Henkel & Airtech Materials Group awarded as JEC Paris Innovation Award Finalist
Application: A new benzoxazine resin-based tooling material
Finalist: Henkel Cooperation
Partners: Airtech Advanced Materials Group and GKN Aerospace Germany
New methods and products for the fabrication of composite parts lead to easier and cost-efficient production processes as well as to higher end product performance. For its innovative Benzoxazine prepreg resin used for a new composite tooling material, Henkel and its partner Airtech Advanced Materials Group were selected as a JEC Innovation Award finalist.
Henkel Benzoxazine Resins with superior process performance
Henkel and Airtech worked closely to define the resin system requirements for an improved tooling pre-impregnated fiber – prepreg for short: The new composite tooling material using Henkel Benzoxazine Resin is designed for repeated cures at 185°C while maintaining good dimensional stability and vacuum integrity. Due to the characteristics of the Henkel Benzoxazine Resin, the prepregs are stable at ambient temperatures, and have a lower exotherm during the curing process which enables shorter cure cycles to be used for manufacture of thick tools without special precautions.
Successful launch of new tooling prepreg
In aircraft engineering, there is an ongoing trend toward lightweight construction. Accordingly, the new tooling prepreg was very well received by the industry. For instance GKN Munich – a leading global supplier to the world's automotive, off-highway and aerospace industry – has quickly adopted the Beta prepreg as a tooling solution for stringer tooling on Airbus A350. The requirement was for a composite tooling system which would be easily machined on the non-moulded face and would provide long high temperature service life. Beta Prepreg meets those requirements and delivers additional benefits of reduced shrinkage, also greater ease and reduces cost of manufacture when compared to BMI tooling prepregs.
Winner of JEC Asia Innovation Award 2010
Application: Film adhesive and adhesive paste for out-of-autoclave processes
Winner: Henkel Cooperation U.S.
Partners: Alenia Aeronautica S.p.A (Italy) and Diamond Aircraft Industries Inc. (Canada)
The autoclave processing of bonded parts has been, and remains, an expensive route to the assembly of composite structures. Large, expensive pressure vessels, high-strength tooling and special adhesives are required to successfully make a part. Companies are eliminating the autoclave process to cut overall costs.
Raw materials, especially resins and adhesives, need to be reformulated to maintain the performance of composite parts. The Hysol® PL 696 film adhesive meets the requirements for out-of-autoclave processing.
Foam elimination during the vacuum bag cure of film adhesives was achieved by formulating and processing changes that avoid the foam generation mechanism.
Structural adhesive performance at large bond thicknesses was preserved through the development of the Hysol® EA 9380 paste adhesive, which is uniquely formulated to maintain the required properties.
With Hysol® PL 696 and Hysol® EA 9380, the autoclave can be removed from the processing scheme, which reduces the overall cost of composite structures.
JEC Innovation Award Finalist 2010
Application: Benzoxazine prepreg resin and film adhesive for Airbus A380 Auxiliary Power Unit housing
Finalist: Henkel Cooperation
Partner: Toho Tenax
Henkel is JEC Innovation Award Finalist with the development of Henkel Benzoxazine prepreg resin and film adhesive for Airbus A380 Auxiliary Power Unit (APU) housing in Section 19.1. In this application the material must withstand high temperature exposure, meet aircraft secondary structural design requirements, and flame, smoke and toxicity (FST) requirements to eliminate possibility of any smoke or toxic gases entering the passenger compartment.
The parts were originally designed using bismaleimide (BMI) resins due to the temperature and FST requirements. Replacement of the BMI with Henkel Benzoxazine resins leads to significant cost reduction in processing with improved toughness while still meeting the high temperature requirements, fluid resistance and flammability.