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, as a key material for coloring and functional modification of TPEs, plays a crucial role in enhancing the performance and expanding the application scope of TPE products. The processing of TPE masterbatch requires precise control of mixing, dispersing, and temperature parameters, as TPEs have specific viscosity, heat resistance, and elasticity characteristics that differ from traditional plastics. Ejima-skru extruders, with their superior mixing and dispersing capabilities, njikwa okpomọkụ ziri ezi, and adaptability to diverse materials, have become the core processing equipment for TPE masterbatch. Zhuoyue, a professional manufacturer of twin-screw extruders, offers a full range of advanced extrusion solutions specifically designed for TPE compounding and masterbatch processing, covering TPE/SBS/TPU/TPR/TPV and other major TPE categories, to meet the diverse needs of manufacturers in different industries.
1. Overview of Thermoplastic Elastomers (TPE): Categories, Properties and Key Characteristics
TPEs are a diverse family of materials, classified into six general commercial categories based on their chemical composition and structure. Each category has unique properties, processing characteristics, and application fields, which directly determine the requirements for masterbatch formulation and extrusion equipment. Understanding the classification and properties of TPEs is the foundation for optimizing masterbatch processing and selecting suitable twin-screw extruders.
1.1 Six General Commercial Categories of TPEs
1.1.1 Styrenic Block Copolymers (TPS, TPE-s).
TPS is the most widely used category of TPEs, accounting for a large share of the global TPE market. It is composed of styrenic blocks (such as polystyrene, PS) and elastomeric blocks (such as polybutadiene, PB; polyisoprene, PI; or ethylene-butylene, EB), connected by covalent bonds. The most common types of TPS include SBS (Styrene-Butadiene-Styrene), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), and SEPS (Styrene-Ethylene-Propylene-Styrene).
Key properties of TPS include excellent flexibility, elasticity, and processability. SEBS and SEPS, which are hydrogenated versions of SBS and SIS, have improved heat resistance, weather resistance, and aging resistance, making them suitable for outdoor and high-temperature applications. TPS materials are easily colored and modified with masterbatch, and their processing temperature ranges from 150℃ to 220℃, which is compatible with most twin-screw extruders. Common applications of TPS include automotive components, wires and cables, 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, weather resistance, 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 is a dynamically vulcanized blend of polyolefin (usually PP) na elastomer (usually EPDM). During processing, the elastomer phase is vulcanized into small particles and uniformly dispersed in the polyolefin matrix, resulting in excellent elasticity, compression set resistance, and heat resistance. TPVs have better mechanical properties and dimensional stability than traditional TPEs, and can withstand long-term high-temperature exposure (up to 150℃).
TPV processing requires precise temperature control and strong shear force to ensure uniform vulcanization and dispersion. The processing temperature ranges from 170℃ to 240℃, and the material has high viscosity during processing, which places high requirements on the torque and wear resistance of twin-screw extruders. TPVs are widely used in automotive seals, hoses, gaskets, and industrial components that require high performance and durability.
1.1.4 Thermoplastic Polyurethanes (TPU).
TPU is a block copolymer composed of hard segments (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, medical 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. It has excellent heat resistance, ọgwụ mgbochi, and mechanical properties, 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), aerospace parts, and industrial machinery.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA is a block copolymer composed of polyamide hard segments and polyether soft segments. It combines the high strength, wear resistance, and chemical resistance of polyamides with the flexibility and elasticity of polyethers. TPA has excellent impact resistance and low temperature performance, and can be used in harsh environments.
The processing temperature of TPA ranges from 230℃ to 290℃, and it has high water absorption, requiring thorough drying before processing. TPA masterbatch processing requires extruders with high wear resistance (due to the high hardness of polyamide) and precise temperature control to avoid material degradation. TPA is widely used in automotive components (such as gears, bearings), electrical connectors, and industrial hoses.
1.2 Key Properties of TPEs Affecting Masterbatch Processing
TPEs have unique properties that distinguish them from traditional plastics, and these properties directly affect the formulation of masterbatch and the selection of extrusion equipment. The key properties to consider in masterbatch processing are as follows:
1.2.1 Elasticity and Flexibility.
TPEs have high elasticity and flexibility, which means that the masterbatch must be compatible with the TPE matrix to avoid reducing the material’s elastic performance. The carrier of the masterbatch should have good compatibility with the TPE, and the dispersant should ensure uniform dispersion of pigments without forming agglomerates that could cause stress concentration and reduce flexibility.
1.2.2 Okpomọkụ Nguzogide.
Different TPE categories have different heat resistance (processing temperature ranges from 150℃ to 290℃). Masterbatch pigments and additives must have heat resistance matching the TPE processing temperature to avoid decomposition, discoloration, or performance degradation during extrusion. Ọmụmaatụ, TPC and TPA require high-temperature resistant pigments and heat stabilizers.
1.2.3 Viscosity and Processability.
TPEs have varying viscosities during processing (TPV and TPC have higher viscosity, while TPS has lower viscosity). This affects the shear force and conveying requirements of the twin-screw extruder. 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) have high water absorption, which can cause bubbles, hydrolysis, and other defects in the masterbatch. The raw materials (TPE, pigments, ihe mgbakwunye) 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 stabilizers, mmanu mmanu) 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, Formulation and Processing Requirements
Masterbatch for TPEs is a concentrated mixture of pigments/dyes, carriers, na mgbakwunye, designed to color TPEs and impart additional functions (such as flame retardancy, antistatic, antibacterial) while maintaining the material’s inherent elastic and processing properties. The formulation and processing of TPE masterbatch are more demanding than those for traditional plastics, due to the unique properties of TPEs. This section details the composition, formulation principles, and processing requirements of TPE masterbatch.
2.1 Core Composition of TPE Masterbatch
Like traditional masterbatch, TPE masterbatch consists of three basic components: pigments/dyes, carriers, na mgbakwunye. The selection and proportion of each component are tailored to the type of TPE and its application requirements.
2.1.1 Pigments/Dyes.
Pigments/dyes are the core components that impart color to TPEs, accounting for 10%-70% of the masterbatch composition (depending on the color intensity and TPE type). The key requirements for pigments/dyes in TPE masterbatch are:
- – 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.
Common pigments used in TPE masterbatch include: inorganic pigments (titanium dioxide for white, carbon black for black, iron oxide for red/yellow), and high-temperature resistant organic pigments (phthalocyanine blue/green, quinacridone red).
2.1.2 Carriers.
Carriers are the matrix of the masterbatch, accounting for 20%-80% of the composition, and play a key role in dispersing pigments and adhering to the TPE matrix. The carrier must have excellent compatibility with both the pigments and the target TPE, as poor compatibility can lead to pigment migration, uneven coloring, and reduced TPE performance. The selection of the carrier is based on the type of TPE:
- – For TPS (SBS, SEBS): Use TPS or PP as the carrier, which has good compatibility and processing fluidity.
- – For TPO/TPE-o: Use PP or PE as the carrier, matching the polyolefin component of the TPO.
- – For TPV/TPE-v: Use PP as the carrier, which is compatible with the PP matrix of the TPV.
- – For TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, respectively, to match the high-temperature processing requirements and compatibility.
The carrier should also have good processing fluidity, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Additives.
Additives are auxiliary components added to improve the processing performance, dispersibility, and functional performance of TPE masterbatch, accounting for 1%-10% of the composition. The type and dosage of additives are determined by the TPE type and application requirements:
- – Dispersants: The most important additive for TPE masterbatch, used to reduce pigment surface tension, prevent agglomeration, and ensure uniform dispersion in the TPE matrix. Common dispersants include polyethylene wax, polypropylene wax, stearic acid, and maleic anhydride grafted waxes. For high-viscosity TPEs (VAT, TPC), high-efficiency dispersants with strong compatibility are preferred.
- – Compatibilizers: Used to improve compatibility between pigments and TPEs, and between masterbatch and TPE matrix. Ọmụmaatụ, maleic anhydride grafted PP is used as a compatibilizer for TPO masterbatch, and polyurethane wax is used for TPU masterbatch.
- – Heat Stabilizers: Used to prevent pigment decomposition and TPE degradation during high-temperature processing. Common heat stabilizers include organic tin stabilizers (for TPU), hindered phenol antioxidants (for TPS, TPO), and phosphite antioxidants (for TPC, TPA).
- – UV Stabilizers and 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, pigments, na mgbakwunye ga-adabarịrị na ebumnuche TPE iji zere ibelata ngbanwe nke ihe, mgbanwe, and mechanical properties. 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%) 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. Ọmụmaatụ, 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 (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.
TPEs (especially TPU, TPA) have high water absorption, so all raw materials (TPE carrier, pigments, ihe mgbakwunye) 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 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).
In addition, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 ntupu) to improve dispersibility, and impurities (metal particles, dust) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigments, 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, mixing time 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. For high-viscosity TPEs, 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.
TPEs (tumadi TPV, TPO) a na-eji emepụta akara ọnụ ụzọ ụgbọ ala, windo akara, mkpuchi mkpuchi, na gaskets, nke na-achọ ezigbo elasticity, weather resistance, 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.
TPEs (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.
TPEs (tumadi TPU, TPC, TPA) na-eji na-emepụta ụgbọ ala mmanụ ụgbọala hoses, ikuku nnabata hoses, na brek hoses, nke chọrọ mma mmanu mmanu, heat resistance, 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, transparency, impact resistance). 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, connectors, and other components, requiring functional masterbatch (antistatic, ire ọkụ, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (tumadi 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, ire ọkụ retardancy, na nguzogide abrasion. The masterbatch requires flame retardancy (meeting UL94 V-0 ọkọlọtọ), antistatic Njirimara, and uniform coloring.
Ndị Extruders dakọtara: HTS PLUS series, Usoro HTE, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPEs (tumadi TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, impact resistance, 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, and other components, 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.
TPEs (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, and wear resistance. 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: 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, emetụ aka dị nro, na gburugburu ebe obibi enyi.
3.4.1 Footwear Industry.
TPEs (tumadi TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, nke chọrọ ezigbo mgbanwe, abrasion resistance, and soft touch. Masterbatch chọrọ agba na-egbuke egbuke, edo dispersibility, na enweghị mbugharị (to avoid staining socks).
Ndị Extruders dakọtara: 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, ihe eji egwuri egwu, and other household items, which require non-toxic, enweghị isi, emetụ aka dị nro, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Ndị Extruders dakọtara: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Medical Devices.
TPEs (tumadi 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 ọkọlọtọ), high transparency (for catheters), and uniform dispersibility.
Ndị Extruders dakọtara: Usoro HTS SUPER na usoro HTS PLUS. The HTS SUPER series has clean production design, njikwa okpomọkụ ziri ezi, avoiding material pollution; the HTS PLUS series has good compatibility with medical grade TPEs, ensuring product sterility and biocompatibility.
3.4.4 Other Industrial Applications.
TPEs are also used to produce drain pipes, industrial gaskets, and mechanical components, which require good chemical resistance, wear resistance, 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, 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, carriers, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
In addition, the screws adopt a modular design, which can freely combine different screw elements (ibuga, ịgwakọta, shearing) 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. 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, 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, production scale, 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 (surface hardness ≥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 (such as automotive seals, high-grade wires and cables, ngwaọrụ ahụike).
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, emebere maka elu-ọgwụgwụ, 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, 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, low energy consumption, 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: 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 (surface hardness ≥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, due to the unique properties of TPEs (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, and application fields, 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%, high-temperature resistant) na chọrọ nke ultra-high dispersibility (enweghị agba tụrụ), heat resistance (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 + forced cooling structure, 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. In addition, 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%, high-temperature resistant) na chọrọ nke ultra-high dispersibility (enweghị agba tụrụ), heat resistance (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 + forced cooling structure, 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. In addition, 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.