Termoplastilised elastomeerid (TPE), mõnikord nimetatakse termoplastiliseks kummiks (TPR), on kopolümeeride või polümeeride füüsikaliste segude klass – tavaliselt plastik ja kumm –, mis ühendavad termoplastide ja elastomeeride omadused. See ainulaadne kombinatsioon võimaldab TPE-sid töödelda nagu termoplaste (ekstrusiooni teel, survevalu, puhumisvormimine, jne.) säilitades samal ajal kummide elastsuse ja painduvuse. Erinevalt traditsioonilistest vulkaniseeritud kummidest, TPE-sid saab sulatada ja ümber töödelda mitu korda ilma märkimisväärse jõudluse vähenemiseta, muutes need keskkonnasõbralikumaks ja kulutõhusamaks. Kuna nõudlus kergekaalu järele, paindlik, ja taaskasutatavate materjalide hulk kasvab erinevates tööstusharudes, nagu autotööstus, elektrilised, ehitus, ja tarbekaubad, TPE-d on muutunud üha populaarsemaks, spetsialiseeritud põhisegu ja ekstrusioonitehnoloogia väljatöötamine, mis on kohandatud nende ainulaadsetele töötlemisnõuetele.
Põhisegu, võtmematerjalina TPE-de värvimiseks ja funktsionaalseks muutmiseks, mängib otsustavat rolli TPE toodete jõudluse parandamisel ja kasutusala laiendamisel. TPE põhisegu töötlemine nõuab segamise täpset kontrolli, hajutamine, ja temperatuuri parameetrid, kuna TPE-del on spetsiifiline viskoossus, kuumakindlus, ja elastsusomadused, mis erinevad traditsioonilistest plastidest. Kahe kruviga ekstruuderid, oma suurepäraste segamis- ja hajutamisvõimetega, täpne temperatuuri reguleerimine, ja kohanemisvõime erinevate materjalidega, on muutunud TPE põhisegu põhiliseks töötlemisseadmeks. Zhuoyue, professionaalne kahe kruviga ekstruuderite tootja, pakub täielikku valikut täiustatud ekstrusioonilahendusi, mis on spetsiaalselt loodud TPE segamiseks ja põhisegu töötlemiseks, hõlmab TPE/SBS/TPU/TPR/TPV ja muid suuremaid TPE kategooriaid, et rahuldada erinevate tööstusharude tootjate erinevaid vajadusi.
1. Termoplastiliste elastomeeride ülevaade (TPE): Kategooriad, Omadused ja põhiomadused
TPE-d on mitmekesine materjalide perekond, klassifitseeritakse kuue üldisesse kaubanduslikku kategooriasse nende keemilise koostise ja struktuuri alusel. Igal kategoorial on ainulaadsed omadused, töötlemise omadused, ja rakendusväljad, mis määravad otseselt kindlaks põhisegu valmistamise ja ekstrusiooniseadmete nõuded. TPEde klassifikatsiooni ja omaduste mõistmine on põhisegu töötlemise optimeerimise ja sobivate kahe kruviga ekstruuderite valimise aluseks..
1.1 Kuus TPE üldist kaubanduslikku kategooriat
1.1.1 Stüreenplokk-kopolümeerid (TPS, TPE-d).
TPS on kõige laialdasemalt kasutatav TPE-de kategooria, moodustab suure osa ülemaailmsest TPE turust. See koosneb stüreenplokkidest (nagu polüstüreen, PS) ja elastomeersed plokid (nagu polübutadieen, PB; polüisopreen, PI; või etüleen-butüleen, EB), ühendatud kovalentsete sidemetega. Kõige tavalisemad TPS-i tüübid hõlmavad SBS-i (Stüreenid-butadieenid-stüreenid), SIS (Stüreen-isopreen-stüreen), SEBS (Stüreen-etüleen-butüleen-stüreen), ja SEPS (Stüreen-etüleen-propüleen-stüreen).
TPS-i põhiomaduste hulka kuulub suurepärane paindlikkus, elastsus, ja töödeldavus. SEBS ja SEPS, mis on SBS-i ja SIS-i hüdrogeenitud versioonid, on paranenud kuumakindlus, ilmastikukindlus, ja vananemiskindlus, muutes need sobivaks kasutamiseks välistingimustes ja kõrgel temperatuuril. TPS-i materjale on lihtne värvida ja põhiseguga modifitseerida, ja nende töötlemistemperatuur on vahemikus 150 ℃ kuni 220 ℃, mis ühildub enamiku kahe kruviga ekstruuderiga. TPS-i levinumad rakendused hõlmavad autokomponente, juhtmed ja kaablid, tarbekaubad, ja meditsiiniseadmed.
1.1.2 Termoplastilised polüolefiinist elastomeerid (TPO, TPE-o).
TPO on polüolefiinide füüsikaline segu (nagu polüpropüleen, PP; või polüetüleen, PE) ja elastomeer (nagu etüleen-propüleen-dieeni monomeer, EPDM). See ühendab polüolefiinide jäikuse elastomeeride elastsusega, ja sellel on suurepärane keemiline vastupidavus, ilmastikukindlus, ja paindlikkus madalal temperatuuril. TPO-d on mittetoksilised, lõhnatu, ja taaskasutatav, muutes need ideaalseks keskkonnasõbralikkust nõudvate rakenduste jaoks.
TPO töötlemistemperatuur on vahemikus 160 ℃ kuni 230 ℃, ja see ühildub hästi erinevate põhisegudega (värvi põhisegu, leegiaeglustav põhisegu, jne.). TPO-sid kasutatakse laialdaselt autode välisosades (nagu kaitseraua katted, poritiiba vooderdised), ehitusmaterjalid (nagu tihendid, tihendid), ja elektrilised komponendid. Tänu nende kõrgele polüolefiinisisaldusele, TPO põhisegu töötlemiseks on vaja hea segamisvõimega ekstruudereid, et tagada pigmentide ja lisandite ühtlane hajumine.
1.1.3 Termoplastilised vulkanisatsioonid (käibemaks, TPE v).
TPV on dünaamiliselt vulkaniseeritud polüolefiinide segu (tavaliselt PP) ja elastomeer (tavaliselt EPDM). Töötlemise ajal, elastomeeri faas vulkaniseeritakse väikesteks osakesteks ja jaotatakse ühtlaselt polüolefiinmaatriksis, mille tulemuseks on suurepärane elastsus, survekomplekti takistus, ja kuumakindlus. TPV-del on paremad mehaanilised omadused ja mõõtmete stabiilsus kui traditsioonilistel TPE-del, ja talub pikaajalist kokkupuudet kõrgel temperatuuril (kuni 150 ℃).
TPV töötlemine nõuab täpset temperatuuri reguleerimist ja tugevat nihkejõudu, et tagada ühtlane vulkaniseerimine ja hajumine. Töötlemistemperatuur on vahemikus 170 ℃ kuni 240 ℃, ja materjalil on töötlemise ajal kõrge viskoossus, mis seab kõrged nõuded kahe kruviga ekstruuderite pöördemomendile ja kulumiskindlusele. TPV-sid kasutatakse laialdaselt autode tihendites, voolikud, tihendid, ja tööstuslikud komponendid, mis nõuavad suurt jõudlust ja vastupidavust.
1.1.4 Termoplastilised polüuretaanid (TPU).
TPU on kõvadest segmentidest koosnev plokk-kopolümeer (diisotsüanaat ja ahela pikendaja) ja pehmed segmendid (polüool). Sellel on suurepärane elastsus, kulumiskindlus, õlikindlus, ja mehaaniline tugevus, ja kõvadust saab reguleerida alates väga pehmest (Kaldal A 30) väga raskeks (Kaldal D 85) muutes kõvade ja pehmete segmentide suhet.
TPU töötlemine on tundlik temperatuuri ja niiskuse suhtes. Töötlemistemperatuur on vahemikus 180 ℃ kuni 250 ℃, ja materjal tuleb enne töötlemist põhjalikult kuivatada (moisture content ≤0.05%) to avoid hydrolysis and bubble formation. TPU masterbatch processing requires extruders with precise temperature control and vacuum exhaust capabilities. TPU is widely used in wires and cables, automotive hoses, footwear, medical catheters, and sports equipment.
1.1.5 Thermoplastic Copolyesters (TPC, TPE-E).
TPC is a block copolymer composed of polyester hard segments and polyether or polyester soft segments. It has excellent heat resistance, keemiline vastupidavus, ja mehaanilised omadused, 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. Sellel on töötlemise ajal kõrge viskoossus ja see nõuab suure pöördemomendi ja täpse temperatuuri reguleerimisega ekstruudereid. TPC põhisegu töötlemine nõuab ka erilist tähelepanu pigmentide ja lisandite hajutamisele, et vältida materjali mehaaniliste omaduste mõjutamist. TPC-sid kasutatakse laialdaselt autokomponentides (nagu õhu sisselaskevoolikud, käigukasti tihendid), kosmosesõidukite osad, ja tööstuslikud masinad.
1.1.6 Termoplastilised polüamiidid (TPA, TPE-A).
TPA on plokk-kopolümeer, mis koosneb polüamiidi kõvadest segmentidest ja polüeetri pehmetest segmentidest. See ühendab endas kõrge tugevuse, kulumiskindlus, ja polüamiidide keemiline vastupidavus koos polüeetrite paindlikkuse ja elastsusega. TPA-l on suurepärane löögikindlus ja madalad temperatuurid, ja seda saab kasutada karmides keskkondades.
TPA töötlemistemperatuur on vahemikus 230 ℃ kuni 290 ℃, ja sellel on kõrge veeimavus, enne töötlemist on vaja põhjalikku kuivatamist. TPA põhisegu töötlemiseks on vaja kõrge kulumiskindlusega ekstruudereid (polüamiidi kõrge kõvaduse tõttu) ja täpne temperatuuri reguleerimine, et vältida materjali lagunemist. TPA-d kasutatakse laialdaselt autokomponentides (nagu hammasrattad, laagrid), elektrilised pistikud, ja tööstuslikud voolikud.
1.2 Põhisegu töötlemist mõjutavad TPE põhiomadused
TPE-del on ainulaadsed omadused, mis eristavad neid traditsioonilistest plastidest, ja need omadused mõjutavad otseselt põhisegu koostist ja ekstrusiooniseadmete valikut. Peamised omadused, mida põhisegu töötlemisel arvestada, on järgmised:
1.2.1 Elastsus ja paindlikkus.
TPE-del on kõrge elastsus ja paindlikkus, mis tähendab, et põhisegu peab ühilduma TPE maatriksiga, et vältida materjali elastsuse vähenemist. Põhisegu kandjal peaks olema hea ühilduvus TPE-ga, ja dispergeerija peaks tagama pigmentide ühtlase hajutamise ilma aglomeraate moodustamata, mis võivad põhjustada stressi kontsentratsiooni ja vähendada paindlikkust.
1.2.2 Kuumakindlus.
Erinevatel TPE kategooriatel on erinev kuumuskindlus (töötlemistemperatuur on vahemikus 150 ℃ kuni 290 ℃). Põhisegu pigmentide ja lisandite kuumuskindlus peab vastama TPE töötlemistemperatuurile, et vältida lagunemist, värvimuutus, või jõudluse halvenemine ekstrusiooni ajal. Näiteks, TPC ja TPA jaoks on vaja kõrgele temperatuurile vastupidavaid pigmente ja soojusstabilisaatoreid.
1.2.3 Viskoossus ja töödeldavus.
TPE-de viskoossus on töötlemise ajal erinev (TPV ja TPC on kõrgema viskoossusega, samas kui TPS-il on madalam viskoossus). See mõjutab kahe kruviga ekstruuderi nihkejõudu ja transpordinõudeid. Kõrge viskoossusega TPE-d nõuavad suure pöördemomendi ja tugeva segamisvõimega ekstruudereid, samas kui madala viskoossusega TPE-d nõuavad materjali ülevoolu vältimiseks ekstrusioonikiiruse täpset juhtimist.
1.2.4 Niiskuse imendumine.
Mõned TPEd (nagu TPU, TPA) neil on kõrge veeimavus, mis võivad tekitada mullid, hüdrolüüs, ja muud põhisegu defektid. Toormaterjalid (TPE, pigmendid, lisandid) tuleb enne töötlemist põhjalikult kuivatada, ja ekstruuder peaks olema varustatud vaakumväljalaskeseadmega niiskuse ja lenduvate ainete eemaldamiseks.
1.2.5 Ühilduvus lisanditega.
TPE-d nõuavad sageli funktsionaalseid lisandeid (nagu antioksüdandid, UV-stabilisaatorid, määrdeained) nende jõudluse parandamiseks. Põhisegu tuleks koostada nii, et lisandid sobivad kokku nii pigmentide kui ka TPE maatriksiga, vältides keemilisi reaktsioone, mis võivad mõjutada toote kvaliteeti.
2. TPE-de põhisegu: Koosseis, Koostamis- ja töötlemisnõuded
TPE-de põhisegu on pigmentide/värvide kontsentreeritud segu, kandjad, ja lisandid, mõeldud TPE-de värvimiseks ja lisafunktsioonide andmiseks (nagu leegiaeglustus, antistaatiline, antibakteriaalne) säilitades samal ajal materjalile omased elastsed ja töötlemisomadused. TPE põhisegu koostis ja töötlemine on nõudlikumad kui traditsiooniliste plastide puhul, TPEde ainulaadsete omaduste tõttu. Selles jaotises kirjeldatakse koostist, formuleerimispõhimõtted, ja TPE põhisegu töötlemisnõuded.
2.1 TPE põhisegu põhikoostis
Nagu traditsiooniline põhisegu, TPE põhisegu koosneb kolmest põhikomponendist: pigmendid/värvid, kandjad, ja lisandid. Iga komponendi valik ja osakaal on kohandatud vastavalt TPE tüübile ja selle rakendusnõuetele.
2.1.1 Pigmendid/värvained.
Pigmendid/värvid on põhikomponendid, mis annavad TPE-dele värvi, arvestust 10%-70% põhisegu koostisest (sõltuvalt värvi intensiivsusest ja TPE tüübist). Peamised nõuded TPE põhisegu pigmentidele/värvidele on järgmised:
- – Kuumakindlus: Peab taluma siht-TPE töötlemistemperatuuri (150℃ -290 ℃) lagunemise või värvimuutuseta. Kõrge temperatuuriga TPE-de jaoks (TPC, TPA), Eelistatakse kõrge temperatuurikindlaid orgaanilisi või anorgaanilisi pigmente.
- – Ühilduvus: Migratsiooni vältimiseks peab see ühilduma TPE maatriksiga, õitsev, või vähenenud elastsus. TPE-ga sarnase polaarsusega pigmendid sobivad paremini kokku (nt., polaarsed pigmendid TPU jaoks, mittepolaarsed pigmendid TPS-i jaoks).
- – Dispergeeritavus: Peab olema kergesti hajutatud TPE maatriksis, et tagada ühtlane värvus ja vältida värvilaike, triibud, või vähenenud mehaanilised omadused. Peenosakesed pigmendid (20-40 võrk) eelistatud on madala aglomeratsiooniga.
- – Keskkonnasõbralikkus: Peab vastama ülemaailmsetele keskkonnakaitsestandarditele (nagu REACH, RoHS) mürgiste või kahjulike ainete vältimiseks (nagu raskemetallid) mis võivad mõjutada inimeste tervist ja keskkonda.
TPE põhisegudes kasutatavad tavalised pigmendid hõlmavad järgmist: anorgaanilised pigmendid (titaandioksiid valge jaoks, tahma mustaks, raudoksiid punase/kollase jaoks), ja kõrge temperatuurikindlad orgaanilised pigmendid (ftalotsüaniin sinine/roheline, kinakridoon punane).
2.1.2 Kandjad.
Kandjad on põhisegu maatriks, arvestust 20%-80% kompositsioonist, ja mängivad võtmerolli pigmentide hajutamisel ja TPE-maatriksi külge kinnitumisel. The carrier must have excellent compatibility with both the pigments and the target TPE, as poor compatibility can lead to pigment migration, uneven coloring, and reduced TPE performance. The selection of the carrier is based on the type of TPE:
- – For TPS (SBS, SEBS): Use TPS or PP as the carrier, which has good compatibility and processing fluidity.
- – For TPO/TPE-o: Use PP or PE as the carrier, matching the polyolefin component of the TPO.
- – For TPV/TPE-v: Use PP as the carrier, which is compatible with the PP matrix of the TPV.
- – For TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, respectively, to match the high-temperature processing requirements and compatibility.
The carrier should also have good processing fluidity, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Additives.
Additives are auxiliary components added to improve the processing performance, dispersibility, and functional performance of TPE masterbatch, arvestust 1%-10% kompositsioonist. The type and dosage of additives are determined by the TPE type and application requirements:
- – Dispersants: The most important additive for TPE masterbatch, used to reduce pigment surface tension, prevent agglomeration, and ensure uniform dispersion in the TPE matrix. Common dispersants include polyethylene wax, polypropylene wax, steariinhape, and maleic anhydride grafted waxes. For high-viscosity TPEs (käibemaks, TPC), high-efficiency dispersants with strong compatibility are preferred.
- – Compatibilizers: Used to improve compatibility between pigments and TPEs, and between masterbatch and TPE matrix. Näiteks, maleic anhydride grafted PP is used as a compatibilizer for TPO masterbatch, and polyurethane wax is used for TPU masterbatch.
- – Heat Stabilizers: 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.
- – Määrdeained: Used to reduce friction between materials and extrusion equipment (screw, tünn, sure peaga), improve processing fluidity, ja vältige materjali kleepumist seadme külge. Levinud määrdeainete hulka kuuluvad steariinhape, kaltsiumstearaat, ja silikoonõli. TPU ja TPA jaoks, Eelistatakse vähese migratsiooniga määrdeaineid, et vältida toote toimivuse mõjutamist.
- – Funktsionaalsed lisandid: Lisatud, et anda TPE-dele erifunktsioone, nagu leegiaeglustid (juhtmete ja kaablite jaoks), antistaatilised ained (elektriliste komponentide jaoks), ja antibakteriaalsed ained (meditsiiniseadmete ja tarbekaupade jaoks).
2.2 TPE põhisegu formuleerimispõhimõtted
TPE põhisegu koostis peab tasakaalustama värviefekti, töötlemise jõudlus, ja TPE-le omased omadused. Peamised põhimõtted on järgmised:
2.2.1 Esiteks ühilduvus.
Kandja, pigmendid, ja lisandid peavad sobima siht-TPE-ga, et vältida materjali elastsuse vähenemist, paindlikkus, ja mehaanilised omadused. Näiteks, mittepolaarse kandja kasutamine polaarse TPU jaoks põhjustab halva ühilduvuse ja pigmendi migratsiooni.
2.2.2 Sobitage kuumakindlus.
The pigments and additives must have heat resistance matching the TPE processing temperature. Näiteks, 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. Näiteks, 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, mürgiste või kahjulike ainete vältimine (nagu raskemetallid, ftalaadid) mis võib turulepääsu piirata.
2.3 TPE põhisegu töötlemisnõuded
TPE põhisegu töötlemine toimub peamiselt kahe kruviga ekstrusioonitehnoloogia abil, mis nõuab tooraine eeltöötluse ranget kontrolli, eelsegamine, ekstrusiooni parameetrid, ja järeltöötlus, et tagada toote kvaliteet. Peamised töötlemisnõuded on järgmised:
2.3.1 Tooraine eeltöötlus.
TPEd (eriti TPU, TPA) neil on kõrge veeimavus, nii et kõik toorained (TPE kandja, pigmendid, lisandid) tuleb enne töötlemist põhjalikult kuivatada. Kuivamistemperatuur ja -aeg määratakse materjali tüübi järgi: TPU/TPA kuivatatakse temperatuuril 100-120 ℃ 6-8 tundi, TPS/TPO kuivatatakse temperatuuril 80-100 ℃ 3-5 tundi, ja pigmendid kuivatatakse temperatuuril 60-80 ℃ 2-4 tundi. Kuivatatud tooraine niiskusesisaldust tuleks kontrollida allpool 0.1% (0.05% TPU/TPA jaoks).
Lisaks, suurte osakeste või aglomeraatidega pigmendid tuleb purustada ja sõeluda (20-40 võrk) to improve dispersibility, and impurities (metal particles, dust) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigmendid, carrier, lisandid) 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 p/min, mixing time 5-10 minutit, 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 (temperatuuri, kruvi kiirus, extrusion pressure, feeding speed) must be precisely controlled to match the TPE type:
- – Temperatuuri juhtimine: The barrel is divided into 4-6 temperatuuri reguleerimise sektsioonid (söötmise osa, sulamisosa, segamise osa, homogeniseeriv sektsioon, die head section). Iga sektsiooni temperatuuri reguleeritakse vastavalt TPE töötlemistemperatuurile. Näiteks, TPS põhisegu: toiteosa 100-120 ℃, sulamissektsioon 160-180 ℃, segamisosa 170-190 ℃, homogeniseerimissektsioon 160-180 ℃, stantsipea sektsioon 150-170 ℃; TPC põhisegu: toiteosa 150-170 ℃, sulamisosa 230-250 ℃, segamisosa 240-260 ℃, homogeniseerimissektsioon 230-250 ℃, stantsipea osa 220-240 ℃. Temperatuuri reguleerimise täpsus peaks jõudma ±1 ℃-ni, et vältida TPE lagunemist ja pigmendi lagunemist.
- – Kruvi kiirus: Kruvi kiirus on vahemikus 200-800 p/min, reguleeritud TPE viskoossuse alusel. Kõrge viskoossusega TPEd (käibemaks, TPC) nõuavad suuremat kruvi kiirust (500-800 p/min) tekitada piisav nihkejõud pigmendi hajutamiseks; madala viskoossusega TPEd (TPS) kasutage mõõdukat kiirust (300-500 p/min) materjali ülevoolu vältimiseks.
- – Ekstrusioonirõhk: Rõhk on vahemikus 5-12 MPa, stabiilselt hoitud (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. For high-viscosity TPEs, 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, elektrilised, ehitus, tarbekaubad, and other industries, and different application fields have different requirements for TPE masterbatch performance (värvi, dispersibility, 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, moodustades rohkem kui 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, paindlik, 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.
TPEd (mainly TPV, TPO) are used to produce automotive door seals, window seals, hood seals, ja tihendid, which require good elasticity, ilmastikukindlus, ja paindlikkus madalal temperatuuril. The masterbatch for these components requires uniform coloring, good weather resistance (UV resistance, 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.
TPEd (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, door panels, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (non-toxic, lõhnatu). 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.
TPEd (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, kuumakindlus, ja mehaaniline tugevus. The masterbatch requires high-temperature resistance, õlikindlus, 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, täpne temperatuuri reguleerimine, and high wear resistance, suitable for TPC/TPA masterbatch processing (high temperature, 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, läbipaistvus, löögikindlus). 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, pistikud, ja muud komponendid, requiring functional masterbatch (antistaatiline, flame-retardant, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEd (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, leegiaeglustus, and abrasion resistance. The masterbatch requires flame retardancy (meeting UL94 V-0 standard), antistaatilised omadused, and uniform coloring.
Matching Extruders: HTS PLUS series, HTE series, 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.
TPEd (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, löögikindlus, 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, ja muud komponendid, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPEd (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV resistance, 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, ja kulumiskindlus. 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.
TPEd (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, kulumiskindlus, 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, mänguasjad, and other household items, which require non-toxic, lõhnatu, 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.
TPEd (mainly TPU, TPS) are used to produce medical catheters, syringes, 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, täpne temperatuuri reguleerimine, 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, kulumiskindlus, ja mehaaniline tugevus. 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, with a reasonable screw pitch, 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, kandjad, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Lisaks, the screws adopt a modular design, which can freely combine different screw elements (conveying, segamine, pügamine) according to the TPE type. Näiteks, 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, koos 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%. Näiteks, 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, ja ennustav hooldus, realizing intelligent production management.
4.1.7 Wide Adaptability.
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 (värvi põhisegu, leegiaeglustav põhisegu, antistatic masterbatch), with pigment content ranging from 10% juurde 70%. They can also be matched with auxiliary equipment (high-speed mixers, dryers, coolers, granulators) 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, production scale, ja rakendusnõuded.
4.2.1 HTS BASIC Series: 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, 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 (käibemaks, TPU, high-concentration TPE masterbatch, leegiaeglustav põhisegu). 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 (leegiaeglustid, antistaatilised ained). 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, meditsiiniseadmed).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
HTS SUPER seeria on Zhuoyue kõrgeima kvaliteediga ekstruuderite seeria, esindab Hiina kahe kruviga ekstruuderite kõrgtaset, mõeldud tipptasemele, suure nõudlusega TPE põhisegu töötlemine (TPA, TPC, ülikõrge kontsentratsiooniga põhisegu, põhisegu uute energiasõidukite / kosmosesõidukite jaoks).
See võtab kasutusele Zhuoyue uusima ülisuure pöördemomendi ülekandeseadme, eripöördemoment 17-20Nm/cm³, kruvi läbimõõt 50-95mm, tootmisvõimsus 1000-3000kg/h. Kruvid on valmistatud uuest kulumiskindlast legeerterasest, läbib katte laserravi (pinna kõvadus ≥70 HRC), service life 3-4 times that of ordinary extruders. Tünn võtab vastu kahekihilise jope + sundjahutusstruktuur, temperatuuri reguleerimise täpsus ±1 ℃, sobib kõrge temperatuuriga TPE töötlemiseks (220-290℃). Mitmeastmeline segamiskruvi kombinatsioon tagab ülikõrge segamise ühtluse (≥98%), sobib ülikõrge kontsentratsiooniga põhisegu jaoks (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, ja ennustav hooldus. 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, madal energiatarbimine, 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% compared with ordinary extruders. 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, TPEde ainulaadsete omaduste tõttu (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 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) Premixing: 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) Varustus: Worn screw mixing elements; blocked die head.
Lahendused: (1) Optimize raw materials: Select fine-particle pigments (20-40 võrk), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 p/min, extend mixing time to 5-10 minutit. (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 (more than 3 minutit) 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).
Lahendused: (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: High Wear of Screw and Barrel
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) Varustus: Screw/barrel material has poor wear resistance.
Lahendused: (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) Premixing: Air mixed into the mixture during premixing.
Lahendused: (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, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (more than 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Varustus: Worn conveying elements; blocked die head.
Lahendused: (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, ja rakendusväljad, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Juhtum 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, Hiina, 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), kuumakindlus (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Lahendus: 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: Esiteks, 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. Teiseks, the barrel is equipped with a double-layer jacket + sundjahutusstruktuur, koos 6 independent temperature control sections, 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. Kolmandaks, 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. Lisaks, 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: Pärast 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 kuud, 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 Juhtum 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, Hiina, 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), kuumakindlus (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Lahendus:
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: Esiteks, 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. Teiseks, the barrel is equipped with a double-layer jacket + sundjahutusstruktuur, koos 6 independent temperature control sections, 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. Kolmandaks, 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. Lisaks, 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:
Pärast 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 kuud, 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.