SBIR-STTR Award

Of the 300 million tons of plastic produced per year most will take over 100 years to biodegrade. Though there is a growing ability to recycle thermoplastic, there is a 3.7% annual growth in the 50 million tons of thermoset plastic which can't be recycled. _x000D_ _x000D_ This project will develop a completely sustainable aliphatic polycarbonate plastic that is uniquely a recyclable thermoset resin. It has the processability of a thermoplastic, but the structural integrity, chemical resistance and_x000D_ adhesion of a thermoset. When heated over 120°C, the tough, crosslinked polymer network fragments into a low viscosity liquid. But this process is reversible. Upon cooling the material once again crosslinks within 6 hours. Such a product will revolutionize the thermoset plastic market that usually has to heat cure their parts. We have already received interest from companies who produce truck bed liners, rail car liners, bowling balls and polyurethane wheels._x000D_ _x000D_ Ultimately, because of its high performance, this material will also displace much of the larger thermoplastics market. Because of its unique structure, this product will biodegrade faster than other plastics or even commercial_x000D_ polycarbonate. And the biodegredation products are safe for the environment.

Of the 300 million tons of plastic produced per year most will require 500 years to biodegrade. Currently only 9% is recycled, and 50 million tons of thermoset plastic produced annually that can't be recycled. This project will develop a sustainable and easily biodegradable polycarbonate plastic that is uniquely a recyclable thermoset resin. We call it a thermosetting thermoplastic because it processes like a thermoplastic, but performs like a thermoset. When heated over 110°C, the tough, cross-linked polymer network fragments into a low viscosity liquid, but upon cooling the resin once again crosslinks. Such a product will revolutionize the thermoset plastic market, not only by its environmental friendliness, but also by providing opportunity for easier processing, cost savings and high performance. Phase I revealed this technology enables powder coatings that cure at very low temperatures, hot melt adhesives that thermoset, glossy decorative coatings that can be spray applied by hot melt, moisture curing coatings that can be applied as thick films and injection moldable plastic that thermosets. These are huge advantages to these multibillion dollar sized markets and to which our company currently sells polycarbonate. Our current production and sales infrastructure can be used to sell this technology.