SBIR-STTR Award

This SBIR Phase I project is designed to determine the feasibility of preparing an environmentally friendly chromium-free solvent-free hybrid ultraviolet (UV) resin coating system suitable for applications such as industrial, automotive, and aerospace corrosion resistance. In particular, the overall objective of this program is to determine the most appropriate segregation of components for a two part chromium-free corrosion-resistant hybrid UV coating system, an appropriate corrosion inhibitor charge level, and an appropriate ratio of reactive rate of cure in the absence of UV light to dry material in shadow areas where the coating may not be exposed to sufficient UV energy for typical UV cure. The hybrid UV resin coating system will be characterized with respect to UV cure rate, secondary cure rate, adhesion, surface hardness, and corrosion resistance. An important aspect of this technology is to significantly reduce exposure of workers and communities to hexavalent chromium, volatile organic compounds (VOCs), and hazardous air pollutant (HAP) materials. Phase I research is designed to demonstrate feasibility and to provide sufficient groundwork for Phase II development of the technology. Phase II will involve the preparation and characterization of fully formulated hybrid resin systems, incorporating pigments and other important components for appropriate color and gloss and to satisfy important property requirements of aerospace primer specification MIL-PRF-23377 and aerospace topcoat specification MIL-PRF-85285. Light Curable Coatings is a technology leader of solvent-free environmentally compliant coating systems, with color UV coating systems. The described chromium-free corrosion-resistant hybrid UV coating system is proprietary to Light Curable Coatings. Anticipated benefits of the proposed approach include dramatically improved environmental friendliness, economics, and productivity capabilities. Since this hybrid resin system contains safer components, application in confined spaces and occupied spaces should be possible without the hazards presented by conventional materials. Environmental savings apply not only in production, but also throughout and beyond the operational lifecycle of vehicles by reducing environmental risks associated with maintenance, storage, and disposal. This research offers a significant positive societal impact in terms of a better quality of life for industrial workers an for all citizens through safer workplaces and a cleaner environment. Supplemental

Keywords:
small business, SBIR, EPA, chromium, corrosion-resistant, corrosion-resistant coating, chromium free, chromium alternative, hybrid UV coating, solvent-free, UV resin coating system, industry, automotive, aerospace, corrosion inhibitor charge level, reactive rate of cure, UV cure, cure rate, adhesion, hardness, exposure, hexavalent chromium, volatile organic compounds, VOCs, hazardous air pollutants, HAPs, hybrid resin system, primer specification, topcoat specification, environmental risk, industrial workers, light curable coating

This SBIR Phase II project is designed to develop and optimize a prototype environmentally friendly, chromium-free, corrosion-resistant, hybrid ultraviolet (UV) coating system with demonstrated properties suitable for industrial, automotive, and aerospace corrosion protection. The objectives of this Phase II project include the optimization of individual formulation components in the development of a fully formulated system suitable for a more complete evaluation according to the major appearance and physical property requirements of aerospace primer specification MIL-PRD-23377 and aerospace topcoat specification MIL-PRE-85285. A commercial objective of this work is the development of a product that meets design specifications for aerospace primer or combined primer/topcoat without requiring the use of a hazardous component such as hexavalent chromium. This proprietary hybrid UV coating system provides immediate cure when exposed to UV light along with a secondary cure mechanism. It has a suitable rate of cure in the absence of UV light to dry overspray to reduce the possibility of contamination from spray painting operations and to dry material in shadow areas where the coating may not be exposed to sufficient UV energy for typical UV cure. An important aspect of this technology is to significantly reduce exposure of workers and communities to hexavalent chromium, volatile organic compounds (VOCs), and hazardous air pollutant (HAP) materials. Phase I research demonstrated feasibility and provided sufficient groundwork for Phase II development of the technology. Light Curable Coatings is a technology leader for solvent-free environmentally compliant coating systems, which include proprietary technology for rapidly cured heavily pigmented coatings with UV light, including low gloss camouflage color UV coating systems. The described chromium-free corrosion-resistant hybrid UV coating system is proprietary to Light Curable Coatings. Anticipated benefits of the proposed approach include dramatically improved environmental friendliness, economics, and productivity capabilities. Because this hybrid resin system contains safer components, application in confined and occupied spaces should be possible without the hazards presented by conventional materials. Environmental savings apply not only in production, but also throughout and beyond the operational lifecycle of industrial parts and vehicles by reducing environmental risks associated with maintenance, storage, and disposal. This research offers a significant positive societal impact in terms of better quality of life for industrial workers and for citizens through safer workplaces and a cleaner environment. Supplemental

Keywords:
small business, SBIR, EPA, UV coatings, hexavalent chromium, aerospace, primer, top coat, corrosion-resistant, volatile organic compounds, VOCs, hazardous air pollutant, HAP, UV light, hybrid resin, industrial workers, spray painting, light curable coatings, corrosion protection