面向介入医疗导管的聚合物微挤出模具设计制造技术与工艺研究
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摘要
随着微加工技术的蓬勃发展,许多产品的轻量化、小型化、微型化、精密化趋势日渐明显。与此同时,传统聚合物挤出成型技术也正在朝着微型化方向发展,出现了聚合物微挤出成型技术,其制品如介入医疗导管、汽车油气路微管、新型塑料光纤等在医疗、汽车、通讯等领域得到了广泛的应用,尤其是高技术含量、高附加值的介入医疗导管。由于介入医疗导管具有尺寸微小、截面形状复杂、几何精度高等特点,使得微挤出模具的设计、制造和成型工艺较为复杂,因而传统的挤出成型技术已经不再完全适用。由于受挤出模具、配套生产工艺等限制,目前我国介入医疗导管及其挤出模具主要依赖进口,其价格昂贵,严重阻碍了我国介入医学的发展。因此,针对介入医疗导管这样较难成型且精度高的微管,本文以聚丙烯(PP)微管的微挤出成型为研究对象,对聚合物微挤出模具的流变学设计、制造方法和成型工艺进行了深入研究。主要研究内容如下：
首先,根据聚合物微管截面型腔的形状以及各型腔在制品截面上分布特点,将微管主要分为中心对称、轴对称和周边均匀分布三大类。并根据这三种类型,制品截面结构由简单到复杂依次分别取最具有代表性的微管进行研究,即中心对称单腔微管、轴对称双腔异型微管和周边均匀分布五腔异径微管。聚合物微挤出模具成型段长度对挤出制品的质量和生产效率起着决定性作用,通过理论推导,建立了微挤出模具成型段长度与流道结构尺寸、聚合物熔体流变学特性之间的关系,确定了微挤出模具成型段长度。针对多腔微挤出模具非对称流道较难实现熔体流动平衡的问题,在挤出流动分析的基础上,结合聚合物熔体流变学理论和优化设计方法,提出了一种基于流动平衡的多腔直角微挤出模具非对称流道结构优化设计方法。该方法以微挤出模具非对称流道内熔体流动平衡性为优化目标,确定模具非对称流道结构关系,以模具转向角为设计变量,建立优化目标函数,对模具流道结构进行优化设计。通过对双腔微管和五腔微管的挤出模具非对称流道进行优化设计,逐步完善了多腔直角微挤出模具非对称流道结构优化设计方法。
其次,针对微挤出模具芯棒微细复杂成型段横截面结构和内部微细注气孔,尤其是多腔直角微挤出模具芯棒微细复杂成型段横截面结构,提出了一种具有细长成型段横截面复杂结构和微细注气孔的微挤出模具芯棒的加工工艺。该工艺针对微挤出模具芯棒成型段细长、易变形、易断裂及其横截面结构微细复杂等难于加工的问题,利用微挤出模具芯棒微细复杂成型段各个截面形状在芯棒轴向相同的共同特点,采用成型电极端面一次性蚀除成型加工技术,实现芯棒成型段的精密加工；同时,针对芯棒内部大深径比微细注气孔难于加工的问题,采用微细电火花阶梯孔渐进式加工方法,实现芯棒内部大深径比微细注气孔的精密加工。通过对单腔、双腔和五腔微挤出模具芯棒成型段的加工,验证和完善了该加工工艺的可行性和通用性。在聚合物微挤出模具装配过程中,装配误差容易导致口模与芯棒成型段处的装配间隙不均匀或挤出成型困难,因而重点研究了芯棒、口模、微调机构和注气管道的装配工艺,装配后的挤出模具能够实现芯棒与口模间隙微调,而不会触及芯棒成型段使其弯曲或断裂,同时,还可实现注气管道高温密封。
最后,针对直径微细、截面复杂、壁厚较薄的微管较容易受挤出工艺影响而难于成型的问题,通过对三类微管,如聚合物中心对称单腔微管、轴对称双腔异型微管和周边均匀分布五腔异径微管的挤出成型实验研究和分析,获得了挤出工艺参数对微管截面的尺寸和形状精度的影响主次顺序和较佳的工艺参数组合,揭示了挤出成型工艺参数对聚合物微管截面的尺寸和形状精度的影响规律。结果表明了型腔注气量对微管截面的尺寸和形状精度尤为重要,注气量大小直接决定了微管截面尺寸及其形状轮廓变化。根据挤出成型工艺规律,在管型腔注气量6ml/min,螺杆转速4r/min,模具温度202℃,牵引速度28m/min的挤出工艺条件下,挤出了最小直径为0.5±0.02mm的单腔微管；在月牙腔和圆腔的注气量均为6ml/min,螺杆转速12r/min,模具温度218℃,水箱真空度20%,牵引速度12m/min的较佳挤出工艺参数下,挤出了满足使用要求且最小直径为1.2±0.02mm的双腔微管,其外轮廓椭圆度、月牙腔椭圆度和圆腔椭圆度分别为：0.8%,1.4%和3.0%；在主型腔和次型腔的注气量均为6ml/min,螺杆转速16r/min,模具温度202℃,水箱真空度0,牵引速度10m/min的较佳挤出工艺下,挤出满足使用要求且最小直径为1.6±0.02mm的五腔微管,其外轮廓椭圆度、主型腔椭圆度和次型腔椭圆度分别是2.9%,2.1%和3.9%。同时,挤出实验也证明了多腔直角微挤出模具非对称流道结构优化设计方法的正确性和实用性。
With the great development of micro-processing technology, many products become more and more light, small, tiny and exact. Simultaneously, traditional polymer extrusion molding is turning to micromation, and the polymer micro-extrusion molding appeared. Some tiny and slim tubes such as interventional medical catheters, automobile oil and gas tubes, new type of plastic optical fibers are used widely in the field of medical treatment, automobile, and communication. And the interventional medical catheters with high technical content, much additional value have enormous room for medical treatment. The characters of the interventional medical catheters are tiny size, complicated section and high geometry accuracy, so the design, manufacture, and extrusion molding process of a micro-extrusion die are very complicated, while the traditional polymer extrusion molding technology is inapplicable. Just because of the limit factors like micro-extrusion dies and matched manufacture process, the interventional medical catheters and micro-extrusion dies in our nation mainly depend on importation at present, and the price is quite expensive. This situation makes against the development of our interventional medicine. So this paper is focused on the micro-extrusion molding of polypropylene micro-tubes, and the key technology which is about the rheological design, manufactural method and micro-estrusion molding process of polymer micro-estrusion dies in the condition of micro-scale effect is also studied. The primary items in this paper are as follows:
Firstly, based on the lumen-sectional shape of micro-tubes and the lumen distribution characteristics on the cross-section of the product, the micro-tubes were divided into three types, such as centrosymmetric, axisymmetric and uniformly distributed. And from simple to complex in turn, single-lumen micro-tubes, double-lumen micro-tubes with different shape lumens and five-lumen micro-tubes with different diameter lumens were listed and researched as the most representative products of these three types in the paper. Considering the land length of the polymer micro-extrusion die was the key to the quality of products and the productive efficiency, single-lumen, double-lumen and five-lumen micro-tubes were taken as objects. The parameter relationships between the land length and the flow channel structure, the rheological characters of polymer melts were deduced by a theory and the land lengths of the three-type micro-extrusion dies were also fixed. Then, for the extrusion dies of multi-lumen micro-tubes, combined the flow analysis of polymer melts with the rheological theory and the optimum design method of polymer melts, a new design method for the right-angle non-symmetry flow channel structure of the micro-extrusion die was put forward. In this method, the flow balance of polymer melts in the non-symmetry flow channel of the right-angle micro-extrusion die was seen as the optimization objective; the steering angle in the extrusion die was taken as a design variable; and the objective function of optimizing the flow channel structure was established. Through the optimization of asymmetric flow channel in the extrusion dies for double-lumen and five-lumen micro-tubes, the optimization design method of the multi-lumen extrusion die was gradually improved.
Secondly, because the lands and air injection holes of the mandrel were very tiny, easily broken and the cross-section structures of the lands were very complex especially for multi-lumen micro-extrusion dies, the precision machining together with micro EDM technology were adopted to process the lands of the mandrel and the die. The cross-section of the mandrel land was processed by once corroding technology of the molding electrode end side. At the same time, the vent with big deep diameter ratio in the mandrel was processed by multi-step punching which combined metal drilling with micro EDM molding and punching. In the course of the assembly of the micro-extrusion die for polymer melts, the assembly error easily leads to asymmetry of the assembly interspace between the lands of the mandrel and the die or leads to difficulty of the extrusive molding. The assembly technics of the mandrel and the die and of the vent pipe and micro adjustable system was studied in this paper. The micro-extrusion die after assembly could do a fine adjustment between the mandrel and made the die not bend or break the land of the mandrel. And also, the vent pipe could be airproofed with high temperature.
Finally, the single factor micro-extrusion molding experiments of single-lumen, double-lumen, and five-lumen micro-tubes were studied and analyzed theoretically because the tubes with fine diameter, complex section, thin wall thickness were difficult to be extruded. Through extrusion experiments, the effect order of main process parameters on the size and shape accuracy of micro-tubes and the optimum combination of process parameters were obtained. Experimental results showed that the air injection velocity effected fiercely and decided directly on the size and shape accuracy of micro-tubes. At the same time, the right-angle extrusion die with the asymmetrical channel for the multi-lumen micro tubes was designed by the method. According to the experiments for the single-lumen micro-tubes, the combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of4r/min, a die temperature of202℃and a pulling speed of28m/min, and a single-lumen micro-tube of the smallest diameter with0.5±0.02mm was fabricated. On the basis of the the experiments for the double-lumen micro-tubes, the optimal combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of12r/min, a die temperature of218"C, a vacuum degree of the water tank of20%and a pulling speed of12m/min, and the better double-lumen micro-tube of the smallest diameter with1.2±0.02mm was obtained. And the ovalities of outside profile, crescent lumen and circular lumen in the tube section were achieved by0.8%,1.4%and3.0%respectively under the optimal combination of process parameters. According to the experiments for the five-lumen micro-tubes, the optimal combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of16r/min, a die temperature of202℃, a vacuum degree of the water tank of0and a pulling speed of10m/min, and the rational five-lumen micro-tube of the smallest diameter with1.6±0.02mm was machined. The ovalities of outside profile, main lumen and secondary lumen in the tube section were reached by2.88%,2.09%and3.9%respectively under the optimal combination of process parameters. Through the extrusion experiments, the correctness of the die design method was verified.
首先,根据聚合物微管截面型腔的形状以及各型腔在制品截面上分布特点,将微管主要分为中心对称、轴对称和周边均匀分布三大类。并根据这三种类型,制品截面结构由简单到复杂依次分别取最具有代表性的微管进行研究,即中心对称单腔微管、轴对称双腔异型微管和周边均匀分布五腔异径微管。聚合物微挤出模具成型段长度对挤出制品的质量和生产效率起着决定性作用,通过理论推导,建立了微挤出模具成型段长度与流道结构尺寸、聚合物熔体流变学特性之间的关系,确定了微挤出模具成型段长度。针对多腔微挤出模具非对称流道较难实现熔体流动平衡的问题,在挤出流动分析的基础上,结合聚合物熔体流变学理论和优化设计方法,提出了一种基于流动平衡的多腔直角微挤出模具非对称流道结构优化设计方法。该方法以微挤出模具非对称流道内熔体流动平衡性为优化目标,确定模具非对称流道结构关系,以模具转向角为设计变量,建立优化目标函数,对模具流道结构进行优化设计。通过对双腔微管和五腔微管的挤出模具非对称流道进行优化设计,逐步完善了多腔直角微挤出模具非对称流道结构优化设计方法。
其次,针对微挤出模具芯棒微细复杂成型段横截面结构和内部微细注气孔,尤其是多腔直角微挤出模具芯棒微细复杂成型段横截面结构,提出了一种具有细长成型段横截面复杂结构和微细注气孔的微挤出模具芯棒的加工工艺。该工艺针对微挤出模具芯棒成型段细长、易变形、易断裂及其横截面结构微细复杂等难于加工的问题,利用微挤出模具芯棒微细复杂成型段各个截面形状在芯棒轴向相同的共同特点,采用成型电极端面一次性蚀除成型加工技术,实现芯棒成型段的精密加工；同时,针对芯棒内部大深径比微细注气孔难于加工的问题,采用微细电火花阶梯孔渐进式加工方法,实现芯棒内部大深径比微细注气孔的精密加工。通过对单腔、双腔和五腔微挤出模具芯棒成型段的加工,验证和完善了该加工工艺的可行性和通用性。在聚合物微挤出模具装配过程中,装配误差容易导致口模与芯棒成型段处的装配间隙不均匀或挤出成型困难,因而重点研究了芯棒、口模、微调机构和注气管道的装配工艺,装配后的挤出模具能够实现芯棒与口模间隙微调,而不会触及芯棒成型段使其弯曲或断裂,同时,还可实现注气管道高温密封。
最后,针对直径微细、截面复杂、壁厚较薄的微管较容易受挤出工艺影响而难于成型的问题,通过对三类微管,如聚合物中心对称单腔微管、轴对称双腔异型微管和周边均匀分布五腔异径微管的挤出成型实验研究和分析,获得了挤出工艺参数对微管截面的尺寸和形状精度的影响主次顺序和较佳的工艺参数组合,揭示了挤出成型工艺参数对聚合物微管截面的尺寸和形状精度的影响规律。结果表明了型腔注气量对微管截面的尺寸和形状精度尤为重要,注气量大小直接决定了微管截面尺寸及其形状轮廓变化。根据挤出成型工艺规律,在管型腔注气量6ml/min,螺杆转速4r/min,模具温度202℃,牵引速度28m/min的挤出工艺条件下,挤出了最小直径为0.5±0.02mm的单腔微管；在月牙腔和圆腔的注气量均为6ml/min,螺杆转速12r/min,模具温度218℃,水箱真空度20%,牵引速度12m/min的较佳挤出工艺参数下,挤出了满足使用要求且最小直径为1.2±0.02mm的双腔微管,其外轮廓椭圆度、月牙腔椭圆度和圆腔椭圆度分别为：0.8%,1.4%和3.0%；在主型腔和次型腔的注气量均为6ml/min,螺杆转速16r/min,模具温度202℃,水箱真空度0,牵引速度10m/min的较佳挤出工艺下,挤出满足使用要求且最小直径为1.6±0.02mm的五腔微管,其外轮廓椭圆度、主型腔椭圆度和次型腔椭圆度分别是2.9%,2.1%和3.9%。同时,挤出实验也证明了多腔直角微挤出模具非对称流道结构优化设计方法的正确性和实用性。
With the great development of micro-processing technology, many products become more and more light, small, tiny and exact. Simultaneously, traditional polymer extrusion molding is turning to micromation, and the polymer micro-extrusion molding appeared. Some tiny and slim tubes such as interventional medical catheters, automobile oil and gas tubes, new type of plastic optical fibers are used widely in the field of medical treatment, automobile, and communication. And the interventional medical catheters with high technical content, much additional value have enormous room for medical treatment. The characters of the interventional medical catheters are tiny size, complicated section and high geometry accuracy, so the design, manufacture, and extrusion molding process of a micro-extrusion die are very complicated, while the traditional polymer extrusion molding technology is inapplicable. Just because of the limit factors like micro-extrusion dies and matched manufacture process, the interventional medical catheters and micro-extrusion dies in our nation mainly depend on importation at present, and the price is quite expensive. This situation makes against the development of our interventional medicine. So this paper is focused on the micro-extrusion molding of polypropylene micro-tubes, and the key technology which is about the rheological design, manufactural method and micro-estrusion molding process of polymer micro-estrusion dies in the condition of micro-scale effect is also studied. The primary items in this paper are as follows:
Firstly, based on the lumen-sectional shape of micro-tubes and the lumen distribution characteristics on the cross-section of the product, the micro-tubes were divided into three types, such as centrosymmetric, axisymmetric and uniformly distributed. And from simple to complex in turn, single-lumen micro-tubes, double-lumen micro-tubes with different shape lumens and five-lumen micro-tubes with different diameter lumens were listed and researched as the most representative products of these three types in the paper. Considering the land length of the polymer micro-extrusion die was the key to the quality of products and the productive efficiency, single-lumen, double-lumen and five-lumen micro-tubes were taken as objects. The parameter relationships between the land length and the flow channel structure, the rheological characters of polymer melts were deduced by a theory and the land lengths of the three-type micro-extrusion dies were also fixed. Then, for the extrusion dies of multi-lumen micro-tubes, combined the flow analysis of polymer melts with the rheological theory and the optimum design method of polymer melts, a new design method for the right-angle non-symmetry flow channel structure of the micro-extrusion die was put forward. In this method, the flow balance of polymer melts in the non-symmetry flow channel of the right-angle micro-extrusion die was seen as the optimization objective; the steering angle in the extrusion die was taken as a design variable; and the objective function of optimizing the flow channel structure was established. Through the optimization of asymmetric flow channel in the extrusion dies for double-lumen and five-lumen micro-tubes, the optimization design method of the multi-lumen extrusion die was gradually improved.
Secondly, because the lands and air injection holes of the mandrel were very tiny, easily broken and the cross-section structures of the lands were very complex especially for multi-lumen micro-extrusion dies, the precision machining together with micro EDM technology were adopted to process the lands of the mandrel and the die. The cross-section of the mandrel land was processed by once corroding technology of the molding electrode end side. At the same time, the vent with big deep diameter ratio in the mandrel was processed by multi-step punching which combined metal drilling with micro EDM molding and punching. In the course of the assembly of the micro-extrusion die for polymer melts, the assembly error easily leads to asymmetry of the assembly interspace between the lands of the mandrel and the die or leads to difficulty of the extrusive molding. The assembly technics of the mandrel and the die and of the vent pipe and micro adjustable system was studied in this paper. The micro-extrusion die after assembly could do a fine adjustment between the mandrel and made the die not bend or break the land of the mandrel. And also, the vent pipe could be airproofed with high temperature.
Finally, the single factor micro-extrusion molding experiments of single-lumen, double-lumen, and five-lumen micro-tubes were studied and analyzed theoretically because the tubes with fine diameter, complex section, thin wall thickness were difficult to be extruded. Through extrusion experiments, the effect order of main process parameters on the size and shape accuracy of micro-tubes and the optimum combination of process parameters were obtained. Experimental results showed that the air injection velocity effected fiercely and decided directly on the size and shape accuracy of micro-tubes. At the same time, the right-angle extrusion die with the asymmetrical channel for the multi-lumen micro tubes was designed by the method. According to the experiments for the single-lumen micro-tubes, the combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of4r/min, a die temperature of202℃and a pulling speed of28m/min, and a single-lumen micro-tube of the smallest diameter with0.5±0.02mm was fabricated. On the basis of the the experiments for the double-lumen micro-tubes, the optimal combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of12r/min, a die temperature of218"C, a vacuum degree of the water tank of20%and a pulling speed of12m/min, and the better double-lumen micro-tube of the smallest diameter with1.2±0.02mm was obtained. And the ovalities of outside profile, crescent lumen and circular lumen in the tube section were achieved by0.8%,1.4%and3.0%respectively under the optimal combination of process parameters. According to the experiments for the five-lumen micro-tubes, the optimal combination of process parameters was determined including an air injection velocity of6ml/min, a screw speed of16r/min, a die temperature of202℃, a vacuum degree of the water tank of0and a pulling speed of10m/min, and the rational five-lumen micro-tube of the smallest diameter with1.6±0.02mm was machined. The ovalities of outside profile, main lumen and secondary lumen in the tube section were reached by2.88%,2.09%and3.9%respectively under the optimal combination of process parameters. Through the extrusion experiments, the correctness of the die design method was verified.
引文
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