Grantee Research Project Results
Green Process for Plastic Chrome
EPA Contract Number: 68HERC20C0002Title: Green Process for Plastic Chrome
Investigators: Brazil, Michael
Small Business: Vergason Technology, Inc
EPA Contact: Richards, April
Phase: II
Project Period: November 1, 2019 through October 31, 2021 (Extended to October 31, 2022)
RFA: Small Business Innovation Research (SBIR) - Phase II (2019) Recipients Lists
Research Category: Urban Air Toxics , Small Business Innovation Research (SBIR) , Heavy Metal Contamination of Soil/Water , SBIR - Manufacturing
Description:
This green approach to manufacturing plastic with decorative chrome will eliminate health and environmental hazards from the chrome electroplating process. The US and global market for decorative chrome on plastic is 12 million m2/year and 84 million m2/year respectively, with 80% in automobile trim, 10% in appliances and 10% in sanitary fixtures. Without a viable commercial alternative, US providers have had to either meet strict US regulations for chrome electroplating at significant expense or offshore operations. The proposer’s PVD approach has met all OEM requirements, but with low yield. A path to resolving the sole remaining problem, intermittent failure in high temperature and humidity, was identified in Phase I. Improvements to equipment, process and fundamental understanding during Phase II will result in a green manufacturing process available to existing US supply chain providers: a PVD chrome on plastic that fully meets all OEM specifications at economical yield.
Hexavalent chrome, lead chromates, barium sulfate and metallic nickel will be completely eliminated from the production of plastic chrome parts, using less than half the electrical power. A modest reduction in manufacturing cost relative to electroplating is anticipated. Broad acceptance of the technology is anticipated based on ongoing evaluations by OEMs in all three market segments, as well as by existing Tier 1 and Tier 2 electroplating suppliers. One commercialization goal is to sell at least one more production tool to the supply chain.
Progress and Final Reports:
SBIR Phase I:
Green Process for Plastic Chrome | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.