1. Introduction:
The full Chinese name of XPE (IXPE) is: chemical (physical) cross-linked polyethylene foam sheet, which is a common foam material. It can be used to manufacture heat insulation, sound insulation, buffer and other products. It is a kind of foam plastic with superior performance. The product is a new type of material that uses LDPE (low-density polyethylene) as the main material, bridging with DCP (crosslinking agent), and foaming with AC (azo foaming agent). During the production process, the modification effect can be achieved by adding other materials.
2. XPE cross-linking foam production line processing flow:
Step 1:Master plate production
Determine the granulation formula according to the product requirements → weigh the PE and additives separately according to the granulation formula ratio → mix them in the internal mixer according to the feeding sequence and mixing time required by the process → put the mixed material into the hopper of the granulation machine and extrude according to the required extrusion process parameters and process flow → cut the particles on the air-cooled mold surface, cool the two-stage cyclone cylinder → screen and further cool the vibrating screen → enter the storage cylinder → weigh → pack.
Step 2: Master plate production
Determine the master plate production formula according to the product requirements → Weigh the PE and required master particles according to the ratio of the production formula → Put them into a mixer for timed mixing → Plasticize and extrude according to the required extrusion process parameters and process flow → Three roll calendering → Cooling and trimming → Traction → Rolling → Weighing → Packaging.
Step 3: Heating and foaming
Select the mother plate according to production requirements → Set relevant parameters and process flow according to foaming process requirements → The mother plate is first cross-linked through the preheating section of the foaming furnace, and then foamed through the foaming section → Cooling and shaping → Correction → Edge cutting → Traction → Static electricity removal → Fixed length winding → Quality inspection → Packaging.
3.Technical parameters
3.1 ZL-35L/55L-135 * 15 internal mixing granulation system
|
Item no. |
Unit name |
Main parameter |
|
1 |
Internal mixer |
The volume of the mixer is 35L~55L |
|
2 |
Feeder |
Volume: 60~80L, power: 1.5KW |
|
3 |
Double wrist feeding machine |
Drive motor power :4KW, variable frequency speed regulation |
|
4 |
Granulators |
Material: 38GrMOALA, surface nitriding thickness 0.4-0.6mm, hardness HV760-940, and polished to<Ra0.8 Material of the barrel: 38GrMOALA, with a surface nitriding thickness of 0.6-0.8mm, a hardness greater than HV940, and polished to<Ra1.6. The drive motor is 55kw, with variable frequency speed regulation. |
|
5 |
Pelletizer |
Drive power:1.5kw, variable frequency speed regulation |
3.2 ZP-150*28 sheet extrusion system
|
Item no. |
Unit name |
Main parameter |
|
1 |
Mixing machine |
Production capacity: 500-600kg/h, driving motor power : 1.5kw |
|
2 |
Extruder |
Screw material: 38GrMOALA, surface nitriding thickness: 0.4-0.6mm, hardness:HV760-940, polish<Ra0.8, drill cooling water holes in the screw core; Barrel material: 38GrMOALA, with a surface nitriding thickness of 0.6-0.8mm, hardness greater than HV940, and polish<Ra1.6. |
|
3 |
Feeder machine |
Integrated automatic feeding, feeding capacity: 300kg/h, power: 1.5kw. |
|
4 |
Calender |
Two calendering rollers: Ø 400 * 1000 ,and one mirror cooling roller Ø 140 * 1000, calendering driving power :3KW, speed controlled by frequency converter, capable of synchronous or individual speed regulation. |
|
5 |
Cooling drawing |
Cooling roller: Ø140*1000 |
|
6 |
Side cutting machine |
The width can be adjusted within the range of 150-800mm |
3.3 FP-22 * 1.5 foaming system
|
Item no. |
Unit name |
Main parameter |
|
1 |
Furnace |
Size: 21500 * 2800 *2500, frame made of channel steel and angle steel, panel made of 1.2mm high-quality cold-rolled plate, insulation layer with a density of 80kg/m3, well insulated rock wool and aluminum silicate. |
|
2 |
Burner |
Heating capacity: 300000 to 400000 kcal/hour |
|
3 |
Sizing device |
Size：1200*2200*1400, Five roll water-cooled shaping, driving power： 1.5kw, variable frequency speed regulation. |
|
4 |
Cooling device |
Cooling fan: two sets, power: 1.1kw |
|
5 |
Deviation correction device |
Electric eye tracking, automatic correction, adjustable position, effectively preventing sheet deviation. |
|
6 |
Cutting machine |
The width can be adjusted within a range of 1.5m |
|
7 |
Haul-off machine |
Variable frequency drive speed regulation |
|
8 |
Winding device |
Double station winding up |
4.Application Fields
XPE is widely used in multiple fields due to its excellent physical and mechanical properties, aging resistance, heat resistance, and environmental characteristics. Including but not limited to industrial, construction, agriculture, chemical, refrigeration, automotive interiors, leisure and sports equipment, etc. Its unique closed cell structure not only provides multiple functions such as insulation, waterproofing, mold prevention, moisture resistance, sound insulation, sound absorption, shock absorption, and buffering, but also is favored by the market due to its light weight, easy processing, and beautiful appearance, with a weather resistance of more than 15 years, which meets environmental standards (i.e. does not contain C.F.C fluorocarbons). The most common application field of XPE is in the automotive interior industry, and now XPE has been widely accepted as a new material by major domestic car manufacturers, such as Dongfeng's various series of trucks, Fukang, Fengshen Blue, Dongfeng Picasso, Mazda, Toyota, Guangzhou Honda, Changan Ford, Southeast Motors, Changchun FAW, Baolong, Beijing Hyundai, and etc. The market has enormous potential and broad prospects.
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