ERC-Small Business: Micropatterning of Film Extrusion Die Surfaces

这是克莱姆森大学先进工程纤维和薄膜工程研究中心（ERC）与Hoowaki LLC之间的合作。CAEFF是一个毕业的，自我维持的ERC（EEC-9731680），继续进行系统级的研究和教育学生先进的纤维和薄膜。Hoowaki LLC是一家小型企业，已完成了第一阶段SBIR（批准号0945386），并在金属模具的表面微结构方面开发了独特的专业知识。Hoowaki-CAEFF克莱姆森团队的愿景是将CAEFF开发的研究和试验台转化为Hoowaki LLC开发的商业产品，从根本上改变挤出聚合物制品的表面性能，以创造巨大的市场并实现重要的社会效益。Hoowaki-CAEFF团队建议开发微图案挤出模头，以在薄膜表面实现微米和亚微米级（纳米级）特征。Hoowaki的研究人员已经证明了聚合物的超疏水微结构，使用批量加工中使用的模具表面上的3D图案。所提出的程序将导致挤出膜所需的微图案和功能性能（如超疏水性），使用连续的，高容量的挤出工艺，这是非常适合规模放大到商业过程。Hoowaki开发的模具将被CAEFF研究人员用于ERC计划主持下开发的挤出试验台。该提案将借鉴CAEFF的定制设计的单层和多层聚合物薄膜挤出试验台配备实时拉曼光谱和X射线衍射能力。广泛的流变和分析仪器，也可在CAEFF，将用于流动和微观结构测量。CAND-Hoowaki团队将使用FiSim软件进行计算机建模，以补充这些实验研究，该软件也是在ERC计划的主持下开发的。使用准确的粘弹性本构方程验证计算机建模预测将系统地指导微图案化的几何形状，以实现超疏水微纹理和减少摩擦性能。更广泛的影响Hoowaki研发经理和CAEFF主任将指导博士后研究助理和研究生，谁反过来将指导一名本科生。因此，将实现研究和教育的一体化，以确保为美国的竞争力培养研究人员。Hoowaki人员还将为博士后，研究生和本科生提供产品开发和创业方面的建议。这项工作预计将有利于社会和美国消费者通过改进包装薄膜，以提高清洁度，改善卫生。由于提高了生产率，预计微图案化模具将导致膜挤出的能量效率提高。此外，减少含氟聚合物涂层，有利于微观纹理，以提高超疏水性，将提供显着的环境效益。

This is a collaboration between the Engineering Research Center (ERC) for Advanced Engineering Fiber and Films (CAEFF) at Clemson University and Hoowaki LLC. CAEFF is a graduated, self-sustaining ERC (EEC-9731680) that continues to conduct systems-level research and educate students on advanced fibers and films. Hoowaki LLC is a small business company that has completed a Phase I SBIR (Grant No. 0945386) and developed unique expertise in surface microstructuring of metal molds. The vision of the Hoowaki-CAEFF Clemson team is to translate research and test-beds developed in CAEFF into commercial products being developed by Hoowaki LLC to radically modify surface properties of extruded polymeric articles to create large markets and to realize important societal benefits. The Hoowaki-CAEFF team proposes to develop micropaterned extrusion dies to attain micron- and submicron-level (nano-level) features on film surfaces. Hoowaki researchers have demonstrated superhydrophobic microstructures of polymers using 3-D patterns on mold surfaces used in batch processing. The proposed program will result in extruded films with desired micro-patterns and functional performance (such as superhydrophobicity) using the continuous, high-volume extrusion process, which is well suited for scale-up to commercial processes. Dies developed by Hoowaki will be used by CAEFF researchers in extrusion test-beds developed under the auspices of the ERC program. The proposal will draw upon CAEFF's custom-designed single- and multi-layer polymer film extrusion test-beds equipped with real-time Raman spectroscopy and x-ray diffraction capabilities. Extensive rheological and analytical instrumentation, also available in CAEFF, will be used for flow and microstructure measurements. CAEFF-Hoowaki team will complement these experimental studies with computer modeling using FiSim software, which was also developed under the auspices of the ERC program. Validated computer modeling predictions using accurate viscoelastic constitutive equations will systematically guide the micropatterning geometries for attaining superhydrophobic microtexture and reduced friction properties.Broader ImpactThe Hoowaki R&D Manager and CAEFF Director will mentor a post-doctoral research associate and a graduate, who in turn will mentor an undergraduate student. Thus, integration of research and education will be accomplished to ensure training of research personnel for U.S. competitiveness. Hoowaki personnel will also advise post-doctoral, graduate, and undergraduate students on aspects of product-development and entrepreneurship. This work is expected to benefit society and U.S. consumers by improving packaging films to improve cleanliness for improved hygiene. The micro-patterned dies are expected to lead to improved energy efficiency of film extrusion due to improved production rates. In addition, reduction of fluoropolymer coatings, in favor of the microtexture to enhance superhydrophobicity, will provide significant environmental benefits.