Southwest Research Institute 2001 Annual Report, Process and Materials Chemistry

The Institute designs, develops, improves, and characterizes materials for government agencies and industrial clients in the aerospace, automotive, dental, household product, medical, and petrochemical fields. Specialization areas include nanotechnology, process engineering, aircraft coatings removal, coatings science, and petroleum products. The Institute's materials chemistry and engineering contract research and development services earned ISO 9002 certification during 2001.

The Institute and the University of Texas Health Science Center at San Antonio (UTHSCSA) have submitted samples of liquid crystal monomers to possible commercialization partners that will be reinforced with uniformly dispersed experimental oxide nanoparticles and existing fillers for evaluation in dental restorations. This process results in a polymer composite with greatly reduced shrinkage and can be pigmented to look like a natural tooth. This material is expected to have improved wear resistance and increased hardness over that provided by existing technology. A multiyear, multimillion-dollar grant, from the National Institutes of Health to UTHSCSA, and the SwRI internal research program are funding the development effort. This year, the Institute earned another U.S. patent for work on the monomers and nanoparticles. Several related patents are pending. SwRI and UTHSCSA are negotiating with commercial dental material suppliers for license rights and co-development funding for production scaleup.

SwRI is examining the potential of a low-shrink polymer composite material, originally developed for dental restoratives, for use in other applications. Staff members are assessing new chemistries that might be suitable as a rapid prototyping material that would not require complex three-dimensional computer models to convert computer-aided design parts drawings to the stereolithography process. SwRI scientists can meet the specifications of many nonmedical applications by making slight modifications to the materials chemistry and by using blends of compounds to obtain the needed strength, curing, shrinkage, and melt viscosities.

Since January 1997, SwRI staff members have operated the robotic water blast booth, dry media blast booth and cabinet, and accelerated ultraviolet light conditioning chambers at the Warner Robins Air Logistics Center (ALC) Structural Analysis Branch to accomplish the goals of various Department of Defense and commercial projects. Goals for the U.S. Air Force have included testing under operational conditions to aid the integration of new processes into ALC and field units. Commercially, goals were focused on testing to qualify new materials under existing military specifications.

SwRI's depaint center activities include gathering data on Air Force weapon systems to address environmental, health, and process reliability concerns and to conform to government regulations mandating reductions in the use of hazardous materials. Staff members assess commercial technology for insertion and integration; provide rapid engineering services for solving coatings reliability, maintainability, and deployability issues; and implement solutions. SwRI is evaluating and qualifying new blast media that leave no residue and require no solvent cleaning and is prototyping new techniques for selectively stripping the topcoat using dry media blasting or pressurized water blasting. Institute engineers are also providing technical support for a project funded by the Environmental Security Technology Certification Program (ESTCP) that evaluates laser stripping processes for small area coatings removal testing, as well as support for the Air Force in the ESTCP Zero VOC (volatile organic compounds) Topcoat Program.

The Institute has a long history of assisting industry with the assessment of new chemical technologies. This year, SwRI fabricated a chemical pilot plant to study improved engineering designs for catalytic reactions. Engineers with backgrounds in chemical, material, mechanical, and electrical fields investigated the new processes, bringing a multidisciplinary approach to problem solving. Industry relies on these capabilities, seeking out experienced pilot-plant operators and engineers from SwRI more than ever in light of the dismantling of corporate research and development facilities and the increase in small businesses with limited experimental facilities.

For the past six years, SwRI has worked with its exclusive licensee, Bernàrd Technologies, Inc., to develop controlled and sustained release products at levels of 1 to 10 parts per million that can control odors and contamination from fungi, bacteria, and viruses in a matter of minutes and that may have activity extended for weeks and months. The technology is formulated in powder form for sachets or directly incorporated into polymer films. Both forms can release chlorine dioxide and other gases over several days or weeks when activated. The Food and Drug Administration provided affirmation this year that the films may be used for direct food contact. Applications include maintaining food quality and food safety, but other potential markets include household, agricultural, and medical device sterilization. Recent research has led to energy activated systems that will be commercialized in the medical, institutional, and consumer product industries.

Copyright© 2002 by Southwest Research Institute. All rights reserved under U.S. Copyright Law and International Conventions. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without permission in writing from the publisher. All inquiries should be addressed to Communications Department, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510, phone (210) 522-2257, fax (210) 522-3547.