Number range CHAPTERComposite Resins and Adhesives from Plants

Richard Wool

The objective of this research is to develop the fundamental science and
engineering in support of recent technology breakthroughs in the field
of high performance, low cost, composite resins and adhesives from plant
oils for new liquid molding and adhesion applications. The research
focuses on: (a) Determination of the optimal Fatty Acid Distribution
(FAD) function of chemically functionalized, plant oils (soy, corn,
linseed, olive, sunflower) using Simulation, Vector percolation Theory
and Experiment, to minimize the recently discovered fragility of
crosslinked triglyceride networks in the matrix; (b) Natural and Glass
Fiber Sizing or Coupling agent development, using di-functionalized high
oleic genetically engineered oils, applied in situ in the liquid molding
manufacturing step (RTM and VARTM)to tailor the fiber-matrix interface
strength; (c) Rubber Toughening particle (Low Tg) development using the
new water-based PSA micro-latex particle technology, applied during
liquid molding to enhance impact strength and promote self-healing of
damage using high energy ion-cluster surfaces developed for SMC; (d)
Interfacial and Matrix Toughening (High Tg) agent development using
chemically modified Lignin; (e) Natural Fiber Preform Binder development
using a highly branched structure of the PSA latex particles (linear
chains); and (f) VARTM manufacture of the first large structures using
natural fiber preforms and the optimized bio-based resins in support of
the Shaped Engineered Wood Substitute (SEWS) materials proposed for new
housing construction and civil infrastructure. Some important results
include the following:

a)  The relationship between genetically engineered fatty acid
    distribution functions of plant oils and the resulting strength and
    stiffness of such chemically functionalized oils has been analyzed
    by vector percolation theory, computer simulation and experiment.

b)  The first latex rubber particles were made by polymerization of
    oleic methyl esters derived from soyoil. Elastomers and their
    properties are being characterized at the DuPont Elastomers
    laboratory in Newark, DE. M

c)  Microphase separating soyoil resins were prepared from soyoil and
    caster oil by alcoholysis with pentaerythriol followed by
    maleinization.

d)  Lignin modification was successfully completed to make it soluble in
    chemically modified soyoil.

e)  The first large hurricane resistant housing structures were prepared
    from natural fibers and soy resin. The natural fibers consisted of
    recycled newspaper, chicken feathers and flax.

f)  Chicken Feather Soy Printed Circuit Boards were made with unique low
    dielectric constants. Intel is evaluating their properties

g)  The first bio-based Pressure Sensitive Adhesive (PSA) was made from
    high olecic, genetically engineered soyoil (Patent Issued Nov 2003)

The environmental impacts are as follows:

Market Information

Industry: Broad Industry

Process: Plastics and Resins

Annual Market Production: 90.9 billion lbs

Feedstock Energy Use: 7,404.00 Btu/lbs

Fuel/Steam Energy Use: 3,608.00 Btu/lbs

Electricity Energy Use: 2,233.00 Btu/lbs

User Inputs

Annual Market Growth Rate: 5.0%

Year of Technology Introduction: 2008

Market Penetration Curve: 20 Year Market Saturation

\% of Market Production Technology will Impact: 9.0%

\% Energy Savings Feedstocks: 48.0%

\% Energy Savings Fuel/Steam: 50.0%

\% Energy Savings Electricity: 10.0%

Solid or Liquid Waste Reduction: 500 lbs per 1000 lbs of product

Non-Combustion Air Pollutants Reduction: 100 lbs per 1000 lbs of product

Technology Impacts

(Based on the input provided above, this technology will have the
following impacts:)

2005 2010 2015 2020

MARKET PENETRATION \* N/A 6.7% 17.7% 39.2%

MARKET (Million lbs) N/A 893 3,010 8,509

ENERGY SAVINGS

Feedstock Energy Savings (trillion Btu) N/A 3.173 10.699 30.240

Fuel/Steam Energy Savings (trillion Btu) N/A 1.611 5.431 15.350

Electricity Savings (trillion Btu) N/A 0.199 0.672 1.900

POLLUTANT REDUCTIONS (lbs)

Carbon (MMTCE/yr) N/A 0.02872 0.09682 0.27366

Nitrogen Oxides (NOX) N/A 442,388 1,491,588 4,216,073

Sulfur Oxides (SOX) N/A 275,580 929,166 2,626,350

Carbon Monoxide (CO) N/A 96,547 325,524 920,115

Volatile Organic Compounds (VOCS) N/A 9,733 32,816 92,757

Particulates N/A 5,223 17,610 49,776

Other (million lbs) N/A 536 1,806 5,105

N/A = not applicable

\* Percent penetration of the market the user selected that their
technology will impact, not the percent penetration of the entire
market, unless the user selected that their technology will impact 100%
of the total market.