Shanghai Daoqin Plastics Co., Ltd.

world upper 第一台柱塞式 extrusion machine 由英格兰 Henry Bewley and Richard Brooman 于 1845 year made formed 功, 而第一台 mono screw extrusion machine is USA William Kiel and John Prior 于 1876 year made formed 功. 历经一 semi development, extrusion molding already formed is polymer processing in most main/primary molding and modified methods. extrusion molding is types high 效, 连续, low cost, 适应面 wide processing molding methods, meanwhile also is types low density, low add value molding processing methods. development precision extrusion molding technology and 装备, meet/satisfy various precision products molding processing requirements, make extrusion molding formed is types high density, high add value processing methods is currently polymer processing technology R&D hot 点之一.

　　1 precision extrusion molding technology R&D 背景

　　1.1 development precision extrusion molding technology necessary property

　　 precision extrusion molding is types through for extrusion process elements control, achieve products dimensions high precision and material micro high uniform molding process. precision extrusion molding main/primary is: extrusion process in process parameters very small, extrusion equipment as non stability, molding products 几何精 degree ratio extrusion molding methods improve/increase 50% above. development precision extrusion technology property main/primary performance in below/following 方面.

　　1.1.1 high precision products molding need

　　以 light fiber, medical grade tube/pipe, sheet/slice 基, 照像胶 sheet/slice sheet/slice 基, 投影胶 sheet/slice is table/sheet series high precision products market demand and day increase. this category of products 几何精 degree ratio products improve/increase 50% above, extrusion molding equipment for this precision products is can is force, must using/adopting precision extrusion molding equipment and technology formed molding processing.

　　1.1.2 specialty material processing molding requirements

　　 for 一 危险 and has material material processing need precision extrusion 装备. 如含红磷 type polymer composite/compounding material extrusion, need control extrusion process, is very easy 燃烧, extrusion process control good, tool has very large property. engineering plastics in high temperature lower separation understanding for machine has property, for has low separation 子挥发 material. PTFE （ PTFE ） and ethylene - 四 fluorine ethylene copolymer （ ETFE ） in temperature degree lower separation understanding fluorine hydrogen gas 体, gas for extrusion equipment has strong/high property, for 人体 肝脏 has very large loss 伤, gas also 会引发 PTFE and ETPE degradation 反映, 因而必 must add made. in military industry field/area, extrusion machine can used for processing, its property 不言而喻, remove system combined design and precision processing outer, extrusion process control is most key/critical safety elements 之一. in upper type type and high temperature easy separation understanding polymer extrusion processing in, precision extrusion machine can 发挥不 can substitute/replace function.

　　1.1.3 reaction extrusion molding requirements

　　现代 extrusion machine remove function outer, also tool chemical reaction device function, material material in extrusion machine in can cost polymerization, chemical grafting, copolymer 获取, 偶联 / crosslinked, can degradation, function and can modified, polymer/macromolecule alloy made 备, nano / high poly material composite/compounding material made and other. reaction extrusion process need control reaction temperature degree, pressure, material material time and its distribution and other process parameters, and reaction material material and outer hot amount and other, extrusion machine is can 胜任, precision extrusion molding machine is various complex reaction extrusion process provide necessary conditions.

　　1.1.4 high speed extrusion 基础

　　据资 material 报道, Japan company D30 mono screw extrusion machine speed high 达 3000r/min, output/production volume can 达 300kg/h. outer di screw extrusion machine used for production PVC pipe/tube, mono machine output/production volume can 达 1100~1500kg/h; di screw extrusion machine screw already ultra- 300mm, long ratio most high 达 100, screw most high speed to 1500r/min, WP company ZSK133 series machine output/production volume to 7000~11000kg/h. medical grade 导购 线 speed degree can to 250m/min, film speed degree can to 500m/min, cable speed degree can to 500m/min above. in extrusion production high speed meanwhile, must achieve ensure molding process precision can 控. if can ensure products molding degree, production speed degree high, waste product more. in 此意义 upper, can precision is high speed 化 基础.

　　1.1.5 decrease/reduce products material consumption need

　　 extrusion molding products 因几何精 degree relatively low formed is separation 惊人, using/adopting extrusion production sheet/plate, sheet/slice, film, tube/pipe thick non-uniform degree generally can 达 8% 至 10%, 由此造 formed material can 达 8% left right. year plastics products output/production volume 21000kt is 基数, extrusion molding products year output/production volume 12600kt 计算, 我国每 year due to extrusion products 几何精 degree low 就浪费掉 100 more resin. if 20% products using/adopting precision extrusion technology and production, 我国每 year can resin consumption amount 10 10,000 tons left right, 经济效益 ultra- 8 100 million yuan.

　　1.2 国 inner outer precision extrusion molding technology and 装备 差距

　　 currently Domestic extrusion sales amount is 8000 余 sleeve/set / year, sales 额 30 100 million yuan left right, Imported extrusion 装备 2000 余 sleeve/set / year, Imported 额 2 100 million USD left right （约 20 100 million 人民币）, Imported extrusion main/primary is large type and precision equipment, its mono is inner equipment 8~10 倍, its add value obvious high inner equipment.

　　 Imported extrusion equipment main/primary has large 口径实壁 tube/pipe and tube/pipe production 线, film production 线, di toward tensile film （ BOPP, BOET, BOPA, BOPS and other ） production 线, tube/pipe production 线, medical grade tube/pipe production 线, sheet/slice and light sheet/slice production 线, use large type di screw extrusion pelletizing 装备, and various 实验室 use more function extrusion and other. this Imported extrusion 装备之 therefore can very high price China market, main/primary technology upper advantages, specific performance in high density, high speed and high efficiency, high can property.

　　图 1 is Japan 伊藤忠 TEXMAC company extrusion di inner tube/pipe medical grade tube/pipe production 装备, 报价 100 10,000 USD. 该装备包括三台 extrusion machine, separation molding inner tube/pipe and outer sleeve/set tube/pipe, inner tube/pipe molding and its and outer sleeve/set tube/pipe composite/compounding in sleeve/set mold in one-time formed. is ensure tube/pipe dimensions stability property, extrusion machine 均配备 melt gears 泵, meanwhile machine using/adopting electrical machine 驱动. in testing 仪随时监控导 tube/pipe dimensions, is ring control system provide necessary data. equipment 经变换 mold, can production various medical grade tube/pipe, 见图 2.

　　 USA PEI （ Precision Extrusion, Inc. ） company used for production medical grade tube/pipe precision extrusion machine, using/adopting design and manufacturing technology, and statistics process control technology, make extrusion machine temperature degree can control in ± 1℃, pipe/tube thick can control in 2% 以 inner. versus ratio lower, high extrusion equipment temperature degree generally in 5℃~10℃, pipe/tube thick in 10% above, 根本无 method meet/satisfy production medical grade tube/pipe, light fiber and other high degree products requirements. this category of high precision extrusion equipment currently main/primary Imported.

　　 high extrusion equipment is in water 平, also is processing water upper and outer water in 15~20 year 差距. in process parameters and products parameters 监测, and control technology using/adopting 方面存 in 差距也 very large, high degree in testing device main/primary Imported, inner can 数, and outer product in 10 year above.

　　1.2.1 design water and technology innovation can force upper 差距

　　国 outer plastics machine processing enterprise has very strong/high design and technology innovation can force, Japan Nissei company has technology research in 心, has 376 名 injection molding technology engineering 师, 占员工总人数 46.1%, patent technology 1470 项. versus ratio lower, inner plastics machine enterprise in large above technology 人员不足 10%, enterprise independent Knowledge less, development new product generally made is 主, CAD, CAE, CAM application also 处于初 grade stage/phase, more enterprise tool 备实质 upper technology innovation can force.

　　1.2.2 国 inner outer machine electrical industry overall water upper 差距

　　国 outer plastics machine manufacturing industry using/adopting CAD, CAE, CAM technology, and high density processing in 心. in recent years development high speed 铣床 主轴转 speed high 达 40000~100000r/min, can obtain Ra≤1μm surface coarse degree; processing degree ultra- 1μm ultra- 精 processing technology and electrical, chemical, ultra- 声波, light and other technology comprehensive in composite/compounding processing, will plastics machine processing water large large improves. outer screw 端面跳动误差不 large 于 0.01mm; screw outer 径误差 can control in 0.005mm below/following; screw outer surface and material inner surface coarse degree Ra large 于 0.2μm injection molding machine sheet/plate 形位公差不 large 于 ± 0.02mm/1000mm. inner in recent years from outer Imported high degree machine processing 装备, overall water and outer water has very large 差距.

　　1.3 precision extrusion technology R&D and application to heavy 视

　　北京 chemical industry large in 教育部骨 dry 教师基金 and 北京市自然科学基金 资助 lower, precision extrusion mechanism research and precision extrusion technology heavy new. 图 3 is chemical industry large plastics machine and plastics engineering research precision extrusion 实验台, 该实验台配备 melt 泵, 伺服驱动 system, heavy add material amount system, in light 测径仪 and other has improve/increase extrusion process precision can plant/unit, also 配备 并联式稳 pressure system, statistics process control （ SPC ） control system and other tool has independent Knowledge patent technology and 装备.

　　北京 chemical industry large already has 一名博士, 五名硕士完 formed precision extrusion mechanism and technology 方面 学位论文, 课题组 in formed inner precision extrusion 实验台 meanwhile, 申报 5 项 patent, 并承接 “ extrusion method production light fiber ” 国家 863 project.

　　2 precision extrusion molding related technology

　　 precision extrusion molding main/primary precision 塑化, precision control, precision molding and other 三方面 technology inner 容. from achieve precision extrusion molding technology main/primary 包括两 方面: 一方面 need most large degree improve/increase extrusion molding process temperature degree, pressure and amount stability property, 另一方面 is through control （闭 ring control, control, statistics process control and other ）手段, for extrusion molding process 波动进行即时自动 adjustment.

　　2.1 improve/increase extrusion process stability property related technology

　　 extrusion molding is 一 十 separation complex production process, in process in, high poly material need solid 体输送, melt, mixed combined, increase pressure, 泵送, molding, cooling solid and other process, to 剪切, tensile, pressure shrink, and add hot, cooling and other function, 发生熔 melt, solid 化, orientation, understanding orientation, crystallization and other complex versus and structure 变化, make extrusion process control difficult degree large. meanwhile, due to extrusion production in products molding and type is in relatively low pressure lower 进行, formed molding process extrusion stability property and outer factors effect/influence relatively large. is upper unstable factors for extrusion molding effect/influence, development series has 助于提 extrusion stability property plant/unit.

　　2.1.1 稳 pressure plant/unit using/adopting

　　（ 1 ） melt gears 泵

　　普通 extrusion molding system need solution main/primary issues is extrusion output/production volume stability property, research table/sheet 明普通 extrusion machine extrusion amount can 达 8%~10%, toward 波动会 make extrusion products toward degree decline. is solution extrusion molding system extrusion stability property, using/adopting melt gears and extrusion machine use. melt gears is types positive 位移输送 plant/unit amount and 泵 转 speed 呈严格 positive ratio 关系.

　　 used for plastics melt melt gears 泵, its main/primary function is will extrusion machine high temperature plastics melt increase pressure, pressure, maintain melt amount stability extrusion machine 头此处 introduction melt 泵, its structure similar liquid pressure in gears 泵. can in high temperature 350℃, pressure 达 35Mpa or more high conditions lower 连续工 as. its main features is structure simple 紧凑, as can 靠, lifespan relatively long.

　　 from 图 4 and 图 5 can to, melt main/primary is 由泵体, front rear cover/cap sheet/plate, versus combined gears, bearings and seals and other formed. gears 齿廓, and cover/cap sheet/plate formed 空间构 formed material 区, 输送区 and material 区. gears is melt core parts, its 结果形式 multiple more 样: combined methods can separation is inner combined and outer combined methods; 按齿廓曲线 can separation is 渐开线 gears, gears, gears and other; toward can separation is gears, gears and gears and other, in plastics melt in most commonly used is 渐开线直齿 or outer combined gears 泵.

　　图 6 is melt gears pressure 效果 实验曲线. table/sheet melt using/adopting can will extrusion process rear pressure reduce 90% above.

　　迄今 is 止, melt gears is application most 广泛 稳 pressure plant/unit.
　　（ 2 ） pressure control device

　　 due to melt gears processing degree high, price 昂贵, in has combined can using/adopting other pressure plant/unit, pressure control device is its in types. pressure control device structure 见图 7.

　　 pressure control device is 基于动态流 amount balanced principle research 出, plant/unit is through stability extrusion pressure achieve 稳流 目. material material extrusion machine screw by machine 头时, generate pressure. pressure material material control device in. is control device 螺旋线旋 toward and extrusion machine 螺旋线旋 toward versus 反, therefore by pressure control device in polymer melt to control device in generate pressure and extrusion machine pressure versus and other is 止. extrusion machine in pressure is positive 弦波形式, extrusion machine inner pressure is 波峰时, requirements control device inner formed pressure is most high, need relatively long filling 段 达 to pressure balanced. extrusion machine pressure is 波谷时, need filling relatively short. 此时, pressure control device to pressure can device function, usually pressure in value 时, raw materials poly in control device in. extrusion machine inner pressure decline 时, poly material material in control device 螺纹 推进 function lower, extrusion machine in, from make pressure and extrusion output/production volume 趋于平稳. due to control device relatively fast, therefore it can made melt extrusion high frequency 波动, for its 进行 实验验证均起 to obvious pressure 效果.

　　（ 3 ）并联式稳 pressure plant/unit

　　针 for 串联式 melt gears 泵 存 in pressure low, lubricated and fault/failure rate high, price and other disadvantages, and pressure control device in can property 差, suitable scope/range disadvantages, R&D 并联式稳 pressure plant/unit, 见图 8, in research and research upper make its 不断完善. this type of 并联式稳 pressure methods can for 传统 串联稳 pressure methods to function.

　　并联式稳 pressure plant/unit pressure 效果见图 9, in 该实验 in, due to using/adopting 并联式稳 pressure plant/unit, can remove 83%~91% pressure and extrusion rate 波动.

　　（ 4 ）锥体 base/seat sleeve/set pressure control plant/unit

　　锥体 base/seat sleeve/set 式稳流 plant/unit structure 见图 10, screw and sleeve/set 筒间形 formed melt runner 就象一 阀门. screw in machine or liquid pressure plant/unit lower 进行轴 toward 移动, 此时阀门 开 degree, screw 锥形头部 and machine upper sleeve/set between 间隙就会改变, make extrusion amount to control.

　　（ 5 ）螺钉 type plant/unit

　　螺钉 type plant/unit structure non simple, 见图 11. through 螺钉旋入 deep degree adjustment, can extrusion machine runner retardant force, to adjustment amount 目.

　　（ 6 ） more ring active 动阀门式稳流 plant/unit

　　Sponaugle design more ring active 动阀门式稳流 plant/unit, 见图 12. plant/unit as principle and base/seat sleeve/set 式稳流 plant/unit full same, in screw 头部开设 若 dry ring type 槽, ring type and solid in extrusion machine upper ring type base/seat formed more 阀门.

　　（ 7 ）鱼雷头移动式稳流 plant/unit

　　鱼雷头稳动式稳流 plant/unit structure 见图 13. can toward 移动 鱼雷头置于 machine 头入口处, extrusion machine inner pressure 发生波动时, 移动鱼雷头 can runner retardant force, to adjustment amount 目.

　　2.1.2 precision extrusion molding machine using/adopting

　　（ 1 ） retardant force can adjustment machine 头

　　 extrusion amount 波动会引起 products toward dimensions 波动, this type of can through adjustment machine runner retardant force add balanced. 图 14 is types retardant force adjustment machine structure 示意图.

　　图 15 is another types retardant force adjustment machine structure 示意图. in amount device testing to extrusion amount 发生波动时, micro device to electrical machine 发出动 as 指令, through system retardant force adjustment ring toward 位移. due to retardant force adjustment ring 位移, make machine retardant force 发生变化, to stability extrusion amount function.

　　（ 2 ）口模间隙自动 adjustment machine 头

　　图 16 is most use types hot screw adjustment plant/unit. its principle is in 膨胀螺栓 external has add hot device, long degree temperature degree 变化而变化.

　　图 17 is upper plant/unit 改进形式, features is 各膨胀螺栓 separation add hot meanwhile, also lubricated 油逆流连续 cooling, make temperature degree 波动变 small.

　　（ 3 ）组 combined 式自动 adjustment machine 头

　　图 18 is types combined 式自动 adjustment machine 头, can adjustment retardant block 处 间隙 and 模唇处 间隙. it is Germany plastics processing research development.

　　（ 4 ） melt viscosity adjustment machine 头

　　 melt viscosity temperature degree rise high reduce, viscosity 变化会 effect/influence to melt flow speed degree. extrusion products toward dimensions 出现偏差时, can through adjustment machine 头口模 temperature degree distribution 进行补偿. 图 19 is Germany Battenfeld company types used for production plastics pipe/tube viscosity adjustment machine 头 照 sheet/slice.

　　2.1.3 失 heavy amount material using/adopting

　　 mono screw precision extrusion machine as more stability, 总会存 in 波动, this type of can through extrusion machine control system add adjustment, can will extrusion machine output/production volume and extrusion machine screw speed or speed degree formed ring, decrease/reduce extrusion products toward dimensions degree. due to extrusion products output/production volume very difficult amount, development 出 失 heavy amount material 斗, its structure 示意图见图 20, relatively good solution extrusion output/production volume in amount issues.

　　失 heavy amount material upper has heavy device, through amount mono time inner material weight decrease/reduce amount, can to extrusion machine output/production volume. extrusion machine PLC control system can according to heavy amount material to extrusion output/production volume value, achieve extrusion output/production volume and machine or extrusion machine electrical machine speed ring control. using/adopting heavy amount material 斗, can for products heavy precision control. 图 21 is using/adopting heavy amount material control extrusion products heavy features 曲线.

　　图 11 in non ring control table/sheet extrusion production 线 工 as 情况, 此时牵引 machine speed degree maintain 不变, products heavy extrusion machine output/production volume 波动而波动. in ring control 区, machine speed degree extrusion output/production volume 波动而变化, products heavy basic upper maintain is 直线. using/adopting heavy amount material control extrusion products heavy, not only can improve/increase products thick uniform degree, but also can in very large degree upper decrease/reduce Raw Materials 浪费.

　　2.2 precision extrusion molding control technology

　　 precision extrusion molding as is extrusion technology development in important direction, is types can achieve products high degree extrusion molding methods. 随 现代 electronics technology and machine processing technology development, especially is 4C （ Computer, Communication, Contorl, CRT ） and IT technology application, make precision extrusion molding production 装备无论 is in machine 械构造 design, also is in technology, and versus data 采集处理 and other 方面都 has development. in precision design, precision processing, precision type, precision 配置 基础 upper, through for system parameters in high degree testing, data 传输以 and control, to for products dimensions degree precision control, can achieve true positive upper precision extrusion molding.

　　 extrusion molding main/primary 包括主 machine （ extrusion machine ） and machine （包括 machine mold, type plant/unit, cooling plant/unit, plant/unit, plant/unit, plant/unit and other ）两部 separation. in extrusion products processing process in, is ensure products dimensions property and processing process stability property, extrusion molding equipment main/primary control parameters machine temperature degree, machine temperature degree, melt pressure, machine speed, 牵引转 speed, speed degree and different products dimensions and other quality indicators: products outer dimensions and 形状, thick and its distribution, surface light degree and other.

　　 in extrusion in, machine control parameters main/primary machine and machine temperature degree, machine pressure and machine speed and other; machine control parameters main/primary 包括牵引 plant/unit, plant/unit, plant/unit as speed degree. in control hard parts upper main/primary using/adopting 二次仪 table/sheet （包括智 can table/sheet, temperature table/sheet ）, speed system, electrical appliances, device, 延时开关, electrical device and other achieve, in control system usually using/adopting ring control system, has parameters between control.

　　 precision extrusion and extrusion main/primary control parameters basic is 一样. in precision extrusion molding in, is for system parameters achieve more 精确, more precision control, using/adopting control and testing device, through for main/primary target/goal quality （如 products 几何精 degree ） control parameters achieve ring control, statistics process control SPC （ Statistical Process Control ）, complex control （如串 grade control, front control and other ）以 and can control and other （如 expert control system, control and other ）, achieve for most target/goal quality （ products 几何精 degree ） precision control. this control methods tool has can table/sheet, electrical appliances is control core 传统仪 table/sheet type control system method achieve function. table/sheet 明, has using/adopting micro device is control core, tool has data and function can 编程序 control device PLC （ Program-mable Logic Controller ）, mono sheet/plate machine and PC machine and other is control core control system, can achieve for system more function ring control.

　　3 precision extrusion molding technology application outlook/prospects

　　 extrusion molding development make can according to products molding requirements, precision design extrusion molding process and extrusion molding equipment. achieve stability extrusion is new type extrusion innovation, machine processing technology water 平 不断 improve/increase, control technology using/adopting, is precision extrusion technology development provide large development 空间. precision products molding, function property products molding, reaction extrusion products molding requirements, and di toward tensile, function degree material, micro foaming products molding process requirements, is precision extrusion technology development strong/high large force. precision extrusion technology development, will for plastics processing generate large effect/influence, application outlook/prospects separation vast.

　　3.1 precision molding will formed is high add value processing industry

　　 in concept in, extrusion molding is high 效, low add value plastics processing methods, precision extrusion molding technology development and application will this 一状态, in precision products molding processing in, can belt/tape high add value, can to formed function. medical grade plastics tube/pipe is 例, outer company already can production tube/pipe, 人工血 tube/pipe, 介入疗 method use and other precision products, this products generally is its Raw Materials value 数百倍 above, has ultra- 一万倍.

　　 precision extrusion is production precision extrusion products conditions, development precision extrusion molding will is plastics machine 械厂家 belt/tape large machine and thick profit. currently precision extrusion molding 装备 价 value is general purpose extrusion molding 装备售价 5~10 倍 above, precision extrusion molding also in stage/phase, development very large.

　　3.2 precision reaction extrusion molding and function

　　现代 reaction extrusion machine remove function outer, also tool chemical reaction device function, material material in extrusion machine in can cost polymerization, chemical grafting, copolymer 获取, 偶联 / crosslinked, can degradation, function and can 团 该 property, polymer/macromolecule alloy made 备, nano / high poly material composite/compounding material made and other. reaction extrusion process need control reaction temperature degree, pressure, material material time and its distribution and other process parameters, and reaction material material and outer hot amount and other, 而普通 extrusion machine is can 胜任. precision extrusion molding machine can achieve for extrusion process parameters precision control, meet/satisfy different reaction system requirements.

　　自 from 1957 year polymer mono 晶, and separation 子链折叠理论以, polymer and micro structure 引起人们 极 large 关注. X 射线衍射, electronics micro 镜, small in dispersion 射, new surface 探针, force micro and other testing technology application, for polymer structure - 形态 - property can between 认识不断 deep 化. already can through extrusion molding process direction and strong/high degree control （ or tensile control ）, made mono or di orientation structure reinforcement material; through cooling process control, and 剪切, tensile and 振动场 诱导, obtain different crystallization structure. through molding processing process control, obtain poly structure 按一定规律变化 function degree material, achieve force 学, optical, electrical and other property can degree distribution requirements. upper poly 集态结果 control technology, requirements for extrusion molding process precision control, can precision extrusion molding technology will in function degree material made 备方面发挥 important function.