Melt pumps hold significant application value in ABS photovoltaic panel extrusion production lines, with core functions including stabilizing pressure and flow, reducing pulsation, homogenizing melt, lowering extruder load, and enhancing production efficiency. These characteristics directly elevate the stability of the extrusion process and product quality. The following analysis is conducted from both technical principles and practical applications:
1. Stable Pressure and Flow Control
ABS (acrylonitrile-butadiene-styrene copolymer), as a thermally sensitive material, is highly responsive to temperature and pressure fluctuations during extrusion. The melt pump employs a positive displacement delivery principle via gear meshing to pressurize and stabilize the melt output from the extruder before feeding it into the die, reducing flow fluctuations by over 90%. For instance, an ABS profile production line at one enterprise saw output drop from 450 kg/h to 380 kg/h due to screw wear without a melt pump; after installation, pressure fluctuations decreased, output rebounded, and dimensional tolerances narrowed significantly.
2. Reducing Melt Pulsation and Optimizing Surface Quality
ABS photovoltaic panels require high light transmittance and surface finish, yet traditional extrusion processes often result in flow marks or ripples due to melt pulsation. The melt pump uses precision gear metering to control melt flow deviation within ±1%, combined with precise temperature control (e.g., ≤1°C fluctuation in PMMA processing) via electric heating systems, eliminating pulsation effects and enhancing light transmission uniformity.
3. Homogenizing Melt and Improving Physical Properties
Localized performance variations in ABS melt may arise from uneven mixing during extrusion. The gear rotation in the melt pump generates shear forces that promote uniform dispersion of additives (e.g., flame retardants, UV stabilizers), improving mechanical strength, weather resistance, and flame retardancy of photovoltaic panels. For example, in EVA photovoltaic film production, the melt pump’s dead-zone-free internal flow channel design prevents resin degradation and ensures film thickness uniformity ≤3%.
1. Extending Equipment Lifespan and Reducing Maintenance Costs
Prolonged operation of ABS extruders leads to screw and barrel wear, increasing die head pressure and extruder load. The melt pump transfers pressurization from the extruder to the pump, enabling low-pressure, low-temperature extruder operation and reducing axial screw force by 30–50%, thereby extending equipment lifespan. For example, one enterprise reported that extruder maintenance intervals extended from every six months to every 18 months after installing a melt pump.
2. Boosting Production Efficiency and Reducing Waste
Frequent startups or color changes in ABS photovoltaic panel production generate significant waste. The melt pump rapidly stabilizes melt parameters (reducing purging time by over 50%), minimizing waste during startup phases. Its linear extrusion characteristics also facilitate synchronization with upstream/downstream equipment (e.g., haul-offs, cutters), further shortening production cycles. For instance, one production line achieved continuous large-diameter ABS pipe manufacturing by paralleling multiple small-to-medium extruders with a melt pump, reducing floor space by 40% and energy consumption by 25%.
3. Meeting High-Precision Demands and Expanding Product Applications
ABS photovoltaic panels demand strict dimensional tolerances (e.g., thickness deviation ≤0.05 mm). The melt pump’s precise metering and pressure stabilization minimize product tolerances, enabling more qualified products per unit weight of ABS raw material. Additionally, it can be串联 (tandem-connected) with twin-screw extruders to form compounding extrusion pelletizing lines, enhancing mixing quality of ABS modified materials and meeting diverse performance requirements for photovoltaic panels.
1. Material Selection
ABS melt temperatures typically range from 200–240°C, necessitating high-temperature, corrosion-resistant materials. Recommended options include nitrided steel gears with stainless steel pump bodies or chromium-nickel alloy steel gears with high-temperature tool steel pump bodies for long-term high-temperature operation.
2. Flow and Pressure Matching
Select melt pump specifications based on production line capacity. For example, a 500 kg/h ABS photovoltaic panel line may require an 800–1200 CC flow range pump with an outlet pressure ≥25 MPa to meet die molding demands.
3. Temperature Control System Design
ABS melt is temperature-sensitive, requiring thermal oil or electric heating systems paired with gear shaft temperature-controlled circulating water to prevent melt degradation from gear meshing shear heat. For instance, EVA melt pumps use rotating joints on shaft ends to maintain temperatures within ±2°C via circulating water.
Melt pumps significantly enhance the stability, product quality, and production efficiency of ABS photovoltaic panel extrusion lines through core functions like pressure/flow stabilization, pulsation reduction, and melt homogenization. Their technical advantages align perfectly with ABS processing characteristics, making them critical for energy conservation, quality improvement, and efficiency gains in photovoltaic panel manufacturing. Proper selection based on capacity, material, and temperature control requirements is essential to unlock their full potential.
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