Black masterbatch is produced using carbon black. Carbon black is a very difficult and dirty mixture that is dusty, light, and fluffy. Unless large-scale treatments are used, it can foul machines and workers and make the work environment dirty. Because of this, the casters generally choose to complete the pre-dispersion of carbon black on a resin carrier, that is, a black masterbatch. This resin carrier is clean, free flowing and easy to use. In addition, in addition to dirty, carbon black has a characteristic that it is difficult to disperse. If the carbon black is directly melted during injection molding, the coloring effect will be very poor. Carbon black streaks and spotted areas without dispersion will appear clearly alongside the less colored areas. Standard injection molding machines do not effectively disperse carbon black.
The difficult-to-dispersive properties of carbon black also plague color masterbatch producers. High-load black masterbatches produced using single or double screw extruders have very poor dispersion. When the end user mixes or molds these black masterbatch, its performance is only slightly better than carbon black, but the effect is equally unsatisfactory. In order to achieve a stable high degree of dispersion, a high level of shearing kneader must be used to mix carbon black, such as a mixture of FCM or BANBURY. With sufficient strength, these mixers allow the carbon black and base resin to be thoroughly mixed together. The type of carbon black used also affects the coloring dispersibility. The smaller the carbon black particles, the more difficult the dispersion is.
The application of thin wax is the most demanding dispersion requirement. The final product of the masterbatch with poor dispersion can be easily seen by the naked eye from the corners. In addition to the lack of aesthetics, the poor dispersion of carbon black in the film significantly reduces the weathering resistance of the black film. Small particles with good dispersion are a major feature of the fiber industry for ropes, yarns, carpets and other industries. Large machines produce 30,000 strands of fine fiber at a rate of more than 5,000 meters per minute. If the dispersion of the masterbatch is too poor, the fiber will be broken, resulting in production downtime.
The second factor that strongly determines the quality of the black masterbatch is the coverage. This factor is especially important for masterbatches used in scrap or recycled polymers. In these cases, the effect of black is to cover the scrap. Other colors in . The large-particle carbon black has a poor coloring ability and is not easy to cover all other colors in the lower layer, and as a result, the final product only obtains a deviation from the color. In the melting process, the ability to correctly select the carbon black with high coloring ability to cover the existing color is the so-called covering power.
The third factor that determines the quality of the black masterbatch is the rheology and fluidity. If a masterbatch itself has good dispersibility, but it cannot flow into the material to be molded, the production effect is not satisfactory. In general, primers used to produce masterbatches have higher rheology. In order to save costs, some masterbatch producers use recycled materials, scraps or recycled materials as resin carriers. The flow properties of the masterbatch thus produced will be significantly reduced, and if the rheology is not good, the mold union will have trouble with the cycle time and appearance treatment. It is worth noting that if the dispersion and rheology are not high, some end users will make up for it by increasing the dilution ratio, but this will only increase the cost of using the masterbatch. The masterbatch with the smallest dilution ratio produces a uniform, dispersive black.
The fourth factor of determining the quality of the black masterbatch is the compatibility. If the masterbatch is produced using chips or recycled materials, it may contain contaminants or other non-meltable polymers. This can cause some unpredictable and difficult constraints, wasting the time and raw materials of the final consumer. At this time, the base resin can be used to produce high quality masterbatch, and the masterbatch has good compatibility during the melting process. Premium masterbatches can be produced using LLDPE, LDPE, HDPE, PP, PS, SAN, PA, and other materials. Special polymer masterbatches are available if engineering grades and stringent physical properties have been noted. Several internationally large masterbatches producers are conducting research to produce so-called "global universal" masterbatches. These masterbatches are widely compatible with other raw materials, have good rheology, and are flexible for application.
Stability should be consistent In today's international economy, international customers are absolutely necessary for the quality of masterbatch and the stability of raw materials, which is the fifth factor that determines the quality of black masterbatch. One of the main manifestations of stability is the smooth carbon black ratio. If the percentage of carbon black is fluctuating, the amount of masterbatch to be melted is not the same, and it is impossible to produce a product of the same hue. Some final producers report that the dilution required by the chemical is usually 5-8%, depending on how much material the masterbatch manufacturer invested in manufacturing. Obviously this is unacceptable. Of course, other factors such as the fluidity and dispersion of the injected melt should be consistent with the amount of charge per batch.
The final factor that determines the quality of the black masterbatch is the shade of the color. There are various carbon black types available on the market for the coloration of masterbatch, but the color and price of each type are also very different. Large particle carbon black has a lower degree of coloration and a different background color than small particle carbon black. Large-grain masterbatches are suitable for use in film production such as garbage bags, but are not suitable for the production of products that are aesthetically pleasing, such as television signage or where UV protection is required, such as agricultural film or external piping. For these products, only the use of high-priced small particle carbon black is used. In addition, low transparency is also a characteristic of small particle carbon black.
Classification and application range of ordinary carbon black SRF carbon black is generally used for the production of garbage bags that do not require strong tinting strength, high coverage or UV protection. Colors tend to be gray-blue, cheap, and relatively easy to disperse, so small manufacturers of masterbatches that are only equipped with single or double-screw extruders will choose this carbon black. The particle size of HAF carbon black is half that of SRF carbon black particles, but the color strength is twice that. It is brownish red, its UV protection ability is significantly stronger than SRF carbon black, and the cost is lower than P carbon black. It has good coverage,
Can be applied in many ways.
P carbon black is suitable for UV protection applications and in the food industry, in reddish blue.
JET carbon black has the most satisfactory color shade, deep, shiny black. Its particles are minimal, but not easy to disperse. Only those manufacturers equipped with high-efficiency shear mixers can achieve consistent dispersion when using JET carbon black. It is also the most expensive of ordinary carbon blacks.
The cost comparison shows that the more expensive masterbatch can economically obtain better production results than the cheap masterbatch. Why is this so? For example, a final producer buys masterbatch produced with SRF carbon black containing 50% carbon black, with a cost factor of 10 per kilogram. He adds 8% of the masterbatch to the polymer to achieve the desired coloring effect; He can also choose to try HAF masterbatch with 45% carbon black, the same coloring effect, the cost factor per kilogram is 16. Since the color strength of HAF carbon black is almost twice that of SRF carbon black, it can significantly reduce the amount of masterbatch input.
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