ACROSOMA速 PANEL TECHNICAL INFORMATION
Technical
Information
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This is not a sandwich panel
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA� is a globally protected name and logo
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Acrosoma® : A new Kind Of Sandwich panels
Sandwich panels in general offer excellent mechanical properties (bending stiffness, stability) in combination with very low areal weights. However, the use of sandwich panels is often limited by their relatively high cost and by their „weak point“, namely the bonding between face-sheets and core, being a potential source for delaminations and damages. Acrosoma® sandwich panels overcome both problems by using revolutionary technologies:
A true reinforcement through the thickness of the panels with stitched zfibres holding the face-sheets together, containing initial damages and providing superior strength against delamination and de-bonding
The automated, continuous manufacturing process (pultrusion) which delivers high quality panels with a high output rate and can be realised at affordable cost
Acrosoma® panels have a standard cross section of 30 mm x 2780 mm and a continuous length of up to 40 m. Typical areal weights are currently between 7 and 17 kg/m²; other areal weights are possible on demand. Other dimensions can be realised short-term on demand and/or the panels can be cut to any shape using standard diamond coated tools. There are optimised composite profiles available to join the panels flat-wise or in corners.
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Acrosoma® : A new Kind Of Sandwich panels
Acrosoma can deliver raw panels, or panels cut to specific size and shape or assembled structures according to the requirements of the customer.
Material properties and input for standard FEM software are available to support an optimised design of structures made from Acrosoma® panels.
On demand, the lay-up of the face-sheets, the resin, the core and the stitching of Acrosoma® panels can be tailored to the specific needs of the customer.
The Acrosoma® Process: preforming
z-stitching
resin injection
curing
Continuously in one machine
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Unique Advantages of Acrosoma® Panels
Adaption of the face-sheets to the actual requirements: •
high (directed) mechanical properties
•
low areal weight and
•
high surface quality
and hence, options for tailoring of the panels for: •
excellent longitudinal stiffness/strength (e.g. for beams)
•
high in-plane shear properties (skins and shear webs) or
•
for combinations of the former two for general use.
The automated manufacturing process ensures constantly good material quality and high output rates combined with low costs. Glass fibres reinforcements of any kind are the standard reinforcement. Carbon fibres can be used instead of in combination with Glass fibres if extreme ratios of strength or stiffness to weight and low thermal expansion are important. Special purpose textiles like stainless steel meshes can be included on demand. Acrosoma® panels come with a smooth, tight surface that is: •
media resistant to even aggressive fluids and chemicals
•
can be easily cleaned, even with a steam cleaner, and
•
offers all possibilities for painting and surface treatment.
The longitudinal edges of the panels are similarly closed and smoothened, so the core material is protected throughout by the laminate face-sheets. The panels do not take up water or other fluid media. Acrosoma® panels offer good thermal insulation (typical 1.2 W/m²K) and can be optimised for fire protection purposes (see Materials >> Matrix Systems for more details).
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Materials >>Foam Core and stitching Acrosoma uses PET foams as standard core material resulting in: • good mechanical properties, • easy recycling and • reasonable fire/smoke/toxicity properties. Other foams like PVC, PU or even inorganic cores are feasible as well, if required. Foam densities between 40 and 100 kg/m³ are used, depending on the required strength in thickness direction.
Removing the foam core (right hand side of sample) reveals insight to the integral z-reinforcement „columns“ between both face-sheets.
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Materials >>Foam Core and stitching Acrosoma’s unique through-the-thickness reinforcement with Aramid fibre stitching yields crucial improvements over standard sandwich panels:
•
•
•
•
extraordinary resistance against initial debondings between face-sheets and foam core (20 times better!) capability to sustain the load even after initial failure, the key for the application in fail-safe constructions outstanding damage tolerance and fatigue properties far beyond any-thing having been achieved with sand-wich materials so far (factor of 15,000 in life cycles!). very good resistance against impact damage (a 1.5 m drop of 5 kg will not result in a permanent damage) the stitching pattern contains the delamination and simple repair methods are available, which can be performed after short training
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Materials >>Foam Core and stitching Acrosoma is familiar with a wide range of suitable resin systems for the manufacturing of their sandwich panels. Standard resins are vinyl ester systems which combine: •
excellent processability (i.e. stable process, high output rate, reliable inner quality)
•
good mechanical properties and
•
moderate cost.
For very high mechanical properties, e.g. in combination with carbon fibres, Acrosoma can use epoxy resins as well. The manufacturing technology, however, is so mature that even inorganic resins with outstanding flame retarding properties can be used for the panels, allowing for the highest fireworthiness certification in marine and off-shore applications. Acrosoma’s standard resin systems offer maximum use temperatures of the panels of up to 120 °C with peaks up to 160°C (low temperatures are not critical at all). Higher temperature resistance can be obtained on request Acrosoma can use the entire variety of plain fibre textiles: •
all kinds of fabrics and weaves
•
veils and continuous strand mats (CSM)
•
multiaxial non-crimp fabric (NCF) etc.
Even steel wire fabrics have been used successfully (they should allow for the stitching). Additionally, special rubber protectors are available for the edges and corners of the Acrosoma® panels to prevent local impact damage.
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Further Options for Tailored Applications on Customer Demand
•
Engineered optimisation of face sheet laminates and foam core
•
Improved temperature stability (heat resistant foam and post-cure of matrix)
•
Integrated local reinforcements in the face-sheets and/or in the foam corestate-of-the-art;
•
Stronger stitching with denser pattern and thicker 3D reinforcement
•
Local reinforcements of the face-sheets during the manufacturing process
•
non-standard thickness/width of the panel
•
variation of panel thickness over width
•
constant curvature of the panel width-wise, leading to long cylindrical panels
State-of-the-art Commercial off the shelf
short-term; new die required mid-term development
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Technical Data of Acrosoma® Panels total thickness 30 mm width 2780 mm
v3 JK/MR June 16, 2011
length "infinite" surface plies (non-structural)
t1 = 0.3 mm
t2 = 4 mm
t3 = 21.4 mm
t2 '= 4 mm
t1' = 0.3 mm
carbon fibre NCF 45° / -45° / 0° / 90°
PU foam 80 kg/m³
carbon fibre NCF 45° / -45° / 0° / 90°
t1 = 0.3 mm
PANEL CV2 0° reinforced carbon light-weight 73 / 0 / 27
standard surface plies see above
SERIES PRODUCTION PANELS
total aeral weight 480 g/m²
PANEL HD 60 standard glass fibre low-cost panel 0° / 90°
standard surface plies see above
t1 = 0.3 mm
OPTIONS CUSTOMISED PANELS ON REQUEST
surface layer
carbon fibre NCF 45° / -45° / 0° / 90°
z-stitching with aramide tow
carbon fibre NCF 45° / -45° / 0° / 90° 300 g/m² fibre weight per ply
2 x 332 tex
total 3600 g/m² CF
stitching pattern 10 x 10 mm
t2 = 1 mm
t3 = 27.4 mm PET foam
carbon fibre UD fabric 500 g/m² 0°
60 kg/m³
carbon fibre NCF 45° / -45° / 0° / 90° carbon fibre NCF 45° / -45° / 0° / 90° 300 g/m² fibre weight per ply total 3600 g/m² CF
total aeral weight 480 g/m²
t2 '= 1 mm
t1' = 0.3 mm
carbon fibre UD fabric 500 g/m² 0°
z-stitching with carbon fibre NCF 300 g/m² 0° 300 g/m² 90°
2 x 332 tex
carbon fibre NCF 300 g/m² 0° 300 g/m² 90°
total 1100 g/m²
stitching pattern 10 x 10 mm
total 1100 g/m²
t2 = 0.7 mm
t3 = 28 mm
t2 '= 0.7 mm
glass fibre continuous strand mat 300 g/m² random
PET foam
glass fibre continuous strand mat 300 g/m² random
aramid tow
60 kg/m³ z-stitching with aramid tow
glass fibre fabric 800 g/m² 0° / 90° total 1100 g/m²
2 x 332 tex
glass fibre fabric 800 g/m² 0° / 90°
stitching pattern 10 x 10 mm
total 1100 g/m²
YOUR CUSTOMISED PANEL
customised layups are possible
t1' = 0.3 mm
Actual pultrusion tool is limited to 30 x 2780 mm external cross section; new tools for individual dimensions can be manufactured: thicker or thinner panels are feasible; width can be adapted in a wide range core materials and both face-sheets z-stitching reinforcement
PET foams are preferred, PU and others possible on request
Any face-sheet lay-up (minimum 200 g/m² in 0° for pulling!)
standard surface plies (see above) are recommended for smooth and tight surface
surface plies (non-structural): random glass fibre mat 180 g/m² + glass fibre fabric 0°/90° 300 g/m²
laminate face-sheet
standard surface plies see above
quasi-isotropic
core with stitching
standard surface plies see above
thick face-sheets
laminate face-sheet
surface plies (non-structural): random glass fibre mat 180 g/m² + glass fibre fabric 0°/90° 300 g/m²
PANEL AAM high-performance Epoxy-Carbon
surface plies (non-structural)
glass, carbon or other fibre materials (even metallic wire fabric)
foam densities of 40 up to 100 g/m³ are state-of-the-art, heavier/lighter foams are feasible on request
fibre volume contents of 55 - 60 % are feasible
stitching pattern widthwise is fixed: 1 stitch/10 mm
thickness from < 1 mm up to 6 mm per face-sheet
stitching pattern lengthwise can be longer/shorter than 10 mm
variation of face-sheet widthwise is possible! (local reinforcements!)
additional parameters to further improve the z-properties can be introduced on demand
FUTURE OPPORTUNITIES
inserts can be introduced in the core during manufacturing
resin system
total areal weight
laminate type
both face-sheets should be similar all duroplastic matrices with quick cure and suitability for pultrusion are feasible ACROSOMA has broad experience in a large variety of Polyesters, Vinylesters. selected Epoxies and fire-retardent ceramic matrices
almost any desired laminate can be realised panels with areal weights of < 5 kg/m² are feasible
high 0° reinforcement is possible (improving longitudinal performance) very high ±30° ... ±45° reinforcement is possible (up to 80%) for shear panels
• defined widthwise curvature to form cylinders • variable thickness in width direction
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. internal longitudinal stiffeners or used for design purposes without the prior written permission of ACROSOMA NV. No part of this document, in whole or in part, may be •reproduced, stored, transmitted, The name “ACROSOMA” is a globally protected name and logo
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Technical Data of Acrosoma® Panels (continued) total thickness 30 mm width 2780 mm length "infinite"
v3 JK/MR June 16, 2011 bending stiffness of panel per mm
face sheet properties resin system
total areal weight
laminate type
tensile strength
tensile modulus
E × I per mm
lengthwise 0°
widthwise 90°
lengthwise 0°
widthwise 90°
lengthwise 0°
widthwise 90°
500 MPa
500 MPa
40 GPa
40 GPa
56,500 GPa mm³
56,500 GPa mm³
780 MPa
480 MPa
67 GPa
32 GPa
37,200 GPa mm³
17,000 GPa mm³
300 MPa
270 MPa
25 GPa
23 GPa
9,400 GPa mm³
8,500 GPa mm³
PANEL AAM highperformance Epoxy-Carbon thick face-sheets
Epoxy temperature range up to 120°C
25 / 50 / 25 17 kg/m²
quasiisotropic
SERIES PRODUCTION PANELS
quasi-isotropic
PANEL CV2 Vinylester 0° reinforced carbon light-weight
temperature range up to 120°C
73 / 0 / 27 8.6 kg/m² 0° reinforced
73 / 0 / 27
PANEL HD 60 Vinylester standard glass fibre low-cost panel
temperature range up to 120°C
50 / 0 / 50 8.9 kg/m²
plus random fibres
0° / 90°
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Technical Data of Acrosoma® Panels (continued) Acrosoma® panel
Areal density
Compressive strength(1)
Compressive modulus(1)
Edgewise compressive strength
Core shear strength(2)
Orientation(3) Unit HD60 HD60C CV5
kg/m² 9.0 11.9 8.4
Z MPa 1.97 2.99 2.45
Z MPa 31.10 62.18 35.29
L MPa 54.52 75.15 35.16
L MPa 0.55 0.86 0.78
(1)Measured result, method ASTM C365 (2)Calculated result, method ASTM C393 and D7450 (3)Orientation of the test. Z-direction is the direction normal to the panel surface, the L-direction is the same as the stitching direction.
Compressive strength 3,5
Edgewise compressive strength
1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0
80
3
70
2,5
60
2
50 40
1,5
30
1
20
0,5
10
0
0 HD60 HD60C
CV5
Core shear strength
HD60 HD60C CV5
HD60 HD60C
CV5
The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Potential Applications for Acrosoma® Buildings, Marine, Off-Shore, Oil-Drilling-Platforms: walls, floors, doors, deep-freeze compartments, elevator cars, small bridges, shear webs of wind energy blades light-weight corrosion-free
strong & stiff easy-to-maintain
fire retardant, rugged
Chemical industry: internal/external fairings and housings, chutes, tanks/containers media resistant thermal insulation
corrosion-free blast-proof
easy-to-clean fire retardant
Cranes and Lifting Devices housings, beams, hoisting frameworks and other structural members light-weight
high strength & stiffness
good fatigue
non critical damage tolerance
Lifting device for aerospace application, made from carbon fibre Acrosoma® panels • 33 x 8 m • weight: 3.6 to. • max. load: 3 to. • z-deflection (loaded): 8 mm The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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Potential Applications for Acrosoma® Jigs & Tools: supporting sub-structures, girders for manual handling, supports, templates light-weight
easy-to-handle
low thermal expansion
easy-to-clean
good dynamic & damping properties
Assembly jig for aerospace application, made from Acrosoma® panels; high precision, no thermal expansion
Transportation, Mobility: truck trailers, cargo containers, tanks, deep-freeze trucks, railway cars, crash structures • light weight • high bending stiffness • rugged (see drop-test on the right) • blast-proof The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name “ACROSOMA” is a globally protected name and logo
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The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name â&#x20AC;&#x153;ACROSOMAâ&#x20AC;? is a globally protected name and logo
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The information contained in this document is the proprietary and exclusive property of ACROSOMA NV except when otherwise indicated. No part of this document, in whole or in part, may be reproduced, stored, transmitted, or used for design purposes without the prior written permission of ACROSOMA NV. The name â&#x20AC;&#x153;ACROSOMAâ&#x20AC;? is a globally protected name and logo