Thermoplastyske elastomers (TPE), soms oantsjutten as Thermoplastic Rubbers (TPR), binne in klasse fan kopolymeren as fysike mingden fan polymeren - typysk in plestik en in rubber - dy't de eigenskippen fan thermoplasten en elastomeren kombinearje. Dizze unike kombinaasje lit TPE's wurde ferwurke as thermoplastyk (fia extrusion, ynjeksje moulding, blow moulding, ensfh.) wylst it behâld fan de elastisiteit en fleksibiliteit fan rubbers. Oars as tradisjonele vulkanisearre rubbers, TPE's kinne meardere kearen wurde smelt en opnij ferwurke sûnder signifikant ferlies fan prestaasjes, wêrtroch't se miljeufreonliker en rendabeler meitsje. As de fraach nei lichtgewicht, fleksibel, en recyclebere materialen groeit oer yndustry lykas automotive, elektryske, konstruksje, en konsuminteguod, TPE's binne hieltyd populêrder wurden, driuwt de ûntwikkeling fan spesjalisearre masterbatch en extrusion technologyen ôfstimd op harren unike ferwurkjen easken.
Masterbatch, as in wichtich materiaal foar kleurjen en funksjonele modifikaasje fan TPE's, spilet in krúsjale rol by it ferbetterjen fan de prestaasjes en it útwreidzjen fan it tapassingsgebiet fan TPE-produkten. De ferwurking fan TPE masterbatch fereasket sekuere kontrôle fan it mingen, fersprieden, en temperatuer parameters, as TPEs hawwe spesifike viscosity, waarmte ferset, en elastisiteitseigenskippen dy't ferskille fan tradisjonele plestik. Twin-screw extruders, mei harren superieure mingen en dispergering mooglikheden, presys temperatuer kontrôle, en oanpassing oan ferskate materialen, binne wurden de kearn ferwurkjen apparatuer foar TPE masterbatch. Zhuoyue, in profesjonele fabrikant fan twin-screw extruders, biedt in folslein oanbod fan avansearre extrusion oplossings spesifyk ûntwurpen foar TPE compounding en masterbatch ferwurkjen, covering TPE / SBS / TPU / TPR / TPV en oare grutte TPE kategoryen, om te foldwaan oan de ferskate behoeften fan fabrikanten yn ferskate yndustry.
1. Oersjoch fan Thermoplastic Elastomers (TPE): Kategoryen, Eigenskippen en kaai skaaimerken
TPE's binne in ferskaat famylje fan materialen, yndield yn seis algemiene kommersjele kategoryen basearre op har gemyske gearstalling en struktuer. Elke kategory hat unike eigenskippen, ferwurkjen skaaimerken, en applikaasje fjilden, dy't direkt bepale de easken foar masterbatch formulearring en extrusion apparatuer. De klassifikaasje en eigenskippen fan TPE's begripe is de basis foar it optimalisearjen fan masterbatchferwurking en it selektearjen fan geskikte twin-screw-ekstruders.
1.1 Seis Algemiene kommersjele kategoryen fan TPE's
1.1.1 Styrenic Block Copolymers (TPS, TPE-s).
TPS is de meast brûkte kategory fan TPE's, goed foar in grut oandiel fan 'e wrâldwide TPE-merk. It is gearstald út styreenyske blokken (lykas polystyrene, PS) en elastomere blokken (lykas polybutadiene, PB; polyisoprene, PI; of ethylene-butyleen, EB), ferbûn troch kovalente obligaasjes. De meast foarkommende soarten TPS omfetsje SBS (Styrenes-Butadienes-Styrenes), SIS (Styreen-Isoprene-Styreen), SEBS (Styreen-ethylene-butyleen-styrene), en SEPS (Styreen-ethylene-propylene-styrene).
Key eigenskippen fan TPS omfetsje poerbêste fleksibiliteit, elastisiteit, en ferwurkberens. SEBS en SEPS, dat binne hydrogenated ferzjes fan SBS en SIS, hawwe ferbettere waarmte ferset, waar ferset, en ferâldering ferset, wêrtroch se geskikt binne foar bûten- en hege temperatuerapplikaasjes. TPS-materialen wurde maklik kleure en oanpast mei masterbatch, en har ferwurkingstemperatuer farieart fan 150 ℃ oant 220 ℃, dat ferienichber is mei de measte twin-screw extruders. Algemiene tapassingen fan TPS omfetsje autokomponinten, draden en kabels, konsumint guod, en medyske apparaten.
1.1.2 Thermoplastyske polyolefinelastomers (TPO, TPE-o).
TPO is in fysike mingsel fan polyolefin (lykas polypropylene, PP; of polyetyleen, PE) en elastomeer (lykas ethylene-propylene-dieen monomer, EPDM). It kombinearret de rigidity fan polyolefins mei de elasticiteit fan elastomers, en hat poerbêste gemyske ferset, waar ferset, en lege temperatuer fleksibiliteit. TPO's binne net-giftig, reukleas, en recycleber, wêrtroch't se ideaal binne foar applikaasjes dy't miljeufreonlikens fereaskje.
De ferwurkingstemperatuer fan TPO farieart fan 160 ℃ oant 230 ℃, en it hat goede komptabiliteit mei ferskate masterbatches (kleur masterbatch, flammefertragende masterbatch, ensfh.). TPO's wurde in soad brûkt yn auto-eksterieurdielen (lykas bumper covers, fender liners), boumaterialen (lykas seehûnen, pakkingen), en elektryske komponinten. Troch har hege polyolefinynhâld, TPO masterbatch-ferwurking fereasket extruders mei goede mingmooglikheden om unifoarme fersprieding fan pigmen en tafoegings te garandearjen.
1.1.3 Thermoplastyske Vulcanizates (btw, TPE v).
TPV is in dynamysk vulkanisearre mingsel fan polyolefin (meastal PP) en elastomeer (meastal EPDM). Tidens it ferwurkjen, de elastomere faze wurdt vulcanized yn lytse dieltsjes en unifoarm ferspraat yn de polyolefin matrix, resultearret yn poerbêste elastisiteit, kompresje set ferset, en waarmte ferset. TPV's hawwe bettere meganyske eigenskippen en dimensionale stabiliteit dan tradisjonele TPE's, en kin fernear lange-termyn hege temperatuer exposure (oant 150 ℃).
TPV-ferwurking fereasket krekte temperatuerkontrôle en sterke skuorkrêft om unifoarme fulkanisaasje en dispersje te garandearjen. De ferwurkingstemperatuer farieart fan 170 ℃ oant 240 ℃, en it materiaal hat hege viskositeit by it ferwurkjen, dy't hege easken stelt oan it koppel en slijtweerstand fan twin-screw extruders. TPV's wurde in protte brûkt yn auto-segels, hoses, pakkingen, en yndustriële komponinten dy't hege prestaasjes en duorsumens nedich binne.
1.1.4 Thermoplastyske polyurethanen (TPU).
TPU is in blok copolymer gearstald út hurde segminten (diisocyanat en kettingferlenger) en sêfte segminten (polyol). It hat poerbêste elastisiteit, abrasion ferset, oalje ferset, en meganyske sterkte, en kin oanpast wurde yn hurdens fan hiel sêft (Shore A 30) oan hiel hurd (Shore D 85) troch it feroarjen fan de ferhâlding fan hurde en sêfte segminten.
TPU-ferwurking is gefoelich foar temperatuer en focht. De ferwurkingstemperatuer farieart fan 180 ℃ oant 250 ℃, en it materiaal moat goed droech wurde foardat it ferwurke wurdt (vochtgehalte ≤0.05%) om hydrolyse en bubbelfoarming te foarkommen. TPU masterbatch ferwurking fereasket extruders mei sekuere temperatuer kontrôle en fakuüm exhaust mooglikheden. TPU wurdt in soad brûkt yn triedden en kabels, auto-slangen, skuon, medyske katheters, en sportapparatuer.
1.1.5 Thermoplastyske copolyesters (TPC, TPE-E).
TPC is in blok copolymer gearstald út polyester hurde segminten en polyether of polyester sêfte segminten. It hat poerbêst waarmte ferset, gemyske ferset, en meganyske eigenskippen, en kin fernear hege temperatueren oant 150 ℃ foar lange perioaden. TPC's hawwe ek goede fleksibiliteit en elastisiteit, wêrtroch't se geskikt foar hege-optreden applikaasjes.
De ferwurkingstemperatuer fan TPC farieart fan 220 ℃ oant 280 ℃, dat is heger as oare TPE kategoryen. It hat hege viskositeit by it ferwurkjen en fereasket extruders mei hege koppel en krekte temperatuerkontrôle. TPC-masterbatch-ferwurking fereasket ek spesjaal omtinken foar de fersprieding fan pigmen en tafoegings om foar te kommen dat de meganyske eigenskippen fan it materiaal beynfloedzje. TPC's wurde in protte brûkt yn auto-ûnderdielen (lykas lucht intake slangen, oerdracht sealen), aerospace dielen, en yndustriële masines.
1.1.6 Thermoplastyske polyamiden (TPA, TPE-A).
TPA is in blok copolymer gearstald út polyamide hurde segminten en polyether sêfte segminten. It kombinearret de hege sterkte, wear ferset, en gemyske ferset fan polyamides mei de fleksibiliteit en elastisiteit fan polyethers. TPA hat poerbêste ynfloedresistinsje en prestaasjes by lege temperatueren, en kin brûkt wurde yn drege omjouwings.
De ferwurkingstemperatuer fan TPA farieart fan 230 ℃ oant 290 ℃, en it hat hege wetterabsorption, easkje yngeande drogen foardat ferwurking. TPA masterbatch ferwurking fereasket extruders mei hege wear ferset (fanwege de hege hurdens fan polyamide) en krekte temperatuerkontrôle om materiaaldegradaasje te foarkommen. TPA wurdt in protte brûkt yn auto-ûnderdielen (lykas gears, lagers), elektryske Anschlüsse, en yndustriële slangen.
1.2 Wichtige eigenskippen fan TPE's dy't ynfloed hawwe op Masterbatch-ferwurking
TPE's hawwe unike eigenskippen dy't har ûnderskiede fan tradisjonele plestik, en dizze eigenskippen direkt ynfloed op de formulearring fan masterbatch en de seleksje fan extrusion apparatuer. De wichtichste eigenskippen om te beskôgje yn masterbatch-ferwurking binne as folget:
1.2.1 Elastisiteit en fleksibiliteit.
TPE's hawwe hege elastisiteit en fleksibiliteit, wat betsjut dat de masterbatch kompatibel wêze moat mei de TPE-matrix om foar te kommen dat de elastyske prestaasjes fan it materiaal ferminderje. De drager fan 'e masterbatch moat in goede kompatibiliteit hawwe mei de TPE, en it dispergeermiddel moat soargje foar unifoarme fersprieding fan pigmen sûnder agglomeraten te foarmjen dy't stresskonsintraasje kinne feroarsaakje en fleksibiliteit ferminderje.
1.2.2 Heat Resistance.
Ferskillende TPE kategoryen hawwe ferskillende waarmte ferset (ferwurkjen temperatuer farieart fan 150 ℃ oant 290 ℃). Masterbatch-pigmen en tafoegings moatte waarmtebestriding hawwe dy't oerienkomme mei de TPE-ferwurkingstemperatuer om ûntbining te foarkommen, ferkleuring, of prestaasjesdegradaasje by extrusion. Bygelyks, TPC en TPA fereaskje hege temperatuer resistinte pigminten en waarmte stabilisatoren.
1.2.3 Viskositeit en ferwurkberens.
TPE's hawwe ferskate viskositeiten tidens ferwurking (TPV en TPC hawwe hegere viskositeit, wylst TPS hat legere viscosity). Dit beynfloedet de skuorkrêft en ferfiereasken fan 'e twin-screw-extruder. TPE's mei hege viskositeit fereaskje extruders mei hege koppel en sterke mingmooglikheden, wylst TPE's mei lege viskositeit easkje krekte kontrôle fan extrusion snelheid om materiaal oerstreaming te foarkommen.
1.2.4 Moisture Absorption.
Guon TPEs (lykas TPU, TPA) hawwe hege wetterabsorption, dy't bubbels feroarsaakje kinne, hydrolyse, en oare defekten yn 'e masterbatch. De grûnstoffen (TPE, pigminten, tafoegings) moat goed droech wurde foardat ferwurking, en de extruder moat wêze foarsjoen fan in fakuüm exhaust apparaat te ferwiderje focht en flechtich stoffen.
1.2.5 Kompatibiliteit mei tafoegings.
TPE's hawwe faak funksjonele tafoegings nedich (lykas antioxidants, UV stabilisatoren, lubricants) om har prestaasjes te ferbetterjen. De masterbatch moat wurde formulearre om te soargjen dat de tafoegings kompatibel binne mei sawol de pigmen as de TPE-matrix, it foarkommen fan gemyske reaksjes dy't de produktkwaliteit kinne beynfloedzje.
2. Masterbatch foar TPE's: Gearstalling, Formulering en ferwurkjen easken
Masterbatch foar TPE's is in konsintrearre mingsel fan pigminten / kleurstoffen, ferfierders, en tafoegings, ûntworpen om TPE's te kleurjen en ekstra funksjes te jaan (lykas flammefertraging, antistatyske, antibakteriële) wylst behâld fan it materiaal syn ynherinte elastyske en ferwurkjen eigenskippen. De formulearring en ferwurking fan TPE masterbatch binne mear easken dan dy foar tradisjonele plestik, fanwege de unike eigenskippen fan TPE's. Dizze seksje beskriuwt de komposysje, formulearringsprinsipes, en ferwurkjen easken fan TPE masterbatch.
2.1 Kearn Gearstalling fan TPE Masterbatch
Lykas tradisjonele masterbatch, TPE masterbatch bestiet út trije basiskomponinten: pigmenten / kleurstoffen, ferfierders, en tafoegings. De seleksje en it oanpart fan elke komponint wurde ôfstimd op it type TPE en har tapassingseasken.
2.1.1 Pigmenten / kleurstoffen.
Pigminten / kleurstoffen binne de kearnkomponinten dy't kleur jaan oan TPE's, accounting foar 10%-70% fan 'e masterbatch-komposysje (ôfhinklik fan de kleurintensiteit en TPE-type). De kaai easken foar pigminten / kleurstoffen yn TPE masterbatch binne:
- – Heat Resistance: Moat wjerstean de ferwurking temperatuer fan it doel TPE (150℃-290 ℃) sûnder ûntbining of ferkleuring. Foar hege temperatuer TPEs (TPC, TPA), hege temperatuer-resistinte organyske pigminten as anorganyske pigminten hawwe de foarkar.
- – Kompatibiliteit: Moat kompatibel wêze mei de TPE-matrix om migraasje te foarkommen, bloeiende, of fermindere elastisiteit. Pigminten mei ferlykbere polariteit as de TPE binne mear kompatibel (bgl., polêre pigminten foar TPU, net-polêre pigminten foar TPS).
- – Dispersibility: Moat maklik wurde ferspraat yn 'e TPE-matrix om unifoarme kleur te garandearjen en kleurflekken te foarkommen, strepen, of fermindere meganyske eigenskippen. Fine-particle pigminten (20-40 mesh) mei lege agglomeraasje hawwe de foarkar.
- – Miljeufreonlikens: Moat foldogge oan wrâldwide noarmen foar miljeubeskerming (lykas REACH, RoHS) om giftige of skealike stoffen te foarkommen (lykas swiere metalen) dat kin ynfloed op minsklike sûnens en it miljeu.
Algemiene pigminten brûkt yn TPE masterbatch omfetsje: anorganyske pigmenten (titanium dioxide foar wyt, koalstof swart foar swart, izer okside foar read / giel), en hege temperatuer resistinte organyske pigminten (phthalocyanine blau / grien, quinacridon read).
2.1.2 Ferfierders.
Dragers binne de matrix fan 'e masterbatch, accounting foar 20%-80% fan de komposysje, en spylje in wichtige rol yn it fersprieden fan pigminten en adhering oan de TPE matrix. De drager moat poerbêste kompatibiliteit hawwe mei sawol de pigmen as de doel-TPE, as minne kompatibiliteit kin liede ta pigmentmigraasje, oneffen kleuring, en fermindere TPE prestaasjes. De seleksje fan 'e drager is basearre op it type TPE:
- – Foar TPS (SBS, SEBS): Brûk TPS of PP as drager, dat hat goede komptabiliteit en ferwurkjen fluidity.
- – Foar TPO/TPE-o: Brûk PP of PE as drager, oerienkomt mei de polyolefinkomponint fan 'e TPO.
- – Foar TPV/TPE-v: Brûk PP as drager, dy't kompatibel is mei de PP-matrix fan 'e TPV.
- – Foar TPU: Brûk TPU as drager, garandearjen fan kompatibiliteit mei de TPU-matrix en it foarkommen fan hydrolyse.
- – Foar TPC/TPE-E en TPA/TPE-A: Brûk TPC of TPA as drager, respektivelik, om te passen oan de easken foar ferwurkjen fan hege temperatueren en kompatibiliteit.
De drager moat ek in goede ferwurkingsfluiditeit hawwe, mei in smeltpunt en ferwurkjen temperatuer konsekwint mei of wat leger as de doel TPE, om unifoarm mingen te garandearjen en TPE-degradaasje te foarkommen.
2.1.3 Additieven.
Additiven binne auxiliary komponinten tafoege om de ferwurkingsprestaasjes te ferbetterjen, dispersibility, en funksjonele prestaasjes fan TPE masterbatch, accounting foar 1%-10% fan de komposysje. It type en dosaasje fan tafoegings wurde bepaald troch it TPE-type en tapassingseasken:
- – Dispersanten: De wichtichste tafoeging foar TPE masterbatch, brûkt om pigment oerflak spanning te ferminderjen, agglomeraasje foarkomme, en soargje foar unifoarme fersprieding yn 'e TPE-matrix. Algemiene dispersanten binne polyetyleenwax, polypropylene wax, stearinezuur, en maleïnezuuranhydride ente waaksen. Foar hege viskositeit TPE's (btw, TPC), dispersanten mei hege effisjinsje mei sterke kompatibiliteit hawwe de foarkar.
- – Kompatibilizers: Wurdt brûkt om kompatibiliteit te ferbetterjen tusken pigminten en TPE's, en tusken masterbatch en TPE matrix. Bygelyks, maleïnezuuranhydride ent PP wurdt brûkt as kompatibilisator foar TPO masterbatch, en polyurethane waaks wurdt brûkt foar TPU masterbatch.
- – Heat Stabilizers: Wurdt brûkt om pigment ûntbining en TPE-degradaasje te foarkommen by ferwurking op hege temperatuer. 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.
- – Lubricants: Used to reduce friction between materials and extrusion equipment (skroef, barrel, die kop), improve processing fluidity, and avoid material sticking to equipment. Algemiene smeermiddelen binne stearinezuur, kalsiumstearaat, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (foar elektryske komponinten), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, pigminten, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, fleksibiliteit, en meganyske eigenskippen. Bygelyks, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. Bygelyks, 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. Hege konsintraasje masterbatch (pigment ynhâld 50%-70%) fereasket mear dispersanten en bettere mingmooglikheden, wylst lege-konsintraasje masterbatch (10%-30%) rjochtet him op komptabiliteit.
2.2.4 Minimalisearje ynfloed op TPE-eigenskippen.
De masterbatch moat de elastisiteit fan 'e TPE net signifikant beynfloedzje, kompresje set, of abrasion ferset. Bygelyks, oermjittige dispersanten of smeermiddelen kinne de meganyske sterkte fan 'e TPE ferminderje.
2.2.5 Miljeubeskerming Compliance.
De formulearring moat foldwaan oan wrâldwide noarmen foar miljeubeskerming, it foarkommen fan giftige of skealike stoffen (lykas swiere metalen, ftalaten) dat koe beheine merk tagong.
2.3 Ferwurkingseasken fan TPE Masterbatch
TPE masterbatch ferwurking wurdt benammen útfierd mei help fan twin-screw extrusion technology, dat fereasket strange kontrôle fan grûnstoffen pretreatment, premixing, extrusion parameters, en postferwurking om produktkwaliteit te garandearjen. De wichtichste ferwurkingseasken binne as folget:
2.3.1 Raw Material Pretreatment.
TPEs (especially TPU, TPA) hawwe hege wetterabsorption, so all raw materials (TPE carrier, pigminten, tafoegings) moat goed droech wurde foardat ferwurking. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 oeren, TPS/TPO is dried at 80-100℃ for 3-5 oeren, and pigments are dried at 60-80℃ for 2-4 oeren. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Derneist, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 mesh) to improve dispersibility, and impurities (metal particles, stof) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigminten, carrier, tafoegings) 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, mingen tiid 5-10 minuten, 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 (temperatuer, screw snelheid, extrusion druk, feeding speed) must be precisely controlled to match the TPE type:
- – Temperatuer kontrôle: The barrel is divided into 4-6 temperatuer kontrôle seksjes (feeding seksje, melting seksje, mingen seksje, homogenizing seksje, die kop seksje). The temperature of each section is adjusted according to the TPE processing temperature. Bygelyks, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Screw Speed: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. High-viscosity TPEs (btw, TPC) require higher screw speed (500-800 rpm) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 rpm) to avoid material overflow.
- – Extrusion druk: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. Foar hege viskositeit TPE's, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (particle size 2-5mm), screened (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, elektryske, konstruksje, konsumint guod, and other industries, and different application fields have different requirements for TPE masterbatch performance (kleur, 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 Yndustry: The Largest Application Field of TPE Masterbatch
De auto-yndustry is de grutste konsumint fan TPE's, goed foar mear as 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.
TPEs (mainly TPV, TPO) are used to produce automotive door seals, finster sealen, hood seals, en pakkingen, which require good elasticity, waar ferset, en lege temperatuer fleksibiliteit. The masterbatch for these components requires uniform coloring, good weather resistance (UV ferset, 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 (hege viskositeit, 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.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, doar panielen, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (non-toxic, reukleas). 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.
TPEs (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, waarmte ferset, en meganyske sterkte. The masterbatch requires high-temperature resistance, oalje ferset, 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, presys temperatuer kontrôle, and high wear resistance, suitable for TPC/TPA masterbatch processing (hege temperatuer, hege viskositeit); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, transparânsje, impact ferset). 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, Anschlüsse, en oare komponinten, requiring functional masterbatch (antistatyske, flammefertragend, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (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, flammefertraging, en abrasion ferset. The masterbatch requires flame retardancy (meeting UL94 V-0 standert), antistatyske eigenskippen, and uniform coloring.
Matching Extruders: HTS PLUS rige, HTE rige, 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.
TPEs (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, impact ferset, 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 Bouw en ferfier yndustry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, en oare komponinten, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPEs (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV ferset, 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, and wear resistance. 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.
TPEs (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, abrasion ferset, 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, boartersguod, and other household items, which require non-toxic, reukleas, 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.
TPEs (mainly TPU, TPS) are used to produce medical catheters, spuiten, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 standert), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, presys temperatuer kontrôle, 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, wear ferset, en meganyske sterkte. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue's Folsleine Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue is al lang dwaande mei it ûndersyk, 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 (hege viskositeit, temperature sensitivity, moisture absorption) en de ferskate behoeften fan fabrikanten (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, mei in ridlike schroef 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, ferfierders, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Derneist, the screws adopt a modular design, which can freely combine different screw elements (oerbringe, mingen, skjirre) according to the TPE type. Bygelyks, 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 temperatuerkontrôle, 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, mei 4-6 independent temperature control sections, temperatuer kontrôle presyzje fan ± 1 ℃, en real-time temperatuermonitoring en alarmfunksjes. De barrel nimt in dûbellaach jasûntwerp oan, it realisearjen fan rappe ferwaarming en koeling, en ferbetterjen temperatuer antwurd snelheid. De diekop is foarsjoen fan in ûnôfhinklik apparaat foar temperatuerkontrôle, soargje foar stabile foarmjouwing fan de masterbatch strip.
4.1.3 Hege Wear Resistance en Corrosie Resistance.
Guon TPE masterbatches (lykas TPA, TPC) befetsje hege hurdens pigminten of tafoegings, dy't de skroef en barrel drage kin. De extruders fan Zhuoyue brûke wearbestindige materialen fan hege kwaliteit en avansearre produksjetechnologyen: HTS PLUS / SUPER / HTE rige skroeven en barrels binne makke fan ymportearre wear-resistant alloy stiel, ûndergiet bimetallic gearstalde of laser cladding behanneling, oerflak hurdens ≥65 HRC (HTS SUPER rige ≥70 HRC), tsjinst libben 2-3 kear dat fan gewoane extruders; HTS BASIC / ZTE rige screws en barrels wurde nitrided, oerflak hurdens ≥60 HRC, foldwaan oan 'e behoeften fan gewoane TPE masterbatchferwurking.
4.1.4 Vacuum Exhaust en Moisture Removal Mooglikheden.
TPE's lykas TPU en TPA hawwe hege wetterabsorption, en focht kin bubbels en defekten yn 'e masterbatch feroarsaakje. Alle Zhuoyue's mid-to-high-end extruders (HTS PLUS/SUPER/HTE) binne foarsjoen fan in fakuüm exhaust apparaat, dat kin effektyf fuortsmite focht, flechtige stoffen, en lucht yn it materiaal, it garandearjen fan de tichtens en kwaliteit fan 'e masterbatch. De fakuümgraad is ferstelber (0.06-0.09MPa), oanpasse oan ferskate easken foar focht ynhâld.
4.1.5 Hege produksje-effisjinsje en enerzjybesparring.
De extruders fan Zhuoyue nimme gearboxen mei hege koppel en optimalisearre skroefstruktueren oan, mei sterke conveying kapasiteit en hege produksje effisjinsje. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. Bygelyks, 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, allinnich de oerienkommende parameters moatte wurde neamd, it foarkommen fan werhelle debuggen. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, en foarsizzend ûnderhâld, it realisearjen fan yntelliginte produksjebehear.
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 (kleur masterbatch, flammefertragende masterbatch, antistatic masterbatch), with pigment content ranging from 10% nei 70%. They can also be matched with auxiliary equipment (high-speed mixers, droegers, koelers, 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, produksje skaal, en applikaasje easken.
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 ynhâld ≤50%). It is equipped with a PLC control system, automatyske temperatuer kontrôle, en 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 (btw, TPU, high-concentration TPE masterbatch, flammefertragende 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 (oerflak hurdens ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (hege viskositeit, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (flammefertragers, antistatic agents). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, medyske apparaten).
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), tsjinst libben 3-4 kear dat fan gewoane extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, en foarsizzend ûnderhâld. 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 (oerflak hurdens ≥60 HRC), foldwaan oan 'e behoeften fan gewoane TPE masterbatchferwurking (pigment ynhâld ≤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, leech enerzjyferbrûk, 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 (oerflak hurdens ≥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% ferlike mei gewoane 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, fanwege de unike eigenskippen fan TPE's (temperature sensitivity, moisture absorption, hege viskositeit), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 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.
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) Equipment: Worn screw mixing elements; blocked die head.
Solutions: (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 minuten. (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.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (mear as 3 minuten) 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).
Solutions: (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 Problem 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) Equipment: Screw/barrel material has poor wear resistance.
Solutions: (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 Problem 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.
Solutions: (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, 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); hege pigment ynhâld (mear as 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Equipment: Worn conveying elements; blocked die head.
Solutions: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, en applikaasje fjilden, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Case 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, Sina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment ynhâld 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), waarmte ferset (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Oplossing: Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Earste, 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. Twadde, the barrel is equipped with a double-layer jacket + forced cooling structure, mei 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. Tredde, 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. Derneist, 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: Nei 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 moannen, 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 Case 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, Sina, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment ynhâld 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), waarmte ferset (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Oplossing:
Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Earste, 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. Twadde, the barrel is equipped with a double-layer jacket + forced cooling structure, mei 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. Tredde, 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. Derneist, 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:
Nei 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 moannen, 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.