CN102514173A - 动态微通道塑料挤出成型装置及方法 - Google Patents
动态微通道塑料挤出成型装置及方法 Download PDFInfo
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Abstract
本发明公开了一种动态微通道塑料挤出成型装置及方法,该装置主要由单螺杆挤出机、动态挤出机头、流体源、水槽、牵引机、收卷装置、数据采集和控制系统组成,在挤出口模出口附近,注射器芯体注射针头端部位置不同时,塑料挤出成型微通道内径也不同,当动态挤出机头内中空注射器芯体沿挤出方向高频短程振动时,导致挤出的塑料内微通道内径动态变化。本发明结构新颖、变化规律多样、加工设备简单、自动化程度高、成型制品挤出稳定、尺寸精度高。
Description
技术领域
本发明涉及一种塑料制品的挤出成型技术,尤其涉及一种动态微通道塑料挤出成型装置及方法。
背景技术
挤出成型主要用于相同横截面的塑料制品的挤出成型,如纤维、薄膜、管材、棒材、板材、异型材,而不能成型变化横截面的塑料制品。医用微管、中空纤维等含有中空小通道塑料制品的加工,也都采用挤出成型。常见的塑料挤出成型小直径中空通道的方法一般是通过在挤出机头口模内安装中空芯体,中空芯体内通注射流体,一般是大气或压缩气体,如剑桥大学Mackley等设计的内含多个平行毛细管的微通道薄膜的成型方法(WO 2005/056272),吴大鸣等设计的用于挤出塑料制品小内孔的成型方法(CN 200310101653.0)。但是,这些中空通道成型方法的内径恒定不变,难以成型中空通道直径动态变化的结构。
塑料波纹管成型方法能够实现中空通道的动态变化,但这类方法存在以下不足之处:(1)通道内径尺寸一般较大,难以加工到微米尺度;(2)通道变化通过机械成型装置后续成型,内径变化规律类型少;(3)外径也动态变化;(4)只适用于单通道管材。
本发明动态微通道塑料挤出成型装置及方法能够弥补以上方法的缺点:一步挤出成型内径动态变化的微通道,产品外径基本不变;能将大量动态微通道集成在一起;动态微通道的变化规律方便可调。
发明内容
本发明目的是针对现有技术的不足,提供一种动态微通道塑料挤出成型装置及方法。本发明用于一步挤出成型变化横截面的塑料制品。
本发明的目的是通过以下技术方案来实现的:一种动态微通道塑料挤出成型装置,它包括:单螺杆挤出机、法兰、收卷装置、动态挤出机头、阀门、压力调节器、流体源、水槽、滑轮、牵引机、数据采集和控制系统等;其中,所述单螺杆挤出机包括:料斗、电机、螺杆、机筒、第一加热圈和加热控制器等;所述电机的转轴与机筒内的螺杆通过联轴器联接,机筒外包覆三段第一加热圈,三段第一加热圈均与加热控制器相连,机筒与动态挤出机头通过法兰相连,法兰之间含有滤网;动态挤出机头外包覆第二加热圈,流体源、压力调节器、阀门和动态挤出机头依次通过管路连接,动态挤出机头下方安放水槽,水槽内固定有滑轮,水槽后面依次安放牵引机和收卷装置。
进一步地,所述数据采集和控制系统包括:压力传感器P1和P2、温度传感器T1-T4、接近开关、带数据卡的计算机和加热控制器等;其中,所述温度传感器T1~T3分别安装在机筒外包覆三段第一加热圈处,温度传感器T1~T3均与加热控制器相连,温度传感器T4安装在动态挤出机头外包覆第二加热圈处,温度传感器T4也与加热控制器相连,压力传感器P1安装在动态挤出机头内,压力传感器P2安装于阀门出口处,接近开关接近牵引机,接近开关、温度传感器和压力传感器均与带数据卡的计算机相连。
进一步地,所述动态挤出机头包括:机头连接头、机头流道入口段、定位螺钉、口模压板、机头口模、机头体、机头盖板、注射器芯体和直线音圈电机:其中,所述机头盖板固定在机头体上;机头连接头固定在机头体上;机头口模位于机头体出口处,由口模压板压紧;定位螺钉旋入机头体,调节机头口模径向位置;机头连接头、机头口模、机头体和机头盖板共同形成一个流道,该流道包括流道入口段、流道收敛段、流道成型段和流道出口;注射器芯体由注射器体与注射针头构成,注射器体一端与直线音圈电机相连,另一端穿过机头盖板进入机头体内,并与注射针头钎焊在一起;注射器体和注射针头的内部通道相通,形成注射器流道;注射器流道与阀门相通。
一种上述装置的动态微通道塑料挤出成型方法,该方法包括以下步骤:
(1)电机驱动单螺杆挤出机内螺杆,塑料原料由料斗加入机筒,在螺杆旋转输送和第一加热圈的电加热作用下,逐渐塑化形成塑料熔体;塑料熔体在螺杆的旋转推动下通过法兰进入动态挤出机头,法兰之间的滤网阻拦未完全塑化的固体和半固体。
(2)塑料熔体从机头连接体进入由机头连接头、机头口模、机头体和机头盖板组成的流道内,并包覆在注射器芯体外;塑料熔体在流道收敛段压力逐步上升到2-5MPa,然后进入流道成型段。
(3)注射器芯体在直线音圈电机驱动下沿挤出方向振动,注射针头端面与机头口模端面之间距离y的运动规律如图8所示(振动方式可以是各种规则或不规则的振动,如图10-15所示);流体源供应的注射流体由注射器流道进入塑料熔体,在塑料熔体的压力和注射流体的压力作用下,形成微通道,微通道界面周期性地变化,从而成型挤出件微通道,塑料熔体也逐步开始冷却固化成为挤出件塑料基体。
(4)带有挤出件微通道的挤出件塑料基体从流道出口挤出,在牵引机的牵拉作用下,通过滑轮进入水槽,循环冷却水对挤出件快速冷却定型,最终成型为动态微通道塑料挤出件。
本发明的有益效果是:
1、本发明能够挤出成型含有内径动态变化的微米级通道的塑料制品;
2、动态微通道的内径、振幅、周期、是否连续贯通等结构参数可以随意改变,装置适应性强;
3、动态微通道塑料制品内部微通道动态变化,外部尺寸基本不变;
4、通过集成,可以将大量动态微通道集合在多动态微通道塑料内;
5、自动化程度高,质量稳定,易于操作,劳动强度小。数据采集和控制系统便于记录分析数据、设定操作参数、编程和自动控制。
附图说明
图1是动态微通道塑料挤出成型装置总装配示意图;
图2是芯体高频振动的动态挤出机头9结构示意图;
图3-6是稳态实验条件下不同注射针头24端部位置时恒定内径微通道塑料挤出成型示意图,其中注射器芯体针头端部与机头口模的距离分别为y1~4,相应的微通道内径为d1~4,y1和d3均为零;
图7是稳态实验条件下,注射器芯体端部位置y与挤出成型的微通道内径d的关系曲线,其中,ymax表示微通道内径d开始最大时对应的y值,ymin表示微通道内径开始为零时对应的y值 ;
图8注射器芯体针头端面与机头口模的距离y简谐振动曲线示意图;
图9是图8所示的注射器芯体高频振动条件下动态微通道塑料挤出成型示意图;
图10-12是举例说明三种注射器芯体高频振动条件下连续动态微通道挤出纵截面;
图13-15是举例说明的三种注射器芯体高频振动条件下不连续动态微通道挤出纵截面;
图中:塑料原料1、料斗2、电机3、螺杆4、机筒5、第一加热圈6、法兰7、收卷装置8、动态挤出机头9、阀门10、压力调节器11、流体源12、水槽13、滑轮14、冷却水15、接近开关16、牵引机17、动态微通道塑料挤出件18、机头连接头19、流道入口段20、连接头固定螺钉21、定位螺钉22、流道收敛段23、注射针头24、铜钎焊焊接接头25、口模压板26、机头口模27、流道出口28、流道成型段29、机头体30、机头盖板31、盖板固定螺钉32、注射器体33、供气管34、供气管流道35、注射器流道36、注射器芯体37、直线音圈电机38、挤出件塑料基体39、挤出件微通道40、塑料熔体41、带数据卡的计算机42、第二加热圈43、加热控制器44。
具体实施方式
动态微通道结构指这种结构材料中微通道横截面沿着塑料制品挤出方向动态变化,微通道可以连续贯通,也可以非连续独立封闭(如图10-15所示),中空通道横截面可以是圆形、三角形、矩形、多边形等结构。多条动态微通道结构能够集成应用于薄膜、管材、片材、板材、异型材等挤出加工塑料得到多动态微通道结构塑料。微通道横截面尺寸主要为50-500微米,也能扩展到毫米和亚微米等小尺度,动态变化周期长度100微米-5毫米。本发明的动态微通道结构新颖、变化规律多样、加工设备简单、自动化程度高、成型制品挤出稳定、尺寸精度高。
本发明提供了一种动态微通道塑料挤出成型装置及方法。一般的中空通道内径稳定,一般采用对塑料熔体内注入压缩空气等流体的方法,挤出过程中保持流体压力和流量、挤出压力、机头结构不变,得到稳定的挤出塑料横截面。
本发明利用了以下原理:稳态挤出条件下,通过中空注射器芯体对塑料熔体注入稳定压力、流量的流体(注射流体可以是空气、压缩气体、硅油等在加工条件下化学、物理稳定的流体,也可以是需要封装的流体状态的药物等),不同注射器芯体端部位置时,塑料挤出成型微通道内径也不同。图3-6展示了注射器芯体针头端部与机头口模的距离分别为y1~4时,相应的微通道内径为d1~4,图7是稳态实验条件下注射器芯体端部位置y与挤出成型的微通道内径d关系曲线(y以挤出方向为正向),从中可见,微通道内径d与注射器芯体端部位置y呈近似线性关系。另外,动态条件下,注射器芯体的高频短程纵向振动能够导致挤出的塑料内微通道内径纵向动态变化。图8显示了注射器芯体针头端面与机头口模的距离y简谐振动曲线示意图,图9是图8所示的注射器芯体高频振动条件下动态微通道塑料挤出成型示意图。通过改变注射器芯体的振动规律,实现挤出微通道内径沿挤出方向的动态变化,图10-12是举例说明三种注射器芯体高频振动条件下连续动态微通道挤出纵截面,图13-15是举例说明的三种注射器芯体高频振动条件下不连续动态微通道挤出纵截面。本发明不仅可以挤出单条动态微通道结构塑料制品,也可以很方便集成为多动态微通道,仅需要在动态挤出机头上增加注射针头的数量,得到含有多条动态微通道结构的薄膜、管材、片材、板材、异型材等挤出加工塑料。
本发明适用于生产内部需要动态变化的微小中空通道的塑料挤出制品,例如:内径动态变化的微混合器、导管、中空纤维、异型材等,中空通道横截面可以是圆形、三角形、矩形、多边形等结构,动态中空通道尺度微米级甚至纳米级。
本发明提供的方法加工得到的动态微通道塑料制品能够应用于微型反应器、微型混合器、微型换热器、微传感器、微流控芯片、毛细管电泳、DNA和蛋白质监测分析、防伪、药物封装材料、药物缓释、光学元件、组织工程支架、泡沫结构材料和医用导管等生物医药应用。
如图1所示,本发明动态微通道塑料挤出成型装置包括以下部件:单螺杆挤出机、法兰7、收卷装置8、动态挤出机头9、阀门10、压力调节器11、流体源12、水槽13、滑轮14、牵引机17、数据采集和控制系统。其中,单螺杆挤出机包括:料斗2、电机3、螺杆4、机筒5、第一加热圈6和加热控制器44。电机3的转轴与机筒5内的螺杆4通过联轴器联接,机筒5外包覆三段第一加热圈6,三段加热圈6均与加热控制器44相连,机筒5与动态挤出机头9通过法兰7相连,法兰7之间含有滤网;动态挤出机头9外包覆第二加热圈43,流体源12、压力调节器11、阀门10和动态挤出机头9依次通过管路连接,动态挤出机头9下方安放水槽13,水槽13内固定有滑轮14,水槽13后面依次安放牵引机17和收卷装置8。
数据采集和控制系统包括:压力传感器P1和P2、温度传感器T1-T4、接近开关16、带数据卡的计算机42、加热控制器44。其中,温度传感器T1~T3分别安装在机筒5外包覆三段第一加热圈6处,温度传感器T1~T3均与加热控制器44相连,加热控制器44根据温度传感器T1~T3测量的温度信息控制流入三段第一加热圈6上电流的通断和大小。温度传感器T4安装在动态挤出机头9外包覆第二加热圈43处,温度传感器T4也与加热控制器44相连,加热控制器44根据温度传感器T4测量的温度信息控制流入第二加热圈43上电流的通断和大小。压力传感器P1安装在动态挤出机头9内,压力传感器P2安装于阀门10出口处,接近开关16接近牵引机17,接近开关16、温度传感器T4和压力传感器P1均与带数据卡的计算机42相连。
如图2所示,动态挤出机头9包括:机头连接头19、定位螺钉22、口模压板26、机头口模27、机头体30、机头盖板31、注射器芯体37和直线音圈电机38:机头盖板31通过盖板固定螺钉32固定在机头体30上;机头连接头19通过连接头固定螺钉21固定在机头体30上;机头口模27位于机头体30出口处,由口模压板26压紧;定位螺钉22旋入机头体30,调节机头口模27径向位置;机头连接头19、机头口模27、机头体30和机头盖板31共同形成一个流道,该流道包括流道入口段20、流道收敛段23、流道成型段29和流道出口28;注射器芯体37由注射器体33与注射针头24构成,注射器体33一端与直线音圈电机38相连,另一端穿过机头盖板31进入机头体30内,并与注射针头24钎焊在一起,钎焊处形成铜钎焊焊接接头25;注射器体33和注射针头24的内部通道相通,形成注射器流道36;注射器流道36通过供气管34内的供气管流道35与阀门10相通。
注射针头24外径较小,一般在0.2-2mm范围内,更小的外径由于加工技术较难实现,优选采用外径0.4mm,内径0.2mm;直线音圈电机38带动注射器芯体37高频短程振动;定位螺钉22旋入机头体30,调节机头口模27径向位置,从而调节流道出口28。流体源12可以根据需要,提供各种注射流体,如可以是装有化学、物理稳定的流体的气罐,也可以是液体泵,提供的注射流体可以为空气、CO2、N2、水蒸气、甘油、硅油等。
动态微通道塑料挤出成型装置典型的工作过程为(以下以单动态微通道挤出机头为例,以低密度聚乙烯(LDPE)作为塑料原料挤出成型,注射流体采用压缩气体,注射器芯体振动频率5Hz简谐振动):
1、开启第一加热圈6和第二加热圈43,四段加热圈依次设定加热温度为160、170、180、180℃;
2、待温度达到设定温度,继续保温30分钟;
3、开启冷却水槽13内水循环,用于对塑料挤出件的冷却定型;
4、开启数据采集系统和控制系统,实时监测温度、压力等加工参数;
5、启动单螺杆挤出机,设定螺杆4转速至15转/分;
6、开始供应压缩空气。首先打开阀门10,调节压力调节器11至0.2MPa,该压力值通过压力传感器P2测量得到;
7、开启直线音圈电机38,注射器芯体37振动,简谐振动振幅2mm,振动频率设置为5Hz;
8、开始在料斗2内加塑料原料1(LDPE);
9、启动牵引机17,接近开关16检测牵引机实时牵引速率;
10、待塑料挤出稳定后,收卷装置8收卷得到最终挤出产品。
本发明动态微通道塑料挤出成型方法包括以下步骤:
1、电机3驱动单螺杆挤出机内螺杆4,塑料原料1由料斗2加入机筒5,在螺杆4旋转输送和第一加热圈6的电加热作用下,逐渐塑化形成塑料熔体41;塑料熔体41在螺杆4的旋转推动下通过法兰7进入动态挤出机头9,法兰7之间的滤网阻拦未完全塑化的固体和半固体。
2、塑料熔体41从机头连接体19进入由机头连接头19、机头口模27、机头体30和机头盖板31组成的流道内,并包覆在注射器芯体37外;塑料熔体41在流道收敛段23压力逐步上升到2-5MPa,然后进入流道成型段29。
3、注射器芯体37在直线音圈电机38驱动下沿挤出方向振动,注射针头24端面与机头口模27端面之间距离y的运动规律如图8所示(振动方式可以是各种规则或不规则的振动,如图10-15所示);流体源12供应的注射流体由注射器流道36进入塑料熔体41,在塑料熔体41的压力和注射流体的压力作用下,形成微通道,微通道界面周期性地变化,从而成型挤出件微通道40,塑料熔体41也逐步开始冷却固化成为挤出件塑料基体39。
4、带有挤出件微通道40的挤出件塑料基体39从流道出口28挤出,在牵引机17的牵拉作用下,通过滑轮14进入水槽13,循环的冷却水15对挤出件快速冷却定型,最终成型为动态微通道塑料挤出件18。
5、塑料挤出件的收卷或裁切:对于不同的动态微通道塑料挤出件18的结构特性,如对于纤维、小导管、薄膜、片材挤出件,安装收卷装置8;而对于一般的管材、板材、异型材,安装裁切装置对动态微通道塑料挤出件18按照产品要求裁切。
本发明动态微通道塑料挤出成型装置及方法适用于生产塑料微管、中空纤维、微型反应器、微型混合器、微型换热器、医用微管等所有需要动态变化微米级内径通道的微结构塑料制品;含有大量动态微通道的多动态微通道塑料,可以作为泡沫材料使用,并且可以方便设计空隙度、开闭孔。适用的塑料原料包括聚乙烯(PE)、聚氯乙烯(PVC)、聚丙烯(PP)、聚苯乙烯(PS)、聚氨酯(PU)、聚酰胺(PA)、聚烯烃弹性体等能够挤出加工的热塑性聚合物。适用的注射流体可以是在加工条件下各种化学、物理稳定的流体,如空气、CO2、N2、水蒸气、甘油、硅油等,也可以是需要封装的流体状态的药物等。
Claims (4)
1.一种动态微通道塑料挤出成型装置,其特征在于,它包括:单螺杆挤出机、法兰(7)、收卷装置(8)、动态挤出机头(9)、阀门(10)、压力调节器(11)、流体源(12)、水槽(13)、滑轮(14)、牵引机(17)、数据采集和控制系统等;其中,所述单螺杆挤出机包括:料斗(2)、电机(3)、螺杆(4)、机筒(5)、第一加热圈(6)和加热控制器(44)等;所述电机(3)的转轴与机筒(5)内的螺杆(4)通过联轴器联接,机筒(5)外包覆三段第一加热圈(6),三段第一加热圈(6)均与加热控制器(44)相连,机筒(5)与动态挤出机头(9)通过法兰(7)相连,法兰(7)之间含有滤网;动态挤出机头(9)外包覆第二加热圈(43),流体源(12)、压力调节器(11)、阀门(10)和动态挤出机头(9)依次通过管路连接,动态挤出机头(9)下方安放水槽(13),水槽(13)内固定有滑轮(14),水槽(13)后面依次安放牵引机(17)和收卷装置(8)。
2.根据权利要求1所述动态微通道塑料挤出成型装置,其特征在于,所述数据采集和控制系统包括:压力传感器P1和P2、温度传感器T1-T4、接近开关(16)、带数据卡的计算机(42)和加热控制器(44)等;其中,所述温度传感器T1~T3分别安装在机筒(5)外包覆三段第一加热圈(6)处,温度传感器T1~T3均与加热控制器(44)相连,温度传感器T4安装在动态挤出机头(9)外包覆第二加热圈(43)处,温度传感器T4也与加热控制器(44)相连,压力传感器P1安装在动态挤出机头(9)内,压力传感器P2安装于阀门(10)出口处,接近开关(16)接近牵引机(17),接近开关(16)、温度传感器T4和压力传感器P1均与带数据卡的计算机(42)相连。
3.根据权利要求1所述动态微通道塑料挤出成型装置,其特征在于,所述动态挤出机头(9)包括:机头连接头(19)、定位螺钉(22)、口模压板(26)、机头口模(27)、机头体(30)、机头盖板(31)、注射器芯体(37)和直线音圈电机(38):其中,所述机头盖板(31)固定在机头体(30)上;机头连接头(19)固定在机头体(30)上;机头口模(27)位于机头体(30)出口处,由口模压板(26)压紧;定位螺钉(22)旋入机头体(30),调节机头口模(27)径向位置;机头连接头(19)、机头口模(27)、机头体(30)和机头盖板(31)共同形成一个流道,该流道包括流道入口段(20)、流道收敛段(23)、流道成型段(29)和流道出口(28);注射器芯体(37)由注射器体(33)与注射针头(24)构成,注射器体(33)一端与直线音圈电机(38)相连,另一端穿过机头盖板(31)进入机头体(30)内,并与注射针头(24)钎焊在一起;注射器体(33)和注射针头(24)的内部通道相通,形成注射器流道(36);注射器流道(36)与阀门(10)相通。
4.一种应用权利要求1所述装置的动态微通道塑料挤出成型方法,其特征在于,该方法包括以下步骤:
(1)电机(3)驱动单螺杆挤出机内螺杆(4),塑料原料(1)由料斗(2)加入机筒(5),在螺杆(4)旋转输送和第一加热圈(6)的电加热作用下,逐渐塑化形成塑料熔体(41);塑料熔体(41)在螺杆(4)的旋转推动下通过法兰(7)进入动态挤出机头(9),法兰(7)之间的滤网阻拦未完全塑化的固体和半固体;
(2)塑料熔体(41)从机头连接体(19)进入由机头连接头(19)、机头口模(27)、机头体(30)和机头盖板(31)组成的流道内,并包覆在注射器芯体(37)外;塑料熔体(41)在流道收敛段(23)压力逐步上升到2-5MPa,然后进入流道成型段(29);
(3)注射器芯体(37)在直线音圈电机(38)驱动下沿挤出方向振动,注射针头(24)端面与机头口模(27)端面之间距离y的运动规律如图8所示(振动方式可以是各种规则或不规则的振动,如图10-15所示);流体源(12)供应的注射流体由注射器流道(36)进入塑料熔体(41),在塑料熔体(41)的压力和注射流体的压力作用下,形成微通道,微通道界面周期性地变化,从而成型挤出件微通道(40),塑料熔体(41)也逐步开始冷却固化成为挤出件塑料基体(39);
(4)带有挤出件微通道(40)的挤出件塑料基体(39)从流道出口(28)挤出,在牵引机(17)的牵拉作用下,通过滑轮(14)进入水槽(13),循环的冷却水(15)对挤出件快速冷却定型,最终成型为动态微通道塑料挤出件(18)。
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