Termoplastični elastomeri (TPE), ponekad se nazivaju i termoplastične gume (TPR), are a class of copolymers or physical mixtures of polymers—typically a plastic and a rubber—that combine the properties of thermoplastics and elastomers. Ova jedinstvena kombinacija omogućuje obradu TPE-a kao termoplasta (putem ekstruzije, injekcijsko prešanje, puhanje, itd.) zadržavajući elastičnost i savitljivost guma. Za razliku od tradicionalnih vulkaniziranih guma, TPE se mogu taliti i ponovno obrađivati više puta bez značajnog gubitka performansi, čineći ih ekološki prihvatljivijima i isplativijima. Kao potražnja za laganim, fleksibilan, i materijali koji se mogu reciklirati rastu u industrijama kao što je automobilska, električni, konstrukcija, i robe široke potrošnje, TPE su postali sve popularniji, poticanje razvoja specijaliziranih masterbatch i ekstruzijskih tehnologija prilagođenih njihovim jedinstvenim zahtjevima obrade.
Masterbatch, kao ključni materijal za bojanje i funkcionalnu modifikaciju TPE-a, igra ključnu ulogu u poboljšanju performansi i proširenju opsega primjene TPE proizvoda. Obrada TPE masterbatch-a zahtijeva preciznu kontrolu miješanja, raspršujući se, i temperaturne parametre, jer TPE imaju specifičnu viskoznost, otpornost na toplinu, i karakteristike elastičnosti koje se razlikuju od tradicionalne plastike. Ekstruderi s dva puža, s njihovim vrhunskim sposobnostima miješanja i raspršivanja, precizna kontrola temperature, i prilagodljivost različitim materijalima, postali su osnovna oprema za obradu TPE masterbatch-a. Zhuoyue, profesionalni proizvođač dvopužnih ekstrudera, nudi cijeli niz naprednih rješenja za ekstruziju posebno dizajniranih za TPE miješanje i obradu masterbatch-a, pokrivajući TPE/SBS/TPU/TPR/TPV i druge glavne TPE kategorije, zadovoljiti raznolike potrebe proizvođača u različitim industrijama.
1. Pregled termoplastičnih elastomera (TPE): kategorije, Svojstva i ključne karakteristike
TPE su raznolika obitelj materijala, klasificirani u šest općih komercijalnih kategorija na temelju njihovog kemijskog sastava i strukture. Svaka kategorija ima jedinstvena svojstva, karakteristike obrade, i polja primjene, koji izravno određuju zahtjeve za formulaciju masterbatch-a i opremu za ekstruziju. Razumijevanje klasifikacije i svojstava TPE-a temelj je za optimizaciju obrade masterbatch-a i odabir prikladnih dvopužnih ekstrudera.
1.1 Šest općih komercijalnih kategorija TPE-a
1.1.1 Stirenski blok kopolimeri (TPS, TPE-s).
TPS je najraširenija kategorija TPE-a, čine veliki udio u globalnom TPE tržištu. It is composed of styrenic blocks (kao što su polistiren, P.S) and elastomeric blocks (kao što je polibutadien, PB; poliizopren, PI; ili etilen-butilen, EB), povezani kovalentnim vezama. The most common types of TPS include SBS (Stireni-butadieni-stireni), SIS (Stiren-izopren-stiren), SEBS (Stiren-etilen-butilen-stiren), i SEPS (Stiren-etilen-propilen-stiren).
Ključna svojstva TPS-a uključuju izvrsnu fleksibilnost, elastičnost, and processability. SEBS i SEPS, koji su hidrogenirane verzije SBS i SIS, imaju poboljšanu otpornost na toplinu, otpornost na vremenske uvjete, i otpornost na starenje, što ih čini prikladnima za vanjsku primjenu i primjenu na visokim temperaturama. TPS materijali se lako boje i modificiraju masterbatchom, a njihova temperatura obrade kreće se od 150 ℃ do 220 ℃, koji je kompatibilan s većinom dvopužnih ekstrudera. Uobičajene primjene TPS-a uključuju automobilske komponente, wires and cables, roba široke potrošnje, i medicinskih uređaja.
1.1.2 Termoplastični poliolefinski elastomeri (TPO, TPE-o).
TPO is a physical blend of polyolefin (kao što su polipropilen, PP; ili polietilena, PE) and elastomer (such as ethylene-propylene-diene monomer, EPDM). Kombinira krutost poliolefina s elastičnošću elastomera, and has excellent chemical resistance, otpornost na vremenske uvjete, and low temperature flexibility. TPOs are non-toxic, odorless, and recyclable, što ih čini idealnim za primjene koje zahtijevaju ekološku prihvatljivost.
Temperatura obrade TPO kreće se od 160 ℃ do 230 ℃, i ima dobru kompatibilnost s raznim masterbatchevima (boja masterbatch, flame-retardant masterbatch, itd.). TPO se široko koriste u vanjskim dijelovima automobila (such as bumper covers, fender liners), građevinski materijali (such as seals, brtve), i električne komponente. Due to their high polyolefin content, TPO masterbatch obrada zahtijeva ekstrudere s dobrim sposobnostima miješanja kako bi se osigurala jednolika disperzija pigmenata i aditiva.
1.1.3 Termoplastični vulkanizati (PDV, TPE v).
TPV je dinamički vulkanizirana mješavina poliolefina (obično PP) and elastomer (obično EPDM). Tijekom obrade, elastomerna faza je vulkanizirana u male čestice i ravnomjerno raspršena u poliolefinskoj matrici, što rezultira izvrsnom elastičnošću, otpor kompresije, i otpornost na toplinu. TPV imaju bolja mehanička svojstva i dimenzionalnu stabilnost od tradicionalnih TPE, i može izdržati dugotrajno izlaganje visokim temperaturama (do 150 ℃).
TPV obrada zahtijeva preciznu kontrolu temperature i jaku silu smicanja kako bi se osigurala jednolika vulkanizacija i disperzija. Temperatura obrade kreće se od 170 ℃ do 240 ℃, a materijal ima visoku viskoznost tijekom obrade, koji postavlja visoke zahtjeve na okretni moment i otpornost na trošenje dvopužnih ekstrudera. TPVs are widely used in automotive seals, crijeva, brtve, i industrijske komponente koje zahtijevaju visoke performanse i trajnost.
1.1.4 Termoplastični poliuretani (TPU).
TPU je blok kopolimer sastavljen od tvrdih segmenata (diisocyanate and chain extender) and soft segments (polyol). It has excellent elasticity, otpornost na habanje, otpornost na ulje, i mehaničku čvrstoću, and can be adjusted in hardness from very soft (obala A 30) to very hard (Shore D 85) promjenom odnosa tvrdih i mekih segmenata.
TPU obrada je osjetljiva na temperaturu i vlagu. Temperatura obrade kreće se od 180 ℃ do 250 ℃, a materijal se prije obrade mora dobro osušiti (moisture content ≤0.05%) to avoid hydrolysis and bubble formation. TPU masterbatch obrada zahtijeva ekstrudere s preciznom kontrolom temperature i mogućnostima vakuumskog ispuha. TPU se široko koristi u žicama i kabelima, automobilska crijeva, obuća, medicinski kateteri, i sportske opreme.
1.1.5 Termoplastični kopoliesteri (TPC, TPE-E).
TPC je blok kopolimer sastavljen od poliesterskih tvrdih segmenata i polieterskih ili poliesterskih mekanih segmenata. Ima izvrsnu otpornost na toplinu, kemijska otpornost, i mehanička svojstva, i može dugo izdržati visoke temperature do 150 ℃. TPC također imaju dobru fleksibilnost i elastičnost, što ih čini prikladnima za aplikacije visokih performansi.
Temperatura obrade TPC-a kreće se od 220 ℃ do 280 ℃, što je više od ostalih TPE kategorija. Ima visoku viskoznost tijekom obrade i zahtijeva ekstrudere s velikim okretnim momentom i preciznom kontrolom temperature. TPC masterbatch obrada također zahtijeva posebnu pozornost na disperziju pigmenata i aditiva kako bi se izbjegao utjecaj na mehanička svojstva materijala. TPC se široko koriste u automobilskim komponentama (kao što su crijeva za dovod zraka, prijenosne brtve), dijelovi zrakoplovstva, i industrijski strojevi.
1.1.6 Termoplastični poliamidi (TPA, TPE-A).
TPA je blok kopolimer sastavljen od poliamidnih tvrdih segmenata i polieterskih mekih segmenata. Kombinira visoku čvrstoću, otpornost na trošenje, i kemijska otpornost poliamida s fleksibilnošću i elastičnošću polietera. TPA ima izvrsnu otpornost na udarce i niske temperature, i može se koristiti u teškim uvjetima.
Temperatura obrade TPA kreće se od 230 ℃ do 290 ℃, i ima visoku sposobnost upijanja vode, zahtijevaju temeljito sušenje prije obrade. TPA masterbatch obrada zahtijeva ekstrudere s visokom otpornošću na trošenje (zbog velike tvrdoće poliamida) i precizna kontrola temperature kako bi se izbjegla degradacija materijala. TPA se široko koristi u automobilskim komponentama (kao što su zupčanici, ležajevi), električni priključci, i industrijska crijeva.
1.2 Ključna svojstva TPE-a koja utječu na obradu Masterbatch-a
TPE imaju jedinstvena svojstva koja ih razlikuju od tradicionalne plastike, a ta svojstva izravno utječu na formulaciju masterbatch-a i odabir opreme za ekstruziju. Ključna svojstva koja treba uzeti u obzir u obradi masterbatch-a su sljedeća:
1.2.1 Elastičnost i fleksibilnost.
TPE imaju visoku elastičnost i fleksibilnost, što znači da masterbatch mora biti kompatibilan s TPE matricom kako bi se izbjeglo smanjenje elastičnih svojstava materijala. Nosač masterbatch-a trebao bi imati dobru kompatibilnost s TPE-om, a disperzant bi trebao osigurati jednoliku disperziju pigmenata bez stvaranja aglomerata koji bi mogli uzrokovati koncentraciju naprezanja i smanjiti fleksibilnost.
1.2.2 Otpornost na toplinu.
Različite kategorije TPE imaju različitu otpornost na toplinu (temperatura obrade kreće se od 150 ℃ do 290 ℃). Masterbatch pigmenti i aditivi moraju imati otpornost na toplinu koja odgovara temperaturi obrade TPE kako bi se izbjeglo raspadanje, obezbojenje, ili degradacija performansi tijekom ekstruzije. Na primjer, TPC i TPA zahtijevaju pigmente otporne na visoke temperature i toplinske stabilizatore.
1.2.3 Viskoznost i sposobnost obrade.
TPE imaju različite viskoznosti tijekom obrade (TPV i TPC imaju veću viskoznost, dok TPS ima manju viskoznost). To utječe na silu smicanja i zahtjeve transporta dvopužnog ekstrudera. High-viscosity TPEs require extruders with high torque and strong mixing capabilities, while low-viscosity TPEs require precise control of extrusion speed to avoid material overflow.
1.2.4 Moisture Absorption.
Some TPEs (such as TPU, TPA) imaju visoku apsorpciju vode, which can cause bubbles, hydrolysis, and other defects in the masterbatch. The raw materials (TPE, pigmenti, aditiva) must be thoroughly dried before processing, and the extruder should be equipped with a vacuum exhaust device to remove moisture and volatile substances.
1.2.5 Compatibility with Additives.
TPEs often require functional additives (such as antioxidants, UV stabilizatori, maziva) to improve their performance. The masterbatch should be formulated to ensure that the additives are compatible with both the pigments and the TPE matrix, avoiding chemical reactions that could affect product quality.
2. Masterbatch for TPEs: Composition, Zahtjevi za formulaciju i obradu
Masterbatch za TPE je koncentrirana mješavina pigmenata/bojila, prijevoznici, i aditiva, dizajniran za bojanje TPE-a i davanje dodatnih funkcija (kao što je otpornost na plamen, antistatik, antibakterijski) zadržavajući materijalu svojstvena elastična svojstva i svojstva obrade. Formulacija i obrada TPE masterbatcha zahtjevniji su od onih za tradicionalnu plastiku, zbog jedinstvenih svojstava TPE-a. Ovaj odjeljak opisuje sastav, načela formulacije, i zahtjevi za obradu TPE masterbatch-a.
2.1 Osnovni sastav TPE Masterbatch-a
Kao tradicionalni masterbatch, TPE masterbatch se sastoji od tri osnovne komponente: pigmenti/bojila, prijevoznici, i aditiva. Odabir i omjer svake komponente prilagođeni su vrsti TPE-a i zahtjevima njegove primjene.
2.1.1 Pigmenti/boje.
Pigmenti/boje su osnovne komponente koje TPE-u daju boju, računovodstvo za 10%-70% of the masterbatch composition (depending on the color intensity and TPE type). The key requirements for pigments/dyes in TPE masterbatch are:
- – Otpornost na toplinu: Must withstand the processing temperature of the target TPE (150℃-290℃) without decomposition or discoloration. For high-temperature TPEs (TPC, TPA), high-temperature resistant organic pigments or inorganic pigments are preferred.
- – Kompatibilnost: Must be compatible with the TPE matrix to avoid migration, blooming, or reduced elasticity. Pigments with similar polarity to the TPE are more compatible (npr., polar pigments for TPU, non-polar pigments for TPS).
- – Dispersibility: Must be easily dispersed in the TPE matrix to ensure uniform coloring and avoid color spots, streaks, or reduced mechanical properties. Fine-particle pigments (20-40 mesh) with low agglomeration are preferred.
- – Environmental Friendliness: Mora zadovoljiti globalne standarde zaštite okoliša (kao što je REACH, RoHS) kako biste izbjegli otrovne ili štetne tvari (kao što su teški metali) koji bi mogli utjecati na ljudsko zdravlje i okoliš.
Uobičajeni pigmenti koji se koriste u TPE masterbatchu uključuju: anorganski pigmenti (titan dioksid za bijelo, čađa za crno, željezni oksid za crveno/žuto), i organski pigmenti otporni na visoke temperature (ftalocianin plavo/zeleno, kinakridon crveno).
2.1.2 Prijevoznici.
Nosači su matrica masterbatcha, računovodstvo za 20%-80% sastava, i igraju ključnu ulogu u dispergiranju pigmenata i prianjanju na TPE matricu. Nosač mora imati izvrsnu kompatibilnost s pigmentima i ciljanim TPE-om, jer loša kompatibilnost može dovesti do migracije pigmenta, neravnomjerno obojenje, i smanjene performanse TPE. Odabir nosača temelji se na vrsti TPE:
- – Za TPS (SBS, SEBS): Koristite TPS ili PP kao nosač, koji ima dobru kompatibilnost i fluidnost obrade.
- – Za TPO/TPE-o: Koristite PP ili PE kao nosač, odgovara poliolefinskoj komponenti TPO.
- – For TPV/TPE-v: Use PP as the carrier, koji je kompatibilan s PP matricom TPV-a.
- – For TPU: Use TPU as the carrier, osiguravanje kompatibilnosti s TPU matricom i izbjegavanje hidrolize.
- – Za TPC/TPE-E i TPA/TPE-A: Koristite TPC ili TPA kao nosač, odnosno, kako bi zadovoljili zahtjeve obrade na visokim temperaturama i kompatibilnost.
Nosač također treba imati dobru fluidnost obrade, s talištem i temperaturom obrade u skladu s ciljnim TPE-om ili malo nižim od njega, kako bi se osiguralo ravnomjerno miješanje i izbjegla degradacija TPE-a.
2.1.3 Dodaci.
Aditivi su pomoćne komponente koje se dodaju radi poboljšanja učinka obrade, dispersibility, i funkcionalna izvedba TPE masterbatcha, računovodstvo za 1%-10% sastava. Vrsta i doza aditiva određena je vrstom TPE i zahtjevima primjene:
- – Dispersants: Najvažniji aditiv za TPE masterbatch, koristi se za smanjenje površinske napetosti pigmenta, prevent agglomeration, i osigurati jednoliku disperziju u TPE matrici. Uobičajeni disperzanti uključuju polietilenski vosak, polypropylene wax, stearic acid, i voskovi cijepljeni maleinskim anhidridom. For high-viscosity TPEs (PDV, TPC), poželjni su visokoučinkoviti disperzanti s jakom kompatibilnošću.
- – Compatibilizers: Koristi se za poboljšanje kompatibilnosti između pigmenata i TPE-a, te između masterbatch-a i TPE matrice. Na primjer, PP s cijepljenim anhidridom maleinske kiseline koristi se kao kompatibilizator za TPO masterbatch, a za TPU masterbatch koristi se poliuretanski vosak.
- – Heat Stabilizers: Koristi se za sprječavanje razgradnje pigmenta i degradacije TPE-a tijekom obrade na visokim temperaturama. Uobičajeni toplinski stabilizatori uključuju organske kositrene stabilizatore (za TPU), ometeni fenolni antioksidansi (za TPS, TPO), i fosfitne antioksidanse (za TPC, TPA).
- – UV stabilizatori i antioksidansi: Koristi se za poboljšanje otpornosti na vremenske uvjete i starenje obojenih TPE proizvoda, sprječavanje blijeđenja boje i degradacije performansi pod utjecajem sunčeve svjetlosti i kisika. Za vanjsku primjenu (kao što su vanjski dijelovi automobila), UV apsorberi i ometeni aminski svjetlosni stabilizatori (HALS) dodaju se.
- – Maziva: Koristi se za smanjenje trenja između materijala i opreme za ekstruziju (vijak, barel, umrijeti glava), poboljšati fluidnost obrade, i izbjegavajte lijepljenje materijala za opremu. Uobičajeni lubrikanti uključuju stearinsku kiselinu, kalcijev stearat, i silikonsko ulje. Za TPU i TPA, poželjna su maziva s niskom migracijom kako bi se izbjegao utjecaj na performanse proizvoda.
- – Funkcionalni dodaci: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (za električne komponente), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
Formulacija TPE masterbatcha mora uravnotežiti učinak bojenja, performanse obrade, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, pigmenti, a aditivi moraju biti kompatibilni s ciljanim TPE kako bi se izbjeglo smanjenje elastičnosti materijala, fleksibilnost, i mehanička svojstva. Na primjer, korištenje nepolarnog nosača za polar TPU dovest će do loše kompatibilnosti i migracije pigmenta.
2.2.2 Match Heat Resistance.
Pigmenti i aditivi moraju imati otpornost na toplinu koja odgovara temperaturi obrade TPE. Na primjer, 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. Na primjer, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (kao što su teški metali, phthalates) that could restrict market access.
2.3 Processing Requirements of TPE Masterbatch
TPE masterbatch processing is mainly carried out using twin-screw extrusion technology, which requires strict control of raw material pretreatment, premixing, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Raw Material Pretreatment.
TPE-ovi (especially TPU, TPA) imaju visoku apsorpciju vode, so all raw materials (TPE carrier, pigmenti, aditiva) must be thoroughly dried before processing. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 sati, TPS/TPO is dried at 80-100℃ for 3-5 sati, and pigments are dried at 60-80℃ for 2-4 sati. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Osim toga, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 mesh) to improve dispersibility, and impurities (metal particles, prah) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigmenti, carrier, aditiva) are mixed in a high-speed mixer according to the formula ratio to form a uniform preliminary mixture. The premixing parameters are adjusted based on the TPE type: mixing speed 800-1200 broj okretaja u minuti, vrijeme miješanja 5-10 minuta, mixing temperature 40-60℃. For high-concentration masterbatch or high-viscosity TPE carriers, the premixing time is extended, and dispersants are added first to coat the pigments, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (temperatura, brzina vijka, extrusion pressure, brzina hranjenja) must be precisely controlled to match the TPE type:
- – Kontrola temperature: The barrel is divided into 4-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, die head section). The temperature of each section is adjusted according to the TPE processing temperature. Na primjer, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Brzina vijka: The screw speed ranges from 200-800 broj okretaja u minuti, adjusted based on TPE viscosity. High-viscosity TPEs (PDV, TPC) require higher screw speed (500-800 broj okretaja u minuti) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 broj okretaja u minuti) to avoid material overflow.
- – Extrusion Pressure: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. For high-viscosity TPEs, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (particle size 2-5mm), screened (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, električni, konstrukcija, roba široke potrošnje, and other industries, and different application fields have different requirements for TPE masterbatch performance (boja, 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 Automobilska industrija: The Largest Application Field of TPE Masterbatch
Automobilska industrija je najveći potrošač TPE-a, račun za više od 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, fleksibilan, and recyclable properties, and TPE masterbatch plays a key role in coloring and functional modification of these components. Glavne automobilske primjene TPE masterbatcha uključuju:
3.1.1 Automobilske brtve i brtve.
TPE-ovi (uglavnom TPV, TPO) koriste se za proizvodnju brtvi za vrata automobila, brtve prozora, brtve haube, i brtve, koji zahtijevaju dobru elastičnost, otpornost na vremenske uvjete, and low temperature flexibility. Masterbatch za ove komponente zahtijeva jednolično bojanje, dobra otpornost na vremenske uvjete (UV otpornost, otpornost na starenje), i kompatibilnost s TPV/TPO matricama.
Odgovarajući ekstruderi: HTS PLUS serija i HTE serija. Serija HTS PLUS ima visok okretni moment i otpornost na trošenje, pogodan za TPV masterbatch obradu (visoka viskoznost, potrebna velika sila smicanja); serija HTE objedinjuje visoke performanse i ekonomičnost, pogodan za TPO masterbatch obradu, s dobrom disperzibilnošću miješanja i prednostima uštede energije.
3.1.2 Komponente interijera automobila.
TPE-ovi (uglavnom TPS, TPU) koriste se za proizvodnju dijelova interijera automobila kao što su obloge ploče s instrumentima, paneli vrata, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (non-toxic, odorless). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Odgovarajući ekstruderi: 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.
TPE-ovi (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, otpornost na toplinu, i mehaničku čvrstoću. The masterbatch requires high-temperature resistance, otpornost na ulje, and uniform dispersibility to avoid affecting the hose’s performance.
Odgovarajući ekstruderi: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, precizna kontrola temperature, and high wear resistance, suitable for TPC/TPA masterbatch processing (visoka temperatura, visoka viskoznost); 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, prozirnost, otpornost na udarce). 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, konektori, and other components, requiring functional masterbatch (antistatik, otporan na plamen, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPE-ovi (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, otpornost na plamen, i otpornost na habanje. The masterbatch requires flame retardancy (meeting UL94 V-0 standard), antistatička svojstva, and uniform coloring.
Odgovarajući ekstruderi: HTS PLUS series, HTE serija, 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.
TPE-ovi (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, otpornost na udarce, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Odgovarajući ekstruderi: 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, and other components, requiring good weather resistance, otpornost na starenje, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPE-ovi (uglavnom TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, UV otpornost, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Odgovarajući ekstruderi: HTS PLUS serija i HTE serija. The HTS PLUS series has good weather-resistant additive mixing capabilities, pogodan za TPV masterbatch obradu; 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.
Odgovarajući ekstruderi: 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.
TPE-ovi (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, otpornost na habanje, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Odgovarajući ekstruderi: 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, igračke, and other household items, which require non-toxic, odorless, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Odgovarajući ekstruderi: 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 Medicinski uređaji.
TPE-ovi (mainly TPU, TPS) are used to produce medical catheters, syringes, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 standard), high transparency (for catheters), and uniform dispersibility.
Odgovarajući ekstruderi: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, precizna kontrola temperature, 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, otpornost na trošenje, i mehaničku čvrstoću. 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 (visoka viskoznost, 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, prijevoznici, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Osim toga, the screws adopt a modular design, which can freely combine different screw elements (prenoseći, miješanje, šišanje) according to the TPE type. Na primjer, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Precise Temperature Control, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, s 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%. Na primjer, 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, i prediktivno održavanje, realizing intelligent production management.
4.1.7 Široka prilagodljivost.
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 (boja masterbatch, flame-retardant masterbatch, antistatic masterbatch), with pigment content ranging from 10% do 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, opseg proizvodnje, and application requirements.
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, i hranjenje, 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 (PDV, TPU, high-concentration TPE masterbatch, flame-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 (visoka viskoznost, 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 (usporivači plamena, 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, medicinski uređaji).
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, i prediktivno održavanje. 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, niska potrošnja energije, 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, zbog jedinstvenih svojstava TPE-a (temperature sensitivity, moisture absorption, visoka viskoznost), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Problem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premixing: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Oprema: Worn screw mixing elements; blocked die head.
Rješenja: (1) Optimize raw materials: Select fine-particle pigments (20-40 mesh), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 broj okretaja u minuti, extend mixing time to 5-10 minuta. (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 (more than 3 minuta) 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).
Rješenja: (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) Oprema: Screw/barrel material has poor wear resistance.
Rješenja: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Problem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premixing: Air mixed into the mixture during premixing.
Rješenja: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Problem 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (more than 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Oprema: Worn conveying elements; blocked die head.
Rješenja: (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, i polja primjene, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Spis 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, Kina, 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), otpornost na toplinu (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Otopina: 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: Prvi, 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. Drugi, the barrel is equipped with a double-layer jacket + forced cooling structure, s 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. Treći, 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. Osim toga, 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: Nakon 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 mjeseca, 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 Spis 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, Kina, 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), otpornost na toplinu (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Otopina:
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: Prvi, 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. Drugi, the barrel is equipped with a double-layer jacket + forced cooling structure, s 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. Treći, 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. Osim toga, 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:
Nakon 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 mjeseca, 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.