High Consistency Silicone Rubber Foams.

Silicone elastomers are high-performance plastics. In the extrusion process, only high-consistency silicone rubbers were used. In order to reduce the cost and weight, silicone rubbers can be foamed during processing. In this study, high-consistency silicone rubber is processed with different physical and chemical blowing agents. The resulting reaction kinetics, as well as the mechanical and morphological properties, had been investigated and compared with each other. This showed that the chemical blowing agent significantly influenced the crosslinking reaction compared to the microspheres and the water/silica mixture tested, but it also achieved the lowest density compared to the physical blowing agents. When evaluating the foam morphology, it became clear that the largest number of pores was achieved with the microspheres and the largest pores when using the water/silica mixture. Furthermore, it has been shown that the different mechanisms of action of the blowing agents have a major influence on the mechanical properties, such as the micro shore hardness and the foam morphology.

Analysis of the Similarity between Injection Molding Simulation and Experiment.

In the plastics industry, CFD simulation has been used for many years to support mold design. However, using simulation as a substitute for experimentation remains a major challenge to this day. This is due to the unknown congruence between simulation and experiment. The present work focuses on a comparison between simulation (generated with the software Moldflow Insight Ultimate from Autodesk Inc., San Francisco, CA, USA) and experiment by using molds of different complexity, where, in contrast to a large number of previous investigations, both the characteristics of the parts and the time series of the process parameters were compared with each other. For this purpose, the high-resolution time series of the process parameters injection pressure, flow rate, and cavity pressure as well as the mass and the dimensions of the manufactured parts were acquired during the experiments and the results were compared with the computations obtained from the simulation. In addition, potential causes like the material data, mesh and solver parameter, and the machine-specific behavior were analyzed to assess which of these causes may be decisive for a deviation between simulation and experiment.

UVC Irradiation as a Surface Treatment of Polycarbonate to Generate Adhesion to Liquid Silicone Rubber in an Overmolding Process.

This study investigates the adhesion properties of polycarbonate (PC) and liquid silicone rubbers (LSR) through surface activation using ultraviolet C (UVC) radiation. While self-adhesive LSRs adhere easily to certain thermoplastic composites such as polybutylene terephthalate (PBT) and polyamides (PAs), bonding to PC typically requires surface treatment due to the lack of compatible functional groups. Previous methods like plasma or flame treatment have been effective, but the use of UVC radiation for surface activation remains unexplored. Through experiments, it was found that UVC surface activation, particularly with ozone-generating lamps, significantly enhances the peel strength between PC and self-adhesive LSRs. The study evaluates the impact of different irradiation times and lamp configurations on peel resistance, surface energy, and composite stability. Results show that UVC/ozone (wavelengths 254 nm and 185 nm) activation increases peel resistance, with distinct differences observed between LSR types. Additionally, the study examines the stability of UVC activation over time and under various storage conditions, highlighting its effectiveness for up to 36 months at room temperature. Furthermore, the relationship between surface energy and peel strength is analyzed, finding that UVC/ozone activation increases surface energy but does not consistently correlate with improved adhesion. The study concludes with a comparison of UVC/ozone activation to alternative surface treatment methods, emphasizing its advantages such as cost-effectiveness and stability while considering limitations regarding substrate compatibility and occupational safety aspects. Overall, UVC/ozone surface activation presents a promising approach for enhancing adhesion in PC-LSR composite systems and holds potential for applications across various industries.

Correlation between the activation energy of PLA respectively PLA/starch composites and mechanical properties with regard to differ accelerated aging conditions.

Within this research semi-crystalline polylactide and composites with 50 wt.% native potato starch were compounded and injection molded. The material was mechanically characterized by tensile, three-point bending, and Charpy impact tests. These tests were carried out in the freshly molded state and after 332 and 792 h of storage at accelerated temperature or humidity. The respective activation energy was calculated by applying the Flynn-Wall-Ozawa method. The focus of the study was to investigate the correlation between the activation energy and the related mechanical and thermal properties. The results showed that the addition of native potato starch as a filler prevents the decrease in activation energy over the course of the experiments. Thus, the PLA/starch composite is more resistant to the two aging conditions than the pure PLA. When considering the mechanical properties, the pure PLA showed a large deviation of results compared to the initial value in a range of +63.88% to -33.96% with regard to the respective aging conditions, whereas the PLA/starch composite properties nearly always remained at the initial values. Through the investigation of the mechanical and thermal properties, it was shown that the steady activation energies are consistent with the mechanical properties, as these have shown only a small deviation of the mechanical properties during the duration of experiments for the PLA/starch composite.

MC-Injection Molding with Liquid Silicone Rubber (LSR) and Acrylonitrile Butadiene Styrene (ABS) for Medical Technology.

The multicomponent injection molding of liquid silicone rubbers (LSR) with thermoplastics, such as polybutylene terephthalate (PBT) or polyamide (PA), is a state-of-the-art technique and is used in the manufacturing process for many components in the automotive industry and in the field of sanitary engineering. Standard thermoplastics, such as acrylonitrile butadiene styrene (ABS), cannot be bonded with silicone rubbers in injection molding because of their low heat deflection temperature. In this study, we investigated ABS grades approved for medical applications to show how dynamic mold heating and various pretreatment methods for thermoplastic surfaces can be used to produce ABS-LSR test specimens. In addition, such components' sterilization effect on the adhesive bond will be shown.

Influence of Ethylene Oxide and Gamma Irradiation Sterilization Processes on the Properties of Poly-L-Lactic-Acid (PLLA) Materials.

In order to encourage the substitution of petrochemical polymers in medical technology with sustainable, bio-based materials, there is an urgent need for further investigations, especially data regarding their sterility performance. Within the scope of the investigations, selected material properties of poly-L-lactic-acid (PLLA), a specific type of poly(lactic-acid) (PLA), were analyzed before and after sterilization (using ethylene oxide or gamma irradiation) in order to investigate deviations in its chemical structure, wettability, optical, and mechanical properties. In particular, parameters such as molecular weight, complex viscosity, tensile strength, water contact angle, and color were discussed. Sterilization temperatures close to the glass transition of PLA, high humidity, and interactions with the ethylene oxide molecules have resulted in an increase in crystallinity, a decrease in elongation at break, and in some cases, a variation in wettability. As a consequence of exposure to high-energy radiation, the material's toughness is reduced due to chain scission, which is manifested through a decrease in molecular weight, an increase in crystallinity, and a partial change in surface energy. For the selected PLLA-materials (Luminy® L130, NP HT 202, and NP HT 203), ethylene oxide sterilization resulted in a comparatively minor variation in the characteristics behavior, and was chosen as the preferred method.

Emission and Mechanical Properties of Glass and Cellulose Fiber Reinforced Bio-Polyamide Composites.

Climate change, access, and monopolies to raw material sources as well as politically motivated trade barriers are among the factors responsible for a shortage of raw materials. In the plastics industry, resource conservation can be achieved by substituting commercially available petrochemical-based plastics with components made from renewable raw materials. Innovation potentials are often not used due to a lack of information on the use of bio-based materials, efficient processing methods, and product technologies or because the costs for new developments are too high. In this context, the use of renewable resources such as fiber-reinforced polymeric composites based on plants has become an important criterion for the development and production of components and products in all industrial sectors. Bio-based engineering thermoplastics with cellulose fibers can be used as substitutes because of their higher strength and heat resistance, but the processing of this composite is still challenging. In this study, composites were prepared and investigated using bio-based polyamide (PA) as a polymer matrix in combination with a cellulosic fiber and, for comparison purposes, a glass fiber. A co-rotating twin-screw extruder was used to produce the composites with different fiber contents. For the mechanical properties, tensile tests and charpy impact tests were performed. Compared to glass fiber, reinforced PA 6.10 and PA 10.10, a significantly higher elongation at break with regenerated cellulose fibers, can be achieved. PA 6.10 and PA 10.10 achieve significantly higher impact strengths with the regenerated cellulose fibers than the composites with glass fibers. In the future, bio-based products will also be used in indoor applications. For characterization, the VOC emission GC-MS analysis and odor evaluation methods were used. The VOC emissions (quantitative) were at a low level but the results of the odor tests of selected samples showed values mostly above the required limit values.

The Influence of Thermal and Mechanical Stress on the Electrical Conductivity of ITO-Coated Polycarbonate Films.

The influence of thermomechanical stress on the conductivity of indium tin oxide (ITO)-coated polycarbonate (PC) films was investigated. PC is the industry's standard material for window panes. ITO coatings on polyethylene terephthalate (PET) films are the main commercially available option; as such, most investigations refer to this combination. The investigations in this study aim to investigate the critical crack initiation strain at different temperatures and crack initiation temperatures for two different coating thicknesses and for a commercially available PET/ITO film for validation purposes. Additionally, the cyclic load was investigated. The results show the comparatively sensitive behavior of the PC/ITO films, with a crack initiation strain at room temperature of 0.3-0.4% and critical temperatures of 58 °C and 83 °C, with high variation depending on the film's thickness. Under thermomechanical loading, the crack initiation strain decreases with increasing temperatures.

Flexible Electrochromic Device on Polycarbonate Substrate with PEDOT:PSS and Color-Neutral TiO2 as Ion Storage Layer.

Electrochromic (EC) windows on glass for thermal and glare protection in buildings, often referred to as smart (dimmable) windows, are commercially available, along with rearview mirrors or windows in aircraft cabins. Plastic-based applications, such as ski goggles, visors and car windows, that require lightweight, three-dimensional (3D) geometry and high-throughput manufacturing are still under development. To produce such EC devices (ECDs), a flexible EC film could be integrated into a back injection molding process, where the films are processed into compact 3D geometries in a single automized step at a low processing time. Polycarbonate (PC) as a substrate is a lightweight and robust alternative to glass due to its outstanding optical and mechanical properties. In this study, an EC film on a PC substrate was fabricated and characterized for the first time. To achieve a highly transmissive and colorless bright state, poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) was used as the working electrode, while titanium dioxide (TiO2) was used as the counter electrode material. They were deposited onto ITO-coated PC films using dip- and slot-die coating, respectively. The electrodes were optically and electrochemically characterized. An ECD with a polyurethane containing gel electrolyte was investigated with regard to optical properties, switching speed and cycling behavior. The ECD exhibits a color-neutral and highly transmissive bright state with a visible light transmittance of 74% and a bluish-colored state of 64%, a fast switching speed (7 s/4 s for bleaching/coloring) and a moderately stable cycling behavior over 500 cycles with a decrease in transmittance change from 10%to 7%.

Analysis and Validation of Varied Simulation Parameters in the Context of Thermoplastic Foams and Special Injection Molding Processes.

The simulation solutions of different plastic injection molding processes are as multifaceted as the field of injection molding itself. In this study, the simulation of a special injection molding process, which generates partially foamed integral components, was parameterized and performed. This partial and physical foaming is realized by a defined volume expansion of the mold cavity. Using the injection molding simulation software Moldex 3D, this so-called Pull and Foam process was digitally reconstructed and simulated. Since the Pull and Foam process is a special injection molding technique for producing foamed components, the validity of the simulation results was analyzed and evaluated. With the use of Moldex 3D, varied settings such as different bubble growth models and mesh topologies were set, parameterized, and then analyzed, to provide differentiated numerical calculation solutions. Actual manufactured components represent the experimental part of this study and are produced for reference. Different evaluation methods were used to quantify morphological quantities such as porosities, local densities, and cell distributions. These methods are based on two-dimensional and three-dimensional imaging techniques such as optical microscopy and X-ray microtomography (µ-CT). Thus, this structural characterization of the manufactured samples serves as the validation basis for the calculated results of the simulations. According to the illustrated results, the adequate selection of bubble growth models and especially mesh topologies must be considered for valid simulation of specific core-back techniques, such as the Pull and Foam injection molding process.

Influence of Accelerated Aging on the Fiber-Matrix Adhesion of Regenerated Cellulose Fiber-Reinforced Bio-Polyamide.

With regard to the sustainability and biological origin of plastic components, regenerated cellulose fiber (RCF)-reinforced polymers are expected to replace other composites in the future. For use under severe conditions, for example, as a housing in the engine compartment, the resistance of the composites and the impact on the fiber and fiber-matrix adhesion must be investigated. Composites of bio-polyamide with a reinforcement of 20 wt.% RCF were compounded using a twin-screw extruder. The test specimens were manufactured with an injection molding machine and aged under conditions of high humidity at 90% r. H, a high temperature of 70 °C, and water storage using a water temperature of 23 °C for 504 h. Mechanical tests, single-fiber tensile tests (SFTT), single-fibre pull-out tests (SFPT), and optical characterization revealed significant changes in the properties of the composites. The results of the SFPT show that accelerated aging had a significant effect on the bio-polymer and an even stronger effect on the fiber, as the single-fiber tensile strength decreased by 27.5%. Supplementary notched impact strength tests revealed a correlation of the impact strength and the accelerated aging of the RCF-reinforced composites. In addition, it could be verified that the tensile strength also decreased at about 37% due to the aging effect on the RCF and a lowered fiber-matrix adhesion. The largest aging impact was on the Young's modulus with a decrease of 45% due to the accelerated aging. In summary, the results show that the strengthening effect with 20 wt.% RCF was highly decreased subsequent to the accelerated aging due to hydrolysis and debonding because of the shrinkage and swelling of the matrix and fiber. These scientific findings are essential, as it is important to ensure that this bio-based material used in the automotive sector can withstand these stresses without severe degradation. This study provides information about the aging behavior of RCF-reinforced bio-based polyamide, which provides fundamental insights for future research.

Modification of Polyamide 66 for a Media-Tight Hybrid Composite with Aluminum.

Metal-plastic composites are becoming increasingly important in lightweight construction. As a combination, e.g., for transmission housings in automobiles, composites made of die-cast aluminum housings and Polyamide 66 are a promising material. The interface between metal and plastic and the properties of the plastic component play an important role with regard to media tightness against transmission oil. The mechanical properties of the plastic can be matched to aluminum by glass fibers and additives. In the case of fiber-reinforced plastics, the mechanical properties depend on the fiber length and their orientation. These structural properties were investigated using computer tomography and dynamic image analysis. In addition to the mechanical properties, the thermal expansion coefficient was also investigated since a strongly different coefficient of the joining partners leads to stresses in the interface. Polyamide 66 was processed with 30 wt% glass fibers to align the mechanical and thermal expansion properties to those of aluminum. In contrast to the reinforcement additives, an impact modifier to improve the toughness of the composite, and/or a calcium stearate to exert influence on the rheological behavior of the composite, were used. The combination of the glass fibers with calcium stearate in Polyamide 66 led to high stiffnesses (11,500 MPa) and strengths (200 MPa), which were closest to those of aluminum. The coefficient of thermal expansion was found to be 6.6 × 10-6/K for the combination of Polyamide 66 with 30 wt% glass fiber and shows a low expansion exponent compared to neat Polamid 66. It was detected that the use of an impact modifier led to less orientated fibers along the injection direction, which resulted in lower modulus and strength in terms of mechanical properties.

Influence of Different Hot Runner-Systems in the Injection Molding Process on the Structural and Mechanical Properties of Regenerated Cellulose Fiber Reinforced Polypropylene.

The increasing demand for renewable raw materials and lightweight composites leads to an increasing request for natural fiber composites (NFC) in series production. In order to be able to use NFC competitively, they must also be processable with hot runner systems in injection molding series production. For this reason, the influences of two hot runner systems on the structural and mechanical properties of Polypropylene with 20 wt.% regenerated cellulose fibers (RCF) were investigated. Therefore, the material was processed into test specimens using two different hot runner systems (open and valve gate) and six different process settings. The tensile tests carried out showed very good strength for both hot runner systems, which were max. 20% below the reference specimen processed with a cold runner and, however, significantly influenced by the different parameter settings. Fiber length measurements with the dynamic image analysis showed approx. 20% lower median values of GF and 5% lower of RCF through the processing with both hot runner systems compared to the reference, although the influence of the parameter settings was small. The X-ray microtomography performed on the open hot runner samples showed the influences of the parameter settings on the fiber orientation. In summary, it was shown that RCF composites can be processed with different hot runner systems in a wide process window. Nevertheless, the specimens of the setting with the lowest applied thermal load showed the best mechanical properties for both hot runner systems. It was furthermore shown that the resulting mechanical properties of the composites are not only due to one structural property (fiber length, orientation, or thermally induced changes in fiber properties) but are based on a combination of several material- and process-related properties.

Weathering of a Polyurethane-Based Gel Electrolyte.

A recently described flexible polyurethane electrolyte was artificially weathered at 25/50 °C and 50% r.h. in air and at 25 °C in a dry nitrogen atmosphere, each with and without UV irradiation. Different formulations and the polymer matrix, used as a reference, were weathered in order to investigate the influence of the amount of conductive lithium salt and the solvent propylene carbonate. The complete loss of the solvent at a standard climate was already observed after a few days, strongly influencing the conductivity and mechanical properties. The essential degradation mechanism appears to be the photo-oxidative degradation of the polyol's ether bonds, which leads to chain scission, oxidation products and negative changes in the mechanical and optical properties. A higher salt content has no effect on the degradation; however, the presence of propylene carbonate intensifies the degradation.

Influence of Chitosan and Grape Seed Extract on Thermal and Mechanical Properties of PLA Blends.

Blends based on polylactic acid (PLA), chitosan, and grape seed extract (GE) were prepared by extrusion and injection molding. The effect of chitosan (5% and 15% on PLA basis) and natural extract (1% on PLA basis) incorporated into the PLA host matrix was explored regarding the thermal and mechanical properties. GE showed antioxidant activity, as determined by the DPPH assay method. Chitosan and GE affect the degree of crystallinity up to 30% as the polysaccharide acts as a nucleating agent, while the extract reduces the mobility of PLA chains. The decomposition temperature was mainly affected by adding chitosan, with a reduction of up to 25 °C. The color of the blends was specially modified after the incorporation of both components, obtaining high values of b* and L* after the addition of chitosan, while GE switched to high values of a*. The elongation at break (EB) exhibited that the polysaccharide is mainly responsible for its reduction of around 50%. Slight differences were accessed in tensile strength and Young's modulus, which were not statistically significant. Blends showed increased irregularities in their surface appearance, as observed by SEM analysis, corresponding to the partial miscibility of both polymers.

Online Prediction of Molded Part Quality in the Injection Molding Process Using High-Resolution Time Series.

Process-data-supported process monitoring in injection molding plays an important role in compensating for disturbances in the process. Until now, scalar process data from machine controls have been used to predict part quality. In this paper, we investigated the feasibility of incorporating time series of sensor measurements directly as features for machine learning models, as a suitable method of improving the online prediction of part quality. We present a comparison of several state-of-the-art algorithms, using extensive and realistic data sets. Our comparison demonstrates that time series data allow significantly better predictions of part quality than scalar data alone. In future studies, and in production-use cases, such time series should be taken into account in online quality prediction for injection molding.

Analysis of the Machine-Specific Behavior of Injection Molding Machines.

The performance of an injection molding machine (IMM) influences the process and the quality of the parts manufactured. Despite increasing data collection capabilities, their machine-specific behavior has not been extensively studied. To close corresponding research gaps, the machine-specific behavior of two hydraulic IMMs of different sizes and one electric IMM were compared with each other as part of the investigations. Both the start-up behavior from the cold state and the behavior of the machine at different operating points were considered. To complement this, the influence of various material properties on the machine-specific behavior was investigated by processing an unreinforced and glass-fiber-reinforced polyamide. The results obtained provide crucial insights into machine-specific behavior, which may, for instance, account for disparities between computer fluid dynamic (CFD) simulations and experimental results. Furthermore, it is expected that the description of the machine-specific behavior can contribute to transfer knowledge when applying transfer learning algorithms. Looking ahead to future research, it is advised to create what is referred to as a "machine fingerprint", and this proposal is accompanied by some preliminary recommendations for its development.

Influence of Fiber Volume in Hybrid Short Glass/Cellulose Reinforced Thermoplastic Compounds.

Glass fibers (GF) and regenerated cellulose fibers (RCF) are possible partners in the hybrid reinforcement of thermoplastics because of their different properties. Due to the weak bonding properties of polypropylene, coupling agents are used and the fiber volume content is set high to achieve high reinforcing effects. A lower fiber content of GF can raise the toughness properties of a reinforced polypropylene which is investigated in this study with different ratios of GF and RCF. The composites are tested in tensile tests, flexural tests and also in notched Charpy impact tests. The results can be used to compare whether a substitution of GF with RCF or the addition of more GF leads to higher mechanical properties. The tensile and Charpy impact results are compared with the Rule of Hybrid Mixtures (RoHM) to show the deviation to the prediction. Better results in terms of stiffness and strength are seen with a higher total fiber volume, while hybrid reinforced specimens show lower toughness values compared to the RCF reinforced reference specimens. Adding 5 vol% GF to 16 vol% RCF results in an increase in tensile strength by 26%, but also a significant decrease in elongation at break by 65%.

Influence of Processing Glass-Fiber Filled Plastics on Different Twin-Screw Extruders and Varying Screw Designs on Fiber Length and Particle Distribution.

Due to their valuable properties (low weight, and good thermal and mechanical properties), glass fiber reinforced thermoplastics are becoming increasingly important. Fiber-reinforced thermoplastics are mainly manufactured by injection molding and extrusion, whereby the extrusion compounding process is primarily used to produce fiber-filled granulates. Reproducible production of high-quality components requires a granulate in which the fiber length is even and high. However, the extrusion process leads to the fact that fiber breakages can occur during processing. To enable a significant quality enhancement, experimentally validated modeling is required. In this study, short glass fiber reinforced thermoplastics (polypropylene) were produced on two different twin-screw extruders. Therefore, the machine-specific process behavior is of major interest regarding its influence. First, the fiber length change after processing was determined by experimental investigations and then simulated with the SIGMA simulation software. By comparing the simulation and experimental tests, important insights could be gained and the effects on fiber lengths could be determined in advance. The resulting fiber lengths and distributions were different, not only for different screw configurations (SC), but also for the same screw configurations on different twin-screw extruders. This may have been due to manufacturer-specific tolerances.

Determination of Local Electrical Properties Using a Potential Field Measurement for Electrically Conductive Carbon Fiber Reinforced Plastics with Metal Contact Pins Joined via Injection Molding.

Carbon fiber reinforced plastics (CFRP) bear a high potential in terms of electrical conductivity and its potential applications. A locally resolved electrical measurement method for these anisotropic materials is a key prerequisite for understanding the structural and manufacturing process-related interrelationships. The aim of this paper is to develop a measurement method that allows this to be achieved and also to investigate areas of overmolded metal contact pins in detail. CFRP samples with polyamide 6 and polycarbonate matrices were used, which were produced by using a custom-designed injection mold. In order to evaluate the measurement results and to correlate them to process related structural properties, reflected light microscopy and X-ray microtomography were used. Typical areas with significant fiber structures of assembly injection molded samples were electrically and structurally characterized to identify correlations. Among further results, the correlation of equipotential lines, acquired from the electrical analysis, with specific fiber orientations within the injection molded samples was demonstrated, fiber-poor areas were identified, and a beneficial influence of weld lines on contact resistances was determined.