Heating and Strain Sensing Elements Based on Segregated Polyethylene/Carbon Black Composites in Polymer Welded Joints

The development of easy and direct real-time monitoring of welded joint quality instead of surface damage analysis is crucial to improve the quality of industrial products. This work presents the results of high-density polyethylene (HDPE)-based composites with various carbon black (CB) content (from 20 to 30 vol.%) for use as a heating element and strain sensor in electrofusion-welded polymer joints. The pyroresistive heating process was used to determine the effect of generated Joule heat during welding on the structure and sensor properties of polymer-carbon composites. It is shown that the generation of Joule heat depends on the nanocarbon content and affects the crystallinity of the polymer matrix. The partial disruption of the conductive path of carbon black particles was observed and, as a result, a decrease in electrical conductivity for composites with lower CB content after welding was found. For the highest CB amount, conductivity increased, which is caused by smaller particle-to-particle distance for filler paths. Therefore, the best balance between pyroresistive and sensor properties was found.

Flexible Positive Temperature Coefficient Composites (PVAc/EVA/GP-CNF) with Room Temperature Curie Point

Polymeric positive temperature coefficient (PTC) materials with low switching temperature points are crucial for numerous electronic devices, which typically function within the room temperature range (0-40 °C). Ideal polymeric PTC materials for flexible electronic thermal control should possess a room-temperature switching temperature, low room-temperature resistivity, exceptional mechanical flexibility, and adaptive thermal control properties. In this study, a novel PTC material with a room-temperature switching temperature and superb mechanical properties has been designed. A blend of a semi-crystalline polymer EVA with a low melting temperature (Tm) and an amorphous polymer (PVAc) with a low glass transition temperature (Tg) was prepared. Low-cost graphite was chosen as the conductive filler, while CNF was incorporated as a hybrid filler to enhance the material's heating stability. PVAc0.4/EVA0.6/GP-3wt.% CNF exhibited the lowest room temperature resistivity, and its PTC strength (1.1) was comparable to that without CNF addition, with a Curie temperature of 29.4 °C. Room temperature Joule heating tests revealed that PVAc0.4/EVA0.6/GP-3wt.% CNF achieved an equilibrium temperature of approximately 42 °C at 25 V, with a heating power of 3.04 W and a power density of 3.04 W/cm2. The Young's modulus of PVAc0.4/EVA0.6/GP-3wt.% CNF was 9.24 MPa, and the toughness value was 1.68 MJ/m3, indicating that the elasticity and toughness of the composites were enhanced after mixing the fillers, and the mechanical properties of the composites were improved by blending graphite with CNF.

Soft Self-Regulating Heating Elements for Thermoplastic Elastomer-Based Electronic Skin Applications

Resistive heating elements can be of particular interest for many applications, such as e-skin. In this study, soft heating elements were developed by combining thermoplastic polyurethane (TPU) with carbon black. In contrast to previous studies on thermoplastic polymer-based thermistors, the heating elements could endure elongations above 100%. Due to the high melting point of the TPU and the carbon filler, the thermistors could be heated up to 180°C without significant deformation. The heating elements were extruded on TPU substrates using material extrusion additive manufacturing in one-step process. Self-regulating behavior to control the maximum temperature was achieved with the application of two different voltages (20 and 25 V) and different current thresholds, between 100 and 800 mA. The heating performance was adjusted by changing the geometry of the sensing elements; an increase in cross section resulted in a lower current density and lower temperature. For the heating elements, variation of the additive manufacturing parameters such as offset, layer height, nozzle speed, and extrusion multiplier resulted in a different width/height aspect ratio of the cross section of the extruded lines, affecting the initial resistivity of the thermistor. Orientation of the carbon filler during extrusion process is one reason for the small change of the longitudinal conductivity of the heating elements. The resulting skin with the integrated heating elements allowed the possibility to perform the in situ heating for the localized healing of structural damage, while maintaining the softness required for the application of soft robotic electronic skin.

Tailored Out-of-Oven Energy Efficient Manufacturing of High-Performance Composites with Two-Stage Self-Regulating Heating via a Double Positive Temperature Coefficient Effect

The needs for sustainable development and energy efficient manufacturing are crucial in the development of future composite materials. Out-of-oven (OoO) curing of fiber-reinforced composites based on smart conductive polymers reduces energy consumption and self-regulates the heating temperature with enhanced safety in manufacturing, presenting an excellent example of such energy efficient approaches. However, achieving the desired curing processes, especially for high-performance systems where two-stage curing is often required, remains a great challenge. In this study, a ternary system consisting of graphene nanoplatelets/HDPE/PVDF was developed, with a double positive temperature coefficient (PTC) effect achieved to fulfill stable self-regulating heating at two temperatures (120 and 150 °C). Systematic studies on both single and double PTC effects were performed, with morphological analysis to understand their pyroresistive behaviors. Compared to the oven curing process, up to 97% reduction in the energy consumption was achieved by the ternary system, while comparable thermal and mechanical properties were obtained in the carbon fiber/epoxy laminates. This work presents a new route to achieve OoO curing with two-stage self-regulating heating, which can be utilized in many high-performance composite applications.

Pyroresistive Properties of Composites Based on HDPE and Carbon Fillers

Electrothermal processes were studied in pyroresistive composites based on high-density polyethylene (HDPE) containing 8 vol.% carbon black (CB), 8 vol.% carbon fibers (CF), and their mixture 4 vol.% CB + 4 vol.% CF. It is shown that the kinetic heating curves of composites are well described by an exponential dependence with a certain heating rate constant k for each type of composite. After a short heating time, the equilibrium temperature T_e is reached in the sample. When the applied voltage exceeds a certain value, the T_e value decreases due to the presence of the positive temperature coefficient of resistance (PTC) effect. Due to the PTC effect, the composites exhibit a self-regulating effect relative to the T_e. Relations between the applied voltage, electric power, and equilibrium temperature are found, the T_e value depends on the applied voltage according to the quadratic law whereas there is a linear relationship between the T_e and electric power. A possible application of such pyroresistive composites is resistance welding of plastics using a heating element (HE) made of a pyroresistive material. The use of HDPE-CB composite to create HE for resistance welding is demonstrated and the welded joint of HDPE parts obtained using HE is shown.

Polymer Composites with Self-Regulating Temperature Behavior: Properties and Characterization

A novel conductive composite material with homogeneous binary polymer matrix of HDPE (HD) and LLDPE (LLD), mixed with conductive filler consisting of carbon black (CB) and graphite (Gr), was tested against a HDPE composite with a similar conductive filler. Even the concentration of the conductive filler was deliberately lower for (CB + Gr)/(LLD + HD), and the properties of this composite are comparable or better to those of (CB + Gr)/HD. The kinetic parameters of the ρ-T curves and from the DSC curves indicate that the resistivity peak is obtained when the polymer matrix is fully melted. When subjected to repeated thermal cycles, the composite (CB + Gr)/(LLD + HD) presented a better electrical behavior than composite CB + Gr)/HD, with an increase in resistivity (ρ_max) values with the number of cycles, as well as less intense NTC (Negative Temperature Coefficient) effects, both for the crosslinked and thermoplastic samples. Radiation crosslinking led to increased ρ_max values, as well as to inhibition of NTC effects in both cases, thus having a clear beneficial effect. Limitation effects of surface temperature and current intensity through the sample were observed at different voltages, enabling the use of these materials as self-regulating heating elements at various temperatures below the melting temperature. The procedure based on physical mixing of the components appears more efficient in imparting lower resistivity in solid state and high PTC (Positive Temperature Coefficient) effects to the composites. This effect is probably due to the concentration of the conductive particles at the surface of the polymer domains, which would facilitate the formation of the conductive paths. Further work is still necessary to optimize both the procedure of composite preparation and the properties of such materials.

Ultrathin Fiber-Mesh Polymer Thermistors

Flexible sensors enable on-skin and in-body health monitoring, which require flexible thermal protection circuits to prevent overheating and operate the devices safely. Here, ultrathin fiber-mesh polymer positive temperature coefficient (PTC) thermistors via electrospinning are developed. The fiber-type thermistors are composed of acrylate polymer and carbon nanofibers. The fibrous composite materials are coated with a parylene to form a core-sheath structure, which improves the repeatability of temperature characteristics. Approximately 5 µm thick fiber-type thermistors exhibit an increase in the resistance by three orders of magnitude within ≈2 °C and repeatable temperature characteristics for up to 400 cycles. The mesh structure enables the thermistor layer to be ultra-lightweight and transparent; the mesh-type thermistor operates with a fiber density of 16.5 µg cm^-2 , whose fiber layer has a transmittance of more than 90% in the 400-800 nm region. By fabricating the mesh thermistor on a 1.4 µm thick substrate, the thermistor operates without degradation when wrapped around a 280 µm radius needle. Furthermore, the gas-permeable property is demonstrated by fabricating the fibrous thermistor on a mesh substrate. The proposed ultrathin mesh polymer PTC thermistors form the basis for on-skin and implantable devices that are equipped with overheat prevention.

Effects of POE and Carbon Black on the PTC Performance and Flexibility of High-Density Polyethylene Composites

High-density polyethylene (HDPE)/carbon black (CB) is widely used in positive temperature coefficient (PTC) composites. In order to expand its applications to fields that need good flexibility, polyolefin elastomer (POE) was incorporated into HDPE/CB composites as a secondary thermoplastic elastomer phase to provide flexibility. The effects of POE and CB content on the PTC performance and flexibility were investigated. Micro morphology and crystallization behavior are closely related to PTC properties. SEM was conducted to reveal phase morphology and filler dispersion, and DSC was conducted to research crystallization behavior. The results show that the incorporation of 18 wt.% POE can decrease the percolation threshold of conductive carbon black from 22.5 wt.% to 16 wt.%. When the CB content is 30 wt.%, the room temperature resistivity gradually increases with the increasing content of POE because of the barrier effect of POE phase, and the PTC intensity is gradually enhanced. Meanwhile, the PTC switching temperature shifts down to a lower temperature. The incorporation of 18 wt.% POE significantly increases the elongation at break, reaching an ultrahigh value of 980 wt.%, which means great flexibility has been achieved in HDPE/POE/CB composites. This work provides a new method of fabricating PTC composites with balanced electrical and mechanical properties.