聚合物熔体表面效应与平板微器件的注塑成型研究
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摘要
表面具有微细结构的塑料平板制件一聚合物平板微器件,可广泛应用于生命、化学分析、光学通讯等领域。微注塑是制造聚合物平板微器件的重要方法,熔体充型是微注塑成型的关键环节,而在微尺度条件下,熔体表面效应有可能对充型质量有显著影响。本文以聚合物平板微器件注塑成型为研究对象,分析表面效应对于熔体充型流动的影响,构建适用于微注塑充型的理论模型和CAE核心分析模块,针对微结构填充不足和平板翘曲等问题,开展微注塑模具制造与注塑成型工艺研究,制造了典型的聚合物平板微器件一微流体器件。主要研究内容如下：
1.熔体表面效应测试与分析研究。实验测试了聚合物材料熔体的表面张力系数以及在硅、镍等基底材料上的静态接触角,分析了温度对表面张力系数及接触角的影响,建立用于描述熔体表面特性和流动充型的理论模型。
2.微注塑充型分析的核心模块构建与充型过程分析。借助开源代码在动量方程中加入描述熔体表面特性的本构方程和微尺度粘度本构方程,构建了适用于微注塑成型CAE充型过程分析模块。针对微沟道的注塑充型过程,数值模拟了微结构部分的填充过程,研究了微尺度下表面效应对微注塑充型过程的作用机制。
3.型芯可插拔式微注塑模具结构设计与制造。针对聚合物平板微器件小批量多样化制造需求,设计并制造了一种型芯可插拔式微注塑模具结构,采用定模板阶梯型插槽配合,实现型芯灵活更换；采用提高模具配合面加工质量、多点对称布置推杆、背向脱模等方法,使得型芯受力均匀,降低硬脆材料型芯的损坏几率；通过辅助抽真空结构减小熔体流动阻力；加入密封框提高型腔密封性。
4.聚合物平板微器件优化实验研究。采用正交实验的方法研究了工艺参数对不同线宽微沟道填充率和平板翘曲变形的影响,确定了关键因素的主次影响顺序,得到实验最佳工艺参数组合；采用调整平板件的应力分布的方法,在制件中设计了辅助微结构减小了翘曲变形量,通过注塑实验验证了方法可行。
5.微流体器件的注塑成型与实验测试。注塑成型了两种微流体器件,其微通道边界平直,没有明显的欠填充缺陷,翘曲量未对键合产生影响,进行多组参数测试没有漏液、键合失效、微通道边缘效应等问题,能满足使用要求。利用制造的蛇形被动式混合器,在1μ1.min-1的进样速度下实现两种液体的均匀混合。利用制造的液滴生成器能够稳定生成直径从153.7岬到69.4岬的微液滴。
Flat polymer micro-device is plastic plate part with micro structures, which is widely applied in life science, chemical analysis, optical communication, etc. Micro injection molding is an important manufacturing method for flat polymer micro-devices. Melt filling is a key step in micro injection molding. The surface effect of melt will be significant to filling quality under micro-scale conditions. In this study, by taking the micro injection molding of polymeric flat micro-device as the research object, the influence of surface effect on filling flow was analyzed, and the theoretical model and core analysis module of CAE were established for the filling process of micro injection molding. In order to solve the problems of filling shortage of micro structures and warpage, the mold fabrication and process research for micro injection molding were carried out. Finally, the micro fluidic devices, typical polymeric plate micro-devices, were fabricated. The main contents of this thesis are as follows:
1. Research of melt surface effect test and analysis
Surface tension coefficient of polymers and static contact angle of polymers on Si, Ni substrates were tested. The influence of temperature on surface tension coefficient and contact angle was analyzed and theoretical model was established to describe the melt surface effect and filling process.
2. Core model establishment and analysis of filling process in micro injection molding
By means of the open source codes, constitutive equations were added into momentum equation to describe the surface effect of melt and micro-scale viscosity. A CAE module was built to analyze the filling process of micro injection molding. Aiming at filling process of micro grooves, numerical simulation was carried out for filling process of micro structures, and the mechanism of surface effect on filling process of micro injection molding was researched under micro-scale condition.
3. Structural design and fabrication of a core-removable micro injection mold
According to the manufacturing requirements of polymeric plate micro-devices such as small quantity and diversification, a core-removable micro injection mold was designed and fabricated. Assembly of step-like slot and fixed mold plate was adopted to realize the flexible replacement of cores. By quality improvement of mating surface in mold, symmetric distribution of various push rods and backward demould, the loads of core were more uniform and the damage probability of cores with brittle-rigid materials was decreased. An assistant vacuum structure was adopted to reduce the resistance of melt fluidic and sealing frame was used to improve sealing performance of cavity.
4. Experimental research on optimization of polymeric plate micro-device
Orthogonal experiment was adopted to investigate the effect of process parameters on filling rate of micro grooves with different widths. The primary-secondary influential order of key factors was determined and combination of optimized levels was obtained. To reduce warpage of flat device, stress distribution was adjusted by the specially designed micro structures in plate device. Experiment results of micro injection verified the validity of this technique.
5. Micro injection molding and experimental test of micro fluidic devices
Two micro fluidic devices were fabricated through micro injection molding, the micro channels boundaries of which were straight. The defect of less filling was not obvious and the warpage did not influence the bonding process. The problems such as liquid leakage, bonding failure and boundary effect of micro channel were not discovered after multi-groups parameter tests. The fabricated snake-shaped passive mixer successfully realized uniform mixing of two kinds of liquids at sample injection speed of 1μl·min-1, and the fabricated droplet generator can steadily generate liquid droplets with various diameters from 153.7μm to 69.4μm. This confirmed that the two devices achieved the requirements of application.
1.熔体表面效应测试与分析研究。实验测试了聚合物材料熔体的表面张力系数以及在硅、镍等基底材料上的静态接触角,分析了温度对表面张力系数及接触角的影响,建立用于描述熔体表面特性和流动充型的理论模型。
2.微注塑充型分析的核心模块构建与充型过程分析。借助开源代码在动量方程中加入描述熔体表面特性的本构方程和微尺度粘度本构方程,构建了适用于微注塑成型CAE充型过程分析模块。针对微沟道的注塑充型过程,数值模拟了微结构部分的填充过程,研究了微尺度下表面效应对微注塑充型过程的作用机制。
3.型芯可插拔式微注塑模具结构设计与制造。针对聚合物平板微器件小批量多样化制造需求,设计并制造了一种型芯可插拔式微注塑模具结构,采用定模板阶梯型插槽配合,实现型芯灵活更换；采用提高模具配合面加工质量、多点对称布置推杆、背向脱模等方法,使得型芯受力均匀,降低硬脆材料型芯的损坏几率；通过辅助抽真空结构减小熔体流动阻力；加入密封框提高型腔密封性。
4.聚合物平板微器件优化实验研究。采用正交实验的方法研究了工艺参数对不同线宽微沟道填充率和平板翘曲变形的影响,确定了关键因素的主次影响顺序,得到实验最佳工艺参数组合；采用调整平板件的应力分布的方法,在制件中设计了辅助微结构减小了翘曲变形量,通过注塑实验验证了方法可行。
5.微流体器件的注塑成型与实验测试。注塑成型了两种微流体器件,其微通道边界平直,没有明显的欠填充缺陷,翘曲量未对键合产生影响,进行多组参数测试没有漏液、键合失效、微通道边缘效应等问题,能满足使用要求。利用制造的蛇形被动式混合器,在1μ1.min-1的进样速度下实现两种液体的均匀混合。利用制造的液滴生成器能够稳定生成直径从153.7岬到69.4岬的微液滴。
Flat polymer micro-device is plastic plate part with micro structures, which is widely applied in life science, chemical analysis, optical communication, etc. Micro injection molding is an important manufacturing method for flat polymer micro-devices. Melt filling is a key step in micro injection molding. The surface effect of melt will be significant to filling quality under micro-scale conditions. In this study, by taking the micro injection molding of polymeric flat micro-device as the research object, the influence of surface effect on filling flow was analyzed, and the theoretical model and core analysis module of CAE were established for the filling process of micro injection molding. In order to solve the problems of filling shortage of micro structures and warpage, the mold fabrication and process research for micro injection molding were carried out. Finally, the micro fluidic devices, typical polymeric plate micro-devices, were fabricated. The main contents of this thesis are as follows:
1. Research of melt surface effect test and analysis
Surface tension coefficient of polymers and static contact angle of polymers on Si, Ni substrates were tested. The influence of temperature on surface tension coefficient and contact angle was analyzed and theoretical model was established to describe the melt surface effect and filling process.
2. Core model establishment and analysis of filling process in micro injection molding
By means of the open source codes, constitutive equations were added into momentum equation to describe the surface effect of melt and micro-scale viscosity. A CAE module was built to analyze the filling process of micro injection molding. Aiming at filling process of micro grooves, numerical simulation was carried out for filling process of micro structures, and the mechanism of surface effect on filling process of micro injection molding was researched under micro-scale condition.
3. Structural design and fabrication of a core-removable micro injection mold
According to the manufacturing requirements of polymeric plate micro-devices such as small quantity and diversification, a core-removable micro injection mold was designed and fabricated. Assembly of step-like slot and fixed mold plate was adopted to realize the flexible replacement of cores. By quality improvement of mating surface in mold, symmetric distribution of various push rods and backward demould, the loads of core were more uniform and the damage probability of cores with brittle-rigid materials was decreased. An assistant vacuum structure was adopted to reduce the resistance of melt fluidic and sealing frame was used to improve sealing performance of cavity.
4. Experimental research on optimization of polymeric plate micro-device
Orthogonal experiment was adopted to investigate the effect of process parameters on filling rate of micro grooves with different widths. The primary-secondary influential order of key factors was determined and combination of optimized levels was obtained. To reduce warpage of flat device, stress distribution was adjusted by the specially designed micro structures in plate device. Experiment results of micro injection verified the validity of this technique.
5. Micro injection molding and experimental test of micro fluidic devices
Two micro fluidic devices were fabricated through micro injection molding, the micro channels boundaries of which were straight. The defect of less filling was not obvious and the warpage did not influence the bonding process. The problems such as liquid leakage, bonding failure and boundary effect of micro channel were not discovered after multi-groups parameter tests. The fabricated snake-shaped passive mixer successfully realized uniform mixing of two kinds of liquids at sample injection speed of 1μl·min-1, and the fabricated droplet generator can steadily generate liquid droplets with various diameters from 153.7μm to 69.4μm. This confirmed that the two devices achieved the requirements of application.
引文
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