Preparation and Characterization of Dopamine-Modified Carbon Fiber Paper Composites for Gas Diffusion Layers

Carbon fibers (CFs) cannot be directly used for the preparation of CF paper because of their chemically inert nature. Herein, the surface of CFs was modified using the spontaneous oxidative self-polymerization of dopamine. By taking full advantage of the spontaneous oxidation and self-polymerization properties of PD to maintain the maximum strength of CFs, a polydopamine-modified CF paper (PDA-CFP) with excellent performance was prepared using PD-modified CFs (PDA-CFs). This increased the proportion of hydrophilic functional groups on the surface of carbon fibers, increased the O/C ratio on the CF surface by 6 times, and improved the bond strength between the modified CF and the adhesive by making full use of the interaction force between polydopamine and PVA fibers. In this way, the primary properties of the CF paper were improved. Overall, the results showed that the dispersion of CF was considerably improved with dopamine modification. In addition, the primary physical properties of PDA-CFP were better than those of virgin CF paper (CFP-0). PDA-CFP exhibited a maximum tensile strength of 2.04 kN·m-1, a minimum resistivity of 0.06055 Ω·cm-1, and a minimum porosity of 72.4%. The tightness was increased by up to 12.1%.

Ultrafast deposition of polydopamine for high-performance fiber-reinforced high-temperature ceramic composites

The low deposition time efficiency and small thickness limit the expansion of polydopamine (PDA) application to fiber-reinforced high-temperature ceramic composites. In this work, the electric field-assisted polymerization (EFAP) route was developed to improve the deposition time efficiency of PDA coating and overcome the thickness limitation. Carbonized polydopamine (C-PDA) coating was used as the interphase of carbon fiber-reinforced ZrB2-based composites (Cf/ZrB2-based composite) to bond rigid fibers and brittle ceramics, where C-PDA coating was prepared by the carbonization of PDA coating. Firstly, uniform and dense PDA coatings were deposited on carbon fibers (Cf) by EFAP. The thickness of PDA coating reached the micron level (over 1800 nm) for the first time. Benefiting from the EFAP route promoting the oxidation process of dopamine (DA) and accelerating the aggregation and in-situ polymerization of DA and its derivatives on the surface of Cf, the deposition rate of PDA coating reached 5589 nm/h, which was 3 orders of magnitude higher than that of the traditional self-polymerization process. By adjusting the EFAP parameters (e.g. DA-concentration, current, and deposition time), the thickness of PDA coating could be conveniently designed from nano-scale to micro-scale. Then, PDA coating was pyrolyzed to obtain C-PDA coating. C-PDA coating was well bonded on Cf without visible cross-sticking among neighboring fibers. C-PDA coating presented a layered structure and the thickness of C-PDA coating could be designed by controlling the thickness of PDA. C-PDA coating was used as the interfacial phase of the Cf/ZrB2-based composite, which ensured that the composite possessed good load-bearing capacity and thermal stability. Moreover, extraordinary damage resistance of the composite was achieved, with work of fracture up to 9936 ± 548 J/m2 at room temperature and 19,082 ± 3458 J/m2 at 1800 °C. The current work provides a high time efficiency processing route for depositing PDA coating on carbon fibers and demonstrates the attractive potential of PDA coating in fiber-reinforced high-temperature ceramic composites.

Facile mussel-inspired polydopamine-coated 3D-printed bioreactors for continuous flow biocatalysis

Enantiopure alcohol production by a flow system of 3D-printed bioreactor with immobilized Geotrichum candidum acetophenone reductase (GcAPRD).

Adhesion Optimization between Incompatible Polymers through Interfacial Engineering

Additive manufacturing technologies such as fused filament fabrication (FFF) open many possibilities in terms of product functionality, including the possibility to integrate a sensor in FFF parts to perform structural health monitoring. In this context, embedding fiber Bragg grating (FBG) sensors into 3D-printed polymeric structures for strain or temperature measurements has attracted increasing attention in recent years. Indeed, offering structural health monitoring functionality can optimize the maintenance cost and increase security compared with conventional materials. However, the transmission of strain and temperature between the polymeric matrix and the FBG polymer jacket requires optimal bonding between them. In this work, the two polymers of interest are polyimide (PI) and poly(lactic acid) (PLA) for the FBG jacket and printed polymer, respectively. The current study investigates the influence of different surface treatment methods on the adhesion between a PI film and a plate of PLA, with PLA and PI being incompatible polymers. The adhesion promotion applied to the PI surface relies on cleaning, plasma activation, roughness modification, or the use of adhesive nanocoating. Bilayer samples of PI-PLA are processed by welding PLA against the treated PI by heating, whereas the adhesion between PI and PLA is measured by peel testing. It is observed that the highest adhesion between PI and PLA is achieved by a combination of mechanical abrasion increasing roughness and the use of polydopamine as an adhesive. This finding is discussed based on a synergetic effect between mechanical interlocking and chemical interaction between the two counterfaces.

Dual-Sizing Effects of Carbon Fiber on the Thermal, Mechanical, and Impact Properties of Carbon Fiber/ABS Composites

Dual-sizing effects with either epoxy or polyurethane (PU) on the thermal, mechanical, and impact properties of carbon fiber/acrylonitrile-butadiene-styrene (ABS) composites produced by extrusion and injection molding processes were investigated. The heat deflection temperature, dynamic mechanical, tensile, flexural, and impact properties of the composites reinforced with either (epoxy + epoxy) or (epoxy + PU) dual-sized carbon fiber were higher than those commercially single-sized with epoxy. The result indicated that the dual-sized carbon fiber significantly contributed not only to improving the heat deflection temperature and the storage modulus, but also to improving the tensile, flexural, and impact properties of carbon fiber/ABS composites. The highest improvement of the composite properties was obtained from the composite with (epoxy + PU) dual-sized carbon fiber. The improvement of the mechanical and impact properties was explained by the enhanced interfacial bonding between carbon fiber and ABS matrix and by the length distribution analysis of carbon fibers present in the resulting composites. The fiber–matrix interfacial behavior was qualitatively well-supported in terms of fiber pull-out, fiber breaking pattern, and debonding gaps between the fiber and the matrix, as observed from the fracture surface topography. This study revealed that the properties of carbon fiber/ABS composites prepared by extrusion and injection molding processes were improved by dual-sizing carbon fiber, which was performed after a commercial epoxy sizing process, and further improved by using PU as an additional sizing material.

Adhesion Engineering in Polymer-Metal Comolded Joints with Biomimetic Polydopamine

Joints that connect thermoplastic polymer matrices (TPMs) and metals, which are obtained by comolding, are of growing importance in numerous applications. The overall performance of these constructs is strongly impacted by the TPM-metal interfacial strength, which can be tuned by tailoring the surface chemistry of the metal prior to the comolding process. In the present work, a model TPM-metal system consisting of poly(methyl methacrylate) (PMMA) and titanium is used to prepare comolded joints. The interfacial adhesion is quantified by wire pullout experiments. Pullout tests prior to and following surface modification are performed and analyzed. Unmodified wires show poor interfacial strength, with a work of adhesion (Ga) value of 3.8 J m-2. To enhance interfacial adhesion, a biomimetic polydopamine (PDA) layer is first deposited on titanium followed by a second layer of a poly(methyl methacrylate-co-methacrylic acid) (P(MMA-co-MAA)) copolymer prior to comolding. During processing, the MAA moieties of the copolymer thermally react with PDA, forming amide bonds, while MMA promotes the formation of secondary bonds and molecular interdigitation with the PMMA matrix. Control testing reveals that neither PDA nor the copolymer provides a substantial increase in adhesion. However, when used in combination, a significant increase in adhesion is detected. This observation indicates a pronounced synergistic effect between the two layers that strengthens the PMMA-titanium bonding. Enhanced adhesion is optimized by tuning the MMA-to-MAA ratio of the copolymer, which shows a maximum at a 24% MAA content and a greatly increased Ga value of 155 J m-2; this value corresponds to a 40-fold increase. Further growth in the Ga values at higher MAA contents is hindered by the thermal cross-linking of MAA; MAA contents above 24% restrict the formation of secondary bonds and molecular interdigitation with the PMMA chains. Our results provide new design principles to produce thermoplastic-metal comolded joints with strong interfaces.

Hierarchical Surface Texturing of Hydroxyapatite Ceramics: Influence on the Adhesive Bonding Strength of Polymeric Polycaprolactone

The tailored manipulation of ceramic surfaces gained recent interest to optimize the performance and lifetime of composite materials used as implants. In this work, a hierarchical surface texturing of hydroxyapatite (HAp) ceramics was developed to improve the poor adhesive bonding strength in hydroxyapatite and polycaprolactone (HAp/PCL) composites. Four different types of periodic surface morphologies (grooves, cylindric pits, linear waves and Gaussian hills) were realized by a ceramic micro-transfer molding technique in the submillimeter range. A subsequent surface roughening and functionalization on a micron to nanometer scale was obtained by two different etchings with hydrochloric and tartaric acid. An ensuing silane coupling with 3-aminopropyltriethoxysilane (APTES) enhanced the chemical adhesion between the HAp surface and PCL on the nanometer scale by the formation of dipole-dipole interactions and covalent bonds. The adhesive bonding strengths of the individual and combined surface texturings were investigated by performing single-lap compressive shear tests. All individual texturing types (macro, micro and nano) showed significantly improved HAp/PCL interface strengths compared to the non-textured HAp reference, based on an enhanced mechanical, physical and chemical adhesion. The independent effect mechanisms allow the deliberately hierarchical combination of all texturing types without negative influences. The hierarchical surface-textured HAp showed a 6.5 times higher adhesive bonding strength (7.7 ± 1.5 MPa) than the non-textured reference, proving that surface texturing is an attractive method to optimize the component adhesion in composites for potential medical implants.

A wet-processed, binder-free sulfur cathode integrated with a dual-functional separator for flexible Li-S batteries

Developing flexible, robust and lightweight sulfur cathodes by rationally designing their structures and configurations through a viable and scalable strategy is a critical enabler for fulfilling flexible lithium-sulfur (Li-S) batteries. However, besides the requirements for cathode flexibility, intrinsic limitations from the shuttling of lithium polysulfides and the growth of Li dendrites have restricted the widespread implementations of Li-S batteries. Here, we report a wet-processed strategy by dissolving and recrystallizing S in a suitable solvent to fabricate a flexible, binder-free S cathode. Integrating the resulting S cathode with a dual-functional separator has demonstrated to be able to suppress both the shuttle effect and growth of dendritic Li. The wet-processed strategy not only enables the fabrication of flexible and binder-free S-nanomat cathodes, but also facilitates the deposition of the cathodes on the separators. Meanwhile, a dual-functional separator is fabricated by vapor-phase polymerization of polypyrrole (PPy) coating on both surfaces of the commercial separator, which leads to the reduction of the shuttle effect and the suppression of the growth of dendritic Li simultaneously. As a result, by integrating the S-nanomat and the dual-functional separator, the cathode exhibits exceptional mechanical properties and electrochemical performance. Li-S pouch cells are further demonstrated to show stable cycling performance in the bending state, indicating the feasibility of the integrated S cathode for flexible Li-S batteries.

Polydopamine-Inspired Surface Modification of Polypropylene Hernia Mesh Devices via Cold Oxygen Plasma: Antibacterial and Drug Release Properties

Mesh infection is a major complication of hernia surgery after polypropylene (PP) mesh implantation. Modifying the PP mesh with antibacterial drugs is an effective way to reduce the chance of infection, but the hydrophobic characteristic of PP fibers has obstructed the drug adhesion. Therefore, to prepare antimicrobial PP mesh with a stable drug coating layer and to slow the drug release property during the hernia repair process has a great practical meaning. In this work, PP meshes were coated by bio-inspired polydopamine (PDA), which can load and release levofloxacin. PP meshes were activated with cold oxygen plasma and then plasma activated PP fibers were coated with PDA. The PDA coated meshes were further soaked in levofloxacin. The levofloxacin loaded PP meshes demonstrate excellent antimicrobial properties for 6 days and the drug release has lasted for at least 24 h. Moreover, a control PP mesh sample without plasma treatment was also prepared, after coating with PDA and loading levofloxacin. The antimicrobial property was sustained only for two days. The maximum inhibition zone of PDA coated meshes with and without plasma treatment was 12.5 and 9 mm, respectively. On all accounts, the modification strategy can facilely lead to long-term property of infection prevention.

One-Step Surface Functionalized Hydrophilic Polypropylene Meshes for Hernia Repair Using Bio-Inspired Polydopamine

An ideal hernia mesh is one that absorbs drugs and withstands muscle forces after mesh implantation. Polypropylene (PP) mesh devices have been accepted as a standard material to repair abdominal hernia, but the hydrophobicity of PP fibers makes them unsuitable to carry drugs during the pre-implantation of PP meshes. In this study, for the first time, one-step functionalization of PP mesh surfaces was performed to incorporate bio-inspired polydopamine (PDA) onto PP surfaces. All PP mesh samples were dipped in the same concentration of dopamine solution. The surface functionalization of PP meshes was performed for 24 h at 37 °C and 80 rpm. It was proved by scanning electron microscopic (SEM) images and Fourier Transform Infrared Spectroscopy (FTIR) results that a thin layer of PDA was connected with PP surfaces. Moreover, water contact angle results proved that surface functionalized PP meshes were highly hydrophilic (73.1°) in comparison to untreated PP mesh surfaces (138.5°). Thus, hydrophilic PP meshes with bio-inspired poly-dopamine functionalization could be a good choice for hernia mesh implantation.