The second of three Prosyma Research Ltd reports to Santar on SAFIRE projects

“Santar Pipe and Forward Programme” 30th August 1991 and “Design of Fibre Lacing Device” 22 January 1993.
S F Bush

Introduction

1. Commissioning the vacuum-forming pipe mandrel (at Santar).
2. Commissioning the Mark VI granulation die (at UMIST).
3. Modifications to Mark VI: manufacture with Polybond coupling agent.
4. Results from AFI fibre.
5. Precoating:
   1. UMIST
   2. Santar
6. Commercial potential for SAFIRE granules: examination of competitor products.

The third of three Prosyma Research Ltd reports to Santar on Granex, 6th December 1990, 5th June 1991 and 15th August 1991.

S F Bush

Summary

The SAFIRE long fibre reinforced pipe and sheet-making processes depend on the production of suitable long-fibre granules. The granules are used either in conjunction with virgin granules or on their own depending on the concentration of fibre required in the final product. Recently the granules have been applied to injection moulding.

For good final product it is apparent that each fibre should (a) be well-wetted by the polymer and (b) should retain a high proportion of its original length. The Granex process is designed to produce granules with these characteristics. This report concentrates on measuring characteristic (a) for a variety of Granex head designs. The last design in the series (Mk Va – March 1991) shows about 65% wetting which is a great improvement on the earliest results (10% – October 1988) though these low levels were not recognised at the time. Further improvements are in hand to raise the wetting level to 95% without increasing fibre breakage.

Prosyma Research Ltd report “Glass Rovings Delivery System” to Santar

S F Bush

Summary

This is a brief report on a system which has been designed to improve steady running in the granule making process at UMIST and Santar.

The system reduces glass roving breakage and therefore increases production run-times. As it stands the system can be further improved, but even as it stands it is a marked improvement on simply drawing roving from a cheese.

Prosyma Research Ltd report to Nueva AG

S F Bush

The overall objectives of the projects over the six months to 30th June 1990 are:

1. Provide the process data for optimising the strength performance of the scale up pipe process, in particular for HD-Hostalen 5010. Part of this objective is to define, if possible, the conditions under which fibre loadings above 2.5 v/v do or do not give broadly proportionate increases in strength and stiffness (SAFIRE A).
2. Provide input to the scale-up design so that the results of objective 1 can be readily implemented (SAFIRE B).
3. Complete the development of the Mark IV granulation head so that the SAFIRE granules can be made in the relevant fibre concentrations (4 – 10% v/v) for the Olefine polymers of main interest (HD, PP, LD) (SAFIRE C).
4. Continue the testing programme to support objectives 1 and 3, in particular focussing on fracture behaviour. Carry out creep experiments for SAFIRE Hostalen at 2% and 3% v/v at 23 and 60 ^oC (SAFIRE D).

Report 6 from a series of 5 Prosyma Research Ltd reports to Ametex AG, 15th February 1989 to 14th January 1990.

Report 6 dated 31st May 1989, Report 7 dated 11th July 1989, Report 8 dated 24th July 1989.
S F Bush

Summary: Part 1

1. During the period under review, SAFIRE project A has followed up the breakthrough in finishing technology achieved in the previous six-month period.
2. On the process itself follow-up has concentrated on establishing the design and operating parameters which determine acceptable and indeed exceptional finish with the new technology, at the same time making many metres of pipe for burst and creep testing.
3. Both polypropylene (PP) and HDPE SAFIRE pipe can be made with fine finishes on a routine basis. While not of direct benefit to the project, the finishing technology gives quite remarkable mirror finishes to virgin pipe.
4. In the period under review, SAFIRE project C has concentrated on producing SAFIRE granules in a wide range of combinations of fibre and polymer, and evaluating these for use in pipes.
5. The signs are that the evaluations made for this purpose will also give a good indication of the commercial potential for SAFIRE granules in combination with Fibre Separating Devices (FSD) sold in their own right. The significance of this potential has become clear from recent information on present commercial products.