Directional Migration and Distribution of Magnetic Microparticles in Polypropylene-Matrix Magnetic Composites Molded by an Injection Molding Assisted by External Magnetic Field.

Surface-functionalized polymer composites with spherical particles as fillers offer great qualities and have been widely employed in applications of sensors, pharmaceutical industries, anti-icing, and flexible electromagnetic interference shielding. The directional migration and dispersion theory of magnetic microparticles in polypropylene (PP)-matrix magnetic composites must be studied to better acquire the functional surface with remarkable features. In this work, a novel simulation model based on multi-physical field coupling was suggested to analyze the directed migration and distribution of magnetic ferroferric oxide (Fe3O4) particles in injection molding assisted by an external magnetic field using COMSOL Multiphysics® software. To accurately introduce rheological phenomena of polymer melt into the simulation model, the Carreau model was used. Particle size, magnetic field intensity, melt viscosity, and other parameters impacting particle directional motion were discussed in depth. The directional distribution of particles in the simulation model was properly assessed and confirmed by experiment results. This model provides theoretical support for the control, optimization, and investigation of the injection-molding process control of surface-functionalized polymer composites.

Combined Approach of Compression Molding and Magnetic Attraction to Micropatterning of Magnetic Polydimethylsiloxane Composite Surfaces with Excellent Anti-Icing/Deicing Performance.

The accumulation of ice and contaminants on the surface of composite insulators will cause high energy consumption or even major hazards to power systems. In this work, the polydimethylsiloxane (PDMS) silicone rubber was modified by surface micropatterning and material compositing. Highly crosslinked poly(cyclotriphosphazene-co-4,4'-sulfonyldiphenol) (PZS) was used to directly coat ferroferric oxide (Fe3O4) nanoparticles. The obtained core-shell Fe3O4@PZS microspheres were loaded with carbon nanotubes (CNTs) to get CNTs/Fe3O4@PZS as the photothermal magnetic filler. The PDMS/CNTs/Fe3O4@PZS surfaces with micronscale truncated cones were prepared via a combined method of compression molding and magnetic attraction. The 1H,1H,2H,2H-perfluorodecyltrichlorosilane-coated template and magnetic field can increase the height of the microstructure to ∼76 µm and maintain the contact angle of microstructured PDMS/CNTs/Fe3O4@PZS surfaces at a high level (∼152°). Compared with the flat PDMS surface, the micronscale truncated cones extend the freezing time from 4.5 to 11.5 min and also undermine the ice adhesion strength from ∼25 to ∼17 kPa for the microstructured PDMS/CNTs/Fe3O4@PZS surface. The temperature of the PDMS/CNTs/Fe3O4@PZS surface molded with magnetic attraction increases linearly with time and the internal magnetic fillers and achieves 280 °C in 10 s. The efficiency of temperature rise is increased by ∼46%, and hence the entire frozen water droplet can melt within 20 s. The strategy combining active deicing with passive anti-icing undoubtedly promotes the development of high efficiency anti-icing materials and can be applied on insulators to prevent icing flashover.