Haydale is a world leader in plasma treatment and nanomaterial functionalisation through its HDPlas process. This process sees sophisticated plasma reactors deliver tuneable levels of functional groups, chemically bonded to substrate surfaces. Using various types of plasma that confer different surface chemistries, including cleaning plasmas for targeted removal of chemical contaminants, 3- dimensional treatment is directed only at exposed surfaces, thus maintaining structural integrity.
Haydale uses its patented plasma process to develop bespoke solutions with varying levels of plasma treatment and functionalisation. Properties can be adapted to develop hydrophilic, hydrophobic, carboxylic, amine and oxidative modifications to a range of materials. These modifications improve the treated material’s incorporation into advanced materials. Currently, Haydale has plasma-treated over 250 different types of material that it has characterised and fingerprinted, enabling specific properties to be targeted in future projects.
Historically, Haydale has been able to provide a functionalised process through the dry plasma HDPlas process with maximum fuctionalisation levels of 21%. The existing graphene oxide market offers a material with traditionally 25 atomic percent oxygen atoms. Graphene oxide is produced by wet chemistry processes; this has issues with scalability and the length of time to produce a batch of material taking days. Typical methods involve environmentally hazardous by-products and unstable intermediates (potentially explosive). Graphene oxide is used for batteries and capacitors as well as in flexible electronics, solar cells, chemical sensors and bio-sensing and as an antibacterial defence.
Having a stable plasma process treating extremely conductive material is challenging, especially in a commercial and scalable process. Having already achieved 21% functionalisation through its scalable process, Haydale has a sound base on which it can build to increase the surface chemistry levels by having a more effective and efficient plasma and chemistry. Having a more powerful plasma means improving the engineering solutions. This includes, but is not limited to, the electrode, gas control systems, power delivery and generation, reaction barrel and chamber and materials of construction. By refining the design and implementing novel components that are bespoke for the application, the plasma can be further enhanced.
Haydale’s primary focus in enhancing the functionalisation levels are improved chemistries, including the feed of the process chemistry and potential mixed chemistry and staged functionalisation treatments. The system operates at a vacuum; the process chemistry is bled into the reaction chamber and, once the treatment parameters are established, the plasma can be struck.
In developing the 28% treatment levels, the above system, chemistries and processing conditions all need to be balanced to ensure a stable, non-arcing and repeatable process, as well as achieving the required output. As the effectiveness of the process increases, so does the aggressiveness of the plasma. If this is not balanced with the above parameters, arcing can occur; this means a sustained spike in electrical current that could lead to a thermal plasma which could be damaging to both the reactor and the material. The main outcome of this is a less effective treatment. Current is controlled by a combination of electrical interlocks and a well-balanced process.
Nonetheless, Haydale has been able to balance all of the above and achieve a repeatable and accurate treatment of levels that are comparable of the wet chemical methods of graphene oxide production. Verified in a letter of support by the Cardiff University, 28% Atomic Percent oxygen has been measured, targeting the existing graphene oxide market. No solvents or harsh chemical treatments are used in this dry and environmentally friendly process and a scalable proven process is already used in industry. This new system can also apply to Haydale’s other properties (hydrophilic, hydrophobic, carboxylic, amine etc.) providing the same environmentally friendly, scalable process now with even more surface chemistry.
Haydale is pleased to announce a new collaboration agreement (“the Agreement”) has now been signed between Haydale Technologies (Thailand) Co., Ltd. (“HTT”) and IRPC Public Company Limited (“IRPC”). The Agreement is to develop the Organic conducting-based printing smart fabric (Contract No. AL.0748/2563), by using Haydale’s functionalised technology, potentially for medical use and related applications.
Due to the COVID-19 pandemic, Haydale has been developing a functionalised graphene coated fabric. The Thailand Textile Institute (THTI) has carried out tests on the coated fabric that show antibacterial finishes in excess of 99.3% on the textile material after 10 washes (AATCC TM100:2012, Staphylococcus aureus ATCC6538 and Escherichia Coli DMST 4212 ATCC 25922).
Following tests, an agreement has now been signed with IRPC to develop the functionalised graphene coated fabric for medical use and related applications. These include the development of a new washable functionalised graphene-enhanced fabric mask. The scope of the project will be to focus on the commercial production of fabric and further development will take place to assess additional fabric properties such as Virus Filtration Efficiency (VFE), UV Protection and EMC protection.
The global healthcare PPE industry has an approximate value of 17 – 19 billion USD (Source: Frost & Sullivan), with huge growth seen in the personal healthcare industry. The graphene coated fabric will provide an additional solution to this industry.
This bespoke ink, developed by Haydale, will be delivered on an exclusive basis for commercial applications. IRPC and HTT have strong confidence that the new graphene coated fabric will be commercially available this year.
Dr. Roman Strauss, Vice President at IRPC, said: “Working together with Haydale, we see a substantial opportunity for a swift development of this product in the short time scales we have set ourselves.”
Keith Broadbent, Haydale CEO, added: “Working with IRPC we are able to quickly react to a current industry requirement. It is great to see that these products are benefiting from our core functionalisation process; particularly the antibacterial nature of the inks and the part they can play in the production of healthcare PPE. With the global PPE requirements continuing to grow, we anticipate this project to be very well received and look forward to seeing this progress to commercialisation.”
Haydale is pleased to announce that, further to a successful Phase 1 collaboration agreement announced on 1 March 2018 in the Interim Results, a Phase 2 collaboration agreement (the “Agreement”) has now been signed between Haydale Technologies (Thailand) Co., Ltd. (“HTT”) and IRPC Public Company Limited (“IRPC”). The Agreement is for IRPC to develop transparent graphene and functionalized acetylene black conductive inks for RFID, NFC and related applications.
The sustainable process sees Haydale functionalise IRPC’s acetylene black product to create the organic RFID ink. The success of this collaboration is expected to pave the way to numerous opportunities in printed electronic applications and be more environmentally friendly than existing inks. The RFID printer market is expected to be a significant market with the global market expected to reach approximately USD 4.82 billion by the end of 2023.
Under the Agreement IRPC will pay an upfront fee to Haydale following signing of contract, with a second payment following submission of the final report.
Dr. Roman Strauss, Vice President at IRPC, said: “This is very exciting and challenging at the same time for IRPC considering our core business in refinery and petrochemicals. However, working closely with Haydale will enable us to capture great opportunity in IoT megatrend.”
Keith Broadbent, Haydale CEO, added: “It is great to see this collaboration progress to phase 2. Our development in the area of RFID antenna is gaining real traction globally and making significant steps towards commercialisation. The RFID marketing is an ideal opportunity for Haydale’s unique solution.”
Haydale is pleased to announce that it has signed a distributor agreement between Haydale and Uwin chemical Technology Co., Ltd. The Agreement is for a period of 24 months and allows Uwinchem exclusive distributor rights to market Haydale’s products in Taiwan.
Uwinchem is a leading provider of advanced materials and chemical process solutions in Taiwan and the Agreement provides the opportunity for it to promote and supply Haydale’s functionalised graphene and other 2D materials to the Taiwan market.
Of particular interest are the medical, automotive and aerospace markets, where Uwinchem will promote composite materials, inks and sensors for semiconductor, thermal management and mechanical benefits.
Titus Huang, President at Uwinchem, said: “Uwinchem welcomes the addition of Haydale’s Graphene and 2D material products and solutions to its portfolio. With Haydale’s products already proven and in use in cutting edge automotive, aeronautical and medical applications, we welcome the opportunity to help clients improve performance significantly.”
Keith Broadbent, Haydale CEO, said: “We are pleased to partner with Uwinchem on its specialist technical areas of expertise. We believe our current range of products and services will provide the next level ground-breaking products in the Taiwanese Market.”
Haydale, the global advanced materials group, has been awarded an Innovate UK Analysis for Innovators (A4I) project to explore the mechanisms by which the Haydale plasma functionalisation processes enables property improvements in polymers containing functionalised nanomaterials; properties such as mechanical strength, thermal, and electrical conductivity.
The project enables Haydale to gain access to world leading experts and cutting-edge facilities by collaborating with the National Physical Laboratory (NPL) and the Science and Technology Facilities Council (STFC) Hartree Centre.
The data produced in this project will help Haydale build on the significant progress it has already made in this area. It will enable Haydale to focusthe development of its entire product range; allowing quick and efficient selection of improved functionalisation chemistries that can optimise the performance of its current products.
Haydale has a range of plasma functionalised nanomaterial (HDPlas®) products which are dispersed in a variety of polymers to enhance customer products. Numerous developments conducted within Haydale have demonstrated that the use of its patented HDPlas® plasma technology is effective in imparting specific functional groupsto the nanomaterial surface for improved compatibility within the host polymer. This nanomaterial surface functionality leads to property enhancements in the final products above and beyond the use of un-functionalised nanomaterials.
This project aims to uncover this mechanism using a dual approach of advanced analytical techniques at NPL and modelling at STFC Hartree Centre. The approach of using analytical facilities with complementary modelling will ensure that the highest level of information is obtained, and that any conclusions are drawn with a high level of confidence and accuracy, thereby potentially enabling product and process development.
Keith Broadbent, Haydale CEO,said: “Haydale has a wealth of knowledge and expertise which hasled to the patenting of its HDPlas® functionalisation process. This analysis by both NPL and STFC will provide more data and practical understanding enabling us to further understand where our nanomaterials will provide benefit and continue to develop our unique processes to ensure we keep in the vanguard of this technology”
Barry Brennan, NPL Senior Research Scientist, said: “Understanding the chemistry of nanomaterials after industrial processing steps is crucial in determining the performance-enhancement in real-world products. We look forward to collaborating with Haydale on their functionalisation process.”
Haydale, the global advanced materials group, is pleased to announce that it has signed an exclusive distributor agreement between Haydale and Dalian Yibang Technology Co., Ltd. The Agreement is for an initial period of 4 years and allows DLYB exclusive distributor rights to market Haydale's electrically conductive graphene-enhanced masterbatch in the Chinese and Taiwanese markets.
The Agreement sees DLYB pay Haydale an initial licence fee and thereafter, the parties will work towards completion of field testing, securing the requisite licences and final certifications from the relevant authorities. Haydale will supply masterbatch and associated consultancy services at an additional cost during the pre-commercialisation phase of the Agreement. Haydale expects the contract to move from the R&D to the commercial phase in 2021 and the parties have agreed minimum annual revenue thresholds which commence at US$300,000 for the calendar year 2021 and increase annually thereafter. In order to ensure the highest standards of quality assurance, the parties have agreed that all masterbatch will be supplied by Haydale from its facilities.
DLYB has been at the forefront of introducing and servicing high-end imported products for 15 years in China, which included the introduction of copper mesh for the purpose of lightning strike protection in both aerospace and wind energy sectors. It has obtained the international aviation quality management certification AS9120 and focuses on cutting-edge and high precision materials and technical solutions for aerospace, marine, railway, wind power, battery energy and industrial filtration industries. Using its existing experience and access to market, DLYB expects to use Haydale's electrically conductive graphene-enhanced masterbatch technology to develop and sell applications into these sectors. Examples of these applications are focused on electrical screening, control of edge glow and the development of lightning strike products for the civil aviation, defence, UAV and wind energy markets.
Yuefeng Zou, CEO at DLYB, said: "Having already introduced leading-edge technology to prevent lightning strike into the Chinese Aerospace and wind energy industries, we are delighted to be working with Haydale and its world leading technology to introduce the next generation of environmentally friendly technology in this field."
Keith Broadbent, Haydale CEO, said: "We are pleased to announce this partnership. With the extensive expertise of Haydale, alongside the market knowledge of DLYB, this new contract will open up fantastic opportunities for the commercialisation of this state of art technology in both China and Taiwan."
Haydale is pleased to announce that, following its contract announcement on 18th September 2018, it will now collaborate with the English Institute for Sport (EIS) and the Welsh Centre for Printing and Coating (WCPC) to deliver a range of advanced wearable technology sport apparel for elite athletes.
Haydale is pleased to report that initial prototype testing has been completed in live performance sessions with elite athletes with very successful results for wearability through its unique coating systems. Alongside supply chain partners, a range of garments are being manufactured in higher quantities for further use in elite sport settings, focusing on efforts to develop flexible and miniaturised electronics. This enhances product feel as well as reducing weight, allowing for optimised athlete performance.
Haydale will now continue to produce performance garments for a range of elite sports in readiness for the Tokyo Olympic and Paralympic Games 2020, supporting the British Olympic and Paralympic teams in innovation and performance gains. Continued collaboration with WCPC & Swansea University has allowed leading scientific research to underpin this product launch.
Dr Matt Parker, Director of Performance Innovation for EIS, states, "To move so quickly to realise the benefit of this new technology in the training environment is testament to everyone involved. To develop a product quickly to meet the specific needs of athletes you need partners who will rise to the challenge with you. We're delighted to have delivered the first of many wearable technology solutions to our athletes."
Keith Broadbent, CEO at Haydale, commented, "It is great to see the reward of this project with EIS and WCPC and we look forward to seeing elite athletes benefit from the improved performance offered through the adapted garments."
Posted By Graphene Council,
Wednesday, September 11, 2019
Updated: Thursday, September 5, 2019
Haydale has been awarded a technology de-risking project by the European Space Agency (ESA), to develop non-metallic gas tanks for spacecraft propulsion systems. This activity is alongside ISP International Space Propulsion Ltd through the ESA ARTES Competitiveness & Growth, in conjunction with UK Space Agency.
The recent market growth of small spacecraft constellations has created a challenge within the existing space propulsion supply chain for low-cost reliable components, which meet the rapid delivery schedule and support the on-going reduction of orbital debris. With the constellation market set to increase rapidly, the development of components that meet these criteria is critical. Haydale’s non-metallic system offers a low-cost alternative with reduced lead time that can be offered in a wider range of configurations to exactly suit the end user requirement.
This award follows on from the successful outcome of the GSTP project in 2018 performed with ESA and the UK Space Agency (UKSA) entitled “Assessments to Prepare and De-Risk Technology Developments - Tank using Advanced Composites.” This latest project will see Haydale develop findings from the GSTP project, performing comprehensive tests to determine the best material and process for developing non-metallic gas tanks.
Upon careful consideration and selection of both material and process, Haydale will formulate and model a largely de-risked tank, prior to the manufacture of development models for full testing. This will result in the qualification for specific Spacecraft Propulsion Systems.
The role of this equipment is to store pressurised gas in a location onboard the spacecraft platform, in a manner that is intrinsically safe, and offers reliable provision of stored media, as and when required by the system. Within this equipment, the product will offer; leak-free storage and delivery on demand of all propellant and pressurised gases stored within, under specified environmental conditions and expected transient load cases; high pressure storage capabilities, with required levels of safety and reliability; highly reliable connections to the feed system and mechanical mounting;
Prominent producers of Satellite technology have been identified and are engaged in developing the specification and tank design for eventual manufacture and deployment.
Keith Broadbent, CEO, Haydale, said: “This funding will allow Haydale to develop existing knowledge in the space industry and we look forward to developing the technology alongside our partners. We are pleased to have gained the support of the Airbus DS Tank Product Group who are interested in the development of competitive non-conventional pressure vessel products, and can provide clear design drivers thanks to their invaluable expertise. With the UK space market growing, Haydale is delighted to be part of this progression.”
Haydale announces that its graphene-enhanced prepreg has now been incorporated in the composite tooling and automotive body panels of the new 'BAC Mono R', which made its debut at Goodwood Festival of Speed.
Briggs Automotive Company (BAC), working alongside both Haydale and Pentaxia, has built the lightweight BAC Mono R body using Haydale’s graphene-enhanced carbon composite materials.
The component parts have been formed using Haydale’s graphene-enhanced tooling materials. The outcome of the process for manufacturing the body parts is a full visual carbon material which can be lacquered or painted as required. Utilisation of graphene-enhanced tooling materials offers the potential for significant improvements in the following aspects:
The coefficient of thermal expansion (CTE) – is more closely matched when using composite tooling. A key issue with the use of metal tooling is a significant mismatch in (CTE)
The need for superior quality – higher dimensional stability tooling is increasing the demand for composite tooling
Current composite tools also suffer from a finite life - wearing of the tool surfaces and microcracking. The use of graphene has the potential to increase the life of the tools
Keith Broadbent, CEO at Haydale, commented: “In the development of this project, Haydale has improved the supply chain and cycle times as well as enabling BAC to reduce weight and increase performance of the material. Whilst this outcome has focused on the automotive sector, the knowledge and improvements made provide a wider opportunity for tooling materials across several markets, particularly where there are throughput constraints.”
Ian Briggs, Design Director at Briggs Automotive Company, added:
“BAC is forever an innovator, and being able to release a new car fully incorporating the use of graphene is just another example of how we’re pushing the boundaries. Niche vehicle manufacturers are of paramount importance in the automotive industry, acting as stepping stones for mass-market production technology – and after the overwhelming success of our R&D project with Haydale and Pentaxia, Mono R could well be a stepping stone for graphene-enhanced composite body panels and tooling reaching the wider automotive industry in the near future.”
Haydale plc has been working with the UK's National Grid to calculate the benefit case of its Composite Transition Piece (CTP), using a method developed by National Grid and verified by PwC during a previous audit. This approach provides a risk rating for the benefits. In this case the risk was assessed by National Grid as ‘low’, meaning that National Grid can have a high level of confidence in the results it will achieve.
There are around 300 locations on the National Transmission System in the UK where gas pipes pass through reinforced concrete walls, for example into valve pits. Currently, several types of seal are used to prevent contamination by water or soil, but when these seals fail technicians face a major task to fix the problem.
National Grid has found that Haydale’s CTP represents a huge step forward in safety and efficiency, solving a major problem for the national gas transmission network at a reduced cost over the system’s life-time. The solution allows easy access to transition pipes at pit wall transitions for inspection and maintenance. Working in conjunction with National Grid, the innovative CTP seal units can be used to plug the gap between the pipe and the wall. It means that technicians can easily remove the unit and check the pipe for corrosion or damage. The CTP can then be replaced quickly in one simple operation.
Financially, the benefits of installing a CTP are significant especially when viewed over the entire design life of the unit. Taking less time to inspect the pit wall area with a CTP fitted means that just under £230k could be saved over a design life of 50 years per unit installed. This is comparing an inspection using the traditional methods with the composite solution.
In addition to the cost benefits, National Grid estimates that 700 fewer hours of ‘at risk’ activities will be needed for each CTP during its design life. Working on the pit wall requires technicians to work inside a pit which may be several meters deep. Benefits can be tracked after the first inspection and continue for the entire design life of 50 years per unit, this can subsequently be extended further following a simple replacement of the seal around the CTP.
There are also environmental benefits and National Grid have calculated that the new approach will save 12 tonnes of carbon equivalent (CO2e) for each CTP over its 50-year lifespan. This is determined by examining tasks such as excavating soil to expose the pit wall and generator power needed on site for the duration of the works
Two key compressor sites have already undergone large-scale works where National Grid have utilised the new CTPs. In total, eight new CTPs have been pre-fabricated and will be installed during the construction of the pit wall, further reducing installation costs. These units, along with one that was installed as part of the original trial, will start to provide benefits after their first inspections.
David Banks, Chairman at Haydale, commented: “With 9 CTPs planned for installation by the end of 2019, we look forward to seeing the benefits realised by National Grid. We look forward to continuing our work with the utilities industry, where the benefit of both composite materials and graphene are now being appreciated.”
Keith Broadbent, CEO at Haydale, commented: “Haydale is pleased to be working with National Grid on this system which is a huge step forward in safety and efficiency for the gas network. With £228,000 average savings per CTP design life and 700 fewer hours carrying out ‘at risk’ activities for each CTP over 50-year period, it is clear to see the benefit that the system offers to the customer.We look forward to working with gas infrastructure owners worldwide who can also benefit from
Paul Ogden, Senior Civil Engineer at National Grid, commented: “Over a six-year period, National Grid expects to install about 60 CTPs on the National Transmission System. This will significantly improve safety as well as creating savings of up to £5 million in the next five to 10 years.”