Search Results (72)

Reducing the environmental impact is a key reason for developing recyclable insulation materials for high-voltage industries. In this study, polypropylene (PP) blends were prepared via melt mixing with styrene–ethylene–butylene–styrene (SEBS), a thermoplastic elastomer, to improve breakdown strengths at various cooling speeds. A systematic investigation was conducted to evaluate the influence of crystal size, degree of crystallinity, and nucleation growth rate on the breakdown strength. Crystallization behavior was analyzed using isothermal and non-isothermal methods based on the Avrami model. Increasing SEBS content reduced crystallinity, with the lowest nucleation growth rate observed at 35% SEBS. Breakdown strength correlated with crystallization behavior and was further validated by Weibull distribution method. Notably, PP/SEBS blends containing 35% SEBS exhibited the highest breakdown strength of 66.4 kV/mm at a cooling speed of 10 °C/mm. This improvement reflected a reduction in the degree of crystallinity from 36.0% to 22.9% and the lowest growth rate constant (k) at 35% SEBS. Furthermore, the predicted lifetime of PP/SEBS blend containing 35% SEBS, calculated using the oxidation induction time and the Arrhenius equation, was 42 years. These findings demonstrate that SEBS content and cooling rate effectively modulate crystallization and breakdown strength, enabling recyclable PP/SEBS with XLPE-comparable performance for sustainable high-voltage insulation. Full article

Additive manufacturing (AM) has become a key element of Industry 4.0, particularly the extrusion AM (EAM) of thermoplastic materials, which is recognized as the most widely used technology. Fused Filament Fabrication (FFF), however, depends on expensive commercially available filaments, making pellet extruder-based EAM techniques more desirable. Large-format EAM systems could benefit from printing lightweight objects with reduced material use and lower power consumption by utilizing hollow rather than solid extrudates. In this study, a custom extruder head was designed and an EAM system capable of extruding inflatable hollow extrudates from a variety of materials was developed. By integrating a co-axial nozzle-needle system, a thermoplastic shell was extruded while creating a hollow core using pressurized nitrogen gas. This method allows for the production of objects with gradient part density and varied mechanical properties by controlling the inflation of the hollow extrudates. The effects of process parameters— such as extrusion temperature, extrusion speed, and gas pressure were investigated—using poly-lactic acid (PLA) and styrene-ethylene-butylene-styrene (SEBS) pellets. The preliminary tests identified the optimal range of these parameters for consistent hollow extrudates. We then varied the parameters to determine their impact on the dimensions of the extrudates, supported by analyses of microscopic images taken with an optical microscope. Our findings reveal that pressure is the most influential factor affecting extrudate dimensions. In contrast, variations in temperature and extrusion speed had a relatively minor impact, whereas changes in pressure led to significant alterations in the extrudate’s size and shape. Full article

In the work presented here, we explore the upcycling of polyethylene terephthalate (PET) that was derived from water bottles. The material was granulated and extruded into a filament compatible with fused filament fabrication (FFF) additive manufacturing platforms. Three iterations of PET combined with a thermoplastic elastomer, styrene ethylene butylene styrene with a maleic anhydride graft (SEBS-g-MA), were made with 5, 10, and 20% by mass elastomer content. The elastomer and specific mass percentages were chosen based on prior successes involving acrylonitrile butadiene styrene (ABS), in which the maleic anhydride graft enabled compatibility between different materials. The rheological properties of PET and the PET/SEBS blends were characterized by the melt flow index and dynamic mechanical analysis. The addition of SEBS-g-MA did not have a significant impact on mechanical properties, as determined by tensile and impact testing, where all test specimens were manufactured by FFF. Delamination of the tensile specimens convoluted the ability to discern differences in the mechanical properties, particularly % elongation. Annealing of the specimens enabled the observation of the effect of elastomer content on the mechanical properties, particularly in the case of impact testing, where the impact strength increased with the increase in SEBS content. However, annealing led to shrinkage of the specimens, detracting from the realized benefits of the thermal process. Scanning electron microscopy of spent tensile specimens revealed that, in the non-annealed condition, SEBS formed nodules that would detach from the PET matrix during the tensile test, indicating that a robust bond was not present. The addition of SEBS-g-MA did allow for shape memory property characterization, where deformation of tensile specimens occurred at room temperature. Specimens from the 20% by mass elastomer content sample group exhibited a shape fixation ratio on the order of 99% and a shape recovery ratio on the order of 80%. This work demonstrates a potential waste reduction strategy to tackle the problem of polymer waste by upcycling discarded plastic into a feedstock material for additive manufacturing with shape memory properties. Full article

Development of multi-component blends to prepare high-performance polymer materials is still challenging, and is a key technology for mechanical recycling of waste plastics. However, a multi-phase compatibilizer is prerequisite to create high-performance multi-component blends. In this study, POE-g-(MAH-co-St) and SEBS-g-(MAH-co-St) compatibilizers are prepared via melt-grafting of maleic anhydride (MAH) and styrene (St) dual monomers to polyolefin elastomer (POE) and poly [styrene-b-(ethylene-co-butylene)-b-styrene] (SEBS), respectively. Subsequently, these compatibilizers are utilized to compatibilize the PA6/PP/ABS/SEBS quaternary blends through melt-blending. When POE-g-(MAH-co-St) and SEBS-g-(MAH-co-St) are added, respectively, both can promote the distribution of the dispersed phases, significantly reducing the dispersed phase size. When adding 10 wt% POE-g-(MAH-co-St) and 10 wt% SEBS-g-(MAH-co-St) together, compared to the non-compatibilized blend, the fracture strength, fracture elongation, and impact strength surprisingly increased by 106%, 593%, and 823%, respectively. It can be attributed to the hierarchical interfacial interactions which facilitate gradual energy dissipation from weak to strong interfaces, resulting in the improvement of mechanical properties. The synergistic effect of the enhanced phase interfacial interactions and toughening effect of elastomer compatibilizer achieved simultaneous growth in strength and toughness. Full article

Magnetorheological elastomers (MREs) are in demand in the field of high-tech microindustries and nanoindustries such as biomedical applications and soft robotics due to their exquisite magneto-sensitive response. Among various MRE applications, programmable actuators are emerging as promising soft robots because of their combined advantages of excellent flexibility and precise controllability in a magnetic system. Here, we present the development of magnetically programmable soft magnetic microarray actuators through field-induced injection molding using MREs, which consist of styrene-ethylene/butylene styrene (SEBS) elastomer and carbonyl iron powder (CIP). The ratio of the CIP/SEBS matrix was designed to maximize the CIP fraction based on a critical solids loading. Further, as part of the design of the magnetization distribution in micropillar arrays, the magnetorheological response of the molten composites was analyzed using the static and dynamic viscosity results for both the on and off magnetic states, which reflected the particle dipole interaction and subsequent particle alignment during the field-induced injection molding process. To develop a high-aspect-ratio soft magnetic microarray, X-ray lithography was applied to prepare the sacrificial molds with a height-to-width ratio of 10. The alignment of the CIP was designed to achieve a parallel magnetic direction along the micropillar columns, and consequently, the micropillar arrays successfully achieved the uniform and large bending actuation of up to approximately 81° with an applied magnetic field. This study suggests that the injection molding process offers a promising manufacturing approach to build a programmable soft magnetic microarray actuator. Full article

Triblock copolymers such as styrene-b-(ethylene-co-butylene)-b-styrene (SEBS) have been widely used as an anion exchange membrane for fuel cells due to their phase separation properties. However, modifying the polymer architecture for optimized membrane properties is still challenging. This research develops a strategy to control the membrane morphology based on quaternized SEBS (SEBS-Q) by dual-tapering the interfacial block sequences. The structural and transport properties of SEBS-Q with various tapering styles at different hydration levels are systematically investigated by coarse-grained molecular simulations. The results show that the introduction of the tapered regions induces the formation of a bicontinuous water domain and promotes the diffusivity of the mobile components. The interplay between the solvation of the quaternary groups and the tapered fraction determines the conformation of polymer chains among the hydrophobic–hydrophilic subdomains. The strategy presented here provides a new path to fabricating fuel cell membranes with controlled microstructures. Full article

Despite polycarbonate (PC) being a widely used engineering plastic, its notch and crack sensitivity pose challenges in critical applications. To address this, PC was blended with elastomeric polymers to explore the improvement in toughness. This study systematically investigates the toughening mechanisms of PC blended with acrylonitrile–butadiene–styrene (ABS), copolyether ester elastomer (COPE), and ABS and styrene–ethylene–butylene–styrene (SEBS) copolymer grafted with maleic anhydride (MA). The morphology and mechanical behavior were evaluated under quasi-static and medium-strain-rate tensile tests and Charpy impact tests using optical, electronic, and atomic force microscopy and Raman mapping spectroscopy. The morphological analysis reveals cavitation and crazing phenomena for COPE and SEBS-g-MA systems, and mostly debonding for ABS, indicating an improvement in toughening. While the addition of ABS improves the PC plastic deformation, modifying ABS with maleic anhydride enhances the elastic modulus. Blending PC with SEBS-g-MA increases the strain at break, and the addition of COPE significantly improves the deformation behavior of PC (by around 115%). This comparative study provides valuable insights into the performance of different PC–elastomer blends under similar conditions, supporting the selection of appropriate materials for given applications. Full article

This study investigated the role of constructing a dual network in toughening bio-based long-chain polyamide 610 (PA610) composites. Rheological studies were conducted to reveal the effects of toughening agent type and content on the material properties. According to the variation trend of mechanical properties and the appearance of a rheological low-frequency plateau of the materials, the percolation network concentration ϕ_c of the toughening agent in the PA610 matrix was determined to be 13.5 vol.%. The interfacial interaction of the composite was evaluated through the percolation theory, and the scaling value v = 1.36 for both indicated the good affinity between PA610 and the toughening agent. Rheology results found that the combination of ethylene terpolymer (PTW) and maleic anhydride-g-styrene-b-(ethylene-butylene)-b-styrene (MAH-SEBS) could achieve an optimal balance between the mechanical properties and fluidity of the composites. Furthermore, the addition of ultra-high-molecular-weight polytetrafluoroethylene (PTFE), in conjunction with the toughening agent, facilitated the construction of a dual semi-interpenetrating network. The strengthened intermolecular interactions restricted the relative slippage and mobility of the polymer chains and therefore enhanced the strength and toughness of the material. This study provides new possibilities and approaches for optimizing the comprehensive properties of bio-based polyamide materials. Full article

Distinguished from traditional vulcanized rubber, which is not reusable, thermoplastic elastomer (TPV) is a material that possesses both the excellent resilience of traditional vulcanized rubber and the recyclability of thermoplastic, and TPVs have been widely studied in both academia and industry because of their outstanding green properties. In this study, new thermoplastic elastomers based on solution polymerized styrene butadiene rubber (SSBR) and thermoplastic elastomers (SEPSs/SEBSs) were prepared by the first dynamic vulcanization process. The high slip resistance and abrasion resistance of SSBR are utilized to improve the poor slip resistance of SEPSs/SEBSs, which provides a direction for the recycling of shoe sole materials. In this paper, the effects of different ratios of the rubber/plastic phase (R/P) on the mechanical properties, rheological properties, micro-morphology, wear resistance, and anti-slip properties of SSBR/TPE TPVs are investigated. The results show that the SSBR/TPE TPVs have good mechanical properties. The tensile strength, tear strength, hardness, and resilience of the TPVs decrease slightly with an increasing R/P ratio. Still, TPVs have a tensile strength of 18.1 MPa when the ratio of R/P is 40/100, and this reaches the performance of the vulcanized rubber sole materials commonly used in the market. In addition, combined with microscopic morphology analysis (SEM), it was found that, with the increase in the R/P ratio, the size of the rubber particles gradually increased, forming a stronger crosslinking network, but the rheological properties of TPVs gradually decreased; crosslinking network enhancement led to the increase in the size of the rubber particles, and the increase in the size of rubber particles made the material in the abrasion of rubber particles fall easily, thus increasing its abrasion volume. Through dynamic mechanical analysis and anti-slip tests, when the R/P ratio was 40/100, the tan δ of TPVs at 0 °C was 0.35, which represents an ordinary vulcanized rubber sole material in the market. The viscoelasticity of TPVs increased with the increase in the R/P ratio, which improved the anti-slip performance of TPVs. SSBR/TPE TPVs are expected to be used in footwear and automotive fields due to their excellent abrasion resistance and anti-slip performance. Full article

This article demonstrates scalable production of liquid metal (LM)-based microwires through the thermal drawing of extrudates. These extrudates were first co-extruded using a eutectic alloy of gallium and indium (EGaIn) as a core element and a thermoplastic elastomer, styrene–ethylene/butylene–styrene (SEBS), as a shell material. By varying the feed speed of the co-extruded materials and the drawing speed of the extrudate, it was possible to control the dimensions of the microwires, such as core diameter and shell thickness. How the extrusion temperature affects the dimensions of the microwire was also analyzed. The smallest microwire (core diameter: 52 ± 14 μm and shell thickness: 46 ± 10 μm) was produced from a drawing speed of 300.1 mm s⁻¹ (the maximum attainable speed of the apparatus used), SEBS extrusion speed of 1.50 mm³ s⁻¹, and LM injection rate of 5 × 105 μL s⁻¹ at 190 °C extrusion temperature. The same extrusion condition without thermal drawing generated significantly large extrudates with a core diameter of 278 ± 26 μm and shell thickness of 430 ± 51 μm. The electrical properties of the microwires were also characterized under different degrees of stretching and wire kinking deformation which proved that these LM-based microwires change electrical resistance as they are deformed and fully self-heal once the load is removed. Finally, the sewability of these microwires was qualitatively tested by using a manual sewing machine to pattern microwires on a traditional cotton fabric. Full article

Printed textile-based flexible batteries are gaining attention in several applications, but they are becoming more relevant to the health care industry in terms of realizing wearable and skin-conformable electronic devices. A flexible battery must ideally be deformable along multiple directions. In this work, with an aim to develop a fully printed omnidirectional deformable battery, we report the fabrication process of a novel single-polymer-based flexible non-rechargeable planar Ag₂O-Zn battery on a textile substrate using the stencil printing method. Except for the electrolyte, all the components of the battery, including the current collectors, the anode, the cathode, and the separator membrane, are fabricated using a single polymer, namely styrene–ethylene–butylene–styrene (SEBS). To fabricate the SEBS separator, we introduce the solvent evaporation-induced phase separation (SEIPS) process. In the SEIPS method, toluene and dimethyl sulfoxide (DMSO) are selected as the solvent–nonsolvent pair. The SEBS: toluene: DMSO system with a wt% ratio of 6:85:9 showed improved performance regarding the OCV tests. A polyacrylic acid (PAA)-based alkaline polymer gel is used as an electrolyte. The demonstrated process is simple, and, with suitable modifications, it should find its use in the development of digitally printed alkaline batteries. Full article

A cost-effective solution to the problems that the automotive industry is facing nowadays regarding regulations on emissions and fuel efficiency is to achieve weight reduction of automobile parts. Glass fiber-reinforced polymers are regularly used to manufacture various components, and some parts may also contain thermoplastic elastomers for toughness improvement. This work aimed to investigate the effect of styrene-(ethylene-co-butylene)-styrene triblock copolymer (E) and treated fly ash (C) on the morphological, thermal, and mechanical properties of long glass fiber (G)-reinforced polypropylene (PP). Results showed that the composites obtained through melt processing methods presented similar thermal stability and improved (nano)mechanical properties compared to 25–30 wt.% G-reinforced PP composites (PP-25G/PP-30G). Specifically, the impact strength and surface hardness were greatly improved. The addition of 20 wt.% E led to a 25–39% increase in impact strength and surface elasticity, while the addition of 6.5 wt.% C led to a 16% increase in surface hardness. The composite based on 25 wt.% G, 6.5 wt.% C, and 20 wt.% E presented the best-balanced properties (8–17% increase in impact strength, 38–41% increase in axial strain, and 35% increase in surface hardness) compared with PP-30G/PP-25G. Structural and morphological analysis confirmed the presence of a strong interaction between the components that make the composites. Based on these results, the PP–G–E–C composites could be presented as a viable material for automotive applications. Full article

This paper aims to enhance the capacitance of electroactive polymer (EAP)-based strain sensors. The enhancement in capacitance was achieved by using a free-standing stretchable polymer film while introducing conducting polymer to fabricate a hybrid dielectric film with controlled conductivity. In this work, styrene-ethylene-butylene-styrene (SEBS) rubber was used as the base material, and dodecyl benzene sulfonate anion (DBSA)-doped polyaniline (PANI) was used as filler to fabricate a hybrid composite conducting film. The maleic anhydride group of the SEBS Rubber and DBSA, the anion of the polyaniline dopant, make a very stable dispersion in Toluene and form a free-standing stretchable film by solution casting. DBSA-doped polyaniline increased the conductivity and dielectric constant of the dielectric film, resulting in a significant enhancement in the capacitance of the EAP-based strain sensor. The sensor presented in this article exhibits capacitance values ranging from 24.7 to 100 µF for strain levels ranging from 0 to 100%, and sensitivity was measured 3 at 100% strain level. Full article

Skin has a dynamic surface and offers essential information through biological signals originating from internal organs, blood vessels, and muscles. Soft and stretchable bioelectronics can be used in wearable machines for long-term stability and to continuously obtain distinct bio-signals in conjunction with repeated expansion and contraction with physical activities. While monitoring bio-signals, the electrode and skin must be firmly attached for high signal quality. Furthermore, the signal-to-noise ratio (SNR) should be high enough, and accordingly, the ionic conductivity of an adhesive hydrogel needs to be improved. Here, we used a chitosan-alginate-chitosan (CAC) triple hydrogel layer as an interface between the electrodes and the skin to enhance ionic conductivity and skin adhesiveness and to minimize the mechanical mismatch. For development, thermoplastic elastomer Styrene-Ethylene-Butylene-Styrene (SEBS) dissolved in toluene was used as a substrate, and gold nanomembranes were thermally evaporated on SEBS. Subsequently, CAC triple layers were drop-casted onto the gold surface one by one and dried successively. Lastly, to demonstrate the performance of our electrodes, a human electrocardiogram signal was monitored. The electrodes coupled with our CAC triple hydrogel layer showed high SNR with clear PQRST peaks. Full article

In wearable bioelectronics, various studies have focused on enhancing prosthetic control accuracy by improving the quality of physiological signals. The fabrication of conductive composites through the addition of metal fillers is one way to achieve stretchability, conductivity, and biocompatibility. However, it is difficult to measure stable biological signals using these soft electronics during physical activities because of the slipping issues of the devices, which results in the inaccurate placement of the device at the target part of the body. To address these limitations, it is necessary to reduce the stiffness of the conductive materials and enhance the adhesion between the device and the skin. In this study, we measured the electromyography (EMG) signals by applying a three-layered hydrogel structure composed of chitosan–alginate–chitosan (CAC) to a stretchable electrode fabricated using a composite of styrene–ethylene–butylene–styrene and eutectic gallium-indium. We observed stable adhesion of the CAC hydrogel to the skin, which aided in keeping the electrode attached to the skin during the subject movement. Finally, we fabricated a multichannel array of CAC-coated composite electrodes (CACCE) to demonstrate the accurate classification of the EMG signals based on hand movements and channel placement, which was followed by the movement of the robot arm. Full article