Termoplastiske elastomerer (TPE), nogle gange omtalt som termoplastiske gummier (TPR), er en klasse af copolymerer eller fysiske blandinger af polymerer - typisk en plastik og en gummi - der kombinerer egenskaberne af termoplast og elastomerer. Denne unikke kombination gør det muligt at behandle TPE'er som termoplast (via ekstrudering, sprøjtestøbning, blæsestøbning, osv.) samtidig med at gummiens elasticitet og fleksibilitet bevares. I modsætning til traditionelle vulkaniserede gummier, TPE'er kan smeltes og oparbejdes flere gange uden væsentligt tab af ydeevne, gør dem mere miljøvenlige og omkostningseffektive. Som efterspørgslen efter letvægts, fleksibel, og genanvendelige materialer vokser på tværs af industrier som bilindustrien, elektriske, konstruktion, og forbrugsgoder, TPE'er er blevet mere og mere populære, driver udviklingen af specialiserede masterbatch- og ekstruderingsteknologier skræddersyet til deres unikke behandlingskrav.
Masterbatch, som et nøglemateriale til farvning og funktionel modifikation af TPE'er, spiller en afgørende rolle i at forbedre ydeevnen og udvide anvendelsesområdet for TPE-produkter. Forarbejdningen af TPE masterbatch kræver præcis kontrol af blandingen, spredes, og temperaturparametre, da TPE'er har specifik viskositet, varmemodstand, og elasticitetsegenskaber, der adskiller sig fra traditionel plast. Ekstrudere med to skruer, med deres overlegne blande- og spredningsevner, præcis temperaturkontrol, og tilpasningsevne til forskellige materialer, er blevet det centrale behandlingsudstyr til TPE masterbatch. Zhuoyue, en professionel producent af dobbeltskrue ekstrudere, tilbyder et komplet udvalg af avancerede ekstruderingsløsninger specielt designet til TPE-kompoundering og masterbatch-behandling, dækkende TPE/SBS/TPU/TPR/TPV og andre større TPE-kategorier, at opfylde de forskellige behov hos producenter i forskellige brancher.
1. Oversigt over termoplastiske elastomerer (TPE): Kategorier, Egenskaber og nøglekarakteristika
TPE'er er en mangfoldig familie af materialer, klassificeret i seks generelle kommercielle kategorier baseret på deres kemiske sammensætning og struktur. Hver kategori har unikke egenskaber, behandlingsegenskaber, og ansøgningsfelter, som direkte bestemmer kravene til masterbatch-formulering og ekstruderingsudstyr. Forståelse af klassificeringen og egenskaberne af TPE'er er grundlaget for optimering af masterbatch-bearbejdning og valg af egnede dobbeltskrue-ekstrudere.
1.1 Seks generelle kommercielle kategorier af TPE'er
1.1.1 Styrenblokcopolymerer (TPS, TPE-s).
TPS er den mest udbredte kategori af TPE'er, tegner sig for en stor del af det globale TPE-marked. Den er sammensat af styrenblokke (såsom polystyren, PS) og elastomere blokke (såsom polybutadien, PB; polyisopren, PI; eller ethylen-butylen, EB), forbundet med kovalente bindinger. De mest almindelige typer af TPS omfatter SBS (Styrener-Butadiener-Styrener), SIS (Styren-Isopren-Styren), SEBS (Styren-ethylen-butylen-styren), og SEPS (Styren-ethylen-propylen-styren).
Nøgleegenskaber ved TPS omfatter fremragende fleksibilitet, elasticitet, og bearbejdelighed. SEBS og SEPS, som er hydrogenerede versioner af SBS og SIS, har forbedret varmebestandighed, vejrbestandighed, og aldringsmodstand, hvilket gør dem velegnede til udendørs- og højtemperaturapplikationer. TPS-materialer kan nemt farves og modificeres med masterbatch, og deres behandlingstemperatur varierer fra 150 ℃ til 220 ℃, som er kompatibel med de fleste dobbeltskrue ekstrudere. Almindelige anvendelser af TPS omfatter bilkomponenter, ledninger og kabler, forbrugsgoder, og medicinsk udstyr.
1.1.2 Termoplastiske polyolefinelastomerer (TPO, TPE-o).
TPO er en fysisk blanding af polyolefin (såsom polypropylen, PP; eller polyethylen, PE) og elastomer (såsom ethylen-propylen-dien-monomer, EPDM). Det kombinerer stivheden af polyolefiner med elasticiteten af elastomerer, og har fremragende kemikalieresistens, vejrbestandighed, og lav temperatur fleksibilitet. TPO'er er ikke-giftige, lugtfri, og genanvendelig, hvilket gør dem ideelle til applikationer, der kræver miljøvenlighed.
Behandlingstemperaturen for TPO varierer fra 160 ℃ til 230 ℃, og det har god kompatibilitet med forskellige masterbatches (farve masterbatch, flammehæmmende masterbatch, osv.). TPO'er er meget udbredt i automotive udvendige dele (såsom kofangerafdækninger, fender liners), byggematerialer (såsom sæler, pakninger), og elektriske komponenter. På grund af deres høje polyolefinindhold, TPO masterbatch-behandling kræver ekstrudere med gode blandeevner for at sikre ensartet spredning af pigmenter og additiver.
1.1.3 Termoplastiske vulkanisater (moms, TPE v).
TPV er en dynamisk vulkaniseret blanding af polyolefin (normalt PP) og elastomer (normalt EPDM). Under behandlingen, elastomerfasen vulkaniseres til små partikler og dispergeres ensartet i polyolefinmatrixen, hvilket resulterer i fremragende elasticitet, kompression sæt modstand, og varmebestandighed. TPV'er har bedre mekaniske egenskaber og dimensionsstabilitet end traditionelle TPE'er, og kan modstå langvarig eksponering ved høje temperaturer (op til 150 ℃).
TPV-behandling kræver præcis temperaturkontrol og stærk forskydningskraft for at sikre ensartet vulkanisering og spredning. Behandlingstemperaturen varierer fra 170 ℃ til 240 ℃, og materialet har høj viskositet under forarbejdning, which places high requirements on the torque and wear resistance of twin-screw extruders. TPVs are widely used in automotive seals, slanger, pakninger, and industrial components that require high performance and durability.
1.1.4 Termoplastisk polyurethaner (TPU).
TPU is a block copolymer composed of hard segments (diisocyanate and chain extender) and soft segments (polyol). It has excellent elasticity, slidstyrke, oliemodstand, and mechanical strength, and can be adjusted in hardness from very soft (Shore A 30) to very hard (Shore D 85) by changing the ratio of hard and soft segments.
TPU processing is sensitive to temperature and moisture. The processing temperature ranges from 180℃ to 250℃, and the material must be thoroughly dried before processing (moisture content ≤0.05%) to avoid hydrolysis and bubble formation. TPU masterbatch-behandling kræver ekstrudere med præcis temperaturkontrol og vakuumudstødningskapacitet. TPU er meget udbredt i ledninger og kabler, automobilslanger, fodtøj, medicinske katetre, og sportsudstyr.
1.1.5 Termoplastiske copolyestere (TPC, TPE-E).
TPC er en blokcopolymer sammensat af hårde polyestersegmenter og bløde polyether- eller polyestersegmenter. Den har fremragende varmebestandighed, kemisk resistens, og mekaniske egenskaber, og kan modstå høje temperaturer op til 150 ℃ i lange perioder. TPC'er har også god fleksibilitet og elasticitet, gør dem velegnede til højtydende applikationer.
Behandlingstemperaturen for TPC varierer fra 220 ℃ til 280 ℃, hvilket er højere end andre TPE-kategorier. Det har høj viskositet under forarbejdning og kræver ekstrudere med højt drejningsmoment og præcis temperaturkontrol. TPC masterbatch-behandling kræver også særlig opmærksomhed på spredningen af pigmenter og additiver for at undgå at påvirke materialets mekaniske egenskaber. TPC'er er meget udbredt i bilkomponenter (såsom luftindtagsslanger, transmissions tætninger), rumfartsdele, og industrimaskiner.
1.1.6 Termoplastiske polyamider (TPA, TPE-A).
TPA er en blokcopolymer sammensat af hårde polyamidsegmenter og bløde polyethersegmenter. Den kombinerer den høje styrke, slidstyrke, og kemisk resistens af polyamider med fleksibiliteten og elasticiteten af polyethere. TPA har fremragende slagfasthed og ydeevne ved lav temperatur, og kan bruges i barske miljøer.
Behandlingstemperaturen for TPA varierer fra 230 ℃ til 290 ℃, og den har høj vandabsorption, kræver grundig tørring før forarbejdning. TPA masterbatch-behandling kræver ekstrudere med høj slidstyrke (på grund af polyamids høje hårdhed) og præcis temperaturkontrol for at undgå materialenedbrydning. TPA er meget udbredt i bilkomponenter (såsom gear, lejer), elektriske stik, og industrislanger.
1.2 Nøgleegenskaber for TPE'er, der påvirker masterbatch-behandling
TPE'er har unikke egenskaber, der adskiller dem fra traditionel plast, og disse egenskaber påvirker direkte formuleringen af masterbatch og valget af ekstruderingsudstyr. De vigtigste egenskaber at overveje i masterbatch-behandling er som følger:
1.2.1 Elasticitet og fleksibilitet.
TPE'er har høj elasticitet og fleksibilitet, hvilket betyder, at masterbatchen skal være kompatibel med TPE-matricen for at undgå at reducere materialets elastiske ydeevne. Bæreren af masterbatchen skal have god kompatibilitet med TPE, og dispergeringsmidlet skal sikre ensartet spredning af pigmenter uden at danne agglomerater, der kan forårsage stresskoncentration og reducere fleksibiliteten.
1.2.2 Varmemodstand.
Forskellige TPE-kategorier har forskellig varmebestandighed (behandlingstemperaturen varierer fra 150 ℃ til 290 ℃). Masterbatch-pigmenter og additiver skal have varmebestandighed, der matcher TPE-behandlingstemperaturen for at undgå nedbrydning, misfarvning, eller ydeevneforringelse under ekstrudering. F.eks, TPC og TPA kræver højtemperaturbestandige pigmenter og varmestabilisatorer.
1.2.3 Viskositet og bearbejdelighed.
TPE'er har varierende viskositeter under forarbejdning (TPV og TPC har højere viskositet, mens TPS har lavere viskositet). Dette påvirker forskydningskraften og transportkravene for dobbeltsnekkeekstruderen. TPE'er med høj viskositet kræver ekstrudere med højt drejningsmoment og stærke blandeevner, mens TPE'er med lav viskositet kræver præcis kontrol af ekstruderingshastigheden for at undgå materialeoverløb.
1.2.4 Fugtabsorption.
Nogle TPE'er (såsom TPU, TPA) har høj vandoptagelse, som kan forårsage bobler, hydrolyse, og andre defekter i masterbatchen. Råvarerne (TPE, pigmenter, tilsætningsstoffer) skal tørres grundigt inden forarbejdning, og ekstruderen skal være udstyret med en vakuumudstødningsanordning for at fjerne fugt og flygtige stoffer.
1.2.5 Kompatibilitet med tilsætningsstoffer.
TPE'er kræver ofte funktionelle additiver (såsom antioxidanter, UV-stabilisatorer, smøremidler) at forbedre deres præstationer. Masterbatchen bør formuleres for at sikre, at tilsætningsstofferne er kompatible med både pigmenterne og TPE-matrixen, undgå kemiske reaktioner, der kan påvirke produktkvaliteten.
2. Masterbatch til TPE'er: Sammensætning, Formulerings- og forarbejdningskrav
Masterbatch for TPE'er er en koncentreret blanding af pigmenter/farvestoffer, transportører, og tilsætningsstoffer, designet til at farve TPE'er og give yderligere funktioner (såsom flammehæmning, antistatisk, antibakteriel) samtidig med at materialets iboende elastiske og forarbejdningsegenskaber bevares. Formuleringen og forarbejdningen af TPE masterbatch er mere krævende end for traditionel plast, på grund af TPE'ernes unikke egenskaber. Dette afsnit beskriver sammensætningen, formuleringsprincipper, og behandlingskrav for TPE masterbatch.
2.1 Kernesammensætning af TPE Masterbatch
Som traditionel masterbatch, TPE masterbatch består af tre grundlæggende komponenter: pigmenter/farvestoffer, transportører, og tilsætningsstoffer. Udvælgelsen og andelen af hver komponent er skræddersyet til typen af TPE og dens anvendelseskrav.
2.1.1 Pigmenter/farvestoffer.
Pigmenter/farvestoffer er de kernekomponenter, der giver farve til TPE'er, regnskab for 10%-70% af masterbatch-sammensætningen (afhængig af farveintensitet og TPE-type). De vigtigste krav til pigmenter/farvestoffer i TPE masterbatch er:
- – Varmemodstand: Skal modstå behandlingstemperaturen for mål-TPE (150℃-290 ℃) uden nedbrydning eller misfarvning. Til højtemperatur-TPE'er (TPC, TPA), Højtemperaturbestandige organiske pigmenter eller uorganiske pigmenter foretrækkes.
- – Kompatibilitet: Skal være kompatibel med TPE-matrixen for at undgå migrering, blomstrende, eller nedsat elasticitet. Pigmenter med lignende polaritet som TPE er mere kompatible (f.eks., polære pigmenter til TPU, ikke-polære pigmenter til TPS).
- – Spredningsevne: Skal let spredes i TPE-matrixen for at sikre ensartet farvning og undgå farvepletter, striber, eller nedsatte mekaniske egenskaber. Finpartikelpigmenter (20-40 mesh) med lav agglomeration foretrækkes.
- – Miljøvenlighed: Skal opfylde globale miljøbeskyttelsesstandarder (såsom REACH, RoHS) for at undgå giftige eller skadelige stoffer (såsom tungmetaller) som kan påvirke menneskers sundhed og miljøet.
Almindelige pigmenter brugt i TPE masterbatch inkluderer: uorganiske pigmenter (titaniumdioxid til hvid, kønsort til sort, jernoxid til rød/gul), og højtemperaturbestandige organiske pigmenter (phthalocyanin blå/grøn, quinacridon rød).
2.1.2 Transportører.
Bærere er masterbatchens matrix, regnskab for 20%-80% af sammensætningen, og spiller en nøglerolle i at sprede pigmenter og klæbe til TPE-matrixen. Bæreren skal have fremragende kompatibilitet med både pigmenterne og mål-TPE, da dårlig kompatibilitet kan føre til pigmentmigrering, ujævn farve, og reduceret TPE-ydelse. Valget af bæreren er baseret på typen af TPE:
- – Til TPS (SBS, SEBS): Brug TPS eller PP som bærer, som har god kompatibilitet og behandlingsfluiditet.
- – Til TPO/TPE-o: Brug PP eller PE som bærer, matcher polyolefinkomponenten i TPO.
- – Til TPV/TPE-v: Brug PP som bærer, som er kompatibel med TPV'ens PP-matrix.
- – Til TPU: Brug TPU som bærer, sikrer kompatibilitet med TPU-matrixen og undgår hydrolyse.
- – Til TPC/TPE-E og TPA/TPE-A: Brug TPC eller TPA som transportør, henholdsvis, for at matche højtemperaturbehandlingskravene og kompatibiliteten.
Bæreren bør også have god bearbejdningsfluiditet, med et smeltepunkt og forarbejdningstemperatur i overensstemmelse med eller lidt lavere end mål-TPE, for at sikre ensartet blanding og undgå TPE-nedbrydning.
2.1.3 Tilsætningsstoffer.
Additiver er hjælpekomponenter tilsat for at forbedre forarbejdningsydelsen, dispergerbarhed, og funktionel ydeevne af TPE masterbatch, regnskab for 1%-10% af sammensætningen. Typen og doseringen af additiver bestemmes af TPE-typen og anvendelseskravene:
- – Dispergeringsmidler: Det vigtigste tilsætningsstof til TPE masterbatch, bruges til at reducere pigmentoverfladespændingen, forhindre agglomeration, og sikre ensartet spredning i TPE-matricen. Almindelige dispergeringsmidler omfatter polyethylenvoks, polypropylen voks, stearinsyre, og maleinsyreanhydrid-podede voksarter. Til højviskositet TPE'er (moms, TPC), højeffektive dispergeringsmidler med stærk kompatibilitet foretrækkes.
- – Kompatibilisatorer: Bruges til at forbedre kompatibiliteten mellem pigmenter og TPE'er, og mellem masterbatch og TPE-matrix. F.eks, maleinsyreanhydrid podet PP bruges som kompatibilisator til TPO masterbatch, og polyurethanvoks bruges til TPU masterbatch.
- – Varmestabilisatorer: Anvendes til at forhindre pigmentnedbrydning og TPE-nedbrydning under højtemperaturbehandling. Almindelige varmestabilisatorer omfatter organiske tinstabilisatorer (til TPU), hæmmede phenol-antioxidanter (til TPS, TPO), og fosfitantioxidanter (til TPC, TPA).
- – UV-stabilisatorer og antioxidanter: Bruges til at forbedre vejrbestandigheden og ældningsbestandigheden af farvede TPE-produkter, forhindrer farvefading og ydeevneforringelse under sollys og ilt. Til udendørs applikationer (såsom udvendige dele til biler), UV-absorberende og hindrede aminlysstabilisatorer (HALS) tilføjes.
- – Smøremidler: Anvendes til at reducere friktionen mellem materialer og ekstruderingsudstyr (skrue, tønde, dø hovedet), forbedre forarbejdningsfluiditeten, og undgå at materiale klæber til udstyret. Almindelige smøremidler omfatter stearinsyre, calciumstearat, og silikoneolie. Til TPU og TPA, smøremidler med lav migration foretrækkes for at undgå at påvirke produktets ydeevne.
- – Funktionelle tilsætningsstoffer: Tilføjet for at give specielle funktioner til TPE'er, såsom flammehæmmere (til ledninger og kabler), antistatiske midler (til elektriske komponenter), og antibakterielle midler (til medicinsk udstyr og forbrugsvarer).
2.2 Formuleringsprincipper for TPE Masterbatch
Formuleringen af TPE masterbatch skal balancere farveeffekt, behandlingsydelse, og TPE iboende egenskaber. Nøgleprincipperne er som følger:
2.2.1 Kompatibilitet først.
Transportøren, pigmenter, og additiver skal være kompatible med mål-TPE for at undgå at reducere materialets elasticitet, fleksibilitet, og mekaniske egenskaber. F.eks, Brug af en ikke-polær bærer til polær TPU vil føre til dårlig kompatibilitet og pigmentmigrering.
2.2.2 Match varmemodstand.
Pigmenterne og tilsætningsstofferne skal have varmebestandighed, der svarer til TPE-behandlingstemperaturen. F.eks, TPC masterbatch bruger højtemperaturbestandige pigmenter (varmemodstand ≥280℃) for at undgå nedbrydning under forarbejdningen.
2.2.3 Optimer spredningsevnen.
Pigmentindholdet og dispergeringsmiddeldoseringen justeres for at sikre ensartet spredning. Højkoncentration masterbatch (pigmentindhold 50%-70%) kræver flere dispergeringsmidler og bedre blandeevner, mens lav koncentration masterbatch (10%-30%) fokuserer på kompatibilitet.
2.2.4 Minimer indvirkningen på TPE-egenskaber.
Masterbatchen bør ikke påvirke TPE'ens elasticitet væsentligt, kompressionssæt, eller slidstyrke. F.eks, for mange dispergeringsmidler eller smøremidler kan reducere TPE'ens mekaniske styrke.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (såsom tungmetaller, 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, forblanding, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Råstofforbehandling.
TPE'er (especially TPU, TPA) har høj vandoptagelse, so all raw materials (TPE carrier, pigmenter, tilsætningsstoffer) skal tørres grundigt inden forarbejdning. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 timer, TPS/TPO is dried at 80-100℃ for 3-5 timer, and pigments are dried at 60-80℃ for 2-4 timer. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Desuden, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 mesh) to improve dispersibility, and impurities (metal particles, støv) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Forblanding.
The dried raw materials (pigmenter, carrier, tilsætningsstoffer) are mixed in a high-speed mixer according to the formula ratio to form a uniform preliminary mixture. The premixing parameters are adjusted based on the TPE type: mixing speed 800-1200 rpm, blandingstid 5-10 minutter, mixing temperature 40-60℃. For high-concentration masterbatch or high-viscosity TPE carriers, the premixing time is extended, and dispersants are added first to coat the pigments, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (temperatur, skruehastighed, ekstruderingstryk, fodringshastighed) must be precisely controlled to match the TPE type:
- – Temperaturkontrol: Tønden er opdelt i 4-6 temperaturkontrolsektioner (fodringsafdeling, smelteafsnit, blandesektion, homogeniserende sektion, dysehovedsektion). Temperaturen i hver sektion justeres i henhold til TPE-behandlingstemperaturen. F.eks, TPS masterbatch: fodringssektion 100-120℃, smeltesektion 160-180 ℃, blandesektion 170-190℃, homogeniseringssektion 160-180 ℃, matricehovedsektion 150-170℃; TPC masterbatch: fodringssektion 150-170℃, smeltesektion 230-250 ℃, blandesektion 240-260 ℃, homogeniseringssektion 230-250 ℃, matricehovedsektion 220-240℃. Temperaturkontrolnøjagtigheden skal nå ±1 ℃ for at undgå TPE-nedbrydning og pigmentnedbrydning.
- – Skruehastighed: Skruens hastighed spænder fra 200-800 rpm, justeret baseret på TPE viskositet. TPE'er med høj viskositet (moms, TPC) kræver højere skruehastighed (500-800 rpm) at generere tilstrækkelig forskydningskraft til pigmentdispersion; TPE'er med lav viskositet (TPS) brug moderat hastighed (300-500 rpm) for at undgå materialeoverløb.
- – Ekstrusionstryk: Trykket varierer fra 5-12MPa, holdt stabil (udsving ≤±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. Til højviskositet TPE'er, 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, elektriske, konstruktion, forbrugsgoder, og andre industrier, and different application fields have different requirements for TPE masterbatch performance (farve, dispergerbarhed, 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 Automotive Industry: The Largest Application Field of TPE Masterbatch
The automotive industry is the largest consumer of TPEs, står for mere end 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, fleksibel, 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'er (mainly TPV, TPO) are used to produce automotive door seals, vindues tætninger, hood seals, og pakninger, which require good elasticity, vejrbestandighed, og lav temperatur fleksibilitet. The masterbatch for these components requires uniform coloring, good weather resistance (UV modstand, 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 (high viscosity, high shear force required); the HTE series integrates high performance and cost-effectiveness, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPE'er (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, dørpaneler, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (ikke-giftige, lugtfri). 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'er (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, varmemodstand, and mechanical strength. The masterbatch requires high-temperature resistance, oliemodstand, 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, præcis temperaturkontrol, and high wear resistance, suitable for TPC/TPA masterbatch processing (høj temperatur, high viscosity); 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, gennemsigtighed, slagfasthed). 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, stik, og andre komponenter, requiring functional masterbatch (antistatisk, flammehæmmende, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPE'er (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, flammehæmning, og slidstyrke. The masterbatch requires flame retardancy (meeting UL94 V-0 standard), antistatiske egenskaber, and uniform coloring.
Matching Extruders: HTS PLUS-serien, HTE-serien, 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'er (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, slagfasthed, 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 Construction and Transportation Industry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, og andre komponenter, 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'er (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV modstand, 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, og slidstyrke. 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'er (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, slidstyrke, 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, legetøj, and other household items, which require non-toxic, lugtfri, 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 Medical Devices.
TPE'er (mainly TPU, TPS) are used to produce medical catheters, sprøjter, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 standard), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, præcis temperaturkontrol, 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, slidstyrke, and mechanical strength. 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 (high viscosity, 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, med en rimelig skruestigning, 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, transportører, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Desuden, the screws adopt a modular design, which can freely combine different screw elements (formidling, blanding, klipning) according to the TPE type. F.eks, 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 Præcis temperaturkontrol, 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). Alle Zhuoyues ekstrudere anvender et avanceret intelligent temperaturkontrolsystem, med 4-6 uafhængige temperaturkontrolsektioner, 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 gange mere end almindelige ekstrudere; 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%. F.eks, HTS SUPER series production capacity reaches 1000-3000kg/h, velegnet til storskala masseproduktion; 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, kun de tilsvarende parametre skal kaldes, undgå gentagen fejlretning. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, overvågning af produktionsdata, og forudsigelig vedligeholdelse, realisere intelligent produktionsstyring.
4.1.7 Bred tilpasningsevne.
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 (farve masterbatch, flammehæmmende masterbatch, antistatisk masterbatch), with pigment content ranging from 10% til 70%. They can also be matched with auxiliary equipment (high-speed mixers, tørretumblere, kølere, granulatorer) 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, produktionsskala, og ansøgningskrav.
4.2.1 HTS BASIC-serien: 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, automatisk temperaturkontrol, and feeding, 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 (moms, TPU, high-concentration TPE masterbatch, flammehæmmende masterbatch). 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 (high viscosity, 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 (flammehæmmere, antistatiske midler). 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, medicinsk udstyr).
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, designed for high-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 gange mere end almindelige ekstrudere. The barrel adopts a double-layer jacket + tvungen kølestruktur, 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, og forudsigelig vedligeholdelse. 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, lavt energiforbrug, 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% sammenlignet med almindelige ekstrudere. 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, på grund af TPE'ernes unikke egenskaber (temperature sensitivity, moisture absorption, high viscosity), 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 Problem 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.
Årsager: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Forblanding: 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) Udstyr: Worn screw mixing elements; blocked die head.
Løsninger: (1) Optimize raw materials: Select fine-particle pigments (20-40 mesh), 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 minutter. (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 Problem 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.
Årsager: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (mere end 3 minutter) 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).
Løsninger: (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, udskift defekte køleelementer. (4) Optimize raw materials: Vælg højtemperaturbestandig TPE; tør råvarer grundigt (fugtindhold ≤0,05 % for TPU/TPA); tilsæt varmestabilisatorer.
5.3 Problem 3: Høj slitage af skrue og tønde
Manifestation: Hurtig slitage af skrue og cylinder, reduceret forskydningskraft og blandeevne; masterbatch-dispergerbarheden falder, udgifter til vedligeholdelse af udstyr stiger.
Årsager: (1) Raw materials: Pigmenter/additiver med høj hårdhed (såsom kønrøg, titaniumdioxid); stor partikelstørrelse. (2) Extrusion parameters: Høj skruehastighed, for stor forskydningskraft; højt ekstruderingstryk. (3) Udstyr: Skrue/tøndemateriale har dårlig slidstyrke.
Løsninger: (1) Optimize raw materials: Vælg lille partikel, pigmenter med lav hårdhed; knuse og sigte råvarer; tilsæt smøremidler for at reducere friktionen. (2) Juster parametre: Reducer skruehastigheden og ekstruderingstrykket passende. (3) Vælg udstyr med høj slidstyrke: Vælg Zhuoyue’s HTS PLUS/SUPER/HTE serie med bimetallisk komposit eller laserbeklædte skruer/tønder.
5.4 Problem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Årsager: (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) Forblanding: Air mixed into the mixture during premixing.
Løsninger: (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 Problem 5: Poor Processing Fluidity, Udstyrsblokering
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Årsager: (1) Raw materials: High TPE viscosity (TPV/TPC); højt pigmentindhold (mere end 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Udstyr: Worn conveying elements; blocked die head.
Løsninger: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; tør råvarer grundigt. (2) Juster parametre: 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, og ansøgningsfelter, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Sag 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, Kina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigmentindhold 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), varmemodstand (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Løsning: 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: Først, 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) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Anden, the barrel is equipped with a double-layer jacket + tvungen kølestruktur, med 6 uafhængige temperaturkontrolsektioner, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Tredje, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Desuden, 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: Efter 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, hvilket er 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 måneder, 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 Sag 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, Kina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigmentindhold 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), varmemodstand (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Løsning:
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: Først, 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) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Anden, the barrel is equipped with a double-layer jacket + tvungen kølestruktur, med 6 uafhængige temperaturkontrolsektioner, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Tredje, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Desuden, 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:
Efter 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, hvilket er 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 måneder, 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.