinding te voorkom, verkleuring, of prestasie agteruitgang tydens ekstrusie. Byvoorbeeld, TPC en TPA benodig hoëtemperatuurbestande pigmente en hittestabiliseerders.
1.2.3 Viskositeit en verwerkbaarheid.
TPE's het verskillende viskositeite tydens verwerking (TPV en TPC het hoër viskositeit, terwyl TPS laer viskositeit het). Dit beïnvloed die skuifkrag en vervoervereistes van die dubbelskroef-ekstruder. Hoë-viskositeit TPE's benodig ekstrueerders met hoë wringkrag en sterk mengvermoë, terwyl lae-viskositeit TPE's presiese beheer van ekstrusiespoed vereis om materiaal oorloop te vermy.
1.2.4 Vogabsorpsie.
Sommige TPE's (soos TPU, TPA) hoë waterabsorpsie hê, wat borrels kan veroorsaak, hidrolise, en ander defekte in die masterbatch. Die grondstowwe (TPE, pigmente, bymiddels) moet deeglik gedroog word voor verwerking, en die ekstruder moet toegerus wees met 'n vakuum-uitlaattoestel om vog en vlugtige stowwe te verwyder.
1.2.5 Verenigbaarheid met bymiddels.
TPE's benodig dikwels funksionele bymiddels (soos antioksidante, UV stabiliseerders, smeermiddels) om hul prestasie te verbeter. Die meesterbatch moet geformuleer word om te verseker dat die bymiddels versoenbaar is met beide die pigmente en die TPE-matriks, vermy chemiese reaksies wat produkkwaliteit kan beïnvloed.
2. Masterbatch vir TPE's: Samestelling, Formulerings- en verwerkingsvereistes
Masterbatch for TPEs is a concentrated mixture of pigments/dyes, carriers, en bymiddels, designed to color TPEs and impart additional functions (soos vlamvertraging, antistaties, antibakteriese) while maintaining the material’s inherent elastic and processing properties. The formulation and processing of TPE masterbatch are more demanding than those for traditional plastics, due to the unique properties of TPEs. This section details the composition, formulation principles, and processing requirements of TPE masterbatch.
2.1 Core Composition of TPE Masterbatch
Like traditional masterbatch, TPE masterbatch consists of three basic components: pigments/dyes, carriers, en bymiddels. The selection and proportion of each component are tailored to the type of TPE and its application requirements.
2.1.1 Pigments/Dyes.
Pigments/dyes are the core components that impart color to TPEs, rekeningkunde vir 10%-70% van die meesterbatch samestelling (afhangende van die kleurintensiteit en TPE-tipe). Die sleutelvereistes vir pigmente/kleurstowwe in TPE-meesterbatch is:
- – Hitteweerstand: Moet die verwerkingstemperatuur van die teiken-TPE weerstaan (150℃-290 ℃) sonder ontbinding of verkleuring. Vir hoë-temperatuur TPE's (TPC, TPA), hoë-temperatuurbestande organiese pigmente of anorganiese pigmente word verkies.
- – Verenigbaarheid: Moet versoenbaar wees met die TPE-matriks om migrasie te vermy, bloei, of verminderde elastisiteit. Pigmente met soortgelyke polariteit as die TPE is meer versoenbaar (bv., polêre pigmente vir TPU, nie-polêre pigmente vir TPS).
- – Verspreidbaarheid: Moet maklik in die TPE-matriks versprei word om eenvormige kleur te verseker en kleurkolle te vermy, strepe, of verminderde meganiese eienskappe. Fynpartikelpigmente (20-40 gaas) met lae agglomerasie word verkies.
- – Omgewingsvriendelikheid: Moet aan globale omgewingsbeskermingstandaarde voldoen (soos REACH, RoHS) om giftige of skadelike stowwe te vermy (soos swaar metale) wat menslike gesondheid en die omgewing kan beïnvloed.
Algemene pigmente wat in TPE-meesterbatch gebruik word, sluit in: anorganiese pigmente (titaandioksied vir wit, koolstofswart vir swart, ysteroksied vir rooi/geel), en hoë-temperatuurbestande organiese pigmente (ftalosianien blou/groen, kinakridon rooi).
2.1.2 Draers.
Draers is die matriks van die meesterbatch, rekeningkunde vir 20%-80% van die samestelling, en speel 'n sleutelrol in die verspreiding van pigmente en hegting aan die TPE-matriks. Die draer moet uitstekende verenigbaarheid met beide die pigmente en die teiken TPE hê, aangesien swak verenigbaarheid tot pigmentmigrasie kan lei, ongelyke kleur, en verminderde TPE-werkverrigting. Die keuse van die draer is gebaseer op die tipe TPE:
- – Vir TPS (SBS, SEBS): Gebruik TPS of PP as die draer, wat goeie verenigbaarheid en verwerkingsvloeibaarheid het.
- – Vir TPO/TPE-o: Gebruik PP of PE as die draer, wat ooreenstem met die poliolefienkomponent van die TPO.
- – Vir TPV/TPE-v: Gebruik PP as die draer, wat versoenbaar is met die PP-matriks van die TPV.
- – Vir TPU: Gebruik TPU as die draer, verseker verenigbaarheid met die TPU-matriks en vermy hidrolise.
- – Vir TPC/TPE-E en TPA/TPE-A: Gebruik TPC of TPA as die draer, onderskeidelik, om by die hoë-temperatuur verwerkingsvereistes en verenigbaarheid te pas.
Die draer moet ook goeie verwerkingsvloeibaarheid hê, met 'n smeltpunt en verwerkingstemperatuur wat ooreenstem met of effens laer as die teiken-TPE, om eenvormige vermenging te verseker en TPE-afbraak te vermy.
2.1.3 Bymiddels.
Bymiddels is hulpkomponente wat bygevoeg word om die verwerkingsprestasie te verbeter, verspreibaarheid, en funksionele prestasie van TPE-meesterbatch, rekeningkunde vir 1%-10% van die samestelling. Die tipe en dosis van bymiddels word bepaal deur die TPE tipe en toepassing vereistes:
- – Dispergeermiddels: Die belangrikste toevoeging vir TPE-meesterbatch, gebruik om pigment oppervlakspanning te verminder, agglomerasie te voorkom, en verseker uniforme verspreiding in die TPE-matriks. Algemene dispergeermiddels sluit poliëtileenwas in, polipropileen was, steariensuur, en maleïenanhidried geënte wasse. Vir hoë-viskositeit TPE's (BTW, TPC), hoë-doeltreffende dispergeermiddels met sterk verenigbaarheid word verkies.
- – Versoenbaar maakers: Word gebruik om verenigbaarheid tussen pigmente en TPE's te verbeter, en tussen masterbatch en TPE-matriks. Byvoorbeeld, maleïenanhidried geënte PP word gebruik as 'n verenigbaarheidsmiddel vir TPO meesterbatch, en poliuretaanwas word vir TPU-meesterbatch gebruik.
- – Hitte stabiliseerders: Used to prevent pigment decomposition and TPE degradation during high-temperature processing. Common heat stabilizers include organic tin stabilizers (for TPU), hindered phenol antioxidants (for TPS, TPO), and phosphite antioxidants (for TPC, TPA).
- – UV Stabilizers and Antioxidants: Used to improve the weather resistance and aging resistance of colored TPE products, preventing color fading and performance degradation under sunlight and oxygen. For outdoor applications (such as automotive exterior parts), UV absorbers and hindered amine light stabilizers (HALS) are added.
- – Smeermiddels: Used to reduce friction between materials and extrusion equipment (skroef, vat, kop dood), verbeter verwerkingsvloeibaarheid, en vermy materiaal wat aan toerusting kleef. Algemene smeermiddels sluit steariensuur in, kalsiumstearaat, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (vir elektriese komponente), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, pigmente, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, buigsaamheid, en meganiese eienskappe. Byvoorbeeld, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. Byvoorbeeld, TPC masterbatch uses high-temperature resistant pigments (heat resistance ≥280℃) to avoid decomposition during processing.
2.2.3 Optimize Dispersibility.
The pigment content and dispersant dosage are adjusted to ensure uniform dispersion. High-concentration masterbatch (pigment content 50%-70%) requires more dispersants and better mixing capabilities, while low-concentration masterbatch (10%-30%) focuses on compatibility.
2.2.4 Minimize Impact on TPE Properties.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. Byvoorbeeld, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (soos swaar metale, phthalates) that could restrict market access.
2.3 Processing Requirements of TPE Masterbatch
TPE masterbatch processing is mainly carried out using twin-screw extrusion technology, which requires strict control of raw material pretreatment, premixing, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Raw Material Pretreatment.
TPE's (especially TPU, TPA) hoë waterabsorpsie hê, so all raw materials (TPE carrier, pigmente, bymiddels) moet deeglik gedroog word voor verwerking. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 ure, TPS/TPO is dried at 80-100℃ for 3-5 ure, and pigments are dried at 60-80℃ for 2-4 ure. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Daarby, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 gaas) to improve dispersibility, and impurities (metal particles, stof) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Voorvermenging.
The dried raw materials (pigmente, carrier, bymiddels) word in 'n hoëspoedmenger volgens die formuleverhouding gemeng om 'n eenvormige voorlopige mengsel te vorm. Die voorafmengparameters word aangepas op grond van die TPE-tipe: mengspoed 800-1200 rpm, mengtyd 5-10 minute, mengtemperatuur 40-60 ℃. Vir hoë-konsentrasie meesterbatch of hoë-viskositeit TPE draers, die voormengtyd word verleng, en dispergeermiddels word eerste bygevoeg om die pigmente te bedek, verbeterde verspreibaarheid.
2.3.3 Ekstrusie Parameters Beheer.
Dubbelskroef-ekstrusie is die kernstap van TPE-meesterbatchverwerking, en die sleutel parameters (temperatuur, skroef spoed, ekstrusie druk, voeding spoed) moet presies beheer word om by die TPE-tipe te pas:
- – Temperatuurbeheer: Die loop is verdeel in 4-6 temperatuurbeheerafdelings (voeding afdeling, smeltafdeling, mengafdeling, homogeniserende afdeling, die kopgedeelte). Die temperatuur van elke afdeling word aangepas volgens die TPE-verwerkingstemperatuur. Byvoorbeeld, TPS meesterbatch: voeding afdeling 100-120 ℃, smeltgedeelte 160-180 ℃, menggedeelte 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Skroef spoed: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. High-viscosity TPEs (BTW, TPC) require higher screw speed (500-800 rpm) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 rpm) to avoid material overflow.
- – Ekstrusie druk: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. Vir hoë-viskositeit TPE's, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (particle size 2-5mm), screened (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, elektries, konstruksie, verbruikersgoedere, and other industries, and different application fields have different requirements for TPE masterbatch performance (kleur, verspreibaarheid, functionality) and production efficiency. Zhuoyue’s full series of twin-screw extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) are specially optimized for TPE masterbatch processing, providing targeted solutions for different TPE categories and application fields. Below is a detailed introduction to the main application fields of TPE masterbatch and the matching Zhuoyue extruder series.
3.1 Motorbedryf: The Largest Application Field of TPE Masterbatch
Die motorbedryf is die grootste verbruiker van TPE's, verantwoordelik vir meer as 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, buigsaam, and recyclable properties, and TPE masterbatch plays a key role in coloring and functional modification of these components. The main automotive applications of TPE masterbatch include:
3.1.1 Automotive Seals and Gaskets.
TPE's (mainly TPV, TPO) are used to produce automotive door seals, venster seëls, hood seals, en pakkings, which require good elasticity, weerbestandheid, en lae temperatuur buigsaamheid. The masterbatch for these components requires uniform coloring, good weather resistance (UV weerstand, aging resistance), and compatibility with TPV/TPO matrices.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has high torque and wear resistance, suitable for TPV masterbatch processing (hoë viskositeit, high shear force required); die HTE-reeks integreer hoë werkverrigting en kostedoeltreffendheid, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPE's (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, deurpanele, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (nie-giftig, reukloos). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPE's (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, hitte weerstand, en meganiese sterkte. The masterbatch requires high-temperature resistance, olie weerstand, and uniform dispersibility to avoid affecting the hose’s performance.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, presiese temperatuurbeheer, and high wear resistance, suitable for TPC/TPA masterbatch processing (hoë temperatuur, hoë viskositeit); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, deursigtigheid, impak weerstand). The masterbatch is formulated according to specific requirements, and the matching extruders are selected based on TPE type and production scale.
3.2 Electrical and Electronic Industry: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, koppelaars, en ander komponente, requiring functional masterbatch (antistaties, vlamvertrager, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPE's (mainly TPU, TPS, TPO) are used as insulation and sheath materials for wires and cables (power cables, ignition wires, headphone wires, connector plugs), which require good electrical insulation, vlamvertraging, en skuurweerstand. The masterbatch requires flame retardancy (meeting UL94 V-0 standaard), antistatiese eienskappe, and uniform coloring.
Matching Extruders: HTS PLUS series, HTE reeks, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPE's (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, impak weerstand, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Matching Extruders: HTS PLUS series and HTS SUPER series. The HTS PLUS series has good compatibility with TPU/TPA, ensuring uniform dispersion; the HTS SUPER series has precise temperature control, avoiding TPA degradation during processing.
3.3 Konstruksie- en vervoerbedryf: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, uitsettingsvoege, subway mats, en ander komponente, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPE's (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV weerstand, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has good weather-resistant additive mixing capabilities, suitable for TPV masterbatch processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, en slytasieweerstand. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPE's (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, skuur weerstand, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Matching Extruders: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, speelgoed, and other household items, which require non-toxic, reukloos, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Matching Extruders: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Mediese Toestelle.
TPE's (mainly TPU, TPS) are used to produce medical catheters, spuite, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 standaard), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, presiese temperatuurbeheer, avoiding material pollution; the HTS PLUS series has good compatibility with medical grade TPEs, ensuring product sterility and biocompatibility.
3.4.4 Other Industrial Applications.
TPEs are also used to produce drain pipes, industrial gaskets, and mechanical components, which require good chemical resistance, slytasie weerstand, en meganiese sterkte. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (hoë viskositeit, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, met 'n redelike skroefspoed, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, carriers, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Daarby, the screws adopt a modular design, which can freely combine different screw elements (oordra, vermenging, skeer) according to the TPE type. Byvoorbeeld, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Precise Temperature Control, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, met 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, surface hardness ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 times that of ordinary extruders; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, volatile substances, and air in the material, ensuring the density and quality of the masterbatch. The vacuum degree is adjustable (0.06-0.09MPa), adapting to different moisture content requirements.
4.1.5 High Production Efficiency and Energy Saving.
Zhuoyue’s extruders adopt high-torque gearboxes and optimized screw structures, with strong conveying capacity and high production efficiency. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. Byvoorbeeld, HTS SUPER series production capacity reaches 1000-3000kg/h, suitable for large-scale mass production; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, en voorspellende instandhouding, intelligente produksiebestuur te realiseer.
4.1.7 Wye aanpasbaarheid.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (kleur meesterbatch, vlamvertragende meesterbatch, antistatiese meesterbatch), with pigment content ranging from 10% aan 70%. They can also be matched with auxiliary equipment (high-speed mixers, droërs, koelers, granuleerders) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, produksie skaal, and application requirements.
4.2.1 HTS BASIC-reeks: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, automatic temperature control, en voeding, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 HTS PLUS Series: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (BTW, TPU, high-concentration TPE masterbatch, vlamvertragende meesterbatch). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (hoë viskositeit, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (vlamvertragers, antistatic agents). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, mediese toestelle).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
The HTS SUPER series is Zhuoyue’s highest-end extruder series, representing the advanced level of China’s twin-screw extruders, ontwerp vir hoë-end, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, en voorspellende instandhouding. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 ZTE Series: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, lae energieverbruik, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% in vergelyking met gewone ekstrueerders. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, due to the unique properties of TPEs (temperature sensitivity, moisture absorption, hoë viskositeit), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Probleem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Voorvermenging: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Toerusting: Worn screw mixing elements; blocked die head.
Oplossings: (1) Optimize raw materials: Select fine-particle pigments (20-40 gaas), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 minute. (3) Adjust extrusion parameters: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Maintain equipment: Replace worn screw elements; clean die head regularly.
5.2 Probleem 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, darkening), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (meer as 3 minute) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Oplossings: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Probleem 3: Hoë slytasie van skroef en vat
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Causes: (1) Raw materials: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion parameters: High screw speed, excessive shear force; high extrusion pressure. (3) Toerusting: Screw/barrel material has poor wear resistance.
Oplossings: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Probleem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Voorvermenging: Air mixed into the mixture during premixing.
Oplossings: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Probleem 5: Poor Processing Fluidity, Toerustingblokkering
Manifestation: Difficult material conveying and extrusion; onstabiele ekstrusiedruk; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); hoë pigment inhoud (meer as 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Toerusting: Worn conveying elements; blocked die head.
Oplossings: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, en toepassingsvelde, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Geval 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), hitte weerstand (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Oplossing: Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Eerstens, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) weerstaan effektief slytasie wat veroorsaak word deur hoë-hardheid pigmente, verlenging van die dienslewe met meer as 3 keer in vergelyking met die kliënt se oorspronklike toerusting. Tweedens, die loop is toegerus met 'n dubbellaag baadjie + forced cooling structure, met 6 independent temperature control sections, bereiking van 'n temperatuurbeheer akkuraatheid van ±1 ℃. Die temperatuur van die menggedeelte word stabiel by 240-260 ℃ beheer, en die homogeniseringsgedeelte by 230-250 ℃, wat streng ooreenstem met die TPC-verwerkingstemperatuurreeks om materiaalafbraak en pigmentverkleuring te vermy. Derde, die toerusting is toegerus met 'n hoë-doeltreffendheid vakuum uitlaat toestel (vakuum graad verstelbaar tot 0.09MPa), wat effektief vog en vlugtige stowwe in die TPC-grondstowwe en masterbatch verwyder, die borrelprobleem wat deur vogabsorpsie veroorsaak word, heeltemal op te los. Daarby, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: Na 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 maande, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.
6.1 Geval 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), hitte weerstand (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Oplossing:
Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Eerstens, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) weerstaan effektief slytasie wat veroorsaak word deur hoë-hardheid pigmente, verlenging van die dienslewe met meer as 3 keer in vergelyking met die kliënt se oorspronklike toerusting. Tweedens, die loop is toegerus met 'n dubbellaag baadjie + forced cooling structure, met 6 independent temperature control sections, bereiking van 'n temperatuurbeheer akkuraatheid van ±1 ℃. Die temperatuur van die menggedeelte word stabiel by 240-260 ℃ beheer, en die homogeniseringsgedeelte by 230-250 ℃, wat streng ooreenstem met die TPC-verwerkingstemperatuurreeks om materiaalafbraak en pigmentverkleuring te vermy. Derde, die toerusting is toegerus met 'n hoë-doeltreffendheid vakuum uitlaat toestel (vakuum graad verstelbaar tot 0.09MPa), wat effektief vog en vlugtige stowwe in die TPC-grondstowwe en masterbatch verwyder, die borrelprobleem wat deur vogabsorpsie veroorsaak word, heeltemal op te los. Daarby, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
Na 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 maande, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.