Nanostructured heaters based on laser-induced graphene (LIG) are promising for heat generation and temperature control in a variety of applications due to their high efficiency as well as a fast, facile, and highly scalable fabrication process. While recent studies have shown that LIG can be written on a wide range of precursors, the reports on LIG-based heaters are mainly limited to polyimide film substrates. Here, we develop and characterize nanostructured heaters by direct writing of laser-induced graphene on nonuniform and structurally porous aramid woven fabric. The synthesis and writing of graphene on aramid fabric is conducted using a 10.6 μm CO 2 laser. The quality of laser-induced graphene and electrical properties of the heater fabric is tuned by controlling the lasing process parameters. Produced heaters exhibit good electrothermal efficiency with steady-state temperatures up to 170 °C when subjected to an input power density of 1.5 W cm −2 . In addition, the permeable texture of LIG−aramid fabric heaters allows for easy impregnation with thermosetting resins. We demonstrate the encapsulation of fabric heaters with two different types of thermosetting resins to develop both flexible and stiff composites. A flexible heater is produced by the impregnation of LIG− aramid fabric by silicone rubber. While the flexible composite heater exhibits inferior electrothermal performance compared to neat LIG−aramid fabric, it shows consistent electrothermal performance under various electrical and mechanical loading conditions. A multifunctional fiber-reinforced composite panel with integrated de-icing functionality is also manufactured using one ply of LIG− aramid fabric heater as part of the composite layup. The results of de-icing experiments show excellent de-icing capability, where a 5 mm thick piece of ice is completely melted away within 2 min using an input power of 12.8 W.
On-demand curing of thermoset polymers with tunable mechanical properties is of great interest for a variety of applications. In this work, we demonstrate rapid, solvent-free synthesis of a cross-linked copolymer using thermal frontal polymerization of dicyclopentadiene (DCPD) and linseed oil at ambient temperature. A series of thermoset copolymers with various concentrations of comonomers are readily prepared to produce polymers with a wide range of ultimate elongation (11−360%), elastic modulus (1.1 GPa to 5.6 MPa), and glass transition temperature (120−31 °C). The addition of linseed oil comonomers to DCPD resin to increase the molecular weight between crosslinks reduces the available energy density for frontal polymerization and improves the elastomeric properties of the produced polymers. Increasing the concentration of linseed oil comonomers results in highly stretchable and flexible elastomers with self-recovery capability after large mechanical deformations. The DCPD resin and the resin containing 50 wt % of linseed oil comonomers are used to demonstrate three-dimensional (3D) printing of stiff and flexible cellular structures, respectively. This study is the first demonstration of low-cost, facile, and energy-efficient 3D printing of stretchable elastomers via frontal polymerization.
Current technologies for the manufacture of fiberreinforced polymer composites are energy-intensive, environmentally unfriendly, and time-consuming and require expensive equipment and resources. In addition, composites typically lack key nonstructural functionalities (e.g., electrical conductivity for deicing, lightning strike protection, and structural health monitoring), which are crucial to many applications such as aerospace and wind energy. Here, we present a new approach for rapid and energy-efficient manufacturing of multifunctional composites without using traditional expensive autoclaves, ovens, or heated molds used for curing of composites. Our approach is predicated on embedding a thin conductive nanostructured paper in the composite layup to act as a resistive heater for triggering frontal polymerization of the matrix thermosetting resin of the composite laminate. Upon passing electric current, the nanostructured paper quickly heats up and initiates frontal polymerization, which then rapidly propagates through the thickness of the laminate, resulting in rapid curing of composites (within seconds to few minutes) irrespective of the size of the composite laminate. The integrated nanostructured paper remains advantageous during the service of the composite part by imparting new functionalities (e.g., deicing) to the cured composite, owing to its excellent electrical conductivity and electrothermal properties. In this work, we first study the influence of several composite processing parameters on the electrothermal properties of the nanostructured paper and determine the power required for rapid initiation of frontal polymerization. We then successfully fabricate a 10 cm × 10 cm composite panel within 1 min using only 4.49 kJ of energy, which is 4 orders of magnitude less than the energy consumed by the traditional bulk, oven-curing technique. Detailed experiments are conducted to provide an in-depth understanding of the effect of heater position, tooling material, and input power on frontal curing of composite laminates. The multifunctional response of produced composites is demonstrated by performing a deicing experiment, where a 50 × 50 × 3 mm 3 cube of ice is completely melted within 3 min using an input power of 77 W.
Nanocomposite film heaters are promising for out-of-oven (OoO) and energy-efficient curing of fiber-reinforced polymer composites. However, the current techniques for manufacturing nanocomposite film heaters are intensive in terms of time and energy and require expensive resources. In this work, we present a facile and rapid approach for preparation of nanocomposite film heaters with excellent heat generation properties based on a frontally polymerizable resin system. This approach enables rapid fabrication of nanocomposite films within a few minutes and without the need for using expensive equipment, making it suitable for mass production of nanocomposite film heaters. Various characterization techniques are used to determine the morphology, composition, and mechanical properties of nanocomposite films. The electrothermal performance of nanocomposite film heaters are then evaluated under various conditions. Nanostructured heaters exhibit excellent Joule heating properties, where temperatures as high as ∼132°C can be reached within only 2 min using a low input power density of ∼2 W cm−2. Finally, a nanocomposite film heater is used for OoO curing of a small composite panel with minimal energy consumption. Using this approach, 0.1 MJ of energy is consumed during the 4-h cure cycle of a commercial prepreg system, which would otherwise require at least 40.5 MJ of energy to cure using a convection oven.
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