- Synthesis of organic intermediates for monomers, ligands and intermediates.
- Synthesis of air and moisture sensitive organometallic catalysts.
- Polymerization: Water-borne urethanes, solvent based homogeneous olefin copolymerization (metallocenes, Ziegler), and emulsion polymerization.
- Vulcanization: Synthetic rubber - bulk and foams.
- Polyurethane coatings: water-based, foamed over textiles and polyolefin non-woven composites.
- Process optimization: DOE, ANOVA, response surface, use of Minitab, Design Expert and JMP.
- Project management: Resource allocation, timelines, milestones and cross-functional conduit.
- Intellectual property: Applications, trademarks, oppositions and infringement.
- Analysis: chromatography (column, GCMS), spectroscopy (FTIR, UV), and spectrometry (NMR, MS).
- Thermo-mechanical testing: DSC, DMA, TGA, and DMTA
- Mechanisms of reaction: Kinetics, isotope effects, and synthesis of deuterium labeled materials.
Independent Consultant, 2013 - Present
- Emulsion chemistry: Urethane, acrylic, silicone and hybrid. Curing processes and product performance.
- Coatings and lamination: Fabric and foam substrates, industrial, protective and class I medical devices.
- Formulation, process and product optimization. DOE, DMAIC, FMEA, VOC and HOQ/QFD.
- Thermo-mechanical analysis of urethane foams for product specifications and process improvement.
Lion Copolymer, Baton Rouge, LA, Research and Development Director, 2009 - 2013
- Directed and coordinated research and development efforts for new product developments and plant support.
- Defined strategies, timelines and managed resources of multiple projects to achieve milestones and targets on timely basis.
- Generated and implemented strategic road map for new product technology development.
- Highly integrated with executive management and BOD for efficient project prioritization and direction.
- Maintained a strong relationship with operations (solution and emulsion processes), for strongly focused implementations and resolutions of existing issues, and new product development.
- Emulsion polymerization. Cold SBR. Specialty polar monomers for specialty polymers.
- Silica silanization optimization in joint venture. 29Si solid state nmr analysis of materials.
- Solution polymerization. Ziegler Natta catalysis and activators.
- Emulsion blend project to synergize system for improved mechanical properties.
- Polymer modification. Maleic anhydride and siloxane grafting.
- GPC, ICP, GCMS, FTIR, RPA, elemental analysis (XRF).
- Polymerization pilot plant design, construction and polymerization strategy.
- Recruited personnel from Ph.D.s to technicians to double size of lab in one year.
- Managed multiple teams composed of six Ph.D. professionals and ten lab technicians.
- Managed IP: Provisional patents and final edition, trademark registrations and oppositions with 100% success rate.
- Upgraded research and analytical lab facility (over $1 million in equipment and lab upgrades) for business platforms.
- Managed two pilot plant constructions, and associated resources and projects during their operation.
- Developed novel filler modification, catalyst technology and emulsion composition. Eleven pending patents.
Sealy Trinity, NC, Research and Development Director-Scientist, 2007 - 2009
- Directed and developed research and development for mattress latex technology $700 million durable goods business.
- Designed experiments to validate robustness of latex foaming process: Determined and validated process parameters for optimum foam stability and product performance.
- Established and performed thermo-mechanical analysis (DSC, TGA, DMA) vulcanized latex foam. Interpreted results.
- Modeled and optimized formulation and vulcanization process conditions.
- Compiled standard operating procedures for the thermo-mechanical analysis equipment for reference use by personnel. Resulted in focused and optimized use of resources.
- Discovered correlation between raw material source and its relationship to product performance issues.
- Ideated and developed novel latex foam formulations and materials.
- Interacted closely with material suppliers to establish specification-properties relationships to optimize the latex foam integrity and subsequent vulcanization process improvements.
Lord Cary, NC, Staff Scientist, 2005 - 2006
- Defined short and long term project goals.
- Managed key chemical process optimization projects. Established critical metrics for analysis of raw materials, intermediates and process products.
- Established critical metrics for HPLC and GC analysis of raw materials, intermediates and process products.
- Purified key process intermediates to generate 100% pure standard for improved analysis and process qualification. Verified purity by acid-base titration, NMR and TGA analyses.
- Contributed directly on syntheses, processes and analysis methodology and improvements.
- Supervised research and production work of personnel in lab and pilot plant projects.
- Applied Design of Experiments methodology in lab and pilot plant for process optimization.
- Used DOE methodology for process optimization.
- Contributed directly on syntheses, processes and analysis methods.
- Established a procedure to reduce stream recycle and acid waste reduction with savings of $100 thousand per year.
- Supervised research and production work of personnel in lab and pilot plant projects.
Dow Chemical, Midland, MI, Research Leader, 1988 - 2004
- Developed INSITE Technology for solution, slurry and gas olefin polymerizations.
- Copolymerized ethylene with various monomers, including specialty, and macromonomers, for specialty polymers (such as modified triblock-type, comb-like).
- Developed supported metallocene catalyst on silica for slurry and gas polymerizations.
- Purchased and designed 5 reactors with different automated configurations as the main infrastructure for solution, slurry and gas olefin polymerizations. Safety was focus #1.
- Designed process using sequential and different catalysts to make tailored polymer structures with performance similar to triblock polymers. Polyethylene or polystyrene macromer side chains, long chain branching.
- Designed reactors for solution, slurry and gas olefin polymerizations.
- Designed and operated the first lab scale polypropylene gas phase reactor at Dow.
- Used Ziegler Natta heterogeneous catalysts to make EP elastomeric copolymers.
- Reduced variability of high throughput process by 75%. Improved reproducibility.
- Synthesized and tested multiple homogeneous coordination catalysts for the polymerization of polar monomers, such as vinyl chloride.
- Extensive experience with NMR: Solution, low and high temperature; multinuclear: 1H, 13C, 19F, 31P, 2D NMR; GC (FID and TCD detectors); GCMS (electron impact and chemical ionization detection); FTIR; UV-Vis; EXAFS; neutron activation; GPC.
- Chromatography: Thin Layer Chromatography (TLC); column chromatography (qualitative, preparative).
- Fractional distillation; spinning band distillation.
- Instron: Tensile, compression, lap shear; weatherometer (NaCl, UV); melt index; brabender mixing.
- Formulated new water-borne polyurethane-urea ionomer (PUUI) materials for elastomers, coating and adhesive applications.
- Made novel water-borne PUUIs containing silicone amorphous segments for water repellent coatings.
- Extensive analysis of catalysts and polyolefin elastomers: 1H-, 13C-, 19F-, 31P-NMR (low and high temperature and use of special techniques: APT, homo/heteronuclear COSY); GPC, GCMS, FTIR, EXAFS, neutron activation (supported catalysts), Instron, weatherometer, melt index.
- Particle size analysis of water-borne polyurethane-urea ionomers. Dual particle size system resulted in a U.S. patent.
- Interacted with Dow European facilities to support ongoing projects.
- Facilitated and managed multiple Six Sigma Black Belt projects.
- Six Sigma Black Belt certification.
Maxdem, Pasadena, CA, Scientist, 1986 - 1988
- Developed high performance material intermediates via thermal rearrangement in vacuo.
- Polymerized intermediates by Grubbs' titanium carbene metathesis catalysts.
- Prepared poly-p-phenylene (PPP) rigid rod intermediates to generate high strength PPP. This lead to the development of Parmax 1200 self-reinforcing polymer (SRP). Technology was sold to Solvay Polymers.
- Analyzed intermediates by solid state NMR.
- Proposal writing for DOD, DARPA and other corporate sponsors.
Productos Alen, Monterrey, Mexico, Chemist
- Hydration of turpentine to generate pine oil. 10 ton (22,000 lb) reactors.
- Fractional vacuum distillation: 3-10 ton (22,000 - 6,600 lb) stills; Raschig rings
- Recovered specific fractions with scent and perfume value for value added to the process: Anethole.
- Recovered waste materials and converted chemically to scent and perfume materials: Terpineol acetate.
- Laboratory (one gallon reactors and stills) to plant scale up.
- Gas chromatography, scent testing.
- Collaborated cross-functionally to develop novel catalyst technology which generated revenue in excess of $1 billion per year in sales. Resulted in multiple patents.
- Identified and drove technological innovation in waterborne polyurethane technology in response to growing market trends in coatings and adhesives, (patent issued).
- Identified root cause of product performance problem in $700 million latex foam durable goods market.
- Ideated, directed and developed new latex foam materials in $700 million durable goods market in company innovation breakthrough.
- Interacted with business, operation and patent functions to define and decide project strategies for continuous improvements and new product development.
- Involved in market analysis and new product costing. Toll process vs. in-house manufacturing.
- Interacted deeply with customer to understand their needs and target resources for project success.
- Directed projects resulting in improved materials and processes and reduced defects by 80% in elastomeric product. Patent granted on new technology.
- Identified root cause of solid material process bottleneck. Modified raw material specs, reduced key process step from 6 minutes to 1 minute per batch. Improved throughput 25%: 6K to 8K pounds per day.
- Increased plant productivity by 25 % in 20 million pounds per year pine oil production by developing an analytical method for raw material and recycled streams.
- Exercise due diligence for project timelines compliance, alignment of resources, and safety and environmental regulations.
- Managed IP and trademark activities: Research and development work, patent filing, and disclosure strategy.
- Authored 45 patent and patent applications. Sixteen patents issued in the U.S.
- Assessed and insure comprehensive safety checks for chemical research and development processes.
- Managed safety coordinator responsibilities for chemical research and development site with 400 employees.
Honors & Publications
- Post-doc, Chemistry, UCLA, Los Angeles, CA
- Six Sigma Black Belt
- Spanish; native
- French and Italian: Reading (technical)
Academic and Professional Affiliations
- American Chemical Society - ACS
- American Association for the Advancement of Science - AAAS
- Rubber Division - ACS
- Institute of Electrical and Electronic Engineers - IEEE
- Received Dow Chemical "Inventor of the Year" Award
Publications and Patents
- Author of a chapter - educational text book.
- Over ten patents.
- Ph.D. Chemistry, California Institute of Technology, Pasadena, CA
- B.S. Chemistry, Tecnologico Monterrey, Monterrey, Mexico