This Small Business Innovation Research Phase I project develops sustainable materials for use in injection molding. The technical problem addressed is the development of novel biobased polymer nanocomposites that are suitable for injection molding. The research objective is to exploit a novel polymer nanostructure known as a stereocomplex to make superior materials suitable for high temperature applications. However, the material must be engineered so that it can still be molded using conventional manufacturing equipment. Carefully controlled experimentation, guided by quantitative calculations, is used to address the relevant technical issues.
The broader impact/commercial potential of this project has many aspects. The biorenewable nature of the materials reduces enhances sustainability. Fundamental scientific issues regarding the hierarchical structure of sterocomplex containing nanocomposites will be addressed and dissemination of results through the patent and open literature is expected. The expected impact is the development of a superior material that enables a greener, more sustainable, plastics products. Target markets include both commodity durable goods applications as well as specialty materials suitable for high temperature capable application such as steam sterilizable bone screws used in medical applications where their biodegradability is essential.
Normal 0 false false false EN-US X-NONE X-NONE The objective of this Small Business Innovation Research Phase I project was to develop sustainable materials for use in manufacturing by injection molding. These novel materials are completely biodegradable but have improved thermal resistance and can be used in many more cases than existing biodegradable plastics. The intellectual merit of the project rests in addressing fundamental issues in macromolecular and supramolecular materials science. The Phase I proof-of-concept was to demonstrate the suitability of these new sustainable materials for injection molding operations using conventional manufacturing machinery. Carefully controlled experimentation, guided by quantitative calculations, addressed the outstanding questions. A specific goal was to produce a material that could be used at high temperature (has a high heat distortion temperature) for uses such as disposable cutlery, disposable homecare products, and bone screws. Key Outcomes The PolyNew team produced a variety of materials for evaluation. Biodegradable nanocomposites were produced via extrusion. The major milestone – the production of supramolecular nanocomposites that can be injection molded – was reached. The materials were injection molded using conventional equipment. These nanocomposites appear to have excellent properties with a heat distortion temperature of 110°C! The most promising formulation gives a 32-degree improvement to the HDT compared to the base resinand an increase in modulus from 3164 to 3828 MPa. In addition, a bar of the nanocomposite could be steam sterilized with minimal dimensional change. Broader Impacts The benefits of the proposed activity to society at large are many. A number of factors indicate that a greener, more sustainable, plastics industry is needed. Bioplastic nanocomposites based on renewable materials can be produced through ecologically responsible conversions using industrial biotechnology and enhanced by nanotechnology. This approach represents a triple technological convergence that results in an emerging class of bioplastics that can be referred to as Ecobionanocomposite.. The project is consistent with Federal policies supporting greater use of biobased products including the Food, Conservation, and Energy Act of 2008, which is designed to ensure that a sufficiently large base of new, non-food, non-feed biomass crops is established to meet demand for renewable energy and bioproducts. Socially, there are advantages associated with employment in the plastics, forestry and agriculture sectors of the economy – the project is fully consistent NSF priorities under its SEES (Science, Education, and Engineering for Sustainability) initiative. These materials satisfy the public’s desire to use greener products with a smaller environmental footprint. The commercialization potential is excellent; markets in the tens of millions of dollars annually can easily be captured. Participation of underrepresented groups is strongly supported as PolyNew is a woman-owned business.
