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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).
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 has led to improvements in the performance over 16 million water meters manufactured by Elster Metering Ltd. since 2008, extending their working lifetimes and reducing maintenance costs. In particular, research on polymeric replacements for the glass in water meters helped Elster establish their product development strategy, and led to changes in the manufactured meter. Brunel University research identifying a specific set of acetal polymers that reduce the degradation of the bodies in water meters has been incorporated in 1.8 million water meters. These meters have less embodied carbon dioxide, and are less prone to theft than the meter with brass components they replace. This innovation allowed Elster to reduce the costs of manufacturing in the UK, thereby maintaining a strong competitive position within the market for water meters.
Fundamental research in collaboration with Royal Mail into luminescence molecules constrained within a water-soluble acrylic polymer matrix has led to the development of novel, water-soluble, ink-jet printable, luminescent inks. These inks are employed by Royal Mail for printing coding patterns on envelopes that can be read by automatic letter-sorting machines. The inks offer excellent performance in humid environments, on coloured paper, and on paper containing optical brighteners, and are safer. Royal Mail delivers, on average, 58 million letters each day, representing annual revenue of £5.2 billion. The research at Lancaster enabling the innovation has a direct impact on the commercial performance of Royal Mail, the safety of its employees and the public, and everyone (commercially and/or privately) using Royal Mail services to send and receive mail correctly, quickly, and at a low cost.
University of Surrey has a strong legacy of research into membrane separation and osmosis, culminating the commercialisation of Surrey's spin-out company Modern Water plc. Modern Water plc. was floated on AIM (London Stock Exchange) in June 2007 raising £30m cash with a market value of £70m.
The research itself is having direct impact via the operating desalination plants in Gibraltar and Oman producing high quality drinking water typically using 30% less energy than conventional desalination plants. In Oman, because of the poor quality of the feed water the forward osmosis process uses 42% less energy per litre of water produced when compared to convential equipment. The two plants currently operating in Oman serve 600 people in Al-Khuluf and 800 people in Naghdah.
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.
New characterisation tools for natural organic matter (NOM) in drinking water are now used as standard practice within water companies such as Severn Trent Water, United Utilities and Yorkshire Water. The tools inform decisions, and help develop strategic plans on catchment management, source selection, treatment optimisation, and disinfection practice. Water companies experienced difficulties in treating high levels of NOM. Cranfield created a novel characterisation toolkit to measure NOM for its electrical charge and hydrophobicity. Also, new techniques for measuring aggregate properties and emerging disinfection by-products have provided a comprehensive analysis. Two novel treatment technologies are currently marketed. These technologies have raised international interest, resulting in industrial development in Australia.
Initial research into polymer nanocomposites and their formation took place at Strathclyde from 2000 - 2010. This was followed by a collaboration with the world's largest manufacturer of composite kitchen sinks, Carron Phoenix Limited, through a 6-year Knowledge Transfer Partnership (KTP) which resulted in a successful new production process of its high-end synthetic granite kitchen sinks. This led to £4 million of capital investment in new production facilities at their Falkirk site, enabling the company to sustain its leading position in the designer kitchen sink market and retain its workforce of over 400 employees in central Scotland, including the 170 workers in the composite sink division in Falkirk. Within the REF period, the research has led to the manufacture and sale of in excess of one million kitchen sinks, generating sales revenue in excess of over £50M and supporting the UK economy.
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.
Research at Brunel University demonstrated how the Powder Impression Moulding (PIM) process can be adapted to form a solid-skinned and foamed core polymer lightweight sandwich panel from 100% mixed post-consumer polymers. The research showed that unlike conventional plastic recycling technologies, this process was tolerant to high concentrations of impurities. It was also shown that coarse flakes could be used as feedstock, removing the need to grind the feedstock to a fine powder. This, for the first time, established the PIM process as a recyling method and provides a source of income for industries collecting post-consumer plastics. In 2009, ERT Plc, who own the IP associated with PIM, signed a licence agreement with 2K Manufacturing Ltd to manufacture and sell a range of flat-board products made from 100% mixed post-consumer plastics. These boards are sold as EcoSheets and are 2K Manufacturing's only product. 2K buy post-consumer recycled plastics from recycling firms who run Municipal Recycling Facilities, (MRF), providing them with increased income from waste collected from consumers, and sell EcoSheets to a variety of industries and distributors for applications in construction, agriculture, flood control facilities and military uses. For commercial reasons, exact production and sales figures are not available, but we estimate that at least 1 million boards have been produced and sold since 2009. The impact on the end user is that, although the price of an EcoSheet is comparable to the plywood board it replaces, EcoSheet does not rot, is more workable, and can be recycled several times.
ERT Plc have licensed the technology enhanced by the Brunel research to a number of other businesses.Thus the research at Brunel has assisted the creation of a new industrial sector, and a new product with many advantages, including reduced reliance on virgin polymers and reduced environmental burdens (such as landfill costs), over the product it replaces. This has created economic and environmental benefits at all stages of the consumer plastic cycle, creating new industries and jobs.