UK Elastomers and Rubbers Roadmap Updated June 2016

Transcription

1 UK Elastomers and Rubbers Roadmap Updated June 2016

2 INTRODUCTION The strategic importance of elastomers and rubbers to nearly all industry sectors in the UK is not fully appreciated. In the UK, the scale of the elastomers and rubbers industry comprises around 500 companies employing 23,000 people with a turnover in excess of 4 billion (Office of National Statistics - UK Manufacturers Sales - Rubber Products). Natural rubber, which is predominantly polyisoprene, has had over a hundred years of development, predominantly incorporating carbon black for tyres. However, synthetic elastomeric materials (elastomers) are sometimes regarded as having a rather dirty image, which was once prevalent in the traditional rubber industry. Today, both elastomers and rubbers are part of many varied developments - as seen by low profile, anti-skid tyres with low noise levels and improved fuel efficiency. They also feature in flexible medical devices and show future promise in products for harsh environments and in flexible electronics. It is estimated that over 50,000 products are based on elastomeric materials. In addition, the prospects for new products, many enabled by nanotechnology, highlight the need for the UK to establish itself as a leader in these new and exciting developments across so many sectors. The Knowledge Transfer Network (KTN) has developed a roadmap for the next five years that will enable academics and companies to work together to benefit from the future impact of elastomers and rubbers within areas that are of particular importance to the UK such as the oil & gas, medical, and defence sectors. KTN has been involved in several strategy documents in the past. The UK produced a roadmap on rubber, Rubber Technology Roadmap 2003, over ten years ago (published in Polymer Process Engineering 03, Editor P D Coates, ISBN ). In 2007 a further document was produced, UK Elastomer Research & Future Direction, which updated the original roadmap. It also contained a substantial summary of many related roadmaps that had been produced throughout the world. In 2014, two workshops were held to refresh and bring the past elastomer and rubber roadmap documents up to date by bringing together the current key players and the wider community. The first event covered the key players and was held at the Institute of Materials, Minerals and Mining, London on 21 March Delegates were from some of the larger UK companies, trade organisations and academia. One of the outputs from the event identified the need to consult the wider rubber, soft matter and design community. Today, the elastomers and rubbers community is broader than the older, traditional rubber goods producers. The second event brought together designers and industry as well as research organisations and was held at Queen Mary University London on 26 June Contributors for both workshops are tabled in Appendix 1. Since the publication of the original Elastomers and Rubbers Roadmap in 2015, progress has been made with the establishment of a centre of excellence and the provision of training in elastomer expertise. These activities are highlighted in the updated infographics on pages 4 and 11. Alternative production of natural rubber Current production of rubbers and elastomers is around 27m tonnes annually, with two thirds being used for tyres. Natural rubber accounts for about half of the annual production (13 million tonnes). In 2014, global demand for natural rubber outstripped supply by 500,000 tonnes. To address this problem, Czech company Mitas is involved in a European project that has put to test agricultural tyres produced from a specific variety of dandelion that produces natural rubber in its tap roots and can be cultivated in temperate regions throughout Europe. 2

3 METHODOLOGY The methodology used for both the recent workshops followed the same procedures employed during the production of previous roadmaps. Experts, in groups of around five to ten, are asked to provide their thoughts and opinions for the four main stages of the process: Where are we now? Where do we want to be? What is stopping us getting there? What needs to be done to overcome the barriers? At each stage, ideas are written down and clustered under common topics before a spokesman from each group presents their findings. This draws comments from the rest of the participants and generally results in a consensus of opinion. Using adhesive stickers, priorities are given to what are considered the most important issues for the second stage of the roadmapping process, enabling a key priority list to be established for subsequent steps. The final outcome is a list of priority items that need action in order to enable the industry to progress in a more dynamic and competitive manner. OUTCOME From all the thoughts and ideas generated by the workshops, the key issues have been grouped together before being prioritised and given approximate timescales. For this roadmap, the important issues that need attention are: Infrastructure Awareness Market focus Technology development Funding and collaboration 3

4 Infrastructure Elastomers and rubbers are used in most industry sectors. Applications are wide and vary from earthmoving vehicle tyres to seals in medical metering valves. Bringing such a diverse community together and finding common ground is therefore difficult. The situation is not dissimilar to that faced by the UK s composites industry in recent years. KTN has played a major role in drawing together the wider composites community into a better coordinated network, which is beginning to work together for the common good. Because of the fragmented interests in elastomers and rubbers it is difficult to obtain meaningful data showing the clear importance of the area to the UK economy. It is similarly difficult to provide market forecasts stemming from the opportunities made possible by nanotechnologies, such as conducting elastomers and vastly improved barrier properties. An Elastomers and Rubber Network should provide information on new market activity by both UK and non-uk companies and also report on new technology developments. What is arguably needed is a Catapult for Elastomers and Rubbers. Innovate UK funds Catapults to encourage economic growth. These are technology and innovation centres where the best of UK Establish a forum and website to inform the elastomers community c.f. composites in UK Centre with specific focus on elastomers businesses, scientists and engineers can work together on research and development. For elastomeric materials, any centre needs to be multi-skilled and international. There should also be an EPSRC Centre for Doctoral Training in Elastomers and Rubbers. These centres train the research leaders of the future and equip them with the knowledge, skills and creative approaches the UK requires. Although there are Centres for Doctoral Training in related areas (Appendix 2) they do not provide a focus on elastomers and rubbers. There is a need to get away from the old image of rubbers and promote the high-tech and high-margin aspects of elastomers and rubbers. A database should be established that lists where to obtain help with processing, R&D and failure problems. In some areas, academics are becoming an integral part of the supply chain but this needs to be extended. Better coordination of activities throughout the supply chain should enable a more rapid introduction of technology. University courses should have more emphasis on what industry needs. The diagram below summarises participants main thoughts. INFRASTRUCTURE National Polymer Processing Centre scheduled for completion Summer 2017 PRIORITY Improved market information for UK Improved promotion of elastomers Database to help with processing, R&D, and failure problems Academia becoming an integral part of the supply chain Focus on new high margin developments Enablement of rapid introduction of technology Courses with emphasis on industry needs Elastomer Training Action Group formed Level 3 BTEC course on elastomers at South Leicester College TIMESCALE (years) 4

5 Awareness It is essential that the elastomers and rubbers community provides data to indicate the importance of the topic to their businesses. Especially in the case of smaller companies, a network should be set up to keep them informed of both market and technical developments. The network could also be a source of information and help companies and education institutes. All this would go a long way to improving the image of elastomers and rubbers. Academics with interests in elastomers and rubbers should promote what they are doing in order to establish better awareness of their capabilities. Case studies of successful new developments should be better publicised, and articles for trade magazines should be written to promote the versatility of elastomers and rubbers. General training courses in elastomers should be prepared, and interesting and exciting presentations to designers would enable them to be more aware of the potential of elastomers. More industry placements would also encourage new graduates to become involved in companies with interests in elastomers and rubbers. For academics without a background in new elastomers and rubbers, base information for lectures would also promote interest and awareness among graduate students. In addition, examples from the medical, leisure (sports particularly) and transport sectors could be presented in a way that could excite pre-university scholars. Provide data highlighting the importance of elastomers AWARENESS Establish a network for an elastomers interest group Improve the image of rubbers PRIORITY Promote academic research to industry Continuously provide elastomer case studies Articles promoting elastomers Provide training courses in elastomers Provide presentations to designers Set up industry placements Provide academics and teachers with lectures on elastomers TIMESCALE (years) 5

6 Market focus In the area of tyre development the main changes have come in the last few years, with drives to improve road-holding and weight reduction resulting in the low-profile tyres we see on cars today. Despite widespread use of elastomers and rubbers in the transport sector, the leading areas in the UK that need more focus are the medical and oil & gas sectors. For the latter, there is strong emphasis on materials for harsh environments. For the medical sector, the UK has a large number of device producers, many of which are reliant on elastomeric materials. Innovation in elastomers and rubbers tends to come from these important sectors. The leisure sector, and particularly sports goods, command high margins and are often innovation leaders. However, other sectors of specific interest to the UK are new elastomer- and rubber-based products in textiles, robotics, and in some areas of electronics. Increasing interest in elastomeric materials for robotic applications Assemble market information to show importanceof elastomers to UK economy MARKET FOCUS Medical PRIORITY Oil and Gas Defence Transport Textiles Robotics Electronics TIMESCALE (years) 6

7 Technology development Transport, especially when it come to tyres, remains an important user in the elastomers and rubbers market. As well as work being carried out on alternative supplies of natural rubber (see inset on page 2), research continues on weight reduction for automotive and aircraft applications as well as improving their strength, reducing noise levels, and generally improving fuel efficiency. Queen Mary University of London (QMUL) is very active in this and in many other aspects of elastomers and rubbers. Currently a high priority for elastomers and rubbers is the possibility being offered by 3D printing/additive manufacturing. The ability to make products rapidly and in small quantities will revolutionise prototyping and will certainly reduce the cost of development dramatically. There is already a lot happening around the world with different polymers but so far there has been little effort in producing elastomeric materials. Another very important area is the revolution that is happening with the introduction of nanomaterials into polymers, mainly with the aim of reducing weight or creating more durable products by integrating reinforcing materials. The real excitement now is with the introduction of graphene, which at very low levels can produce electrically conducting polymeric materials, as well as improving barrier properties. To date, elastomers and rubbers have not been thoroughly examined in this respect, but the potential for improved conducting and barrier elastomers as well as rubbers opens up a lot of opportunities for both EMI shielding and environmental sealing. Smart, adaptive materials are a further important field that will provide new products in a variety of different sectors. There is specific interest in smart sensors making use of the electrical conductivity properties of some nanomaterials. Fracture analysis of elastomeric materials is an issue for most applications and it is a field in which the UK has specific expertise, with advanced fracture modelling and fatigue resistance. Abrasion resistance is also an important area in which the UK has specific interests, again with modelling and testing. The UK s strengths in practical multiscale and micro-mechanical modelling, particularly at QMUL, make it a world leader in this area, which can reduce time, effort and cost when prototyping. Graphene-treated rubber bands as inexpensive body motion sensors Researchers at Trinity College Dublin and Surrey University have infused regular rubber bands with graphene to create very cheap body motion sensors that could have a major impact on healthcare. The treated bands remain stretchy, but thanks to the graphene, they are also electrically conductive. If they are connected to a power source and then stretched, there is a detectable effect on the current flowing through them, even with only very slight movement. It has been reported that it is possible to sense motions associated with functions such as breathing, pulse and joint movement. This development could influence sports performance, as well as potentially alerting carers if there was a change in a patient s respiration or heart rate, or if they ceased moving for too long. Other uses might be for lightweight sensor garments that would be worn by vulnerable patients such as premature babies. 7

8 Two other specific topics that have raised interest at the workshops have been the potential to use elastomers as replacements for plasticised PVC, which is coming under scrutiny, and the use of electrospinning with elastomers. Elastomers are also needed for harsh, extreme environments, and there should be a focus on energy harvesting products. The trend towards increased sustainability will lead to more effort being directed at using biomaterials in the elastomers and rubbers sector. Natural rubber is expected to lead the drive for reducing the carbon footprint. Generally though, there is a requirement for the faster introduction of technologies with a better focus on new products and processes, especially in the highermargin markets. In manufacturing, it is important to look at basic fabrication processes to identify more efficient technologies in terms of material use and energy use. Greater familiarity with innovations in the plastics industry will be helpful to elastomer technology. Additive manufacturing Nanomaterials Conducting elastomers Barrier elastomers Smart materials (adaptive materials) PRIORITY Biomaterials (improved sustainability) Electrospinning of elastomers Elastomers as replacements for plasticized PVC Generally: Elastomers for harsh environments Focus on energy harvesting products Faster introduction of technologies More focus on new products and processes TECHNOLOGY DEVELOPMENT TIMESCALE (years) 8

9 Funding and collaboration Many companies, especially the smaller ones, are not fully aware of the funding opportunities that are available within the UK and Europe. Innovate UK has recognised the importance of advanced materials to the UK economy and has a number of funded programmes, aimed at improving the UK s influence in this area, for both small and large companies ( Smart Awards ( smart) are particularly popular and tackle the funding gap often experienced by many small and early-stage companies with innovative ideas and high-growth ambition and potential. They offer co-funding to UK-based pre-start-ups, start-ups, micro businesses and SMEs to carry out R&D projects that could lead to successful new products, processes and services. Another funded initiative is the Feasibility Studies Competition for Technology-Inspired Innovation ( connect.innovateuk.org/ web/tech-inspired-comp). Innovate UK stimulates innovation across its core technology areas to help ensure that small and micro businesses in the UK are well equipped to respond to society s current and future challenges. For example, they recently allocated up to 2m to invest in feasibility studies lasting up to three months, each costing no more than 33,000 in total (up to 25,000). Projects are collaborative or carried out by a single company. Awareness of UK funding SMART Technology inspired - Advanced Materials FUNDING & COLLABORATION PRIORITY Awareness of EU funding Erasmus (training and education) Marie Curie (research postings) General funding for Advanced Materials Establish an EPSRC Centre for Doctoral Training in Elastomers Apprenticeships focused on elastomers Secondments from universities to industry TIMESCALE (years) 9

10 Innovate UK also has initiatives offering help with proof of market, proof of concept, and development of prototypes. The elastomers and rubber community need to make more use of such funded programmes. Increased awareness is needed of competitions that are funded by the EU. These tend to be more collaborative programmes between universities and companies in different member states. Again, advanced materials are one of the key areas for funding and there is a variety of opportunities. However, elastomers and rubbers would also benefit from the EU Erasmus Programme ( eu/programmes/erasmus-plus/index_en.htm), which is for training and education. There are also EU Marie Curie Fellowships ( mariecurieactions/about-msca/actions/index_en.htm) for researchers working across all disciplines, from life-saving healthcare to blue-sky science. The scheme also supports industrial doctorates, combining academic research with work in companies and other innovative training that enhances employability and career development. The establishment of an EPSRC Centre for Doctoral Research in Elastomers and Rubbers, mentioned earlier, would also enhance the UK s future ability in this important area. Secondments from universities to industry would also be welcomed, especially for four-year undergraduate courses that demand a year in industry. Effort should be made to encourage more elastomer and rubber companies to take on these placements. A key issue for the future is the need to establish more apprenticeships in the field of elastomers and rubbers. Generally more pull needs to come from the industries involved in elastomers and rubbers. Industry should also be encouraged to help academics with ideas for final-year student projects that will influence their career choices. 10

11 KEY ESSENTIAL NEXT STEPS In order for the UK to make the most of the likely expansion and growth in elastomers and rubbers the following key priorities have to be addressed as quickly as possible. Through the workshops organised by KTN, the first steps have been taken to enabling the UK to become a well-coordinated unit able to be more productive in creating new products in the elastomers and rubbers markets. Following the workshops organised by KTN and with additional KTN support steps have been taken to establish an Elastomer Training Action Group (ELTAG - chaired by BRPPA) and a programme is in place at the University of Warwick to establish a National Polymer Processing Centre, which will include elastomer processing and characterisation equipment. This will enable the UK to become a well-coordinated unit, able to be more productive when it comes to creating new products in the elastomers and rubbers markets. Establish a forum/network and website to inform the elastomers community Centre with specific focus on elastomers National Polymer Processing Centre scheduled for completion Summer 2017 INFRASTRUCTURE Improved market information for UK PRIORITY AREAS Provide data highlighting the importance of elastomers Elastomers in additive manufacturing Nanomaterials to provide conducting elastomers or barrier elastomers Smart materials (adaptive materials) based on elastomers AWARENESS TECHNOLOGY DEVELOPMENT Assemble market information to show importance of elastomers to the UK economy MARKET FOCUS Explore and encourage suitable areas for funding FUNDING & COLLABORATION TIMESCALE (years) 11

12 APPENDICES Appendix 1 Contributors to the Elastomers and Rubbers Roadmap Industry Academia Trade Associations / Institutes / Others Alsitek Loughborough University AZ-Technology Ambascience Northumbria University BRPPA Artis Nottingham University Design Students Dow Corning Queen Mary London Independent Consultants Dyson Precision Staffordshire University Institute of Materials, Minerals & Mining Fenner Warwick University KTN Enteric TARRC Eriks UKTI Fullerex Gabrielle Miller Co Jaguar Land Rover Linkline Group PolyChem Rainbow Winters Smith & Nephew Te Connectivity Tex Fabrics Transport for London Trelleborg Tyco International Vlkan 12

13 Appendix 2 Centre with expertise in elastomeric materials Centre with relevance to elastomeric materials School of Engineering and Materials Science Department of Materials Soft Matter & Functional Surfaces* Functional Materials* Composite Manufacture* Polymers, Soft Matter & Colloids* Advanced Composites for Innovation & Science* Materials for Demanding Environments* Sustainable & Functional Nano* Additive Manufacturing & 3-D Printing* Graphene Technology* *EPSRC Centres for Doctoral Training Universities involved Queen Mary University of London Loughborough Durham, Leeds, Edinburgh BCFN Bristol Bristol, Nottingham, Manchester, Cranfield Sheffield Bristol Manchester Cambridge Nottingham, Liverpool, Newcastle, Loughborough Cambridge 13

14 ABOUT THE KNOWLEDGE TRANSFER NETWORK The Knowledge Transfer Network (KTN) is the UK s innovation network. It brings together businesses, entrepreneurs, academics and funders to develop new products, processes and services. Working with large and small companies, government agencies, research organisations, tech hubs, start-ups, public funding bodies, venture capitalists and private investors, KTN has built a unique network that helps enterprising people and companies reach their potential. Established and funded by Innovate UK to foster better collaboration between science, creativity and business, KTN has specialist teams covering all sectors of the economy from defence to the digital economy, the built environment to biotechnology. KTN has helped thousands of businesses secure funding to drive innovation and it continues supporting them throughout their business cycle to see that investment through to success. To find out more about KTN and the latest support available for innovators and pioneering companies visit: ktn-uk.co.uk

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