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Carbon Black Dispersion Detector
he JS3600L Carbon Black Dispersion Detection System is specifically designed to assess the dispersion of pigment and carbon black in polyolefin pipes, fittings, and compounds.
Carbon black serves as an excellent UV stabilizer, functioning as both a superior light absorber and an effective light-shielding agent. Consequently, it significantly enhances the UV resistance and anti-aging performance of plastic products. However, the content of carbon black and the uniformity of its dispersion within the plastic matrix exert a decisive influence on the UV protection, mechanical properties, and overall service life of the final product.
To address this critical quality parameter, the system precisely measures the scale, morphology, and dispersion characteristics of carbon black particles. By establishing the intrinsic relationship between these microscopic parameters and macroscopic performance indicators—such as mechanical strength, anti-static properties, and moisture absorption behavior—the JS3600L carbon black dispersion analyzer provides invaluable insights. As a result, this positively impacts quality assurance protocols, production process optimization, and new product development for plastic materials, while simultaneously promoting the rapid advancement of technological capabilities within enterprises and across the industry.
Standards Compliance: The system is fully compliant with GB/T 18251-2019, ISO 18553, and ASTM D5596-2003.
Typical Workpieces: Polyolefin pipes, fittings, and compounds.
Carbon black
The JS3600L Carbon Black Dispersion Detection System incorporates a comprehensive suite of advanced hardware and software features designed for precise, efficient, and user-friendly operation.
In terms of core detection capabilities, the system supports a wide range of particle size distribution, spanning from micrometer to millimeter scale. Specifically, it adopts a high-quality domestically produced biological microscope coupled with a 5‑megapixel CMOS image sensor, significantly improving image resolution and analytical clarity. Furthermore, the software provides a moving ruler function, enabling measurement between any two points on the captured image. In addition, the system automatically segments adhesive particles, and users can simply click on a particle image to display its complete set of measurement parameters.
Regarding data handling and software integration, the instrument utilizes a USB 2.0 data interface, ensuring broad compatibility with a wide range of microcomputers. Moreover, the instrument operates independently from the computer and can be connected to any desktop, laptop, or mobile PC equipped with a USB port. Notably, the system is capable of saving individual particle images for detailed review and documentation. Furthermore, the software features extremely powerful data reporting and statistical functions, supporting various data result report formats to meet diverse user requirements.
As for software compatibility and usability, the platform is compatible with multiple operating systems, including WIN7, WINXP, VISTA, and WIN2000, and adapts seamlessly to screens of various resolutions. Additionally, the software offers a high degree of personalization, providing measurement guides and numerous auxiliary functions to facilitate ease of operation. Consequently, measurement results output rich datasets that are saved in a database for subsequent retrieval and analysis. Users can filter data by any parameter—such as operator name, sample name, date, or time—and share the database with other software to achieve comprehensive data sharing and integration.
In terms of physical design and performance, the instrument features an attractive appearance combined with a compact, small‑volume, and lightweight construction. Moreover, it delivers high measurement accuracy, excellent repeatability, and short measurement cycles. Finally, considering the confidentiality requirements of test results, the system ensures that only authorized operators can access the corresponding information, while database reading and data processing functions further streamline the analytical workflow. Ultimately, this carbon black dispersion analyzer combines robust optical engineering with intelligent software to deliver a reliable, high‑performance solution for quality control and research applications.
The JS3600L Carbon Black Dispersion Detection System delivers robust technical performance through a carefully engineered combination of optical, imaging, and analytical components.
In terms of measurement principle and range, the system employs the image analysis method, covering a wide particle size measurement range from 0.5 μm to 10,000 μm. Specifically, the particle size equivalence principle utilizes both equal area circle diameter and equivalent short diameter for accurate characterization. Furthermore, the system provides comprehensive particle size statistical parameters, including volume (weight) distribution and particle number distribution.
Regarding analytical performance, under normal conditions, the entire measurement and analysis time—from the start of measurement to the display of results—is completed in less than 3 minutes. In addition, the system achieves excellent reproducibility of 3% based on volume‑averaged diameter, ensuring consistent and reliable results across multiple measurements.
As for imaging capabilities, the system is equipped with a 5‑megapixel digital camera delivering an imaging resolution of 2592 × 1944 pixels, with the same dimensions applied to the captured image size. Moreover, the optical magnification is set at 100×, while the CMOS pixel size matches the 2592 × 1944 resolution. Notably, the system achieves a horizontal clarity of 800 lines and a signal‑to‑noise ratio (S/N Ratio) greater than 52 dB, ensuring clear, high‑quality images for precise analysis.
Regarding hardware and connectivity, the communication interface utilizes a USB connection for seamless data transfer. The sample stage dimensions are 10 mm × 3 mm, designed for convenient specimen placement. Finally, in terms of power requirements, the microscope operates on a flexible power supply of 110–120 V / 220–240 V, 0.42 A / 0.25 A, 50 Hz / 60 Hz. Consequently, this carbon black dispersion analyzer offers a versatile and reliable platform suitable for diverse laboratory environments.
The carbon black dispersion analyzer integrates modern electronic technology with the traditional microscopic method to deliver precise, automated particle characterization.
In the first stage of the process, a camera captures images of the carbon black particles after they have been magnified by the optical microscope. Specifically, the microscope magnifies the tiny particles to be measured and projects their images onto the photosensitive surface of a CCD camera. Subsequently, the camera converts these optical images into video signals, which are then transmitted via a USB data cable and stored in the computer’s processing system.
Once the image signal enters the computer memory, the system automatically analyzes and calculates a comprehensive set of parameters for each carbon black particle cluster. These parameters include scale characteristics—such as equivalent diameter, long diameter, short diameter, area, and perimeter—as well as morphological characteristics—including roundness, rectangularity, and aspect ratio. Furthermore, the computer recognizes the edges of particles based on the received digitized microscopic image signals, and then calculates the relevant parameters of each particle according to a predetermined equivalent pattern.
Generally speaking, a single image—representing one field of view of the imaging device—contains anywhere from several to hundreds of particles. In each field of view, the imaging instrument can automatically calculate the size and shape parameters of all particles present, and generate a test report through statistical analysis. If the number of already measured particles is insufficient for statistical significance, the microscope stage can be adjusted to switch to the next field of view, and testing can continue and accumulate data seamlessly.
Regarding particle size equivalence, most tested particles are not spherical. Therefore, the particle size referred to in the results is the equivalent diameter of a circle. Notably, the imaging instrument can adopt different equivalence methods according to customer needs—such as equal area circle, equivalent short diameter, or equivalent long diameter. Consequently, this carbon black dispersion detection system offers a distinct advantage: in addition to precise particle size measurement, it can perform general morphological feature analysis that is both intuitive and highly reliable.
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■Package: Wooden case
The important application and influence of carbon black additives in PE pipes
Application and Challenges of PE Pipe
Polyethylene (PE) pipes and fittings are widely used across municipal water supply, industrial infrastructure, and agricultural irrigation due to their excellent low‑temperature impact resistance, flexibility, and corrosion resistance. However, during actual production and service, these pipes often face high‑temperature environments or prolonged exposure to direct sunlight, which can accelerate material decomposition and aging, consequently shortening their service life. To address this critical issue, a specialized additive—carbon black—is introduced to significantly enhance the weather resistance of PE pipes. Specifically, carbon black acts as an effective UV stabilizer, absorbing harmful ultraviolet radiation and shielding the polymer matrix from photo‑oxidative degradation. As a result, the carbon black dispersion detection system serves as an indispensable quality control tool to ensure the uniform dispersion of carbon black within the polymer, thereby maximizing the protective benefits and long‑term performance of PE piping products.
The function and source of carbon black
Carbon black is a widely used additive in plastic products, primarily valued for its ability to enhance weather resistance. Specifically, by incorporating carbon black, the anti‑aging performance of PE pipes can be significantly improved, enabling them to remain stable under high temperature or direct sunlight and thereby extending their service life.
In terms of its origin, carbon black is a black powdery carbon material produced from petroleum by‑products, natural gas, or coal through a series of chemical reactions such as incomplete combustion or pyrolysis. Furthermore, it plays a crucial role across multiple industries—including rubber, coatings, and inks—where it is commonly employed as both a pigment and a filler.
However, it should be noted that the manufacturing process of carbon black may inevitably introduce a small amount of impurities, primarily consisting of incompletely oxidized carbon particles and ash content. Consequently, in the production of PE pipes, where carbon black serves as an essential UV stabilizer to significantly improve pipeline weather resistance, the uniform dispersion and purity of carbon black become critical quality parameters. As a result, the carbon black dispersion detection system provides an indispensable analytical tool for verifying these characteristics and ensuring optimal pipe performance.
Application of carbon black in PE pipes
Carbon black plays a crucial role in the production process of PE pipes. Specifically, it serves as a key UV stabilizer, significantly improving the weather resistance of pipelines. By incorporating carbon black, the aging resistance of PE pipes is substantially enhanced, thereby extending their service life. Beyond these protective functions, carbon black also improves the processing performance of PE pipes, making the production process smoother and more efficient.
In terms of its working mechanism, once carbon black is added to PE pipes, it forms a uniform protective layer within the material. This layer effectively absorbs and scatters ultraviolet rays, significantly reducing UV‑induced damage to the polymer matrix. Simultaneously, carbon black enhances the oxidation resistance of PE pipes, preventing aging and cracking. Consequently, the overall service life of the pipes is extended. In summary, carbon black greatly improves the anti‑aging performance of plastic products, and the carbon black dispersion detection system ensures that this critical additive is uniformly dispersed to maximize its protective benefits.
The Importance and Selection of Carbon Black
To ensure the quality and performance of PE pipes, the selection of carbon black must comply with relevant national standards, with specific indicators defined according to actual usage requirements. Several key parameters must be carefully controlled.
First, the carbon black content in PE pipe materials needs to be maintained within the range of 2–5% to effectively block ultraviolet rays. In addition, the particle size of carbon black should be as fine as possible—typically between 20 and 50 nanometers—to ensure uniform dispersion within the polymer matrix. Furthermore, the ash content of carbon black, which represents the total amount of non‑carbon substances including inorganic salts and other non‑combustible residues, directly affects the performance of PE pipes. Therefore, to ensure stable pipe performance, the ash content is generally required to be controlled below 5%.
Consequently, these three critical parameters—content, particle size, and ash content—must be rigorously monitored to guarantee the long‑term reliability of PE piping systems. As a result, the carbon black dispersion detection system serves as an essential quality control tool for verifying these specifications and ensuring consistent product performance.
Related industry standards
Several national standards define the requirements for carbon black content and dispersion in polyolefin pipe materials. These standards collectively ensure that the quality and performance of PE piping systems are consistently maintained.
First, GB/T 18251-2019 — “Method for the assessment of pigment or carbon black dispersion in polyolefin pipes, fittings and compounds” — specifically elaborates on the method for determining carbon black content in polyolefin pipe materials, and applies to polyolefin materials such as PE, PP, and PB–.
Furthermore, GB/T 13663.1-2017 — “Polyethylene (PE) piping systems for water supply — Part 1: General” — provides comprehensive regulations on PE water supply pipe materials, covering classification, requirements, and test methods. Notably, this standard explicitly specifies that the carbon black content in PE100 and PE80 grade pipe materials should be controlled within the range of 0% to 5%–.
Additionally, GB/T 15558.2-2023 — “Buried polyethylene(PE) piping systems for the supply of gaseous fuels — Part 2: Pipes” — provides detailed regulations on buried PE pipe materials, also covering classification, requirements, and test methods. Importantly, it emphasizes that the carbon black content in PE100 and PE80 grade pipe materials should also be maintained at 0% to 5%–.
In summary, these standards establish a clear regulatory framework for carbon black content in PE pipes, and the carbon black dispersion detection system provides the essential analytical capability to verify compliance with these specifications. By implementing rigorous dispersion testing, manufacturers can guarantee the long-term reliability and performance of their PE piping products.
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