Variable frequency microwave processing of thermoplastic composites

Abstract

The range of applications for variable frequency microwave (VFM) facilities (2–18 GHz) has been extended to thermoplastic composites. Five thermoplastic polymer matrix composites are processed and discussed, including 33 wt-% random carbon fibre reinforced polystyrene [PS–CF (33%)], and low density polyethylene [LDPE–CF (33%)]; 33 wt-% random glass fibre reinforced polystyrene [PS–GF (33%)], low density polyethylene [LDPE–GF (33%)]and Nylon 66 [Nylon 66–GF (33%)]. Bond strengths of lap joints were tested in shear and results were compared with those obtained using fixed frequency (2·45 GHz) microwave processing. The primer or coupling agent used was a 5 min, two part adhesive containing 100%liquid epoxy and 8% amine, which was more readily microwave reactive than the composites themselves. The VFM was operated under software control, which provided automatic data logging facilities. Results indicate that VFM can produce strong bonds for PS and LDPE.     

Variable‐frequency microwave curing of benzocyclobutene

Polymer dielectrics are widely used in the microelectronics industry for several applications including interlevel dielectrics, encapsulants, and passivating layers. To attain the desired properties, these materials need to be processed via lengthy cure cycles. Variable frequency microwave (VFM) processing has been investigated as a rapid curing alternative for the processing of thin‐film dielectrics. Previous studies on epoxies and polyimide‐based materials have shown significant reduction in cure time and improvement in properties on VFM processing. In this study, VFM curing of Dow Chemical Cyclotene? 3022 benzocyclobutene (BCB) was investigated. The kinetics of the cure reaction were studied by Fourier transform infrared (FTIR) spectroscopy. FTIR studies indicated no significant differences in chemical structure between VFM and thermally cured films. The electrical, optical, mechanical, and chemical properties of VFM‐processed films were characterized and compared with thermally processed films to determine the effectiveness of microwave processing. The results showed that VFM curing of BCB is feasible, and properties comparable to thermally cured films can be attained. The residual stress of partially cured BCB was lower for VFM processing than for traditional thermal processing. The residual stress in fully cured BCB was similar. Improvements such as shorter cure times and lower processing temperatures than conventional thermal processing can be achieved. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 3055–3067, 2002; DOI 10.1002/app.10286     

Dielectric property measurements in design of industrial scale hybrid kiln

Abstract

It has been appreciated for some years now that the dielectric properties of a material need to be considered if microwave processing is to progress from an empirical basis. The present paper describes the evaluation of materials for use in a pilot plant scale hybrid kiln. Previous kilns at Staffordshire University using microwaves as the only source of energy operated at 2·45 GHz but a new pilot plant scale hybrid kiln for operation at 896 MHz with 75 kW of microwave power is under development with improved, more complex, insulation and firing arrangements. For this reason a range of new refractory and insulation materials has been assessed, e.g. support tubes for heating elements and previously used products and materials measured at only 2·45 GHz have been remeasured at 911 MHz. The results of dielectric property measurements are presented for a range of refractory materials together with an assessment of their likely interactions with the microwave environment.     

Chemical recycling of polymer composites induced by selective variable frequency microwave heating

The application of variable frequency microwave (VFM) heating to achieve rapid thermal depolymerization of polymer composites is reported for the first time. The thermal and chemical influence of composite additives on polymer decomposition has been studied for a set of chemically recyclable polymers, including polyphthalaldehyde, polypropylene carbonate, two polyhydroxyalkanoates, and nylon 6. Carbon-based additives, specifically nanocarbon particles, were used as effective microwave absorbers to controllably degrade the surrounding polymer matrix into valuable, monomeric compounds. Depolymerization and byproduct confirmation were quantified by gel permeation chromatography and nuclear magnetic resonance spectroscopy. Synergistic effects can be leveraged from pre-treating composite samples to further reduce the total microwave energy required to depolymerize composite samples. This study establishes the use of VFM heating for chemical recycling of polymer composites that can be leveraged toward a plastic circular economy.     

Microwave material processing—a review

Microwave heating is caused by the ability of the materials to absorb microwave energy and convert it to heat. This article represents a review on fundamentals of microwave heating and their interaction with materials for various applications in a comprehensive manner. Experimental studies of single, multimode, and variable frequency microwave processing were reviewed along with their applications. Modeling of microwave heating based on Lambert's law and Maxwell's electromagnetic field equations have also been reviewed along with their applications. Modeling approaches were used to predict the effect of resonances on microwave power absorption, the role of supports for microwave heating, and to determine the nonuniformity on heating rates. Various industrial applications on thermal processing have been reviewed. There is tremendous scope for theoretical and experimental studies on the athermal effects of microwaves. Some of the unresolved problems are identified and directions for further research are also suggested. © 2011 American Institute of Chemical Engineers AIChE J, 2012     

Selective Stress Relaxation on Chemically Strengthened Glass Sheets for Conventional Wheel Cutting

We introduce, for the first time to the best of our knowledge, the use of variable frequency microwave (VFM)‐assisted second ion exchange to selectively modify the compressive stress CS in chemically strengthened glass sheets, which allows for separation of these glass sheets into smaller pieces using a conventional cutting tool. The CS in paste‐coated zones, in the regions where it is desired for separation of the glass sheets, was successfully manipulated via VFM‐assisted second ion exchange, substituting the larger alkali ions in glass by smaller ions of the paste. Its effect on chemically strengthened glass was characterized using a strain viewer, an optical microscope, and an electron probe microanalyzer. We also report on the scribability and breakability across the stress relaxation zones. The results reveal a CS loss of only 3%, from 677 to 656 MPa, in the paste‐uncoated zones, and complete CS relaxation, down to 0 MPa, in the paste‐coated regions. The areas of relaxed CS enable the separation of the strengthened glass sheets using conventional wheel cutting.     

Study of the structural and dielectric properties of ceramic obtained from residual electrocoagulation

ABSTRACT

This work aims to develop an eco-friendly ceramic obtained from the sludge generated in the textile industry treatment by electrocoagulation to demonstrate a possibility of natural raw materials’ extraction decrease. The sludge generated by the electrocoagulation treatment was treated by some sintering processes. The presence of two crystalline phases was confirmed through the Rietveld refinement: Fe₂O₃ and NiCr₂O₄. In the microwave range it is possible to confirm the relative stability of dielectric permittivity over the wide frequency range. The Temperature Coefficient of Capacitance results demonstrate that the samples can be classified as a class 4 ceramic capacitor. The activation energy measurement profile is similar for all samples. The results showed that samples obtained from the sludge present low dielectric permittivity, two thermo-activated processes one to water loss and another to conduction with activation energy of approximately 0.6?eV for all analysed samples. The manufactured samples can be applied as a barrier layer capacitor and dielectric resonator antennas.     

Preparation,dielectric property and microwave absorption property of Cu doped SiC nanopowder by combustion synthesis

Abstract

Cu doped SiC nanopowders have been prepared via combustion synthesis, using silicon powder and carbon black as the raw materials, copper powder as the doping source and polytetrafluoroethylene as the chemical activator respectively. The microstructure of prepared nanopowders has been characterised by X-ray diffraction and scanning electronic microscope. The electric permittivities of prepared SiC nanopowders in the frequency range of 8·2–12·4 GHz have been determined. Results show that prepared β-SiC nanopowders have fine spherical particles and narrow particle size distribution, and a quantity of SiC whisker increases with increasing Cu doping content. The Cu₃Si impurity has been generated when Cu content is up to 10%. The β-SiC doped with 10% Cu has the highest real part ?′ and dielectric loss tanδ values. The 5% Cu doped SiC nanopowder with matching thickness of 2 or 2·5 mm exhibits the best microwave absorption properties in the frequency range of 8·2–12·4 GHz.     

PROCESS DRYING PRACTICE

ABSTRACT

Drying experiments were carried out using a special microwave surface to examine the drying kinetics of corn and potato samples. The process of internal moisture and heat transfer was analyzed in the light of the experimental data obtained. The effects of several dielectric field parameters were also studied. It was found that the modified exponential law describes the water removal proc-ess of both materials within an acceptable confidence range when the specific microwave performance is the driving force for the internal moisture movement. Furthermore, the inner composition of the materials determines their reaction to the effect of microwave fields.     

Electromagnetic shielding performance of carbon foams

The electromagnetic shielding performance of carbon foams is measured using the nested reverberation chamber method in the frequency band 1–4 GHz, which is the frequency range of most cellular phones and microwave ovens. Good values of shielding effectiveness are obtained even with a small thickness of carbon foam. The results are used to assess the correct electrical conductivity values for the investigated materials using a multiple reflection model to compute the material transmission coefficient. The potential applications of such materials are in the lightweight microwave shielding structures that are partially transparent to optical frequencies.     

Low temperature cure of epoxy thermosets attaining high Tg using a uniform microwave field

It is demonstrated for the first time that an epoxy thermoset resin can be cured at temperatures well below its T_g∞. This study compared the use of a uniform variable frequency microwave (VFM) field to standard oven curing at temperatures above and below T_g∞. Using T_g, tan δ, modulus, and FTIR measurements, it is shown that the reaction of BFDGE with MDA to attain a product with T_g∞ of 133 °C is achieved by VFM at temperatures from 100 to 140 °C; in contrast, the thermal cure normally requires 170 °C to attain the same T_g∞ and the same extent of cure. By following the pregel cure reaction with ¹³C‐NMR spectroscopy, it was determined that the lower cure temperatures of VFM cure predominately lead to chain extension and smaller amounts of crosslinking compared to the thermal cure. To explain these results, it is suggested that, after gelation, with VFM cure there is higher mobility from dipole rotations that continues the cure to completion without vitrification. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44222.     

HOT AIR AND MICROWAVE DRYING OF ONIONS: A COMPARATIVE STUDY

ABSTRACT

This comparative study of conventional (hot air) drying and microwave drying of the onion was carried out on a hot air pilot plant drier for conventional drying where all characteristics (temperature, humidity, and velocity) could be adjusted and controlled. A data logger connected to a computer captured all data. And for microwave drying, a drying tunnel Fitted with a forward/backward movement was used. Mass loss and product surface temperature were monitored for both processing. Factors controlled where: frequency of movement, microwave power, air extraction rate. Other elements included shape (slices/pieces) and variety of product

Drying duration and maximum drying rate constituted comparative criterion for the processes. Quality was measured by the reducing sugars and polyfructans content. Analysis of variance for the microwave drying process suggests that the effective factors were microwave power followed by onion variety and shape respectively. For quality criterion by far the most effective was variety, followed by the interaction of shape and the forward-backward movement of the conveyor. For conventional drying the most effective factor was air temperature for drying duration, and variety for maximum drying rate.     

Microwave processing of sprayed alumina composite for enhanced performance

To meet the challenging in-service requirements, surfaces of many mechanical components need to be modified. This can be achieved by altering the surface properties through deposition technique followed by suitable post processing. Apart from the conventional methods, laser treatment is the most popular post processing technique. Of late, microwave heating is emerging as one of the potential post processing sources. Microwave processing of materials is fundamentally different from traditional techniques. In microwave processing, energy is directly transferred to the material through interaction of electromagnetic waves with molecules leading to volumetric heating. However, for processing of transparent (to microwaves) materials, a technique known as microwave hybrid heating (MHH) can be used. In this study, MHH is used for post processing of plasma deposited alumina–titania ceramic composite coatings on steel substrate; resulting properties of the post processed coatings are evaluated. Results show reduction in porosity, enhancement in microhardness, and wear resistance of the irradiated coatings owing to microstructural changes and densification. Results are discussed with suitable illustrations.     

R&D OPPORTUNITES IN DRYING OF ADVANCED ELECTRO-CERAMICS

ABSTRACT

This article presents an inaoduction to the various drying processes operational in the ceramic processing industry, with special emphasis on electro ceramics. An attempt is made to arouse the interest of drying specialists in fields other than ceramics to participate in a concentrated group effort to solve a number of existing problems related to ceramics drying. The importance of materials education is highlighted by referring to a few examples depicting the effect of the drying process on the final product quality. It is argued that with more research, conventional processes like spray drying, rotary drum drying, etc. can be improved or replaced with alternative processes like freeze drying, microwave drying, infrared drying and vibrated fluidized bed drying.     

DRYING COFFEE BEANS IN VIBRATED TRAYS DRYER

ABSTRACT

This work shows the early development of the vibrated trays dryer. The flow of particles is controlled by vibration applied to them. The operating conditions of five springs were determined and the best spring parameters were defined. The spring parameters selected were; shear stress equal 218 MPa and Hooke's constant, K equal 8540 N7sol;m. The dryer was tested using coffee beans flowing into crossed currents with the processing air. The dispersion coefficient was determined using both the Taylor Dispersion Model and the Free Dispersion Model.     

IMPROVING ENERGY EFFICIENCY IN COMBINED MICROWAVE-CONVECITVE DRYING

ABSTRACT

Convective-microwave drying has been recognized as a convenient option for drying of valuable materials. However, the advantages of the method must be carefully evaluated in order to establish the limits for full scale operating conditions because, as demonstrated in this work, the reduction in the absolute drying time as a function of the applied microwave power is devalued by an increase in the unabsorbed microwave energy, decreasing the overall energy efficiency of the drying process.

Experimental study of the energy efficiency of combined microwave-convective drying of agar gel and Gelidium seaweeds was carried out in a laboratory scale microwave-convective dryer by continuously following the absorption of microwave energy by the sample as well as the change of the sample mass during the drying process, under different operating conditions. Several drying strategies based on the on-off application of the microwave power were proposed and evaluated from the point of view of both drying kinetics and energy efficiency in order to program and rationalize the use of microwave energy in the combined microwave-convective drying process.     

New understandings of how dielectric properties of fruits and vegetables are affected by heat-induced dehydration: A review

Abstract

Dielectric heating (DH) is an alternative to traditional conductive heating. Preservation of fruits and vegetables through drying based on DH is faster than conventional heating systems, needing less processing time, and delivering a better dehydrated product as well as reduced treatment costs. Dielectric properties (DPs) are significant physical qualities that are affected by microwave (MW) and radio frequency (RF) heating systems; these attributes directly affect the electromagnetic arrangement and currents surrounding the materials. In other words, DPs define the response of materials in electric fields at the desired frequency and temperature. Thus, DPs of materials are of increasing interest in the agricultural and food-processing fields. The principles of the DPs of fruits and vegetables according to frequency, temperature, and composition are crucial in the designing and handling of MW and RF heating operations. A consideration of DPs is required to ensure the quality of fruits and vegetables is enhanced throughout the drying process for better quality final products. This review aimed to provide a comprehensive update on the prospects of DH for drying of fruits and vegetables. The factors that affect the DPs during the dehydration process of fruits and vegetables and discussions about the correlation among these factors were also provided. In addition, the fundamentals of DPs and their measurement techniques were also discussed. This study is an update on the state-of-the-art DH system and illustrates the important influence of DPs on the radiative heating of fruits and vegetables.     

MICROWAVE DRYING OF MULTICOMPONENT SOLS

ABSTRACT

Extensive studies on microwave drying of multicomponent materials have been carried out in order to determine dielectric properties of metalsiloxane sols, define the healing and drying characteristics of metalsiloxane sols and gels, develop the mathematical model of thermal processing, and design the continuous microwave dryer that could be used in an industrial scale     

Measurements of anisotropic complex permittivity of liquid crystals at microwave frequencies

Recent interest in application of liquid crystals for tuning of microwave frequency range devices generated a need for better microwave characterization of these anisotropic and DC electric and magnetic fields sensitive materials. We report on measurements of the complex permittivity tensor of two liquid crystals and on determination of their DC electric field bias dependence. Measurements were carried out using a novel microwave cylindrical dielectric resonator technique which utilizes TE₀₁₁ and TM₀₁₁ modes. Liquid crystals are inserted into the inner hole in the dielectric resonator. Results of measurements have shown significant anisotropy in crystals dielectric properties and also allow estimates of tunability and tuning speed. The measurements showed some promises for liquid crystals to be used for tuning, but more characterization and technological work is needed.     

Dielectric Drying

ABSTRACT

Dielectric heating is a term which covers both radio frequency (RF) and microwave systems. It has been used for industrial drying for many years because it has a number of advantages over other drying processes. These advantages include the volumetric dissipation of energy throughout a product, and the ability to automatically level any moisture variation within it. It is generally true to say that these techniques can only be justified in processes involving material of “high” value being processed in modest quantities but when combination with other fuel fired techniques there may be opportunities to broaden the range of applications. In addition to a desciption of current industrial applications, the theory of dielectric heating, the similarities and differences between RF and microwave are discussed together the effects of the dielectric roperties of a product on the design of the equipment