Engineering Plastics Geavanceerde dubbelschroefsextrusietechnologie Verwerkingsoplossingen en industriële toepassingen

Met de snelle vooruitgang van de mondiale industrialisatie, de vraag naar hoogwaardige materialen in de automobielsector, elektrisch en elektronisch, bouw, medische en andere terreinen neemt met de dag toe. Technische kunststoffen, als een belangrijk hoogwaardig materiaal, hebben in veel kerntoepassingsscenario's geleidelijk de traditionele metalen materialen en algemene kunststoffen vervangen vanwege hun uitstekende mechanische eigenschappen, hittebestendigheid, corrosiebestendigheid, maatvastheid en verwerkbaarheid. Extrusietechnologie met dubbele schroef is de kernverwerkingstechnologie van technische kunststofverbindingen, en de prestaties van extrusieapparatuur bepalen rechtstreeks de kwaliteit, productie-efficiëntie en toepassingseffect van technische kunststofproducten.

Wij streven ernaar professionele dubbelschroefsextrusieoplossingen te bieden voor de verwerking van technische kunststoffen, vertrouwend op onze onafhankelijk ontwikkelde en vervaardigde extruders uit de HTS-serie met versnellingsbakken met hoog koppel, die speciaal zijn ontworpen voor de verwerkingseigenschappen en toepassingsbehoeften van technische kunststoffen. In dit artikel worden de prestatiekenmerken uitgebreid toegelicht, classificatie, verwerkingsproblemen van technische kunststoffen, de kernrol van dubbelschroefsextrusietechnologie bij de verwerking van technische kunststoffen, de voordelen van onze extruders uit de HTS-serie en hun gerichte aanpassing aan technische kunststoffen, evenals de specifieke toepassingsgebieden, verwerkingstechnieken en veelvoorkomende problemen en oplossingen. Door gedetailleerde technische parameters aan te vullen, verwerkingsgegevens en industriële toepassingsgevallen, het artikel zal worden verrijkt 3000-4000 woorden, het bieden van uitgebreide en professionele referentie voor technische kunststofverwerkende bedrijven, technici en relevante praktijkmensen.

1. Overzicht van de technische kunststofindustrie en kernprestatiekenmerken

1.1 Huidige situatie en ontwikkelingstrend van de engineering plastics-industrie

Technische kunststoffen verwijzen naar een klasse kunststofmaterialen die kunnen worden gebruikt als structurele materialen en mechanische belastingen kunnen dragen in een breed temperatuurbereik. Vergeleken met algemene kunststoffen (zoals polyethyleen PE, polypropyleen PP, polyvinylchloride PVC), technische kunststoffen hebben uitstekende uitgebreide prestaties, en kan voldoen aan de zware gebruikseisen in de industriële productie en productie van hoogwaardige producten. De afgelopen jaren, gedreven door de modernisering van downstream-industrieën, zoals de lichtgewicht auto-industrie, elektrische en elektronische intelligentie, en high-endisatie van medische apparatuur, de mondiale markt voor technische kunststoffen heeft een gestage en snelle groeitrend laten zien.

Volgens relevante branchegegevens, de mondiale omvang van de markt voor technische kunststoffen is groter geworden 100 miljard dollar, en er wordt verwacht dat het een samengesteld jaarlijks groeipercentage van 7%-10% in de komende vijf jaar. Onder hen, Azië-Pacific is 's werelds grootste productie- en consumptiemarkt voor technische kunststoffen, goed voor meer dan 55% van het mondiale marktaandeel, voornamelijk als gevolg van de snelle ontwikkeling van de automobielsector, elektrische en elektronische industrie in China, India en andere landen, evenals de voortdurende verbetering van de industriële ondersteunende capaciteit en het technologische innovatieniveau. China, als 's werelds grootste consument en producent van technische kunststoffen, heeft een enorme marktvraag, en de jaarlijkse productie en consumptie groeien met dubbele cijfers, vooral op het gebied van nieuwe energievoertuigen, 5G-communicatie, en medische apparaten, de vraag naar hoogwaardige technische kunststoffen vertoont een explosieve groeitrend.

De ontwikkelingstrend van de technische kunststofindustrie komt voornamelijk tot uiting in vijf aspecten: Eerst, hoge prestaties en functionaliteit. Met de voortdurende verbetering van de gebruikseisen in stroomafwaartse velden, technische kunststoffen ontwikkelen zich in de richting van een hogere hittebestendigheid, hogere sterkte, betere slijtvastheid en speciale functies (zoals vlamvertraging, antistatisch, antibacterieel, straling weerstand), aan te passen aan de zware werkomgeving van hoge temperaturen, hoge druk, corrosie en straling; seconde, lichtgewicht en integratie. In de automobielsector, ruimtevaart en andere gebieden, om de doelstellingen op het gebied van energiebesparing en emissiereductie te bereiken, technische kunststoffen worden steeds vaker gebruikt ter vervanging van metalen materialen, en de integratie van productontwerp wordt steeds hoger, waardoor het aantal onderdelen kan worden verminderd, vereenvoudig het productieproces en verlaag de kosten; derde, milieubescherming en recycleerbaarheid. Met de versterking van het mondiale milieubeschermingsbeleid en de verbetering van het bewustzijn over milieubescherming, de ontwikkeling en toepassing van recycleerbare technische kunststoffen, biologisch afbreekbare technische kunststoffen en milieuvriendelijke verwerkingstechnologieën zijn de focus van de industrie geworden, het terugdringen van de milieuvervuiling veroorzaakt door plastic afval; vierde, intelligentie en precisie van verwerkingsapparatuur. Technische kunststoffen hebben een hoge verwerkingsmoeilijkheid en strenge kwaliteitseisen, die hogere eisen stellen aan verwerkingsapparatuur. Intelligent, nauwkeurige en efficiënte dubbelschroefsextruders en automatische productielijnen zijn de mainstream van de industrie geworden, real-time monitoring realiseren, automatische parameteraanpassing en voorspellend onderhoud van het verwerkingsproces; vijfde, diversificatie van toepassingsgebieden. Technische kunststoffen breiden zich geleidelijk uit vanuit de traditionele automobielsector, elektrische en elektronische velden naar nieuwe energie, medisch, ruimtevaart, bouw en andere opkomende gebieden, het openen van nieuwe marktruimte.

Tegen deze achtergrond, extrusietechnologie met dubbele schroef, als de kernverwerkingstechnologie van technische kunststofverbindingen, is de sleutel geworden tot het verbeteren van het concurrentievermogen van industriële kunststofbedrijven. Technische kunststoffen zijn gevoelig voor oververhitting en hydrolytische afbraak, en stellen hoge eisen aan de verwerkingstemperatuur, schuifkracht, verblijftijd en nauwkeurigheid van de temperatuurregeling. Onze extruders uit de HTS-serie zijn speciaal ontworpen voor de verwerkingseigenschappen van technische kunststoffen, met hoog koppel, hoge snelheid, nauwkeurige temperatuurregeling en uitstekende dispergeerbaarheid, die de verwerkingsproblemen van technische kunststoffen effectief kunnen oplossen en bedrijven kunnen helpen hoogwaardige kwaliteit te bereiken, efficiënte en stabiele productie.

1.2 Kernprestatiekenmerken van technische kunststoffen

Vergeleken met algemene kunststoffen en metalen materialen, technische kunststoffen hebben unieke uitgebreide prestaties, wat hun brede toepassing op verschillende industriële gebieden bepaalt. De kernprestatiekenmerken van technische kunststoffen worden voornamelijk weerspiegeld in de volgende vijf aspecten, die ook speciale eisen stellen aan hun verwerkingstechnologie en uitrusting:

1.2.1 Uitstekende hittebestendigheid en koudebestendigheid

Technische kunststoffen hebben een breed temperatuuraanpassingsbereik, die goede mechanische eigenschappen kan behouden (kracht, taaiheid, hardheid) in zowel hoge als lage temperatuuromgevingen. Vergeleken met algemene kunststoffen, die gewoonlijk hun mechanische eigenschappen verliezen bij 80-120 ℃, de meeste technische kunststoffen kunnen stabiel werken bij 100-250 ℃, en enkele speciale technische kunststoffen (zoals PEEK, PI) kan zelfs werken bij temperaturen boven 300℃. Tegelijkertijd, technische kunststoffen hebben ook een goede koudebestendigheid, die bij lage temperaturen een goede taaiheid kunnen behouden (onder -40℃), en zijn niet gemakkelijk te brosse breuken. Deze prestatie maakt technische kunststoffen geschikt voor gebruik in omgevingen met barre temperaturen, zoals automotoronderdelen (hoge temperatuur) en elektrische apparatuur voor buiten (lage temperatuur).

De uitstekende hittebestendigheid van technische kunststoffen is voornamelijk te danken aan hun speciale moleculaire structuur (zoals aromatische ringen, heterocyclische ringen) en sterke intermoleculaire krachten, waardoor ze niet gemakkelijk smelten en ontleden bij hoge temperaturen. Echter, dit brengt ook bepaalde moeilijkheden met zich mee voor de verwerking: Er is een hogere verwerkingstemperatuur nodig om ze te laten smelten en weekmaken, en nauwkeurige temperatuurregeling is nodig om thermische ontleding te voorkomen.

1.2.2 Goede corrosiebestendigheid en duurzaamheid

Technische kunststoffen hebben een uitstekende chemische stabiliteit en corrosieweerstand, en zijn niet gemakkelijk te corroderen door zuren, alkaliën, zouten, organische oplosmiddelen en andere chemicaliën. Vergeleken met metalen materialen, die gemakkelijk roesten en corroderen, technische kunststoffen hebben een langere levensduur in agressieve chemische omgevingen. Bijvoorbeeld, polyamide (PA) technische kunststoffen zijn bestand tegen de meeste organische oplosmiddelen en zwakke zuren en alkaliën; polycarbonaat (PC) technische kunststoffen zijn bestand tegen corrosie door niet-oxiderende zuren en zouten; polyfenyleensulfide (PPS) technische kunststoffen zijn bestand tegen corrosie door bijna alle chemicaliën, behalve sterk oxiderende zuren.

In aanvulling, technische kunststoffen hebben een goede weersbestendigheid en verouderingsbestendigheid, en zijn niet gemakkelijk af te breken en te verouderen onder invloed van zonlicht, regen, zuurstof en andere omgevingsfactoren, wat hun langdurig stabiel gebruik in buiten- en ruwe omgevingen garandeert. Deze prestaties zorgen ervoor dat technische kunststoffen op grote schaal worden gebruikt in chemische apparatuur, elektrische apparatuur voor buiten, auto-exterieuronderdelen en andere gebieden.

1.2.3 Eenvoudige verwerking en hoge productie-efficiëntie

Vergeleken met metalen materialen, technische kunststoffen hebben de voordelen van eenvoudige verwerking, eenvoudig productieproces en hoge productie-efficiëntie. Metalen materialen hebben meestal complexe verwerkingsprocedures nodig, zoals smeden, gieten, bewerking, die een hoog energieverbruik hebben, laag rendement en hoge kosten; terwijl technische kunststoffen kunnen worden verwerkt door extrusie, spuitgieten, blaasvormen en andere methoden, die massaproductie kan realiseren, vereenvoudigen het productieproces, verminderen het energieverbruik en de productiekosten. Bijvoorbeeld, de verwerkingscyclus van een technisch kunststof auto-onderdeel door middel van spuitgieten bedraagt ​​slechts enkele seconden tot tientallen seconden, terwijl de verwerkingscyclus van hetzelfde metalen onderdeel enkele uren tot meerdere dagen kan duren.

Echter, technische kunststoffen hebben ook bepaalde verwerkingsproblemen: ze zijn gevoelig voor oververhitting en hydrolytische afbraak, en zijn gemakkelijk te ontleden als de verwerkingstemperatuur te hoog is of de verblijftijd te lang is; tegelijkertijd, sommige technische kunststoffen (zoals PA) hebben een hoge wateropname, wat het verwerkingseffect en de productkwaliteit beïnvloedt. Daarom, het is noodzakelijk om professionele verwerkingsapparatuur en wetenschappelijke verwerkingstechnieken te gebruiken om de verwerkingskwaliteit te garanderen.

1.2.4 Uitstekende maatvastheid en elektrische isolatie

Technische kunststoffen hebben een goede maatvastheid, en de krimpsnelheid is klein (gebruikelijk 0.3%-1.5%) tijdens verwerking en gebruik, die de maatnauwkeurigheid van producten kan garanderen en vervorming kan voorkomen. Deze prestaties zijn vooral belangrijk voor onderdelen met hoge precisie, zoals elektrische connectoren, precisiecomponenten voor auto's, medische apparaten, enz. The good dimensional stability of engineering plastics is mainly due to their high crystallinity, low water absorption (except for some varieties such as PA) en sterke intermoleculaire krachten.

In aanvulling, most engineering plastics have excellent electrical insulation performance, 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, connectoren, 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). Bijvoorbeeld, de specifieke sterkte van glasvezelversterkt polyamide (PA66+GF30) is hoger dan die van gewoon koolstofstaal, die het gewicht van producten effectief kan verminderen en tegelijkertijd de mechanische prestaties kan garanderen. Deze prestaties zijn vooral belangrijk in de automobielsector, lucht- en ruimtevaart en andere gebieden die streven naar lichtgewicht en energiebesparing, waardoor het brandstofverbruik en de CO2-uitstoot kunnen worden verminderd.

Tegelijkertijd, technische kunststoffen hebben ook een uitstekende slijtvastheid en wrijvingsweerstand, en de wrijvingscoëfficiënt is klein, die gebruikt kunnen worden bij de productie van slijtvaste onderdelen (zoals tandwielen, lagers, glijdende blokken) zonder extra smering of met minder smering, het verlagen van de onderhoudskosten van producten. Bijvoorbeeld, polyoxymethyleen (POM) technische kunststoffen hebben een uitstekende slijtvastheid en staan ​​bekend als “kunststof staal”, die veel wordt gebruikt bij de productie van tandwielen voor auto's, elektrische componenten en andere slijtvaste onderdelen.

1.3 Gemeenschappelijke classificatie van technische kunststoffen

Technische kunststoffen kunnen worden onderverdeeld in verschillende typen, afhankelijk van hun chemische structuur, prestatieniveau en toepassingsgebied. De gebruikelijke classificatiemethoden zijn als volgt, wat helpt om de verwerkingskenmerken en toepassingsscenario's van verschillende technische kunststoffen beter te begrijpen, en geschikte extrusieapparatuur en verwerkingstechnieken selecteren:

1.3.1 Classificatie op prestatieniveau

Volgens het prestatieniveau, technische kunststoffen kunnen worden onderverdeeld in algemene technische kunststoffen en speciale technische kunststoffen.

• Algemene technische kunststoffen: Het zijn de meest gebruikte technische kunststoffen, met relatief volwassen productietechnologie, gematigde prijs en goede uitgebreide prestaties. De belangrijkste variëteiten zijn polyamide (PA), polycarbonaat (PC), polyoxymethyleen (POM), polyethyleentereftalaat (HUISDIER), polybutyleentereftalaat (PBT), enz. Algemene technische kunststoffen worden voornamelijk in de automobielsector gebruikt, elektrisch en elektronisch, huishoudelijke apparaten en andere gebieden, zoals auto-onderdelen, elektrische connectoren, schalen voor huishoudelijke apparaten, enz.
• Speciale technische kunststoffen: Ze hebben meer uitstekende prestaties (zoals een hogere hittebestendigheid, corrosiebestendigheid, mechanische eigenschappen) dan algemene technische kunststoffen, maar de productietechnologie is complex en de prijs is hoog. De belangrijkste varianten zijn polyfenyleensulfide (PPS), polyetheretherketon (KIJKJE), polyimide (PI), polysulfon (PSU), polyethersulfon (PES), enz. Speciale technische kunststoffen worden voornamelijk gebruikt in hoogwaardige sectoren zoals de lucht- en ruimtevaart, medische apparaten, nieuwe energie, en chemische apparatuur, zoals ruimtevaartcomponenten, medische implantaten, elektrische componenten die bestand zijn tegen hoge temperaturen, enz.

1.3.2 Classificatie op basis van chemische structuur

Volgens de chemische structuur van de moleculaire keten, technische kunststoffen kunnen worden onderverdeeld in polyamide (PA), polycarbonaat (PC), polyoxymethyleen (POM), polyester (HUISDIER, PBT), polyfenyleensulfide (PPS), polyetheretherketon (KIJKJE), enz. Elk type technisch plastic heeft zijn eigen unieke prestatiekenmerken en verwerkingsvereisten:

• Polyamide (PA): Ook bekend als nylon, het heeft een uitstekende mechanische sterkte, slijtvastheid, taaiheid en chemische bestendigheid, maar heeft een hoge wateropname, wat de maatvastheid beïnvloedt. Veel voorkomende variëteiten zijn PA6, PA66, PA11, PA12, enz. Het wordt veel gebruikt in auto-onderdelen (versnellingen, lagers, inlaatspruitstukken), elektrische connectoren, textiel vezels, enz.
• Polycarbonaat (PC): Het heeft een uitstekende transparantie, slagsterkte, hittebestendigheid en elektrische isolatie, maar heeft een slechte slijtvastheid en is gemakkelijk te krassen. Het wordt veel gebruikt in elektrische en elektronische velden (bedradingsborden, lampafdekkingen), automobielgebieden (koplamp lenzen, instrumentenpanelen), medische velden (medische containers), enz.
• Polyoxymethyleen (POM): Het heeft een uitstekende slijtvastheid, wrijvingsweerstand, maatvastheid en mechanische sterkte, en is niet gemakkelijk om water te absorberen. It is known as “kunststof staal” en wordt veel gebruikt in auto-onderdelen (versnellingen, glijdende blokken), electrical components (schakelaars, lagers), mechanical parts, enz.
• Polyester (HUISDIER, PBT): PET has excellent transparency, heat resistance and mechanical strength, and is mainly used in fibers, films, bottles and other fields; PBT has excellent chemical resistance, electrical insulation and processing fluidity, and is widely used in electrical and electronic fields (connectoren, relays), auto-onderdelen, enz.
• Polyphenylene Sulfide (PPS): It has excellent heat resistance (long-term use temperature up to 200-220℃), corrosiebestendigheid, flame retardancy and electrical insulation, but has poor toughness. It is widely used in high-temperature resistant electrical components, automotive engine parts, chemical equipment, enz.
• Polyether Ether Keton (KIJKJE): It has excellent comprehensive performance, long-term use temperature up to 250-300℃, good corrosion resistance, mechanical strength and biocompatibility. It is mainly used in high-end fields such as aerospace, medische implantaten, and high-temperature resistant electrical components.

1.3.3 Classificatie per toepassingsgebied

According to the application field, engineering plastics can be divided into automotive-grade engineering plastics, electrical-grade engineering plastics, medical-grade engineering plastics, aerospace-grade engineering plastics, enz. Different application fields have different requirements on the performance of engineering plastics. Bijvoorbeeld, automotive-grade engineering plastics require good heat resistance, impact strength and weather resistance; electrical-grade engineering plastics require good electrical insulation and flame retardancy; medical-grade engineering plastics require good biocompatibility and sterility; aerospace-grade engineering plastics require good high-temperature resistance, low weight and high strength.

2. Core Processing Technology of Engineering Plastics: Twin-Screw Extrusion Technology

Engineering plastics processing mainly includes extrusion, spuitgieten, blaasvormen, molding and other methods, among which twin-screw extrusion technology is the core technology for the production of engineering plastic compounds (such as modified engineering plastics, reinforced engineering plastics) and semi-finished products (such as pipes, vellen, vezels). Compared with single-screw extrusion technology, twin-screw extrusion technology has the advantages of strong shearing force, goed mengeffect, nauwkeurige temperatuurregeling, 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

Zoals eerder vermeld, technische kunststoffen hebben uitstekende uitgebreide prestaties, maar hun verwerkingsmoeilijkheden zijn ook groter dan die van algemene kunststoffen, voornamelijk vanwege hun speciale moleculaire structuur en prestatiekenmerken. De belangrijkste verwerkingsproblemen van technische kunststoffen en de bijbehorende vereisten voor extrusieapparatuur zijn als volgt:

2.1.1 Gevoeligheid voor oververhitting en hydrolytische afbraak

De meeste technische kunststoffen (zoals PA, PBT, PPS) zijn gevoelig voor oververhitting en hydrolytische afbraak. Als de verwerkingstemperatuur te hoog is of de verblijftijd in de extruder te lang is, de moleculaire keten van het technische plastic zal breken, resulterend in thermische ontleding, wat de mechanische eigenschappen zal verminderen, hittebestendigheid en andere prestaties van het product, en zelfs verkleuring veroorzaken, carbonisatie en andere defecten. In aanvulling, sommige technische kunststoffen (zoals PA) hebben een hoge wateropname, en het vocht in het materiaal zal hydrolytische afbraak veroorzaken tijdens het verwerkingsproces bij hoge temperaturen, die de productkwaliteit beïnvloeden.

Dit brengt twee belangrijke eisen aan extrusieapparatuur naar voren: Eerst, nauwkeurige temperatuurregelingscapaciteit, die de verwerkingstemperatuur strikt kan controleren binnen het optimale bereik van technische kunststoffen, vermijd plaatselijke oververhitting, en de nauwkeurigheid van de temperatuurregeling moet ± 1 ℃ bereiken; seconde, korte verblijftijd, waardoor de tijd dat het materiaal in het extrudervat blijft, kan worden verkort, vermijd thermische ontleding en hydrolytische afbraak. Dubbelschroefsextruders hebben de voordelen van een korte verblijftijd (gebruikelijk 1-5 notulen) en nauwkeurige temperatuurregeling, die geschikter zijn voor de verwerking van technische kunststoffen dan extruders met één schroef (verblijftijd 5-10 notulen).

2.1.2 Hoge eisen aan meng- en dispergerende werking

In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, koolstofvezel, talk, vlamvertragers, compatibilizers) to improve the performance of the product (such as reinforcing, toughening, vlamvertragend). Bijvoorbeeld, 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. In aanvulling, the modular design of the twin-screw can freely combine different screw elements (such as conveying elements, mengelementen, shearing elements) 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, KIJKJE) 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; tegelijkertijd, the extruder is equipped with a high-precision pressure sensor, 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, which involves the interaction of multiple factors such as temperature, druk, shear force and time. 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, pijpen, vellen, vezels) through the die head. The specific working principle and process flow are as follows:

2.2.1 Raw Material Pretreatment

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 (zoals PA, PC, POM), modifiers (such as glass fiber, koolstofvezel, talk, vlamvertragers), compatibilizers, lubricants and other additives. The pretreatment steps are as follows:

• Drying Treatment: De meeste technische kunststoffen (zoals PA, PBT, PPS) hebben een hoge wateropname, and the moisture in the raw materials will cause hydrolytic degradation during high-temperature processing, resulting in product defects (such as bubbles, scheuren, reduced mechanical properties). Daarom, the raw materials must be dried before processing. The drying temperature and time are determined according to the type of engineering plastic: Bijvoorbeeld, PA6 is dried at 80-100℃ for 4-6 uur, PA66 is dried at 100-120℃ for 6-8 uur, PBT is dried at 120-140℃ for 2-4 uur, PPS is dried at 150-160℃ for 3-5 uur. The moisture content of the dried raw materials should be controlled below 0.1%-0.2%.
• Premixing Treatment: Volgens de formuleverhouding, 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. De mengsnelheid is over het algemeen 800-1200 toerental, en de mengtijd is 5-10 notulen. 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 (such as glass fiber), 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 mesh.

2.2.2 Feeding and Conveying

The premixed raw materials are sent to the feeding hopper of the twin-screw extruder through a screw feeder or a belt feeder. The feeding device of the extruder is usually equipped with a frequency conversion speed regulation function, 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 Smeltend, Mixing and Shearing

The materials entering the extrusion cavity of the twin-screw extruder are pushed forward continuously by the rotating screws. The extrusion cavity is composed of a screw and a barrel, and the volume of the extrusion cavity gradually decreases along the axis direction. When the screws rotate, the materials are gradually compressed under the action of the screws and the barrel, and the pressure in the extrusion cavity gradually increases (generally 5-15MPa).

Tegelijkertijd, the materials are subjected to strong shear force and friction force generated by the relative movement between the screws and the barrel, as well as between the screw flights. 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. The friction force can also generate a certain amount of heat, die wordt gecombineerd met de externe verwarming van het vat (elektrische verwarming of stoomverwarming) to make the engineering plastic resin gradually melt and plasticize.

Het vat van de extruder is meestal verdeeld in 4-6 secties voor temperatuurregeling (voedingsgedeelte, smeltende sectie, menggedeelte, homogeniserende sectie, die head section), and the temperature of each section is precisely controlled according to the type of engineering plastic. Bijvoorbeeld, 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

De volledig gesmolten, mixed and dispersed material is pushed to the die head of the extruder by the screws. The die head is designed according to the shape of the final product: for the production of engineering plastic compounds (korrels), 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, vellen, vezels, 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, pijpen, vellen). The temperature of the die head is slightly lower than that of the homogenizing section, 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 Afkoeling en stolling

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℃, and the cooling time is 2-5 notulen; 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 (korrels), 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 (de deeltjesgrootte is over het algemeen 2-5 mm, die kan worden aangepast aan de behoeften van de klant). 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.

In aanvulling, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (zoals te groot, te kleine of geagglomereerde deeltjes); the inspection step is to detect the performance (such as mechanical strength, hittebestendigheid, dimensionale nauwkeurigheid) 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, voornamelijk inclusief grondstofkenmerken, formule verhouding, voormengeffect, extrusieparameters en matrijskopstructuur. 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 Kenmerken van grondstoffen

Het type, deeltjesgrootte, moisture content and purity of raw materials have a great impact on the extrusion effect. Bijvoorbeeld, 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%; als het vochtgehalte te hoog is, it will cause hydrolytic degradation of the material and bubbles in the product. The purity of raw materials is also very important; impurities in raw materials (such as metals, stones, stof) will not only affect the product quality, but also wear the screw and barrel of the extruder, and even cause equipment blockage.

2.3.2 Formula Ratio

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. Bijvoorbeeld, toevoegen 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. The type and dosage of additives also need to be reasonably matched: 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, improve processing fluidity, 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 Premix-effect

Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. Als het voormengen ongelijkmatig is, 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. Om het voormengeffect te garanderen, het is noodzakelijk om de mengsnelheid te regelen, mengtijd en mengtemperatuur: the mixing speed is 800-1200 toerental, de mengtijd is 5-10 notulen, en de mengtemperatuur wordt geregeld op 40-60 ℃ (Een geschikte temperatuur kan de hechting van additieven verbeteren en een uniforme menging bevorderen).

2.3.4 Extrusieparameters

Extrusion parameters are the most important factors affecting the extrusion effect, mainly including screw speed, extrusion temperature and extrusion pressure.

• Schroefsnelheid: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 naar 1000 toerental. Our HTS series extruders can reach a maximum speed of 1000 toerental. The higher the screw speed, the greater the shear force and friction force received by the materials, the better the mixing and dispersing effect of modifiers, and the higher the production efficiency. Echter, if the screw speed is too high, the residence time of the materials in the extrusion cavity is too short, resulting in incomplete melting of the resin, insufficient mixing of materials, and uneven product quality; if the screw speed is too low, the shear force and friction force are insufficient, the modifiers cannot be fully dispersed, and the production efficiency is low. 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, KIJKJE), 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.
• Extrusion Temperature: 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. The temperature of the feeding section is lower (slightly higher than the drying temperature of the raw materials), which is mainly to prevent the materials from caking and ensure smooth feeding; the temperature of the melting section is medium, which is mainly to promote the melting and plasticization of the resin; the temperature of the mixing section is higher, wat voornamelijk bedoeld is om het afschuif- en mengeffect te verbeteren, and promote the uniform dispersion of modifiers; de temperatuur van de homogenisatiesectie is iets lager dan die van de mengsectie, wat voornamelijk bedoeld is om de uniforme temperatuur en viscositeit van de materialen te garanderen, en vermijd thermische ontleding; de temperatuur van de matrijskopsectie is iets lager dan die van de homogenisatiesectie, 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.
• Extrusiedruk: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. De druk in de extrusieholte wordt voornamelijk bepaald door de compressieverhouding van de schroef, de grootte van het matrijsgat en de schroefsnelheid. Hoe hoger de extrusiedruk, the better the mixing and dispersing effect of materials, and the denser the product. Echter, als de druk te hoog is, het zal het energieverbruik en de slijtage van de apparatuur verhogen, en zelfs ervoor zorgen dat de matrijskop blokkeert; als de druk te laag is, de materialen kunnen niet volledig worden gecomprimeerd en gemengd, the product is loose, en de prestaties zijn onstabiel. 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 Matrijskopstructuur

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 (korrels), 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

We have long been engaged in the research, development and production of high-performance twin-screw extruders, and have accumulated rich experience in the field of engineering plastics processing. Volgens de verwerkingskenmerken van technische kunststoffen (gevoeligheid voor oververhitting en hydrolytische afbraak, hoge eisen aan meng- en dispergerende werking, hoge viscositeit) en toepassingsbehoeften, speciaal voor de verwerking van technische kunststoffen hebben wij de dubbelschroefsextruders uit de HTS-serie ontwikkeld. Onze extruders uit de HTS-serie maken gebruik van versnellingsbakken met een hoog koppel, met een specifiek koppel van 14 Nm/cm³ en een maximaal toerental tot 1000 tpm, waarmee een hoger rendement kan worden behaald, kortere verblijftijd, betere dispergeerbaarheid en nauwkeurigere temperatuurregeling, perfect aangepast aan de verwerkingsbehoeften van verschillende technische kunststoffen.

3.1 Kernvoordelen van extruders uit de HTS-serie voor de verwerking van technische kunststoffen

3.1.1 Hoog koppel en hoge snelheid, Hoge productie-efficiëntie

Technische kunststoffen hebben een hoge viscositeit en een slechte verwerkingsvloeibaarheid, 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 series and HTS SUPER series) or imported from leading European manufacturers (HTS BASIC series), 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.

Tegelijkertijd, 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. In aanvulling, the high speed design also greatly improves the production efficiency: compared with ordinary extruders, 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 notulen, which is much shorter than that of ordinary twin-screw extruders (5-10 notulen) and single-screw extruders (10-15 notulen). 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.

In aanvulling, 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 Nauwkeurige temperatuurregeling, Stable Performance

The HTS series extruders adopt an advanced intelligent temperature control system, which can realize precise control of the temperature of each section of the barrel and the die head. The temperature control precision can reach ±1℃, die de verwerkingstemperatuur strikt kan controleren binnen het optimale bereik van technische kunststoffen, avoid local overheating and thermal decomposition of the material. The temperature control system is equipped with a real-time monitoring and alarm function: if the temperature of any section exceeds the set range, the system will issue an alarm prompt in time, and even automatically adjust the heating power or shut down the equipment if necessary, to avoid equipment failure and product quality problems.

In aanvulling, 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 Excellent Mixing and Dispersing Effect

The HTS series extruders adopt an intermeshing co-rotating twin-screw structure, with a reasonable screw pitch, lead and compression ratio design. The intermeshing and rotating of the twin screws can generate strong shear force and kneading force, which can fully break the agglomerates of modifiers (such as glass fiber, koolstofvezel, talk), 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 (such as conveying elements, mengelementen, shearing elements) can be freely combined according to the type of engineering plastic and modifier. Bijvoorbeeld, 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 Hoge slijtvastheid, Lange levensduur

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 (zoals 38CrMoAlA), and undergo bimetallic composite treatment or laser cladding treatment. The surface hardness of the screw and barrel can reach ≥65 HRC (HTS BASIC series) and ≥70 HRC (HTS PLUS series and HTS SUPER series), die een extreem sterke slijtvastheid en corrosieweerstand heeft, and can effectively resist the wear caused by high-hardness modifiers. Dit verlengt de levensduur van de schroef en de cilinder aanzienlijk: the service life of the screw and barrel of the HTS series extruders is 2-3 times that of ordinary extruders, reducing the frequency of component replacement and the maintenance cost of the equipment.

In aanvulling, we bieden ook professionele slijtagedetectiediensten voor de schroef en de cilinder. Ons technisch team zal voor klanten regelmatig de slijtagegraad van de schroef en cilinder detecteren, een gedetailleerd slijtagerapport uitbrengen, en gerichte vervangings- en onderhoudssuggesties doen, ensuring that customers only replace components when necessary, avoiding unnecessary waste.

3.1.6 Wide Application Range, Strong Flexibility

The HTS series extruders have a wide application range, which can adapt to the processing needs of various engineering plastics, including general engineering plastics (PA, PC, POM, HUISDIER, PBT) and special engineering plastics (PPS, KIJKJE, 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, enz.

The modular design of the HTS series extruders (schroef, loop, sterf hoofd, enz.) makes the replacement of components more convenient and quick. When customers need to adjust the product type (such as switching from PA processing to PPS processing) or modify the formula, they only need to replace the corresponding components, without replacing the entire equipment, which reduces the cost of equipment transformation and improves the flexibility and adaptability of the equipment. In aanvulling, the HTS series extruders can also be matched with different auxiliary equipment (zoals hogesnelheidsmixers, drogers, coolers, granulators, screening machines, packaging machines) to form a complete automatic production line, realizing continuous production from raw material pretreatment to product packaging.

3.1.7 Intelligent Control, Eenvoudige bediening en onderhoud

The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, wat eenvoudig en intuïtief is, eenvoudig te bedienen. Het systeem kan meerdere sets productformules en verwerkingsparameters opslaan. When customers produce different types of engineering plastics, ze hoeven alleen de bijbehorende formule en parameters aan te roepen, zonder herhaaldelijk debuggen, wat tijd bespaart en de productie-efficiëntie verbetert.

The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (zoals temperatuur, druk, schroef snelheid, feeding speed) 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, which can realize remote parameter adjustment, production data monitoring and predictive maintenance of equipment, realizing intelligent production management.

In aanvulling, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. De schroef, loop, snijkop en andere componenten kunnen snel worden gedemonteerd en gemonteerd, wat de onderhoudstijd en arbeidsintensiteit vermindert. Ons after-sales serviceteam zorgt voor een professionele installatie, inbedrijfstelling en training voor klanten, ervoor te zorgen dat klanten de apparatuur soepel kunnen gebruiken.

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 series, HTS PLUS series and HTS SUPER series. Elke serie heeft zijn eigen kenmerken en gerichte aanpassingsscenario's, die door klanten kunnen worden geselecteerd op basis van hun eigen productieschaal, producttype, budget en andere factoren.

3.2.1 Extruders uit de HTS BASIC-serie: 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. This series of extruders uses medium-torque gearboxes from leading European manufacturers, which have the advantages of stable performance, laag geluidsniveau, high efficiency and long service life. The medium-torque design (specific torque 10-12Nm/cm³) can meet the processing needs of most general engineering plastics (such as PA6, PA66, POM, HUISDIER, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).

Qua constructief ontwerp, the HTS BASIC series extruders adopt a twin-screw parallel co-rotating structure, with a screw diameter ranging from 30mm to 65mm, and a compression ratio of 4～8, which can be adjusted according to the type of engineering plastic. The barrel is made of wear-resistant alloy steel with nitriding treatment, and the screw is made of wear-resistant and corrosion-resistant alloy steel, which has good wear resistance. The extruder is equipped with a PLC control system and a touch screen operation interface, which can realize automatic feeding, automatic temperature control, automatic pressure control and automatic cutting, and is simple and easy to operate.

The production capacity of the HTS BASIC series extruders ranges from 100kg/h to 500kg/h, 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. One of the biggest advantages of this series is that it can provide flexible options through different configuration combinations. Customers can choose different screw elements, stervende hoofden, feeding devices, drying devices and post-processing equipment according to their own product types, production capacity and budget, so as to form a production line suitable for their own needs. The HTS BASIC series extruders have a reasonable price, which can help enterprises reduce the initial investment cost.

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.

De extruders uit de HTS PLUS-serie hebben een schroefdiameter variërend van 65 mm tot 110 mm, een compressieverhouding van 5~10, and a screw speed range of 200～800 rpm. De schroef en het vat nemen een bimetaalcomposietbehandeling aan, die een hogere slijtvastheid en corrosieweerstand heeft (surface hardness ≥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, die nauwkeurige controle van extrusieparameters en realtime monitoring van productiegegevens kan realiseren, 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 Extruders uit de HTS SUPER-serie: Top-End Choice for High-End Engineering Plastics

De extruders uit de HTS SUPER-serie maken gebruik van het nieuwste transmissieapparaat met ultrahoog koppel, onafhankelijk door ons ontwikkeld, met een specifiek koppel van 14 Nm/cm³ en een maximaal toerental tot 1000 tpm. Gericht op het hoge koppel en de hoge snelheidskarakteristieken van deze serie, het structurele ontwerp van elk belangrijk onderdeel van de extruder is volledig geoptimaliseerd, Dit is onze allerbeste extruderserie, vertegenwoordigt het geavanceerde niveau van de Chinese extruderontwikkeling. This series of extruders is mainly designed for the processing of high-end special engineering plastics (zoals PEEK, 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, high performance and intelligence.

De extruders uit de HTS SUPER-serie hebben een schroefdiameter variërend van 80 mm tot 130 mm, een compressieverhouding van 6~12, and a screw speed range of 250～1000 rpm. De schroef en het vat maken gebruik van geïmporteerd slijtvast gelegeerd staal en lasercladtechnologie, which has extremely high wear resistance and corrosion resistance (surface hardness ≥70 HRC), and can adapt to the processing of special engineering plastics with high temperature resistance, high viscosity and high-hardness modifiers. The extruder is equipped with an intelligent PLC + cloud touch screen control system, which can realize remote parameter adjustment, production data monitoring, predictive maintenance of equipment and data analysis, realizing intelligent production management.

The production capacity of the HTS SUPER series extruders ranges from 1000kg/h to 3000kg/h, which is suitable for the large-scale production of high-end special engineering plastics and high-performance modified engineering plastics. This series of extruders has the advantages of high precision, strong customization, multi-function and stable performance, which can meet the most stringent processing requirements of high-end engineering plastics. The short residence time (1-2 notulen) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. In aanvulling, 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, Bedrijven moeten hun eigen productiebehoeften uitgebreid in overweging nemen, productsoorten, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. Hieronder volgen enkele specifieke selectiesuggesties:

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, POM, HUISDIER, 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 (filling amount 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 (KIJKJE, 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. Voor kleinschalige productie (100kg/u – 500kg/u), 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/u – 2000kg/u), 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/u – 3000kg/u), 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 (such as flame retardants, compatibilizers, reinforcing agents) tegelijkertijd, 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. Bijvoorbeeld, 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. In aanvulling, 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. In aanvulling, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, inclusief installatie, inbedrijfstelling, technische opleiding, 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, high-speed mixer, cooler, granulator, screening machine, packaging machine, enz. 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. Bijvoorbeeld, 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

Technische kunststoffen, with their excellent comprehensive performance, have been widely used in automotive, elektrisch en elektronisch, medisch, ruimtevaart, chemisch, 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. Onderstaand, 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: Lichtgewicht, 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, POM, PC, PBT, PPS, enz., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: lichtgewicht, high temperature resistance, slijtvastheid, dimensional stability and low VOC (vluchtige organische stoffen), which require the extruder to have precise temperature control, excellent mixing and dispersing effect and stable production capacity.

For automotive interior parts (zoals instrumentenpanelen, deurpanelen, air ducts) made of general engineering plastics (PA6, POM, PC/ABS alloy), the HTS BASIC series extruders can meet the processing needs. Its flexible configuration can adjust the processing parameters according to the performance requirements of interior parts, ensure the smooth surface and dimensional stability of the product, and its low energy consumption and cost can reduce the production cost of automotive parts. For automotive engine parts (such as intake manifolds, cylinder head covers, oil pans) made of high-temperature resistant and wear-resistant engineering plastics (PA66+GF30, PPS), the HTS PLUS series extruders are more suitable. Its high torque and excellent mixing and dispersing effect can ensure the uniform dispersion of glass fiber, improve the strength and high temperature resistance of the product, and its wear-resistant screw and barrel can adapt to the wear of glass fiber, 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 (KIJKJE, 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.

Casestudy: 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 notulen) 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% naar 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, bedradingsborden, relays, motoren, cable ties, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, vlamvertraging, dimensionale stabiliteit, 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, connectoren) 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 (PPS, 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, PA, KIJKJE, PSU, enz., which are mainly used in medical containers, medische katheters, medische implantaten, surgical instruments and other products. The core requirements for extrusion processing are: high precision, no pollution, stabiele prestaties, 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 (medical-grade 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, medische implantaten) made of medical-grade special engineering plastics (PEEK van medische kwaliteit, 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 (Good Manufacturing Practice) 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, enz., 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, stabiele prestaties, 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, slijtvastheid, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, KIJKJE, PVDF (polyvinylidene fluoride), enz., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: corrosiebestendigheid, slijtvastheid, stabiele prestaties, 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 (PPS, 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 (KIJKJE, 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, door de invloed van grondstoffen, processing parameters, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Onderstaand, we will summarize the common problems in engineering plastics extrusion processing, analyseer hun oorzaken, 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 Problem 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, bubbels, 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.

Causes: 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. De schroefsnelheid is te laag, 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.

Oplossingen: 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 (temperature control precision ±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 notulen; 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 Problem 2: Uneven Dispersion of Modifiers

Symptoms: The final product has uneven texture, obvious agglomeration of modifiers (such as glass fiber, koolstofvezel), and the mechanical properties (kracht, taaiheid, slijtvastheid) are uneven, which cannot meet the use requirements. This problem is common in the processing of modified engineering plastics.

Causes: 1. The premixing effect of raw materials is poor, and the modifiers are not uniformly adhered to the surface of the resin; 2. De schroefsnelheid is te laag, 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.

Oplossingen: 1. Optimize the premixing process, increase the mixing speed (800-1200toerental) and mixing time (5-10 notulen), 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 mesh) and meets the processing requirements.

5.3 Problem 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 (such as glass fiber, koolstofvezel) on the screw and barrel during the processing of reinforced engineering plastics.

Causes: 1. The screw and barrel are made of materials with poor wear resistance, 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.

Oplossingen: 1. Select extruders with high wear resistance, 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 PLUS) and ≥70 HRC (HTS SUPER), 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. In aanvulling, our professional technical team can provide regular wear detection services for the screw and barrel, en gerichte vervangings- en onderhoudssuggesties doen.

5.4 Problem 4: Unstable Product Size and Dimensional Deformation

Symptoms: The size of the extruded product (such as granules, pijpen, vellen) 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.

Causes: 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.

Oplossingen: 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. Optimaliseer het koelproces, ensure uniform cooling speed, adjust the cooling water temperature (20-30℃) and cooling time (2-5 notulen) 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 Problem 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.

Causes: 1. De schroefsnelheid is te laag, 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.

Oplossingen: 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. In aanvulling, the HTS series extruders adopt an optimized structural design and high-efficiency motor, which can reduce energy consumption by 15%-20% compared with ordinary extruders.

6. Conclusion and Future Development Trend

Technische kunststoffen, als een belangrijk hoogwaardig materiaal, 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, productie-efficiëntie en toepassingseffect van technische kunststofproducten. Our HTS series twin-screw extruders, including HTS BASIC, HTS PLUS and HTS SUPER, are specially designed for the processing characteristics of engineering plastics (gevoeligheid voor oververhitting en hydrolytische afbraak, hoge eisen aan meng- en dispergerende werking, hoge viscositeit), with the advantages of high torque, hoge snelheid, nauwkeurige temperatuurregeling, uitstekende slijtvastheid, 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.

Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, elektrische en elektronische intelligentie, new energy and medical high-endization, the demand for high-performance, 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:

Eerst, 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. Tegelijkertijd, 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.

Seconde, high performance and high efficiency. The demand for high-end engineering plastics (zoals PEEK, 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 (schroef, loop, versnellingsbak) will be further optimized to improve wear resistance, corrosion resistance and service life. Tegelijkertijd, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.

Derde, 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. Tegelijkertijd, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.

Vierde, 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; tegelijkertijd, 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.