SURFACE ENGINEERING AT THE NANO- AND MACRO-SCALE

Surface engineering plays a pivotal role in enhancing material performance and functionality at both the macro and nano scales. At the macro scale, surface engineering is crucial for improving the mechanical, chemical, and thermal properties of materials, thereby extending their lifespan, and enabling them to withstand harsh environmental conditions. This is especially relevant in industries such as aerospace, automotive, and construction where materials are exposed to extreme temperatures, corrosive substances, and mechanical stress. Surface patterning is a technique that involves creating specific patterns or structures on the surface of materials. This approach can significantly impact the thermal properties of materials, leading to improved heat transfer, thermal conductivity, and overall thermal performance. Surface engineering at the nano scale becomes increasingly important due to the unique properties and behaviors exhibited by materials at this level. Nanostructured surfaces offer enhanced strength, durability, and responsiveness to external stimuli. Tailoring the surface properties at the nanoscale allows for precise control over factors like adhesion, friction, and wettability, leading to improvements in areas such as lubrication, wear resistance, and composite manufacturing. These advancements are critical in the development of cutting-edge technologies, such as nanoelectronics, biomaterials, and sensors. In the realm of energy conversion and storage, surface modifications at the nano scale can significantly enhance catalytic activity, promoting more efficient fuel cells and batteries. Plasma processing offers a promising approach to modify the basal plane of graphene, bridging the gap between chemical and physical methods. This document investigates the effects of C4F8 and O2 plasma source gases on graphene nanoplatelets. Precise control allows low-temperature plasma treatment to modify the graphene nanoplatelet surface without altering its intrinsic structure. This provides new opportunities for surface engineering in advanced composites. Plasma treatments enable tailored immersion characteristics and the introduction of functional groups, creating desired bonding environments. Currently, battery thermal management systems in pouch cell systems rely on the use of cold plates. The design of these cold plates creates limitations, such as increased weight and reduced energy density. To overcome these challenges, the integration of cold plate designs into existing pouch cell materials is investigated, and a novel manufacturing method is developed. The novel manufacturing process is based on roll-molding, which allows for easy adoption at the manufacturing level by leveraging existing roll-to-roll lamination processes. Proof-of-concept experiments conducted using laboratory-scale equipment demonstrate the feasibility of the approach. Furthermore, the document presents insights into scaling up the manufacturing process and identifies semi-optimized rolling conditions to produce state-of-the-art cold plate designs. Additionally, advanced materials were developed as superior alternatives to current 3-layer laminates, offering enhanced properties and manufacturability. These materials have the potential to enhance battery pack performance and functionality beyond existing limitations. The findings presented in this document provide valuable insights for advancing battery packing technologies, paving the way for more efficient, reliable, and high-performance battery systems in various applications.