Panel Material Research Articles

A functionalization approach of decorative poplar veneer accomplished via reactive dyeing followed by in-situ synthesis of ZnO-Ag nanoparticles

Fast-growing wood has been widely used in manufacturing decorative material for wood-based panels. However, the deterioration of the decorative quality of the decorative material is still a hard nut to crack. The single decorative function of this material also makes it challenging to meet the requirements of the current consumer market. In this study, a novel method for the preparation of decorative poplar veneer that integrated multiple functions was proposed. It was accomplished via reactive dyeing of poplar veneer followed by in-situ synthesis of ZnO-Ag nanoparticles (NPs) at room temperature. The critical functional parameters and preparation mechanism of the functional decorative material were systematically analyzed. Results demonstrated that ZnO and Ag NPs were synchronously formed through the in-situ redox of metal ions and subsequent self-assembly in an alkaline medium. The ZnO-Ag NPs were uniformly distributed on the surface of dyed wood. The color change of the prepared decorative material was reduced by at least 40 % due to the physical obstruction of the ZnO-Ag NPs layer. More importantly, the antibacterial, hydrophobic, and flame retardant properties of the prepared material were also synchronously improved. This study provided a new approach to improving the quality of wood-based decorative materials.

Experimental and numerical study of light, fragile vent covers under vented gas explosions

In this study, the venting functions of autoclaved aerated concrete (AAC) and gypsum vent covers under gas explosion conditions were examined for the first time. Eleven sets of field tests were performed, data such as overpressuretime history and rupture pressure data were collected, and failure modes were recorded and analysed. The results show that the AAC and gypsum panels can substantially reduce the internal peak overpressure and duration, and the AAC panel is the venting component with the best performance. The dynamic rupture pressure of venting covers obviously differs from the internal peak overpressure and static failure overpressure, so the opening process and dynamic effect of venting covers should be considered in the design. A numerical model of the AAC panel was established in LS-DYNA. In a parametric study, the panel thickness, material strength, boundary conditions and rate of overpressure rise considerably affected the rupture pressure. On this basis, an empirical formula for the rupture pressure and its applicable range is presented.

Comparative analysis of the heavy-weight floor impact noises using different types of EVA resilient materials

The present study aims to improve the floor impact noises using various shapes of EVA resilient materials in composite floor structures. In order to this, three different types of EVA resilient materials were used including flat plate, deck plate type and cavity type of EVA boards. All the composite structure consisted of PP panel, PET and EVA resilient materials with a total depth from 30mm to 40mm. Total of 9 specimens were made for floor impact sound measurements. All the floor impact sound measurements were done at the recognized testing authority using bang machine. The values of L'I,Fmax,AW were deduced from every measurements. As a result, among the various types EVA resilient materials, most high performances were drawn when cavity type of EVA resilient material was used. It was shown that the average L'I,Fmax,AW value of cavity type was 46dB while 47dB for deck plate type, 48dB for flat plate were measured in average. It can be recognized that the good performance of cavity type EVA materials is caused by the both air layer gap beneath EVA board and air cavity inside the EVA board as well as the low dynamic elastic modulus of EVA.

Study on the Preparation and Performance of Lightweight Wallboards from MSWIBA Foam Concrete.

To reduce land use and avoid further pollution, incineration for power generation has become the main method for municipal solid waste treatment. This research focused on the potential for transforming Municipal Solid Waste Incineration Bottom Ash (MSWIBA) into a finely ground powder. The impact of the powder's fineness and the amount of water used on its effectiveness was analyzed using a method called grey theory. MSWIBA was used as a partial substitute for cement in making MSWIBA foam concrete and lightweight wall panels. By modifying the fineness and water utilization of the recycled micro-powder, its maximum activity index can be increased to 90.1. This study determined the influence of factors including apparent dry density, water-cement ratio, foaming agent dilution ratio, and admixture dosage on the strength of the recycled foam concrete, and established the optimal mix ratio. This study employed a combination of physical experiments and numerical simulations to elucidate the impact of panel material, core layer thickness, and layer sequence on sound insulation performance. The simulation results were in close agreement with the experimental findings.

Simplified formulas for calculating bearing capacities of standing seam metal roof systems under uniformly distributed downward and upward loads

Finite Element (FE) models of standing seam metal roof systems (SSMRSs) are established and verified by experimental results. A comprehensive parametric study on the bearing capacities of SSMRSs under uniformly distributed loads through FE simulations encompassing 281 SSMRSs is conducted. Simplified formulas for calculating the bearing capacities of SSMRSs under uniformly distributed loads are proposed as functions of fundamental parameters, including roof panel thickness, roof panel width, purlin spacing, material strength, friction coefficient, and support head width. These simplified formulas avoid the necessity for calculating the effective section during the verification of bending failure and avoid the necessity for wind uplift experiments during the verification of connection failure of the SSMRSs in conventional building codes and guidelines. The results show that for per 0.1 mm increase in roof panel thickness, the ultimate bearing capacities under downward and upward loads increase by about 14.03 % and 19.88 %; for per 100 mm increase in roof panel width, they decrease by about 27.14 % and 36.45 %; for per 200 mm increase in purlin spacing, they decrease by about 12.82 % and 5.01 %; for per 20 MPa increase in material strength, they increase by about 11.40 % and 2.24 %; for per 0.1 increase in friction coefficient, they increase by about 3.16 % and 9.01 %. Future studies can focus on the ultimate bearing capacities of SSMRSs under non-uniform loads with temporal and spatial fluctuation.

High-temperature effect on continuous glass fiber reinforced polypropylene multilayer composite and corrugated sandwich panels

The high-temperature mechanical behaviors of Multi-Layer Composite Panels (MCP) and Corrugated Sandwich Panels (CSP) of Continuous Glass Fiber-Reinforced Polypropylene (CGFRPP) are critical for their application in aerospace fields, which have been rarely mentioned in previous studies. High-temperature quasi-static tensile and compression tests on CGFRPP MCP are conducted first. The results showed that the tensile and compression strength, stiffness, and tensile modulus of MCP decreased with increasing temperature. The Gibson model was found to be more suitable for predicting the high-temperature mechanical performance of MCP after comparing the calculated results of different theoretical models with experimental data. Secondly, high-temperature planar compression tests were conducted on the CGFRPP CSP, revealing that the main failure modes were corrugated core buckling and delamination between the face panel and core material, with delamination being intensified at higher temperatures. Therefore, we proposed a strength theoretical model that considers structural buckling failure and interface delamination failure, and introduced the influence factor to evaluate the effect of interface delamination on structural strength.

Sustainable insulation panel for buildings made of rice husks and posidonia

The design of the building envelope is crucial to achieve adequate thermal comfort by means of insulating materials that prevent heat flow without excessive energy costs. Generally, materials based on fossil fuel content a large carbon footprint, so when environmental criteria are becoming increasingly important, it is necessary to search for more sustainable insulation materials with a low environmental impact, lower energy use or few CO2 emissions. The aim of this work is focussed on using the agricultural residue or plant debris that sea expels, specifically rice husk and posidonia oceanic leaves. The properties of both materials are studied by experimental tests at different densities to define appropriate thermal conductivity. In addition, acoustic performance, sensitivity to water, durability (mould fungus), mechanical properties and fire reaction are tested to evaluate their behaviour in comparison to other commercial insulation materials. The results highlight the proper performance of rice husks and posidonia as material for insulation panels with 0.055 and 0.045 W/mK of thermal conductivity, respectively. Furthermore, rice husks and posidonia offer a promising reaction to fire with low heat release and smoke production for an element that has been critical in buildings in past catastrophic fires.

Compressive behavior of Body-Centered-Cubic (BCC)-like ultra-lightweight Carbon Fiber Reinforced Polymer (CFRP) lattice-based sandwich structures

3D lattice structures comprise a connected network of segments that allow positioning of the base material where needed while maintaining an open-cell characteristic. These structures represent an ideal lightweight core material for high-performance sandwich panels. This work presents, for the first time, the performance of lattice-based cores fabricated via indirect additive manufacturing using pultruded Carbon Fiber Reinforced Polymer (CFRP) rods. The CFRP sandwich panels were tested under out-of-plane compression, and their compressive properties and failure modes were predicted via analytical and FE analyses, later contrasted with mechanical testing. Finally, the study compares favorably with similar core materials found in the literature.

Numerical study of the thermal performance of a single-channel cooling PV system using baffles and different nanofluids

The present numerical study reports the performance of a cooling system for solar photovoltaic panels (PV) using different nanofluids (Al2O3, CuO, and ZnO). A novel parallel flow channel with strategically placed baffles was analyzed to improve the heat transfer between the back of PV and the nanofluid. The nanoparticles' Brownian motion and the nanofluid temperature effect were considered. Computational fluid dynamics was used to simulate the interaction between the fluid in motion and panel materials. Various nanoparticle concentrations, Reynolds numbers (18–1800), and solar radiation values (200–1000 W/m2) were examined. The results showed that the nanofluid composed of CuO was the most effective, improving thermal efficiency by 5.67 % compared to pure water in the lowest Re range. A 10 % vol. concentration of Al2O3 reduced temperature by up to 15 % and increased electrical efficiency by 4 % when the Re varied from 18 to 42. However, increasing the Re number and having low solar radiation values decreased the contribution of the nanofluid. Additionally, using baffles in the flow channel improved electrical efficiency by 2 %.

Selection of Optimal Bending Types in Die Process of L-Shaped Panels Considering the Springback Behaviours

In die designing, one of the most crucial decisions is selecting the appropriate die process required to produce panels. The challenge for die designer is to comprehend the behaviour of the panel material in relation to the die processes. If the die process is not correctly determined before die fabrication, severe panel spring back may occur, which can become difficult and require additional time and effort to rectify. This paper presents research aimed at understanding the behaviour of different types of bending process combinations concerning the spring back occurrence during the stamping process of an L-shaped design intent panel. Using simulation and experiment, three types of materials with different tensile properties of 270 MPa, 440 MPa and 590 MPa, but the same thickness of 1.8 mm, were selected. The results were compared, analysed and optimized by using Response Surface Methodology (RSM) method. The results demonstrate that one-process bending with full bending (compress type) approach, is the most suitable for the three materials type L-shaped panel. The study provides guidelines for die design engineers, industrial practitioners and researchers to decide on the best approach for die process decisions, when dealing with specific panels properties, shape and thickness.

An Innovative AgNP-based Solar Panel Coating and Farmland Fertility Optimization (FFO) based Power Extraction Methodology for Grid Systems

In the power electronic system, coated solar panels attracted a lot of interest in present times. The proposed work aims to achieve two key objectives: maximal power extraction and solar panel coating. To reduce the cost of coating material for solar panels, Silver Nano Particles (AgNPs) are first collected from the leaves of Rose periwinkle plants. This strategy aims to achieve maximal power extraction by coating solar panels with green synthesized silver nanoparticles. To reduce the cost of coating material, Rosy periwinkle plant leaves are used to synthesize silver nanoparticles or AgNPs. To ascertain the framework's capacity for measuring energy both before and after the panels are coated with AgNP, this study theoretically analyses the data. The power current and voltage-current characteristics of the study were validated, enabling an examination of the study's effectiveness. The coated type outperformed the normal solar panel by 2%, according to the results. With a new approach called Farmland Fertility Optimization – Maximum Power Position Tracking, the precise peak site for increased energy yield is discovered. The bi-directional converter is also utilized to mitigate stress and increase voltage gain. To improve the power quality with fewer harmonics, the 3-phase inverter and the LC filtering circuits are used. Finally, a variety of performance measures are used to confirm the results of coated solar panels using power-tracking control techniques. The findings suggest that AgNP-coated solar panels provide the best possible electrical energy with improved voltage, current, and power quality. Performance evaluation shows that the coated solar panel's power tracking efficiency has increased to 99% with decreased harmonics of 2.52%.

Environmentally Sustainable Raised Access Flooring Product Development

Raised access floors are nowadays widely used in buildings. A novel raised access flooring product is developed by this research, with a set of sustainable features, including less environmental impact and high strength. Its floor panels are made of polyurethane (PU) reinforced with glass fibre, which is light-weight and fire-resistant, replacing the traditional floor panel materials, and the panels are supported by simplified steel stringers to reinforce the strength of the flooring product. Instead of the conventional sandwich design consisting of a core material encapsulated by outer layers, the new floor panel design adopts the reinforced PU as its sole material, which not only simplifies the structure but also reduces floor weight and costs. The sustainable advantage is further approved by the environmental life cycle assessments of the new raised flooring product in comparison to traditional ones made of cement and woodchips, with results showing that the new floor product’s total environmental impact is 52% less than cement floor and 47% less than woodchip board floor. Further, the finite element analysis (FEA) was carried out, and the experimental test was conducted to verify the FEA results, indicating that the new product’s strength is higher than the requirements of the raised access flooring product standards. There is no raised access flooring product made of PU reinforced with glass fibre available in the market, and, hence, the new product developed by this research is a novel contribution.

91‐1: Invited Paper: Micro‐LED Stamp Transfer & Repair Technology for Tiling Display

Micro‐LED technology is believed to be the next generation of display, which has attracted increasing interests from academia and display industry. Combined with the efforts of of panel makers, LED manufacturers, equipment and materials makers, the yield and performance of Micro‐LED is becoming more competitive over that of a few years ago. Stamp transfer is still the closest mass transfer technology towards the possibility of mass production of Micro‐LED. Along with more mature inspection and repair, slicing, driving and demura technology, Vistar has developed a full‐process solution for the fabrication of 102 inch large area splicing display, constructed with 4.78 inch Micro‐LED display modules. After the construction of the first Micro‐LED pilot line in Mainland China in Aug 2020, Vistar took another leap in the construction of the first Micro‐LED mass production line, which laid foundation in Sep 2023. It is a big step closer to a future of Micro‐LED filled with displays.

56‐1: Invited Paper: Mechanical Strength Improvement of Foldable Panel with COE

It is significant to reduce power consumption and thickness of foldable display with larger size. Color filter on Encapsulation (COE), as one of the most critical technologies, has excellent performance in terms of power consumption and thinning. COE refers to the technical proposal replacing polarizer with color filter on the surface of encapsulation(COE). However, we have encountered two problems of reduced mechanical strength in the mass production. One of the problems is panel peeling in module process, and the other one is cracking during drop test. This paper has studied the root cause of COE panel strength reduction from panel design, process and material. As a result we achieved the same mechanical strength as polarizer panel.

Effect of blade materials on the undershot water turbine performance

Undershot waterwheel at low flow with an average discharge of 0.12 m3/s and 613.2 W water horsepower are used to turn the waterwheel. The rotation results obtained with aluminum material is 24 RPM which has a density of 2.71 g/cm3 while the lowest rotation is owned by a galvanic of 20 RPM with a density of 7.49 g/cm3. From the experiment, it was found that the difference between the materials used was due to the different density. The efficiency of waterwheels with aluminum material has the highest value, namely 30%, while the lowest using acrylic material has an efficiency of 23%. For the highest generator efficiency using aluminum material with an efficiency of 4.2%, the second has an efficiency of 3.6% using Aluminum Composite Panel material. Aluminum has the highest efficiency because it has less density than galvanized. In addition, the thickness of aluminum is also very influential, where aluminum has a thickness of 1.14 mm while Galvanized has 0.98 mm.

The screen panel material for the future

The screen panel material for the future

Sikahyflex-Epoxy Mixed Adhesive’s Effect on the Aluminum-Composite Joint’s Shear Tensile Strength for the Automotive Industry

The automotive industry sector encounters challenges in the construction of connections between different materials. Hence, a breakthrough is needed in the automotive industry in manufacturing connections between different wall panel materials. Mixed adhesive materials for different materials are required and represent an innovation in the manufacturing process for joints of different materials due to the need for stiff and slightly ductile adhesives. This research aims to analyze the effect of using a sikahyflex-epoxy mixture adhesive in aluminum-composite joints on the shear tensile strength of the joints for the automotive industry. This research serves as an innovation in dissimilar material connection systems by developing the use of mixed adhesives and cocofiber aluminum-composite adherend materials with environmentally friendly and corrosion-resistant properties. The research material used aluminum 5083-cocofiber composite. The adherend surface was roughened employing sandpaper of #60, #80, and #150. The adhesive used the addition of sikahyflex adhesive to the epoxy adhesive with additional variations of 10%, 20%, 30%, and 40% sikahyflex. Connections between different materials with the single lap joint type refer to ASTM D1002. The roughness test results yielded the best roughness grade #150 on the surface of the aluminum adherend and coco fiber composite. The shear tensile test results by adding 40% sikahyflex adhesive, 0.4 mm adhesive thickness, and #150 sandpapering resulted in a 20% increase in shear tensile strength in the single lap joint of 2.51 N/mm2. The surface roughness enhanced the adhesive bond strength between mechanical interlocking adhesives and adherend. Meanwhile, the failure modes observed in macro observations included thin-layer cohesive failure, cohesive failure, two-stage failure, and stock-break failure modes. The SEM observation revealed that in the initial propagation of microcracking and voids, which mark the initial onset of adhesive failure, tearing took place, leading to a failure mode in the aluminum-composite coco fiber single overlap joint.

Experimental Investigation of the Three-Point Bending Property of a Sandwich Panel with a Metal Rubber Core

Sandwich structures and porous materials have been applied widely in various fields due to their excellent mechanical performance, and multifunctional composites will have a significant engineering demand in the future. Studying damped composites’ mechanical properties and failure forms has significant engineering value and significance. However, the current connecting processes for sandwich panels and porous materials must be improved. Therefore, to explore the ambiguity of the connection interface between the core material and panel in sandwich panels, as well as the mechanical properties of such structures, a sandwich panel with a metal rubber core material was prepared using vacuum brazing and cementing processes. Microscopic examinations using scanning electron microscopy and energy-dispersive spectroscopy were conducted to observe the physical bonding mechanism at the interface of the sandwich panel. The results indicate that the brazed sandwich panels exhibited a more uniform and continuous interface than the cemented sandwich panels. This work designs three-point bending compression experiments to investigate the effects of core material thickness, density, and preparation process on the bending mechanical properties of the sandwich panel. Failure modes of the sandwich panel during the experiments are analyzed. The experimental results show that the failures of the brazed sandwich panels are attributable to the bending deformation of the panel and the shear failure of the metal wire core material. The cemented sandwich panels exhibit separation failures in the area below the indenter and at both ends of the panel. The core material’s thickness and density significantly influence the bending performance of the sandwich panels. An increase in the core material’s thickness and density effectively enhances the sandwich panels’ peak load and energy absorption capacity.

Industrial-scale manufacturing of particleboards using agricultural waste camellia oleifera shells

The search for materials made from renewable resources and free of toxic substances is a global trend towards cleaner production, which can be extended to the development of wood-based panels. However, the industrial sector of wood-based panels has been facing several gaps and challenges related to the shortage of wood raw materials for panel manufacturing with the toxic emissions of traditional adhesives. Camellia oleifera shell (COS), as a common waste, is a potential alternative raw material for wood-based panels and also has an important role in alleviating environmental stress. Faced with these problems, the aim of this study was to assess the technical feasibility and environmental aspects of manufacturing particleboard from COS waste at scale. For this purpose, particles made from conventional eucalyptus species were used as particleboard reinforcing phase. Particleboard was manufactured and tested by varying some production parameters, namely: of 10, 20 and 30% content of COS addition; and adhesive types of melamine-urea-formaldehyde (MUF) and polymeric 4–4 diphenylmethane diisocyanate (pMDI) adhesives. The results showed that the physical-mechanical properties of COS-based particleboards were satisfactory for a 10% MUF resin loading or a 3.5% pMDI resin loading. COS-based particleboards with 20–30% COS content similarly met the standards and requirements for non-structural applications. This study presents an informative discussion for decision makers in the wood-based panel industry, providing a trade-off between lower adhesive application and higher COS substitution that is more suitable for direct production at total plant scale.

Application of Gaba-Gaba Egg Rack Bio-Composite as Material Wall Meeting Room Acoustics

Bio composite materials are a combination of two or more natural polymer materials or biofiber (natural fibers) which can be degraded as reinforcement and polymer or matrix. Natural fibers generally have the ability to absorb sound well and have basic properties as composite reinforcements. If a wave hits a material, the wave can be straightened, reflected and absorbed. The ability of composite structures to absorb sound can be used to reduce noise levels. This research models a combination of egg rack waste mixed with sago leaf stem (gaba-gaba) waste as a bio-composite material for room acoustic panels. This research uses a material modeling engineering method which is a pure experiment, with the stages of making test samples based on fixed variables and measurable variables and then testing to obtain the material absorption coefficient, then the test results are based on the specified variables, then applying the material to the meeting room. After that tested the acoustic level of the room, especially the meeting room.