MADFLEX SAMPLE BOOK. Supported by. Composite Research s.r.l. Turin, Italy

Transcription

1 6 MADFLEX SAMPLE BOOK Composite Research s.r.l. Turin, Italy Supported by

2 Summary The MadFlex: One Material, A Thousand Solutions... 2 MadFlex Extreme Thinness... 8 Cut Resistant... 9 Aesthetic Finishing Soft Touch Marvellously Translucent Double Coating In Aesthetic Carbon Maximum Structural Performances Top Performance MadFlex Sample Book 1

3 The MadFlex: One Material, A Thousand Solutions Flexibility and stiffness on a single panel. This is what makes the MadFlex unique. In fact, thanks to its innovative mechanical features, you can have a panel that is flexible, even rollable, on the one side, while it is absolutely crushproof on the other. The MadFlex is a composite material panel, having a layered structure, particularly a sandwich-like structure. It comprises two outer layers and an intermediate one. Of course, depending on the application to develop, CoRe will choose the best geometry and the most suitable combination of materials to build the sandwich. The company has already tested a number of different solutions, using for example carbon fibres, Kevlar, aramidic fibres, foam and others, obtaining excellent results. Lightness Easy to transport Structural strength Thermal insulating Thermoformable Resistant to chemical agents Thermic insulating Fireproof Temperature resistant Biocompatible Anti-seismic Endless surface finishing The MadFlex can be applied to any industrial segment that is looking for lighter, safer, easier to modulate materials, with a lower environmental impact. Thanks to the infinite combinations of available materials and its extreme modularity, it can be used for both small components (e.g. interior car) and bigger and more complex ones (e.g. tensile structures). Thermoformed curved MadFlex MadFlex Sample Book 2

4 TEST METHOD Max value configurations Min value configurations Bending stiffness rigid side Bending stiffness rollable side Tensile strength Flexural strength Flatwise compressive strength [N m2/m] [N m2/m] [kn/m] [MPa] [MPa] ASTM ASTM ASTM ASTM ASTM D7250/D7250M D7250/D7250M D3039/D3039M D7250/D7250M C365/C365M 250 2, ,4 13 0, ,2 MadFlex Mechanical Properties The uniqueness of the MadFlex is that it combines the pros of existing fabrics (lightness, thinness, flexibility) with those of traditional materials (strength, rigidity, shear strength). However, comparing it with these would be limiting. All in one. In fact, not only can the MadFlex replace existing fabrics and materials, but, given its mechanical features, it can also simplify entire projects by abolishing the use of cables, junctions and struts. Moreover, the MadFlex has intrinsic insulation abilities, which allow manufacturers to avoid additional layers, thus saving materials and labour. In order to create a proper prototype, CoRe will work alongside its customers to develop an engineering project that meets the required needs and represents excellence. Sandwich with a hinge in MadFlex VS Sandwich with a mechanical hinge Compared to rigid structural materials, as metals and polymers, with the same stiffness and mechanical strength, the MadFlex presents the following advantages: lightness storage and transportability (9 m MadFlex can be wrapped in a roll of 20 cm) insulating capacity environmental impact possibility to avoid complex and expensive mechanisms to create folding parts a wide range of aesthetic finishes (also translucent) partial elasticity, which allows reducing vibrations, making it excellent from an anti-seismic point of view. MadFlex Sample Book 3

5 Tensile Strength Density Tensile Strength/Density ratio K (thermal conductivity) Light transm. Elong. at break Flame resistance MPa kg/m³ W/(m C) ABS 40-45* ,038-0,043 0,14-0, % Low Glass ,008-0,08 0,5-1 > 80% < 1% Very Good Structural * ,007-0, % 3-35% Excellent Aluminium Structural Steel * ,025-0, % 15-25% Excellent MADFLEX ** ** 0,12-0,6 0,04-0,06** 0-25% 3% Very good *Yield strength **Equivalent value Comparison between 1m x 1m panels, supported at the two sides and with the same deflection under a 200 kg load. The weight of the different solutions depends on the density and the thickness of each panel. The figure shows the convection heat loss compared with the base case (MadFlex) considering two different temperatures above (lower) and below (higher) the plane. ABS (plastic) 10 kg Heat loss 210% MADFLEX 1.7 kg ALUMINIUM 7.8 kg Heat loss 100% Heat loss 300% SAFETY GLASS 7.7 kg Heat loss 280% STEEL 16.2 kg Heat loss 300% The Madflex is 5-6 times lighter than a sheet of ABS (polymer material) of the same flexural rigidity and 3-4 times lighter than a sheet of ABS of the same flexural resistance. Thanks to its lightness, it is more environmentally friendly: The greenhouse gases released to produce it are about half of those issued to produce an ABS panel with equivalent mechanical properties, and its insulating capacity are over 5 times higher. Even if it is neither flexible nor insulating, today aluminium may be considered as one of the strongest alternative to the MadFlex. However, in terms of stiffness and resistance, there is absolutely no comparison. In fact, a 1.8 kg 11 mm thick panel in MadFlex corresponds to a 10 kg 3.5 mm thick aluminium sheet. Moreover, from an environmental point of view, the production cost of aluminium is 5 times higher than the one of the MadFlex. MadFlex Sample Book 4

6 The charts show a comparison between 1 m 2 sheets in different materials and with the same deflection under a load of 200 N. Thermal transmittance U (UNI EN ISO 6946:2008) Global warming ABS safety glass aluminium steel Madflex W/(m² C) ABS (plastic) safety glass aluminium steel Madflex 0,00 20,00 40,00 60,00 80,00 CO2eq Weight ABS (plastic) safety glass aluminium steel Madflex 0 5 kg Compared to architectural membranes, the Madflex is more advantageous in terms of: Reduction of the load on the load-bearing / supporting structures Reduction in weight and bulk in transport Insulating ability Increased tensile strength and stiffness, impact resistance and puncture Possibility to create shapes and designs otherwise impossible Elimination / reduction of maintenance costs and works in case of structures supported by compressed air. PVC polyester PTFE fiberglass silicone fiberglass coated coated coated Resistance Weight kn/m g/m² W/(m² C) U (thermal transm.) Light transm. Elong. at break Flame resistance ,5-7, % 18-30% Good ,5-7, % 3-12% Excellent Similar to PTFE f. glass 40-50% 3-12% Excellent TENARA Fabric % 10-40% Excellent ETFE film MADFLEX ,6 (1 layer) 2,9 (2 layers) 2,4 (1 cm) -3,6 (0,5 cm) 90% % Very Good 0-25% 3% Very good MadFlex Sample Book 5

7 MadFlex is a product on-demand. Composite Research can create tailored solutions, able to satisfy customers requests. We can build ad hoc panels, modulating the MadFlex mechanical properties, its chemical characteristics and the aesthetic finishing. In other words, from a single patented idea, we can obtain a thousand solutions. R&D is the key. Our company continuously carries on an R&D activity in order to enhance the performances of the MadFlex, aiming at reducing costs and environmental impacts. Since the creation of the first panel, we have reduced the costs of the materials about 80% and enhanced the mechanical performances, coming to preserving 2/3 of the original flexural strength after 100,000 bending cycles. At present, we are focusing on testing new raw materials and productive processes, which will allow increasing significantly the MadFlex flexural stiffness and failure bending moment, without affecting its weight and costs. The specific Madflex productive process provides the finished product with flexibility, even when generally rigid materials such as carbon fiber are used. In this way, it is possible to create components and products with a high aesthetic value and totally new mechanical properties. Moreover, CoRe can produce new aesthetic variants of the MadFlex starting from any material available in the form of foils or fabrics. Infinite aesthetic finishes, from carbon and aluminized fabrics, to vegetable fibers with wood effect. The Madflex can be pasted to other materials or components during both the production phase and the following stages. Metallic parts and threaded components can be easily integrated inside or on the surface of the MadFlex. The MadFlex can be easily produced along with traditional sandwich panels, obtaining components that are rigid in some areas and flexible in others. Similarly, it is possible to create fabrics with reinforced areas in Madflex. MadFlex Sample Book 6

8 MadFlex 1.0 The 1.0 version is the result of the first tests run on the panel, which led to the filing of the MadFlex patent. It clearly represents the principle underlying the MadFlex: It is very solid and stiff on the one side, while it is extremely flexible and rollable on the other. What makes it suitable as a structural material is that it perfectly combines strength to extreme lightness and manageability. Thickness mm 5 Areal weight kg/m² 1.3 Tensile strength kn/m 500 ASTM D3039/D3039M Failure bending moment N m/m 170 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 30 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.5 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 7.5 DIN Value esteemed through the test DIN52612 executed on the MadFlex foam core: Experimental tests have shown a negligible deviation between the heat transfer coefficient of the MadFlex and the esteemed one based on this method. MadFlex Sample Book 7

9 Extreme Thinness The super thin MadFlex meets the demand of those companies, which try to compact large surfaces into smaller units. For example, you can roll a 1.8 mm panel around a tube with a diameter of 4 cm. In this way, a 4-meter panel can be stored in a roll with a diameter of only 8 cm. Besides its thickness, it is extremely light, self-sustaining and it shows a tensile resistance higher than the one of traditional technical textiles (polyester/pvc, glass fiber/ptfe, tenara, etfe films, dacron, kevlar or carbon fiber fabrics). Thickness mm 1.8 Areal weight kg/m² 0,7 Tensile strength kn/m 400 ASTM D3039/D3039M Failure bending moment N m/m 90 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 10 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.2 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 22.5 DIN52612 Thickness mm 3.5 Areal weight kg/m² 1 Tensile strength kn/m 370 ASTM D3039/D3039M Failure bending moment N m/m 120 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 25 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.2 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 11.2 DIN52612 MadFlex Sample Book 8

10 Cut Resistant The peculiar feature of this MadFlex is that it can resist to cut and perforation damages, still overcoming 100,000 bending cycles. Thanks to the use of specific coatings (e.g. metallic layers, Kevlar or aluminised glass fibre), not only can this panel be highly strong, but it also preserves the unique mechanical performances of the basic version. Thickness mm 6 Areal weight kg/m² 1.65 Tensile strength kn/m 450 ASTM D3039/D3039M Failure bending moment N m/m 230 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 40 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.6 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 6.2 DIN52612 Thickness mm 5.5 Areal weight kg/m² 1.75 Tensile strength kn/m 500 ASTM D3039/D3039M Failure bending moment N m/m 225 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 55 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.4 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 7.2 DIN52612 MadFlex Sample Book 9

11 Aesthetic Finishing Soft Touch. While preserving the same mechanical features of the 1.0 version, this MadFlex is also pleasant to the touch and shock absorbent. The perfect choice of the materials allows an excellent thermal and acoustic insulation: thermal transmittance U lower than 1.9 W/(m 2 C) according to UNI EN ISO 6946:2008 for horizontal elements, and equal to 2.5 to according DIN Thickness mm 11 Areal weight kg/m² 1.5 Tensile strength kn/m 500 ASTM D3039/D3039M Failure bending moment N m/m 170 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 30 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.5 ASTM D7250/D7250M Flatwise compressive strength MPa n.d. ASTM C365/C365M Heat transfer coefficient W/ m² K 2.5 DIN52612 Marvellously Translucent. This MadFlex is the perfect solution for those who need to create structures and applications with natural diffused light. The panel can also be projected in order to show thinner and brighter areas. Despite the translucency, it has an excellent insulating power: thermal transmittance U equal to 3.5 W/(m 2 C) according to UNI EN ISO 6946:2008 for horizontal elements, and equal to 7.5 according to DIN To obtain a higher thermic and acoustic insulation, it is possible to create a thicker panel. Thickness mm 5 Areal weight kg/m² 0.95 Tensile strength kn/m 400 ASTM D3039/D3039M Failure bending moment N m/m 180 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 35 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.3 ASTM D7250/D7250M Flatwise compressive strength MPa 1.2 ASTM C365/C365M Heat transfer coefficient W/ m² K 7.5 DIN52612 MadFlex Sample Book 10

12 Double Coating In Aesthetic Carbon. Besides its excellent mechanical properties, this MadFlex is perfect for high-end and luxurious products. Thanks to its double layer in aesthetic carbon, it can be easily applied for example to sports cars, yachts, and upmarket furnishing and design solutions. Thickness mm 5.5 Areal weight kg/m² 1.2 Tensile strength kn/m 450 ASTM D3039/D3039M Failure bending moment N m/m 275 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 105 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 0.8 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 7.2 DIN52612 Maximum Structural Performances Not deformable on the rigid side, this MadFlex has an extremely high tensile resistance. It can also be used to replace structural metallic part. Thickness Mm 11 Areal weight kg/m² 1.8 Tensile strength kn/m 700 ASTM D3039/D3039M Failure bending moment N m/m 480 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 240 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 1.5 ASTM D7250/D7250M Flatwise compressive strength MPa 1.5 ASTM C365/C365M Heat transfer coefficient W/ m² K 3.6 DIN52612 MadFlex Sample Book 11

13 Top Performance The top performance panel combines lightness with excellent mechanical features. It can resist to vibrations and strikes, fireproof, resistant to UV radiations and highly insulating. Tests prove it can overcome 100,000 bending cycles. Such properties make this panel perfect to be applied in the automotive, aerospace and nautical sectors. Thickness mm 5.5 Areal weight kg/m² 1.4 Tensile strength kn/m 700 ASTM D3039/D3039M Failure bending moment N m/m 360 ASTM D7250/D7250M Bending stiffness rigid side N m²/m 45 ASTM D7250/D7250M Bending stiffness rollable side N m²/m 1.6 ASTM D7250/D7250M Heat transfer coefficient W/ m² K 7.2 DIN52612 We have the MadFlex. And now, you? What will you make of it? MadFlex Sample Book 12