Nhựa kỹ thuật Công nghệ ép đùn trục vít đôi tiên tiến Giải pháp xử lý và ứng dụng công nghiệp

Với sự phát triển nhanh chóng của công nghiệp hóa toàn cầu, nhu cầu về vật liệu hiệu suất cao trong ô tô, điện và điện tử, sự thi công, y tế và các lĩnh vực khác đang tăng lên từng ngày. Nhựa kỹ thuật, như một vật liệu hiệu suất cao quan trọng, đã dần thay thế các vật liệu kim loại truyền thống và nhựa thông thường trong nhiều tình huống ứng dụng cốt lõi do tính chất cơ học tuyệt vời của chúng, khả năng chịu nhiệt, chống ăn mòn, độ ổn định kích thước và khả năng xử lý. Công nghệ ép đùn trục vít đôi là công nghệ xử lý cốt lõi của hợp chất nhựa kỹ thuật, và hiệu suất của thiết bị ép đùn quyết định trực tiếp đến chất lượng, Hiệu quả sản xuất và hiệu quả ứng dụng của sản phẩm nhựa kỹ thuật.

Chúng tôi cam kết cung cấp các giải pháp ép đùn trục vít đôi chuyên nghiệp cho gia công nhựa kỹ thuật, dựa vào máy đùn dòng HTS được phát triển và sản xuất độc lập của chúng tôi với hộp số mô-men xoắn cao, được thiết kế đặc biệt cho các đặc tính xử lý và nhu cầu ứng dụng của nhựa kỹ thuật. Bài viết này sẽ trình bày chi tiết một cách toàn diện về các đặc tính hiệu suất, phân loại, khó khăn trong xử lý nhựa kỹ thuật, vai trò cốt lõi của công nghệ ép đùn trục vít đôi trong chế biến nhựa kỹ thuật, những ưu điểm của máy đùn dòng HTS của chúng tôi và khả năng thích ứng có mục tiêu của chúng với nhựa kỹ thuật, cũng như các lĩnh vực ứng dụng cụ thể, kỹ thuật xử lý và các vấn đề và giải pháp chung. Bằng cách bổ sung các thông số kỹ thuật chi tiết, xử lý chi tiết và các trường hợp ứng dụng trong ngành, bài viết sẽ được làm phong phú thêm 3000-4000 từ, cung cấp tài liệu tham khảo toàn diện và chuyên nghiệp cho các doanh nghiệp chế biến nhựa kỹ thuật, kỹ thuật viên và những người hành nghề có liên quan.

1. Tổng quan về ngành Nhựa Kỹ thuật và Đặc tính Hiệu suất Cốt lõi

1.1 Hiện trạng và xu hướng phát triển của ngành Nhựa Kỹ Thuật

Nhựa kỹ thuật là loại vật liệu nhựa có thể được sử dụng làm vật liệu kết cấu và chịu tải trọng cơ học trong phạm vi nhiệt độ rộng.. So với nhựa thông thường (chẳng hạn như polyetylen PE, nhựa PP, PVC polyvinyl clorua), nhựa kỹ thuật có hiệu suất toàn diện tuyệt vời hơn, và có thể đáp ứng các yêu cầu sử dụng khắc nghiệt trong sản xuất công nghiệp và sản xuất sản phẩm cao cấp. Trong những năm gần đây, được thúc đẩy bởi việc nâng cấp các ngành công nghiệp hạ nguồn như ô tô hạng nhẹ, trí tuệ điện và điện tử, và thiết bị y tế cao cấp, Thị trường nhựa kỹ thuật toàn cầu đang có xu hướng tăng trưởng ổn định và nhanh chóng.

Theo dữ liệu ngành liên quan, quy mô thị trường nhựa kỹ thuật toàn cầu đã vượt quá 100 tỷ đô la Mỹ, và dự kiến ​​sẽ duy trì tốc độ tăng trưởng kép hàng năm là 7%-10% trong năm năm tới. Trong số đó, Châu Á - Thái Bình Dương là thị trường sản xuất và tiêu thụ nhựa kỹ thuật lớn nhất thế giới, chiếm hơn 55% về thị phần toàn cầu, chủ yếu là do sự phát triển nhanh chóng của ô tô, ngành công nghiệp điện và điện tử ở Trung Quốc, Ấn Độ và các nước khác, cũng như việc không ngừng nâng cao năng lực hỗ trợ công nghiệp và trình độ đổi mới công nghệ. Trung Quốc, với tư cách là nhà sản xuất và tiêu dùng nhựa kỹ thuật lớn nhất thế giới, có nhu cầu thị trường rất lớn, và sản lượng và tiêu thụ hàng năm đang tăng trưởng với tốc độ hai con số, đặc biệt là trong lĩnh vực xe năng lượng mới, 5truyền thông G, và thiết bị y tế, nhu cầu về nhựa kỹ thuật hiệu suất cao đang có xu hướng tăng trưởng bùng nổ.

Xu hướng phát triển của ngành nhựa kỹ thuật chủ yếu thể hiện ở 5 khía cạnh: Đầu tiên, hiệu suất và chức năng cao. Với sự cải tiến liên tục của các yêu cầu sử dụng ở các lĩnh vực hạ nguồn, nhựa kỹ thuật đang phát triển theo hướng chịu nhiệt cao hơn, sức mạnh cao hơn, khả năng chống mài mòn tốt hơn và các chức năng đặc biệt (chẳng hạn như khả năng chống cháy, chống tĩnh điện, kháng khuẩn, kháng bức xạ), để thích ứng với môi trường làm việc khắc nghiệt của nhiệt độ cao, áp suất cao, ăn mòn và bức xạ; thứ hai, nhẹ và tích hợp. Trong ô tô, hàng không vũ trụ và các lĩnh vực khác, để đạt được mục tiêu tiết kiệm năng lượng và giảm phát thải, Nhựa kỹ thuật ngày càng được sử dụng nhiều hơn để thay thế vật liệu kim loại, và sự tích hợp của thiết kế sản phẩm ngày càng cao hơn, có thể làm giảm số lượng các bộ phận, đơn giản hóa quá trình sản xuất và giảm chi phí; thứ ba, bảo vệ môi trường và khả năng tái chế. Với việc tăng cường các chính sách bảo vệ môi trường toàn cầu và nâng cao nhận thức về bảo vệ môi trường, phát triển và ứng dụng nhựa kỹ thuật có thể tái chế, nhựa kỹ thuật phân hủy sinh học và công nghệ xử lý thân thiện với môi trường đã trở thành trọng tâm của ngành, giảm ô nhiễm môi trường do rác thải nhựa; thứ tư, trí thông minh và độ chính xác của thiết bị xử lý. Nhựa kỹ thuật có độ khó gia công cao và yêu cầu khắt khe về chất lượng, đưa ra yêu cầu cao hơn về thiết bị chế biến. Thông minh, máy đùn trục vít đôi chính xác và hiệu quả và dây chuyền sản xuất tự động đã trở thành xu hướng chủ đạo của ngành, thực hiện giám sát thời gian thực, tự động điều chỉnh tham số và bảo trì dự đoán quá trình xử lý; thứ năm, đa dạng hóa các lĩnh vực ứng dụng. Nhựa kỹ thuật đang dần mở rộng từ ô tô truyền thống, lĩnh vực điện và điện tử sang năng lượng mới, thuộc về y học, hàng không vũ trụ, xây dựng và các lĩnh vực mới nổi khác, mở ra không gian thị trường mới.

Trong bối cảnh này, công nghệ đùn trục vít đôi, là công nghệ xử lý cốt lõi của các hợp chất nhựa kỹ thuật, đã trở thành chìa khóa nâng cao năng lực cạnh tranh của các doanh nghiệp nhựa kỹ thuật. Nhựa kỹ thuật rất nhạy cảm với quá nhiệt và suy thoái thủy phân, và có yêu cầu cao về nhiệt độ xử lý, lực cắt, độ chính xác kiểm soát thời gian và nhiệt độ. Máy đùn dòng HTS của chúng tôi được thiết kế đặc biệt cho các đặc tính xử lý của nhựa kỹ thuật, với mô-men xoắn cao, tốc độ cao, precise temperature control and excellent dispersibility, which can effectively solve the processing difficulties of engineering plastics and help enterprises achieve high-quality, efficient and stable production.

1.2 Core Performance Characteristics of Engineering Plastics

Compared with general plastics and metal materials, engineering plastics have unique comprehensive performance, which determines their wide application in various industrial fields. The core performance characteristics of engineering plastics are mainly reflected in the following five aspects, which also put forward special requirements for their processing technology and equipment:

1.2.1 Excellent Heat Resistance and Cold Resistance

Engineering plastics have a wide temperature adaptation range, which can maintain good mechanical properties (sức mạnh, sự dẻo dai, độ cứng) trong cả môi trường nhiệt độ cao và nhiệt độ thấp. So với nhựa thông thường, thường mất tính chất cơ học ở 80-120oC, hầu hết các loại nhựa kỹ thuật có thể hoạt động ổn định ở 100-250oC, và một số loại nhựa kỹ thuật đặc biệt (chẳng hạn như PEEK, PI) thậm chí có thể làm việc ở nhiệt độ trên 300oC. Đồng thời, nhựa kỹ thuật cũng có khả năng chịu lạnh tốt, có thể duy trì độ dẻo dai tốt ở nhiệt độ thấp (dưới -40oC), và không dễ bị gãy giòn. Hiệu suất này làm cho nhựa kỹ thuật phù hợp để sử dụng trong môi trường nhiệt độ khắc nghiệt, chẳng hạn như các bộ phận động cơ ô tô (nhiệt độ cao) và thiết bị điện ngoài trời (nhiệt độ thấp).

Khả năng chịu nhiệt tuyệt vời của nhựa kỹ thuật chủ yếu là do cấu trúc phân tử đặc biệt của chúng (chẳng hạn như vòng thơm, vòng dị vòng) và lực liên phân tử mạnh, khiến chúng không dễ tan chảy và phân hủy ở nhiệt độ cao. Tuy nhiên, điều này cũng mang lại những khó khăn nhất định cho việc xử lý: nhiệt độ xử lý cao hơn là cần thiết để làm cho chúng tan chảy và dẻo hóa, và cần phải kiểm soát nhiệt độ chính xác để tránh sự phân hủy nhiệt.

1.2.2 Khả năng chống ăn mòn và độ bền tốt

Nhựa kỹ thuật có tính ổn định hóa học tuyệt vời và khả năng chống ăn mòn, và không dễ bị ăn mòn bởi axit, chất kiềm, muối, dung môi hữu cơ và các hóa chất khác. So với vật liệu kim loại, dễ bị rỉ sét và ăn mòn, nhựa kỹ thuật có tuổi thọ cao hơn trong môi trường hóa học khắc nghiệt. Ví dụ, polyamide (PA) nhựa kỹ thuật có khả năng chống lại hầu hết các dung môi hữu cơ và axit và kiềm yếu; polycacbonat (máy tính) nhựa kỹ thuật có khả năng chống ăn mòn bởi axit và muối không oxy hóa; polyphenylen sunfua (PPS) nhựa kỹ thuật có khả năng chống ăn mòn bởi hầu hết các hóa chất ngoại trừ axit oxy hóa mạnh.

Ngoài ra, nhựa kỹ thuật có khả năng chống chịu thời tiết tốt và chống lão hóa, và không dễ bị phân hủy và lão hóa dưới tác động của ánh sáng mặt trời, cơn mưa, oxy và các yếu tố môi trường khác, đảm bảo sử dụng ổn định lâu dài trong môi trường ngoài trời và khắc nghiệt. Hiệu suất này làm cho nhựa kỹ thuật được sử dụng rộng rãi trong các thiết bị hóa học, thiết bị điện ngoài trời, phụ tùng ngoại thất ô tô và các lĩnh vực khác.

1.2.3 Dễ dàng xử lý và hiệu quả sản xuất cao

So với vật liệu kim loại, nhựa kỹ thuật có ưu điểm là dễ gia công, quy trình sản xuất đơn giản và hiệu quả sản xuất cao. Vật liệu kim loại thường cần các quy trình xử lý phức tạp như rèn, vật đúc, gia công, có mức tiêu thụ năng lượng cao, hiệu quả thấp và chi phí cao; while engineering plastics can be processed by extrusion, injection molding, blow molding and other methods, which can realize mass production, simplify the production process, reduce energy consumption and production cost. Ví dụ, the processing cycle of an engineering plastic automotive part by injection molding is only a few seconds to tens of seconds, while the processing cycle of the same metal part may take several hours to several days.

Tuy nhiên, engineering plastics also have certain processing difficulties: they are sensitive to overheating and hydrolytic degradation, and are easy to decompose if the processing temperature is too high or the residence time is too long; at the same time, some engineering plastics (chẳng hạn như PA) have high water absorption, which affects the processing effect and product quality. Therefore, cần sử dụng thiết bị chế biến chuyên nghiệp, kỹ thuật chế biến khoa học để đảm bảo chất lượng chế biến..

1.2.4 Độ ổn định kích thước tuyệt vời và cách điện

Nhựa kỹ thuật có độ ổn định kích thước tốt, và tỷ lệ co ngót là nhỏ (thường xuyên 0.3%-1.5%) trong quá trình chế biến và sử dụng, có thể đảm bảo độ chính xác về kích thước của sản phẩm và tránh biến dạng. Hiệu suất này đặc biệt quan trọng đối với các bộ phận có độ chính xác cao, chẳng hạn như đầu nối điện, linh kiện chính xác ô tô, thiết bị y tế, vân vân. Độ ổn định kích thước tốt của nhựa kỹ thuật chủ yếu là do độ kết tinh cao của chúng, hấp thụ nước thấp (ngoại trừ một số giống như PA) và lực liên phân tử mạnh.

Ngoài ra, hầu hết các loại nhựa kỹ thuật đều có hiệu suất cách điện tuyệt vời, có thể duy trì hiệu suất cách nhiệt tốt trong dải nhiệt độ và dải tần rộng, và không dễ dẫn điện và hồ quang. Điều này làm cho nhựa kỹ thuật được sử dụng rộng rãi trong lĩnh vực điện, điện tử, chẳng hạn như bảng dây, quan hệ cáp, đầu nối, rơle, động cơ và các thành phần điện khác.

1.2.5 Trọng lượng nhẹ và cường độ riêng cao, Khả năng chống mài mòn vượt trội

Nhựa kỹ thuật có đặc tính nhẹ (mật độ là 1/3-1/5 vật liệu kim loại) và cường độ riêng cao (cường độ trên một đơn vị trọng lượng tương đương hoặc thậm chí cao hơn vật liệu kim loại). Ví dụ, cường độ riêng của polyamit gia cố bằng sợi thủy tinh (PA66+GF30) cao hơn thép cacbon thông thường, có thể giảm trọng lượng của sản phẩm một cách hiệu quả đồng thời đảm bảo hiệu suất cơ học. Hiệu suất này đặc biệt quan trọng trong ô tô, hàng không vũ trụ và các lĩnh vực khác theo đuổi trọng lượng nhẹ và tiết kiệm năng lượng, which can reduce fuel consumption and carbon emissions.

Đồng thời, engineering plastics also have outstanding wear resistance and friction resistance, and the friction coefficient is small, which can be used in the production of wear-resistant parts (such as gears, bearings, sliding blocks) without additional lubrication or with less lubrication, reducing the maintenance cost of products. Ví dụ, polyoxymethylene (POM) engineering plastics have excellent wear resistance and are known as “plastic steel”, which is widely used in the production of automotive gears, electrical components and other wear-resistant parts.

1.3 Common Classification of Engineering Plastics

Engineering plastics can be divided into different types according to their chemical structure, performance level and application field. The common classification methods are as follows, giúp hiểu rõ hơn về đặc điểm xử lý và kịch bản ứng dụng của các loại nhựa kỹ thuật khác nhau, và lựa chọn thiết bị ép đùn và kỹ thuật xử lý thích hợp:

1.3.1 Phân loại theo mức độ hiệu suất

Theo mức độ thực hiện, Nhựa kỹ thuật có thể được chia thành nhựa kỹ thuật tổng hợp và nhựa kỹ thuật đặc biệt.

• Nhựa Kỹ Thuật Tổng Hợp: Chúng là loại nhựa kỹ thuật được sử dụng rộng rãi nhất, với công nghệ sản xuất tương đối trưởng thành, giá vừa phải và hiệu suất toàn diện tốt. Các giống chính bao gồm polyamit (PA), polycacbonat (máy tính), polyoxymethylene (POM), polyetylen terephthalat (THÚ CƯNG), polybutylen terephthalat (PBT), vân vân. Nhựa kỹ thuật tổng hợp chủ yếu được sử dụng trong ô tô, điện và điện tử, thiết bị gia dụng và các lĩnh vực khác, chẳng hạn như phụ tùng ô tô, kết nối điện, vỏ thiết bị gia dụng, vân vân.
• Nhựa kỹ thuật đặc biệt: Họ có hiệu suất tuyệt vời hơn (chẳng hạn như khả năng chịu nhiệt cao hơn, chống ăn mòn, tính chất cơ học) hơn nhựa kỹ thuật nói chung, nhưng công nghệ sản xuất phức tạp và giá thành cao. Các giống chính bao gồm polyphenylene sulfide (PPS), xeton polyether ether (PEEK), polyimit (PI), polysulfone (PSU), polyethersulfone (PES), vân vân. Nhựa kỹ thuật đặc biệt chủ yếu được sử dụng trong các lĩnh vực cao cấp như hàng không vũ trụ, thiết bị y tế, năng lượng mới, và thiết bị hóa chất, chẳng hạn như các thành phần hàng không vũ trụ, cấy ghép y tế, linh kiện điện chịu nhiệt độ cao, vân vân.

1.3.2 Phân loại theo cấu trúc hóa học

Theo cấu trúc hóa học của chuỗi phân tử, nhựa kỹ thuật có thể được chia thành polyamit (PA), polycacbonat (máy tính), polyoxymethylene (POM), polyester (THÚ CƯNG, PBT), polyphenylen sunfua (PPS), xeton polyether ether (PEEK), vân vân. Mỗi loại nhựa kỹ thuật có đặc tính hoạt động và yêu cầu xử lý riêng:

• Polyamide (PA): Còn được gọi là nylon, nó có độ bền cơ học tuyệt vời, chống mài mòn, độ dẻo dai và kháng hóa chất, nhưng có khả năng hấp thụ nước cao, ảnh hưởng đến sự ổn định kích thước. Các giống phổ biến bao gồm PA6, PA66, PA11, PA12, vân vân. It is widely used in automotive parts (gears, bearings, intake manifolds), kết nối điện, textile fibers, vân vân.
• Polycarbonate (máy tính): It has excellent transparency, sức mạnh tác động, heat resistance and electrical insulation, but has poor wear resistance and is easy to scratch. It is widely used in electrical and electronic fields (wiring boards, lamp covers), automotive fields (headlamp lenses, instrument panels), medical fields (medical containers), vân vân.
• Polyoxymetylen (POM): It has excellent wear resistance, friction resistance, dimensional stability and mechanical strength, and is not easy to absorb water. It is known as “plastic steel” and is widely used in automotive parts (gears, sliding blocks), linh kiện điện (công tắc, bearings), mechanical parts, vân vân.
• Polyester (THÚ CƯNG, PBT): PET has excellent transparency, heat resistance and mechanical strength, and is mainly used in fibers, phim, bottles and other fields; PBT has excellent chemical resistance, electrical insulation and processing fluidity, and is widely used in electrical and electronic fields (đầu nối, rơle), phụ tùng ô tô, vân vân.
• Polyphenylene Sulfide (PPS): It has excellent heat resistance (long-term use temperature up to 200-220℃), chống ăn mòn, flame retardancy and electrical insulation, but has poor toughness. It is widely used in high-temperature resistant electrical components, automotive engine parts, chemical equipment, vân vân.
• Polyether Ether Ketone (PEEK): 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, cấy ghép y tế, and high-temperature resistant electrical components.

1.3.3 Phân loại theo trường ứng dụng

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, vân vân. Different application fields have different requirements on the performance of engineering plastics. Ví dụ, 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, injection molding, blow molding, 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) và bán thành phẩm (chẳng hạn như đường ống, tấm, sợi). So với công nghệ đùn trục vít đơn, Công nghệ ép đùn trục vít đôi có ưu điểm là lực cắt mạnh, hiệu ứng trộn tốt, kiểm soát nhiệt độ chính xác, thời gian cư trú ngắn và khả năng thích ứng mạnh mẽ với nguyên liệu thô, có thể giải quyết hiệu quả những khó khăn trong xử lý nhựa kỹ thuật (chẳng hạn như độ nhạy với quá nhiệt và suy thoái thủy phân, hiệu ứng trộn kém, hiệu quả xử lý thấp) và đảm bảo chất lượng sản phẩm nhựa kỹ thuật.

2.1 Khó khăn trong xử lý nhựa kỹ thuật và yêu cầu đối với thiết bị ép đùn

Như đã đề cập trước đó, nhựa kỹ thuật có hiệu suất toàn diện tuyệt vời, nhưng độ khó xử lý của chúng cũng cao hơn so với nhựa thông thường, chủ yếu là do cấu trúc phân tử đặc biệt và đặc tính hiệu suất của chúng. Những khó khăn chính trong quá trình xử lý nhựa kỹ thuật và các yêu cầu tương ứng đối với thiết bị ép đùn như sau:

2.1.1 Nhạy cảm với quá nhiệt và phân hủy thủy phân

Hầu hết các loại nhựa kỹ thuật (chẳng hạn như PA, PBT, PPS) nhạy cảm với quá nhiệt và suy thoái thủy phân. Nếu nhiệt độ xử lý quá cao hoặc thời gian lưu trong máy đùn quá dài, chuỗi phân tử của nhựa kỹ thuật sẽ bị đứt, dẫn đến phân hủy nhiệt, sẽ làm giảm tính chất cơ học, khả năng chịu nhiệt và hiệu suất khác của sản phẩm, và thậm chí gây ra sự đổi màu, cacbon hóa và các khuyết tật khác. Ngoài ra, some engineering plastics (chẳng hạn như PA) have high water absorption, và độ ẩm trong vật liệu sẽ gây ra sự phân hủy thủy phân trong quá trình xử lý ở nhiệt độ cao, ảnh hưởng tới chất lượng sản phẩm.

Điều này đặt ra hai yêu cầu chính đối với thiết bị ép đùn: Đầu tiên, precise temperature control capacity, which can strictly control the processing temperature within the optimal range of engineering plastics, avoid local overheating, and the temperature control precision should reach ±1℃; thứ hai, short residence time, which can reduce the time that the material stays in the extruder barrel, avoid thermal decomposition and hydrolytic degradation. Twin-screw extruders have the advantages of short residence time (thường xuyên 1-5 phút) and precise temperature control, which are more suitable for engineering plastics processing than single-screw extruders (residence time 5-10 phút).

2.1.2 High Requirements on Mixing and Dispersing Effect

In engineering plastics processing, it is often necessary to add modifiers (such as glass fiber, sợi carbon, bột talc, chất chống cháy, chất tương thích) to improve the performance of the product (such as reinforcing, toughening, chất chống cháy). Ví dụ, 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. Ngoài ra, the modular design of the twin-screw can freely combine different screw elements (such as conveying elements, trộn các yếu tố, 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, PEEK) 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; at the same time, 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, áp lực , 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, đường ống, tấm, sợi) 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 (chẳng hạn như PA, máy tính, POM), modifiers (such as glass fiber, sợi carbon, bột talc, chất chống cháy), chất tương thích, chất bôi trơn và các chất phụ gia khác. Các bước tiền xử lý như sau:

• Xử lý sấy khô: Hầu hết các loại nhựa kỹ thuật (chẳng hạn như PA, PBT, PPS) have high water absorption, và độ ẩm trong nguyên liệu thô sẽ gây ra sự phân hủy thủy phân trong quá trình xử lý ở nhiệt độ cao, dẫn đến lỗi sản phẩm (chẳng hạn như bong bóng, vết nứt, giảm tính chất cơ học). Therefore, nguyên liệu phải được sấy khô trước khi chế biến. Nhiệt độ và thời gian sấy được xác định tùy theo loại nhựa kỹ thuật: Ví dụ, PA6 được sấy khô ở nhiệt độ 80-100oC trong 4-6 giờ, PA66 được sấy khô ở 100-120oC trong 6-8 giờ, PBT được sấy khô ở 120-140oC trong 2-4 giờ, PPS được sấy khô ở 150-160oC cho 3-5 giờ. Độ ẩm của nguyên liệu khô phải được kiểm soát dưới đây 0.1%-0.2%.
• Xử lý trộn trước: Theo công thức tỷ lệ, nhựa kỹ thuật khô, chất biến tính và chất phụ gia được đưa vào máy trộn tốc độ cao để trộn trước. 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. The mixing speed is generally 800-1200 vòng/phút, and the mixing time is 5-10 phút. 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 tan chảy, 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).

Đồng thời, 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, which is combined with the external heating of the barrel (electric heating or steam heating) to make the engineering plastic resin gradually melt and plasticize.

The barrel of the extruder is usually divided into 4-6 temperature control sections (feeding section, melting section, mixing section, homogenizing section, die head section), and the temperature of each section is precisely controlled according to the type of engineering plastic. Ví dụ, 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

The fully melted, 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 (hạt), 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, tấm, sợi, 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, đường ống, tấm). 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 Làm mát và hóa rắn

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 phút; 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 (hạt), 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 (the particle size is generally 2-5mm, which can be adjusted according to customer needs). 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.

Ngoài ra, the final product also needs to undergo post-processing steps such as screening, inspection and packaging. The screening step is to remove unqualified products (such as too large, too small or agglomerated particles); the inspection step is to detect the performance (such as mechanical strength, khả năng chịu nhiệt, dimensional accuracy) 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, mainly including raw material characteristics, formula ratio, premixing effect, extrusion parameters and die head structure. 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 Raw Material Characteristics

The type, particle size, moisture content and purity of raw materials have a great impact on the extrusion effect. Ví dụ, 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%; if the moisture content is too high, 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, dust) 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. Ví dụ, adding 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, cải thiện tính lưu loát xử lý, 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 Premixing Effect

Premixing is the foundation of extrusion processing. The uniformity of premixing directly affects the mixing and dispersing effect of modifiers during extrusion. If the premixing is uneven, 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. To ensure the premixing effect, it is necessary to control the mixing speed, mixing time and mixing temperature: the mixing speed is 800-1200 vòng/phút, the mixing time is 5-10 phút, and the mixing temperature is controlled at 40-60℃ (appropriate temperature can improve the adhesion of additives and promote uniform mixing).

2.3.4 Extrusion Parameters

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

• Tốc độ trục vít: The screw speed of twin-screw extruders for engineering plastics generally ranges from 100 ĐẾN 1000 vòng/phút. Our HTS series extruders can reach a maximum speed of 1000 vòng/phút. 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. Tuy nhiên, 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, PEEK), 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, which is mainly to enhance the shear and mixing effect, and promote the uniform dispersion of modifiers; the temperature of the homogenizing section is slightly lower than the mixing section, which is mainly to ensure the uniform temperature and viscosity of the materials, and avoid thermal decomposition; the temperature of the die head section is slightly lower than the homogenizing section, 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.
• Extrusion Pressure: The extrusion pressure of engineering plastics twin-screw extrusion generally ranges from 5 to 15MPa. The pressure in the extrusion cavity is mainly determined by the compression ratio of the screw, the die hole size and the screw speed. The higher the extrusion pressure, the better the mixing and dispersing effect of materials, and the denser the product. Tuy nhiên, if the pressure is too high, it will increase the energy consumption and wear of the equipment, and even cause the die head to block; if the pressure is too low, the materials cannot be fully compressed and mixed, the product is loose, and the performance is unstable. 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 Die Head Structure

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 (hạt), 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. According to the processing characteristics of engineering plastics (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, high viscosity) and application needs, we have developed the HTS series twin-screw extruders specially for engineering plastics processing. Our HTS series extruders adopt high-torque gearboxes, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm, which can obtain higher output, shorter residence time, better dispersibility and more precise temperature control, perfectly adapting to the processing needs of various engineering plastics.

3.1 Core Advantages of HTS Series Extruders for Engineering Plastics Processing

3.1.1 High Torque and High Speed, High Production Efficiency

Engineering plastics have high viscosity and poor processing fluidity, which require the extruder to have strong torque and conveying capacity. Our HTS series extruders adopt high-torque gearboxes independently developed and manufactured by us (HTS PLUS 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.

Đồng thời, 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. Ngoài ra, 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 phút, which is much shorter than that of ordinary twin-screw extruders (5-10 phút) and single-screw extruders (10-15 phút). 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.

Ngoài ra, 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 Precise Temperature Control, 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℃, which can strictly control the processing temperature within the optimal range of engineering plastics, 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.

Ngoài ra, 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, sợi carbon, bột talc), 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, trộn các yếu tố, shearing elements) can be freely combined according to the type of engineering plastic and modifier. Ví dụ, 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 High Wear Resistance, Long Service Life

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 (such as 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), which has extremely strong wear resistance and corrosion resistance, and can effectively resist the wear caused by high-hardness modifiers. This greatly extends the service life of the screw and barrel: 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.

Ngoài ra, we also provide professional wear detection services for the screw and barrel. Our technical team will regularly detect the wear degree of the screw and barrel for customers, issue a detailed wear report, and put forward targeted replacement and maintenance suggestions, 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, máy tính, POM, THÚ CƯNG, PBT) and special engineering plastics (PPS, PEEK, 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, vân vân.

The modular design of the HTS series extruders (vít, thùng, đầu chết, vân vân.) 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. Ngoài ra, the HTS series extruders can also be matched with different auxiliary equipment (such as high-speed mixers, dryers, 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, Easy Operation and Maintenance

The HTS series extruders adopt a PLC intelligent control system and a touch screen operation interface, which is simple and intuitive, easy to operate. The system can store multiple sets of product formulas and processing parameters. When customers produce different types of engineering plastics, they only need to call the corresponding formula and parameters, without repeated debugging, which saves time and improves production efficiency.

The system is also equipped with a real-time monitoring function, which can monitor the key parameters of the extrusion process (such as temperature, áp lực , tốc độ vít, 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.

Ngoài ra, the HTS series extruders adopt a reasonable structural design, which makes the maintenance more convenient. The screw, thùng, die head and other components can be disassembled and assembled quickly, which reduces the maintenance time and labor intensity. Our after-sales service team will provide professional installation, commissioning and training services for customers, ensuring that customers can use the equipment smoothly.

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. Each series has its own characteristics and targeted adaptation scenarios, which can be selected by customers according to their own production scale, product type, budget and other factors.

3.2.1 HTS BASIC Series Extruders: 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, low noise, 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, THÚ CƯNG, PBT) and low-to-medium modified engineering plastics (such as glass fiber reinforced PA with filling amount ≤30%).

Về mặt thiết kế kết cấu, 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, đầu chết, 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.

The HTS PLUS series extruders have a screw diameter ranging from 65mm to 110mm, a compression ratio of 5～10, and a screw speed range of 200～800 rpm. The screw and barrel adopt bimetallic composite treatment, which has higher wear resistance and corrosion resistance (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, which can realize precise control of extrusion parameters and real-time monitoring of production data, ensuring the stability of the extrusion process and the quality of the product.

The production capacity of the HTS PLUS series extruders ranges from 500kg/h to 2000kg/h, which is suitable for the large-scale production of general engineering plastics, high-modified engineering plastics and special engineering plastics (such as PPS). This series of extruders has excellent mixing and dispersing effect, short residence time and high production efficiency, which can effectively solve the processing difficulties of high-viscosity and high-modified engineering plastics, and help enterprises improve product quality and production efficiency.

3.2.3 HTS SUPER Series Extruders: Top-End Choice for High-End Engineering Plastics

The HTS SUPER series extruders adopt the latest ultra-high torque transmission device independently developed by us, with a specific torque of 14Nm/cm³ and a maximum speed of up to 1000rpm. Aiming at the high torque and high speed characteristics of this series, the structural design of each key component of the extruder has been completely optimized, which is our highest-end extruder series, representing the advanced level of China’s extruder development. This series of extruders is mainly designed for the processing of high-end special engineering plastics (chẳng hạn như 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.

The HTS SUPER series extruders have a screw diameter ranging from 80mm to 130mm, a compression ratio of 6～12, and a screw speed range of 250～1000 rpm. The screw and barrel adopt imported wear-resistant alloy steel and laser cladding technology, 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 phút) and precise temperature control can effectively avoid the thermal decomposition of special engineering plastics, ensuring the excellent performance of the product. Ngoài ra, 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, enterprises need to comprehensively consider their own production needs, product types, processing scale, budget and other factors to ensure that the selected equipment can meet the actual processing needs and bring maximum economic benefits. The following are some specific selection suggestions:

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, THÚ CƯNG, 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 (PEEK, 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. For small-scale production (100kg/giờ – 500kg/giờ), 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/giờ – 2000kg/giờ), 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/giờ – 3000kg/giờ), 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, chất tương thích, reinforcing agents) at the same time, 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. Ví dụ, 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. Ngoài ra, 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. Ngoài ra, enterprises should also consider the after-sales service of the equipment. Our HTS series extruders provide a complete after-sales service system, including installation, vận hành thử, technical training, regular maintenance and quick replacement of spare parts, which can reduce the later operation risk of enterprises.

3.3.5 Consider the Compatibility with Auxiliary Equipment

Twin-screw extrusion processing of engineering plastics needs to be matched with a series of auxiliary equipment, such as raw material drying equipment, high-speed mixer, cooler, granulator, screening machine, packaging machine, vân vân. 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. Ví dụ, 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

Nhựa kỹ thuật, with their excellent comprehensive performance, have been widely used in automotive, điện và điện tử, thuộc về y học, hàng không vũ trụ, hóa chất, 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. Dưới, 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: Nhẹ, 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, máy tính, PBT, PPS, vân vân., which are mainly used in engine parts, interior parts, exterior parts and electrical components. The core requirements for extrusion processing are: nhẹ, high temperature resistance, chống mài mòn, dimensional stability and low VOC (hợp chất hữu cơ dễ bay hơi), đòi hỏi máy đùn phải kiểm soát nhiệt độ chính xác, hiệu quả trộn và phân tán tuyệt vời và năng lực sản xuất ổn định.

Đối với các bộ phận nội thất ô tô (chẳng hạn như bảng điều khiển, tấm cửa, ống dẫn khí) làm bằng nhựa kỹ thuật tổng hợp (PA6, POM, Hợp kim PC/ABS), máy đùn dòng HTS BASIC có thể đáp ứng nhu cầu xử lý. Cấu hình linh hoạt của nó có thể điều chỉnh các thông số xử lý theo yêu cầu hiệu suất của các bộ phận bên trong, đảm bảo bề mặt mịn và ổn định kích thước của sản phẩm, và mức tiêu thụ năng lượng thấp và chi phí của nó có thể làm giảm chi phí sản xuất phụ tùng ô tô. Đối với các bộ phận động cơ ô tô (chẳng hạn như ống nạp, nắp đầu xi lanh, chảo dầu) làm bằng nhựa kỹ thuật chịu nhiệt độ cao và chịu mài mòn (PA66+GF30, PPS), máy đùn dòng HTS PLUS phù hợp hơn. 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 (PEEK, 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.

Nghiên cứu điển hình: 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 phút) 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% ĐẾN 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, wiring boards, rơle, động cơ, quan hệ cáp, lamp covers and other components. The core requirements for extrusion processing are: excellent electrical insulation, khả năng chống cháy, ổn định kích thước, corrosion resistance and low toxicity, đòi hỏi máy đùn phải kiểm soát nhiệt độ chính xác, good mixing and dispersing effect and strict quality control capacity.

For general electrical components (such as cable ties, đầu nối) làm bằng nhựa kỹ thuật tổng hợp (PA6, PBT, máy tính), 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, PEEK, PSU, vân vân., which are mainly used in medical containers, medical catheters, cấy ghép y tế, surgical instruments and other products. The core requirements for extrusion processing are: độ chính xác cao, no pollution, hiệu suất ổn định, 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, cấy ghép y tế) made of medical-grade special engineering plastics (medical-grade PEEK, medical-grade PSU), the HTS SUPER series extruders with high-precision configuration are required. Its fully optimized screw structure and precise temperature control can ensure the dimensional accuracy of the product (tolerance ≤±0.01mm), and the clean production environment and no pollution design can meet the biocompatibility requirements of medical products; the cloud control function can realize real-time monitoring and recording of the production process, which is convenient for medical product traceability and meets the GMP (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, vân vân., 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, hiệu suất ổn định, 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, chống mài mòn, high temperature resistance and pressure resistance. The main engineering plastics used in the chemical field include PPS, PEEK, PVDF (polyvinylidene fluoride), vân vân., which are mainly used in chemical equipment, pipelines, valves, pumps and other products. The core requirements for extrusion processing are: chống ăn mòn, chống mài mòn, hiệu suất ổn định, 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 (PEEK, 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, due to the influence of raw materials, processing parameters, equipment performance and other factors, various problems often occur, which affect the product quality and production efficiency. Dưới, we will summarize the common problems in engineering plastics extrusion processing, analyze their causes, 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, bubbles, 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. The screw speed is too low, resulting in insufficient shear force and prolonged residence time; 5. The flow channel of the die head is blocked, resulting in material accumulation and local overheating.

Solutions: 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 phút; 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, sợi carbon), and the mechanical properties (sức mạnh, sự dẻo dai, chống mài mòn) 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. The screw speed is too low, resulting in insufficient shear force and kneading force, and the modifiers cannot be fully broken and dispersed; 3. The combination of screw elements is unreasonable, and the number of mixing elements and shearing elements is insufficient; 4. The extrusion temperature is too low, the material is not fully melted, and the modifiers cannot be uniformly dispersed in the resin matrix; 5. The particle size of the modifier is too large or uneven.

Solutions: 1. Optimize the premixing process, increase the mixing speed (800-1200vòng/phút) and mixing time (5-10 phút), 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, sợi carbon) 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.

Solutions: 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. Ngoài ra, our professional technical team can provide regular wear detection services for the screw and barrel, and put forward targeted replacement and maintenance suggestions.

5.4 Problem 4: Unstable Product Size and Dimensional Deformation

Symptoms: The size of the extruded product (such as granules, đường ống, tấm) 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.

Solutions: 1. Use the precise temperature control system of the HTS series extruders to ensure the stability of the extrusion temperature, and avoid temperature fluctuation; 2. Adjust the feeding speed and screw speed to ensure the stability of the extrusion speed, and use the frequency conversion speed regulation function of the HTS series extruders to realize the synchronous adjustment of feeding and extrusion; 3. Optimize the cooling process, ensure uniform cooling speed, adjust the cooling water temperature (20-30oC) and cooling time (2-5 phút) 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. The screw speed is too low, the conveying capacity is insufficient; 2. The extrusion temperature is too low, the material viscosity is too high, the conveying resistance is increased, and the production capacity is reduced; 3. The combination of screw elements is unreasonable, the conveying efficiency is low; 4. The feeding device is blocked or the feeding speed is insufficient, resulting in insufficient feeding; 5. The screw and barrel are worn, the conveying capacity is reduced, and the energy consumption is increased.

Solutions: 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. Ngoài ra, the HTS series extruders adopt an optimized structural design and high-efficiency motor, có thể giảm mức tiêu thụ năng lượng bằng cách 15%-20% compared with ordinary extruders.

6. Kết luận và xu hướng phát triển trong tương lai

Nhựa kỹ thuật, như một vật liệu hiệu suất cao quan trọng, đang đóng một vai trò ngày càng quan trọng trong việc nâng cấp công nghiệp toàn cầu, và công nghệ ép đùn trục vít đôi là sự hỗ trợ cốt lõi cho quá trình xử lý nhựa kỹ thuật chất lượng cao. Hiệu suất của thiết bị ép đùn quyết định trực tiếp đến chất lượng, Hiệu quả sản xuất và hiệu quả ứng dụng của sản phẩm nhựa kỹ thuật. Máy đùn trục vít đôi dòng HTS của chúng tôi, bao gồm cả HTS CƠ BẢN, HTS PLUS và HTS SUPER, được thiết kế đặc biệt cho các đặc tính xử lý của nhựa kỹ thuật (sensitivity to overheating and hydrolytic degradation, high requirements on mixing and dispersing effect, high viscosity), với lợi thế của mô-men xoắn cao, tốc độ cao, kiểm soát nhiệt độ chính xác, khả năng chống mài mòn tuyệt vời, phạm vi ứng dụng rộng rãi và điều khiển thông minh. Họ có thể cung cấp các giải pháp xử lý có mục tiêu cho các loại nhựa kỹ thuật khác nhau và các quy mô doanh nghiệp khác nhau, giúp doanh nghiệp giải quyết khó khăn trong xử lý, nâng cao chất lượng sản phẩm và hiệu quả sản xuất, và nâng cao khả năng cạnh tranh trên thị trường.

Looking forward to the future, with the continuous upgrading of downstream industries such as automotive lightweight, trí tuệ điện và điện tử, 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:

Đầu tiên, 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. Đồng thời, 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.

Thứ hai, high performance and high efficiency. The demand for high-end engineering plastics (chẳng hạn như 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 (vít, thùng, hộp số) will be further optimized to improve wear resistance, corrosion resistance and service life. Đồng thời, the energy consumption of the equipment will be further reduced, realizing high-efficiency and energy-saving production.

thứ ba, 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. Đồng thời, we will provide more personalized customized solutions according to the special processing needs of customers, meeting the diverse market demands.

thứ tư, 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; at the same time, 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.