SBIR-STTR Award

The broader impact/commercial potential of this project involves a significant enhancement in the properties of wood polymer composites (WPCs) by the commercialization of a highly effective bio-based coupling agent made from renewable sources such as plant oils instead of petroleum. By significantly enhancing the properties of WPCs, substantial benefit to society will result by providing new application opportunities for these relatively low cost, light weight biocomposites. Globally millions of metric tons of WPCs are produced each year. Currently, WPCs are used for applications that do not require high load bearing characteristics due to limitations in modulus, strength, and creep. The technical concepts proposed for the Phase I effort are expected to enable higher modulus and strength, by facilitating the use of higher wood flour (WF) loadings, as well as lower deformation by introducing crosslinks into the matrix phase. Although this proposal is focused on the utility of these novel bio-based copolymers as high performance coupling agents, these copolymers have also been demonstrated to be excellent binders for coatings. Thus, commercialization of these copolymers is expected to have a broader impact on society beyond use as coupling agents. This Small Business Technology Transfer Phase I project will determine the feasibility of novel bio-based polymers to serve as highly effective coupling agents for WPCs. The most common WPCs are based on WF as the dispersed-phase and high density polyethylene (HDPE) as the matrix. WF is a very desirable reinforcement for composites because it is inexpensive, abundant, biodegradable, high modulus, high strength, light weight, and non-abrasive toward processing equipment. The major technical challenge for HDPE/WF composites is obtaining adequate compatibility between the WF fibers and the HDPE matrix. Although the modulus and tensile strength of WF fibers is approximately 40 and 20 times higher than that of the HDPE matrix, respectively, the mechanical property enhancements provided by the WF cannot be fully realized without effective compatibilization. It is the team?s belief that the bio-based polymers proposed for the project possess the ideal chemical composition for effectively coupling the HDPE matrix to the WF fibers to maximize mechanical properties. In addition, the polymers are capable of introducing crosslinks into the matrix phase, which are expected to reduce polymer creep. For the Phase I project, the effect of the chemical composition of the bio-based coupling agent will be a primary factor investigated.

The broader impact/commercial potential of this Small Business Innovation Research Phase II project is to provide the paint and coatings industry with new high-performance, cost-competitive polymer/resin systems that reduce solvent emissions and use of petrochemicals. In addition, these new polymer/resin systems enable one-component, ambient-cure coatings to be produced. This means that highly protective coatings can be produced without the need for mixing multiple components together prior to application or applying heat or light to cure the coatings. The one-component, ambient-cure features of these polymer/resin systems largely eliminate waste and energy costs associated with coating application and lend themselves to the production of paints and coatings that can be applied by the average person. Compared to the current state-of-the-art in one-component, ambient-cured resins, these new polymer/resin systems provide dramatically shorter drying times, dramatically better chemical resistance, and much higher film hardness, while exhibiting excellent impact resistance and flexibility. The highly desirable properties of these new cost-competitive polymer/resin systems will enable commercial success, while their low solvent emissions and high renewable content will reduce impact on the environment.The objectives of this Phase II research project are to: 1) further optimize the polymer/resin systems to produce compositions that minimize solvent content and maximize performance, while meeting the cost constraints of the market; 2) put in place a pilot-line to provide potential customers with adequate sample sizes to enable their own evaluation of potential products, 3) generate weathering, corrosion, and storage/shelf stability data to further understand the application potential of optimized polymer/resin systems; and 4) optimize the polymer/resin production process to minimize cost and minimize production waste. By meeting these objectives, the Phase II project will result in the generation of new polymer/resin systems that will enable the development and commercialization of new paints and coatings that are one-component, ambient-cured, low in solvent content that exhibit exceptional properties, while being primarily based on renewable materials. Optimized polymer/resin systems will be provided to potential customers for their own internal evaluation. If necessary, feedback from customer evaluations will be used to modify polymer/resin system composition to meet customer needs. By the end of the Phase II project, the technology will be ready to proceed to manufacturing scale-up and product commercialization.