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Santoprene TPV for solar applications

　　Santoprene TPV is a material that combines the easy processing properties of thermoplastic with the durability of thermoset rubber, and has been commercially available for thirty years. It is used in a wide variety of industries, including automotive, construction, home appliances, sanitary ware, and power tools. With the booming of the solar industry, its excellent performance has been successfully applied in this industry as well. 　　Typical successful applications in solar energy are: photovoltaic connectors and solar street light seals. 　　As we all know: the photovoltaic industry for the connector material requirements are very demanding: 1: weather resistance - the requirements of the resistance to weathering. 　　1: weather resistance - require good ozone resistance or even reach f1 outdoor use grade 　　2: flame retardant - required to achieve V-1 grade or higher 5VA grade 　　3: Temperature resistance - -40 ℃ to 80 ℃ cycle test 　　4: Environmental protection - in line with ROHS and REACH regulations; recyclable 　　5: Flexibility - requires good resilience and excellent sealing performance 　　6: low temperature - in minus 40 ℃ to maintain good flexural and impact resistance 　　7: Voltage resistance - can withstand certain voltage breakdown, excellent insulation performance 　　For this particular application of PV, ExxonMobil recommends two material-specific specifications: black: 151-70W256 and natural: 251-80W232, which have been used successfully.

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5 practical points of TPE/TPR injection molding process

　I. If the surface of the product is strict, it must be dried before injection. Generally, the hopper drying is 70~80℃/2h or pallet drying is 80~100℃/1h. For pallet drying, it should be noted that the thickness of material layer is generally not more than 50mm. It is recommended to use tray drying. If there is blistering on the surface of the injection molded strip, or cut open the strip and find that there is a hole inside, or find that the surface of the product and scattered silver wire, it can be determined that the TPE/TPR raw materials contain too much moisture. 　　Second. Try to use low-temperature injection molding. Under the premise of ensuring the quality of plasticization, try to reduce the extrusion temperature, and the use of increased injection pressure and screw speed to reduce the viscosity of the melt, to improve the purpose of fluidity. When the surface of the strip injected from the nozzle is smooth and shiny, the plasticization quality is good. If the strip injected from the nozzle is very bright, it can be determined that the barrel temperature can be reduced. If you try to use low temperature injection, you can reduce the cooling time and improve the production efficiency of customers. 　　III. Upper parabolic temperature setting. The temperature is highest in the middle zone of the screw, slightly lower in the charging section and slightly lower in the nozzle. Typical temperature settings are 150~170℃ (feeding), 170~180℃ (middle), 190~200℃ (front), 180℃ (nozzle). This temperature setting is only for reference, the specific temperature can be adjusted according to the specific physical properties of different TPE and TPR materials. If you find that the content of the product bulges (gas is wrapped inside) and the gate is easy to break when demoulding, you can refer to trick two to make adjustments. 　　IV. Keep the pressure as small as possible. Generally speaking, the holding pressure should be lower than the injection pressure, and the holding time can be determined by weighing the product, and the weight of the product should not increase, or the shrinkage mark accepted by the customer should be used. If it is found that the gate is easy to break during demoulding and the trick 2 does not work, then it should be feasible to reduce the holding pressure. 　　V. In case of several stages of injection, the speed should be from slow to fast. Because of this, the gas inside the mold can be discharged easily. If there is gas inside the product (bulging inside) or there is a dent, this method can be used to adjust the product if trick 2 does not work.

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【Injection molding knowledge】TPE material common shrinkage water marks and other phenomena processing methods

　TPE product shrinkage refers to the phenomenon that the surface raw materials at the wall thickness are pulled in due to volume shrinkage during the cooling and hardening process of the product, which results in the appearance of depression marks on the product surface. 　　TPE shrinkage phenomenon usually has the following reasons. 　　1 injection molding process problems (such as low injection pressure, insufficient holding time, high mold temperature, insufficient cooling time, etc.) 　　2 structural design problems (uneven thickness of the glue bit, improper ratio of rib width to glue bit thickness, too thick glue bit thickness of the product, etc.) 　　3 mold processing problems (feed opening too small or runner cross-section too small, etc.) 　　4. Material aspect (shrinkage difference). 　　TPE shrinkage solutions: 　　1, increase the injection pressure, holding pressure, and extend the injection time. For tpe plastic with high fluidity, high pressure will produce flying edge and cause collapse pit, it should be adapted to reduce the material temperature, lower the barrel front section and nozzle temperature, so that the change of melt volume into the cavity is reduced and easy to cold solidify; for high viscosity plastic, the barrel temperature should be increased to make the mold filling easy. When shrinkage occurs in the gate area, the holding time should be extended. 　　2, Increase the injection speed to make the part filled and eliminate most of the shrinkage. 　　3, Thin-walled parts should increase the mold temperature to ensure smooth material flow; thick-walled parts should reduce the mold to speed up the curing of the skin to set. 　　4, appropriately increase the cooling time to reduce thermal shrinkage. Extend the cooling residence time of the parts in the mold, maintain a uniform production cycle, increase the back pressure, the front section of the screw to retain a certain buffer pad, etc. are conducive to reducing shrinkage phenomenon. 　　5, low precision products should be released from the mold early to let it cool slowly in the air or hot water, which can make the shrinkage depression smooth and does not affect the use. 　　6, the temperature is too high or too low, will not be able to achieve the effect of pressure-holding. 　　7, the amount of rubber injection is not enough, increase the amount of injection glue.

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【Case Share】TPE high-grade cell phone protective case overmolding

　　Cell phone cases are an important branch of injection molding production. There are 2 major series of cell phone cases, hard rubber and soft rubber. Hard rubber materials generally have PC, PC/ABS, etc. Soft rubber materials generally have TPE (TPR, TPU, etc.), hard rubber materials are injection molding, soft rubber materials are also injection molding. 　　Soft rubber has many advantages, mainly resistance to stretching, not deformed, soft, good toughness, non-slip, impact resistance, good fall resistance. Disadvantages are easy to stick to dust, poor heat dissipation, hair "sticky", easy to lose color, the product is thicker. Soft plastic cell phone cover injection molding production later generally have to post-processing, such as screen printing, color printing, transfer printing, drip processing and other more complex. But the injection molding itself does not seem to be complicated but it is quite difficult. The defects that are easy to appear in the production of soft plastic cell phone cover injection molding: sticky mold, shrinkage, batch front, bubble, long cycle time. The solution of the above problems depends on good mold design, material selection, parameters and machine selection. 　　The case is a high-grade soft plastic cell phone case injection molding production. One of the high grade is reflected in the thickness, the thickness of common soft rubber is more than 1mm, but this product is only 0.55mm, the second is the material, high-grade TPE material. The size of the product is about 125*60*8mm, the single weight of the product is about 8g, and the total weight of the product with water outlet is about 30g. 　　First is the material, the customer has specified TPE. second mold design. This product is characterized by thin, too weak strength, easy to stick film, in order to increase the effect of release, double-sided with a local fine skin pattern design. Four sides of the power hole opening key and other structures with side core. In order to improve the production efficiency and consider the stability of the production, the mold cavity one out of one. Considering the beauty of the product, the mold parting line is designed at the bottom edge. Considering the low temperature of the mold, which is also a common practice for soft plastic injection molds, a three-plate design is used. 　　The runner is manufactured with direct fire pattern. The gate design is critical. There are generally 2 kinds of entry points for this type of mold in the industry. 　　1) It is the edge of the bottom edge. 2) At the part of the camera hole. Considering the beauty of our high-grade products, we adopt the camera hole water entry design, and at the same time, considering the exhaust, the camera hole water outlet part of the wall is empty. At the same time this split water outlet in the subsequent processing of punching and cutting to remove. 　　The third is the machine selection. Because the product is very thin, just the product body flow length ratio of about 120 / 0.55 = 220, and then take into account the water mouth, flow length ratio of about 250, such a large flow length ratio for the general machine is very long to eat, to use high-speed machine. 　　The fourth is the parameters. Parameter test process is more complex, mainly sticky mold problems, shrinkage and batch front problems. After several tests, the following parameters were determined. Low mold temperature, high material temperature, short injection time, precise switching position, and precise holding pressure. On this basis, the cycle time is gradually shortened.

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【Case Share】TPE elastomer material applied to high-end sealing strip

　　Seal, is a product that seals something so that it cannot be easily opened, and plays the role of shock absorption, waterproof, sound insulation, heat insulation, dustproof, and fixing. Seals are made of rubber, paper, metal, plastic and other materials. Since the 80s, the seals have been applied to various industries such as automobile, doors and windows, cabinets, refrigerators, containers, etc. According to the requirements of different industries, we have developed unique products such as automobile seals, mechanical seals, door and window seals, etc. 　　Recently, the customer needs to make a TV inner casing sealing strip, the requirements, the material dimensional stability, the material does not deformation shrinkage after assembly. Engineering reference customers to provide OK material samples to make samples, preliminary analysis: material is PP plus TPV modified material, physical analysis: hardness: 94-95A, the focus is to open the mold when the shrinkage rate of the material to be true. The product is 1.1 long and is injection molded by more than 800T machine. 　　Through comparison and analysis, the engineering first recommended one of our company: ENB95A2-03, to the customer test molding out of the mold OK, but compared with OK board, the surface is too bright, the size of the length is greater than the design length NG. test material back and engineering communication, analysis of the reasons, the material surface bright, TPV composition is low. The dimensional stability of the material is not enough and the shrinkage rate is not right. Engineering into the improvement program: 1. Add more TPV content, improve the material elegance. 2. Canna rice calcium carbonate to improve the temperature stability of the material 3. Use high temperature resistant PP modified again to provide sample material to the customer test material: ENB95A3-01, the results NG, material size stability, the effect is not good, the reason is: the use of high molecular weight SEBS 533 in the material, polymer material shrinkage is larger, so need to be modified with medium molecular materials, again a sample: ENB95A -SL, after the customer trial material forming OK, 5 days size test is stable state OK, this project mass production success. 　　Summary: Through this project trial material comparison, from the material shrinkage and dimensional stability, ENB95A-SL is better than ENB95A3-01. The dimensional stability of medium molecular SEBS material is better, and the product is not easy to produce stress deformation or shrinkage in the injection process. Such seal products, if the product size requirements are high, all can use this solution.

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[TPE injection molding tips] A few simple steps to solve the problem of TPE products bubbles

　　TPE material will not decompose under the general injection temperature, so its bubble generation only comes from water gas.　Influencing factors are: mold temperature, being pressure, melt speed, injection time all have influence 　　In the process of punching the mold is disturbed by gas, often in the product surface appear silver filigree, or tiny bubbles, or in the thick wall of the product to form bubbles. The source of these gases mainly involves raw materials containing moisture or volatile substances or melting agent in excess, but also may be too high material temperature, tpe plastic subjected to heat for a long time, degradation occurs and the production of degradation gas, the causes of these many, involving factors oh may have injection molding machine and mold and many other aspects. 　　Solution. 　　1, drying. First dry the material, if not, you need to adjust the process. 　　2, adjust the injection speed, it may be that the material flow is very fast, the injection speed is very fast, resulting in the mold internal air is not eliminated in a timely manner, in the joint line position is easy to line into a bubble. 　　3, the injection mold to increase the exhaust bad (a simple solution is to add a small piece of paper in the middle of the mold to see if the bubble is less, such as less then the mold exhaust is a problem. 　　4, adjust the mold temperature, the temperature is too high, the TPE material inside the low molecular composition will escape to form bubbles. 　　5, appropriate to increase the back pressure of the screw, the barrel inside the air out

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TPE injection molded products are insufficiently filled, how to improve the process?

(1) Improper feed adjustment, lack of material or excessive material. Inaccurate feeding measurement or abnormal feeding control system operation, abnormal injection cycle caused by injection molding machine or mold or operating conditions, low pre-plastic back pressure, or low particle density in the barrel may cause material shortage. For large particles, For granular materials with many voids, plastics with large changes in specific volume of crystallinity, and plastics with higher viscosity, the amount of material should be adjusted higher, and the amount of material should be adjusted larger when the material temperature is high. When there is too much material at the end of the barrel, the screw will consume extra injection pressure to compress and push the excess stock in the barrel during injection, which greatly reduces the effective injection pressure of the plastic entering the mold cavity. The product is difficult to fill. 　　 (2) The injection pressure is too low, the injection time is short, and the plunger or screw returns too early. 　　Molten plastic has higher viscosity and poor fluidity at lower working temperature, so it should be injected at higher pressure and speed. For example, in the production of ABS color parts, the high temperature resistance of the colorant limits the heating temperature of the barrel, which has to be compensated by higher injection pressure and longer injection time than usual. 　　 (3) The injection speed is slow. 　　Injection speed is of great significance for some products with complex shapes, large thickness changes, and long processes, as well as plastics with higher viscosity, such as toughened ABS. When the product cannot be filled with high pressure, high-speed injection should be considered to overcome the problem of dissatisfaction. 　　 (4) The material temperature is too low. The temperature of the front end of the barrel is low, and the viscosity of the molten material entering the cavity rises to the point where it is difficult to flow prematurely due to the cooling effect of the mold, which hinders the filling of the far end; the rear section of the barrel is a plastic with low temperature and high viscosity Difficult flow hinders the forward movement of the screw. As a result, it seems that the pressure indicated by the pressure gauge is sufficient, but the melt actually enters the cavity at low pressure and low speed; If the nozzle temperature is low, it may be that the nozzle is in contact with the cold mold for a long time during the fixed feeding and loses heat, or the nozzle heating ring is insufficiently heated or has poor contact, resulting in low material temperature, which may block the mold's feeding channel; if the mold does not have cold material Well, with self-locking nozzles and post-feeding procedures, the nozzles can maintain the necessary temperature; the nozzle is too cold when it is just turned on, and sometimes a flame gun can be used for external heating to accelerate the temperature of the nozzle.

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TPE wire performance advantages and processing problem solutions

The application of TPE wire is popular, with excellent tensile properties, comfortable hand feeling, good elasticity and good abrasion resistance. TPE has the elasticity of rubber, excellent tensile properties, adjustable hardness, and comfortable and smooth touch. Easy to process. TPE inherits the characteristics of easy processing of traditional PVC. TPE rubber materials can be conveniently produced and processed by extruders of various wires (such as earphone cables, USB cables, automotive electronic cables, computer cables, etc.), and can be injection molded by a small vertical injection molding machine. Plugs (such as earphone plugs, USB plugs, DC plugs, etc.). Excellent chemical properties. TPE is a SEBS substrate, which has good aging resistance, weather resistance, and low temperature resistance. It still maintains a soft and comfortable hand feeling at a low temperature of minus -50 degrees without becoming hard. 　　 When the TPE wire is pressed, the wire is unstable, it is normal, that is, a little cold water on the machine head will affect the stability of the wire, there is no absolute stability! TPE wire extrusion adhesion and surface smoothness problems are outstanding. 　　 Adhesion: If the conductor is preheated and requires high adhesion, if the rubber material does not change color, try to increase the preheating temperature or voltage, use a pressurized mold, or adjust the distance inside the head, and hit back as much as possible. Wire bridge distance, outer diameter, and insulation thickness, as well as non-eccentricity. Try the first section but the sink! If conditions permit, you can adjust the hardness of the rubber. Use the softest rubber as possible, and the adhesion will be better. The rubber used for the outlet should be adjusted according to the weather, and the hardness of the rubber should be adjusted appropriately. Finally, the conductor adopts irregular twisting Together, increase the contact area between the rubber compound and the conductor! 　　Surface smoothness: 　　 The screw temperature is appropriate, and the plasticizing effect of the rubber compound is better. The pressure during extrusion, as the pressure increases, the surface will be smoother, check if it is scratched after exiting the wire (die mouth scratches or die mouth residue)

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TPE Thermoplastic Elastomer Flame Retardant Development Analysis

Thermoplastic elastomer TPE (Thermoplastic Elastomer), also known as artificial rubber or synthetic rubber. Its products not only have the high elasticity, aging resistance, and oil resistance of traditional cross-linked vulcanized rubber, but also have the characteristics of convenient processing and wide processing methods for ordinary plastics. TPE plastic is mainly composed of two parts, one is plastic as the continuous phase, and the other is rubber as the dispersed phase. Usually rubber needs to be combined with softening oil or plasticizer. Vulcanizing agents and some auxiliary additives are also essential. In addition, in order to reduce costs or improve certain aspects of performance, some inorganic fillers will also be added. According to the material composition, it can be divided into: styrene (SBS, SIS, SEBS, SEPS), olefin (TP0, TPV), diene (TPB, TPI), vinyl chloride (TPVC, TCPE), urethane ( TPU), esters (TPEE), amides (TPAE), organic fluorines (TPF), silicones and vinyls, etc., cover almost all areas of synthetic rubber and synthetic resins. Listed below are several common TPE components. However, there are many components in the TPE thermoplastic elastomer formulation system. Due to the differences in the structure and properties of the components, the mechanism is not clear, which brings great difficulty to the flame retardant treatment. There will also be great safety hazards during the use process, which gives TPE The use of the product brings certain limitations. So, what difficulties may TPE flame-retardant treatment encounter? 　　1, the choice of flame retardant is difficult 　　The flame retardant has poor compatibility with the substrate. When the amount of flame retardant added in the elastic system is slightly larger, especially in the halogen-free flame retardant, the elastic modulus, flexibility, mechanical properties, and abrasion resistance of TPS will be greatly reduced, the fluidity of the melt will become poor, and the elastomer will be difficult. Molded, and flame retardant migration is prone to occur on the surface, which constitutes environmental pollution. 　　2, the flame retardant mechanism is not clear 　　 TPS system is mainly a multiphase mixed structure of rubber, polyolefin resin, plasticizer and filler. Although there are relatively mature formulations and examples for halogen-free flame retardant polyolefin resins. However, the flame-retardant mechanisms of SEBS, polyolefin-based PP and PE are actually different. It is difficult for a flame retardant to flame-retardate multiple plastic components at the same time. 　　3, plasticizer reduces flame retardancy 　　TPE plastics often need to add plasticizers (white oil) in order to reduce the hardness and make the hand feel softer, usually with 26#, 32# white oil, 70# white oil as the main four types. Due to the difference in limiting oxygen index and fluidity of the four oils, and the natural flammability of oils greatly reduces the flame retardancy of elastomers, how to solve the relationship between plasticizers and flame retardants when producing low-hardness products? Choosing the type of white oil is very important. 　　 Based on the difficulties that may be encountered above, what are the actual problems that may be encountered during the processing of flame-retardant TPE? What are the corresponding solutions? 　　1, the wire surface is not smooth 　　 TPE wire processing often occurs. It is usually caused by improper temperature adjustment and uneven mixing of flame retardants. It may also be caused by incorrect mold selection. Of course, it has a lot to do with the material formulation. Experienced manufacturers will eliminate equipment problems and find the right temperature after repeated adjustments. However, engineers should be cautious about selecting suitable materials and specific formulas. It is recommended to communicate more with the raw material supplier, know the physical properties of the material and processing precautions, and choose the right material, it will get twice the result with half the effort! TPU wire is better than TPE wire surface processing. 　　2, precipitation on the wire surface 　　 So far there is no material that can guarantee no precipitation at all. The specific precipitation performance is: the surface is white, oily or misty. With current technology, this problem has not been solved yet. It is recommended that customers choose a material with a slight whitening surface when choosing, and this precipitation will not affect its physical and electrical properties. Do not use materials with oil on the surface, as they will easily fall off and peel off during use. In addition, the precipitation is also divided into serious and serious. The precipitation of good materials is slight, and it is not easy to occur in a short period of time, even if it occurs with a gentle hand rub. 　　3, the surface is white and peeling off the glue 　　 whitening is caused by the addition of PP and PE com

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