Thermoplastic Elastomers (TPE), Nigba miiran tọka si bi Awọn Rubbers Thermoplastic (TPR), jẹ kilasi ti copolymers tabi awọn apopọ ti ara ti awọn polima—paapaa ṣiṣu ati roba kan—ti o darapọ awọn ohun-ini ti thermoplastics ati awọn elastomers. Apapo alailẹgbẹ yii ngbanilaaye awọn TPE lati ṣe ilọsiwaju bi awọn thermoplastics (nipasẹ extrusion, abẹrẹ igbáti, fe igbáti, ati be be lo.) lakoko idaduro elasticity ati irọrun ti awọn rubbers. Ko ibile vulcanized rubbers, Awọn TPE le yo ati tun ṣe ni igba pupọ laisi ipadanu iṣẹ ṣiṣe pataki, ṣiṣe wọn siwaju sii ore ayika ati iye owo-doko. Bi awọn eletan fun lightweight, rọ, ati awọn ohun elo atunlo dagba kọja awọn ile-iṣẹ bii ọkọ ayọkẹlẹ, itanna, ikole, ati awọn ọja onibara, Awọn TPE ti di olokiki pupọ, iwakọ idagbasoke ti specialized masterbatch ati extrusion imo ero sile lati wọn oto processing awọn ibeere.
Masterbatch, bi ohun elo bọtini fun kikun ati iyipada iṣẹ ti awọn TPE, ṣe ipa pataki ni imudara iṣẹ ṣiṣe ati faagun ipari ohun elo ti awọn ọja TPE. Sise ti TPE masterbatch nilo iṣakoso kongẹ ti dapọ, kaakiri, ati iwọn otutu paramita, bi TPEs ni pato iki, ooru resistance, ati awọn abuda elasticity ti o yatọ si awọn pilasitik ibile. Twin-dabaru extruders, pẹlu wọn superior dapọ ati dispersing agbara, kongẹ otutu iṣakoso, ati adaptability si Oniruuru ohun elo, ti di awọn mojuto processing ohun elo fun TPE masterbatch. Zhuoyue, a ọjọgbọn olupese ti ibeji-dabaru extruders, offers a full range of advanced extrusion solutions specifically designed for TPE compounding and masterbatch processing, covering TPE/SBS/TPU/TPR/TPV and other major TPE categories, to meet the diverse needs of manufacturers in different industries.
1. Overview of Thermoplastic Elastomers (TPE): Categories, Properties and Key Characteristics
TPEs are a diverse family of materials, classified into six general commercial categories based on their chemical composition and structure. Each category has unique properties, processing characteristics, and application fields, which directly determine the requirements for masterbatch formulation and extrusion equipment. Understanding the classification and properties of TPEs is the foundation for optimizing masterbatch processing and selecting suitable twin-screw extruders.
1.1 Mefa General Commercial Isori ti TPEs
1.1.1 Styrenic Àkọsílẹ Copolymers (TPS, TPE-awọn).
TPS jẹ ẹya ti o gbajumo julọ ti awọn TPE, iṣiro fun ipin nla ti ọja TPE agbaye. O ti wa ni kq ti styrenic ohun amorindun (bii polystyrene, PS) ati awọn bulọọki elastomeric (bii polybutadiene, PB; polyisoprene, PI; tabi ethylene-butylene, EB), ti a ti sopọ nipasẹ covalent ìde. Awọn oriṣi ti o wọpọ julọ ti TPS pẹlu SBS (Styrenes-Butadienes-Styrenes), SIS (Styrene-Isoprene-Styrene), SEBS (Styrene-Ethylene-Butylene-Styrene), ati SEPS (Styrene-Ethylene-Propylene-Styrene).
Awọn ohun-ini bọtini ti TPS pẹlu irọrun ti o dara julọ, rirọ, ati processing. SEBS ati SEPS, eyiti o jẹ awọn ẹya hydrogenated ti SBS ati SIS, ti dara si ooru resistance, oju ojo resistance, ati ti ogbo resistance, ṣiṣe wọn dara fun ita gbangba ati awọn ohun elo otutu otutu. Awọn ohun elo TPS ni irọrun ni awọ ati yipada pẹlu masterbatch, ati awọn sakani iwọn otutu sisẹ wọn lati 150 ℃ si 220 ℃, eyi ti o ni ibamu pẹlu julọ ibeji-dabaru extruders. Awọn ohun elo ti o wọpọ ti TPS pẹlu awọn paati adaṣe, onirin ati kebulu, awọn ọja onibara, ati awọn ẹrọ iwosan.
1.1.2 Thermoplastic Polyolefin Elastomers (TPO, TPE-o).
TPO jẹ idapọ ti ara ti polyolefin (bii polypropylene, PP; tabi polyethylene, PE) ati elastomer (gẹgẹ bi awọn ethylene-propylene-diene monomer, EPDM). O daapọ rigidity ti awọn polyolefins pẹlu elasticity ti elastomer, ati ki o ni o tayọ kemikali resistance, oju ojo resistance, ati kekere otutu ni irọrun. TPOs kii ṣe majele, olfato, ati atunlo, ṣiṣe wọn apẹrẹ fun awọn ohun elo to nilo ore ayika.
Awọn iwọn otutu processing ti TPO wa lati 160 ℃ si 230 ℃, ati awọn ti o ni o ni ti o dara ibamu pẹlu orisirisi masterbatches (awọ masterbatch, ina-retardant masterbatch, ati be be lo.). Awọn TPOs ni lilo pupọ ni awọn ẹya ita ita (gẹgẹbi awọn ideri bompa, Fender liners), ile elo (gẹgẹ bi awọn edidi, gaskets), ati itanna irinše. Nitori akoonu polyolefin giga wọn, TPO masterbatch processing nilo awọn extruders pẹlu awọn agbara dapọ dara lati rii daju pipinka aṣọ ti awọn awọ ati awọn afikun.
1.1.3 Thermoplastic Vulcanizates (VAT, TPE v).
TPV jẹ idapọmọra vulcanized ti polyolefin (nigbagbogbo PP) ati elastomer (nigbagbogbo EPDM). Nigba processing, ipele elastomer ti wa ni vulcanized sinu awọn patikulu kekere ati pe o tuka ni iṣọkan ni matrix polyolefin, Abajade ni o tayọ elasticity, funmorawon ṣeto resistance, ati ooru resistance. Awọn TPV ni awọn ohun-ini ẹrọ ti o dara julọ ati iduroṣinṣin iwọn ju awọn TPE ibile lọ, ati pe o le duro ni igba pipẹ ifihan iwọn otutu giga (soke si 150 ℃).
Sisẹ TPV nilo iṣakoso iwọn otutu kongẹ ati agbara rirun lati rii daju vulcanization aṣọ ati pipinka. Awọn sakani iwọn otutu processing lati 170 ℃ si 240 ℃, ati awọn ohun elo ni o ni ga iki nigba processing, eyi ti o gbe ga awọn ibeere lori iyipo ati ki o wọ resistance ti ibeji-dabaru extruders. Awọn TPV ti wa ni lilo pupọ ni awọn edidi mọto, hoses, gaskets, ati awọn paati ile-iṣẹ ti o nilo iṣẹ ṣiṣe giga ati agbara.
1.1.4 Thermoplastic Polyurethane (TPU).
TPU ni a Àkọsílẹ copolymer kq ti lile apa (diisocyanate ati pq extender) ati asọ àáyá (polyol). O ni o ni o tayọ elasticity, abrasion resistance, epo resistance, ati darí agbara, ati pe o le ṣe atunṣe ni lile lati rirọ pupọ (Etikun A 30) si gidigidi (Okun D 85) nipa yiyipada awọn ipin ti lile ati rirọ apa.
Sisẹ TPU jẹ ifarabalẹ si iwọn otutu ati ọrinrin. Awọn iwọn otutu processing lati 180 ℃ si 250 ℃, ati pe ohun elo naa gbọdọ gbẹ daradara ṣaaju ṣiṣe (akoonu ọrinrin ≤0.05%) lati yago fun hydrolysis ati o ti nkuta Ibiyi. TPU masterbatch processing nilo awọn extruders pẹlu iṣakoso iwọn otutu deede ati awọn agbara eefi igbale. TPU ni lilo pupọ ni awọn okun onirin ati awọn kebulu, ọkọ ayọkẹlẹ hoses, bàtà, egbogi catheters, ati idaraya ẹrọ.
1.1.5 Thermoplastic Copolyesters (TPC, TPE-E).
TPC jẹ copolymer bulọọki ti o ni awọn apakan lile polyester ati polyether tabi awọn apakan rirọ polyester. O ni o ni o tayọ ooru resistance, kemikali resistance, ati darí-ini, ati ki o le withstand ga awọn iwọn otutu soke si 150 ℃ fun gun akoko. TPCs tun ni irọrun ti o dara ati rirọ, ṣiṣe wọn dara fun awọn ohun elo iṣẹ-giga.
Awọn iwọn otutu processing ti awọn sakani TPC lati 220 ℃ si 280 ℃, eyiti o ga ju awọn ẹka TPE miiran lọ. O ni iki giga lakoko sisẹ ati nilo awọn extruders pẹlu iyipo giga ati iṣakoso iwọn otutu deede. Ṣiṣẹda Masterbatch TPC tun nilo akiyesi pataki si pipinka ti awọn awọ ati awọn afikun lati yago fun ni ipa awọn ohun-ini ẹrọ ti ohun elo naa.. Awọn TPCs ni lilo pupọ ni awọn paati adaṣe (gẹgẹbi awọn okun gbigbe afẹfẹ, awọn edidi gbigbe), Ofurufu awọn ẹya ara, ati ẹrọ ise.
1.1.6 Thermoplastic Polyamides (TPA, TPE-A).
TPA jẹ copolymer bulọọki ti o ni awọn apakan lile polyamide ati awọn apakan rirọ polyether. O daapọ awọn ga agbara, wọ resistance, ati kemikali resistance ti polyamides pẹlu irọrun ati elasticity ti polyethers. TPA ni o ni o tayọ ikolu resistance ati kekere iwọn otutu išẹ, ati pe o le ṣee lo ni awọn agbegbe lile.
Awọn iwọn otutu processing ti TPA lati 230 ℃ si 290 ℃, ati pe o ni gbigba omi giga, nilo gbigbe ni kikun ṣaaju ṣiṣe. TPA masterbatch processing nilo extruders pẹlu ga yiya resistance (nitori lile lile ti polyamide) ati iṣakoso iwọn otutu deede lati yago fun ibajẹ ohun elo. TPA jẹ lilo pupọ ni awọn paati adaṣe (gẹgẹ bi awọn jia, bearings), itanna asopo, ati ise hoses.
1.2 Awọn ohun-ini bọtini ti awọn TPE ti o ni ipa lori Ṣiṣẹda Masterbatch
Awọn TPE ni awọn ohun-ini alailẹgbẹ ti o ṣe iyatọ wọn lati awọn pilasitik ibile, ati awọn ohun-ini wọnyi taara ni ipa lori iṣelọpọ ti masterbatch ati yiyan ohun elo extrusion. Awọn ohun-ini bọtini lati ronu ni sisẹ masterbatch jẹ atẹle:
1.2.1 Rirọ ati Irọrun.
Awọn TPE ni rirọ giga ati irọrun, eyiti o tumọ si pe masterbatch gbọdọ wa ni ibamu pẹlu matrix TPE lati yago fun idinku iṣẹ rirọ ohun elo naa.. Awọn ti ngbe masterbatch yẹ ki o ni ibamu to dara pẹlu TPE, ati awọn dispersant yẹ ki o rii daju aṣọ pipinka ti awọn pigments lai lara agglomerates ti o le fa wahala ifọkansi ati ki o din ni irọrun.
1.2.2 Ooru Resistance.
O yatọ si TPE isori ni orisirisi awọn ooru resistance (awọn sakani iwọn otutu sisẹ lati 150 ℃ si 290 ℃). Masterbatch pigments ati awọn afikun gbọdọ ni ooru resistance ti o baamu iwọn otutu sisẹ TPE lati yago fun jijẹ, discoloration, tabi ibaje iṣẹ nigba extrusion. Fun apere, TPC ati TPA nilo awọn pigments sooro otutu otutu ati awọn amuduro ooru.
1.2.3 Viscosity ati Processability.
Awọn TPE ni awọn viscosities oriṣiriṣi lakoko sisẹ (TPV ati TPC ni iki ti o ga julọ, nigba ti TPS ni o ni kekere iki). Eyi ni ipa lori agbara rirẹ ati awọn ibeere gbigbe ti extruder-skru twin. Awọn TPE ti o ga-giga nilo awọn extruders pẹlu iyipo giga ati awọn agbara idapọmọra to lagbara, lakoko ti awọn TPE ala-kekere nilo iṣakoso kongẹ ti iyara extrusion lati yago fun apọju ohun elo.
1.2.4 Gbigba Ọrinrin.
Diẹ ninu awọn TPE (gẹgẹ bi awọn TPU, TPA) ni gbigba omi ti o ga, eyi ti o le fa awọn nyoju, hydrolysis, ati awọn abawọn miiran ninu masterbatch. Awọn ohun elo aise (TPE, pigmenti, awọn afikun) gbọdọ wa ni daradara si dahùn o ṣaaju ki o to processing, ati awọn extruder yẹ ki o wa ni ipese pẹlu kan igbale eefi ẹrọ lati yọ ọrinrin ati iyipada oludoti.
1.2.5 Ibamu pẹlu Additives.
Awọn TPE nigbagbogbo nilo awọn afikun iṣẹ-ṣiṣe (gẹgẹbi awọn antioxidants, UV stabilizers, lubricants) lati mu iṣẹ wọn dara si. O yẹ ki o ṣe agbekalẹ masterbatch lati rii daju pe awọn afikun jẹ ibaramu pẹlu awọn awọ mejeeji ati matrix TPE, yago fun awọn aati kemikali ti o le ni ipa lori didara ọja.
2. Masterbatch fun awọn TPE: Tiwqn, Agbese ati Processing awọn ibeere
Masterbatch fun awọn TPE jẹ adalu ogidi ti awọn awọ/awọ, awọn ti ngbe, ati awọn afikun, ti a ṣe lati ṣe awọ awọn TPE ati fifun awọn iṣẹ afikun (bii idaduro ina, antistatic, antibacterial) lakoko mimu ohun elo rirọ ati awọn ohun-ini sisẹ. Ilana ati sisẹ ti TPE masterbatch jẹ ibeere diẹ sii ju awọn ti awọn pilasitik ibile lọ, nitori awọn ohun-ini alailẹgbẹ ti awọn TPE. Abala yii ṣe alaye akojọpọ, agbekalẹ agbekale, ati processing awọn ibeere ti TPE masterbatch.
2.1 Mojuto Tiwqn ti TPE Masterbatch
Bi ibile masterbatch, TPE masterbatch ni awọn paati ipilẹ mẹta: pigments / àwọ, awọn ti ngbe, ati awọn afikun. Yiyan ati ipin ti paati kọọkan ni a ṣe deede si iru TPE ati awọn ibeere ohun elo rẹ.
2.1.1 Pigments/Dyes.
Awọn pigments/dyes jẹ awọn paati mojuto ti o funni ni awọ si awọn TPE, iṣiro fun 10%-70% ti akopọ masterbatch (da lori kikankikan awọ ati iru TPE). Awọn ibeere bọtini fun awọn pigments/dyes ni TPE masterbatch jẹ:
- – Ooru Resistance: Gbọdọ koju iwọn otutu processing ti TPE afojusun (150℃-290℃) lai jijera tabi discoloration. Fun awọn TPE iwọn otutu giga (TPC, TPA), awọn pigments Organic sooro otutu otutu tabi awọn awọ eleto ni o fẹ.
- – Ibamu: Gbọdọ wa ni ibamu pẹlu matrix TPE lati yago fun ijira, aladodo, tabi dinku elasticity. Awọn pigments pẹlu iru polarity si TPE jẹ ibaramu diẹ sii (f.eks., pola pigments fun TPU, ti kii-pola pigments fun TPS).
- – Pinpin: Gbọdọ ni irọrun tuka ni matrix TPE lati rii daju awọ aṣọ ati yago fun awọn aaye awọ, ṣiṣan, tabi dinku darí-ini. Fine-patiku pigments (20-40 apapo) pẹlu kekere agglomeration ti wa ni fẹ.
- – Ayika Friendliness: Gbọdọ pade awọn iṣedede aabo ayika agbaye (gẹgẹ bi awọn REACH, RoHS) lati yago fun majele tabi ipalara (bi eru awọn irin) ti o le ni ipa lori ilera eniyan ati ayika.
Awọn pigmenti ti o wọpọ ti a lo ninu TPE masterbatch pẹlu: inorganic pigments (titanium oloro fun funfun, erogba dudu fun dudu, ohun elo afẹfẹ fun pupa / ofeefee), ati ki o ga-otutu sooro Organic pigments (phthalocyanine buluu / alawọ ewe, quinacridone pupa).
2.1.2 Awọn aruwo.
Awọn ọkọ ayọkẹlẹ jẹ matrix ti masterbatch, iṣiro fun 20%-80% ti akopọ, ati ki o ṣe ipa bọtini ni pipinka awọn awọ-ara ati titọmọ si matrix TPE. Ti ngbe gbọdọ ni ibamu ti o dara julọ pẹlu mejeeji awọn pigments ati TPE afojusun, bi ko dara ibamu le ja si pigment ijira, awọ ti ko ni deede, ati dinku iṣẹ TPE. Yiyan ti awọn ti ngbe da lori iru TPE:
- – Fun TPS (SBS, SEBS): Lo TPS tabi PP bi awọn ti ngbe, eyi ti o ni ibamu ti o dara ati processing fluidity.
- – Fun TPO/TPE-o: Lo PP tabi PE bi awọn ti ngbe, ti o baamu paati polyolefin ti TPO.
- – Fun TPV/TPE-v: Lo PP bi awọn ti ngbe, eyiti o ni ibamu pẹlu matrix PP ti TPV.
- – Fun TPU: Lo TPU bi awọn ti ngbe, aridaju ibamu pẹlu TPU matrix ati yago fun hydrolysis.
- – Fun TPC/TPE-E ati TPA/TPE-A: Lo TPC tabi TPA bi awọn ti ngbe, lẹsẹsẹ, lati baramu awọn ibeere processing iwọn otutu giga ati ibamu.
Awọn ti ngbe yẹ ki o tun ni o dara processing fluidity, pẹlu aaye yo ati iwọn otutu processing ni ibamu pẹlu tabi die-die kere ju TPE afojusun, to ensure uniform mixing and avoid TPE degradation.
2.1.3 Awọn afikun.
Awọn afikun jẹ awọn paati oluranlọwọ ti a ṣafikun lati mu ilọsiwaju sisẹ ṣiṣẹ, dispersibility, ati iṣẹ ṣiṣe ti TPE masterbatch, iṣiro fun 1%-10% ti akopọ. Iru ati iwọn lilo awọn afikun jẹ ipinnu nipasẹ iru TPE ati awọn ibeere ohun elo:
- – Awọn onipinpin: Afikun pataki julọ fun TPE masterbatch, lo lati din pigment dada ẹdọfu, idilọwọ agglomeration, ati rii daju pipinka aṣọ ni matrix TPE. Awọn kaakiri ti o wọpọ pẹlu epo-eti polyethylene, epo-eti polypropylene, stearic acid, ati maleic anhydride tirun waxes. Fun awọn TPE-giga (VAT, TPC), awọn dispersants ti o ga julọ pẹlu ibaramu to lagbara ni o fẹ.
- – Awọn ibaramu: Ti a lo lati mu ibaramu pọ si laarin awọn pigments ati awọn TPE, ati laarin masterbatch ati TPE matrix. Fun apere, maleic anhydride tirun PP ni a lo bi ibaramu fun TPO masterbatch, ati epo-eti polyurethane ti lo fun TPU masterbatch.
- – Ooru Stabilizers: Ti a lo lati ṣe idiwọ ibajẹ pigmenti ati ibajẹ TPE lakoko ṣiṣe iwọn otutu giga. Awọn amuduro igbona ti o wọpọ pẹlu awọn amuduro tin Organic (fun TPU), idiwo phenol antioxidants (fun TPS, TPO), ati awọn antioxidants phosphite (fun TPC, TPA).
- – UV Stabilizers ati Antioxidants: Ti a lo lati mu ilọsiwaju oju ojo duro ati resistance ti ogbo ti awọn ọja TPE awọ, idilọwọ idinku awọ ati ibajẹ iṣẹ labẹ imọlẹ oorun ati atẹgun. Fun awọn ohun elo ita gbangba (gẹgẹbi awọn ẹya ita ita gbangba), UV absorbers ati idiwo amine ina amuduro (HALS) ti wa ni afikun.
- – Awọn lubricants: Ti a lo lati dinku ija laarin awọn ohun elo ati ohun elo extrusion (dabaru, agba, kú orí), mu processing fluidity, ki o si yago fun ohun elo duro si ẹrọ. Awọn lubricants ti o wọpọ pẹlu stearic acid, kalisiomu stearate, ati epo silikoni. Fun TPU ati TPA, awọn lubricants pẹlu ijira kekere ni o fẹ lati yago fun ni ipa iṣẹ ṣiṣe ọja.
- – Awọn afikun iṣẹ-ṣiṣe: Fi kun lati fun awọn iṣẹ pataki si awọn TPE, gẹgẹ bi awọn ina retardants (fun onirin ati kebulu), awọn aṣoju antistatic (for electrical components), ati awọn aṣoju antibacterial (fun awọn ẹrọ iwosan ati awọn ọja onibara).
2.2 Awọn Ilana agbekalẹ ti TPE Masterbatch
Ilana ti TPE masterbatch gbọdọ dọgbadọgba ipa awọ, processing iṣẹ, ati TPE atorunwa-ini. Awọn ilana pataki jẹ bi atẹle:
2.2.1 Ibamu First.
Awọn ti ngbe, pigmenti, ati awọn afikun gbọdọ wa ni ibamu pẹlu TPE afojusun lati yago fun idinku rirọ ohun elo naa, irọrun, ati darí-ini. Fun apere, lilo awọn ti kii-pola ti ngbe fun pola TPU yoo ja si ko dara ibamu ati pigment migration.
2.2.2 Baramu Heat Resistance.
Awọn pigments ati awọn afikun gbọdọ ni resistance ooru ti o baamu iwọn otutu sisẹ TPE. Fun apere, TPC masterbatch nlo awọn pigments sooro iwọn otutu giga (ooru resistance ≥280℃) lati yago fun jijera nigba processing.
2.2.3 Je ki Dispersibility.
Akoonu pigmenti ati iwọn lilo kaakiri ti wa ni titunse lati rii daju pipinka aṣọ. Ga-fojusi masterbatch (pigment akoonu 50%-70%) nbeere diẹ dispersants ati ki o dara dapọ agbara, nigba ti kekere-fojusi masterbatch (10%-30%) fojusi lori ibamu.
2.2.4 Din Ipa lori Awọn ohun-ini TPE.
Masterbatch ko yẹ ki o ni ipa ni pataki rirọ TPE, funmorawon ṣeto, tabi abrasion resistance. Fun apere, awọn kaakiri pupọ tabi awọn lubricants le dinku agbara ẹrọ ti TPE.
2.2.5 Ibamu Idaabobo Ayika.
Ilana naa gbọdọ pade awọn iṣedede aabo ayika agbaye, yago fun majele tabi ipalara oludoti (bi eru awọn irin, phthalates) ti o le ni ihamọ wiwọle oja.
2.3 Ṣiṣe awọn ibeere ti TPE Masterbatch
TPE masterbatch processing ni a ṣe ni akọkọ nipa lilo imọ-ẹrọ extrusion ibeji-skru, eyiti o nilo iṣakoso ti o muna ti iṣaju ohun elo aise, iṣaju, extrusion sile, ati lẹhin-processing lati rii daju didara ọja. Awọn ibeere processing bọtini jẹ bi atẹle:
2.3.1 Aise Ohun elo Pretreatment.
TPEs (paapa TPU, TPA) ni gbigba omi ti o ga, nitorina gbogbo awọn ohun elo aise (TPE ti ngbe, pigmenti, awọn afikun) gbọdọ wa ni daradara si dahùn o ṣaaju ki o to processing. Iwọn otutu gbigbẹ ati akoko jẹ ipinnu nipasẹ iru ohun elo naa: TPU/TPA ti gbẹ ni 100-120 ℃ fun 6-8 wakati, TPS/TPO ti gbẹ ni 80-100 ℃ fun 3-5 wakati, and pigments are dried at 60-80℃ for 2-4 wakati. The moisture content of dried raw materials should be controlled below 0.1% (0.05% for TPU/TPA).
In addition, pigments with large particle sizes or agglomerates should be crushed and sieved (20-40 apapo) to improve dispersibility, and impurities (metal particles, dust) should be removed to avoid wear on extrusion equipment and defects in masterbatch.
2.3.2 Premixing.
The dried raw materials (pigmenti, carrier, awọn afikun) are mixed in a high-speed mixer according to the formula ratio to form a uniform preliminary mixture. The premixing parameters are adjusted based on the TPE type: mixing speed 800-1200 rpm, mixing time 5-10 minutes, mixing temperature 40-60℃. For high-concentration masterbatch or high-viscosity TPE carriers, the premixing time is extended, and dispersants are added first to coat the pigments, improving dispersibility.
2.3.3 Extrusion Parameters Control.
Twin-skru extrusion jẹ igbesẹ akọkọ ti TPE masterbatch processing, ati awọn paramita bọtini (otutu, dabaru iyara, extrusion titẹ, iyara ono) gbọdọ wa ni iṣakoso ni deede lati baamu iru TPE:
- – Iṣakoso iwọn otutu: Agba ti pin si 4-6 awọn apakan iṣakoso iwọn otutu (ono apakan, yo apakan, dapọ apakan, homogenizing apakan, kú ori apakan). Iwọn otutu ti apakan kọọkan jẹ atunṣe ni ibamu si iwọn otutu processing TPE. Fun apere, TPS masterbatch: apakan ifunni 100-120 ℃, yo apakan 160-180 ℃, dapọ apakan 170-190 ℃, homogenizing apakan 160-180 ℃, kú ori apakan 150-170 ℃; TPC masterbatch: apakan ifunni 150-170 ℃, yo apakan 230-250 ℃, dapọ apakan 240-260 ℃, homogenizing apakan 230-250 ℃, kú ori apakan 220-240 ℃. The temperature control precision should reach ±1℃ to avoid TPE degradation and pigment decomposition.
- – Screw Speed: The screw speed ranges from 200-800 rpm, adjusted based on TPE viscosity. High-viscosity TPEs (VAT, TPC) require higher screw speed (500-800 rpm) to generate sufficient shear force for pigment dispersion; low-viscosity TPEs (TPS) use moderate speed (300-500 rpm) to avoid material overflow.
- – Extrusion Pressure: The pressure ranges from 5-12MPa, kept stable (fluctuation ≤±0.5MPa) to ensure uniform mixing and shaping. High-viscosity TPEs require higher pressure, while low-viscosity TPEs use moderate pressure.
- – Feeding Speed: Adjusted to match the screw speed and extrusion speed, ensuring stable and uniform feeding. Fun awọn TPE-giga, a forced feeding device is used to avoid material accumulation.
2.3.4 Post-Processing.
After extrusion, the strip-shaped masterbatch is cooled (water tank cooling, 20-30℃), granulated (patiku iwọn 2-5mm), se ayewo (lati yọ awọn patikulu ti ko yẹ), ati akopọ (edidi ati ọrinrin-ẹri apoti). Fun ọrinrin-kókó TPE masterbatch (TPU, TPA), ọja ti o pari ti gbẹ lẹẹkansi ṣaaju iṣakojọpọ lati ṣe idiwọ gbigba ọrinrin.
3. Awọn aaye Ohun elo ti TPE Masterbatch ati Tuntun Zhuoyue Extruder Solutions
Awọn TPE ti wa ni lilo pupọ ni ọkọ ayọkẹlẹ, itanna, ikole, awọn ọja onibara, ati awọn ile-iṣẹ miiran, ati awọn aaye ohun elo oriṣiriṣi ni awọn ibeere oriṣiriṣi fun iṣẹ TPE masterbatch (awọ, dispersibility, iṣẹ-ṣiṣe) ati ṣiṣe iṣelọpọ. Zhuoyue ni kikun jara ti ibeji-dabaru extruders (HTS Ipilẹ / Plus / Super, ZTE, HTE) jẹ iṣapeye pataki fun sisẹ TPE masterbatch, pese awọn ipinnu ifọkansi fun oriṣiriṣi awọn ẹka TPE ati awọn aaye ohun elo. Ni isalẹ ni ifihan alaye si awọn aaye ohun elo akọkọ ti TPE masterbatch ati jara Zhuoyue extruder ti o baamu.
3.1 Automotive Industry: The Largest Application Field of TPE Masterbatch
The automotive industry is the largest consumer of TPEs, iṣiro fun diẹ ẹ sii ju 40% of the global TPE market. TPEs are used in a wide range of automotive components due to their lightweight, rọ, 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, window seals, hood seals, and gaskets, which require good elasticity, oju ojo resistance, ati kekere otutu ni irọrun. The masterbatch for these components requires uniform coloring, good weather resistance (UV resistance, aging resistance), and compatibility with TPV/TPO matrices.
Matching Extruders: HTS PLUS series and HTE series. HTS PLUS jara ni iyipo giga ati yiya resistance, o dara fun TPV masterbatch processing (high viscosity, ga rirun agbara ti a beere); jara HTE ṣepọ iṣẹ ṣiṣe giga ati ṣiṣe-iye owo, o dara fun TPO masterbatch processing, pẹlu ti o dara dapọ dispersibility ati agbara-fifipamọ awọn anfani.
3.1.2 Automotive Inu ilohunsoke irinše.
TPEs (o kun TPS, TPU) ti wa ni lo lati gbe awọn Oko inu ilohunsoke irinše bi irinse nronu awọn awọ ara, enu paneli, idari oko eeni, ati armrests, eyi ti o nilo ti o dara ni irọrun, asọ ifọwọkan, ati ayika ore (ti kii-majele ti, olfato). Masterbatch nilo awọn awọ didan, aṣọ dispersibility, ko si si ijira (lati yago fun idoti miiran inu ilohunsoke irinše).
Matching Extruders: HTS BASIC jara ati HTE jara. HTS BASIC jara jẹ iye owo-doko, o dara fun kekere ati alabọde-won olupese producing TPS inu ilohunsoke masterbatch; awọn HTE jara ni o ni ti o dara dapọ dispersibility ati kekere agbara agbara, o dara fun iṣelọpọ titobi nla ti TPU / TPS masterbatch inu ilohunsoke.
3.1.3 Automotive Hoses ati Tubing.
TPEs (o kun TPU, TPC, TPA) ti wa ni lo lati gbe awọn Oko idana hoses, awọn okun gbigbe afẹfẹ, ati awọn okun fifọ, eyi ti o nilo ti o dara epo resistance, ooru resistance, ati darí agbara. Masterbatch nilo resistance otutu otutu, epo resistance, ati dispersibility aṣọ lati yago fun ni ipa awọn iṣẹ okun.
Matching Extruders: HTS SUPER jara ati HTS PLUS jara. HTS SUPER jara ni iyipo giga-giga, kongẹ otutu iṣakoso, ati ki o ga yiya resistance, o dara fun TPC / TPA masterbatch processing (ga otutu, high viscosity); jara HTS PLUS ni aabo ooru to dara ati awọn agbara dapọ, o dara fun TPU masterbatch processing.
3.1.4 Miiran Automotive irinše.
Awọn TPE tun lo lati ṣe agbejade awọn ideri eruku ọkọ ayọkẹlẹ, awọn window onigun mẹta, air Ajọ, ati breakers, which require different properties (such as dust resistance, akoyawo, impact resistance). The masterbatch is formulated according to specific requirements, and the matching extruders are selected based on TPE type and production scale.
3.2 Itanna ati Itanna Industry: Functional TPE Masterbatch Applications
The electrical and electronic industry is another important application field of TPEs, where TPEs are used to produce wires and cables, connectors, and other components, requiring functional masterbatch (antistatic, flame-retardant, high-temperature resistant) to meet safety and performance requirements.
3.2.1 Wires and Cables.
TPEs (o kun 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, flame retardancy, and abrasion resistance. The masterbatch requires flame retardancy (meeting UL94 V-0 standard), antistatic properties, 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 (o kun TPU, TPA) are used to produce electrical connectors, plugs, and socket housings, which require good electrical insulation, impact resistance, ati ayika ore. The masterbatch requires uniform coloring, high-temperature resistance, ko si si ijira.
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: Awọn ohun elo TPE Masterbatch Alatako oju-ọjọ
Ni awọn ikole ati irinna ile ise, Awọn TPE ti wa ni lilo lati gbe awọn edidi, imugboroosi isẹpo, alaja awọn maati, and other components, to nilo ti o dara oju ojo resistance, aging resistance, ati irọrun iwọn otutu kekere lati ṣe deede si awọn agbegbe ita gbangba lile.
3.3.1 Igbẹhin Igbẹhin ati Imugboroosi isẹpo.
TPEs (mainly TPV, TPO) ti wa ni lo lati gbe awọn ile ilẹkun ati window edidi, Aṣọ odi edidi, ati awọn isẹpo imugboroosi, eyi ti o nilo ti o dara oju ojo resistance, UV resistance, ati funmorawon ṣeto resistance. Masterbatch nilo awọn amuduro UV ati awọn antioxidants lati mu ilọsiwaju oju ojo duro, ati awọ aṣọ lati baramu ile aesthetics.
Matching Extruders: HTS PLUS series and HTE series. Ẹya HTS PLUS ni awọn agbara idapọmọra arosọ oju-ọjọ to dara, o dara fun TPV masterbatch processing; jara HTE jẹ fifipamọ agbara ati lilo daradara, o dara fun iṣelọpọ titobi nla ti TPO masterbatch.
3.3.2 Awọn ohun elo gbigbe.
Awọn TPE ni a lo lati ṣe awọn maati alaja, road noise reduction mats, and transportation vehicle seals, which require good shock absorption, noise reduction, ati ki o wọ resistance. The masterbatch requires uniform dispersibility and good compatibility with TPE matrices to maintain shock absorption performance.
Matching Extruders: HTS BASIC jara ati HTE jara. HTS BASIC jara jẹ iye owo-doko, 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, asọ ifọwọkan, ati ayika ore.
3.4.1 Footwear Industry.
TPEs (o kun TPU, TPS) are used to produce shoe soles, shoe uppers, and shoe accessories, eyi ti o nilo ti o dara ni irọrun, abrasion resistance, and soft touch. Masterbatch nilo awọn awọ didan, aṣọ dispersibility, ko si si ijira (to avoid staining socks).
Matching Extruders: HTS BASIC series and ZTE series. The ZTE series has excellent cost performance, o dara fun kekere ati alabọde-won awọn olupese bata bata; HTS BASIC jara ni o ni ti o dara dapọ dispersibility, aridaju aṣọ awọ ti bata atẹlẹsẹ masterbatch.
3.4.2 Ìdílé ati Ojoojumọ Awọn ohun elo.
Awọn TPE ti wa ni lilo lati gbe awọn kapa, coasters, awọn maati ẹsẹ, awọn nkan isere, ati awọn ohun elo ile miiran, eyi ti o nilo ti kii-majele ti, olfato, asọ ifọwọkan, ati imọlẹ awọn awọ. Masterbatch nilo ore ayika (pade ounje olubasọrọ awọn ajohunše fun coasters / mu) and uniform coloring.
Matching Extruders: ZTE jara ati HTS BASIC jara. jara ZTE rọrun lati ṣiṣẹ, kekere ni iye owo itọju, o dara fun kekere-ipele, olona-orisirisi gbóògì; jara HTS BASIC ni ibamu aabo ayika ti o dara masterbatch, pade ounje olubasọrọ awọn ajohunše.
3.4.3 Awọn Ẹrọ Iṣoogun.
TPEs (o kun TPU, TPS) ti wa ni lo lati gbe awọn egbogi catheters, awọn sirinji, ati awọn iboju iparada, eyi ti o nilo ti kii-majele ti, ifo, ati biocompatible. Masterbatch nilo aabo ayika ipele iṣoogun (ipade ISO 10993 standard), ga akoyawo (fun awọn catheters), ati isokan dispersibility.
Matching Extruders: HTS SUPER jara ati HTS PLUS jara. HTS SUPER jara ni apẹrẹ iṣelọpọ mimọ, kongẹ otutu iṣakoso, yago fun idoti ohun elo; jara HTS PLUS ni ibamu to dara pẹlu awọn TPE ti oogun, aridaju ọja ailesabiyamo ati biocompatibility.
3.4.4 Miiran ise Awọn ohun elo.
Awọn TPE tun lo lati gbe awọn paipu ṣiṣan jade, ise gaskets, ati darí irinše, eyi ti o nilo ti o dara kemikali resistance, wọ resistance, ati darí agbara. Masterbatch jẹ agbekalẹ ni ibamu si awọn ibeere ile-iṣẹ kan pato, and the matching extruders are selected based on TPE type and production scale.
4. Zhuoyue ká Full Series Extruders: Awọn solusan Ọjọgbọn fun TPE Masterbatch Processing
Zhuoyue ti pẹ ti ṣiṣẹ ninu iwadii naa, idagbasoke, ati gbóògì ti ga-išẹ twin-skru extruders, ati pe o ni iriri ọlọrọ ni TPE masterbatch processing. Da lori awọn abuda iṣelọpọ alailẹgbẹ ti awọn TPE (high viscosity, otutu ifamọ, ọrinrin gbigba) 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. Gbogbo Zhuoyue ká ibeji-skru extruders gba ohun intermeshing àjọ-yiyi be, pẹlu kan reasonable dabaru ipolowo, asiwaju, ati funmorawon ratio design. Awọn intermeshing ati yiyi ti awọn skru ibeji n ṣe ina agbara rirun ti o lagbara ati ipa-ọṣọ, eyi ti o le ni kikun adehun pigment agglomerates ati rii daju aṣọ pipinka ti pigments, awọn ti ngbe, ati awọn afikun ninu matrix TPE. Awọn dapọ uniformity Gigun diẹ ẹ sii ju 95%, eyi ti o ga ju ti awọn extruders lasan lọ.
In addition, awọn skru gba apẹrẹ apọjuwọn kan, eyi ti o le larọwọto darapọ o yatọ si dabaru eroja (gbigbe, dapọ, irẹrun) gẹgẹ bi TPE iru. Fun apere, TPV/TPC masterbatch ti o ga-giga nilo idapọ diẹ sii ati awọn eroja irẹrun lati jẹki pipinka; TPS masterbatch kekere iki nlo awọn eroja gbigbe diẹ sii lati mu ilọsiwaju iṣelọpọ ṣiṣẹ.
4.1.2 Iṣakoso iwọn otutu deede, Yẹra fun Ibajẹ TPE.
Awọn TPE jẹ ifarabalẹ si iwọn otutu, ati iwọn otutu pupọ tabi iwọn otutu le ja si ibajẹ ohun elo (gẹgẹ bi awọn TPU hydrolysis, TPC pq scission). Gbogbo awọn extruders Zhuoyue gba eto iṣakoso iwọn otutu ti oye to ti ni ilọsiwaju, pẹlu 4-6 ominira otutu Iṣakoso ruju, iwọn otutu iṣakoso konge ti ± 1 ℃, ati ibojuwo otutu akoko gidi ati awọn iṣẹ itaniji. Agba naa gba apẹrẹ jaketi meji-Layer, mimo dekun alapapo ati itutu, ati imudarasi iyara esi iwọn otutu. Ori kú ti ni ipese pẹlu ẹrọ iṣakoso iwọn otutu ominira, aridaju idurosinsin mura ti awọn masterbatch rinhoho.
4.1.3 Resistance Wọ Ga ati Ipata Resistance.
Diẹ ninu TPE masterbatches (gẹgẹ bi awọn TPA, TPC) ni awọn pigments giga-lile tabi awọn afikun, eyi ti o le wọ dabaru ati agba. Awọn extruders Zhuoyue lo awọn ohun elo ti o ni agbara ti o ga julọ ati awọn imọ-ẹrọ iṣelọpọ: Awọn skru jara HTS PLUS/SUPER/HTE ati awọn agba jẹ ti irin alloy sooro asọ ti a ko wọle, kqja bimetallic apapo tabi lesa cladding itọju, líle dada ≥65 HRC (HTS SUPER jara ≥70 HRC), aye iṣẹ 2-3 igba ti arinrin extruders; HTS BASIC/ZTE jara skru ati awọn agba ti wa ni nitrided, líle dada ≥60 HRC, pade awọn iwulo ti deede TPE masterbatch processing.
4.1.4 Eefi igbale ati Awọn agbara Yiyọ Ọrinrin.
Awọn TPE bii TPU ati TPA ni gbigba omi giga, ati ọrinrin le fa awọn nyoju ati abawọn ninu masterbatch. Gbogbo awọn extruders aarin-si-giga-opin Zhuoyue (HTS PLUS/SUPER/HTE) ti wa ni ipese pẹlu kan igbale eefi ẹrọ, eyi ti o le fe ni yọ ọrinrin, 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%. Fun apere, 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, and predictive maintenance, realizing intelligent production management.
4.1.7 Wide Adaptability.
Zhuoyue’s full series of extruders can adapt to the processing of all TPE categories (TPS/SBS/TPU/TPR/TPV/TPC/TPA) and masterbatch types (awọ masterbatch, ina-retardant masterbatch, antistatic masterbatch), with pigment content ranging from 10% si 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
Ọkọọkan ti awọn extruders Zhuoyue ni awọn abuda iṣẹ ṣiṣe alailẹgbẹ ati awọn oju iṣẹlẹ aṣamubadọgba ti a fojusi, ati awọn olupese le yan awọn yẹ jara gẹgẹ bi wọn TPE iru, gbóògì asekale, ati ohun elo awọn ibeere.
4.2.1 HTS Ipilẹ Series: Rọ ati iye owo-doko fun TPE Masterbatch deede.
HTS BASIC jara jẹ ọja ti o ni idiyele idiyele ti a ṣe apẹrẹ fun awọn aṣelọpọ kekere ati alabọde ti n ṣe agbejade Masterbatch TPE lasan (TPS, kekere-fojusi TPO / TPU masterbatch). O nlo awọn apoti jia alabọde-alabọde lati ọdọ awọn aṣelọpọ Yuroopu, iyipo pato 10-12Nm/cm³, dabaru opin 30-65mm, gbóògì agbara 100-500kg / h.
Awọn jara adopts nitrided skru ati awọn agba, pẹlu ti o dara yiya resistance, o dara fun arinrin TPE masterbatch processing (akoonu pigmenti ≤50%). O ti ni ipese pẹlu eto iṣakoso PLC, laifọwọyi otutu iṣakoso, ati ono, rọrun lati ṣiṣẹ. Apẹrẹ dabaru apọjuwọn ngbanilaaye iṣeto rọ ni ibamu si awọn ibeere Masterbatch TPS/TPO. HTS BASIC jara jẹ yiyan pipe fun awọn aṣelọpọ iwọn kekere ati alabọde pẹlu isuna to lopin, fojusi lori arinrin TPE masterbatch gbóògì (gẹgẹbi awọn ọja ile, arinrin onirin ati kebulu).
4.2.2 HTS PLUS jara: Ga-Torque fun Engineering TPE ati High-Fifi Masterbatch.
HTS PLUS jara wa ni ipo bi ọja aarin-si-giga, Pataki ti a ṣe fun ṣiṣe ibeere TPE masterbatch giga (VAT, TPU, ga-fojusi TPE masterbatch, ina-retardant masterbatch). O gba awọn apoti jia ti o ga ni ominira ni idagbasoke nipasẹ Zhuoyue, iyipo pato 13-16Nm/cm³, dabaru opin 40-75mm, gbóògì agbara 300-1200kg / h.
Awọn jara nlo bimetallic apapo skru ati awọn agba (líle dada ≥65 HRC), pẹlu o tayọ yiya resistance ati ipata resistance, o dara fun TPV / TPC masterbatch processing (high viscosity, ga-lile pigments). O ti wa ni ipese pẹlu a 5-6 apakan kongẹ iwọn otutu iṣakoso eto ati igbale eefi ẹrọ, yago fun TPU hydrolysis ati ibaje TPC. Awọn eroja idapọmọra imudara ṣe idaniloju pipinka aṣọ ti awọn awọ ifọkansi giga (50%-70%) ati awọn afikun iṣẹ-ṣiṣe (ina retardants, awọn aṣoju antistatic). jara HTS PLUS dara fun iwọn alabọde ati awọn aṣelọpọ iwọn nla ti n ṣe agbejade Masterbatch TPE ti o ni agbara giga. (gẹgẹbi awọn edidi ọkọ ayọkẹlẹ, ga-ite onirin ati kebulu, egbogi awọn ẹrọ).
4.2.3 HTS SUPER jara: Ultra-High Performance fun High-Opin TPE Masterbatch.
HTS SUPER jara jẹ jara extruder ti o ga julọ ti Zhuoyue, nsoju ipele to ti ni ilọsiwaju ti China ká twin-skru extruders, apẹrẹ fun ga-opin, ga-eletan 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), aye iṣẹ 3-4 igba ti arinrin 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, and predictive maintenance. 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 (líle dada ≥60 HRC), pade awọn iwulo ti deede TPE masterbatch processing (akoonu pigmenti ≤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, kekere agbara agbara, ati iye owo itọju kekere, suitable for small manufacturers, small workshops, ati awọn ile-iṣẹ iṣelọpọ kekere, olona-orisirisi TPE masterbatch (gẹgẹbi awọn nkan isere kekere, awọn ọja ile agbegbe).
4.2.5 HTE jara: Išẹ ti o ga julọ ati Solusan Imudara-doko.
HTE jara ṣepọ iṣẹ giga ati ṣiṣe-iye owo, ti a ṣe apẹrẹ fun awọn aṣelọpọ iwọn alabọde ti n ṣe igbesoke didara ọja ati iwọn iṣelọpọ pọ si. O gba awọn apoti jia ti o ga ni ominira ni idagbasoke nipasẹ Zhuoyue, iyipo pato 12-14Nm/cm³, dabaru opin 35-70mm, gbóògì agbara 200-800kg / h.
Awọn jara nlo bimetallic apapo skru ati awọn agba (líle dada ≥65 HRC), pẹlu ti o dara yiya resistance, o dara fun TPU / TPO masterbatch processing. O gba igbekalẹ dabaru iṣapeye ati mọto fifipamọ agbara ṣiṣe giga, agbara agbara dinku nipasẹ 18%-25% akawe pẹlu arinrin extruders. Eto iṣakoso iwọn otutu gangan ti apakan 5 ati ẹrọ imukuro igbale ṣe idaniloju didara ọja, ati awọn eroja ti o dapọ ti o ni ilọsiwaju ṣe idaniloju pipinka aṣọ. HTE jara ṣe iwọntunwọnsi iṣẹ ati idiyele, o dara fun awọn aṣelọpọ iwọn alabọde ti n ṣe agbejade iwọn alabọde TPE masterbatch (gẹgẹbi awọn paati inu inu ọkọ ayọkẹlẹ, arinrin egbogi awọn ẹrọ, aarin-ite onirin ati kebulu).
5. Awọn iṣoro ati awọn solusan ti o wọpọ ni TPE Masterbatch Twin-Screw Extrusion Processing
Ni TPE masterbatch processing, nitori awọn ohun-ini alailẹgbẹ ti awọn TPE (otutu ifamọ, ọrinrin gbigba, high viscosity), orisirisi isoro igba waye, ni ipa lori didara ọja ati ṣiṣe iṣelọpọ. Da lori awọn ọdun ti iriri, Zhuoyue ṣe akopọ awọn iṣoro ti o wọpọ, itupale wọn okunfa, ati pese awọn solusan ti o baamu lati ṣe iranlọwọ fun awọn aṣelọpọ yarayara yanju awọn iṣoro iṣelọpọ.
5.1 Isoro 1: Dispersibility ti ko dara, Awọn aaye awọ ati ṣiṣan ni Masterbatch
Ìfihàn: Uneven kikun ti masterbatch, kedere pigment agglomerates, awọn aaye awọ ati ṣiṣan ni awọn ọja TPE, atehinwa ọja aesthetics ati darí-ini.
Awọn okunfa: (1) Awọn ohun elo aise: Iwọn patiku pigment ti tobi ju, agglomeration jẹ pataki; ko dara ibamu laarin pigmenti / ti ngbe ati TPE; insufficient dispersant doseji. (2) Premixing: Iyara idapọmọra kekere, kukuru dapọ akoko, uneven premixing. (3) Extrusion sile: Iyara dabaru kekere, insufficient rirẹ-run agbara; kekere extrusion otutu, yo ti ko pe ti TPE ti ngbe. (4) Ohun elo: Wọ dabaru dapọ eroja; dina kú ori.
Awọn ojutu: (1) Je ki aise ohun elo: Yan awọn pigmenti patiku daradara (20-40 apapo), gbẹ daradara; yan ti ngbe ni ibamu pẹlu TPE; mu dispersant doseji (1%-5% ti pigmenti doseji). (2) Ṣe ilọsiwaju iṣaju: Mu iyara dapọ pọ si 800-1200 rpm, fa dapọ akoko lati 5-10 minutes. (3) Satunṣe extrusion sile: Mu iyara dabaru pọ si (500-800 rpm fun awọn TPE-giga); mu iwọn otutu extrusion pọ si lati rii daju yo pipe ti TPE. (4) Ṣe itọju ohun elo: Ropo wọ dabaru eroja; mọ kú ori nigbagbogbo.
5.2 Isoro 2: Ibajẹ TPE ati Discoloration Masterbatch
Ìfihàn: Masterbatch discolors (ofeefee, okunkun), n ṣe õrùn ti o yatọ; TPE products have reduced elasticity and mechanical strength, even brittle fracture.
Awọn okunfa: (1) Extrusion temperature is too high, exceeding TPE heat resistance limit. (2) Long material residence time (more than 3 minutes) in the extruder. (3) Poor equipment cooling, local overheating of the barrel. (4) Awọn ohun elo aise: TPE has poor heat resistance; moisture content is too high (causing TPU hydrolysis).
Awọn ojutu: (1) Adjust temperature: Reduce mixing/homogenizing section temperature, control within TPE processing range; check temperature sensor accuracy. (2) Shorten residence time: Mu iyara dabaru pọ si, reduce screw compression ratio. (3) Maintain cooling system: Clean cooling pipes, replace faulty cooling elements. (4) Je ki aise ohun elo: Select high-temperature resistant TPE; dry raw materials thoroughly (moisture content ≤0.05% for TPU/TPA); add heat stabilizers.
5.3 Isoro 3: High Wear of Screw and Barrel
Ìfihàn: Rapid wear of screw and barrel, reduced shear force and mixing capacity; masterbatch dispersibility decreases, equipment maintenance cost increases.
Awọn okunfa: (1) Awọn ohun elo aise: High-hardness pigments/additives (such as carbon black, titanium dioxide); large particle size. (2) Extrusion sile: High screw speed, excessive shear force; high extrusion pressure. (3) Ohun elo: Screw/barrel material has poor wear resistance.
Awọn ojutu: (1) Je ki aise ohun elo: 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 Isoro 4: Bubbles in Masterbatch
Ìfihàn: Bubbles in masterbatch particles, affecting product density and mechanical properties; TPE products have pores and defects.
Awọn okunfa: (1) Awọn ohun elo aise: High moisture content (especially TPU/TPA); volatile substances in pigments/additives. (2) Extrusion sile: Low extrusion temperature, incomplete melting; insufficient vacuum exhaust. (3) Premixing: Air mixed into the mixture during premixing.
Awọn ojutu: (1) Dry raw materials thoroughly: Extend drying time, increase drying temperature. (2) Satunṣe extrusion sile: 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 Isoro 5: Poor Processing Fluidity, Equipment Blockage
Ìfihàn: Difficult material conveying and extrusion; unstable extrusion pressure; die head or extrusion cavity blockage.
Awọn okunfa: (1) Awọn ohun elo aise: High TPE viscosity (TPV/TPC); high pigment content (more than 70%); high moisture content (causing agglomeration). (2) Extrusion sile: Low temperature, incomplete melting; low screw speed, insufficient conveying capacity. (3) Ohun elo: Worn conveying elements; dina kú ori.
Awọn ojutu: (1) Je ki aise ohun elo: 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) Ṣe itọju ohun elo: Replace worn conveying elements; clean die head and extrusion cavity regularly.
6. Awọn ọran Ohun elo Iṣeṣe ti Zhuoyue Extruders ni TPE Masterbatch Processing
Lati mọ daju awọn anfani iṣẹ ti awọn extruders Zhuoyue ni TPE masterbatch processing, apakan yii ṣafihan ọpọlọpọ awọn ọran iṣe, ibora ti o yatọ si TPE isori, production scales, and application fields, n ṣe afihan awọn ojutu ifọkansi ti a pese nipasẹ Zhuoyue.
6.1 Ọran 1: HTS SUPER Series ni TPC Masterbatch Processing fun Automotive Hoses
Onibara abẹlẹ: A o tobi Oko paati olupese ni Shanghai, China, ṣe agbejade awọn okun TPC ti o ga ni iwọn otutu fun awọn ọkọ agbara titun. Onibara nilo lati gbejade Masterbatch TPC (pigment akoonu 60%, high-temperature resistant) pẹlu awọn ibeere ti olekenka-ga dispersibility (ko si awọn aaye awọ), ooru resistance (260℃), ati iduroṣinṣin ipele. Awọn ohun elo atilẹba ni awọn iṣoro ti iyipo ti ko to, riru iṣakoso iwọn otutu, ati ko dara dispersibility, eyi ti ko le pade awọn ibeere.
Ojutu: Zhuoyue ṣeduro awọn olutayo jara HTS SUPER (dabaru opin 75mm, iyipo pato 18Nm/cm³) ni idapo pelu kan pipe laifọwọyi gbóògì ila, pẹlu a ga-ṣiṣe togbe, ga-iyara aladapo, ati konge granulator, ti a ṣe deede si awọn iwulo processing TPC masterbatch ti alabara. Iṣeto mojuto ati awọn igbese iṣapeye jẹ atẹle: Ni akọkọ, dabaru gba apẹrẹ apapo idapọpọ-ipele pupọ, iṣakojọpọ awọn eroja irẹrun-giga ati awọn eroja kaakiri lati fọ ni kikun pigment agglomerates ati rii daju pipinka aṣọ. 60% awọn awọ ifọkansi giga ni matrix TPC. Awọn lesa-agbada dabaru dada (líle ≥70 HRC) fe ni koju yiya ṣẹlẹ nipasẹ ga-lile pigments, extending awọn iṣẹ aye nipa diẹ ẹ sii ju 3 igba akawe si awọn onibara ká atilẹba ẹrọ. Keji, agba naa ti ni ipese pẹlu jaketi-ila meji + forced cooling structure, pẹlu 6 ominira otutu Iṣakoso ruju, iyọrisi iṣakoso iwọn otutu konge ti ± 1 ℃. Iwọn apakan idapọmọra jẹ iṣakoso iduroṣinṣin ni 240-260 ℃, ati apakan homogenizing ni 230-250 ℃, muna ibaamu iwọn otutu iwọn otutu sisẹ TPC lati yago fun ibajẹ ohun elo ati iyipada awọ pigment. Kẹta, awọn ẹrọ ti wa ni ipese pẹlu kan ga-ṣiṣe igbale eefi ẹrọ (igbale ìyí adijositabulu soke si 0.09MPa), eyiti o yọkuro ọrinrin ni imunadoko ati awọn oludoti iyipada ninu awọn ohun elo aise TPC ati masterbatch, lohun patapata isoro ti o ti nkuta ṣẹlẹ nipasẹ ọrinrin gbigba. In addition, HTS SUPER jara ti ni ipese pẹlu eto iṣakoso awọsanma ti oye, eyiti ngbanilaaye alabara lati tọju awọn paramita processing masterbatch TPC, pe wọn pẹlu titẹ ọkan nigbati o ba yipada awọn ipele, ati atẹle data iṣelọpọ ni akoko gidi, imudarasi iduroṣinṣin ipele ati idinku awọn aṣiṣe iṣẹ.
Ipa imuse: Lẹhin 1 oṣu ti fifi sori ẹrọ ati igbimọ, awọn HTS SUPER jara extruders ifowosi fi sinu gbóògì. Awọn abajade idanwo fihan pe TPC masterbatch ti a ṣe ni isokan apapọ ti ≥98%, ko si awọn aaye awọ tabi awọn ṣiṣan, ati ipa pipinka pigment jẹ pataki dara julọ ju ohun elo atilẹba ti alabara lọ. Masterbatch n ṣetọju iṣẹ iduroṣinṣin lẹhin sisẹ iwọn otutu giga ni 260 ℃, pẹlu ko si discoloration tabi ibaje, ni kikun pade awọn ibeere ti awọn okun ọkọ ayọkẹlẹ ọkọ ayọkẹlẹ agbara titun. Agbara iṣelọpọ de 1500kg / h, eyi ti o jẹ 40% ti o ga ju ohun elo atilẹba lọ, nigba ti agbara agbara dinku nipasẹ 22%, significantly atehinwa awọn onibara ká gbóògì owo. Yiya ti awọn skru ati awọn agba ti dinku pupọ, ati awọn ọmọ itọju ti wa ni tesiwaju lati 1 osu si 6 osu, atehinwa itọju owo nipa diẹ ẹ sii ju 50%. Awọn okun TPC ti alabara ti a ṣe ti masterbatch yii ti kọja iwe-ẹri didara ile-iṣẹ adaṣe, pẹlu o tayọ ga-otutu resistance ati darí agbara, ati pe a ti pese ni aṣeyọri si awọn aṣelọpọ ọkọ ayọkẹlẹ agbara tuntun. Onibara ṣe idanimọ gaasi ojutu extrusion Zhuoyue, ati lẹhinna fowo si adehun ifowosowopo igba pipẹ, rira 5 diẹ sii awọn eto ti HTS SUPER jara extruders lati faagun iwọn iṣelọpọ.
6.1 Ọran 1: HTS SUPER Series ni TPC Masterbatch Processing fun Automotive Hoses
Onibara abẹlẹ:
A o tobi Oko paati olupese ni Shanghai, China, ṣe agbejade awọn okun TPC ti o ga ni iwọn otutu fun awọn ọkọ agbara titun. Onibara nilo lati gbejade Masterbatch TPC (pigment akoonu 60%, high-temperature resistant) pẹlu awọn ibeere ti olekenka-ga dispersibility (ko si awọn aaye awọ), ooru resistance (260℃), ati iduroṣinṣin ipele. Awọn ohun elo atilẹba ni awọn iṣoro ti iyipo ti ko to, riru iṣakoso iwọn otutu, ati ko dara dispersibility, eyi ti ko le pade awọn ibeere.
Ojutu:
Zhuoyue ṣeduro awọn olutayo jara HTS SUPER (dabaru opin 75mm, iyipo pato 18Nm/cm³) ni idapo pelu kan pipe laifọwọyi gbóògì ila, pẹlu a ga-ṣiṣe togbe, ga-iyara aladapo, ati konge granulator, ti a ṣe deede si awọn iwulo processing TPC masterbatch ti alabara. Iṣeto mojuto ati awọn igbese iṣapeye jẹ atẹle: Ni akọkọ, dabaru gba apẹrẹ apapo idapọpọ-ipele pupọ, iṣakojọpọ awọn eroja irẹrun-giga ati awọn eroja kaakiri lati fọ ni kikun pigment agglomerates ati rii daju pipinka aṣọ. 60% awọn awọ ifọkansi giga ni matrix TPC. Awọn lesa-agbada dabaru dada (líle ≥70 HRC) fe ni koju yiya ṣẹlẹ nipasẹ ga-lile pigments, extending awọn iṣẹ aye nipa diẹ ẹ sii ju 3 igba akawe si awọn onibara ká atilẹba ẹrọ. Keji, agba naa ti ni ipese pẹlu jaketi-ila meji + forced cooling structure, pẹlu 6 ominira otutu Iṣakoso ruju, iyọrisi iṣakoso iwọn otutu konge ti ± 1 ℃. Iwọn apakan idapọmọra jẹ iṣakoso iduroṣinṣin ni 240-260 ℃, ati apakan homogenizing ni 230-250 ℃, muna ibaamu iwọn otutu iwọn otutu sisẹ TPC lati yago fun ibajẹ ohun elo ati iyipada awọ pigment. Kẹta, awọn ẹrọ ti wa ni ipese pẹlu kan ga-ṣiṣe igbale eefi ẹrọ (igbale ìyí adijositabulu soke si 0.09MPa), eyiti o yọkuro ọrinrin ni imunadoko ati awọn oludoti iyipada ninu awọn ohun elo aise TPC ati masterbatch, lohun patapata isoro ti o ti nkuta ṣẹlẹ nipasẹ ọrinrin gbigba. In addition, HTS SUPER jara ti ni ipese pẹlu eto iṣakoso awọsanma ti oye, eyiti ngbanilaaye alabara lati tọju awọn paramita processing masterbatch TPC, pe wọn pẹlu titẹ ọkan nigbati o ba yipada awọn ipele, ati atẹle data iṣelọpọ ni akoko gidi, imudarasi iduroṣinṣin ipele ati idinku awọn aṣiṣe iṣẹ.
Ipa imuse:
Lẹhin 1 oṣu ti fifi sori ẹrọ ati igbimọ, awọn HTS SUPER jara extruders ifowosi fi sinu gbóògì. Awọn abajade idanwo fihan pe TPC masterbatch ti a ṣe ni isokan apapọ ti ≥98%, ko si awọn aaye awọ tabi awọn ṣiṣan, ati ipa pipinka pigment jẹ pataki dara julọ ju ohun elo atilẹba ti alabara lọ. Masterbatch n ṣetọju iṣẹ iduroṣinṣin lẹhin sisẹ iwọn otutu giga ni 260 ℃, pẹlu ko si discoloration tabi ibaje, ni kikun pade awọn ibeere ti awọn okun ọkọ ayọkẹlẹ ọkọ ayọkẹlẹ agbara titun. Agbara iṣelọpọ de 1500kg / h, eyi ti o jẹ 40% ti o ga ju ohun elo atilẹba lọ, nigba ti agbara agbara dinku nipasẹ 22%, significantly atehinwa awọn onibara ká gbóògì owo. Yiya ti awọn skru ati awọn agba ti dinku pupọ, ati awọn ọmọ itọju ti wa ni tesiwaju lati 1 osu si 6 osu, atehinwa itọju owo nipa diẹ ẹ sii ju 50%. Awọn okun TPC ti alabara ti a ṣe ti masterbatch yii ti kọja iwe-ẹri didara ile-iṣẹ adaṣe, pẹlu o tayọ ga-otutu resistance ati darí agbara, ati pe a ti pese ni aṣeyọri si awọn aṣelọpọ ọkọ ayọkẹlẹ agbara tuntun. Onibara ṣe idanimọ gaasi ojutu extrusion Zhuoyue, ati lẹhinna fowo si adehun ifowosowopo igba pipẹ, rira 5 diẹ sii awọn eto ti HTS SUPER jara extruders lati faagun iwọn iṣelọpọ.