Let $p$ be a prime and $n \geq 1$ some integer. Furthermore, let $G$ be a finite group where $p$-Sylow subgroups have order $p^n$. Denote by $n_p(G)$ the number of Sylow $p$-subgroups of $G$. Denote the number of elements in the union of all Sylow $p$-subgroups of $G$ by $f_p(G)$. I am interested in finding lower bounds for $f_p(G)$ that do not depend on the group $G$, but only on $n_p(G)$, the number of Sylow $p$-subgroups.
By Sylow's theorem, we know that $n_p(G) = kp + 1$ for some integer $k \geq 0$. If $k = 0$, then it is clear that $f_p(G) = p^n$. If $k = 1$, we can show that $f_p(G) = p^{n+1}$. Furthermore, if $k > 1$, then by a theorem of Miller (see this question) we have $f_p(G) > p^{n+1}$, so by Frobenius theorem [*] $f_p(G) \geq p^{n+1} + p^n$. We can also improve this with Frobenius theorem to $f_p(G) \geq 2p^{n+1} - p^n$ by noticing that the number $f_p(G) - 1$ is divisible by $p-1$.
My question is this:
Can we find a better lower bound for $f_p(G)$ when $k > 1$?
I guess it would probably make sense that when $G$ has many Sylow subgroups, then there are many distinct elements among the subgroups. Thus I am also interested in the following question:
Can we show that $f_p(G) \rightarrow \infty$ as $k \rightarrow \infty$?
To make this precise, what I am asking here is for a function $g$ satisfying the following:
For any group $G$ with Sylow $p$-subgroups of order $p^n$ and $n_p(G) = kp + 1$, we have $f_p(G) \geq g(k)$.
$g(k) \rightarrow \infty$ as $k \rightarrow \infty$
Of course, for both questions the case $n = 1$ is easy, because then we know the value of $f_p(G)$ precisely. If $n = 1$, then $f_p(G) = (kp+1)(p-1)+1$ so for both questions we have a positive answer.
I think the following example shows that $f_p(G)$ gets arbitrarily large values. By Dirichlet's theorem, there exist arbitrarily large primes $q$ such that $q \equiv 1 \mod{p}$. Then in a direct product $G = C_{p^{n-1}} \times H$, where $H$ is a non-abelian group of order $pq$, the Sylow subgroups of $G$ have $C_{p^{n-1}}$ as their common intersection. There are exactly $q$ Sylow $p$-subgroups, because otherwise $G$ would be nilpotent but its subgroup $H$ is not. Therefore the number of elements in the $p$-Sylow subgroups is $f_p(G) = q(p^{n} - p^{n-1}) + p^{n-1}$, and this goes to infinity as $q$ goes to infinity.
[*] Frobenius' Theorem says that when $G$ is a finite group with order divisible by $k$, the number of solutions to $x^k = 1$ in $G$ is a multiple of $k$. It is easy to see that $f_p(G)$ is the number of solutions to $x^{p^n} = 1$ in $G$.
LATER EDIT: Okay, the second question is not so difficult if I have this right. Any Sylow $p$-subgroup consists of $p^n$ elements from the $f_p(G)$ elements in the union, so we have the inequality $f_p(G)^{p^n} \geq n_p(G) = kp + 1$, and thus $$f_p(G) \geq (kp+1)^{p^{-n}}$$
which goes to infinity as $k \rightarrow \infty$. For huge $k$ this is better than the lower bound $f_p(G) \geq 2p^{n+1} - p^n$. However, this is an extremely weak bound and not so interesting, it seems to me useful only for showing that $f_p(G) \rightarrow \infty$ as $k \rightarrow \infty$.