Thermoplastic Elastomers (TPE), mgbe ụfọdụ a na-akpọ ya Thermoplastic Rubbers (TPR), bụ klas nke copolymers ma ọ bụ ngwakọta anụ ahụ nke polymers-nke na-abụkarị plastik na rọba-na-ejikọta njirimara nke thermoplastics na elastomer.. Ngwakọta pụrụ iche a na-enye ohere ịhazi TPE dị ka thermoplastics (site na extrusion, injection ịkpụzi, ịfụ ịkpụzi, wdg.) mgbe ị na-ejigide elasticity na mgbanwe nke rubbers. N'adịghị ka omenala vulcanized rubbers, Enwere ike ịgbaze TPEs ma megharịa ọtụtụ oge na-enweghị nnukwu mfu nke arụmọrụ, na-eme ka ha bụrụ enyi na gburugburu ebe obibi na ọnụ ahịa. Dị ka ọchịchọ fechaa, mgbanwe, na ihe ndị nwere ike imegharịgharị na-eto n'ofe ụlọ ọrụ dịka ụgbọ ala, eletriki, ihe owuwu, na ngwa ahịa, TPE aghọwowanye ewu ewu, na-akwọ ụgbọala mmepe nke ọkachamara masterbatch na extrusion teknụzụ ahaziri ha pụrụ iche nhazi chọrọ.
Masterbatch, dị ka isi ihe maka agba agba na arụ ọrụ nke TPE, na-arụ ọrụ dị mkpa n'ịkwalite arụmọrụ yana ịgbasa ngwa ngwa nke ngwaahịa TPE. Nhazi nke TPE masterbatch chọrọ njikwa ziri ezi nke ịgwakọta, na-agbasasị, na ọnọdụ okpomọkụ, dị ka TPE nwere kpọmkwem viscosity, okpomọkụ na-eguzogide, na njirimara elasticity nke dị iche na plastik ọdịnala. Ejima-skru extruders, na ha elu agwakọta na-agbasasị ike, njikwa okpomọkụ ziri ezi, na ime mgbanwe maka ihe dị iche iche, aghọwo akụrụngwa nhazi isi maka TPE masterbatch. Zhuoyue, ọkachamara emeputa nke ejima-screw extruders, na-enye ihe ngwọta extrusion dị elu zuru oke nke emebere maka nhazi TPE na nhazi masterbatch, na-ekpuchi TPE / SBS / TPU / TPR / TPV na isi TPE ndị ọzọ, iji gboo mkpa dị iche iche nke ndị na-emepụta ihe na ụlọ ọrụ dị iche iche.
1. Nkọwa nke Thermoplastic Elastomers (TPE): Otu, Njirimara na njirimara igodo
TPE bụ ezinụlọ ihe dị iche iche, nkewapụtara n'ụdị azụmahịa izugbe isii dabere n'ihe mejupụtara kemịkal na nhazi ha. Ụdị nke ọ bụla nwere ihe pụrụ iche, njirimara nhazi, na mpaghara ngwa, nke na-ekpebi kpọmkwem ihe achọrọ maka nhazi masterbatch na ngwa extrusion. Ịghọta nhazi na akụrụngwa nke TPE bụ ntọala maka ịkwalite nhazi nhazi na ịhọrọ ndị ejima-screw extruders kwesịrị ekwesị..
1.1 Otu isii izugbe azụmahịa nke TPE
1.1.1 Styrenic Block Copolymers (TPS, TPE-s).
TPS bụ ụdị TPE kachasị eji eme ihe, na-aza ajụjụ maka oke oke nke ahịa TPE zuru ụwa ọnụ. Ihe mejupụtara ya bụ styrenic blocks (dị ka polystyrene, PS) na elastomeric blocks (dị ka polybutadiene, PB; polyisoprene, PI; ma ọ bụ ethylene-butylene, EB), ejikọrọ na covalent agbụ. Ụdị TPS kachasị agụnye SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), na SEPS (Styrene-Ethylene-Propylene-Styrene).
Njirimara ndị dị mkpa nke TPS gụnyere ezigbo mgbanwe, elasticity, na nhazi usoro. SEBS na SEPS, nke bụ ụdị hydrogenated nke SBS na SIS, enweela nkwalite okpomọkụ ka mma, iguzogide ihu igwe, na iguzogide ịka nká, na-eme ka ha dị mma maka ngwa n'èzí na okpomọkụ dị elu. Ihe TPS na-adị mfe agba ma jiri masterbatch gbanwee ya, na ha nhazi okpomọkụ ranges si 150 ℃ ka 220 ℃, nke dakọtara na ọtụtụ ejima-screw extruders. Ngwa a na-ahụkarị nke TPS gụnyere akụrụngwa ụgbọ ala, wires na eriri, ngwa ahịa, na ngwaọrụ ahụike.
1.1.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o).
TPO bụ ngwakọta anụ ahụ nke polyolefin (dị ka polypropylene, PP; ma ọ bụ polyethylene, PE) na elastomer (dị ka ethylene-propylene-diene monomer, EPDM). Ọ na-ejikọta siri ike nke polyolefins na elasticity nke elastomers, ma nwee ezigbo nguzogide kemịkalụ, iguzogide ihu igwe, na obere okpomọkụ mgbanwe. TPO adịghị egbu egbu, enweghị isi, na recyclable, na-eme ka ha dị mma maka ngwa na-achọ ọdịmma gburugburu ebe obibi.
The nhazi okpomọkụ nke TPO ranges si 160 ℃ ka 230 ℃, na ọ nwere ezi ndakọrịta na dị iche iche masterbatches (agba masterbatch, Ọkụ na-egbochi ire ọkụ, wdg.). A na-ejikarị TPO eme ihe na akụkụ mpụta ụgbọ ala (dị ka mkpuchi mkpuchi, fender liners), ihe owuwu ụlọ (dị ka akara, gaskets), na akụrụngwa eletrik. N'ihi nnukwu ọdịnaya polyolefin ha, TPO masterbatch nhazi chọrọ extruders nwere ezigbo agwakọta ike iji hụ na otu dispersion nke pigments na mgbakwunye..
1.1.3 Thermoplastic Vulcanizates (VAT, TPE v).
TPV bụ ngwakọta nke polyolefin na-apụtaghị ìhè (na-emekarị PP) na elastomer (na-emekarị EPDM). N'oge nhazi, A na-ekewa usoro elastomer n'ime obere irighiri ihe ma gbasasịa n'otu n'otu na matriks polyolefin., na-eme ka elasticity dị mma, mkpakọ setịpụrụ nguzogide, na okpomọkụ iguzogide. Ndị TPV nwere akụrụngwa igwe dị mma yana nkwụsi ike akụkụ karịa TPE ọdịnala, ma nwee ike iguzogide ikpughe oke okpomọkụ dị ogologo oge (ruo 150 ℃).
Nhazi TPV chọrọ njikwa okpomoku ziri ezi yana ike shii siri ike iji hụ na vulcanization otu na mgbasa. The nhazi okpomọkụ ranges si 170 ℃ ka 240 ℃, na ihe nwere nnukwu viscosity n'oge nhazi, nke na-etinye ihe dị elu chọrọ na torque ma na-eyi nguzogide nke ejima-screw extruders. A na-ejikarị TPV eme ihe na akara ụgbọ ala, hoses, gaskets, na akụrụngwa mmepụta ihe na-achọ ọrụ dị elu na ịdịte aka.
1.1.4 Thermoplastic polyurethane (TPU).
TPU bụ ngọngọ copolymer nke akụkụ siri ike mejupụtara (diisocyanate and chain extender) and soft segments (polyol). It has excellent elasticity, abrasion resistance, oil resistance, and mechanical strength, and can be adjusted in hardness from very soft (Shore A 30) to very hard (Shore D 85) by changing the ratio of hard and soft segments.
TPU processing is sensitive to temperature and moisture. The processing temperature ranges from 180℃ to 250℃, and the material must be thoroughly dried before processing (moisture content ≤0.05%) to avoid hydrolysis and bubble formation. TPU masterbatch processing requires extruders with precise temperature control and vacuum exhaust capabilities. TPU is widely used in wires and cables, automotive hoses, akpụkpọ ụkwụ, ọgwụ catheters, and sports equipment.
1.1.5 Thermoplastic Copolyesters (TPC, TPE-E).
TPC is a block copolymer composed of polyester hard segments and polyether or polyester soft segments. Ọ nwere ezigbo nguzogide okpomọkụ, ọgwụ mgbochi, na n'ibu Njirimara, and can withstand high temperatures up to 150℃ for long periods. TPCs also have good flexibility and elasticity, making them suitable for high-performance applications.
The processing temperature of TPC ranges from 220℃ to 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), akụkụ ikuku, na ígwè ọrụ mmepụta ihe.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA is a block copolymer composed of polyamide hard segments and polyether soft segments. Ọ na-ejikọta ike dị elu, eyi iguzogide, na nguzogide kemịkalụ nke polyamides na mgbanwe na elasticity nke polyethers. TPA nwere nguzogide mmetụta dị mma na arụmọrụ dị ala, enwere ike iji ya na gburugburu ebe siri ike.
The nhazi okpomọkụ nke TPA ranges si 230 ℃ ka 290 ℃, na o nwere oke mmiri absorption, na-achọ ihicha nke ọma tupu nhazi. TPA masterbatch nhazi chọrọ extruders na elu eyi iguzogide (n'ihi nnukwu ike nke polyamide) na njikwa okpomọkụ ziri ezi iji zere mmebi ihe. A na-eji TPA eme ihe n'ọtụtụ ebe na akụrụngwa ụgbọ ala (dị ka gia, bearings), njikọ eletrik, na ulo oru hoses.
1.2 Njirimara igodo nke TPE na-emetụta nhazi Masterbatch
TPE nwere ihe pụrụ iche na-eme ka ha dị iche na plastik ọdịnala, na ihe ndị a na-emetụta kpọmkwem nhazi nke masterbatch na nhọrọ nke ngwa extrusion. Ihe ndị dị mkpa ị ga-atụle na nhazi masterbatch bụ ndị a:
1.2.1 Ngbanwe na mgbanwe.
TPE nwere nnukwu ngbanwe na mgbanwe, nke pụtara na masterbatch ga-adaba na matriks TPE iji zere ibelata arụmọrụ nke ihe ahụ.. Onye na-ebu masterbatch kwesịrị inwe ezigbo ndakọrịta na TPE, na onye na-ekesa kwesịrị ịhụ na mgbasa nke pigmenti n'otu n'otu na-enweghị ịmepụta agglomerates nke nwere ike ime ka nchekasị uche ma belata mgbanwe..
1.2.2 Okpomọkụ Nguzogide.
Ụdị TPE dị iche iche nwere nguzogide okpomọkụ dị iche iche (nhazi okpomọkụ ranges si 150 ℃ ka 290 ℃). Masterbatch pigmenti na ihe mgbakwunye ga-enwerịrị nguzogide okpomọkụ dabara na nhazi TPE iji zere ire ere, discoloration, ma ọ bụ mmebi arụmọrụ n'oge extrusion. Ọmụmaatụ, TPC na TPA chọrọ pigmenti na-eguzogide okpomọkụ na okpomọkụ stabilizers.
1.2.3 Viscosity na Processability.
TPE nwere viscosities dị iche iche n'oge nhazi (TPV na TPC nwere viscosity dị elu, ebe TPS nwere obere viscosity). Nke a na-emetụta ike shiee na nnyefe chọrọ nke ejima-screw extruder. TPE nke viscosity dị elu chọrọ ndị na-apụ apụ nwere oke ike na ike ịgwakọta ike, ebe TPE nke viscosity dị ala chọrọ njikwa ziri ezi nke ọsọ extrusion iji zere oke ihe.
1.2.4 Mmiri mmiri absorption.
Ụfọdụ TPE (dị ka TPU, TPA) nwere nnukwu mmiri absorption, nke nwere ike ime ka afụ, hydrolysis, na ntụpọ ndị ọzọ na masterbatch. The akụrụngwa (TPE, pigmenti, ihe mgbakwunye) a ghaghị akpọnwụ nke ọma tupu nhazi, na extruder kwesịrị ka a kwadebere ya na ihe na-ekpochapụ agụụ iji wepụ mmiri mmiri na ihe ndị na-agbanwe agbanwe.
1.2.5 Ndakọrịta na mgbakwunye.
TPE na-achọkarị mgbakwunye na-arụ ọrụ (dị ka antioxidants, UV stabilizers, mmanu mmanu) iji meziwanye arụmọrụ ha. Ekwesịrị ịhazi masterbatch iji hụ na ihe mgbakwunye ahụ dakọtara na ma pigmenti na matriks TPE., na-ezere mmeghachi omume kemịkalụ nwere ike imetụta ogo ngwaahịa.
2. Masterbatch maka TPE: Ihe mejupụtara, Nhazi na nhazi chọrọ
Masterbatch maka TPE bụ ngwakọta agbakọbara nke pigmenti/ede, ndị na-ebu, na mgbakwunye, emebere ka agba TPEs wee kesaa ọrụ ndị ọzọ (dị ka ire ọkụ retardancy, antistatic, antibacterial) mgbe ị na-ejigide ihe na-agbanwe agbanwe na nhazi ihe. Nhazi na nhazi nke TPE masterbatch na-achọsi ike karịa nke maka plastik ọdịnala, n'ihi ihe pụrụ iche nke TPE. Akụkụ a na-akọwa ihe mejupụtara ya, ụkpụrụ nhazi, na nhazi chọrọ nke TPE masterbatch.
2.1 Ihe mejupụtara isi nke TPE Masterbatch
Dị ka omenala masterbatch, TPE masterbatch nwere ihe atọ bụ isi: pigmenti/akwa ákwà, ndị na-ebu, na mgbakwunye. A na-ahazi nhọrọ na oke nke akụkụ nke ọ bụla na ụdị TPE na ngwa ngwa ya.
2.1.1 Pigmenti/Eji esijiji.
Pigment/edi bụ isi ihe na-enye TPE agba, aza ajụjụ maka 10%-70% nke ihe mejupụtara masterbatch (dabere na agba agba na ụdị TPE). Isi ihe achọrọ maka pigmenti / akwa na TPE masterbatch bụ:
- – Okpomọkụ Nguzogide: Kwesịrị iguzogide okpomọkụ nhazi nke TPE ezubere iche (150℃-290℃) na-enweghị ire ere ma ọ bụ ngbanwe. Maka TPE dị elu (TPC, TPA), Okpomọkụ na-eguzogide organic pigmenti ma ọ bụ inorganic pigment na-ahọrọ.
- – Ndakọrịta: Ga-adabarịrị na matriks TPE iji zere mbugharị, na-eto eto, ma ọ bụ belata elasticity. Pigmenti nwere polarity yiri TPE dabara adaba (eg., pigmenti polar maka TPU, pigmenti na-abụghị polar maka TPS).
- – Mgbasa: Ekwesịrị ịgbasa ngwa ngwa na matriks TPE iji hụ na agba edo edo ma zere ntụpọ agba, streaks, ma ọ bụ belata n'ibu Njirimara. Ezi urughuru pigmenti (20-40 ntupu) na ala agglomeration na-ahọrọ.
- – Enyi na gburugburu ebe obibi: Ga-erurịrị ụkpụrụ nchedo gburugburu ebe obibi zuru ụwa ọnụ (dị ka REACH, RoHS) iji zere ihe na-egbu egbu ma ọ bụ ihe na-emerụ ahụ (dị ka ọla dị arọ) nke nwere ike imetụta ahụike mmadụ na gburugburu ebe obibi.
pigmenti ndị a na-ejikarị na TPE masterbatch gụnyere: inorganic pigmenti (titanium dioxide maka ọcha, carbon ojii maka oji, ígwè oxide maka ọbara ọbara / odo), na elu-okpomọkụ na-eguzogide organic pigmenti (phthalocyanin acha anụnụ anụnụ / akwụkwọ ndụ akwụkwọ ndụ, quinacridone uhie).
2.1.2 Ndị na-ebu.
Ndị na-ebu bu matriks nke masterbatch, aza ajụjụ maka 20%-80% nke mejupụtara, ma rụọ ọrụ dị mkpa n'ịgbasa pigmenti na ịrapara na matrix TPE. Onye na-ebu ya ga-enwerịrị ndakọrịta dị mma na ma pigmenti na TPE lekwasịrị anya, dị ka adịghị mma ndakọrịta nwere ike iduga pigmenti Mbugharị, agba na-enweghị isi, ma belata arụmọrụ TPE. Nhọrọ nke onye na-ebu ya dabere na ụdị TPE:
- – Maka TPS (SBS, SEBS): Jiri TPS ma ọ bụ PP dị ka onye na-ebu, nke nwere ezigbo ndakọrịta na nhazi fluidity.
- – Maka TPO/TPE-o: Jiri PP ma ọ bụ PE dị ka onye na-ebu ya, dakọtara akụkụ polyolefin nke TPO.
- – Maka TPV/TPE-v: Jiri PP dị ka onye na-ebu, nke dakọtara na PP matrix nke TPV.
- – Maka TPU: Jiri TPU dị ka onye na-ebu, n'ịhụ na ndakọrịta na TPU matrix na izere hydrolysis.
- – Maka TPC/TPE-E na TPA/TPE-A: Jiri TPC ma ọ bụ TPA dị ka onye na-ebu, n'otu n'otu, iji kwekọọ na nhazi oke okpomọkụ chọrọ na ndakọrịta.
Onye na-ebu ya kwesịkwara inwe mmiri nhazi nhazi nke ọma, na ebe mgbaze na nhazi okpomọkụ kwekọrọ ma ọ bụ dịtụ ala karịa TPE ezubere iche, iji hụ na ngwakọta otu ma zere mmebi TPE.
2.1.3 Ihe mgbakwunye.
Ihe mgbakwunye bụ ihe enyemaka agbakwunyere iji melite arụmọrụ nhazi, dispersibility, na arụmọrụ arụ ọrụ nke TPE masterbatch, aza ajụjụ maka 1%-10% nke mejupụtara. Ụdị na usoro ọgwụgwọ nke mgbakwunye na-ekpebi ụdị TPE na ngwa chọrọ:
- – Ndị na-ekesa: Ihe mgbakwunye kachasị mkpa maka TPE masterbatch, eji ebelata pigmenti elu esemokwu, gbochie agglomeration, ma hụ na mgbasa otu dị na matriks TPE. Ndị na-agbasasịkarị gụnyere polyethylene wax, polypropylene wax, stearic acid, na maleic anhydride anyadokwa waxes. Maka TPE nke viscosity dị elu (VAT, TPC), A na-ahọrọ ndị na-ekesa ndị na-arụ ọrụ dị elu na ndakọrịta siri ike.
- – Ihe ndakọrịta: Ejiri ya kwalite ndakọrịta n'etiti pigmenti na TPE, na n'etiti masterbatch na TPE matrix. Ọmụmaatụ, A na-eji maleic anhydride anyadokwa PP dị ka ihe ndakọrịta maka TPO masterbatch, na polyurethane wax na-eji maka TPU masterbatch.
- – Okpomọkụ Stabilizers: A na-eji egbochi mmebi pigmenti na mmebi TPE n'oge nhazi okpomọkụ dị elu. Ndị na-eme ka ọkụ na-ekpo ọkụ na-agụnye ihe stabilizers organic (maka TPU), mgbochi phenol antioxidants (maka TPS, TPO), na phosphite antioxidants (maka TPC, TPA).
- – UV Stabilizers na Antioxidants: Ejiri ya iji melite nguzogide ihu igwe na nguzogide ịka nká nke ngwaahịa TPE nwere agba, igbochi agba agba na mmebi arụmọrụ n'okpuru ìhè anyanwụ na oxygen. Maka ngwa n'èzí (dị ka akpaaka mputa akụkụ), UV absorbers na mgbochi amine ìhè stabilizers (HALS) na-agbakwunyere.
- – Mmanụ aṅụ: Ejiri iji belata esemokwu n'etiti ihe na akụrụngwa extrusion (ịghasa, gbọmgbọm, nwuo isi), melite nhazi fluidity, ma zere ihe ịrapara na akụrụngwa. Ihe mmanu ndị a na-ahụkarị gụnyere stearic acid, calcium stearate, na mmanụ silicone. Maka TPU na TPA, mmanu mmanu nwere obere mbugharị ka a na-ahọrọ iji zere imetụta arụmọrụ ngwaahịa.
- – Ihe mgbakwunye na-arụ ọrụ: Agbakwunyere iji nye ọrụ pụrụ iche na TPE, dị ka ọkụ retardants (maka wires na eriri), ndị ọrụ antistatic (maka akụrụngwa eletriki), na ọgwụ nje antibacterial (maka ngwaọrụ ahụike na ngwa ahịa).
2.2 Ụkpụrụ nhazi nke TPE Masterbatch
Nhazi nke TPE masterbatch ga-edozi mmetụta agba, nhazi arụmọrụ, na TPE akụrụngwa. Ụkpụrụ ndị bụ isi bụ ndị a:
2.2.1 Ndakọrịta mbụ.
Onye na-ebu, pigmenti, na mgbakwunye ga-adabarịrị na ebumnuche TPE iji zere ibelata ngbanwe nke ihe, mgbanwe, na n'ibu Njirimara. Ọmụmaatụ, iji ụgbọ ala na-abụghị polar maka TPU polar ga-eduga na ndakọrịta na-adịghị mma na ịkwaga pigmenti.
2.2.2 Nguzogide Okpomọkụ Dakọtara.
Ihe ndị ahụ pigmenti na ihe mgbakwunye ga-enwerịrị nguzogide okpomọkụ dabara na ọnọdụ nhazi TPE. Ọmụmaatụ, TPC masterbatch na-eji pigmenti na-eguzogide okpomọkụ (okpomọkụ eguzogide ≥280 ℃) iji zere ire ere n'oge nhazi.
2.2.3 Welie mgbasa ozi.
A na-edozi ọdịnaya pigmenti na usoro ihe na-ekesa iji hụ na mgbasa otu. Masterbatch nwere nnukwu uche (ọdịnaya pigmenti 50%-70%) chọrọ ndị na-ekesa ihe na ike ịgwakọta ka mma, mgbe obere uche masterbatch (10%-30%) na-elekwasị anya na ndakọrịta.
2.2.4 Wedata mmetụta na Njirimara TPE.
Masterbatch ekwesịghị imetụta elasticity TPE, ntọala mkpakọ, ma ọ bụ abrasion eguzogide. Ọmụmaatụ, ndị na-ekesa oke ma ọ bụ mmanu mmanu nwere ike ibelata ike arụ ọrụ TPE.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (dị ka ọla dị arọ, 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 (especially TPU, TPA) nwere nnukwu mmiri absorption, so all raw materials (TPE carrier, pigmenti, ihe mgbakwunye) a ghaghị akpọnwụ nke ọma tupu nhazi. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 awa, TPS/TPO is dried at 80-100℃ for 3-5 awa, and pigments are dried at 60-80℃ for 2-4 awa. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
Na mgbakwunye, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 ntupu) to improve dispersibility, and impurities (metal particles, uzuzu) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigmenti, carrier, ihe mgbakwunye) are mixed in a high-speed mixer according to the formula ratio to form a uniform preliminary mixture. The premixing parameters are adjusted based on the TPE type: mixing speed 800-1200 rpm, oge agwakọta 5-10 nkeji, ngwakọta okpomọkụ 40-60 ℃. Maka Masterbatch dị elu ma ọ bụ ndị na-ebu TPE viscosity dị elu, a na-agbatị oge nke premixing, na ndị na-ekesa na-ebu ụzọ gbakwunye ka ha na-ekpuchi pigmenti, imeziwanye dispersibility.
2.3.3 Njikwa ihe ndị na-emepụta ihe.
Ejima-skru extrusion bụ isi nzọụkwụ nke TPE masterbatch nhazi, na isi paramita (okpomọkụ, ịghasa ọsọ, extrusion nrụgide, nri ọsọ) a ga-achịkwarịrị nke ọma ka ọ dabara na ụdị TPE:
- – Njikwa okpomọkụ: A na-ekewa gbọmgbọm ahụ n'ime 4-6 ngalaba njikwa okpomọkụ (ngalaba nri, ngalaba agbaze, ngwakọta ngalaba, ngalaba homogenizing, anwụ isi ngalaba). A na-edozi ọnọdụ okpomọkụ nke ngalaba ọ bụla dịka nhazi nhazi TPE. Ọmụmaatụ, TPS masterbatch: ngalaba nri 100-120 ℃, agbaze akụkụ 160-180 ℃, ngwakọta akụkụ 170-190 ℃, homogenizing ngalaba 160-180 ℃, anwụ isi ngalaba 150-170 ℃; Ọnụahịa kasị elu nke TPC: ngalaba nri 150-170 ℃, agbaze akụkụ 230-250 ℃, ngwakọta akụkụ 240-260 ℃, homogenizing ngalaba 230-250 ℃, anwụ isi ngalaba 220-240 ℃. Usoro njikwa okpomọkụ kwesịrị iru ± 1 ℃ iji zere mmebi TPE na decomposition pigment..
- – Ịghasa Ọsọ: Ọsọ ịghasa sitere na 200-800 rpm, gbanwee dabere na viscosity TPE. TPE nke viscosity dị elu (VAT, TPC) chọrọ elu ịghasa ọsọ (500-800 rpm) iji mepụta ike shiee zuru oke maka mgbasa pigmenti; obere viscosity TPEs (TPS) jiri oke ọsọ ọsọ (300-500 rpm) iji zere ijubiga ihe ókè.
- – Nrụgide Extrusion: Nrụgide sitere na 5-12MPa, guzosie ike (mgbanwe ≤± 0.5MPa) iji hụ na agwakọta otu na ịkpụzi. TPE nke viscosity dị elu chọrọ nrụgide dị elu, ebe TPE na-enweghị viscosity na-eji oke nrụgide.
- – Ọsọ inye nri: Edoziri iji dakọọ ọsọ ịghasa na ọsọ extrusion, na-eme ka nri kwụsiri ike na otu. Maka TPE nke viscosity dị elu, a na-eji ngwaọrụ inye nri mmanye iji zere nchịkọta ihe.
2.3.4 Nhazi mgbe emechara.
Mgbe extrusion, a na-ajụkwa masterbatch nke yiri warara (mmiri tank jụrụ, 20-30℃), granulated (urughuru size 2-5mm), kpuchie (iji wepụ ihe ndị na-erughị eru), na ngwugwu (nkwakọ ngwaahịa agbachiri na iru mmiri). Maka TPE masterbatch nwere mmetụta iru mmiri (TPU, TPA), A na-akpọcha ngwaahịa emechara ọzọ tupu nkwakọ ngwaahịa iji gbochie mmịpụta mmiri.
3. Ubi ngwa nke TPE Masterbatch na dakọtara Zhuoyue Extruder Solutions
A na-ejikarị TPE eme ihe na ụgbọ ala, eletriki, ihe owuwu, ngwa ahịa, na ụlọ ọrụ ndị ọzọ, na mpaghara ngwa dị iche iche nwere ihe dị iche iche chọrọ maka ịrụ ọrụ TPE masterbatch (agba, dispersibility, arụmọrụ) na mmepụta arụmọrụ. Zhuoyue zuru usoro nke ejima screw extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) bụ nke kachasị maka nhazi TPE masterbatch, inye ngwọta ezubere iche maka ụdị TPE dị iche iche na mpaghara ngwa. N'okpuru bụ mmeghe zuru ezu na mpaghara ngwa ngwa nke TPE masterbatch na usoro Zhuoyue extruder dabara na ya..
3.1 Ụlọ ọrụ ụgbọ ala: Ubi ngwa kachasị ukwuu nke TPE Masterbatch
Ụlọ ọrụ ụgbọ ala bụ ndị kasị ukwuu nke TPE, aza ajụjụ karịa 40% nke ahịa TPE zuru ụwa ọnụ. A na-eji TPE eme ihe n'ọtụtụ akụrụngwa ụgbọ ala n'ihi ịdị arọ ha, mgbanwe, na ihe eji emeghari, na TPE masterbatch na-arụ ọrụ dị mkpa na agba agba na mgbanwe ọrụ nke ihe ndị a. Ngwa ngwa akpaaka nke TPE masterbatch gụnyere:
3.1.1 Akara ụgbọ ala na Gasket.
TPE (tumadi TPV, TPO) a na-eji emepụta akara ọnụ ụzọ ụgbọ ala, windo akara, mkpuchi mkpuchi, na gaskets, nke na-achọ ezigbo elasticity, iguzogide ihu igwe, na obere okpomọkụ mgbanwe. The masterbatch maka ihe ndị a chọrọ agba agba, ezigbo ihu igwe na-eguzogide (Nguzogide UV, iguzogide ịka nká), yana ndakọrịta na matrices TPV/TPO.
Ndị Extruders dakọtara: Usoro HTS PLUS na usoro HTE. Usoro HTS PLUS nwere oke torque na iyi nguzogide, adabara maka nhazi TPV masterbatch (elu viscosity, elu shiee ike chọrọ); usoro HTE na-ejikọta arụmọrụ dị elu na ọnụ ahịa ọnụ ahịa, adabara TPO masterbatch nhazi, na ezi agwakọta dispersibility na ume-azọpụta uru.
3.1.2 Ngwa ime ime ụgbọ ala.
TPE (tumadi TPS, TPU) A na-eji emepụta ihe ndị dị n'ime ụgbọ ala dịka akpụkpọ anụ, ọnụ ụzọ ụzọ, steeịlụ mkpuchi, na ogwe aka, nke chọrọ ezigbo mgbanwe, emetụ aka dị nro, na gburugburu ebe obibi enyi (adịghị egbu egbu, enweghị isi). Masterbatch chọrọ agba na-egbuke egbuke, edo dispersibility, na enweghị mbugharị (iji zere imebi ihe ndị ọzọ dị n'ime).
Ndị Extruders dakọtara: Usoro HTS BASIC na usoro HTE. Usoro HTS BASIC dị ọnụ ahịa, kwesịrị ekwesị maka ndị na-emepụta obere na ndị na-emepụta ihe na-emepụta TPS ime masterbatch; usoro HTE nwere ezigbo mgbasa ozi agwakọta yana oriri ike dị ala, adabara nnukwu mmepụta nke TPU / TPS ime masterbatch.
3.1.3 Hoses ụgbọ ala na tubing.
TPE (tumadi TPU, TPC, TPA) na-eji na-emepụta ụgbọ ala mmanụ ụgbọala hoses, ikuku nnabata hoses, na brek hoses, nke chọrọ mma mmanu mmanu, okpomọkụ na-eguzogide, and mechanical strength. Masterbatch chọrọ nguzogide okpomọkụ dị elu, oil resistance, na dispersibility edo iji zere emetụta arụmọrụ nke sooks.
Ndị Extruders dakọtara: Usoro HTS SUPER na usoro HTS PLUS. Usoro HTS SUPER nwere oke torque dị elu, njikwa okpomọkụ ziri ezi, na akwa mgbochi iyi, adabara maka nhazi TPC/TPA masterbatch (elu okpomọkụ, elu viscosity); usoro HTS PLUS nwere ezigbo nguzogide okpomọkụ na ike ịgwakọta, adabara maka nhazi TPU masterbatch.
3.1.4 Ngwa akpaaka ndị ọzọ.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, nghọta, mmetụta iguzogide). 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
Ụlọ ọrụ eletriki na eletrọnịkị bụ mpaghara ngwa ọzọ dị mkpa nke TPE, ebe a na-eji TPE emepụta wires na eriri, njikọ, na ihe ndị ọzọ, chọrọ masterbatch na-arụ ọrụ (antistatic, ire ọkụ, elu-okpomọkụ na-eguzogide) iji zute nchekwa na arụmọrụ chọrọ.
3.2.1 Waya na eriri.
TPE (tumadi TPU, TPS, TPO) a na-eji ihe mkpuchi na ihe mkpuchi maka wires na eriri (eriri ọkụ, mgbanye wires, ekweisi wires, nkwụnye njikọ), nke chọrọ mkpuchi ọkụ eletrik dị mma, ire ọkụ retardancy, na nguzogide abrasion. The masterbatch chọrọ ire retardanity (nzukọ UL94 V-0 ọkọlọtọ), antistatic Njirimara, na edo agba.
Ndị Extruders dakọtara: Usoro HTS PLUS, Usoro HTE, na usoro HTS SUPER. Usoro HTS PLUS nwere ezigbo ọkụ-retardant masterbatch agwakọta ike, adabara TPO / TPU waya na cable masterbatch; usoro HTE dị ọnụ ahịa, adabara obere na ọkara-sized mmepụta; usoro HTS SUPER dị mma maka njedebe dị elu, nhazi ihe nleba anya dị elu nke ire ere-retardant masterbatch.
3.2.2 Electrical Connectors and Plugs.
TPE (tumadi TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, nke chọrọ mkpuchi ọkụ eletrik dị mma, mmetụta iguzogide, na gburugburu ebe obibi enyi. The masterbatch requires uniform coloring, high-temperature resistance, na enweghị mbugharị.
Ndị Extruders dakọtara: 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: Ngwa TPE Masterbatch na-eguzogide ihu igwe
Na ụlọ ọrụ ihe owuwu na njem njem, A na-eji TPE emepụta akara, nkwonkwo mgbasawanye, ute ụgbọ oloko, na ihe ndị ọzọ, na-achọ ezigbo iguzogide ihu igwe, iguzogide ịka nká, na mgbanwe okpomọkụ dị ala iji mee mgbanwe na gburugburu ebe dị n'èzí siri ike.
3.3.1 Akara Mwube na Mgbasa Mgbasa.
TPE (tumadi TPV, TPO) a na-eji emepụta ọnụ ụzọ ụlọ na windo windo, ákwà mgbochi mgbidi akàrà, na nkwonkwo mgbasawanye, nke chọrọ ezigbo iguzogide ihu igwe, Nguzogide UV, na mkpakọ setịpụrụ iguzogide. The Masterbatch chọrọ UV stabilizers na antioxidants iji melite iguzogide ihu igwe, na agba agba dabara na ihe ịchọ mma ụlọ.
Ndị Extruders dakọtara: Usoro HTS PLUS na usoro HTE. Usoro HTS PLUS nwere ezigbo mgbakwunye ihu igwe na-eguzogide ike, adabara maka nhazi TPV masterbatch; usoro HTE na-echekwa ike na ịrụ ọrụ nke ọma, adabara maka nnukwu mmepụta nke TPO masterbatch.
3.3.2 Ngwa njem.
A na-eji TPE emepụta akwa ụgbọ oloko, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, na-eyi nguzogide. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Ndị Extruders dakọtara: Usoro HTS BASIC na usoro HTE. Usoro HTS BASIC dị ọnụ ahịa, 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: Ngwa TPE Masterbatch dị iche iche
A na-ejikarị TPE eme ihe n'ahịa ahịa na ụlọ ọrụ ndị ọzọ, nwere ụdị ngwa dị iche iche yana ihe achọrọ masterbatch dị iche iche, na-elekwasị anya na agba, emetụ aka dị nro, na gburugburu ebe obibi enyi.
3.4.1 Ụlọ ọrụ akpụkpọ ụkwụ.
TPE (tumadi TPU, TPS) a na-eji emepụta akpụkpọ ụkwụ akpụkpọ ụkwụ, elu akpụkpọ ụkwụ, na ngwa akpụkpọ ụkwụ, nke chọrọ ezigbo mgbanwe, abrasion resistance, na mmetụ dị nro. Masterbatch chọrọ agba na-egbuke egbuke, edo dispersibility, na enweghị mbugharị (iji zere ịkwa sọks).
Ndị Extruders dakọtara: Usoro HTS BASIC na usoro ZTE. Usoro ZTE nwere arụmọrụ ọnụ ahịa dị mma, kwesịrị ekwesị maka ndị na-emepụta akpụkpọ ụkwụ obere na ọkara; usoro HTS BASIC nwere ezigbo ngwakọta agwakọta, n'ịhụ uniile agba nke akpụkpọ ụkwụ naanị masterbatch.
3.4.2 Mkpa ezinaụlọ na kwa ụbọchị.
A na-eji TPE emepụta aka, coasters, akwa ụkwụ, ihe eji egwuri egwu, na ihe ndị ọzọ dị n'ụlọ, nke na-achọ adịghị egbu egbu, enweghị isi, emetụ aka dị nro, na agba na-egbuke egbuke. The masterbatch chọrọ gburugburu enyi na enyi (izute ụkpụrụ kọntaktị nri maka coasters/hands) na edo agba.
Ndị Extruders dakọtara: Usoro ZTE na usoro HTS BASIC. Usoro ZTE dị mfe iji rụọ ọrụ, ọnụ ala na-eri mmezi, adabara obere-ogbe, multi-iche mmepụta; usoro HTS BASIC nwere ezigbo ndakọrịta gburugburu ebe obibi masterbatch, izute ụkpụrụ kọntaktị nri.
3.4.3 Ngwa ahụike.
TPE (tumadi TPU, TPS) na-eji na-emepụta ọgwụ catheters, sirinji, na ihe mkpuchi ahụike, nke na-achọ adịghị egbu egbu, akpali mmasị, na biocompatible. Masterbatch chọrọ nchedo gburugburu ebe obibi ọkwa ahụike (nzukọ ISO 10993 ọkọlọtọ), elu nghọta (maka catheters), na edo dispersibility.
Ndị Extruders dakọtara: Usoro HTS SUPER na usoro HTS PLUS. Usoro HTS SUPER nwere nhazi mmepụta dị ọcha, njikwa okpomọkụ ziri ezi, na-ezere mmetọ ihe; Usoro HTS PLUS nwere ezigbo ndakọrịta na ọkwa ahụike TPE, n'ịhụ na ngwaahịa ịmụ nwa na biocompatibility.
3.4.4 Ngwa ụlọ ọrụ ndị ọzọ.
A na-ejikwa TPE na-emepụta ọkpọkọ mmiri, ụlọ ọrụ gaskets, na akụrụngwa akụrụngwa, nke chọrọ ezigbo nguzogide kemịkalụ, eyi iguzogide, and mechanical strength. 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 (elu 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, na usoro HTE. 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, ndị na-ebu, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Na mgbakwunye, the screws adopt a modular design, which can freely combine different screw elements (ibuga, ịgwakọta, ịkpacha ajị) according to the TPE type. Ọmụmaatụ, 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, ya na 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. gbọmgbọm ahụ na-anabata imewe jaket nke okpukpu abụọ, na-aghọta ngwa ngwa kpo oku na jụrụ, na ịkwalite ọsọ nzaghachi okpomọkụ. A na-eji ngwaọrụ na-achịkwa ọnọdụ okpomọkụ nwere onwe ya, n'ịhụ n'ike n'ike nhazi nke masterbatch strip.
4.1.3 Nguzogide iyi dị elu na nguzogide corrosion.
Ụfọdụ TPE masterbatches (dị ka TPA, TPC) nwere pigmenti siri ike ma ọ bụ ihe mgbakwunye, nke nwere ike na-eyi ịghasa na gbọmgbọm. Ndị na-apụ apụ nke Zhuoyue na-eji ihe ndị na-eguzogide iyi dị elu na teknụzụ mmepụta ihe dị elu: HTS PLUS/SUPER/HTE usoro skru na orù bụ nke ọla na-eguzogide iyi na-eguzogide., na-enweta ọgwụgwọ bimetallic composite ma ọ bụ ihe mkpuchi laser, ike elu ≥65 HRC (Usoro HTS SUPER ≥70 HRC), ndụ ọrụ 2-3 ugboro nke ndị nkịtị extruders; HTS BASIC/ZTE usoro skru na orù bụ 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, ihe na-agbanwe agbanwe, na ikuku na ihe, n'ịhụ njupụta na mma nke masterbatch. Enwere ike ịhazi ogo agụụ agụụ (0.06-0.09MPa), na-eme mgbanwe dị iche iche chọrọ ọdịnaya mmiri.
4.1.5 Ịmepụta arụmọrụ dị elu yana nchekwa ike.
Ndị na-ebupụ Zhuoyue na-eji igbe gia dị elu yana arụ ọrụ skru kachasị mma., na ikike mbufe siri ike na nrụpụta nrụpụta dị elu. Tụnyere ndị nkịtị extruders, mmepụta arụmọrụ na-abawanye site 20%-50%, na ike oriri na-ebelata site 15%-25%. Ọmụmaatụ, HTS SUPER usoro mmepụta ikike ruru 1000-3000kg / h, adabara maka nnukwu mmepụta ihe; ZTE usoro mmepụta ike bụ 50-400kg / h, suitable for small-batch production.
4.1.6 Njikwa ọgụgụ isi na arụ ọrụ dị mfe.
All extruders na-anakwere a PLC nwere ọgụgụ isi njikwa usoro na ihuenyo mmetụ ọrụ interface, nke nwere ike ịchekwa ruo 100 tent nke usoro na nhazi parameters. Mgbe ị na-agbanwe n'etiti TPE masterbatches dị iche iche, naanị ihe ndị kwekọrọ na ya kwesịrị ka a kpọọ ya, na-ezere mmezi ugboro ugboro. Usoro HTS SUPER nwere ọrụ njikwa igwe ojii, na-aghọta n'ime ime oke mmezi, mmepụta data nlekota oru, na mmezi amụma, na-aghọta njikwa mmepụta ọgụgụ isi.
4.1.7 Ndakọrịta zuru oke.
Zhuoyue zuru usoro nke extruders nwere ike ime mgbanwe na nhazi nke ụdị TPE niile (TPS/SBS/TPU/TPR/TPV/TPC/TPA) na ụdị masterbatch (agba masterbatch, Ọkụ na-egbochi ire ọkụ, antistatic masterbatch), nwere pigmenti ọdịnaya sitere na 10% ka 70%. A pụkwara iji ngwá ọrụ inyeaka tụnyere ha (ngwa ngwa mixers, igwe nkụ, ngwa nju oyi, granulators) na-etolite a zuru akpaka mmepụta akara.
4.2 Okwu mmalite nke Zhuoyue's Extruder Series maka nhazi TPE Masterbatch
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, mmepụta ọnụ ọgụgụ, and application requirements.
4.2.1 Usoro HTS BASIC: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, automatic temperature control, na inye nri, dị mfe iji rụọ ọrụ. Nhazi nke skru modular na-enye ohere nhazi mgbanwe dịka TPS/TPO masterbatch chọrọ. Usoro HTS BASIC bụ nhọrọ dị mma maka ndị na-emepụta obere na ndị na-emepụta obere ego nwere oke ego, na-elekwasị anya na mmepụta TPE masterbatch nkịtị (dị ka ngwongwo ụlọ, wires nkịtị na eriri).
4.2.2 Usoro HTS PLUS: High-Torque maka Engineering TPE na High-Concentration Masterbatch.
A na-edobe usoro HTS PLUS dị ka ngwaahịa dị n'etiti ruo elu, Ezubere nke ọma maka nhazi TPE masterbatch dị elu (VAT, TPU, TPE masterbatch dị elu, Ọkụ na-egbochi ire ọkụ). Ọ na-anabata igbe gia dị elu nke Zhuoyue mepụtara n'adabereghị ya, torque kpọmkwem 13-16Nm/cm³, dayameta nke ịghasa 40-75mm, mmepụta ike 300-1200kg / h.
Usoro a na-eji skru bimetallic composite skru na barrel (ike elu ≥65 HRC), na magburu onwe eyi nguzogide na corrosion eguzogide, suitable for TPV/TPC masterbatch processing (elu 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 (ọkụ retardants, ndị ọrụ antistatic). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (dị ka akara ụgbọ ala, wires na eriri dị elu, ngwaọrụ ahụike).
4.2.3 HTS SUPER Series: Arụmọrụ dị elu maka TPE Masterbatch dị elu.
Usoro HTS SUPER bụ usoro extruder kachasị elu nke Zhuoyue, na-anọchite anya ọkwa dị elu nke ndị na-ebupụ ejima ejiri China, emebere maka elu-ọgwụgwụ, Nhazi TPE Masterbatch dị elu (TPA, TPC, ultra-high-concentration masterbatch, masterbatch maka ụgbọ ala ume ọhụrụ / ikuku).
Ọ na-anabata ngwaọrụ mgbasa ozi kacha ọhụrụ nke Zhuoyue, torque kpọmkwem 17-20Nm/cm³, ịghasa dayameta 50-95mm, mmepụta ike 1000-3000kg / h. E ji ígwè alloy ọhụrụ na-eguzogide eyi ihe mere kposara ahụ, na-enweta ọgwụgwọ laser cladding (elu ike ≥70 HRC), ndụ ọrụ 3-4 ugboro nke ndị nkịtị extruders. Mgbọmgbọm ahụ na-eji jaket nwere okpukpu abụọ + usoro mmanye jụrụ oyi, okpomọkụ akara nkenke ±1 ℃, adabara maka nhazi TPE dị elu (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, na-aghọta n'ime ime oke mmezi, fault early warning, na mmezi amụma. 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 Usoro ZTE: 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, obere ike oriri, 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 Usoro HTE: Arụmọrụ dị elu yana ngwọta ejikọta ọnụ na-efu.
Usoro HTE na-ejikọta arụmọrụ dị elu na ọnụ ahịa ọnụ ahịa, emebere maka ndị na-emepụta ọkara na-ebuli ogo ngwaahịa na ịgbasa ọnụ ọgụgụ mmepụta. Ọ na-anabata igbe gia dị elu nke Zhuoyue mepụtara n'adabereghị ya, torque kpọmkwem 12-14Nm/cm³, dayameta nke ịghasa 35-70mm, mmepụta ike 200-800kg / h.
Usoro a na-eji skru bimetallic composite skru na barrel (ike elu ≥65 HRC), with good wear resistance, adabara maka nhazi TPU/TPO masterbatch. Ọ na-anabata usoro ịghasa kachasị na moto na-azọpụta ike dị elu, ike oriri belatara site 18%-25% tụnyere ndị nkịtị extruders. Sistemụ njikwa okpomọkụ nke akụkụ 5 na ngwaọrụ iyuzucha ikuku na-ahụ maka ịdịmma ngwaahịa, na enwekwukwa Ịgwakọta ọcha hụ na edo dispersion. Usoro HTE na-edozi arụmọrụ yana ọnụ ahịa, dabara adaba maka ndị na-emepụta ọkara na-emepụta TPE masterbatch ọkara (dị ka akpaaka n'ime ime components, nkịtị ọgwụ ngwaọrụ, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, n'ihi ihe pụrụ iche nke TPE (temperature sensitivity, moisture absorption, elu 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 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: Obere ịghasa ọsọ, ezughị oke ike shiee; obere extrusion okpomọkụ, agbaze na-ezughị ezu nke ụgbọelu TPE. (4) Akụrụngwa: Ihe ndị na-agwakọta ihe nkedo na-eyi; egbochiri anwụ isi.
Ngwọta: (1) Bulite akụrụngwa akụrụngwa: Họrọ pigmenti dị mma (20-40 ntupu), kpochaa nke ọma; họrọ ụgbọelu dakọtara na TPE; dịkwuo dispersant onunu ogwu (1%-5% nke pigmenti onunu ogwu). (2) Melite premixing: Welie ọsọ ngwakọta gaa 800-1200 rpm, ịgbatị oge ngwakọta ka 5-10 nkeji. (3) Gbanwee paramita extrusion: Mụbaa ọsọ ịghasa (500-800 rpm maka nnukwu viscosity TPEs); mụbaa okpomọkụ extrusion iji hụ na agbaze nke TPE zuru oke. (4) Na-echekwa akụrụngwa: Dochie ihe ịghasa eyi; isi anwụ anwụ mgbe niile.
5.2 Problem 2: Mmebi TPE na ngbanwe nke Masterbatch
Manifestation: Masterbatch nwere agba (agba odo, na-agba ọchịchịrị), na-emepụta isi pụrụ iche; Ngwaahịa TPE ebelatala elasticity na ike igwe, ọbụna mgbaji gbajiri agbaji.
Causes: (1) Okpomọkụ extrusion dị elu, gafere oke nguzogide okpomọkụ TPE. (2) Ogologo oge obibi ihe onwunwe (karịrị 3 nkeji) na extruder. (3) Ngwa ngwa jụrụ oyi, oke ọkụ mpaghara nke gbọmgbọm ahụ. (4) Raw materials: TPE nwere nguzogide okpomọkụ na-adịghị mma; ọdịnaya ọdịnaya dị oke elu (na-eme ka TPU hydrolysis).
Ngwọta: (1) Gbanwee okpomọkụ: Belata ngwakọta / homogenizing akụkụ okpomọkụ, njikwa n'ime oke nhazi TPE; lelee ihe mmetụta okpomọkụ ziri ezi. (2) Mee ka oge obibi dị mkpụmkpụ: Mụbaa ọsọ ịghasa, belata ịghasa mkpakọ ruru. (3) Jikwaa usoro jụrụ oyi: Ọkụ ọkpọ jụrụ oyi, dochie ihe jụrụ oyi na-ezighi ezi. (4) Bulite akụrụngwa akụrụngwa: Họrọ TPE na-eguzogide okpomọkụ; akọrọ akụrụngwa nke ọma (mmiri ọdịnaya ≤0.05% maka TPU/TPA); tinye okpomọkụ stabilizers.
5.3 Problem 3: Uwe dị elu nke Screw na Barrel
Manifestation: Mkpọsa na gbọmgbọm iyi ngwa ngwa, ibelata ike shiee na ike ịgwakọta; masterbatch dispersibility na-ebelata, ọnụ ahịa mmezi akụrụngwa na-abawanye.
Causes: (1) Raw materials: Elu-ike ike pigmenti/ mgbakwunye (dị ka carbon ojii, titanium dioxide); nnukwu urughuru nha. (2) Extrusion parameters: Ọsọ ịghasa dị elu, oke shiee ike; elu extrusion mgbali. (3) Akụrụngwa: Ihe nkedo / gbọmgbọm nwere nguzogide eyi adịghị mma.
Ngwọta: (1) Bulite akụrụngwa akụrụngwa: Họrọ obere urughuru, obere ike pigmenti; zọpịa ma sie ihe ndị dị ndụ; tinye mmanu mmanu iji belata esemokwu. (2) Gbanwee paramita: Belata ịghasa ọsọ na extrusion nrụgide nke ọma. (3) Họrọ akụrụngwa na-eguzogide uwe dị elu: Họrọ usoro Zhuoyue's HTS PLUS/SUPER/HTE nwere ihe mejupụtara bimetallic ma ọ bụ skru/orù nwere laser..
5.4 Problem 4: Afụ na Masterbatch
Manifestation: Afụ na ụmụ irighiri ihe masterbatch, na-emetụta njupụta ngwaahịa na akụrụngwa akụrụngwa; Ngwaahịa TPE nwere pores na ntụpọ.
Causes: (1) Raw materials: Nnukwu mmiri ọdịnaya (karịsịa TPU/TPA); ihe na-agbanwe agbanwe na pigmenti / mgbakwunye. (2) Extrusion parameters: Obere okpomọkụ extrusion, agbaze na-ezughị ezu; ezughị ezu iyuzucha ikuku. (3) Premixing: Agwakọta ikuku n'ime ngwakọta n'oge premixing.
Ngwọta: (1) Ghichaa akụrụngwa nke ọma: Gbatịkwuo oge ihicha, mụbaa ihicha okpomọkụ. (2) Gbanwee paramita extrusion: Dịkwuo extrusion okpomọkụ; melite agụụ iyuzucha (ogo agụụ ≥0.08MPa). (3) Bulite premixing: Belata ngwakọ agwakọta nke ọma ka ịzena ngwakọta ikuku; jiri igwekota mechiri emechi.
5.5 Problem 5: Ọdịda Nhazi Na-adịghị mma, Mgbochi akụrụngwa
Manifestation: Ihe siri ike ibufe na extrusion; nrụgide extrusion na-ejighị n'aka; anwụ isi ma ọ bụ extrusion oghere mgbochi.
Causes: (1) Raw materials: Nnukwu viscosity TPE (TPV/TPC); elu pigmenti ọdịnaya (karịrị 70%); nnukwu mmiri ọdịnaya (na-eme ka agglomeration). (2) Extrusion parameters: Obere okpomọkụ, agbaze na-ezughị ezu; obere ịghasa ọsọ, ezughị oke ikike ibuga. (3) Akụrụngwa: Ihe ndị na-ebufe eyi; egbochiri anwụ isi.
Ngwọta: (1) Bulite akụrụngwa akụrụngwa: Belata ọdịnaya pigmenti; họrọ TPE obere viscosity; akọrọ akụrụngwa nke ọma. (2) Gbanwee paramita: Dịkwuo extrusion okpomọkụ; mụbaa ịghasa ọsọ; jiri oghere buru ibu dochie isi anwụ. (3) Na-echekwa akụrụngwa: Dochie ihe mbufe eyi; na-ehicha isi anwụ na oghere extrusion mgbe niile.
6. Okwu ngwa bara uru nke Zhuoyue Extruders na TPE Masterbatch Processing
Iji nyochaa uru arụmọrụ nke ndị extruders Zhuoyue na nhazi TPE masterbatch, ngalaba a na-ewebata ọtụtụ ikpe bara uru, na-ekpuchi ụdị TPE dị iche iche, production scales, na mpaghara ngwa, na-egosipụta azịza ezubere iche nke Zhuoyue nyere.
6.1 Ikpe 1: HTS SUPER Series na TPC Masterbatch Processing for Automotive Hoses
ndabere ndị ahịa: Onye nrụpụta akụrụngwa akụrụngwa buru ibu na Shanghai, China, na-emepụta oghere TPC na-eguzogide okpomọkụ maka ụgbọ ala ike ọhụrụ. Onye ahịa kwesịrị imepụta TPC masterbatch (ọdịnaya pigmenti 60%, elu-okpomọkụ na-eguzogide) na chọrọ nke ultra-high dispersibility (enweghị agba tụrụ), okpomọkụ na-eguzogide (260℃), na ogbe kwụsie ike. Akụrụngwa izizi nwere nsogbu nke torque ezughi oke, njikwa okpomọkụ na-ejighị n'aka, na ogbenye dispersibility, nke na-enweghị ike imezu ihe achọrọ.
Ngwọta: Zhuoyue kwadoro usoro HTS SUPER extruders (ịghasa dayameta 75mm, torque kpọmkwem 18Nm/cm³) jikọtara ya na akara mmepụta akpaka zuru oke, gụnyere igwe nkụ dị elu, igwekota ngwa ngwa, na nkenke granulator, ahaziri na mkpa nhazi TPC masterbatch nke onye ahịa. Isi nhazi na njikarịcha usoro bụ ndị a: Mbụ, ịghasa adopts a multi-ogbo Ịgwakọta imewe, na-ejikọta ihe ndị na-egweri elu na-achụsasị ihe iji mebie pigmenti agglomerates n'ụzọ zuru ezu ma hụ na mgbasa nke otu. 60% pigmenti dị elu na matriks TPC. Ihe mkpuchi nke laser (ike ≥70 HRC) n'ụzọ dị irè na-eguzogide iyi nke pigmenti siri ike na-akpata, ịgbatị ndụ ọrụ site karịa 3 ugboro tụnyere ndị ahịa si ngwá ọrụ mbụ. Nke abụọ, a na-eji akwa jaket nwere okpukpu abụọ kwadoro gbọmgbọm ahụ + usoro mmanye jụrụ oyi, ya na 6 independent temperature control sections, na-enweta nzizi njikwa okpomọkụ nke ± 1 ℃. A na-achịkwa ọnọdụ okpomọkụ nke ngalaba ngwakọta na 240-260 ℃, na ngalaba homogenizing na 230-250 ℃, na-adaba n'ụzọ zuru oke na nhazi okpomọkụ nke TPC iji zere mmebi ihe na ngbanwe nke pigmenti. Nke atọ, a na-eji ngwá ọrụ na-arụ ọrụ nke ọma na-arụ ọrụ nke ọma (ogo agụụ na-agbanwe agbanwe ruo 0.09MPa), nke na-ewepụ nke ọma mmiri na ihe ndị na-agbanwe agbanwe na akụrụngwa TPC na masterbatch, kpamkpam na-edozi nsogbu afụ kpatara site na mmiri absorption. Na mgbakwunye, usoro HTS SUPER nwere usoro njikwa igwe ojii nwere ọgụgụ isi, nke na-enye ndị ahịa ohere ịchekwa paramita nhazi nhazi TPC masterbatch, jiri otu pịa kpọọ ha mgbe ị na-atụgharị batches, na nyochaa mmepụta data ozugbo, imeziwanye nkwụsi ike batch na ibelata njehie arụmọrụ.
Mmetụta mmejuputa: Mgbe 1 ọnwa nke ntinye na ntinye ọrụ, HTS SUPER usoro extruders tinye n'ihu ọha na mmepụta. 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 ọnwa, reducing maintenance costs by more than 50%. Ọdọ mmiri TPC nke ndị ahịa mere nke masterbatch a agafeela asambodo ịdị mma ụlọ ọrụ ụgbọ ala, na magburu onwe elu-okpomọkụ eguzogide na n'ibu ike, ewebatala ya nke ọma maka ndị na-emepụta ụgbọ ala ọhụrụ. Onye ahịa ahụ ghọtara nke ọma ngwọta extrusion nke Zhuoyue, ma mesịa bịanye aka n'akwụkwọ nkwekọrịta nkwekọrịta ogologo oge, ịzụrụ 5 ọtụtụ tent nke HTS SUPER usoro extruders iji gbasaa ọnụ ọgụgụ mmepụta.
6.1 Ikpe 1: HTS SUPER Series na TPC Masterbatch Processing for Automotive Hoses
ndabere ndị ahịa:
Onye nrụpụta akụrụngwa akụrụngwa buru ibu na Shanghai, China, na-emepụta oghere TPC na-eguzogide okpomọkụ maka ụgbọ ala ike ọhụrụ. Onye ahịa kwesịrị imepụta TPC masterbatch (ọdịnaya pigmenti 60%, elu-okpomọkụ na-eguzogide) na chọrọ nke ultra-high dispersibility (enweghị agba tụrụ), okpomọkụ na-eguzogide (260℃), na ogbe kwụsie ike. Akụrụngwa izizi nwere nsogbu nke torque ezughi oke, njikwa okpomọkụ na-ejighị n'aka, na ogbenye dispersibility, nke na-enweghị ike imezu ihe achọrọ.
Ngwọta:
Zhuoyue kwadoro usoro HTS SUPER extruders (ịghasa dayameta 75mm, torque kpọmkwem 18Nm/cm³) jikọtara ya na akara mmepụta akpaka zuru oke, gụnyere igwe nkụ dị elu, igwekota ngwa ngwa, na nkenke granulator, ahaziri na mkpa nhazi TPC masterbatch nke onye ahịa. Isi nhazi na njikarịcha usoro bụ ndị a: Mbụ, ịghasa adopts a multi-ogbo Ịgwakọta imewe, na-ejikọta ihe ndị na-egweri elu na-achụsasị ihe iji mebie pigmenti agglomerates n'ụzọ zuru ezu ma hụ na mgbasa nke otu. 60% pigmenti dị elu na matriks TPC. Ihe mkpuchi nke laser (ike ≥70 HRC) n'ụzọ dị irè na-eguzogide iyi nke pigmenti siri ike na-akpata, ịgbatị ndụ ọrụ site karịa 3 ugboro tụnyere ndị ahịa si ngwá ọrụ mbụ. Nke abụọ, a na-eji akwa jaket nwere okpukpu abụọ kwadoro gbọmgbọm ahụ + usoro mmanye jụrụ oyi, ya na 6 independent temperature control sections, na-enweta nzizi njikwa okpomọkụ nke ± 1 ℃. A na-achịkwa ọnọdụ okpomọkụ nke ngalaba ngwakọta na 240-260 ℃, na ngalaba homogenizing na 230-250 ℃, na-adaba n'ụzọ zuru oke na nhazi okpomọkụ nke TPC iji zere mmebi ihe na ngbanwe nke pigmenti. Nke atọ, a na-eji ngwá ọrụ na-arụ ọrụ nke ọma na-arụ ọrụ nke ọma (ogo agụụ na-agbanwe agbanwe ruo 0.09MPa), nke na-ewepụ nke ọma mmiri na ihe ndị na-agbanwe agbanwe na akụrụngwa TPC na masterbatch, kpamkpam na-edozi nsogbu afụ kpatara site na mmiri absorption. Na mgbakwunye, usoro HTS SUPER nwere usoro njikwa igwe ojii nwere ọgụgụ isi, nke na-enye ndị ahịa ohere ịchekwa paramita nhazi nhazi TPC masterbatch, jiri otu pịa kpọọ ha mgbe ị na-atụgharị batches, na nyochaa mmepụta data ozugbo, imeziwanye nkwụsi ike batch na ibelata njehie arụmọrụ.
Mmetụta mmejuputa:
Mgbe 1 ọnwa nke ntinye na ntinye ọrụ, HTS SUPER usoro extruders tinye n'ihu ọha na mmepụta. 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 ọnwa, reducing maintenance costs by more than 50%. Ọdọ mmiri TPC nke ndị ahịa mere nke masterbatch a agafeela asambodo ịdị mma ụlọ ọrụ ụgbọ ala, na magburu onwe elu-okpomọkụ eguzogide na n'ibu ike, ewebatala ya nke ọma maka ndị na-emepụta ụgbọ ala ọhụrụ. Onye ahịa ahụ ghọtara nke ọma ngwọta extrusion nke Zhuoyue, ma mesịa bịanye aka n'akwụkwọ nkwekọrịta nkwekọrịta ogologo oge, ịzụrụ 5 ọtụtụ tent nke HTS SUPER usoro extruders iji gbasaa ọnụ ọgụgụ mmepụta.