Mixing and Thermal Transport Behavior in a Pin or Non-Pin Extruder Equipped with a Field Synergy Elongation Screw.

The ductile forming process of a polymer in a standard screw extruder and pin-barrel extruder, equipped with or without a field synergy elongation screw, was investigated by the finite element method. In order to assess the mixing and heat transfer capabilities of screws, characteristic parameters such as the mixing efficiency, segregation scale, and temperature distribution of different structures were analyzed and compared. The results indicated that the flow pattern of the polymer melt in the extruder was significantly influenced by the screw structure and was improved by the newly designed field synergy screw configuration, which brought a desirable elongational flow to enhance the radial convection. This was attributed to the unique radial wedge-shaped repeated convergence region of the field synergy elongation screw, increasing the synergistic effect between the velocity field, velocity gradient field, and temperature gradient field and thus improving the heat transfer and mixing efficiency. After adding barrel pins, the flow was forced to split, resulting in a more significant stretching effect on the melt. The field synergy effect in the pin mixed region was strengthened, which further increased the heat and mass transfer efficiency of the screw. However, increasing barrel pins could also lead to undesired temperature fluctuation and flow resistance, which have a negative impact on the melt uniformity. This study offers an important reference for optimizing screw structure to obtain strong mixing and heat transfer performances.

Formulation and Performance of NBR/CR-Based High-Damping Rubber Composites for Soundproof Using Orthogonal Test.

Multiple functional-material-filled nitrile butadiene rubber/chloroprene rubber (NBR/CR) acoustic composites were extensively studied and prepared. According to the orthogonal test table L25 (56), 25 groups of samples were prepared by using a low-temperature one-time rubber mixing process. With tensile strength, average transmission loss, and damping peak as indexes, the influence degree of different factors and levels on the properties of acoustic composites was quantitatively discussed and analyzed. The matrix weight analysis was employed to optimize the material formula of rubber composites, and the corresponding influence weight was given. Results showed that the acoustic composite with blending ratio of 70/30 for NBR/CR matrix had preferable mechanical and acoustic properties; adding mica powder (MP) and montmorillonite (MMT) in matrix contributed to improve all above three indexes owing to their specific lamellar structures; hollow glass beads (HGB) had a positive influence on improving acoustic property due to its hollow microcavities, however, it had a negative impact on damping property because of the smooth spherical surfaces. Accordingly, the optimal formulation was found to be NBR/CR blending ratio of 70/30, MP of 10 phr (per hundred rubber), HGB of 4 phr, and MMT of 10 phr.

Design and Ductile Behavior of Torsion Configurations in Material Extrusion to Enhance Plasticizing and Melting.

In the present work, the ductile formation mechanism of a newly proposed torsion configuration has been investigated. One of the unique attributes of this paper is the first-time disclosure of the design and fabrication of a novel prototype screw with torsional flow character validating the orthogonal test model experimentally. The torsional spiral flow patterns that occurred in the torsion channel cause a ductile deformation of polymer in the form of a spiral, which in turn enhances the radial convection, achieving an effective mass transfer of material from the top region to the bottom region and vice versa. Furthermore, the characteristic parameters of torsion configuration have a significant influence on the plasticizing and melting capability of polymer. By range analysis and weight matrix analysis, the best factor and level combination was obtained. Results indicated that the aspect ratio of the torsion channel is almost equal to 1, and the plasticizing and melting capability of polymer is optimal. This novel design innovation offers a paradigm shift in the energy-efficient plasticization of polymer compounds.

Enhancing Mixing and Thermal Management of Recycled Carbon Composite Systems by Torsion-Induced Phase-to-Phase Thermal and Molecular Mobility.

A novel torsion screw has been proposed to resolve the inadequate control of mass transfer and the thermal management of two component polymer blends and their carbon fiber composites. The novel torsional screw distinctly introduced radial flow in the torsion screw channel, which is a significant improvement over the flow pattern developed by the conventional screw. The heat transfer and mixing behavior of melt mixtures are enhanced by adapting screws with torsion elements compared with the traditional screw elements. Heat transfer efficacy in the polypropylene-polystyrene bi-phasic extrusion process improved with the increase in torsion element numbers. An increased number of newly designed torsional elements also improved the dispersion of minor phase in bi-phase polypropylene-polystyrene composition and their carbon fiber composites. The unique flow pattern induced by the torsion elements shows a synergistic effect on the melt-phase mass flow and the thermal flow field facilitating phase-to-phase thermal and molecular mobility and enhanced fiber orientation, crystallinity and mechanical properties of composite made from recycled carbon fiber/polypropylene. Microtomographs of recycled carbon fiber demonstrated the extraordinary ability of a torsion screw element to orient carbon fiber in both axial and radial directions.

Application of Biodegradable and Biocompatible Nanocomposites in Electronics: Current Status and Future Directions.

With the continuous increase in the production of electronic devices, large amounts of electronic waste (E-waste) are routinely being discarded into the environment. This causes serious environmental and ecological problems because of the non-degradable polymers, released hazardous chemicals, and toxic heavy metals. The appearance of biodegradable polymers, which can be degraded or dissolved into the surrounding environment with no pollution, is promising for effectively relieving the environmental burden. Additionally, biodegradable polymers are usually biocompatible, which enables electronics to be used in implantable biomedical applications. However, for some specific application requirements, such as flexibility, electric conductivity, dielectric property, gas and water vapor barrier, most biodegradable polymers are inadequate. Recent research has focused on the preparation of nanocomposites by incorporating nanofillers into biopolymers, so as to endow them with functional characteristics, while simultaneously maintaining effective biodegradability and biocompatibility. As such, bionanocomposites have broad application prospects in electronic devices. In this paper, emergent biodegradable and biocompatible polymers used as insulators or (semi)conductors are first reviewed, followed by biodegradable and biocompatible nanocomposites applied in electronics as substrates, (semi)conductors and dielectrics, as well as electronic packaging, which is highlighted with specific examples. To finish, future directions of the biodegradable and biocompatible nanocomposites, as well as the challenges, that must be overcome are discussed.