HIGH-FLYING POLYMERS. Solutions for the aviation industry

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1 HIGH-FLYING POLYMERS Solutions for the aviation industry

2 EDITORIAL UNLIMITED POLYMER SOLUTIONS New standards in the aviation industry Our mission is to constantly redefine the limits of the possible and to be present as a leading innovator in the construction, automotive and industrial sectors. REHAU secures long-term competitive advantages and a high degree of reliability through outstanding innovation. Industry-specific expertise from the three business divisions is brought together to develop new materials, formulations and products, and to advance these through to series production. Our structure, as an independent, family-owned company with an international outlook, gives us flexibility and our 127 sales offices, 42 production sites and 16 administrative offices ensure we are always right where our customers need us. High performance in every respect. 2

3 CONTENTS 1 Expertise in every area An innovative development partner for many types of aircraft Materials and formulations from REHAU production sites Professional solutions for the aviation industry 8 2 Energy efficiency made easy RAU-FLIGHT the material innovation 11 3 REHAU flies high Profiles Seat track covers Bumper system Cover profiles Lighting covers Systems Handrails PSU intermediate rail Air ducts Mouldings Edge protector Overhead locker brackets Fibre-composite components Retainers and slide guides for window systems Clamping rails for side wall panels Guide rails for side wall panels Silicone profiles Standard ABS components Interior area seals Silicone hoses RTM hose 35 3

4 4 1 EXPERTISE IN EVERY AREA REHAU aviation

5 1.1 AN INNOVATIVE DEVELOPMENT PARTNER for many types of aircraft REHAU has been a recognised partner of the aviation industry since 1980 and works constantly to drive forward developments. The innovative new material RAU-FLIGHT is significant for the industry, offering customers improved cost efficiency and energy balance. References: - Airbus S.A.S. - Airbus Operations GmbH - Fokker Aircraft - ATR - FACC - Diehl Aircabin - Zodiac - Diehl Comfort Modules - Lufthansa Technik - Airbus Helicopters - Ruag - Decorative Products - P3 Group - STELIA Aerospace - B/E Aerospace 5

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7 EXPERTISE IN EVERY AREA 1.2 MATERIALS AND FORMULATIONS from REHAU production sites Development of its own materials has been a cornerstone of REHAU s engineering success since the company was founded. Top priority is always given to quality, reliability and benefit for the customer. With several thousand formulations for the various sectors, REHAU now possesses one of the largest material portfolios worldwide. The object of REHAU s material, process and product developers is sustainable management of valuable resources and low-waste production through active recycling concepts. Thus, particular attention is paid to the processing characteristics of materials in REHAU s production works. With more than 40 production sites worldwide, our researchers and developers have the perfect base to ensure their materials are fit for production and the market. Consequently, this yields synergies for the premium products that represent REHAU on the market. Plant Port Elizabeth, ZA Impact strength test 7

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9 EXPERTISE IN EVERY AREA 1.3 PROFESSIONAL SOLUTIONS for the aviation industry REHAU s development engineers and technicians accompany the product from the initial idea to development, installation and final use. They are at the customer s side to provide advice and support, allowing easy implementation of special requirements and innovative solutions. Bending test Our production and process engineering departments offer a host of solutions to meet any requirement, from one-off production to series production, and they work to optimise manufacturing processes. In reworking, REHAU relies on various options, such as painting, surface finishing and fabrication, in order to implement the various product properties. Abrasion test REHAU s in-house material development department provides cost-effective and beneficial solutions, even for customised applications. In the logistics department, REHAU provides optimal conditions and made-to-measure solutions right through to just-in-time deliveries. Process expertise Material expertise: Production processes: Design: Material development: Processing: Fabrication/finishing: Painting: Details RAU-SIK, RAU-FLIGHT, RAU-FLIGHT PA Extrusion, injection moulding, extrusion blow moulding, thermo forming CATIA V5, FEM calculation, moldflow simulation RAU-FLIGHT PC, PA6, PA66, PA12, PEI, PPSU, PPS, TPE and silicone (Shore 50 and 70) Milling, grinding, CNC, drilling, bonding, painting Smooth and textured aeronautialapproved painting systems 9

10 2 ENERGY EFFICIENCY made easy with RAU-FLIGHT In the aviation industry, every gram counts. Lightweight construction has always been a significant factor in aviation, not least because of flight physics. In addition to lightweight structures, light innovative materials also make a vital contribution. The use of these materials reduces energy consumption, thus improving cost efficiency, and also makes a sustainable environmental contribution. Improved cost efficiency with consistent properties Through the use of intelligent polymer solutions, REHAU is able to provide customers with tailored solutions that not only have a positive impact on the energy balance but also meet engineering and design requirements. The RAU-FLIGHT material family was specially developed for the aviation industry and achieves a weight reduction of up to 10%. The challenge was to maintain the mechanical properties of the approved basic materials and the technical feasibility to produce an end product suitable for series production. Fabrication operations, such as milling, painting, bonding etc., are still possible in accordance with the original material properties. The new material RAU-FLIGHT can be customised to meet specific customer requirements; e.g. high-temperature applications with PPSU or PC for light-scattering effects. The relevant fire regulations are verified as part of the development process, and also during classification if necessary. RAU-FLIGHT, the unique material principle: glass bubbles embedded in the polymer matrix Magnified 300 times Magnified 3,000 times 10

11 ENERGY EFFICIENCY MADE EASY 2.1 RAU-FLIGHT THE MATERIAL INNOVATION For an A320, AIRBUS estimates an annual aviation fuel saving of 1,970 litres per 10 kg of saving in unloaded weight. Kerosene savings are achieved thanks to a weight reduction of up to 10% in existing polymer components with an assumed total weight of 100 kg per MSN. AIRBUS S.A.S photo by S. Ramadier Effect per aircraft in a machine usage time of 1 year 2,000 litres Effect per aircraft in a machine usage time of 15 years 30,000 litres Effect per fleet of 150 aircraft in a machine usage time of 15 years 4,500,000 litres 11

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13 ENERGY EFFICIENCY MADE EASY In the polyamide sector, REHAU has succeeded in creating a perfect RAU-FLIGHT PA formulation. This material has been approved by AIRBUS in accordance with AIMS RAU-FLIGHT PA sets completely new standards in terms of appearance and feel. It completely eliminates the surface treatment of dyed PA profiles normally carried out afterwards in order to prevent the material-specific lustre. The surface can be created by the extrusion die, which gives the profile a consistent, matt and uniform appearance. Surface marks that are typical of the process, such as extrusion drag lines, or marks caused by subsequent treatment, are a thing of the past. During this process, these surfaces can also be combined with and matched to additional components. A sophisticated structural design makes it possible to produce thinner walled components in comparison with other polyamides, which makes an additional contribution to weight optimisation but does not restrict the load-bearing capacity. 13

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15 REHAU FLIES HIGH Our products for the aviation industry Seat rail covers The safe connection point between passenger and aircraft Bumper system The bodyguard for lightweight structures Cover profiles The clever transition between different floor coverings Lighting covers Elegant design with sophisticated functional details Handrails Ergonomic and functional safety PSU intermediate rail The elegant connection between operating unit and overhead locker Air ducts For a pleasant and hygienic atmosphere in the aircraft

16 3.3.1 Edge protector Safely covered, both in the overhead locker and on the handrails Overhead locker brackets The reliable support in the overhead locker Retainers and slide guides for window systems Permanent fixing of interior elements Guide rails for side wall panels The custom-fit connection between wall panels Clamping rails for side wall panels Fixation between side walls panels and the fuselage. 3.5 Silicone profiles The professionals for sealing, fixing and covering. 3.6 RAUSILAM hose Silicone hoses for production of fibrereinforced components. 15

17 3 REHAU FLIES HIGH Our products

18 Profiles Seat rail covers Function Surface Material Process The seats inside the cabin are mounted on aluminium rails. The positions and spacings are variable. The aluminium rails are covered with seat rail covers between the attachment points of the seats. Brushed uniform matt Polyamide 12 (RAU-PA), flame-retardant, coloured, brushed matt RAUFLIGHT PA, flame-retardant, coloured Extrusion 16

19 Bumper system Function Surface Material Process Protection of lightweight structures, cable routing Uniform matt Polyamide 12 (RAU-PA), flame-retardant, coloured, brushed matt RAUFLIGHT PA, flame-retardant, coloured Extrusion (retainer and cover profiles), injection moulding (end caps) 17

20 Cover profiles 52 Function Surface Material Process Decorative profiles to cover gaps Partially brushed Flame-retardant materials approved for aircraft use; e.g. polyamide 12 (RAU-PA), polycarbonate (RAU-PC), etc. Extrusion ABS 5786 ABA Material: RAU-PA 592 Mat. no ABS 5786 AAA Material: RAU-PA 592 Mat. no Stamping Printing ABS 5790 AB Material: RAU-PA 592 Mat. no Printing Adhesive tape ABS 5759 Material: RAU-PA 592 Mat. no Printing 20 ABS 0317 AA Material: RAU-PA 592 Mat. no Printing 8.6 ABS 0318 Material: RAU-PA 592 Mat. no

21 Printing 48.6 Material: RAU-PC 440 Mat. no Material: RAU-PA 592 Mat. no Material: RAU-PA 592 Mat. no Material: ABS 143 Mat. no Material: RAU-PC 440 Mat. no Material: RAU-PC 440 Mat. no

22 Lighting covers Translucent cover profiles Function Material Process Translucent lighting cover Polycarbonate (RAU-PC), flame-retardant, transparent, UV-stabilised Extrusion Material: RAU-PC 440 Co-extrusion with integrated SIK seal Mat. no , ,

23 Lighting covers Coextruded lighting cover Function Material Process Transparent lighting cover Polycarbonate (RAU-PC), flame-retardant, transparent, UV-stabilised, polycarbonate (RAU-PC), flame-retardant, coloured, aluminium foil Co-extrusion, mechanical processing (milling, cutting to length), assembly (clamp insertion) RAU-PC, coloured RAU-PC, coloured RAU-PC, transparent Aluminium insert, 57 mm x 0.3 mm Due to the low wall thickness, an integrated layer of aluminium foil keeps some product areas opaque. Hinge Profile 21

24 Lighting covers Function Material Process Translucent lighting cover Polycarbonate (RAU-PC), flame-retardant, transparent, UV-stabilised Extrusion, mechanical processing (edge-milling) Material: RAU-PC 440 Mat. no Material: RAU-PC 440 Mat. no Material: RAU-PC 440 Mat. no

25 Systems Handrails Function Material Process Handrail Polyetherimide (RAU-PEI) Extrusion, mechanical processing (milling, cutting to length), injection moulding, assembly Material: RAU-PEI 140 Mat. no Material: RAU-PEI 140 Mat. no

26 PSU intermediate rail Function Material Process Cover between PSU (Personal Service Unit) and overhead locker Polyetherimide (RAU-PEI), silicone Extrusion, mechanical processing (milling, cutting to length), injection moulding, painting, assembly Rail Silicone seal Holder End cap Material: RAU-PEI 140 Mat. no

27 Air ducts Profile Function Material Process Air duct Polyetherimide (RAU-PEI), silicone Extrusion, mechanical processing (milling, cutting to length), injection moulding, painting, assembly Injection Silicone seal Material: RAU-PEI 140 Mat. no

28 Mouldings Edge protector Function Material Process Edge protection mouldings cover sandwich components, hiding gaps between two overhead lockers Polycarbonate (RAU-PC), silicone Injection moulding, extrusion, cutting to size and bonding silicone profiles Material: RAU-PC 440 Mat. no Material: RAU-PC 440 Mat. no

29 Overhead locker brackets Function Material Process Provides support in overhead locker 30% carbon-fibre reinforced polyphenyl sulphide (RAU- PPS) Injection moulding, mechanical finishing, painting, assembly Material: RAU-PPS 150 Mat. no. - 27

30 3.4 Fibre-composite components Retainers and slide guides for window systems Function Material Process Fixing for interior parts; e.g. in emergency exit area Glass-fibre fabric with polyetherimide (RAU-PEI), carbon-fibre fabric with polyetherimide (RAU-PEI) Thermoforming consolidated panels, mechanical finishing Material: RAU-TC Mat. no Material: RAU-TC Mat. no. - Material: RAU-TC Mat. no

31 3.4.1 Function Material Process Guide for window blind Polycarbonate (RAU-PC), glass-fibre fabric with polyetherimide (RAU-PEI) Injection moulding (window funnel), thermoforming of window blind guide Assembly Assembly of window funnel Window Material: RAU-PC 440 Mat. no Material: RAU-PC 440 Mat. no Material: RAU-TC Mat. no Material: RAU-TC Mat. no

32 Tracks for side wall panels Function Material Process Connecting rails for side wall panels Glass fibre fabric with polyetherimide (RAU-PEI) Thermoforming consolidated panels, mechanical finishing Material: RAU-TC Mat. no

33 Clamping rails for side wall panels Screw, pane, safety pane Function Material Process Note: Fixes side wall panels to fuselage Carbon fibre fabric with polyetherimide (RAU-PEI) Thermoforming consolidated panels, mechanical finishing, assembly Prototype tool available. The rail has passed the AIRBUS static test. Retainingbracket Blind rivet Rail Clip bonded to track Material: RAU-TC Mat. no. - 31

34 Silicone profiles Standard ABS components Product Function Material Process Standard profile (AIRBUS), gap hider for side wall panels and hatracks, further standard profiles and developments on request Sealing/hiding gaps/fixing elements Silicone DAN 1106 AIMS RAU-SIK 8968 DAN 1107 AIMS RAU-SIK 8964 Extrusion 16 ABS 0306 B20 Material: RAU-SIK 8968 Mat. no Pressurisation ABS 5744 AA Material: RAU-SIK 8968 Mat. no Pressurisation ABS 5748 AA Material: RAU-SIK 8968 Mat. no

35 Printing ABS 0307 AB Material: RAU-SIK 8968 Mat. no Printing ABS 5753 AA Material: RAU-SIK 8968 Mat. no Printing ABS 0305 LC Material: RAU-SIK 8968 Mat. no Printing ABS 0305 LB Material: RAU-SIK 8968 Mat. no DAN 262 CG Mat. no Material: 3Printing RAU-SIK ABS 0306 B01 ABS 0306 C01 Material: RAU-SIK 8968 RAU-SIK 8964 Mat. no

36 Standard ABS components Printing ABS 5748 AB Material: RAU-SIK 8968 Mat. no ABS 0306 B02 ABS 0306 C02 Material: RAU-SIK 8968 RAU-SIK 8964 Mat. no Printing ABS 0399 AA Material: RAU-SIK 8968 Mat. no Printing ABS 0398 A01 Material: RAU-SIK 8968 Mat. no

37 Interior area seals Printing RAU-SIK 8968 Mat. no RAU-SIK 8968 Mat. no RAU-SIK 8968 Mat. no RAU-SIK 8968 Mat. no RAU-SIK 8968 Mat. no Fabrication: Water-jet cut RAU-SIK 8325 Mat. no Fabrication: Compression moulded part, slotted 35

38 3.5.2 Interior area seals Material: RAU-SIK 8968 Mat. no Fabrication: Adhesive tape application 4.8 Material: RAU-SIK 8968 Mat. no Fabrication: Punching + adhesive tape application 145 Printing Material: RAU-SIK 8964 Mat. no Fabrication: Punching + forming bonding Material: RAU-SIK Mat. no Material: RAU-SIK 8964 Mat. no Material: RAU-SIK 8964 Mat. no Material: RAU-SIK 8964 Mat. no Material: RAU-SIK 8968 Mat. no Material: RAU-SIK 8968 Mat. no Material: RAU-SIK 8968 Mat. no

39 Silicone hoses RTM hose Product RAUSILAM FG 8 x 13.6d Function Reinforced RAUSILAM hose for resin injection in resin transfer moulding process Material Silicone Process Extrusion Material: RAU-SIK 8763 Mat. no Advantages of the RAUSILAM hose - High safety, including temperature resistance up to 180 C for short periods of time - Resistant to heat and pressure - Plasticiser-free, in contrast to other flexible hose systems - Reduction of volatile compounds through annealing during production, thus almost no migration/contamination in the resin - Ensures good gliding properties without the use of talc - High flexibility thanks to PES filament reinforcement - Possible to check/monitor the burst pressure - Transparent solution without talc, thus no contamination of the resin and full monitoring of resin flow-related impurities, blistering and premature cross-linking - Product independently tested and used by the aviation industry 37

40 AIRBUS S.A.S photo by Master Films / P. Pigeyre

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42 EXPERTISE AND RELIABILITY REHAU stands for the highest professionalism and quality Quality is crucial to our success. By meeting the quality standards and requirements of our customers, we make a significant contribution to their satisfaction. At all REHAU locations, we work to worldwide-applicable quality principles and regulations. We re never far away. For locations, visit This document is protected by copyright. All rights based on this are reserved. No part of this publication may be translated, reproduced or transmitted in any form or by any similar means, electronic or mechanical, photocopying, recording or otherwise, or stored in a data retrieval system. Our verbal and written advice relating to technical applications is based on experience and is to the best of our knowledge correct but is given without obligation. The use of REHAU products in conditions that are beyond our control or for applications other than those specified releases us from any obligation in regard to claims made in respect of the products. We recommend that the suitability of any REHAU product for the intended application should be checked. Utilization and processing of our products are beyond our control and are therefore exclusively your responsibility. In the event that a liability is nevertheless considered, any compensation will be limited to the value of the goods supplied by us and used by you. Our warranty assumes consistent quality of our products in accordance with our specification and in accordance with our general conditions of sale. REHAU AG + Co Rheniumhaus Rehau Subject to technical changes. IND716 EN