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På grund av den rådande klimatförändringen och de globala problem som plast orsakar i miljön blir det allt viktigare att dagens linjära materialanvändning ändras till en cirkulär användning. Inom fordonsindustrin har kravet på ökad tillgänglighet och kvalitet på återvunna material identifierats. Som följd startades forskningsprojektet Sustainable Vehicle Interior Solutions (SVIS) samordnat av RISE IVF där behovet av en mer hållbar produktion av fordonsinteriörer tas upp. Ett mål är att minska och återvinna produktionsavfall. Den här studien undersöker möjligheten att återvinna textil och plast från en interiör komponent av multimaterial, som i detta fall är en textilklädd plaststolpe. Stolpen är gjord av polykarbonat (PC)/poly(akrylnitril-butadien-styren) (ABS) plast och polyestertextil (PET). Mekanisk återvinning utfördes på den textilklädda stolpen. Möjligheten att separera textil från plast undersöktes och testades i en kvarn med en dammavskiljare. Prover innehållande olika mängder PET förberedes och återvanns för att studera påverkan av PET på materialegenskaperna. Två olika kompatibiliseringsmedel användes för att undersöka om blandningarnas kompatibilitet ökade. Hur väl textil separerats från plast analyserades genom jämförelse av bulkdensitet mellan proverna. För att undersöka effekten av kompatibiliseringsmedel och hur förekomsten av PET påverkar PC/ABS utfördes mekanisk testning, DSC och SEM. Resultaten visade att separationen av textil från plast inte var fullständig på grund av mycket hög vidhäftning mellan textilen och plasten. Bibehållna mekaniska egenskaper, förutom brottförlängning, erhölls för alla återvunna prover oavsett PET-mängd. Därför var det möjligt att dra slutsatsen om att förekomsten av PET inte påverkar materialets egenskaper negativt och att separation eller tillsats av kompatibiliseringsmedel inte är nödvändigt. Vidare visar resultaten att PET blir blandbar med PC men inte påverkar ABS-fasen. Kemisk återvinning genom glykolys utfördes på svart och beige polyestertextil av PET erhållet som avklipp från produktionen av stolparna. Glykolysen utfördes i laboratorieskala med etylenglykol (EG) som lösningsmedel. Reaktionen ägde rum vid 230℃ under 1 timme med överskott av lösningsmedel och en Mg-Al blandad oxidkatalysator. Slutprodukten separerades från rester genom flera filtreringssteg och analyserades med DSC. Från resultatet observerades det att den erhållna slutprodukten var den önskade bis(2-hydroxyetyl) tereftalat (BHET) monomeren. Färgämnen från textilen fanns fortfarande kvar i monomeren efter depolymerisation. Därför utfördes avfärgning. För den svarta textilen testades adsorption med aktivt kol och extraktion med etylenglykol som avfärgningsmetoder. För den beige textilen utfördes enbart adsorption med aktivt kol. De avfärgade produkterna analyserades genom färgmätning och/eller genom jämförelse med varandra. Resultatet visade att adsorption med aktivt kol är en effektiv avfärgningsmetod för den beige textilen, men inte för den svarta textilen. Framgångsrik avfärgning av den svarta textilen erhölls istället genom extraktion med etylenglykol. Sammanfattningsvis, mekanisk återvinning av den textilklädda stolpen resulterar i bibehållna värden för de mekaniska egenskaperna hos det återvunna materialet, förutom för brottförlängnigen. Detta bör göra det återvunna materialet lämpligt för användning i fordonsapplikationer, men inte för återvinning i ett slutet kretslopp (closed loop recycling) på grund av säkerhetsaspekter hos stolpen. Om hög kraft appliceras måste materialet kunna ändra form utan att gå sönder. Återvinning genom glykolys visar potential för att den avklippta polyestertextilen kan återvinnas i ett slutet kretslopp eftersom den avfärgade monomeren skulle kunna ompolymeriseras till ny PET. Det kan undersökas i framtida studier. / Due to the current climate change and the global problems plastics cause in the environment, it becomes increasingly important that today’s linear use of materials is changed to a circular use. In the automotive industry, the demand for increased availability and quality of recycled materials has been recognized. Following this, the research project Sustainable Vehicle Interior Solutions (SVIS) coordinated by RISE IVF was started in which the need for a more sustainable production of vehicle interiors is addressed. An objective is to reduce and recycle production waste. This study investigates the possibility to recycle textile and plastic from an interior multi-material component which in this case is a textile dressed plastic pillar. The pillar is made of polycarbonate (PC)/poly(acrylonitrile butadiene styrene) (ABS) plastic and polyester (PET) textile.  Mechanical recycling was performed on the textile dressed pillar. The possibility to separate textile from plastic was investigated and tested in a mill with a dust separator. Samples containing different amounts of PET were prepared and recycled to study the influence of PET. Two different compatibilizers were used to investigate potential improvement in compatibility of the blends. The level of separation of textile from plastic was analyzed by comparison of bulk density between the samples. To investigate the effect of compatibilizers and how the presence of PET influences the PC/ABS, mechanical testing, DSC and SEM were performed. The results showed that the separation of textile from plastic was not complete due to very high adhesion between the textile and plastic. Retained mechanical properties, except for the strain at break, were obtained for all recycled samples. Therefore, it could be concluded that the presence of PET does not affect the properties of the material negatively and separation or addition of compatibilizer is unnecessary. The results further show that PET becomes miscible with PC but does not affect the ABS phase. Chemical recycling through depolymerization with glycolysis was performed on black and beige polyester (PET) textile waste obtained as cut-off from the production of the pillars. The glycolysis was performed in lab-scale with ethylene glycol (EG) as solvent. The reaction took place at 230℃ for 1h with excess of solvent and a Mg-Al mixed oxide catalyst. The final product was separated from residues through several filtration steps and analyzed with DSC. From the result it could be observed that the obtained final product was the desired bis(2-hydroxyethyl) terephthalate (BHET) monomer. Dyes from the textile were still present in the monomer after depolymerization. Therefore, decolorization was performed. For the black textile, adsorption with active carbon and extraction with ethylene glycol were tested as decolorization methods. For the beige textile, solely adsorption with active carbon was performed. The decolorized products were analyzed by color measurement and/or through comparison to each other. The result showed that adsorption with active carbon is an effective decolorization method for the beige textile, but not for the black textile. Successful decolorization of the black textile was instead obtained by extraction with ethylene glycol.  To conclude, mechanical recycling of the textile dressed pillar results in retained values of the mechanical properties of the recycled material, except for the strain at break. This should make the recycled material suitable for use in automotive application, though not closed loop recycling because of safety aspects of the pillar. If high force is applied, the material needs to be able to change shape without breaking. Recycling through depolymerization shows potential for closed loop recycling of the polyester textile cut-off since the decolorized monomer could be repolymerized into new PET. This could be investigated in future studies.

No / In tensile stretching, many polymers undergo strain localization. The geometrical form of the localization can take the form of either a shear band or an approximately symmetric neck. We present a constitutive model of the early stages of deformation that predicts which form the localization will take. The model consists of an Eyring process acting with a Gaussian network that is implemented numerically. A Levy-Mises flow rule associated with the Eyring process has a tendency to produce shear bands. A relatively stiff Gaussian network is used in a model of polycarbonate that ensures that most of the strain is taken up by the Eyring process, resulting in shear banding. In contrast, a relatively soft Gaussian network is used in a model of polyethylene, which takes up the greater part of the strain, resulting in a neck. The predictions are compared with experiments. For polyethylene, a two-Eyring-process model is introduced for better accuracy.

The marked increase in surface-to-volume ratio associated with microscale devices for hemodialysis leads to problems with hemocompatibility and blood flow distribution that are more challenging to manage than those encountered at the conventional scale. In this work, stable surface modifications with pendant polyethylene oxide (PEO) chains were produced on polycarbonate microchannel and polyacrylonitrile membrane materials used in construction of microchannel hemodialyzer test articles. These coatings were evaluated in relation to protein repulsion, impact on urea permeability through the membrane, and impact on bubble retention through single-channel test articles. PEO layers were prepared by radiolytic grafting of PEO-PBD-PEO (PBD = polybutadiene) triblock copolymers to microchannel and membrane materials. Protein adsorption was detected by measurement of surface-bound enzyme activity following contact of uncoated and PEO-coated surfaces with ��-galactosidase. Protein adsorption was decreased on PEO-coated polycarbonate and polydimethyl siloxane (PDMS) materials by 80% when compared to the level recorded on uncoated materials. Protein adsorption on membrane materials was not decreased with PEO-PBD-PEO treatment; a PEI (polyethylene imide) layer exists on the AN69 ST membrane which is intended to trap heparin during membrane pre-treatment. It is still unclear how this PEI layer interacts with PEO-PBD-PEO. Neither the PEO-PBD-PEO triblocks nor the irradiation process was observed to have any effect on polyacrylonitrile membrane permeability to urea, nor did the presence of additional fibrinogen and bovine serum albumin (BSA) in the urea filtrate. The PEO-PBD-PEO treatment was not able to visibly reduce bubble retention during flow through single-channel polycarbonate test articles, however, the rough surfaces of the laser-etched polycarbonate microchannels may be causing this bubble retention. This surface treatment holds promise as a means for imparting safe, efficacious coatings to blood processing equipment that ensure good hemocompatibility and blood flow distribution, with no adverse effects on mass transfer. / Graduation date: 2013

Glasträger sind in einer auf Transparenz ausgerichteten Bauweise zunehmend gefragt. Üblicherweise bestehen diese lastabtragenden Elemente aus mehreren Glasscheiben, verbunden mit Polyvinylbutyral-Folie (PVB-Folie), und gleichen in ihrem Aufbau somit Verbund-Sicherheitsglas (VSG). VSG-Träger besitzen bei vollständigem Glasbruch keine Resttragfähigkeit und werden daher in Dicke und Aufbau mit dem Ziel ausgelegt, vollständigen Glasbruch zu vermeiden. Hybride Glasträger kombinieren in der Regel Glas mit einem duktilen Material und besitzen im Falle des vollständigen Glasbruchs ein duktiles Versagensverhalten. Sie stellen damit eine vielversprechende Option zur Erfüllung des geforderten Sicherheitsniveaus bei Glasträgern dar. Die in der vorliegenden Arbeit betrachteten hybriden Träger entstehen durch die flächige Verklebung von Glas- und transparenten Kunststoffscheiben mit einem ebenfalls transparenten Klebstoff. Bei vollständigem Glasbruch stellt sich ein Tragverhalten ein, bei dem infolge des Klebstoffverbunds der Kunststoff die Zugspannungen und das gebrochene Glas weiterhin Druckspannungen aufnimmt. Die erste Auswahl von Klebstoff und Kunststoff basiert auf Voruntersuchungen an kleinformatigen Prüfkörpern. Die erforderliche Kantenqualität von Floatglas wurde anhand von Vierpunkt-Biegeuntersuchungen bestimmt. Zur weiteren Beurteilung der Eignung des Klebstoffs dienen Klimawechseltests an kleinformatigen Hybridbauteilen, da zwischen Glas und Kunststoff deutliche Unterschiede in der Temperaturausdehnung vorliegen. Aufbauend auf den durchgeführten Untersuchungen wurden das Kunststoffmaterial Polycarbonat und ein niedrigviskoser UV- und strahlungshärtender Acrylatklebstoff, der im ausgehärteten Zustand über hohe Nachgiebigkeit verfügt, für die weiteren mechanischen Untersuchungen an Prüfkörpern im Bauteilformat ausgewählt. Kurzzeitversuche mit kraftgesteuerter Belastungsaufbringung und unter Variation von Polycarbonatdicke, Trägerhöhe und Glasart geben Aufschluss über das Trag- und Resttragfähigkeitsverhalten. Sie stellen die prinzipielle Wirkweise der Hybridträger vor und nach Bruch dar. Vergleichende Versuche an VSG-Trägern demonstrieren die fehlende Resttragfähigkeit dieser Elemente. Belastungsversuche an reinen Polycarbonatscheiben verdeutlichen die Notwendigkeit der Stabilisierung der Hybridträger durch das gebrochene Glas. Langzeitversuche fanden bei statischer Belastung der intakten und gebrochenen Hybridträger statt. Lasthöhe und Belastungsdauer der gebrochenen Träger orientieren sich an realistischen Einsatzbedingungen. Die Versuche zeigen die Unterschiede bei der Entwicklung des Bruchbilds aufgrund der geringeren Last und ermöglichen die Untersuchung des Resttragfähigkeitsverhaltens unter Dauerlast sowie des Ablaufs und der Hintergründe des Trägerversagens. Aufbauend auf den durchgeführten Versuchen erfolgt eine Einteilung der unterschiedlichen Trägerzustände in drei Stadien mit Angaben zu einer einfachen analytischen Betrachtung. Die Diskussion der erhaltenen Ergebnisse sowie ein Ausblick auf weiteren Untersuchungsbedarf schließen die Arbeit ab. / In transparency-oriented architecture, glass beams are increasingly in demand. These load-bearing elements usually consist of multiple glass panes, bonded with polyvinyl butyral foil (PVB foil), and are comparable to laminated safety glass. These glass beams do not assure any level of post-breakage performance after complete glass breakage. Therefore glass thickness and assembly of the beams are chosen with the objective of avoiding complete glass breakage at all costs. Hybrid glass beams typically combine glass with a ductile material and offer a ductile failure mode in case of complete glass breakage. For this reason they represent a promising solution to meet the required safety levels for glass beams. This study deals with hybrid glass beams which are made by bonding panes of glass and transparent plastics using a transparent adhesive. In case of complete glass breakage the plastic material, which is connected to the glass by the adhesive bond, bears the tensile stress whereas the glass is still able to carry the compressive stress. The pre-selection of plastic and adhesive is based on preliminary tests on small specimens. The required quality of the edges of annealed glass was determined by specific four-point bending tests. Because of the considerable difference in thermal expansion between glass and plastics, alternating climate tests were executed on small hybrid components to further evaluate the suitability of the adhesive. Based on the research conducted, the plastic material polycarbonate and a UV- and light-curing acrylate adhesive, which shows a very flexible behavior when hardened, were chosen for further mechanical tests on larger specimens. Short-term tests with constantly increasing load and varying polycarbonate thickness, beam height and glass type provide information on the load-bearing capacity before and the residual load-bearing capacity after glass breakage of the hybrid beams. Comparative tests on laminated glass beams demonstrate the missing residual load-bearing capacity of these components. Loading tests on polycarbonate panes illustrate the need for stabilization of the hybrid beams by the broken glass. Long-term tests were executed by static loading of the intact and broken hybrid beams. The load level and the load duration of the broken beams are based on realistic working conditions. The tests show the difference in the development of the fracture pattern resulting of the lower load and allow the examination of the residual load-bearing capacity at continuous load as well as the process and the reasons behind the beam failure. Based on the tests conducted, three different states of the hybrid beams are categorized and detailed for their easy analytical approach. A discussion of the obtained results and an outlook on further needed research complete the study.

Blends of poly butylene terephthalate (PBT) and polycarbonate (PC) form a very important class of commercial blends in numerous applications requiring materials with good chemical resistance, impact resistance even at low temperatures, and aesthetic and flow characteristics. PC and PBT are usually blended in a twin screw extruder (TSE). Product melt volume flow rate (MVR) is a property used to monitor product quality while blending the PC/PBT in a twin screw extruder. It is usually measured off line in a quality control laboratory using extrusion plastometer on samples collected discretely during the compounding operation. Typically a target value representing the desired value of the quality characteristics for an in-control process, along with upper and lower control limits are specified. As long as the MVR measurement is within the control limits, the sample is approved and the whole compounded blend is assumed to meet the specification. Otherwise, the blend is rejected. Because of infrequent discrete sampling, corrective actions are usually applied with delay, thus resulting in wasted material. It is important that the produced PC/PBT blend pellets have consistent properties. Variability and fault usually arise from three sources: human errors, feed material variability, and machine operation (i.e. steady state variation). Among these, the latter two are the major ones affecting product quality. The resulting variation in resin properties contributes to increased waste products, larger production cost and dissatisfied customers. Motivated by this, the objective of this project was to study the compounding operation of PC/PBT blend in a twin screw extruder and to develop a feasible methodology that can be applied on-line for monitoring properties of blends on industrial compounding operations employing available extruder input and output variables such as screw speed, material flow rate, die pressure and torque. To achieve this objective, a physics-based model for a twin screw extruder along with a MVR model were developed, examined and adapted for this study, and verified through designed experiments. This dynamic model for a TSE captures the important dynamics, and relates measurable process variables (screw speed, torque, feed rates, pressure etc.) to ones that are not being measured (material holdups and compositions at the partially and filled section along a TSE barrel). This model also provides product quality sensors or inferential estimation techniques for prediction of viscosity and accordingly MVR. The usefulness of the model for inferential MVR sensing and fault diagnosis was demonstrated on experiments performed on a 58 mm co-rotating twin-screw extruder for an industrial compounding operation at a SABIC Innovative Plastics plant involving polycarbonate – poly butylene terephthalate blends. The results showed that the model has the capability of identifying faults (i.e., process deviation from the nominal conditions) in polymer compounding operations with the twin screw extruder. For instance, the die pressure exhibited a change as a function of changes in raw materials and feed composition of PC and PBT. In the presence of deviations from nominal conditions, the die pressure parameters are updated. These die pressure model parameters were identified and updated using the recursive parameter estimation method. The recursive identification of the die pressure parameters was able to capture very well the effects of changes in raw material and/or composition on the die pressure. In addition, the developed MVR model showed a good ability in monitoring product MVR on-line and inferentially from output process variables such as die pressure which enables quick quality control to maintain products within specification limits and to minimize waste production.

In this work, the compounding of polycarbonate (PC) / poly-butylene terephthalate (PBT) blends was studied for the purpose of improving quality of products with reduced wastage and finally to satisfaction of end users. The effect of material rheological characteristics and processing conditions on compounding of PC /PBT was investigated through statistical experiments carried out on a 58 mm twin-screw extruder at SABIC Innovative Plastics Limited (formerly GE Plastics Limited) in Cobourg, Ontario. Melt Volume-Flow Rate (MVR) is the most commonly used property to monitor the quality of products of PC/PBT blends. The MVR was studied with different sampling times and correlations between product properties (melt flow) and processing conditions (screw speed, flow rates) were discussed. The rheological behavior of PC/PBT blends was investigated by dynamic and capillary rheometers. The effects of processing conditions (screw speed, feed rate) on viscosity were measured and it was found that the Cox-Merz rule is not valid for PC/PBT blends. The change of morphology of PC/PBT blends was observed under a scanning electron microscope (SEM) by using different types of samples. Those samples were (i) PC/PBT blends pellets, (ii) PC/PBT blend samples, but collected after completing the rheological tests in the parallel plate rheometer, and (iii) PC/PBT blend samples, but collected after completing the rheological tests in the capillary rheometer. There was evidence that the samples collected after completing the tests in the parallel and capillary rheometer might be degraded due to temperature and time.

Blends of poly butylene terephthalate (PBT) and polycarbonate (PC) form a very important class of commercial blends in numerous applications requiring materials with good chemical resistance, impact resistance even at low temperatures, and aesthetic and flow characteristics. PC and PBT are usually blended in a twin screw extruder (TSE). Product melt volume flow rate (MVR) is a property used to monitor product quality while blending the PC/PBT in a twin screw extruder. It is usually measured off line in a quality control laboratory using extrusion plastometer on samples collected discretely during the compounding operation. Typically a target value representing the desired value of the quality characteristics for an in-control process, along with upper and lower control limits are specified. As long as the MVR measurement is within the control limits, the sample is approved and the whole compounded blend is assumed to meet the specification. Otherwise, the blend is rejected. Because of infrequent discrete sampling, corrective actions are usually applied with delay, thus resulting in wasted material. It is important that the produced PC/PBT blend pellets have consistent properties. Variability and fault usually arise from three sources: human errors, feed material variability, and machine operation (i.e. steady state variation). Among these, the latter two are the major ones affecting product quality. The resulting variation in resin properties contributes to increased waste products, larger production cost and dissatisfied customers. Motivated by this, the objective of this project was to study the compounding operation of PC/PBT blend in a twin screw extruder and to develop a feasible methodology that can be applied on-line for monitoring properties of blends on industrial compounding operations employing available extruder input and output variables such as screw speed, material flow rate, die pressure and torque. To achieve this objective, a physics-based model for a twin screw extruder along with a MVR model were developed, examined and adapted for this study, and verified through designed experiments. This dynamic model for a TSE captures the important dynamics, and relates measurable process variables (screw speed, torque, feed rates, pressure etc.) to ones that are not being measured (material holdups and compositions at the partially and filled section along a TSE barrel). This model also provides product quality sensors or inferential estimation techniques for prediction of viscosity and accordingly MVR. The usefulness of the model for inferential MVR sensing and fault diagnosis was demonstrated on experiments performed on a 58 mm co-rotating twin-screw extruder for an industrial compounding operation at a SABIC Innovative Plastics plant involving polycarbonate – poly butylene terephthalate blends. The results showed that the model has the capability of identifying faults (i.e., process deviation from the nominal conditions) in polymer compounding operations with the twin screw extruder. For instance, the die pressure exhibited a change as a function of changes in raw materials and feed composition of PC and PBT. In the presence of deviations from nominal conditions, the die pressure parameters are updated. These die pressure model parameters were identified and updated using the recursive parameter estimation method. The recursive identification of the die pressure parameters was able to capture very well the effects of changes in raw material and/or composition on the die pressure. In addition, the developed MVR model showed a good ability in monitoring product MVR on-line and inferentially from output process variables such as die pressure which enables quick quality control to maintain products within specification limits and to minimize waste production.