Research Papers

Modeling of Glue Penetration Into Natural Fiber Reinforcements by Roller Infusion

[+] Author and Article Information
Lai Jiang

Department of Mechanical Engineering,
Prairie View A&M University,
700 University Drive,
Prairie View, TX 77446
e-mail: lajiang@pvamu.edu

Daniel F. Walczyk

Center for Automation and
Technology Systems (CATS),
Rensselaer Polytechnic Institute,
110 8th Street,
Troy, NY 12180

Bingbing Li

Department of Manufacturing Systems
Engineering and Management,
California State University,
18111 Nordhoff Street,
Northridge, CA 91330

Manuscript received June 9, 2017; final manuscript received October 17, 2017; published online February 12, 2018. Assoc. Editor: Donggang Yao.

J. Manuf. Sci. Eng 140(4), 041006 (Feb 12, 2018) (11 pages) Paper No: MANU-17-1364; doi: 10.1115/1.4038514 History: Received June 09, 2017; Revised October 17, 2017

Roller infusion by nip rollers is widely used in the infusion industry with broad applications, which is also adopted as one of the seven steps of a newly developed manufacturing process for making fungal mycelium-based biocomposites. One important technical issue related to infusion textile reinforcements for such biocomposites is how to predict and control the infusion fluid penetration depth, which directly affects the quality and performances of the preformed textile skins. Currently, the analytical relations between the modeling parameters and the final infusion penetration depth are still not well understood. Few studies have been performed on such topic and some of which used oversimplified assumptions. A new analytical model is developed in this paper, and the infusion penetration curves are plotted based on certain input parameters including infusion speed, infusion fluid flow rate, and clamping forces of the two rollers. The model-calculated results are then validated by experiments that are performed with the same parameters. The measured parameters of prepared non-Newtonian starch-based natural glue are used both in the modeling and experiments, and the results are close enough for model validation.

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Fig. 1

Roll infusion process used for infusing porous media

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Fig. 2

(a) SEM image of mycelium hyphae growing on a natural fiber and (b) schematic of biocomposite sandwich panels and laminates [1520]

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Fig. 3

Manufacturing steps for mycelium-bound biocomposite sandwich structures [1520]

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Fig. 4

Schematic illustrating the vertical roll infusion on a porous textile reinforcement

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Fig. 5

Measured viscosity of the starch-based natural glue versus its shear rate (log–log plot)

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Fig. 6

Pressure distribution between the roller and the flat reinforcement for different values of ν1

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Fig. 7

Penetration depth curves of a non-Newtonian fluid for one side in porous reinforcement resulting from pressure of two nip rollers

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Fig. 8

Penetration depth curve due to glue flowing on the reinforcement surface (V = 26 mm/s)

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Fig. 9

Overall penetration depth of the roller infuser (pneumatic cylinder pressure = 17.2 kPa or 2.5 psi, V = 26 mm/s)

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Fig. 10

The roller impregnator prototype

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Fig. 11

Biotex jute fabrics and bulk purchased roll

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Fig. 12

Biotex jute used in infusion tests and the cutting die

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Fig. 13

Cylinder pressure versus force chart

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Fig. 14

Comparison of model predicted penetration plies and experimental measured values under three different roller clamping forces

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Fig. 15

Relations between three factors and the final penetration depth



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