SBIR Phase II: Photo-Curable Silicon Oxycarbide Fiber for Diesel Engine Particulate Filters

SBIR 第二阶段：用于柴油发动机颗粒过滤器的光固化碳氧化硅纤维

• 批准号: 0239336
• 负责人: Edward Pope
• 金额: $ 50万
• 依托单位: MATECH Advanced Materials
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2003
• 资助国家: 美国
• 起止时间: 2003-01-15 至 2005-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0239336&HistoricalAwards=false
• 关键词: SBIR; Phase; II; Photo; Curable

This Small Business Innovation Research Phase II project will scale-up a manufacturing process for curable preceramic polymers in the fabrication of high yield and low cost Silicon Oxycarbide (SOC) fibers and bonded fiber mats for diesel engine particulate filters. In the Phase I effort, SOC fibers and fiber mats were successfully fabricated and the critical materials properties required for the diesel particulate filter application were attained. This development represents the first Silicon Oxycarbide glass-ceramic fibers to be fabricated from curable poly(dimethyl)siloxanes. In addition, the photo-curable and chemically-curable polysiloxane preceramic polymers demonstrated also have potential as a binder or matrix phases for other structural composites. This Phase II effort seeks to optimize fiber mat production techniques through collaboration with Cummins Engine Company's subsidiary Fleetguard/Nelson (FGN), the world's largest manufacturer of filters for the automobile and truck market. In the project, critical factors related to automated manufacturing, process scale-up, fiber mat performance characteristics, and performance testing will be addressed to ensure a smooth transition to a commercial product. The diesel particulate filter (DPF) market will grow dramatically due to EPA requirements that all diesel vehicles be equipped with diesel particulate filters by 2007, thereby significantly improving the nation's air quality. The diesel manufacturing industry in North America now exceeds $85 billion in gross output annually. Total U. S. "on road" vehicles requiring DPF's will exceed 3 million units annually, resulting in a potential on road market size of in excess of $6 billion per year. The DPF product to be scaled up in this project has comparable performance to the current extruded ceramic honeycomb filter but with a projected unit cost of about one-tenth. This will have a dramatic impact on diesel filtration system costs with substantial environmental, energy, and trade deficit benefits.

这个小型企业创新研究第二阶段项目将扩大可固化陶瓷聚合物的制造工艺，以制造高产量和低成本的氧化碳化硅(SOC)纤维和柴油发动机微粒过滤器用粘合纤维垫。在第一阶段的工作中，成功地制备了SOC纤维和纤维垫，并达到了柴油机微粒过滤器应用所需的关键材料性能。这是第一个由可固化的聚二甲基硅氧烷制成的氧化碳化硅微晶玻璃纤维。此外，所展示的光固化和化学固化的聚硅氧烷前驱体聚合物也具有作为其他结构复合材料的粘结剂或基质相的潜力。这项第二阶段的工作旨在通过与康明斯发动机公司的子公司FleetGuard/Nelson(FGN)合作，优化纤维毡的生产技术，FGN是世界上最大的汽车和卡车市场过滤器制造商。在该项目中，将解决与自动化制造、工艺放大、纤维毡性能特性和性能测试相关的关键因素，以确保平稳过渡到商业产品。柴油微粒过滤器(DPF)市场将大幅增长，因为美国环保署要求到2007年，所有柴油车都必须配备柴油微粒过滤器，从而显著改善国家的空气质量。北美的柴油制造业现在每年的总产值超过850亿美元。美国每年需要DPF的“上路”车辆总数将超过300万辆，导致潜在的道路市场规模每年超过60亿美元。该项目中将扩大的DPF产品的性能与目前挤压成型的陶瓷蜂窝过滤器相当，但预计单位成本约为十分之一。这将对柴油过滤系统的成本产生巨大影响，带来巨大的环境、能源和贸易逆差好处。