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Haydale graphene-enhanced composite tooling and automotive body panels

Posted By Graphene Council, The Graphene Council, Wednesday, July 17, 2019

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.”

Tags:  Briggs Automotive Company  Graphene  Haydale  Ian Briggs  Keith Broadbent 

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UK's National Grid Verifies Viability of Graphene Composite Application

Posted By Graphene Council, The Graphene Council, Tuesday, May 21, 2019
Updated: Monday, May 20, 2019
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
the product.”

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.”

Tags:  composites  David Banks  Graphene  Haydale  Keith Broadbent  National Grid  Paul Ogden 

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Contract awarded to develop graphene ink-based heaters for gas pre-heating

Posted By Graphene Council, The Graphene Council, Wednesday, March 6, 2019
Updated: Wednesday, March 6, 2019
Haydale, is pleased to announce it will be collaborating with Northern Gas Networks (NGN) and the Energy Innovation Centre, on a study to investigate the feasibility of developing a modern, innovative, fully compliant graphene-based preheat solution for use on gas operational sites.
 
The graphene solution has the potential to be more efficient and reliable than existing systems and has in-built flexibility to either retrofit onto existing pipes or to be built into new heat exchangers. Phase One of the 30-week project will see Haydale working directly with NGN, the gas distributer for the North East, Northern Cumbria and much of Yorkshire.
 
Modern gas pre-heating systems, whilst more efficient than traditional Water Bath Heaters (WBHs), have larger electrical power requirements and require backup generators to remain operational in the event of a power cut. Maintaining gas supplies is of vital importance to the Gas Distribution Networks and as such, backup power is used to ensure that sites can remain operational should the electrical supply be interrupted.  
 
WBHs are gas-powered and use low voltage solenoids in their control, so can remain operational from the very low voltage (VLV) supply which is backed up by batteries on site. WBHs however can be considered inefficient both environmentally and in terms of heat transfer.
 
Development of graphene-based, high conductivity inks and coatings that can be applied to surfaces have the potential to provide even heating across large areas with a very thin profile. This technology is made possible by Haydale’s patented HDPlas process which promotes efficient dispersion of nanomaterials into polymers and carriers. 
 
With this innovative technology, flexible construction methods have the potential for several different solutions such as external fitment to existing pipes, internal fitment to existing pipes or integration into new replacement composite pipe sections which may include heat-exchanging internal surfaces. 
 
Should this initial feasibility project prove successful, future development stages will progress to field-based trials.
 
Dr Matthew Thornton, Senior Manager for Haydale Composite Solutions, said: “We are excited to be working with NGN and EIC to develop our graphene-based heater technology for use on the gas distribution network. The opportunity to demonstrate the feasibility of graphene-based heaters as a viable alternative to incumbent pre-heat systems presents a fantastic opportunity for Haydale in this innovative sector.”

Keith Broadbent, COO for Haydale, said: “This solution for the gas networks shows another commercial route for the functionalised graphene inks that are being produced by Haydale. We look forward to working with both Northern Gas Networks and the Energy Innovation Centre to progress this route to market.”
 
Gareth Payne, Project Manager for Northern Gas Networks, said: “I’m really excited to be leading this project on behalf of NGN, working with Haydale Composite Solutions and supported by the EIC. If this project proves successful, then we could be looking at a real game changer in terms of preheating systems that can be utilised on gas distribution sites. We hope this project will lead to collaborative working with other networks to develop the idea further, as NGN continues to explore low-carbon technologies in order to deliver a cleaner, greener future for customers.”

David Turner-Bennett, Gas Innovation Engineer for the Energy Innovation Centre, said: “We are thrilled to be facilitating this project with NGN and Haydale. This project has the potential to revolutionise pre-heating systems in the gas industry and demonstrates NGN’s commitment to securing a low-carbon future. It’s a pleasure to work with and support a ground-breaking project that involves people like Gareth and Matthew who are passionate about change. We hope to see other networks follow NGN’s lead and collaborate to develop this idea further.”

Tags:  Graphene  Haydale  Keith Broadbent  Matthew Thornton  nanomaterials  Northern Gas Networks 

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Haydale in Collaborative SMART Expertise Programme on Applications of Functionalised Micro & Nano Materials

Posted By Graphene Council, The Graphene Council, Tuesday, February 12, 2019

Haydale is pleased to announce that it is working alongside Swansea University, GTS Flexibles, Alliance Labels, Tectonic International, ScreenTec, Alliance Labels, Malvern Panalytical and the English Institute of Sport on a Welsh Government SMART Expertise Program. The programme, funded by the Welsh Government as part of its European Development Fund, is intended to benefit industry in Wales through the development of new concepts and advanced functionalised inks using Haydale’s advanced materials.

Combining expertise from across the consortium, the programme will see the creation of a product pipeline for the scale up to volume production of Applications of Functionalised Micro & Nano Materials, also known as the AFM2 Product Pipeline. This is designed to speed up the process required to take products from proof of concept into volume and profitable products. With a focus on market pull, the AFM2 Product Pipeline will turn a demand driven idea into a bench prototype followed by pilot production for market and customer evaluation.

The first examples to shape this pipeline development will be provided by the English Institute of Sport (EIS), Tectonic and GTS Flexibles, with an intention to generate a steady feed of new concepts into the pipeline to ensure its sustainability beyond the project.
 
As previously announced, Haydale, in collaboration with WCPC, has developed and refined a range of proprietary printing inks utilising its functionalised graphene for the development of advanced wearable technology to be embedded into a range of apparel for elite athletes in training for the 2020 Olympic and Paralympic Games. The functionalised inks fulfil a range of functions in sensing and conditioning, combined with ease of printing for use in the rapidly growing wearable technology market. 
 
Professor Tim Claypole MBE, Director, the Welsh Centre for Printing and Coating, Swansea University, said: “This is a really exciting project which will take innovative concepts manufactured by printing of advanced functional materials and rapidly transitioned them from proof of concept into volume, profitable products. It will drive more applications for inks containing the unique functionalised nano carbons created by the Haydale Plasma Functionalisation process.”
 
Keith Broadbent, Haydale COO, said: “The close relationship with our colleagues at WCPC is now bearing fruit with a range of robust, stable, high performing functionalised inks and coatings emerging from extensive development work and finding applications in wearable technology, printed sensors and thermal management.”

Tags:  Alliance Labels  Graphene  GTS Flexibles  Haydale  Malvern Panalytical  ScreenTec  Swansea University  Tectonic International 

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World’s First Graphene Skinned Plane

Posted By Terrance Barkan, Monday, August 13, 2018

 

 

The University of Central Lancashire (UCLAN) made an announcement about the recent unveiling of the world’s first graphene skinned plane at the internationally renowned Farnborough air show.

 

Haydale, (AIM: HAYD), the global advanced materials group, has supplied graphene enhanced prepreg material for Juno, a three-metre wide graphene-enhanced composite skinned aircraft, that was revealed as part of the ‘Futures Day’ at Farnborough Air Show 2018.

 

The prepreg material, developed by Haydale, has potential value for fuselage and wing surfaces in larger scale aero and space applications especially for the rapidly expanding drone market and, in the longer term, the commercial aerospace sector. By incorporating functionalised nanoparticles into epoxy resins, the electrical conductivity of fibre-reinforced composites has been significantly improved for lightning-strike protection, thereby achieving substantial weight saving and removing some manufacturing complexities. 

 

The Juno project, led by UCLAN, has been an ideal demonstration for the viability of the prepreg material for structural applications and the ability to manufacture components using traditional composite manufacturing methods. Further developments are underway to produce the next iteration of lightning strike protection materials based on these nano-carbon enhanced prepregs.

 

This technology also has performance benefits for a wide range of applications and industries including large offshore wind turbines, marine, oil and gas, and electronics and control systems.

 

Haydale worked with the aerospace engineering team at University of Central Lancashire, Sheffield Advanced Manufacturing Research Centre and the University of Manchester’s National Graphene Institute to develop the unmanned aerial vehicle, that also includes graphene batteries and 3D printed parts.

 

Ray Gibbs, Haydale CEO, said: “We are delighted to be part of the project team. Juno has highlighted the capability and benefit of using graphene properly dispersed into composite materials to meet key issues faced by the market, such as reducing weight to increase range, defeating lightning strike and protecting aircraft skins against ice build-up.”

 

David Banks, Haydale Chairman, said: “The unveiling of this plane shows how the use of graphene can offer great benefit to the aerospace industry, highlighting the potential near term commercial impact of graphene within this significant market.”

Tags:  Aerospace  composite  functionalized graphene  Haydale  Juno  Prepreg  UCLAN  University of Central Lancashire 

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Haydale Technologies and Imagine Intelligent Materials sign strategic partnership agreement

Posted By Terrance Barkan, Monday, October 30, 2017
Updated: Monday, October 30, 2017

Haydale Technologies and Imagine Intelligent Materials have signed a strategic agreement to establish graphene-based conductive coatings capability in North America.

The agreement includes:

  • Haydale to acquire exclusive license to Imagine IM’s “Plant In A Box” graphene processing technology
  • Establishes US supply chain for revolutionary graphene-based conductive coatings that are purpose-designed for global US$22bn geosynthetics marketplace
  • Coatings product proven in Australian market and being installed as part of Coal Seam Gas containment systems to enable hole detection pre-final commissioning
  • Haydale will import inventory of imgne® X3 to support planned field trials and early adopter orders

The signing of a Letter of Intent (LOI) between Haydale and Imagine IM marks the first step in establishing a strategic collaboration between two companies that are leading globally the development of commercial applications using graphene.

In parallel with this, Haydale has issued a Purchase Order to Imagine IM for a quantity of Imgne X3 that will be sufficient to enable 50,000m2 of conductive geotextile to be manufactured. This will ensure that there is available supply in the US ahead of the commissioning of a full-scale plant at Haydale’s manufacturing facility in Greer, SC.

The first full-scale Imagine IM graphene research plant was officially opened in August 2017 by Australia’s Assistant Minister for Industry, Craig Laundy. This followed the establishment of a pilot plant in 2016. The Assistant Minister, opening the plant, said: “Imagine IM have demonstrated a capacity to both develop and manufacture highly effective end products which have revolutionary implications for manufacturing industries in Australia. They’ve done that by embracing new technologies, linking with global value chains, and developing high value-added products.”

The agreement between Haydale and Imagine IM Is intended to enable more industrial end-users to accelerate the take up of graphene-based composites and coatings into global advanced manufacturing supply chains. It will also mean that production of materials that make geosynthetic materials “smart” will be fast tracked in the US.

Chris Gilbey, CEO of Imagine IM said, “Combining Imagine IM’s proven graphene manufacturing processes with Haydale’s advanced materials manufacturing expertise will be a significant step toward delivering disruptive graphene-based coatings solutions into the North American market. It comes on the back of successful product installations in Australia and a full order book for product to our licensee Geofabrics Australasia, the leading textile manufacturer in Australia.

Ray Gibbs, CEO of Haydale Graphene Industries PLC, said “This is a very important strategic step in Haydale’s global growth plan.  This partnership builds on our existing nano dispersion know how and patented material doping technology  and now extends our graphene footprint in the US. It also gives Haydale direct access to the world’s largest market for coated geosynthetics.  This is just the what we see as a major opportunity for further collaboration with Imagine IM on a wide range of graphene enhanced applications.”

Trevor Rudderham, President and CEO of Haydale Technologies Inc, said, “We are very pleased to sign this strategic agreement with Imagine IM. They are an impressive company with world leading product and process technology in the graphene arena. This will be Haydale Technologies first graphene related manufacturing initiative in the US and is an exciting development for us.  Our team in Greer, SC has the process engineering, application expertise and sales capability in advanced materials to ensure this will be a very successful endeavour for both Haydale and Imagine IM.”

Note: Haydale Graphene Industries and Imagine IM are Corporate Members of The Graphene Council.  

Tags:  conductive coatings  conductive geotextile  Haydale  Imagine Intelligent Materials 

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Graphene Commercialization is closer than you think.

Posted By Terrance Barkan, Friday, October 21, 2016

When we conducted our survey of more than 400 graphene researchers, developers, producers and users earlier this year, less than 10% thought that graphene was a sustainable commercial market today. However, almost 2/3’s felt that graphene would develop into a sustainable commercial market in 6 years or less. (Survey 2016)

 

Based on the feedback and discussions at the Graphene Canada 2016 conference held in Montreal recently, graphene commercialization is a lot closer than most people are aware. 

 

Because graphene has properties that can be applied to such a wide range of potential applications, it is not always easy to see where this material is already being used or where development is most advanced. 

 

A graphene “killer application”?

 

There has been a lot of hype around graphene because of its superlative properties and the promise it holds for radical or revolutionary new applications, products and solutions.

 

There has been an equal measure of disappointment that it has not yet produced a “killer application”, a solution that solves a major problem that is possible because of graphene’s unique properties. 

 

The less sexy, but much more likely path to successful commercialization of graphene, lies in its use in more traditional materials like composites, thermosets (such as epoxies, polyurethane and polyester) and plastics. 

 

For example, Huntsman Advanced Materials (a division of the Huntsman Corporation, a publicly traded global manufacturer and marketer of differentiated chemicals with $10 billion in revenues) is working with graphene specialist firm Haydale to develop graphene enhanced ARALDITE® resins for composite applications. These products are used in the industrial composites, automotive and aerospace markets.

 

 

Huntsman's ARALDITE® resins are being enhanced using Haydale’s expertise in functionalisation of Graphene Nano Platelets (GNP’S) and other nano materials to create highly loaded master batches and to improve thermal / electrical conductivity and mechanical performance. The ultimate objective of the collaboration will be to commercialise graphene enhanced ARALDITE® resins for a range of applications in the

composites market.

 

It is telling that Huntsman, a company whose chemical products number in the thousands and are sold worldwide, has identified graphene as a critical new additive to enhance one of their most important industrial products. 

 

The global polymer market alone is worth at least $658 billion. Even if only a small percentage of this market begins using graphene as a standard additive to improve product performance, it will help support a viable market for graphene producers and formulators. 

 

Better Together

 

Additive Manufacturing, or 3D Printing, is a relatively new and exciting area of activity that is revolutionizing how objects are designed, prototyped and made. It is also a perfect example of how graphene can be used in combination with other traditional materials to create new capabilities and products. 

 

There are already three companies that offer graphene impregnated 3D printing filaments (Haydale, Graphene 3d Labs and Directa Plus) that are in turn letting creative designers develop products that are electrically conductive or that have superior physical properties (stronger, scratch resistant, better UV protections, etc.). 

 

Graphene is added to traditional polymers, paints and coatings to change their performance characteristics. Another company, NanoXplore is producing products as far ranging as specialty paints to fishing buoys (floats that are used in conjunction with fishing nets, crab pots, and related applications) that use graphene to make these products more robust and survivable in very harsh marine environments. 

 

 

What is unique about graphene is that it can make a significant improvement with very small loadings (as little as 1% or less) as compared to competing materials that may require as much as 25-30% loads to make significant performance differences. 

 

What this means is that although graphene materials are currently quite expensive per gram or kilogram, the very low loading levels makes graphene a competitive additive on a cost / benefit basis. 

 

The Future

 

It is difficult to overstate the enormous potential graphene holds to impact an almost unlimited range of industrial sectors, from water treatment to aerospace, from opto-electrical sensors to energy storage, from bio-medical applications to basic materials. 

 

So while university scientists and corporate research and development departments around the world continue to work on the more complicated problems where graphene might disrupt industries like semi-conductors or new generation photocells, graphene is proving its worth in somewhat mundane but equally important industrial materials applications. 

 

Tags:  3D Printing  Commercialization  Directa Plus  Fullerex  Graphene 3d Labs  Haydale  Huntsman  NanoXplore  Paints 

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