Tag Archives: wind turbines

A use for fullerenes—inside insulation plastic for high-voltage cables

A Jan. 27, 2015 news item on Nanowerk, describes research which suggests that there may a new use for buckminsterfullerenes (or what they’re calling ‘carbon nanoballs’),

Researchers at Chalmers University of Technology [Sweden] have discovered that the insulation plastic used in high-voltage cables can withstand a 26 per cent higher voltage if nanometer-sized carbon balls are added. This could result in enormous efficiency gains in the power grids of the future, which are needed to achieve a sustainable energy system.

The renewable energy sources of tomorrow will often be found far away from the end user. Wind turbines, for example, are most effective when placed out at sea. Solar energy will have the greatest impact on the European energy system if focus is on transport of solar power from North Africa and Southern Europe to Northern Europe.

“Reducing energy losses during electric power transmission is one of the most important factors for the energy systems of the future,” says Chalmers researcher Christian Müller. “The other two are development of renewable energy sources and technologies for energy storage.”

The Jan. 27, 2015 Chalmers University of Technology press release (also on EurekAlert) by Johanna Wilde, which originated the news item, provides more information about the research,

Together with colleagues from Chalmers and the company Borealis in Stenungsund, he [Müller] has found a powerful method for reducing energy losses in alternating current cables.  The results were recently published in Advanced Materials, a highly ranked scientific journal.

The researchers have shown that different variants of the C60 carbon ball, a nanomaterial in the fullerene molecular group, provide strong protection against breakdown of the insulation plastic used in high-voltage cables. Today the voltage in the cables has to be limited to prevent the insulation layer from getting damaged. The higher the voltage the more electrons can leak out into the insulation material, a process which leads to breakdown.

It is sufficient to add very small amounts of fullerene to the insulation plastic for it to withstand a voltage that is 26 per cent higher, without the material breaking down, than the voltage that plastic without the additive can withstand.

“Being able to increase the voltage to this extent would result in enormous efficiency gains in power transmission all over the world,” says Christian Müller. “A major issue in the industry is how transmission efficiency can be improved without making the power cables thicker, since they are already very heavy and difficult to handle.”

Using additives to protect the insulation plastic has been a known concept since the 1970s, but until now it has been unknown exactly what and how much to add. Consequently, additives are currently not used at all for the purpose, and the insulation material is manufactured with the highest possible degree of chemical purity.

In recent years, other researchers have experimented with fullerenes in the electrically conductive parts of high-voltage cables. Until now, though, it has been unknown that the substance can be beneficial for the insulation material.

The Chalmers researchers have now demonstrated that fullerenes are the best voltage stabilizers identified for insulation plastic thus far. This means they have a hitherto unsurpassed ability to capture electrons and thus protect other molecules from being destroyed by the electrons.

To arrive at these findings, the researchers tested a number of molecules that are also used within organic solar cell research at Chalmers. The molecules were tested using several different methods, and were added to pieces of insulation plastic used for high-voltage cables. The pieces of plastic were then subjected to an increasing electric field until they crackled. Fullerenes turned out to be the type of additive that most effectively protects the insulation plastic.

The press release includes some facts about buckyballs or buckminsterfullerenes or fullerenes or C60 or carbon nanoballs, depending on what you want to call them,

 Facts: Carbon ball C60

  • The C60 carbon ball is also called buckminsterfullerene. It consists of 60 carbon atoms that are placed so that the molecule resembles a nanometer-sized football. C60 is included in the fullerene molecular class.
  • Fullerenes were discovered in 1985, which resulted in the Nobel Prize in Chemistry in 1996. They have unique electronic qualities and have been regarded as very promising material for several applications. Thus far, however, there have been few industrial usage areas.
  • Fullerenes are one of the five forms of pure carbon that exist. The other four are graphite, graphene/carbon nanotubes, diamond and amorphous carbon, for example soot.

Here’s a link to and a citation for the research paper,

A New Application Area for Fullerenes: Voltage Stabilizers for Power Cable Insulation by Markus Jarvid, Anette Johansson, Renee Kroon, Jonas M. Bjuggren, Harald Wutzel, Villgot Englund, Stanislaw Gubanski, Mats R. Andersson, and Christian Müller. Advanced Materials DOI: 10.1002/adma.201404306 Article first published online: 12 DEC 2014

© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim

This paper is behind a paywall.

Here’s an image of wind turbines, an example of equipment which could benefit greatly from better insulation.,

Images: Lina Bertling, Jan-Olof Yxell, Carolina Eek Jaworski, Anette Johansson, Markus Jarvid, Christian Müller

Images: Lina Bertling, Jan-Olof Yxell, Carolina Eek Jaworski, Anette Johansson, Markus Jarvid, Christian Müller

You can find this image and others by clicking on the Chalmers University press release link (assuming the page hasn’t been moved). You can find more information about Borealis (the company Müller is working with) here.

Let’s make our turbine blades really big (greater than 75 metres) with new nanocomposite

The is a story about balsa wood, wind farms, turbine blades, and nanocomposites according to a June 25, 2014 news item on ScienceDaily,

In wind farms across North America and Europe, sleek turbines equipped with state-of-the-art technology convert wind energy into electric power. But tucked inside the blades of these feats of modern engineering is a decidedly low-tech core material: balsa wood.

Like other manufactured products that use sandwich panel construction to achieve a combination of light weight and strength, turbine blades contain carefully arrayed strips of balsa wood from Ecuador, which provides 95 percent of the world’s supply.

For centuries, the fast-growing balsa tree has been prized for its light weight and stiffness relative to density. But balsa wood is expensive and natural variations in the grain can be an impediment to achieving the increasingly precise performance requirements of turbine blades and other sophisticated applications.

As turbine makers produce ever-larger blades — the longest now measure 75 meters, almost matching the wingspan of an Airbus A380 jetliner — they must be engineered to operate virtually maintenance-free for decades. In order to meet more demanding specifications for precision, weight, and quality consistency, manufacturers are searching for new sandwich construction material options.

Now, using a cocktail of fiber-reinforced epoxy-based thermosetting resins and 3D extrusion printing techniques, materials scientists at the Harvard School of Engineering and Applied Sciences (SEAS) and the Wyss Institute for Biologically Inspired Engineering have developed cellular composite materials of unprecedented light weight and stiffness.

A June 25, 2014 Harvard University news release (also on EurekAlert), which originated the news item, goes on to describe the new technology in more detail while throwing 3D printing into the mix,

Until now, 3D printing has been developed for thermo plastics and UV-curable resins—materials that are not typically considered as engineering solutions for structural applications. “By moving into new classes of materials like epoxies, we open up new avenues for using 3D printing to construct lightweight architectures,” says principal investigator Jennifer A. Lewis, the Hansjörg Wyss Professor of Biologically Inspired Engineering at Harvard SEAS. “Essentially, we are broadening the materials palate for 3D printing.”

“Balsa wood has a cellular architecture that minimizes its weight since most of the space is empty and only the cell walls carry the load. It therefore has a high specific stiffness and strength,” explains Lewis, who in addition to her role at Harvard SEAS is also a Core Faculty Member at the Wyss Institute. “We’ve borrowed this design concept and mimicked it in an engineered composite.”

Lewis and Brett G. Compton, a former postdoctoral fellow in her group, developed inks of epoxy resins, spiked with viscosity-enhancing nanoclay platelets and a compound called dimethyl methylphosphonate, and then added two types of fillers: tiny silicon carbide “whiskers” and discrete carbon fibers. Key to the versatility of the resulting fiber-filled inks is the ability to control the orientation of the fillers.

The direction that the fillers are deposited controls the strength of the materials (think of the ease of splitting a piece of firewood lengthwise versus the relative difficulty of chopping on the perpendicular against the grain).

Lewis and Compton have shown that their technique yields cellular composites that are as stiff as wood, 10 to 20 times stiffer than commercial 3D-printed polymers, and twice as strong as the best printed polymer composites. The ability to control the alignment of the fillers means that fabricators can digitally integrate the composition, stiffness, and toughness of an object with its design.

“This paper demonstrates, for the first time, 3D printing of honeycombs with fiber-reinforced cell walls,” said Lorna Gibson, a professor of materials science and mechanical engineering at the Massachusetts Institute of Technology and one of world’s leading experts in cellular composites, who was not involved in this research. “Of particular significance is the way that the fibers can be aligned, through control of the fiber aspect ratio—the length relative to the diameter—and the nozzle diameter. This marks an important step forward in designing engineering materials that mimic wood, long known for its remarkable mechanical properties for its weight.”

“As we gain additional levels of control in filler alignment and learn how to better integrate that orientation into component design, we can further optimize component design and improve materials efficiency,” adds Compton, who is now a staff scientist in additive manufacturing at Oak Ridge National Laboratory. “Eventually, we will be able to use 3D printing technology to change the degree of fiber filler alignment and local composition on the fly.”

The work could have applications in many fields, including the automotive industry where lighter materials hold the key to achieving aggressive government-mandated fuel economy standards. According to one estimate, shedding 110 pounds from each of the 1 billion cars on the road worldwide could produce $40 billion in annual fuel savings.

3D printing has the potential to radically change manufacturing in other ways too. Lewis says the next step will be to test the use of thermosetting resins to create different kinds of architectures, especially by exploiting the technique of blending fillers and precisely aligning them. This could lead to advances not only in structural materials, but also in conductive composites.

Previously, Lewis has conducted groundbreaking research in the 3D printing of tissue constructs with vasculature and lithium-ion microbatteries.

Here’s a link to and citation for the paper,

3D-Printing of Lightweight Cellular Composites by Brett G. Compton and Jennifer A. Lewis. Advanced Materials DOI: 10.1002/adma.201401804 Article first published online: 18 JUN 2014

© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim

This paper is behind a paywall.