Processing Pitfalls? What to Avoid with Filled TPE Thermoplastic Elastomers?

Filled TPE thermoplastic elastomers achieve cost reduction and performance optimization through filler addition, making them widely used in product manufacturing. However, adding fillers alters the base material's inherent properties, often leading to various processing issues that impact production efficiency and product quality. Pay close attention to these common pitfalls highlighted in our guide.

I. Poor Flowability Hinders Molding

First, the particle size of TPE fillers, their addition ratio, and their compatibility with the base material all affect material flowability. If filler particles are too fine, the addition ratio is too high, or compatibility is poor, material flow resistance increases. This can lead to material shortages during injection molding, uneven surfaces or even material breakage during extrusion, causing production stoppages.

II. Equipment Wear and Increased Maintenance Costs

Some fillers possess high hardness, causing continuous friction against equipment components during processing. Long-term use may wear down screws, barrels, and other parts, resulting in uneven material plasticization, fluctuating product performance, shortened equipment lifespan, and increased maintenance expenses.

III. Surface Defects and Poor Appearance

Uneven filler dispersion or poor bonding with the base material can lead to surface defects like pitting or whitening. Impurities in fillers or improper processing temperatures may also cause spotting or color variations, compromising appearance consistency.

IV. Fluctuating Mechanical Properties and Unstable Quality

Poor dispersion and bonding of fillers can cause variations in mechanical properties like strength and elasticity. This may result in reduced elongation at break, increased brittleness, and susceptibility to fracture, affecting product reliability.

V. Bubbling, Odor, and Environmental Compliance Issues

Moisture absorption or insufficient drying of fillers can cause bubbling during high-temperature processing. Volatile impurities in fillers or minor reactions with base materials may release odors, making compliance with certain environmental standards difficult.

Zhongsu Wang's Insights:

To avoid these issues during processing of filled TPE thermoplastic elastomers, select compatible fillers, optimize process parameters, ensure proper material pretreatment and equipment maintenance. Conduct small-batch trial production and debugging to balance efficiency and quality, ensuring smooth production.