Polymer Research and Coatings Technology

SwRI staff members assist clients with the commercialization of specialty materials, such as controlled-release biocidal films and nanoparticle-polymer composites, both invented at the Institute. Work also is being done with films possessing special electro-optical and sensing properties, glass coatings with controlled surface properties, and high-temperature polymer composites. The Institute is committed to helping clients understand market needs and adapting or developing technology that addresses improved performance, cost, intellectual property, scale-up requirements, and environmental or regulatory concerns.

An internal research program to fabricate a membrane-based thin-film display has led to development of a number of nano- and microfabrication techniques that have been used in externally sponsored projects. These techniques employ a combination of emerging and existing materials and methods including self-assembling monolayers, microcontact printing, microlithography, surface chemistry modification, and electropolymerization to build a number of novel devices. The devices include a solid-state nitric oxide sensor and a thin-fuel-film thickness sensor that could be applied in the automotive industry to emissions detection and fuel system development, respectively. Micrometer-scale metallic electrode arrays, also developed at SwRI, could be used to develop sensors for various industrial applications.

Using the electrode pair pattern shown in this scanning electron micrograph, SwRI scientists developed a beta-alumina-based sensor for the automotive industry, capable of monitoring NOx emissions produced during combustion. SwRI's experience in using innovative materials and methods allows fabrication of sensors for a wide range of applications.

An Institute-developed process for the nonaqueous synthesis of oxide nanoparticles has been used in making composites. The process has contributed to a five-year, $3.4 million award by the National Institutes of Health to the University of Texas Health Science Center at San Antonio and SwRI to develop new dental restoratives. The glassy material can be made translucent by adding a particulate to match tooth color. To extend filling life, SwRI scientists have made liquid crystal monomers that can be photo-polymerized with very little shrinkage. Composites produced with other metal oxides using similar technology could be used in applications that require low polymerization shrinkage.

A fourth U.S. patent has been issued to the Institute relating to bisoxazoline-phenolic thermoset resins, also called polyether amide resins, and their composite applications. SwRI scientists have ongoing programs in the area of high-performance thermoset polymers for use in carbon fiber and glass fiber composites for aircraft, industrial, surface transportation, and marine applications. SwRI currently is formulating its newest patented resin as a room temperature liquid for improved processing.

Films and powders that release chlorine dioxide in a controlled fashion at variable intervals have been developed by the Institute and are being commercialized by Bernard Technologies, Inc., of Chicago, Illinois. Chlorine dioxide is a powerful biocide that can kill fungi, bacteria, and viruses at levels of 0.1 to 1 part per million in a few minutes. Production of the controlled-release system has been scaled to a commercial level. Near-term markets for the chlorine dioxide biocide include the household, agricultural, and consumer packaging industries. Disease transmission control, medical devices, and self-sterilizing packaging applications are in development.

A multidisciplinary team at SwRI is collaborating to solve performance problems associated with new polymer coatings being developed for aircraft, electronics, and consumer products to meet strict environmental regulations while providing improved thermal resistance, corrosion protection, and durability. SwRI studies surface treatments, adhesion, polymer chemistry, structural impacts, automated processing, and removal aspects for these coatings.

For the U.S. Air Force Coatings Technology Integration Office, an SwRI technician measures the film thickness of a newly applied aerospace primer to ensure compliance with military specifications and industry procedures.

SwRI is the primary technical contractor for the U.S. Air Force Coatings Technology Integration Office (CTIO). SwRI technical contributions to coating technology include materials chemistry and polymerization studies, analytical techniques and instrumentation development, corrosion control and assessment, environmental regulations and pollution prevention, robotics and automation, equipment design and specification, and composite materials structural assessments.

SwRI has extensive experience in the design and system integration of both manual and automated coating removal facilities. Current programs include designing a manual plastic media blasting and aircraft washdown facility for the U.S. Air Force and a similar facility being designed for a commercial client. Use of plastic media minimizes the hazardous waste disposal problems associated with chemical stripping. The media can be reused for multiple paint stripping cycles. SwRI also is evaluating process improvements to increase stripping speeds to reduce costs and to reduce potential substrate damage.

To meet stringent environmental regulations, new paints are being formulated that have low volatile organic compound content, contain waterborne polymers, or can be applied as airless sprays. Specifications for pot-life, or the time before paint becomes unusable, currently rely on flowability measurements using a Ford cup, a device into which paint is poured and then released over a measured period of time. SwRI has determined that using the Ford cup test on new paints can yield relative errors of up to 20 percent, possibly leading to inaccurate perform-ance predictions. New rheological techniques have been recommended by SwRI polymer chemists to select new paints that meet performance specifications without compromising coating integrity.

SwRI employs a solid-media blast booth for controlled, automated blasting of test specimens to evaluate and develop new blast equipment, processes, and media. The booth incorporates a programmable x-y positioner for remote operation. A media recovery and cleaning system allows near-continuous operation. SwRI has employed this booth for strippability studies on composite structures and aircraft flight control surfaces to determine any damaging effects.

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