Tomasz Czarnecki, EconCore / email: Tomasz.Czarnecki@econcore.com - - PowerPoint PPT Presentation

Honeycomb Sandwich Panel Technology

Tomasz Czarnecki, EconCore / email: Tomasz.Czarnecki@econcore.com Matchmaking Event - RWTH Aachen 31 Jan 2017

Introduction: Sandwich construction by nature

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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

Sandwich in Construction and Transportation

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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

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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

Potential of Sandwich Construction

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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

Conventional honeycomb production processes

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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

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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

EconCore – Global Operations

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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’s licensees – references / applications

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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 Examples of thermoformed honeycomb parts

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ThermHex organosandwich – mechanical performance

Weight reduction (=cost reduction) Rigidity increase

MONOLITIC PANELS ECONCORE HONEYCOMB TECHNOLOGY ORGANO-SANDWICH PANELS

METAL SHEET ORGANO-SHEET

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ThermHex organosandwich – thermoforming/overmolding

Process

Preheating (e.g. with IR) Transfer of the Organo- sandwich into the mould Forming while closing the mould Functionalisation/

• vermoulding

Demoulding of the part Pick up of the Organo-sandwich 1-step

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Engineering thermoplastic based honeycomb developments

PROJECT 1: Organo-Sandwich – lightweight and cost-competitive thermoplastic sandwich panels and parts

• Applications Development
• Converting process (e.g. thermoforming) optimisation
• Sandwich part functionalisation
• Down-stream integration of production process steps

HIGHLIGHTS:

• Cost savings thru continuous sandwich panel and part production process / high

level integration

• High rigidity at minimal amount of material resources
• Reduction of weight and CO2 emissions
• Environmentally Friendly
• Short cycle, cost-efficient conversion into the final part

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ThermHex organosandwich – integration

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(FR / FST qualified) PC material based honeycomb core

HIGHLIGHTS:

• Not only for aircraft applications (larger volume applications in mass transportation

fit well)

• Fire resistance performance competitive to conventional and expensive NOMEX

honeycombs

• Competitive cost (due to continuous production process)
• Temperature resistance enhancement / Physical performance adaptation compared

to conventional honeycombs

Engineering thermoplastic based honeycomb developments

PROJECT 2: Development of engineering thermoplastic based honeycombs and sandwich panels as well as development of related applications