Search Results (10)

Hydrogen is increasingly adopted as a clean energy carrier for storing and transporting low-carbon energy. Achieving a practical volumetric energy density for real-world deployment typically requires compression to several hundred bar, which in turn demands dedicated high-pressure infrastructure. Because valves are indispensable for isolation and flow control within this infrastructure, durable sealing valve materials become a key reliability and safety requirement. This assembly-level screening study compares two valve configurations with different polymer assemblies: EPDM O-rings with PEEK seats/bushing and NBR O-rings with POM seats/bushing. Four new identical 500-bar ball valves were tested (two EPDM/PEEK and two NBR/POM). For each seal configuration, one valve was cycled 5000 times at 500 bar in helium (inert baseline), and a second identical valve was cycled 5000 times at 500 bar in hydrogen to isolate hydrogen effects from mechanical/metallic wear. Leakage was tracked during cycling, and seals were analyzed by SEM/EDX after testing. The EPDM/PEEK configuration remained leak-tight in both gases, with no cracking observed in the elastomer or thermoplastic components. The NBR/POM configuration exhibited POM bushing fracture during cycling and minor external leakage at the stem during the hydrogen phase, accompanied by micro-fissures on the NBR O-ring surface. EDX indicated composition changes after cycling, including oxygen and fluorine enrichment and occasional metallic transfer species, consistent with surface films and deposits. Under the present valve geometry and cycling protocol, EPDM/PEEK provided robust sealing, whereas NBR/POM showed failure modes relevant to high-pressure service. These findings are intended as configuration-level screening evidence to be used in valves rather than as a full qualification of the individual materials. Full article

Polypropylene-based multiphase compositions with a disperse elastomer phase provide superior impact strength. Making this property indifferent to processing steps requires stabilization of the morphology of these materials. Various approaches have been tested over time, each of which shows limitations in terms of performance or applicability. Using polyethylene (PE) homo- and copolymers capable of silane-based crosslinking as modifiers was explored in the present study, which allows decoupling of the mixing and crosslinking processes. Commercial silane-copolymerized low-density PE (LD-PEX) from a high-pressure process and silane-grafted high-density PE (HD-PEX) were studied as impact modifiers for different types of PP copolymers, including non-modified reference PE grades, LDPE and HDPE. Blends based on ethylene–propylene random copolymers (PPR) and based on impact- (PPI) and random-impact (PPRI) copolymers show improvements of the stiffness–impact balance; however, to different degrees. While the absolute softest and most ductile compositions are achieved with the already soft PPRI copolymer base, the strongest relative effects are found for the PPR based blends. Modifiers with lower density are clearly superior in the toughening effect, with the LD-PEX including acrylate as second comonomer sticking out due to its glass transition around −40 °C. The impact strength improvement found in most compositions (except at very high content) results, however, not from the expected phase stabilization. For comparable systems, particle sizes are normally higher with crosslinking, probably because the process already starts during mixing. Thermoplastic processability could be retained in all cases, but the drop in melt flow rate limits the practical applicability of such systems. Full article

The complex multiphase morphology of thermoplastic elastomers based on styrene-block copolymers (TPSs) affects their flow behavior significantly and in a way which may not be considered by commonly used characterization and evaluation procedures. To evaluate the relevance of non-Newtonian flow phenomena for the validity of rheometric data in processing, three commercially available TPSs with comparable hardness of about 60 Shore A but with different application fields were selected and characterized using parallel plate and high-pressure capillary rheometry. The validity of the rheometric data is assessed by modeling the flow in a high-pressure capillary rheometer by a computational fluid dynamics (CFD) simulation. The results were discussed in conjunction with close-up images of samples taken after the measurement. The materials show clearly different rheological behaviors but depend on the respective shear and geometrical conditions. In particular, for the material with the lowest viscosity, doubling the capillary diameter resulted in a disproportionate increase of the pressure loss by up to one third. Only the capillary flow of this material could not be reproduced by the CFD simulation. The results indicate that conventionally determined rheometric data of TPSs are of limited use in evaluating process flows for various material grades. Full article

Hydrogenated styrene-butadiene-styrene block copolymer (SEBS)/polypropylene (PP) blended thermoplastic elastomer (TPE) is suitable for preparing the automotive interiors because of its excellent elasticity, softness, weather resistance, low odor, low VOC and other environmental-friendly properties. The skin of the automobile instrument panel is an appearance part, which requires excellent friction loss resistance of surface. In this paper, the high-flow SEBS/PP blended thermoplastic elastomer (TPE) suitable for the preparation of injection molding skins for automobile instrument panel was studied. By comparing the Taber abrasion and cross-scratch properties, the effects of SEBS’s molecular weight, styrene content in the molecule, molecular structure and types of lubricating agents on the friction loss properties of the material were investigated. The results show that under the same SEBS molecular structure, the higher the molecular weight within a certain range, the better the wear resistance of high-flow SEBS/PP type TPE, but the ultra-high molecular weight exhibits lower wear resistance than high molecular weight; The high-flow SEBS/PP blended TPE prepared by medium styrene content SEBS has better abrasion resistance; TPE prepared by star SEBS is better than linear SEBS; Adding silane-based lubricating agents is beneficial to improve the friction loss resistance of the material, especially combined use of high and low molecular weight silicone. Full article

Low pressure fluid transport (1) applications often require low and precise volumetric flow rates (2) including low leakage to reduce additional costly and complex sensors. A peristaltic pump design (3) was realized, with the fluid’s flexible transport channel formed by a solid cavity and a wobbling plate comprising a rigid and a soft layer (4). In operation, the wobbling plate is driven externally by an electric motor, hence, the soft layer is contracted and unloaded (5) during pump-cycles transporting fluid from low to high pressure sides. A thorough characterization of the pump system is required to design and dimension the components of the peristaltic pump. To capture all these parameters and their dependencies on various operation-states, often complex and long-lasting dynamic 3D FE-simulations are required. We present, here, a holistic design methodology (6) including analytical as well as numerical calculations, and experimental validations for a peristaltic pump with certain specifications of flow-rate range, maximum pressures, and temperatures. An experimental material selection process is established and material data of candidate materials (7) (liquid silicone rubber, acrylonitrile rubber, thermoplastic-elastomer) are directly applied to predict the required drive torque. For the prediction, a semi-physical, analytical model was derived and validated by characterizing the pump prototype. Full article

This work investigates the effect of ground rubber tire (GRT) particle size and their concentration on the morphological, mechanical, physical, and thermal properties of thermoplastic elastomer (TPE) blends based on recycled high-density polyethylene (rHDPE). In our methodology, samples are prepared via melt blending (twin-screw extrusion followed by compression molding) to prepare different series of blends using GTR with three different particle sizes (0–250 μm, 250–500 μm, and 500–850 μm) for different GTR concentrations (0, 20, 35, 50, and 65 wt.%). The thermal properties are characterized by differential scanning calorimeter (DSC), and the morphology of the blends is studied by scanning electron microscopy (SEM). The mechanical and physical properties of the blends are investigated by quasi-static tensile and flexural tests, combined with impact strength and dynamic mechanical analysis (DMA). The SEM observations indicate some incompatibility and inhomogeneity in the blends, due to low interfacial adhesion between rHDPE and GTR (especially for GTR > 50 wt.%). Increasing the GTR content up to 65 wt.% leads to poor interphase (high interfacial tension) and agglomeration, resulting in the formation of voids around GTR particles and increasing defects/cracks in the matrix. However, introducing fine GTR particles (0–250 μm) with higher specific surface area leads to a more homogenous structure and uniform particle dispersion, due to improved physical/interfacial interactions. The results also show that for a fixed composition, smaller GTR particles (0–250 μm) gives lower melt flow index (MFI), but higher tensile strength/modulus/elongation at break and toughness compared to larger GTR particles (250–500 μm and 500–850 μm). Full article

Polydimethylsiloxane (PDMS) has been used in microfluidic systems for years, as it can be easily structured and its flexibility makes it easy to integrate actuators including pneumatic pumps. In addition, the good optical properties of the material are well suited for analytical systems. In addition to its positive aspects, PDMS is well known to adsorb small molecules, which limits its usability when it comes to drug testing, e.g., in organ-on-a-chip (OoC) systems. Therefore, alternatives to PDMS are in high demand. In this study, we use thermoplastic elastomer (TPE) films thermally bonded to laser-cut poly(methyl methacrylate) (PMMA) sheets to build up multilayered microfluidic devices with integrated pneumatic micro-pumps. We present a low-cost manufacturing technology based on a conventional CO₂ laser cutter for structuring, a spin-coating process for TPE film fabrication, and a thermal bonding process using a pneumatic hot-press. UV treatment with an Excimer lamp prior to bonding drastically improves the bonding process. Optimized bonding parameters were characterized by measuring the burst load upon applying pressure and via profilometer-based measurement of channel deformation. Next, flow and long-term stability of the chip layout were measured using microparticle Image Velocimetry (uPIV). Finally, human endothelial cells were seeded in the microchannels to check biocompatibility and flow-directed cell alignment. The presented device is compatible with a real-time live-cell analysis system. Full article

The pressure-induced-flow (PIF) processing can effectively prepare high-performance polymer materials. This paper studies the influence of pressure-induced-flow processing on the morphology, thermodynamic and mechanical properties of polypropylene (PP)/polyamide 6 (PA6) blends, PP/polyolefin elastomer (POE) blends and PP/thermoplastic urethane (TPU) blends. The results show that pressure-induced-flow processing can significantly improve the thermodynamic and mechanical properties of the blends by regulating internal structure. Research shows that the pressure-induced-flow processing can increase the strength and the toughness of the blends, particularly in PP/TPU blends. Full article

Flexible thermoplastic elastomers (TPE) were prepared for fused deposition modeling (FDM) or 3D printing. These materials can be used for medical purposes such as disposable soft splints and other flexible devices. Blends of 50% epoxidized natural rubber (ENR-50) and block rubber (Standard Thai Rubber 5L (STR5L)) with polycaprolactone (PCL) were produced and compared. The purpose of this study was to investigate the properties of natural rubber (NR) and PCL in simple blends with PCL contents of 40%, 50%, and 60% by weight (except at 75% for morphology study) in the base mixture (NR/PCL). The significant flow factors for FDM materials, such as melting temperature (T_m) and melt flow rate (MFR), were observed by differential scanning calorimetry (DSC) and via the melt flow index (MFI). In addition, the following mechanical properties were also determined: tensile strength, compression set, and hardness. The results from DSC showed that the melting temperature changed slightly (1–2 °C) with amount of PCL used, and there was a suspicious point in the 50/50 blends with both types of rubber. The lowest melting enthalpy of both blends was found at the 50/50 blended composition. The MFI results showed that PCL significantly affected the melt flow rate of both blends. The ENR-50/PCL blend flowed better than the STR5L/PCL blend. The conclusion was that this was due to the morphology of its phase structure having better uniformity than that of the STR5L/PCL blend. In compression set testing or measuring shape recovery, rubber directly influenced the recovery in all blends. The ENR-50/PCL blend had less recovery than the STR5L/PCL blend, probably due to the functional effects of epoxide groups and polarity mismatch. The hard phase PCL significantly affected the hardness of samples but improved shape recovery of the material. The ENR-50/PCL blend had better tensile properties than the STR5L/PCL blend. The elongation at break of both blends improved with a high rubber content. Hence, the ENR-50/PCL blend was superior to STR5L/PCL for printing purposes due to its better miscibility, uniformity, and flow, which are the keys to success for optimizing the fused deposition modeling conditions as well as the overall mechanical properties of products. Most blends in this study were only slightly different, but the 50/50 blend of ENR-50/PCL seemed to be near optimal for 3D printing. Full article

As the market for minimally invasive surgery has grown, the demand for high-precision and high-performance catheters has increased. Catheters for the diagnosis and treatment of cardiovascular or cerebrovascular disease mainly use a braided wire tube with a polymer inner liner and outer jacket to improve the pushability and trackability. The outer jacket should have an accurate inner and outer diameter and while maintaining a wall thickness of 150 µm or less. In this study, we designed and manufactured a tip and die capable of extruding an outer jacket with a wall thickness of 150 µm or less using a medical thermoplastic elastomer for manufacturing 8Fr (2.64 mm diameter) thin-walled tubes. The ovality and inner/outer diameters of the tube were studied according to changes in the screw speed (mass flow rate), puller speed, air pressure applied to the lumen, and distance between the quench and head, which are the main variables of microextrusion processes. The screw speed (mass flow rate), puller speed, and air pressure affected the inner/outer diameter of the tube, with screw speed and puller speed having the largest influence on diameter. The air pressure and distance between quench and head had the greatest influence on ovality. The results show the effect of different processing parameters on the characteristics of the extruded tube, which will help to establish a stable extrusion process for the manufacture of outer jackets for braided catheter shafts. Full article