Invented
more than 30 years ago, KEVLAR is the
grandfather of the super fibers. But
innovations at DuPont’s Spruance plant
in Richmondkeep the high-strength material
looking forever young.
by
James A. Bacon
One
December morning in 2002, police
officers Shane Waite and Rick
Edwards were patrolling a
neighborhood in the city of Richmond known for drug trafficking. They stopped a vehicle to
check its registration. As Waite
approached the car, the driver
hopped out and reached for his
waistband. A struggle ensued, and
then the driver broke free. As Waite
made chase, the driver turned and
fired six rounds from a .357 caliber
handgun, hitting the policeman in
the chest.
A
bundle of Kevlar fiber
Waite’s
body armor stopped the bullet. He and
Edwards returned fire and dropped the
assailant. Waite was treated at a local
hospital for severe bruising – even with
body armor, the bullet had the same impact
as if someone had slammed him in the chest
with a hammer – but he lived to tell the
tale.
Waite
is one of 2,750 law
enforcement
officers nationally who have survived
potentially fatal or disabling
injuries because they were wearing
personal body armor
–- much of it made with Kevlar, manufactured, ironically
enough, by DuPont in Waite’s home
town of Richmond. Numerous products
- Spectra, Zylon, Dyneema, Twaron
– have invaded the marketplace
since DuPont’s miracle fiber was
first field tested for body armor in
1975, but Kevlar remains as
synonymous today with super-strong
fabrics as Kleenex is with paper
tissues and Xerox with copiers.
Although Kevlar is a mature product, DuPont has
breathed new life into it by
refining manufacturing processes,
devising synergies with new
materials, inventing novel ways of
using the same fiber and developing new
applications. “Kevlar is
approaching 30 years, but I
wouldn’t call it old,” says
Alexa Dembek, global business
manager for DuPont’s life
protection division. “There have
been many innovations since that
molecule was discovered. … The
basic molecule has not changed, but
the technology that allows that
molecule to realize its full
potential continues to advance.”
While meeting
surging war-time demand for the
fiber in military
body armor in the past two years, the Kevlar team has unveiled
an upgraded body-armor product for
the U.S. law-enforcement market and
introduced anti-terror protections
for aircraft such as armored cockpit
doors and blast-resistant cargo
containers. Meanwhile, on the home
front, Spruance has
developed an entirely new civilian
product -- high-strength panels to
guard homeowners against debris
hurled by tornadoes.
Note:
This article is republished by permission
of Explorations,
a quarterly publication of the University
of Virginia office of Research and
Graduate Studies.
Dr.
Cato Laurencin has been attracted to the
versatility of polymers since he first
encountered them in a college chemistry
class. “At the time, we were just
beginning to understand their applications
in a biomedical setting,” he recalls.
“I thought it was fascinating.” Today,
Laurencin, the Lillian T. Pratt
Distinguished Professor and chair of the
department of orthopaedic surgery, is
leading the effort to use polymers as drug
delivery systems and to help regenerate
bone, ligament, and tendon tissues.
Laurencin
has worked to develop a number of
polymers, including the polyphosphazenes
and polyanhydrides, that have the
advantage of degrading into nontoxic
substances that can be readily excreted by
the body. “One of the advantages of
these polymers is that they degrade in a
dependable and reproducible manner in the
presence of water,” Laurencin explains.
“This makes them particularly
advantageous.”
In
the 1980s, Laurencin was part of the team
that developed a dime-sized polymer wafer
to deliver chemotherapy to tumor sites in
the brain. It is used to treat
glioblastoma multiforme (GBM), one of the
deadliest of all cancers. The wafer,
impregnated with carmustine, is placed in
the cavity left after surgery to remove a
GBM tumor, where it dissolves evenly like
a bar of soap, discouraging the appearance
of new tumors. Its dependable degradation
ensures the release of a steady flow of
this potent anticancer drug, reducing the
danger of overdose. His work has also led
to the development of degradable polymer
systems that deliver antibiotics locally
for the treatment of osteomyelitis, a bone
disease.
Laurencin
is using biodegradable polymers to create
scaffolding that can be used to support
bone grafts. Today, the gold standard for
bone grafts is bone taken from another
part of a patient’s body, but this
technique has its limitations. Patients
run the risk of inflammation, infection,
and chronic pain that occasionally
outlasts the pain of the primary surgical
procedure. Quantities of bone tissue that
can be harvested are limited, creating a
supply problem as well.
Laurencin
uses a polymer that can be formed into a
three-dimensional matrix incorporating
tiny microspheres. These microspheres are
connected, creating a scaffold along which
new bone tissue can grow. These structures
can carry bone-forming cells from the
patient’s body as well as factors that
promote the growth of bone tissue and
blood vessels. As new bone is created, the
polymer matrix is slowly resorbed by the
body.
Laurencin’s
research is driven by his firsthand
experience as a physician specializing in
shoulder and knee surgery. “ My clinical
practice serves as the motivator for my
work,” he says. “Many of the repairs
orthopaedic surgeons perform could be
enhanced with engineered tissue.”
Because
Laurencin’s work spans a number of
disciplines, he was attracted by the
University’s eagerness to foster
collaborative research. He holds
professorships in biomedical engineering
and chemical engineering in addition to
orthopaedic surgery—and has been named
one of only fifteen University Professors,
an appointment that entitles him to teach
in any school or department.
The Fall
Issue of Explorations described
other cutting-edge nanotechnology research
underway at the University of Virginia.
Other articles include:
To
Our Readers
The
Quest for Leadership in Nanotechnology
A
Fluid Approach to Life
A
New Spin on Electronics
The
Complex Ethics of Small Changes
Designing
New Metals
Next-Generation
Catalysts
Currents
in the Blood
Note
to readers: Links to these articles are no
longer functional.
News
Business
DuPont
Engineering Polymers
will
create 20 new jobs with a major new polymer
plant in
Chesterfield
County
. The plant will meet increasing demand for
DuPont Zytel HTN high-performance polyamide
resins with 30 million pounds per year of
capacity. Located adjacent to DuPont’s
existing Richmond
site in
Chesterfield
County, the new facility is scheduled for startup
by the end of 2004. “The expansion will
more than double our base polymer capacity
for Zytel
HTN,” said Clive Robertson, Global
Business Manager for the material. The move
supports growing markets for the material in
automotive, electronic and other consumer
and industrial sectors. “ (Press release,
Oct. 20, 2003).
More.
Albemarle
Corporation
has completed its acquisition of Paris-based
Atofina
S.A.'s
bromine fine chemicals business, a unit with
annual revenues of over $25 million. Said Albemarle
Business Director Joe Tedder: "This
acquisition establishes global leadership
positions for
Albemarle in bromine and bromine fine chemicals,
particularly for pharmaceutical and
agricultural markets." Albemarle,
head-
quartered in
Richmond, Virginia,
operates two business units, Polymer
Chemicals and Fine Chemicals, which generate
revenues of $1 billion serving the life
sciences market. (Press release, Dec.
2, 2004.)
Airgas,
Inc.,
a distributor
of industrial, medical and specialty gases,
has dedicated its new liquid carbon dioxide
and dry-ice manufacturing plant in Hopewell. The $10
million, world-class facility on the grounds
of Honeywell's
Hopewellcomplex began producing liquid carbon
dioxide for customers earlier in the year. The
production of ammonia at Honeywell’s
Caprolactam production site generates a
steady, reliable stream of gaseous carbon
dioxide that feeds the new Airgas facility.
(Press release, Nov. 12).
More.
Industrial
TurnAround Corporation,
a Chester-based construction and engineering
firm serving the chemical, film and fibers
sector, has announced its merger with
Electrical Mechanical Services, Inc., an
industrial service company also based in Chester. The combination creates a company with
more than 250 professional and field
personnel and revenues of $30 million.
(Website,
October 15, 2003). More.
Products
Alfa
Laval Inc.,
a global leader in high-
speed
separators, and Millipore Corporation, a
multinational bioscience company, have
announced a joint marketing agreement in the
USAfor the integration of equipment used for
the recovery of biopharmaceutical proteins
generated by cell culture and fermentation.
Under the agreement, the partnership will
promote Alfa Laval’s high-speed
biotechnology centrifuges. Alfa
Laval USA's corporate offices
and Process Technology
Division are located in Richmond.
(Website, December 2003). More.
Ethyl
Corporation,
a Richmond-based producer
of chemical additives, has launched its
first line of additives created specifically
for the metalworking industry. Under the
brand name TecGARD, the new line includes
emulsifiers, extreme pressure/antiwear
agents, corrosion inhibitors, demist
additives, quench additives, industrial
additives, and lubricity additives. Ethyl
contends the chemicals will enhance machine
performance in the industry's toughest
working environments, from steel mills to
aluminum-container fabricators. (Press
release, January 6, 2003.)
Albemarle
Corp., the
world's largest producer of fire retardants,
has introduced SAYTEX RX as an alternative
to pentaBDE, a widely used retardant being
phased out of production. SAYTEX meets the
foam manufacturing industry's need for a
high-
efficiency flame retardant, offering
superior thermal stability and good
anti-scorch properties for high- and low-density foams used in furniture,
bedding, automobiles and packaging.
Albemarle is headquartered in Richmond. (Press
release, Nov. 13, 2003.)
Technology
The
University of Virginia’s School of
Engineering and Applied Science has
broken ground on Wilsdorf Hall, a building
that will bring researchers in materials
science, chemical engineering and
nanotechnology under one roof. The $39
million, five-story structure will contain
research laboratories, faculty offices,
conference rooms, computational facilities
and work-study areas. Said Dean Richard
Miksad: “By bringing together researchers
from different disciplines, this building
should encourage interdisciplinary research,
especially in the field of
nanotechnology.” (News story, Sept. 18). More.