Expanded Beads of High Melt Strength Polypropylene Moldable at Low Steam Pressure by Foam Extrusion

Design, Manufacturing and Acoustic Assessment of Polymer Mouthpieces for Trombones

Brass instruments mouthpieces have been historically built using metal materials, usually brass. With the auge of additive manufacturing technologies new possibilities have arisen, both for testing alternative designs and for using new materials. This work assesses the use of polymers for manufacturing trombone mouthpieces, specifically PLA and Nylon. The acoustical behavior of these two mouthpieces has been compared with the obtained from a third one, built from brass. Both additive and subtractive manufacturing techniques were used, and the whole manufacturing process is described. The mouthpieces were acoustically assessed in an anechoic chamber with the collaboration of a professional performer. The harmonic analysis confirmed that all the manufactured mouthpieces respect the harmonic behavior of the instrument. An energy analysis of the harmonics revealed slight differences between the mouthpieces, which implies differences in the timbre of the instrument. Although these subtle differences would not be acceptable when performing with the instrument in an orchestra, they could be perfectly valid for early learners, personal rehearsals or any kind of alternative performance.

Microfoamed Strands by 3D Foam Printing

We report the design, production, and characterization of microfoamed strands by means of a green and sustainable technology that makes use of CO₂ to create ad-hoc innovative bubble morphologies. 3D foam-printing technology has been recently developed; thus, the foaming mechanism in the printer nozzle is not yet fully understood and controlled. We study the effects of the operating parameters of the 3D foam-printing process to control and optimize CO₂ utilization through a maximization of the foaming efficiency. The strands’ mechanical properties were measured as a function of the foam density and explained by means of an innovative model that takes into consideration the polymer’s crystallinity content. The innovative microfoamed morphologies were produced using a bio-based and compostable polymer as well as polylactic acid and were then blown with CO₂. The results of the extensive experimental campaigns show insightful maps of the bubble size, density, and crystallinity as a function of the process parameters, i.e., the CO₂ concentration and temperature. A CO₂ content of 15 wt% enables the acquirement of an incredibly low foam density of 40 kg/m³ and porosities from the macro-scale (100–900 μm) to the micro-scale (1–10 μm), depending on the temperature. The foam crystallinity content varied from 5% (using a low concentration of CO₂) to 45% (using a high concentration of CO₂). Indeed, we determined that the crystallinity content changes linearly with the CO₂ concentration. In turn, the foamed strand’s elastic modulus is strongly affected by the crystallinity content. Hence, a corrected Egli’s equation was proposed to fit the strand mechanical properties as a function of foam density.

Polymer Composite with Enhanced Thermal Conductivity and Insulation Properties through Aligned Al2O3 Fiber

Thermoplastic polyolefins, such as polyethylene (PE), are traditionally one of the most widely used polymer classes with applications in the electric industry, and their nanocomposites have caught the interest of researchers. The linear filler is shown to be beneficial in decreasing the charge injection and hindering the formation of charge packs. So, we demonstrate a novel composite with excellent properties. The low-density polyethylene (LDPE) composite with aligned aluminum oxide (Al₂O₃) fiber has been prepared in electric field conditions. The direction of the Al₂O₃ fiber was parallel to the thickness direction of the LDPE composite. The breakdown strength of the Al₂O₃/LDPE composite with 0.2% aligned Al₂O₃ fiber was 498 kV/mm, which is higher than other fillers induced. The aligned Al₂O₃ fiber has effect on preventing accumulation of space charge and reducing the amount of free electron in the material. In addition, the thermal conductivity of the LDPE composite (0.22 W/m·K) was increased to 0.85 W/m·K when doped with 0.5 wt% aligned Al₂O₃ fiber. The present structure provides a new possibility for mass new nanocomposites with excellent microstructures and remarkable functionality.

The Investigation of Key Factors in Polypropylene Extrusion Molding Production Quality

This study took food-grade polypropylene packaging products as the research project and discussed how to control the polypropylene extrusion sheet thickness and vacuum thermoforming quality and weight. The research objective was to find the key factors for reducing costs and energy consumption. The key aspects that may influence the polypropylene extrusion molding quality control were analyzed using literature and in-depth interviews with scholars and experts. These four main aspects are (1) key factors of polypropylene extrusion sheet production, (2) key factors of the extrusion line design, (3) key factors of polypropylene forming and mold manufacturing, and (4) key factors of mold and thermoforming line equipment design. These were revised and complemented by the scholar and expert group. There are 49 subitems for discussion. Thirteen scholars and experts were invited to use qualitative and quantitative research methods. A Delphi questionnaire survey team was organized to perform three Delphi questionnaire interviews. The statistical analyses of encoded data such as the mean (M), mode (Mo), and standard deviation (SD) of various survey options were calculated. Seeking a more cautious research theory and result, the K-S simple sample test was used to review the fitness and consistency of the scholars’ and experts’ opinions on key subitem factors. There are ten key factors in the production quality, including “A. Main screw pressure”, “B. Polymer temperature”, “C. T-die lips adjustment thickness”, “D. Cooling rolls pressing stability”, “E. Cooling rolls temperature stability”, “F. Extruder main screw geometric design”, “G. Heating controller is stable”, “H. Thermostatic control”, “I. Vacuum pressure”, and “J. Mold forming area design”. The key factors are not just applicable to classical polypropylene extrusion sheet and thermoforming production but also to related process of extrusion and thermoforming techniques in expanded polypropylene (EPP) sheets and polylactic acid (PLA). This study aims to provide a key technical reference for enterprises to improve quality to enhance the competitiveness of products, reduce production costs, and achieve sustainable development, energy savings, and carbon reductions.