Yi-Jun Pan

Preparation and Compatibility Evaluation of Polypropylene/High Density Polyethylene Polyblends

This study proposes melt-blending polypropylene (PP) and high density polyethylene (HDPE) that have a similar melt flow index (MFI) to form PP/HDPE polyblends. The influence of the content of HDPE on the properties and compatibility of polyblends is examined by using a tensile test, flexural test, Izod impact test, scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), polarized light microscopy (PLM), and X-ray diffraction (XRD). The SEM results show that PP and HDPE are incompatible polymers with PP being a continuous phase and HDPE being a dispersed phase. The FTIR results show that the combination of HDPE does not influence the chemical structure of PP, indicating that the polyblends are made of a physical blending. The DSC and XRD results show that PP and HDPE are not compatible, and the combination of HDPE is not correlated with the crystalline structure and stability of PP. The PLM results show that the combination of HDPE causes stacking and incompatibility between HDPE and PP spherulites, and PP thus has incomplete spherulite morphology and a smaller spherulite size. However, according to mechanical property test results, the combination of HDPE improves the impact strength of PP.

Nonwoven fabric/spacer fabric/polyurethane foam composites: Physical and mechanical evaluations

In the first stage, polyethylene terephthalate (PET) fibers and Kevlar fibers are combined at a blending ratio of 80/ 20 wt% in order to form PET/Kevlar nonwoven fabrics. Two pieces of PET/Kevlar nonwoven fabrics that enclose a carbonfiber (CF) interlayer are then needle punched in order to form PET/Kevlar/CF (PKC) composites. In the second stage, the sandwiches compose PKC composites as the top and the bottom layers, as well as an interlayer that is composed of a spacer fabric and polyurethane (PU) foam. PU foams have different densities of 200, 210, 220, 230, and 240 kg/m3. These resulting nonwoven fabric/spacer fabric/PU foam sandwiches are then tested using a drop-weight impact test, a compression test, a bursting strength test, a sound absorption test, and a horizontal burning test. The test results indicate that the optimal properties of sandwiches occur with their corresponding PU foam density as follows: an optimal residual stress (240 kg/m3), an optimal compressive strength (240 kg/m3), and an optimal bursting strength (220 kg/m3). In addition, the sandwiches reach the HF1 level according to the horizontal burning test results. They also have an average electromagnetic interference shielding effectiveness of -48 dB, as well as a sound absorption coefficient of 0.5 in a frequency between 1500-2500 Hz, which indicates a satisfactory sound absorption effect. The nonwoven fabric/spacer fabric/PU foam sandwiches proposed in this study are mechanically strong, sound absorbent, and fire retardant, and can be used in construction material and electromagnetic shielding composites.

Sound Absorbent, Flame Retardant Warp Knitting Spacer Fabrics: Manufacturing Techniques and Characterization Evaluations

This study proposes a combination for reciprocal reinforcement between warp knitting spacer fabrics and PU foams. PET/Kevlar nonwoven fabrics are made with an 80:20 ratio and an incorporation of various needle-punching speed of 100, 150, 200, 250, and 300 needles/min. Ascribing to having an optimal bursting strength, sound absorption coefficient, and limited oxygen index (LOI), the PET/Kevlar nonwoven fabric that is made by 200 needles/min are selected to be combined with a glass-fiber fabric by applying needle punch in order to form a surface layer. Next, warp knitting spacer fabrics and the nonwoven fabrics are laminated, followed by being combined with polyurethane (PU) foam that are featured with different densities of 200, 210, 220, 230, and 240 kg/m3 in order to form spacer fabric/PU foam composites with multiple functions. The composites are then tested with a drop-weight test, a compression test, a bursting strength test, a sound absorption test, and a horizontal burning test. The test results indicate that all spacer fabric/PU foam composites reach a horizontal burning level of HF1, and their sound absorption coefficients at 2500-4000 Hz also suggest a satisfactory sound absorption. In particular, the optimal residual stress and compressive strength are present when the composites contain 210 kg/m3 PU foam. Similarly, the optimal bursting strength of the composites occurs when they are composed of 230 kg/m3 PU foam. The spacer fabric/PU foam composites are proven to have high strengths, sound absorption, and fire retardant, and thus have promising potentials for use as construction materials and light weight composite planks.

Fabrication of poly(vinyl alcohol) nanofibers by wire electrode-incorporated electrospinning

Wire electrodes for needleless electrospinning consist of stainless steel wires in place of cylinder electrodes. The effects of different numbers of constituent stainless steel wires on the morphology and diameter of polyvinyl alcohol (PVA) fibers are examined. With 1, 2, 3, or 4 stainless steel wires being twisted as wire electrodes, an 8, 10, or 12 wt.% polyvinyl alcohol (PVA) solution is electrospun into PVA nanofibers by using a needleless electrospinning machine. The morphology and diameter of PVA nanofibers is observed by scanning electron microscopy. The combination of the number of stainless steel wires (two), PVA solution (10 wt.%), and the collecting distance (10 cm) results in the finest diameter and an evenly formed fiber morphology. In addition, the nanofibers exhibit a wide range of diameters when electrospun with an electrode consisting of more than two stainless steel wires. Compared with the cylinder electrode, the use of a wire electrode can form nanofibers, which results in a more even morphology.

Polylactic acid/carbon fiber composites: Effects of functionalized elastomers on mechanical properties, thermal behavior, surface compatibility, and electrical characteristics

In this study, the maleic anhydride grafted styrene-ethylene-butylene-styrene block copolymer (SEBS-g-MA) is used as the compatilizer for polylactic acid (PLA)/carbon fiber (CF) composites. The effects of SEBS-g-MA on the mechanical properties, thermal behavior, interfacial compatibility, and electrical characteristics of composites are then evaluated. The mechanical property tests indicate that when the amount of compatilizer increases, the tensile properties and flexural property of the composites decrease while their impact strength increases. The SEM results show that the compatilizer can decrease the interstices between PLA and CF, and thereby augments their interfacial compatibility. The differential scanning calorimetry (DSC) results confirm that the compatilizer results in a greater crystallization temperature and a greater crystallinity of the composites. The electrical characteristic results indicate that neither PLA nor SEBS-g-MA is not interfered with the conductive network that is constructed by CF, which is exemplified by an average electromagnetic shielding effect of above −30 dB. This study confirms that SEBS-g-MA can improve interfacial compatibility and toughness, as well as attain good electrical characteristics of PLA/CF composites.

Effects of Structure Design on Resilience and Acoustic Absorption Properties of Porous Flexible-foam Based Perforated Composites

In this paper, perforated composite panel was combined with porous and resonance structures to investigate the influence on acoustic absorption and resilient properties. The perforated composite panel was fabricated based on highdensity flexible-foam via perforating and reinforcing with laminated hybrid nonwoven fabric. Effect of aperture size (AS) (ranging from 3 mm to 6 mm), perforation ratio (PR) (5 %, 10 %, 15 % and 20 %) and perforation depth (PD) (25 %, 50 %, 75 % and 100 %) on the compressive hardness, rebound resilience and acoustic absorption properties was explored. Multiply hybrid nonwoven fabric which was fabricated with low-melting point polyester (LMPET), flame-retardant polyester (FRPET) and recycled Kevlar fibers was utilized to reinforce the flexible composites and improve the acoustic property. Nonwoven that was fabricated with entangled LMPET fibers had porous structures which could reinforce the flexible foam and enhance the acoustic absorption properties. The result revealed that the continuity and supporting of porous flexible foam had directly influence the compressive hardness. The maximum hardness of the flexible-foam based perforated composites reached 420 N. The rebound resilience result showed that the sample had high resilient structure and the resilience was up to 48 %. The perforated flexible composites plate (PFP) with 4 mm-AS performed the highest acoustic absorption coefficient at 0.9. The acoustic absorption coefficient was higher than 0.8 in the frequency range from 800 to 1600 Hz and 1600 to 2400 Hz when perforated composites had 4 mm-AS at 5 % and 10 % perforation ratio. With the increase in perforation ratio, absorption peak moved from 3200 Hz to 4000 Hz. Hybrid nonwoven laminated layer help to broaden the frequency range of acoustic absorption of perforated high-density flexible foam based composites panel. Acoustic absorption coefficient was higher than 0.4 when frequency ranging from 900 Hz to 4000 Hz.

Polypropylene/high-density polyethylene/carbon fiber composites: Manufacturing techniques, mechanical properties, and electromagnetic interference shielding effectiveness

This study uses polypropylene (PP)/high-density polyethylene (HDPE) polyblends (80/20 wt.%) as matrices, which are then melt-blended with inorganic carbon fibers (CF) as reinforcement to form electrically conductive PP/HDPE composites. Tensile test, flexural test, Izod impact test, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and X-ray diffraction (XRD) are performed to evaluate different physical properties of samples. A surface resistance and electromagnetic interference shielding effectiveness (EMI SE) measurements are used to evaluate the electrical properties of the PP/HDPE/CF composites. Test results show that an increasing content of carbon fibers results in an 18 %, 23 %, and 60 % higher tensile strength, flexural strength, and impact strength, respectively. SEM results show that carbon fibers break as a result of applied force, thereby bearing the force and increasing the mechanical properties of composites. DSC and XRD results show that the addition of carbon fibers causes heterogeneous nucleation in PP/HDPE polyblends, thereby increasing crystallization temperature. However, the crystalline structure of PP/HDPE composites is not affected. Surface resistivity results show that 5 wt.% of carbon fibers can form a conductive network in PP/HDPE polyblends and reduce the surface resistivity from 12×1012 ohm/sq to 4×103 ohm/sq. EMI SE results show that, with a 20 wt.% CF and a frequency of 2-3 GHz, the average EMI SE of PP/HDPE/CF composites is between -48 and -52 dB, qualifying their use for EMI SE, which is required for standard electronic devices.

Elastic knits with different structures composed by using wrapped yarns: Function and comfort evaluations

In this study, the wrap yarns are made with antibacterial/green charcoal plied yarns as the wrap material and moisture management yarns as the core by using a rotary twisting machine. The wrap yarns and Tetoron® elastic yarns are then combined with different structures in order to form elastic knits. The elastic knits are then evaluated for their functions in terms of their antibacterial properties, far infrared radiation rate, and anion counts, as well as comfort in terms of settling time, wicking performance, water vapor permeability, softness, and air permeability, in order to examine the influences of jersey structure, stripe structures and mesh structures. The test results indicate that the combination of five green charcoal filaments and a mesh structure provides the elastic knits with the maximum functions and comfort, due to a high content of functional fibers per unit area. The optimal FIR emissivity reaches 0.89, maximum anion amount is 673±21.4, and the highest permeability is 63.9±2.6 cm3/cm2/s. As a result, the proposed elastic knits have an adjustable fabric structure that is feasible to meet any requirements and thus has a broad application range.

Applications of geotextiles made of PET-filament-based nonwoven fabrics

Climate change has been occuring in recent years. The extraordinary changes lead to high temperatures, floods, and typhoons that become a significant threat to people’s lives and property. Therefore, engineering methods have become important, as they decrease the level of people’s loss caused by natural disasters. Synthetic fibers have been commonly used in geotechnical engineering field since their invention, and are now widely available. Whether geotextiles are made using fabrics or nonwoven fabrics, water permeability and appropriate strength are their indispensable properties in reinforcement, separation, filtration, drainage, and protection. In this study, polyester (PET) filaments and nonwoven fabrics are combined using hot pressing, during which different weight amounts of filament are used. The composites are tested for delamination strength, tensile strength, tear strength, burst strength, and puncture strength to characterize the filament-based geotextiles. The experimental results show that a high needle punching depth has a negative influence on the strengths of geotextiles. Moreover, the geotextiles exhibit the optimal tensile and tearing strength when they are hot pressed at 170 °C, and optimal burst strength and puncture strength when they are hot pressed at 180 °C.

Using nonwoven fabrics as culture mediums for extensive green roofs: physical properties and cooling effect

Based on the requirements of extensive green roofs, ploylactide (PLA) fibers, cotton fibers, polyester (PET), and low-melting-point LMPET fibers are combined and produced culture mediums for Crassulaceae plants. The resulting mediums are tested for their physical properties and found to be light weight, which is a required condition for plant growth. These features contribute to efficient construction and maintenance. In addition, the optimal cooling effect of the culture mediums is 9.6 °C, which significantly reduces the amount of heat that invades indoor spaces. The decrease in the amount of heat indoors results in a lower demand for air conditioning so as to achieve energy conservation. The results derived from this study help in the promotion of green roofs, thereby slowing down the urban heat island effect and global warming.