Elastómeros termoplásticos (TPE), ás veces denominadas cauchos termoplásticos (TPR), son unha clase de copolímeros ou mesturas físicas de polímeros, normalmente un plástico e un caucho, que combinan as propiedades dos termoplásticos e elastómeros.. Esta combinación única permite que os TPE se procesen como termoplásticos (mediante extrusión, moldaxe por inxección, moldaxe por soplado, etc.) conservando a elasticidade e flexibilidade das gomas. A diferenza das gomas vulcanizadas tradicionais, Os TPE pódense fundir e reprocesar varias veces sen perda significativa de rendemento, facéndoos máis respectuosos co medio ambiente e rendibles. Como a demanda de lixeiro, flexible, e os materiais reciclables crecen en industrias como a automoción, eléctrica, construción, e bens de consumo, Os TPE son cada vez máis populares, impulsando o desenvolvemento de tecnoloxías especializadas de masterbatch e extrusión adaptadas aos seus requisitos de procesamento únicos.
Masterbatch, como material clave para a cor e a modificación funcional dos TPE, desempeña un papel crucial para mellorar o rendemento e ampliar o ámbito de aplicación dos produtos TPE. O procesamento do masterbatch de TPE require un control preciso da mestura, dispersándose, e parámetros de temperatura, xa que os TPE teñen viscosidade específica, resistencia á calor, e características de elasticidade que se diferencian dos plásticos tradicionais. Extrusoras de dobre parafuso, coas súas superiores capacidades de mestura e dispersión, control de temperatura preciso, e adaptabilidade a materiais diversos, convertéronse no equipo principal de procesamento para masterbatch TPE. Zhuoyue, un fabricante profesional de extrusoras de dobre parafuso, ofrece unha gama completa de solucións de extrusión avanzadas deseñadas especificamente para a composición de TPE e o procesamento de masterbatch, que abarca TPE/SBS/TPU/TPR/TPV e outras categorías importantes de TPE, para satisfacer as diversas necesidades dos fabricantes en diferentes industrias.
1. Visión xeral dos elastómeros termoplásticos (TPE): Categorías, Propiedades e características clave
Os TPE son unha familia diversa de materiais, clasificados en seis categorías comerciais xerais en función da súa composición química e estrutura. Cada categoría ten propiedades únicas, características de procesamento, e campos de aplicación, que determinan directamente os requisitos para os equipos de formulación e extrusión de masterbatch. Comprender a clasificación e as propiedades dos TPE é a base para optimizar o procesamento de masterbatch e seleccionar extrusoras de dobre parafuso adecuadas..
1.1 Seis categorías comerciais xerais de TPE
1.1.1 Copolímeros de bloque estirénico (TPS, TPE-s).
TPS é a categoría de TPE máis utilizada, representa unha gran parte do mercado global de TPE. Está composto por bloques estirénicos (como o poliestireno, PD) e bloques elastoméricos (como o polibutadieno, PB; poliisopreno, PI; ou etileno-butileno, EB), unidos por enlaces covalentes. Os tipos máis comúns de TPS inclúen SBS (Estirenos-Butadienos-Estirenos), SIS (Estireno-Isopreno-Estireno), SEBS (Estireno-Etileno-Butileno-Estireno), e SEPS (Estireno-etileno-propileno-estireno).
As principais propiedades do TPS inclúen unha excelente flexibilidade, elasticidade, e procesabilidade. SEBS e SEPS, que son versións hidroxenadas de SBS e SIS, teñen unha resistencia á calor mellorada, resistencia á intemperie, e resistencia ao envellecemento, facéndoos axeitados para aplicacións ao aire libre e a altas temperaturas. Os materiais TPS son facilmente coloreados e modificados con masterbatch, e a súa temperatura de procesamento oscila entre 150 ℃ e 220 ℃, que é compatible coa maioría das extrusoras de dobre parafuso. As aplicacións comúns de TPS inclúen compoñentes de automóbiles, fíos e cables, bens de consumo, e dispositivos médicos.
1.1.2 Elastómeros termoplásticos de poliolefina (TPO, TPE-o).
TPO é unha mestura física de poliolefina (como o polipropileno, PP; ou polietileno, PE) e elastómero (como monómero de etileno-propileno-dieno, EPDM). Combina a rixidez das poliolefinas coa elasticidade dos elastómeros, e ten unha excelente resistencia química, resistencia á intemperie, e flexibilidade a baixa temperatura. Os TPO non son tóxicos, inodoro, e reciclables, converténdoos en idóneos para aplicacións que requiren respeto ao medio ambiente.
A temperatura de procesamento do TPO varía entre 160 ℃ e 230 ℃, e ten boa compatibilidade con varios masterbatches (masterbatch de cores, masterbatch ignífugo, etc.). Os TPO son amplamente utilizados en pezas exteriores de automóbiles (como as tapas de parachoques, forros de defensa), materiais de construción (como as focas, xuntas), e compoñentes eléctricos. Debido ao seu alto contido en poliolefinas, TPO masterbatch processing requires extruders with good mixing capabilities to ensure uniform dispersion of pigments and additives.
1.1.3 Vulcanizados termoplásticos (IVE, TPE v).
TPV is a dynamically vulcanized blend of polyolefin (usually PP) e elastómero (usually EPDM). During processing, the elastomer phase is vulcanized into small particles and uniformly dispersed in the polyolefin matrix, resulting in excellent elasticity, resistencia de compresión, e resistencia á calor. TPVs have better mechanical properties and dimensional stability than traditional TPEs, and can withstand long-term high-temperature exposure (up to 150℃).
TPV processing requires precise temperature control and strong shear force to ensure uniform vulcanization and dispersion. The processing temperature ranges from 170℃ to 240℃, and the material has high viscosity during processing, o que require altos requisitos de par e resistencia ao desgaste das extrusoras de dobre parafuso. Os TPV son amplamente utilizados nos selos de automóbiles, mangueiras, xuntas, e compoñentes industriais que requiren un alto rendemento e durabilidade.
1.1.4 Poliuretanos termoplásticos (TPU).
TPU é un copolímero de bloques composto por segmentos duros (diisocianato e extensor de cadea) e segmentos brandos (poliol). Ten unha elasticidade excelente, resistencia á abrasión, resistencia ao aceite, e resistencia mecánica, e pódese axustar en dureza desde moi suave (Costa A 30) a moi duro (Costa D 85) cambiando a proporción de segmentos duros e brandos.
O procesamento de TPU é sensible á temperatura e á humidade. A temperatura de procesamento varía entre 180 ℃ e 250 ℃, e o material debe secar completamente antes do procesamento (contido de humidade ≤0,05%) para evitar a hidrólise e a formación de burbullas. O procesamento de masterbatch de TPU require extrusoras con control de temperatura preciso e capacidades de escape ao baleiro. O TPU úsase amplamente en fíos e cables, mangueiras de automoción, calzado, catéteres médicos, e equipamento deportivo.
1.1.5 Copoliésteres termoplásticos (TPC, TPE-E).
TPC é un copolímero de bloque composto por segmentos duros de poliéster e segmentos brandos de poliéter ou poliéster. Ten unha excelente resistencia á calor, resistencia química, e propiedades mecánicas, e pode soportar altas temperaturas de ata 150 ℃ durante longos períodos. Os TPC tamén teñen boa flexibilidade e elasticidade, facéndoos axeitados para aplicacións de alto rendemento.
A temperatura de procesamento do TPC varía de 220 ℃ a 280 ℃, que é superior a outras categorías de TPE. Ten unha alta viscosidade durante o procesamento e require extrusoras con alto par e control de temperatura preciso. TPC masterbatch processing also requires special attention to the dispersion of pigments and additives to avoid affecting the material’s mechanical properties. TPCs are widely used in automotive components (such as air intake hoses, transmission seals), pezas aeroespaciais, e maquinaria industrial.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA is a block copolymer composed of polyamide hard segments and polyether soft segments. It combines the high strength, wear resistance, and chemical resistance of polyamides with the flexibility and elasticity of polyethers. TPA has excellent impact resistance and low temperature performance, and can be used in harsh environments.
The processing temperature of TPA ranges from 230℃ to 290℃, and it has high water absorption, requiring thorough drying before processing. O procesamento de masterbatch TPA require extrusoras con alta resistencia ao desgaste (debido á alta dureza da poliamida) e control preciso da temperatura para evitar a degradación do material. O TPA é amplamente utilizado en compoñentes de automóbiles (como engrenaxes, rodamentos), conectores eléctricos, e mangueiras industriais.
1.2 Propiedades clave dos TPE que afectan ao procesamento de Masterbatch
Os TPE teñen propiedades únicas que os distinguen dos plásticos tradicionais, e estas propiedades afectan directamente á formulación do masterbatch e á selección dos equipos de extrusión. As propiedades clave a considerar no procesamento de masterbatch son as seguintes:
1.2.1 Elasticidade e Flexibilidade.
Os TPE teñen alta elasticidade e flexibilidade, o que significa que o masterbatch debe ser compatible coa matriz TPE para evitar reducir o rendemento elástico do material. O transportista do masterbatch debe ter unha boa compatibilidade co TPE, e o dispersante debe garantir a dispersión uniforme dos pigmentos sen formar aglomerados que poidan causar concentración de estrés e reducir a flexibilidade..
1.2.2 Resistencia á calor.
As diferentes categorías de TPE teñen diferente resistencia á calor (temperatura de procesamento varía de 150 ℃ a 290 ℃). Os pigmentos e aditivos masterbatch deben ter unha resistencia á calor que coincida coa temperatura de procesamento do TPE para evitar a descomposición, decoloración, ou degradación do rendemento durante a extrusión. Por exemplo, TPC e TPA requiren pigmentos resistentes a altas temperaturas e estabilizadores térmicos.
1.2.3 Viscosidade e procesabilidade.
Os TPE teñen viscosidades variables durante o procesamento (TPV e TPC teñen maior viscosidade, mentres que o TPS ten menor viscosidade). Isto afecta á forza de corte e aos requisitos de transporte da extrusora de dobre parafuso. Os TPE de alta viscosidade requiren extrusoras con alto par e fortes capacidades de mestura, mentres que os TPE de baixa viscosidade requiren un control preciso da velocidade de extrusión para evitar o desbordamento do material.
1.2.4 Absorción de humidade.
Algúns TPE (como TPU, TPA) teñen unha alta absorción de auga, que pode provocar burbullas, hidrólise, e outros defectos no masterbatch. As materias primas (TPE, pigmentos, aditivos) debe secar completamente antes do procesamento, e a extrusora debe estar equipada cun dispositivo de escape ao baleiro para eliminar a humidade e as substancias volátiles.
1.2.5 Compatibilidade con aditivos.
Os TPE adoitan necesitar aditivos funcionais (como antioxidantes, Estabilizadores UV, lubricantes) para mellorar o seu rendemento. O masterbatch debe formularse para garantir que os aditivos sexan compatibles tanto cos pigmentos como coa matriz de TPE, evitando reaccións químicas que poidan afectar á calidade do produto.
2. Masterbatch para TPE: Composición, Requisitos de formulación e procesamento
Masterbatch para TPE é unha mestura concentrada de pigmentos/colorantes, transportistas, e aditivos, deseñado para colorear TPE e impartir funcións adicionais (como o retardo de chama, antiestático, antibacteriano) mantendo as propiedades elásticas e de procesamento inherentes ao material. A formulación e procesamento do masterbatch de TPE son máis esixentes que os dos plásticos tradicionais, debido ás propiedades únicas dos TPE. Esta sección detalla a composición, principios de formulación, e requisitos de procesamento do masterbatch TPE.
2.1 Composición básica de TPE Masterbatch
Como o masterbatch tradicional, O masterbatch TPE consta de tres compoñentes básicos: pigmentos/colorantes, transportistas, e aditivos. A selección e proporción de cada compoñente adáptanse ao tipo de TPE e aos requisitos de aplicación.
2.1.1 Pigmentos/Tintes.
Os pigmentos/colorantes son os compoñentes fundamentais que dan cor aos TPE, contabilizando 10%-70% da composición do masterbatch (dependendo da intensidade da cor e do tipo de TPE). Os principais requisitos para pigmentos/colorantes no masterbatch de TPE son:
- – Resistencia á calor: Debe soportar a temperatura de procesamento do TPE obxectivo (150℃ -290 ℃) sen descomposición nin decoloración. Para TPE de alta temperatura (TPC, TPA), prefiren os pigmentos orgánicos resistentes a altas temperaturas ou os pigmentos inorgánicos.
- – Compatibilidade: Debe ser compatible coa matriz TPE para evitar a migración, florecendo, ou elasticidade reducida. Os pigmentos con polaridade similar ao TPE son máis compatibles (p.ex., pigmentos polares para TPU, pigmentos apolares para TPS).
- – Dispersibilidade: Debe dispersarse facilmente na matriz de TPE para garantir unha cor uniforme e evitar manchas de cor, raias, ou propiedades mecánicas reducidas. Pigmentos de partículas finas (20-40 malla) con baixa aglomeración son preferibles.
- – Respecto ao medio ambiente: Debe cumprir as normas mundiais de protección ambiental (como REACH, RoHS) para evitar substancias tóxicas ou nocivas (como metais pesados) que poidan afectar á saúde humana e ao medio ambiente.
Os pigmentos comúns utilizados no masterbatch de TPE inclúen: pigmentos inorgánicos (dióxido de titanio para branco, negro de carbón por negro, óxido de ferro para vermello/amarelo), e pigmentos orgánicos resistentes a altas temperaturas (azul/verde de ftalocianina, vermello quinacridona).
2.1.2 Transportistas.
Os portadores son a matriz do masterbatch, contabilizando 20%-80% da composición, e desempeñan un papel fundamental na dispersión dos pigmentos e na adhesión á matriz de TPE. O portador debe ter unha excelente compatibilidade cos pigmentos e co TPE obxectivo, xa que a mala compatibilidade pode levar á migración do pigmento, cor desigual, e redución do rendemento do TPE. A selección do transportista baséase no tipo de TPE:
- – Para TPS (SBS, SEBS): Use TPS ou PP como operador, que ten unha boa compatibilidade e fluidez de procesamento.
- – Para TPO/TPE-o: Use PP ou PE como portador, igualando o compoñente de poliolefina do TPO.
- – Para TPV/TPE-v: Use o PP como portador, que é compatible coa matriz PP do TPV.
- – Para TPU: Use TPU como soporte, garantindo a compatibilidade coa matriz de TPU e evitando a hidrólise.
- – Para TPC/TPE-E e TPA/TPE-A: Use TPC ou TPA como operador, respectivamente, para cumprir cos requisitos de procesamento a alta temperatura e compatibilidade.
O transportista tamén debe ter unha boa fluidez de procesamento, cun punto de fusión e unha temperatura de procesamento consistentes ou lixeiramente inferiores ao TPE obxectivo, para garantir unha mestura uniforme e evitar a degradación do TPE.
2.1.3 Aditivos.
Os aditivos son compoñentes auxiliares engadidos para mellorar o rendemento do procesamento, dispersibilidade, e rendemento funcional do masterbatch TPE, contabilizando 1%-10% da composición. O tipo e a dosificación dos aditivos están determinados polo tipo de TPE e os requisitos de aplicación:
- – Dispersantes: O aditivo máis importante para o masterbatch de TPE, usado para reducir a tensión superficial do pigmento, evitar a aglomeración, e garantir unha dispersión uniforme na matriz de TPE. Os dispersantes comúns inclúen cera de polietileno, cera de polipropileno, ácido esteárico, e ceras enxertadas con anhídrido maleico. Para TPE de alta viscosidade (IVE, TPC), prefírense dispersantes de alta eficiencia cunha forte compatibilidade.
- – Compatibilizadores: Úsase para mellorar a compatibilidade entre pigmentos e TPE, e entre masterbatch e matriz TPE. Por exemplo, O PP inxertado con anhídrido maleico úsase como compatibilizante para o masterbatch de TPO, e cera de poliuretano utilízase para o masterbatch de TPU.
- – Estabilizadores de calor: Úsase para evitar a descomposición do pigmento e a degradación do TPE durante o procesamento a alta temperatura. Os estabilizadores térmicos comúns inclúen os estabilizadores orgánicos de estaño (para TPU), antioxidantes fenólicos obstaculizados (para TPS, TPO), e antioxidantes fosfitos (para TPC, TPA).
- – Antioxidantes e estabilizadores UV: Úsase para mellorar a resistencia á intemperie e á resistencia ao envellecemento dos produtos de TPE de cores, evitando o desvanecemento da cor e a degradación do rendemento baixo a luz solar e o osíxeno. Para aplicacións ao aire libre (como pezas exteriores de automóbiles), Absorbedores de UV e estabilizadores de luz de amina obstaculizada (HALS) engádense.
- – Lubricantes: Úsase para reducir a fricción entre materiais e equipos de extrusión (parafuso, barril, morrer cabeza), mellorar a fluidez do procesamento, e evitar que o material se pegue ao equipamento. Os lubricantes comúns inclúen o ácido esteárico, estearato de calcio, e aceite de silicona. Para TPU e TPA, prefírense lubricantes con baixa migración para non afectar o rendemento do produto.
- – Aditivos Funcionais: Engadido para impartir funcións especiais aos TPE, como retardadores de chama (para fíos e cables), axentes antiestáticos (para compoñentes eléctricos), e axentes antibacterianos (para dispositivos médicos e bens de consumo).
2.2 Principios de formulación de TPE Masterbatch
A formulación do masterbatch TPE debe equilibrar o efecto colorante, rendemento de procesamento, e propiedades inherentes de TPE. Os principios fundamentais son os seguintes:
2.2.1 Primeiro de compatibilidade.
O transportista, pigmentos, e os aditivos deben ser compatibles co TPE obxectivo para evitar reducir a elasticidade do material, flexibilidade, e propiedades mecánicas. Por exemplo, usar un portador non polar para TPU polar levará a unha mala compatibilidade e migración de pigmentos.
2.2.2 Combina a resistencia á calor.
Os pigmentos e aditivos deben ter unha resistencia á calor que coincida coa temperatura de procesamento do TPE. Por exemplo, O masterbatch TPC utiliza pigmentos resistentes a altas temperaturas (resistencia á calor ≥280℃) para evitar a descomposición durante o procesamento.
2.2.3 Optimizar a dispersibilidade.
O contido de pigmento e a dosificación do dispersante axústanse para garantir unha dispersión uniforme. Masterbatch de alta concentración (contido de pigmento 50%-70%) require máis dispersantes e mellores capacidades de mestura, mentres que o masterbatch de baixa concentración (10%-30%) céntrase na compatibilidade.
2.2.4 Minimizar o impacto nas propiedades de TPE.
O masterbatch non debería afectar significativamente a elasticidade do TPE, conxunto de compresión, ou resistencia á abrasión. Por exemplo, dispersantes ou lubricantes excesivos poden reducir a resistencia mecánica do TPE.
2.2.5 Cumprimento de Protección Ambiental.
A formulación debe cumprir as normas mundiais de protección ambiental, evitando substancias tóxicas ou nocivas (como metais pesados, ftalatos) que pode restrinxir o acceso ao mercado.
2.3 Requisitos de procesamento de TPE Masterbatch
O procesamento de masterbatch TPE realízase principalmente mediante a tecnoloxía de extrusión de dobre parafuso, o que require un control estrito do pretratamento da materia prima, premestura, parámetros de extrusión, e posprocesamento para garantir a calidade do produto. Os principais requisitos de procesamento son os seguintes:
2.3.1 Pretratamento de materias primas.
TPEs (especialmente TPU, TPA) teñen unha alta absorción de auga, polo que todas as materias primas (Portador de TPE, pigmentos, aditivos) debe secar completamente antes do procesamento. A temperatura e o tempo de secado están determinados polo tipo de material: TPU/TPA se seca a 100-120 ℃ para 6-8 horas, TPS/TPO se seca a 80-100 ℃ para 3-5 horas, e os pigmentos secan a 60-80 ℃ para 2-4 horas. O contido de humidade das materias primas secas debe controlarse a continuación 0.1% (0.05% para TPU/TPA).
Ademais, os pigmentos con gran tamaño de partículas ou aglomerados deben ser triturados e peneirados (20-40 malla) para mellorar a dispersibilidade, e impurezas (partículas metálicas, po) debe eliminarse para evitar o desgaste dos equipos de extrusión e defectos no masterbatch.
2.3.2 Premestura.
As materias primas secas (pigmentos, transportista, aditivos) mestúranse nun mesturador de alta velocidade segundo a proporción da fórmula para formar unha mestura preliminar uniforme. Os parámetros de premestura axústanse en función do tipo de TPE: velocidade de mestura 800-1200 rpm, tempo de mestura 5-10 minutos, temperatura de mestura 40-60 ℃. Para lotes mestres de alta concentración ou soportes de TPE de alta viscosidade, amplíase o tempo de premestura, e engádense primeiro dispersantes para recubrir os pigmentos, mellorando a dispersibilidade.
2.3.3 Control de parámetros de extrusión.
A extrusión de dobre parafuso é o paso central do procesamento de masterbatch TPE, e os parámetros clave (temperatura, velocidade do parafuso, presión de extrusión, velocidade de alimentación) debe controlarse con precisión para que coincida co tipo de TPE:
- – Control de temperatura: O barril divídese en 4-6 seccións de control de temperatura (sección de alimentación, sección de fusión, sección de mestura, sección de homoxeneización, sección de cabeza de troquel). A temperatura de cada sección axústase segundo a temperatura de procesamento do TPE. Por exemplo, Masterbatch TPS: sección de alimentación 100-120 ℃, sección de fusión 160-180 ℃, sección de mestura 170-190 ℃, sección de homoxeneización 160-180 ℃, sección de cabezal 150-170 ℃; Masterbatch TPC: sección de alimentación 150-170 ℃, sección de fusión 230-250 ℃, sección de mestura 240-260 ℃, sección de homoxeneización 230-250 ℃, sección de cabezal 220-240 ℃. A precisión do control de temperatura debe alcanzar ± 1 ℃ para evitar a degradación do TPE e a descomposición do pigmento.
- – Velocidade do parafuso: A velocidade do parafuso varía de 200-800 rpm, axustado en función da viscosidade do TPE. TPE de alta viscosidade (IVE, TPC) require maior velocidade do parafuso (500-800 rpm) para xerar forza cortante suficiente para a dispersión do pigmento; TPE de baixa viscosidade (TPS) use velocidade moderada (300-500 rpm) para evitar o desbordamento do material.
- – Presión de extrusión: A presión varía de 5-12 MPa, mantido estable (flutuación ≤±0,5MPa) para garantir unha mestura e conformación uniformes. Os TPE de alta viscosidade requiren unha maior presión, mentres que os TPE de baixa viscosidade usan presión moderada.
- – Velocidade de alimentación: Axustado para coincidir coa velocidade do parafuso e a velocidade de extrusión, garantindo unha alimentación estable e uniforme. Para TPE de alta viscosidade, utilízase un dispositivo de alimentación forzada para evitar a acumulación de material.
2.3.4 Post-procesamento.
Despois da extrusión, arrefríase o masterbatch en forma de tira (refrixeración do tanque de auga, 20-30℃), granulado (tamaño de partícula 2-5 mm), cribado (para eliminar partículas non cualificadas), e envasado (envases selados e a proba de humidade). Para masterbatch de TPE sensible á humidade (TPU, TPA), o produto acabado sécase de novo antes do envasado para evitar a absorción de humidade.
3. Campos de aplicación de TPE Masterbatch e Matching Zhuoyue Extruder Solutions
Os TPE son amplamente utilizados na automoción, eléctrica, construción, bens de consumo, e outras industrias, e os diferentes campos de aplicación teñen diferentes requisitos para o rendemento do masterbatch de TPE (cor, dispersibilidade, funcionalidade) e eficiencia da produción. Serie completa de extrusoras de dobre parafuso de Zhuoyue (HTS BASIC/PLUS/SUPER, ZTE, HTE) están especialmente optimizados para o procesamento de masterbatch TPE, proporcionando solucións específicas para diferentes categorías de TPE e campos de aplicación. A continuación móstrase unha introdución detallada aos principais campos de aplicación do masterbatch de TPE e da serie de extrusoras Zhuoyue correspondentes..
3.1 Industria da automoción: O campo de aplicación máis grande de TPE Masterbatch
A industria do automóbil é o maior consumidor de TPE, contabilizando máis de 40% do mercado global de TPE. Os TPE úsanse nunha ampla gama de compoñentes de automóbiles debido ao seu peso lixeiro, flexible, e propiedades reciclables, e o masterbatch TPE xoga un papel fundamental na cor e na modificación funcional destes compoñentes. As principais aplicacións automotrices do masterbatch TPE inclúen:
3.1.1 Selos e xuntas de automoción.
TPEs (principalmente TPV, TPO) utilízanse para producir selos de portas de automóbiles, selos de fiestras, selos de capó, e xuntas, que requiren unha boa elasticidade, resistencia á intemperie, e flexibilidade a baixa temperatura. O masterbatch para estes compoñentes require unha cor uniforme, boa resistencia á intemperie (Resistencia UV, resistencia ao envellecemento), e compatibilidade con matrices TPV/TPO.
Extrusoras coincidentes: Serie HTS PLUS e serie HTE. A serie HTS PLUS ten un alto par e resistencia ao desgaste, adecuado para procesamiento de masterbatch TPV (alta viscosidade, alta forza de corte necesaria); a serie HTE integra alto rendemento e rendibilidade, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, paneis de portas, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (non-toxic, inodoro). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Extrusoras coincidentes: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPEs (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, mangueiras de entrada de aire, e mangueiras de freo, que requiren unha boa resistencia ao aceite, resistencia á calor, e resistencia mecánica. O masterbatch require resistencia a altas temperaturas, resistencia ao aceite, e dispersibilidade uniforme para non afectar o rendemento da mangueira.
Extrusoras coincidentes: Serie HTS SUPER e serie HTS PLUS. A serie HTS SUPER ten un par ultra alto, control de temperatura preciso, e alta resistencia ao desgaste, adecuado para procesamiento de masterbatch TPC/TPA (alta temperatura, alta viscosidade); a serie HTS PLUS ten unha boa resistencia á calor e capacidade de mestura, adecuado para o procesamento de masterbatch de TPU.
3.1.4 Outros compoñentes do automóbil.
Os TPE tamén se usan para producir cubertas antipolvo de automóbiles, ventás triangulares, filtros de aire, e rompedores, que requiren propiedades diferentes (como a resistencia ao po, transparencia, resistencia ao impacto). O masterbatch está formulado segundo requisitos específicos, e as extrusoras correspondentes son seleccionadas en función do tipo de TPE e da escala de produción.
3.2 Industria eléctrica e electrónica: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, conectores, and other components, requiring functional masterbatch (antiestático, retardante de chama, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (mainly TPU, TPS, TPO) are used as insulation and sheath materials for wires and cables (power cables, ignition wires, headphone wires, connector plugs), which require good electrical insulation, flame retardancy, e resistencia á abrasión. The masterbatch requires flame retardancy (meeting UL94 V-0 estándar), antistatic properties, and uniform coloring.
Extrusoras coincidentes: HTS PLUS series, HTE series, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, apto para pequenas e medianas producións; a serie HTS SUPER é apta para gama alta, procesamento de masterbatch ignífugo de alta concentración.
3.2.2 Conectores e enchufes eléctricos.
TPEs (mainly TPU, TPA) utilízanse para producir conectores eléctricos, enchufes, e carcasas de enchufes, which require good electrical insulation, resistencia ao impacto, and environmental friendliness. O masterbatch require unha cor uniforme, resistencia a altas temperaturas, and no migration.
Extrusoras coincidentes: Serie HTS PLUS e serie HTS SUPER. A serie HTS PLUS ten unha boa compatibilidade con TPU/TPA, garantindo unha dispersión uniforme; a serie HTS SUPER ten un control preciso da temperatura, evitando a degradación do TPA durante o procesamento.
3.3 Industria da construción e do transporte: Aplicacións Masterbatch TPE resistentes á intemperie
No sector da construción e do transporte, Os TPE úsanse para producir selos, xuntas de dilatación, alfombras do metro, and other components, que requiren unha boa resistencia á intemperie, resistencia ao envellecemento, e flexibilidade de baixa temperatura para adaptarse a ambientes exteriores duros.
3.3.1 Construction Seals and Expansion Joints.
TPEs (principalmente TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, Resistencia UV, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Extrusoras coincidentes: Serie HTS PLUS e serie HTE. The HTS PLUS series has good weather-resistant additive mixing capabilities, adecuado para procesamiento de masterbatch TPV; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, and wear resistance. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Extrusoras coincidentes: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPEs (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, resistencia á abrasión, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Extrusoras coincidentes: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, toys, and other household items, which require non-toxic, inodoro, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Extrusoras coincidentes: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Dispositivos Médicos.
TPEs (mainly TPU, TPS) are used to produce medical catheters, syringes, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 estándar), high transparency (for catheters), and uniform dispersibility.
Extrusoras coincidentes: Serie HTS SUPER e serie HTS PLUS. The HTS SUPER series has clean production design, control de temperatura preciso, avoiding material pollution; the HTS PLUS series has good compatibility with medical grade TPEs, ensuring product sterility and biocompatibility.
3.4.4 Other Industrial Applications.
TPEs are also used to produce drain pipes, industrial gaskets, and mechanical components, which require good chemical resistance, wear resistance, e resistencia mecánica. The masterbatch is formulated according to specific industrial requirements, e as extrusoras correspondentes son seleccionadas en función do tipo de TPE e da escala de produción.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (alta viscosidade, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, transportistas, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Ademais, the screws adopt a modular design, which can freely combine different screw elements (conveying, mesturando, shearing) according to the TPE type. Por exemplo, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Control de temperatura preciso, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, con 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, surface hardness ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 times that of ordinary extruders; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, volatile substances, and air in the material, ensuring the density and quality of the masterbatch. The vacuum degree is adjustable (0.06-0.09MPa), adapting to different moisture content requirements.
4.1.5 High Production Efficiency and Energy Saving.
Zhuoyue’s extruders adopt high-torque gearboxes and optimized screw structures, with strong conveying capacity and high production efficiency. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. Por exemplo, HTS SUPER series production capacity reaches 1000-3000kg/h, adecuado para a produción en masa a gran escala; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, and predictive maintenance, realizing intelligent production management.
4.1.7 Wide Adaptability.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (masterbatch de cores, masterbatch ignífugo, antistatic masterbatch), with pigment content ranging from 10% a 70%. They can also be matched with auxiliary equipment (high-speed mixers, secadores, coolers, granulators) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, production scale, and application requirements.
4.2.1 Serie HTS BASIC: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, control automático de temperatura, and feeding, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 Serie HTS PLUS: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (IVE, TPU, high-concentration TPE masterbatch, masterbatch ignífugo). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (alta viscosidade, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (retardantes de chama, axentes antiestáticos). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, dispositivos médicos).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
The HTS SUPER series is Zhuoyue’s highest-end extruder series, representing the advanced level of China’s twin-screw extruders, designed for high-end, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98 %), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, and predictive maintenance. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 ZTE Series: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, baixo consumo de enerxía, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% compared with ordinary extruders. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, debido ás propiedades únicas dos TPE (temperature sensitivity, moisture absorption, alta viscosidade), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Problem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premestura: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Equipos: Worn screw mixing elements; blocked die head.
Solutions: (1) Optimize raw materials: Select fine-particle pigments (20-40 malla), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 minutos. (3) Adjust extrusion parameters: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Maintain equipment: Replace worn screw elements; clean die head regularly.
5.2 Problem 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, darkening), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (máis que 3 minutos) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Solutions: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Problem 3: High Wear of Screw and Barrel
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Causes: (1) Raw materials: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion parameters: High screw speed, excessive shear force; high extrusion pressure. (3) Equipos: Screw/barrel material has poor wear resistance.
Solutions: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Problem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premestura: Air mixed into the mixture during premixing.
Solutions: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Problem 5: Poor Processing Fluidity, Bloqueo de equipos
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (máis que 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Equipos: Worn conveying elements; blocked die head.
Solutions: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, e campos de aplicación, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Caso 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (contido de pigmento 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), resistencia á calor (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Solución: Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Primeiro, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Segundo, the barrel is equipped with a double-layer jacket + forced cooling structure, con 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Terceiro, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Ademais, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: Despois 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 meses, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.
6.1 Caso 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (contido de pigmento 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), resistencia á calor (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Solución:
Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Primeiro, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Segundo, the barrel is equipped with a double-layer jacket + forced cooling structure, con 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Terceiro, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Ademais, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
Despois 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 meses, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.