SOLUTIONS

04 MAJOR NOISE ABATEMENT PROJECT Hamburg gets a highway with a lid on top

16 RAUVISIO CRYSTAL SLIM Extra-slim polymer glass for furniture construction

22 HIGH-FLYING POLYMERS Lightweight design above the clouds

Furniture

The magazine for the furniture sector 19 th issue/ 11.2014

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dear Readers,

”Design For Furniture” is now ”Furniture Solutions”! I take great pride in unveiling the latest issue of our customer magazine which has a new name, a diff erent look, and a broader range of content.

So why is everything new? It‘s a question that you, our readers, might well be asking yourselves now. the new name embodies our guiding principle. We see ourselves as your reliable partner – a partner who will work with you to develop innovative solutions for life, home and work in tomorrow‘s world.

that‘s why we – the rEHAU company – are deliberately step-ping aside from the limelight a little in this new issue so that our partners and customers can have their say in our articles. We look at the mindsets, ideas and intelligent technologies – viewed from diff erent perspectives – that play their parts in developing innovative concepts for living.

With our cover story, we aim to focus your attention on a short article about an issue that concerns us all: traffi c noise, and how urban development measures to reduce noise can enhance the quality of life. noise abatement is a major issue that is frequently debated in cities across the world, but its role in everyday offi ce life is often underestimated or even neglected. It‘s worth noting here that near-fi eld acoustic absorption solutions are far easier to implement than structural measures on the building envelope.

Our panorama feature focuses on a topic that goes beyond the world of furniture. take off with us to enjoy a fascinating excur-sion into the aviation industry – one of the many sectors that we support as a polymer specialist – and gain inspiration for your own applications.

We hope you enjoy reading our magazine, and that it will off er you plenty of stimulating and interesting suggestions!

Jürgen WernerHead of Furniture Division

EDItOrIAL

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ImprInt

Furniture SolutionsA magazine of the rEHAU AG + Co

PublisherrEHAU AG + Co, rheniumhaus, 95111 rehau

Issueno. 19 / november 2014

Project management Verena Kaschlan

Editorial team matthias HaaslerAnne HuneckeVerena Kaschlan thomas ponaterFranz Vodermeier

Design conceptArt Directionmarion HerrmannVeit Larisch

TextIrin rodatz, GOOS COmmUnICAtIOn

PhotographyEtH Zürich, Gramazio & Kohler, titelbild, S. 3, 8 - 11Jörg Gulden, S. 2 DEGES/V-KOn media, S. 4Hamburg city – Agency for the city development and environment, S. 3, 5marcin melanowicz, S. 3, 12 - 15thomas Leichsenring, S. 3, 16 - 20Airbus S. A. S., S. 3, 22, 23

PrintFrischmann Druck und medien GmbH & CO. KG, DE Amberg

Paperprinted on FSC-certified paper

PublishedBi-annually

08 PORTRAIT

PERFECT ROOM ACOUSTICSDesign panel prototype unveiled after two years of research

12 PROjecT

DESIGNING OPEN SPACESHotel Arłamów opts for rELAZZO

16 PROducT

RAUVISIO CRYSTAL SLIMExtra-slim polymer glass for furniture construction

18 PRAcTIce

THE ZERO JOINT A craftsmanship business invests in the hot air process

22 PANORAMA

HIGH-FLYING POLYMERSLightweight design above the clouds

PeRsPecTIve

MAJOR NOISE ABATEMENT PROJECT Hamburg gets a highway with a lid on top

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MAJOR NOISE ABATEMENT PROJECTHamburg gets a highway with a lid on top

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A section of the A7 stretching almost 90 kilo- meters from the Elbe tunnel to the Bordesholm interchange is being widened to accom-modate the increase in traffic volume. And as part of the project to add another two lanes to the highway, the Hanseatic City of Hamburg is launching a noise abatement project that will set trends for the future. the so-called “Hamburger Deckel” project, as it is known, involves the construction of a ca-nopy over the A7 at three points, with a total length of 3.483 meters. parks and allotments will cover the tops of the tunnels.

Nobody wants a 17-meter high wall in their garden

put a lid on it. this isn‘t a new idea. For over 20 years, a residents‘ initiative named “Ohne Dach ist Krach” (“no roof, too much racket”) has been calling for sections of the highway to be covered over. It is due at least in part to persistent lobbying by a number of citizens that this demand is now becoming a reality – but the decision to take this route is not an entirely voluntary choice by the City of Hamburg. Since the new noise Abatement

Ordinance came into force in 2005, immis-sion limits for noise abatement must be met when new buildings are constructed or major changes to roads are made. 59 decibels by day and 49 by night. noise levels in the Hamburg districts of Othmarschen and Bah-renfeld must not exceed these values after the upgrading of the A7. plans to build noise protection walls to comply with the limits had to be discarded. After all, nobody wants a 17-meter high wall in their garden.

A stroll through the little park alongside the Othmarscher Kirchen-weg in Hamburg is like visiting a tiny corner of paradise in the heart of the city. But there‘s just one thing that spoils the idyllic calm: instead of twittering birds, what visitors can mostly hear is traffic noise. That‘s because the longest highway in Germany is about 250 meters away. The A7 starts at the danish border and contin-uous through to Austria. It is therefore the route that connects the north and south of the Federal Republic – so it carries a very heavy volume of traffic. There is no other place where so many cars pass as close to a built-up residential area. At present, this section of the A7 in Hamburg carries a constant flow of 152,000 cars and trucks per day, and experts expect the figure to rise to 165,000 over the coming years.

At 964 kmthe A7 highway between Austria and Denmark is Germany‘s longest motorway.

About 50 %of Germany‘s population feel bothered by road traffic noise in the areas where they live.

152,000 motor vehicles Every day, 152,000 motor vehicles use the section of the A7 between the Hamburg north-West highway interchange and the Hamburg-Stellingen junction.

Hamburg

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Noise cannot be measured – only sound waves this is why the “Deckel” advocated by the citizens‘ initiative came into the picture. It is an expensive undertaking for the city, even if a large proportion of the money is coming from the Federal government.

Why spend so much money so that a few thousand Hamburg residents can sleep slightly better? Isn‘t road noise an inevitable consequence of the modern world? Espe-cially in a metropolis such as Hamburg? But according to professor Dr. August Schick of the University of Oldenburg, who has been researching into noise for decades, action is highly advisable: “traffic noise is a major problem in many European countries – in Germany alone, 15 per cent of citizens are exposed to noise pollution in excess of 65 decibels. there‘s absolutely no doubt that this level is damaging to health.”

noise is an interesting phenomenon. It can‘t actually be measured. It‘s only possible to measure the sound waves that are trans-ported as oscillations in the air and are then perceived as noises and tones. Sound waves become noise when they are felt to be disruptive or annoying. the point when this

we know HOW

“In a quiet residential location” – an aspect that is im-portant to many people when choosing a home, and an advantage that residents living close to the A7 should be able to enjoy in a few years‘ time. “desk in a quiet office” should also be a quality argument for job advertisements.

Conversations among colleagues or ringing telephones are not unusual noises, but their frequencies can become exceptionally stressful: noise makes it more difficult to understand speech, requires greater listening effort, leads more quickly to fatigue and can increase error rates. the latest studies indicate that up to 20 % of performance attrition among employees is due solely to poor room acoustics. Given that personnel expenses may amount to over 80 % of a company‘s costs, this translates into significant economic losses.

And yet the solution is so obvious: rEHAU Acoustic Solutions offer a varied range of innovative options to create offices where employees will feel comfortable. these products include the 1 rAUVOLEt acoustic-line, a patented sound-absorbing tambour door system that stands out from its competitors. With the height-adjustable 2 rAUWOrKS screen system, all employees can adapt their shared workstation to their own acoustic and visual requirements. With a matching design, our acoustically effective 3 rAUWOrKS partition system was developed for flexible room partitioning in open space. 4 rAUWOrKS front, our cabinet closure system, is ideal not only as an individual screening solution but also as a whiteboard or pinboard for spontaneous discussions.

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Noise abatement enhances quality of life – in offices as well

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limit is reached is judged subjectively. One thing is certain: noise above a certain audible frequency is damaging to health. Above 90 decibels, the body reacts with earache, and hearing may be damaged. Long-term noise pollution also causes stress reactions, and may entail serious consequences such as cardiovascular diseases, arteriosclerosis and high blood pressure. So there‘s no need to stand next to a jackhammer to experience noise pollution that can put health at risk: for example, normal office noise with telephones ringing (80 dB) and discussions among colleagues (60 dB) is quite enough to cause damage.

More green, less noise – but there is still criticism

And traffic noise poses an even greater threat: a survey by the Federal German Environment Agency (UBA) in 2012 showed that well over half of people living in residential areas felt disturbed or annoyed by noise from road traffic. the “Hamburg Deckel” is a flagship project which will now ensure that a huge step forward is taken in noise abatement, at least in Hamburg. And, incidentally, it will have other posi-tive side-effects: greening the lid makes sense from the ecological perspective, and

it will increase the quality of life for local residents. not least, city districts that have been separated since the highway was built will grow back together. Although it will create more greenery and reduce noise, a major project such as this one is also bound to attract criticism: the cost, the long construction period including an increased risk of tailbacks on the A7, the relocation of allotments – all these issues are fuelling heated discussions. However, all of this will probably be forgotten in twenty years‘ time, when the citizens of Hamburg will hear birdsong as they stroll along the landscaped “Deckel” by the Elbe.

From building to room acoustics

Actions to reduce noise in offices should be given attention well before people start to feel disturbed by the noise level. Even then, it is still not too late to improve the working atmosphere – but noise abatement should ideally begin with the construction of a building. the basic principle is: interior acoustic solutions based on sound absorption can only take effect if sound insulation is guaranteed by constructional features. these include suitably planned building envelopes and, of course, multiple-glazed windows that keep the noise outside. nor should there be any “cardboard walls” between rooms – otherwise, every conversation can be overheard in the next room.

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PERFECT ROOM ACOUSTICS Design panel prototype unveiled after two years of research

Over the last two years, ReHAu has worked with three project partners – the swiss Federal Institute of Technology (eTH), Zurich, the swiss Federal Laboratories for Materials science and Technology (eMPA) and strauss elektroakustik – to develop the prototype for an innovative paneling system that can meet demanding acoustical requirements in a variety of room situations, including open-plan offices, con-ference rooms and even auditoriums. What‘s more, this system meets the latest standards for interior design and it can be manufactured on an industrial scale.

the high-caliber team included prof. matthias Kohler and prof. Fabio Gramazio of the EtH Zurich, Kurt Eggenschwiler of EmpA Dübendorf, together with acoustics expert Jürgen Strauss and Stefan Bräuer of rEHAU AG + Co. the pre-development phase has now been com-pleted, and so we talked with the key figures about this exceptional project, its origins and its development.

Please could you start out by explaining the origin of this idea for a research and development project?

Stefan Bräuer: About ten years ago, we members of the rEHAU team submitted the first patents for the acoustic-line range, and we laun-ched the products on the market shortly afterwards. Workplace design

is an increasingly important issue in the office furniture segment, because it has now been proven that employees‘ performance and productivity can be enhanced if they feel comfortable. Acoustics is an absolute key factor here. Good solutions based on absorbers have been around for some time. But especially in extensive communication zones (open space), the aim is for disruptive sound to disappear while maintaining good intelligibility of speech. So we asked ourselves: Where is this journey leading?

In your quest for a solution, you formed a project team comprising scientists from various research institutes and technical experts from industry. What were the advantages of this collaboration?

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The Project Team – Profiles

Prof. Fabio Gramazio profession: Graduate in archi-tecture, EtH; Swiss Society of Engineers and Architects (SIA), Association of Swiss Architects (BSA) Age: 44 years name an event that was espe-cially important in shaping your career: Founding the “Gramazio & Kohler” architectural practice together with matthias KohlerInformation:www.gramaziokohler.arch.ethz.ch

Prof. Matthias Kohler profession: Graduate in archi-tecture, EtH; Swiss Society of Engineers and Architects (SIA), Association of Swiss Architects (BSA) Age: 46 years name an event that was espe-cially important in shaping your career: Founding the “Gramazio & Kohler” architectural practice together with Fabio GramazioInformation: www.gramaziokohler.arch.ethz.ch

Kurt Eggenschwiler profession: Head of Department, graduate electrical engineer (EtH), graduate in acoustics, SGA-SSA (Swiss Acoustical Society) Age: 57 years name an event that was especially important in shaping your career: As a student at the EtH Zurich, I had the chance to attend lectures on acoustics and to write a semester paper on the same subject Information: www.empa.ch/akustik

Jürgen Strauss profession: physics laboratory technician Age: 49 years name an event that was espe-cially important in shaping your career: Attending a concert in the Zurich tonhalle when I was 18 years old. the “Symphonie Fan-tastique” by Hector Berlioz was performed; the double basses and timpani made it clear to me that more impressive basses can be heard and felt in a large concert hall than in pop music. Information: www.strauss-elektroakustik.com

Stefan Bräuer profession: Graduate engineer Age: 50 years name an event that was espe-cially important in shaping your career: project work at the Insti-tute of plastics processing (IKV) in Aachen, developing acoustics expertise and technology in the Furniture Division since 2004 Information: www.rehau.com/acoustic-solutions

Sincere thanks are due to all those involved in the project; their dedication played a key part in the success of this research venture: EtH Zurich: Dr. ralf Bärtschi, thomas Cadalbert, Guilherme da Silva Carvalho, Luis Gisler, David Jenny, Clemens Klein, Lauren Vasey, max VomhofEmpA: Dr. Kurt Heutschi, Dr. p.J. Lee, Stefan plüss rEHAU: Juliane Boeldicke, rainer Bollhorst, Cyril Kunz, Silvio rödel, Kai Schlegl, nils Wagner, thorsten Zwenzner

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Matthias Kohler: my colleague Fabio Gramazio and I had long been focusing on room acoustics phenomena in relation to architecture, particularly in the fields of digital design solutions and robot-based construction processes. It‘s marvelous for us to see that the content of our research at the EtH Zurich is yielding practical benefits, and that interest in it is even being expressed by industry.

Stefan Bräuer: Another development which benefited all of us was that the EtH Zurich managed to convince the Swiss Commission for technology and Innovation (KtI) of this project‘s scientific relevance, so it was sponsored for two years.

What is so special about the acoustic paneling system?

Jürgen Strauss: Until now, acoustic room conditioning in most offices has only been achieved by means of absorption. this is a good way of eliminating disturbances due to excess reverberation, flutter echoes or other noise sources. But as absorption increases, the acoustic im-pression of the room deteriorates. this prompted us to opt for acoustic diffusion, but we had to put in a great deal of basic work first.

Kurt Eggenschwiler: the most unusual feature of all here was the combination of acoustic effectiveness with design – something that is otherwise lacking in diffusors of this sort. And as an acoustician, I can confirm that the panel functions perfectly!

What were the prerequisites for developing the design? Kurt Eggenschwiler: I supplied the basic rules of physics that had to be taken into account in the design in order to achieve optimal acoustics. the whole structure could be designed very mathematically but in that case, design would lose out.

Matthias Kohler: that‘s why we tried as a team to incorporate two additional factors as well as mere functionality: design freedom for architects and end customers, and a guarantee that the product could be realistically manufactured and would remain affordable. this was one of the greatest challenges.

Stefan Bräuer: And that‘s where we were needed in our capacity as polymer specialists: due to the design, we opted for injection molding and a thermoplastic fastening system without adhesive. thanks to ultrasound, the robot can bond the parts together within seconds.

This paneling system aims to produce perceptual or psychoacoustic effects, as they are known. But it also endeavors to deliver solutions for socioacoustic issues – that is to say, acoustically induced group formation and dynamics. How is this aspect relevant in the world of work?

Jürgen Strauss: With pure absorption, there is no enveloping effect due to reflection from the walls that surround the room, so speakers and listeners feel separated from one another. Diffusors create a clo-ser connection between the two parties to a discussion. this approach also allows good conversation among relatively large groups – but at the same time, the group is not split up again due to the much-feared resonance rise in the speaker‘s volume in rooms with excessive reverberation. Let‘s take the example of a restaurant: people speak louder and louder to be heard above the others. When the maximum is reached, the construct collapses and it becomes quieter – only to build up yet again. Acoustic diffusion has a calming influence on a group.

You carried out a practical test where participants read a poem aloud to each other in an unconditioned part of the room, and then again between the two diffusor walls. Why exactly did you choose a poem by Hölderlin?

Jürgen Strauss: We needed a short but very demanding text for this experiment – and that‘s why I thought of a poem titled “Half of Life” (“Hälfte des Lebens” in German). reading a poem aloud impromptu is always a challenge – and understanding it is equally difficult. But it seemed to be considerably easier between our wall panels. Incidental-ly, the poem ends with words that mean “the walls stand there speech- less and cold” – just like acoustic absorbers, which merely swallow up the sound. that‘s a problem which our panel has solved.

Two prototypes have already been produced. What‘s the schedule for ongoing implementation?

Stefan Bräuer: We‘re currently in the evaluation phase. We think it‘s important to obtain clear market feedback so that we can gear our next steps to it. to open up possibilities for continuing this develop-ment activity, we aim bring other areas on board (such as the office furniture sector) and integrate them more closely in order to optimize the practical suitability of the products. Anyone interested can put one of the prototypes through practical tests in our rEHAU Art exhibition center – and of course, we shall be glad to provide anthologies of poetry by Hölderlin to read aloud.

The final ”Acoustic Brick” is composed of a main body

and a secondary insert.

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350 m

m

108 mm

144

mm

Body

Insert

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DESIGNING OPEN SPACESHotel Arłamów opts for RELAZZO

Quality to the highest standard

the rELAZZO decking system for terraces is manufactured from a high-grade wood-polymer composite. With six attractive color shades, two surface structures, three profile geometries and two combinable widths, rELAZZO offers limitless possibilities for design.

PROJECT

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the Bieszczady mountains are located in the extreme south-east of poland. this is a sparsely populated region that many regard as one of the country‘s loveliest stretches of landscape. Unlike the tatra, this semi-highland countryside has hardly been opened up to tourism. And yet this unspoiled natural landscape with its unique unforested ridges – known as the “polonina” – is becoming increasingly popular. Until now, guests were mostly accommodated in simple hotels and vacation apartments. But since 2013, visitors with more sophisticated tastes can find what they are looking for at the Hotel Arłamów, with its superb complex of buildings. As well as comfortable rooms and apartments, this hotel boasts an extensive conference and wellness area, but its most impressive

asset is its delightful location on the rim of the mountain range. At first glance, it‘s impossible to tell that several chapters of 20th-century European history played out behind the traditional facade of the Arłamów. the building was erected in the 1960s as a secluded and secret recreation and relaxation facility for the government. Back then, the stunning views were reserved for officials of the people‘s republic of poland and their guests. the complex reached the nadir of its history in 1982: the Solidarność trade union was gaining influence, and the government imposed martial law. Lech Wałęsa, the then chairman of the trade union who went on to receive the nobel peace prize and become president of poland, was interned in the Arłamów for several months at this time.

Historical and modern influences combined

these inglorious events took place a long time ago. After the downfall of communism, the building initially reverted to the local authority and was then carefully renovated and modernized, with the addition of several new structures. nowadays the Arłamów welcomes guests from all over the world who enjoy the standards of comfort that the inter-national public expects. One of the highlights is the spa and wellness facility that extends over three stories. Cutting-edge materials were used to renovate and fit out the building – which is why rELAZZO from rEHAU was selected for the terrace design. 5,000 square meters of this material in the terra color

The historic Hotel Arłamów achieved fame due to its inglorious history – but nowadays, what draws attention to the hotel building is its superb range of recreation and relaxation activities.

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5,000 m² RELAZZO deckingwas installed in the magnificent spa and wellness area at the Hotel Arłamów.

50 % wood componentrELAZZO decking board has a 50 % wood component. As compared to the usual types of WpC decking boards available on the market, rEHAU has the most balanced ratio between the wood and polymer components – as is clearly evident from its look and feel, and its service lifetime.

www.rehau.com/relazzo

shade were installed, making it the largest project of this sort in Europe to date. rELAZZO is a wood-polymer composite: this non-slip, splinter-free material is a convincing choice for outdoor applications. Especially in highly frequented public areas, this product scores over wooden planking because it offers a significantly longer service lifetime as well as low cleaning and maintenance outlay. So the Hotel Arłamów recounts a story of progress on both the technological and political fronts – against a panoramic backdrop that few hotels can rival.

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Hotel Arłamów S.A.Arłamów,38-700 Ustrzyki Dolnepolandwww.arlamow.pl

we know HOW

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Glass furniture strikes a special note in any room: with its characteristic transparency, it embodies a modern lightness of style in interior design. so it comes as no surprise that there is increasing demand for high-caliber furniture that skillfully combines glass with other materials such as wood or stainless steel. In fact, glass is equally popular in private homes and public areas such as hotels or offices.

RAUVISIO CRYSTAL SLIMExtra-slim polymer glass for furniture construction

With the friendly assistance of Küchen Sieber GmbH, Weißdorf

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However, there are limits to the use of real glass in furniture construction – individu-al sizes and decorative features call for intensive planning, and processors have to maintain large inventories so that they can cover a certain variety. Glass is also suscepti-ble to shocks and breakage during proces-sing. In cases where the characteristics of glass mean that it is no longer practical or profitable, the market for vertical applications has now been revolutionized by rAUVISIO

crystal, our flexible glass laminate: this pro-duct combines the visual advantages of glass with the positive features of thermoplastic laminates. End users can see no difference between real glass and rAUVISIO crystal – and they are delighted by its authentic brilliance.

In the past, rAUVISIO crystal was only availa-ble as a system composite pressed onto an mDF substrate in thicknesses of 16 and 19

millimeters. now rEHAU has added an espe-cially slim 5-millimeter version to the range: the reduced weight has a positive impact on transport and packaging costs, and it makes installation easier.

As you would expect, the slim version offers all the tried-and-tested benefits of rAUVISIO crystal: it is resilient in everyday use, break-resistant and flexible during processing – key advantages for cutting to customized sizes, drilling and individual shaping. this product is also easy to clean, and liquids simply drip off the surface. rAUVISIO crystal slim is ideal for a variety of vertical indoor applications: for example, as a solution for kitchen splash backs or sliding doors, and also to fill in fronts. It is available in three color selections: Bianco, perla and magnolia. perfect for ma-ximum design freedom – and “light” in every sense of the word!

RAUVISIO crystal slim used as a splash back in the kitchen

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“The zero joint is a quality argument that positions us in a niche, so we stand out from the competition.”

Torsten Ungnader, proprietor of the raumeffekt furniture manufactory

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raumeffektthe furniture manufactory

the corporate history of the raumeffekt furniture manufactory began in 1996 with the renovation and extension of a former farmhouse to create a modern workshop and office complex, which also includes a 300 m2 showroom. What started out as a small craftsman-ship enterprise has since grown into a medium-sized company. the furniture manufactory collaborates with archi-tects on project work, and produces furniture for end consumers.

www.raumeffekt.de

I N T R O D U C I N G

THE ZERO JOINT – THE ICING ON THE CAKEA craftsmanship business invests in the hot air process

By developing the zero joint technology, the industry has set a trend in motion – and now, growing numbers of end consumers are deliberately opting for lounge, bathroom or kitchen furniture with zero joints. Of course, the perfect look created by the appearance of a seamless joint between the edge and the board is a convincing advantage; but most important of all, this technique‘s practical features deliver benefits in day-to-day use: the absence of adhesive is a very positive environmental aspect. And without glue, there are no joints to attract deposits of dust and dirt – a particular advantage for light-colored furniture. There‘s also the fact that no moisture can penetrate between the board and the edge – a real quality argument in the furniture sector.

many industrial enterprises have already switched their production to zero joint manufacture. But is such a change also worth-while for smaller craftsmanship

businesses? And if so, which technology is best: laser, hot air or plasma? We discussed these questions with torsten Ungnader, the proprietor of the “raumeffekt” furniture ma-nufactory in Bockelwitz, Saxony. Since 1996, this midsize enterprise with 15 employees has been supplying carpentry products as well as collaborating on projects with archi-tects and producing furniture for end consu-mers. “We deliberately describe ourselves as a furniture manufactory, because we serve all our customers individually and work to very high standards. In the early days when we were a fledgling carpentry business, we tried to take on and execute every order. But over the years, we deliberately began to specialize in high-quality furniture. Follow-ing this route also meant that we had to

purchase new machines to achieve the best possible results. We succeeded – and as a result, our client base also changed”, torsten Ungnader explains. A new edgebander became necessary last year. this prompted mr. Ungnader to wonder whether now might be the time to invest in zero joint technology: “to continue to stand out on the market with our high-caliber products, it‘s only natural that we have to keep up with the times. the upshot is that we now occupy a niche with excellent prospects for the future thanks to zero joint technology, which is the subject of such widespread promotion in the press and at trade shows. You could say that we offer the ’icing on the cake‘”.

Zero joint technology: a niche with future prospects raumeffekt applies up to 80,000 meters of edging per year – not a lot, compared to a large enterprise that may handle as much as several million meters. Initial cost calculations quickly made it clear that laser or plasma machines would not pay their way because procurement costs would be many times higher.

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“We looked at various manufacturers and we also experimented on site with our own edgebands and boards. At the end of the day, we found the airtec machine was most convincing because of its highly stable machine frame and equipment. What‘s more, we can still use this machine to apply normal edgebands with adhesive”, mr. Ungnader adds in explanation of his decision.

the machine was delivered and set up at the start of the year, after which technicians trained three employees. “But that wasn‘t

Temperature, pressure and feed rate – the right combination is essential

for the perfect edge.

the end of the story”, mr. Ungnader notes. “We experimented for a few months on edgebands from various manufacturers – with temperature, pressure and feed rate. Of course, there are some parameters that are recommended by the machine manufacturer and the edgeband suppliers. But as we‘ve learned, the same machine with the same equipment does not necessarily mean that one single processing method is valid.

to sum it up: you have to perform many tests to get the perfect edge.

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we know HOW

Three technologies for zero joints

Laser technology In this process, a laser activates the functional layer which melts and bonds permanently with the rough surface of the substrate. Laser technology is now used in numerous industrial production methods.

Hot air technology Hot compressed air is used to melt the functional layer in this process. Customers operating on a commercial scale as well as smaller fabricators appreciate this technology because its investment costs are lower than for the laser method.

Plasma technology When a customer uses the plasma process, air plasma exits from a nozzle onto the functional layer of the edgeband. the special layer is activated and the edge is bonded to the substrate without joints.

At present, there are three zero joint processes in which the functional polymer layer is melted to create a permanent bond with the board: the laser, hot air and plasma technologies. All three processes are suitable for RAuKANTeX laser edge, which always achieves a per-fect match between the functional layer and the edge.

Months of experimentation to get the perfect edge – but a new computer operating system would be worse

“Only after six months were we finally able to say that we had truly mastered the 2-mm edgebands. Incidentally, we achieved the best results here with rAUKAntEX laser edge, so now we only work with the rEHAU product.” But when asked whether the switch to zero joint technology could be compared to a new operating system on a computer, mr. Ungnader responded: ”no, a new operating system is worse!”

Shortly after start-up, it became clear that the firm needed to purchase a second compressor which could also maintain stable pressure when processing large parts. All in all, the investment in this new technology harbored several surprises for the raumeffekt company. But torsten Ungnader wants to wait five years before assessing whether the venture has actually paid off. One thing is already clear to him: ”Our first major order for the new hot air machine was for a very luxurious private house. Since the color scheme is entirely white, we were able to present zero joint technology as a key quality argument to the architectural practice – and that‘s why we won the order. the architect and the client are full of enthusiasm!”

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HIGH-FLYING POLYMERSLightweight design above the clouds

pAnOrAmA

Airbus, eurocopter, Fokker, Lufthansa – ReHAu‘s customer portfolio reads like a Who‘s Who of the aviation world. No wonder. ReHAu is a recognized partner for the aircraft industry and since 1980, we have been developing materials that are literally worth their weight in gold for the sector. That‘s because in aviation, every single gram counts. Lightweight construction is therefore a highly significant factor in aircraft design for reasons related to aerophysics, among others.

we know HOW

As well as the furniture sector, ReHAu offers its services as a polymer specialist to many other industries. In each issue, our Panorama feature will give you insights into a different sector of industry. This time, you can learn how the aviation industry benefits from our intelligent polymer products.

The principle of our RAU-FLIGHT material (enlarged 3,000 times): the polymer matrix is interspersed with glass bubbles to make the material lighter.

Polymer solutions – for aviation too

Application areas in aircraft interiors include bumper protection systems, cable ducts, seat track covers and floor edge trims.

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But as well as lightweight structures, a particularly crucial part is played here by innovative lightweight materials. And this is a field where rEHAU is an international trailblazer: since the company‘s earliest days, its production facilities have developed several thousand formulations for a vari-ety of sectors, so rEHAU now has what is probably one of the most extensive portfolios of materials anywhere in the world. thanks to intelligent polymer products, rEHAU suc-ceeds time after time in offering customers exactly the solutions they need – solutions that set standards in terms of engineering, design and sustainability. Aviation is one of the many industries to have benefited from these achievements. the rAU-FLIGHt family

of materials was developed specifically for use in aviation. Its characteristics ensure that energy requirements are substantially reduced, thereby making the aircraft fleet more cost-effective and sustainable. How‘s it done? With the greatest of ease – because rAU-FLIGHt achieves weight reductions of over ten percent on some components! this seems quite straightforward at first glance. But an example of a calculation will illustrate the full effect: a handrail system in an Airbus A320 has a total weight of about 48 kilograms – but with rAU-FLIGHt, this is reduced by about 5 kilograms. this means that one aircraft would cut its kerosene con-sumption by about 2,000 liters per year. With a fleet of 150 planes used for an average of

15 years, the fuel savings would amount to no less than 4.5 million liters. passengers can find rAU-FLIGHt installed in a variety of different places in the aircraft cabin. Apart from its low weight, rAU-FLIGHt also offers advantages over comparable standard materials when it comes to look and feel. Its surface is consistent, matt and uniform – so there is no need for the post-treatment that is usually required with other materials. the smart structural design makes it possible to manufacture components with thinner walls than would be possible with other linear polymers. the result: additional weight opti-mization combined with optimal load-bearing capacity. rAU-FLIGHt – helping the aviation industry to lighten up!

rEHAU AG + Cowww.rehau.com/furniture

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