Le adhartas luath ann an gnìomhachas cruinneil, iarrtas airson stuthan àrd-choileanaidh ann an càraichean, dealain agus eileagtronaigeach, togail, tha raointean meidigeach agus eile a’ dol am meud bho latha gu latha. Plastaig innleadaireachd, mar phrìomh stuth àrd-choileanadh, mean air mhean air stuthan meatailt traidiseanta agus plastaic coitcheann a chuir an àite ann an iomadh suidheachadh tagraidh bunaiteach air sgàth na feartan meacanaigeach sàr-mhath aca, strì an aghaidh teas, strì an aghaidh creimeadh, seasmhachd meud agus comas giullachd. Is e teicneòlas eas-tharraing dà-sgriubha am prìomh theicneòlas giollachd de choimeasgaidhean plastaig innleadaireachd, agus tha coileanadh uidheamachd eas-tharraing gu dìreach a’ dearbhadh càileachd, èifeachdas toraidh agus buaidh tagraidh stuthan plastaig innleadaireachd.
Tha sinn dealasach a thaobh a bhith a’ toirt seachad fuasglaidhean eas-tharraing proifeasanta dà-sgriubha airson giollachd plastaic innleadaireachd, an urra ris na h-extruders sreath HTS againn a tha air an leasachadh gu neo-eisimeileach agus air an dèanamh le bogsaichean gèar àrd-torque, a tha air an dealbhadh gu sònraichte airson feartan giullachd agus feumalachdan tagraidh plastaic innleadaireachd. Bheir an artaigil seo mion-sgrùdadh farsaing air feartan coileanaidh, seòrsachadh, duilgheadasan giullachd innleadaireachd plastaig, prìomh àite teicneòlas eas-tharraing dà-sgriubha ann an giullachd plastaig innleadaireachd, na buannachdan a tha aig ar luchd-sgaoilidh sreath HTS agus an atharrachadh cuimsichte air plastaic innleadaireachd, a bharrachd air na raointean tagraidh sònraichte, dòighean làimhseachaidh agus duilgheadasan agus fuasglaidhean cumanta. Le bhith a’ cur ri crìochan teicnigeach mionaideach, mion-fhiosrachadh giollachd agus cùisean tagraidh gnìomhachais, the article will be enriched to 3000-4000 facail, providing comprehensive and professional reference for engineering plastics processing enterprises, technicians and relevant practitioners.
1. Overview of Engineering Plastics Industry and Core Performance Characteristics
1.1 Current Situation and Development Trend of Engineering Plastics Industry
Engineering plastics refer to a class of plastic materials that can be used as structural materials and bear mechanical loads in a wide temperature range. Compared with general plastics (such as polyethylene PE, polypropylene PP, polyvinyl chloride PVC), engineering plastics have more excellent comprehensive performance, and can meet the harsh use requirements in industrial production and high-end product manufacturing. Anns na bliadhnachan mu dheireadh, driven by the upgrading of downstream industries such as automotive lightweight, fiosrachadh dealain is dealanach, agus àrd-deireadh innealan meidigeach, tha margaidh plastaic innleadaireachd na cruinne air gluasad seasmhach is luath a nochdadh.
A rèir dàta gnìomhachais buntainneach, tha meud margaidh plastaig innleadaireachd cruinne air a dhol thairis air 100 billean dolar na SA, agus thathar an dùil ìre fàis bliadhnail iom-fhillte de 7%-10% anns na còig bliadhna ri teachd. Nam measg, Is e Asia-Pacific am margaidh cinneasachaidh is caitheamh plastaig innleadaireachd as motha san t-saoghal, cunntas a thoirt air barrachd na 55% de roinn margaidh na cruinne, sa mhòr-chuid air sgàth leasachadh luath càraichean, gnìomhachasan dealain is dealanach ann an Sìona, Na h-Innseachan agus dùthchannan eile, a bharrachd air leasachadh leantainneach air comas taic gnìomhachais agus ìre ùr-ghnàthachadh teicneòlach. Sìona, mar an neach-cleachdaidh agus riochdaire plastaic innleadaireachd as motha san t-saoghal, tha iarrtas mòr sa mhargaidh, and the annual output and consumption are growing at a double-digit rate, especially in the fields of new energy vehicles, 5G communications, agus innealan meidigeach, the demand for high-performance engineering plastics is showing an explosive growth trend.
The development trend of the engineering plastics industry is mainly reflected in five aspects: a’ chiad, high performance and functionalization. With the continuous improvement of use requirements in downstream fields, engineering plastics are developing towards higher heat resistance, higher strength, better wear resistance and special functions (such as flame retardancy, antistatic, antibacterial, radiation resistance), to adapt to the harsh working environment of high temperature, high pressure, corrosion and radiation; an dàrna, lightweight and integration. In the automotive, aerospace and other fields, in order to achieve energy saving and emission reduction goals, engineering plastics are increasingly used to replace metal materials, and the integration of product design is becoming higher and higher, which can reduce the number of parts, simplify the production process and reduce costs; an treas, environmental protection and recyclability. With the strengthening of global environmental protection policies and the improvement of environmental protection awareness, the development and application of recyclable engineering plastics, biodegradable engineering plastics and environmentally friendly processing technologies have become the focus of the industry, reducing environmental pollution caused by plastic waste; fourth, intelligence and precision of processing equipment. Tha duilgheadas giullachd àrd aig plastaic innleadaireachd agus riatanasan càileachd teann, a chuir air adhart riatanasan nas àirde air uidheamachd giollachd. Inntinneach, tha extruders dà-sgriubha mionaideach agus èifeachdach agus loidhnichean cinneasachaidh fèin-ghluasadach air a thighinn gu bhith mar phrìomh shruth sa ghnìomhachas, a’ coileanadh sgrùdadh fìor-ùine, atharrachadh paramadair fèin-ghluasadach agus cumail suas ro-innse air a’ phròiseas giollachd; an còigeamh, iomadachadh raointean tagraidh. Tha plastaic innleadaireachd a’ leudachadh mean air mhean bho chàraichean traidiseanta, raointean dealain is dealanach gu lùth ùr, lèigheil, aerospace, togail agus raointean eile a tha a’ tighinn am bàrr, fosgladh àite margaidh ùr.
An aghaidh a' chùl-fhiosrachaidh seo, teicneòlas eas-tharraing dà-sgriubha, mar phrìomh theicneòlas giollachd de choimeasgaidhean plastaig innleadaireachd, air a thighinn gu bhith na phrìomh dhòigh air farpaiseachd iomairtean plastaic innleadaireachd a leasachadh. Engineering plastics are sensitive to overheating and hydrolytic degradation, and have high requirements on processing temperature, shear force, residence time and temperature control precision. Our HTS series extruders are specially designed for the processing characteristics of engineering plastics, with high torque, high speed, precise temperature control and excellent dispersibility, which can effectively solve the processing difficulties of engineering plastics and help enterprises achieve high-quality, efficient and stable production.
1.2 Core Performance Characteristics of Engineering Plastics
Compared with general plastics and metal materials, engineering plastics have unique comprehensive performance, which determines their wide application in various industrial fields. Tha prìomh fheartan coileanaidh plastaic innleadaireachd air an nochdadh sa mhòr-chuid anns na còig taobhan a leanas, a chuir air adhart cuideachd riatanasan sònraichte airson an teicneòlas giullachd agus an uidheamachd aca:
1.2.1 Sàr-aghaidh teas agus strì an aghaidh fuachd
Tha raon atharrachaidh teòthachd farsaing aig plastaic innleadaireachd, a chumas deagh fheartan meacanaigeach (neart, cruas, cruas) an dà chuid ann an àrainneachdan teòthachd àrd agus ìosal. Compared with general plastics, a bhios mar as trice a’ call am feartan meacanaigeach aig 80-120 ℃, faodaidh a’ mhòr-chuid de phlastaig innleadaireachd obrachadh gu seasmhach aig 100-250 ℃, agus cuid de phlastaig innleadaireachd sònraichte (leithid PEEK, PI) faodaidh eadhon obrachadh aig teòthachd os cionn 300 ℃. Aig an aon àm, tha deagh sheasamh an aghaidh fuachd aig plastaic innleadaireachd cuideachd, a tha comasach air deagh chruas a chumail aig teòthachd ìosal (gu h-ìosal -40 ℃), agus chan eil iad furasta am briseadh briste. Tha an coileanadh seo a’ dèanamh plastaigean innleadaireachd a tha freagarrach airson an cleachdadh ann an àrainneachdan teodhachd cruaidh, leithid pàirtean einnsean chàraichean (teòthachd àrd) agus uidheamachd dealain a-muigh (teòthachd ìosal).
Tha an sàr-aghaidh teas de phlastaig innleadaireachd gu ìre mhòr mar thoradh air an structar moileciuil sònraichte aca (leithid fàinneachan aromatic, fàinneachan heterocyclic) agus feachdan làidir eadar-mholacileach, a tha gan dèanamh nach eil furasta an leaghadh agus an lobhadh aig teòthachd àrd. Ge-tà, tha seo cuideachd a’ toirt cuid de dhuilgheadasan ann an giullachd: tha feum air teòthachd giollachd nas àirde gus toirt orra leaghadh agus plastachadh, agus tha feum air smachd teothachd mionaideach gus lobhadh teirmeach a sheachnadh.
1.2.2 Deagh sheasamh an aghaidh creimeadh agus seasmhachd
Tha seasmhachd ceimigeach sàr-mhath agus strì an aghaidh creimeadh aig plastaic innleadaireachd, agus chan eil iad furasta a bhith air an corrachadh le acids, alkalis, salainn, organic solvents and other chemicals. Compared with metal materials, which are easy to rust and corrode, engineering plastics have longer service life in harsh chemical environments. Mar eisimpleir, polyamide (PA) engineering plastics are resistant to most organic solvents and weak acids and alkalis; polycarbonate (PC) engineering plastics are resistant to corrosion by non-oxidizing acids and salts; polyphenylene sulfide (PPS) engineering plastics are resistant to corrosion by almost all chemicals except strong oxidizing acids.
A bharrachd air, engineering plastics have good weather resistance and aging resistance, and are not easy to degrade and age under the action of sunlight, rain, oxygen and other environmental factors, which ensures their long-term stable use in outdoor and harsh environments. This performance makes engineering plastics widely used in chemical equipment, outdoor electrical equipment, automotive exterior parts and other fields.
1.2.3 Easy Processing and High Production Efficiency
Compared with metal materials, engineering plastics have the advantages of easy processing, simple production process and high production efficiency. Metal materials usually need complex processing procedures such as forging, casting, innealachadh, which have high energy consumption, low efficiency and high cost; while engineering plastics can be processed by extrusion, cumadh stealladh, blow molding and other methods, which can realize mass production, simplify the production process, reduce energy consumption and production cost. Mar eisimpleir, the processing cycle of an engineering plastic automotive part by injection molding is only a few seconds to tens of seconds, while the processing cycle of the same metal part may take several hours to several days.
Ge-tà, engineering plastics also have certain processing difficulties: they are sensitive to overheating and hydrolytic degradation, and are easy to decompose if the processing temperature is too high or the residence time is too long; Aig an aon àm, some engineering plastics (leithid PA) tha sùghadh uisge àrd aca, which affects the processing effect and product quality. Uime sin, it is necessary to use professional processing equipment and scientific processing techniques to ensure the processing quality.
1.2.4 Excellent Dimensional Stability and Electrical Insulation
Engineering plastics have good dimensional stability, and the shrinkage rate is small (usually 0.3%-1.5%) during processing and use, which can ensure the dimensional accuracy of products and avoid deformation. This performance is particularly important for high-precision parts, such as electrical connectors, automotive precision components, innealan meidigeach, etc. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) agus feachdan làidir eadar-mholacileach.
A bharrachd air, most engineering plastics have excellent electrical insulation performance, which can maintain good insulation performance in a wide temperature range and frequency range, and are not easy to conduct electricity and arc. This makes engineering plastics widely used in electrical and electronic fields, such as wiring boards, cable ties, connectors, relays, motors and other electrical components.
1.2.5 Light Weight and High Specific Strength, Outstanding Wear Resistance
Engineering plastics have the characteristics of light weight (density is 1/3-1/5 of metal materials) and high specific strength (strength per unit weight is equivalent to or even higher than that of metal materials). Mar eisimpleir, neart sònraichte polyamide ath-neartachadh snàithleach glainne (PA66+GF30) nas àirde na stàilinn gualain àbhaisteach, a dh’ fhaodadh cuideam thoraidhean a lughdachadh gu h-èifeachdach fhad ‘s a nì iad cinnteach à coileanadh meacanaigeach. Tha an coileanadh seo gu sònraichte cudromach ann an càraichean, aerospace agus raointean eile a tha an tòir air cuideam aotrom agus sàbhaladh lùtha, a dh’ fhaodadh caitheamh connaidh agus sgaoilidhean gualain a lughdachadh.
Aig an aon àm, tha neart caitheamh sònraichte agus strì an aghaidh brisidh aig plastaic innleadaireachd cuideachd, agus tha an co-èifeachd brisidh beag, a dh'fhaodar a chleachdadh ann a bhith a 'dèanamh phàirtean caitheamh-dhìonach (leithid gèaraichean, giùlan, blocaichean sleamhnachaidh) às aonais lubrication a bharrachd no le nas lugha de lubrication, lùghdachadh cosgais cumail suas bathar. Mar eisimpleir, polyoxymethylene (POM) tha deagh neart caitheamh aig plastaic innleadaireachd agus canar iad “stàilinn plastaig”, which is widely used in the production of automotive gears, electrical components and other wear-resistant parts.
1.3 Common Classification of Engineering Plastics
Engineering plastics can be divided into different types according to their chemical structure, performance level and application field. The common classification methods are as follows, which helps to better understand the processing characteristics and application scenarios of different engineering plastics, and select appropriate extrusion equipment and processing techniques:
1.3.1 Classification by Performance Level
According to the performance level, engineering plastics can be divided into general engineering plastics and special engineering plastics.
- General Engineering Plastics: They are the most widely used engineering plastics, with relatively mature production technology, prìs meadhanach agus coileanadh coileanta math. Am measg nam prìomh sheòrsachan tha polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), terephthalate polyethylene (Peata), terephthalate polybutylene (PBT), etc. Tha plastaic innleadaireachd coitcheann air a chleachdadh sa mhòr-chuid ann an càraichean, dealain agus eileagtronaigeach, innealan dachaigh agus raointean eile, leithid pàirtean càr, luchd-ceangail dealain, sligean inneal dachaigh, etc.
- Plastaig innleadaireachd sònraichte: Tha coileanadh nas sàr-mhath aca (leithid dìon teas nas àirde, strì an aghaidh creimeadh, feartan meacanaigeach) na plastaig innleadaireachd coitcheann, ach tha an teicneòlas toraidh iom-fhillte agus tha a’ phrìs àrd. Am measg nam prìomh sheòrsachan tha polyphenylene sulfide (PPS), polyether ketone (PEIC), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), etc. Tha plastaig innleadaireachd sònraichte air a chleachdadh sa mhòr-chuid ann an raointean àrd-ìre leithid aerospace, innealan meidigeach, lùth ùr, agus uidheam ceimigeach, leithid co-phàirtean aerospace, implantan meidigeach, co-phàirtean dealain àrd-teòthachd, etc.
1.3.2 Seòrsachadh a rèir Structar Ceimigeach
According to the chemical structure of the molecular chain, engineering plastics can be divided into polyamide (PA), polycarbonate (PC), polyoxymethylene (POM), polyester (Peata, PBT), polyphenylene sulfide (PPS), polyether ketone (PEIC), etc. Each type of engineering plastic has its own unique performance characteristics and processing requirements:
- Polyamide (PA): Also known as nylon, it has excellent mechanical strength, strì an aghaidh caitheamh, toughness and chemical resistance, but has high water absorption, which affects the dimensional stability. Common varieties include PA6, PA66, PA11, PA12, etc. It is widely used in automotive parts (gears, giùlan, intake manifolds), luchd-ceangail dealain, textile fibers, etc.
- Polycarbonate (PC): It has excellent transparency, neart buaidh, heat resistance and electrical insulation, but has poor wear resistance and is easy to scratch. It is widely used in electrical and electronic fields (wiring boards, lamp covers), automotive fields (headlamp lenses, instrument panels), medical fields (medical containers), etc.
- Polyoxymethylene (POM): It has excellent wear resistance, friction resistance, dimensional stability and mechanical strength, and is not easy to absorb water. It is known as “stàilinn plastaig” and is widely used in automotive parts (gears, blocaichean sleamhnachaidh), electrical components (suidse, giùlan), mechanical parts, etc.
- Polyester (Peata, PBT): PET has excellent transparency, heat resistance and mechanical strength, and is mainly used in fibers, filmichean, bottles and other fields; PBT has excellent chemical resistance, electrical insulation and processing fluidity, and is widely used in electrical and electronic fields (connectors, relays), pàirtean càr, etc.
- Polyphenylene Sulfide (PPS): Tha an aghaidh teas sàr-mhath aige (long-term use temperature up to 200-220℃), strì an aghaidh creimeadh, flame retardancy and electrical insulation, but has poor toughness. It is widely used in high-temperature resistant electrical components, automotive engine parts, chemical equipment, etc.
- Polyether Ether Ketone (PEIC): It has excellent comprehensive performance, long-term use temperature up to 250-300℃, good corrosion resistance, mechanical strength and biocompatibility. It is mainly used in high-end fields such as aerospace, implantan meidigeach, and high-temperature resistant electrical components.
1.3.3 Classification by Application Field
According to the application field, engineering plastics can be divided into automotive-grade engineering plastics, electrical-grade engineering plastics, medical-grade engineering plastics, aerospace-grade engineering plastics, etc. Different application fields have different requirements on the performance of engineering plastics. Mar eisimpleir, automotive-grade engineering plastics require good heat resistance, impact strength and weather resistance; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, cuideam ìosal agus àrd neart.
2. Prìomh theicneòlas giollachd de phlastaig innleadaireachd: Teicneòlas eas-tharraing Twin-Screw
Tha giollachd plastaic innleadaireachd sa mhòr-chuid a’ toirt a-steach eas-tharraing, cumadh stealladh, cumadh buille, cumadh agus dòighean eile, am measg sin tha teicneòlas eas-tharraing dà-sgriubha na phrìomh theicneòlas airson cinneasachadh todhar plastaig innleadaireachd (leithid plastaig innleadaireachd atharraichte, plastaig innleadaireachd neartaichte) agus toraidhean leth-chrìochnaichte (leithid pìoban, duilleagan, snàithleach). An coimeas ri teicneòlas eas-tharraing aon-sgriubha, Tha buannachdan aig teicneòlas eas-tharraing dà-sgriubha bho fheachd rùsgaidh làidir, deagh bhuaidh measgachadh, smachd teòthachd mionaideach, ùine còmhnaidh goirid agus sùbailteachd làidir airson stuthan amh, as urrainn fuasgladh fhaighinn air duilgheadasan giullachd plastaig innleadaireachd (leithid cugallachd ri cus teasachadh agus truailleadh hydrolytic, droch bhuaidh measgachadh, èifeachdas giollachd ìosal) and ensure the quality of engineering plastic products.
2.1 Processing Difficulties of Engineering Plastics and Requirements for Extrusion Equipment
As mentioned earlier, engineering plastics have excellent comprehensive performance, but their processing difficulty is also higher than that of general plastics, mainly due to their special molecular structure and performance characteristics. The main processing difficulties of engineering plastics and the corresponding requirements for extrusion equipment are as follows:
2.1.1 Sensitivity to Overheating and Hydrolytic Degradation
Most engineering plastics (leithid PA, PBT, PPS) are sensitive to overheating and hydrolytic degradation. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, a lùghdaicheas feartan meacanaigeach, strì an aghaidh teas agus coileanadh eile an toraidh, agus eadhon ag adhbhrachadh dath dath, carbonization agus uireasbhaidhean eile. A bharrachd air, some engineering plastics (leithid PA) tha sùghadh uisge àrd aca, agus bidh an taiseachd anns an stuth ag adhbhrachadh truailleadh hydrolytic tron phròiseas giollachd àrd-teòthachd, toirt buaidh air càileachd toraidh.
Tha seo a’ cur air adhart dà phrìomh riatanas airson uidheamachd eas-tharraing: a’ chiad, comas smachd teothachd mionaideach, as urrainn smachd teann a chumail air an teòthachd giollachd taobh a-staigh an raon as fheàrr de phlastaig innleadaireachd, seachain cus teas ionadail, agus bu chòir cruinneas smachd teothachd ruighinn ± 1 ℃; an dàrna, ùine còmhnaidh goirid, a dh’ fhaodadh an ùine a bhios an stuth a’ fuireach anns a’ bharaille extruder a lughdachadh, seachain lobhadh teirmeach agus truailleadh hydrolytic. Tha buannachdan aig extruders dà-sgriubha airson ùine còmhnaidh goirid (usually 1-5 mionaidean) agus smachd teothachd mionaideach, which are more suitable for engineering plastics processing than single-screw extruders (àm còmhnaidh 5-10 mionaidean).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, freumhag gualain, talc, luchd-dìon lasair, compatibilizers) to improve the performance of the product (such as reinforcing, toughening, lasair-aghaidh). Mar eisimpleir, adding glass fiber to PA can improve its strength and dimensional stability; adding flame retardants to PBT can improve its flame retardancy. The uniform mixing and dispersion of modifiers in the engineering plastic matrix is crucial to the performance of the final product. If the mixing and dispersing effect is poor, the modifiers will agglomerate, resulting in uneven performance of the product, and even reduce the mechanical properties of the product.
Feumaidh seo gum bi feachd rùsgaidh làidir agus comas measgachaidh aig an uidheamachd eas-tharraing. Bidh extruders dà-sgriubha a’ gabhail ri structar dà-sgriubha co-chuairteachaidh no counter-rothlach, agus faodaidh an gluasad coimeasach eadar na sgriothan feachd rùsgaidh làidir agus feachd glùineachaidh a ghineadh, a tha comasach air na h-innealan-atharrachaidh a bhriseadh gu tur, dèan na mion-atharraichean sgapte gu cothromach ann am matrix plastaig innleadaireachd, agus dèanamh cinnteach à buaidh measgachadh is sgapadh. A bharrachd air, faodaidh dealbhadh modular an sgriubha chàraid diofar eileamaidean sgriubha a thoirt còmhla gu saor (leithid eileamaidean giùlan, measgachadh eileamaidean, eileamaidean rùsgaidh) a rèir an t-seòrsa plastaig innleadaireachd agus mion-atharrachaidh, tuilleadh leasachaidh air a’ bhuaidh measgachaidh agus sgapadh.
2.1.3 Riatanasan àrda a thaobh caitheamh an aghaidh uidheamachd
Ann an giullachd plastaig innleadaireachd neartaichte (leithid PA air a dhaingneachadh le fiber glainne, carbon fiber reinforced PPS), the added glass fiber, carbon fiber and other modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder during the extrusion process. If the screw and barrel have poor wear resistance, they will be worn quickly, resulting in reduced shearing force and mixing capacity of the extruder, affecting the product quality and reducing the service life of the equipment.
This requires the screw and barrel of the extruder to be made of high-quality wear-resistant materials and processed by advanced manufacturing technology. Our HTS series extruders adopt imported wear-resistant alloy steel for the screw and barrel, and undergo bimetallic composite treatment or laser cladding treatment, a tha gu mòr a’ leasachadh an aghaidh caitheamh agus an aghaidh creimeadh an sgriubha agus a’ bharaille, agus is urrainn dhaibh atharrachadh gu bhith a’ giullachd plastaigean innleadaireachd daingnichte le atharraichean cruas àrd.
2.1.4 Riatanasan àrda air làimhseachadh fluidity agus smachd cuideam
Cuid de phlastaig innleadaireachd (leithid PPS, PEIC) tha slaodachd àrd agus dìth làimhseachaidh siùbhlach, a dh’ fheumas comas giùlain làidir agus comas smachd cuideam a bhith aig an extruder gus dèanamh cinnteach à adhartas rèidh eas-tharraing. Mura h-eil an comas giùlain gu leòr no ma tha an smachd cuideam neo-sheasmhach, bidh e ag adhbhrachadh astar eas-tharraing neo-chòmhnard, meud toraidh neo-sheasmhach, agus eadhon bacadh uidheamachd.
Tha comas giùlain làidir aig extruders dà-sgriubha agus comas smachd cuideam seasmhach. Faodaidh eadar-luachadh nan sgriothan càraid feachd pumpaidh làidir a ghineadh, which can effectively convey high-viscosity engineering plastic materials; Aig an aon àm, the extruder is equipped with a high-precision pressure sensor, which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, which involves the interaction of multiple factors such as temperature, cuideam, shear force and time. The core purpose is to melt and plasticize the engineering plastic raw materials and modifiers, mix them uniformly, and then extrude them into the required shape (such as particles, pìoban, duilleagan, snàithleach) through the die head. Tha am prionnsapal obrach sònraichte agus sruth pròiseas mar a leanas:
2.2.1 Pretreatment Stuth Raw
Tha pretreatment stuthan amh na bhunait airson giollachd eas-tharraing plastaic innleadaireachd, a bheir buaidh dhìreach air buaidh giollachd agus càileachd toraidh. Tha na stuthan amh de phlastaig innleadaireachd sa mhòr-chuid a’ toirt a-steach roisinn plastaig innleadaireachd (leithid PA, PC, POM), luchd-atharrachaidh (such as glass fiber, freumhag gualain, talc, luchd-dìon lasair), compatibilizers, bealaidh agus stuthan cur-ris eile. Tha na ceumannan pretreatment mar a leanas:
- Làimhseachadh a 'tiormachadh: Most engineering plastics (leithid PA, PBT, PPS) tha sùghadh uisge àrd aca, agus bidh an taiseachd anns na stuthan amh ag adhbhrachadh truailleadh hydrolytic aig àm giollachd àrd-teòthachd, mar thoradh air easbhaidhean toraidh (leithid builgeanan, sgàinidhean, lùghdachadh feartan meacanaigeach). Uime sin, feumaidh na stuthan amh a bhith air an tiormachadh mus tèid an giullachd. Tha an teòthachd agus an ùine tiormachaidh air an co-dhùnadh a rèir an seòrsa de phlastaig innleadaireachd: Mar eisimpleir, Tha PA6 air a thiormachadh aig 80-100 ℃ airson 4-6 uairean, Tha PA66 air a thiormachadh aig 100-120 ℃ airson 6-8 uairean, PBT is dried at 120-140℃ for 2-4 uairean, PPS is dried at 150-160℃ for 3-5 uairean. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: According to the formula ratio, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. The mixing speed is generally 800-1200 rpm, and the mixing time is 5-10 mionaidean. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (such as glass fiber), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 mogal.
2.2.2 A 'biadhadh agus a' giùlan
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding. Tha an hopair beathachaidh cuideachd uidheamaichte le inneal tiormachaidh gus casg a chuir air na stuthan amh bho bhith a’ gabhail a-steach taiseachd a-rithist nuair a bhios iad ag ithe.
2.2.3 A' leaghadh, A 'measgachadh agus a' rùsgadh
Tha na stuthan a tha a’ dol a-steach do chuas eas-tharraing an extruder dà-sgriubha air am putadh air adhart gu leantainneach leis na sgriothan rothlach. Tha an cuas eas-tharraing air a dhèanamh suas de sgriubha agus baraille, agus bidh meud a’ chuas eas-tharraing a ’dol sìos mean air mhean air taobh an axis. Nuair a thionndaidheas na sgriothan, tha na stuthan air an teannachadh mean air mhean fo ghnìomhachd nan sgriothan agus a’ bharaille, agus bidh an cuideam anns a’ chuas eas-tharraing ag àrdachadh mean air mhean (san fharsaingeachd 5-15MPa).
Aig an aon àm, tha na stuthan fo smachd feachd rùsgaidh làidir agus feachd brisidh air a chruthachadh leis a’ ghluasad dàimheach eadar na sgriothan agus am baraille, a bharrachd air eadar na tursan-adhair sgriubha. Faodaidh an fheachd rùsgaidh agus an fheachd suathaidh na cruinneachaidhean de mhion-atharraichean a bhriseadh gu tur, dèan na mion-atharraichean air an sgapadh gu cothromach anns an roisinn plastaig innleadaireachd leaghte, agus a’ brosnachadh fusion agus co-chòrdalachd eadar an inneal-atharrachaidh agus an roisinn. Faodaidh an fheachd brisidh cuideachd beagan teas a ghineadh, a tha air a chur còmhla ri teasachadh taobh a-muigh a 'bharaille (teasachadh dealain no teasachadh smùid) gus an roisinn plastaig innleadaireachd a leaghadh agus a phlastaig mean air mhean.
Mar as trice tha baraille an extruder air a roinn ann 4-6 earrannan smachd teothachd (roinn beathachaidh, earrann leaghaidh, earrann measgachadh, roinn homogenizing, roinn ceann bàs), agus tha teòthachd gach earrann air a smachdachadh gu mionaideach a rèir an seòrsa plastaig innleadaireachd. Mar eisimpleir, nuair a bhios tu a’ giullachd PA66+GF30 (snàithleach glainne air a dhaingneachadh PA66), is e teòthachd na h-earrainn beathachaidh 120-140 ℃, tha an earrann leaghaidh 250-260 ℃, tha an earrann measgachadh 260-270 ℃, tha an earrann homogenizing 250-260 ℃, agus tha an earrann ceann die 240-250 ℃. Faodaidh an smachd teothachd mionaideach dèanamh cinnteach gu bheil an roisinn air a leaghadh gu h-iomlan gun lobhadh teirmeach, agus tha na mion-atharraichean air an sgapadh gu cothromach.
2.2.4 Extrusion agus cumadh
An làn leaghadh, tha stuth measgaichte agus sgapte air a phutadh gu ceann die an extruder leis na sgriothan. Tha an ceann die air a dhealbhadh a rèir cumadh an toraidh deireannach: airson a bhith a’ dèanamh todhar plastaig innleadaireachd (gràinneagan), tha an ceann die air a uidheamachadh le grunn thuill bàis cruinn (tha àireamh agus meud nan tuill bàsachadh air an co-dhùnadh a rèir meud gràin nan gràinneagan); airson pìoban a dhèanamh, duilleagan, snàithleach, tha an ceann die air a dhealbhadh ann an cumaidhean co-fhreagarrach (leithid bàs cruinn airson pìoban, bàsachadh còmhnard airson duilleagan).
Tha an stuth air a thoirt a-mach às a’ cheann die aig astar àrd gus toraidhean leth-chrìochnaichte leantainneach a chruthachadh (such as strips for granules, pìoban, duilleagan). The temperature of the die head is slightly lower than that of the homogenizing section, which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, agus tha an ùine fuarachaidh 2-5 mionaidean; for pipes and sheets, air cooling or water spray cooling is used, agus bu chòir smachd a chumail air an astar fuarachaidh gus deformachadh toraidh a sheachnadh air sgàth fuarachadh neo-chòmhnard. Faodaidh fuarachadh luath toirt air na toraidhean leth-chrìochnaichte daingneachadh gu sgiobalta, cumail suas cumadh agus meud nan toraidhean, agus a’ leasachadh feartan meacanaigeach nan toraidhean.
2.2.6 Gearradh agus post-giollachd
An dèidh fuarachadh agus solidification, tha na toraidhean leth-chrìochnaichte air an giullachd a-steach don toradh deireannach tro ghearradh no ceumannan iar-ghiollachd eile. Airson cinneasachadh stuthan plastaig innleadaireachd (gràinneagan), thèid na stiallan fuarach a chuir gu granulator airson gearradh, agus tha an granulator uidheamaichte le sgian rothlach, as urrainn na stiallan a ghearradh gu toraidhean gràineach le meud èideadh (mar as trice tha meud na gràin 2-5mm, a ghabhas atharrachadh a rèir feumalachdan luchd-cleachdaidh). Airson pìoban agus siotaichean a dhèanamh, tha na toraidhean leth-chrìochnaichte fuarach air an gearradh a-steach don fhad a tha a dhìth tro inneal gearraidh; airson cinneasachadh snàithleach, bidh na filamentan fuarach air an tarraing agus air an leòn gus toraidhean fiber a chruthachadh.
A bharrachd air, feumaidh an toradh deireannach cuideachd a dhol tro cheumannan iar-ghiollachd leithid sgrìonadh, sgrùdadh agus pacadh. Is e an ceum sgrìonaidh toraidhean gun teisteanas a thoirt air falbh (leithid ro mhòr, mìrean ro bheag no cruinnichte); is e an ceum sgrùdaidh coileanadh a lorg (leithid neart meacanaigeach, strì an aghaidh teas, cruinneas meud) den toradh gus dèanamh cinnteach gu bheil e a’ coinneachadh ri riatanasan an neach-ceannach; is e an ceum pacaidh an toradh barrantaichte a phacadh ann an dòigh seulaichte agus dìon-taise gus casg a chuir air an toradh bho bhith a’ gabhail a-steach taiseachd agus a ’toirt buaidh air càileachd.
2.3 Prìomh fhactaran a bheir buaidh air plastaic innleadaireachd Buaidh eas-tharraing dà-sgriubha
Bidh buaidh eas-tharraing dà-sgriubha a’ toirt buaidh dhìreach air càileachd agus coileanadh thoraidhean plastaig innleadaireachd. Tha grunn nithean ann a tha a’ toirt buaidh air a’ bhuaidh eas-tharraing, sa mhòr-chuid a’ toirt a-steach feartan stuthan amh, co-mheas foirmle, buaidh premixing, crìochan eas-tharraing agus structar ceann bàs. Le bhith a’ maighstireachd nam prìomh nithean sin agus a’ dèanamh atharrachaidhean saidheansail faodaidh sin dèanamh cinnteach à seasmhachd a’ bhuaidh eas-tharraing agus cunbhalachd càileachd toraidh.
2.3.1 Feartan stuthan amh
An seòrsa, meud gràin, tha susbaint taiseachd agus purrachd stuthan amh a’ toirt buaidh mhòr air a ’bhuaidh eas-tharraing. Mar eisimpleir, bu chòir meud gràinean roisinn plastaig innleadaireachd agus mion-atharraichean a bhith èideadh; ma tha meud nam pìosan mì-chothromach, bidh e a 'leantainn gu leaghadh neo-chòmhnard agus measgachadh stuthan. Feumar smachd teann a chumail air susbaint taiseachd stuthan amh gu h-ìosal 0.1%-0.2%; ma tha an taiseachd ro àrd, bidh e ag adhbhrachadh truailleadh hydrolytic den stuth agus builgeanan san toradh. The purity of raw materials is also very important; impurities in raw materials (such as metals, stones, duslach) will not only affect the product quality, but also wear the screw and barrel of the extruder, and even cause equipment blockage.
2.3.2 Formula Ratio
The formula ratio of engineering plastic compounds (the ratio of resin, modifiers and additives) is the key to determining the performance of the product. The type and dosage of modifiers should be determined according to the performance requirements of the product. Mar eisimpleir, a' cur 20%-40% of glass fiber to PA can significantly improve its strength and dimensional stability, but excessive glass fiber will reduce the toughness and processing fluidity of the product. The type and dosage of additives also need to be reasonably matched: faodaidh compatibilizers an co-chòrdalachd eadar mion-atharraichean agus roisinn a leasachadh, agus tha an dosachadh san fharsaingeachd 0.5%-2%; faodaidh bealaidh an suathadh eadar stuthan agus uidheamachd a lughdachadh, leasachadh fluidity giollachd, agus tha an dosachadh san fharsaingeachd 0.3%-1%; faodaidh antioxidants casg a chuir air an stuth bho bhith a’ truailleadh oxidation teirmeach aig àm giollachd, agus tha an dosachadh san fharsaingeachd 0.1%-0.5%.
2.3.3 Buaidh Premixing
Is e premixing bunait giollachd eas-tharraing. Bidh èideadh premixing a’ toirt buaidh dhìreach air buaidh measgachadh is sgapadh luchd-atharrachaidh rè eas-tharraing. Ma tha an premixing neo-chothromach, chan urrainnear na mion-atharraichean a chumail gu co-ionnan ri uachdar an roisinn, mar thoradh air cruinneachadh ionadail de mhion-atharraichean, measgachadh neo-chòmhnard de stuthan rè eas-tharraing, agus lùghdachadh ann an coileanadh toraidh. Gus dèanamh cinnteach à buaidh premixing, tha e riatanach smachd a chumail air astar measgachadh, measgachadh ùine agus teòthachd measgachadh: tha an astar measgachadh 800-1200 rpm, tha an ùine measgachadh 5-10 mionaidean, agus tha an teòthachd measgachadh air a smachdachadh aig 40-60 ℃ (faodaidh teòthachd iomchaidh leasachadh a dhèanamh air a bhith a 'cur ris na stuthan agus a' brosnachadh measgachadh èideadh).
2.3.4 Paramadairean eas-tharraing
Is e paramadairean eas-tharraing na factaran as cudromaiche a bheir buaidh air a’ bhuaidh eas-tharraing, sa mhòr-chuid a’ toirt a-steach astar sgriubha, teòthachd eas-tharraing agus cuideam eas-tharraing.
- Luas sgriubha: Tha astar sgriubha extruders dà-sgriubha airson plastaic innleadaireachd sa chumantas eadar 100 gu 1000 rpm. Faodaidh an t-sreath extruders sreath HTS againn astar as àirde a ruighinn 1000 rpm. Mar as àirde an astar sgriubha, mar as motha am feachd rùsgaidh agus an fheachd brisidh a gheibh na stuthan, 's ann as fheàrr a bhios buaidh measgachaidh agus sgapadh luchd-atharrachaidh, agus mar as àirde an èifeachdas toraidh. Ge-tà, ma tha astar an sgriubha ro àrd, tha ùine còmhnaidh nan stuthan anns a’ chuas eas-tharraing ro ghoirid, mar thoradh air leaghadh neo-iomlan an roisinn, measgachadh gu leòr de stuthan, agus càileachd toraidh neo-chothromach; ma tha astar an sgriubha ro ìosal, chan eil an fheachd rùsgaidh agus an fheachd brisidh gu leòr, chan urrainn na h-atharraichean a bhith air an sgapadh gu tur, agus tha an èifeachdas toraidh ìosal. Bu chòir astar an sgriubha atharrachadh a rèir an seòrsa plastaig innleadaireachd agus an seòrsa mion-atharrachaidh: airson plastaic innleadaireachd àrd-viscosity (leithid PPS, PEIC), tha feum air astar sgriubha nas ìsle gus dèanamh cinnteach gu bheil leaghadh agus measgachadh gu leòr ann; airson plastaic innleadaireachd daingnichte (leithid PA air a dhaingneachadh le fiber glainne), tha feum air astar sgriubha nas àirde gus dèanamh cinnteach gu bheil snàithleach glainne a’ sgapadh gu cothromach.
- Teòthachd extrusion: Is e an teòthachd eas-tharraing an rud as cudromaiche airson dèanamh cinnteach à leaghadh agus plastadh plastaic innleadaireachd. Feumar smachd mionaideach a chumail air teòthachd gach earrann den bharaille agus ceann bàsachadh a rèir an seòrsa plastaig innleadaireachd. Tha teòthachd an earrann beathachaidh nas ìsle (beagan nas àirde na an teòthachd tiormachaidh de na stuthan amh), which is mainly to prevent the materials from caking and ensure smooth feeding; tha teòthachd na h-earrainn leaghaidh meadhanach, which is mainly to promote the melting and plasticization of the resin; the temperature of the mixing section is higher, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of modifiers; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, which is to ensure the shaping effect of the semi-finished products. The temperature control precision should reach ±1℃ to avoid local overheating and thermal decomposition of the material.
- Extrusion Brùthadh: Mar as trice tha an cuideam eas-tharraing de phlastaig innleadaireachd às-tharraing dà-sgriubha a’ dol bho 5 gu 15MPa. Tha an cuideam anns a’ chuas eas-tharraing air a dhearbhadh sa mhòr-chuid le co-mheas teannachaidh an sgriubha, meud an toll-bàis agus astar an sgriubha. Mar as àirde an cuideam eas-tharraing, 's ann as fheàrr a bhios buaidh measgachadh agus sgapadh stuthan, agus mar as dlùithe an toradh. Ge-tà, ma tha an cuideam ro àrd, àrdaichidh e caitheamh lùtha agus caitheamh an uidheim, agus eadhon a 'toirt air a' cheann bàs bacadh; ma tha an cuideam ro ìosal, chan urrainn na stuthan a bhith làn dhlùthadh agus measgachadh, tha an toradh sgaoilte, agus tha an coileanadh neo-sheasmhach. Bu chòir an cuideam eas-tharraing atharrachadh a rèir an seòrsa plastaig innleadaireachd agus cumadh an toraidh: airson stuthan àrd-slaodachd agus toraidhean le tuill bàis beaga, tha feum air cuideam eas-tharraing nas àirde.
2.3.5 Structar Die Head
Tha structar ceann die sa mhòr-chuid a’ toirt a-steach an cumadh, meud agus àireamh nan tuill bàsachadh, a bheir buaidh dhìreach air buaidh cumadh agus càileachd an toraidh. Airson cinneasachadh stuthan plastaig innleadaireachd (gràinneagan), bu chòir gum biodh an ceann bàsachadh air a uidheamachadh le grunn thuill bàis èideadh, agus bu chòir meud nan tuill bàis a bhith air a mhaidseadh ri meud gràin an toraidh; airson pìoban agus siotaichean a dhèanamh, bu chòir an ceann die a dhealbhadh a rèir cumadh agus meud an toraidh, agus bu chòir an t-sianal sruthadh den cheann-bàsachadh a bhith rèidh gus cruinneachadh stuthan agus cus teasachadh ionadail a sheachnadh. Bu chòir inneal smachd teothachd a bhith aig a’ cheann bàsachadh cuideachd gus dèanamh cinnteach à teòthachd èideadh a’ chinn bàsachadh agus cumadh seasmhach an toraidh.
3. An t-Sreath HTS Extruders againn: Fuasglaidhean proifeasanta airson giullachd plastaig innleadaireachd
Tha sinn air a bhith an sàs anns an rannsachadh o chionn fhada, leasachadh agus cinneasachadh àrd-choileanadh dà-sgriubha extruders, agus tha iad air eòlas beairteach a chruinneachadh ann an raon innleadaireachd giullachd phlastaig. A rèir feartan giollachd plastaig innleadaireachd (cugallachd ri cus teasachadh agus truailleadh hydrolytic, riatanasan àrd air buaidh measgachadh agus sgapadh, slaodachd àrd) agus feumalachdan tagraidh, tha sinn air extruders dà-sgriubha sreath HTS a leasachadh gu sònraichte airson giollachd plastaic innleadaireachd. Bidh an t-sreath extruders sreath HTS againn a’ gabhail ri bogsaichean gèar àrd-torque, le torque sònraichte de 14Nm / cm³ agus astar as àirde suas ri 1000rpm, a gheibh toradh nas àirde, ùine còmhnaidh nas giorra, dispersibility nas fheàrr agus smachd teothachd nas mionaidiche, ag atharrachadh gu foirfe a rèir feumalachdan giullachd diofar phlastaig innleadaireachd.
3.1 Buannachdan bunaiteach de luchd-sgaoilidh sreath HTS airson giollachd plastaigean innleadaireachd
3.1.1 Torque àrd agus astar àrd, High Production Efficiency
Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS series and HTS SUPER series) or imported from leading European manufacturers (HTS BASIC series), with a specific torque of 14Nm/cm³, which is much higher than that of ordinary twin-screw extruders (general torque is 8-12Nm/cm³). The high torque design ensures that the extruder can stably convey high-viscosity engineering plastic materials, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
Aig an aon àm, the HTS series extruders have a high speed design, with a maximum speed of up to 1000rpm. Faodaidh an astar àrd feachd rùsgaidh làidir agus feachd measgachadh a ghineadh, a tha comasach air na h-innealan-atharrachaidh a bhriseadh gu tur, dèan na mion-atharraichean sgapte gu cothromach anns a’ mhaitrix resin, agus a’ leasachadh buaidh measgachaidh is sgapadh. A bharrachd air, tha an dealbhadh àrd-astar cuideachd a’ leasachadh èifeachdas toraidh gu mòr: an coimeas ri extruders àbhaisteach, faodar èifeachdas cinneasachaidh extruders sreath HTS àrdachadh le 30%-50%, as urrainn coinneachadh ri feumalachdan cinneasachaidh mòr iomairtean plastaic innleadaireachd.
3.1.2 Ùine còmhnaidh goirid, Gu h-èifeachdach a 'seachnadh truailleadh teirmeach
Leis gu bheil plastaic innleadaireachd mothachail air cus teasachadh agus truailleadh hydrolytic, tha ùine còmhnaidh stuthan anns an extruder deatamach. Bidh an t-sreath extruders sreath HTS againn a’ gabhail ri structar sgriubha làn-leasaichte agus dealbhadh baraille, le ùine còmhnaidh goirid de a-mhàin 1-3 mionaidean, a tha tòrr nas giorra na an fheadhainn a th’ ann an eas-tharraing àbhaisteach dà-sgriubha (5-10 mionaidean) and single-screw extruders (10-15 mionaidean). The short residence time can effectively reduce the contact time between the material and high temperature, avoid thermal decomposition and hydrolytic degradation of the material, and ensure the mechanical properties and heat resistance of the product.
A bharrachd air, the screw of the HTS series extruders adopts a modular design, and different screw elements can be freely combined according to the type of engineering plastic, which can further adjust the residence time of the material, ensuring that different types of engineering plastics can obtain the optimal residence time during processing.
3.1.3 Precise Temperature Control, Stable Performance
The HTS series extruders adopt an advanced intelligent temperature control system, a dh'fhaodas smachd mionaideach a thoirt air teòthachd gach earrann den bharaille agus an ceann bàsachadh. Faodaidh cruinneas smachd teothachd ruighinn ± 1 ℃, as urrainn smachd teann a chumail air an teòthachd giollachd taobh a-staigh an raon as fheàrr de phlastaig innleadaireachd, seachain cus teasachadh ionadail agus lobhadh teirmeach den stuth. Tha an siostam smachd teothachd uidheamaichte le gnìomh sgrùdaidh is rabhaidh fìor-ùine: ma tha teòthachd earrann sam bith nas àirde na an raon stèidhichte, cuiridh an siostam a-mach inneal-rabhaidh ann an ùine, agus eadhon atharraich an cumhachd teasachaidh gu fèin-ghluasadach no dùin an uidheamachd ma tha sin riatanach, gus fàilligeadh uidheamachd agus duilgheadasan càileachd toraidh a sheachnadh.
A bharrachd air, bidh am baraille de extruders sreath HTS a’ gabhail ri dealbhadh seacaid le còmhdach dùbailte, a dh'fhaodas teasachadh agus fuarachadh luath a thoirt gu buil, agus ag adhartachadh astar freagairt smachd teothachd. Tha an ceann die cuideachd uidheamaichte le inneal smachd teothachd neo-eisimeileach, a nì cinnteach gu bheil teòthachd èideadh a’ chinn bàsachadh agus cumadh seasmhach an toraidh.
3.1.4 Buaidh measgachadh is sgapadh sàr-mhath
Bidh an t-sreath extruders sreath HTS a’ gabhail ri structar dà-sgriubha co-rothlach, le pitch sgriubha reusanta, dealbhadh co-mheas luaidhe agus teannachaidh. Faodaidh eadar-fhilleadh agus cuairteachadh nan sgriubhaichean càraid feachd rùsgaidh làidir agus feachd glùineachaidh a ghineadh, a tha comasach air na h-innealan-atharrachaidh a bhriseadh gu tur (such as glass fiber, freumhag gualain, talc), dèan na mion-atharraichean air an sgapadh gu cothromach anns a’ mhaitrix resin plastaig innleadaireachd, agus dèanamh cinnteach à buaidh measgachadh is sgapadh. Faodaidh èideadh measgachadh extruders sreath HTS ruighinn barrachd air 95%, which is much higher than that of ordinary twin-screw extruders (85%-90%).
Bidh an sgriubha de extruders sreath HTS a’ gabhail ri dealbhadh modular, agus diofar sheòrsaichean de sgriubha eileamaidean (leithid eileamaidean giùlan, measgachadh eileamaidean, eileamaidean rùsgaidh) faodar a chur còmhla gu saor a rèir an seòrsa plastaig innleadaireachd agus mion-atharrachaidh. Mar eisimpleir, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (leithid PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 High Wear Resistance, Long Service Life
Ann an giullachd plastaig innleadaireachd neartaichte (leithid PA air a dhaingneachadh le fiber glainne, carbon fiber reinforced PPS), the added modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder. Our HTS series extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.
The screw and barrel of the HTS series extruders are made of imported wear-resistant alloy steel (such as 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. Faodaidh cruas uachdar an sgriubha agus a’ bharaille ruighinn ≥65 HRC (HTS BASIC series) agus ≥70 HRC (HTS PLUS series and HTS SUPER series), aig a bheil neart caitheamh làidir agus strì an aghaidh creimeadh, agus is urrainn dhaibh gu h-èifeachdach seasamh an aghaidh a’ chaitheamh a tha air adhbhrachadh le luchd-atharrachaidh àrd-chruaidh. Tha seo gu mòr a’ leudachadh beatha seirbheis an sgriubha agus a’ bharaille: tha beatha seirbheis an sgriubha agus baraille de extruders sreath HTS 2-3 amannan nas motha na extruders àbhaisteach, lùghdachadh tricead ath-chur phàirtean agus cosgais cumail suas an uidheim.
A bharrachd air, bidh sinn cuideachd a’ toirt seachad seirbheisean lorg caitheamh proifeasanta airson an sgriubha agus am baraille. Bidh an sgioba teignigeach againn gu cunbhalach a’ lorg ìre caitheamh an sgriubha agus a’ bharaille airson luchd-ceannach, cuir a-mach aithisg caitheamh mionaideach, agus molaidhean cuimsichte airson ath-chur agus cumail suas a chur air adhart, dèanamh cinnteach nach cuir luchd-ceannach an àite phàirtean ach nuair a bhios feum orra, a’ seachnadh sgudal neo-riatanach.
3.1.6 Raon tagraidh farsaing, Strong Flexibility
The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (PA, PC, POM, Peata, PBT) and special engineering plastics (PPS, PEIC, PSU, PES). The extruders can also adapt to the processing of various modified engineering plastics, such as reinforced engineering plastics (glass fiber reinforced, carbon fiber reinforced), toughened engineering plastics, flame-retardant engineering plastics, antistatic engineering plastics, etc.
The modular design of the HTS series extruders (sgread, baraille, ceann bàs, etc.) makes the replacement of components more convenient and quick. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, they only need to replace the corresponding components, without replacing the entire equipment, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. A bharrachd air, the HTS series extruders can also be matched with different auxiliary equipment (such as high-speed mixers, dryers, coolers, granulators, screening machines, packaging machines) to form a complete automatic production line, realizing continuous production from raw material pretreatment to product packaging.
3.1.7 Intelligent Control, Easy Operation and Maintenance
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, easy to operate. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, chan fheum iad ach am foirmle agus na crìochan co-fhreagarrach a ghairm, gun debugging a-rithist, which saves time and improves production efficiency.
Tha an siostam cuideachd uidheamaichte le gnìomh sgrùdaidh fìor-ùine, as urrainn sùil a chumail air prìomh pharamadairean a’ phròiseas eas-tharraing (leithid teòthachd, cuideam, astar sgriubha, astar beathachaidh) ann an àm fìor, agus clàraich an dàta toraidh (leithid toradh, ùine giollachd) airson ceist agus mion-sgrùdadh nas fhaide air adhart. Airson an t-sreath HTS SUPER extruders, bidh sinn cuideachd a’ toirt seachad gnìomh smachd sgòthan, a dh'fhaodas atharrachadh paramadair iomallach a thoirt gu buil, sgrùdadh dàta toraidh agus cumail suas ro-innse air uidheamachd, a’ toirt gu buil riaghladh cinneasachaidh tuigseach.
A bharrachd air, bidh an t-sreath extruders HTS a’ gabhail ri dealbhadh structarail reusanta, a nì an cumail suas nas goireasaiche. An sgriubha, baraille, faodar ceann bàsachadh agus co-phàirtean eile a chuir às a chèile agus a chruinneachadh gu sgiobalta, a lughdaicheas an ùine cumail suas agus dian saothair. Bheir an sgioba seirbheis iar-reic againn seachad stàladh proifeasanta, coimiseanadh agus seirbheisean trèanaidh do luchd-ceannach, dèanamh cinnteach gun urrainn do luchd-ceannach an uidheamachd a chleachdadh gu rèidh.
3.2 Seòrsan Bathar Extruder Sreath HTS agus an atharrachadh gu Plastaigean Innleadaireachd
In order to meet the diverse processing needs of engineering plastics enterprises of different scales and product types, we have launched three main product types in the HTS series: HTS BASIC series, HTS PLUS series and HTS SUPER series. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.
3.2.1 HTS BASIC Series Extruders: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, low noise, high efficiency and long service life. The medium-torque design (specific torque 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, Peata, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
In terms of structural design, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type of engineering plastic. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. The extruder is equipped with a PLC control system and a touch screen operation interface, a dh'fhaodas biadhadh fèin-ghluasadach a thoirt gu buil, smachd teothachd fèin-ghluasadach, smachd cuideam fèin-ghluasadach agus gearradh fèin-ghluasadach, agus tha e sìmplidh agus furasta obrachadh.
Tha comas cinneasachaidh an t-sreath HTS BASIC extruders a ’dol bho 100kg / h gu 500kg / h, a tha freagarrach airson iomairtean giollachd plastaic innleadaireachd meadhanach agus beag a bhios gu ìre mhòr a’ toirt a-mach plastaic innleadaireachd coitcheann agus plastaig innleadaireachd atharraichte ìosal gu meadhanach. Is e aon de na buannachdan as motha a tha san t-sreath seo gum faod e roghainnean sùbailte a thoirt seachad tro mheasgachadh rèiteachaidh eadar-dhealaichte. Faodaidh luchd-ceannach diofar eileamaidean sgriubha a thaghadh, bàs cinn, innealan beathachaidh, innealan tiormachaidh agus uidheamachd iar-ghiollachd a rèir an seòrsa toraidh fhèin, comas toraidh agus buidseat, gus loidhne riochdachaidh a chruthachadh a tha iomchaidh airson na feumalachdan aca fhèin. Tha prìs reusanta aig extruders sreath HTS BASIC, a chuidicheas iomairtean gus a’ chiad chosgais tasgaidh a lughdachadh.
3.2.2 Sreath HTS PLUS Extruders: Roghainn àrd-choileanadh airson plastaigean innleadaireachd agus toraidhean atharraichte
Bidh an t-sreath extruders sreath HTS PLUS a’ gabhail ri bogsaichean gèar àrd-torque air an leasachadh gu neo-eisimeileach agus air an dèanamh leinn, with a specific torque of 14Nm/cm³, aig a bheil torque nas làidire agus comas giùlan luchdan na an t-sreath HTS BASIC. Tha an t-sreath seo de extruders air a dhealbhadh sa mhòr-chuid airson a bhith a’ giullachd plastaic innleadaireachd àrd-choileanadh, plastaig innleadaireachd àrd-atharraichte agus plastaic innleadaireachd sònraichte (leithid PPS), a tha freagarrach airson iomairtean giollachd plastaig innleadaireachd meadhanach agus mòr a tha a’ leantainn àrd-choileanadh agus àrd-èifeachdas.
Tha trast-thomhas sgriubha eadar 65mm agus 110mm aig an t-sreath extruders sreath HTS PLUS, co-mheas teannachaidh de 5～10, and a screw speed range of 200～800 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (surface hardness ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, carbon fiber reinforced PPS) and high-hardness modifiers. The extruder is equipped with an advanced intelligent temperature control system and a high-precision pressure sensor, which can realize precise control of extrusion parameters and real-time monitoring of production data, ensuring the stability of the extrusion process and the quality of the product.
The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, plastaig innleadaireachd àrd-atharraichte agus plastaic innleadaireachd sònraichte (leithid PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics
The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us, le torque sònraichte de 14Nm / cm³ agus astar as àirde suas ri 1000rpm. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (leithid PEEK, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, high performance and intelligence.
The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～1000 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, which has extremely high wear resistance and corrosion resistance (surface hardness ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. The extruder is equipped with an intelligent PLC + cloud touch screen control system, a dh'fhaodas atharrachadh paramadair iomallach a thoirt gu buil, production data monitoring, predictive maintenance of equipment and data analysis, a’ toirt gu buil riaghladh cinneasachaidh tuigseach.
The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 mionaidean) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. A bharrachd air, the HTS SUPER series extruders can also be customized according to the special processing needs of customers, providing personalized solutions.
3.3 Selection Suggestions for Engineering Plastics Extruders
When selecting twin-screw extruders for engineering plastics processing, enterprises need to comprehensively consider their own production needs, product types, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. The following are some specific selection suggestions:
3.3.1 Determine the Extruder Series According to the Type of Engineering Plastics
Different types of engineering plastics have different processing requirements, which determine the selection of extruder series. For general engineering plastics (PA6, PA66, POM, Peata, PBT) with low modification degree (filling amount ≤30%), the HTS BASIC series is sufficient to meet the processing needs. Its medium torque and flexible configuration can balance processing effect and cost, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (filling amount 30%-50%, leithid PA air a dhaingneachadh le fiber glainne, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (leithid PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (PEIC, PI, PSU, PES) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), the HTS SUPER series must be selected. Its ultra-high torque, maximum 1000rpm speed and fully optimized key structure can cope with the high viscosity, high temperature resistance and strict processing requirements of high-end materials, avoid thermal decomposition and material degradation, and ensure the high performance of the final product.
3.3.2 Determine the Screw Diameter and Production Capacity According to the Processing Scale
The screw diameter of the twin-screw extruder directly determines the production capacity, and enterprises need to select the appropriate screw diameter according to their own production scale and order demand. For small-scale production (100kg/u – 500kg/u), such as small-batch customization, product research and development or small orders, the HTS BASIC series with screw diameter of 30mm – 65mm is suitable; for medium-scale production (500kg/u – 2000kg/u), such as mass production of general modified engineering plastics, the HTS PLUS series with screw diameter of 65mm – 110mm can meet the demand; for large-scale production (1000kg/u – 3000kg/u), such as large-scale production of high-end special engineering plastics or large orders from downstream enterprises, the HTS SUPER series with screw diameter of 80mm – 130mm is the best choice. It should be noted that when selecting, enterprises should not blindly pursue large production capacity. They should also consider the fluctuation of order quantity. If the order quantity is unstable, they can choose equipment with adjustable speed and flexible production capacity (such as HTS BASIC series with frequency conversion speed regulation function) to avoid waste of equipment resources and energy.
3.3.3 Consider the Modification Demand and Mixing Effect
If the enterprise’s main products are modified engineering plastics, the mixing and dispersing effect of the extruder is the key factor to be considered. For products that need to add a variety of modifiers (leithid lasraichean-aghaidh, compatibilizers, reinforcing agents) Aig an aon àm, it is necessary to select extruders with excellent mixing performance, such as HTS PLUS series and HTS SUPER series with modular mixing screw elements. These two series can freely combine conveying elements, mixing elements and shearing elements according to the type of modifier, adjust the mixing intensity and residence time, and ensure that various modifiers are uniformly dispersed in the resin matrix. Mar eisimpleir, when processing flame-retardant modified PBT, more mixing elements can be configured to ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. A bharrachd air, if the enterprise has the demand of multi-variety and small-batch modification, it is recommended to select the extruder with quick replacement of screw elements (such as the modular screw design of HTS series), which can reduce the time of equipment adjustment and improve production efficiency.
3.3.4 Consider the Cost Budget and Comprehensive Benefits
Cost budget is an important factor for enterprises to select equipment, but it is not advisable to pursue low cost blindly. It is necessary to balance the initial purchase cost, later maintenance cost, energy consumption and production efficiency to maximize the comprehensive benefits. The HTS BASIC series has the lowest initial purchase cost, low energy consumption and simple maintenance, which is suitable for enterprises with limited budget and small production scale; the HTS PLUS series has a moderate initial purchase cost, but its high production efficiency, long service life and stable processing effect can reduce the later maintenance cost and improve product qualification rate, which is suitable for medium and large-sized enterprises with certain budget and pursuit of high performance; the HTS SUPER series has the highest initial purchase cost, but it can process high-end products with high added value, and its intelligent control and long service life can reduce labor cost and maintenance cost in the later period, which is suitable for large-scale enterprises with sufficient budget and focus on high-end market. A bharrachd air, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, gabhail a-steach stàladh, coimiseanadh, technical training, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.
3.3.5 Consider the Compatibility with Auxiliary Equipment
Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, high-speed mixer, cooler, granulator, screening machine, packaging machine, etc. When selecting the extruder, enterprises need to consider the compatibility between the extruder and auxiliary equipment to ensure the smooth operation of the entire production line. Our HTS series extruders can be perfectly matched with various standard auxiliary equipment, and can also be customized according to the enterprise’s existing auxiliary equipment to avoid the waste caused by the incompatibility between new equipment and old auxiliary equipment. Mar eisimpleir, if the enterprise already has a high-speed mixer with a mixing capacity of 500kg, it can select the HTS PLUS series extruder with a production capacity of 500kg/h – 800kg/h to match it, ensuring the coordination of raw material premixing and extrusion production.
4. Application Fields of Engineering Plastics and Matching HTS Series Extruder Solutions
Plastaig innleadaireachd, with their excellent comprehensive performance, have been widely used in automotive, dealain agus eileagtronaigeach, lèigheil, aerospace, ceimigeach, construction and other fields. Different application fields have different requirements on the performance of engineering plastic products, which also puts forward different requirements on extrusion processing equipment. Gu h-ìosal, we will elaborate on the application characteristics of engineering plastics in major fields and the matching HTS series extruder solutions, providing targeted reference for enterprises in different fields.
4.1 Automotive Field: Aotrom, High Temperature Resistance and Wear Resistance
With the development of automotive lightweight and energy-saving and emission-reduction, engineering plastics have become an important material for automotive parts, gradually replacing traditional metal materials. The engineering plastics used in the automotive field mainly include PA, POM, PC, PBT, PPS, etc., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: aotrom, high temperature resistance, strì an aghaidh caitheamh, dimensional stability and low VOC (todhar organach luaineach), which require the extruder to have precise temperature control, excellent mixing and dispersing effect and stable production capacity.
For automotive interior parts (such as instrument panels, pannalan dorais, adhair ducts) made of general engineering plastics (PA6, POM, PC/ABS alloy), the HTS BASIC series extruders can meet the processing needs. Its flexible configuration can adjust the processing parameters according to the performance requirements of interior parts, ensure the smooth surface and dimensional stability of the product, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66+GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (PEIC, PI), the HTS SUPER series extruders are required. Its ultra-high torque, precise temperature control and short residence time can avoid thermal decomposition of high-temperature resistant materials, ensure the insulation performance and corrosion resistance of the product, and meet the strict requirements of new energy vehicles on parts performance.
Sgrùdadh Cùise: A large automotive parts manufacturer specializing in new energy vehicle battery parts selected our HTS SUPER series extruders (screw diameter 100mm) to process carbon fiber reinforced PEEK battery shells. The PEEK material has high viscosity and high temperature resistance, and the carbon fiber filling amount reaches 40%, which has extremely high requirements on extrusion equipment. The HTS SUPER series extruders, with their ultra-high torque of 14Nm/cm³ and maximum speed of 1000rpm, generate strong shear force and mixing force, which makes the carbon fiber uniformly dispersed in the PEEK matrix; the precise temperature control system (precision ±1℃) strictly controls the processing temperature at 380-400℃, avoiding thermal decomposition of PEEK; the short residence time (1.5 mionaidean) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% gu 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Insaladh dealain, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Engineering plastics are mainly used in electrical connectors, wiring boards, relays, motaran, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, lasair-mhilleadh, seasmhachd meud, corrosion resistance and low toxicity, which require the extruder to have precise temperature control, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, connectors) made of general engineering plastics (PA6, PBT, PC), the HTS BASIC series extruders are suitable. Its flexible configuration can match different die heads to produce components of different shapes and sizes; the precise temperature control ensures the electrical insulation performance of the product, and the low cost can meet the mass production needs of general electrical components. For high-precision electrical components (such as relays, motor windings) made of flame-retardant modified engineering plastics (PBT+GF30+flame retardant, PA66+flame retardant), the HTS PLUS series extruders are preferred. Its high mixing and dispersing effect can ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency, and meet the UL94 V-0 flame retardant standard; the precise dimensional control can ensure the dimensional accuracy of high-precision components, avoiding assembly failure. For high-end electrical components (such as high-temperature resistant connectors, aerospace electrical components) made of special engineering plastics (PPS, PSU, PES), the HTS SUPER series extruders are required. Its ultra-high torque and excellent wear resistance can cope with the high viscosity and high hardness of special engineering plastics, and the precise temperature control and short residence time can ensure the electrical insulation performance and high temperature resistance of the product, meeting the strict requirements of high-end electrical and electronic products.
4.3 Medical Field: Biocompatibility, Sterility and Precision
The medical field has extremely strict requirements on materials, and engineering plastics used in the medical field must have good biocompatibility, sterility, corrosion resistance and dimensional stability, and must not produce toxic and harmful substances. The main engineering plastics used in the medical field include PC, PA, PEIC, PSU, etc., which are mainly used in medical containers, catheters meidigeach, implantan meidigeach, surgical instruments and other products. The core requirements for extrusion processing are: high precision, no pollution, stable performance, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (medical-grade PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, implantan meidigeach) made of medical-grade special engineering plastics (medical-grade PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (Good Manufacturing Practice) requirements of the medical field.
4.4 Aerospace Field: High Temperature Resistance, Low Weight and High Strength
The aerospace field has extremely high requirements on the performance of materials, and engineering plastics used in the aerospace field must have excellent high temperature resistance, low weight, high strength, corrosion resistance and radiation resistance. The main engineering plastics used in the aerospace field include PEEK, PI, PSU, PES, etc., which are mainly used in aerospace components, aircraft interior parts, satellite components and other products. The core requirements for extrusion processing are: ultra-high precision, ultra-high temperature resistance, stable performance, which require the extruder to have the highest level of torque, speed and temperature control capacity.
Due to the extremely strict processing requirements of aerospace-grade engineering plastics, only the HTS SUPER series extruders can meet the demand. Its ultra-high torque transmission device, maximum 1000rpm speed and fully optimized key components can cope with the high viscosity and high temperature resistance of aerospace-grade materials (long-term use temperature up to 300℃); the laser-clad screw and barrel have extremely high wear resistance and corrosion resistance, which can adapt to the processing of high-hardness modifiers (such as carbon fiber, ceramic fiber); the intelligent PLC + cloud touch screen control system can realize precise control of extrusion parameters, and the remote monitoring and predictive maintenance function can ensure the stable operation of equipment in long-term continuous production; the customizable configuration can meet the special processing needs of various aerospace components, ensuring the high performance and high reliability of the product.
4.5 Chemical Field: Corrosion Resistance and Wear Resistance
The chemical field has harsh working environment, and engineering plastics used in the chemical field must have excellent corrosion resistance, strì an aghaidh caitheamh, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEIC, PVDF (polyvinylidene fluoride), etc., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: strì an aghaidh creimeadh, strì an aghaidh caitheamh, stable performance, which require the extruder to have excellent wear resistance and corrosion resistance, and stable pressure control capacity.
For chemical pipelines and valves made of general corrosion-resistant engineering plastics (PPS, PVDF), the HTS PLUS series extruders are suitable. Its bimetallic composite screw and barrel have excellent corrosion resistance and wear resistance, which can adapt to the corrosion of chemical media and the wear of materials; the stable pressure control capacity can ensure the uniform wall thickness of pipelines and valves, avoiding leakage caused by uneven wall thickness. For high-pressure chemical equipment and corrosion-resistant components made of high-end corrosion-resistant engineering plastics (PEIC, PI), the HTS SUPER series extruders are required. Its ultra-high torque and stable conveying capacity can cope with the high viscosity of high-end corrosion-resistant materials, and the laser-clad screw and barrel have extremely high corrosion resistance and wear resistance, which can meet the long-term use requirements in harsh chemical environments; the precise temperature control can avoid thermal decomposition of materials, ensuring the corrosion resistance and pressure resistance of the product.
5. Common Problems and Solutions in Engineering Plastics Twin-Screw Extrusion Processing
In the actual twin-screw extrusion processing of engineering plastics, due to the influence of raw materials, paramadairean giollachd, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Gu h-ìosal, we will summarize the common problems in engineering plastics extrusion processing, analyze their causes, and provide corresponding solutions combined with the characteristics of our HTS series extruders, helping enterprises solve practical processing problems and improve production efficiency.
5.1 Trioblaid 1: Thermal Decomposition and Discoloration of Materials
Symptoms: During the extrusion process, the material appears yellowing, blackening, carbonization and other phenomena, and the final product has discoloration, builgeanan, cracks and other defects, and the mechanical properties are significantly reduced. This problem is mainly caused by the sensitivity of engineering plastics to overheating and hydrolytic degradation.
Causes: 1. The extrusion temperature is too high or the temperature of a certain section of the barrel is too high, resulting in thermal decomposition of the material; 2. The residence time of the material in the extruder is too long, leading to excessive heating and decomposition; 3. The raw materials are not dried thoroughly, and the moisture in the materials causes hydrolytic degradation during high-temperature processing; 4. The screw speed is too low, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
Solutions: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (temperature control precision ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 mionaidean; 3. Strengthen the drying treatment of raw materials, strictly control the moisture content below 0.1%-0.2%, and use the drying device matched with the HTS series extruders to prevent the raw materials from absorbing moisture again during feeding; 4. Check and clean the die head regularly to ensure the smooth flow channel, avoid material accumulation; 5. If the problem persists, adjust the screw element combination, increase the number of conveying elements, and reduce the number of mixing elements to speed up the material conveying and shorten the residence time.
5.2 Trioblaid 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (such as glass fiber, freumhag gualain), and the mechanical properties (neart, cruas, strì an aghaidh caitheamh) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
Causes: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. The screw speed is too low, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.
Solutions: 1. Optimize the premixing process, increase the mixing speed (800-1200rpm) and mixing time (5-10 mionaidean), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, use the high-speed performance of the HTS series extruders to generate strong shear force and kneading force, and fully break the agglomerates of modifiers; 3. Adjust the combination of screw elements, increase the number of mixing elements and shearing elements, and use the modular screw design of the HTS series extruders to customize the optimal screw combination according to the type of modifier; 4. Properly increase the extrusion temperature to ensure that the material is fully melted, which is conducive to the uniform dispersion of modifiers; 5. Crush and sieve the modifier to ensure that its particle size is uniform (20-40 mogal) and meets the processing requirements.
5.3 Trioblaid 3: Wear of Screw and Barrel
Symptoms: After a period of use, the extrusion capacity of the extruder decreases, the shear force and mixing effect are reduced, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (such as glass fiber, freumhag gualain) on the screw and barrel during the processing of reinforced engineering plastics.
Causes: 1. The screw and barrel are made of materials with poor wear resistance, which cannot resist the wear of high-hardness modifiers; 2. The filling amount of the modifier is too high (≥50%), and the wear is intensified; 3. The particle size of the modifier is too large, which increases the wear on the screw and barrel; 4. The extrusion pressure is too high, which increases the friction between the material and the screw and barrel; 5. The screw and barrel are not maintained regularly, and the material residue accelerates the wear.
Solutions: 1. Select extruders with high wear resistance, such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS PLUS) agus ≥70 HRC (HTS SUPER), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, and apply lubricating oil appropriately to reduce friction and extend the service life. A bharrachd air, our professional technical team can provide regular wear detection services for the screw and barrel, agus molaidhean cuimsichte airson ath-chur agus cumail suas a chur air adhart.
5.4 Trioblaid 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, pìoban, duilleagan) is uneven, the shrinkage rate exceeds the standard (＞1.5%), and the product has deformation, warpage and other phenomena, which affects the assembly and use of the product.
Causes: 1. The extrusion temperature is unstable, resulting in uneven melting and plasticization of the material, and uneven shrinkage during cooling; 2. The extrusion speed is unstable, leading to uneven extrusion amount and unstable product size; 3. The cooling speed is uneven, resulting in uneven internal and external stress of the product, leading to deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
Solutions: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 mionaidean) for strip cooling, and use air cooling or water spray cooling for pipes and sheets to avoid uneven cooling; 4. Check and optimize the die head structure, ensure the smooth flow channel, and adjust the die head temperature to ensure uniform material flow; 5. Strengthen the drying treatment of raw materials, strictly control the moisture content, and reduce the impact of moisture on product shrinkage.
5.5 Trioblaid 5: Low Extrusion Efficiency and High Energy Consumption
Symptoms: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
Causes: 1. The screw speed is too low, the conveying capacity is insufficient; 2. The extrusion temperature is too low, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, the conveying capacity is reduced, and the energy consumption is increased.
Solutions: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Adjust the combination of screw elements, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, replace the worn components in time, and maintain the conveying capacity of the extruder, reducing energy consumption. A bharrachd air, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% an coimeas ri extruders àbhaisteach.
6. Conclusion and Future Development Trend
Plastaig innleadaireachd, mar phrìomh stuth àrd-choileanadh, are playing an increasingly important role in global industrial upgrading, and twin-screw extrusion technology is the core support for the high-quality processing of engineering plastics. The performance of extrusion equipment directly determines the quality, èifeachdas toraidh agus buaidh tagraidh stuthan plastaig innleadaireachd. Our HTS series twin-screw extruders, including HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (cugallachd ri cus teasachadh agus truailleadh hydrolytic, riatanasan àrd air buaidh measgachadh agus sgapadh, slaodachd àrd), with the advantages of high torque, high speed, smachd teòthachd mionaideach, excellent wear resistance, wide application range and intelligent control. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, fiosrachadh dealain is dealanach, new energy and medical high-endization, the demand for high-performance, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
A’ chiad, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. Aig an aon àm, digital simulation technology will be widely used in the design and debugging of extruders, reducing the research and development cycle and debugging time of equipment.
An dàrna, high performance and high efficiency. The demand for high-end engineering plastics (leithid PEEK, PI) will continue to increase, which will promote the continuous upgrading of extruder performance. The future extruders will have higher torque, higher speed and more precise temperature control capacity, and the key components (sgread, baraille, bogsa gèar) will be further optimized to improve wear resistance, corrosion resistance and service life. Aig an aon àm, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
An treas, customization and diversification. Different application fields and different products have increasingly personalized requirements for extrusion processing. The future extruders will adopt a more flexible modular design, which can quickly replace screw elements, die heads and other components according to customer needs, realizing the processing of multiple varieties and small batches. Aig an aon àm, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
An ceathramh, environmental protection and greenization. With the strengthening of global environmental protection policies, environmental protection will become an important development direction of extrusion equipment. The future extruders will adopt more environmentally friendly materials and manufacturing processes, reduce energy consumption and pollutant emissions; Aig an aon àm, they will be more compatible with recyclable engineering plastics and biodegradable engineering plastics, promoting the green development of the engineering plastics industry.
We will always adhere to the concept of technological innovation, focus on the development needs of the engineering plastics industry, continuously invest in research and development, optimize the performance of HTS series extruders, improve after-sales service, and provide more professional, efficient and intelligent twin-screw extrusion solutions for global engineering plastics processing enterprises, helping the high-quality development of the engineering plastics industry.