Nga Elastomers Hangarau (TPE), i etahi wa ka kiia ko te Rubbers Thermoplastic (TPR), he karaehe o te kapolymers, te ranunga tinana ranei o te polymers—te tikanga he kirihou me te rapa—e whakakotahi ana i nga ahuatanga o te thermoplastics me te elastomers.. Ma tenei huinga ahurei ka taea te tukatuka i nga TPE penei i te thermoplastics (mā te tangohanga, whakarewa werohanga, pupuhi pupuhi, etc.) i te wa e mau tonu ana te elasticity me te ngawari o nga rapa. Kaore i rite ki nga rapa puia, Ka taea te rewa me te tukatuka ano i nga TPE i nga wa maha kaore he mate nui o te mahi, kia pai ake te taiao me te whai hua. Ka rite ki te tono mo te ngawari, ngawari, me nga taonga hangarua ka tipu puta noa i nga umanga penei i te motuka, hiko, hangahanga, me nga taonga kaihoko, Kua kaha ake te rongonui o nga TPE, te taraiwa i te whakawhanaketanga o nga hangarau rangatira motuhake me nga hangarau tangohanga e rite ana ki o raatau whakaritenga tukatuka ahurei.
Masterbatch, hei rauemi matua mo te tae me te whakarereke mahi o nga TPE, he mahi nui ki te whakarei ake i te mahi me te whakawhänui i te horahanga tono o nga hua TPE. Ko te tukatuka o te TPE masterbatch me tika te whakahaere o te whakaranu, marara, me nga tawhā pāmahana, i te mea he pokey motuhake nga TPE, ātete wera, me nga ahuatanga elasticity he rereke ki nga kirihou tuku iho. Ko nga extruders mahanga, me o raatau kaha ki te whakaranu me te marara, mana pāmahana pū, me te urutau ki nga rauemi kanorau, kua waiho hei taputapu tukatuka matua mo TPE masterbatch. Zhuoyue, he kaihanga ngaio o extruders twin-screw, e tuku ana i te katoa o nga otinga tangohanga matatau i hangaia mo te whakakotahitanga TPE me te tukatuka masterbatch, e hipoki ana i te TPE / SBS / TPU / TPR / TPV me etahi atu waahanga TPE nui, ki te whakatutuki i nga hiahia rereke o nga kaihanga i roto i nga ahumahi rereke.
1. Tirohanga o te Thermoplastic Elastomers (TPE): Ngā Kāwai, Ngā Āhuatanga me ngā Āhuatanga Matua
Ko nga TPE he whanau kanorau o nga rawa, ka whakarōpūtia kia ono ngā kāwai arumoni whānui i runga i te hanganga matū me te hanganga. He āhuatanga ahurei kei ia kāwai, āhuatanga tukatuka, me nga mara tono, e whakatau tika ana i nga whakaritenga mo te hanga masterbatch me nga taputapu tangohanga. Ko te maarama ki te whakarōpūtanga me nga ahuatanga o nga TPE te turanga mo te arotau i te tukatuka masterbatch me te whiriwhiri i nga extruders mahanga-screw pai..
1.1 E ono nga waahanga hokohoko whanui o nga TPE
1.1.1 Styrenic Block Copolymers (TPS, TPE-s).
Ko TPS te waahanga e whakamahia nuitia ana mo nga TPE, te kaute mo te waahanga nui o te maakete TPE o te ao. He poraka styrenic kei roto (penei i te polystyrene, PS) me nga poraka elastomeric (penei i te polybutadiene, PB; polyisoprene, PI; ethylene-butylene ranei, EB), honoa e nga here kovalent. Ko nga momo TPS tino noa ko SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), me SEPS (Styrene-Ethylene-Propylene-Styrene).
Ko nga ahuatanga matua o TPS ko te tino ngawari, te elasticity, me te kaha ki te tukatuka. SEBS me SEPS, he putanga hauwai o SBS me SIS, kua pai ake te parenga wera, ātete huarere, me te ātete tawhito, kia pai ai mo nga tono o waho me te pāmahana teitei. He ngawari te tae o nga taonga TPS me te whakarereke me te masterbatch, me o ratou pāmahana tukatuka mai i te 150 ℃ ki te 220 ℃, he hototahi ki te nuinga o nga extruders mahanga-screw. Ko nga tono noa o te TPS ko nga waahanga miihini, waea me nga taura, taonga kaihoko, me nga taputapu rongoa.
1.1.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o).
Ko te TPO he ranunga tinana o te polyolefin (penei i te polypropylene, PP; polyethylene ranei, PE) me te elastomer (pēnei i te monomer ethylene-propylene-diene, EPDM). Ka whakakotahi i te rigidity o polyolefins me te elasticity o te elastomers, a he tino pai te aukati matū, ātete huarere, me te ngawari o te pāmahana iti. Ko nga TPO kaore he paitini, haungakore, me te hangarua, kia pai ai mo nga tono e hiahia ana kia pai te taiao.
Ko te pāmahana tukatuka o TPO mai i te 160 ℃ ki te 230 ℃, a he pai te hototahi ki nga momo masterbatches (huinga matua tae, masterbatch aukati mura, etc.). Ka whakamahia nga TPO ki nga waahanga o waho o nga motuka (penei i nga uhi parepare, riipene whariki), taonga hanga (penei i nga kekeno, pūmau), me nga waahanga hiko. Na to ratou ihirangi polyolefin teitei, Ko te tukatuka masterbatch TPO e hiahia ana ki nga extruders me te pai o te whakauru ki te whakarite i te marara o nga poaka me nga taapiri..
1.1.3 Ngaaariki Vulcanizates (Taake, TPE v).
Ko te TPV he whakakotahitanga whakaraerae o te polyolefin (te tikanga PP) me te elastomer (ko te tikanga EPDM). I te wa e tukatuka ana, ko te wahanga elastomer ka whakaraerae ki nga matūriki iti ka marara rite i roto i te matrix polyolefin, hua i roto i te elasticity pai, te atete huinga huinga, me te parenga wera. He pai ake nga ahuatanga miihini me te pumau o te taha o nga TPV i nga TPE tawhito, a ka taea e ia te tu atu mo te wa roa mo te wa roa (ki te 150 ℃).
Ko te tukatuka TPV e hiahia ana kia tika te whakahaere i te pāmahana me te kaha kutikuti hei whakarite i te whakarara me te whakamararatanga. Ko te pāmahana tukatuka mai i te 170 ℃ ki te 240 ℃, me te mea he nui te pokey i te wa e tukatuka ana, e whakatakoto ana i nga whakaritenga nui ki runga i te taipana me te mau atete o nga extruders mahanga. Ka whakamahia nuitia nga TPV ki nga hiri miihini, ngongo ngongo, pūmau, me nga waahanga ahumahi e hiahia ana ki te mahi nui me te roa.
1.1.4 Polyurethanes Thermoplastic (TPU).
Ko te TPU he copolymer poraka he waahanga uaua (diisocyanate me te whakaroa mekameka) me nga waahanga ngawari (polyol). He tino pai te elasticity, ātete abrasion, ātete hinu, me te kaha miihini, a ka taea te whakatika i te pakeke mai i te ngawari rawa (Takoto A 30) ki tino uaua (Takutai D 85) mā te huri i te ōwehenga o ngā wāhanga mārō me ngā wāhanga ngohe.
Ko te tukatuka TPU he ngawari ki te mahana me te makuku. Ko te pāmahana tukatuka mai i te 180 ℃ ki te 250 ℃, a me tino whakamaroke nga mea i mua i te tukatuka (makuku ≤0.05%) hei karo i te hauwai me te hanga mirumiru. Ko te tukatuka masterbatch TPU e hiahia ana ki nga extruders me te whakahaere i te pāmahana tika me te kaha o te whakapau korehau.. Kei te whakamahia nuitia te TPU ki nga waea me nga taura, ngongo waka, hu, ngongo rongoa, me nga taputapu hakinakina.
1.1.5 Ngaaariki Copolyesters (TPC, TPE-E).
Ko te TPC he kapolymer paraka i titoa mai i nga waahanga maariki polyester me nga waahanga ngawari polyether, polyester ranei.. He tino pai te parenga wera, ātete matū, me nga ahuatanga miihini, a ka taea e ia te tu atu ki te wera teitei ki te 150 ℃ mo te wa roa. He pai te ngawari me te ngawari o nga TPC, kia pai ai mo nga tono mahi teitei.
Ko te pāmahana tukatuka o TPC mai i te 220 ℃ ki te 280 ℃, he teitei ake i era atu waahanga TPE. He pokey teitei i te wa e tukatuka ana me te hiahia ki nga extruders me te taipana teitei me te mana o te pāmahana. Ko te tukatuka masterbatch TPC me aro nui ki te marara o nga poaka me nga taapiri kia kore ai e pa ki nga taonga miihini o nga rawa.. Ka whakamahia nga TPC ki nga waahanga miihini (penei i nga ngongo whakauru hau, hiri tuku), nga waahanga rererangi, me nga miihini ahumahi.
1.1.6 Polyamides Thermoplastic (TPA, TPE-A).
Ko te TPA he copolymer poraka i titoa mai i nga waahanga pakeke polyamide me nga waahanga ngohengohe polyether. Ka whakakotahi i te kaha teitei, kakahu ātete, me te aukati matū o nga polyamides me te ngawari me te ngawari o nga polyeter. He pai te atete a te TPA me te mahi iti o te pāmahana, a ka taea te whakamahi i nga taiao kino.
Ko te pāmahana tukatuka o TPA mai i te 230 ℃ ki te 290 ℃, a he nui tona momi wai, requiring thorough drying before processing. TPA masterbatch processing requires extruders with high wear resistance (due to the high hardness of polyamide) and precise temperature control to avoid material degradation. TPA is widely used in automotive components (penei i nga taputapu, puri), tūhono hiko, 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. Ko te kaikawe o te masterbatch kia pai te hototahi ki te TPE, a me whakarite e te kai whakamarara te marara rite o nga poaka me te kore e hanga agglomerates ka taea te kukū te ahotea me te whakaiti i te ngawari..
1.2.2 Parenga Wera.
He rereke te wera o nga waahanga TPE rereke (te pāmahana tukatuka mai i 150 ℃ ki 290 ℃). Ko nga poaka Masterbatch me nga taapiri me whai wera wera kia rite ki te pāmahana tukatuka TPE kia kore ai e pirau, te paheketanga, te paheketanga ranei o te mahi i te wa o te tangohanga. Hei tauira, Ko te TPC me te TPA e hiahia ana ki nga poaka aatete-nui me te whakapumau wera.
1.2.3 Viscosity and Processability.
He rereke nga pokey o nga TPE i te wa e tukatuka ana (Ko te TPV me te TPC he pokey teitei ake, i te TPS he iti te pokey). This affects the shear force and conveying requirements of the twin-screw extruder. High-viscosity TPEs require extruders with high torque and strong mixing capabilities, while low-viscosity TPEs require precise control of extrusion speed to avoid material overflow.
1.2.4 Moisture Absorption.
Some TPEs (such as TPU, TPA) he nui te momi wai, which can cause bubbles, hydrolysis, and other defects in the masterbatch. The raw materials (TPE, pigments, tāpiritanga) must be thoroughly dried before processing, and the extruder should be equipped with a vacuum exhaust device to remove moisture and volatile substances.
1.2.5 Compatibility with Additives.
TPEs often require functional additives (such as antioxidants, Whakapumau UV, whakahinuhinu) to improve their performance. The masterbatch should be formulated to ensure that the additives are compatible with both the pigments and the TPE matrix, te karo i nga tauhohenga matū ka pa ki te kounga o te hua.
2. Masterbatch mo nga TPE: Te tito, Whakaritenga Whakaritenga me te Tukatuka
Ko te Masterbatch mo nga TPE he ranunga whakakoi o nga poaka/waikano, kaikawe, me nga taapiri, i hangaia ki te tae i nga TPE me te tuku atu i nga mahi (penei i te mura o te mura, antistatic, paturopi) i te wa e mau tonu ana nga taonga rapa me te tukatuka o nga rawa. Ko te hanga me te tukatuka o TPE masterbatch he nui ake te tono atu i era mo nga kirihou tuku iho, na nga ahuatanga ahurei o nga TPE. Ko tenei waahanga he korero mo te hanganga, tikanga hanga, me nga whakaritenga tukatuka o TPE masterbatch.
2.1 Tito Matua o TPE Masterbatch
Pērā i te masterbatch tuku iho, E toru nga waahanga matua o TPE masterbatch: nga karaehe/waikano, kaikawe, me nga taapiri. Ko te kowhiringa me te wahanga o ia waahanga ka whakangao ki te momo TPE me ona whakaritenga tono.
2.1.1 Pigments/Wakano.
Ko nga pigments/waikano nga waahanga matua e tuku tae ana ki nga TPE, kaute mo 10%-70% o te titonga masterbatch (i runga i te kaha o te tae me te momo TPE). Ko nga whakaritenga matua mo nga poaka/waikano i roto i te TPE masterbatch ko:
- – Parenga Wera: Me tu ki te pāmahana tukatuka o te TPE ūnga (150℃-290℃) me te kore he pirau, he rereke ranei te tae. Mo nga TPE teitei (TPC, TPA), he pai ake nga whakangau pararopi aatete ki te pāmahana teitei, ki nga poaka pararopi ranei.
- – Hototahi: Me hototahi ki te matrix TPE kia kore ai e heke, e pua ana, kua whakahekehia ranei te elasticity. Ko nga pigments e rite ana ki te polarity ki te TPE he pai ake te hototahi (e.g., poaka polar mo te TPU, poaka kore-polar mo TPS).
- – Te whakamararatanga: Me ngawari te marara ki roto i te TPE matrix kia rite te tae me te karo i nga waahi tae, korikori, kua whakahekehia ranei nga taonga miihini. Pika matūriki pai (20-40 mata) ki te iti agglomeration pai ake.
- – Te Taiao: Me tutuki nga paerewa tiaki taiao o te ao (penei i te REACH, RoHS) ki te karo i nga mea paitini, kino ranei (penei i nga konganuku taumaha) tera pea ka pa ki te hauora o te tangata me te taiao.
Ko nga poaka noa e whakamahia ana i roto i te TPE masterbatch kei roto: whakangao parakore (titanium hauhā mo te ma, waro pango mo te pango, te waikura rino mo te whero/kowhai), me nga poaka pararopi e atete ana ki te pāmahana teitei (phthalocyanine puru/matomato, quinacridone whero).
2.1.2 Kaikawe.
Ko nga kaikawe te matrix o te masterbatch, kaute mo 20%-80% o te titonga, me te whai waahi nui ki te whakamarara i nga poaka me te piri ki te matrix TPE. Me tino pai te hototahi o te kaikawe ki nga poaka e rua me te TPE whainga, i te mea he ngoikore te hototahi ka arahi ki te heke o te pigment, tae koretake, me te whakaheke i te mahi TPE. Ko te whiriwhiringa o te kaikawe kei runga i te momo TPE:
- – Mo TPS (SBS, SEBS): Whakamahia te TPS, te PP ranei hei kaikawe, he pai te hototahi me te wīwī tukatuka.
- – Mo TPO/TPE-o: Whakamahia te PP, te PE ranei hei kawe, he rite ki te waahanga polyolefin o te TPO.
- – Mo TPV/TPE-v: Whakamahia te PP hei kawe, he hototahi ki te PP matrix o te TPV.
- – Mo te TPU: Whakamahia te TPU hei kawe, te whakarite i te hototahi ki te matrix TPU me te karo i te hauwai.
- – Mo TPC/TPE-E me TPA/TPE-A: Whakamahia te TPC, te TPA ranei hei kaikawe, ia, kia rite ki nga whakaritenga tukatuka teitei me te hototahi.
Ko te kaikawe kia pai hoki te rere o te tukatuka, me te ira whakarewa me te pāmahana tukatuka e rite ana ki te iti iho ranei i te TPE i whaaia, hei whakarite i te whakakotahitanga orite me te karo i te paheketanga o te TPE.
2.1.3 Nga taapiri.
Ko nga taapiri he waahanga awhina kua taapirihia hei whakapai ake i te mahi tukatuka, whakamararatanga, me te mahinga mahi a te TPE masterbatch, kaute mo 1%-10% o te titonga. Ko te momo me te inenga o nga taapiri ka whakatauhia e te momo TPE me nga whakaritenga tono:
- – Nga Whakarara: Ko te taapiri tino nui mo TPE masterbatch, whakamahia ki te whakaiti i te ahotea o te mata, aukati i te agglomeration, me te whakarite kia marara rite i roto i te matrix TPE. Ko nga marara noa ko te wax polyethylene, waki polypropylene, waikawa stearic, me nga waxes anhydride maleic i honoa. Mo nga TPE tino-nui (Taake, TPC), he pai ake nga dispersants tino kaha me te hototahi kaha.
- – Kaiwhakariterite: Ka whakamahia hei whakapai ake i te hototahitanga i waenga i nga poaka me nga TPE, me waenganui i te masterbatch me te TPE matrix. Hei tauira, maleic anhydride honoa PP ka whakamahia hei hototahi mo te masterbatch TPO, ka whakamahia te wax polyurethane mo TPU masterbatch.
- – Pūmau Wea: Ka whakamahia hei aukati i te paheketanga o te poaka me te paheketanga o te TPE i te wa e tukatuka ana te pāmahana teitei. Ko nga whakapumau wera noa ko nga whakapumau tine pararopi (mo TPU), te aukati i nga antioxidants phenol (mo TPS, TPO), me nga antioxidants phosphite (mo TPC, TPA).
- – Ko nga Whakapumau UV me nga Antioxidants: Ka whakamahia hei whakapai ake i te parenga huarere me te atete tawhito o nga hua TPE tae, te aukati i te memenge tae me te paheketanga o te mahi i raro i te ra me te hāora. Mo nga tono o waho (penei i nga waahanga o waho motuka), Ko nga kaihoroi UV me nga whakapumau marama amine (HALS) ka tapiritia.
- – Whakahinuhinu: Ka whakamahia hei whakaiti i te waku i waenga i nga rawa me nga taputapu tangohanga (tīwiri, oko, matenga mate), whakapai ake i te rere o te tukatuka, me te karo i nga taonga e piri ana ki nga taputapu. Ko nga whakahinuhinu noa ko te waikawa stearic, konupūmā stearate, 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 (mo nga waahanga hiko), 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, pigments, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, ngawari, me nga ahuatanga miihini. Hei tauira, 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. Hei tauira, 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. Hei tauira, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Tautukunga Tiaki Taiao.
Me tutuki te hanganga ki nga paerewa tiaki taiao o te ao, te karo i nga mea paitini, kino ranei (penei i nga konganuku taumaha, phthalates) ka taea te aukati i te uru ki te maakete.
2.3 Nga Whakaritenga Tukatuka o TPE Masterbatch
Ko te tukatuka masterbatch TPE te nuinga o te whakahaere ma te whakamahi i te hangarau tangohanga mahanga, e hiahia ana kia kaha te whakahaere i te maimoatanga o mua, premixing, tawhā extrusion, me te tukatuka i muri mai hei whakarite i te kounga o nga hua. Ko nga whakaritenga tukatuka matua e whai ake nei:
2.3.1 Rawa Rawa Maamaa.
Nga TPE (rawa TPU, TPA) he nui te momi wai, na nga rauemi mata katoa (Kaikawe TPE, pigments, tāpiritanga) must be thoroughly dried before processing. Ko te pāmahana me te wa whakamaroke ka whakatauhia e te momo rauemi: Ka whakamarokehia te TPU/TPA ki te 100-120 ℃ mo 6-8 haora, Ka whakamarokehia te TPS/TPO ki te 80-100 ℃ mo 3-5 haora, ka whakamarokehia nga poaka ki te 60-80 ℃ mo 2-4 haora. Ko te makuku o nga rauemi mata maroke me whakahaere i raro nei 0.1% (0.05% mo TPU/TPA).
I tua atu, ko nga poaka he nui te rahi o te matūriki me te agglomerates me kuru, ka tatari (20-40 mata) hei whakapai ake i te mararatanga, me nga poke (matūriki whakarewa, puehu) me tango kia kore e mau ki nga taputapu tangohanga me nga koha o te masterbatch.
2.3.2 Whakaranu-mua.
Ko nga rauemi mata maroke (pigments, kaikawe, tāpiritanga) ka konatunatua ki te whakaranu tere-tere kia rite ki te ōwehenga tātai hei hanga i te ranunga tuatahi. Ko nga tawhā premixing ka whakatikahia i runga i te momo TPE: tere whakaranu 800-1200 rpm, te wa whakaranu 5-10 meneti, te pāmahana whakaranu 40-60 ℃. Mo nga kaikawe rangatira nui-nui, ki nga kaikawe TPE-nui ranei, kua roa te wa whakaranu, a ka tapirihia nga mea whakamarara i te tuatahi ki te whakakakahu i nga poaka, te whakapai ake i te mararatanga.
2.3.3 Mana Tawhā Tangohanga.
Ko te tangohanga mahanga-rua ko te taahiraa matua o te tukatuka masterbatch TPE, me nga tawhā matua (pāmahana, tere tīwiri, pehanga tangohanga, tere whangai) must be precisely controlled to match the TPE type:
- – Te Mana Mana: The barrel is divided into 4-6 nga waahanga whakahaere pāmahana (wahanga whangai, wahanga rewa, wahanga ranu, wāhanga homogenizing, die head section). The temperature of each section is adjusted according to the TPE processing temperature. Hei tauira, 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.
- – Tere Tiu: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. High-viscosity TPEs (Taake, TPC) require higher screw speed (500-800 rpm) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 rpm) to avoid material overflow.
- – Pehenga Tangohanga: 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. Mo nga TPE tino-nui, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (particle size 2-5mm), screened (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, hiko, hangahanga, taonga kaihoko, me etahi atu ahumahi, and different application fields have different requirements for TPE masterbatch performance (tae, whakamararatanga, functionality) and production efficiency. Zhuoyue’s full series of twin-screw extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) are specially optimized for TPE masterbatch processing, providing targeted solutions for different TPE categories and application fields. Below is a detailed introduction to the main application fields of TPE masterbatch and the matching Zhuoyue extruder series.
3.1 Ahumahi Automotive: The Largest Application Field of TPE Masterbatch
Ko te umanga miihini te kaihoko nui rawa atu o nga TPE, kaute mo neke atu i te 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, ngawari, 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.
Nga TPE (mainly TPV, TPO) are used to produce automotive door seals, hiri matapihi, hood seals, me nga peeke, which require good elasticity, ātete huarere, me te ngawari o te pāmahana iti. The masterbatch for these components requires uniform coloring, good weather resistance (ātete UV, 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 (pokey teitei, high shear force required); ko te raupapa HTE e whakauru ana i nga mahi teitei me te whai hua-utu, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
Nga TPE (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, awhi tatau, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (kore-paitini, haungakore). 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.
Nga TPE (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, ātete wera, me te kaha miihini. The masterbatch requires high-temperature resistance, ātete hinu, 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, mana pāmahana pū, and high wear resistance, suitable for TPC/TPA masterbatch processing (teitei te pāmahana, pokey teitei); 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, mārama, parenga paanga). 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, tūhonohono, me etahi atu waahanga, requiring functional masterbatch (antistatic, whakapuru mura, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
Nga 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, te mura o te mura, me te aukati abrasion. The masterbatch requires flame retardancy (meeting UL94 V-0 paerewa), āhuatanga antistatic, and uniform coloring.
Matching Extruders: HTS PLUS series, HTE raupapa, 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.
Nga TPE (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, parenga paanga, 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 Hangahanga me te Ahumahi Waka: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, me etahi atu waahanga, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
Nga TPE (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, ātete UV, 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, me te mau atete. 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.
Nga TPE (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, ātete abrasion, 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, taonga takaro, and other household items, which require non-toxic, haungakore, 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 Nga taputapu rongoa.
Nga TPE (mainly TPU, TPS) are used to produce medical catheters, syringes, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 paerewa), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, mana pāmahana pū, 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, kakahu ātete, me te kaha miihini. 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, whanaketanga, 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 (pokey teitei, 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, me te raupapa HTE. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, kaikawe, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
I tua atu, the screws adopt a modular design, which can freely combine different screw elements (tuku, whakaranu, kutikuti hipi) according to the TPE type. Hei tauira, 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, me 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%. Hei tauira, 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, me te tiaki matapae, realizing intelligent production management.
4.1.7 Wide Adaptability.
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 (huinga matua tae, masterbatch aukati mura, te roopu matua antistatic), with pigment content ranging from 10% ki 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, tauine whakaputa, me nga whakaritenga tono.
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, mana pāmahana aunoa, me te whangai, 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 (Taake, TPU, high-concentration TPE masterbatch, masterbatch aukati mura). 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 (pokey teitei, 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 (whakapuru mura, 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, nga taputapu rongoa).
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, hangaia mo teitei-mutunga, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, me te tiaki matapae. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 ZTE Series: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, iti kohi pūngao, me te utu tiaki iti, 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, na nga ahuatanga ahurei o nga TPE (temperature sensitivity, moisture absorption, pokey teitei), 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) Whakaranu-mua: 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) Taputapu: Worn screw mixing elements; blocked die head.
Nga otinga: (1) Optimize raw materials: Select fine-particle pigments (20-40 mata), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 meneti. (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 (nui atu i 3 meneti) 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).
Nga otinga: (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: Te mau o te Tiu me te Paera
Manifestation: He tere te mau o te tīwiri me te oko, kua heke te kaha kutikuti me te kaha ranu; ka heke te mararatanga masterbatch, ka piki ake te utu tiaki taputapu.
Causes: (1) Raw materials: Pika-pakeke/whakapiri (penei i te waro pango, titanium hauhā); rahi matūriki nui. (2) Extrusion parameters: tere tīwiri teitei, te kaha kutikuti; pehanga extrusion teitei. (3) Taputapu: He ngoikore te aatete ki te kakahu o nga mea o te wiu/paera.
Nga otinga: (1) Optimize raw materials: Tīpakohia te matūriki iti, nga pigments iti-pakeke; kuru me te tatari i nga rauemi mata; tāpiri hinu hei whakaiti i te waku. (2) Whakaritea tawhā: Whakaititia te tere tīwiri me te pēhanga tangohanga tika. (3) Tīpakohia nga taputapu kaakahu teitei: Kōwhiria te raupapa HTS PLUS/SUPER/HTE a Zhuoyue me te hiato bimetallic me nga hiu/paera whakakakahuria taiaho ranei.
5.4 Problem 4: Mirumiru i roto i te Masterbatch
Manifestation: Nga mirumiru kei roto i nga matūriki matua, e pa ana ki te kiato hua me nga ahuatanga miihini; Ko nga hua TPE he pores me nga hapa.
Causes: (1) Raw materials: Te nui o te makuku (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Whakaranu-mua: Air mixed into the mixture during premixing.
Nga otinga: (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); te ihirangi pigment teitei (nui atu i 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Taputapu: Worn conveying elements; blocked die head.
Nga otinga: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Whakaritea tawhā: 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, me nga mara tono, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Take 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, Haina, 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), ātete wera (260℃), and batch stability. The original equipment had problems of insufficient torque, te mana pāmahana kore, and poor dispersibility, which could not meet the requirements.
Rongoā: Zhuoyue recommended the HTS SUPER series extruders (tīwiri 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: Tuatahi, 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. Tuarua, the barrel is equipped with a double-layer jacket + forced cooling structure, me 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. Tuatoru, 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. I tua atu, 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: I muri 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 marama, 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 Take 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, Haina, 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), ātete wera (260℃), and batch stability. The original equipment had problems of insufficient torque, te mana pāmahana kore, and poor dispersibility, which could not meet the requirements.
Rongoā:
Zhuoyue recommended the HTS SUPER series extruders (tīwiri 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: Tuatahi, 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. Tuarua, the barrel is equipped with a double-layer jacket + forced cooling structure, me 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. Tuatoru, 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. I tua atu, 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:
I muri 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 marama, 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.