SBIR Phase II: Surface Modified Polypropylene and Ultra- High Strength Polyethylene Fibers and Their Composites

这个小企业创新研究第二阶段项目的目标是完成选定的环氧树脂和水泥复合材料的开发和规模化研究。二期计划包括：(1)开发和扩大超高分子量聚乙烯和聚丙烯纤维的磷酸化；(2)以超高分子量聚乙烯或聚丙烯为基材，开发和升级超高分子量聚乙烯环氧复合材料和水泥复合材料；(3)确定并与制造合作伙伴合作建设中试规模的表面活化设施；(4)准备和评价所寻求产品的原型；(5)在市场分析的基础上，编制复合材料中试工厂全面生产计划。第三阶段的活动将包括试验性工厂的建造/生产和综合系统的实地评价。该项目是第一阶段完成的三个部分中的两个部分的延续。第二阶段的目的是确定使用表面活化超高分子量聚乙烯（UHMW-PE）纤维在极低负荷下增强环氧树脂和丙烯酸树脂和水泥的可行性，以提高拉伸强度和冲击韧性。第一阶段的结果表明，化学活化的超高分子量聚乙烯（UHMW-PE）和聚丙烯（PP）纤维不仅可以改善环氧树脂和水泥的性能，而且在纤维负载量约为0.3%至2.5%的情况下，丙烯酸树脂的性能也有较小的改善。这一点，以及与丙烯酸复合材料作为骨水泥相关的监管问题，导致了环氧树脂和水泥复合材料的第二阶段研究的重点。该复合材料技术有望创造出新一代高强度、抗冲击水泥复合材料，纤维含量小于等于1%（按体积计），环氧复合材料纤维含量为5-30%。这些系统的潜在应用包括(I)环氧树脂、装甲板和电器的复合材料；(2)桥梁修复用水泥复合材料、水泥板、排水管道。

This Small Business Innovation Research Phase II project objective is to complete the development and scale-up study of selected epoxy and cement composites. Phase II plans include (1) developing and up-scaling the phosphonylation of UHMW-PE and PP fibers; (2) developing and up-scaling UHMW-PE epoxy composites and cement composites based on UHMW-PE or PP fibers; (3) identifying and collaborating with a manufacturing partner in constructing pilot-scale surface activation facilities; (4) preparing and evaluating prototypes of sought products; and (5) preparing composite pilot plant full manufacturing plans at the conclusion of market analysis. Phase III activities will include pilot plant construction/production and field evaluation of composite systems. This project represents a continuation of two of the three segments completed in Phase I. The latter was intended to and did determine the feasibility of using surface activated ultrahigh molecular weight polyethylene (UHMW-PE) fibers for reinforcing epoxy and acrylic resins and cement at very low loadings for improved tensile strength ad impact toughness. Phase I results show that not only chemically activated UHMW-PE but also polypropylene (PP) fibers can improve the sought properties of epoxy resin and cement and, to a lesser extent, an acrylic resin at fiber loadings of about 0.3 to 2.5% by volume. This, and the regulatory issues associated with acrylic composites for use as bone cement led to the focusing of Phase II study on epoxy and cement composites. The subject composite technology is expected to lead to the creation of a new generation of high strength, impact-resistant cement composites with 1% or less (by volume) fiber loading and epoxy composites with 5-30% fiber contents. Potential application of these systems include their use as (I) epoxy, composites for armor plates, and appliances; and (2) cement composites for bridge rehabilitation, cement boards, and drainage conduits.