The document describes a new lightweight SCBA system called Project Heroes that replaces traditional SCBA cylinders. It provides a history of the technology and intellectual property, describes the product including advantages over traditional SCBA packs, discusses testing performed, and outlines the path to product maturity including optimization, certification, manufacturing, and risks.

1. Next Generation Structural
Fire Fighting PPE with Chemical/Biological Protection
PROJECT HEROES®
Light Weight SCBA
Pressure Vessel
Overview
Technical Advisory Board
Richard M. Duffy
International Association of Fire Fighters
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Presentation Overview
• Introduction
• Company and Technology
History
• Product Description
• Product Maturity
• Risk
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Purpose 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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2. Technology History
Liner Material changed from Winding process Cell design refined into 2-cell
Polyurethane to Hytrel optimized for both string. Mfg processes further
(DuPont) Kevlar and carbon defined. Teamed up with
• FDA approved and meets fiber wrapping. contract manufacturer.
DOT thermal requirements Burst Pressure in
excess of 10,000
DuPont supports psig achieved.
Bubble on tube development to validate cell
technology design
developed
2006
2005
2003 2004
2001 2002
1990’s
1980’s
Sanders Industrial
Design founded to Burst Pressures over 7800 psi Vulcore Industrial
continue polymer achieved using Kevlar wrapped formed to develop the
Polymer Hytrel technology
pressure vessel
tube bail
1998-1999- development
out system Cell design progressed to double
designed 2000 NASA
Cell design ended cell configuration for ease of
for high White Sands
changed from filament winding (HyperComp)
altitude bail tests for use
with high “bubble on a tube”
out (Spec Extensive successful test program
pressure to a 2 part injection
ops) completed with DuPont
oxygen molded “ovoid” cell
(successful)
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Product Description
Intellectual 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 # 7,121,423B2
Flexible Pressure Vessel Apparatus and Method for Making the Same:
Patent # ZL02814917.3
Cellular 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 Cores braided
Core wound using
with para-aramid
pre-preg Carbon
Wound cores are
Cell Assembly covered combined with manifold
and regulator First Stage
with foam and outer Regulator
shell with proper straps
Cell Manifold
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3. Product Description
• 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.
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Product Description
SCBA - PPVT vs. Composite Cylinder
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)
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Product Description
Testing performed to date
The 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 air
Permeation testing ongoing with a 2200 psi cell using nitrogen and
helium
No pressure loss after 2 years
Comprehensive 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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4. Product Description
Testing/Analysis performed to date
Comprehensive 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 fragmentation
Researched/analyzed filament winding process which indicates,
with using CADWIND winding software, that higher pressures can
be reached using the same amount of winding material
Preliminary prototype testing to date
Thermal testing of the cell cores in flash over chamber
No effect on integrity
Tower testing currently in progress with prototype pack @ 500 psi
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Product Description
Current State of Product
Cell technology developed, tested and matured to point of
application integration
Current prototype on air and being tower tested
2 Cell configuration ready for integration into manufacturing and
certification
Optimizing cell core using advanced blow molding technology
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Path to
Product Maturity
or
Where We Are Now
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5. Product 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 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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Manufacturing
• 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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6. Schedule & 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 & 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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IAFF’s DHS Grant Award
IAFF’
• 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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7. Field Trials
• 500 psi
• Half-hour FirePack Units
• Hour FirePack Units
• Rotating Field Sites
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