There isn't a definitive consensus on what type of resin should serve as the carrier for masterbatches. Some companies opt for what they call an "application-specific carrier," meaning they choose a carrier that matches the base material being used. This method works quite well for masterbatches with a low pigment concentration, as it prevents layer separation and minimizes any impact on the material's properties. However, it becomes more challenging when dealing with masterbatches containing a high pigment load. At such concentrations, achieving adequate pigment dispersion can be difficult, especially if a low molecular weight wax is used to facilitate faster infiltration. The issue here is that the shear force required for effective dispersion cannot be adequately transferred.
Other manufacturers take a different approach by using a "compatible carrier" system. They select a material that shares partial compatibility with the base substance. This often demands a flexible approach to the carrier selection process. Nevertheless, for certain products with specific applications, like those requiring dot-shaped gluing, issues such as gas formation, surface defects (like silver streaking), or even phase separation might arise during localized molding processes. Therefore, the choice of a fundamental carrier isn't uniform across all masterbatch formulations. Instead, it needs to be tailored based on the molding conditions, the composition of the materials involved, and the final application of the product.
When we've worked with various masterbatch producers, many tend to use resins that correspond directly to the base material to avoid compatibility issues. High-quality color masterbatch manufacturers often incorporate silicone oil into their formulations. The primary goal here is likely to enhance both dispersibility and fluidity. While silicone oil is effective, its high cost can be a limiting factor, and overuse may lead to problems. One significant concern is that its low molecular weight can result in precipitation, affecting printability and finish quality. On the other hand, cheaper alternatives like white mineral oil or stearic acid might decompose and emit unpleasant odors, especially in high-temperature environments during summer months.
In summary, the primary focus when developing color masterbatches is ensuring excellent dispersibility and fluidity. Achieving these goals while balancing cost, performance, and compatibility remains a complex challenge for manufacturers. Each formulation decision must consider the broader implications on the final product’s properties and usability.
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