CN1112456A - 用于中空纤维束的缠绕管、制造方法及其制造设备 - Google Patents

用于中空纤维束的缠绕管、制造方法及其制造设备 Download PDF

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CN1112456A
CN1112456A CN94113091A CN94113091A CN1112456A CN 1112456 A CN1112456 A CN 1112456A CN 94113091 A CN94113091 A CN 94113091A CN 94113091 A CN94113091 A CN 94113091A CN 1112456 A CN1112456 A CN 1112456A
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pipe
thin slice
workbench
plastic tab
cuts
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CN1039394C (zh
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米田淳
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Nippon Glass Co (jp) Osaka Japan
Nissho Corp
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Abstract

一个用于中空纤维束的缠绕管，其由用超声波在 它的对边缘进行焊接的塑料薄片组成，其内表面的水 平面上没有缝。

Description

本发明涉及了一种用于中空纤维束的缠绕管，更具体地说，是保护中空纤维束不受破损或污染的一种管状元件，直到中空纤维束套在用于血液透析，血液过滤，血液全过滤或类似的血液处理设备的壳体或筒形容器。
当给血液处理设备例如渗析器使用中空纤维时，保护中空纤维不受损害或污染直到中空纤维束套入血液处理设备的筒形容器是一种惯例，现已采用的中空纤维束的保护措施是用了一种毛面光洁度薄片或是一种塑料的热压管。例如，用塑料薄片绕着中空纤维束把中空纤维保护起来，并且用如图5所示的几块粘性胶带把塑料薄片的重叠部分固定住，或是用如图6所示的把中空纤维束套入一个热压塑料管。
可是，这些保护元件都存在着一些未解决的问题。例如，塑料薄片的使用就给操作者握住带来困难。另外，当用塑料薄片缠绕住中空纤维束时，这束中空纤维的最外部分由于它们阻碍着薄片内部和外部末端间的重叠部分，损害现象时常发生，这样就引起了在血液过程中血液的渗漏。此时，当套上筒形容器时，阻碍塑料薄片重合部分的中空纤维向下折叠，致使中空纤维堵塞或折叠。因此，为了避免血液的漏出就需要用新的来替换受过损害的中空纤维。另一些麻烦是绕着中空纤维的这些薄片向它的外端拐角向下转动，以及中空纤维的这些缠绕物品变成一种扁平结构。在这种情况下，被绕制物品在自动传输过程中偶尔要阻碍传输设备，结果致使绕制操作工作停止。
以上在使用薄片中产生的这些问题，借助于使用热压管都得到了解决。但是，使用现行的热压铸模技术来制做带有毛面光洁度内表面的热压管是不可能的。因为，当从热压保护管向作为血液处理设备的筒形容器拉出中空纤维时，在管和中空纤维之间的磨擦系数很大，结果是由于中空纤维弯曲而造成损害。这样，就需要用新的中空纤维来替换受到损害的中空纤维。
因此，本发明的一个目的是提供一个用于缠绕中空纤维束的管，使用它能防止中空纤维避免薄片的阻挡，或是当装入缠绕管时向下弯叠，或是掉出管外。
本发明的另一个目的是提供一个用于中空纤维束的缠绕管，它可以防止在自动传输过程中被传输设备阻挡。
本发明还有一个目的是提供一种用于中空纤维的缠绕管的制造方法和设备。
按照本发明，这些和其他的目的都是由所提供的用于中空纤维束的缠绕管解决的，这些缠绕管由呈空筒形状的塑料薄片组成，所说的薄片用超声波在纵向对边上焊接而成，并且其内表面水平面上没有偏差。
更可取的情况下，缠绕管的内表面，中心线平均粗糙度（Ra）范围从3.0到4.5μm，由JIS-B-0601限定。
作为用作塑料薄片的材料，它们可以使用如烯烃树脂，聚酯，聚四氟乙烯。从经济的或从加工工艺的观点来看，使用烯烃树脂例如聚乙烯，聚丙烯，聚丁烯以及类似物最好。
上述的缠绕管可以是这样预制，例如可以使用包括几个步骤的一种方法：
（a）将塑料薄片进行切断到预定宽度；
（b）在薄片相对的纵向侧边部分重叠，把薄片卷成一个筒形；
（c）用超声波焊接薄片的重叠部分，以形成一个在它的内表面水平面上没有偏差的管；以及
（d）按预定长度切断成品管。
上述缠绕管用一种设备加以制造，其包括：
一个薄片切断工作台，它按照预定的宽度切断连续传输过来的塑料薄片；
一个薄片拉制工作台，它用来给所说的薄片切断工作台供给塑料薄片，并且用来给下一工作台供给切断的薄片；
一个用来弄圆切断薄片的薄片倒圆工作台，它用以提供在对面纵向侧边局部重叠部分的筒形。
一个用超声波焊接方法把薄片重叠部分结合在一起的管成型工作台，以形成具有无缝内表面的管；以及
一个管切断工作台，它按照预定的长度切断管。
管成型工作台由一个铸模组成，这个铸模有一个在纵向上贯通的通孔，以及铸模上带有的一个狭槽，以使超声波焊接操作杆插入通孔；一个筒形芯棒与用于倒圆薄片的铸模的通孔同轴；一个带有一个焊接操作杆的超声波焊接装置它用来把超声波施加到在铸模和筒形芯棒之间所供给的塑料薄片重叠部分的表面。
在上述的设备中，靠薄片拉制工作台把塑料薄片从薄片滚筒拉制出来，并且供给到薄片切断工作台，在那里按预定的宽度把薄片切断。然后，把薄片输送到薄片倒圆工作台，在那里薄片被弄圆变成一个筒形，以便于薄片的相对侧边部分互相重叠起来。然后，被倒圆的薄片被引入到在铸模和芯棒间形成的空间，以使薄片的重叠部分位于铸模的狭槽之下，然后用超声波进行焊接。
本发明上述和其他目的，特征和各种优点，将通过下面结合各个最佳实施例的说明以及参照各个附图变得很明显。
图1是用来制造缠绕中空纤维束的管的设备侧视图；
图2是说明在图1设备中管成型工作台的透视图；
图3是图2的管成型工作台的剖视图；
图4是按照本发明的一个缠绕管的透视图；
图5是说明已有技术缠绕管的一个例子的透视图；
图6是说明已有技术缠绕管的另一个实例的透视图。
现在参考图1至3进行说明，按照本发明这里给出了一个用于制造缠绕中空纤维束的缠绕管的加工设备，它包括一个薄片卷筒固定工作台1，一个按照预定宽度切断塑料薄片的薄片切断工作台2，一个薄片拉制工作台3，一个用来导引薄片至下个工作台的薄片倒圆工作台4，在这个工作台上同时在薄片纵向侧边对面把它重叠起来变成一个筒形，一个管成型工作台5，在这个工作台上用超声波焊接被倒圆薄片的重叠部分以形成一个管，一个管拉制工作台6，一个根据预定长度将管切断的管切断工作台7，以及一个管推出工作台8。这些工作台是沿着塑料薄片经过的路线进行排列的。
薄片卷筒固定工作台1包含一个卷筒支架11和一个薄片卷轴12，这个卷轴可旋转地安装在支架11上，以及支承着其上卷绕着塑料薄片S的滚筒B。塑料薄片S被薄片拉制工作台3从薄片滚筒13拉出来，并输送给薄片切断工作台2，在那里按预定宽度进行截断操作。薄片S的宽度是按照所要生产的缠绕管的内部直径来确定的，以使管的圆周长度的总和与薄片S的对面侧边重叠宽度相等。薄片S的重叠宽度基本上是确定的，以便使它的长度等于超声波焊接操作杆59的宽度。
薄片切断工作台2包括一对互相隔开放置的切刀（附图中没有示出），用以按预定的宽度切断塑料薄片S。
薄片拉制工作台3包括一对由弹性材料（例如天然橡胶、合成橡胶）制成的卷轴（3a、3b）。
然后，薄片S被送至管成型工作台10，这个工作台包括薄片倒圆工作台4和管成形工作台5。薄片倒圆工作台4包含一个带有锥形凹槽43的薄片导向元件42，一个棒支承元件41和一个芯棒57。芯棒57由棒支承元件41仅在一端支承，并朝向管成形工作台5延伸。芯棒57通过锥形凹槽43，与一个后面将要提到的空腔或铸模通孔同轴延伸，它的端点在离开铸模51的排出口位置上。
管成型工作台5包括一个铸模51，一个成形杆57，以及一个超声波焊接装置58。这个铸模51被分成三部分，即一个上左模部件511，一个上右模部件512，以及一个下模部件513，它们在纵向有各自的凹槽，以在它们之间形成一个圆筒形空腔或通孔55。上左模部件511与如图2中所示的一个气缸52相连接。同样，上右模部件512与一个气缸53相连接。上左和上右模部件511和512可以借助于气缸52和53在远离或靠近芯棒57的方向上运动以便打开或关闭模具。另一方面，下模部件513与一个气缸54相连接，借助于气缸下模部件向上和向下运动。
在制作管的过程中，上左和上右模部件511和512在气缸52和53的作用下，向内运动或是向着靠近芯棒57的方向运动，而下模部件513在气缸54的作用下，向上运动或是向着靠近芯棒57的方向上运动。然而在已靠近模具的状态下，上模部件511和512之间带有一定间隔地安排，给出一个长狭切口或裂缝，以插入超声波焊接装置58的焊接操作杆59。
超声波焊接装置58的焊接操作杆59是锥形的，以便于使它的宽度约等于在上左和上右模部件511和512之间狭长槽56的宽度。操作杆59的下端截面呈矩形，操作时插入狭槽56。
管拉制工作台6接着管成工作台10排放着，它由一对卷轴（在图中没有示出）组成。卷轴可由弹性材料（例如天然橡胶、合成橡胶）制成。管切断工作台7包括一个切刀元件，它是为切断管而安放的，切刀的排列方向垂直于管的轴线。
在操作静止的状态下，铸模打开并且处于各个模部件静止位置上。铸模打开是由模部件511，512和513各自按在图3中所示的箭头A，B，C方向运动而实现的。在最初阶段，塑料薄片S是用手从薄片卷筒13拉出来的，然后通过导向元件42的导向槽43把薄片插入在芯棒57和模部件511，512，513间的空间。在这些操作的过程中，薄片S被绕成一个带有在相对纵向侧边上重叠部分的筒形。完成了薄片S的预备操作后，其余的操作就如下述的自动进行工作了。
首先，由于模部件511，512和513按图3中所示箭头A，B，C的各自相反方向运动，直到模部件511，512，513把塑料薄片S靠住如图2和3所示的芯棒57压紧，这时铸模51紧闭住。然后超声波焊接装置58的焊接操作杆59被插入在上模部件511和512之间的狭长槽56，直至它将薄片S的重叠部分压靠在芯棒57表面。薄片S的重叠部分被从焊接操作杆59发射出的超声波焊接成一个圆筒部分或一个管。在超声波焊接期间，由于薄片S重叠部分的内侧被压靠在芯棒57的表面，那么制作的管内表面水平面上没有产生任何偏差。
在超声波焊接之后，模部件511，512和513返回至各自的静止位置，便于打开铸模51。薄片S被焊成筒形部分后由管拉制工作台6进行拉制。与此同时，从薄片卷筒1上拉出一段新的薄片S，并将薄片S送到管成形工作台10，在相互同步的条件下，驱动薄片拉制工作台3和管拉制工作台10的卷轴。然后，薄片拉制工作台的拉制操作以及管拉制工作台6的拉制操作就停止了。为了提供所需长度的一个缠绕管，被焊接过的并送到管推出工位8的薄片S的筒状部分在管切断工作台7被截断，然后从管推出工作台8把它取出。接着，模部件511，512和513向内运动再次关闭模具51，上述的连续操作过程重复进行。
在连续操作过程中，从薄片卷筒1送去的塑料薄片S绕制成一个筒状，以使在通过薄片倒圆工作台4时，薄片的对面侧边部分地互相重叠，然后，在通过管成形工作台5时，用超声波焊接装置58焊接薄片的重叠部分，使之形成一个管。
从以上描述可了解到，按照本发明所制出这种管的长度和内部直径可选择性确定的，它通过替代模部件和芯棒和/或通过调整薄片切断工作台以及管切断工作台来确定的，这样，根据所希望得到的尺寸来制造各种各样的缠绕管产品是可能做到的。
使用上述设备，生产出一种缠绕中空纤维束的管，它的内径30mm，长度为2000mm，聚丙烯薄片厚度为0.3mm，宽度120mm，中心线平均粗糙度（Ra）如表1中所示。中心线平均粗糙度（Ra）是用接触型表面测量系统（Model    TALY    SURF-6，是由Rank    Taylor    Hobson    Ltd.制造的）测得的。
使用直径为230μm的万根中空纤维束，把它套入加工成的每个缠绕管中，用来测定纤维破损或渗漏的发生率。其结果和比较样品的结果一起放在表1中。在表1中，带星号的样品指明的缠绕管超出本发明的范围，“SS”是“超声波”的缩写。
比较的样品是用聚丙烯经热压模制而成的，这样它的内径为30mm，长度为2000mm。表1给出每个样品的中心线平均粗糙度（Ra）值，测得的比较样品的表面粗糙度值在1.6到3.0范围内。
表1
No.        制造方法        Ra        破损        渗漏        样品数目
(μm)        (%)        (%)
1        SS焊接        3.1        1.0        0        100
2        SS焊接        3.7        0        0.74        270
3        SS焊接        4.3        0.3        3.2        1000
4*        SS焊接        5.2        0.2        2.0        1000
5*        SS焊接        6.0        0.13        5.8        1500
6*        热压成形        2.0        2.37        1.1        3000
7*        热压成形        2.3        1.11        1.85        270
8*        热压成形        2.6        0.32        2.61        750
9*        热压成形        2.7        0.7        8.8        1000
从表1所示的结果可以看出，纤维破损发生率的增加随Ra而减少，而渗漏发生率增加随Ra增加而增加。另外，对于所用缠绕管，它的内表面具有中心线平均粗糙度（Ra）范围在3.0至4.5时更好。在一台电子显微镜下观察样品4号和5号的内表面，可看出它们内表面的明显凸起物是造成高的渗漏发生率之原因。
因此，在插入缠绕管过程中，本发明所制造的管把中空纤维的破损和渗漏减至最小是可能的，反过来说，提高血处理设备产量也是可能做到的。此外，对于减少用于再调整或产品质量控制的所需时间是可能的，产品即是装有中空纤维束的筒形容器。
虽然，已结合几个最佳实施例并参考附图并参考附图对本发明给予充分描述，对本领域里熟练人员来讲，各种变化和改型是很明显的。这些变化和改型应理解为包含在由权利要求所限定的本发明的范围之内。

Claims (5)

1、一种用于缠绕中空纤维束的缠绕管，所说的缠绕管由用超声波在它对边进行焊接的塑料薄片组成，在管的内表面水平面上没有偏差。
2、按照权利要求1所述的缠绕管，其特征是管的内表面有由JIS-B-0601所限定的中心线平均粗糙度（Ra）范围从3.0到4.5μm。
3、按照权利要求1所述的缠绕管，其特征是塑料薄片的材料可从由烯烃树酯，聚酯和聚四氟乙烯组成的组中选择。
4、用来缠绕中空纤维束的缠绕管的制造方法，其包含几个步骤：
（a）按预定宽度切断塑料薄片；
（b）把薄片弄圆成筒形，在薄片的对面纵侧边部分重叠起来；
（c）用超声波焊接薄片的重叠部分，以形成一个在它的内表面水平面上没有偏差的管；以及
（d）按预定长度切断制成的管。
5、用来缠绕中空纤维束的缠绕管的制造设备，包括：
一个薄片切断工作台，它按照一个预定的宽度切断连续传输过来的塑料薄片；
一个薄片拉制工作台，它用来给所说的薄片切断工作台输送塑料薄片，并给下个工作台输送切断的薄片；
一个薄片倒圆工作台，它用于把切断的薄片弄圆，以便提供一个在相对纵侧边带有部分重叠部分的筒形；
一个管成形工作台，它用超声波焊接方法把薄片的重叠部分结合起来，以形成一个内表面无缝的管；以及
一个管切断工作台，它按照一个预定的长度切断管。
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EP0662387B1 (en) 2001-10-17
CN1039394C (zh) 1998-08-05
ES2165863T3 (es) 2002-04-01
US5882752A (en) 1999-03-16
PT662387E (pt) 2002-01-30
EP0662387A2 (en) 1995-07-12
DE69428669D1 (de) 2001-11-22

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