Innovative sensor-based processing technology of nanostructured multifunctional hybrids and composites MULTIHYBRIDS

Transcription

1 Innovative sensor-based processing technology of nanostructured multifunctional hybrids and composites MULTIHYBRIDS Piero CAVIGLIASSO Proplast - Plastics Innovation Pole - Italy

2 Participant no. Participants organisation name Short name Country 1 Consorzio per la Promozione della Cultura Plastica PROPLAST I 2 Centre National de la Recherche Scientifique Délégation Rhône-Auvergne. CNRS F 3 Aston University ASTON UK 4 Leistritz Extrusiontechnik GmbH LAG-LEX D 5 C.E.A.S.T. S.p.A. - Compagnia Europea Apparecchi Scientifici Torino CEAST I 6 Leibniz-Institut für Polymerforschung Dresden e.v. IPF D 7 University of Minho UMinho P 8 PEMŐ Plastic Processing Corporation PEMU HU 9 Schneider Electric Industries SAS SCHNEIDER F 10 Basell Poliolefine Italia S.p.A. BASELL I 11 Association pour la Recherche et le Développement des Méthodes et Processus Industriels ARMINES F 12 University of Trieste UNITS I 13 Technologie-orientierte Partikel-, Analysen- und Sensortechnik TOPAS D 14 SYNPO, akciova spolecnost SYNPO CZ 15 OPW Doskomp Sp. z o.o. DOSKOMP PL 16 Budapest University of Technology and Economics BUTE HU 17 Université Louis Pasteur ULP-LIPHT F 18 Materials Design & Processing S.r.l. MDP I 19 Commissariat à l'energie Atomique CEA F 20 ELETTRONICA CONDUTTORI S.R.L. ELC I 21 PLASTIQUES RG PLASTIQUES RG F 22 European Center for Nanostructured Polymers and Nanocomposites ECNP INT

3 Background to Multihybrids concepts From the call knowledge-based achievement of of a production process which which would would lead lead from from the the concept idea idea to to a defined product without without the the necessity of of further further process adjustment and/or and/or prototype production Within MULTIHYBRIDS Multifunctional polymer nanocomposites

4 Background to Multihybrids concepts Nanocomposites state of the art Within MULTIHYBRIDS extraordinary combination of of properties enhancement with with less less than than 5% 5% of of nanofillers but but not not yet yet a rational basis basis available concerning: --materials formulation --process --characterisation Inspection of of the the nanostructuration mechanism throughout the the nanocomposite processing

5 Multihybrids main objectives Selection of sensors and probes for in-line monitoring of processing nanostructuration Assessment of viability of alternative approaches to nanofillers introduction in the polymer matrix -preformed organophilic nanofillers - in processing nanofillers modification - in processing nanofillers synthesis Validation of morphology evaluation methods Validation through production by by extrusion compounding of of thermoplastic polymer nanocomposites to to be be tailor tailor made made for for several specific applications selected by by the the industrial partners

6 MULTIHYBRIDS MAIN MAIN OBJECTIVE multi multi equipped extruder to to monitor nanocomposite extrusion process

7 Multihybrids approach ADVANCED SPACIALITY MULTIFUNCTIONAL NANOMATERIALS Newly developed materials Reactive processing Melt -reactive blending In process monitoring Newly developed production processes Modification of commercial nanofillers for reaction/compatibilisation Ex-situ-synthesis of nanofillers from inorganic precursors. Masterbathces Newly developed nanofillers

8 Multihybrids expertise integration Nanofillers and In-line Process nanocomposite Monitoring characterisation LIPTH - light scattering TOPAS - Particle size IPF Spectroscopy UMinho - Rheology On-line/Off-line Characteristics Monitoring CEAST rheology ASTON in-situ compatibilisation PROPLAST - morphology, thermal, combustion MDP - LCA Process modelling and optimisation ARMINES-flow modeling UNITS-molecular simulation Nanocomposite production BASELL-polyolefin based materials In Situ nanofillers synthesis and modification Nanofillers and nanocomposite CNRS - sol-gel without solvent preparation BUTE - inorganic-organic silicon compounds Melt Blending PROPLAST melt blending & reactive processing LAG-LEX extruder set up MultiHybrids Project Industrial application SCHNEIDER - E&E PEMU - automotive ELC electrical cables SYNPO automotive coatings PLASTIQUES RG packaging CEA MEMS-µfuel cells Dissemination & training tools and facilities DOSKOMP e-learning ECNP - facilities

9 Multihybrids approach SP2 Nanofactory implementation WP2.1 End use materials: preparation WP2.2 Real time monitoring of the nanocomposite/hybrid formation Preparation of different typologies of nanocomposites by melt blending and reactive blending for partners in SP4 Production of new generation of nanocomposites in agreement with industrial applications Final choice of the most suitable techniques for in-line/on-line monitoring SP4 Post-production analysis WP4.1 Characterisation of extent of dispersion and distribution of nanofillers in polymers WP4.2 Characterisation and robustness of through on-line and off-line characterization WP4.3 Characterisation of the end-use required properties WP4.4 Process scale-up Characterisation of nanofiller morphology evolution and structure of nanocomposites produced Validation of in-line and on-line methodology Nanocomposite structure/material properties: preliminary roadmap for endusers to achieve the desired properties Decision on the adaptability of portable sensors to semi-industrial production scale SP5 Product Competitiveness WP5.1 Scale up assessment for all targeted application WP5.2 Design of prototypes WP5.3 Prototypes manufacturing and evaluation of product properties WP5.5 Life Cycle Engineering Definition of the economic impact for each end-user Definition of design of each prototype Evaluation of the prototype product evaluation of the environmental impacts of the new materials developed

10 Multihybrids: main technical achievements after 42 months

11 Multihybrids: main technical achievements in the first three years and contractors involved Modeling/simulation of the nanocomposite preparation by melt blending Selection and adaptability check of the sensors to the extrusion process Production of new generation of nanocomposites in agreement with industrial applications Specification of the in-line/on-line methods for industrial use on extruders Validation of the on-line and in-line process methods by comparison with different off-line methods

12 Studied materials Application sector End-User Partners End use/strategy Properties to be addressed /enhanced Materials: NC composition Electrical cables ELC, Proplast, ECNP, AUPPP Insulating material Flame retardancy Maintaining mech.properties before and after thermal ageing PP+Reograd (BUTE)+MMT + Sepio+ stabiliser TPU+Reograd (BUTE)+MMT +Sepio Low voltage circuit breaker SCHNEIDER Proplast,, ECNP 1. PA6 based material 2. Alternative PP based material (glass fibers use predicted) Flame retardancy Maintaining of mech.properties Flame retardancy Maintaining of mech.properties PA6+CD1 Addition of GF to be checked PP500N+nanofillers+ GF FR to be checked Packaging: Butter tube Fresh products tube Cosmetics tube PLASTIQUE RG CNRS-IMP, Proplast, ECNP Substitution of benchmark materials Standard barrier resistance properties Improvement of impact resistance Antibacterial properties PP+PPgMA+C20A UV and barrier resistance checked PP+F100 UV and barrier resistance underway PP/TiO 2 and PP/EVOH/ TiO 2 Antimocrobial resistance underway

13 Studied materials

14 Common strategy followed in the project Layered nanofillers Needle-like nanofillers In situ TiO 2 Nanotubes Barrier properties Flame retardancy Paint adhesion Flame retardancy (glow wire) Antibacterial Conductivity SCHNEIDER SCHNEIDER PLASTIQUES CEA PLASTIQUES PEMU ELC SYNPO CEA

15 Monitoring techniques choice Partner Sensoring Technical solution developed field within MULTIHYBRIDS CEAST Rheology Capillary IPF Spectroscopy NIR Ultrasonic IPF/TOPAS Optical Particle sensoring UNIMINHO Rheology Shear ULP-LIPTH Optical Light scattering sensor Techniques already validated and tested on a large scale apparatus Different status of industrial portability

16 Last 6 months activities Design of prototypes Prototypes manufacturing and properties evaluation Demonstrator manufacturing and validation