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Research carried out by Prof. Ton Peijs and colleagues has led to significant breakthroughs in engineering plastics: PURE® and its licensed Tegris® technology, which are lightweight self- reinforced alternatives to traditional polypropylene (PP) composites such as glass-fibre or natural- fibre-reinforced PP. Environmentally friendly and 100% recyclable, these strong and ultra-light self- reinforced plastics have been successfully used across a number of applications, from suitcases and sports gear to protective armour and automotive panels, with impressive results. When used for car, truck and van components, they have been shown to help lower exhaust emission levels and increase fuel economy.
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.
Research into die drawing of polymers at Bradford has resulted in a new building material that is stronger and more durable than wood; and new bioresorbable shape-memory polymers for use in medical implants that reduce patient trauma and costs. The wood replacement material is commercialised by the United Forest Products/Dow USA 2010 spin out company Eovations LLC for use in a range of construction applications; the bioresorbable shape-memory polymers have recently been patented (4 patents filed) by Smith & Nephew for use in soft tissue fixations. These impacts form part of a range of exploitations of our oriented polymer 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.
Research at the University of Manchester has supported the development of drinks vending systems for Mars Drinks. The research has demonstrated that a detailed understanding of the relationship between the structure and properties of the polymeric components is vital for the design and performance of two drinks vending systems, Flavia (single-portion fresh beverages) and Klix (in-cup beverages). This research has contributed to major improvements in materials selection, quality control, cost reduction and performance. These drinks vending systems were developed originally in the UK in collaboration with the University of Manchester, with Flavia now also manufactured in the USA and marketed worldwide by Mars Drinks with an estimated sales value of > US$400m per annum.
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.
We developed technology that uses polymer particles to replace much of the water that is employed in conventional clothes washing. The innovative technology is protected by several international patents and was commercialised in 2006 via the spin-out company Xeros Ltd. In August 2012, Xeros sold its first commercial-scale (25kg capacity) machine in the UK high street market and also installed the commercial-scale machine at a US commercial laundry, enabling typical savings of upto 70% less water, 50% less chemicals and 50% less energy than traditional methods and, hence, significantly reduced carbon footprint; Xeros plans to introduce a domestic-scale washing machine in 2014.
Professor Stephen Russell's fundamental and applied research on the formation, structure and properties of nonwoven fabrics has directly led to the creation and continued success of the Nonwovens Innovation and Research Institute (NIRI) Ltd a University of Leeds spin-out company. Formed in 2005 to exploit Russell's research, NIRI has grown annual sales revenue to ~£1 million supplying products and services that have enabled many medium-sized enterprises (SMEs) and global public limited companies (PLCs) to launch improved or new products, growing their market share and positively impacting consumers. Additionally, the research has enabled NIRI to independently establish and co-fund new commercial joint ventures that have resulted in the development of new IP (intellectual property)-protected products for improving global health and security. NIRI has grown its workforce to twenty (mainly University graduates) and has been profitable from the first year of trading.
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.
A significant body of research in ultrasonics at the University of Strathclyde led to the formation of Alba Ultrasound Limited in 2000. This successful UK engineering manufacturing company designs and manufactures high quality wideband ultrasonic array transducers for sonar applications to a worldwide client base, delivering benefits ranging from naval and maritime security through to safer ocean environments and informed exploitation of marine resources. Alba Ultrasound's unique array transducers constitute the sensor front-end in many leading sonar systems, and its innovative products are incorporated in a range of sonar devices used by the military and commercial companies. Through application of Strathclyde research, the company has experienced a significant period of growth during 2008-2013, with a three-fold increase in employees and turnover rising from £750k to £3.8M.