글로벌 산업화가 급속히 진행되면서, 자동차용 고성능 소재 수요, 전기 및 전자, 건설, 의료 및 기타 분야는 날로 증가하고 있습니다.. 엔지니어링 플라스틱, 핵심 고성능 소재로, 우수한 기계적 특성으로 인해 많은 핵심 응용 시나리오에서 전통적인 금속 재료와 일반 플라스틱을 점차 대체해 왔습니다., 내열성, 내식성, 치수 안정성 및 가공성. 이축 압출 기술은 엔지니어링 플라스틱 컴파운드의 핵심 가공 기술입니다., 압출 장비의 성능이 품질을 직접적으로 결정합니다., 엔지니어링 플라스틱 제품의 생산효율 및 응용효과.
우리는 엔지니어링 플라스틱 가공을 위한 전문적인 트윈 스크류 압출 솔루션을 제공하기 위해 최선을 다하고 있습니다., 높은 토크 기어박스를 갖춘 당사가 독립적으로 개발 및 제조한 HTS 시리즈 압출기에 의존, 엔지니어링 플라스틱의 가공 특성 및 응용 요구 사항에 맞게 특별히 설계되었습니다.. 이 기사에서는 성능 특성에 대해 포괄적으로 설명합니다., 분류, 엔지니어링 플라스틱의 가공 어려움, 엔지니어링 플라스틱 가공에서 이축 압출 기술의 핵심 역할, HTS 시리즈 압출기의 장점과 엔지니어링 플라스틱에 대한 목표 적용, 특정 응용 분야뿐만 아니라, 처리 기술과 일반적인 문제 및 솔루션. 상세한 기술 매개변수를 보완함으로써, 처리 내용 및 산업 적용 사례, 기사가 풍성해질 것입니다 3000-4000 단어, 엔지니어링 플라스틱 가공 기업에 포괄적이고 전문적인 참고 자료 제공, 기술자 및 관련 실무자.
1. 엔지니어링 플라스틱 산업 개요 및 핵심 성능 특성
1.1 엔지니어링 플라스틱 산업 현황 및 발전 동향
엔지니어링 플라스틱은 구조재로 사용될 수 있고 넓은 온도 범위에서 기계적 하중을 견딜 수 있는 플라스틱 소재의 한 종류를 말합니다.. 일반 플라스틱에 비해 (폴리에틸렌 PE와 같은, 폴리프로필렌 PP, 폴리염화비닐 PVC), engineering plastics have more excellent comprehensive performance, and can meet the harsh use requirements in industrial production and high-end product manufacturing. 최근에는, driven by the upgrading of downstream industries such as automotive lightweight, electrical and electronic intelligence, and medical device high-endization, the global engineering plastics market has shown a steady and rapid growth trend.
관련 업계 데이터에 따르면, the global engineering plastics market size has exceeded 100 10억 달러, 의 복합 연간 성장률을 유지할 것으로 예상됩니다. 7%-10% 앞으로 5년 안에. 그 중, Asia-Pacific is the world’s largest engineering plastics production and consumption market, 이상을 회계 55% 세계 시장 점유율의, mainly due to the rapid development of automotive, electrical and electronic industries in China, 인도 및 기타 국가, as well as the continuous improvement of industrial supporting capacity and technological innovation level. 중국, as the world’s largest engineering plastics consumer and producer, 시장 수요가 크다, 연간 생산량과 소비량이 두 자릿수 비율로 증가하고 있다., 특히 신에너지 차량 분야에서, 5지커뮤니케이션즈, 의료기기, 고성능 엔지니어링 플라스틱에 대한 수요가 폭발적인 성장세를 보이고 있습니다..
엔지니어링 플라스틱 산업의 발전 추세는 주로 다섯 가지 측면에서 반영됩니다.: 첫 번째, 고성능 및 기능화. 다운스트림 분야의 사용 요구 사항이 지속적으로 개선됨에 따라, 엔지니어링 플라스틱은 더 높은 내열성을 향해 발전하고 있습니다., 더 높은 강도, 더 나은 내마모성과 특수 기능 (난연성과 같은, 정전기 방지, 항균, 방사선 저항), 고온의 가혹한 작업 환경에 적응하기 위해, 고압, 부식과 방사선; 두번째, 경량 및 통합. 자동차 분야, 항공우주 및 기타 분야, 에너지 절약 및 배출 감소 목표를 달성하기 위해, 엔지니어링 플라스틱은 금속 재료를 대체하는 데 점점 더 많이 사용되고 있습니다., 제품 디자인의 통합이 점점 더 높아지고 있습니다., 부품 수를 줄일 수 있는, 생산 공정을 단순화하고 비용을 절감; 제삼, 환경 보호 및 재활용성. 글로벌 환경보호 정책 강화와 환경보호 인식 제고로, 재활용 가능한 엔지니어링 플라스틱의 개발 및 응용, 생분해성 엔지니어링 플라스틱과 친환경 가공 기술이 업계의 초점이 되었습니다., 플라스틱 폐기물로 인한 환경오염을 줄이는; 네번째, 가공 장비의 지능성과 정밀도. 엔지니어링 플라스틱은 가공 난이도가 높고 품질 요구 사항이 엄격합니다., 처리 장비에 대한 더 높은 요구 사항을 제시합니다.. 지능적인, 정확하고 효율적인 이축 압출기와 자동 생산 라인이 업계의 주류가 되었습니다., 실시간 모니터링 구현, 자동 매개변수 조정 및 처리 프로세스의 예측 유지관리; 제오, 응용 분야의 다양화. 엔지니어링 플라스틱은 전통적인 자동차에서 점차 확대되고 있습니다., 전기 및 전자 분야를 새로운 에너지로, 의료, 항공우주, 건설 및 기타 신흥 분야, 새로운 시장 공간을 개척하다.
이런 배경에서, 트윈 스크류 압출 기술, 엔지니어링 플라스틱 컴파운드의 핵심 가공기술로, 엔지니어링 플라스틱 기업의 경쟁력을 향상시키는 열쇠가 되었습니다.. 엔지니어링 플라스틱은 과열 및 가수분해에 민감합니다., 처리 온도에 대한 높은 요구 사항이 있습니다., 전단력, 체류 시간 및 온도 제어 정밀도. 당사의 HTS 시리즈 압출기는 엔지니어링 플라스틱의 가공 특성에 맞게 특별히 설계되었습니다., 높은 토크로, 고속, 정밀한 온도 조절과 우수한 분산성, 엔지니어링 플라스틱의 가공 어려움을 효과적으로 해결하고 기업이 고품질을 달성하도록 도울 수 있습니다., 효율적이고 안정적인 생산.
1.2 엔지니어링 플라스틱의 핵심 성능 특성
일반 플라스틱, 금속재료에 비해, 엔지니어링 플라스틱은 독특하고 포괄적인 성능을 가지고 있습니다., 다양한 산업 분야에서의 폭넓은 적용을 결정하는 요소. 엔지니어링 플라스틱의 핵심 성능 특성은 주로 다음 5가지 측면에 반영됩니다., 또한 처리 기술 및 장비에 대한 특별한 요구 사항을 제시합니다.:
1.2.1 우수한 내열성 및 내한성
엔지니어링 플라스틱은 온도 적응 범위가 넓습니다., 좋은 기계적 성질을 유지할 수 있는 것 (힘, 인성, 경도) 고온 및 저온 환경 모두에서. 일반 플라스틱에 비해, 일반적으로 80-120℃에서 기계적 성질을 잃습니다., 대부분의 엔지니어링 플라스틱은 100~250℃에서 안정적으로 작동합니다., 및 일부 특수 엔지니어링 플라스틱 (PEEK와 같은, PI) 300℃ 이상의 온도에서도 작동 가능. 동시에, 엔지니어링 플라스틱은 내한성도 우수합니다., 저온에서 좋은 인성을 유지할 수 있는 것 (-40℃ 이하), 부서지기 쉬운 파괴가 쉽지 않습니다.. 이러한 성능 덕분에 엔지니어링 플라스틱은 열악한 온도 환경에서 사용하기에 적합합니다., 자동차 엔진 부품 등 (고온) 및 실외 전기 장비 (저온).
엔지니어링 플라스틱의 우수한 내열성은 주로 특수한 분자 구조에 기인합니다. (such as aromatic rings, heterocyclic rings) and strong intermolecular forces, which makes them not easy to melt and decompose at high temperatures. 하지만, this also brings certain difficulties to processing: higher processing temperature is required to make them melt and plasticize, and precise temperature control is needed to avoid thermal decomposition.
1.2.2 Good Corrosion Resistance and Durability
Engineering plastics have excellent chemical stability and corrosion resistance, and are not easy to be corroded by acids, 알칼리, salts, organic solvents and other chemicals. Compared with metal materials, which are easy to rust and corrode, engineering plastics have longer service life in harsh chemical environments. 예를 들어, 폴리아미드 (아빠) engineering plastics are resistant to most organic solvents and weak acids and alkalis; 폴리카보네이트 (PC) 엔지니어링 플라스틱은 비산화성 산과 염에 의한 부식에 강합니다.; 폴리페닐렌 설파이드 (조달청) 엔지니어링 플라스틱은 강산화성 산을 제외한 거의 모든 화학물질에 의한 부식에 강합니다..
게다가, 엔지니어링 플라스틱은 내후성과 내노화성이 우수합니다., 햇빛의 작용으로 분해 및 노화가 쉽지 않습니다., 비, 산소 및 기타 환경 요인, 실외 및 열악한 환경에서 장기간 안정적인 사용을 보장합니다.. 이러한 성능으로 인해 엔지니어링 플라스틱은 화학 장비에 널리 사용됩니다., 야외 전기 장비, 자동차 외장 부품 및 기타 분야.
1.2.3 쉬운 가공과 높은 생산 효율성
Compared with metal materials, 엔지니어링 플라스틱은 가공이 쉽다는 장점이 있습니다., 간단한 생산 공정과 높은 생산 효율성. 금속 재료는 일반적으로 단조 등 복잡한 가공 공정이 필요합니다., 주조, 가공, 에너지 소모가 많은 것, 효율성이 낮고 비용이 높음; 엔지니어링 플라스틱은 압출 가공이 가능하지만, 사출 성형, 블로우 성형 및 기타 방법, 대량생산을 실현할 수 있는, 생산 과정을 단순화하다, 에너지 소비 및 생산 비용 절감. 예를 들어, 사출 성형에 의한 엔지니어링 플라스틱 자동차 부품의 가공 주기는 불과 몇 초에서 수십 초에 불과합니다., 동일한 금속 부품의 처리 주기는 몇 시간에서 며칠이 걸릴 수 있습니다..
하지만, 엔지니어링 플라스틱에는 가공상의 어려움도 있습니다.: 과열 및 가수분해에 민감합니다., 가공온도가 너무 높거나 체류시간이 너무 길면 분해되기 쉽습니다.; 동시에, 일부 엔지니어링 플라스틱 (PA와 같은) 수분 흡수율이 높다, 가공 효과와 제품 품질에 영향을 미치는. 그러므로, 가공 품질을 보장하려면 전문 가공 장비와 과학적 가공 기술을 사용해야 합니다..
1.2.4 우수한 치수 안정성 및 전기 절연성
엔지니어링 플라스틱은 치수 안정성이 우수합니다., 그리고 수축률이 작아요 (대개 0.3%-1.5%) 처리 및 사용 중에, 제품의 치수 정확도를 보장하고 변형을 방지할 수 있습니다.. 이 성능은 고정밀 부품에 특히 중요합니다., 전기 커넥터와 같은, 자동차 정밀 부품, 의료기기, 등. 엔지니어링 플라스틱의 우수한 치수 안정성은 주로 높은 결정화도에 기인합니다., 낮은 수분 흡수 (PA 등 일부 품종을 제외하고) and strong intermolecular forces.
게다가, 대부분의 엔지니어링 플라스틱은 우수한 전기 절연 성능을 가지고 있습니다., which can maintain good insulation performance in a wide temperature range and frequency range, and are not easy to conduct electricity and arc. This makes engineering plastics widely used in electrical and electronic fields, such as wiring boards, cable ties, 커넥터, relays, motors and other electrical components.
1.2.5 Light Weight and High Specific Strength, Outstanding Wear Resistance
Engineering plastics have the characteristics of light weight (density is 1/3-1/5 of metal materials) and high specific strength (strength per unit weight is equivalent to or even higher than that of metal materials). 예를 들어, the specific strength of glass fiber reinforced polyamide (PA66+GF30) is higher than that of ordinary carbon steel, which can effectively reduce the weight of products while ensuring the mechanical performance. 이 성능은 자동차 분야에서 특히 중요합니다., 경량화 및 에너지 절약을 추구하는 항공우주 및 기타 분야, 연료 소비와 탄소 배출을 줄일 수 있는.
동시에, 엔지니어링 플라스틱은 내마모성과 내마찰성이 뛰어납니다., 그리고 마찰계수가 작아요, 내마모성 부품 생산에 사용할 수 있습니다. (기어와 같은, 문장, 슬라이딩 블록) 추가 윤활 없이 또는 윤활을 적게 사용하여, 제품의 유지관리 비용 절감. 예를 들어, 폴리옥시메틸렌 (포엠) 엔지니어링 플라스틱은 우수한 내마모성을 가지며 다음과 같이 알려져 있습니다. “플라스틱 강철”, 자동차 기어 생산에 널리 사용되는 것, 전기 부품 및 기타 내마모성 부품.
1.3 엔지니어링 플라스틱의 일반적인 분류
엔지니어링 플라스틱은 화학구조에 따라 다양한 종류로 구분됩니다., 성능 수준 및 적용 분야. 일반적인 분류 방법은 다음과 같습니다, 다양한 엔지니어링 플라스틱의 가공 특성과 응용 시나리오를 더 잘 이해하는 데 도움이 됩니다., 적절한 압출 장비 및 가공 기술을 선택합니다.:
1.3.1 성능 수준에 따른 분류
퍼포먼스 레벨에 따라, 엔지니어링 플라스틱은 일반 엔지니어링 플라스틱과 특수 엔지니어링 플라스틱으로 구분됩니다..
- 일반 엔지니어링 플라스틱: 가장 널리 사용되는 엔지니어링 플라스틱입니다., 비교적 성숙한 생산 기술을 갖춘, 적당한 가격과 좋은 종합 성능. 주요 품종에는 폴리아미드가 포함됩니다. (아빠), 폴리카보네이트 (PC), 폴리옥시메틸렌 (포엠), 폴리에틸렌 테레프탈레이트 (애완 동물), 폴리부틸렌 테레프탈레이트 (PBT), 등. 일반 엔지니어링 플라스틱은 주로 자동차에 사용됩니다., 전기 및 전자, 가전 제품 및 기타 분야, 자동차 부품과 같은, 전기 커넥터, 가전 제품 껍질, 등.
- 특수 엔지니어링 플라스틱: 그들은 더 우수한 성능을 가지고 있습니다 (such as higher heat resistance, 내식성, 기계적 성질) than general engineering plastics, but the production technology is complex and the price is high. The main varieties include polyphenylene sulfide (조달청), 폴리에테르에테르케톤 (몰래 엿보다), polyimide (PI), polysulfone (PSU), polyethersulfone (PES), 등. Special engineering plastics are mainly used in high-end fields such as aerospace, 의료기기, new energy, and chemical equipment, such as aerospace components, medical implants, high-temperature resistant electrical components, 등.
1.3.2 Classification by Chemical Structure
According to the chemical structure of the molecular chain, engineering plastics can be divided into polyamide (아빠), 폴리카보네이트 (PC), 폴리옥시메틸렌 (포엠), polyester (애완 동물, PBT), 폴리페닐렌 설파이드 (조달청), 폴리에테르에테르케톤 (몰래 엿보다), 등. Each type of engineering plastic has its own unique performance characteristics and processing requirements:
- 폴리아미드 (아빠): Also known as nylon, it has excellent mechanical strength, 내마모성, toughness and chemical resistance, but has high water absorption, which affects the dimensional stability. 일반적인 품종에는 PA6이 포함됩니다., PA66, PA11, PA12, 등. 자동차 부품에 널리 사용됩니다. (기어, 문장, 흡기 매니폴드), 전기 커넥터, 직물 섬유, 등.
- 폴리카보네이트 (PC): 투명성이 우수합니다, 충격 강도, 내열성 및 전기 절연성, 그러나 내마모성이 약하고 긁히기 쉽습니다.. 전기전자 분야에서 널리 사용됩니다. (배선판, 램프 커버), 자동차 분야 (전조등 렌즈, 계기판), 의료 분야 (의료 용기), 등.
- 폴리옥시메틸렌 (포엠): 내마모성이 우수합니다., 마찰 저항, 치수 안정성 및 기계적 강도, 그리고 물을 흡수하기 쉽지 않아요. 그것은 다음과 같이 알려져 있습니다. “플라스틱 강철” 자동차 부품에 널리 사용됩니다. (기어, 슬라이딩 블록), 전기 부품 (스위치, 문장), 기계 부품, 등.
- 폴리에스테르 (애완 동물, PBT): PET는 투명성이 우수합니다., 내열성 및 기계적 강도, 주로 섬유에 사용됩니다., 영화, 병 및 기타 분야; PBT는 내약품성이 우수합니다., 전기 절연성 및 가공 유동성, 전기 및 전자 분야에서 널리 사용됩니다. (커넥터, relays), 자동차 부품, 등.
- 폴리페닐렌 황화물 (조달청): 내열성이 우수합니다 (200-220℃까지 장기 사용 온도), 내식성, 난연성 및 전기 절연성, 하지만 인성이 약하다. 고온 내성 전기 부품에 널리 사용됩니다., 자동차 엔진 부품, 화학 장비, 등.
- 폴리에테르에테르케톤 (몰래 엿보다): 그것에는 우수한 종합적인 성과가 있습니다, 250-300℃까지 장기 사용 온도, 좋은 내식성, 기계적 강도 및 생체 적합성. 주로 항공우주 등 고급 분야에 사용됩니다., medical implants, 및 고온 내성 전기 부품.
1.3.3 응용분야별 분류
적용분야에 따라, 엔지니어링 플라스틱은 자동차 등급 엔지니어링 플라스틱으로 나눌 수 있습니다., 전기 등급 엔지니어링 플라스틱, 의료용 엔지니어링 플라스틱, 항공우주 등급 엔지니어링 플라스틱, 등. 다양한 응용 분야에는 엔지니어링 플라스틱의 성능에 대한 요구 사항이 다릅니다.. 예를 들어, 자동차 등급 엔지니어링 플라스틱은 우수한 내열성을 요구합니다., 충격강도 및 내후성; 전기 등급 엔지니어링 플라스틱에는 우수한 전기 절연성과 난연성이 필요합니다.; 의료용 엔지니어링 플라스틱은 우수한 생체적합성과 무균성을 요구합니다.; 항공우주 등급 엔지니어링 플라스틱에는 우수한 고온 저항이 필요합니다., 낮은 무게와 높은 강도.
2. 엔지니어링 플라스틱 핵심가공기술: 트윈 스크류 압출 기술
엔지니어링 플라스틱 가공에는 주로 압출이 포함됩니다., 사출 성형, 블로우 성형, 성형 및 기타 방법, 그 중 이축 압출 기술은 엔지니어링 플라스틱 컴파운드 생산의 핵심 기술입니다. (변형된 엔지니어링 플라스틱과 같은, 강화 엔지니어링 플라스틱) 및 반제품 (파이프와 같은, 시트, fibers). Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong shearing force, 좋은 혼합 효과, 정확한 온도 조절, short residence time and strong adaptability to raw materials, which can effectively solve the processing difficulties of engineering plastics (such as sensitivity to overheating and hydrolytic degradation, poor mixing effect, low processing efficiency) and ensure the quality of engineering plastic products.
2.1 Processing Difficulties of Engineering Plastics and Requirements for Extrusion Equipment
앞서 언급했듯이, engineering plastics have excellent comprehensive performance, but their processing difficulty is also higher than that of general plastics, mainly due to their special molecular structure and performance characteristics. The main processing difficulties of engineering plastics and the corresponding requirements for extrusion equipment are as follows:
2.1.1 Sensitivity to Overheating and Hydrolytic Degradation
Most engineering plastics (PA와 같은, PBT, 조달청) are sensitive to overheating and hydrolytic degradation. If the processing temperature is too high or the residence time in the extruder is too long, the molecular chain of the engineering plastic will break, resulting in thermal decomposition, which will reduce the mechanical properties, heat resistance and other performance of the product, and even cause discoloration, carbonization and other defects. 게다가, 일부 엔지니어링 플라스틱 (PA와 같은) 수분 흡수율이 높다, and the moisture in the material will cause hydrolytic degradation during the high-temperature processing process, affecting the product quality.
This puts forward two key requirements for extrusion equipment: 첫 번째, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, and the temperature control precision should reach ±1℃; 두번째, short residence time, which can reduce the time that the material stays in the extruder barrel, avoid thermal decomposition and hydrolytic degradation. Twin-screw extruders have the advantages of short residence time (대개 1-5 분) 그리고 정확한 온도 조절, which are more suitable for engineering plastics processing than single-screw extruders (체류 시간 5-10 분).
2.1.2 High Requirements on Mixing and Dispersing Effect
In engineering plastics processing, it is often necessary to add modifiers (유리섬유와 같은, 탄소섬유, 활석, 난연제, 호환성화제) to improve the performance of the product (such as reinforcing, toughening, 난연제). 예를 들어, adding glass fiber to PA can improve its strength and dimensional stability; adding flame retardants to PBT can improve its flame retardancy. The uniform mixing and dispersion of modifiers in the engineering plastic matrix is crucial to the performance of the final product. If the mixing and dispersing effect is poor, the modifiers will agglomerate, resulting in uneven performance of the product, and even reduce the mechanical properties of the product.
This requires the extrusion equipment to have strong shearing force and mixing capacity. Twin-screw extruders adopt intermeshing co-rotating or counter-rotating twin-screw structure, and the relative movement between the screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the engineering plastic matrix, and ensure the mixing and dispersing effect. 게다가, the modular design of the twin-screw can freely combine different screw elements (전달 요소와 같은, 혼합 요소, 전단 요소) according to the type of engineering plastic and modifier, further improving the mixing and dispersing effect.
2.1.3 High Requirements on Wear Resistance of Equipment
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), the added glass fiber, carbon fiber and other modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder during the extrusion process. If the screw and barrel have poor wear resistance, they will be worn quickly, resulting in reduced shearing force and mixing capacity of the extruder, affecting the product quality and reducing the service life of the equipment.
This requires the screw and barrel of the extruder to be made of high-quality wear-resistant materials and processed by advanced manufacturing technology. Our HTS series extruders adopt imported wear-resistant alloy steel for the screw and barrel, and undergo bimetallic composite treatment or laser cladding treatment, which greatly improves the wear resistance and corrosion resistance of the screw and barrel, and can adapt to the processing of reinforced engineering plastics with high hardness modifiers.
2.1.4 High Requirements on Processing Fluidity and Pressure Control
Some engineering plastics (such as PPS, 몰래 엿보다) have high viscosity and poor processing fluidity, which require the extruder to have strong conveying capacity and pressure control capacity to ensure the smooth progress of extrusion. If the conveying capacity is insufficient or the pressure control is unstable, it will cause uneven extrusion speed, unstable product size, and even equipment blockage.
Twin-screw extruders have strong conveying capacity and stable pressure control capacity. The intermeshing of the twin screws can generate strong pumping force, which can effectively convey high-viscosity engineering plastic materials; 동시에, 압출기에는 고정밀 압력 센서가 장착되어 있습니다., which can monitor the extrusion pressure in real time and adjust the screw speed and feeding speed automatically to ensure the stability of the extrusion pressure and the smooth progress of processing.
2.2 Working Principle and Process Flow of Engineering Plastics Twin-Screw Extrusion
The twin-screw extrusion process of engineering plastics is a complex physical and chemical process, 이는 온도와 같은 여러 요인의 상호 작용을 포함합니다., 압력, 전단력과 시간. The core purpose is to melt and plasticize the engineering plastic raw materials and modifiers, mix them uniformly, and then extrude them into the required shape (such as particles, 파이프, 시트, fibers) through the die head. 구체적인 작동 원리와 프로세스 흐름은 다음과 같습니다:
2.2.1 원료 전처리
Raw material pretreatment is the foundation of engineering plastics extrusion processing, which directly affects the processing effect and product quality. The raw materials of engineering plastics mainly include engineering plastic resin (PA와 같은, PC, 포엠), modifiers (유리섬유와 같은, 탄소섬유, 활석, 난연제), 호환성화제, lubricants and other additives. 전처리 단계는 다음과 같습니다:
- 건조처리: Most engineering plastics (PA와 같은, PBT, 조달청) 수분 흡수율이 높다, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, 균열, reduced mechanical properties). 그러므로, 원료는 가공 전에 건조되어야 합니다.. The drying temperature and time are determined according to the type of engineering plastic: 예를 들어, PA6 is dried at 80-100℃ for 4-6 시간, PA66 is dried at 100-120℃ for 6-8 시간, PBT is dried at 120-140℃ for 2-4 시간, PPS is dried at 150-160℃ for 3-5 시간. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
- Premixing Treatment: 공식 비율에 따르면, the dried engineering plastic resin, modifiers and additives are put into a high-speed mixer for premixing. The purpose of premixing is to make the modifiers and additives uniformly adhere to the surface of the resin particles, improve the mixing effect during extrusion, and avoid local agglomeration of modifiers. 혼합 속도는 일반적으로 800-1200 rpm, 그리고 혼합시간은 5-10 분. For some modifiers with poor compatibility (such as glass fiber and PA), a compatibilizer should be added during premixing to improve the compatibility between the modifier and the resin.
- Crushing and Sieving: For engineering plastic resins with large particle size or modifiers with uneven particle size (유리섬유와 같은), crushing and sieving treatment should be carried out to ensure the uniformity of raw materials and avoid affecting the mixing and dispersing effect during extrusion. The particle size of the crushed raw materials should be controlled at 20-40 망사.
2.2.2 공급 및 운반
The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. 압출기의 공급 장치에는 일반적으로 주파수 변환 속도 조절 기능이 장착되어 있습니다., which can adjust the feeding speed according to the screw speed and extrusion speed to ensure that the materials enter the extrusion cavity stably and uniformly, avoiding material accumulation or insufficient feeding. The feeding hopper is also equipped with a drying device to prevent the raw materials from absorbing moisture again during feeding.
2.2.3 녹는, Mixing and Shearing
이축 압출기의 압출 구멍으로 들어가는 재료는 회전하는 나사에 의해 연속적으로 앞으로 밀려납니다.. 압출 캐비티는 스크류와 배럴로 구성됩니다., 압출 공동의 부피는 축 방향을 따라 점차 감소합니다.. 나사가 회전할 때, 재료는 나사와 배럴의 작용으로 점차 압축됩니다., 압출 캐비티의 압력이 점차 증가합니다. (generally 5-15MPa).
동시에, 재료는 스크류와 배럴 사이의 상대적인 움직임으로 인해 생성되는 강한 전단력과 마찰력을 받습니다., 뿐만 아니라 스크류 플라이트 사이에도. The shear force and friction force can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the melted engineering plastic resin, and promote the fusion and compatibility between the modifier and the resin. 마찰력은 일정량의 열을 발생시킬 수도 있습니다., 이는 배럴의 외부 가열과 결합됩니다. (전기 가열 또는 증기 가열) to make the engineering plastic resin gradually melt and plasticize.
압출기의 배럴은 일반적으로 다음과 같이 나뉩니다. 4-6 온도 조절 섹션 (먹이 섹션, 녹는 부분, 혼합 섹션, 균질화 섹션, 다이 헤드 섹션), and the temperature of each section is precisely controlled according to the type of engineering plastic. 예를 들어, when processing PA66+GF30 (glass fiber reinforced PA66), the temperature of the feeding section is 120-140℃, the melting section is 250-260℃, the mixing section is 260-270℃, the homogenizing section is 250-260℃, and the die head section is 240-250℃. The precise temperature control can ensure that the resin is fully melted without thermal decomposition, and the modifiers are uniformly dispersed.
2.2.4 Extrusion and Shaping
완전히 녹은 것, 혼합 및 분산된 재료는 스크류에 의해 압출기의 다이 헤드로 밀려납니다.. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (과립), the die head is equipped with multiple circular die holes (the number and size of die holes are determined according to the particle size of the granules); for the production of pipes, 시트, fibers, the die head is designed into corresponding shapes (such as circular die for pipes, flat die for sheets).
The material is extruded from the die head at a high speed to form continuous semi-finished products (such as strips for granules, 파이프, 시트). 다이 헤드의 온도는 균질화 섹션의 온도보다 약간 낮습니다., which can prevent the material from decomposing due to excessive temperature and ensure the shaping effect of the semi-finished products. The extrusion speed is controlled according to the type of engineering plastic and the shape of the product, generally ranging from 0.5-5m/min.
2.2.5 Cooling and Solidification
The extruded semi-finished products are sent to a cooling device for rapid cooling and solidification. The cooling method is determined according to the shape of the product: for strips (granule production), water tank cooling is usually used, and the cooling water temperature is controlled at 20-30℃, 그리고 쿨링타임은 2-5 분; for pipes and sheets, air cooling or water spray cooling is used, and the cooling speed should be controlled to avoid product deformation due to uneven cooling. Rapid cooling can make the semi-finished products solidify quickly, maintain the shape and size of the products, and improve the mechanical properties of the products.
2.2.6 Cutting and Post-Processing
After cooling and solidification, the semi-finished products are processed into the final product through cutting or other post-processing steps. For the production of engineering plastic compounds (과립), the cooled strips are sent to a granulator for cutting, and the granulator is equipped with a rotary knife, which can cut the strips into granular products with uniform size (입자 크기는 일반적으로 2-5mm입니다., 고객 요구에 따라 조정될 수 있습니다.). For the production of pipes and sheets, the cooled semi-finished products are cut into the required length through a cutting machine; for the production of fibers, the cooled filaments are drawn and wound to form fiber products.
게다가, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (너무 큰 것 같은, 너무 작거나 뭉친 입자); the inspection step is to detect the performance (such as mechanical strength, 내열성, 치수 정확도) of the product to ensure that it meets the customer’s requirements; the packaging step is to package the qualified product in a sealed and moisture-proof manner to prevent the product from absorbing moisture and affecting the quality.
2.3 Key Factors Affecting Engineering Plastics Twin-Screw Extrusion Effect
The effect of twin-screw extrusion directly affects the quality and performance of engineering plastic products. There are many factors affecting the extrusion effect, 주로 원료 특성을 포함, 공식 비율, 사전 혼합 효과, 압출 매개변수 및 다이 헤드 구조. Mastering these key factors and making scientific adjustments can ensure the stability of the extrusion effect and the consistency of product quality.
2.3.1 원료 특성
유형, 입자 크기, moisture content and purity of raw materials have a great impact on the extrusion effect. 예를 들어, the particle size of engineering plastic resin and modifiers should be uniform; if the particle size is uneven, it will lead to uneven melting and mixing of materials. The moisture content of raw materials must be strictly controlled below 0.1%-0.2%; 수분 함량이 너무 높으면, it will cause hydrolytic degradation of the material and bubbles in the product. 원료의 순도도 매우 중요합니다; 원료의 불순물 (금속과 같은, 돌, 먼지) will not only affect the product quality, 압출기의 나사와 배럴도 마모됩니다., 장비를 막히게 할 수도 있습니다..
2.3.2 공식 비율
The formula ratio of engineering plastic compounds (the ratio of resin, modifiers and additives) is the key to determining the performance of the product. The type and dosage of modifiers should be determined according to the performance requirements of the product. 예를 들어, 첨가 20%-40% of glass fiber to PA can significantly improve its strength and dimensional stability, but excessive glass fiber will reduce the toughness and processing fluidity of the product. 첨가제의 종류와 복용량도 합리적으로 일치해야 합니다.: compatibilizers can improve the compatibility between modifiers and resin, and the dosage is generally 0.5%-2%; lubricants can reduce the friction between materials and equipment, 가공 유동성 향상, and the dosage is generally 0.3%-1%; antioxidants can prevent the material from thermal oxidation degradation during processing, and the dosage is generally 0.1%-0.5%.
2.3.3 사전 혼합 효과
Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. 사전 혼합이 고르지 않은 경우, the modifiers cannot be uniformly adhered to the surface of the resin, resulting in local agglomeration of modifiers, uneven mixing of materials during extrusion, and reduced product performance. 사전 혼합 효과를 보장하려면, 혼합 속도를 조절해야 합니다., 혼합 시간 및 혼합 온도: the mixing speed is 800-1200 rpm, 혼합 시간은 5-10 분, 혼합온도는 40~60℃로 조절됩니다. (적절한 온도는 첨가제의 접착력을 향상시키고 균일한 혼합을 촉진할 수 있습니다.).
2.3.4 압출 매개변수
Extrusion parameters are the most important factors affecting the extrusion effect, 주로 나사 속도 포함, 압출 온도 및 압출 압력.
- 나사 속도: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 에게 1000 rpm. Our HTS series extruders can reach a maximum speed of 1000 rpm. 나사 속도가 높을수록, 재료가 받는 전단력과 마찰력이 커질수록, the better the mixing and dispersing effect of modifiers, 생산 효율이 높을수록. 하지만, 나사 속도가 너무 높은 경우, 압출 캐비티 내 재료의 체류 시간이 너무 짧습니다., resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; 나사 속도가 너무 느린 경우, 전단력과 마찰력이 충분하지 않습니다., the modifiers cannot be fully dispersed, 그리고 생산효율도 낮고. The screw speed should be adjusted according to the type of engineering plastic and the type of modifier: for high-viscosity engineering plastics (such as PPS, 몰래 엿보다), a lower screw speed is needed to ensure sufficient melting and mixing; for reinforced engineering plastics (such as glass fiber reinforced PA), a higher screw speed is needed to ensure the uniform dispersion of glass fiber.
- 압출 온도: The extrusion temperature is the key to ensuring the melting and plasticization of engineering plastics. The temperature of each section of the barrel and die head must be precisely controlled according to the type of engineering plastic. 공급 부분의 온도가 더 낮습니다. (slightly higher than the drying temperature of the raw materials), 이는 주로 재료가 굳는 것을 방지하고 원활한 공급을 보장하는 것입니다.; 녹는 부분의 온도는 중간입니다, which is mainly to promote the melting and plasticization of the resin; 혼합 섹션의 온도가 더 높습니다., 이는 주로 전단 및 혼합 효과를 향상시키는 것입니다., and promote the uniform dispersion of modifiers; 균질화 섹션의 온도는 혼합 섹션보다 약간 낮습니다., 이는 주로 재료의 균일한 온도와 점도를 보장하는 것입니다., 그리고 열분해를 피하십시오; 다이 헤드 섹션의 온도는 균질화 섹션보다 약간 낮습니다., which is to ensure the shaping effect of the semi-finished products. The temperature control precision should reach ±1℃ to avoid local overheating and thermal decomposition of the material.
- 압출 압력: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. 압출 캐비티의 압력은 주로 스크류의 압축비에 의해 결정됩니다., 다이 구멍 크기 및 나사 속도. 압출압력이 높을수록, the better the mixing and dispersing effect of materials, and the denser the product. 하지만, 압력이 너무 높으면, 장비의 에너지 소비와 마모가 증가합니다., 다이 헤드가 막힐 수도 있습니다.; 압력이 너무 낮은 경우, 재료를 완전히 압축하고 혼합할 수 없습니다., the product is loose, 그리고 성능이 불안정해요. The extrusion pressure should be adjusted according to the type of engineering plastic and the shape of the product: for high-viscosity materials and products with small die holes, a higher extrusion pressure is needed.
2.3.5 다이 헤드 구조
The die head structure mainly includes the shape, size and number of die holes, which directly affects the shaping effect and quality of the product. For the production of engineering plastic compounds (과립), the die head should be equipped with multiple uniform die holes, and the size of the die holes should be matched with the particle size of the product; for the production of pipes and sheets, the die head should be designed according to the shape and size of the product, and the flow channel of the die head should be smooth to avoid material accumulation and local overheating. The die head should also be equipped with a temperature control device to ensure the uniform temperature of the die head and the stable shaping of the product.
3. Our HTS Series Extruders: Professional Solutions for Engineering Plastics Processing
우리는 오랫동안 연구에 참여해 왔습니다., development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, 고점도) and application needs, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, perfectly adapting to the processing needs of various engineering plastics.
3.1 Core Advantages of HTS Series Extruders for Engineering Plastics Processing
3.1.1 High Torque and High Speed, 높은 생산 효율성
Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS 시리즈 및 HTS SUPER 시리즈) or imported from leading European manufacturers (HTS BASIC 시리즈), with a specific torque of 14Nm/cm³, which is much higher than that of ordinary twin-screw extruders (general torque is 8-12Nm/cm³). The high torque design ensures that the extruder can stably convey high-viscosity engineering plastic materials, avoid material accumulation and equipment blockage, and improve the stability of the extrusion process.
동시에, the HTS series extruders have a high speed design, with a maximum speed of up to 1000rpm. The high speed can generate strong shear force and mixing force, which can fully break the agglomerates of modifiers, make the modifiers uniformly dispersed in the resin matrix, and improve the mixing and dispersing effect. 게다가, the high speed design also greatly improves the production efficiency: 일반 압출기에 비해, the production efficiency of HTS series extruders can be increased by 30%-50%, which can meet the large-scale production needs of engineering plastics enterprises.
3.1.2 Short Residence Time, Effectively Avoiding Thermal Degradation
As engineering plastics are sensitive to overheating and hydrolytic degradation, the residence time of materials in the extruder is crucial. Our HTS series extruders adopt an optimized screw structure and barrel design, with a short residence time of only 1-3 분, which is much shorter than that of ordinary twin-screw extruders (5-10 분) and single-screw extruders (10-15 분). The short residence time can effectively reduce the contact time between the material and high temperature, avoid thermal decomposition and hydrolytic degradation of the material, and ensure the mechanical properties and heat resistance of the product.
게다가, the screw of the HTS series extruders adopts a modular design, and different screw elements can be freely combined according to the type of engineering plastic, which can further adjust the residence time of the material, ensuring that different types of engineering plastics can obtain the optimal residence time during processing.
3.1.3 정밀한 온도 제어, 안정적인 성능
The HTS series extruders adopt an advanced intelligent temperature control system, 배럴 및 다이 헤드의 각 섹션의 온도를 정밀하게 제어할 수 있는 제품입니다.. The temperature control precision can reach ±1℃, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating and thermal decomposition of the material. 온도 제어 시스템에는 실시간 모니터링 및 경보 기능이 장착되어 있습니다.: if the temperature of any section exceeds the set range, 시스템은 제 시간에 경보 프롬프트를 발행합니다, 필요한 경우 자동으로 가열 전력을 조정하거나 장비를 종료할 수도 있습니다., 장비 고장 및 제품 품질 문제를 방지하기 위해.
게다가, the barrel of the HTS series extruders adopts a double-layer jacket design, which can realize rapid heating and cooling, and improve the response speed of temperature control. The die head is also equipped with an independent temperature control device, which ensures the uniform temperature of the die head and the stable shaping of the product.
3.1.4 탁월한 혼합 및 분산 효과
The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, 합리적인 나사 피치로, 리드 및 압축비 설계. 두 개의 나사가 서로 맞물려 회전함으로써 강한 전단력과 반죽력을 발생시킬 수 있습니다., which can fully break the agglomerates of modifiers (유리섬유와 같은, 탄소섬유, 활석), make the modifiers uniformly dispersed in the engineering plastic resin matrix, and ensure the mixing and dispersing effect. The mixing uniformity of the HTS series extruders can reach more than 95%, which is much higher than that of ordinary twin-screw extruders (85%-90%).
The screw of the HTS series extruders adopts a modular design, and different types of screw elements (전달 요소와 같은, 혼합 요소, 전단 요소) can be freely combined according to the type of engineering plastic and modifier. 예를 들어, when processing reinforced engineering plastics with glass fiber, more shearing elements can be configured to enhance the shearing effect and ensure the uniform dispersion of glass fiber; when processing engineering plastics with high viscosity (such as PPS), more mixing elements can be configured to improve the mixing effect and ensure the uniform viscosity of the material.
3.1.5 높은 내마모성, 긴 서비스 수명
In the processing of reinforced engineering plastics (such as glass fiber reinforced PA, carbon fiber reinforced PPS), the added modifiers have high hardness, which will cause serious wear to the screw and barrel of the extruder. Our HTS series extruders adopt high-quality wear-resistant materials and advanced manufacturing technology to ensure the wear resistance of the core components.
The screw and barrel of the HTS series extruders are made of imported wear-resistant alloy steel (38CrMoAlA와 같은), and undergo bimetallic composite treatment or laser cladding treatment. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC 시리즈) and ≥70 HRC (HTS PLUS 시리즈 및 HTS SUPER 시리즈), 내마모성과 내식성이 매우 강한 제품입니다., and can effectively resist the wear caused by high-hardness modifiers. 이는 스크류와 배럴의 사용 수명을 크게 연장시킵니다.: the service life of the screw and barrel of the HTS series extruders is 2-3 일반 압출기의 몇 배, reducing the frequency of component replacement and the maintenance cost of the equipment.
게다가, 우리는 또한 스크류 및 배럴에 대한 전문적인 마모 감지 서비스를 제공합니다.. 우리 기술팀은 고객을 위해 스크류와 배럴의 마모 정도를 정기적으로 감지합니다., 상세한 마모 보고서 발행, 목표한 교체 및 유지 관리 제안을 제시합니다., 고객이 필요한 경우에만 구성 요소를 교체하도록 보장, 불필요한 낭비 방지.
3.1.6 넓은 적용 범위, 강력한 유연성
The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (아빠, PC, 포엠, 애완 동물, PBT) and special engineering plastics (조달청, 몰래 엿보다, PSU, PES). The extruders can also adapt to the processing of various modified engineering plastics, such as reinforced engineering plastics (glass fiber reinforced, carbon fiber reinforced), toughened engineering plastics, flame-retardant engineering plastics, antistatic engineering plastics, 등.
The modular design of the HTS series extruders (나사, 통, 다이 헤드, 등.) 구성 요소 교체를 더욱 편리하고 빠르게 만듭니다.. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, 해당 구성 요소만 교체하면 됩니다., 장비 전체를 교체하지 않고, 장비 변형 비용을 줄이고 장비의 유연성과 적응성을 향상시킵니다.. 게다가, the HTS series extruders can also be matched with different auxiliary equipment (고속 믹서와 같은, 건조기, 쿨러, 과립기, 스크리닝 기계, 포장 기계) 완전한 자동 생산 라인을 형성하기 위해, 원료 전처리부터 제품 포장까지 연속 생산 실현.
3.1.7 Intelligent Control, 쉬운 작동 및 유지 관리
The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, 작동하기 쉬운. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, 해당 공식과 매개변수만 호출하면 됩니다., 반복적인 디버깅 없이, 시간을 절약하고 생산 효율성을 향상시킵니다..
The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (온도와 같은, 압력, 나사 속도, 먹이는 속도) in real time, and record the production data (such as output, processing time) for later query and analysis. For the HTS SUPER series extruders, we also provide a cloud control function, 원격 매개변수 조정을 실현할 수 있는, 생산 데이터 모니터링 및 장비 예측 유지보수, 지능형 생산관리 실현.
게다가, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. 나사, 통, 다이 헤드 및 기타 구성 요소를 신속하게 분해 및 조립할 수 있습니다., 유지보수 시간과 노동 강도를 줄여줍니다.. 우리의 애프터 서비스 팀은 전문적인 설치를 제공할 것입니다, 고객을 위한 시운전 및 교육 서비스, 고객이 장비를 원활하게 사용할 수 있도록 보장.
3.2 HTS Series Extruder Product Types and Their Adaptation to Engineering Plastics
In order to meet the diverse processing needs of engineering plastics enterprises of different scales and product types, we have launched three main product types in the HTS series: HTS BASIC 시리즈, HTS PLUS 시리즈 및 HTS SUPER 시리즈. 각 시리즈에는 고유한 특성과 목표 적응 시나리오가 있습니다., 고객이 자체 생산 규모에 따라 선택할 수 있는 제품, 제품 유형, 예산 및 기타 요인.
3.2.1 HTS BASIC 시리즈 압출기: Flexible and Cost-Effective Choice for General Engineering Plastics
The HTS BASIC series extruders are a cost-effective product series designed for engineering plastics processing enterprises with medium and small production scales or initial entry into the industry. 이 압출기 시리즈는 선도적인 유럽 제조업체의 중간 토크 기어박스를 사용합니다., 안정적인 성능의 장점이 있는, 저소음, 고효율 및 긴 서비스 수명. The medium-torque design (특정 토크 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, 포엠, 애완 동물, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).
구조설계 측면에서는, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, 나사 직경 범위는 30mm ~ 65mm입니다., 압축률은 4~8입니다., which can be adjusted according to the type of engineering plastic. 배럴은 질화 처리된 내마모성 합금강으로 만들어졌습니다., 나사는 내마모성 및 내식성 합금강으로 만들어졌습니다., 내마모성이 우수합니다.. 압출기에는 PLC 제어 시스템과 터치스크린 작동 인터페이스가 장착되어 있습니다., 자동 공급을 실현할 수 있는, 자동 온도 조절, 자동 압력 제어 및 자동 절단, 간단하고 조작하기 쉽습니다..
HTS BASIC 시리즈 압출기의 생산 능력은 100kg/h ~ 500kg/h 범위입니다., which is suitable for medium and small-sized engineering plastics processing enterprises that mainly produce general engineering plastics and low-to-medium modified engineering plastics. 이 시리즈의 가장 큰 장점 중 하나는 다양한 구성 조합을 통해 유연한 옵션을 제공할 수 있다는 것입니다.. 고객은 다양한 나사 요소를 선택할 수 있습니다., 다이 헤드, 공급 장치, 자체 제품 유형에 따른 건조 장치 및 후처리 장비, 생산능력과 예산, so as to form a production line suitable for their own needs. The HTS BASIC series extruders have a reasonable price, 기업의 초기 투자 비용을 줄이는 데 도움이 될 수 있습니다..
3.2.2 HTS PLUS Series Extruders: High-Performance Choice for Engineering Plastics and Modified Products
The HTS PLUS series extruders adopt high-torque gearboxes independently developed and manufactured by us, with a specific torque of 14Nm/cm³, which has stronger torque and load-bearing capacity than the HTS BASIC series. This series of extruders is mainly designed for the processing of high-performance engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS), which is suitable for medium and large-scale engineering plastics processing enterprises that pursue high performance and high efficiency.
HTS PLUS 시리즈 압출기의 스크류 직경은 65mm~110mm입니다., 압축비 5~10, and a screw speed range of 200～800 rpm. 나사와 배럴은 바이메탈 복합 처리를 채택합니다., 내마모성과 내식성이 더 높은 것 (표면 경도 ≥65 HRC), and can adapt to the processing of reinforced engineering plastics with high filling amount (such as glass fiber reinforced PA with filling amount 30%-50%, carbon fiber reinforced PPS) and high-hardness modifiers. The extruder is equipped with an advanced intelligent temperature control system and a high-precision pressure sensor, 압출 매개변수의 정밀한 제어와 생산 데이터의 실시간 모니터링을 실현할 수 있는 제품입니다., ensuring the stability of the extrusion process and the quality of the product.
The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.
3.2.3 HTS SUPER 시리즈 압출기: Top-End Choice for High-End Engineering Plastics
HTS SUPER 시리즈 압출기는 당사가 독자적으로 개발한 최신 초고토크 전달 장치를 채택합니다., with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. 본 시리즈의 높은 토크와 고속 특성을 목표로, 압출기의 각 핵심 구성 요소의 구조 설계가 완전히 최적화되었습니다., 이는 당사의 최고급 압출기 시리즈입니다., 중국 압출기 개발의 고급 수준을 대표. This series of extruders is mainly designed for the processing of high-end special engineering plastics (PEEK와 같은, PI, PSU, PES) and high-performance modified engineering plastics (such as carbon fiber reinforced PEEK, glass fiber reinforced PI), which is suitable for large-scale high-end engineering plastics processing enterprises that pursue high precision, 고성능과 지능.
HTS SUPER 시리즈 압출기의 스크류 직경은 80mm ~ 130mm입니다., 압축비 6~12, and a screw speed range of 250～1000 rpm. 나사와 배럴은 수입된 내마모성 합금강과 레이저 클래딩 기술을 채택합니다., 내마모성과 내식성이 매우 높은 제품입니다. (표면 경도 ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. 압출기에는 지능형 PLC가 장착되어 있습니다. + 클라우드 터치스크린 제어 시스템, 원격 매개변수 조정을 실현할 수 있는, 생산 데이터 모니터링, predictive maintenance of equipment and data analysis, 지능형 생산관리 실현.
HTS SUPER 시리즈 압출기의 생산 능력은 1000kg/h ~ 3000kg/h 범위입니다., which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. 이 일련의 압출기에는 고정밀도의 장점이 있습니다., 강력한 맞춤화, 다기능 및 안정적인 성능, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 분) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. 게다가, the HTS SUPER series extruders can also be customized according to the special processing needs of customers, providing personalized solutions.
3.3 Selection Suggestions for Engineering Plastics Extruders
When selecting twin-screw extruders for engineering plastics processing, 기업은 자신의 생산 요구를 종합적으로 고려해야 합니다., 제품 유형, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. 다음은 몇 가지 구체적인 선택 제안 사항입니다.:
3.3.1 Determine the Extruder Series According to the Type of Engineering Plastics
Different types of engineering plastics have different processing requirements, which determine the selection of extruder series. For general engineering plastics (PA6, PA66, 포엠, 애완 동물, PBT) with low modification degree (filling amount ≤30%), the HTS BASIC series is sufficient to meet the processing needs. Its medium torque and flexible configuration can balance processing effect and cost, which is very suitable for small and medium-sized enterprises that just start to engage in engineering plastics processing or focus on general-purpose products. For high-modified engineering plastics (충전량 30%-50%, such as glass fiber reinforced PA, carbon fiber reinforced PBT) and special engineering plastics with moderate processing difficulty (such as PPS), the HTS PLUS series is the preferred choice. Its high torque of 14Nm/cm³ and excellent mixing and dispersing capacity can effectively solve the problem of uneven dispersion of high-content modifiers, and its wear-resistant screw and barrel can adapt to the wear of hard modifiers, ensuring stable production. For high-end special engineering plastics (몰래 엿보다, PI, PSU, PES) and high-performance modified engineering plastics (filling amount ≥50%, such as carbon fiber reinforced PEEK), the HTS SUPER series must be selected. Its ultra-high torque, maximum 1000rpm speed and fully optimized key structure can cope with the high viscosity, high temperature resistance and strict processing requirements of high-end materials, avoid thermal decomposition and material degradation, and ensure the high performance of the final product.
3.3.2 Determine the Screw Diameter and Production Capacity According to the Processing Scale
The screw diameter of the twin-screw extruder directly determines the production capacity, and enterprises need to select the appropriate screw diameter according to their own production scale and order demand. 소규모 생산용 (100kg/h – 500kg/h), such as small-batch customization, product research and development or small orders, the HTS BASIC series with screw diameter of 30mm – 65mm is suitable; for medium-scale production (500kg/h – 2000kg/h), such as mass production of general modified engineering plastics, the HTS PLUS series with screw diameter of 65mm – 110mm can meet the demand; for large-scale production (1000kg/h – 3000kg/h), such as large-scale production of high-end special engineering plastics or large orders from downstream enterprises, the HTS SUPER series with screw diameter of 80mm – 130mm is the best choice. It should be noted that when selecting, enterprises should not blindly pursue large production capacity. They should also consider the fluctuation of order quantity. If the order quantity is unstable, they can choose equipment with adjustable speed and flexible production capacity (such as HTS BASIC series with frequency conversion speed regulation function) to avoid waste of equipment resources and energy.
3.3.3 Consider the Modification Demand and Mixing Effect
If the enterprise’s main products are modified engineering plastics, the mixing and dispersing effect of the extruder is the key factor to be considered. For products that need to add a variety of modifiers (난연제와 같은, 호환성화제, reinforcing agents) 동시에, it is necessary to select extruders with excellent mixing performance, such as HTS PLUS series and HTS SUPER series with modular mixing screw elements. These two series can freely combine conveying elements, mixing elements and shearing elements according to the type of modifier, adjust the mixing intensity and residence time, and ensure that various modifiers are uniformly dispersed in the resin matrix. 예를 들어, when processing flame-retardant modified PBT, more mixing elements can be configured to ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency; when processing glass fiber reinforced PA, more shearing elements can be configured to break the agglomeration of glass fiber and improve the bonding force between glass fiber and resin. 게다가, if the enterprise has the demand of multi-variety and small-batch modification, it is recommended to select the extruder with quick replacement of screw elements (such as the modular screw design of HTS series), which can reduce the time of equipment adjustment and improve production efficiency.
3.3.4 Consider the Cost Budget and Comprehensive Benefits
Cost budget is an important factor for enterprises to select equipment, but it is not advisable to pursue low cost blindly. It is necessary to balance the initial purchase cost, later maintenance cost, energy consumption and production efficiency to maximize the comprehensive benefits. The HTS BASIC series has the lowest initial purchase cost, low energy consumption and simple maintenance, which is suitable for enterprises with limited budget and small production scale; the HTS PLUS series has a moderate initial purchase cost, but its high production efficiency, long service life and stable processing effect can reduce the later maintenance cost and improve product qualification rate, which is suitable for medium and large-sized enterprises with certain budget and pursuit of high performance; the HTS SUPER series has the highest initial purchase cost, but it can process high-end products with high added value, and its intelligent control and long service life can reduce labor cost and maintenance cost in the later period, which is suitable for large-scale enterprises with sufficient budget and focus on high-end market. 게다가, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, 설치 포함, 시운전, technical training, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.
3.3.5 Consider the Compatibility with Auxiliary Equipment
Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, 고속 믹서, cooler, granulator, screening machine, packaging machine, 등. When selecting the extruder, enterprises need to consider the compatibility between the extruder and auxiliary equipment to ensure the smooth operation of the entire production line. Our HTS series extruders can be perfectly matched with various standard auxiliary equipment, and can also be customized according to the enterprise’s existing auxiliary equipment to avoid the waste caused by the incompatibility between new equipment and old auxiliary equipment. 예를 들어, if the enterprise already has a high-speed mixer with a mixing capacity of 500kg, it can select the HTS PLUS series extruder with a production capacity of 500kg/h – 800kg/h to match it, ensuring the coordination of raw material premixing and extrusion production.
4. Application Fields of Engineering Plastics and Matching HTS Series Extruder Solutions
엔지니어링 플라스틱, with their excellent comprehensive performance, have been widely used in automotive, 전기 및 전자, 의료, 항공우주, 화학적인, construction and other fields. Different application fields have different requirements on the performance of engineering plastic products, which also puts forward different requirements on extrusion processing equipment. 아래에, we will elaborate on the application characteristics of engineering plastics in major fields and the matching HTS series extruder solutions, providing targeted reference for enterprises in different fields.
4.1 Automotive Field: 경량, High Temperature Resistance and Wear Resistance
With the development of automotive lightweight and energy-saving and emission-reduction, engineering plastics have become an important material for automotive parts, gradually replacing traditional metal materials. The engineering plastics used in the automotive field mainly include PA, 포엠, PC, PBT, 조달청, 등., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: 경량, high temperature resistance, 내마모성, dimensional stability and low VOC (휘발성 유기 화합물), which require the extruder to have precise temperature control, excellent mixing and dispersing effect and stable production capacity.
For automotive interior parts (계기판과 같은, 도어 패널, air ducts) made of general engineering plastics (PA6, 포엠, PC/ABS alloy), HTS BASIC 시리즈 압출기는 가공 요구 사항을 충족할 수 있습니다.. 유연한 구성으로 내부 부품의 성능 요구 사항에 따라 처리 매개변수를 조정할 수 있습니다., 제품의 매끄러운 표면과 치수 안정성을 보장합니다., 낮은 에너지 소비와 비용으로 자동차 부품 생산 비용을 절감할 수 있습니다.. 자동차 엔진 부품용 (흡기 매니폴드와 같은, 실린더 헤드 커버, 오일 팬) 고온 내성 및 내마모성 엔지니어링 플라스틱으로 제작 (PA66+GF30, 조달청), HTS PLUS 시리즈 압출기가 더 적합합니다.. 높은 토크와 우수한 혼합 및 분산 효과로 유리섬유의 균일한 분산을 보장합니다., 제품의 강도와 고온 저항을 향상시킵니다., 내마모성 스크류와 배럴은 유리 섬유의 마모에 적응할 수 있습니다., ensuring long-term stable production. For high-end new energy vehicle parts (such as battery shell, motor insulation parts) made of high-end special engineering plastics (몰래 엿보다, PI), the HTS SUPER series extruders are required. Its ultra-high torque, precise temperature control and short residence time can avoid thermal decomposition of high-temperature resistant materials, ensure the insulation performance and corrosion resistance of the product, and meet the strict requirements of new energy vehicles on parts performance.
사례 연구: A large automotive parts manufacturer specializing in new energy vehicle battery parts selected our HTS SUPER series extruders (screw diameter 100mm) to process carbon fiber reinforced PEEK battery shells. The PEEK material has high viscosity and high temperature resistance, and the carbon fiber filling amount reaches 40%, which has extremely high requirements on extrusion equipment. The HTS SUPER series extruders, with their ultra-high torque of 14Nm/cm³ and maximum speed of 1000rpm, generate strong shear force and mixing force, which makes the carbon fiber uniformly dispersed in the PEEK matrix; the precise temperature control system (precision ±1℃) strictly controls the processing temperature at 380-400℃, avoiding thermal decomposition of PEEK; the short residence time (1.5 분) effectively reduces the material degradation, ensuring the strength and insulation performance of the battery shell. After using the HTS SUPER series extruders, the production efficiency of the enterprise is increased by 40%, the product qualification rate is increased from 88% 에게 99%, and the production cost is reduced by 15%, which has won high recognition from the enterprise.
4.2 Electrical and Electronic Field: Electrical Insulation, Flame Retardancy and Dimensional Stability
The electrical and electronic field is one of the earliest and most widely used fields of engineering plastics. Engineering plastics are mainly used in electrical connectors, 배선판, relays, 모터, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, 난연성, 치수 안정성, corrosion resistance and low toxicity, which require the extruder to have precise temperature control, good mixing and dispersing effect and strict quality control capacity.
For general electrical components (such as cable ties, 커넥터) made of general engineering plastics (PA6, PBT, PC), the HTS BASIC series extruders are suitable. Its flexible configuration can match different die heads to produce components of different shapes and sizes; the precise temperature control ensures the electrical insulation performance of the product, and the low cost can meet the mass production needs of general electrical components. For high-precision electrical components (such as relays, motor windings) made of flame-retardant modified engineering plastics (PBT+GF30+flame retardant, PA66+flame retardant), the HTS PLUS series extruders are preferred. Its high mixing and dispersing effect can ensure the uniform dispersion of flame retardants, avoid local flame retardancy insufficiency, and meet the UL94 V-0 flame retardant standard; the precise dimensional control can ensure the dimensional accuracy of high-precision components, avoiding assembly failure. For high-end electrical components (such as high-temperature resistant connectors, aerospace electrical components) made of special engineering plastics (조달청, PSU, PES), the HTS SUPER series extruders are required. Its ultra-high torque and excellent wear resistance can cope with the high viscosity and high hardness of special engineering plastics, and the precise temperature control and short residence time can ensure the electrical insulation performance and high temperature resistance of the product, meeting the strict requirements of high-end electrical and electronic products.
4.3 Medical Field: Biocompatibility, Sterility and Precision
The medical field has extremely strict requirements on materials, and engineering plastics used in the medical field must have good biocompatibility, sterility, corrosion resistance and dimensional stability, and must not produce toxic and harmful substances. The main engineering plastics used in the medical field include PC, 아빠, 몰래 엿보다, PSU, 등., which are mainly used in medical containers, 의료용 카테터, medical implants, surgical instruments and other products. The core requirements for extrusion processing are: 높은 정밀도, no pollution, 안정적인 성능, which require the extruder to have high cleanliness, precise temperature control and strict quality control capacity.
For general medical products (such as medical containers, ordinary catheters) made of medical-grade general engineering plastics (의료용 PC, medical-grade PA), the HTS BASIC series extruders with special cleanliness configuration can meet the requirements. We can customize the screw and barrel with high cleanliness, no dead angle design for the HTS BASIC series, avoid material residue and pollution, and match the sterile feeding and packaging system to ensure the sterility of the product. For high-precision medical products (such as precision catheters, medical implants) made of medical-grade special engineering plastics (의료용 PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (우수제조관리기준) requirements of the medical field.
4.4 Aerospace Field: High Temperature Resistance, Low Weight and High Strength
The aerospace field has extremely high requirements on the performance of materials, and engineering plastics used in the aerospace field must have excellent high temperature resistance, low weight, high strength, corrosion resistance and radiation resistance. The main engineering plastics used in the aerospace field include PEEK, PI, PSU, PES, 등., which are mainly used in aerospace components, aircraft interior parts, satellite components and other products. The core requirements for extrusion processing are: ultra-high precision, ultra-high temperature resistance, 안정적인 성능, which require the extruder to have the highest level of torque, speed and temperature control capacity.
Due to the extremely strict processing requirements of aerospace-grade engineering plastics, only the HTS SUPER series extruders can meet the demand. Its ultra-high torque transmission device, maximum 1000rpm speed and fully optimized key components can cope with the high viscosity and high temperature resistance of aerospace-grade materials (long-term use temperature up to 300℃); the laser-clad screw and barrel have extremely high wear resistance and corrosion resistance, which can adapt to the processing of high-hardness modifiers (such as carbon fiber, ceramic fiber); the intelligent PLC + cloud touch screen control system can realize precise control of extrusion parameters, and the remote monitoring and predictive maintenance function can ensure the stable operation of equipment in long-term continuous production; the customizable configuration can meet the special processing needs of various aerospace components, ensuring the high performance and high reliability of the product.
4.5 Chemical Field: Corrosion Resistance and Wear Resistance
The chemical field has harsh working environment, and engineering plastics used in the chemical field must have excellent corrosion resistance, 내마모성, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, 몰래 엿보다, PVDF (polyvinylidene fluoride), 등., which are mainly used in chemical equipment, pipelines, 밸브, pumps and other products. The core requirements for extrusion processing are: 내식성, 내마모성, 안정적인 성능, which require the extruder to have excellent wear resistance and corrosion resistance, and stable pressure control capacity.
For chemical pipelines and valves made of general corrosion-resistant engineering plastics (조달청, PVDF), the HTS PLUS series extruders are suitable. Its bimetallic composite screw and barrel have excellent corrosion resistance and wear resistance, which can adapt to the corrosion of chemical media and the wear of materials; the stable pressure control capacity can ensure the uniform wall thickness of pipelines and valves, avoiding leakage caused by uneven wall thickness. For high-pressure chemical equipment and corrosion-resistant components made of high-end corrosion-resistant engineering plastics (몰래 엿보다, PI), the HTS SUPER series extruders are required. Its ultra-high torque and stable conveying capacity can cope with the high viscosity of high-end corrosion-resistant materials, and the laser-clad screw and barrel have extremely high corrosion resistance and wear resistance, which can meet the long-term use requirements in harsh chemical environments; the precise temperature control can avoid thermal decomposition of materials, ensuring the corrosion resistance and pressure resistance of the product.
5. Common Problems and Solutions in Engineering Plastics Twin-Screw Extrusion Processing
In the actual twin-screw extrusion processing of engineering plastics, 원자재의 영향으로, 처리 매개변수, equipment performance and other factors, 다양한 문제가 자주 발생합니다, which affect the product quality and production efficiency. 아래에, we will summarize the common problems in engineering plastics extrusion processing, 원인을 분석하다, and provide corresponding solutions combined with the characteristics of our HTS series extruders, helping enterprises solve practical processing problems and improve production efficiency.
5.1 문제 1: Thermal Decomposition and Discoloration of Materials
Symptoms: During the extrusion process, the material appears yellowing, blackening, carbonization and other phenomena, and the final product has discoloration, 거품, cracks and other defects, and the mechanical properties are significantly reduced. This problem is mainly caused by the sensitivity of engineering plastics to overheating and hydrolytic degradation.
원인: 1. The extrusion temperature is too high or the temperature of a certain section of the barrel is too high, resulting in thermal decomposition of the material; 2. The residence time of the material in the extruder is too long, leading to excessive heating and decomposition; 3. The raw materials are not dried thoroughly, and the moisture in the materials causes hydrolytic degradation during high-temperature processing; 4. The screw speed is too low, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.
솔루션: 1. Adjust the extrusion temperature according to the type of engineering plastic, strictly control the temperature of each section of the barrel and die head within the optimal range, and use the precise temperature control function of the HTS series extruders (온도 조종 정밀도 ±1℃) to avoid local overheating; 2. Increase the screw speed appropriately (within the range suitable for the material) to shorten the residence time of the material. The HTS series extruders can reach a maximum speed of 1000rpm, which can effectively shorten the residence time to 1-3 분; 3. Strengthen the drying treatment of raw materials, strictly control the moisture content below 0.1%-0.2%, and use the drying device matched with the HTS series extruders to prevent the raw materials from absorbing moisture again during feeding; 4. Check and clean the die head regularly to ensure the smooth flow channel, avoid material accumulation; 5. If the problem persists, adjust the screw element combination, increase the number of conveying elements, and reduce the number of mixing elements to speed up the material conveying and shorten the residence time.
5.2 문제 2: Uneven Dispersion of Modifiers
Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (유리섬유와 같은, 탄소섬유), and the mechanical properties (힘, 인성, 내마모성) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.
원인: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. The screw speed is too low, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.
솔루션: 1. 사전 혼합 프로세스 최적화, 혼합 속도를 증가 (800-1200rpm) 그리고 믹싱시간 (5-10 분), add an appropriate amount of compatibilizer to improve the compatibility between the modifier and the resin, and use a high-speed mixer matched with the HTS series extruders to ensure uniform premixing; 2. Increase the screw speed appropriately, use the high-speed performance of the HTS series extruders to generate strong shear force and kneading force, and fully break the agglomerates of modifiers; 3. Adjust the combination of screw elements, increase the number of mixing elements and shearing elements, and use the modular screw design of the HTS series extruders to customize the optimal screw combination according to the type of modifier; 4. Properly increase the extrusion temperature to ensure that the material is fully melted, which is conducive to the uniform dispersion of modifiers; 5. Crush and sieve the modifier to ensure that its particle size is uniform (20-40 망사) and meets the processing requirements.
5.3 문제 3: Wear of Screw and Barrel
Symptoms: After a period of use, the extrusion capacity of the extruder decreases, the shear force and mixing effect are reduced, the product quality is unstable, and even the screw and barrel are stuck. This problem is mainly caused by the wear of high-hardness modifiers (유리섬유와 같은, 탄소섬유) on the screw and barrel during the processing of reinforced engineering plastics.
원인: 1. 스크류와 배럴은 내마모성이 약한 재질로 제작되었습니다., which cannot resist the wear of high-hardness modifiers; 2. The filling amount of the modifier is too high (≥50%), and the wear is intensified; 3. The particle size of the modifier is too large, which increases the wear on the screw and barrel; 4. The extrusion pressure is too high, which increases the friction between the material and the screw and barrel; 5. The screw and barrel are not maintained regularly, and the material residue accelerates the wear.
솔루션: 1. 내마모성이 높은 압출기를 선택하세요., such as HTS PLUS series and HTS SUPER series. Their screws and barrels are made of imported wear-resistant alloy steel and undergo bimetallic composite treatment or laser cladding treatment, with surface hardness ≥65 HRC (HTS 플러스) and ≥70 HRC (HTS 슈퍼), which can effectively resist the wear of high-hardness modifiers; 2. Control the filling amount of the modifier within a reasonable range. If high filling amount is required, select the HTS SUPER series extruders with better wear resistance; 3. Crush and sieve the modifier to reduce its particle size and reduce wear; 4. Adjust the extrusion parameters to control the extrusion pressure within the optimal range (5-15MPa), avoid excessive pressure; 5. Regularly maintain the screw and barrel, clean the material residue in time, and apply lubricating oil appropriately to reduce friction and extend the service life. 게다가, our professional technical team can provide regular wear detection services for the screw and barrel, 목표한 교체 및 유지 관리 제안을 제시합니다..
5.4 문제 4: Unstable Product Size and Dimensional Deformation
Symptoms: The size of the extruded product (such as granules, 파이프, 시트) is uneven, the shrinkage rate exceeds the standard (＞1.5%), and the product has deformation, warpage and other phenomena, which affects the assembly and use of the product.
원인: 1. The extrusion temperature is unstable, resulting in uneven melting and plasticization of the material, and uneven shrinkage during cooling; 2. The extrusion speed is unstable, leading to uneven extrusion amount and unstable product size; 3. The cooling speed is uneven, resulting in uneven internal and external stress of the product, leading to deformation; 4. The die head structure is unreasonable, the flow channel is not smooth, and the material flow is uneven; 5. The raw materials have high water absorption, and the moisture causes uneven shrinkage during processing.
솔루션: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 분) for strip cooling, and use air cooling or water spray cooling for pipes and sheets to avoid uneven cooling; 4. Check and optimize the die head structure, ensure the smooth flow channel, and adjust the die head temperature to ensure uniform material flow; 5. Strengthen the drying treatment of raw materials, strictly control the moisture content, and reduce the impact of moisture on product shrinkage.
5.5 문제 5: Low Extrusion Efficiency and High Energy Consumption
Symptoms: The production capacity of the extruder is lower than the design standard, the energy consumption per unit product is high, and the production cost is increased, which affects the economic benefits of the enterprise.
원인: 1. The screw speed is too low, the conveying capacity is insufficient; 2. The extrusion temperature is too low, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, the conveying capacity is reduced, and the energy consumption is increased.
솔루션: 1. Increase the screw speed appropriately (within the range suitable for the material) to improve the conveying capacity and production efficiency. The HTS series extruders can reach a maximum speed of 1000rpm, which can significantly improve production efficiency; 2. Properly increase the extrusion temperature to reduce the material viscosity, reduce the conveying resistance, and improve the conveying efficiency; 3. Adjust the combination of screw elements, increase the number of conveying elements, optimize the screw lead and compression ratio, and improve the conveying efficiency. The modular screw design of the HTS series extruders can realize the quick adjustment of screw elements; 4. Check and clean the feeding device regularly, ensure the smooth feeding, and adjust the feeding speed to match the screw speed, avoid insufficient feeding; 5. Regularly detect the wear degree of the screw and barrel, replace the worn components in time, and maintain the conveying capacity of the extruder, reducing energy consumption. 게다가, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% 일반 압출기에 비해.
6. Conclusion and Future Development Trend
엔지니어링 플라스틱, 핵심 고성능 소재로, are playing an increasingly important role in global industrial upgrading, and twin-screw extrusion technology is the core support for the high-quality processing of engineering plastics. The performance of extrusion equipment directly determines the quality, 엔지니어링 플라스틱 제품의 생산효율 및 응용효과. Our HTS series twin-screw extruders, HTS BASIC 포함, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, 고점도), with the advantages of high torque, 고속, 정확한 온도 조절, 우수한 내마모성, wide application range and intelligent control. They can provide targeted processing solutions for different types of engineering plastics and different scales of enterprises, helping enterprises solve processing difficulties, improve product quality and production efficiency, and enhance market competitiveness.
미래를 기대합니다, with the continuous upgrading of downstream industries such as automotive lightweight, electrical and electronic intelligence, new energy and medical high-endization, 고성능에 대한 요구, functional and environmentally friendly engineering plastics will continue to grow, which will also put forward higher requirements on twin-screw extrusion technology and equipment. The future development trend of engineering plastics twin-screw extruders will be mainly reflected in four aspects:
첫 번째, intelligence and digitalization. With the development of Industry 4.0, twin-screw extruders will be more integrated with intelligent technologies such as Internet of Things, big data and artificial intelligence. The HTS series extruders will further optimize the cloud control function, realize real-time monitoring, data analysis, predictive maintenance and intelligent adjustment of the entire production process, reduce labor intervention, and improve production efficiency and product consistency. 동시에, digital simulation technology will be widely used in the design and debugging of extruders, reducing the research and development cycle and debugging time of equipment.
두번째, high performance and high efficiency. The demand for high-end engineering plastics (PEEK와 같은, PI) will continue to increase, which will promote the continuous upgrading of extruder performance. The future extruders will have higher torque, higher speed and more precise temperature control capacity, and the key components (나사, 통, 변속 장치) will be further optimized to improve wear resistance, corrosion resistance and service life. 동시에, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.
제삼, customization and diversification. Different application fields and different products have increasingly personalized requirements for extrusion processing. The future extruders will adopt a more flexible modular design, which can quickly replace screw elements, die heads and other components according to customer needs, realizing the processing of multiple varieties and small batches. 동시에, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.
네번째, environmental protection and greenization. With the strengthening of global environmental protection policies, environmental protection will become an important development direction of extrusion equipment. The future extruders will adopt more environmentally friendly materials and manufacturing processes, reduce energy consumption and pollutant emissions; 동시에, they will be more compatible with recyclable engineering plastics and biodegradable engineering plastics, promoting the green development of the engineering plastics industry.
We will always adhere to the concept of technological innovation, focus on the development needs of the engineering plastics industry, continuously invest in research and development, optimize the performance of HTS series extruders, improve after-sales service, and provide more professional, efficient and intelligent twin-screw extrusion solutions for global engineering plastics processing enterprises, helping the high-quality development of the engineering plastics industry.