Scholarlink

<p>This study addresses the critical challenge of harmonizing circular economy goals with stringent fire safety requirements in additive manufacturing. We investigate geometry-induced melt-plug sealing in 3D-printed high-recycled-content flame-retardant polycarbonate (SORPLAS) composite lattices. By integrating mechanical testing, ISO 5660-1 cone calorimetry with gas analysis, and COMSOL thermal-flow simulations, we evaluated three nominally equal-porosity lattice architectures (circular, rhombic, and triangular) fabricated from PC, pure SORPLAS, and carbon-filled SORPLAS. Results demonstrate a dual dominance pattern: for mechanical performance, lattice geometry is the primary determinant (η²<i>p</i> = 0.948 for UTS), whereas for fire-response endpoints, material formulation is the primary driver (η²<i>p</i> = 0.40–0.50 for pHRR and Peak-MLR). Lattice geometry acts as a kinetic regulator governing the integrity and temporal evolution of melt plugging. Circular and triangular lattices promote molten polymer backfilling to delay peak heat release, whereas rhombic lattices facilitate ventilation and accelerate post-peak decay. Two critical trade-offs are revealed: first, mechanical performance is reduced by the addition of 1 wt% coarse recycled carbon powder, as SEM analysis indicates poor interfacial adhesion and particle agglomeration; and second, geometry-induced sealing suppresses heat release but restricts oxygen transport, leading to an elevated CO/CO₂ ratio and extended smoke tail. These findings provide concrete design guidelines for high-mix low-volume applications such as electric vehicle battery module barriers under the Distributed Recycling and Additive Manufacturing model.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Geometry-induced melt-plug sealing: a test methodology and design for porous PC/SORPLAS composites

  • 期刊论文

  • 发表日期：

    2026年4月24日

查看全文
  • Yen-Ting Li,
  • Wei Hsiang Lee,
  • Cheng Wei Tai

摘要

This study addresses the critical challenge of harmonizing circular economy goals with stringent fire safety requirements in additive manufacturing. We investigate geometry-induced melt-plug sealing in 3D-printed high-recycled-content flame-retardant polycarbonate (SORPLAS) composite lattices. By integrating mechanical testing, ISO 5660-1 cone calorimetry with gas analysis, and COMSOL thermal-flow simulations, we evaluated three nominally equal-porosity lattice architectures (circular, rhombic, and triangular) fabricated from PC, pure SORPLAS, and carbon-filled SORPLAS. Results demonstrate a dual dominance pattern: for mechanical performance, lattice geometry is the primary determinant (η²p = 0.948 for UTS), whereas for fire-response endpoints, material formulation is the primary driver (η²p = 0.40–0.50 for pHRR and Peak-MLR). Lattice geometry acts as a kinetic regulator governing the integrity and temporal evolution of melt plugging. Circular and triangular lattices promote molten polymer backfilling to delay peak heat release, whereas rhombic lattices facilitate ventilation and accelerate post-peak decay. Two critical trade-offs are revealed: first, mechanical performance is reduced by the addition of 1 wt% coarse recycled carbon powder, as SEM analysis indicates poor interfacial adhesion and particle agglomeration; and second, geometry-induced sealing suppresses heat release but restricts oxygen transport, leading to an elevated CO/CO₂ ratio and extended smoke tail. These findings provide concrete design guidelines for high-mix low-volume applications such as electric vehicle battery module barriers under the Distributed Recycling and Additive Manufacturing model.