熱可塑性エラストマー (TPE), 熱可塑性ゴムと呼ばれることもあります (TPR), 熱可塑性プラスチックとエラストマーの特性を組み合わせたコポリマーまたはポリマーの物理的混合物の一種であり、通常はプラスチックとゴムです。. このユニークな組み合わせにより、TPE を熱可塑性プラスチックのように加工できるようになります。 (押し出しによる, 射出成形, ブロー成形, 等) ゴムの弾力性と柔軟性を保ちながら. 従来の加硫ゴムとは異なります, TPE は、性能を大幅に損なうことなく、何度でも溶解および再処理できます。, より環境に優しく、コスト効率が高くなります. 軽量化の要求としては, フレキシブル, リサイクル可能な材料は自動車などの業界全体で増加しています, 電気, 工事, そして消費財, TPE の人気はますます高まっています, 独自の加工要件に合わせた特殊なマスターバッチおよび押出技術の開発を推進.
マスターバッチ, TPEの着色および機能修飾のための重要な材料として, TPE製品の性能を向上させ、適用範囲を拡大する上で重要な役割を果たします。. TPE マスターバッチの処理には、混合の正確な制御が必要です, 分散する, および温度パラメータ, TPE には特定の粘度があるため、, 耐熱性, 従来のプラスチックとは異なる弾性特性. 二軸押出機, 優れた混合分散能力を備えています。, 正確な温度制御, 多様な材質への適応性, TPEマスターバッチの中核処理装置となっています. 卓越, 二軸押出機の専門メーカー, TPE 配合およびマスターバッチ処理用に特別に設計された、幅広い高度な押出ソリューションを提供します, TPE/SBS/TPU/TPR/TPV およびその他の主要な TPE カテゴリをカバー, 異業種メーカーの多様なニーズに応える.
1. 熱可塑性エラストマーの概要 (TPE): カテゴリー, 特性と主な特徴
TPE は多様な材料ファミリーです, 化学組成と構造に基づいて 6 つの一般的な商業カテゴリーに分類されます。. 各カテゴリには独自のプロパティがあります, 加工特性, および応用分野, マスターバッチ配合および押出装置の要件を直接決定します。. TPE の分類と特性を理解することは、マスターバッチ処理を最適化し、適切な二軸押出機を選択するための基礎となります。.
1.1 TPE の 6 つの一般商業カテゴリー
1.1.1 スチレン系ブロック共重合体 (TPS, TPE).
TPS は TPE の中で最も広く使用されているカテゴリです, 世界のTPE市場で大きなシェアを占めている. スチレンブロックで構成されています (ポリスチレンなど, PS) およびエラストマーブロック (ポリブタジエンなど, PB; ポリイソプレン, PI; またはエチレンブチレン, EB), 共有結合でつながっている. 最も一般的なタイプの TPS には SBS が含まれます (スチレン-ブタジエン-スチレン), SIS (スチレン-イソプレン-スチレン), SEBS (スチレン-エチレン-ブチレン-スチレン), およびSEPS (スチレン-エチレン-プロピレン-スチレン).
TPS の主な特性には優れた柔軟性が含まれます, 弾性, 加工性と. SEBSとSEPS, SBS と SIS の水素添加バージョンです。, 耐熱性が向上しました, 耐候性, 耐老化性, 屋外および高温用途に適しています。. TPS マテリアルはマスターバッチを使用して簡単に着色および修正できます。, 加工温度は150℃～220℃です。, ほとんどの二軸押出機と互換性があります. TPS の一般的な用途には自動車部品が含まれます, ワイヤーとケーブル, 消費財, および医療機器.
1.1.2 熱可塑性ポリオレフィンエラストマー (TPO, TPE-o).
TPO はポリオレフィンの物理ブレンドです (ポリプロピレンなどの, PP; またはポリエチレン, PE) そしてエラストマー (エチレン・プロピレン・ジエンモノマーなど, EPDM). ポリオレフィンの剛性とエラストマーの弾性を兼ね備えています。, 耐薬品性に優れています, 耐候性, 低温での柔軟性. TPOは無毒です, 無臭, そしてリサイクル可能, 環境への配慮が必要な用途に最適です。.
TPOの加工温度は160℃～230℃です。, さまざまなマスターバッチとの互換性が良好です (カラーマスターバッチ, 難燃性マスターバッチ, 等). TPOは自動車の外装部品に広く使用されています (バンパーカバーなどの, フェンダーライナー), 建築資材 (シールなどの, ガスケット), および電気部品. ポリオレフィン含有量が高いため、, TPO マスターバッチ処理には、顔料と添加剤を均一に分散させるための優れた混合能力を備えた押出機が必要です。.
1.1.3 熱可塑性加硫物 (バット, TPE v).
TPV は動的に加硫されたポリオレフィンのブレンドです (通常PP) そしてエラストマー (通常はEPDM). 処理中, エラストマー相は加硫されて小さな粒子になり、ポリオレフィンマトリックス中に均一に分散されます。, 優れた弾力性を実現, 圧縮永久歪み耐性, そして耐熱性. TPV は、従来の TPE よりも優れた機械的特性と寸法安定性を備えています。, 長期間の高温暴露に耐えることができます (150℃まで).
TPV 加工には、均一な加硫と分散を確保するための正確な温度制御と強力なせん断力が必要です。. 加工温度は170℃～240℃です。, 加工中に材料の粘度が高くなる, 二軸押出機のトルクと耐摩耗性に高い要件が課される. TPV は自動車シールに広く使用されています, ホース, ガスケット, 高性能・耐久性を必要とする産業用部品など.
1.1.4 熱可塑性ポリウレタン (TPU).
TPUはハードセグメントで構成されるブロックコポリマーです。 (ジイソシアネートと鎖延長剤) およびソフトセグメント (ポリオール). 弾力性に優れています, 耐摩耗性, 耐油性, そして機械的強度, 非常に柔らかいものから硬さの調整が可能です (ショアA 30) 非常に難しい (ショアD 85) ハードセグメントとソフトセグメントの比率を変更することにより.
TPU加工は温度と湿気に敏感です. 加工温度は180℃～250℃です。, 加工前に材料を完全に乾燥させる必要があります (含水率 ≤0.05%) 加水分解と気泡の形成を避けるため. TPU マスターバッチ処理には、正確な温度制御と真空排気機能を備えた押出機が必要です. TPUはワイヤーやケーブルに広く使用されています, 自動車用ホース, 履物, 医療用カテーテル, スポーツ用品.
1.1.5 熱可塑性コポリエステル (TPC, TPE-E).
TPC は、ポリエステルのハードセグメントとポリエーテルまたはポリエステルのソフトセグメントで構成されるブロックコポリマーです。. 耐熱性に優れています, 耐薬品性, および機械的特性, 150℃までの高温にも長時間耐えられます。. TPC は柔軟性と弾性にも優れています。, 高性能アプリケーションに適したものにする.
TPCの加工温度は220℃～280℃です。, これは他の TPE カテゴリよりも高いです. 加工中は粘度が高いため、高トルクと正確な温度制御を備えた押出機が必要です。. TPC マスターバッチ処理では、材料の機械的特性への影響を避けるために、顔料や添加剤の分散にも特別な注意を払う必要があります。. TPC は自動車部品に広く使用されています (エアインテークホースなど, トランスミッションシール), 航空宇宙部品, および産業機械.
1.1.6 熱可塑性ポリアミド (TPA, TPE-A).
TPAはポリアミドのハードセグメントとポリエーテルのソフトセグメントで構成されるブロックコポリマーです。. 高い強度を兼ね備えています, 耐摩耗性, ポリアミドの耐薬品性とポリエーテルの柔軟性と弾性を兼ね備えています。. TPAは耐衝撃性と低温性能に優れています。, 過酷な環境でも使用可能.
TPAの加工温度は230℃～290℃です。, そして吸水性も高いので, 加工前に完全な乾燥が必要. 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, ベアリング), 電気コネクタ, 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. マスターバッチのキャリアは TPE と良好な互換性を持っている必要があります。, 分散剤は、応力集中を引き起こして柔軟性を低下させる可能性のある凝集物を形成することなく、顔料を均一に分散させる必要があります。.
1.2.2 耐熱性.
TPE カテゴリが異なると耐熱性も異なります (加工温度範囲は150℃～290℃). マスターバッチ顔料と添加剤は、分解を避けるために、TPE 加工温度に適合する耐熱性を備えている必要があります。, 変色, または押出時の性能低下. 例えば, TPC と TPA には高温耐性の顔料と熱安定剤が必要です.
1.2.3 粘度と加工性.
TPE は加工中に粘度が変化します (TPVとTPCは粘度が高い, TPSは粘度が低いのに対し、). これは、二軸押出機のせん断力と搬送要件に影響します。. 高粘度の TPE には、高トルクと強力な混合能力を備えた押出機が必要です, 一方、低粘度の TPE では、材料のオーバーフローを避けるために押出速度を正確に制御する必要があります。.
1.2.4 吸湿性.
一部の TPE (TPUなど, TPA) 吸水性が高い, 気泡が発生する可能性があります, 加水分解, マスターバッチのその他の欠陥. 原材料 (TPE, 顔料, 添加物) 加工前に完全に乾燥させる必要があります, 押出機には水分や揮発性物質を除去するための真空排気装置が装備されている必要があります。.
1.2.5 添加剤との適合性.
TPE は多くの場合、機能性添加剤を必要とします (抗酸化物質など, 紫外線安定剤, 潤滑剤) 彼らのパフォーマンスを向上させるために. マスターバッチは、添加剤が顔料と TPE マトリックスの両方に適合するように配合する必要があります。, 製品の品質に影響を与える可能性のある化学反応を回避する.
2. TPE用マスターバッチ: 構成, 配合および加工要件
TPE 用のマスターバッチは、顔料/染料の濃縮混合物です。, キャリア, そして添加物, TPE を着色し、追加機能を付与するように設計されています。 (難燃性など, 静電気防止, 抗菌) 素材本来の伸縮性と加工特性を維持しながら. TPE マスターバッチの配合と加工は、従来のプラスチックの配合と加工よりも要求が厳しいです。, TPE のユニークな特性による. このセクションでは構成について詳しく説明します, 配合原理, TPEマスターバッチの処理要件.
2.1 TPEマスターバッチのコア構成
従来のマスターバッチと同様, TPE マスターバッチは 3 つの基本コンポーネントで構成されます: 顔料/染料, キャリア, そして添加物. 各コンポーネントの選択と割合は、TPE の種類とその用途要件に合わせて調整されます。.
2.1.1 顔料/染料.
顔料/染料は、TPE に色を与える中心的な成分です。, を説明する 10%-70% マスターバッチ組成の (色の濃さとTPEの種類に応じて). TPE マスターバッチの顔料/染料の主な要件は次のとおりです。:
- – 耐熱性: ターゲットTPEの処理温度に耐える必要がある (150℃～290℃) 分解や変色がないこと. 高温TPE用 (TPC, TPA), 高温耐性のある有機顔料または無機顔料が好ましい.
- – 互換性: 移行を回避するには、TPE マトリックスとの互換性が必要です, 咲く, または弾力性が低下する. TPE と同様の極性を持つ顔料はより適合性が高い (例えば, TPU用極性顔料, TPS用無極性顔料).
- – 分散性: 均一な着色を確保し、カラースポットを避けるために、TPE マトリックスに容易に分散する必要があります。, 縞模様, または機械的特性が低下する. 微粒子顔料 (20-40 メッシュ) 凝集が少ないものが好ましい.
- – 環境への配慮: 世界的な環境保護基準を満たさなければなりません (リーチなど, RoHS) 有毒または有害な物質を避けるため (重金属などの) 人間の健康や環境に影響を与える可能性があるもの.
TPE マスターバッチで使用される一般的な顔料には次のものがあります。: 無機顔料 (白用二酸化チタン, 黒にはカーボンブラック, 赤/黄色用酸化鉄), 高温耐性有機顔料 (フタロシアニンブルー/グリーン, キナクリドンレッド).
2.1.2 キャリア.
キャリアはマスターバッチのマトリックスです, を説明する 20%-80% 構成の, 顔料を分散させ、TPE マトリックスに付着させる上で重要な役割を果たします。. キャリアは顔料とターゲット TPE の両方に対して優れた相溶性を持たなければなりません。, 相溶性が悪いと顔料の移行が起こる可能性があるため, 色ムラ, TPE のパフォーマンスが低下する. キャリアの選択は TPE のタイプに基づいて行われます:
- – TPS用 (SBS, SEBS): キャリアとして TPS または PP を使用する, 良好な適合性と処理流動性を備えています.
- – TPO/TPE-o向け: キャリアとしてPPまたはPEを使用してください, TPOのポリオレフィン成分に適合.
- – TPV/TPE-vの場合: キャリアとしてPPを使用, TPVのPPマトリックスと互換性があります.
- – TPU用: キャリアとしてTPUを使用, TPUマトリックスとの適合性を確保し、加水分解を回避します。.
- – TPC/TPE-E および TPA/TPE-A の場合: キャリアとして TPC または TPA を使用する, それぞれ, 高温処理要件と互換性を適合させるため.
キャリアは良好な加工流動性も必要です, 融点と加工温度は目標の TPE と一致するか、それよりわずかに低い, 均一な混合を確保し、TPE の劣化を防ぐため.
2.1.3 添加剤.
添加剤とは、加工性能を向上させるために添加される補助的な成分です。, 分散性, TPE マスターバッチの機能的パフォーマンス, を説明する 1%-10% 構成の. 添加剤の種類と投与量は、TPE の種類と用途の要件によって決まります。:
- – 分散剤: TPEマスターバッチにとって最も重要な添加剤, 顔料の表面張力を下げるために使用されます, 凝集を防ぐ, TPE マトリックス内での均一な分散を保証します。. 一般的な分散剤にはポリエチレンワックスが含まれます, ポリプロピレンワックス, ステアリン酸, 無水マレイン酸グラフトワックス. 高粘度TPE用 (バット, TPC), 高い相溶性を備えた高効率の分散剤が好ましい.
- – 相溶化剤: 顔料とTPEの相溶性を向上させるために使用されます。, マスターバッチと TPE マトリックスの間. 例えば, 無水マレイン酸グラフトPPはTPOマスターバッチの相溶化剤として使用されます, TPUマスターバッチにはポリウレタンワックスを使用.
- – 熱安定剤: 高温処理時の顔料の分解とTPEの劣化を防ぐために使用されます。. 一般的な熱安定剤には有機錫安定剤が含まれます。 (TPU用), ヒンダードフェノール系酸化防止剤 (TPS用, TPO), および亜リン酸系酸化防止剤 (TPC用, TPA).
- – UV安定剤と酸化防止剤: 着色TPE製品の耐候性、耐老化性を向上させるために使用されます。, 太陽光や酸素下での色褪せや性能低下を防ぎます。. 屋外用途向け (自動車外装部品など), 紫外線吸収剤とヒンダードアミン系光安定剤 (ハルス) 追加されます.
- – 潤滑剤: 材料と押出装置の間の摩擦を軽減するために使用されます。 (スクリュー, バレル, ダイヘッド), 加工の流動性を向上させる, 材料が機器に付着するのを防ぎます. 一般的な潤滑剤にはステアリン酸が含まれます, ステアリン酸カルシウム, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (電気部品用), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, 顔料, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, 柔軟性, および機械的特性. 例えば, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. 例えば, TPC masterbatch uses high-temperature resistant pigments (heat resistance ≥280℃) to avoid decomposition during processing.
2.2.3 Optimize Dispersibility.
The pigment content and dispersant dosage are adjusted to ensure uniform dispersion. High-concentration masterbatch (pigment content 50%-70%) requires more dispersants and better mixing capabilities, while low-concentration masterbatch (10%-30%) focuses on compatibility.
2.2.4 Minimize Impact on TPE Properties.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. 例えば, 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 (重金属などの, 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) 吸水性が高い, so all raw materials (TPE carrier, 顔料, 添加物) 加工前に完全に乾燥させる必要があります. The drying temperature and time are determined by the material type: TPU/TPA is dried at 100-120℃ for 6-8 時間, TPS/TPO is dried at 80-100℃ for 3-5 時間, and pigments are dried at 60-80℃ for 2-4 時間. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
加えて, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 メッシュ) to improve dispersibility, and impurities (metal particles, ほこり) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (顔料, carrier, 添加物) 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 回転数, 混合時間 5-10 分, mixing temperature 40-60℃. For high-concentration masterbatch or high-viscosity TPE carriers, the premixing time is extended, and dispersants are added first to coat the pigments, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (温度, スクリュー速度, 押出圧力, 送り速度) must be precisely controlled to match the TPE type:
- – 温度制御: The barrel is divided into 4-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, die head section). The temperature of each section is adjusted according to the TPE processing temperature. 例えば, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – スクリュー速度: The screw speed ranges from 200-800 回転数, adjusted based on TPE viscosity. High-viscosity TPEs (バット, TPC) require higher screw speed (500-800 回転数) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 回転数) to avoid material overflow.
- – 押出圧力: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. 高粘度TPE用, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
押出後, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (particle size 2-5mm), screened (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, 電気, 工事, 消費財, and other industries, and different application fields have different requirements for TPE masterbatch performance (色, 分散性, functionality) and production efficiency. Zhuoyue’s full series of twin-screw extruders (HTSベーシック/プラス/スーパー, ZTE, HTE) are specially optimized for TPE masterbatch processing, providing targeted solutions for different TPE categories and application fields. Below is a detailed introduction to the main application fields of TPE masterbatch and the matching Zhuoyue extruder series.
3.1 自動車産業: The Largest Application Field of TPE Masterbatch
自動車産業は TPE の最大の消費者です, 以上を占めています 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, フレキシブル, and recyclable properties, and TPE masterbatch plays a key role in coloring and functional modification of these components. The main automotive applications of TPE masterbatch include:
3.1.1 Automotive Seals and Gaskets.
TPE (mainly TPV, TPO) are used to produce automotive door seals, ウィンドウシール, hood seals, とガスケット, which require good elasticity, 耐候性, 低温での柔軟性. The masterbatch for these components requires uniform coloring, good weather resistance (耐紫外線性, aging resistance), and compatibility with TPV/TPO matrices.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has high torque and wear resistance, suitable for TPV masterbatch processing (high viscosity, high shear force required); the HTE series integrates high performance and cost-effectiveness, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPE (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, ドアパネル, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (無毒, 無臭). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPE (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, 耐熱性, そして機械的強度. The masterbatch requires high-temperature resistance, 耐油性, and uniform dispersibility to avoid affecting the hose’s performance.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, 正確な温度制御, and high wear resistance, suitable for TPC/TPA masterbatch processing (高温, high viscosity); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, 透明性, 耐衝撃性). 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, コネクタ, およびその他のコンポーネント, requiring functional masterbatch (静電気防止, 難燃性, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPE (mainly TPU, TPS, TPO) are used as insulation and sheath materials for wires and cables (power cables, ignition wires, headphone wires, connector plugs), which require good electrical insulation, 難燃性, そして耐摩耗性. The masterbatch requires flame retardancy (meeting UL94 V-0 標準), 帯電防止特性, and uniform coloring.
Matching Extruders: HTS PLUS series, HTEシリーズ, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPE (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, 耐衝撃性, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Matching Extruders: HTS PLUS series and HTS SUPER series. The HTS PLUS series has good compatibility with TPU/TPA, ensuring uniform dispersion; the HTS SUPER series has precise temperature control, avoiding TPA degradation during processing.
3.3 Construction and Transportation Industry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, およびその他のコンポーネント, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPE (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, 耐紫外線性, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has good weather-resistant additive mixing capabilities, suitable for TPV masterbatch processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, そして耐摩耗性. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Matching Extruders: HTS BASIC series and HTE series. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPE (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, 耐摩耗性, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Matching Extruders: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, おもちゃ, and other household items, which require non-toxic, 無臭, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Matching Extruders: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Medical Devices.
TPE (mainly TPU, TPS) are used to produce medical catheters, 注射器, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 標準), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, 正確な温度制御, 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, 耐摩耗性, そして機械的強度. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (high viscosity, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, キャリア, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
加えて, the screws adopt a modular design, which can freely combine different screw elements (運ぶ, 混合, 剪断) according to the TPE type. 例えば, 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, と 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, surface hardness ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 times that of ordinary extruders; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, volatile substances, and air in the material, ensuring the density and quality of the masterbatch. The vacuum degree is adjustable (0.06-0.09MPa), adapting to different moisture content requirements.
4.1.5 High Production Efficiency and Energy Saving.
Zhuoyue’s extruders adopt high-torque gearboxes and optimized screw structures, with strong conveying capacity and high production efficiency. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. 例えば, HTS SUPER series production capacity reaches 1000-3000kg/h, suitable for large-scale mass production; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, and predictive maintenance, realizing intelligent production management.
4.1.7 幅広い適応性.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (カラーマスターバッチ, 難燃性マスターバッチ, 帯電防止マスターバッチ), with pigment content ranging from 10% に 70%. They can also be matched with auxiliary equipment (high-speed mixers, dryers, coolers, granulators) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, 生産規模, および申請要件.
4.2.1 HTS BASIC Series: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, automatic temperature control, and feeding, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 HTS PLUS Series: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (バット, TPU, high-concentration TPE masterbatch, 難燃性マスターバッチ). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (high viscosity, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (難燃剤, antistatic agents). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, 医療機器).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
The HTS SUPER series is Zhuoyue’s highest-end extruder series, representing the advanced level of China’s twin-screw extruders, designed for high-end, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, 温度制御精度±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%) および TPA/TPC マスターバッチ処理.
このシリーズにはインテリジェントなクラウド制御システムが搭載されています, realizing remote parameter adjustment, 故障の早期警告, and predictive maintenance. 大規模な場合に適しています, ハイエンド TPE マスターバッチを生産する高水準メーカー (自動車用高温ホースなど, 精密電気コネクタ, 航空宇宙部品).
4.2.4 ZTEシリーズ: 費用対効果の高いユニバーサル TPE マスターバッチ.
ZTEシリーズはコスト効率の高い製品として位置付けられています, 加工品質とコストのバランスをとるメーカー向けに設計, 汎用の通常の TPE マスターバッチの製造 (低濃度TPS/TPO/TPUマスターバッチ). 二軸平行同回転構造を採用, 比トルク 8-11Nm/cm3, ネジ径25～65mm, 生産能力 50-400kg/h.
このシリーズは窒化処理されたネジとバレルを使用しています (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). 4セクションの温度制御システムを搭載しています, シンプルなタッチスクリーン操作, easy to learn and master. The ZTE series has a simple structure, 低エネルギー消費, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% compared with ordinary extruders. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, TPE のユニークな特性による (temperature sensitivity, moisture absorption, high viscosity), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Problem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Premixing: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Equipment: Worn screw mixing elements; blocked die head.
ソリューション: (1) Optimize raw materials: Select fine-particle pigments (20-40 メッシュ), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 回転数, extend mixing time to 5-10 分. (3) Adjust extrusion parameters: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Maintain equipment: Replace worn screw elements; clean die head regularly.
5.2 Problem 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, darkening), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (より多い 3 分) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
ソリューション: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Problem 3: High Wear of Screw and Barrel
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Causes: (1) Raw materials: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion parameters: High screw speed, excessive shear force; high extrusion pressure. (3) Equipment: Screw/barrel material has poor wear resistance.
ソリューション: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Problem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premixing: Air mixed into the mixture during premixing.
ソリューション: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Problem 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (より多い 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Equipment: Worn conveying elements; blocked die head.
ソリューション: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, および応用分野, demonstrating the targeted solutions provided by Zhuoyue.
6.1 場合 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, 中国, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), 耐熱性 (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
解決: Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: 初め, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. 2番, the barrel is equipped with a double-layer jacket + forced cooling structure, と 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. 三番目, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. 加えて, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: 後 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 月, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.
6.1 場合 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, 中国, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), 耐熱性 (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
解決:
Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: 初め, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. 2番, the barrel is equipped with a double-layer jacket + forced cooling structure, と 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. 三番目, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. 加えて, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
後 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 月, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.