INTRODUCING THE MADFLEX

Transcription

1 INTRODUCING THE MADFLEX NAUTICAL SECTOR Composite Research s.r.l. Turin, Italy Supported by

2 Summary 1. The MadFlex: Properties And Advantages Boat Awnings Walkways Inflatables And Tenders Interior Design Sails... 9 Nautical sector 1

3 1. The MadFlex: Properties And Advantages 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 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 Nautical sector 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. Nautical sector 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. The charts show a comparison between 1 m 2 sheets in different materials and with the same deflection under a load of 200 N. ABS safety glass aluminium steel Madflex Thermal transmittance U (UNI EN ISO 6946:2008) W/(m² C) Nautical sector 4

6 Weight Global warming ABS (plastic) safety glass aluminium steel Madflex 0 5 kg ABS (plastic) safety glass aluminium steel Madflex 0,00 20,00 40,00 60,00 80,00 CO2eq 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 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. Nautical sector 5

7 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. Here is a sample of possible MadFlex configurations. SUPER THIN MADFLEX Rollable around a tube with a diameter of only 4 cm METALLIC MADFLEX Resistant to cut and perforation damages TRANSLUCENT MADFLEX Ideal for structures and applications with natural diffused light AESTHETIC FINISH Double coating in aesthetic carbon 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. Nautical sector 6

8 2. Boat Awnings The MadFlex is ideal for producing innovative awnings and removable or retractable roofing and shading systems, which allow closing parts of the boat, without preventing enjoying the sunshine and the air of the sea. At present, existing awnings are made of canvas and are kept rigid by metal frames or hooks positioned on the shaft sides. They are generally awkward to assemble and disassemble in function of the climatic and privacy needs and they usually vibrate and are noisy in the presence of wind or high speed of the vessel. Thanks to the unique properties of the MadFlex, it is possible to improve the design of these structures, creating modern, comfortable and elegant systems, with metallic finishes or carbon fiber effect. Why should you use the MadFlex? Less vibration, ideal at high speed Possibility of automating the opening and closing systems Possibility of partial closure Ease and speed of assembly compared to traditional awnings in canvas Reduction or complete absence of metal supports Improved thermal insulation Better resistance to deterioration and ease of cleaning Greater freedom of design and aesthetic solutions Thermoforming, which allows designers to explore new geometries for space optimization even with moving parts such as awnings. Nautical sector 7

9 3. Walkways Another possible application of the MadFlex concerns the creation of innovative walkways for boats. In fact, the flexural asymmetry of the material allows replacing the metal joints present on traditional products, obtaining lighter and easier to create solutions. Using the MadFlex would allow rethinking the design of these walkways, creating roll-up and extractable systems. In other words, why the MadFlex? Lightness of the material, also due to the replacement of metal joints with solutions in composite meterials Optimization in the production cycle: One single process with no need for subsequent finishing Reduction of the dimensions, without problems relating to the field of view on the shaft 4. Inflatables And Tenders The MadFlex opens the way for important innovations in the field of inflatable systems and small boats. It would be ideal for the total or partial coating of the air chambers, creating durable inflatable keels, which are resistant to abrasion, perforation and impact, easy to clean and dry and with similar hydrodynamic performances to those of rigid hulls. Replacing rigid parts such as the floor area with roll-up plans in MadFlex would also allow creating easier to carry inflatable rafts and tenders, which can be stored in smaller spaces. Nautical sector 8

10 5. Interior Design The possibility of creating surfaces and components with a minimum encumbrance, combined with the extreme lightness, resistance, insulating capacity and a wide range of aesthetic finishes make the MadFlex an ideal material to achieve functional design components for yachts and sailboats. Only by way of example, here is a list of possible applications: sliding walls, doors, flaps and screens extendable shelves, tables, chairs and other space-saving furnishing shading systems and insulating shutters, suitable to any geometry, even curve 6. Sails Compared to traditional solutions, the MadFlex could represent a sensitive improvement in the production of sails or portions of them, in terms of aerodynamic performances. At the same time, it could also support the spread of rigid sails, whose use is at present limited to high-level competitions. In fact, thanks to the use of modular ribs in MadFlex, it possible to create sails that can maintain a predefined shape with the desired aerodynamic profile, combined to the possibility to roll it. MadFlex vs traditional sails: Increased efficiency: The sail in MadFlex reduces the heeling force Possibility of increasing the aerodynamic thrust and, consequently, the speed of the boat even with weak wind Greater design freedom Nautical sector 9

11 Like rigid sails, some design solutions allow a greater maneuverability and the possibility of automation, thus entering the motor boats market segment. MadFlex vs existing rigid sails: Ease of transport and assembly: No need to hoist the sail with a crane Possibility to lower the sail, even partially, in case of necessity (storms or strong wind) The aerodynamic profile may be changed depending on the wind direction; in this way, it is possible to use asymmetrical profiles, which are even more efficient. Suitable not only to sports sailing fans, but also in civilian contexts. We have the MadFlex. And now, you? What will you make of it? Nautical sector 10