Q Could you please describe your company?
A Haydale Ltd. is a nanomaterials company providing industrial solutions by developing customised, application-specific advanced materials. The company, based in Ammanford, South Wales, is a global leader in facilitating the commercial application of graphenes and other nanomaterials. Our patent-pending enabling technology, a low temperature, scalable, plasma functionalisation process provides a route to develop new customised materials enhanced by graphene and other nanomaterials. The technology provides a rapid and highly cost-efficient method of supplying tailored solutions to enhance applications for both raw materials suppliers and product manufacturers.An important point to note is that we are not a manufacturer of the raw nanomaterials – we source the most appropriate feedstock and use our plasma surface treatment process to improve properties such as dispersion, which enables the full potential of graphene and other nanomaterials to be realised commercially. Given the complexity of graphene and the different requirements for each potential application (cost structure, material, scalability and production technique, for example), the ‘one size fits all’ approach, adopted by many companies looking to functionalise graphene, is not relevant for many applications and it is not surprising that research departments are struggling to find the right materials. To address this market requirement, our plasma process and ‘three levels of customisation’ model (attached) allow us to provide customised enhancement solutions which are tailored in accordance with the specific needs of the customer. The so-called ‘wonder material’ is set to revolutionise a wide array of industries and working towards its commercialisation and the realisation of its full potential is particularly exciting. The extraordinary mechanical and electrical properties have the potential to outperform existing materials across a plethora of different commercial and industrial applications. However, at a technological and development level, there are still challenges that stand in the way of achieving full commercialisation.
Q What are the key technological challenges to overcome in order to realise the full potential of graphene?
A Introducing a new material concept into a supply chain is not trivial, and the wide range of useful properties observed in graphene open numerous possibilities and routes, and a seemingly endless list of target markets, each requiring different material specifications, performance and cost targets. The term ‘graphene’ encompasses a family of diverse materials with different forms, manufacturing routes, properties and uses. In addition to the ‘large area’ epitaxial form of interest for display screens and electronics, particulate graphene ranges from few-layer graphene (FLG) comprising several atomic layers of carbon, to so-called many-layer graphene, or graphene nanoplatelets (GNPs), which typically comprise 5-50 layers. This issue flags up the need for standardised nomenclature and taxonomy to help meaningful communication. Different production techniques also add to the complex picture, with each technique delivering a different material, scalability and cost structure. It’s not surprising that so many research departments across the globe are exploring the possibilities and contributing to the estimated 1000 publications per month. A key factor overlooked in nanomaterials development has been the critical role of surface chemistry in determining the effectiveness of a nano additive. Graphene is inherently inert, has a high surface area (e.g. >1000 sq.m/gm) which can pose a challenge or an opportunity for dispersion and compatibility with a host system. When the surface chemistry is optimised, we have seen that the full potential of nanomaterials at low percentage additions can be realised, producing significant property benefits. Functionalisation, or surface modification, is not a completely new approach, but existing methods which use chemical treatments, can functionalise, but at a high cost in terms of surface degradation, contamination, and environmental and ecological costs due to the hazardous waste stream associated with their use which can outweigh their benefits. Furthermore, the surface chemical functional groups available are limited to the groups inherent in the available acids. The process of surface functionalisation developed by Haydale uses a low temperature plasma, into which chemical species are introduced which surface functionalise the graphene with side-groups such as COOH, NH3, O2, and F. This allows for a very precise functionalisation in terms of the chemical side groups attached and their density, both factors which have a significant effect on the performance of the graphene.
Q What is the current status of the graphene market?
A Although commercial applications are currently limited, the potential of graphene to open up exciting new markets is immense. Wearable computing, for example, is finally taking off now that all the elements from power sources, energy harvesting devices, printable sensors, wireless communication into mobile communications are all established technologies. Graphene could potentially enhance some of these, but its flexibility and conductivity for printable conductive tracks could be the final link to develop ruggedised flexible systems. As mentioned previously, the research interest is huge, and much of this now aimed at applications development. Investment interest has also increased, and several graphene companies including Haydale have floated on the public markets attracting large valuations which demonstrates a continued appetite from graphene investment. However, graphene is still in search of a ‘killer application’ that delivers a unique value proposition or first mover advantage. This is probably not far off, and may actually not be in a high-profile end-use, but an application hidden from view but which solves a vital technical challenge or represents a commercial benefit.
Q How do you see the graphene market developing in the next years?
A All pointers indicate towards the industry growing rapidly and although current market value has been estimated at $20 million for 2014, recent reports from IDTechEx estimate a rapid rise to around $400 million over the next decade. But of course, the key is that we successfully develop the technology to enable the material’s full commercialisation. Whilst we believe that the technology required to achieve this is available, investment is needed for development and scale-up to make a real difference. Recent investment from the European Union (EU), which has committed €1 billion over the next decade to research in graphene and other 2D materials, together with significant investment in UK the graphene infrastructure by the UK government over the past two years, has certainly helped and raised confidence within the investor community. However, further commitment will most likely be required if graphene is to achieve its full potential and revolutionise a wide range of industries in the coming years, which it certainly has the promise to do.If you bear in mind that materials vary depending on the intended application, the graphene market is likely to segment into many numbers of sectors. Functional inks are technologically the lowest hanging fruit, offering low temperature processing, compatibility with several printing processes, and also ruggedness with potential applications for RFID and smart packaging. Energy storage is another very attractive target market for graphene and supercapacitors represent a high-growth sector – IDTechEx expects this market to register a 30% CAGR over the coming decade. The polymers and composite sector is also large and highly segmented with many needs. Here, graphene can deliver value as an additive, specifically through graphene nanoplatelets (GNPs), for a wide range of applications in the aerospace, automotive, construction, renewable energy, defence and marine industries.A significant proportion of graphene research is currently engaged in producing uniform single layer graphene sheets, predominantly by Asian electronics giants LG and Samsung for use in electrical applications. However from a short to medium term perspective, there is an alternative approach which is more relevant in solving engineering challenges. This approach focuses on the particulate graphene form which can be produced in large quantities in various thicknesses, such as FLG and GNPs. According to the IDTechEx report, this approach is expected to have huge impacts across energy storage, transparent conductive films and composite materials and these markets alone could represent significant commercial and societal benefits.
Q In the markets you mentioned, what materials is graphene competing with?
A The first big application identified and one which has been the subject of intense patent activity, has been coating of large areas such as screens and displays with a transparent conductive film. Indium Tin Oxide (ITO) has a dominant position in this market, but has serious cost issues due to the limited natural supplies of Indium, an issue which graphene is likely to overcome. Further off is the concept of graphene-based electronics to replace silicon. In engineering, there are a range of fillers used currently which have various properties which could be replaced by graphene, such as graphite. Graphite is used in applications such as a polymers, ink and battery anodes, to add variously electrical conductivity, thermal stability or colouration. Probably the key advantage of graphene is that it could be a functional additive and maybe enhance two or more performance parameters – industry will not replace unless they see a distinct business advantage.
Q What graphene enabled products can we expect to see in the next 2 years?
A Every industry has challenges due to emerging legislation, environmental issues and customer demands. Enhanced mechanical performance of polymers and composites could realise lighter weight structures which in transport would reduce the environmental impact, and in sporting goods enhance performance. Energy storage is a key area likely to develop graphene-enhanced supercapacitors and batteries. Coatings are ubiquitous and readily enhanced by low levels of particulate additions, for example an electrically conducting de-icing coating for aircraft has been patented and the scope is huge.
Q How do you see your company impacting these markets?
A Haydale now plays a crucial role as an enabling technology to facilitate the commercialisation of graphenes and other nanomaterials. Our low temperature plasma (under 100°C) patent-pending process provides the ability for both raw materials manufacturers and end-user application developers to tailor the functionalisation of their material. Because the process operates at a low pressure and low temperature, we are able to treat both organic mined powders and other synthetically produced nanomaterial powders. The critical role of surface functionalisation has shown us that there is not a ‘one size fits all’ graphene, and surface chemistry needs to be finely tuned in order to see the full effects of graphene. The key benefits are homogeneous dispersion and chemical interaction with a matrix.The Haydale HDPlas® process is not aggressive and eliminates the risk of damage to the material being processed. An additional benefit is that the process can remove impurities in the raw material and does not introduce any physical defects. Its low energy consumption and avoidance of waste stream make it a preferable option to the existing chemical treatment of nanoparticles. The choice of the most appropriate raw materials for each specific application through our global supply agreements (AMG mining is one such example), allows us to operate on a ‘Three Levels of Customisation™’ model. Optimising material selection, functional group, and degree of functionalisation, allows us to provide a bespoke solution for each specific application, allowing our customers to achieve their desired results. Our process was positively commented on by the National Physical Laboratory in February 2014, and together with this we have seen some excellent research results utilising our functionalised materials during 2014. Strategic partnership is a key part of our business approach, and we are always keen to engage with potential partners and customers. Promising results have recently been reported for epoxy resins. The Aerospace Corporation examined the nano-reinforcement of resin by GNPs functionalised by our plasma process. In the research paper, which was published in Applied Polymer Science (J.APPL.POLYM.SCI 2014, DOI: 10.1002/APP.40802), the epoxy material reinforced by our functionalised GNPs showed a paradigm shift in performance, with a 200% increase in tensile strength and modulus over the original resin, and an increase in toughness of over 125%. Due to the promotion of dispersion and chemical bonding with the epoxy matrix, the authors concluded that the results point to the surface functionalisation as the key parameter influencing the effectiveness of nano-reinforcement. Work at Cardiff University under the the European Community’s Seventh Framework ‘Clean Sky Joint Technology Initiative’ Programme (FP7/2007-2013) examined carbon fibre epoxy composites produced by resin infusion. The mechanical property enhancements compared to non-loaded resin were significant, for example, compression strength (up 13%) and compression after impact (up 50%) which promises a new generation of improved composite materials for high performance applications such as aerospace, automotive and wind energy. Haydale welcome enquiries from all industry sectors interested in exploring how graphene might provide a route to improved and novel materials to meet specific challenges (info@haydale.com), or to participate in research consortia.
To find out more about Haydale’s proprietary plasma process and graphene-based conductive inks, visit http://www.haydale.com email info@haydale.com or call +44 (0)1269 842946.
For technical press enquiries, please contact James Hayward, The Scott Partnership; +44 (0)1477 539539, or email haydale@scottpr.com.
For financial press enquiries, please contact Trevor Phillips, Media Relations Officer; +44 (0)7889 153628, or email trevor.phillips@hermesfinancialpr.co.uk.
About Graphene
Graphene is a form of carbon that exists as a sheet, one atom thick with its atoms arranged into a two-dimensional honeycomb structure. It is at least 100 times stronger than steel; conducts electricity better than copper and has been suggested as a possible replacement for silicon in electronics.
About Haydale
Haydale is a global leader in facilitating the commercial application of graphenes. As an enabling technology, Haydale by working with both raw material suppliers and product manufacturers can provide a rapid and highly cost efficient method of supplying tailored solutions to enhance an application. Haydale has patents pending for a low temperature plasma (under 100 deg C) process that overcomes a key barrier to the functionalisation of large scale production of Graphene Nano Platelets (GNPs) and Carbon Nano Tubes (CNTs). The process can functionalise with a range of standard and exotic chemical groups (Fluorine is one such example), where the amount of chemicals can be tailored to the customer needs. Good dispersion optimises the properties and performance and ensures it delivers as specified. In particular the Haydale plasma functionalisation process is capable of being tailored to produce a wide range of surface modifications, including chemical groups suitable for bonding or repelling specific chemicals. This process will substantially improve compatibility between the nanomaterials and any matrix or binder material. The Haydale plasma process does not use wet chemistry, neither does it damage the material being processed, rather it can clean up impurities inherent in the raw material and may even repair some of the defects in the base material. The technology is a low energy user and most importantly environmentally friendly. The Haydale method is an enabling technology where working with a raw material producer can add value to the base product and tailor the outputs to meet the target applications of the end user. Now housed in a new facility for processing and handling nanomaterials with a lab facility, Haydale combined with a scalable technology, is facilitating the application of graphenes and other nanomaterials in fields such as inks, sensors, energy storage, photovoltaics, composites, paints and coatings. www.haydale.com
