Thermoplastic extruder melt pump as a high temperature and high viscosity polymer melt conveying core equipment, its application scope covers plastics, rubber, chemical fiber, pipeline chemical and other industrial fields, and with the technological progress to the extension of emerging industries. The following is its specific application scope and typical scene analysis:
Pipe and sheet
melt pump by eliminating extruder pressure fluctuations (fluctuations can be controlled within ± 1%), so that the pipe wall thickness uniformity is significantly improved. For example, in the production of PVC pipes, it reduces thickness deviations from 5% in conventional processes to less than 1%, and in the production of bi-oriented polypropylene (BOPP) film, thickness deviations are reduced from 5% to less than 1% to meet the demand for high-end packaging materials.
Film & Sheet
Film: Melt pumps ensure uniform distribution of melt to the mold opening, resulting in improved PE film thickness consistency and reduced defective rates for agricultural and packaging films.
Sheet: In the production of optical-grade PET sheet and high-barrier packaging film, its stable pressure and flow characteristics can avoid surface flow marks, uneven thickness and other problems, and at the same time, through the shearing effect of the internal gear to eliminate the melt “dead zone” residues, improve surface finish and transparency.
Pelletizing and Compounding
Melt pumps are used in tandem with twin-screw extruders to improve compounding quality and reduce energy consumption. For example, an automotive parts manufacturer to adopt this program, glass fiber reinforced plastic products, tensile strength increased by 15%, material loss reduced by 20%; processing of each kilogram of material to reduce energy consumption by 25% -50%.
Tire tread rubber
Melt pump will mix the rubber melt accurately transported to the extrusion mold, to ensure that the tread rubber size accuracy and quality stability. For example, in the production of automotive tires, it can control the flow of rubber melt, so that the dimensional accuracy of seals meets the requirements of high standards, and the product qualification rate is significantly improved.
Rubber seals
Through precise flow control, the melt pump ensures uniform wall thickness of seals, avoiding performance degradation due to dimensional deviation, and meet the aerospace and automotive industry's demand for high reliability of seals.
Polyester Fiber (PET)
melt pumps will be polyester melt uniformly transported to the spinning assembly, stabilizing the spinning pressure, so that the fiber is uniform in thickness and thickness, and optimize the performance of the strength, gloss and so on. For example, after an international enterprise adopts five gears melt pump, the spinning breakage rate decreases by 40%, and the monofilament fiber unevenness rate decreases from 2.5% to 0.8%.
Differentiated fibers
In the production of nylon, acrylic and other chemical fibers, the precise flow control of the melt pump to support the development of functional fibers, such as antimicrobial, flame retardant fibers, to meet the textile industry's demand for high-quality fibers.
Pipeline melt pumps
Pipeline melt pumps are used for smooth pressurized transmission of high viscosity media in polymer fluids, such as polyethylene, polypropylene and other materials in the pipeline transmission, to ensure stable pressure, to avoid clogging or leakage of the pipeline.
Chemical Melt Pump
For the conveying and metering of low and medium viscosity materials (such as resins and paints), its precision flow channel design can eliminate the dead space in the flow channel, reduce the polymer residue, and improve product quality.
3D printing
Large-size FDM printing: melt pumps to solve the problem of extrusion instability caused by long-distance filament feeding, so that the printing speed increased by 50%, and the bonding strength of the interlayer increased by 30%. Concrete 3D printing: Drawing on the melt pump principle to develop a mortar delivery system, so that the compressive strength of building components discrete coefficient from 15% to less than 5%.
Specialty Engineering Plastics Processing
In the processing of polyether ether ketone (PEEK), polyimide (PI) and other high-temperature materials (above 400°C), the melt pump maintains a metering accuracy of 0.2%, so that the temperature resistance level of the aircraft engine parts has been raised from 260°C to 320°C, and the service life has been extended by three times.
Wet Process and Battery Manufacturing
The melt pump delivers the polyethylene/paraffin mixture to the mold head with ±0.5% accuracy, forming a microporous structure that directly affects the safety performance of the battery. For example, after the introduction of this technology by an enterprise, the diaphragm puncture strength has been increased from 300g/μm to 500g/μm, and the yield rate has exceeded 95%.
Plastics Recycling and Environmental Protection
Recycled Material Treatment: Melt pump homogenizes viscosity fluctuations due to raw material differences, narrowing the range of melt index fluctuations of recycled HDPE from ±15% to ±3%, which is applied to food contact grade packaging.
Chemical Recycling: Precise control of material residence time in PET depolymerization reaction increases depolymerization rate from 85% to 98%.
High-precision flow control
The flow accuracy can reach ±0.5% or even higher, which meets the scenarios of strict control of melt dosage for precision medical plastic products, optical films, and so on.
Pressure stabilizing function
Buffering pressure fluctuation by internal flow channel design, for example, in plastic sheet extrusion, when the extruder screw speed changes, the melt pump can keep the outlet pressure stable to ensure the flatness of the sheet.
Energy Saving and Consumption Reduction
Allows the extruder to operate at low pressure, reducing mechanical energy to heat and reducing energy consumption by 30%-50%.
Precise temperature control reduces heating power by 20%, and the annual power saving of an enterprise is equivalent to reducing 42,000 tons of carbon dioxide emissions.
Extend the life of the equipment
Reduce the axial force borne by the extruder screw, reduce the pressure inside the screw barrel, extend the service life of the equipment and reduce maintenance costs.
Thermoplastic extruder melt pump with its high precision, stable pressure, energy saving and other technical advantages, has become the core equipment for extrusion molding in traditional industries such as plastics, rubber, chemical fiber, etc., and has shown broad prospects in emerging fields such as 3D printing, special engineering plastics, battery manufacturing, plastics recycling and so on. With the integration of precision manufacturing and intelligent control technology, its application scope will continue to expand, providing more efficient and stable melt conveying solutions for industrial production.
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