Composite Technology Centre GmbH (CTC, Stade, Germany) specializes in developing cost-effective serial-production composite technologies. A subsidiary of Airbus (Toulouse, France), CTC undertook studies in to find more productive but less costly methods of fabricating carbon fiber-reinforced polymer (CFRP) sandwich constructions. Evonik Foams Inc. - ROHACELL (Darmstadt, Germany) submitted samples of its new ROHACELL HERO polymethacrylimide (PMI) closed-cell foam to CTC for evaluation as a core-material alternative to traditional honeycomb. The new PMI foam is the fruit of an unusual Evonik effort to develop a new polymethacrylimide (PMI) foam product that can mimic honeycomb core’s tendency to show visible laminate damage. Although foam is touted as a means to prevent water-ingress into surface-damaged aircraft parts, PMI foam’s greatest asset in other applications — its superior impact resistance compared to honeycomb core products — makes it difficult for aircraft maintenance and repair organizations (MROs) to visually identify damage on aircraft sandwich constructions during part inspections. Evonik’s HERO product is specifically formulated to accommodate this need in PMI foam performance properties.
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CTC evaluated three CFRP sandwich construction design options: (1) autoclaved, honeycomb-cored, carbon/epoxy prepreg; (2) autoclaved PMI-cored, carbon/epoxy prepreg; and (3) an out-of-autoclave (OOA) alternative featuring PMI core between faceskins of carbon fiber infused with liquid epoxy resin. Options 2 and 3 required significantly less time and cost than option 1. Option 3 was the best, at 19% lower weight and 25% lower cost than option 1. Further, it cut 18 hours off production time (a 43% savings) because the process eliminated the lengthy core potting step and the two cure cycles typically necessary to integrate the prepreg skins and honeycomb. “These significant savings in time and cost were achieved for a simple part,” says Remo Hinz, CTC’s R&D project leader, “As part complexity increases, the savings in processing time and costs exponentially increase in favor of an infused foam core over an autoclaved honeycomb sandwich design.”
On the basis of the CTC evaluation, nose landing-gear doors for a Dornier 728 aircraft were successfully fabricated as a technology demonstrator by INVENT GmbH (Braunschweig, Germany). The ROHACELL 71 HERO (75 kg/m3 density) arrived preshaped, via CNC machining, by Evonik’s ROHACELL SHAPES division and was sandwiched between dry carbon fiber fabrics (see photo, above). The layup was infused with Hexcel (Stamford, Conn.) Airbus-qualified RTM 6 epoxy infusion resin.
Evonik reports that the PMI core not only prevents problems seen in honeycomb-cored constructions, such as water ingress, but also eliminates skin debonding due to potting compound deterioration. In addition, the core’s greater elongation (9 to 10 percent) and impact resistance makes it viable for exterior aircraft parts.
Impact tests were conducted at 35 Joule impact energy by the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM (Halle, Germany), according to ASTM D/DM–11, on specimens cut from the PMI-cored infused laminate and the original honeycomb/prepreg laminate. Nondestructive testing confirmed that damage size and depth in each were comparable.
Professor Axel Herrmann, CTC’s managing director, concludes, “ROHACELL HERO is, technically, the better and safer material to specify for sandwich construction, as water ingress issues are eliminated and debonding failure risks are significantly reduced.” Evonik, therefore, is working on several structural applications with Airbus, and says that the first Airbus aircraft part specified with its PMI foam will enter service during .
Flame Retardant PMI Foam – Your Solution to Fire Safety
As a manufacturer located in China, we take pride in offering the best quality products at competitive prices. Our latest addition to our product line is Flame Retardant PMI Foam, a game-changer in fire safety technology.
In today's world, fire incidents are a significant concern for both individuals and businesses. Whether it is for residential or commercial use, it is essential to be equipped with solutions that can minimize the risk of fire and save lives and property. Our Flame Retardant PMI Foam is designed to do exactly that.
So, what is Flame Retardant PMI Foam?
Flame Retardant PMI Foam is a high-density, closed-cell foam made from polymethacrylimide or PMI, a superior quality resin, and other additives. This foam is infused with fire retardant agents that make it highly resistant to fire.
Flame Retardant PMI Foam has a unique structure that makes it highly efficient in resisting fire. Its closed-cell construction means that it does not easily absorb water or other liquids, making it even more resistant to fire. It also has a low heat transfer property, which enables it to withstand higher temperatures.
How is Flame Retardant PMI Foam made?
Flame Retardant PMI Foam is produced through a continuous manufacturing process under controlled conditions. The PMI resin and additives are mixed and heated, and then extruded into a continuous sheet form. The foam is then cross-linked using gamma radiation to provide stability and rigidity.
Flame Retardant PMI Foam can be produced in various densities and thicknesses, making it ideal for a wide range of applications in various sectors.
Applications of Flame Retardant PMI Foam
Flame Retardant PMI Foam has a wide range of applications in different sectors. It can be used in the following fields:
1. Building and construction – Flame Retardant PMI Foam can be used as insulation for walls, roofs, and floors in buildings. It can also be used in ceilings, doors, windows, and HVAC systems.
2. Automotive – This foam can be used in soundproofing, thermal insulation, and cushioning in automotive applications.
3. Aerospace – Flame Retardant PMI Foam is perfect for use in aircraft insulation, gasketing, and sealing due to its lightweight and resistance to fire.
4. Marine industry – This foam can also be of great use in marine applications for insulation and buoyancy purposes.
5. Sports and leisure – Flame Retardant PMI Foam can be used in fitness equipment, protective gear, and seat cushions in sports and leisure applications.
Why choose Flame Retardant PMI Foam?
1. Fire resistance – Our Flame Retardant PMI Foam has been certified as an "A" class fire-resistant material, which is the highest rating for flammability resistance.
2. High insulation property – Our foam has a low thermal conductivity of 0.023 W/mK, making it highly efficient in insulating.
3. Lightweight – Flame Retardant PMI Foam is lightweight but still provides excellent cushioning and protection.
4. Cost-effective – Our Flame Retardant PMI Foam is cost-effective, with the ability to reduce energy costs in buildings and insulation in vehicles.
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5. Environmentally friendly – Our foam does not contain CFCs or other ozone-depleting gases, making it environmentally friendly.
Certifications
At our factory, we have put our Flame Retardant PMI Foam through comprehensive tests and obtained certifications from some of the reputable certification bodies, including RoHS, REACH, and ISO.
Conclusion
Flame Retardant PMI Foam is a revolutionary foam that provides exceptional fire resistance, thermal insulation, and cushioning properties. It has numerous applications and is cost-effective, making it an ideal material for use in various sectors. Our foam is also eco-friendly, which increases its appeal to environmentally conscious consumers.
If you are looking for a reliable supplier of Flame Retardant PMI Foam, look no further than us. We have the expertise and experience to deliver high-quality products and are committed to providing our clients with excellent customer service. Contact us for more information and to place your orders.
Description
This Flame Retardant PMI Foam is a new type of foam prepared by taking methacrylic acid (MAA) and acrylonitrile (AN) as monomers and adding a certain amount of TBPMI as flame retardant. It does not contain any Freon and is an environmentally friendly material with fire resistance up to FAR 25.853 and ATM and other related standards. Compared with similar products, it has good dispersion, strong flame retardancy and compressive strength, and can maintain excellent mechanical properties.
Features
Our Flame Retardant PMI Foam can well meet the requirements of pressure, temperature and time for various curing methods, and is widely used in aerospace, CT medical bed plates, high-speed trains and among construction materials, and is currently the hardest structural core material under the same density conditions. In addition it has outstanding resistance to heavy impact, and its high strength and stiffness make the material have good process performance.
Specification
Product name
PMI foam core
Density
32-205KG/m3
Thickness
2-40mm
Color
White/light yellow
Application
Radar radome，Vacuum Foming,Marine industry,Rail transit,Aerospace
Pore(XK): It has excellent mechanical properties and good surface adhesion. It is mainly used for carbon fiber prepreg vacuum autoclave molding.
Coarse holes(CK): It has better machinability and surface adhesion, and is mainly used for carbon fiber prepreg compression molding.
Ultra-fine holes(CX): with extremely low glue absorption, mainly used for buoys, water equipment and light drones.
Application
PMI Used in aviation, aerospace, shipbuilding, medical, wind power, transportation and other fields
Contact us to discuss your requirements of PMI Foam Carbon Fiber Panels. Our experienced sales team can help you identify the options that best suit your needs.