Continuous Production of Honeycomb Sandwich Panels All Aboard with - - PDF document

▶
continuous production of honeycomb sandwich panels all
SMART_READER_LITE
LIVE PREVIEW

Continuous Production of Honeycomb Sandwich Panels All Aboard with - - PDF document

Apr 01, 2023 275 likes •489 views

Continuous Production of Honeycomb Sandwich Panels All Aboard with Light and Cost-efficient Technology John Sewell, EconCore Innovation Day of CFK Valley Belgium Composites and RailWay 29 June 2016, Brussels Introduction: Sandwich

slide-1
SLIDE 1

1 Continuous Production of Honeycomb Sandwich Panels All Aboard with Light and Cost-efficient Technology

John Sewell, EconCore Innovation Day of CFK Valley Belgium – Composites and RailWay 29 June 2016, Brussels

Introduction: Sandwich construction by nature

2

The efficient use of material and energy is a fundamental principle of nature.

Nature set the examples – let’s save resources

Section of a bird wing Section of an iris leaf Honeybee comb Section of a human skull

slide-2
SLIDE 2

2 Sandwich in Construction and Transportation

3

Stephenson 1830

Sandwich frame in locomotive by Stephenson

Important historical examples of sandwich construction in transportation

Bi-plane wing construction by Chanute

Chanute 1894, 1903 (Wright flyer) Fairbairn 1845

Tubular Bridge design by Stephenson and Fairbain Sandwich metal wing design by Junkers

Junkers 1915

Sandwich construction today

4

Aerospace Trains Trucks Cars Building

Sandwich constructions are composed of

  • Two thin facings (skins, liners)
  • One thick low density core
  • Bonding layers (adhesive)

Adhesive Core material Adhesive

Sandwich applications

Lower skin Upper skin Packaging Recreational vehicles

slide-3
SLIDE 3

3 Potential of Sandwich Construction

5

Effect of the sandwich thickness:

  • Geometrical definitions

(symmetrical sandwich materials)

t t h

Economic advantage depends on low core material cost and low production cost

82.3 % weight saving 82.3 % cost saving

Core material types

6 … but high manufacturing costs

Sandwich core materials

Homogeneous support of the skins

Foam cores

Structured (non-homogeneous) support of the skins

Punctual support

Textile/pin cores

Regional support

Cup shaped cores

Bi-directional support

Honeycomb cores

Unidirectional support

Corrugated cores

Core types

Best material properties

slide-4
SLIDE 4

4 Conventional honeycomb production processes

7

Thermoplastic honeycomb production by extrusion Tubular honeycombs Out-of-plane extruded honeycombs

From: Tubus Waben, Polycore Plascore, Hexacor From: Nidaplast, Nida-Core Extrusion of single tubes Collecting the tubes Cutting to a honeycomb Welding to a block Extrusion small honeycomb blocks Extruder Extruder saw saw Welding to a bigger block and cutting to a honeycomb

  • require the production of blocks and the cutting from blocks
  • result in a low degree of automation and in relatively high costs

Both processes

ThermHex: Continuous production process

8

Aerospace Packaging Industry

Internal structure and mechanical properties Production concept and machinery

  • Honeycomb cores from a continuous film through a step-by-step in-line process

⇒ Automatic production ⇒ Low production costs ⇒ Best mechanical properties ⇒ Major cost reduction

New Honeycomb Cores ThermHex

Thermoplastic Honeycomb

  • Automated in-line production leading to very low production costs
  • Direct lamination of skins allows in-line production of panels
slide-5
SLIDE 5

5 EconCore – Global Operations

9

EconCore N.V. – ThermHex Waben GmbH

  • EconCore N.V – technologies for cost efficient

production of honeycomb core and sandwich parts

  • founded: 22.12.2005
  • ThermHex Waben GmbH – production of

thermoplastic honeycomb cores

  • production start: 01.04.2010

Production & sales

  • f honeycomb cores

Licensing and technology development

EconCore Technology - ThermHex

10

Continuous production of ThermHex honeycomb panels

...or by direct polymer film extrusion Schematic view on the film fed ThermHex panel production line

slide-6
SLIDE 6

6 Value chain

11

raw materials

(for core and skins)

Core material producer Sandwich panel producer Assembly plant In-line core Sandwich material In-line post preparation producer processing End user Part producer

sandwich constituents

(core, skin and bonding layer)

sandwich panel (sandwich material) sandwich part sandwich structure bonding / lamination forming assembling core production

Sandwich production value chain

Summary – ThermHex Applications

12

slide-7
SLIDE 7

7 ThermHex production lines - references

13 1 EconCore (Belgium) - Lab Line – 400mm width Started in 2005, For PP, PET, ABS, PC, PA, etc. 2 EconCore (Belgium) Demonstration Line – 1400mm Operational since 2006 – improvement & modification ongoing 3 Gifu Plastics (Japan) PP Core + PP skins – 1400mm Operational since mid 2009, 2nd line started in 2012 4 ThermHex Waben (Europe) PP Core only – 1200/1400mm Since 2010, Daughter Company of EconCore 5 Karton (Europe) PP Core + PP skins – 1400mm Operational since September 2010 6 Renolit GOR (Europe) PP and composite skins– 1500mm Operational since 2013 7 RoPlast (Turkey) PP and composite skins– (2100mm) Operational since 2014 8 TATA Steel (Europe) Metal skins – (1550mm) Operational since Nov 2015 … 14

ThermHex – PP honeycomb panels PP-ThermHex parts – by TECCELL

Web link to Teccell http://www.risu.co.jp/teccell/index_e.html

slide-8
SLIDE 8

8

15

ThermHex – PP honeycomb panels

16

ThermHex – PP honeycomb panels

  • PP panels for packaging and sign & display markets
  • Karton is a number 1 producer of fluted PP board in Europe
  • Karton annual revenue 200 Million Euro/year
  • www.karton.it
slide-9
SLIDE 9

9

17

ThermHex – automotive solutions

  • WPC-ThermHex board – GORCELL

Automotive & furniture

Web link to Renolit - Gorcell http://www.renolit.com/composites/en/products/automotive/honeycomb-structure/ 18

ThermHex by Renolit - GORCELL

  • WPC-ThermHex board – GORCELL

MASERATI GHIBLI

courtesy of Renolit

FIAT 500L

slide-10
SLIDE 10

10

19

Aluminium Composite Panels

Over 50% weight savings of ThermHex Panel compared to traditional Aluminium Composite Panel Flexural Stiffness, 3 point bending, 1000 mm span lenght, 300 mm panel width, 10 N load

20

Steel Composite Panels

slide-11
SLIDE 11

11

21

Metal Composite Panels

Applications:

  • building facades
  • roofing / flooring
  • interior cladding / cleanrooms
  • separation walls
  • visual communication
  • solar energy modules
  • furniture
  • automotive
  • mass transportation interiors
  • lightweight (airfreight) containers
  • ...

22

ThermHex – PP honeycomb cores – composites industry

Polypropylene honeycombs for the composites industry in 3 – 30 mm thickness

  • ThermHex Products

Machinery at ThermHex:

  • Width: 1,4 m (standard 1,2m)
  • Max. speed: 10 m/min
  • Annual output: > 1 million m²

Production hall in Halle/Saale

  • Available area: 4000 m²
slide-12
SLIDE 12

12

23

ThermHex PP honeycomb cores – markets & applications

  • for large complex composite parts
  • for wind pre-fabricated modules in buildings and energy generation

(bathroom pods, windmill covers, …), yachts, swimming pools, trucks, automotive, ... ThermHex PP cores with PET nonwoven

24

ThermHex PP honeycomb cores – markets & applications

ThermHex PP cores with adhesive layers

  • for automotive body panel stiffening
slide-13
SLIDE 13

13

25

PA honeycomb and “organicsheet” developments

26

ThermHex sandwich panel for heavy duty applications

ThermHex honeycomb with 0/90° UD Glass fiber / PP composite skins ThermHex honeycomb with woven glass fiber / PP composite skins ThermHex honeycomb with woven Carbon fiber / epoxy composite skins

slide-14
SLIDE 14

14

27

ThermHex organosandwich – mechanical performance

Weight reduction (=cost reduction) Rigidity increase

28

ThermHex organosandwich – thermoforming/overmolding

slide-15
SLIDE 15

15

29

ThermHex panel edge closure and fixtures

30

Honeycomb - Properties

Thermal insulation e.g. for wall or inner cladding

skins ThermHex PP skin strip Thin PP cell walls Still air entrapped in the cells (more than 95% volume fraction) Heat flow

A thermal barrier against conduction created by still air and PP Air movements suppressed or rather eliminated – air entrapped in the cells Radiative effects limited – conductive skins separated

slide-16
SLIDE 16

16

31

Honeycomb - Properties

Acoustic absorption e.g. for wall cladding, separation walls

Steel skins Air filled, one side open ThermHex cells Sound waves damping of the noise (acoustic vibrations are transferred to the

  • pposite skin – panel

stiffness driven)

Tests proved good sound absorption ability of the ThermHex core Dissipation of the sound waves in the one side open honeycomb structure

One or two (for separation walls) side perforated skins Air filled, one side open ThermHex cells Sound waves Improved damping

  • f the noise – sound

absorption (energy dissipated in the core structure)

Fire resistant parts / elements, e.g. ship building, public transportation…

ThermHex PP – metal skin

No modifications needed to achive class B, according to EN13823

B – s2 – d0 / B – s1 – d0 (TATA)

ThermHex PP – steel skin (TATA)

Passenger vehicles

UN R118 annex – PASS (TATA) PET honeycomb based ThermHex panel tested according

to the railway interior-designed

DIN 5510-2

S4-SR2-ST2

32

Honeycomb - Properties

slide-17
SLIDE 17

17

33

(FR / FST qualified) PC material based honeycomb core

  • Fire resistance performance

competitive to conventional and expensive NOMEX honeycombs

  • Target applications include aircraft

interiors and parts for mass transportation

FST thermoplastic honeycomb development

34

FST thermoplastic honeycomb development

Development work initiated with DIEHL AIRCABIN, leading supplier of aircraft interior components Aircraft applications requirements are similar but tougher than the railway applications requirements Cost saving requirements are more evident in the railway sector

Thanks to European Commission for the support under INCOM EC FP7, Grant agreement no: 608746

slide-18
SLIDE 18

18

35

courtesy of Diehl Aircabin

Density FST Surface quality Mechanical properties Drapability Thermal resistance Costs Media resistance

Target value: 29 - 48 kg/m³ Flammability Heat Release Smoke density Toxicity Few surface defects Compression strength Shear strenght Shear modulus Resistance to high humidity and Skydrol Permanent: -20°C to 55°C Temporary: -40° to 70°C Satisfactory drapability for the manufacture

  • f complex geometries

FST thermoplastic honeycomb development

Key requirements of sandwich cores for cabin interiors

36

FST thermoplastic honeycomb development

Excellent fire resistance test results

courtesy of Diehl Aircabin

slide-19
SLIDE 19

19

37

Materials choice – application depending

Raw Material Cost

Heat Resistance / Processing Temperature

ThermHex Core Material Type

PET, PVC ABS ABS high heat polyolefins PA12 PA6 Other PAs (PA66, 46, etc. PPS PEEK PEI

  • Processability on the core production level PROVEN
  • Processability on the core production level needs further investigations / investment

biobased PC PC/ABS blends PMMA

Summary – ThermHex Technology

38

MINIMAL WEIGHT MINIMAL COST

MINIMAL ENVIRONMENTAL IMPACT

slide-20
SLIDE 20

20 EconCore – ThermHex Technology

39

Let´s build the future of honeycomb sandwich materials together!

Thank You !