Posted tagged ‘impact’

Artificial photosynthesis

August 23, 2011

Artificial photosynthesis is one of the newer ways researchers are exploring to capture the energy of sunlight reaching earth.

01-photosynthetic reaction-receive sunlight as photons-transfer energy to a network of pigment protein complexes

Photosynthesis:

01-Photosynthesis-basics-operation-oxygen release-hydrogen splits


Photosynthesis is the conversion of sunlight, carbon dioxide, and water into usable fuel and it is typically discussed in relation to plants where the fuel is carbohydrates, proteins, and fats. Using only 3 percent of the sunlight that reaches the planet, plants collectively perform massive energy conversions, converting just over 1,100 billion tons of CO2 into food sources for animals every year.

Photovoltaic Technology:

This harnessing of the sun represents a virtually untapped potential for generating energy for human use at a time when efforts to commercialize photovoltaic–cell technology are underway. Using a semiconductor–based system, photovoltaic technology converts sunlight to electricity, but in an expensive and somewhat inefficient manner with notable shortcomings related to energy storage and the dynamics of weather and available sunlight.

Artificial Photosynthesis:

01-photosynthesis system-Artificial Photosynthesis-Artificial Photosynthesis Solar energy to produce hydrogen directly used in fuel cell

Two things occur as plants convert sunlight into energy:

  • Sunlight is harvested using chlorophyll and a collection of proteins and enzymes, and
  • Water molecules are split into hydrogen, electrons, and oxygen.

These electrons and oxygen then turn the CO2 into carbohydrates, after which oxygen is expelled.

Rather than release only oxygen at the end of this reaction, an artificial process designed to produce energy for human use will need to release liquid hydrogen or methanol, which will in turn be used as liquid fuel or channeled into a fuel cell. The processes of producing hydrogen and capturing sunlight are not a problem. The challenge lies in developing a catalyst to split the water molecules and get the electrons that start the chemical process  to produce the hydrogen.

There are a number of promising catalysts available, that, once perfected, could have a profound impact on how we address the energy supply challenge:

  • Manganese directly mimics the biology found in plants.
  • Titanium Dioxide is used in dye-sensitized cell.
  • Cobalt Oxide is very abundant, stable and efficient as a catalyst

Artificial Photosynthesis Operation:

01-artificial Photosynthesis-arrays of microwave coated catalysts-split water to make hydrogen or liquid hydrocarbon fuels

Under the fuel through artificial photosynthesis scenario, nano tubes embedded within a membrane would act like green leaves, using incident solar radiation (H³) to split water molecules (H2O), freeing up electrons and oxygen (O2) that then react with carbon dioxide (CO2) to produce a fuel, shown here as methanol (CH3OH). The result is a renewable green energy source that also helps scrub the atmosphere of excessive carbon dioxide from the burning of fossil fuels.

01-artificial photosynthesis solar collector to energy-concentrated solar radiation- convert photosynthesis to Hydrogen and oxygen

History:

Plants use organic compounds that need to be continuously renewed. Researchers are looking for inorganic compounds that catalyze the needed reactions and are both efficient and widely available.

The research has been significantly boosted by the application of nano technology. It’s a good example of the step wise progress in the scientific world.

Studies earlier in the decade showed that crystals iridium efficiently drove the reduction of CO2, but iridium is extremely rare so technology that required its use would be expensive and could never be used on a large scale.

Cobalt crystals were tried. They worked, and cobalt is widely available, but the original formulations weren’t at all efficient.

Things changed with the introduction of nano technology.

The main point is that this unique approach increasing appears to be feasible. It has the advantage of harnessing solar energy in a form that can be stored and used with greater efficiency than batteries and it is at least carbon neutral.

PRESSURE FORMING

August 22, 2011

01-pressure forming-products-intricate contours-tight radii-


Material & Description

ABS

Good general purpose material, very tough yet very hard and rigid, good impact and electrical. Available in gauges from .040 to .475 with several extruded textures. Comes opaque and can be matched in custom colors.

ABS/PC

A blend or alloy of ABS and polycarbonate that thermoforms well, weathers well, good color retention, very hard, excellent impact.

ABS/PVC

Flame retardant, tough.

Acrylic

Outstanding weather resistance, excellent optics and electrical properties, poor impact, high gloss and deep luster. Available in standard gauges from .080 to over 1″. Available in clear, transparent and opaque colors.

Acrylic, cell cast

Excellent optics and hot strength, more expensive. Acrylic, continuous and extrusion cast.
Large volume use and best price, good optics.

Acrylic film

3 or 6 mil film for laminating, decorating, and weathering of extruded ABS.

DR Acrylic

Modified acrylic with higher impact properties.

Acrylic/PVC

A blend of acrylic and PVC that is a tough, chemical-resistant material that weathers well and is flame resistant. Available in custom colors.

HDPE (high-density polyethylene)

Crystalline, very tough materials, good weather resistance with UV inhibitors, resistant to many chemicals. Available in standard gauges from .040 to .500. Available in opaque custom colors. Tough and stiff. Good low temperature. Economical.

HMWPE (high molecular weight)

Excellent environmental stress crack properties, thermoforms well, good low temperature.

HIPS (high impact polystyrene)

Good general-purpose material, rigid. Available in clear but usually opaque custom colors from .030 to .350, low cost.

PVC (vinyl)

Good general-purpose material, good abrasion and chemical resistance. Available in clear but usually opaque custom colors from .030 to .125.

Expanded PVC

Stiff, light, flat, thermoformable. Available in stock colors and gauges, generally 3 and 6 mm but others also available.

PETG

Clear, higher impact than acrylic, easy to form. Available in gauges from .030 to .500.

01-pressure forming-blow forming-Thermoform-Console-automobile parts

Pressure Forming:

Pressure Forming is the method used to produce injection mold quality, high definition plastic component parts, housings and containers without the huge expense of tooling. It involves positive pressure to force the heated plastic into the mold cavity. This is called pressure thermoforming or blow forming

Pressure Forming Working Operation:

01-pressure forming-20-150 psi pressure-temperature controlled mold cavity

The highly versatile pressure forming process utilizes air pressure, from 20 to 150 psi, to force the heated sheet into a temperature controlled mold cavity. Vent holes are provided in the mold to exhaust the trapped air. The final part features sharp definition of intricate contours and tight radii. Textures and accurate details are built right into the tooling. Low-cost, highly aesthetic plastic parts of varying sizes are possible due to the application of air pressure, as well as more sophisticated process controls that better monitor tool and sheet temperatures while controlling material shrinkage during forming.

01-pressure forming-products-intricate contours-tight radii-

Types Of Molding operation:

  • Positive Mold
  • Negative Mold

01-pressure forming process-positive molds-cost advantages-pressure forming over thermo forming

Negative molds  have concave cavities. A positive mold has a convex shape.

Pressure Forming over Thermo Forming:

The basic advantage of Pressure Forming over Thermo forming is the cost advantage for small production items. The mould cost for thermo forming is considerably higher in comparison to pressure forming thus for a lower quantity precision job the best suitable method used is pressure forming.

Application:

Pressure forming is used to create in a wide array of plastic products used for packaging of food trays, blisters, covers, internal parts, housings equipment, bezels, bases, and spare parts for use in business machines, electronics, computers and peripherals, bio-medical applications, and instruments.

Features:

Pressure forming achieves features beyond the capabilities of vacuum forming including louvers, ribs, recessed areas, crisp details and logos.

Pressure forming is ideal for small to medium sized production runs that do not justify the high cost of injection molding dies. Additionally, because the aluminum tooling used in pressure forming has an unlimited lifecycle, due to the non-abrasive process versus injection, it saves a great deal of money over many years of continued use. Pressure form tooling usually costs less than 10% the cost of an injection tool. There is also a significant time savings (sometimes 25%) in tooling lead time. Sheet gauges .020″ – .500″ are capable of being pressure formed.