Dynamics of the sub-ambient gelation and shearing of solutions of P3HT and P3HT blends towards active layer formation in bulk heterojunction organic solar cells

Organic solar cells (OSCs) containing an active layer consisting of a nanostructured blend of a conjugated polymer like poly(3-hexylthiophene) (P3HT) and an electron acceptor have the potential of competing against silicon-based photovoltaic panels. However, this potential is largely unfulfilled first due to interrelated production and stability issues of organic solar cells and second due to the unscalable nature of the generally employed spin coating process used for the fabrication of organic solar cells. Furthermore, alternatives to spin coating, especially relying on continuous polymer processing methods like extrusion and coating, cannot be readily applied due to the typically low shear viscosity and elasticity of polymer solutions making up the active layer. Recently, He et al. have reported that the gelation of P3HT with [6,6]-phenyl-C61-butyric acid methyl ester (PC60BM) under sub-ambient conditions can provide a new route to the processing of the active layers of bulk heterojunction solar cells. Furthermore, increases in power conversion efficiencies (PCEs) of the P3HT/PC60BM active layer were determined to be possible under certain shearing and thermal histories of the P3HT/PC60BM gels. Here oscillatory and steady torsional flows were used to investigate the gel formation dynamics of P3HT with a recently proposed non-fullerene acceptor o-IDTBR under sub-ambient conditions and compared with the gelation behavior of P3HT/PC60BM blends. The rheological material functions as well as the gel strengths defined on the basis of linear viscoelastic material functions, characterized via small-amplitude oscillatory shearing, were observed to be functions of the P3HT and o-IDTBR concentrations, the solvent used and the shearing conditions. Overall, the P3HT gels which formed upon quenching to sub-zero temperatures were found to be stable during small-amplitude oscillatory shear (linear viscoelastic range) but broke down even at the relatively low shear rates associated with steady torsional flows, suggesting that the shearing conditions used during the processing of gels of P3HT and blends of P3HT with small molecule acceptors can alter the gel structure, possibly leading to changes in the resulting active layer performance.

Three-Dimensional, Non-Isothermal Simulations of the Effect of Speed Ratio in Partially-Filled Rubber Mixing

Three-dimensional, transient, non-isothermal calculations have been carried out using a commercial computational fluid dynamics (CFD) software in a two-wing rotor-equipped chamber partially-filled (75% fill factor) with rubber, to analyze the mixing efficiency for three different rotor speed ratios of 1, 1.125 and 1.5. The moving mesh technique has been used to incorporate the motion of the rotors. The Eulerian based volume of fluid (VOF) method has been used to track the interface between the two fluids, which are rubber and air. To assign the highly viscous and non-Newtonian properties of rubber, the Carreau-Yasuda model along with an exact Arrhenius formulation that accounts for the shear and temperature dependent viscosity, has been used here. Governing equations including the continuity, momentum and energy equations have been solved to characterize the flow field and various mixing parameters. Eulerian-based fields such as velocity magnitude, viscous heat generation, and average temperature and viscosity are compared between cases with different speed ratios. Dispersive and distributive mixing behaviour are assessed through a Lagrangian approach that tracks the paths of a set of massless particles. Statistical quantities such as cumulative distribution of maximum shear stress, cluster distribution index, and axial and inter-chamber particle transfer rates are calculated and presented as well. Results showed that the speed ratio of 1.5 displayed the best dispersive and distributive mixing characteristics in comparison to the other cases.

Simulation of Co-Rotating Twin Screw Extrusion Process Subject to Pressure-Dependent Wall Slip at Barrel and Screw Surfaces: 3D FEM Analysis for Combinations of Forward- and Reverse-Conveying Screw Elements

Mathematical modeling and simulation of the coupled flow, deformation, heat and mass transfer, and rate of reactions occurring in the twin screw extruder allow the optimization of process parameters and the screw and barrel geometries. In mathematical modeling of the twin screw extrusion process the conventional flow boundary condition at the screw and barrel walls is the no-slip condition. However, most complex fluids, including polymers, polymeric suspensions and blends, exhibit wall slip, with the slip behavior depending on the intrinsic properties of the materials being processed, the operating conditions, the geometries of the barrel, screw and the die, and the properties of the solid surfaces. Typically, the slip velocity is specified to be a function of temperature, stress condition at the wall and the materials of construction. However, recent investigations have further revealed that the wall slip behavior can also be significantly affected by pressure. With an objective of considering the effects of wall slip on the dynamics of twin screw extrusion, fully-intermeshing co-rotating twin screw extrusion of a concentrated suspension is analyzed using three-dimensional finite element method, FEM, subject to the wall slip boundary condition. The wall slip boundary condition is first applied systematically to barrel and screw surfaces individually followed by the application of wall slip to both surfaces simultaneously. In an integrated fashion both the forward-conveying (pressure-generating) and reverse-conveying (pressure-losing) screw sections are considered. The effects of pressure on wall slip are also analyzed and elucidated.

A Direct 3D Numerical Simulation Code for Extrusion and Mixing Processes

This work focuses on the development of a general finite element code devoted to the three-dimensional direct simulation of mixing processes of complex fluids. The code, developed from the CimLib© Library, is based on a domain immersion method coupled with a “level-set” approach to represent the rigid moving boundaries, such as screws and rotors, as well as free surfaces. These techniques, combined with the use of automatized parallel computing, allow calculating the time-dependent flow of generalized Newtonian fluids in large and complex processes, involving moving free surfaces which are treated by a level-set/Hamilton-Jacobi method. Three examples of flow case studies are presented in this paper: the flow within the mixing section of a twinscrew extruder, the flow in an internal mixer and the flow in a batch mixer.

Three-dimensional Finite Element Solution of the Flow in Single and Twin-Screw Extruders

This work is aimed at the numerical modeling of the flow inside single and twin-screw extruders. Numerical solutions are obtained using a recently developed immersed boundary finite element method capable of solving the flow in the presence of complex non-stationary solid boundaries. The method is first validated against the solution obtained on a body-conforming grid for a single screw extruder and then applied to a twin-screw mixer. The time dependent single screw problem can also be solved in a rotating reference frame for which a steady state solution can be obtained. This allows the evaluation of time integration errors of the moving immersed interface algorithm. For instance the flow is considered isothermal and the material behaves as a Generalized Newtonian fluid. Because the viscosity depends on the shear rate, solutions will be shown for various rotation velocities of the screw and compared with solutions obtained on body-conforming grids. The method is shown to give very accurate results and can be used for a more in-depth investigation of the material behavior in extruders.

An Integrated Approach for Numerical Analysis of Coupled Flow and Heat Transfer in Co-rotating Twin Screw Extruders

The co-rotating twin screw extrusion process is widely employed in chemical industries for the processing of complex fluids including various polymers, suspensions, emulsions and gels. Here we propose a new integrated modeling strategy that is based on the numerical analysis of pressure-generating extrusion elements concomitantly with the pressure-losing extrusion elements of the co-rotating twin screw extrusion process for non-Newtonian fluids under nonisothermal conditions. The numerical analysis undertakes three-dimensional (3-D) finite element simulations of any multiple combinations of forwarding and reversing fully-flighted screw elements with other types of elements including kneading discs staggered in the forward or reverse configurations and the die. The abilities of the methodologies in simulating the coupled flow and heat transfer in industrially-relevant mixing sections or pressurization/die shaping are demonstrated with predictions of the degree of fill and typical velocity, deformation rate, stress magnitude, pressure distributions as functions of various operating parameters and basic twin screw extrusion geometries for a viscoplastic type generalized Newtonian fluid.

Tip-clearance Effect on Mixing Performance of Twin Screw Extruders

In order to evaluate the tip-clearance effect on mixing, 3-D numerical simulations were applied to kneading block section of co-rotating twin screw extruders. The software we used was originally developed for non-Newtonian and non-isothermal flow analysis based on the finite element technique. The marker-particle tracking analysis was also developed in order to estimate the particle path, residence time distribution, stress and strain history, and so on.

The stress distribution obtained by the above-mentioned simulations suggested the following mixing mechanisms. The kneading block with the small tip-clearance (TC) caused the bimodal stress distribution which had peaks in both high and low stress level. The marker-particles which overpassed the TC formed the peak at the high stress level and the other particles contributed to the peak at the low stress level. In other words, a large number of particles evaded the TC and it caused heterogeneous stress induced mixing. On the other hand, the large tip-clearance caused the narrow and sharp stress distribution because most of the particles passed over the TC. The stress level was not high, however, homogeneous stress induced mixing was expected. Since the tip-clearance applied a significant effect to the dispersive mixing, it should be optimised in accordance with the material design.

Three-dimensional Numerical Study of the Mixing Behaviour of Twin-screw Elements

In this work the numerical modeling of the flow inside co-rotating twin-screw extruders is performed and solutions are analyzed to determine the mixing behavior of two screw elements: conveying and mixing elements. The flow around intermeshing screws is computed using an immersed boundary finite element method capable of dealing with complex moving solid boundaries. The flow is considered isothermal and the material behaves as a generalized non-Newtonian fluid. Because the viscosity depends on the shear rate, solutions will be shown for various rotation velocities of the screw. The 3D solutions are then analyzed in order to determine various parameters characterizing the flow mixing such as the residence time and the linear stretch. Residence time distribution inside the twin-screw extruder is first computed by using a particle tracking algorithm based on a fourth order Runge-Kutta method. A large number of particles are tracked inside the extruder and the resulting particle data is used to determine the distribution of the residence time and of the linear stretch. The spatial distribution of the residence time is also computed by solving a transport equation tracking the injection time of the polymer melt. The methodology shows important differences in the mixing behavior of the screw elements considered.

Unitary bioresorbable cage/core bone graft substitutes for spinal arthrodesis coextruded from polycaprolactone biocomposites

A unitary bioresorbable cage/core bone graft substitute consisting of a stiff cage and a softer core with interconnected porosity is offered for spinal arthrodesis. Polycaprolactone, PCL, was used as the matrix and hydroxyapatite, HA, and β-tricalcium phosphate, TCP, were used in the formulation of the cage layer to impart modulus increase and osteoconductivity while the core consisted solely of PCL. The crystallinity, biodegradation rate (under accelerated conditions) and mechanical properties, i.e., the uniaxial compression, relaxation modulus upon step compression and cyclic compressive fatigue properties, of the co-extruded cage/core bone graft substitutes could be manipulated by changes in the concentration of HA/TCP in the cage layer. The cyclic fatigue behavior of the cage/core bone graft substitutes were also compared to the behavior of bovine vertebral cancellous bone characterized under similar testing conditions. The biocompatibility of the cage/core bone graft substitutes were assessed via in vitro culturing of human bone marrow derived stromal cells, BMSCs. The cell proliferation rates, time dependencies of the alkaline phosphates (ALP) activity and the expressions of bone markers, i.e., Runx2, ALP, collagen type I, osteopontin and osteocalcin, and the collected μ-CT images demonstrated the differentiation of BMSCs via osteogenic lineage and formation of mineralized bone tissue to indicate the biocompatibility of the cage/core bone graft substitutes.

Biomass pretreatment strategies via control of rheological behavior of biomass suspensions and reactive twin screw extrusion processing

Twin screw extrusion based pretreatment of biomass is an attractive option due to its flexibility to carry out chemical reactions under relatively high stresses, temperatures and pressures. However, extrusion processes are rarely utilized in biomass pretreatment because such processing is constrained by rheological behavior of typical biomass suspensions. Without the manipulation of their rheological behavior, biomass suspensions become unprocessable within the extruder at modest biomass concentrations. Here it is demonstrated that gelation agents can render biomass suspensions processable. Specifically, carboxy methyl cellulose, CMC, could be used in conjunction with alkaline pretreatment of hardwood-type biomass and enabled separation of lignin from cellulose fibers. Furthermore, recycled black liquor, obtained upon pretreatment, was determined to be as effective as CMC for rendering biomass suspensions flowable by again facilitating the concomitant application of high shearing stresses and chemical treatment for the pretreatment of the biomass in the twin screw extruder.

In vitro analysis and mechanical properties of twin screw extruded single-layered and coextruded multilayered poly(caprolactone) scaffolds seeded with human fetal osteoblasts for bone tissue engineering

In vitro culturing and mechanical properties of three types of three-dimensional poly(caprolactone) scaffolds with interconnecting open-foam networks are reported. The scaffolds targeted bone tissue regeneration and were fabricated using twin screw extrusion and coextrusion techniques, for continuous mixing/shaping and formation of single or multilayers with distinct and tailorable porosities and pore sizes. Human fetal preosteoblastic cells, hFOB, were cultured on the extruded and coextruded scaffolds under osteogenic supplements and the samples of the resulting tissue constructs were removed and characterized for cell viability and proliferation using the MTS assay, differentiation, and mineralized matrix synthesis via the alkaline phosphatase, ALP, activity and Alizarin Red staining and cell migration using confocal microscopy and scanning electron microscopy. The hFOB cells formed a confluent lining on scaffold surfaces, migrated to the interior and generated abundant extracellular matrix after 2 weeks of culturing, indicative of the promise of such scaffolds for utilization in tissue engineering. The scaffolds and tissue constructs exhibited compressive fatigue behavior that was similar to that of cancellous bone, suggesting the suitability of their use as bone graft substitutes especially for repair of critical-sized defects or nonunion fractures.