04 Fakultät Energie-, Verfahrens- und Biotechnik
Permanent URI for this collectionhttps://elib.uni-stuttgart.de/handle/11682/5
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Item Open Access Constitutive correlations for mass transport in fibrous media based on asymptotic homogenization(2023) Maier, Lukas; Kufferath-Sieberin, Lars; Pauly, Leon; Hopp-Hirschler, Manuel; Gresser, Götz T.; Nieken, UlrichMass transport in textiles is crucial. Knowledge of effective mass transport properties of textiles can be used to improve processes and applications where textiles are used. Mass transfer in knitted and woven fabrics strongly depends on the yarn used. In particular, the permeability and effective diffusion coefficient of yarns are of interest. Correlations are often used to estimate the mass transfer properties of yarns. These correlations commonly assume an ordered distribution, but here we demonstrate that an ordered distribution leads to an overestimation of mass transfer properties. We therefore address the impact of random ordering on the effective diffusivity and permeability of yarns and show that it is important to account for the random arrangement of fibers in order to predict mass transfer. To do this, Representative Volume Elements are randomly generated to represent the structure of yarns made from continuous filaments of synthetic materials. Furthermore, parallel, randomly arranged fibers with a circular cross-section are assumed. By solving the so-called cell problems on the Representative Volume Elements, transport coefficients can be calculated for given porosities. These transport coefficients, which are based on a digital reconstruction of the yarn and asymptotic homogenization, are then used to derive an improved correlation for the effective diffusivity and permeability as a function of porosity and fiber diameter. At porosities below 0.7, the predicted transport is significantly lower under the assumption of random ordering. The approach is not limited to circular fibers and may be extended to arbitrary fiber geometries.Item Open Access Automatic joining of electrical components to smart textiles by ultrasonic soldering(2021) Micus, Sebastian; Haupt, Michael; Gresser, Götz T.A suitable connection method to automatically produce E-textiles does not exist. Ultrasonic soldering could be a good solution for that since it works with flux-free solder, which avoids embrittlement of the textile integrated wires. This article describes the detailed process of robot-assisted ultrasonic soldering of e-textiles to printed circuit boards (PCB). The aim is to understand the influencing factors affecting the connection and to determine the corresponding solder parameters. Various test methods are used to evaluate the samples, such as direct optical observation of the microstructure, a peeling tensile test, and a contact resistance measurement. The contact strength increases by reducing the operating temperature and the ultrasonic time. The lower operating temperature and the reduced ultrasonic time cause a more homogeneous metal structure with less defects improving the mechanical strength of the samples.Item Open Access Material monitoring of a composite dome pavilion made by robotic coreless filament winding(2021) Mindermann, Pascal; Rongen, Bas; Gubetini, Drilon; Knippers, Jan; Gresser, Götz T.A hemispherical research demonstration pavilion was presented to the public from April to October 2019. It was the first large-scale lightweight dome with a supporting roof structure primarily made of carbon- and glass-fiber-reinforced composites, fabricated by robotic coreless filament winding. We conducted monitoring to ascertain the sturdiness of the fiber composite material of the supporting structure over the course of 130 days. This paper presents the methods and results of on-site monitoring as well as laboratory inspections. The thermal behavior of the pavilion was characterized, the color change of the matrix was quantified, and the inner composition of the coreless wound structures was investigated. This validated the structural design and revealed that the surface temperatures of the carbon fibers do not exceed the guideline values of flat, black façades and that UV absorbers need to be improved for such applications.Item Open Access Adaptive winding pin and hooking capacity model for coreless filament winding(2023) Mindermann, Pascal; Gresser, Götz TCoreless filament winding is a manufacturing process used for fiber-reinforced composites, resulting in high-performance lightweight lattice structures. Load transmission elements, which are assembled from commercially available standardized parts, often restrict the component design. A novel adaptive winding pin was developed, which is made by additive manufacturing and can therefore be adjusted to specific load conditions resulting from its position within the component. This allows to decouple the fiber arrangement from the winding pin orientation, which allows a fully volumetric framework design of components. A predictive model for the pin capacity was derived and experimentality validated. The hooking conditions, pin capacity, and occupancy were considered in the creation of a digital design tool.Item Open Access Integrating electronics to textiles by ultrasonic welding for cable-driven applications for smart textiles(2021) Micus, Sebastian; Rostami, Sahar Golmohammadi; Haupt, Michael; Gresser, Götz T.; Meghrazi, Milad Alizadeh; Eskandarian, LadanThe connection between flexible textiles and stiff electronic components has always been structurally weak and a limiting factor in the establishment of smart textiles in our everyday life. This paper focuses on the formation of reliable connections between conductive textiles and conventional litz wires using ultrasonic welding. The paper offers a promising approach to solving this problem. The electrical and mechanical performance of the samples were investigated after 15 and 30 wash-and-dry cycles in a laundry machine. Here the contact resistances and their peeling strength were measured. Furthermore, their connection properties were analysed in microsections. The resistance of the joints increased more than 300%, because the silver-coated wires suffered under the laundry cycles. Meanwhile, the mechanical strength during the peeling test decreased by only about 20% after 15 cycles and remained the same after 30 cycles. The good results obtained in this study suggest that ultrasonic welding offers a useful approach to the connection of textile electronics to conductive wires and to the manufacture of smart textiles.Item Open Access Design of fiber-composite/metal-hybrid structures made by multi-stage coreless filament winding(2022) Mindermann, Pascal; Müllner, Ralf; Dieringer, Erik; Ocker, Christof; Klink, René; Merkel, Markus; Gresser, Götz T.The methods presented in this study assist in fabricating load-bearing structures with high mass-specific mechanical performance at various scales. Possible applications include primary and secondary structures in engineering, architecture, automotive, or aerospace industries.Additive manufacturing processes, such as coreless filament winding with fiber composites or laser powder bed fusion with metals, can produce lightweight structures while exhibiting process-specific characteristics. Those features must be accounted for to successfully combine multiple processes and materials. This hybrid approach can merge the different benefits to realize mass savings in load-bearing structures with high mass-specific stiffnesses, strict geometrical tolerances, and machinability. In this study, a digital tool for coreless filament winding was developed to support all project phases by natively capturing the process-specific characteristics. As a demonstration, an aluminum base plate was stiffened by a coreless wound fiber-composite structure, which was attached by additively manufactured metallic winding pins. The geometrical deviations and surface roughness of the pins were investigated to describe the interface. The concept of multi-stage winding was introduced to reduce fiber–fiber interaction. The demonstration example exhibited an increase in mass-specific component stiffness by a factor of 2.5 with only 1/5 of the mass of a state-of-the-art reference. The hybrid design approach holds great potential to increase performance if process-specific features, interfaces, material interaction, and processes interdependencies are aligned during the digitized design phase.Item Open Access Flax fibre yarn coated with lignin from renewable sources for composites(2022) Möhl, Claudia; Weimer, Timo; Caliskan, Metin; Hager, Tom; Baz, Stephan; Bauder, Hans-Jürgen; Stegmaier, Thomas; Wunderlich, Werner; Gresser, Götz T.The present experimental work analyses the potential of lignin as a matrix for materials made from renewable resources for composite components and the production of hybrid semi-finished products by coating a flax fibre yarn. Natural fibres, due to their low density, in combination with lignin can be a new renewable source for lightweight products. For this purpose, the extrusion process was adapted to lignin as a matrix material for bio-based composites and coating of natural fibre yarns. A commercial flax yarn is the basis for the lignin coating by extrusion. Subsequently, the coated flax yarn was characterised with regard to selected yarn properties. In order to produce composite plates, the lignin-coated flax yarn was used as warp yarn in a bidirectional fabric due to its insufficient flexibility transversely to the yarn axis. The commercial flax yarn was used as weft yarn to increase the fibre volume content. The tensile and flexural properties of the bio-based composite material were determined. There was a significant difference in the mechanical properties between the warp and weft directions. The results show that lignin can be used as matrix material for bio-based natural fibre composites and the coating of natural fibre yarns is an alternative to spun hybrid yarns.Item Open Access Development of natural fibre-reinforced semi-finished products with bio-based matrix for eco-friendly composites(2022) Möhl, Claudia; Weimer, Timo; Caliskan, Metin; Baz, Stephan; Bauder, Hans-Jürgen; Gresser, Götz T.Increasing resource consumption and a growing amount of textile waste increase the importance of a circular economy and recycling in the fashion and apparel industry. Environmentally friendly bio-based composites made from cellulosic fibres obtained from textile waste, and polymers based on renewable raw materials present a possible solution. In this study, the development of textile semi-finished products based on medium-to-long cotton and flax fibres obtained from textile waste in combination with a bio-based thermoplastic matrix for lightweight applications is investigated. For the production of natural fibre-polylactide hybrid yarns, fibre slivers with improved fibre orientation and blending are produced. Subsequently, quasi-unidirectional woven fabrics are produced and consolidated into bio-based composites. Textile and mechanical properties of hybrid yarns as well as bio-composites are analysed with regard to the influence of fibre length, fibre distribution in the yarn, yarn structure and fibre volume content. The results show that the production of bio-based semi-finished products can be a potential way for upcycling textile waste.Item Open Access Impact of long-term weathering on the properties of a digestate-based biocomposite(2021) Gebhardt, Marion; Milwich, Markus; Gresser, Götz T.; Lemmer, AndreasNatural fibre composites are increasingly used. For many applications, the long-term stability of the mechanical properties is crucial. Therefore, the effects of weathering of a biocomposite made from fibrous digestate and bio-based thermoset are investigated. The fibre component of the composite comes from digestate of a German biogas station which processes hop vines as main substrate. The matrix is a plant-oil-based epoxy resin. The samples were alternately exposed to UV radiation and moisture for various lengths of time. Afterwards, the material strength and water absorption were tested. As a result, the weathering leads to a decrease of strength but not to a high increase of water uptake.Item Open Access Self-cooling textiles : substrate independent energy-free method using radiative cooling technology(2024) Zimmermann, Lea; Stegmaier, Thomas; Kaya, Cigdem; Gresser, Götz T.Due to climate change, population increase, and the urban heat island effect (UHI), the demand for cooling energy, especially in urban areas, has increased and will further increase in the future. Technologies such as radiative cooling offer a sustainable and energy-free solution by using the wavelength ranges of the atmosphere that are transparent to electromagnetic radiation, the so-called atmospheric window (8-13 µm), to emit thermal radiation into the colder (3 K) outer space. Previous publications in the field of textile building cooling have focused on specific fiber structures and textile substrate materials as well as complex multi-layer constructions, which restrict the use for highly scaled outdoor applications. This paper describes the development of a novel substrate-independent coating with spectrally selective radiative properties. By adapting the coating parameters and combining low-emitting and solar-reflective particles, along with a matrix material emitting strongly in the mid-infrared range (MIR), substrate-independent cooling below ambient temperature is achieved. Moreover, the coating is designed to be easily applicable, with a low thickness, to ensure high flexibility and scalability, making it suitable for various applications such as membrane architecture, textile roofs, or tent construction. The results show a median daytime temperature reduction (7 a.m.-7 p.m.) of 2 °C below ambient temperature on a hot summer day.