Source: UNIVERSITY OF DELAWARE submitted to NRP
ADVANCED MATERIALS FROM CHICKEN FEATHERS AND SOYBEANS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
NRI COMPETITIVE GRANT
Reporting Frequency
Annual
Accession No.
0204470
Grant No.
2005-35504-16137
Cumulative Award Amt.
(N/A)
Proposal No.
2005-02675
Multistate No.
(N/A)
Project Start Date
Sep 1, 2005
Project End Date
Aug 31, 2009
Grant Year
2005
Program Code
[71.2]- (N/A)
Recipient Organization
UNIVERSITY OF DELAWARE
(N/A)
NEWARK,DE 19717
Performing Department
(N/A)
Non Technical Summary
This project will deliver a new advanced materials technology that can be used for producing high performance and low cost carbon fibers from chicken feathers. It will provide fundamental information and functional properties of the new fibers and their composites with soyoil resin. Several new high-volume applications of the bio-composites will be considered and these include low dielectric constant printed circuit boards for electronic materials (with Intel), sheet molding compounds for automotive applications, hurricane resistant roofing, thermoplastic composite (with USDA), and many other advanced materials applications, including windmill blades, bridge decks, and sporting goods. In addition to developing a new generation of environmentally friendly green materials form renewable resources, this research will also provide a profitable solution to a growing ag-waste disposal and health issue in the agricultural community.
Animal Health Component
(N/A)
Research Effort Categories
Basic
100%
Applied
(N/A)
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
51118201000100%
Knowledge Area
511 - New and Improved Non-Food Products and Processes;

Subject Of Investigation
1820 - Soybean;

Field Of Science
1000 - Biochemistry and biophysics;
Goals / Objectives
The goal of this research is to investigate the fundamentals of the development of high performance, low cost, carbon fibers from chicken feathers and their use as a fibrous component in bio-composites. The specific objectives to achieve this goal are as follows: 4.2.1 Develop high performance, low cost hollow carbon fibers from chicken feathers. 4.2.2 Characterize the fundamental functional properties of the carbon fibers and their soy-based bio-composites. 4.2.3 Explore the application potentials of new bio-composites derived from carbon fibers and soyoil resins with several collaborators.
Project Methods
We plan to develop high performance hollow carbon fibers through Pyrolysis of chicken feathers. These unique materials when combined with soy-based resins will be the basis for a new generation of bio-based composites for several high volume applications. Wool and his group have developed the chemistry, physics and engineering properties of soy-based polymers. By controlling the fatty acid distribution function of the oils, the molecular architecture of the polymer has been designed with the appropriate chemistry to produce linear, branched, lightly crosslinked and highly crosslinked bio-based polymers. This has resulted in composites resins, sheet molding compound, elastomers, pressure sensitive adhesives, coatings, foams and new electronic materials from chicken feathers. The development of bio-based advanced materials from renewable resources, such as high modulus carbonized chicken feathers and soyoil, is quite attractive both from an economic and environmental perspective. Recently, efforts have been made to develop processes for making fiber materials from chicken feather waste. Feather fibers are composed of the protein keratin, which exists in two microcrystalline forms in the fiber and the quill. Keratin fibers are hollow, light materials, with an aspect ratio of about 1000 with a typical diameter of 6 micrometers and length of 3-20 mm. It has been shown by Hong and Wool that the low density chicken feather fibers also have very low dielectric constants suited to electronic materials. However, the as-delivered chicken fibers with a modulus E approx = 3 GPa are not as stiff as fiberglass, graphite or even most natural lignin-cellulose fibers. Based on our initial carbonization studies, the potential to make high performance hollow carbon fibers from keratin fibers with moduli in the range 30-100 GPa and strength in the range of 1-10 GPa, is very exciting and will be pursued in this research. If successful, we expect to demonstrate that they can be used with soy-resins as advanced bio-based composite materials in a large number of high volume applications from housing, automotive and sports goods, to electronic materials and fuel cells. Graphite fibers for high performance composites are one of the most important advanced engineering materials produced today. The best carbon fibers are made by Pyrolysis of oriented fibers such as microcrystalline polyacrylonitrile; the oriented keratin microcrystalline feather fibers provide an intriguing candidate for carbonization. If the overall hollow structure and integrity can be maintained while the mass is reduced, there could be a significant advantage gained in the strength-to-weight ratio. With suitable chemical functionalization and viscosity, we have shown that the molding process of soybean resins is similar to that of conventional thermosetting liquid molding resins, using RTM, VARTM, S MC. We have designed functionalized triglycerides to make John Deere tractor parts, harvester bodies, hurricane resistant housing with natural fibers, pressure sensitive adhesives, foams, tissue scaffolds, elastomers, and nanocomposites with carbon-nanotubes & nanoclays.

Progress 09/01/05 to 08/31/09

Outputs
OUTPUTS: The Wool Research ACRES Group made a movie for Sundance TV about the Printed Circuit Boards from Chicken Feathers which will be aired on June 16 in a program called "Gadgets" Broad Impacts: Success in the use of Carbonized Chicken Feathers for Hydrogen Storage would solve a major issue for the Hydrogen Power generation and eliminate chicken feather waste problems Collaborations: Microsoft Corp has requested the development of new printed circuit boards using soybean resins and chicken feather fillers developed in this project. The work up is currently being done in collaboration with Rogers Corp (will make the base boards with copper cladding), Hunter PCB (Will make the prototype PCB under advisement from Microsoft), Cara Plastics Inc (will design the soy-based resin), DynaChem Inc (Will scale-up the bio-based resin) and Feather Fiber Corp (will supply the FF mats for the PCB's in a future phase II) PARTICIPANTS: Not relevant to this project. TARGET AUDIENCES: Not relevant to this project. PROJECT MODIFICATIONS: Not relevant to this project.

Impacts
1. Development of new eco friendly printed circuit boards for the electronic materials industry; ongoing collaboration with Micosoft, Rogers Corp, Hunter PCB and Cara Plastics and DynaChem Inc. 2. Production of Carbonized chicken feather fiber for Advanced Composites 3. Use of Carbonized Chicken feather fibers as Carbon Microtubes for Hydrogen Storage 4. Design of Hurricane Resistant Roofs with Chicken Feather Fiber,lignin toughening agents, soyoil-based foam and plant oil composite resins

Publications

  • Zhan, M.; Wool R. P. New copper-clad laminate from chicken feathers. The 11th Annual Green Chemistry and Engineering Conference, Washington, D.C., U.S.A., June 26-29, 2007
  • Zhan, M.; Wool R. P. Composites from natural fibers and soybean oil. Pan American Advanced Studies Institute on Sustainability and Green Chemistry, Mexico City, Mexico, May 29-Jun 10, 2007
  • Lu J, Wool RP, Novel thermosetting resins for SMC applications from linseed oil: Synthesis, characterization, and properties JOURNAL OF APPLIED POLYMER SCIENCE 99 (5): 2481-2488 MAR 5 2006
  • Wool RP, Adhesion at polymer-polymer interfaces: a rigidity percolation approach COMPTES RENDUS CHIMIE 9 (1): 25-44 JAN 2006; ERATA, 9 (9): 1234-1234 SEP 2006
  • Zhu L, Wool RP, Nanoclay reinforced bio-based elastomers: Synthesis and characterization POLYMER 47 (24): 8106-8115 NOV 8 2006
  • Can E, Wool RP, Kusefoglu S, Soybean and castor oil based monomers: Synthesis and copolymerization with styrene JOURNAL OF APPLIED POLYMER SCIENCE 102 (3): 2433-2447 NOV 5 2006
  • Can E, Wool RP, Kusefoglu S,Soybean and castor-oil-based thermosetting polymers: mechanical properties JOURNAL OF APPLIED POLYMER SCIENCE 102 (2): 1497-1504 OCT 15 2006
  • Dweib MA, Hu B, Shenton HW, Wool, RP, Bio-based composite roof structure: Manufacturing and processing issues COMPOSITE STRUCTURES 74 (4): 379-388 AUG 2006
  • Wool RP, Bunker SP, Polymer-solid interface connectivity and adhesion: Design of a bio-based pressure sensitive adhesive, JOURNAL OF ADHESION 83 (10): 907-926 2007
  • Esen H, Kusefoglu S, Wool RP, Photolytic and free-radical polymerization of monomethyl maleate esters of epoxidized plant oil triglycerides, JOURNAL OF APPLIED POLYMER SCIENCE 103 (1): 626-633 JAN 5 2007
  • Wool, R.P. Twinkling Fractal Theory of the Glass Transition and Yield, ABSTRACTS OF PAPERS OF THE AMERICAN CHEMICAL SOCIETY, PMSE 559, Aug 23, Boston MA 2007
  • Wool R. P., Entanglement Models for Bio-Based Polymer Rheology: Percolation or Packing ABSTRACTS OF PAPERS OF THE AMERICAN CHEMICAL SOCIETY, POLY, Aug 23, Boston MA 2007
  • Wool R. P., Self-Healing Materials: A Review, J. Soft Matter, 4, 400-418 2008
  • Lu J, Wool R.P., Additive toughening effects on new bio-based thermosetting resins from plant oils, COMPOSITES SCIENCE AND TECHNOLOGY Volume: 68 Issue: 3-4 Pages: 1025-1033 Published: MAR 2008
  • Lu J, Wool RP, Sheet molding compound resins from soybean oil: Thickening Behavior and mechanical properties, POLYMER ENGINEERING AND SCIENCE 47 (9)1469-1479 SEP 2007
  • Erman Senoz, Richard P. Wool, Hydrogen Storage on Carbonized Chicken Feather Fibers, The 11th Annual Green Chemistry & Engineering Conference, Washington, D.C., USA, June 2007
  • Bonnaillie LM, Wool RP, Thermosetting foam with a high bio-based content from acrylated epoxidized soybean oil and carbon dioxide, JOURNAL OF APPLIED POLYMER SCIENCE 105 (3): 1042-1052 AUG 5 2007
  • Campanella A, Bonnaillie LM, Wool RP, Polyurethane Foams from Soyoil Based Polyols , JOURNAL OF APPLIED POLYMER SCIENCE Volume: 112 Issue: 4 Pages: 2567-2578 Published: MAY 15 2009
  • Wool, R.P., Twinkling Fractal Theory of the Glass Transition, JOURNAL OF POLYMER SCIENCE PART B-POLYMER PHYSICS Volume: 46 Issue: 24 Pages: 2765-2778 Published: DEC 15 2008
  • Lu J, Wool RP, Additive toughening effects on new bio-based thermosetting resins from plant oils, COMPOSITES SCIENCE AND TECHNOLOGY Volume: 68 Issue: 3-4 Pages: 1025-1033 Published: MAR 2008
  • Wool R.P. Self-healing materials: a review, SOFT MATTER Volume: 4 Issue: 3 Pages: 400-418 Published: 2008
  • Wool R. P., Advanced Bio-Based Polymers and Composites, Plenary Address, Proceedings of Fiber Reinforced Composites Conference 2007, Dec 9-12, Port Elizabeth, SA 2007
  • Wool R.P. The Importance of Interfaces in Thermoplastic Matrix Composites and their Tailoring During Manufacture, Proceedings of the 28th International Symposium on Materials Science, 3-6 Sept, (2007) Risoe, Denmark
  • Wool R. P.Triglyceride Based Polymers and Composites, Proceedings of Bioresins Conference, Pira International, Nov 29-30 (2007), Atlanta GA
  • Erman Senoz, Richard P. Wool, Hydrogen Storage on Carbonized Chicken Feather Fibers, The 12th Annual Green Chemistry & Engineering Conference, Washington D.C., U.S.A, June 2008
  • Zhan, M. Wool R. P. Bio-based Dielectric Materials for Printed Circuit Boards. The 12th Annual Green Chemistry and Engineering Conference, Washington, D.C., U.S.A., June 24-26, 2008


Progress 09/01/05 to 09/01/06

Outputs
Advance Materials from Chicken Feathers and Soybeans Chicken feathers are a great feedstock for the synthesis of advanced materials due to the massive amounts of feathers that are wasted in agriculture. In the United States alone, the poultry industry disposes of 5 billion pounds of feathers/year. One aspect of this research is to utilize this renewable resource for the use of inexpensive, high-performance, hollow carbon fibers which may then be used in reinforcement of composites. Another objective of this study is to develop a new composite from soybean resins and chicken feather fibers with a low dielectric constant, low dielectric loss, good mechanical properties and good thermal properties. The synthesized materials will be tested for use in printed circuit boards (PCB). High-performance carbonized chicken feathers The structure of chicken feathers was proposed to have a 37 wt% carbon content, based on the composition of amino acids in keratin, with a predicted feather composition of 92% keratin. The actual carbon content was examined through elemental analysis (Prevalere Life Sciences, Inc.) and is shown to contain 48 wt% carbon. Upon carbonization, the feathers maintained a carbon content of 46%. With the addition of 3 wt% carbonized chicken feathers a composite has shown an increased storage modulus by 52% (1.106 GPa) and the loss modulus by 22%. If the fibers are matted together they are able to withstand more force. Infusing 27 wt% chicken feather mats (uncarbonized) in a vacuum assisted resin transfer molding system (VARTM) allowed for an 82% increase in the storage modulus (1.331 GPa) and 11% decrease in the loss modulus (0.119 GPa). Bio-based electronic materials Composites were made and the mass fraction of fibers has been increased to about 50 wt%, or 65 vol%, which is a great improvement. The dielectric constants of mostly used epoxy-based materials are 4.2-4.7 and the dielectric loss is about 0.02 at 1 MHz. The dielectric constants of these composites are suitable for applications, but the dielectric loss is still high. Further study will be done on the dissipation factor.The coefficient of thermal expansion (CTE) of the materials is also of importance. Thermal stresses can form in the board structure due to the CTE mismatch between the dielectric and the metal lines. Such stresses may cause delamination if adhesion at the interface is poor. During the boards fabrication thermal stability is also important. Feather fibers are also stable at around 200 C. The dielectric constant and loss can be further lowered by choosing less polar groups on the resin and more saturation in the oil. Modifying feather fibers can also improve both mechanical and electrical properties. The removal of polar groups through the pyrolysis process may enhance the dielectric constant if the hollow structure and mechanical properties may be retained. It could be another way to improve the properties of the dielectrics. More studies will be done in the future. The thermal conductivity of the dielectric and the adhesion to the other materials, such as copper film, at the metal/polymer interface will also be investigated and optimized.

Impacts
The development of bio-based advanced materials from renewable resources, such as high modulus carbonized keratin fibers from chicken feathers and plant oil from soybean, is quite attractive from both an economic and environmental perspectives, and is an important aspect for the longevity of the composites industry. Most importantly, we are proposing research that can significantly reduce agricultural waste by reusing it as a valuable feedstock for advanced high performance materials. Waste poultry feathers are becoming an environmental problem worldwide. In the United States alone, more than one billion kilograms of feathers are produced annually in the nations poultry processing plants as a by-product of poultry production. Disposal of the feather waste is expensive and difficult. A more expensive disposal method is the conversion of chicken feathers to a protein rich animal feed. However, with the evolution of diseases such as Bovine Spongiform Encephalopathy, commonly known as Mad Cow Disease, there has been a recent push to limit the practice of treating animal processing waste for agricultural consumption. Our solution is to pyrolyze the feathers into high performance carbon fibers of considerable value. This solution will eliminate the feather disposal problem, minimize the health problem and generate an economically valuable new bio-based product. The research will focus on (a) Carbonization of Keratin fibers, (b) Composite Applications of Carbonized Fibers and (c) Green Electronic Materials.

Publications

  • No publications reported this period