evalith® honeycombs in thermoset infusion process

Evalith® Honeycombs

In Thermoset Infusion Process

Johns Manville 2015©

A New Generation of Honeycombs Based on Polyester Spunbond

for Thermoset Applications


Introduction of Johns Manville‘s spunbond

Introduction into Evalith® honeycombs

Impregnation of Evalith® honeycombs

Performance of Evalith® honeycombs

Application examples of Evalith® honeycombs


Johns Manville

Johns Manville Major fiber glass manufacturer in North

America and Europe. Over 150 years of proud history ;

A Berkshire Hathaway company since 2001. Leader in key markets

Johns Manville Engineered Products Glass Fibers

• Glass fibers for compositereinforcement, glass nonwovens,and wallboard reinforcement

Nonwovens• Glass and polyester nonwovens for

roofing, flooring, filtration, and etc.


Johns Manville produces polyester (PET) spunbond nonwoven fabrics for the following market applications:

Commercial RoofingCarrier material in bitumen based roofing products for flat roofs and underslating for pitched roofs

FiltrationAutomotive – cabin air

Liquid filtration – pool & spa, coolant oils

Air filtration – industrial baghouse filtration

Specialty – cover stock for HVAC and HEPA filter medias, support for PTFE lamination

Reinforcements

Carpet

Geotextile

Specialty

Spunbond


Quench air

Stretch nozzle

Lay belt

Rotary plate

Spin packPolyester Filaments

Compressedair

Spunbond Process Overview


chips hopper

extruder

spinneret

filaments

winderdryerbinderneedle loom

conveyor belt

accumulator

Spunbond Process Overiew


Filament Structure

SheathCore ←

Regular Polyester Heterofil Polyester

Spunbond Filaments


Introduction into NW Honeycombs

Honeycombs are used in various applications to reduce weight and increase mechanical performance

Typically honeycombs cores are used between two layers of reinforced material (e.g. FRP panels)

Honeycombs can be based on paper, thermoplastic resin, Nomex, Aluminium…

Evalith® spunbond honeycombs offer higher end performance honeycombs at reasonable cost

Foam filled honeycombs allow thermal insulation in dynamic applications at reasonable cost


Honeycomb Welding Process:

Evalith® spunbond is continuously inserted into honeycomb process

Welding process: Nonwoven layers are sequentially heat-melted -> compressed -> impregnated and joined

Expansion process: The material stack is reheated to softening temperature -> extended -> cooled and fixed

Evalith® Honeycomb Process


Sustainability: Through innovative welding process no need for auxiliary (glueing) materials

Economics: Fast and economic process

Versatility: Infusion resins include foams and thermoset systems

Optimization: Nonwoven honeycombs are breathable and porous –

• For excellent infusion processes

• For excellent mechanical bonding of skin and core

• Amount of porosity and depth can be tailored

Porous area

Solid area

Porous area

Microscopic cross sectional view of a honeycomb wall Microscopic view of a honeycomb wall surface

Evalith® Honeycombs Advantages


Thermoformable

Resin impregnated

Foam filled

100% thermoplastic PETCompressive : 0,9 Mpa @ 50 kg/m³Temperature resist. (short): > 200° C

Phenolic / Sat PET / Epoxy / PU resin compressive: > 8 Mpa @ 80 kg/m³ compressive: > 1160 psi @ 5 lb/ft³

Low friabilityHigh compressive (impregnated)Thermal conduction: 0,03 W/mK @ 85 kg/m³

Dazzling Array of Evalith® Honeycombs


Evalith® honeycombs for a unique variety of requirements and processes:

Lightweight: Honeycombs offer high mechanical performance at low weights (e.g. >0,8 Mpa @ 50 kg/m³, up to 8MPa compression load for thermoset impregnated honeycombs)

Outstanding impact and shear resistance: Honeycombs impregnated with thermoset resinOffer optimized bonding between skin and core

Evalith® Honeycombs Performance

Johns Manville ©2014


Evalith® honeycombs for a unique variety of requirements and processes:

Improved material bonding: good bonding of thermoplastic polyester fibers to filling materials like foams and resins

Complex shaping: Honeycombs offer very good thermoforming performance

Johns Manville ©2014



Evalith® Honeycombs Impregnation Process

Honeycombs between two structural composite sheets

• Wall structures can be impregnated with same resin as skin and cured in one shot

• Honeycomb walls will take up resin from skin layer prepregs (capillary effect)

• => Optimized bonding from honeycomb structures to skin layers can be achieved in all cases


Evalith® Honeycombs Impregnation Process

Process requirements:

• Time for impregnation of honeycombs: ~ 20 sec (@ 1 inch width)

• Resin take up: approx. 50 – 60% of honeycomb weight added by resin (weight of honeycomb: ~ 50 kg/m³

panel of 1 inch adds ~ 1 kg/m² of resin into honeycomb walls)

• One shot impregnation of skin and core enhances shear resistance



3 point bending test According to ISO 14125 Sample size max. load Flexural stress Flexural strain εf

mm N MPa mmFloor panel:

FRP/underliner/honeycomb/FRP, 30 mm 200,0 10.298 27,9 8,8

Side wallFRP/honeycomb/FRP, 20 mm

200,0 6.414,5 39,5 9,6

Front wallFRP/honeycomb/FRP, 26 mm

200,0 >12.000 >40

compressive testAccording to ISO 14126

Compression test plate max. load max load impression depth

mm2 N N/mm2 mm

Floor panel: FRP/underliner/honeycomb/FRP, 30 mm

3600 21.705 6,03 1,54

Side wallFRP/honeycomb/FRP, 20 mm

3600 23.083 6,41 1,40

Front wallFRP/honeycomb/FRP, 26 mm

3600 22.271 6,19 1,22

PU foam panelFoam filled honeycomb, 23 mm

2500 20.000 8.00 1,70

compressive testAccording to ISO 14126

Weight / specific max. load working load specific load

Kg / kg/m² N N N/kg

Customer evaluation floor panel: FRP/underliner/honeycomb/FRP,

35 mm 1,76 / 9,8 21.000 16.500 9.375


Impregnated: mechanical stability

Formed: forming processes

Filled: Foam impregnated

Transportation / construction floor panels:

Value proposition• cost of ownership (life cycle)• ease of repair• lightweight

Transportation interior trim

Value proposition• good thermoforming process • vibration / noise dampening

Insulation PanelsRenewable Energy

Value proposition • shear resistance• insulation


Evalith® Honeycombs Value Chain

Spunbond Honeycomb Polyiso Foam

Sandwich Panel Application

Process Impregnation & composite manufacturing

http://www.jm.com/


Application Examples

Thermoset Resin Impregnated: mechanical stabilityfire resistance

PU Foam Filled: Foam impregnatedShear resistance

Automotive


Evalith® Honeycombs Propertiesimpact

insulation properties

material cost

thermo- formability

resistance to humidity

peel strength

FCI (thermoset impregnated)

PURcomb (foam filled)


Evalith® Honeycombs Properties vs Paperimpact


material cost

thermo- formability


peel strength



Paper honeycombs


impact


material cost

thermo- formability


peel strength



PP honeycombs

Evalith® Honeycombs Properties vs PP


impact


material cost

thermo- formability


peel strength



Aluminum honeycombs

Evalith® Honeycombs Properties vs Alu


Evalith® Honeycombs

Julia MoegelBusiness Development Manager Nonwovens Europe Johns Manville Europe GmbHMax-Fischer-Str. 11 | 86399 Bobingen | GermanyP: +49 8234 9670-542 | M: +49 172 6211985F: +49 8234 9670-558 | [email protected] | www.jm.com

For further information we would be delighted to assist!

mailto:[email protected]

http://www.jmeurope.com/

evalith® honeycombs in thermoset infusion process

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