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At least 757 records · Page 42

Electronically and ionically conductive porous material and method for manufacture of resin wafers therefrom

An electrically and ionically conductive porous material including a thermoplastic binder and one or more of anion exchange moieties or cation exchange moieties or mixtures thereof and/or one or more of a protein capture resin and an electrically conductive material. The thermoplastic binder immobilizes the moieties with respect to each other but does not substantially coat the moieties and forms the electrically conductive porous material. A wafer of the material and a method of making the material and wafer are disclosed.

36 MATERIALS SCIENCE↗

Sealed substrate carrier for electroplating

One embodiment relates to a substrate carrier for use in electroplating a plurality of substrates. The substrate carrier includes a non-conductive carrier body on which the substrates are held, and conductive lines are embedded within the carrier body. A conductive bus bar is embedded into a top side of the carrier body and is conductively coupled to the conductive lines. A thermoplastic overmold covers a portion of the bus bar, and there is a plastic-to-plastic bond between the thermoplastic overmold and the non-conductive carrier body. Other embodiments, aspects and features are also disclosed.

42 ENGINEERING↗

Condensation Risk of Mechanically Attached Roof Systems in Cold Climate Zones

A white roof, cool roof, is constructed to decrease thermal loads from solar radiation, therefore saving energy by decreasing the cooling demands. Unfortunately, cool roofs with mechanically attached membrane, have shown to have a higher risk of intermediate condensation in the materials below the membrane in certain climates (Ennis & Kehrer, 2011) and in comparisons with similar construction with a darker exterior surface (Bludau, Zirkelbach, & Kuenzel, 2009). As a consequence, questions have been raised regarding the sustainability and reliability of using cool roof membranes in Northern U.S. climate zones. A white roof surface reflects more of the incident solar radiation in comparisons with a dark surface, which makes a distinguished difference on the surface temperature of the roof. However, flat roofs with either a light or dark surface and if facing a clear sky, are constantly losing energy to the sky due to the exchange of infrared radiation. This phenomenon exists both during the night and the day. During the day, if the sun shines on the roof surface, the exchange of infrared radiation typically becomes insignificant. During nights and in cold climates, the temperature difference between the roof surface and the sky can deviate up to 20 C (Hagentoft, 2001) which could result in a very cold surface temperature compared to the ambient temperature. Further, a colder surface temperature of the roof increases the energy loss and the risk of condensation in the building materials below the membrane. In conclusion, both light and dark coated roof membranes are cooled by the infrared radiation exchange during the night, though a darker membrane is more heated by the solar radiation during the day, thus decreasing the risk of condensation. The phenomenon of night time cooling from the sky and the lack of solar gains during the day is not likely the exclusive problem concerning the risk of condensation in cool roofs with mechanically attached membranes. Roof systems with thermoplastic membranes are prone to be more effected by interior air intrusion into the roof construction; both due to the wind induced pressure differences and due to the flexibility and elasticity of the membrane (Molleti, Baskaran, Kalinger, & Beaulieu, 2011). Depending on the air permeability of the material underneath the membrane, wind forces increase the risk of fluttering (also referred as billowing) of the thermoplastic membrane. Expectably, the wind induced pressure differences creates a convective air flow into the construction i.e. Page 2 air intrusion. If the conditions are right, moisture from the exchanging air may condensate on surfaces with a temperature below dew-point. The definite path of convective airflows through the building envelope is usually very difficult to determine and therefore simplified models (K nzel, Zirkelbach, & Scfafaczek, 2011) help to estimate an additional moisture loads as a result of the air intrusion. The wind uplifting pressure in combination with wind gusts are important factors for a fluttering roof. Unfortunately, the effect from a fluctuating wind is difficult to estimate as this is a highly dynamic phenomenon and existing standards (ASTM, 2011a) only take into account a steady state approach i.e. there is no guidance or regulations on how to estimate the air intrusion rate. Obviously, a more detailed knowledge on the hygrothermal performance of mechanically attached cool roof system is requested; in consideration to varying surface colors, roof air tightness, climate zones and indoor moisture supply.

Pallin, Simon B↗

A Model for Fiber Length Attrition in Injection-Molded Long-Fiber Composites

Long-fiber thermoplastic (LFT) composites consist of an engineering thermoplastic matrix with glass or carbon reinforcing fibers that are initially 10 to 13 mm long. When an LFT is injection molded, flow during mold filling orients the fibers and degrades the fiber length. Fiber orientation models for injection molding are well developed, and special orientation models for LFTs have been developed. Here we present a detailed quantitative model for fiber length attrition in a flowing fiber suspension. The model tracks a discrete fiber length distribution (FLD) at each spatial node. Key equations are a conservation equation for total fiber length, and a breakage rate equation. The breakage rate is based on buckling of fibers due to hydrodynamic forces, when the fibers are in unfavorable orientations. The FLD model is combined with a mold filling simulation to predict spatial and temporal variations in fiber length distribution in a mold cavity during filling. The predictions compare well to experiments on a glassfiber/ PP LFT molding. Fiber length distributions predicted by the model are easily incorporated into micromechanics models to predict the stress-strain behavior of molded LFT materials. Author to whom correspondence should be addressed; electronic mail: ctucker@illinois.edu 1

TuckerIII, Charles L.↗

High rate fabrication of compression molded components

A method for fabricating a thermoplastic composite component comprises inductively heating a thermoplastic pre-form with a first induction coil by inducing current to flow in susceptor wires disposed throughout the pre-form, inductively heating smart susceptors in a molding tool to a leveling temperature with a second induction coil by applying a high-strength magnetic field having a magnetic flux that passes through surfaces of the smart susceptors, shaping the magnetic flux that passes through surfaces of the smart susceptors to flow substantially parallel to a molding surface of the smart susceptors, placing the heated pre-form between the heated smart susceptors; and applying molding pressure to the pre-form to form the composite component.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Flame-retardant copolymers of dialkyl (meth)acryloyloxyalkyl phosphate or dialkyl (meth)acryloyloxyalkyl phosphonate monomers and polymer foams based made therefrom

Polymer foam bodies are made from phosphorus-containing thermoplastic random copolymers of a dialkyl (meth)acryloyloxyalkyl phosph(on)ate. Foam bodies made from these copolymers exhibit increased limiting oxygen indices and surprisingly have good properties. In certain embodiments, the phosphorus-containing thermoplastic copolymer is blended with one or more other polymers and formed into nanofoams.

36 MATERIALS SCIENCE↗

Tailorable Adhesives for Multi-material Joining, Facile Repair and Re-assembly

Joining of materials and components is inevitable as it allows versatility in assembly and repair along with reduction in time and cost of manufacturing. This work uses ‘active adhesives’ that inherit all the benefits of bonded joints, such as lightweight, eliminate holes and associated stress-concentrations, and overcomes the shortcomings of disassembly and repair. Thermoplastic adhesives modified by the incorporation of electrically conductive graphene nanoplatelets at a concentration above the percolation point provide a unique synergy of mechanical, thermal and electrical properties. While the choice of the thermoplastic is governed by the desired application the addition of the graphene nanoplatelets allows energy to be deposited primarily in the adhesive. The percolated network of graphene particles in the adhesive at less than 2% can quickly couple to high frequency radiation (microwave, or MW) via non-contact methods and increase the adhesive temperature to above the required processing temperatures. The adhesive melts and flows over the adherends and upon cooling forms a structural adhesive bond. Furthermore, the process can be used to disassemble the adhesive joint if repair or reworking is required. In this work, the concept of aforementioned active adhesives was studied using varying graphene contents in nylon-6 adhesive. Activation and re-assembly was studied on in-plane (lap-shear) joints. Structural behavior of re-assembled joints was found to be similar to thermally bonded joints. Overall, active adhesives such as the ones attempted in this work have a great potential in a wide range of applications wherein in-situ repair, re-assembly and recyclability are essential.

36 MATERIALS SCIENCE↗

Large-scale additive manufacturing with reactive polymers

The focus on large-scale polymer Additive Manufacturing (AM) has previously been on thermoplastic materials. However, Magnum Venus Products (MVP) along with researchers at Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) are introducing a unique AM system capable of depositing reactive polymers in a large format. The system’s footprint is 4.88 m (16ft) x 2.44 m (8ft). The benefits of printing with reactive polymers rather than thermoplastic polymers include reduced dependence on temperature control of the process, chemical reactions across the bead-to-bead interfaces, and increased toolpath flexibility that is currently unattainable with existing large-scale systems. This flexible AM system can be used with a variety of polymers, and pre-processin and post-processing operations will be performed outside of the printer on a removable print bed. Examples of printed structures and machine capabilities leading to improved productivity of AM equipment are presented herein.

Lindahl, John↗

The Influence of Rheology on Melt Processing Conditions of Carbon Fiber Reinforced Polyetherimide for Big Area Additive Manufacturing

An approach is presented for determining the melt processing conditions of high temperature amorphous thermoplastics, specifically carbon fiber reinforced polyetherimide (PEI), for Big Area Additive Manufacturing (BAAM). PEI is a high performance thermoplastic that is attractive for various high temperature applications in the automotive and aircraft industry. For PEI to be processed successfully with BAAM, it must be stable over a range of temperatures and print conditions to ensure the final part possesses the desired strength and modulus. Under this approach, thermal properties are first analyzed to identify the lower and upper operating limits for the polymer and then extensive rheological characterization is carried out at selected temperatures within these bounds. This study investigates the effect of temperature, fiber loading, and processing environment on rheology in order to identify suitable process parameters for extruding carbon-fiber reinforced PEI on BAAM.

Ajinjeru, Christine↗

MODELLING FIBER ORIENTATION DURING ADDITIVE MANUFACTURING COMPRESSION MOLDING PROCESSES

The production of high-performance thermoplastic composites reinforced with short carbon fibers can be achieved by a novel “additive manufacturing-compression molding” technique. An advantage of such combination is two-fold: controlled fiber orientation in additive manufacturing and less void content by compression molding. In this study, a computational fluid dynamics model has been developed to predict the behavior of printed layers during fiber-reinforced thermoplastic extrusion and subsequent compression molding. The fiber orientation was modelled with a simple quadratic closure model. The interaction between the fibers is included using a rotary diffusion coefficient which becomes significant in concentrated regimes. Finally, the second order orientation tensor is coupled with the momentum equation as an anisotropic part of the stress term. The effect of processing parameters on the behavior of printed layers was investigated to determine the favorable printing scenarios. The developed numerical model enables design of high-performance composites with tunable mechanical properties.

Seta, Berin↗

Additive manufacturing method and assembly

Methods and assemblies for additive manufacturing portions of components with enhanced strength are provided. The assemblies comprise a first deposition head and an apparatus for causing one or more reinforcement fibers to extend more than two layers within previously-deposited layers of build material. The first deposition head is configured to deposit a plurality of layers of a filament comprising a reinforcement fiber and thermoplastic material. The apparatus may comprise a needle point configured to be inserted into the plurality of layers to displace the reinforcement fiber so that it extends two or more of the plurality of layers. The apparatus may additionally or alternatively comprise a second deposition head having a needle tip configured to be inserted into the plurality of layers to inject a length of a second filament comprising thermoplastic material and a reinforcement fiber so that the reinforcement fiber of the second filament extends two or more layers of the plurality of layers of the first filament.

Barr, Christian G.↗

All-acrylic multigraft copolymer superelastomers

Thermoplastic elastomer compositions comprising acrylic multigraft copolymers are described. The multigraft copolymers comprise a rubbery polyacrylate backbone and a plurality of randomly spaced glassy polyacrylate side chains. The multigraft copolymers can be prepared using a facile grafting through method that can provide copolymers with enhanced purity. The acrylic multigraft copolymers exhibit microphase separated morphologies and “superelastomeric” properties, including an elongation at break, stress at break, and/or strain recovery behavior that exceeds that of conventional triblock copolymer polyacrylate thermoplastic elastomers.

Mays, Jimmy W.↗

High resolution and high flexibility fiber optical cables and microfabrication methods for making same

The present disclosure relates to methods of forming a fiber optic core, and a fiber optic component with a highly uniform cladding covering the fiber optic core. In one microfabrication process a first sacrificial tubing is provided which has a predetermined inner diameter. A quantity of a curable polymer is also provided. The first sacrificial tubing is at least partially filled with the curable polymer. The curable polymer is then cured. The first sacrificial tubing is then removed to produce a finished fiber optic core. Additional operations may be performed by which the fiber optic core is placed inside a thermoplastic tubing, which is itself placed inside a sacrificial heat shrink. Heat is applied to reflow the thermoplastic tubing around the fiber optic core, thus forming a highly uniform thickness cladding. When the sacrificial heat shrink tubing is removed a finished fiber optic component is present. Additional microfabrication methods are disclosed which involve dip coating a pre-formed fiber optic core in a polymer, and then curing the polymer to form a finished fiber optic component with a uniform thickness cladding.

Kampasi, Komal↗

Wind Turbine Blade Repurposing and Recycling: Coupling Repurposing Methods with 3D Printing Technology

Fiber-reinforced thermoplastic composites continue to be implemented in several marketsbecause of their strength capacity and light weight. Especially in the wind industry, wind bladesare made of this material which makes them ideal for wind energy generation, but bladesbecome a problem at end-of-life. Because recycling thermoplastic composites technologiesare still not cost and environmentally effective, research in this space is needed. This paperpresents a case study for coupling repurposed wind turbine blades and 3D printing technology.The purpose is to remanufacture decommissioned wind blades into bus stop roof and seatingsections to then use recycled glass fiber from a decommissioned wind turbine blade to 3Dprint structural and/or fixtures needed in the assembly. We provide an overview of the designprocess, and the development process steps in repurposing and 3D printing the material,delving into key parameters required for a successful implementation.

Henao, Yulizza↗

Fabrication of Extruded Polyphenylsulfone – Boron Nitride Composite Tapes

Polyphenylsulfone (PPSU) is a high-temperature, chemically resistant thermoplastic with high impact resistance that is often used in interior aircraft cabin components, medical devices, and membranes. The aforementioned properties have led to interest investigating PPSU’s compatibility with hexagonal boron nitride (hBN) platelets as a thermally conductive, electrical composite insulator for high power-density electric machines. Preliminary trials extruding PPSU-hBN composite tapes showed promising dielectric properties and higher thermal conductivity as a function of hBN concentration compared to their neat analog. On the other hand, only few studies have reported on the extrusion process and resulting thermo-mechanical properties for PPSU and its composites made with chopped fiber reinforcement or fillers, none of which containing boron nitride filler. Prospects may exist for this type of material to be incorporated into extrusion-based additive manufacturing techniques to print other composites bearing unique properties useful for aerospace. Loading levels with up to approximately 23 wt% were achieved using micro-size BN platelets without observing any significant affects to PPSU’s glass-transition temperature. This work includes a description of the rheological properties of PPSU, the extrusion parameters for mixing and compounding the PPSU-hBN composite tapes, and the thermal and thermo-mechanical properties of PPSU-hBN composites.

polyphenylsulfone↗

Hydrothermal Conditioning of Physical Hydrogels Prepared from a Midblock-Sulfonated Multiblock Copolymer

Since nanostructured amphiphilic macromolecules capable of affording high ion and water transport are becoming increasingly important in a wide range of contemporary energy and environmental technologies, the swelling kinetics and temperature dependence of water uptake are investigated in a series of midblock-sulfonated thermoplastic elastomers. Upon self-assembly, these materials maintain a stable hydrogel network in the presence of a polar liquid. In this study, real-time water-sorption kinetics in copolymer films prepared by different casting solvents are elucidated by synchrotron small-angle X-ray scattering and gravimetric measurements, which directly correlate nanostructural changes with macroscopic swelling to establish fundamental structure-property behavior. By monitoring the equilibrium swelling capacity of these materials over a range of temperatures, an unexpected transition in the vicinity of 50 degrees C has been discovered. Furthermore, depending on copolymer morphology and degree of sulfonation, hydrothermal conditioning of specimens to temperatures above this transition permits retention of superabsorbent swelling at ambient temperature.

36 MATERIALS SCIENCE↗

On the strength of transversely isotropic rocks: On the strength of transversely isotropic rocks

Accurate prediction of strength in rocks with distinct bedding planes requires knowledge of the bedding plane orientation relative to the load direction. Thermal softening adds complexity to the problem since it is known to have significant influence on the strength and strain localization properties of rocks. In this paper, we utilize a recently proposed thermoplastic constitutive model appropriate for rocks exhibiting transverse isotropy in both the elastic and plastic responses to predict their strength and strain localization properties. Recognizing that laboratory-derived strengths can be influenced by material and geometric inhomogeneities of the rock samples, we consider both stress-point and boundary-value problem simulations of rock strength behavior. Both plane strain and 3D loading conditions are considered. Results of the simulations of the strength of a natural Tournemire shale and a synthetic transversely isotropic rock suggest that the mechanical model can reproduce the general U-shaped variation of rock strength with bedding plane orientation quite well. We show that this variation could depend on many factors, including the stress loading condition (plane strain versus 3D), degree of anisotropy, temperature, shear-induced dilation versus shear-induced compaction, specimen imperfections, and boundary restraints, among others.

42 ENGINEERING↗

Reliability in the characterization of fiber length distributions of injection molded long carbon fiber composites

The mechanical properties of a discontinuous fiber reinforced composite material are dependent on the length of the reinforcing fibers. Long-fiber thermoplastic (LFT) composites offer a compromise between ease of manufacture and mechanical properties for structural applications and are conventionally made using fibers that are initially 10–14 mm long. However, fiber attrition during the injection molding process significantly reduces the final fiber lengths in molded composite and produces a fiber length distribution (FLD), which depends on the processing parameters. Thus, accurate FLD measurements are important for reliable predictions of the composite properties. Here, we present a detailed methodology for experimentally measuring the FLD in LFT composites based on best practices. Possible biases occurring during the measurement process are discussed and their effect on the measured FLD and averaged fiber length values are evaluated. We then employ a Mori–Tanaka implementation of the Eshelby model to predict the elastic stiffness of the LFT composite and analyze the sensitivity of the stiffness values to the biases in the FLD measurements.

long-fiber thermoplastics, injection molding, fibe↗