CN114717552B - 一种涂层材料及其在医疗器械领域的应用 - Google Patents

一种涂层材料及其在医疗器械领域的应用 Download PDF

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CN114717552B
CN114717552B CN202210507512.1A CN202210507512A CN114717552B CN 114717552 B CN114717552 B CN 114717552B CN 202210507512 A CN202210507512 A CN 202210507512A CN 114717552 B CN114717552 B CN 114717552B
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CN114717552A (zh
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刘国栋
姚磊
欧振林
唐能
纪连栋
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Xiangya Hospital of Central South University
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Abstract

本发明涉及一种涂层材料及其在医疗器械领域的应用。本发明以TiN、SiO2、CeO2和WS2为粉末原料，采用同步送粉法激光熔覆在医用不锈钢基体表面制备复合涂层，以TiN为基础材料，搭配SiO2、CeO2、WS2等辅助原料制备得到的复合涂层具有优异的耐腐蚀性能和耐磨性能。该复合涂层材料可以应用于组织钳等医用器械以延长其使用寿命。

Description

一种涂层材料及其在医疗器械领域的应用
技术领域
本发明涉及激光熔覆涂层领域，具体涉及一种涂层材料及其在医疗器械领域的应用。
背景技术
组织钳又叫鼠齿钳，有长、短、粗齿之分。根据钳前端齿的深浅分为有损伤和无损伤两种：齿深的为有损伤组织钳，用于夹持软组织和皮瓣，如夹持牵引被切除的病变部位，以利于手术进行，齿浅的为无损伤组织，可钳夹闭合血管。医疗实践中，组织钳已广泛应用于各类外科手术，与此同时，其耐腐蚀性能和耐磨性能直接决定了组织钳的使用寿命。因此，有必要设计一种耐腐蚀性能和耐磨性能都优异的组织钳手术器具。
发明内容
针对现有技术存在的问题，本发明旨在提供一种激光熔覆涂层材料及其在医疗器械领域的应用。
本发明提供了一种涂层材料，所述涂层材料采用激光熔覆工艺制备而得，制备过程包括以下步骤：
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为合适的尺寸；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：在氩气保护下进行激光熔覆，熔覆过程中激光功率为1200-1500W，扫描速度为700-800mm/min，送粉速度为5-6g/min，搭接率为30-40%，光斑直径为3.2-3.5mm，氩气流量为10-12L/min，激光熔覆的粉末原料为80-90重量份TiN、10-12重量份SiO2、3-9重量份CeO2和5-17重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于400-500℃下热处理3.5-4h，然后随炉冷却至室温。
优选地，所述衬底的尺寸为10cm×6cm×2cm。
优选地，所述激光熔覆采用DL-HL-T10000型高功率横流CO2激光器。
进一步地，本发明还提供了一种涂层材料在医疗器械领域的应用，所述涂层材料选自上述涂层材料中的任意一种。
优选地，所述医疗器械为组织钳。
本发明以TiN、SiO2、CeO2和WS2为粉末原料，采用同步送粉法激光熔覆在医用不锈钢基体表面制备复合涂层，以TiN为基础材料，搭配SiO2、CeO2、WS2等辅助原料制备得到的复合涂层具有优异的耐腐蚀性能和耐磨性能。该复合涂层材料可以应用于组织钳等医用器械以延长其使用寿命。
具体实施方式
下面通过具体实施例来验证本发明的技术效果，但是本发明的实施方式不局限于此。
实施例1
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、5重量份CeO2和5重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
实施例2
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、5重量份CeO2和12重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
实施例3
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、5重量份CeO2和17重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
实施例4
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、3重量份CeO2和12重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
实施例5
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、9重量份CeO2和12重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
对比例1
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2和12重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
对比例2
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、20重量份CeO2和5重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
对比例3
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2和5重量份CeO2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
对比例4
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为10cm×6cm×2cm；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：采用DL-HL-T10000型高功率横流CO2激光器，在氩气保护下进行激光熔覆，熔覆过程中激光功率为1500W，扫描速度为700mm/min，送粉速度为5g/min，搭接率为30%，光斑直径为3.2mm，氩气流量为10L/min，激光熔覆的粉末原料为80重量份TiN、10重量份SiO2、5重量份CeO2和30重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于500℃下热处理4h，然后随炉冷却至室温。
接下来，我们对实施例1-5和对比例1-4中样品的耐腐蚀性能和耐磨性能进行测试，具体如下：
耐腐蚀性测试：在模拟体液（SBF）中，37℃下对样品长期保护能力的测试。本发明将包含涂层的不锈钢片进行封装，防止边缘效应，而后将其各自置于盛有模拟液的烧杯中，用保鲜膜封住烧杯口，放入37℃的恒温水浴锅中，每两天更新一次模拟体液，并记录样品开始发生腐蚀的情况；
耐磨性测试：采用CETR-3型摩擦磨损试验机评价各样品的耐磨性能，载荷为5N，摩擦副为直径5mm的GCr15钢球，摩擦频率为8Hz，摩擦行程3mm，摩擦时间60min，并用电子天平称量磨损前后的质量以计算磨损量。
各样品的实验结果如表1所示，表中用“√”表示优秀，用“○”表示合格，用“×”表示不合格。其中，开始发生腐蚀的时间大于550h评级为优秀，开始发生腐蚀的时间介于480-550h之间评级为合格，开始发生腐蚀的时间小于480h评级为不合格；磨损量小于0.5mg评级为优秀，磨损量介于0.5-0.8mg之间评级为合格，磨损量大于0.8mg评级为不合格。
表1 各样品实验数据
编号 硬度 磨损量
实施例1 √ ○
实施例2 √ √
实施例3 √ √
实施例4 ○ √
实施例5 ○ √
对比例1 × √
对比例2 ○ ×
对比例3 × ×
对比例4 × √
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和变型，这些改进和变型也应视为本发明的保护范围。

Claims (5)

1.一种涂层材料，其特征在于，所述涂层材料采用激光熔覆工艺制备而得，制备过程包括以下步骤：
基材选取：以医用不锈钢作为基材，通过机械线切割将其加工为合适的尺寸；
基材预处理：对基材进行喷砂处理，而后依次选用丙酮和去离子水在超声辅助下清洗基材，然后在氮气下烘干待用；
激光熔覆制备复合涂层：在氩气保护下进行激光熔覆，熔覆过程中激光功率为1200-1500W，扫描速度为700-800mm/min，送粉速度为5-6g/min，搭接率为30-40%，光斑直径为3.2-3.5mm，氩气流量为10-12L/min，激光熔覆的粉末原料为80-90重量份TiN、10-12重量份SiO2、3-9重量份CeO2和5-17重量份WS2；
热处理：将沉积有复合涂层的医用不锈钢放入马弗炉中，于400-500℃下热处理3.5-4h，然后随炉冷却至室温。
2.一种如权利要求1所述的涂层材料，其特征在于，所述基材 的尺寸为10cm×6cm×2cm。
3.一种如权利要求1所述的涂层材料，其特征在于，所述激光熔覆采用DL-HL-T10000型高功率横流CO2激光器。
4.一种涂层材料在医疗器械领域的应用，其特征在于，所述涂层材料选自权利要求1-3所述的任意一种。
5.一种如权利要求4所述的应用，其特征在于，所述医疗器械为组织钳。
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