Recent Progress in Processing Functionally Graded Polymer Foams.

Polymer foams are an important class of engineering material that are finding diverse applications, including as structural parts in automotive industry, insulation in construction, core materials for sandwich composites, and cushioning in mattresses. The vast majority of these manufactured foams are homogeneous with respect to porosity and structural properties. In contrast, while cellular materials are also ubiquitous in nature, nature mostly fabricates heterogeneous foams, e.g., cellulosic plant stems like bamboo, or a human femur bone. Foams with such engineered porosity distribution (graded density structure) have useful property gradients and are referred to as functionally graded foams. Functionally graded polymer foams are one of the key emerging innovations in polymer foam technology. They allow enhancement in properties such as energy absorption, more efficient use of material, and better design for specific applications, such as helmets and tissue restorative scaffolds. Here, following an overview of key processing parameters for polymer foams, we explore recent developments in processing functionally graded polymer foams and their emerging structures and properties. Processes can be as simple as utilizing different surface materials from which the foam forms, to as complex as using microfluidics. We also highlight principal challenges that need addressing in future research, the key one being development of viable generic processes that allow (complete) control and tailoring of porosity distribution on an application-by-application basis

Mechanical Properties of Flax Tape-Reinforced Thermoset Composites

Three thermoset resin systems—bio-epoxy, epoxy, and polyester-with 30 v% flax fiber reinforcement have been studied to identify the optimal fiber−resin combination in a typical composite structure. Tensile, interface and interlaminar shear strength together with flexural and impact damage tolerance were compared in this study. The results revealed that mechanical and interfacial properties were not significantly affected by the different resin systems. Microscopy studies reveal that epoxy laminates predominantly fail by fibre linear breakage, polyester laminates by fiber pull-out, and bio-epoxy laminates by a combination of the two. The higher failure strains and pull-out mechanism may explain the better impact damage tolerance of polyester composites. Flow experiments were also conducted, revealing faster impregnation and lower void content with polyester resin, followed by bio-epoxy, due to their lower viscosities. Overall, bio-epoxy resin demonstrates comparable performance to epoxy and polyester resins for use in (semi-)structural bio-composites

A Review of Permeability and Flow Simulation for Liquid Composite Moulding of Plant Fibre Composites

Liquid composite moulding (LCM) of plant fibre composites has gained much attention for the development of structural biobased composites. To produce quality composites, better understanding of the resin impregnation process and flow behaviour in plant fibre reinforcements is vital. By reviewing the literature, we aim to identify key plant fibre reinforcement-specific factors that influence, if not govern, the mould filling stage during LCM of plant fibre composites. In particular, the differences in structure (physical and biochemical) for plant and synthetic fibres, their semi-products (i.e., yarns and rovings), and their mats and textiles are shown to have a perceptible effect on their compaction, in-plane permeability, and processing via LCM. In addition to examining the effects of dual-scale flow, resin absorption, (subsequent) fibre swelling, capillarity, and time-dependent saturated and unsaturated permeability that are specific to plant fibre reinforcements, we also review the various models utilised to predict and simulate resin impregnation during LCM of plant fibre composites

Mapping thermal conductivity across bamboo cell walls with scanning thermal microscopy

Funder: Leverhulme Trust; doi: https://doi.org/10.13039/501100000275Funder: Lower Austrian Research and Education Society NFB (Project No. SC16-00)Abstract: Scanning thermal microscopy is a powerful tool for investigating biological materials and structures like bamboo and its cell walls. Alongside nanoscale topographical information, the technique reveals local variations in thermal conductivity of this elegant natural material. We observe that at the tissue scale, fibre cells in the scattered vascular tissue would offer preferential pathways for heat transport due to their higher conductivities in both anatomical directions, in comparison to parenchymatic cells in ground tissue. In addition, the transverse orientation offers more resistance to heat flow. Furthermore, we observe each fibre cell to compose of up to ten layers, with alternating thick and thin lamellae in the secondary wall. Notably, we find the thin lamellae to have relatively lower conductivity than the thick lamellae in the fibre direction. This is due to the distinct orientation of cellulose microfibrils within the cell wall layers, and that cellulose microfibrils are highly anisotropic and have higher conductivity along their lengths. Microfibrils in the thick lamellae are oriented almost parallel to the fibre cell axis, while microfibrils in the thin lamellae are oriented almost perpendicular to the cell axis. Bamboo grasses have evolved to rapidly deposit this combination of thick and thin layers, like a polymer composite laminate or cross-laminated timber, for combination of axial and transverse stiffness and strength. However, this architecture is found to have interesting implications on thermal transport in bamboo, which is relevant for the application of engineered bamboo in buildings. We further conclude that scanning thermal microscopy may be a useful technique in plant science research, including for phenotyping studies

Chemical composition of processed bamboo for structural applications.

Natural materials are a focus for development of low carbon products for a variety of applications. To utilise these materials, processing is required to meet acceptable industry standards. Laminated bamboo is a commercial product that is currently being explored for structural applications, however there is a gap in knowledge about the effects of commercial processing on the chemical composition. The present study utilised interdisciplinary methods of analysis to investigate the effects of processing on the composition of bamboo. Two common commercial processing methods were investigated: bleaching (chemical treatment) and caramelisation (hygrothermal treatment). The study indicated that the bleaching process results in a more pronounced degradation of the lignin in comparison to the caramelised bamboo. This augments previous research, which has shown that the processing method (strip size) and treatment may affect the mechanical properties of the material in the form of overall strength, failure modes and crack propagation. The study provides additional understanding of the effects of processing on the properties of bamboo.This work was funded by a Leverhulme Trust Programme Grant, and EPSRC Grant EP/K023403/1

Transdisciplinary top-down review of hemp fibre composites: From an advanced product design to crop variety selection

Given the vast amount of available research in the area of natural fibre composites, a significant step forward in the development of next-generation plant fibre-based products would be to devise a framework for rational design. The authors use a top-down approach, starting with an example final product to define the product specifications for high-performance hemp fibre-reinforced composites. Thereafter, all process steps are critically analysed: from textile preform and reinforcement yarn production, to fibre extraction and the agricultural process chain, to the microbiology of field retting, to cultivation and selection of crop variety. The aim of the analysis is to determine how far the current state of knowledge and process technologies are in order to use hemp fibres in high- performance composites. Based on this critical evaluation of the state-of-the-art, it can be stated that hemp will be found in high-performance composites in the short-to-medium term. There is, however, a need for performance optimisation especially through the selection of crop variety, best practices in retting, and effective fibre extraction methods to obtain more consistent fibre qualities suitable for reinforcement spinning and composite preform manufacturing processes

Investigations by AFM of Ageing Mechanisms in PLA-Flax Fibre Composites during Garden Composting.

PLA-flax non-woven composites are promising materials, coupling high performance and possible degradation at their end of life. To explore their ageing mechanisms during garden composting, microstructural investigations were carried out through scanning electron microscopy (SEM) and atomic force microscopy (AFM). We observe that flax fibres preferentially degrade 'inwards' from the edge to the core of the composite. In addition, progressive erosion of the cell walls occurs within the fibres themselves, 'outwards' from the central lumen to the periphery primary wall. This preferential degradation is reflected in the decrease in indentation modulus from around 23 GPa for fibres located in the preserved core of the composite to 3-4 GPa for the remaining outer-most cell wall crowns located at the edge of the sample that is in contact with the compost. Ageing of the PLA matrix is less drastic with a relatively stable indentation modulus. Nevertheless, a change in the PLA morphology, a significant decrease in its roughness and increase of porosity, can be observed towards the edge of the sample, in comparison to the core. This work highlights the important role of intrinsic fibre porosity, called lumen, which is suspected to be a major variable of the compost ageing process, providing pathways of entry for moisture and microorganisms that are involved in cell wall degradation

Curved-crease origami face shields for infection control

The COVID-19 pandemic has created enormous global demand for personal protective equipment (PPE). Face shields are an important component of PPE for front-line workers in the context of the COVID-19 pandemic, providing protection of the face from splashes and sprays of virus-containing fluids. Existing face shield designs and manufacturing procedures may not allow for production and distribution of face shields in sufficient volume to meet global demand, particularly in Low and Middle-Income countries. This paper presents a simple, fast, and cost-effective curved-crease origami technique for transforming flat sheets of flexible plastic material into face shields for infection control. It is further shown that the design could be produced using a variety of manufacturing methods, ranging from manual techniques to high-volume die-cutting and creasing. This demonstrates the potential for the design to be applied in a variety of contexts depending on available materials, manufacturing capabilities and labour. An easily implemented and flexible physical-digital parametric design methodology for rapidly exploring and refining variations on the design is presented, potentially allowing others to adapt the design to accommodate a wide range of ergonomic and protection requirements