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Workers at the University of Leeds researched, then developed and patented the `hot compaction' process for the manufacture of single polymer composites [1]. In this process highly oriented polymer fibres are heated so that a proportion of the surface of every oriented element melts. Upon cooling, this skin recrystallises to form the matrix of a self-reinforced fibre composite. Important resultant properties include high stiffness and strength, lightweight and outstanding impact strength, leading to a material with crucial commercial advantage. The reach of this impact is demonstrated by commercialisation of the polymer composite over a wide range of applications including anti-ballistic body armour, sports goods (Nike, Bauer), lightweight luggage (Samsonite), audio speakers (Wharfedale) and radar covers for helicopters (Westland). Examples include Samsonite using the material Curv® to manufacture two new high profile product ranges (Cosmolite and Cubelite) and Bauer using it in their elite-level ice hockey skate range (SUPREME and VAPOR).
Nanoforce Technology Ltd. is a spin-out company wholly owned by QMUL, active in the field of polymeric and ceramic materials. Bridging the gap between academic research and industrial applications, Nanoforce has done business with over 100 companies since 2008, providing the key research expertise and specialist facilities to enable the development of new materials and commercial products, including Sugru® a room temperature vulcanizing silicone rubber, Zelfo® a self-binding cellulose material, and BiotexTM a range of high-performance yarns, fabrics and pre- consolidated sheets based renewable resources such as PLA and natural flax fibres. Nanoforce has been promoting the development and commercialisation of spark plasma sintering (SPS) since 2006, which resulted in Kennametal recently opening the first commercial SPS facility in the UK to produce advanced ceramic armour. Nanoforce's clients have included large multi-nationals such as DSM, Dow Chemical, General Electric, SABIC, L'Oreal, Shell, Sibelco, governmental agencies such as Defence Science and Technology Laboratory (Dstl), and a large number of SME's.
Ulster research groups in the fields of composites and metal forming have had a long-term and fruitful engagement with major industries such as Caterpillar (FG Wilson), Rolls Royce and Bombardier. Since 2008 this has resulted in new patented technologies, significant cost/performance improvement in manufacturing, the delivery of on-site industrial training, the formation of spin-out companies and the establishment of the £6m N. Ireland Advanced Composites and Engineering Centre with currently 10 member companies. In particular, Ulster research has been at the heart of patented Bombardier processes which underpinned their strategic entry into the commercial narrow body aircraft market which is worth $43billion per annum globally. The C Series wing programme, which utilises composites, employs 800 people directly in Belfast at full production, with a further 2,000 employed in the supply chain. As of today, Bombardier has global orders and commitments for 388 C Series aircraft, which include firm orders for 177 of the new airliner.
XeraCarb Ltd is a spin-out company formed in 2011 to exploit a class of ceramic composite materials co-invented by Jones. These materials were first devised in 2008 via a Materials and Engineering Research Institute (MERI) Knowledge Transfer activity and developed from 2009 onwards through a series of UK Ministry of Defence (UK MoD)-funded research projects. XeraCarb was spun out after the underpinning research won a national award in 2011 as the most promising UK materials system for commercialisation. The applications for XeraCarb's materials range from body- and vehicle-armour to kiln furniture and wear-resistant components. The company has attracted significant venture capital investment and is valued at over £1m. It has set up an independent production facility, has appointed employees, has been awarded a TSB grant, has materials undergoing trials in respect of a number of applications, and has delivered its first orders.
The development of disentangled, ultrahigh molecular weight polyethylene at Loughborough University since January 2007 has provided an environmental friendly route to the manufacture of high modulus, high tensile strength tapes with applications ranging from body armour to helmets, ropes and cables. Commercialisation is being undertaken by the Japanese company Teijin, in the Netherlands, under the brand name Endumax®. The new business, started in 2011, now employs >80 staff and predicts annual sales of >€15M from 2014 with an increase of ~10% over the first five years. Competitors such as Du Pont (Tensylon®) and DSM (Dyneema BT10®) have also initiated development of products using the new process route.
A manufacturing process developed by Bradford researchers has revolutionised the way endodontists perform root canal treatments. When coated with a hydrophilic polymer, the highly-filled hygroscopic material has enabled UK company DRFP to develop SmartPoint — a new endodontic technique that dramatically reduces failure rates of root canal treatments from 11-30% over five years to approximately 1%, and gives lower levels of post-operative pain when compared with conventional techniques. The technology has won three awards for innovation and DRFP has expanded significantly, with a dedicated production facility and sales team offering visits to dentists to demonstrate the benefits of the technology.
Viewing carbon nanotubes (CNTs) as very rigid polymer molecules led to research on turning them into useful materials. Strategic investments to develop different aspects of this research have been made by two separate companies. A process for the synthesis of CNTs was transferred to Thomas Swan Ltd who have made significant investment, and are now Europe's leading supplier of high-quality CNTs. In 2003 a process was invented to spin CNT fibres directly from a synthesis reactor. The process is intrinsically cheaper than the conventional process for carbon fibre and it produces a tougher and more versatile product. The University of Cambridge (UCAM) spin-out company Q-Flo Ltd (created in 2004 to achieve focus on transfer of this technology) and Plasan (multinational manufacturer of vehicle defensive armour) formed a joint venture in 2010 which has enabled the first-stage scale-up of manufacture.
This case study is about the development of flame retardant (FR) polypropylene yarns used in upholstery fabrics for domestic and office furniture, automotive and floor coverings that will have predictable and reproducible fire retardant properties when subjected to standard testing procedures. Through the UK DTI funded project FLAMTECH (2002-2005) shared by Camira Fabrics Ltd., and the university, a range of novel polypropylene yarns having higher levels of consistent fire performance than the previously existing products in the market place were developed. A testing protocol which could establish individual fibre/yarn/fabric structural-fire property relationships and correlate these with (and hence predict) final fabric performance was also established. The project overlapped a concurrent EPSRC funded research in which nanocomposite fibres (including polypropylene) with improved flame retardancy and reduced melt dripping were developed. Camira were also members of the consortium managing this project. The major commercial outcome from these projects since 2005 is a flame retardant polypropylene product being marketed by Camira fabrics within their Perfentex brand and others are also being considered. This work also inspired the Production Director of Camira Fabrics to register at Bolton as a PhD-by-publication candidate and hence gain more knowledge about the subject area, as evidenced by the publication of her research papers (see Paper 1, Section 3).
Electrical power companies are tasked with operating a highly reliable and robust power system. Electrical power outages (blackouts) have serious consequences for the companies concerned as well as society. The health of electrical insulating materials is critical for the reliability of these systems as it often determines equipment lifetime.
Leicester was the first to demonstrate experimentally that polymer based nanocomposite materials could increase the service life and reliability of electrical insulation as used in high voltage power transmission systems. Its research has also led to the development of measurement techniques to assess the health and the extent of thermal ageing of HV power cables.
National Grid has used Leicester's research findings to manage and monitor its electricity transmission equipment, with resulting impacts on its safety, efficiency and financial economy. Borealis, a major international supplier of insulating materials has used the research to solve manufacturing problems and to set up test facilities for medium voltage cables. A Knowledge Transfer Partnership with Alstom Grid has led to the the establishment of a £1M commercial size HVDC cable test facility which has attracted £0.5M investment from cable manufacturers worldwide.
The Thin Film Centre (TFC) group at UWS pioneered thin film materials and processes for plastic electronics with Dupont Teijin Films (DTF) Ltd and Plastic Logic (PL) Ltd over a period of nine years. This work was pivotal to the growth of PL from a start-up position resulting in the first all-polymer e-book reader and was the basis of a world leading position in the supply of specialised substrates for DTF Ltd.