Thermoplastic Elastomers (TPE), ka linako tse ling e bitsoa Thermoplastic Rubbers (TPR), Ke sehlopha sa li-copolymers kapa metsoako ea 'mele ea li-polymers - eo hangata e leng polasetiki le rabara - e kopanyang thepa ea thermoplastic le elastomers.. Motsoako ona o ikhethang o lumella li-TPE hore li sebetsoe joalo ka thermoplastics (ka extrusion, ho bopa ka ente, ho bopa, etc.) ha e ntse e boloka elasticity le ho feto-fetoha ha lirabara. Ho fapana le liraba tsa setso tse vulcanized, Li-TPE li ka qhibiliha 'me tsa sebetsoa khafetsa ntle le tahlehelo e kholo ea ts'ebetso, ho etsa hore li baballe tikoloho le ho baballa chelete. Joalo ka tlhoko ea boima bo bobebe, tenyetsehang, le lisebelisoa tse ka sebelisoang hape li hola ho pholletsa le liindasteri tse kang tsa likoloi, motlakase, kaho, le thepa ea bareki, Li-TPE li se li tumme haholo, ho tsamaisa nts'etsopele ea mahlale a ikhethang a masterbatch le extrusion a tsamaellanang le litlhoko tsa bona tse ikhethang tsa ts'ebetso.
Masterbatch, e le lisebelisoa tsa bohlokoa bakeng sa ho kenya mebala le ho fetola ts'ebetso ea TPE, e bapala karolo ea bohlokoa ho ntlafatseng ts'ebetso le ho holisa sekhahla sa ts'ebeliso ea lihlahisoa tsa TPE. Ts'ebetso ea TPE masterbatch e hloka taolo e nepahetseng ea ho kopanya, qhalanya, le litekanyetso tsa mocheso, kaha li-TPE li na le viscosity e khethehileng, ho hanyetsa mocheso, le litšobotsi tsa elasticity tse fapaneng le li-plastiki tsa setso. Li-extruders tsa li-twin-screw, ka bokhoni ba bona bo phahameng ba ho kopanya le ho hasanya, taolo e nepahetseng ea mocheso, le ho ikamahanya le maemo ho lisebelisoa tse fapaneng, li fetohile lisebelisoa tsa mantlha tsa ts'ebetso ea TPE masterbatch. Zhuoyue, moetsi ea hloahloa oa li-fahla-screw extruders, e fana ka mefuta e mengata ea tharollo e tsoetseng pele ea extrusion e etselitsoeng ho kopanya TPE le masterbatch process, e koahelang TPE/SBS/TPU/TPR/TPV le mekhahlelo e meng e meholo ea TPE, ho fihlela litlhoko tse fapaneng tsa baetsi ba liindasteri tse fapaneng.
1. Kakaretso ea Thermoplastic Elastomers (TPE): Lihlopha, Thepa le Litšobotsi tsa Bohlokoa
Li-TPE ke lelapa le fapaneng la lisebelisoa, e arotsoe ka lihlopha tse tšeletseng tse akaretsang tsa khoebo ho ipapisitsoe le sebopeho sa tsona sa lik'hemik'hale le sebopeho sa tsona. Sehlopha se seng le se seng se na le thepa e ikhethang, litšobotsi tsa ho sebetsa, le masimo a kopo, tse khethollang ka ho toba litlhoko tsa tlhahiso ea masterbatch le thepa ea extrusion. Ho utloisisa likarolo le thepa ea li-TPE ke motheo oa ho ntlafatsa ts'ebetso ea masterbatch le ho khetha li-extruder tse loketseng tse mafahla..
1.1 Likarolo tse Tšeletseng tsa Kakaretso tsa Khoebo tsa li-TPE
1.1.1 Li-copolymers tsa styrenic Block (TPS, TPE-s).
TPS ke sehlopha se sebelisoang haholo sa li-TPE, e ikarabellang bakeng sa karolo e kholo ea 'maraka oa lefats'e oa TPE. E entsoe ka li-styrenic blocks (joalo ka polystyrene, PS) le li-blocks tsa elastomeric (joalo ka polybutadiene, PB; polyisoprene, PI; kapa ethylene-butylene, EB), e hokahaneng ka litlamo tsa covalent. Mefuta e atileng haholo ea TPS e kenyelletsa SBS (Li-styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), le SEPS (Styrene-Ethylene-Propylene-Styrene).
Lintho tsa bohlokoa tsa TPS li kenyelletsa ho feto-fetoha ha maemo ho hoholo, elasticity, le tshebetso. SEBS le SEPS, e leng mefuta ea hydrogenated ea SBS le SIS, ba ntlafalitse ho hanyetsa mocheso, khanyetso ea boemo ba leholimo, le ho hana ho tsofala, ho etsa hore li tšoanelehe bakeng sa lits'ebetso tsa kantle le mocheso o phahameng. Lisebelisoa tsa TPS li mebala habonolo ebile li fetotsoe ka masterbatch, 'me mocheso oa bona oa ho sebetsa o tloha ho 150 ℃ ho ea ho 220 ℃, e tsamaellanang le bongata ba mafahla. Lisebelisoa tse tloaelehileng tsa TPS li kenyelletsa likarolo tsa koloi, lithapo le likhoele, thepa ea bareki, le lisebelisoa tsa bongaka.
1.1.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o).
TPO ke motsoako oa 'mele oa polyolefin (joalo ka polypropylene, PP; or polyethylene, PE) and elastomer (such as ethylene-propylene-diene monomer, EPDM). It combines the rigidity of polyolefins with the elasticity of elastomers, and has excellent chemical resistance, khanyetso ea boemo ba leholimo, and low temperature flexibility. TPOs are non-toxic, odorless, and recyclable, making them ideal for applications requiring environmental friendliness.
The processing temperature of TPO ranges from 160℃ to 230℃, and it has good compatibility with various masterbatches (mmala masterbatch, masterbatch e thibelang malakabe, etc.). TPOs are widely used in automotive exterior parts (such as bumper covers, fender liners), thepa ea ho haha (such as seals, likhase), and electrical components. Due to their high polyolefin content, TPO masterbatch processing requires extruders with good mixing capabilities to ensure uniform dispersion of pigments and additives.
1.1.3 Thermoplastic Vulcanisates (VAT, TPE v).
TPV ke motsoako o matla oa polyolefin (hangata PP) and elastomer (hangata EPDM). Nakong ea ts'ebetso, karolo ea elastomer e kenngoa ka har'a likaroloana tse nyane ebe e qhalakanngoa ka mokhoa o ts'oanang ho polyolefin matrix., e hlahisang elasticity e ntle haholo, compression set hanyetsoa, le ho hanyetsa mocheso. Li-TPV li na le lisebelisoa tse betere tsa mochini le botsitso ba sebopeho ho feta li-TPE tsa setso, mme e ka mamella kgahlamelo ya nako e telele ya mocheso o phahameng (ho fihlela ho 150 ℃).
Ts'ebetso ea TPV e hloka taolo e nepahetseng ea mocheso le matla a matla a ho kuta ho netefatsa hore vulcanization e ts'oana le ho hasana. Mocheso oa ho sebetsa o tloha ho 170 ℃ ho isa ho 240 ℃, 'me thepa e na le viscosity e phahameng nakong ea ts'ebetso, e behang ditlhoko tse phahameng hodima torque le ho aparela kganyetso ya mafahla a sekerufu. Li-TPV li sebelisoa haholo litiisong tsa likoloi, hose, likhase, le likarolo tsa indasteri tse hlokang ts'ebetso e phahameng le ho tšoarella.
1.1.4 Thermoplastic Polyurethanes (TPU).
TPU ke block copolymer e entsoeng ka likarolo tse thata (disocyanate le ketane extender) le likarolo tse bonolo (polyol). E na le elasticity e ntle haholo, kganetso ya ho abrasion, ho hanyetsa oli, le matla a mochine, 'me e ka fetoloa ka thata ho tloha bonolo haholo (Shore A 30) ho thata haholo (Shore D 85) ka ho fetola karo-karolelano ea likarolo tse thata le tse bonolo.
Ts'ebetso ea TPU e tsotella mocheso le mongobo. Mocheso oa ho sebetsa o tloha ho 180 ℃ ho isa ho 250 ℃, mme thepa e tlameha ho omisoa hantle pele e sebetsoa (mongobo ≤0.05%) ho qoba hydrolysis le sebopeho sa bubble. Ts'ebetso ea TPU masterbatch e hloka li-extruder tse nang le taolo e nepahetseng ea mocheso le bokhoni ba ho ntša vacuum. TPU e sebelisoa haholo ho lithapo le likhoele, liphaephe tsa likoloi, lieta, li-catheters tsa bongaka, le thepa ea lipapali.
1.1.5 Li-copolyester tsa Thermoplastic (TPC, TPE-E).
TPC ke block copolymer e entsoeng ka likarolo tse thata tsa polyester le likarolo tse bonolo tsa polyether kapa polyester.. E na le ho hanyetsa mocheso o babatsehang, khanyetso ea lik'hemik'hale, le thepa ea mechine, mme e ka mamella mocheso o phahameng ho fihla ho 150 ℃ nako e telele. Li-TPC li boetse li na le ho feto-fetoha ha maemo le elasticity e ntle, ho etsa hore li tšoanelehe bakeng sa lits'ebetso tsa ts'ebetso e phahameng.
Mocheso oa ts'ebetso oa TPC o tloha ho 220 ℃ ho isa ho 280 ℃, e leng holimo ho feta mekhahlelo e meng ea TPE. E na le viscosity e phahameng nakong ea ts'ebetso 'me e hloka li-extruder tse nang le torque e phahameng le taolo e nepahetseng ea mocheso. Ts'ebetso ea TPC masterbatch e boetse e hloka tlhokomelo e khethehileng ho hasane ha mebala le li-additives ho qoba ho ama thepa ea mochini.. Li-TPC li sebelisoa haholo likarolong tsa likoloi (joalo ka liphaephe tse kenyang moea, litiiso tsa phetiso), likarolo tsa sefofane, le mechine ea indasteri.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA ke block copolymer e entsoeng ka likarolo tse thata tsa polyamide le likarolo tse bonolo tsa polyether.. E kopanya matla a phahameng, apara khanyetso, le khanyetso ea lik'hemik'hale ea polyamides ka ho feto-fetoha ha maemo le elasticity ea polyethers. TPA e na le ts'ebetso e matla ea ho hanyetsa le ts'ebetso e tlase ea mocheso, mme e ka sebediswa dibakeng tse thata.
Mocheso oa ho sebetsa oa TPA o tloha ho 230 ℃ ho isa ho 290 ℃, 'me e na le metsi a mangata, e hlokang ho omisoa hantle pele ho sebedisoa. Ts'ebetso ea TPA masterbatch e hloka li-extruder tse nang le khanyetso e phahameng ea ho roala (ka lebaka la boima bo phahameng ba polyamide) le taolo e nepahetseng ea mocheso ho qoba ho senyeha ha lintho. TPA e sebelisoa haholo likarolong tsa likoloi (joalo ka likere, dibering), lihokelo tsa motlakase, le liphaephe tsa indasteri.
1.2 Lintho tsa Bohlokoa tsa TPE tse Amang Masterbatch Processing
Li-TPE li na le thepa e ikhethang e li khethollang ho li-plastiki tsa setso, 'me thepa ena e ama ka ho toba ho etsoa ha masterbatch le khetho ea thepa ea extrusion. Mehaho ea bohlokoa eo u lokelang ho e ela hloko ts'ebetsong ea masterbatch ke e latelang:
1.2.1 Elasticity le Fetola.
Li-TPE li na le elasticity e phahameng le ho fetoha habonolo, ho bolelang hore masterbatch e tlameha ho lumellana le matrix a TPE ho qoba ho fokotsa ts'ebetso ea elasticity ea thepa.. Motho ea tsamaisang masterbatch o lokela ho lumellana hantle le TPE, le dispersant lokela ho etsa bonnete ba ho hasana junifomo ea li-pigments ntle le ho etsa li-agglomerate tse ka bakang khatello ea maikutlo le ho fokotsa ho fetoha ha maemo..
1.2.2 Ho hanyetsa Mocheso.
Mefuta e fapaneng ea TPE e na le ho hanyetsa mocheso o fapaneng (mocheso oa ho sebetsa o tloha ho 150 ℃ ho isa ho 290 ℃). Li-pigments le li-additives tsa Masterbatch li tlameha ho ba le khanyetso ea mocheso e ts'oanang le mocheso oa ts'ebetso oa TPE ho qoba ho bola, phetoho mmala, kapa ho senyeha ha tshebetso nakong ya extrusion. Ka mohlala, TPC le TPA li hloka li-pigments tse hanyetsanang le mocheso o phahameng le li-stabilizers tsa mocheso.
1.2.3 Viscosity le Processability.
Li-TPE li na le li-viscosity tse fapaneng nakong ea ts'ebetso (TPV le TPC li na le viscosity e phahameng, ha TPS e na le viscosity e tlase). Sena se ama matla a ho kuta le ho fetisa litlhoko tsa "twin-screw extruder".. Li-TPE tsa viscosity tse phahameng li hloka li-extruder tse nang le torque e phahameng le bokhoni bo matla ba ho kopanya, ha li-TPE tsa viscosity tse tlase li hloka taolo e nepahetseng ea lebelo la extrusion ho qoba ho tlala lintho tse bonahalang.
1.2.4 Mongobo oa Mongobo.
Li-TPE tse ling (joalo ka TPU, TPA) ho monya metsi haholo, e ka bakang dipudula, hydrolysis, le liphoso tse ling ho masterbatch. Thepa e tala (TPE, mebala, tlatsetso) e tlameha ho omisoa hantle pele e sebetsa, 'me extruder e lokela ho ba le sesebelisoa sa vacuum exhaust ho tlosa mongobo le lintho tse fetohang..
1.2.5 Ho lumellana le Li-additives.
Hangata li-TPE li hloka li-additives tse sebetsang (joalo ka li-antioxidants, Li-stabilizers tsa UV, mafura) ho ntlafatsa tshebetso ya bona. Masterbatch e lokela ho etsoa ho netefatsa hore li-additives li lumellana le li-pigments le TPE matrix., ho qoba liphetoho tsa lik'hemik'hale tse ka amang boleng ba sehlahisoa.
2. Masterbatch bakeng sa li-TPE: Sebopeho, Litlhoko tsa ho theha le ho sebetsa
Masterbatch bakeng sa TPEs ke motsoako o kopaneng oa li-pigment/dae, bajari, le litlatsetso, e etselitsoe ho mebala TPE le ho fana ka mesebetsi e meng (joalo ka ho lieha ha lelakabe, antistatic, antibacterial) ha u ntse u boloka thepa ea tlhaho ea elastic le ho sebetsa. Ho hlophisoa le ho sebetsa ha TPE masterbatch ho hlokahala ho feta tsa polasetiki ea setso, ka lebaka la thepa e ikhethang ea li-TPE. Karolo ena e qaqisa tlhamo, melao-motheo ea tlhahiso, le litlhoko tsa ho sebetsa tsa TPE masterbatch.
2.1 Sebopeho sa mantlha sa TPE Masterbatch
Joalo ka masterbatch ea setso, TPE masterbatch e na le likarolo tse tharo tsa motheo: mebala/dae, bajari, le litlatsetso. Khetho le karolo ea karolo ka 'ngoe li ikamahanya le mofuta oa TPE le litlhoko tsa eona tsa kopo.
2.1.1 Li-pigments/Dye.
Li-pigments/dae ke likarolo tsa mantlha tse fanang ka mebala ho li-TPE, accounting for 10%-70% ea sebopeho sa masterbatch (ho itšetlehile ka matla a 'mala le mofuta oa TPE). Litlhoko tsa bohlokoa tsa li-pigments/dae ho TPE masterbatch ke:
- – Ho hanyetsa Mocheso: E tlameha ho mamella mocheso oa ts'ebetso oa sepheo sa TPE (150℃-290 ℃) without decomposition or discoloration. For high-temperature TPEs (TPC, TPA), high-temperature resistant organic pigments or inorganic pigments are preferred.
- – Ho lumellana: Must be compatible with the TPE matrix to avoid migration, blooming, or reduced elasticity. Pigments with similar polarity to the TPE are more compatible (mohlala, polar pigments for TPU, non-polar pigments for TPS).
- – Dispersibility: Must be easily dispersed in the TPE matrix to ensure uniform coloring and avoid color spots, streaks, or reduced mechanical properties. Fine-particle pigments (20-40 letlooeng) with low agglomeration are preferred.
- – Environmental Friendliness: Must meet global environmental protection standards (such as REACH, RoHS) to avoid toxic or harmful substances (such as heavy metals) that could affect human health and the environment.
Common pigments used in TPE masterbatch include: inorganic pigments (titanium dioxide for white, carbon black for black, iron oxide bakeng sa bofubedu/bosehla), le li-pigments tsa tlhaho tse hanyetsanang le mocheso o phahameng (phthalocyanine blue/green, quinacridone e khubelu).
2.1.2 Bajari.
Bajari ke matrix a masterbatch, accounting for 20%-80% ea sebopeho, le ho bapala karolo ea bohlokoa ho qhalaneng li-pigments le ho khomarela matrix a TPE. Sesebelisoa se tlameha ho lumellana hantle le li-pigments le sepheo sa TPE, kaha ho se lumellane ho ka lebisa ho phallo ea mebala, mebala e sa lekaneng, le ho fokotsa ts'ebetso ea TPE. Khetho ea sesebelisoa e ipapisitse le mofuta oa TPE:
- – Bakeng sa TPS (SBS, SEBS): Sebelisa TPS kapa PP joalo ka mofani oa thepa, e nang le tumellano e ntle le mokelikeli wa ho sebetsa.
- – Bakeng sa TPO/TPE-o: Sebelisa PP kapa PE joalo ka mofani oa thepa, e tsamaellanang le karolo ea polyolefin ea TPO.
- – Bakeng sa TPV/TPE-v: Sebelisa PP joalo ka sesebelisoa, e tsamaellanang le PP matrix ea TPV.
- – Bakeng sa TPU: Use TPU as the carrier, ensuring compatibility with the TPU matrix and avoiding hydrolysis.
- – For TPC/TPE-E and TPA/TPE-A: Use TPC or TPA as the carrier, ka ho latellana, to match the high-temperature processing requirements and compatibility.
Sesebelisoa se boetse se lokela ho ba le metsi a sebetsang hantle, with a melting point and processing temperature consistent with or slightly lower than the target TPE, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Tlatsetso.
Li-additives ke likarolo tse thusang tse kenyelletsoeng ho ntlafatsa ts'ebetso ea ts'ebetso, dispersibility, and functional performance of TPE masterbatch, accounting for 1%-10% ea sebopeho. The type and dosage of additives are determined by the TPE type and application requirements:
- – Li-disperants: The most important additive for TPE masterbatch, used to reduce pigment surface tension, prevent agglomeration, and ensure uniform dispersion in the TPE matrix. Li-disperants tse tloaelehileng li kenyelletsa boka ba polyethylene, boka ba polypropylene, asiti ea stearic, le boka ba maleic anhydride e hlomathisitsoeng. Bakeng sa li-TPE tse nang le viscosity e phahameng (VAT, TPC), li-disperants tse sebetsang hantle tse nang le tumellano e matla li khethoa.
- – Likopano: E sebelisoa ho ntlafatsa tšebelisano lipakeng tsa li-pigment le li-TPE, le pakeng tsa masterbatch le TPE matrix. Ka mohlala, maleic anhydride grafted PP e sebelisoa e le setlatsi sa TPO masterbatch, le boka ba polyurethane e sebelisoa bakeng sa TPU masterbatch.
- – Li-stabilizers tsa mocheso: E sebelisetsoa ho thibela ho senyeha ha pigment le ho senyeha ha TPE nakong ea ts'ebetso e phahameng ea mocheso. Li-stabilizers tse tloaelehileng tsa mocheso li kenyelletsa li-organic tin stabilizers (bakeng sa TPU), e thibela phenol antioxidants (bakeng sa TPS, TPO), le li-antioxidants tsa phosphite (bakeng sa TPC, TPA).
- – Li-stabilizers tsa UV le Antioxidants: E sebelisoa ho ntlafatsa khanyetso ea boemo ba leholimo le khanyetso ea botsofali ea lihlahisoa tsa TPE tse mebala, preventing color fading and performance degradation under sunlight and oxygen. For outdoor applications (such as automotive exterior parts), UV absorbers and hindered amine light stabilizers (HALS) are added.
- – Lisebelisoa: Used to reduce friction between materials and extrusion equipment (screw, moqomo, shoa hlooho), ntlafatsa ho sebetsa ha fluidity, le ho qoba thepa ho khomarela thepa. Litlolo tse tloaelehileng li kenyelletsa asiti ea stearic, calcium stearate, and silicone oil. For TPU and TPA, lubricants with low migration are preferred to avoid affecting product performance.
- – Functional Additives: Added to impart special functions to TPEs, such as flame retardants (for wires and cables), antistatic agents (bakeng sa likarolo tsa motlakase), and antibacterial agents (for medical devices and consumer goods).
2.2 Formulation Principles of TPE Masterbatch
The formulation of TPE masterbatch must balance coloring effect, processing performance, and TPE inherent properties. The key principles are as follows:
2.2.1 Compatibility First.
The carrier, mebala, and additives must be compatible with the target TPE to avoid reducing the material’s elasticity, tenyetseha, le thepa ea mechine. Ka mohlala, using a non-polar carrier for polar TPU will lead to poor compatibility and pigment migration.
2.2.2 Match Heat Resistance.
The pigments and additives must have heat resistance matching the TPE processing temperature. Ka mohlala, TPC masterbatch uses high-temperature resistant pigments (heat resistance ≥280℃) to avoid decomposition during processing.
2.2.3 Optimize Dispersibility.
The pigment content and dispersant dosage are adjusted to ensure uniform dispersion. High-concentration masterbatch (pigment content 50%-70%) requires more dispersants and better mixing capabilities, while low-concentration masterbatch (10%-30%) focuses on compatibility.
2.2.4 Minimize Impact on TPE Properties.
The masterbatch should not significantly affect the TPE’s elasticity, compression set, or abrasion resistance. Ka mohlala, excessive dispersants or lubricants may reduce the TPE’s mechanical strength.
2.2.5 Environmental Protection Compliance.
The formulation must meet global environmental protection standards, avoiding toxic or harmful substances (such as heavy metals, phthalates) that could restrict market access.
2.3 Processing Requirements of TPE Masterbatch
TPE masterbatch processing is mainly carried out using twin-screw extrusion technology, which requires strict control of raw material pretreatment, premixing, extrusion parameters, and post-processing to ensure product quality. The key processing requirements are as follows:
2.3.1 Raw Material Pretreatment.
TPEs (especially TPU, TPA) ho monya metsi haholo, so all raw materials (TPE carrier, mebala, tlatsetso) e tlameha ho omisoa hantle pele e sebetsa. The drying temperature and time are determined by the material type: TPU/TPA e omisitsoe ho 100-120 ℃ bakeng sa 6-8 lihora, TPS/TPO e omisitsoe ho 80-100 ℃ bakeng sa 3-5 lihora, 'me li-pigments li omisitsoe ho 60-80 ℃ bakeng sa 2-4 lihora. Mongobo oa lihlahisoa tse omisitsoeng o lokela ho laoloa ka tlase 0.1% (0.05% bakeng sa TPU/TPA).
Holim'a moo, li-pigments tse nang le boholo bo boholo ba likaroloana kapa li-agglomerate li lokela ho siloa le ho siloa (20-40 letlooeng) ho ntlafatsa dispersibility, le ditshila (likaroloana tsa tšepe, lerole) e lokela ho tlosoa ho qoba ho apara ka thepa ea extrusion le mefokolo ho masterbatch.
2.3.2 Ho kopanya.
Thepa e omisitsoeng (mebala, mojari, tlatsetso) li tsoakoa ka motsoako oa lebelo le phahameng ho latela karo-karolelano ea foromo ho etsa motsoako o tšoanang oa pele. Mekhahlelo ea premixing e lokisoa ho latela mofuta oa TPE: ho kopanya lebelo 800-1200 rpm, ho kopanya nako 5-10 metsotso, ho kopanya mocheso 40-60 ℃. Bakeng sa bajari ba TPE ba phahameng ba concentration kapa ba nang le viscosity e phahameng, nako ea premixing e atolosoa, 'me li- dispersants li eketsoa pele ho koahela mebala, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-screw extrusion is the core step of TPE masterbatch processing, and the key parameters (mocheso, lebelo la sekoti, extrusion pressure, feeding speed) must be precisely controlled to match the TPE type:
- – Taolo ea Mocheso: The barrel is divided into 4-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, die head section). The temperature of each section is adjusted according to the TPE processing temperature. Ka mohlala, TPS masterbatch: feeding section 100-120℃, melting section 160-180℃, mixing section 170-190℃, homogenizing section 160-180℃, die head section 150-170℃; TPC masterbatch: feeding section 150-170℃, melting section 230-250℃, mixing section 240-260℃, homogenizing section 230-250℃, die head section 220-240℃. Ho nepahala ha taolo ea mocheso ho lokela ho fihla ± 1 ℃ ho qoba ho senyeha ha TPE le ho senyeha ha pigment.
- – Screw Speed: Lebelo la sekoti se tloha ho 200-800 rpm, e fetotsoe ho latela viscosity ea TPE. Li-TPE tsa viscosity tse phahameng (VAT, TPC) hloka lebelo le holimo la screw (500-800 rpm) ho hlahisa matla a lekaneng a ho kuta bakeng sa ho hasana ha mmala; li-TPE tsa viscosity tse tlase (TPS) sebedisa lebelo le itekanetseng (300-500 rpm) ho qoba ho tlala ka dintho tse bonahalang.
- – Khatello ea Extrusion: Khatello e tsoa ho 5-12MPa, boloka botsitso (ho feto-fetoha ha maemo ≤± 0.5MPa) ho etsa bonnete ba ho kopanya le sebopeho se ts'oanang. Li-TPE tsa viscosity tse phahameng li hloka khatello e phahameng, ha li-TPE tsa viscosity tse tlase li sebelisa khatello e itekanetseng.
- – Lebelo la ho fepa: E fetotsoe hore e tsamaellane le lebelo la screw le lebelo la extrusion, ho netefatsa phepo e tsitsitseng le e ts'oanang. Bakeng sa li-TPE tse nang le viscosity e phahameng, sesebelisoa sa ho fepa se qobelloang se sebelisoa ho qoba ho bokella lintho tse bonahalang.
2.3.4 Kamora ho sebetsa.
Ka mor'a extrusion, masterbatch e bopehileng joaloka strip e pholisitsoe (pholiso ea tanka ea metsi, 20-30℃), granulated (boholo ba likaroloana 2-5mm), hlahliloe (to remove unqualified particles), and packaged (sealed and moisture-proof packaging). For moisture-sensitive TPE masterbatch (TPU, TPA), the finished product is dried again before packaging to prevent moisture absorption.
3. Application Fields of TPE Masterbatch and Matching Zhuoyue Extruder Solutions
TPEs are widely used in automotive, motlakase, kaho, thepa ea bareki, and other industries, and different application fields have different requirements for TPE masterbatch performance (mmala, dispersibility, functionality) and production efficiency. Zhuoyue’s full series of twin-screw extruders (HTS BASIC/PLUS/SUPER, ZTE, HTE) are specially optimized for TPE masterbatch processing, providing targeted solutions for different TPE categories and application fields. Below is a detailed introduction to the main application fields of TPE masterbatch and the matching Zhuoyue extruder series.
3.1 Indasteri ea Likoloi: The Largest Application Field of TPE Masterbatch
Indasteri ea likoloi ke moreki e moholo oa li-TPE, accounting ho feta 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, tenyetsehang, and recyclable properties, and TPE masterbatch plays a key role in coloring and functional modification of these components. The main automotive applications of TPE masterbatch include:
3.1.1 Automotive Seals and Gaskets.
TPEs (mainly TPV, TPO) are used to produce automotive door seals, lifensetere litiiso, hood seals, le li-gaskets, which require good elasticity, khanyetso ea boemo ba leholimo, and low temperature flexibility. The masterbatch for these components requires uniform coloring, good weather resistance (Ho hanyetsa UV, aging resistance), and compatibility with TPV/TPO matrices.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has high torque and wear resistance, suitable for TPV masterbatch processing (high viscosity, high shear force required); the HTE series integrates high performance and cost-effectiveness, suitable for TPO masterbatch processing, with good mixing dispersibility and energy-saving advantages.
3.1.2 Automotive Interior Components.
TPEs (mainly TPS, TPU) are used to produce automotive interior components such as instrument panel skins, liphanele tsa mamati, steering wheel covers, and armrests, which require good flexibility, soft touch, and environmental friendliness (e senang chefo, odorless). The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining other interior components).
Matching Extruders: Letoto la HTS BASIC le letoto la HTE. The HTS BASIC series is cost-effective, suitable for small and medium-sized manufacturers producing TPS interior masterbatch; the HTE series has good mixing dispersibility and low energy consumption, suitable for large-scale production of TPU/TPS interior masterbatch.
3.1.3 Automotive Hoses and Tubing.
TPEs (mainly TPU, TPC, TPA) are used to produce automotive fuel hoses, air intake hoses, and brake hoses, which require good oil resistance, ho hanyetsa mocheso, le matla a mochine. The masterbatch requires high-temperature resistance, ho hanyetsa oli, and uniform dispersibility to avoid affecting the hose’s performance.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has ultra-high torque, taolo e nepahetseng ea mocheso, and high wear resistance, suitable for TPC/TPA masterbatch processing (mocheso o phahameng, high viscosity); the HTS PLUS series has good heat resistance and mixing capabilities, suitable for TPU masterbatch processing.
3.1.4 Other Automotive Components.
TPEs are also used to produce automotive dust covers, triangle windows, air filters, and breakers, which require different properties (such as dust resistance, ponaletso, khanyetso ea tšusumetso). The masterbatch is formulated according to specific requirements, and the matching extruders are selected based on TPE type and production scale.
3.2 Indasteri ea Motlakase le Elektronike: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, likhokahanyo, le likarolo tse ling, requiring functional masterbatch (antistatic, e thibelang lelakabe, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (mainly TPU, TPS, TPO) are used as insulation and sheath materials for wires and cables (power cables, ignition wires, headphone wires, connector plugs), which require good electrical insulation, ho hloleha ha lelakabe, le ho hanyetsa abrasion. The masterbatch requires flame retardancy (meeting UL94 V-0 maemo), thepa ea antistatic, and uniform coloring.
Matching Extruders: HTS PLUS series, HTE series, and HTS SUPER series. The HTS PLUS series has good flame-retardant masterbatch mixing capabilities, suitable for TPO/TPU wire and cable masterbatch; the HTE series is cost-effective, suitable for small and medium-sized production; the HTS SUPER series is suitable for high-end, high-concentration flame-retardant masterbatch processing.
3.2.2 Electrical Connectors and Plugs.
TPEs (mainly TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, khanyetso ea tšusumetso, and environmental friendliness. The masterbatch requires uniform coloring, high-temperature resistance, and no migration.
Matching Extruders: HTS PLUS series and HTS SUPER series. The HTS PLUS series has good compatibility with TPU/TPA, ensuring uniform dispersion; the HTS SUPER series has precise temperature control, avoiding TPA degradation during processing.
3.3 Construction and Transportation Industry: Weather-Resistant TPE Masterbatch Applications
In the construction and transportation industry, TPEs are used to produce seals, expansion joints, subway mats, le likarolo tse ling, requiring good weather resistance, aging resistance, and low temperature flexibility to adapt to harsh outdoor environments.
3.3.1 Construction Seals and Expansion Joints.
TPEs (mainly TPV, TPO) are used to produce building door and window seals, curtain wall seals, and expansion joints, which require good weather resistance, Ho hanyetsa UV, and compression set resistance. The masterbatch requires UV stabilizers and antioxidants to improve weather resistance, and uniform coloring to match building aesthetics.
Matching Extruders: HTS PLUS series and HTE series. The HTS PLUS series has good weather-resistant additive mixing capabilities, suitable for TPV masterbatch processing; the HTE series is energy-saving and efficient, suitable for large-scale production of TPO masterbatch.
3.3.2 Transportation Components.
TPEs are used to produce subway mats, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, le ho apara ho hanyetsa. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Matching Extruders: Letoto la HTS BASIC le letoto la HTE. The HTS BASIC series is cost-effective, suitable for small-batch production; the HTE series has good mixing capabilities, ensuring uniform dispersion of shock-absorbing additives.
3.4 Consumer Goods and Other Industries: Diverse TPE Masterbatch Applications
TPEs are widely used in consumer goods and other industries, with diverse application scenarios and varying masterbatch requirements, focusing on color, soft touch, and environmental friendliness.
3.4.1 Footwear Industry.
TPEs (mainly TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, which require good flexibility, kganetso ya ho abrasion, and soft touch. The masterbatch requires bright colors, uniform dispersibility, and no migration (to avoid staining socks).
Matching Extruders: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, suitable for small and medium-sized footwear manufacturers; the HTS BASIC series has good mixing dispersibility, ensuring uniform coloring of shoe sole masterbatch.
3.4.2 Household and Daily Necessities.
TPEs are used to produce handles, coasters, foot mats, libapalisoa, and other household items, which require non-toxic, odorless, soft touch, and bright colors. The masterbatch requires environmental friendliness (meeting food contact standards for coasters/handles) and uniform coloring.
Matching Extruders: ZTE series and HTS BASIC series. The ZTE series is simple to operate, low in maintenance cost, suitable for small-batch, multi-variety production; the HTS BASIC series has good environmental protection masterbatch compatibility, meeting food contact standards.
3.4.3 Medical Devices.
TPEs (mainly TPU, TPS) are used to produce medical catheters, li-syringe, and medical masks, which require non-toxic, sterile, and biocompatible. The masterbatch requires medical grade environmental protection (meeting ISO 10993 maemo), high transparency (for catheters), and uniform dispersibility.
Matching Extruders: HTS SUPER series and HTS PLUS series. The HTS SUPER series has clean production design, taolo e nepahetseng ea mocheso, avoiding material pollution; the HTS PLUS series has good compatibility with medical grade TPEs, ensuring product sterility and biocompatibility.
3.4.4 Other Industrial Applications.
TPEs are also used to produce drain pipes, industrial gaskets, and mechanical components, which require good chemical resistance, apara khanyetso, le matla a mochine. The masterbatch is formulated according to specific industrial requirements, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue’s Full Series Extruders: Professional Solutions for TPE Masterbatch Processing
Zhuoyue has long been engaged in the research, development, and production of high-performance twin-screw extruders, and has accumulated rich experience in TPE masterbatch processing. Based on the unique processing characteristics of TPEs (high viscosity, temperature sensitivity, moisture absorption) and the diverse needs of manufacturers (different TPE categories, production scales, application fields), Zhuoyue has launched a full series of extruders suitable for TPE masterbatch processing, including HTS BASIC, HTS PLUS, HTS SUPER, ZTE, and HTE series. Each series has targeted performance advantages, providing personalized and efficient processing solutions for TPE masterbatch manufacturers of different scales.
4.1 Core Advantages of Zhuoyue’s Extruders for TPE Masterbatch Processing
Zhuoyue’s extruders are specially optimized for TPE masterbatch processing, with the following core advantages to meet the strict requirements of TPE processing:
4.1.1 Excellent Mixing and Dispersing Effect.
TPE masterbatch requires uniform dispersion of pigments and additives to avoid affecting the material’s elasticity and mechanical properties. All Zhuoyue’s twin-screw extruders adopt an intermeshing co-rotating structure, with a reasonable screw pitch, lead, and compression ratio design. The intermeshing and rotating of the twin screws generate strong shear force and kneading force, which can fully break pigment agglomerates and ensure uniform dispersion of pigments, bajari, and additives in the TPE matrix. The mixing uniformity reaches more than 95%, which is far higher than that of ordinary extruders.
Holim'a moo, the screws adopt a modular design, which can freely combine different screw elements (fetisa, ho kopanya, ho kuta) according to the TPE type. Ka mohlala, high-viscosity TPV/TPC masterbatch requires more mixing and shearing elements to enhance dispersion; low-viscosity TPS masterbatch uses more conveying elements to improve production efficiency.
4.1.2 Taolo e Nepahetseng ea Mocheso, Avoiding TPE Degradation.
TPEs are sensitive to temperature, and excessive temperature or temperature fluctuation can lead to material degradation (such as TPU hydrolysis, TPC chain scission). All Zhuoyue’s extruders adopt an advanced intelligent temperature control system, ka 4-6 independent temperature control sections, temperature control precision of ±1℃, and real-time temperature monitoring and alarm functions. The barrel adopts a double-layer jacket design, realizing rapid heating and cooling, and improving temperature response speed. The die head is equipped with an independent temperature control device, ensuring stable shaping of the masterbatch strip.
4.1.3 High Wear Resistance and Corrosion Resistance.
Some TPE masterbatches (such as TPA, TPC) contain high-hardness pigments or additives, which can wear the screw and barrel. Zhuoyue’s extruders use high-quality wear-resistant materials and advanced manufacturing technologies: HTS PLUS/SUPER/HTE series screws and barrels are made of imported wear-resistant alloy steel, undergoing bimetallic composite or laser cladding treatment, surface hardness ≥65 HRC (HTS SUPER series ≥70 HRC), service life 2-3 times that of ordinary extruders; HTS BASIC/ZTE series screws and barrels are nitrided, surface hardness ≥60 HRC, meeting the needs of ordinary TPE masterbatch processing.
4.1.4 Vacuum Exhaust and Moisture Removal Capabilities.
TPEs such as TPU and TPA have high water absorption, and moisture can cause bubbles and defects in the masterbatch. All Zhuoyue’s mid-to-high-end extruders (HTS PLUS/SUPER/HTE) are equipped with a vacuum exhaust device, which can effectively remove moisture, volatile substances, and air in the material, ensuring the density and quality of the masterbatch. The vacuum degree is adjustable (0.06-0.09MPa), adapting to different moisture content requirements.
4.1.5 High Production Efficiency and Energy Saving.
Zhuoyue’s extruders adopt high-torque gearboxes and optimized screw structures, with strong conveying capacity and high production efficiency. Compared with ordinary extruders, production efficiency is increased by 20%-50%, and energy consumption is reduced by 15%-25%. Ka mohlala, HTS SUPER series production capacity reaches 1000-3000kg/h, suitable for large-scale mass production; ZTE series production capacity is 50-400kg/h, suitable for small-batch production.
4.1.6 Intelligent Control and Easy Operation.
All extruders adopt a PLC intelligent control system and touch screen operation interface, which can store up to 100 sets of formula and processing parameters. When switching between different TPE masterbatches, only the corresponding parameters need to be called, avoiding repeated debugging. The HTS SUPER series is equipped with cloud control functions, realizing remote parameter adjustment, production data monitoring, le tlhokomelo e boletsoeng esale pele, realizing intelligent production management.
4.1.7 Bophara bo Fetohang.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (mmala masterbatch, masterbatch e thibelang malakabe, antistatic masterbatch), with pigment content ranging from 10% ho 70%. They can also be matched with auxiliary equipment (high-speed mixers, dryers, coolers, granulators) to form a complete automatic production line.
4.2 Detailed Introduction of Zhuoyue’s Extruder Series for TPE Masterbatch Processing
Each series of Zhuoyue’s extruders has unique performance characteristics and targeted adaptation scenarios, and manufacturers can select the appropriate series according to their TPE type, sekala sa tlhahiso, le litlhoko tsa kopo.
4.2.1 HTS BASIC Series: Flexible and Cost-Effective for Ordinary TPE Masterbatch.
The HTS BASIC series is a cost-effective product designed for small and medium-sized manufacturers producing ordinary TPE masterbatch (TPS, low-concentration TPO/TPU masterbatch). It uses medium-torque gearboxes from leading European manufacturers, specific torque 10-12Nm/cm³, screw diameter 30-65mm, production capacity 100-500kg/h.
The series adopts nitrided screws and barrels, with good wear resistance, suitable for ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a PLC control system, automatic temperature control, le ho fepa, simple to operate. The modular screw design allows flexible configuration according to TPS/TPO masterbatch requirements. The HTS BASIC series is an ideal choice for small and medium-sized manufacturers with limited budget, focusing on ordinary TPE masterbatch production (such as household goods, ordinary wires and cables).
4.2.2 HTS PLUS Series: High-Torque for Engineering TPE and High-Concentration Masterbatch.
The HTS PLUS series is positioned as a mid-to-high-end product, specially designed for high-demand TPE masterbatch processing (VAT, TPU, high-concentration TPE masterbatch, masterbatch e thibelang malakabe). It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 13-16Nm/cm³, screw diameter 40-75mm, production capacity 300-1200kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with excellent wear resistance and corrosion resistance, suitable for TPV/TPC masterbatch processing (high viscosity, high-hardness pigments). It is equipped with a 5-6 section precise temperature control system and vacuum exhaust device, avoiding TPU hydrolysis and TPC degradation. The enhanced mixing elements ensure uniform dispersion of high-concentration pigments (50%-70%) and functional additives (tse thibelang malakabe, antistatic agents). The HTS PLUS series is suitable for medium-sized and large-scale manufacturers producing high-quality TPE masterbatch (such as automotive seals, high-grade wires and cables, lisebelisoa tsa bongaka).
4.2.3 HTS SUPER Series: Ultra-High Performance for High-End TPE Masterbatch.
The HTS SUPER series is Zhuoyue’s highest-end extruder series, representing the advanced level of China’s twin-screw extruders, designed for high-end, high-demand TPE masterbatch processing (TPA, TPC, ultra-high-concentration masterbatch, masterbatch for new energy vehicles/aerospace).
It adopts Zhuoyue’s latest ultra-high torque transmission device, specific torque 17-20Nm/cm³, screw diameter 50-95mm, production capacity 1000-3000kg/h. The screws are made of new wear-resistant alloy steel, undergoing laser cladding treatment (surface hardness ≥70 HRC), service life 3-4 times that of ordinary extruders. The barrel adopts a double-layer jacket + forced cooling structure, temperature control precision ±1℃, suitable for high-temperature TPE processing (220-290℃). The multi-stage mixing screw combination ensures ultra-high mixing uniformity (≥98%), suitable for ultra-high-concentration masterbatch (70%-80%) and TPA/TPC masterbatch processing.
The series is equipped with an intelligent cloud control system, realizing remote parameter adjustment, fault early warning, le tlhokomelo e boletsoeng esale pele. It is suitable for large-scale, high-standard manufacturers producing high-end TPE masterbatch (such as automotive high-temperature hoses, precision electrical connectors, aerospace components).
4.2.4 ZTE Series: Cost-Effective for Universal TPE Masterbatch.
The ZTE series is positioned as a cost-effective product, designed for manufacturers balancing processing quality and cost, producing universal ordinary TPE masterbatch (low-concentration TPS/TPO/TPU masterbatch). It adopts a twin-screw parallel co-rotating structure, specific torque 8-11Nm/cm³, screw diameter 25-65mm, production capacity 50-400kg/h.
The series uses nitrided screws and barrels (surface hardness ≥60 HRC), meeting the needs of ordinary TPE masterbatch processing (pigment content ≤50%). It is equipped with a 4-section temperature control system, simple touch screen operation, easy to learn and master. The ZTE series has a simple structure, tšebeliso e tlase ea matla, and low maintenance cost, suitable for small manufacturers, small workshops, and enterprises producing small-batch, multi-variety TPE masterbatch (such as small toys, local household goods).
4.2.5 HTE Series: High Performance and Cost-Effective Integrated Solution.
The HTE series integrates high performance and cost-effectiveness, designed for medium-sized manufacturers upgrading product quality and expanding production scale. It adopts high-torque gearboxes independently developed by Zhuoyue, specific torque 12-14Nm/cm³, screw diameter 35-70mm, production capacity 200-800kg/h.
The series uses bimetallic composite screws and barrels (surface hardness ≥65 HRC), with good wear resistance, suitable for TPU/TPO masterbatch processing. It adopts an optimized screw structure and high-efficiency energy-saving motor, energy consumption reduced by 18%-25% compared with ordinary extruders. The 5-section precise temperature control system and vacuum exhaust device ensure product quality, and the enhanced mixing elements ensure uniform dispersion. The HTE series balances performance and cost, suitable for medium-sized manufacturers producing medium-grade TPE masterbatch (such as automotive interior components, ordinary medical devices, mid-grade wires and cables).
5. Common Problems and Solutions in TPE Masterbatch Twin-Screw Extrusion Processing
In TPE masterbatch processing, ka lebaka la thepa e ikhethang ea li-TPE (temperature sensitivity, moisture absorption, high viscosity), various problems often occur, affecting product quality and production efficiency. Based on years of experience, Zhuoyue summarizes common problems, analyzes their causes, and provides corresponding solutions to help manufacturers quickly solve production problems.
5.1 Problem 1: Poor Dispersibility, Color Spots and Streaks in Masterbatch
Manifestation: Uneven coloring of masterbatch, obvious pigment agglomerates, color spots and streaks in TPE products, reducing product aesthetics and mechanical properties.
Causes: (1) Raw materials: Pigment particle size is too large, agglomeration is serious; poor compatibility between pigment/carrier and TPE; insufficient dispersant dosage. (2) Ho kopanya: Low mixing speed, short mixing time, uneven premixing. (3) Extrusion parameters: Low screw speed, insufficient shear force; low extrusion temperature, incomplete melting of TPE carrier. (4) Thepa: Worn screw mixing elements; blocked die head.
Litharollo: (1) Optimize raw materials: Select fine-particle pigments (20-40 letlooeng), dry thoroughly; select carrier compatible with TPE; increase dispersant dosage (1%-5% of pigment dosage). (2) Improve premixing: Increase mixing speed to 800-1200 rpm, extend mixing time to 5-10 metsotso. (3) Adjust extrusion parameters: Increase screw speed (500-800 rpm for high-viscosity TPEs); increase extrusion temperature to ensure complete melting of TPE. (4) Maintain equipment: Replace worn screw elements; clean die head regularly.
5.2 Problem 2: TPE Degradation and Masterbatch Discoloration
Manifestation: Masterbatch discolors (yellowing, darkening), generates peculiar smell; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Causes: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (ho feta 3 metsotso) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Raw materials: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Litharollo: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Increase screw speed, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Optimize raw materials: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Problem 3: High Wear of Screw and Barrel
Manifestation: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Causes: (1) Raw materials: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion parameters: High screw speed, excessive shear force; high extrusion pressure. (3) Thepa: Screw/barrel material has poor wear resistance.
Litharollo: (1) Optimize raw materials: Select small-particle, low-hardness pigments; crush and sieve raw materials; add lubricants to reduce friction. (2) Adjust parameters: Reduce screw speed and extrusion pressure appropriately. (3) Select high-wear-resistant equipment: Choose Zhuoyue’s HTS PLUS/SUPER/HTE series with bimetallic composite or laser-clad screws/barrels.
5.4 Problem 4: Bubbles in Masterbatch
Manifestation: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Causes: (1) Raw materials: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion parameters: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Ho kopanya: Air mixed into the mixture during premixing.
Litharollo: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Adjust extrusion parameters: Increase extrusion temperature; improve vacuum exhaust (vacuum degree ≥0.08MPa). (3) Optimize premixing: Reduce mixing speed appropriately to avoid air mixing; use a closed mixer.
5.5 Problem 5: Poor Processing Fluidity, Equipment Blockage
Manifestation: Difficult material conveying and extrusion; khatello e sa tsitsang ea extrusion; die head or extrusion cavity blockage.
Causes: (1) Raw materials: High TPE viscosity (TPV/TPC); high pigment content (ho feta 70%); high moisture content (causing agglomeration). (2) Extrusion parameters: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Thepa: Worn conveying elements; blocked die head.
Litharollo: (1) Optimize raw materials: Reduce pigment content; select low-viscosity TPE; dry raw materials thoroughly. (2) Adjust parameters: Increase extrusion temperature; increase screw speed; replace die head with larger holes. (3) Maintain equipment: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Practical Application Cases of Zhuoyue Extruders in TPE Masterbatch Processing
To verify the performance advantages of Zhuoyue’s extruders in TPE masterbatch processing, this section introduces several practical cases, covering different TPE categories, production scales, le masimo a kopo, demonstrating the targeted solutions provided by Zhuoyue.
6.1 Nyeoe 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background: A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), ho hanyetsa mocheso (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Tharollo: Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Ea pele, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Ea bobeli, the barrel is equipped with a double-layer jacket + forced cooling structure, ka 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Ea boraro, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Holim'a moo, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect: Kamora 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 likhoeli, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.
6.1 Nyeoe 1: HTS SUPER Series in TPC Masterbatch Processing for Automotive Hoses
Customer Background:
A large automotive component manufacturer in Shanghai, China, produces high-temperature resistant TPC hoses for new energy vehicles. The customer needs to produce TPC masterbatch (pigment content 60%, high-temperature resistant) with requirements of ultra-high dispersibility (no color spots), ho hanyetsa mocheso (260℃), and batch stability. The original equipment had problems of insufficient torque, unstable temperature control, and poor dispersibility, which could not meet the requirements.
Tharollo:
Zhuoyue recommended the HTS SUPER series extruders (screw diameter 75mm, specific torque 18Nm/cm³) combined with a complete automatic production line, including a high-efficiency dryer, high-speed mixer, and precision granulator, tailored to the customer’s TPC masterbatch processing needs. The core configuration and optimization measures are as follows: Ea pele, the screw adopts a multi-stage mixing combination design, integrating high-shear kneading elements and dispersing elements to fully break down pigment agglomerates and ensure uniform dispersion of 60% high-concentration pigments in the TPC matrix. The laser-clad screw surface (hardness ≥70 HRC) effectively resists wear caused by high-hardness pigments, extending the service life by more than 3 times compared to the customer’s original equipment. Ea bobeli, the barrel is equipped with a double-layer jacket + forced cooling structure, ka 6 independent temperature control sections, achieving a temperature control precision of ±1℃. The mixing section temperature is stably controlled at 240-260℃, and the homogenizing section at 230-250℃, strictly matching the TPC processing temperature range to avoid material degradation and pigment discoloration. Ea boraro, the equipment is equipped with a high-efficiency vacuum exhaust device (vacuum degree adjustable up to 0.09MPa), which effectively removes moisture and volatile substances in the TPC raw materials and masterbatch, completely solving the bubble problem caused by moisture absorption. Holim'a moo, the HTS SUPER series is equipped with an intelligent cloud control system, which allows the customer to store the TPC masterbatch processing parameters, call them with one click when switching batches, and monitor production data in real time, improving batch stability and reducing operational errors.
Implementation Effect:
Kamora 1 month of installation and commissioning, the HTS SUPER series extruders officially put into production. The test results show that the TPC masterbatch produced has a mixing uniformity of ≥98%, no color spots or streaks, and the pigment dispersion effect is significantly better than the customer’s original equipment. The masterbatch maintains stable performance after high-temperature processing at 260℃, with no discoloration or degradation, fully meeting the requirements of new energy vehicle automotive hoses. The production capacity reaches 1500kg/h, which is 40% higher than the original equipment, while the energy consumption is reduced by 22%, significantly reducing the customer’s production costs. The wear of screws and barrels is greatly reduced, and the maintenance cycle is extended from 1 month to 6 likhoeli, reducing maintenance costs by more than 50%. The customer’s TPC hoses made of this masterbatch have passed the automotive industry quality certification, with excellent high-temperature resistance and mechanical strength, and have been successfully supplied to major new energy vehicle manufacturers. The customer highly recognized Zhuoyue’s extrusion solution, and subsequently signed a long-term cooperation agreement, purchasing 5 more sets of HTS SUPER series extruders to expand production scale.