Browse Topic: Polymers
High-frequency whine noise in electric vehicles (EVs) is a significant issue that impacts customer perception and alters their overall view of the vehicle. This undesirable acoustic environment arises from the interaction between motor polar resonance and the resonance of the engine mount rubber. To address this challenge, the proposal introduces an innovative approach to predicting and tuning the frequency response by precisely adjusting the shape of rubber flaps, specifically their length and width. The approach includes the cumulation of two solutions: a precise adjustment of rubber flap dimensions and the integration of ML. The ML model is trained on historical data, derived from a mixture of physical testing conducted over the years and CAE simulations, to predict the effects of different flap dimensions on frequency response, providing a data-driven basis for optimization. This predictive capability is further enhanced by a Python program that automates the optimization of flap
Road noise caused by road excitation is a critical factor for vehicle NVH (Noise, Vibration, and Harshness) performance. However, assessing the individual contribution of components, particularly bushings, to NVH performance is generally challenging, as automobiles are composed of numerous interconnected parts. This study describes the application of Component Transfer Path Analysis (CTPA) on a full vehicle to provide insights into improving NVH performance. With the aid of Virtual Point Transformation (VPT), blocked forces are determined at the wheel hubs; afterward, a TPA is carried out. As blocked forces at the wheel hub are independent of the vehicle dynamics, these forces can be used in simulations of modified vehicle components. These results allow for the estimation of vehicle road noise. To simulate changes in vehicle components, including wheel/tire and rubber bushings, Frequency-Based Substructuring (FBS) is used to modify the vehicle setup in a simulation model. In this
Mechanical light detection and ranging (LiDAR) units utilize spinning lasers to scan surrounding areas to enable limited autonomous driving. The motors within the LiDAR modules create vibration that can propagate through the vehicle frame and become unwanted noise in the cabin of a vehicle. Decoupling the module from the body of the vehicle with highly damped elastomers can reduce the acoustic noise in the cabin and improve the driving experience. Damped elastomers work by absorbing the vibrational energy and dispelling it as low-grade heat. By creating a unique test method to model the behavior of the elastomers, a predictable pattern of the damping ratio yielded insight into the performance of the elastomer throughout the operating temperature range of the LiDAR module. The test method also provides an objective analysis of elastomer durability when exposed to extreme temperatures and loading conditions for extended periods of time. Confidence in elastomer behavior and life span was
This specification covers a synthetic rubber in the form of sheet, strip, tubing, molded shapes, and extrusions. This specification should not be used for molded rings, compression seals, molded O-ring cord, and molded-in-place gaskets for aeronautical and aerospace applications
This SAE Standard outlines the requirements for a preformed thermosetting hose intended for use in heavy-duty vehicle engines, such as air cleaner inlet, crank case vent, or air cleaner to turbo or to engine inlet.
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. Its efficiency could be further increased by integration of joining processes, which would otherwise be separate processes requiring additional time and equipment. In this work, an integrative two-step thermoforming process for hollow box structures is presented. The starting point are two organosheets, i.e. fiber-reinforced thermoplastic sheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and
Traditional silicon-based solar cells are completely opaque, which works for solar farms and roofs but would defeat the purpose of windows. However, organic solar cells, in which the light absorber is a kind of plastic, can be transparent.
Purdue University material engineers have created a patent-pending process to develop ultrahigh-strength aluminum alloys that are suitable for additive manufacturing because of their plastic deformability.
Conventional solid polymer electrolyte batteries perform poorly due to structural limitations that hinder an optimal electrode contact. This could not eliminate the issue of “dendrites”, where lithium grows in tree-like structures during repeated charging and discharging cycles. Dendrites are a critical issue, as an irregular lithium growth can disrupt battery connections, potentially causing fires and explosions.
Composite materials are created by combining two or more different materials, such as a filler or fibrous reinforcement dispersed in a polymer matrix. The primary goal of developing composites is to improve properties while reducing weight, making them ideal for the sustainable development of the automotive industry. Poly(lactic acid) (PLA) has emerged as a promising polymer matrix for composites due to its ecological and biodegradable nature, as well as its good mechanical properties (tensile strength and modulus of elasticity), though it remains limited when compared to engineering polymers such as acrylonitrile butadiene styrene (ABS) and acrylonitrile styrene acrylate (ASA). Cotton fibers have gained visibility in recent years as reinforcement in various matrices due to their low cost, renewable origin, and relative abundance. Incorporating cotton fibers into PLA can improve its mechanical properties, enhancing attributes such as tensile strength and stiffness, which makes the
Heat shrink polymer is a type of material used in many industries’ segments due to their ability to contract and fit snugly around objects when heat is applied. These products are commonly commercialized in tube format (e.g.: sleeves), made from polyolefin or fluoropolymers, which have the property of shrinking when heated. Nanomaterials present many applications, and their usage is a remarkable tool aiming to improve many properties of materials. Then, many improvements including increase of performance and price reduction may be achieved due to its unique properties when nanomaterials are used into heat shrink polymer sleeves. This work presents a systematic review about the state of the art on heat-shrinkable materials for the automotive industry. As a methodology, articles from the last 10 years on the subject were selected. The keywords “heat shrink” AND “nanomaterial” AND “tubes OR sleeves” were used in three different databases, being “Scopus”, “Web of Science” and “MDPI”. After
3D-printed microscopic particles, so small that to the naked eye they look like dust, have applications in drug and vaccine delivery, microelectronics, microfluidics, and abrasives for intricate manufacturing. However, the need for precise coordination between light delivery, stage movement, and resin properties makes scalable fabrication of such custom microscale particles challenging. Now, researchers at Stanford University have introduced a more efficient processing technique that can print up to 1 million highly detailed and customizable microscale particles a day.
Los Angeles-based plastics contract manufacturer Kal Plastics deployed UR10e trimming cobot for a fraction of the cost and lead time of a CNC machine, cut trimming time nearly in half, and reduced late shipments to under one percent — all while improving employee safety and growth opportunities.
Electric vehicles (EVs) are particularly susceptible to high-frequency noise, with rubber eigenmodes significantly influencing these noise characteristics. Unlike internal combustion engine (ICE) vehicles, EVs experience pronounced variations in dynamic preload during torque rise, which are substantially higher. This dynamic preload variation can markedly impact the high-frequency behaviour of preloaded rubber bushings in their installed state. This study investigates the effects of preload and amplitude on the high-frequency dynamic performance of rubber bushings specifically designed for EV applications. These bushings are crucial for vibration isolation and noise reduction, with their role in noise, vibration, and harshness (NVH) management being more critical in EVs due to the absence of traditional engine noise. The experimental investigation examines how preload and excitation amplitude variations influence the dynamic stiffness, damping properties, and overall performance of
Lead-filled aprons are currently used for atomic number (Z)-grade radiation shielding in the medical industry to protect personnel from hazardous gamma radiation. These apron garments are made with lead-filled elastomeric sheets encased in polymeric fabrics and are both heavy and bulky to meet necessary shielding requirements. In addition, there are environmental safety concerns surrounding disposal of these garments due to their lead content. An innovator at NASA Langley Research Center has developed a novel method for making thin, lightweight radiation shielding that can be sprayed or melted onto common textiles used in clothing such as cotton, nylon, polyester, Nomex, and Kevlar.
From your car’s navigation display to the screen you are reading this on, luminescent polymers — a class of flexible materials that contain light-emitting molecules — are used in a variety of today’s electronics. Luminescent polymers stand out for their light-emitting capability, coupled with their remarkable flexibility and stretchability, showcasing vast potential across diverse fields of application.
Plasma is a state of matter, like a solid, liquid, or gas. When sufficient energy is applied to a gas, it becomes ionized, transitioning into the plasma state. With precise application and control, plasma can alter surface properties of a metal or plastic part without compromising the underlying material.
A lighter, colorable and fully recyclable thermoplastic body seal from Cooper Standard won the annual Innovations in Lightweighting Award given by the Society for Automotive Analysts. At the society's December meeting, Jay Murdock, senior product development engineer for Cooper Standard, accepted the award and said its FlexiCore product was designed with an eye on strong trends in what OEMs want from suppliers: sustainability, carbon neutrality, lightweighting and recyclability.
Material solutions for thermal management, protection and assembly. Today's ADAS designers are adding more electronic components and redundant computing systems to printed circuit boards (PCBs). These heat-generating electronic assemblies are installed in enclosures that provide environmental protection, but the high heat generated by high-performance computing systems can degrade ADAS performance or cause device failure. Not all thermal management materials can withstand temperatures up to 200 C (392 F), and most do not retain their flexibility at elevated temperatures. This creates a problem when PCB components expand and contract at different rates due to mismatches in their coefficients of thermal expansion.
This material type has resistance to hot air, but generally has poor resistance to fuels and lubricants, but usage is not limited to such applications. Each application should be considered separately. This material type has a typical service temperature range of -85 to 500 °F (-65 to 260 °C). The operating temperature range of the material is a general temperature range, but the presence of particular fluids and design parameters may modify this range. Recommendations on the material selection are based on available technical data and are offered as suggestions only. Each user should make his own tests to determine the suitability for his own particular use.
Fused Deposition Modeling (FDM), a form of Additive Manufacturing (AM), has emerged as a groundbreaking technology for the production of complex shapes from a variety of materials. Acrylonitrile Butadiene Styrene (ABS) is an opaque thermoplastic that is frequently employed in additive manufacturing (AM) due to its affordability and user-friendliness. The purpose of this investigation is to enhance the FDM parameters for ABS material and develop predictive models that anticipate printing performance by employing the Adaptive Neuro-Fuzzy Inference System (ANFIS). Through experimental trials, an investigation was conducted to evaluate the influence of critical FDM parameters, including layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including mechanical properties, surface polish, and dimensional accuracy. The utilization of design of experiments (DOE) methodology facilitated a systematic examination of parameters. A predictive model was
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly nature, affordability, and ease of processing. This study aims to optimize the parameters of Fused Deposition Modeling (FDM) for PLA material using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The researchers performed experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional accuracy, surface finish, and mechanical properties. The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. The TOPSIS approach, a technique for making decisions
Fused Deposition Modeling (FDM) is a highly adaptable additive manufacturing method that is extensively employed for creating intricate structures using a range of materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability, making it well-suited for use in industries such as footwear, automotive, and consumer goods. Hoses, gaskets, seals, external trim, and interior components are just a few of the many uses for thermoplastic polyurethanes (TPU) in the automobile industry. The objective of this study is to enhance the performance of Fused Deposition Modeling (FDM) by optimizing the parameters specifically for Thermoplastic Polyurethane (TPU) material. This will be achieved by employing a Taguchi-based Grey Relational Analysis (GRA) method. The researchers conducted experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses
A team led by Emily Davidson has reported that they used a class of widely available polymers called thermoplastic elastomers to create soft 3D printed structures with tunable stiffness. Engineers can design the print path used by the 3D printer to program the plastic’s physical properties so that a device can stretch and flex repeatedly in one direction while remaining rigid in another. Davidson, an assistant professor of chemical and biological engineering, says this approach to engineering soft architected materials could have many uses, such as soft robots, medical devices and prosthetics, strong lightweight helmets, and custom high-performance shoe soles.
Soft skin coverings and touch sensors have emerged as a promising feature for robots that are both safer and more intuitive for human interaction, but they are expensive and difficult to make. A recent study demonstrates that soft skin pads doubling as sensors made from thermoplastic urethane can be efficiently manufactured using 3D printers.
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