Manufacturing method for TPE thermoplastic elastomers

TPE thermoplastic elastomers are high-performance materials that combine the elasticity of rubber with the processing convenience of plastics. Their unique plasticity and environmental friendliness make them an ideal alternative to traditional rubber materials. However, their excellent performance does not come about by chance, but is achieved through a series of precisely controlled manufacturing processes. Understanding the manufacturing methods not only helps optimize production processes and improve product quality but also provides theoretical support for material selection and application. So, what are the manufacturing methods for TPE thermoplastic elastomers? Below, the TPE team at Shenzhen Zhongsu Wang will provide a detailed introduction.  

The manufacturing methods for TPE thermoplastic elastomers are as follows:  

I.Chemical Synthesis Method

The chemical synthesis method involves using specific chemical reactions to synthesize TPE with specific structures and properties from monomers or oligomers. Depending on the type of polymerization reaction, the chemical synthesis method can be further divided into the following categories:

Anionic polymerization: Anionic polymerization is the recognized method for synthesizing specific block copolymers and can achieve polydispersity (Mw/Mn < 1.05) through anionic polymerization. In industry, anionic polymerization is used to prepare several important types of block copolymers, including S-B-S-type and S-I-S-type TPEs, suitable for monomers such as styrene (including substituted styrene), butadiene, and isoprene.

Cationic polymerization: Also known as carbocationic polymerization, it is used for monomers that cannot be polymerized via anionic polymerization, such as the synthesis of styrene-based thermoplastic elastomers containing S-IB-S-type isobutylene monomers, such as poly(styrene-b-isobutylene-b-styrene) (S-IB-S).

‌Coordinative polymerization‌: Coordinative polymerization using Ziegler-Natta catalysts or metallocene catalysts is used to synthesize block copolymer-based thermoplastic elastomers with controlled structures, such as OBC block copolymer elastomers.

Addition polymerization: Using addition polymerization methods, diisocyanates, long-chain diols, and chain extenders are employed to synthesize multi-block thermoplastic polyurethanes.

Other methods: These include dynamic vulcanization (for thermoplastic rubber vulcanization), esterification and condensation (for polyamide elastomers), ester exchange (for copolyester elastomers), catalytic polymerization of olefins (for thermoplastic polyolefins RTPOs), and direct copolymerization (such as the copolymerization of ethylene and methyl acrylate, producing certain ionomer-type thermoplastic elastomers), etc.

II. Polymer blending method

Polymer blending involves physically or chemically blending rubber with plastics and other polymers to form composite materials with thermoplastic elastomer properties. Depending on the blending method, polymer blending can be further classified into the following types:

Melt blending: The main equipment used includes sealed rubber mixers, open rubber mixers, extruders, etc. Melt blending does not involve issues such as solvent contamination, solvent toxicity, or dehydration and solvent removal, and is widely used in rubber/plastic systems.

Solution blending: Rubber and plastic polymers are dissolved in an appropriate solvent, then thoroughly mixed through stirring and blending, and finally the solvent is removed to obtain the blend.

Emulsion blending: Emulsions of rubber and plastic polymers are mixed, then the emulsion is broken and dried to obtain the blend.

As described above, the production of TPE thermoplastic elastomers is a complex process involving multidisciplinary knowledge. For material manufacturers and application developers, a deep understanding of TPE production methods is not only a technical requirement but also a key factor in seizing market opportunities and enhancing competitiveness. Through continuous technological innovation and process optimization, TPE will undoubtedly play an increasingly important role in the future of the materials industry.