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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Solvent-Cast Solid Electrolyte Membranes Based on a Charged Rigid-Rod Polymer and Ionic Liquids

Solid-state electrolytes are attractive for use in electrochemical devices because they remove the need for a flammable liquid electrolyte while contributing to the structural integrity of the device. We have recently developed a class of solid electrolytes, termed molecular ionic composites (MICs), composed of ionic liquids (ILs) and a rigid-rod polyelectrolyte, poly(2,2'-disulfonyl-4,4'-benzidine terephthalamide) (PBDT). MIC materials, originally obtained through an ion-exchange process between IL and PBDT aqueous solution, possess an unprecedented combination of high ionic conductivity, high thermal stability, low flammability and widely tunable tensile storage moduli. Here we present a facile solvent casting method for preparing MIC membranes. These membranes are uniform, flexible, and tough, with tunable composition and thickness (≥ 40 μm). Unlike the previous ion-exchange method, which only allowed incorporation of hydrophilic ILs, we can now incorporate hydrophobic ILs to prepare MIC membranes for, e.g. battery electrolytes. A sodium (Na) metal symmetric cell constructed with a PBDT-Pyr 14 TFSI membrane as the solid electrolyte shows long-term stable cycling (> 500 h.) at 60 °C. Furthermore, the ability to prepare MICs using both hydrophilic and hydrophobic ILs initiates a wider range of MIC materials and broadens the array of applications accessible by MIC membranes.

25 ENERGY STORAGE↗
DOE OSTI2020

Freestanding self-assembled sulfonated pentablock terpolymer membranes for high flux pervaporation desalination

Pervaporation desalination has several advantages over competing desalination technologies, most notably an ability to select for or against volatile organic compounds and the ability to process high salinity feeds at a low transmembrane pressure. Pervaporation has not been commercialized for desalination applications because of its energy intensity. However, emerging processes such as hydraulic fracturing produce high total dissolved solids (>30-45 g/L) byproduct streams that exceed the operational limits of traditional reverse osmosis and could be treated by pervaporation. Here, we demonstrate free-standing pervaporation membranes with excellent permeance and high salt removal based on a partially sulfonated pentablock terpolymer with the tradename Nexar™. Pervaporation membranes were easily cast from this material with desalination performances comparable or superior to commercially available membranes. We found that the polymer degree of sulfonation and casting solvent polarity had a significant impact on the membranes’ water uptake but only a modest impact on the pervaporation desalination performance. Membranes with a degree of sulfonation of 52% (2.0 meq g –1 IEC) and a casting solution composed of 50 wt% n-propanol and 50 wt% toluene achieved a water flux of 3.32 kg m -2 h -1 (permeance 135 kg m -2 h -1 bar -1 ) with 99.5% salt removal in pervaporation from a 32 g/L –1 sodium chloride feed solution at room temperature. We demonstrated that dense, non-porous NexarTM pervaporation membrane permeance and salt separation performance were superior to commercial pervaporation membranes and equivalent to commercial membrane distillation membranes, which have much larger pores. Here, this study demonstrates that commercially available sulfonated pentablock terpolymers are excellent membranes for pervaporation desalination because of their ease of casting and excellent performance.

42 ENGINEERING↗
DOE OSTI2025

Generalizable Porous Aromatic Framework‐Included Polymer Membranes for Diffusion‐Enhanced Gas Separations

Industrial separation processes account for 10-15% of global energy consumption. Membrane-based processes are less energy-intensive than traditional gas separation technologies; however, enhanced material separation performance and stability for numerous gas mixtures are needed for widespread industrial adoption. This work presents a generalizable strategy for preparing mixed-matrix gas separation membranes exceeding the performance upper bounds of existing polymer membranes for a wide variety of industrial gases. By incorporating robust porous aromatic framework (PAF) particles into various dense commercial polymer matrices, gas diffusivity and solubility can be enhanced. For diverse gas mixtures (e.g., CO2/N2, O2/N2, He/CH4, H2/N2, and C2H4/C2H6), the resulting composite membranes exhibit enhanced gas permeabilities-by as much as 520%-and largely unchanged selectivities even after 6 years of aging under simulated flue gas conditions. These improvements arise from the ultrahigh porosity, excellent chemical compatibility, and unique physicochemical properties of the embedded PAF particles. Functionalizing the PAFs with polyamines also enables composite membranes that achieve among the highest reported performances against plasticization, a common obstacle in commercializing gas separation membranes. Significantly, the PAF-1 particles are readily dispersible in various common membrane casting solvents, suggesting their broader utility as a filler for designing high-performance membranes for many industrial gas separations.

Uliana, Adam A↗
DOE OSTI2025

A comprehensive review on valorization of chestnut processing wastes into bio‐based composites and bioplastics

Abstract This review examines the characterization and utilization of chestnut processing wastes (35%) in the production of bioplastics and biocomposites. In this review, a Web of Science search without any publishing year restriction on the biochemical compositions of all the components of Castanea sativa . The obtaining of bioplastics and biocomposites based on C. sativa was reviewed. First, it highlights the biochemical composition and antioxidant properties of chestnut fruit, shell, burrs, leaves, flowers, and wood focusing on the most important compounds, such as phenolic acids, flavonoids, carbohydrates, Klason lignin, cellulose, and glucan, which can enhance the properties of these materials. Then the review covers using several chestnut extracts and fillers in bioplastics production through solvent casting technique. The mechanical, structural, bioactive properties, and moisture content were optimized through the composition and production. The color, UV absorption, antioxidant, and antimicrobial activity were also discussed. Biocomposites reinforced with chestnut burs, shells, or wood flour increased the intended properties. The enhancements in tensile strength, elastic modulus, and the effects of a pre‐treatment were evaluated. Additionally, it discusses material recovery, recycling, and reuse, particularly how it affects the biodegradability of composites incorporating chestnut waste residues. Highlights Chestnut fruit, shells, and burrs are rich in starch, lignin, and cellulose. The waste of chestnut processing can be used in bioplastics and biocomposites. Chestnut‐based films and biocomposites exhibit promising mechanical properties. The antimicrobial activity, making films, and composites proper for food packaging. New techniques boost performance, offering alternatives to conventional plastics.

Silva, Simão B. [REQUIMTE/LAQV, ISEP, Polytechnic ↗
DOE OSTI2022

Amorphization and Crystallization of Hexanitroazobenzene (HNAB) Using Conventional DSC and Flash DSC

Abstract The present work presents results from an investigation of the glass transition and crystallization behaviors of HNAB tested over more than five orders of magnitude of cooling rate from 0.005 °C/s to 600 °C/s (0.3 to 36000 °C/min) by a combination of conventional and Flash differential scanning calorimetry (DSC). The work quantifies the influence of the thermal amorphization route on the properties of this high explosive. Cooling rates faster than 100 °C/s (6000 °C/min) result in amorphous HNAB as expected from prior work, but we also find that amorphization of the HNAB occurs at cooling rates slower than 0.008 °C/s (0.5 °C/min). The behavior of the amorphous HNAB made by slow cooling is compared with that of amorphous HNAB made by fast cooling, as well as with that made by solvent casting in terms of glass transition temperature, apparent activation energy of glass transition, and dynamic fragility parameter m . Besides, the non‐isothermal crystallization response as a function of cooling rate is also reported. The thermal stability and decomposition energy of amorphous HNAB are compared with those of the crystalline counterpart, being similar heats of decomposition of 3295 and 3392 J/g, respectively; suggesting that the amorphous HNAB will have similar thermal stability and chemical energy to the crystalline form.

Koh, Yung P.↗
DOE OSTI2019

A Simple Approach for the Synthesis of Cellulose Nanofiber Reinforced Chitosan/PVP Bio Nanocomposite Film for Packaging

The development of chitosan-based food packaging film has been increasing due to its wider availability, biodegradability, low-cost, and renewability. The purpose of this study was to develop cellulose nanofibers (CNFs) reinforced Chitosan/PVP(CHP) green bio nanocomposite film by solvent casting method with enhanced barrier and mechanical property. CNFs of dimension 9–11 nm and 100–200 nm were extracted from jute fibers by directly treating it with HNO{sub 3}–NaNO{sub 2} mixture. Bio nanocomposite films were synthesized with various concentrations of CNFs and evaluated using SEM, TGA/DTG and XRD to analyze the morphology, thermal behavior and crystallinity of bio nanocomposite films. SEM analysis revealed the uniform dispersion of CNFs in CHP matrix. Thermal stability of prepared bio nanocomposite films was improved with the loading of 5 wt% of cellulose nanofibers. ATR(FT-IR) spectra shows physical interaction between all the components of bio nanocomposite film. The bio nanocomposite films were also characterized for physical property like thickness, mechanical testing and barrier properties. The addition of CNFs significantly enhanced the mechanical property of bio nanocomposite films. Furthermore, water and oxygen transmission rate of bio nanocomposite film decreased with the increase in CNFs concentration. Overall the performed studies confirmed, the use of CNFs in polymer matrix makes it possible to produce a flexible, transparent, thermally stable bio nanocomposite film with enhanced mechanical and barrier properties for food packaging applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Long-Term Aging in Miscible Polymer Nanocomposites

Here we find that the initial, solvent-cast state of nanoparticles (NPs) in a polymer matrix temporally evolves during thermal annealing such that, at steady state, NPs maximize their distance from each other subject to mass balance constraints. The observed timescales for this unexpected structural reorganization, as probed by small-angle X-ray scattering, are temperature-dependent and can be prohibitively large, especially at temperatures around and below 1.2Tg. X-ray photon correlation spectroscopy measurements during reorganization reveal that the collective NP dynamics slow down with annealing at constant temperature; this is accompanied by changes in the low-frequency regime in macroscopic viscoelastic measurements in equilibrated materials. By ruling out other potential sources for these effects (i.e., electrostatic interactions, adsorbed layers), we attribute these results to a long-ranged repulsive force between the NPs caused by fluctuations in the polymer phase, i.e., the "anti-Casimir" effect proposed by Obhukhov and Semenov [Long-range interactions in polymer melts: The anti-Casimir effect. Phys Rev Lett 2005, 95 (3), 038305]. Thus, our results highlight the important role of long-term, slow NP reorganization on the structure and, subsequently, the properties of polymer nanocomposites (PNCs), even in the case of nominally miscible polymer nanoparticle hybrids.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Inline Rolling Shear Alignment: Deposition and Long-Range Order of Block Polymer Templates in a Fast, Single-Step Process

We report the first demonstration of a rapid, single-step technique to align block polymer, thin-film nanostructures that is amenable to continuous speeds ≥10 mm/s. This method, termed Inline Rolling Shear Alignment (IRSA), uses an elastomeric roller coupled with an electric hysteresis brake to shear films before the casting solvent fully evaporates, and it can enable high throughput, large-area manufacturing of patterns such as nanowire templates. IRSA is adaptable to various polymer systems including diblock and triblock polymers, and a post-shear annealing step can yield high-quality nanostructures with orientation parameters >0.99 and defect densities as low as 5 defect-pairs/μm 2 . To demonstrate the effectiveness of IRSA, platinum nanowires were produced from this rapid deposition and alignment approach using poly(styrene-b-2-vinylpyridine), followed by open-air, atmospheric-pressure plasma etching. Furthermore, this integrated concept, with 50x faster operation than existing processes, could be leveraged for cost-effective manufacturing of macroscopically aligned nanostructures in roll-to-roll systems.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Revealing temperature-dependent polymer aggregation in solution with small-angle X-ray scattering

We report that improving the morphology of bulk heterojunction active layers remains a primary challenge for organic photovoltaics (OPVs), and much research has been devoted to achieving this through modifying OPV casting solutions to control film formation and crystallinity. Yet, the solution conformation of conjugated polymers used in OPVs is largely unknown. Here, we report observations of temperature dependent aggregation (TDA) through small-angle X-ray scattering (SAXS) investigations of polymer conformation in chlorobenzene:dichlorobenzene casting solvent as a function of temperature for PffBT4T-2OD, a polymer known to display TDA, and its derivative PffBT3T-2OD which displays significantly reduced TDA. We find that, upon cooling below 80 °C, PffBT4T-2OD forms large crystalline aggregates in solution, while its derivative PffBT3T-2OD forms mostly amorphous aggregates of similar size with some evidence of short-range order. This change in solution aggregation behavior is reflected in the lack of gelation by PffBT3T-2OD upon film deposition by spin coating. Grazing-incidence wide-angle X-ray scattering (GIWAXS) revealed a preferred face-on π–π stacking orientation for PffBT3T-2OD films while PffBT4T-2OD's π–π stacking peak was isotropic. We combine these findings to suggest that the presence of crystalline seed aggregates in PffBT4T-2OD solution quickly form an isotropic crystallite network upon cooling while PffBT3T-2OD's amorphous aggregates more slowly crystallize resulting in improved processability of PffBT3T-2OD.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

High-Performance AEM LTE with Advanced Membranes, Ionomers and PGM-Free Electrodes

Alkaline low temperature electrolysis (LTE) systems enjoy several potential advantages over acid-based LTE systems including facile oxygen evolution reaction (OER) kinetics and electrodes that can use little to no platinum group metals (PGM). The polymer membranes and membrane electrode assembly (MEA) structures going into alkaline electrochemical systems have seen significant advances in recent years. The objective of this project is to combine state-of-the-art alkaline polymer electrolyzer components into one optimized membrane electrode assembly (MEA) system to achieve DOE low temperature electrolysis (LTE) goals. The benefit of individual component advances cannot be fully appreciated until all aspects and components of the MEA are working at an equally high level of performance. New electrode fabrication methods were developed where solvent cast catalyst/ionomer solutions were used in place of insoluble ionomers to significantly improve adhesion. The membranes were improved in terms of durability and mechanical properties. The OER and HER catalysts were improved and made more durable.

08 HYDROGEN↗
DOE OSTI2023

Characterization of CNC Nanoparticles Prepared via Ultrasonic-Assisted Spray Drying and Their Application in Composite Films

The ultrasonic-assisted spray dryer, also known as a nano spray dryer and predominantly used on a lab scale in the pharmaceutical and food industries, enables the production of nanometer-sized particles. In this study, the nano spray dryer was applied to cellulosic materials, such as cellulose nanofibrils (CNFs) and cellulose nanocrystals (CNCs). CNC suspensions were successfully dried, while the CNF suspensions could not be dried, attributable to their longer fibril lengths. The nano spray drying process was performed under different drying conditions, including nebulizer hole sizes, solid concentrations, and gas flow rates. It was confirmed that the individual particle size of nano spray-dried CNCs (nano SDCNCs) decreased as the nebulizer hole sizes and solid contents of the suspensions decreased. The production rate of the nano spray dryer increased with higher solid contents and lower gas flow rates. The resulting nano SDCNCs were added to a polyvinyl alcohol (PVA) matrix as a reinforcing material to evaluate their reinforcement behavior in a plastic matrix using solvent casting. After incorporating the 20 wt.% nano SDCNCs into the PVA matrix, the tensile strength and tensile modulus elasticity of the neat PVA nanocomposite film increased by 22% and 32%, respectively, while preserving the transparency of the films.

36 MATERIALS SCIENCE↗
DOE OSTI2025

On-Demand Selection of the Latent Domain Orientation in Spray-Deposited Block Copolymer Thin Films

With their ability to self-assemble spontaneously into well-defined nanoscale morphologies, block copolymer (BCP) thin films are a versatile platform to fabricate functional nanomaterials. An important challenge to wider deployment of BCPs in nanofabrication is combining precise control over the nanoscale domain orientation in BCP assemblies with scalable deposition techniques that are applicable to large-area, curved, and flexible substrates. Here, in this study, we show that spray-deposited smooth films of a nominally disordered BCP exhibit latent orientations, which can be prescriptively selected by controlling solvent evaporation during spray casting. Subsequent solvent vapor annealing triggers assembly toward highly ordered cylindrical morphologies along the pathway determined by solvent evaporation in the prior spray deposition stage. Faster evaporation promotes assembly of vertically oriented cylinders spanning the entire film thickness (100–300 nm). In comparison, slow solvent evaporation permits intermicellar aggregation and incipient cylinder formation in solution, which induces horizontal cylinder assembly upon annealing. The evaporatively controlled latent orientation mechanism presented herein elucidates how nonequilibrium phenomena during casting govern successive self-assembly pathways and facilitates a versatile method to dictate the domain orientation of BCP thin films on demand on flexible and highly curved substrates or in distinct pattern areas on the same substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Large-Grained Cylindrical Block Copolymer Morphologies by One-Step Room-Temperature Casting

We report a facile method of ordering block copolymer (BCP) morphologies in which the conventional two-step casting and annealing steps are replaced by a single-step process where microphase separation and grain coarsening are seamlessly integrated within the casting protocol. This is achieved by slowing down solvent evaporation during casting by introducing a non-volatile solvent into the BCP casting solution what effectively prolongs the duration of the grain-growth phase. We demonstrate the utility of this solvent evaporation annealing (SEA) method by producing well-ordered large molecular-weight BCP thin films in a total processing time shorter than 3 minutes without resorting to any extra laboratory equipment other than a basic casting-device i.e., spin- or blade-coater. By analyzing the morphologies of the quenched samples, we identify a relatively narrow range of polymer concentration in the wet film, just above the order-disorder concentration, to be critical for obtaining large-grained morphologies. This finding is corroborated by the analysis of the grain-growth kinetics of horizontally-oriented cylindrical domains where relatively large growth exponents (1/2) are observed, indicative of a more rapid defect-annihilation mechanism in the concentrated BCP solution than in thermally-annealed BCP melts. Furthermore, the analysis of temperature-resolved kinetics data allows us to calculate the Arrhenius activation energy of the grain-coarsening in this one-step BCP ordering process.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Direct ink writing techniques for in situ gelation and solidification

Direct ink writing (DIW) is an extrusion-based 3D printing method which prints near ambient temperatures and has one of the broadest printable material selections among additive manufacturing techniques. However, DIW uses viscoelastic materials susceptible to collapse during printing. Overall, one promising route to improve the structural integrity of viscoelastic inks is using in situ curing methods to increase the yield strength of the printed structures after deposition. This review summarizes progress in three representative methods of in situ curing for DIW, including ultra-violet-induced crosslinking, rapid cure of reactive ingredients, and flash vaporization of a solution’s solvent to coagulate dissolved polymers.

36 MATERIALS SCIENCE↗
DOE OSTI2025

PFSA-Ionomer Dispersions to Thin-Films: Interplay Between Sidechain Chemistry and Dispersion Solvent

In fuel-cell catalyst layers (CLs), ionomers exists as nanoscale thin-films binding catalyst particles, wherein ionic and gaseous species transport to catalyst sites. To improve film function, ionomers have been designed based on the prototypical perfluorosulfonic acid (PFSA). Since CLs are fabricated through solution-based processing of inks, understanding how ink/dispersion solvent impacts ionomer interactions and function is important to guide future ionomer design. Herein, PFSA and its chemical derivatives are characterized from dispersion (in solvent) to thin film (cast on support) to investigate the impact of solvent water content on ionomer dispersion (structure, acidity) and resulting film properties. Dispersion characterization reveals that secondary aggregate structure depends on the sidechain chemistry, but all PFSA-based ionomers evolve similarly as dispersion becomes water-rich. The differences in aggregation alter ionomer adsorption and thin film morphology. Further, hydrophilic domain spacing and orientation are affected primarily by sidechain chemistry, and modulated by solvent composition. Thin-film conductivity correlates with hydration and nanodomain alignment, signifying the role of morphology in properties. Overall, this work provides insights into how chemistry can be used to coarse-tune structure–property relationships, while processing solvent is for fine-tuning of dispersion-film interplay for controlling CL-ionomer function, which can be translated to other chemistries and ink formulations.

25 ENERGY STORAGE↗
DOE OSTI2020

Dry-pressed lithium nickel cobalt manganese oxide (NCM) cathodes enabled by holey graphene host

There is an increasing demand for electric vehicle batteries with higher energy densities that can be manufactured with low cost utilizing environmentally friendly processes. Lithium nickel cobalt manganese oxides (NCM), such as LiNi(0.5)Co(0.2)Mr(0.3)O(2) (NCM523), are commonly used in commercial lithium ion batteries for electric vehicle applications. These cathodes are typically fabricated using environmentally hazardous, energy intensive, and time-consuming solvent-based slurry casting processes. Polymeric binders, also required for cathode preparation, add weight and can undergo parasitic reactions during battery cycling. Here we report a facile, solvent-free, binder-free, and rapid cold-press electrode fabrication process to prepare high mass loading NCM cathodes within minutes. This process is enabled by the use of holey graphene, a unique lightweight, compressible carbon nanomaterial that serves as both a binder and an electrically conductive matrix. NCM cathodes fabricated by this method are stable and exhibit good active material utilization. A significant advantage for the dry-press process is that the electrode mass loadings can be readily increased simply by adding more composite powder to the compression molding die, resulting in improved areal capacities that are attractive for applications requiring high energy per unit footprint. (C) 2020 Elsevier Ltd. All rights reserved.

25 ENERGY STORAGE↗
DOE OSTI2025

High Throughput Solvent-free Manufacturing of Battery Electrodes

The project goal is to develop and demonstrate an advanced solvent-free lithium-ion battery electrode process through proposed Advanced Dry Electrode Process (ADEP) equipment, which is expected to exhibit a better binder fibrillization and high throughput and suitable for high performance electrode manufacturing, and commonize the anode and cathode dry processing equipment, supply chain and operation for lithium-ion battery OEMs for replacing the solvent-based slurry casting. Our proposed approach will facilitate low-cost battery production by addressing the following gaps in present dry electrode processing: • Extend the dry electrode fabrication process to lithium-ion battery anode manufacturing • Increase the active material content for anodes and cathodes • Intensify the process through improved mixing, powder rheology and surface modifications • Enable processing of next-generation electrode materials that are not stable to solvent or ambient air exposure. The project objectives include the development of anode-compatible binder and binder fibrillization promoter for low irreversible capacity loss, low electrode binder content yet higher film mechanical strength, and the optimization of solvent-free anode and cathode process for low cost (>60% electrode cost reduction), high performance (10% increase in energy density without sacrificing cycle life) and high throughput to enable next generation lithium-ion battery electrode production. Solvent-free electrode manufacturing will also enable next-generation cell designs based on prelithiated anodes or solid-state electrolytes.

25 ENERGY STORAGE↗
DOE OSTI2022

Kinetic processes of phase separation and aggregation behaviors in slot-die processed high efficiency Y6-based organic solar cells

Morphological optimization has proved to be one crucial factor contributing to the 19% efficiency of Y6-based organic solar cells (OSCs). Although the relationship between component miscibility and film morphology has been established, it has not been clarified how the film formation processes proceed, especially for methods compatible with large-area fabrication, i.e. slot-die coating, which restricts the further optimization of the morphology. Herein, we comprehensively investigate the effect of miscibility and the film-formation kinetic process on film morphology during processing with different solvents. A highest power conversion efficiency (PCE) of 17.38% can be obtained in a D18:Y6 device processed with slot-die coating in an open-air environment. However, due to their relatively poor miscibility, incorporating a trace amount of chlorobenzene (CB) into CF can sufficiently promote Y6 aggregation, leading to increased phase separation and thus the average PCE drops to 15.16%. In contrast, a PM6:Y6 blend shows insensitive changes in the kinetic process as well as the final morphology, and thus in the comparable PCEs when cast with different solvents, which is ascribed to their relatively good miscibility. As a result, this work provides scientific guidelines for device optimization by combining the intermediate gap from miscibility to kinetic process and their impact on final morphology.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗