Thermoplastic Elastomers (TPE), Wani lokaci ana kiransa Thermoplastic Rubbers (Farashin TPR), wani nau'in copolymer ne ko gaurayawan jiki na polymers - yawanci filastik da roba - waɗanda ke haɗa kaddarorin thermoplastics da elastomers.. Wannan haɗin na musamman yana ba da damar sarrafa TPEs kamar thermoplastics (ta hanyar extrusion, allura gyare-gyare, busa gyare-gyare, da dai sauransu.) yayin da yake riƙe da elasticity da sassauci na rubbers. Ba kamar na gargajiya vulcanized roba, Ana iya narkar da TPEs kuma a sake sarrafa su sau da yawa ba tare da babban asarar aiki ba, yana sa su zama masu dacewa da muhalli da tsada. Kamar yadda ake bukata don nauyi, m, kuma kayan da za a sake amfani da su suna girma a cikin masana'antu kamar na kera motoci, lantarki, gini, da kayan masarufi, TPEs sun zama sananne, tuƙi ci gaban na musamman masterbatch da extrusion fasahar kerar da su musamman aiki bukatun.
Masterbatch, a matsayin maɓalli mai mahimmanci don canza launi da aikin gyare-gyare na TPEs, yana taka muhimmiyar rawa wajen haɓaka aiki da faɗaɗa iyakokin aikace-aikacen samfuran TPE. Yin sarrafa TPE masterbatch yana buƙatar madaidaicin kulawar haɗuwa, tarwatsawa, da sigogin zafin jiki, kamar yadda TPEs suna da takamaiman danko, zafi juriya, da halayen elasticity wanda ya bambanta da robobi na gargajiya. Twin-screw extruders, tare da iyawarsu na haɗawa da tarwatsawa, madaidaicin sarrafa zafin jiki, da daidaitawa ga kayan aiki daban-daban, sun zama ainihin kayan aiki don TPE masterbatch. Zhuoyue, ƙwararrun masana'anta na twin-screw extruders, yayi cikakken kewayon ci-gaba extrusion mafita musamman tsara don TPE compounding da masterbatch aiki, Rufe TPE / SBS / TPU / TPR / TPV da sauran manyan nau'ikan TPE, don saduwa da buƙatun daban-daban na masana'antun a cikin masana'antu daban-daban.
1. Bayanin Thermoplastic Elatomers (TPE): Categories, Kayayyaki da Halayen Maɓalli
TPEs dangi ne na kayan daban-daban, an rarraba shi zuwa nau'ikan kasuwanci na gabaɗaya guda shida bisa la'akari da tsarin sinadaransu da tsarinsu. Kowane rukuni yana da kaddarorin musamman, aiki halaye, da filayen aikace-aikace, wanda kai tsaye ƙayyadaddun buƙatun don ƙirar masterbatch da kayan aikin extrusion. Fahimtar rarrabuwa da kaddarorin TPEs shine tushe don haɓaka aikin sarrafa kayan masarufi da zaɓar masu fitar da tagwayen dunƙule masu dacewa..
1.1 Babban Rukunin Kasuwanci shida na TPEs
1.1.1 Styrenic Block Copolymers (TPS, TPE-s).
TPS shine nau'in TPE da aka fi amfani dashi, yin lissafin babban kaso na kasuwar TPE ta duniya. Ya ƙunshi tubalan styrenic (kamar polystyrene, PS) da kuma elastomeric blocks (kamar polybutadiene, PB; polyisoprene, PI; ko ethylene-butylene, EB), haɗa ta covalent bonds. Mafi yawan nau'ikan TPS sun haɗa da SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), da SEPS (Styrene-Ethylene-Propylene-Styrene).
Maɓalli na TPS sun haɗa da kyakkyawan sassauci, elasticity, da kuma aiwatarwa. SEBS da SEPS, wanda shine nau'ikan hydrogenated na SBS da SIS, sun inganta juriya na zafi, juriya yanayi, da juriyar tsufa, sa su dace da aikace-aikacen waje da zafin jiki. Abubuwan TPS suna da sauƙin canza launin kuma an gyara su tare da masterbatch, kuma zafin aiki da suke aiki daga 150 ℃ zuwa 220 ℃, wanda ya dace da mafi yawan masu fitar da tagwaye. Aikace-aikacen gama gari na TPS sun haɗa da abubuwan haɗin mota, wayoyi da igiyoyi, kayan masarufi, da na'urorin likitanci.
1.1.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o).
TPO wani abu ne na jiki na polyolefin (kamar polypropylene, PP; ko polyethylene, PE) da elastomer (kamar ethylene-propylene-diene monomer, EPDM). Yana haɗuwa da rigidity na polyolefins tare da elasticity na elastomers, kuma yana da kyakkyawan juriya na sinadarai, juriya yanayi, da ƙananan zafin jiki. TPOs ba masu guba bane, mara wari, da sake yin amfani da su, sanya su manufa don aikace-aikacen da ke buƙatar abokantaka na muhalli.
The aiki zafin jiki na TPO jeri daga 160 ℃ zuwa 230 ℃, kuma yana da kyau dacewa tare da daban-daban masterbatches (launi masterbatch, harshen wuta-retardant masterbatch, da dai sauransu.). Ana amfani da TPOs sosai a cikin sassan waje na mota (kamar su rufe fuska, fender liners), kayan gini (kamar hatimi, gaskets), da kayan aikin lantarki. Saboda babban abun ciki na polyolefin, TPO masterbatch aiki yana buƙatar extruders tare da kyakkyawar damar haɗawa don tabbatar da rarrabuwa iri ɗaya na pigments da ƙari..
1.1.3 Thermoplastic Vulcanizates (VAT, TPE v).
TPV shine cakuda polyolefin mai ƙarfi mai ƙarfi (yawanci PP) da elastomer (yawanci EPDM). Lokacin sarrafawa, lokacin elastomer yana vulcanized cikin ƙananan barbashi kuma an tarwatsa iri ɗaya a cikin matrix polyolefin., haifar da kyakkyawan elasticity, matsawa saita juriya, da juriya na zafi. TPVs suna da ingantattun kaddarorin inji da kwanciyar hankali fiye da TPEs na gargajiya, kuma yana iya jure yanayin zafi mai tsayi na dogon lokaci (har zuwa 150 ℃).
sarrafa TPV yana buƙatar madaidaicin kulawar zafin jiki da ƙarfi mai ƙarfi don tabbatar da ɓarke iri ɗaya da tarwatsewa. The aiki zafin jiki jeri daga 170 ℃ zuwa 240 ℃, kuma kayan yana da babban danko yayin aiki, wanda ke sanya manyan buƙatu akan jujjuyawar wutar lantarki da sa juriya na masu fitar da tagwayen dunƙule. Ana amfani da TPV da yawa a cikin hatimin mota, hoses, gaskets, da kayan aikin masana'antu waɗanda ke buƙatar babban aiki da karko.
1.1.4 Thermoplastic polyurethane (TPU).
TPU toshe copolymer ne wanda ya ƙunshi sassa masu wuya (diisocyanate da sarkar tsawo) da sassa masu laushi (polyol). Yana da kyakkyawan elasticity, juriya abrasion, juriya mai, da ƙarfin injina, kuma ana iya daidaita shi cikin taurin daga taushi sosai (Shore A 30) da wuya sosai (Shore D 85) ta hanyar canza rabon sassa masu wuya da taushi.
TPU aiki yana kula da zafin jiki da danshi. The aiki zafin jiki jeri daga 180 ℃ zuwa 250 ℃, kuma dole ne a bushe kayan da kyau kafin sarrafawa (abun ciki danshi ≤0.05%) don kauce wa hydrolysis da kumfa samuwar. TPU masterbatch sarrafa na bukatar extruders tare da madaidaicin sarrafa zafin jiki da kuma injin shaye damar. Ana amfani da TPU sosai a cikin wayoyi da igiyoyi, mota hoses, takalma, likita catheters, da kayan wasanni.
1.1.5 Thermoplastic Copolyesters (Farashin TPC, TPE-E).
TPC wani toshe copolymer ne wanda ya ƙunshi sassan polyester hard segments da polyether ko polyester taushi sassan.. Yana da kyakkyawan juriya na zafi, sinadaran juriya, da kayan aikin injiniya, kuma yana iya jure yanayin zafi har zuwa 150 ℃ na dogon lokaci. TPCs kuma suna da kyakkyawan sassauci da elasticity, yin su dace da high-yi aikace-aikace.
The aiki zafin jiki na TPC jeri daga 220 ℃ zuwa 280 ℃, which is higher than other TPE categories. It has high viscosity during processing and requires extruders with high torque and precise temperature control. 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), sassan sararin samaniya, da injunan masana'antu.
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, sa juriya, 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 aiki zafin jiki na TPA jeri daga 230 ℃ zuwa 290 ℃, kuma yana da yawan sha ruwa, ana buƙatar bushewa sosai kafin sarrafawa. TPA masterbatch sarrafa na bukatar extruders tare da high lalacewa juriya (saboda babban taurin polyamide) da madaidaicin sarrafa zafin jiki don guje wa lalata kayan abu. Ana amfani da TPA ko'ina a cikin kayan aikin mota (kamar gears, bearings), masu haɗa wutar lantarki, da kuma masana'antu hoses.
1.2 Maɓallin Abubuwan TPEs Suna Tasirin Tsarin Masterbatch
TPEs suna da kaddarorin musamman waɗanda ke bambanta su da robobi na gargajiya, kuma waɗannan kaddarorin kai tsaye suna shafar ƙirar masterbatch da zaɓin kayan aikin extrusion. Mabuɗin kaddarorin da za a yi la'akari da su a cikin sarrafa masterbatch sune kamar haka:
1.2.1 Nauni da sassauci.
TPEs suna da babban elasticity da sassauci, which means that the masterbatch must be compatible with the TPE matrix to avoid reducing the material’s elastic performance. The carrier of the masterbatch should have good compatibility with the TPE, and the dispersant should ensure uniform dispersion of pigments without forming agglomerates that could cause stress concentration and reduce flexibility.
1.2.2 Juriya mai zafi.
Different TPE categories have different heat resistance (processing temperature ranges from 150℃ to 290℃). Masterbatch pigments and additives must have heat resistance matching the TPE processing temperature to avoid decomposition, canza launi, or performance degradation during extrusion. Misali, TPC and TPA require high-temperature resistant pigments and heat stabilizers.
1.2.3 Viscosity and Processability.
TPEs have varying viscosities during processing (TPV da TPC suna da danko mafi girma, yayin da TPS yana da ƙananan danko). Wannan yana rinjayar ƙarfin ƙarfi da isar da buƙatun na tagwayen-screw extruder. TPEs masu ƙarfi suna buƙatar extruders tare da babban juzu'i da ƙarfin haɗuwa mai ƙarfi, yayin da ƙananan ƙarancin TPEs na buƙatar daidaitaccen iko na saurin extrusion don guje wa zubar da kayan abu.
1.2.4 Ciwon Danshi.
Wasu TPEs (kamar TPU, TPA) suna da yawan sha ruwa, wanda zai iya haifar da kumfa, hydrolysis, da sauran lahani a cikin masterbatch. Da albarkatun kasa (TPE, pigments, additives) dole ne a bushe sosai kafin sarrafa, kuma mai fitar da wuta ya kamata a sanye shi da na'urar da za ta cire damshi da abubuwa masu canzawa.
1.2.5 Dace da Additives.
TPEs sau da yawa suna buƙatar ƙari na aiki (irin su antioxidants, UV stabilizers, man shafawa) don inganta ayyukansu. Ya kamata a tsara masterbatch don tabbatar da cewa abubuwan ƙari sun dace da duka pigments da matrix na TPE., guje wa halayen sinadarai waɗanda zasu iya shafar ingancin samfur.
2. Masterbatch don TPEs: Abun ciki, Ƙirƙira da Bukatun Gudanarwa
Masterbatch don TPEs babban cakuda ne na pigments/ rini, masu dako, da ƙari, tsara don canza launin TPEs da ba da ƙarin ayyuka (kamar jinkirin wuta, antistatic, antibacterial) yayin da yake kiyaye abubuwan da ke tattare da kayan roba da kayan aiki. Ƙirƙirar da sarrafa TPE masterbatch sun fi buƙata fiye da na robobi na gargajiya, saboda keɓaɓɓen kaddarorin TPEs. Wannan sashe yayi cikakken bayani akan abun da ke ciki, ka'idodin tsarawa, da bukatun aiki na TPE masterbatch.
2.1 Babban Haɗin gwiwar TPE Masterbatch
Kamar masterbatch na gargajiya, TPE masterbatch ya ƙunshi abubuwa na asali guda uku: pigments / rini, masu dako, da ƙari. Zaɓin da rabon kowane sashi an keɓance shi da nau'in TPE da bukatun aikace-aikacen sa.
2.1.1 Pigments/Dyes.
Pigments/dyes sune ainihin abubuwan da ke ba da launi ga TPEs, lissafin kudi 10%-70% na masterbatch abun da ke ciki (dangane da tsananin launi da nau'in TPE). Mabuɗin buƙatun don pigments/dyes a cikin TPE masterbatch sune:
- – Juriya mai zafi: Dole ne ya yi tsayayya da zafin aiki na TPE manufa (150℃-290 ℃) ba tare da lalacewa ko canza launi ba. Don TPEs masu zafi (Farashin TPC, TPA), An fi so ingantattun launuka masu jure zafin jiki ko inorganic pigments.
- – Daidaituwa: Dole ne ya dace da matrix na TPE don guje wa ƙaura, furanni, ko rage elasticity. Pigments masu kama da polarity zuwa TPE sun fi dacewa (misali, polar pigments ga TPU, wadanda ba iyakacin duniya pigments ga TPS).
- – Watsewa: Dole ne a tarwatsa cikin sauƙi a cikin matrix na TPE don tabbatar da canza launin iri ɗaya da guje wa tabo masu launi, tsiri, ko rage inji Properties. Fine-barbashi pigments (20-40 raga) tare da ƙananan agglomeration an fi so.
- – Abokan Muhalli: Dole ne ya cika ka'idojin kare muhalli na duniya (kamar KAI, RoHS) don guje wa abubuwa masu guba ko cutarwa (kamar karafa masu nauyi) wanda zai iya shafar lafiyar ɗan adam da muhalli.
Alamomin gama gari da ake amfani da su a cikin TPE masterbatch sun haɗa da: inorganic pigments (titanium dioxide ga fari, carbon baki ga baki, baƙin ƙarfe oxide ga ja / rawaya), da kuma high-zazzabi resistant Organic pigments (phthalocyanin blue/kore, quinacridone ja).
2.1.2 Masu ɗaukar kaya.
Masu ɗauka sune matrix na masterbatch, lissafin kudi 20%-80% na abun da ke ciki, kuma suna taka muhimmiyar rawa wajen tarwatsa pigments da kuma bin matrix TPE. The carrier must have excellent compatibility with both the pigments and the target TPE, as poor compatibility can lead to pigment migration, uneven coloring, and reduced TPE performance. The selection of the carrier is based on the type of TPE:
- – For TPS (SBS, SEBS): Use TPS or PP as the carrier, which has good compatibility and processing fluidity.
- – For TPO/TPE-o: Use PP or PE as the carrier, matching the polyolefin component of the TPO.
- – For TPV/TPE-v: Use PP as the carrier, which is compatible with the PP matrix of the TPV.
- – For TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, bi da bi, to match the high-temperature processing requirements and compatibility.
Ya kamata kuma mai ɗaukar kaya ya kasance yana da ingantaccen ruwa mai sarrafa shi, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Additives.
Abubuwan da ake ƙarawa sune ƙarin abubuwan da aka ƙara don haɓaka aikin sarrafawa, dispersibility, and functional performance of TPE masterbatch, lissafin kudi 1%-10% na abun da ke ciki. The type and dosage of additives are determined by the TPE type and application requirements:
- – Masu watsewa: The most important additive for TPE masterbatch, used to reduce pigment surface tension, prevent agglomeration, and ensure uniform dispersion in the TPE matrix. Abubuwan tarwatsawa na yau da kullun sun haɗa da kakin polyethylene, polypropylene kakin zuma, stearic acid, and maleic anhydride grafted waxes. For high-viscosity TPEs (VAT, Farashin TPC), high-efficiency dispersants with strong compatibility are preferred.
- – Masu jituwa: Used to improve compatibility between pigments and TPEs, kuma tsakanin masterbatch da TPE matrix. Misali, Ana amfani da maleic anhydride grafted PP azaman mai daidaitawa don TPO masterbatch, kuma ana amfani da kakin polyurethane don TPU masterbatch.
- – Heat Stabilizers: Ana amfani dashi don hana lalata launi da lalata TPE yayin aiki mai zafi. Matsalolin zafi na gama-gari sun haɗa da masu tabbatar da kwano na halitta (don TPU), hana phenol antioxidants (don TPS, TPO), da kuma phosphite antioxidants (don TPC, TPA).
- – UV Stabilizers da Antioxidants: An yi amfani dashi don haɓaka juriya na yanayi da juriya na tsufa na samfuran TPE masu launi, hana lalata launi da lalata aiki a ƙarƙashin hasken rana da oxygen. Don aikace-aikacen waje (kamar sassa na waje na mota), Masu ɗaukar UV da masu hana amine haske stabilizers (HALS) ana karawa.
- – Man shafawa: Ana amfani da shi don rage gogayya tsakanin kayan aiki da kayan aikin extrusion (dunƙule, ganga, mutu kafa), inganta sarrafa ruwa, kuma kauce wa abin da ke manne da kayan aiki. Man shafawa na yau da kullun sun haɗa da stearic acid, calcium stearate, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (for electrical components), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, pigments, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, sassauci, da kayan aikin injiniya. Misali, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. Misali, TPC masterbatch uses high-temperature resistant pigments (heat resistance ≥280℃) to avoid decomposition during processing.
2.2.3 Optimize Dispersibility.
The pigment content and dispersant dosage are adjusted to ensure uniform dispersion. High-concentration masterbatch (pigment content 50%-70%) requires more dispersants and better mixing capabilities, while low-concentration masterbatch (10%-30%) focuses on compatibility.
2.2.4 Minimize Impact on TPE Properties.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. Misali, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Yarda da Kariyar Muhalli.
Dole ne tsarin ya cika ka'idojin kare muhalli na duniya, guje wa abubuwa masu guba ko cutarwa (kamar karafa masu nauyi, phthalates) wanda zai iya hana shiga kasuwa.
2.3 Bukatun aiwatar da TPE Masterbatch
Ana aiwatar da sarrafa TPE masterbatch galibi ta amfani da fasahar extrusion tagwaye, wanda ke buƙatar kulawa mai tsauri na pretreatment na albarkatun kasa, premixing, extrusion sigogi, da kuma bayan-aiki don tabbatar da ingancin samfur. Mabuɗin sarrafawa sune kamar haka:
2.3.1 Raw Material Pretreatment.
TPEs (musamman TPU, TPA) suna da yawan sha ruwa, don haka duk albarkatun kasa (Mai ɗaukar TPE, pigments, additives) dole ne a bushe sosai kafin sarrafa. Ana ƙayyade zafin jiki da lokacin bushewa ta nau'in kayan: An bushe TPU/TPA a 100-120 ℃ don 6-8 hours, An bushe TPS/TPO a 80-100 ℃ don 3-5 hours, kuma pigments suna bushe a 60-80 ℃ don 2-4 hours. Ya kamata a sarrafa danshi na busassun albarkatun ƙasa a ƙasa 0.1% (0.05% don TPU/TPA).
Bugu da kari, pigments tare da manyan barbashi masu girma dabam ko agglomerates ya kamata a murkushe da sieved (20-40 raga) don inganta dispersibility, da kazanta (karfe barbashi, kura) ya kamata a cire don kauce wa lalacewa a kan kayan aikin extrusion da lahani a cikin masterbatch.
2.3.2 Premixing.
Busassun albarkatun kasa (pigments, mai ɗaukar kaya, additives) ana gauraye su a cikin mahaɗa mai sauri bisa ga tsarin ƙira don samar da cakuɗen farko na iri ɗaya. Ana daidaita sigogin ƙaddamarwa bisa nau'in TPE: hadawa gudun 800-1200 rpm, lokacin hadawa 5-10 mintuna, Mix zafin jiki 40-60 ℃. Don babban taro na masterbatch ko masu ɗaukar nauyin TPE masu ƙarfi, an ƙara lokacin premixing, kuma ana ƙara masu rarrabawa da farko don suturta pigments, inganta watsawa.
2.3.3 Sarrafa Ma'auni na Extrusion.
Twin-screw extrusion shine ainihin matakin sarrafa TPE masterbatch, da mabuɗin maɓalli (zafin jiki, dunƙule gudun, matsa lamba extrusion, gudun ciyarwa) dole ne a sarrafa shi daidai don dacewa da nau'in TPE:
- – Kula da Zazzabi: An raba ganga zuwa 4-6 sassan kula da zafin jiki (sashen ciyarwa, sashin narkewa, hadawa sashe, homogenizing sashe, mutu head section). Ana daidaita yawan zafin jiki na kowane sashe bisa ga yanayin sarrafa TPE. Misali, Babban darajar TPS: sashen ciyarwa 100-120 ℃, narkewa sashe 160-180 ℃, hadawa sashe 170-190 ℃, homogenizing sashe 160-180 ℃, mutu shugaban sashe 150-170 ℃; Babban darajar TPC: sashen ciyarwa 150-170 ℃, narkewa 230-250 ℃, hadawa sashe 240-260 ℃, homogenizing sashe 230-250 ℃, mutu shugaban sashe 220-240 ℃. Madaidaicin kula da zafin jiki ya kamata ya isa ± 1 ℃ don guje wa lalata TPE da bazuwar pigment..
- – Gudun dunƙulewa: The dunƙule gudun jeri daga 200-800 rpm, daidaitawa dangane da dankon TPE. TPEs masu ƙarfi (VAT, Farashin TPC) na bukatar mafi girma dunƙule gudun (500-800 rpm) don samar da isassun ƙarfin ƙarfi don tarwatsa pigment; ƙananan danko TPEs (TPS) amfani da matsakaicin gudun (300-500 rpm) don gujewa ambaliya.
- – Matsi na Extrusion: Matsakaicin iyaka daga 5-12MPa, kiyaye barga (canzawa ≤± 0.5MPa) don tabbatar da hadawar uniform da siffa. TPEs masu ƙarfi suna buƙatar matsa lamba mafi girma, yayin da TPE masu ƙarancin danko suna amfani da matsakaicin matsa lamba.
- – Gudun Ciyarwa: Daidaita don dacewa da saurin dunƙule da saurin extrusion, tabbatar da kwanciyar hankali da abinci iri ɗaya. For high-viscosity TPEs, ana amfani da na'urar ciyar da tilas don guje wa tara kayan abu.
2.3.4 Bayan-Processing.
Bayan extrusion, masterbatch mai siffar tsiri yana sanyaya (tankin ruwa sanyaya, 20-30℃), granulated (girman barbashi 2-5mm), tacewa (don cire abubuwan da ba su cancanta ba), kuma kunshe (marufi da marufi mai tabbatar da danshi). Don Masterbatch na TPE mai raɗaɗi (TPU, TPA), An sake busar da samfurin da aka gama kafin marufi don hana ɗaukar danshi.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, lantarki, gini, kayan masarufi, and other industries, and different application fields have different requirements for TPE masterbatch performance (launi, dispersibility, functionality) and production efficiency. Zhuoyue’s full series of twin-screw extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) are specially optimized for TPE masterbatch processing, providing targeted solutions for different TPE categories and application fields. Below is a detailed introduction to the main application fields of TPE masterbatch and the matching Zhuoyue extruder series.
3.1 Masana'antar Motoci: The Largest Application Field of TPE Masterbatch
Masana'antar kera motoci ita ce mafi yawan masu amfani da TPEs, lissafin kudi fiye da 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, m, and recyclable properties, and TPE masterbatch plays a key role in coloring and functional modification of these components. The main automotive applications of TPE masterbatch include:
3.1.1 Automotive Seals and Gaskets.
TPEs (mainly TPV, TPO) are used to produce automotive door seals, rufe taga, hood seals, da gaskets, which require good elasticity, juriya yanayi, da ƙananan zafin jiki. The masterbatch for these components requires uniform coloring, good weather resistance (Juriya UV, aging resistance), and compatibility with TPV/TPO matrices.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has high torque and wear resistance, suitable for TPV masterbatch processing (high viscosity, high shear force required); the HTE series integrates high performance and cost-effectiveness, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, bangarorin kofa, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (mara guba, mara wari). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPEs (mainly TPU, Farashin TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, zafi juriya, da ƙarfin injina. The masterbatch requires high-temperature resistance, juriya mai, and uniform dispersibility to avoid affecting the hose’s performance.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, madaidaicin sarrafa zafin jiki, and high wear resistance, suitable for TPC/TPA masterbatch processing (high zafin jiki, high viscosity); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, bayyana gaskiya, tasiri juriya). The masterbatch is formulated according to specific requirements, and the matching extruders are selected based on TPE type and production scale.
3.2 Electrical and Electronic Industry: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, masu haɗin kai, da sauran sassa, requiring functional masterbatch (antistatic, harshen wuta, 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, jinkirin wuta, da abrasion juriya. The masterbatch requires flame retardancy (meeting UL94 V-0 misali), antistatic Properties, and uniform coloring.
Matching Extruders: HTS PLUS series, HTE series, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPEs (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, tasiri juriya, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Matching Extruders: HTS PLUS series and HTS SUPER series. The HTS PLUS series has good compatibility with TPU/TPA, ensuring uniform dispersion; the HTS SUPER series has precise temperature control, avoiding TPA degradation during processing.
3.3 Construction and Transportation Industry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, da sauran sassa, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPEs (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, Juriya UV, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has good weather-resistant additive mixing capabilities, suitable for TPV masterbatch processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, da sanya juriya. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPEs (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, juriya abrasion, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Matching Extruders: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, kayan wasan yara, and other household items, which require non-toxic, mara wari, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Matching Extruders: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Medical Devices.
TPEs (mainly TPU, TPS) are used to produce medical catheters, sirinji, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 misali), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, madaidaicin sarrafa zafin jiki, 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, sa juriya, da ƙarfin injina. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (high viscosity, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, masu dako, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Bugu da kari, the screws adopt a modular design, which can freely combine different screw elements (isarwa, hadawa, shege) according to the TPE type. Misali, 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 Madaidaicin Kula da Zazzabi, 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, tare da 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, Farashin 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%. Misali, HTS SUPER series production capacity reaches 1000-3000kg/h, suitable for large-scale mass production; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, da kuma kula da tsinkaya, realizing intelligent production management.
4.1.7 Faɗin daidaitawa.
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 (launi masterbatch, harshen wuta-retardant masterbatch, antistatic masterbatch), with pigment content ranging from 10% ku 70%. They can also be matched with auxiliary equipment (high-speed mixers, dryers, coolers, granulators) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, sikelin samarwa, da aikace-aikace bukatun.
4.2.1 HTS BASIC Series: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, automatic temperature control, and feeding, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 HTS PLUS Series: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (VAT, TPU, high-concentration TPE masterbatch, harshen wuta-retardant masterbatch). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (high viscosity, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (harshen wuta, antistatic agents). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, na'urorin likitanci).
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, Farashin 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, da kuma kula da tsinkaya. 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, karancin makamashi, 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, saboda keɓaɓɓen kaddarorin TPEs (temperature sensitivity, moisture absorption, high viscosity), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Matsala 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premixing: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Kayan aiki: Worn screw mixing elements; blocked die head.
Magani: (1) Optimize raw materials: Select fine-particle pigments (20-40 raga), 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 mintuna. (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 Matsala 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 (fiye da 3 mintuna) 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).
Magani: (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 Matsala 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) Kayan aiki: Screw/barrel material has poor wear resistance.
Magani: (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 Matsala 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premixing: Air mixed into the mixture during premixing.
Magani: (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 Matsala 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment abun ciki (fiye da 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Kayan aiki: Worn conveying elements; blocked die head.
Magani: (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, da filayen aikace-aikace, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Harka 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 (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), zafi juriya (260℃), and batch stability. The original equipment had problems of insufficient torque, m zazzabi kula, and poor dispersibility, which could not meet the requirements.
Magani: Zhuoyue recommended the HTS SUPER series extruders (dunƙule diamita 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: Na farko, 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. Na biyu, the barrel is equipped with a double-layer jacket + forced cooling structure, tare da 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. Na uku, 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. Bugu da kari, 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: Bayan 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 watanni, 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 Harka 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 (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), zafi juriya (260℃), and batch stability. The original equipment had problems of insufficient torque, m zazzabi kula, and poor dispersibility, which could not meet the requirements.
Magani:
Zhuoyue recommended the HTS SUPER series extruders (dunƙule diamita 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: Na farko, 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. Na biyu, the barrel is equipped with a double-layer jacket + forced cooling structure, tare da 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. Na uku, 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. Bugu da kari, 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:
Bayan 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 watanni, 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.