SBIR-STTR Award

There is great anticipation and an urgent need to develop a low viscosity, affordable, non-styrene based, flame resistant resin system similar to the vinyl ester Derekane 510A and curable at room temperature. This resin system, compliments of Dow Chemical, is a Brominated bisphenol and has work quite well relative to confined place. There is a need to find an alternate material that will produce non-toxic gaseous material when subjected to flame. The current halogenated resin has a tendency to breakdown and form acidic fumes which are more dangerous in most cases than the fire itself. The objective of this proposal is to develop a resin system similar to Derekane 510A in every respect except for that fact that it will be non-styrene based and laden with halides.

Benefit:
The commercialization strategy of moving the result of this invention to the market is quite straightforward. The strategy will involve forming an Integrated Product Team (IPT). As a matter of fact the members of the team will include DuPont Electronic Technologies, whose main market objective is to service the electronics industry with highly branched, low metal polymers with photo-resist capability. Following a successful development of the base material in Phase I, DuPont will play a significant role in Phase II of the project. It will be an easy selection process for DuPont to select an end user of the product from their impressive customer list. DuPont also has ISO 9000 certified manufacture plant in Dayton, Ohio to scale up whatever material is developed through this effort. To date, more than nine resins have been commercialized by A.T.A.R.D. Laboratories. The success and experience gained in establishing a commercial base for former products will enable us to transition the technology into a commercialized product.

Keywords:
Composites, Composites, fire, High Temperature Resins, VARTM, Smoke Toxicity

The objective of this proposal is to develop a new and affordable, flame resistant resin equal to or better in performance than dicyanate ester of bisphenol C. It is highly desirable that the resin has a low viscosity at ambient temperature when used in the fabrication of fiberglass reinforced composite articles. The article, a 48 0x9D x48 0x9D x0.25 0x9D fiberglass fabric (24 ounces per square yard), will be subjected to a room corner test by the Navy as a proof of concept and validation of the superiority of the newly developed resin. The Problem Many have tried to accomplish the objective of developing an affordable, low viscosity resin that is curable at ambient temperature in the past. Although Derakane 510A, the workhorse of the industry, meets almost all the requirements at ambient temperature; it has a very short pot-life as well as a short time to ignition when subjected to flame. The presence of styrene and other suspect carcinogens as well as the high heat release of the cured laminate make it unsuitable for the Navys present and future usage. The solution to this problem is clear, development of an affordable, lower viscosity, non-carcinogenic, non-toxic replacement for phenolic resins and halogenated vinyl esters, specifically Derakane 510A must be achieved. The composite panels produced from this new resin are expected to meet the time to ignition, low heat release and non-smoking requirements set forth by the Navy. This resin will be superior to Derakane 510A in physical, thermal and rheological properties, as well as flame and chemical resistance. The Opportunity It has been shown that a thermoset system based on bisphenol C when properly processed will meet and exceed most fire or flame resistance requirements. However, there are associated processing limitations to the Cyanation of bisphenol C.

Benefit:
A natural progression in the development of a product is to find people to use it. The resin system developed under this program will require commercialization in order for the Navy to get a return on its investment. Commercialization of products is the mainstay of Shad, Inc. since many of the resins we have developed are currently being used commercially both by the government and in civilian applications. Following a successful Phase II program, Shad, Inc. will be well positioned to manufacture the flame resistant resin material. Solid laminates and sandwich composites, with FSS materials will be used to fabricate a large structural item. A VaRTM process will be utilized to provide life-cycle maintenance and inspection capability to the end-user. Shad, Inc. will jointly explore other applications for this technology in other marine, industrial, and automotive applications as well as in the average consumers home where there are well-defined advantages to fire resistant, high temperature resins. The significance of the flame resistant resin will include: PERFORMANCE The flame resistant, low viscosity resin will have the potential to provide improved FST, structural and electrical performance characteristics for marine, industrial and aerospace composites. COST The components used in the synthesis of this resin will be cost effective and readily available allowing the flame resistant resin produce to compete with Derakane 510A on every level. FIRE, SMOKE AND TOXICITY ABATEMENT - A principal rejection item for the use of composite materials, FST issues can begin to be controlled and resolved using fire resistant resin materials.

Keywords:
Dicyanate ester of bisphenol C, Non-carcinogenic, low viscosity, Affordable, flame resistant, VARTM, High Temperature Resins, fire