SBIR Phase II: Development of High Speed Process Technology for the Manufacturing of Cost Effective Polymer Rebar

SBIR 第二阶段：开发用于制造具有成本效益的聚合物钢筋的高速工艺技术

• 批准号: 1534785
• 负责人: Matthew Kero
• 金额: $ 74.43万
• 依托单位: Neuvokas Corporation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2015
• 资助国家: 美国
• 起止时间: 2015-08-15 至 2019-01-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1534785&HistoricalAwards=false
• 关键词: SBIR; Phase; II; Development; Speed

This Small Business Innovation Research (SBIR) Phase II project will focus on developing the process required to produce fiber reinforced polymer (FRP) rebar at scale. FRP rebar offers significant performance advantages when compared to uncoated steel rebar. These advantages include a sevenfold weight reduction, no corrosion - which in turn permits a 30% reduction in concrete usage (and a corresponding 15 billion ton reduction in CO2 emissions) - and equivalent tensile strength at smaller diameters compared to steel rebar products. FRP rebar is being produced but has limited market acceptance due to its high cost. The high-speed process to be developed in this project will allow price parity when compared to uncoated steel and enable a hundredfold improvement in process speeds compared to current FRP manufacturing. Combined, these improvements will allow entry to the $140 billion global market for steel rebar and allow mass market adoption of FRP rebar. Additionally, basalt mine waste will be explored and, where possible, utilized as a raw material for fiber production. The broader impact/commercial potential of this project includes job creation and environmental impacts. With implementation of this process up to 35 manufacturing jobs can be created immediately. The company's high speed process combines a thermoset resin and basalt fiber as primary reinforcements within the FRP composite. A consortium of pultruders has collectively organized the Fiber Reinforced Polymer Rebar Manufacturers Council and has developed FRP rebar into a viable product over the last 20 years, with a $1.2 billion market at present. Currently, no FRP rebar product is offered at price parity with uncoated steel rebar, and to reach this price parity a high speed process has been invented. This novel process will be optimized and further developed by the completion of this Phase II SBIR project. Basalt fiber, an emerging material with the potential to replace carbon and other fibers in a variety of applications will be brought into large-scale industrial usage with the completion of this project. The Phase I project permitted the determination of the performance characteristics of thermoset resins which have not been commonly used in pultrusion, enabling product validation. This Phase II project will address a range of manufacturing challenges that will be encountered in the production of FRP rebar at industrial scale, allowing a commercially viable final product that can be offered at price parity with steel rebar.

这项小型企业创新研究（SBIR）第二阶段项目将重点介绍开发生产纤维增强聚合物（FRP）钢筋的过程。 与未涂层的钢钢筋相比，FRP钢筋具有显着的性能优势。 这些优点包括减轻重量的七倍，无腐蚀 - 反过来允许混凝土用法降低30％（以及相应的150亿吨二氧化碳排放）以及与钢钢筋产物相比，直径相比，较小的直径的等效拉伸强度。 FRP钢筋正在生产，但由于其高成本，市场接受程度有限。 与未涂层的钢相比，该项目中要开发的高速流程将允许价格平价，并且与当前的FRP制造相比，过程速度可以提高一百倍。 这些改进将允许进入1400亿美元的钢钢筋市场，并允许大众市场采用FRP钢筋。 此外，还将探索玄武岩矿废物，并在可能的情况下用作纤维生产的原料。 该项目的更广泛的影响/商业潜力包括创造就业和环境影响。 通过实施此过程，最多可以立即创建35个制造工作。 该公司的高速过程将热固性树脂和玄武岩纤维与FRP复合材料中的主要增强材料相结合。 一个裁缝群体集体组织了纤维增强的聚合物钢筋钢筋制造商委员会，并在过去20年中已将FRP钢筋发展成为可行的产品，目前有12亿美元的市场。 目前，没有与未涂层的钢钢筋出售的FRP钢筋产品，并且为了达到这个价格奇偶校验，已经发明了高速流程。 通过该阶段II阶段SBIR项目的完成，将对这个新颖的过程进行优化和进一步开发。 玄武岩纤维是一种新兴材料，有可能替代各种应用中的碳和其他纤维，将在该项目的完成后将大规模的工业用法带入大规模的工业用途。 第一阶段项目允许确定热固性树脂的性能特征，这些特性尚未用于裁缝，从而实现产品验证。 该第二阶段项目将解决一系列制造挑战，这些挑战将在工业规模的FRP钢筋生产中遇到，从而使商业上可行的最终产品可以与Steel Rebar的价格奇偶性提供。