Honeycomb Sandwich Panel Technology

Transcription

1 Honeycomb Sandwich Panel Technology Tomasz Czarnecki, EconCore / Tomasz.Czarnecki@econcore.com Matchmaking Event - RWTH Aachen 31 Jan 2017

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

3 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 Fairbairn 1845 Bi-plane wing construction by Chanute Junkers 1915 Tubular Bridge design by Stephenson and Fairbain Sandwich metal wing design by Junkers 3

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

5 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

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

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

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

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

10 EconCore s licensees references / applications 10

11 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 11

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

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

14 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

15 ThermHex organosandwich integration 15

16 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