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 The efficient use of material and energy is a fundamental principle of nature. Section of a bird wing Section of an iris leaf Section of a human skull Honeybee comb Nature set the examples – let’s save resources 2

Sandwich in Construction and Transportation Important historical examples of sandwich construction in transportation Stephenson 1830 Chanute 1894, 1903 (Wright flyer) Sandwich frame in locomotive by Stephenson Bi-plane wing construction by Chanute Fairbairn 1845 Junkers 1915 Tubular Bridge design by Stephenson and Fairbain Sandwich metal wing design by Junkers 3

Sandwich construction today Upper skin Sandwich constructions are composed of • Two thin facings (skins, liners) Adhesive • One thick low density core Core material • Bonding layers (adhesive) Adhesive Lower skin Sandwich applications Trains Recreational vehicles Aerospace Building Packaging Trucks Cars 4

Potential of Sandwich Construction Effect of the sandwich thickness: • Geometrical definitions (symmetrical sandwich materials) t h t 82.3 % weight saving 82.3 % cost saving Economic advantage depends on low core material cost and low production cost 5

Core material types Core types Sandwich core materials Homogeneous Structured (non-homogeneous) support of the skins support of the Best material properties skins Regional Unidirectional Punctual Bi-directional Foam cores support support support support Textile/pin cores Cup shaped cores Corrugated cores Honeycomb cores … but high manufacturing costs 6

Conventional honeycomb production processes Thermoplastic honeycomb production by extrusion Tubular honeycombs Welding Collecting the tubes to a block Cutting to a saw Extruder honeycomb From: Extrusion of single tubes Tubus Waben, Polycore Plascore, Hexacor Out-of-plane extruded honeycombs saw Extruder Welding to a bigger block Extrusion small honeycomb blocks From: and cutting to a honeycomb Nidaplast, Nida-Core Both processes • require the production of blocks and the cutting from blocks • result in a low degree of automation and in relatively high costs 7

ThermHex : Continuous production process • Honeycomb cores from a continuous film through a step-by-step in-line process Aerospace Packaging Industry New Honeycomb Cores Internal structure Production concept and mechanical and machinery ThermHex properties Thermoplastic Honeycomb  Automatic production  Best mechanical properties  Low production costs  Major cost reduction • Automated in-line production leading to very low production costs • Direct lamination of skins allows in-line production of panels 8

EconCore – Global Operations EconCore N.V. – ThermHex Waben GmbH Licensing and technology development • EconCore N.V – technologies for cost efficient production of honeycomb core and sandwich parts • founded: 22.12.2005 Production & sales of honeycomb cores • ThermHex Waben GmbH – production of thermoplastic honeycomb cores • production start: 01.04.2010 9

EconCore’s licensees – references / applications 10

ThermHex sandwich panel for heavy duty applications ThermHex honeycomb with 0/90 ° ThermHex honeycomb with woven UD Glass fiber / PP composite skins glass fiber / PP composite skins Examples of thermoformed honeycomb parts 11

ThermHex organosandwich – mechanical performance Weight reduction (=cost reduction) Rigidity increase METAL SHEET ORGANO-SHEET MONOLITIC PANELS ECONCORE HONEYCOMB TECHNOLOGY ORGANO-SANDWICH PANELS 12

ThermHex organosandwich – thermoforming/overmolding Pick up of the Organo-sandwich Preheating (e.g. with IR) Process Demoulding of the part Transfer of the Organo- sandwich into the mould Forming while Functionalisation/ closing the mould overmoulding 1-step 13

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 • 14

ThermHex organosandwich – integration 15

Engineering thermoplastic based honeycomb developments PROJECT 2: Development of engineering thermoplastic based honeycombs and sandwich panels as well as development of related applications (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 16