Piezoelectric shear wave sensors for high frequency inline viscosity monitoring
Innovative piezoelectric shear wave sensors enable real-time, high-frequency viscosity monitoring of polymer melts during injection molding, enhancing precision and efficiency in manufacturing processes.
Overview
This solution involves the development of piezoelectric shear wave sensors designed for high-frequency inline viscosity monitoring of polymer melts, particularly in the context of injection molding. The sensors utilize high-frequency sound waves (10-100kHz) to measure the stress response and phase shift in polymer melt flows, outputting the complex modulus and viscosity. This technology aims to improve the precision of viscosity measurements, which are crucial for optimizing manufacturing processes and ensuring product quality.
Technical specifications
- High-frequency sound waves: Operates at 10-100 kHz to measure viscosity in polymer melts.
- Penetration depth: Effective within 3-10 mm, suitable for most injection nozzles.
- Calibration: Inline setup calibrated with bulk rheometry to ensure accurate viscosity correlation.
- Temperature control: Incorporates cooling strategies to manage temperature fluctuations during measurements.
- Custom piezo setup: Successfully measured properties of polymers like poly(dimethyl siloxane) elastomers.
Technology readiness level
Currently at TRL 2, this technology is in the early stages of development. Future validation plans include building a high-temperature piezoelectric setup, calibrating signal responses, and incorporating cooling systems to ensure effective performance at high operating temperatures. Further development will involve refining the system for practical applications in manufacturing environments.
About North Carolina State University
North Carolina State University is a large, comprehensive public land‑grant research university in Raleigh. Its on‑campus research and technology park co‑locates corporate R&D groups, government partners, and faculty labs, enabling shared facilities, prototyping, and agile contracting. Located in North Carolina’s Research Triangle, partners tap a dense regional ecosystem while engaging through a statewide extension network and a mature co‑op program that deliver field deployment and workforce pipelines. Multiple pilot and demonstration facilities support scale‑up and validation toward pre‑commercial readiness. Research is supported by competitive funding from major federal agencies, including NSF, USDA, DOE, and DOD, and a dedicated technology transfer office with clear IP pathways helps accelerate commercialization.
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