SBIR Phase I: Development of Advanced Composite Materials for Athletic Equipment

This Small Business Innovation Research Phase I project is for the development of end user-moldable advanced polyimine composite inputs for the athletic protective gear market (which is valued at $16.6 billion). Currently, plastic products must be produced using industrial manufacturing techniques that have high tooling costs. As a result, manufacturers produce a small range of predetermined sizes and shapes, which do not provide a custom fit for end users. In the case of athletic gear, there is a growing market for hard-shell protective equipment which can be custom molded for a better fit. Polyimine polymers and advanced composites offer a compelling blend of strength and malleability in order to create more user-friendly lightweight and durable advanced composites that may be shaped by the end-user. In addition to creating greater user customization, both the virgin polyimine polymer and advanced composites that incorporate polyimines are easily and economically recyclable. The total U.S. composite materials market is a $30 billion market, representing 36% of the global composites sector. Polyimine polymers and advanced composite derivatives will reduce environmental waste and increase manufacturing efficiencies across a broad range of vertical markets in the composites sector including personal protective equipment, aerospace, automotive, and infrastructural materials. The intellectual merit of this project derives from the development of the unique chemistry of polyimine polymers. Polymers can be broadly grouped into two categories, thermosets and thermoplastics. Thermosets are strong due to the chemical characteristics of the plastic. However, once cured, thermosets cannot be reshaped. As a result, thermosets are neither repairable, nor are they efficiently recyclable. In contrast, thermoplastics, which are weaker than thermosets, may be molded and remolded. However, remolding requires very high industrial temperatures of between 400 and 600 deg. F. Polyimine polymers are moldable and remoldable thermoset materials. Importantly, these polymers combine high rigidity and tough mechanical properties with mild molding temperatures. This Phase I research project will include developing end user moldable composite materials that are a maximum of ¼ inch in thickness and meet industry standards for limb joint protective equipment. Material testing and mechanical characterization will relate to testing requirements arising from composite prototype development including but not limited to: delamination, fiber-dependent moldability, fiber-dependent flex, fiber-dependent tensile, fiber/resin-dependent pass-through impact force, and failure analysis.