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At least 19 records

Multiscale Modeling and Experimental Insights into High-Temperature Soil Biodegradation Dynamics of Semi-Crystalline Poly(Lactic Acid) Nonwoven Fabrics

This study investigates the biodegradation of semi-crystalline poly(lactic acid) (PLA) nonwovens (NWs) in soil at 58 °C using both experimental and mathematical modeling approaches. The model utilizes a system of parabolic diffusion-reaction partial differential equations (PDEs) to elucidate chemical transformations over time and in space. It accounts for phenomena such as the diffusion of water and lactic acid monomers through the polymer matrix and into the surrounding soil, along with their microbial breakdown. It also accounts for the initial PLA crystallinity and predicts its evolution in time. The model is solved numerically for a single filament, and the results were used to shed light on PLA NW transformations observed in soil over a 180-day incubation period. Various characterization techniques, including scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and Raman spectroscopy, were employed to assess morphological changes, crystallinity, and molecular changes in the NWs throughout the experiment. By comparing the experimental data with the model predictions, the hydrolysis rate coefficient was found to be 3.37 × 10 -7 s -1 , while the rate of microbial degradation of lactic acid monomers was faster, of the order of 9.63 × 10 -7 s -1 . The findings highlight the significant role of crystallinity in the biodegradation process. The PLA degradation ceases when no amorphous material remains, and the crystallinity reaches 0.8, as observed in the experiments by day 120. Furthermore, this research contributes to a deeper understanding of PLA biodegradation dynamics and offers insights for effectively managing biodegradable materials in environmental settings.

Diffusion−reaction modeling↗

Nonwoven Fabric Uses and Prospects in Human Space Flight

The US space shuttle fleet has been flying for over 20 years. Although the shuttle operates in a unique exterior environment, the interior is intentionally made to be as close to the "normal" human environment as possible. The filtration needs of the shuttle are not substantially different from those of a large mobile home or camper, supporting the needs of a family of seven for up to two weeks. Therefore, most of the materials that are used to filter the air, water, and other fluids on the Shuttle are similar or identical to those employed in other sectors of the transportation industry. The only significantly different feature of the space environment is the unique "three-phase" nature of the air (with suspended liquids and solids ranging in size from aerosol droplets to binoculars). Such suspended debris contributes to the air filtration and waste management problem. Careful flow management and cleanliness practices help to mitigate the effect of debris, and liquid spills are rare, seldom making it to the filters. (It has been common on all spacecraft to look first for lost items on the air intake filters, since all objects ultimately migrate there in the flow. Liquids tend to seep rather than "spill", and so tend to aggregate in a ball near the source.) In addition to the basic fluids of the interior environment (water and water wastes, air, and its constituent supply gasses) the shuttle also has unfiltered fluid systems for Freon, hydrogen, helium, ammonia, hydraulic fluid, and propellants. Only the propellant system, owing to its uncommon chemistry, represents a fluid system that is not typical of household or medical applications. Careful external filtration prior to flight assures the cleanliness in these closed systems.

Bacon, Jack↗

Durability of Disposable N95 Mask Material When Exposed to Improvised Ozone Gas Disinfection

The principle finding of this report is that both commercial and a novel material used for N95 mask filters can endure many cycles of disinfection by ozone gas (20 ppm for 30 minutes) without detectable degradation or loss of filtration efficiency. N95 masks and surgical masks (hereafter referred to as masks) typically use a filtration material fabricated from meltblown polypropylene. To achieve maximum filtration efficiency while maintaining a reasonable pressure drop, these nonwoven fabrics are also electrostatically charged (corona discharge is the most common method used), to maximize attraction and capture of aerosols and solid particulates. Under normal circumstances, the reuse of masks is generally discouraged, but in times of crisis has become a necessity, making disinfection after each use a necessity. To be acceptable, any disinfection procedure must cause minimal degradation to the performance of the filter material. Possible performance degradation mechanisms include mechanical damage, loss of electrostatic charge, or both. One of the most practical and direct ways to measure combined mechanical and electrostatic integrity, and the subsequent ability to reuse mask filter material, is by the direct measurement of filtration efficiency. In this paper, we report that small numbers of disinfection cycles at reasonable virucidal doses of ozone do not significantly degrade the filtration efficiency of meltblown polypropylene filter material. By comparison, laundering quickly results in a significant loss of filtration efficiency and requires subsequent recharging to restore the electrostatic charge and filtration efficiency. A common assumption among biomedical scientists that ozone is far too destructive for this application. However, these direct measurements show that mask materials, specifically the filtration material, can withstand dozens of ozone disinfection cycles without any measurable degradation of filtration efficiency, nor any visible discoloration or loss of fiber integrity. The data are clear: when subjected to a virucidal dose of ozone for a much longer duration than is required for viral inactivation, there was no degradation of N95 filtration efficiency. The specific dosages of ozone needed for ~99% viral inactivation are thought to be at least 10 ppm for up to 30 minutes based upon an extensive literature review, but to standardize our testing, we consider a dose of 20 ppm for 30 minutes to be a reasonable and conservatively high ozone disinfection cycle. Finally, the material tested in this study withstood dosages of up to 200 ppm for 90 minutes, or alternatively 20 ppm for up to 36 hours, without detectable degradation, and further testing suggests that up to 30 or more disinfection cycles (at 20 ppm for 30 minutes) would result in less than a 5% loss of filtration efficiency. This report does not address the effect of ozone cycling on other mask components, such as elastics.

60 APPLIED LIFE SCIENCES↗

Uranium Sorbent Development

This report describes the synthesis of amidoxime-based sorbents for uranium extraction from natural waters. Two sorbents were tested, a commercial polyacrylonitrile-based commercial yarn and a nonwoven polypropylene fabric that was grafted with polyacrylonitrile and itaconic acid. The commercial yarn was chosen due to the ease of access and anticipated reproducibility. The polypropylene fabric was produced exclusively during the previous DOE funded Uranium from Seawater campaign and is no longer available. The polypropylene fabric represented a comparison against material developed to extract uranium from seawater, not freshwater.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Applications of fibrous substrates containing insolubilized phase change polymers

Incorporation of polyethylene glycols into fibrous substrates produces several improved functional properties when they are insolubilized by crosslinking with a methylolamide resin or by polyacetal formation by their reaction with glyoxal. The range of molecular weights of polyols that may be insolubilized is broad as are the curing conditions (0.25-10 min at 80-200C). Most representative fiber types and blends (natural and synthetic) and all types of fabric constructions (woven, nonwoven and knit) have been modified by incorporation of the bound polyols. The most novel property is the thermal adaptability of the modified substrates to many climatic conditions. This adaptability is due to the high latent heat of the crosslinked polyols that function as phase change materials, the hydrophilic nature of the crosslinked polymer and its enhanced thermal conductivity. Other enhanced properties imparted to fabrics include flex and flat abrasion, antimicrobial activity, reduced static charge, resistance to oily soils, resiliency, wind resistance and reduced lint loss. Applications commercialized in the U.S. and Japan include sportswear and skiwear. Several examples of electric sets of properties useful for specific end uses are given. In addition, other uses are biomedical horticultural, aerospace, indoor insulation, automotive interiors and components and packaging material.

Vigo, Tyrone L.↗

Advanced stitching technology

In the design of textile composites, the selection of materials and constructional techniques must be matched with product performance, productivity, and cost requirements. Constructional techniques vary. A classification of various textile composite systems is given. In general, the chopped fiber system is not suitable for structural composite applications because of fiber discontinuity, uncontrolled fiber orientation and a lack of fiber integration or entanglement. Linear filament yarn systems are acceptable for structural components which are exposed to simple tension in their applications. To qualify for more general use as structural components, filament yarn systems must be multi-directionally positioned. With the most sophisticated filament winding and laying techniques, however, the Type 2 systems have limited potential for general load-bearing applications because of a lack of filament integration or entanglement, which means vulnerability to splitting and delamination among filament layers. The laminar systems (Type 3) represented by a variety of simple fabrics (woven, knitted, braided and nonwoven) are especially suitable for load-bearing panels in flat form and for beams in a roled up to wound form. The totally integrated, advanced fabric system (Type 4) are thought to be the most reliable for general load-bearing applications because of fiber continuity and because of controlled multiaxial fiber orientation and entanglement. Consequently, the risk of splitting and delamination is minimized and practically omitted. Type 4 systems can be woven, knitted, braided or stitched through with very special equipment. Multiaxial fabric technologies are discussed.

Scardino, Frank L.↗

Design for producing fiberglass fabric in a lunar environment

The purpose of this project was to design a method of producing a fabric material on the lunar surface from readily available glass fibers. Various methods for forming fabrics were analyzed to determine which methods were appropriate for the lunar conditions. A nonwoven process was determined to be the most suitable process for making a fabric material out of fiberglass under these conditions. Various resins were considered for adhering the fibers. A single thermoplastic resin (AURUM) was found to be the only applicable resin. The end product of the process was determined to be suitable for use as a roadway surfacing material, canopy materials, reflective material, or packaging material. A cost analysis of the lunar process versus shipping the end-product from the earth suggests that the lunar formation is highly feasible. A design for a lunar, nonwoven process was determined and included in the following document.

Dorrity, J. Lewis↗

Design for producing fiberglass fabric in a lunar environment

The purpose of this project was to design a method of producing a fabric material on the lunar surface from readily available glass fibers. Various methods for forming fabrics were analyzed to determine which methods were appropriate for the lunar conditions. A nonwoven process was determined to be the most suitable process for making a fabric material out of fiberglass under these conditions. Various resins were considered for adhering the fibers. A single thermoplastic resin (AURUM) was found to be the only applicable resin. The end product of the process was determined to be suitable for use as a roadway surfacing material, canopy material, reflective material, or packaging material. A cost analysis of the lunar process versus shipping the end-product from the Earth suggests that the lunar formation is highly feasible. A design for a lunar, nonwoven process was determined and is included.

Benson, Rafer M.↗

Hybrid Filter Membrane

Cabin environmental control is an important issue for a successful Moon mission. Due to the unique environment of the Moon, lunar dust control is one of the main problems that significantly diminishes the air quality inside spacecraft cabins. Therefore, this innovation was motivated by NASA s need to minimize the negative health impact that air-suspended lunar dust particles have on astronauts in spacecraft cabins. It is based on fabrication of a hybrid filter comprising nanofiber nonwoven layers coated on porous polymer membranes with uniform cylindrical pores. This design results in a high-efficiency gas particulate filter with low pressure drop and the ability to be easily regenerated to restore filtration performance. A hybrid filter was developed consisting of a porous membrane with uniform, micron-sized, cylindrical pore channels coated with a thin nanofiber layer. Compared to conventional filter media such as a high-efficiency particulate air (HEPA) filter, this filter is designed to provide high particle efficiency, low pressure drop, and the ability to be regenerated. These membranes have well-defined micron-sized pores and can be used independently as air filters with discreet particle size cut-off, or coated with nanofiber layers for filtration of ultrafine nanoscale particles. The filter consists of a thin design intended to facilitate filter regeneration by localized air pulsing. The two main features of this invention are the concept of combining a micro-engineered straight-pore membrane with nanofibers. The micro-engineered straight pore membrane can be prepared with extremely high precision. Because the resulting membrane pores are straight and not tortuous like those found in conventional filters, the pressure drop across the filter is significantly reduced. The nanofiber layer is applied as a very thin coating to enhance filtration efficiency for fine nanoscale particles. Additionally, the thin nanofiber coating is designed to promote capture of dust particles on the filter surface and to facilitate dust removal with pulse or back airflow.

Laicer, Castro↗

Characterization of Mechanical Performance of Composites Fabricated Using Innovative Carbon Fiber Wet Laid Process

Recent innovation in production of optimized nonwoven wet laid (WL) carbon fiber (CF) mats raised the question of optimal translation of the performance and isotropy into composites formed through these dry preforms. This work explores the mechanical behavior of composites produced from WL-CF mats in conjunction with the microstructure predicted through Object Oriented Finite Element Analysis (OOF). The mats used for the composites were prepared in two dispersion regimes using 25.4 mm long CF. The mixing regimes discussed in the author’s previous work, are identified as Method 1 for the traditional processing regime and Method 2 for the innovative regime that provided optimal nonwoven WL-CF mats. Composite panels from Method 2 mats showed a normalized tensile strength increase of 52% over those from Method 1 panels. Reproducibility analysis of composites made from Method 2 mats demonstrated a standard deviation of 2% in fiber weight content, 2% in tensile modulus and 9% in tensile strength, while composites made from Method 1 mats demonstrated a standard deviation of 5% in fiber weight content, 5% in tensile modulus and 17% in tensile strength. Systematic study of the microstructure and its analysis through OOF confirmed the isotropy translation of mats produced through method 2 to the composites. This study validated the hypothesis that optimal nonwoven mats lead to a well-balanced composite with optimal performance and that non-optimal nonwoven mats do not pack into a well-balanced composite.

36 MATERIALS SCIENCE↗

Flax fiber-reinforced fatty acid vitrimer biocomposite with enhanced chemical recyclability

Here, this study unveils a sustainable, easily recyclable biocomposite, leveraging the dynamic nature of covalently adaptive bonds in a vitrimer matrix. The fabrication involved a fatty acid-derived vitrimer as the polymer matrix and multi-layered, nonwoven flax mat as reinforcing scaffold. The incorporation of these fibers significantly improved the mechanical performance of the vitrimer matrix uniformly. The ester-based covalently adaptive network plays a crucial role in enabling exceptional fiber-matrix bonding, as well as recyclability. The vitrimer matrix dissolves in ethylene glycol through transesterification, facilitating complete material recovery and biocomposite recycling without compromising the original properties of the matrix and reinforcing fibers.

36 MATERIALS SCIENCE↗

Friction and wear of TPS fibers: A study of the adhesion and friction of high modulus fibers

The adhesional and frictional forces between filaments in a woven fabric or felt, strongly influenced the processability of the fiber and the mechanical durability of the final product. Even though the contact loads between fibers are low, the area of contact is extremely small giving rise to very high stresses; principally shear stresses. One consequence of these strong adhesional and frictional forces is the resistance of fibers to slide past each other during weaving or when processed into nonwoven mats or felts. Furthermore, the interfiber frictional forces may cause surface damage and thereby reduce the fiber strength. Once formed into fabrics, flexural handling and manipulation of the material again causes individual filaments to rub against each other resulting in modulus, brittle fibers such as those used in thermal protection systems (TPS). The adhesion and friction of organic fibers, notably polyethylene terephthalate (PET) fibers, have been extensively studied, but there has been very little work reported on high modulus inorganic fibers. An extensive study was made of the adhesion and friction of flame drawn silica fibers in order to develop experimental techniques and a scientific basis for data interpretation. Subsequently, these methods were applied to fibers of interest in TPS materials.

Bascom, Willard D.↗

How Will We Keep Warm on the Red Planet?

Among the many challenges that the Mars environment poses for EVA (extravehicular activity) space suit designers, development of an appropriate thermal insulation is one of the most important. The latest in thermal insulation technologies that could be applied or modified for planetary exploration have been reviewed. These include porous and hollow structures, phase change materials, soluble gas elements, as well as vacuum enclosures and fibrous materials. Using current technology, none of these structures offers all of the features needed for Mars exploration, namely lightweight, low bulk, high flexibility, and low thermal insulation. Nonwoven fibrous materials are still the prime design candidates because they are more flexible than other structures while having good resiliency. They are usually safe to use. They are also available in many types of materials, fiber shapes, as well as fabric densities and constructions. However, a recent study conducted at the NASA Johnson Space Center shows clearly that these structures alone are not sufficient to provide effective thermal insulation in the harsh Mars environment. A more promising solution is being developed using aerogel fillers in the nonwoven structures.

Orndoff, Evelyne↗

Charging Experiments and Filtration Testing on Facemask Materials: Towards Goals of Full Performance Restoration of Used N95 Masks and Enhancement of Common-Fabric Facemasks

Different techniques have been developed for sanitizing N95 masks while retaining whatever charge remains on them. However, these sanitizing methods do not address the fact that the electrical charge, filtration efficacy, and breathability of such masks may be expected to degrade during long-term use based on mechanisms known in the literature. In this study, approaches to electrically (re)charging facemask filter materials were explored in response to the COVID-19 induced shortage of N95 masks. The effort consisted of charging experiments followed by filtration testing conducted at the coupon level during a month-long period (May 2020). The main focus of the work was to develop a recharging technique which could eventually be adapted and used as part of a broader full-performance restoration process for used N95 masks, e.g., which might employ simple washing by alcohol or soapy water as a preceding step for sanitization and declogging. Most tested coupons were therefore nonwoven meltblown fibrous polypropylene (PP) filter media extracted from decades old N95 masks. Keeping in mind commonly used cloth facemasks, limited trials were also performed with some commercially available fabrics. Charging was done at elevated temperature and was followed by cooling to freeze in the applied charges produced from corona discharges using different electrode configurations and parameter combinations, or from triboelectric rubbing. Charging was also focused on using potentially scalable equipment, e.g., Van de Graaff generators or consumer ionic hair products. Some degree of success was achieved with one of the fabrics and the PP filter media which was first purposefully discharged to have typical filtration efficiency (FE) of ~35%. Numerous attempts at corona charging discharged media resulted in filtration efficiency (FE) ≥ 80 – 85%. Some measure of charge robustness was also established via stable performance during loading testing. However, results where FE ≥ 90% were not reliably repeatable and no results met the FE ≥ 95% goal due to shortcomings of the charging process. The best three trials for PP media statistically met the FE ≥ 90% criteria, amounted to a small percentage of the trials relying on an ionic hair dryer, and are attributed to good embedding of charges via aerodynamic force. Triboelectric charging significantly enhanced the viability of one of the polyester fabrics –measured FE increased from 19% up to 46% while maintaining a reasonably low pressure drop.

N95↗

Multiple Stream Low-Cost Recycling Method

The global composite industry generates large quantities of waste and which mostly end as landfill due to lack of meaningful end-use applications for the multiple waste streams. In a recent report by the Electric Power Research Institute (EPRI), waste generated by the wind industry could reach 370,000 tons a year of composite wind energy blades being decommissioned and scrapped. Wind energy is just one major industry utilizing composite materials. The waste generated by industry includes End-of-Life (EoL) materials and manufacturing process scrap. GreenTex Solutions has developed a unique and innovative technology to recycle the composite waste streams in a range of forms made from production waste and EoL materials. This includes manufacturing waste materials such as dry chopped fiber tow, loose fibers, shredded fibers from reinforcement fabrics, cured/semi-cured prepregs, and it also includes fully-cured composite structure waste (such as edge trims from cured parts) from manufacturing aircraft, automobiles, wind blades, boats, and composite cylinders (tanks). Current recycling methods involve recovering the structural fiber by removing the matrix resin through methods such as pyrolysis. The resulting fibers are used in injection molding or wet laid nonwoven mats and other usable forms. The GreenTex technology bypasses these intermediate steps to create the lowest possible recycling processing costs and the lowest embodied energy/CO2 emissions. The end-product from the GreenTex technology is a finished industrial composite part/application versus intermediate fibers or fabrics. The GreenTex manufacturing process enables cross-industry reuse of recycled feedstock by taking waste from multiple industries (wind energy, aerospace, marine, etc.) and recycles the waste into a product used in other industries. The initial target market application is structural flooring for intermodal shipping containers and truck bodies. One of the team’s key partners is Wabash National which produced 29,000 truck bodies in 2019. The current flooring system is comprised of solid oak “butcher board” laminated panels. Additionally, Mediterranean Shipping Containers (MSC) transports over 1.8 million twenty-foot equivalent units per year in intermodal shipping containers. The current container floor is laminated hardwood that is harvested from the rain forests of Central and South America. The project is to develop a flooring system made from recycled composites that can be qualified for both companies (Wabash and MSC). Initial prototypes validated that the recycled composites panels are lighter and thinner with much higher mechanical strength. These results suggest a typical truck trailer would have 20% lower tare weight. The GreenTex technology is not limited to flooring and is widely applicable to other transportation elements such as walls, roof elements, cab areas and related structural components. Under this project different composite waste streams were evaluated and then combined to develop a formulation that would meet the targeted performance criteria for a flooring system. Wet compression molding was used to fabricate plaques at different tonnage using various composite waste streams. The plaques were tested for flexure and impact.

36 MATERIALS SCIENCE↗

High Kinetic Energy Penetrator Shielding and High Wear Resistance Materials Fabricated with Boron Nitride Nanotubes (BNNTS) and BNNT Polymer Composites

Boron nitride nanotubes (BNNTs), boron nitride nanoparticles (BNNPs), carbon nanotubes (CNTs), graphites, or combinations, are incorporated into matrices of polymer, ceramic or metals. Fibers, yarns, and woven or nonwoven mats of BNNTs are used as toughening layers in penetration resistant materials to maximize energy absorption and/or high hardness layers to rebound or deform penetrators. They can be also used as reinforcing inclusions combining with other polymer matrices to create composite layers like typical reinforcing fibers such as Kevlar.RTM., Spectra.RTM., ceramics and metals. Enhanced wear resistance and usage time are achieved by adding boron nitride nanomaterials, increasing hardness and toughness. Such materials can be used in high temperature environments since the oxidation temperature of BNNTs exceeds 800.degree. C. in air. Boron nitride based composites are useful as strong structural materials for anti-micrometeorite layers for spacecraft and space suits, ultra strong tethers, protective gear, vehicles, helmets, shields and safety suits/helmets for industry.

Kang, Jin Ho↗

High Kinetic Energy Penetrator Shielding and High Wear Resistance Materials Fabricated with Boron Nitride Nanotubes (BNNTS) and BNNT Polymer Composites

Boron nitride nanotubes (BNNTs), boron nitride nanoparticles (BNNPs), carbon nontubes (CNTs), graphites, or their combinations, are incorporated into matrices of polymer, ceramic or metals. Fibers, yarns, and woven or nonwoven mates of BNNTs are uses as toughening layers in penetration resistant materials to maximize energy absorption and/or high hardness layers to rebound or deform penetrators. They can be also uses as reinforcing inclusions combining with other polymer matrices to create composite layer like typical reinforcing fibers such as Kevlar (Registered Trademark), Spectra (Registered Trademark) ceramics and metals. Enhanced wear resistance and prolonged usage time, even under harsh conditions, are achieved by adding boron nitride nanomaterials because both hardness and toughness are increased. Such materials can be used in high temperature environments since the oxidation temperature of BNNTs exceeds 800 C in air. Boron nitride based composite materials are useful as strong structural materials for anti-micrometeorite layers for spacecraft and space suits, ultra strong tethers, protective gear for the human body as well as for vehicles, helmets, shields and safety suits/helmets for industry.

Kang, Jin Ho↗

Establishment of a Vertically Integrated Domestic Manufacturing Process for Production of Substrates Needed for Manufacture of Gas Diffusion Layers

In this project, AvCarb, LLC evaluated the baseline performance metrics of commercial carbon veils and their corresponding Gas Diffusion Layers (GDLs) with the goal of establishing an optimized, vertically integrated production system for wet-laid nonwoven substrates used in gas diffusion media for electrochemical energy storage and conversion devices. Mechanical testing and microstructural characterization were conducted and used to develop a multiscale computational model capable of simulating and predicting the performance of GDLs in fuel cells. Although the project successfully generated foundational transport and modeling data, it was terminated prior to identifying the critical GDL design parameters necessary for full optimization. The program aimed to improve carbon veil fabrication through enhanced fiber dispersion, fiber-fiber adhesion control, and improved web formation, enabling the production of high-quality, uniform substrates. Simulations were intended to guide mixing and solution delivery system design and process conditions, followed by production-scale trials to evaluate fiber dispersion, web uniformity, and mechanical robustness. At full deployment, the proposed production line would have been capable of producing approximately 650,000 m² of carbon veil annually. This capability remains strategically important, as the United States currently lacks a domestic source of wet-laid nonwoven carbon substrates that satisfy the stringent quality requirements for fuel-cell GDLs and electrolyzers representing an ongoing supply-chain vulnerability. Beyond supply-chain benefits, the project established a robust benchmarking dataset for existing commercial carbon veils while advancing next-generation material concepts targeting improved performance and manufacturing consistency.

Olson, Cynthia Lemay↗