2006 Annual Report
Our objectives address the goals of the Strategic Plan of National Program 306, "Quality and Utilization of Agricultural Products." Specifically, the project supports Goal 1, Objective 1.1 of the Strategic Plan to "Provide Science-based Knowledge and Technologies to Generate New or Improved High-Quality, Value-Added products and processes to Expand Domestic and Foreign Markets for Agricultural Commodities." The research supports the program component of natural fibers and materials, under the Commodity Classification Code C2110 and STP Codes 220.127.116.11 (Industrial Processes and Products) and 18.104.22.168. (Fiber Products).
How serious is the problem? This is a very serious problem because we need a concerted program within the Southern Regional Research Center (SRRC), the National Program Staff, and stakeholders to capture inventions and generate value from them through business development. To develop intellectual property generated with cotton, involvement of industry executives are needed to get early innovators and adaptors involved to build momentum to develop inventions and transform them into marketable products.
Why does it matter? Cotton was king in the south until disruptive changes were introduced by polyester, nylon, and other plastic fibers [polyethylene (PEO), and polypropylene (PPO)]. The 30-year U.S. market share (1970-2000) for cellulose fibers decreased from 43 to 8% of all fibers consumed (Chem. & Eng. News, 5-15-00, p.25), and composite formulators avoid using cotton in composites citing incompatibility of cotton with metals and plastics (Polym. Mater. Enc., 1996, Vol. C, Wiley, 1079). This trend can be reversed by successful fulfillment of the objectives in this research project, forging alliances with forward thinking cotton industry executives, appropriation of intellectual property developed with cotton, and generating an industry structure that brings new inventions into competitive markets. Consequently, the effort will enable the cotton industry, generators of the starting material, cotton, to create, capture, and deliver value to consumers through inventions made at Southern Regional Research Center (SRRC).
FY 2007: (9) Sub-Objective 1.1. Scale-up production of promising polymers. Prepare highlofts and barrier fabrics on small scale and test them with inorganic formulations and new polymers and phosphonates. (10) Sub-Objective 2.1. Benzylated cotton solution will be mixed with cycloaddition polymers and extruded into fibrs or cast into films. (11) Sub-Objective 2.2. Characterize structural and thermal properties of polymers blends. (12) Sub-Objective 3.1. Scale-up procedures to modify cotton's functional groups. Generate large batches of these polymers. (13) Sub-Objective 3.2. Continue characterization of novel polymers. (14) Sub-Objective 3.3. Explore and explain the curing behavior of pre-polymers by thermal and mechanical methods. (15) Sub-Objective 4.2. Seek Cooperative Research and Development Agreements (CRADA) partner to develop size-less weaving technologies. (16) Sub-Objective 4.3. Prepare and test loom components modified with ceramic, polyethylene, and other proprietary grafted coatings for improved size-less weaving properties.
FY 2008: (17) Sub-Objective 1.1. Generate durable flame and antimicrobial formulations of new polymer/cotton nonwoven composites. (18) Sub-Objective 1.2. Characterize polymer/cotton nonwoven composites. Conduct burst, compression recovery, rupture, and resiliency tests. Determine insulation value and flammability. (19) Sub-Objective 2.1. Optimize properties of benzylated cottons and cycloaddition products. (20) Sub-Objective 2.2. Generate structure property relationships. (21) Sub-Objective 2.3. Begin developing methods to generate breathable fabrics. (22) Sub-Objective 3.3. Prepare and characterize cotton-based thermosets and composities. Characterize thermosets as adhesives and composites. (23) Sub-Objective 4.4. Test fabric appearance, hand, dimensional stability and finishing performance.
FY 2009: (24) Sub-Objective 1.1. Scale-up formulations. Finalize formulations of new polymer/cotton nonwoven composites. Explore commercial uses and transfer technology to interested and users. (25) Sub-Objective 1.2. Characterize the thermal, solution, physical, and surface properties of new polymer/cotton non-wowen composites. (26) Sub-Objective 2.1. Scale-up preparations of fibers and films. Develop methods to transfer membranes to fabrics and characterize these products. (27) Sub-Objective 2.2. Characterize fabrics from films and fibers. (28) Sub-Objective 2.3. Finalize formulations for the preparation of breathable fabrics. Conduct moisture permeation studies on breathable fabrics. (29) Sub-Objective 3.3. Develop new thermoset processing conditions. Finalize a process to generate cotton-based thermosets and explore costings formulations. (30) Sub-Objective 3.4. Evaluate cotton-based thermosets for end-use applications, e.g., adhesives, coatings, and composites. (31) Sub-Objective 4.5. Evaluate compact ring-spun yarns, and carded rotor-spun yarns conditions for these yarns. Transfer size-less weaving technology to industry.
The effect of cotton mercerization on its absorbance characteristics in nonwovens was investigated and shown to not enhance absorbancy.
This post-doctoral appointment will terminate at the end of 2006; however, work on the topic area will continue with the same individual for an additional year at no cost to the ARS.
Hurricane Katrina significantly disrupted the progress of the project during 2005-2006. Along with loss of facilities, there was some loss of personnel that limited progress as well.
(1) Success in objective 1 will afford: (a) Novel fibers for flame resistant (FR) highlofts and barrier linings; (b) Crosslinkers that provide woven fabrics that have permanent press protection and dimensional stability; and (c) Plastics that graft or entangle cotton nonwovens for enhanced dimensional stability, allow heat printing, and protect against attack by microbes and flame. (2) Success in Objective 2 will afford blended cotton fibers that are elastic so that technical textiles like Gore-Tex can be produced. (3) Success in Objective 3 will afford new cotton-based plastics for the development of adhesives, and load bearing building materials. (4) Success in Objective 4 will afford new knowledge and technologies about sizeless weaving.
The developing of the envisioned products have significant impact on the cotton industry. The formulation of flame-resistant cotton fabrics opened potentially new large markets to cotton fibers that are currently being filled by synthetics. Technical cottons (water repelling cottons, flexible cotton-based fibers, cotton-based adhesives, etc.) will also add to potential markets. The development of size-less weaving processes will eliminate two processing steps that are currently necessary, whereby reducing processing costs and reducing the environmental impact of weaving. The incorporation of cotton into non-wovens products has the potential to impact several large downstream industries from automobile manufacturers to medical textile processors.
Sizeless weaving on large pilot scale has been carried out on a modern weaving loom.
Cotton-based plastic composites have been prepared on lab scale.
Absorbency characteristics of 100% cotton non-woven fabrics were evaluated.
Cotton has been chemically trated (benzylated) for water repellancy.
Cotton has been chemically treated with a vareity of synthetic materials to render different performance properties to cotton.
The above accomplishments relate to the National Program 306, "Quality and Utilization of Agricultural Products." Specifically, the project supports Goal 1, Objective 1.1 of the Strategic Plan to "Provide Science-Based Knowledge and Technologies to Generate New or Improved High-Quality, Value-Added products and processes to Expand Domestic and Foreigh Markets for Agricultural Commodities."
Furthermore, many industrial representatives visited SRRC to consult and understand the sizefree weaving work and the flame resistant and antimicrobial non-wovens work.