Effect of vacuum venting and mold wettability on the replication of micro-structured surfaces

Micro injection molding enables the manufacture of micro-scale features with good accuracy at high production rates. However, the replication of complex micro and nano features is still challenging hindering the development of new functional surface topographies. The marked thermal gradient between injected polymer and mold surface and the reduced dimensions promote a rapid drop of melt temperature that causes the incomplete filling of the micro features. This study aims to investigate the combined effects of vacuum venting and mold wettability on the replication of micro-structured surfaces. A low-viscosity polystyrene and a cyclic olefin copolymer were selected and their wetting properties were evaluated. The results showed that a polymer with high wetting properties and an elevated viscosity dependence on temperature improves the replication of the micro features. Moreover, high interfacial effects can be exploited to significantly enhance the filling ratio when applying vacuum venting.

     

Novel flexible network polymers consisting of oligomeric primary polymer chains originated in the mechanistic discussion of multiallyl crosslinking polymerization

Summary It is well known that allyl monomers polymerize only with difficulty and yield polymers having low molecular weights, i.e., oligomers. Inevitably, free-radical multiallyl crosslinking polymerization provides network polymers consisting of oligomeric primary polymer chains, i.e., having abundant dangling chains. This led to the development of novel flexible network polymers such as amphiphilic network polymers (I) consisting of short primary polymer chains and long crosslink units with opposite polarities, simultaneous interpenetrating networks (II) consisting of both polyurethane (PU) and polymethacrylate (PM) networks with oligomeric primary polymer chains, and network polymers (III) consisting of centipede-type primary polymer chains. Thus, the solution copolymerizations of benzyl methacrylate with tricosaethylene glycol dimethacrylate in the presence of lauryl mercaptan yielded I consisting of nonpolar, short primary polymer chains and polar, long crosslink units. The opposite type of I was prepared by the copolymerization of 2-hydroxyethyl methacrylate, a polar monomer having a hydroxyl group, with heneicosapropylene glycol dimethacrylate, a nonpolar monomer having a poly(oxypropylene) unit. The equimolar polyaddition crosslinking reaction of poly(methyl methacrylate-co-2-methacryloyloxyethyl isocyanate) with tri(oxytetramethylene) glycol, leading to PU networks, and the free-radical crosslinking copolymerization of methyl methacrylate with tri(oxytetramethylene) dimethacrylate in the presence of CBr₄, leading to PM networks, were progressed simultaneously, providing II formed via the topological crosslink between PU and PM network structures. The post-copolymerizations of oligomeric allyl methacrylate/alkyl methacrylate precopolymers, having different amounts of pendant allyl groups and different molecular weights, with allyl benzoate/vinyl benzoate monomer mixtures were conducted to give III.     

Experimental study of the Mode I adhesive fracture energy in DCB specimens bonded with a polyurethane adhesive

The Mode I fracture energy of a polyurethane adhesive with low Young’s modulus was investigated. Metal adherends in standardized double cantilever beam (DCB) tests are typically too stiff for soft adhesives, making it difficult to measure the fracture energy accurately. However, soft adhesives, such as a single-component polyurethane adhesive tested in this paper, are in high demand in the automobile industry. Thus, accurate measurement techniques must be established. Flexible substrates composed of spring steel were used for the DCB tests to accommodate the deformation of the adhesive layer. First, the applicability of the flexible substrates was discussed using specimens bonded with an epoxy adhesive. For soft adhesives, however, the deformation of the adhesive layer must be considered in the calculation methods of the fracture energy. Although the deformation effect on the DCB tests has been discussed with Winkler’s elastic foundation, the crack length must be measured along with the load and displacement. To overcome the difficulty of measuring the crack length, a calculation method based on Winkler’s elastic foundation was introduced applying the compliance-based beam method (CBBM). Finally, the fracture energy of the polyurethane adhesive was discussed by comparing the calculation methods with and without measuring the crack length.     

Photoelectric properties of ABA‐type triblock copolymers designed using fluorine‐containing polyimide macroinitiators with polyhedral oligomeric silsesquioxane

4,4′‐(Hexafluoro‐isopropylidene) diphthalic anhydride‐2,3,5,6‐tetramethyl‐1,4‐phenylenediamine (6FDA‐TeMPD) was synthesized and reacted with polyhedral oligomeric silsesquioxane (POSS) to form an ABA‐type triblock copolymer by atom transfer radical polymerization. The solid‐state and optical properties of the resulting copolymers were systematically investigated, and their electronic states were analyzed. As the POSS concentration increased, the transparency across the entire wavelength range increased. In the ABA‐type triblock copolymers, a new transition was observed between the highest occupied molecular orbital in POSS and the lowest unoccupied molecular orbital in 6FDA‐TeMPD because of their high molecular size dispersion. Since the refractive index of 6FDA‐TeMPD decreased linearly as the POSS concentration increased, the refractive index of the ABA‐type triblock copolymers of 6FDA‐TeMPD with POSS could be easily controlled. POLYM. ENG. SCI., 57:1207–1213, 2017. © 2017 Society of Plastics Engineers     

Pilot-Scale Operation of a Concrete Sludge Recycling Plant and Simultaneous Production of Calcium Carbonate

A pilot-scale plant to treat concrete sludge and produce calcium carbonate (CaCO₃) and an environmental purification agent (phosphorus adsorbent derived from concrete sludge, PAdeCS®) was designed, constructed, and operated. Concrete sludge from a concrete pile and pole production plant, boiler gas containing CO₂, and groundwater were used in the plant. The process involved calcium extraction from concrete sludge into water, followed by reaction of the calcium with CO₂ to produce crystalline CaCO₃. The pilot-scale plant was operated for 1 week, and the mass flows, conversion of CO₂ to CaCO₃, and net CO₂ emissions of the process were estimated. High-purity CaCO₃ (>97%) suitable for industrial use was obtained. Based on the power consumption of the process and the amount of CO₂ sequestered into CaCO₃, a net reduction in CO₂ emissions can be achieved using this process. The produced PAdeCS can be used as an inexpensive substitute for calcium series environmental purification agents.     

Two-step migration of particles in evaporating bimodal suspension films at high Peclet numbers

During the drying of bimodal colloidal suspensions containing particles of various sizes, smaller particles preferentially migrate to the top surface under particular drying conditions, leading to undesirable drying defects in batteries and in other coating applications. Despite extensive previous studies, the migration mechanism is far from being understood because few in situ observations are available to support the hypotheses. To remedy this, we use real-time photoluminescence (PL) microscopy to investigate the migration of small fluorescent latex particles co-dispersing with large nonemissive latex particles. Comparing the measured PL intensity with that predicted by a model allows us to determine the quantity of small particles near the evaporating surface. The results reveal that the fluorescent particles segregate in two steps: The primary segregation occurs early in the evaporation stage, whereas the secondary stepwise migration occurs when the air–liquid interface invades the particle consolidation layer. The latter migration is attributed to the flow-induced motion of small particles that move through interstitial spaces between large particles.     

In situ bioremediation of a cis-dichloroethylene-contaminated aquifer utilizing methane-rich groundwater from an uncontaminated aquifer

At a trichloroethylene (TCE)-contaminated site in Chikura, Chiba, Japan, TCE had spread over to the first and second aquifers over years. After 8 years of pumping and treatment, finally derivative of TCE, cis-dichloroethylene (c-DCE) remained only in the second aquifer. In this study, feasibility of a low cost in situ bioremediation utilizing groundwater of the third aquifer, which contained natural dissolved methane possibly derived from natural gas field nearby, to stimulate methane-oxidizing bacteria was examined. In vitro experiment showed that a mixture of the groundwater from the second and third aquifers stimulated a growth of methane oxidizing bacteria and enhanced c-DCE degradation. The groundwater of the third aquifer was introduced into the second aquifer in situ. The population of methanotrophs with high V(max) and K(m) for methane uptake increased, resulting in successful degradation of c-DCE at a monitoring well 2m downgradient of the injection well.     

GFP expression by intracellular gene delivery of GFP-coding fragments using nanocrystal quantum dots

Gene therapy is an attractive approach to supplement a deficient gene function. Although there has been some success with specific gene delivery using various methods including viral vectors and liposomes, most of these methods have a limited efficiency or also carry a risk for oncogenesis. We herein report that quantum dots (QDs) conjugated with nuclear localizing signal peptides (NLSP) successfully introduced gene-fragments with promoter elements, which promoted the expression of the enhanced green fluorescent protein (eGFP) gene in mammalian cells. The expression of eGFP protein was observed when the QD/gene-construct was added to the culture media. The gene-expression efficiency varied depending on multiple factors around QDs, such as (1) the reading direction of the gene-fragments, (2) the quantity of gene-fragments attached on the surface of the QD-constructs, (3) the surface electronic charges varied according to the structure of the QD/gene-constructs, and (4) the particle size of QD/gene complex varied according to the structure and amounts of gene-fragments. Using this QD/gene-construct system, eGFP protein could be detected 28 days after the gene-introduction whereas the fluorescence of QDs had disappeared. This system therefore provides another method for the intracellular delivery of gene-fragments without using either viral vectors or specific liposomes.     

Classification method of severe accident condition for the development of severe accident instrumentation and monitoring system in nuclear power plant

Instrumentation and monitoring systems in a nuclear power plant are very important to monitor plant conditions for safe operations and a plant shutdown. The severe accident at TOKYO ELECTRIC POWER COMPANY's Fukushima Daiichi Nuclear Power Station (hereinafter called as TF1) in March 2011 caused several severe situations such as core damage, hydrogen explosion, etc. Lessons learned from the severe accident at TF1 show that an appropriate operable instrumentation and monitoring system for a severe accident should be developed so that the system will deliver an appropriate performance for mitigation of severe accident condition in a nuclear power plant.

This paper proposes the classification method of severe accident condition for the development of an appropriate operable instrumentation and monitoring system for a severe accident based on the problem analysis of monitoring variables during the severe accident at TF1. The classification is formed on the basis of the integrity of boundary for plant safety and the successful (or unsuccessful) condition of the cooling water injection, and is used for an establishment of defining severe accident environmental conditions for the instrumentation and monitoring system. Examples of the establishment method are also shown in this paper.     

Heavy metal leaching from aerobic and anaerobic landfill bioreactors of co-disposed municipal solid waste incineration bottom ash and shredded low-organic residues

In this study, heavy metal leaching from aerobic and anaerobic landfill bioreactor test cells for co-disposed municipal solid waste incineration (MSWI) bottom ash and shredded low-organic residues has been investigated. Test cells were operated for 1 year. Heavy metals which were comparatively higher in leachate of aerobic cell were copper (Cu), lead (Pb), boron (B), zinc (Zn), manganese (Mn) and iron (Fe), and those apparently lower were aluminum (Al), arsenic (As), molybdenum (Mo), and vanadium (V). However, no significant release of heavy metals under aerobic conditions was observed compared to anaerobic and control cells. Furthermore, there was no meaningful correlation between oxidation-reduction potential (ORP) and heavy metal concentrations in the leachates although some researchers speculate that aeration may result in excessive heavy metal leaching. No meaningful correlation between dissolved organic carbon (DOC) and leaching of Cu and Pb was another interesting observation. The only heavy metal that exceeded the state discharge limits (10mg/l, to be enforced after April 2005) in the aerobic cell leachate samples was boron and there was no correlation between boron leaching and ORP. Higher B levels in aerobic cell should be due to comparatively lower pH values in this cell. However, it is anticipated that this slightly increased concentrations of B (maximum 25mg/l) will not create a risk for bioreactor operation; rather it should be beneficial for long-term stability of the landfill through faster washout. It was concluded that aerobization of landfills of heavy metal rich MSWI bottom ash and shredded residues is possible with no dramatic increase in heavy metals in the leachate.