双腔医用导管的气体辅助成型设备与工艺研究
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摘要
双腔医用导管是一类特殊的中空异型管材,具有截面尺寸小、内腔形状不规则、壁厚不均匀的特点,对成型设备与工艺要求严格,与传统的管材挤出存在较大差异。
本文研制出精确气体流量控制系统并将其引入挤出过程,向双腔注入恒流量气体辅助熔融态PA12挤出成型,是一种新颖的导管成型工艺。为得到较好的导管截面形状,本文从材料的流变特性、机头设计、注气流量的控制以及挤出工艺参数的调节四个方面进行了实验研究,得出的结论对双腔导管的挤出成型有一定的参考作用。
导管挤出过程中,熔体粘度的影响显著。本文首先对PA12材料特性进行了毛细管流变测试,分析了粘度与温度、剪切速率之间的关系,为挤出温度的控制提供了重要的参考依据。基于气体辅助成型的机头口模、芯棒、注气孔和对中调节设计,是本文的一大特色。
本课题重点研究不同气体流量下的高聚物熔体壁的变形情况,并用挠度对这种变形趋势进行表征。挠度用二次抛物线进行了拟合,较好的反映了实验结果,并探讨了抛物线二次项系数的变化规律,同时还建立了熔体壁厚与注气流量之间的关系。针对双腔医用导管的不规则截面,提出了椭圆度和壁厚均匀度两个截面形状表征参数,并研究了机头温度、螺杆转速、牵引速率和注气流量对两个表征参数的影响,优化了挤出工艺参数。为满足医用要求,最后对医用导管的双腔流速进行了实验测量和理论计算。
Double lumen medical catheter is a kind of special hollow profile tube with small cross-section, irregular shape of inner lumen and non-uniform wall thickness, which is strict to extrusion equipments and processing. It differs from traditional tube extrusion processing.
In this dissertation, gas flow controller system was designed.In extrusion process, precision gas flow controller system injects constant flow gas to double lumen of PA12 melt to assist molding, which is an innovation point of the dissertation. It is also a new-style extrusion processing of catheters. In order to obtain good cross-section shape of catheter, PA12 rheologic behavior, die design, gas flow and extrusion processing parameters were studied on the basis of experiments. The conclusions will guide extrusion processing of medical catheters.
Melt viscosity has significant influence on extrusion of catheters. Firstly, PA12 was tested by capillary rheometer. The relationship among viscosity, temperature and shear rate was established, which provide important reference for temperature control during catheter extrusion. The design of dies, mandrel, gas hole and Centering adjustment based on gas-assisted molding is a big feature.
The key study is the deformation of polymer melt wall at different gas flow in this dissertation, which was attributed by deflection curve. The results showed that deflection curve of PA12 melt conformed to second-degree parabola. Moreover, the changing rules of second-degree coefficient were discussed and the relationship between melt wall thickness and gas flow was found. To attribute medical catheter's cross-section shape, ellipticity and wall thickness uniformity were presented. The factors which influenced shape of catheter cross-section, including die temperature, screw rotational speed, tractive rate and the gas flow were analyzed, which made processing parameters optimized. At last, flow velocity of double lumen was measured experimentally and computed theoretically.
本文研制出精确气体流量控制系统并将其引入挤出过程,向双腔注入恒流量气体辅助熔融态PA12挤出成型,是一种新颖的导管成型工艺。为得到较好的导管截面形状,本文从材料的流变特性、机头设计、注气流量的控制以及挤出工艺参数的调节四个方面进行了实验研究,得出的结论对双腔导管的挤出成型有一定的参考作用。
导管挤出过程中,熔体粘度的影响显著。本文首先对PA12材料特性进行了毛细管流变测试,分析了粘度与温度、剪切速率之间的关系,为挤出温度的控制提供了重要的参考依据。基于气体辅助成型的机头口模、芯棒、注气孔和对中调节设计,是本文的一大特色。
本课题重点研究不同气体流量下的高聚物熔体壁的变形情况,并用挠度对这种变形趋势进行表征。挠度用二次抛物线进行了拟合,较好的反映了实验结果,并探讨了抛物线二次项系数的变化规律,同时还建立了熔体壁厚与注气流量之间的关系。针对双腔医用导管的不规则截面,提出了椭圆度和壁厚均匀度两个截面形状表征参数,并研究了机头温度、螺杆转速、牵引速率和注气流量对两个表征参数的影响,优化了挤出工艺参数。为满足医用要求,最后对医用导管的双腔流速进行了实验测量和理论计算。
Double lumen medical catheter is a kind of special hollow profile tube with small cross-section, irregular shape of inner lumen and non-uniform wall thickness, which is strict to extrusion equipments and processing. It differs from traditional tube extrusion processing.
In this dissertation, gas flow controller system was designed.In extrusion process, precision gas flow controller system injects constant flow gas to double lumen of PA12 melt to assist molding, which is an innovation point of the dissertation. It is also a new-style extrusion processing of catheters. In order to obtain good cross-section shape of catheter, PA12 rheologic behavior, die design, gas flow and extrusion processing parameters were studied on the basis of experiments. The conclusions will guide extrusion processing of medical catheters.
Melt viscosity has significant influence on extrusion of catheters. Firstly, PA12 was tested by capillary rheometer. The relationship among viscosity, temperature and shear rate was established, which provide important reference for temperature control during catheter extrusion. The design of dies, mandrel, gas hole and Centering adjustment based on gas-assisted molding is a big feature.
The key study is the deformation of polymer melt wall at different gas flow in this dissertation, which was attributed by deflection curve. The results showed that deflection curve of PA12 melt conformed to second-degree parabola. Moreover, the changing rules of second-degree coefficient were discussed and the relationship between melt wall thickness and gas flow was found. To attribute medical catheter's cross-section shape, ellipticity and wall thickness uniformity were presented. The factors which influenced shape of catheter cross-section, including die temperature, screw rotational speed, tractive rate and the gas flow were analyzed, which made processing parameters optimized. At last, flow velocity of double lumen was measured experimentally and computed theoretically.
引文
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[1O]黄兴元,柳和生,周国发,罗忠民,李绅元.气体辅助挤出的实验研究[J].中国塑料.2005,19(3):17-19
[11]黄兴元,柳和生,周国发,罗忠民,李绅元.气体辅助挤出中影响气垫形成及稳定性因素分析[J].塑性工程学报.2005,12(5):101-104
[12]鄢超,柳和生,黄兴元.聚合物气体辅助挤出成型[J].中国塑料.2003,17(11):15-17
[13]Waldman F A.The Processing of Microcellular Foams[D].Massachusetts Institute of Technology,1982
[14]牟文杰,吴舜英.微孔泡沫塑料成型技术[J].塑料.2001,30(3):34
[15]JackA.气体辅助注射成型原理及应用[M].北京:化学工业出版社.2003
[16]于盛睿,杨建根.氮气气体辅助注射控制台的技术改造[J].工程塑料应用.2005,33(7):56-57
[17]申开智.塑料成型模具[M].北京:中国轻工业出版社.2002
[18]李文星,郭得有,潘红珊.气体辅助注塑成型技术与设备[J].农机化研究.2002(3):146
[19]谢建正.气体辅助注塑设计[J].机械工程师.2004.1:79-80
[20]吴大鸣,刘颖,郭奕崇.精密医用塑料导管的应用前景[J].塑料制造.2006.6:38-44
[21]Richard JZ,Donald DS.Thermoplastic polyurethanes:materials for catheters[M].In:H.Planck,eds.Polyurethane in Biomedical Engineering Ⅱ,Amsterdam:Elsevier Science Publisher.1986:1-18
[22]Mutlu K,Solomom DD.Thermoplastic elastomeric hydrophilic Polyetherurethane expandable catheter[P].USP5061254,1991
[23]Onwunaka TO,Onwumere FC and Lambert JM.Thermoplastic polyurethane blends[P].USP5281677,1994
[24]唐伟家.医用管TPE料[J].弹性体.2002,12(3):44
[25]曹常在,刘志民,向欣芳,白景美.我国医用塑料产业的现状及发展[J].中国塑料2002,16(1):3-5
[26]WuDa ming,LiXiao lin,LiuYing.Factors affecting pre cision of extrusion[J].Plastics,2003,32(1):26-30.
[27]瞿金平.聚合物塑化挤出新概念[J].华南理工大学学报:自然科学版,1992,20(4):1 8.
[28]蔡永洪,瞿金平.单螺杆振动诱导熔体输运模型与实验研究[J].华南理工大学学报:自然科学版,2006,34(10):44 49.
[29]朱复华.挤出理论及其应用[M].北京:轻工出版社.2000
[30]Chris Rau wendaal著.陈文英等译.塑料挤出(Polymer Extrusion)[M].轻工出版社.1996
[31]操亚平,吴大鸣,龙文保.单螺杆挤出机的产率波动[J].塑料.2000,3.
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[33]刘会举.高聚物精密挤出机理初探(二).影响高聚物精密挤出的设备因素[D].北京化工大学硕士学位论文,2001,5:47-65
[34]李晓林,吴大鸣.单螺杆挤出机并联式稳压装置的稳压原理及计算[J].北京化工大学学报2003,30(2):54-57
[35]王斌修,王婉,郭丽华.微细介入导管的挤出机头设计[J].现代塑料加工应用.2005,17(5):44-46
[36]郭丽华,王婉,王斌修.医用介入导管的扩口模具设计[J].塑料2005,34(4):72-74
[37]文生平,赵国平,瞿金平.精密挤出成型过程中的多变量模糊解耦控制[J].华南理工大学学报:自然科学版,2007,35(12):1-5.
[38]张玉龙,蔡志勇.工程塑料牌号手册[M].北京:化学工业出版社.2006.3
[39]邓如生,魏运方,陈步宁.聚酰胺树脂及其应用[M].北京:化学工业出版社.2002.12
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