DTI funded collaborative research opportunity : Studio projects e.g. Polymer nano-composites

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1 Presentation to 2 nd IAG DTI funded collaborative research opportunity : Studio projects e.g. Polymer nano-composites Sekhar Chakravorty Date: 19 March 2003

2 Studio projects The Studios are NPL / Industry partnership projects which are selected and managed by NPL. Over 1 million allocated by the DTI UK companies are invited to submit outline proposals

3 Objectives: To develop and / or to exploit measurement techniques in the industrial environment to increase competitiveness of the UK s production and professional services industries. To encourage near market research

4 Studio projects might involve collaborative work to: develop new test methods, models or databases for industrial use. compare measurement test procedures used in different industrial environments, which will result in the establishment of best practice measurement procedures, and enable benchmarking of industrial processes. assess feasibility (paper based or experimental) for a larger project that might be funded as a DTI core project. research a solution to a generic industrial measurement problem. address any measurement problems arising from the characterisation, performance, processing, modelling or degradation of materials. develop and exploit technology transfer mechanisms for the uptake of measurement methods and models.

5 Industrial Participation : Each studio project will normally be expected to involve at least 3 collaborating U.K. companies (including University spin-off companies) and NPL. Projects supported by SME s (i.e. companies with up to 249 employees) will be given higher priority, but not all companies need to be SMEs. Written expressions of interest needed from the potentially participating companies.

6 Funding arrangement : Over 1 million DTI funding has been earmarked for new studio projects in the period October 2002 December Up to 20 studio projects could be funded under this programme. Typical project size: 50k - 150k Duration: 6 months to 2 years All studio projects will be supported on a sharedcost basis. DTI to provide 50% of the cost, collaborating companies to provide 15% in cash and 35% in-kind. ( e.g. 3 companies each investing 5k cash can get access to a project of the size 100,000 )

7 Expected Outputs : case studies new or significantly improved test methods standard procedures aimed for eventual use as draft standard codes of practice engineering procedures / guides models databases articles in the trade press scientific papers other articles (e.g. newsletter) workshops / training courses presentations at seminars / conferences

8 Dissemination : The work should be disseminated appropriately to the project partners, UK industrial associations, working groups, clubs etc. closely involved in the project. A delay before dissemination of outputs (normally 12 months) is usual. Other IPR matters can be discussed.

9 Application Procedure : Application is open throughout the year UK companies are invited to discuss project ideas with NPL staff The selection is based upon merit as well as on first come first served basis The initial approval of a Studio project is usually given within 3 weeks after submitting a two-page project outline A full proposal would then be required NPL assistance is available in preparing proposals It is possible to start a Studio project within 8-10 weeks after the initial submission

10 Further information & NPL contacts General Enquiry: Dr David Mulligan / Mr Clive Scoggins The Materials Centre, National Physical Laboratory, Teddington, Middlesex, TW11 0LW Tel: / 6343 ; Fax: / 6046 Nano-Composites : Dr. Sekhar Chakravorty Tel: sekhar.chakravorty@npl.co.uk Heat Transfer : Mr Chris Brown Tel: chris.brown@npl.co.uk Rheology : Dr Martin rides Tel: martin.rides@npl.co.uk Soft Metrology : Dr Paul Tomlins Tel: paul.tomlins@npl.co.uk Materials Performance : Dr Greg Dean Tel: greg.dean@npl.co.uk

11 Polymer Nano-Composites An overview

12 Nano-materials work at The Materials Centre Nano-tribology Nano-composites Nano-modelling Nano-coatings Nano-hard materials Nano-functional

13 Nano-materials in automotive sector Engine parts, e.g. fans Door frames Interior design paints bumpers lubricants Small equipment, e.g. mirrors Decorative/structural Interior elements AND: large variety of sensors & actuators based on MEMS technology: accelerometers, pressure sensors

14 Polymer Nano-composites Market 7% - 15% each year Estimated production >600,000 tonnes by 2010 Major area of growth in the UK economy in the next 20 years Over 70 organisations currently working Opportunities still considered abundant Major funding sources : Basic Technologies, Foresight, EU Framework VI New funding source : NPL Studio projects for UK based industry funded by the DTI

15 The key areas of growth in the next 5-10 years UV protection gels Drug delivery systems Lubricants Scratch free paints New fire retardant materials New scratch / abrasion resistant materials Superior strength fibres and films Anti-corrosion barrier coatings Light-weight heat resistant materials

16 Properties (with 2-5 vol% clay addition) Weight saving 15-20% Tensile Strength > 40% Tensile Modulus >70% Flexural Strength >60% Flexural Modulus >125% Heat Distortion Temperature: from 65 C to 150 C Impact Resistance =< 10% Lower Water Sensitivity Lower Permeability to Gases Lower Thermal Co-efficient of Expansion Excellent Flame Retardancy, Excellent UV resistance Excellent Barrier Properties

17 TEM of nylon 6-clay nano-composite

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19 Generic Nano-composite Formulation HBP (dendrimers) (dispersed, multiple grafts) POSS reinforcement (grafted on chain) R Si R Si O O O O OR Si Si O R O Si R Si O O O O O Si R Si R Clays (Montmorillonite) Dispersed, exfoliated, intercalated Combine them?!

20 NPL s Strength Measurements Thermal properties (PVT, DSC, Thermal Conductivity, DMA) Mechanical & structural properties Tensile/compression testing of small specimen (Nanotest machine); Nano-hardness/Modulus measurement Structural studies (SEM, TEM, AFM, SAM, XRD) Rheology (MFR, cone/plate rheometry, elongational/shear) Modelling & Visualisation

21 NPL nano-test machine

22 Results of NPL pilot study: DSC DSC test data of Nylon 6 unfilled (blue) and nano-clay filled (pink) materials at 5 C/min, 20 C/min and 80 C/min cooling rates C/min cooling Normalized Heat Flow Endo Up (W/g) Peak C Delta H J/g 80 C/min Cooling 20 C/min Cooling Peak C Delta H J/g Peak C Delta H J/g Peak C Delta H J/g Peak C Delta H J/g Peak C Delta H J/g Temperature, C

23 Results of NPL pilot study : Iso-baric PVT data at 20 C/min cooling rate, 800 bar Specific Volume (Shrinkage), cm^3/g Solid onset of crystallisation end of crystallisation Temperature, C Nylon/Clay, 800 bar Melt end of crystallisation onset of crystallisation Nylon 6 unfilled, 800 bar

24 Results of NPL pilot study : Viscosity 1.00E+04 Viscosity, Pa.s 1.00E E Strain % Nylon 6 unfilled Nylon6 / Clay nano-composite

25 Performance of a polymer clay nano-composite compacted at 50 & 800 bar Nano hardness (compacted at 50 bar) Nano hardness (compacted at 800 Bar) Modulus (compacted at 50 bar) Modulus (compacted at 800 Bar) Nano-hardness (GPa) Modulus (GPa) 0 Nylon 6/clay 50 bar Nylon 6, unfilled 50 bar Nylon 6/clay 800 bar Nylon 6, unfilled 800 bar 0

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30 NPL in Polymer Nano-composites Work Developing novel test methods and mathematical models Linking nano-scale results with macro- and micro-scale performance Experimental facilities include: TEM, SEM, AFM, SAM, SIMM, AES, XPS, SNOM, X-ray Diffraction, Nano-indenter, Nanodeflection equipment, thermal (DSC, PVT, Thermal Conductivity etc.) and rheological equipment. A strong and dedicated mathematical modelling and visualisation team NPL report MATC(A)123, Sept.2002 summarises present nano-materials research activities DTI funded collaborative Studio projects : UK Industry are invited to submit outline proposals