High-speed centrifuge rotor and manufacturing method thereof

Abstract

The invention provides a high-speed centrifuge rotor which ensures dynamic balance of the rotor under high-speed rotation and ensures damping vibration attenuation while reducing the overall mass of the rotor. The rotor inner core comprises a rotor inner core body, the position of a central shaft of the rotor inner core body is connected with a shaft sleeve installation hole, a plurality of concave centrifugal cup installation positioning cavities are further annularly distributed in the upper surface of the rotor inner core body, and corresponding ventilation hole channels are further formed in the rotor inner core body; and a carbon fiber rotor housing; the rotor inner core body is formed by one-time punch forming of a carbon fiber material, and the periphery of the rotor inner core body is coated with a carbon fiber rotor shell.

Description

Technical Field

[0001] This invention relates to the technical field of high-speed centrifuge structures, specifically high-speed centrifuge rotors. The invention also provides a method for manufacturing the high-speed centrifuge rotor. Background Technology

[0002] High-speed centrifuges are widely used in biopharmaceuticals, serving as pilot-scale production tools for large-volume cell collection, vaccine or protein purification, and blood component separation. Existing high-speed centrifuge rotors are all made of aluminum alloy, with a density of approximately 2.7 g / cm³. 3 When used as the rotor of a blood centrifuge, it has the following drawbacks: a. It has high rotational inertia, slow start / stop response, and high energy consumption. The core requirements for blood centrifuges are precise speed control and rapid start-up and shutdown (to avoid damage to blood components due to prolonged centrifugation); however, aluminum alloy rotors are heavy and have high rotational inertia: they require more power to start up and take a long time to reach the target speed; when braking, the large inertia makes stopping take a long time, which not only reduces centrifugation efficiency but may also affect the activity of blood cells due to prolonged high-speed rotation. b. Dynamic balance is prone to instability at high speeds, affecting separation accuracy. Blood centrifugation requires extremely high uniformity of rotation speed (different blood components have small differences in sedimentation coefficients, and fluctuations in rotation speed can lead to unclear separation and stratification); aluminum alloy has low specific strength, and at the high rotation speeds of 10,000–30,000 r / min commonly used in blood centrifuges, centrifugal force can cause slight creep or deformation of the rotor, disrupting the dynamic balance accuracy at the factory, resulting in increased equipment vibration, which in turn leads to blurred blood stratification and decreased purity of serum / plasma extraction; c. Poor damping and vibration reduction, high operating noise, and easy damage to samples. Blood samples are very sensitive to vibration; excessive vibration can cause problems such as red blood cell rupture and platelet activation. Given the aforementioned drawbacks of aluminum alloy rotors, there is an urgent need to develop a high-speed centrifuge rotor that can reduce the overall mass of the rotor, ensure dynamic balance of the rotor under high-speed rotation, and ensure damping and vibration reduction. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a high-speed centrifuge rotor that reduces the overall mass of the rotor while ensuring dynamic balance under high-speed rotation and ensuring damping vibration reduction.

[0004] A high-speed centrifuge rotor, characterized in that it comprises: The rotor inner core body has a central shaft connected to a bushing mounting hole. The upper surface of the rotor inner core body is also surrounded by several recessed centrifugal cup mounting and positioning cavities. Corresponding ventilation channels are also arranged on the rotor inner core body. And the carbon fiber rotor housing; The rotor core is formed by one-time stamping of carbon fiber material, and the outer periphery of the rotor core is covered by a carbon fiber rotor shell.

[0005] Its further features are: The carbon fiber rotor housing includes a bottom stop ring and a covering sleeve that conforms to the outer periphery of the rotor inner core body. The bottom stop ring is located radially outside the lower surface of the rotor inner core body, and the covering sleeve wraps around the outer periphery of the rotor inner core body.

[0006] A method for manufacturing a high-speed centrifuge rotor, characterized by comprising the following steps: S1 rotor inner core body is molded as a single piece; S2 winds carbon fiber cloth around the outer periphery of the rotor inner core body, so that the carbon fiber cloth winds to form a carbon fiber rotor shell. After S3 is completed and wrapped, it is placed in an autoclave and a semi-finished product is formed by a stepped temperature curing process. S4 removes the semi-finished product and performs precision milling to ensure that the semi-finished product meets the processing requirements; S5 surface coating.

[0007] Its further features are: In step S1, carbon fiber cloth is selected as the material. During the one-piece molding process, the shape of the rotor core body, the bushing mounting hole, the centrifuge cup mounting and positioning, and the ventilation channel are all formed in one step without the need for subsequent splicing processing. This avoids the stress concentration and uneven mass distribution problems caused by cutting and welding in the processing of aluminum alloy rotors. The dynamic balance accuracy of the carbon fiber rotor can reach the micron level at the factory. The vibration amplitude is extremely low at high speed, which is fully compatible with the stringent requirements of blood centrifugation for speed stability and prevents the sample from being damaged by vibration. In step S2, a five-axis winding device is used to wind multiple points at a set angle. The winding tension is controlled at 25N±2N to ensure uniform fiber distribution. The winding is at least two layers, and each layer is pre-cured with infrared after winding. In step S2, carbon fiber is oriented and laid up, and the thickness of the carbon fiber layup is increased at the outer edge of the rotor and in the stress concentration area to improve the local tensile strength. In step S3, the maximum temperature of the autoclave is 130℃, the pressure is 0.6MPa, and the temperature is maintained for 3 to 4 hours; In step S4, excess material on the surface of the semi-finished product is removed by precision milling, so that the rotor core body and carbon fiber rotor shell of the semi-finished product form an integrated structure. In step S5, paint is sprayed on the upper surface and outer periphery of the semi-finished product. The functional performance of the paint layer needs to meet the standards and be resistant to weak acids and alkalis.

[0008] With the solution of this invention, the rotor core body is obtained by one-time stamping of carbon fiber material, and the outer periphery of the rotor core body is covered with a carbon fiber rotor shell, the carbon fiber density being approximately 1.5–1.8 g / cm³. 3 It is only about 60% the weight of aluminum alloy; the moment of inertia is significantly reduced, the start-up and shutdown speeds are faster, the single centrifugation cycle can be shortened, and the energy consumption of the equipment is reduced; moreover, the specific strength of carbon fiber material is far greater than that of aluminum alloy, the deformation at high speed is minimal, and because the rotor core body is formed by one-time stamping and the carbon fiber rotor shell is set in the centrifugation stress concentration area on the outer periphery of the rotor core body, the dynamic balance stability is stronger, which can ensure the consistency of centrifugation accuracy; the carbon fiber structure has excellent damping and vibration reduction performance, which can absorb the vibration energy during rotation, resulting in lower operating noise and a significant reduction in the impact of vibration on samples; it reduces the overall mass of the rotor while ensuring the dynamic balance of the rotor at high speed and ensuring damping and vibration reduction. Attached Figure Description

[0009] Figure 1 This is a three-dimensional schematic diagram of the high-speed centrifuge rotor of the present invention; Figure 2 A cross-sectional view of a high-speed centrifuge employing the high-speed centrifuge rotor of the present invention; The names corresponding to the serial numbers in the diagram are as follows: Rotor inner core body 10, connecting shaft sleeve mounting hole 11, centrifugal cup mounting and positioning cavity 12, ventilation channel 13, carbon fiber rotor shell 20, bottom stop ring 21, covering sleeve 22; High-speed centrifuge rotor 100, metal sleeve 200, metal shaft 300, rotor carbon fiber top cover 400, rotor cover stainless steel handle 500. Detailed Implementation

[0010] High-speed centrifuge rotor, see Figure 1 It includes: The rotor inner core body 10 has a central shaft connected to a bushing mounting hole 11. The upper surface of the rotor inner core body 10 is also surrounded by several concave centrifugal cup mounting and positioning cavities 12. Corresponding ventilation channels 13 are also arranged on the rotor inner core body 10. And carbon fiber rotor housing 20; The rotor core body 10 is made of carbon fiber material and is formed by one-time stamping. The outer periphery of the rotor core body 10 is covered with a carbon fiber rotor shell 20.

[0011] In a specific embodiment, the carbon fiber rotor housing 20 includes a bottom stop ring 21 and a covering sleeve 22 that conforms to the outer periphery of the rotor inner core body 10. The bottom stop ring 21 is located on the radially outer side of the lower surface of the rotor inner core body 10, and the covering sleeve 22 wraps around the outer periphery of the rotor inner core body 10. When the rotor inner core body 10 is stamped, a covering area is reserved on the radially outer side of its lower surface. The bottom stop ring 21 covers the covering area, and finally, the inner side of the lower surface is formed into an integral plane through precision milling.

[0012] The manufacturing method of a high-speed centrifuge rotor includes the following steps: S1 rotor inner core body is molded as a single piece; The material is T800 grade carbon fiber cloth with a product density of 1.6 g / cm3. During the one-piece molding process, the shape of the rotor core, the bushing mounting hole, the centrifuge cup mounting and positioning, and the ventilation channel are all formed in one step, without the need for subsequent splicing processing. This avoids the stress concentration and uneven mass distribution problems caused by cutting and welding in the processing of aluminum alloy rotors. The dynamic balance accuracy of the carbon fiber rotor can reach the micron level at the factory. The vibration amplitude is extremely low at high speed, which is fully compatible with the stringent requirements of blood centrifugation for speed stability and prevents the sample from being damaged by vibration. S2 winds carbon fiber cloth around the outer periphery of the rotor inner core body, so that the carbon fiber cloth winds to form a carbon fiber rotor shell. It uses a five-axis winding machine to rotate 30° at multiple points for winding, and the winding tension is controlled at 25N±2N to ensure uniform fiber distribution. The winding is done in two layers, and each layer is pre-cured by infrared after winding. The temperature of the five-axis winding equipment was set at 80℃ to enhance interlayer bonding. During winding, carbon fiber is laid in a directional manner, and the thickness of the carbon fiber layup is increased at the outer edge of the rotor and in the stress concentration area to improve the local tensile strength; After the S3 is completed and wrapped, it is placed in a hot autoclave and a semi-finished product is formed by a stepped temperature curing process. The maximum temperature of the hot autoclave is 130℃, the pressure is 0.6MPa, and the heat is maintained for 4 hours. S4 removes the semi-finished product and performs precision milling to ensure that the semi-finished product meets the processing requirements; Excess material on the surface of the semi-finished product is removed by precision milling, so that the rotor core body and the carbon fiber rotor shell of the semi-finished product are integrated into one structure. S5 surface coating; The upper surface and outer perimeter of the semi-finished product are painted. The functional performance of the paint layer must meet the standards and be resistant to weak acids and alkalis. The outer ring and outer perimeter of the upper surface of the finished product must achieve a Grade A appearance. The inner area of ​​the upper surface of the finished product must achieve a Grade B appearance.

[0013] Its innovative characteristics are analyzed as follows: The rotor core is integrally molded to ensure the rotor's dynamic balance accuracy. This avoids the stress concentration and uneven mass distribution problems caused by cutting and welding in traditional metal rotor processing. The dynamic balance accuracy of the finished product can reach the micron level. The vibration amplitude is extremely low at high speeds, which is fully compatible with the stringent requirements of blood centrifugation for speed stability and prevents the sample from being damaged by vibration. This allows a smooth, non-porous, and dense protective layer to be formed on the rotor surface. Bloodstains can be removed simply by wiping during cleaning, eliminating the need for complicated disinfection processes, thus reducing maintenance costs and the probability of cross-contamination. When winding carbon fiber cloth, the carbon fiber is laid in an oriented manner to enhance the anti-centrifugal force performance at high speeds. In the process, the carbon fiber can be laid in an oriented manner at an angle according to the stress characteristics of the rotor (such as the edge where the centrifugal force is the greatest): the thickness of the carbon fiber layup is increased at the outer edge of the rotor and in stress concentration areas to improve the local tensile strength and ensure that the rotor will not creep, deform or crack under high-speed conditions above 30,000 r / min. Compared with the problem of "insufficient overall rigidity" of aluminum alloy rotors, the limiting speed of carbon fiber foam rotors is increased by more than 50%, and the safety redundancy is higher, avoiding equipment safety hazards at high speeds. The material utilization rate of the molding process can reach over 90%, which is much higher than that of aluminum alloy rotor cutting (material utilization rate is only 50%~60%), thus reducing waste generation; In the outer layer winding process of carbon fiber rotors for blood centrifuges, carbon fiber bundles are typically wound at a specific angle onto the outer surface of the rotor core, and then cured to form a dense reinforcing layer. The core advantages of this process are as follows: 1. Targeted reinforcement of centrifugal force to increase rotor limit speed: When the rotor of a blood centrifuge rotates at high speed, the outer edge bears the greatest centrifugal force and is the part most prone to deformation or breakage. The outer layer winding can be designed by adjusting the winding angle of the carbon fiber so that the fiber direction is consistent with the direction of the centrifugal force. The ultra-high tensile strength (3-7 GPa) of carbon fiber can be used to directly resist the tensile stress of the outer edge. 2. Enhanced impact and fatigue resistance, extending rotor life: Blood centrifuge rotors may be subjected to certain impact loads during loading, unloading, transportation, or abnormal start-up and shutdown, and long-term high-speed operation may also cause fatigue damage: The outer layer of wrapped carbon fiber can effectively disperse impact energy and prevent local cracking of the rotor core; the fatigue resistance of carbon fiber far exceeds that of metals and pure foam materials, and it can withstand tens of thousands of high-speed start-up and shutdown cycles, increasing the rotor's service life to 2 to 3 times that of aluminum alloy rotors.

[0014] The high-speed centrifuge, assembled from high-speed centrifuge rotors, has the following structure: Figure 2 It includes a high-speed centrifuge rotor 100, a metal sleeve 200, a metal shaft 300, a carbon fiber rotor cover 400, and a stainless steel handle for the rotor cover 500. When applied to a blood centrifuge, its beneficial effects are as follows: Significantly reduce energy consumption and save operating costs Lightweight design reduces drive energy consumption; rotor density is controlled at 1.5–1.8 g / cm³. 3 It is only 60% of the weight of aluminum alloy, and the rotational moment of inertia is greatly reduced; no high-power drive is required during the start-up and shutdown of the centrifuge, and the power consumption of a single centrifugation cycle is reduced by 30% to 50%; during long-term continuous operation, the total energy consumption of the equipment can be reduced by more than 25%.

[0015] Improve blood centrifugation yield and increase equipment turnover rate The rapid start-stop, short centrifugation cycle, and low moment of inertia characteristics reduce the time for the rotor to reach the target speed (10,000–30,000 r / min) by 40%–60%, and the braking and stopping time by more than 50%. The total time for a single centrifugation operation is reduced by 20%–30%, and the number of blood samples that the equipment can process per day is increased by more than 25%, directly improving productivity. Improve the purity of blood component separation and ensure sample activity Low vibration reduces sample damage. Vibration during high-speed rotation of aluminum alloy rotors can easily cause red blood cell rupture and platelet activation, leading to impurities in serum / plasma. The vibration reduction performance of the rotor in this invention can reduce the sample damage rate by 60% to 80%, increase the purity of the separated serum by 15% to 20%, and increase the platelet activity retention rate by more than 25%. Dynamic balance stability ensures separation accuracy. The integrated inner core molding + outer layer winding process avoids the dynamic balance instability problem caused by the processing stress of aluminum alloy rotors. The speed fluctuation is controlled within ±5r / min, the sedimentation and stratification boundaries of different blood components are clear, and the separation purity is significantly better than that of traditional metal rotors.

[0016] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0017] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-speed centrifuge rotor, characterized in that, It includes: The rotor inner core body has a central shaft connected to a bushing mounting hole. The upper surface of the rotor inner core body is also surrounded by several recessed centrifugal cup mounting and positioning cavities. Corresponding ventilation channels are also arranged on the rotor inner core body. And the carbon fiber rotor housing; The rotor core is formed by one-time stamping of carbon fiber material, and the outer periphery of the rotor core is covered by a carbon fiber rotor shell.

2. The high-speed centrifuge rotor according to claim 1, characterized in that: The carbon fiber rotor housing includes a bottom stop ring and a covering sleeve that conforms to the outer periphery of the rotor inner core body. The bottom stop ring is located radially outside the lower surface of the rotor inner core body, and the covering sleeve wraps around the outer periphery of the rotor inner core body.

3. A method for manufacturing a high-speed centrifuge rotor, used to manufacture the high-speed centrifuge rotor as described in claim 1 or 2, characterized in that, It includes the following steps: S1 rotor inner core body is molded as a single piece; S2 winds carbon fiber cloth around the outer periphery of the rotor inner core body, so that the carbon fiber cloth winds to form a carbon fiber rotor shell. After S3 is completed and wrapped, it is placed in an autoclave and a semi-finished product is formed by a stepped temperature curing process. S4 removes the semi-finished product and performs precision milling to ensure that the semi-finished product meets the processing requirements; S5 surface coating.

4. The method for manufacturing a high-speed centrifuge rotor as described in claim 3, characterized in that... In step S1, carbon fiber cloth is selected as the material. During the one-piece molding process, the shape of the rotor core body, the bushing mounting hole, the centrifugal cup mounting and positioning, and the ventilation channel are all formed in one step without the need for subsequent splicing processing.

5. The method of using the high-speed centrifuge rotor according to claim 3, characterized in that: In step S2, a five-axis winding machine is used to wind multiple points at a set angle. The winding tension is controlled at 25N±2N to ensure uniform fiber distribution. The winding is at least two layers, and each layer is pre-cured with infrared after winding.

6. The method for manufacturing a high-speed centrifuge rotor according to claim 5, characterized in that: Directional carbon fiber layup is used, and the thickness of the carbon fiber layup is increased at the outer edge of the rotor and in stress concentration areas to improve local tensile strength.

7. The method for manufacturing a high-speed centrifuge rotor according to claim 3, characterized in that: In step S3, the autoclave has a maximum temperature of 130°C and a pressure of 0.6 MPa, and is kept at that temperature for 3 to 4 hours.

8. The method for manufacturing a high-speed centrifuge rotor according to claim 3, characterized in that: In step S4, excess material on the surface of the semi-finished product is removed by precision milling, so that the rotor core body and the carbon fiber rotor shell of the semi-finished product form an integrated structure.

9. The method for manufacturing a high-speed centrifuge rotor according to claim 3, characterized in that: In step S5, paint is sprayed on the upper surface and outer periphery of the semi-finished product. The functional performance of the paint layer needs to meet the standards and be resistant to weak acids and alkalis.

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