high-flying polymers - Aircraft Interiors Expo

Transcription

HIGH-FLYING POLYMERS
SOLUTIONS FOR THE AVIATION INDUSTRY
www.rehau.com
Construction
Automotive
Industry
Unlimited Polymer Solutions
NEW STANDARDS IN THE AVIATION INDUSTRY
Our mission is to redefine the limits of the possible ever new and
maintain a strong presence in the construction, automotive and industry sectors. REHAU secures long-term competitive advantages
by means of outstanding innovations and a high degree of reliability. Industry-specific know-how obtained from the three business
divisions is expertly brought together to develop new materials,
formulations and products and to advance them through to series
production. As an independent globally active family-owned company we are tops in flexibility and our 127 sales offices, 42 production sites and 16 administration offices make sure we are always right there where our customers need us. High-performance
in every respect.
2
CONTENTS
1.
Expertise in every area
2.
Energy efficiency made easy
3.
REHAU flies high
1.1 Innovative development partner at home in many
aircrafts . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Materials and formulations from REHAU
production sites . . . . . . . . . . . . . . . . . . . . . 6
1.3 Professional solutions for the aviation industry . . . . . . . . 8
2.1
RAU-FLIGHT – the material innovation . . . . . . . . . . 10
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.2
3.6 3.6.1 Profiles
Seat track covers . . . . . . . . . . . . . . . . . . . . Bumper system . . . . . . . . . . . . . . . . . . . . .
Cover profiles . . . . . . . . . . . . . . . . . . . . . . Light covers . . . . . . . . . . . . . . . . . . . . . . .
Systems
Handrails . . . . . . . . . . . . . . . . . . . . . . . . PSU intermediate rail . . . . . . . . . . . . . . . . . . Air ducts . . . . . . . . . . . . . . . . . . . . . . . . Mouldings
Edge protection profiles . . . . . . . . . . . . . . . .
Luggage compartment brackets . . . . . . . . . . . . . Fibre composites components
Retainer and slide guide for window systems . . . . . . . Clamping rails for side wall panels . . . . . . . . . . . . Tracks for side wall panels . . . . . . . . . . . . . . . Silicone profiles
Standard ABS components . . . . . . . . . . . . . . . .
Interior area seals . . . . . . . . . . . . . . . . . . . .
Silicone hoses
RTM hose . . . . . . . . . . . . . . . . . . . . . . . .
14
15
16
18
21
22
23
24
25
26
28
29
30
33
35
Due to the system conversion to SAP, in 2012 our article numbers have changed to material numbers. The previous article numbers have become material numbers with one extra
digit: old: 123456 (Article number)
new: 1123456 (material number)
To illustrate this in the catalogue, we have visually identified the additional digit: 1 = 1, e.g.: 1123456, Please note that in the system all quotations, order confirmations,
dispatch notes and invoices will largely only be issued with the 7-digit number.
3
1
EXPERTISE IN EVERY AREA
REHAU has been
an acknowledged
partner to the aircraft
industry since 1980,
always pushing the
pace of development
work.
References:
-Airbus S.A.S.,
Airbus Operations
GmbH
-Fokker Aircraft
-ATR
-FACC
-Diehl Aircabin
-Zodiac
-Diehl Comfort
Modules
-Lufthansa Technik
-Eurocopter
-Ruag
-Decorative Products
-P3 Voith
©©AIR FRANCE / Virginie VALDOIS
4
INNOVATIVE DEVELOPMENT PARTNER
at home in many aircrafts
1.1
RAU-FLIGHT, the new,
innovative material,
is crucial to the
sector. It ensures the
customer obtains
better cost efficiency
and a better energy
balance.
5
1.2
MATERIALS AND FORMULATIONS
FROM THE REHAU PRODUCTION SITES
Developing its own materials has been one of the cornerstones of
REHAU‘s technical success ever since the company was founded.
During this development, the quality, reliability and products that
benefit the customer have always been given top priority. With
several thousand different formulations for the various business
sectors, REHAU probably now possesses one of the largest
material portfolios worldwide.
A sustainable approach to using valuable resources
with production methods producing little waste and
active recycling concepts continue to be mission of
the REHAU material, process and product developers. This is why special attention is paid to the
processing characteristics of materials in REHAU
production facilities. With more than 40 Production
sites worldwide, researchers and developers have a
perfect basis upon which to make sure their materials are fit for production and the market.
Consequently, this produces the synergies for the
premium products for which REHAU is renowned on
the market.
6
Plant Port Elizabeth, ZA
Impact strength test
7
1.3
PROFESSIONAL SOLUTIONS
FOR THE AVIATION INDUSTRY
REHAU development engineers and technicians see the product
through from the initial idea through the development, all the way
to the installation and finally its use. They are at the customer‘s
side to provide advice and support making it possible to implement
even special requirements and innovative solutions
without problems.
Our production and process engineering
departments offer a host of solutions to meet any
requirement from single-piece production to series
production and optimised manufacturing processes.
REHAU‘s in-house material development department provides solutions that are optimised both
in terms of costs and benefits, even for custom
applications.
In the downstream processes, REHAU opts for
varied options such as painting, surface finishing
and fabrication in order to implement the various
product properties.
In the logistics department, REHAU provides
optimum basic conditions and made-to-measure
solutions right through to just-in-time deliveries.
Process expertise
Details
Material expertise: . . . . . . . . . . . . . . . . . . RAU-SIK, RAU-FLIGHT, RAU-FLIGHT PA
Production processes: . . . . . . . . . . . . . . . . Extrusion, injection moulding, extrusion
blow moulding, thermoforming
Design: . . . . . . . . . . . . . . . . . . . . . . . CATIA V5, FEM calculation, mouldflow simulation
Material development: . . . . . . . . . . . . . . . . RAU-FLIGHT
Processing: . . . . . . . . . . . . . . . . . . . . . PC, PA6, PA66, PA12, PEI, PPSU, PPS, TPE and
silicone (shore 50 and 70)
Fabrication/finish: . . . . . . . . . . . . . . . . . . Milling, grinding, CNC, drilling, bonding,
painting
Painting: . . . . . . . . . . . . . . . . . . . . . . Smooth and textured painting systems
approved for the aviation industry
8
Bending test
Abrasion test
9
2
RAU-FLIGHT
THE MATERIAL INNOVATION
ENERGY ANALYSIS
In the aviation industry, every gram counts. Light-weight
construction has always been crucial not least by virtue of the
physics of flight. Along with light-weight structures, light-weight
innovative materials have also made a vital contribution to this. The
use of these materials reduces the energy consumption and thus
helps improve cost efficiency and in addition to this, also makes a
sustainable ecological contribution.
Improved cost efficiency with consistent
properties
RAU-FLIGHT, the unique
material principle:
„glass bubbles“ embedded in the
polymer matrix
magnified 300 times
magnified 3000 times
10
Again and again, REHAU succeeds in providing
customers with made-to-measure solutions by
means of intelligent polymer solutions, which not
only have a positive impact on the energy balance
but also meet the highest of demands in terms of
engineering and design.
The material family RAU-FLIGHT was specially
developed for the aviation industry, which achieves
a weight reduction by up to 10 %.
The challenge lay in maintaining the mechanical
values of approved initial materials whilst producing
an end product suitable for series production. Fabrication operations, such as milling, painting, bonding
etc. continues to be possible based on the original
material properties.
The new RAU-FLIGHT material can be specially
customised to meet specific customer requirements
e.g. high-temperature applications with PPSU or PC
for light scattering effects.
The relevant fire regulations are demonstrated as
part of the development, if required also during the
qualification.
RAU-FLIGHT
2.1
THE MATERIAL INNOVATION
© AIRBUS S.A.S. 2012 - photo by S. Ramadier
AIRBUS estimates an annual aviation fuel saving of 1970 litres
per 10 kg unloaded weight saving for an A320. Kerosene savings
achieved by a weight reduction of up to 10 % in existing polymer
components with an assumed total weight of 100 kg per MSN.
Effect per aircraft operating over
a period of 1 year
Effect per aircraft operating over
a period of 15 years
Effect per fleet of 150 aircraft
operating over a period of
15 years
≈ 2,000 litres
≈ 30,000 litres
≈ 4,500.000 litres
11
In the polyamide sector, REHAU has succeeded in creating a
perfect RAU-FLIGHT PA formulation. This material was approved by
AIRBUS to AIMS 04-01-025.
RAU-FLIGHT PA sets completely new standards
in terms of appearance and feel.
The normally subsequent surface treatments of
through-coloured PA profiles is completely eliminated in order to prevent the gloss caused by the
material.
The surface can be created by the extrusion die.
Consequently, the profile surface appears consistently matt and uniform.
Surface marks, such as extrusion drag lines, typical
for the process or marks of subsequent treatment
are a thing of the past. During this process, these
surfaces can also be perfectly combined and matched to additional components.
A sophisticated constructive design makes it
possible to produce components with thinner walls
than other polyamides for example, which provides
an additional contribution towards optimising the
weight but does not limit the load-bearing capacity.
Application areas are bumper systems, cable
guides, seat track covers and floor end strips.
12
3.2.1
3.6
3.3.2
3.5
3.1.4
3.5
3.2.2
3.5
3.3.1
3.2.3
3.1.4
3.5
3.4.3
3.1.2
3.4.2
3.4.1
3.1.1
3.1.1
3 REHAU FLIES HIGH
3.6
REHAU PRODUCTS
3.3.2
3.5
3.1.4
3.2.2
3.1.1
Seat track covers
The safe connection point
between passenger and aircraft.
3.1.2
Bumper system
The bodyguard for light-weight
structures.
3.1.3
Cover profiles
The clever transition between
different floor coverings.
3.1.4
Light covers
Classy design with sophisticated
function details.
3.2.1
Handrails
Ergonomic and functional safety.
3.2.2
PSU intermediate rail
The luxurious connection between operating unit and luggage
compartment.
3.2.3
Air ducts
For a pleasant and hygienic
atmosphere in the aircraft.
3.5
3.3.1
3.2.3
3.5
3.1.3
3.1.1
3.1.1
3.3.1
Edge protector
Safely covered, be it luggage
compartment or handrails.
3.3.2
Luggage compartment brackets
The reliable support in the
luggage compartment.
3.4.1
Retainer and slide guide
for window systems
Permanent fixing of interior
elements.
3.4.2
Clamping rails for side wall
panels
For fixing side wall panels to the
fuselage.
3.4.3
Tracks for side walls
The perfectly fitting connection
between wall panels.
3.5
Silicone profiles
The professionals when it comes
to sealing, fixing and covering.
3.6
RAUSILAM hose
Silicone hoses to produce fibrereinforced components.
13
3.
REHAU FLIES HIGH
REHAU PRODUCTS
3.1.1
3.1.1
Seat track covers
Function
Aircraft seas are mounted on aluminium tracks. The
seat position and distance are variable. Between the
fixing points of the seats, the aluminium tracks are
covered with seat track covers.
Brushed uniform matt
Polyamide 12 (RAU-PA), flame-retardant, coloured
Extrusion
Surface
Material
Process
Embossing
33
12.5
Profiles
5.5
3.1
Printing
12.2
Standard:
Material:
Mat.no.
RAU-PA 592
-
Standard:
Material:
Mat.no.
ABS 0317
RAU-PA 592
1954731
Standard:
Material:
Mat.no.
ABS 0318
RAU-PA 592
1954721
20
13
12.3
50.4
Printing
8.6
31
12.2
14
Printing
Attention: The extended material number applies for all SAP countries: 1 = 1
7.9
13.6
25
Printing
Standard:Material: RAU-PA 592
Mat.no. -
3.1.2
Standard: Material: RAU-PA 592
Mat.no. -
3.1.2
Bumper system
Function Surface Material Process
Protection of light-weight structures, guiding cables
Brushed uniform matt
Polyamide 12 (RAU-PA), flame-retardant, coloured
Extrusion (retainer and cover profiles), injection
moulding (end caps)
Mat.no. -
Mat.no. -
8,7
14,8
Printing
Attention: The extended material number applies for all SAP countries 1 = 1
Mat.no. -
15
3.1.3
3.1.3 Cover profiles
Function Thin decorative profiles bonded on aluminium carrier
profiles in the area of the door covers the joint between
the carpet and the plastic floor coverings e.g. in
galleys, toilets and other screening profiles.
Surface Brushed
Material Polyamide 12 (RAU-PA), flame-retardant, coloured,
adhesive tape
ProcessExtrusion
52
4.9
9
3
Standard: ABS 5786 ABA
Material: RAU-PA 592
Mat.no. 1953068
5.1
50
4.4
5
Standard: ABS 5786 AAA
Mat.no. 1953058
34.7
Printing
Adhesive tape
16
Standard: ABS 5759
Mat.no. 1953952
2.9
31.5
34.8
7.4
11.7
Printing
48.6
Standard:Material: RAU-PC 440
Mat.no. 1959180
Mat.no. -
37
9
11
14.5
3.4
Mat.no. -
5
Standard: Material: ABS 143
Mat.no. -
17
3.1.4
3.1.4
Light covers
Translucent cover profiles
Function
Material
Translucent light cover
Polycarbonate (RAU-PC), flame-retardant,
transparent, UV-stabilised
Extrusion
Process
22,5
32.5
Standard:
Material:
Mat.no.
RAU-PC 440
-
Standard:
Material:
Mat.no.
RAU-PC 440
-
31.5
58,7
Standard:
Material:
Mat.no.
18
RAU-PC 440 Coextrusion with integrated SIK seal
-
3.1.4
Light covers
Coextruded light cover
Function Material Transparent light cover
Polycarbonate (RAU-PC), flame-retardant, transparent,
UV-stabilised,
Polycarbonate (RAU-PC), flame-retardant, coloured,
aluminium foil
ProcessCoextrusion,
Mechanical processing (milling, cutting to length),
assembly (clamp insertion)
20.7
3.1.4 71.6
Standard:Material: RAU-PC 440
Mat.no. -
Clamp
Profile
RAU-PC, coloured
RAU-PC,
coloured
RAU-PC, transparent
Aluminium insert, 57 mm x 0.3 mm
Due to the thin wall thickness, an integrated aluminium foil keeps some product
areas opaque.
19
3.1.4
3.1.4 Light covers
Function Material Translucent light cover
Polycarbonate (RAU-PC), flame-retardant, transparent,
UV-stabilised
ProcessExtrusion,
Mechanical processing (edge milling)
Standard: Material: RAU-PC 440
Mat.no. -
Mat.no. -
20
3.2.1
3.2Systems
3.2.1 Handrails
Function Handrails
Material Polyetherimide (RAU-PEI)
ProcessExtrusion,
injection moulding
Assembly
Standard:Material: RAU-PEI 140
Mat.no. -
Mat.no. -
21
3.2.2
3.2.2 PSU- intermediate rail
Holder
Function Cover between PSU (Personal Service Unit) and
luggage compartment
Material Polyetherimid (RAU-PEI),
silicone
ProcessExtrusion,
injection moulding
Painting
Assembly
Rail
Silicone seal
End cap
Standard: Material: RAU-PEI 140
Mat.no. -
22
3.2.3
3.2.3 Air ducts
Function Material Air conduction
Polyetherimid (RAU-PEI),
silicone
ProcessExtrusion,
injection moulding
Painting
Assembly
Profile
Injection moulded part
Silicone seal
Mat.no. -
23
3.3.1
3.3Mouldings
3.3.1 Edge protection profiles
Function The mouldings for protecting edges serve the purpose
of covering sandwich components and hide gaps
between 2 luggage compartments
Polycarbonat (RAU-PC),
silicone
Injection moulding
Extrusion
Cutting to size and gluing silicone profiles in place
Material Process
Mat.no. -
Mat.no. -
24
3.3.2
3.3.2 Luggage compartment brackets
Function Material Support in the luggage compartment
30 % carbon fibre reinforced polyphenyl sulphide
(RAU-PPS)
Injection moulding,
Mechanical finishing, painting
Assembly
Process
Standard:Material: RAU-PPS 150
Mat.no. -
25
3.4 Fibre composite materials
3.4.1 Retainer and slide guide for window systems
Function Material For fixing interior parts e.g. emergency escape area
Glass fibre fabric with polyetherimide (RAU-PEI), carbon
fibre reinforced polyetherimide (RAU-PEI)
Thermoforming consolidated panels,
mechanical finishing
Process
Standard: Material: RAU-TC 13307
Mat.no. -
26
Mat.no. -
Mat.no. -
Assembly
3.4.1
Assembly of window funnel
Window
Mat.no. -
Function Material Process
Guiding the window blind
Polycarbonate (RAU-PC),
Glass fibre fabric with polyetherimide (RAU-PEI)
Injection moulding (window funnel),
Thermoforming of window blind guide
Mat.no. -
Mat.no. -
Mat.no. -
27
3.4.2
3.4.2 Clamping rails for side wall panels
Tracks for connecting side wall panels
Glass fibre fabric polyetherimide (RAU-PEI)
Thermoforming of consolidated panels,
mechanical finishing
3.4.2
Mat.no. -
28
3.4.3
3.4.3 Tracks for side wall panels
Screw, pane, safety pane
Note:
Fixing side wall panels to the fuselage
Carbon fibre fabric with polyetherimide (RAU-PEI)
Thermoforming of consolidated panels,
Mechanical finishing, assembly
Prototype tool available.
The track has passed the AIRBUS static test.
Blind rivet
Clip bonded to track
Retaining bracket
Track
Mat.no. -
29
3.5.1
3.5 Silicone profiles
3.5.1 Standard ABS components
Product Standard: ABS 0306 B20
Material: RAU-SIK 8968
Mat.no. 1834584
16
26
3
Standard profile (AIRBUS),
Gap hider for side wall panels and hat racks, further
standard profiles and developments on request
Function
Sealing/hiding gaps/fixing elements
Material Silicone
DAN 1106 ∙ AIMS 04-07-003 ∙ RAU-SIK 8968
DAN 1107 ∙ AIMS 04-07-006 ∙ RAU-SIK 8964
ProcessExtrusion
16
12
Printing
Standard: ABS 5744 AA
Mat.no. 1834494
12
30
Printing
Mat.no. 1834504
3.5.1
16
3.5.1
8
20.3
Printing
7.7
Standard: ABS 0307 AB
Mat.no. 1834003
Printing
Mat.no. 1834514
22
12
2.5
Printing
Standard: ABS 0305 LC
Mat.no. 1802013
2.5
Printing
Printing
Standard: DAN 262 CG
Mat.no. 1834604
25.4
3
9.8
10.6
Standard: ABS 0305 LB
Mat.no. 1802003
Standard: Material: Mat.no. ABS 0306 B01
ABS 0306 C01
RAU-SIK 8968
RAU-SIK 8964
1834013
31
15
Printing
Standard: ABS 5748 AB
Mat.no. 1834594
35
3
17
Standard: Material: Mat.no. ABS 0306 B02
ABS 0306 C02
RAU-SIK 8968
RAU-SIK 8964
1834023
15
14.5
Printing
17
32
Mat.no. 1834394
Printing
8.5
Standard: ABS 0398 A01
Mat.no. 1834384
3.5.2
3.5.2
3.5.2
3.5.2 Interior area seals
10.1
14.5
Printing
30.7
4
Mat.no. 1834095
20.3
Mat.no. 1834484
Mat.no. 1834085
Mat.no. 1850758
Fabrication:jet-cut
Mat.no. 1834354
3
4
28
Mat.no. 1825541
Fabrication: Compression moulded
part, slotted
33
20
Mat.no. 1834175
Fabrication: Punching + adhesive tape application
7
Mat.no. 1834075
Fabrication: Adhesive tape application
11.8
4.8
18.8
34
Printing
Mat.no. 1834224
Fabrication: punching + forming
bonding
23.5
Mat.no. 1834274
3
15
11
1
45
Mat.no. 1834074
3.2
Material: RAU-SIK
Mat.no. 1834314
3,9
18
w
26,5
25
Mat.no. 1834176
Mat.no. 1834714
47
50,8
7
Mat.no. 1834178
34
1,5
Mat.no. 1834179
3.6.1
3.6 Silicone hoses
3.6.1 RTM hose
Product Function RAUSILAM FG 8 x 13.6d
Reinforced RAUSILAM hose to inject resin
during the resin transfer moulding process
MaterialSilicone
ProcessExtrusion
Mat.no. 1807388
Advantages of the RAUSILAM hose
- Very safe in terms of temperature resistance, short period of time up
to 180°C
- Resistant to heat and pressure
- Free from plasticisers compared to other flexible hose systems
- Reduction of volatile matter when annealing during production,
thanks to this virtually no migration/contamination of the resin
- Ensuring good gliding properties without the use of talcum
- High flexibility thanks to PES filament reinforcement
- Possible to check/monitor the burst pressure
- Transparent solution without talcum, therefore no contamination of
the resin by talcum and complete monitoring of the resin flow in
terms of contamination, blistering and premature crosslinking is
possible
- Product independently tested and used product by the aviation
industry
35
EXPERTISE AND RELIABILITY
REHAU STANDS FOR ULTIMATE PROFESSIONALISM AND QUALITY
Quality is crucial to our success. By
meeting the quality standards and
requirements of our customers, we make a
significant contribution to their satisfaction.
At all REHAU locations, we work to quality
principles and regulations applicable
worldwide.
The dimensions shown in this leaflet are approximate. In regard to tolerances, our Conditions of Sale apply exclusively.
We therefore recommend that you verify the suitability for your intended purpose of designs contained in this leaflet. The
methods of application, utilization and processing of our products are outside our control and are therefore exclusively your
responsibility. Our warranty covers consistency of quality of our products in accordance with our specification, as laid down
in our recognized Conditions of Sale. Where there is any question of liability, any compensation shall be limited to the value
of the goods supplied by us and used by you.
REHAU SALES OFFICES
AE: Middle East, +971 4 8835677, dubai@rehau.com AR: Buenos Aires, +54 11 48986000, buenosaires@rehau.com AT: Linz, +43 732 3816100, linz@rehau.com Wien, +43 2236 24684, wien@rehau.com Graz, +43 361 403049, graz@
rehau.com AU: Adelaide, +61 8 82990031, adelaide@rehau.com B
risbane, +61 7 55271833, brisbane@rehau.com M
elbourne, +61 3 95875544, melbourne@rehau.com P erth, +61 8 94564311, perth@rehau.com Sydney, +61 2 87414500,
sydney@rehau.com AZ: Baku, +99 412 5110792, baku@rehau.com B
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axias do Sul, +55 54 32146606, caxias@rehau.com M
irassol, +55 17 32535190, mirassol@rehau.com R
ecife, +55 81 32028100,
recife@rehau.com BY: Minsk, +375 17 2450209, minsk@rehau.com C
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ontreal, +1 514 9050345, montreal@rehau.com S
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N: Guangzhou,
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com S
henyang, +86 24 22876807, shenyang@rehau.com Q
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10.2013

high-flying polymers - Aircraft Interiors Expo

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