Fire Pack Presentation Tac (2)

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Next Generation StructuralNext Generation Structural

Fire Fighting PPE with Chemical/Biological ProtectionFire Fighting PPE with Chemical/Biological Protection

PROJECT HEROES®

Light Weight SCBA Pressure Vessel

OverviewTechnical Advisory Board

Richard M. DuffyInternational Association of Fire Fighters

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Presentation OverviewPresentation Overview

• Introduction• Company and Technology

History• Product Description• Product Maturity • Risk

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Purpose and GoalPurpose and Goal

To replace current SCBA cylinder and support frame with a lighter weight, conformable, non-fragmentary thermal plastic pressure vessels

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1990’s

Polymer tube bail out system designed for high altitude bail out (Spec ops)

Bubble on tube technology developed

1998-1999-2000 NASA White Sands tests for use with high pressure oxygen (successful)

1980’s

2005

2001 2002 2003 2004

Sanders Industrial Design founded to continue polymer pressure vessel development

Cell design changed from “bubble on a tube”to a 2 part injection molded “ovoid” cell

Liner Material changed from Polyurethane to Hytrel (DuPont)• FDA approved and meets DOT thermal requirements

DuPont supports development to validate cell design

Burst Pressures over 7800 psi achieved using Kevlar wrapped Hytrel

Cell design progressed to double ended cell configuration for ease of filament winding (HyperComp)

Extensive successful test program completed with DuPont

Winding process optimized for both Kevlar and carbon fiber wrapping. Burst Pressure in excess of 10,000 psig achieved.

Vulcore Industrial formed to develop the technology

Technology HistoryTechnology History

2006

Cell design refined into 2-cell string. Mfg processes further defined. Teamed up with contract manufacturer.

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Product DescriptionProduct DescriptionIntellectual Property

1. Owned by Stan Sanders and Sanders Industrial Designs, Inc.

2. Vulcore Industrial, a division of SID, Inc., is the primary developer of the technologies

3. All patents are free and clear of any encumbrances

4. Action received on all three (3) core patents on file at the U.S. Patent Office.Ovoid Flexible Pressure Vessel, Apparatus and Method for Making Same:

Patent # 7,124,908B2 and Patent # 7,121,423B2Flexible Pressure Vessel Apparatus and Method for Making the Same:

Patent # ZL02814917.3Cellular Reservoir Flexible Pressure Vessel, Apparatus for Making the Same:

Patent # 7,131,553B2

5. Constant reinforcement of patent base – currently two in progress

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Inner cores are molded Hytrel

First StageRegulator

Cell Manifold

Cores braided with para-aramid Core wound using

pre-preg Carbon

Wound cores are combined with manifold

and regulatorCell Assembly covered

with foam and outer shell with proper straps

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• Advantages over current SCBA cylinders and support frame

– Weight+ A 70% reduction over conventional

SCBA pack– Low profile

+ Less than 2.00 inches compared to an average of 7 inches on a conventional SCBA pack

+ Due to the streamlined profile, the pack will significantly lower the risk of entanglement

– Flexibility+ Pack will flex with the curvature of the

back to provide for increased mobility in confined spaces.

Product DescriptionProduct Description

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Cell Material & Foam maintains integrity for over 10 minutes at 350 deg F

Kevlar/Nomex outer cover will survive up to 1000 deg F

Meets or exceeds standards for turnout gear

Low profile

Flexible

Life expectancy of inner cores same or greater than conventional composite cylinder

50% weight reduction

Capable for piggy backing for extended duration (90 cu. Ft. @ ½ weight – HAZMAT)


SCBA SCBA -- PPVT vs. Composite CylinderPPVT vs. Composite Cylinder

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Testing performed to dateThe Hytrel core material has been tested by SID and meets medical standards

NASA, along with SID, has tested the core material with both oxygen and airPermeation testing ongoing with a 2200 psi cell using nitrogen and helium

No pressure loss after 2 yearsComprehensive pressure and cycle testing (in excess of 10,000 cycles) on multiple vessels

Burst pressures (4:1) at end of cycling exceeded current burst requirements (3:1)Results indicate vessels will meet or exceed both U.S. and European qualification standards for pressure vessels

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Testing/Analysis performed to dateComprehensive engineering and regulatory analysis performed

No issues identified in meeting U.S. & European Standards

Filament wound and pressure tested 330 ml double-ended Hytrel core cells

Burst pressures reached or exceeded 10,000 psi with no fragmentationResearched/analyzed filament winding process which indicates, with using CADWIND winding software, that higher pressures can be reached using the same amount of winding materialPreliminary prototype testing to date

Thermal testing of the cell cores in flash over chamberNo effect on integrity

Tower testing currently in progress with prototype pack @ 500 psi

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Current State of ProductCell technology developed, tested and matured to point of application integrationCurrent prototype on air and being tower tested2 Cell configuration ready for integration into manufacturing and certification

Optimizing cell core using advanced blow molding technology


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Path to Path to Product MaturityProduct Maturity

ororWhere We Are NowWhere We Are Now

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Product Development CenterProduct Development Center• Optimize core and winding processes• Generate regulatory plan for DOT certification• Complete detail design and documentation of SCBA fire pad

– Bill of material– Drawings– Specifications

• Set-up test capability to perform necessary testing to support verification, validation, DOT, and European certification efforts.– Process Documents– Acceptance Test Procedures– Verification Test Procedures– Validation Test Procedures– Analysis Reports

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Product Development CenterProduct Development Center

• Perform Testing for Certification– Verification Test Reports– Validation Test Report

• Generate documentation package for submittal to DOT

• Submit documentation to DOT • Support DOT requests for further information• Obtain DOT certification• Create Public Awareness of new System

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ManufacturingManufacturing

• Current Status– SID/VI controls manufacturing process and

holds all design and mfg certifications + Molding (development)+ Braiding (proven and optimizing)+ Winding (proven and optimizing)+ Assembly (proven and optimizing)

– Genesis Manufacturing will be the contract manufacturer

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Schedule & FundingSchedule & Funding

Optimize molding and winding processes 3 months

Design and Documentation 3 months

Fabricate Production Test Units 4 months

Testing 3 months

DOT Package Generation and Submittal 2 months

DOT Certification 3 months*

Public Awareness ongoing

In parallel

* requires support of outside agencies

ESTIMATED TIME TO COMPLETION 15 MONTHS

ESTIMATED COSTS $1.8 - 2 MIL

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Risks & MitigationRisks & Mitigation• Risks

– Acquisition of winding material+ Ballistics products priority

– Protests from current SCBA bottle manufacturers + DOT process

– DOT now approved the use of carbon wrapped composite cylinders using plastic liners. ( DOT-SP 14209)

– Prolonged certification program involving NIOSH, NFPA, CBRN

+ SCBA OEM ability to approve system • Mitigation

– IAFF– SCBA OEM’s– Fire Departments

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IAFFIAFF’’s DHS Grant Awards DHS Grant Award

• TAC – 3 meetings• DOT pressure vessel approval• SCBA OEMs (2) Implementation• Testing and certification under NIOSH• Field Testing (3)• Provide DHS a Technology Display Ensemble

(TDE)• Commercial Product (15 months)

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Field TrialsField Trials

• 500 psi• Half-hour FirePack Units• Hour FirePack Units• Rotating Field Sites

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Business

Fire Pack Presentation Tac (2)