聚合物叶片挤出机熔体正位移输送和混合特性研究
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摘要
高分子材料成型加工是高能耗过程作业,目前普遍采用螺杆机械,如螺杆挤出机、螺杆注射机等,在螺杆机械中物料塑化输运主要是靠螺杆旋转时对物料的拖曳作用,固体输送为摩擦拖曳,熔体输送为粘性拖曳,物料的速度梯度与其流动和变形方向垂直,这种流动与变形受剪切应力支配,所以当前的高分子材料加工方法普遍存在物料塑化输运所经历的热机械历程长、能耗高、设备结构大、对物料特性依赖性强等缺陷。华南理工大学瞿金平教授创造性发明了拉伸流变控制的高分子材料塑化输运方法及设备(叶片挤出理论设备),使得物料在塑化输送过程中受拉伸应力支配,尝试从塑化输运机理上解决当前高分子材料成型加工过程中物料经历的热机械历程长、能耗高的问题。这一独特的加工方法深刻地影响了聚合物塑化挤出过程,使得聚合物的加工应用和理论都发生了巨大的变化。因此从理论和实验上深刻地揭示这种改变对聚合物产生的影响就具有重要的科学意义和现实意义。
本文对基于拉伸流变的聚合物塑化输运设备和方法进行了原理分析,对聚合物熔体在叶片单元中的塑化输运过程进行了深入的分析讨论,首次提出了聚合物熔体在叶片挤出机输送过程相应的物理模型和数学模型,得出了叶片挤出机中熔体周向和轴向速度分布、压力分布、应力分布,分析聚合物在拉伸场支配的多物理场耦合作用下塑化输运过程参数与工艺条件、结构参数、材料特性参数之间的定量关系;首次对叶片塑化挤出过程中拉伸场的存在进行了定量描述,证实了聚合物熔体在叶片挤出机中的塑化输运过程受拉伸流变支配。并根据流场分析,讨论了周期性正应力场和拉伸场对聚合物微观结构、分子运动的影响,指出叶片挤出机中存在的拉伸流场和周期性正应力场对聚合物塑化输运能起到节能高效的效果。
同时本文对叶片挤出机输送能力和制品测试进行了大量的实验研究。分别利用转子直径为? 40、长径比为10的叶片挤出机和螺杆直径为? 45,长径比为20的传统单螺杆挤出机进行HDPE、LDPE和PP输送特性实验研究,同时对叶片挤出和螺杆挤出LDPE、PP以及LDPE/纳米CaCO3和PP/纳米CaCO3在相同产量下的制品进行了力学性能、热性能、微观凝聚态结构测试。对叶片挤出设备的生产能力、挤出功耗与螺杆挤出设备进行了比较,同时对于叶片挤出制品与螺杆挤出制品的各项性能也进行了实验比较。
试验研究表明:聚合物叶片挤出机具有良好的正位移输送特性,在输送物料具有高效、低耗、输送特性“硬”等优点的同时,还能保证挤出制品良好的制品质量。与螺杆挤出相比,叶片挤出机输送效率更高,对模头压力敏感性低,单产功耗更低,节能降耗效果更好;在制品性能测试中发现,与螺杆挤出片材相比,叶片挤出机挤出LDPE、PP以及纳米CaCO3填充LDPE和PP体系片材的力学性能明显好于螺杆挤出片材,并且在制品热性能和微观形态上也有一定改善,同时发现叶片挤出能将获得最佳填充体系力学性能填充比提高2%～3%。
实验结果与理论推导和理论预测相吻合,证明了本文理论推导的正确性。叶片挤出理论和设备是一种全新的聚合物加工理论和设备,本文提出了叶片挤出熔体输运流变模型,为进一步研究叶片塑化挤出理论打下了良好的基础。这些研究为将来聚合物叶片塑化输运理论及设备的推广提供了重要的理论和实验依据。
Polymer processing is a high-energy process operation, and screw machinery is widespread applied to the polymer processing, such as screw extruders, screw injection molding machine and so on. The screw plasticating and conveying equipments based on shear rheology are generally adopted in polymer processing, in which materiels are dominated by shear stress. Therefore, there are some ubiquity disadvantages of the current methods of polymer materials processing, such as long thermo-mechanical, high energy consumption, too big equipment structure, and dependence on material properties. Jinping Qu, the professor of SCUT has put forward and invented a polymer vane plasticating and conveying method based on elongational rheology which is different from the one of the screw plasticating and conveying and it can make the flow and deformation of polymer dominated by elongational stress field. The method has many advantages over conventional plasticating method, such as shorting thermo-mechanical experience of plasticating and conveying, reducing the energy consumption of plasticating and conveying, and improving adaptability to diverse materials. Therefore, study of the impact on polymer by experiment and theory ways will bring out great science and realistic significance.
The principle of polymer vane plasticating and conveying method based on elongational rheology was analyzed in this paper. The axial rectangular slot squeezing flow model and circumferential converging wedge channel flow model were established according to the basic structure and working principle of vane unit, and combined with the necessary assumption, the expressions of velocity distribution, pressure distribution, strain distribution of melt in the vane unit were analyzed and discussed. Elongational flow field of vane extruder was expressed quantificationally for the first time, and it proved that melt conveying in vane extruder was controlled by elongation field. Based on the analysis of flow filed, the influence of periodically normal stress field and elongational flow field to microstructure and molecule of polymer under vane extruder procesing were discussed, and affirmed that periodically normal stress field and elongational flow field were the key factors of energy saving and high effect to the transportation and plasticization of polymer.
As opposed to screw extruder, the transmission capacity and product testing processed by vane extruder were studied through a large number of experiments in this paper. The vane extruder with rotator diameter ? 40 and aspect ratio 10, and the screw extruder with rotator diameter ? 45 and aspect ratio 20 were used to the conveying experimental studies by processing HDPE, LDEP and PP respectively. At the same time, the mechanical properties, thermal properties, micro-structure of the products of LDPE, PP, LDPE/na-no CaCO3, PP/na-no CaCO3 processed by vane extruder and screw extruder were tested.
Results from theory analysis and experiment revealed that: comparing with screw extruder, vane extruder proved that the device is reliable, efficient with improved production quality and lower energy consuming. The mechanics properties of samples of LDPE, PP processed by vane extruder are better than the samples porceessed by screw extruder, and the thermal properties and micro-structure also improved. For the filling system of LDPE/na-no CaCO3, PP/na-no CaCO3, the samples processed by vane extruder can improve the best mechanics properties of fill ratio to 2%～3% compared with screw extruder samples.
The comparison of the results coming from the theoretical calculation and the experiment reveals that these theory models are valid and useful. This study will serve as the theory and experiment basis for the optimum conditions of vane extruder design and processing polymer.
本文对基于拉伸流变的聚合物塑化输运设备和方法进行了原理分析,对聚合物熔体在叶片单元中的塑化输运过程进行了深入的分析讨论,首次提出了聚合物熔体在叶片挤出机输送过程相应的物理模型和数学模型,得出了叶片挤出机中熔体周向和轴向速度分布、压力分布、应力分布,分析聚合物在拉伸场支配的多物理场耦合作用下塑化输运过程参数与工艺条件、结构参数、材料特性参数之间的定量关系;首次对叶片塑化挤出过程中拉伸场的存在进行了定量描述,证实了聚合物熔体在叶片挤出机中的塑化输运过程受拉伸流变支配。并根据流场分析,讨论了周期性正应力场和拉伸场对聚合物微观结构、分子运动的影响,指出叶片挤出机中存在的拉伸流场和周期性正应力场对聚合物塑化输运能起到节能高效的效果。
同时本文对叶片挤出机输送能力和制品测试进行了大量的实验研究。分别利用转子直径为? 40、长径比为10的叶片挤出机和螺杆直径为? 45,长径比为20的传统单螺杆挤出机进行HDPE、LDPE和PP输送特性实验研究,同时对叶片挤出和螺杆挤出LDPE、PP以及LDPE/纳米CaCO3和PP/纳米CaCO3在相同产量下的制品进行了力学性能、热性能、微观凝聚态结构测试。对叶片挤出设备的生产能力、挤出功耗与螺杆挤出设备进行了比较,同时对于叶片挤出制品与螺杆挤出制品的各项性能也进行了实验比较。
试验研究表明:聚合物叶片挤出机具有良好的正位移输送特性,在输送物料具有高效、低耗、输送特性“硬”等优点的同时,还能保证挤出制品良好的制品质量。与螺杆挤出相比,叶片挤出机输送效率更高,对模头压力敏感性低,单产功耗更低,节能降耗效果更好;在制品性能测试中发现,与螺杆挤出片材相比,叶片挤出机挤出LDPE、PP以及纳米CaCO3填充LDPE和PP体系片材的力学性能明显好于螺杆挤出片材,并且在制品热性能和微观形态上也有一定改善,同时发现叶片挤出能将获得最佳填充体系力学性能填充比提高2%～3%。
实验结果与理论推导和理论预测相吻合,证明了本文理论推导的正确性。叶片挤出理论和设备是一种全新的聚合物加工理论和设备,本文提出了叶片挤出熔体输运流变模型,为进一步研究叶片塑化挤出理论打下了良好的基础。这些研究为将来聚合物叶片塑化输运理论及设备的推广提供了重要的理论和实验依据。
Polymer processing is a high-energy process operation, and screw machinery is widespread applied to the polymer processing, such as screw extruders, screw injection molding machine and so on. The screw plasticating and conveying equipments based on shear rheology are generally adopted in polymer processing, in which materiels are dominated by shear stress. Therefore, there are some ubiquity disadvantages of the current methods of polymer materials processing, such as long thermo-mechanical, high energy consumption, too big equipment structure, and dependence on material properties. Jinping Qu, the professor of SCUT has put forward and invented a polymer vane plasticating and conveying method based on elongational rheology which is different from the one of the screw plasticating and conveying and it can make the flow and deformation of polymer dominated by elongational stress field. The method has many advantages over conventional plasticating method, such as shorting thermo-mechanical experience of plasticating and conveying, reducing the energy consumption of plasticating and conveying, and improving adaptability to diverse materials. Therefore, study of the impact on polymer by experiment and theory ways will bring out great science and realistic significance.
The principle of polymer vane plasticating and conveying method based on elongational rheology was analyzed in this paper. The axial rectangular slot squeezing flow model and circumferential converging wedge channel flow model were established according to the basic structure and working principle of vane unit, and combined with the necessary assumption, the expressions of velocity distribution, pressure distribution, strain distribution of melt in the vane unit were analyzed and discussed. Elongational flow field of vane extruder was expressed quantificationally for the first time, and it proved that melt conveying in vane extruder was controlled by elongation field. Based on the analysis of flow filed, the influence of periodically normal stress field and elongational flow field to microstructure and molecule of polymer under vane extruder procesing were discussed, and affirmed that periodically normal stress field and elongational flow field were the key factors of energy saving and high effect to the transportation and plasticization of polymer.
As opposed to screw extruder, the transmission capacity and product testing processed by vane extruder were studied through a large number of experiments in this paper. The vane extruder with rotator diameter ? 40 and aspect ratio 10, and the screw extruder with rotator diameter ? 45 and aspect ratio 20 were used to the conveying experimental studies by processing HDPE, LDEP and PP respectively. At the same time, the mechanical properties, thermal properties, micro-structure of the products of LDPE, PP, LDPE/na-no CaCO3, PP/na-no CaCO3 processed by vane extruder and screw extruder were tested.
Results from theory analysis and experiment revealed that: comparing with screw extruder, vane extruder proved that the device is reliable, efficient with improved production quality and lower energy consuming. The mechanics properties of samples of LDPE, PP processed by vane extruder are better than the samples porceessed by screw extruder, and the thermal properties and micro-structure also improved. For the filling system of LDPE/na-no CaCO3, PP/na-no CaCO3, the samples processed by vane extruder can improve the best mechanics properties of fill ratio to 2%～3% compared with screw extruder samples.
The comparison of the results coming from the theoretical calculation and the experiment reveals that these theory models are valid and useful. This study will serve as the theory and experiment basis for the optimum conditions of vane extruder design and processing polymer.
引文
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