Partners collaborate on honeycomb panels

EconCore, Toray Advanced Composites and Bostik have announced the development of a thermoplastic honeycomb core sandwich panel for use in aircraft interiors.

By using Toray Cetex reinforced thermoplastic laminates as skins, EconCore’s thermoplastic honeycomb core based on thermoplastic chemistries with FST qualification, and Bostik’s flame retardant thermoplastics polyester web adhesive, the collaboration sees the new material pass fire, smoke and toxicity regulations applying to aircraft interiors.

The three companies came together to provide a sustainable solution to more expensive and labour-intensive fabrication of parts based on conventional sandwich layup that is currently used in aerospace, such as that of phenolic prepreg skins and phenolic impregnated aramid honeycomb core.

The thermoset system requires lengthy and expensive handling and processing of the sandwich components into the final part which can take several hours, including the curing process, whereas, by using EconCore’s continuous process and compression moulding, the new thermoplastic technology can take around 60 seconds to form the desired shape.

Tomasz Czarnecki, COO of EconCore, said: “With the FST thermoplastic honeycomb technology, we are looking for cost savings at both ends; within the continuously produced honeycomb core and panel, as well as within the fast, easy and clean conversion of a sandwich panel into a lightweight sandwich part.”

www.econcore.com