JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 104

sandwich

gies have a chance of being adopted. However, cost reduction is a global trend and
the needs are also present in other sectors
where new developments arise every day.
Quite often though, the newly developed
materials are too expensive to be accepted
by the market. Interestingly, structuring
relatively expensive materials into lowdensity configurations instead of heavier
(and hence more costly) monolithic parts
can help to overcome the challenges.

Fig. 9: ThermHex honeycomb in various material
options: FST polycarbonate and Toray's Nanoalloy®
polyamide

appreciate the sustainability of these material solutions. Cooperating with Tier 1 suppliers and with the support of equipment
manufacturers and thermoforming experts,
such as R+S Technik GmbH, EconCore
produced automotive door inserts based
on a PP honeycomb core and natural fibrePP composite skins (figure 8). Due to the
sandwich concept, the application of even
very light facings onto the honeycomb
core allows to achieve the required rigidity
levels while the complex shape is achieved
with a traditional thermoforming process.
Consequently, the weight of the part ranges
from 700 to 900 gsm and, depending on
the specific needs, sets the weight savings at
over 50% compared to conventional PP or
ABS injection-moulded parts and monolithic natural fibre composite parts.

Within a joint development agreement with
Toray Industries Inc., EconCore developed
a honeycomb solution with a special type
of polyamide based on Toray's recipe.
NanoalloY® is a thermoplastic system where
a nano-scaled dispersion of elastomers
within a polymeric matrix allows to achieve
an exceptional performance level, especially
with regard to impact absorption (figure 9).
Honeycomb structures as such, due to the
self-supporting, vertical cell walls that under
out-of-plane dynamic load introduction may
buckle in an energy-absorption preferred
way, show good impact resistance in general.
Now, by adapting also the material system to
Toray's polyamide, the performance can be
further optimised and this at affordable costs
of the final composite product.

Fire-smoke-toxicity
Collaborating with other chemical and
polymer industry players as well as
OEM's from the aircraft interiors sector,
EconCore is also looking into the direction of high-performance polymer-based
honeycomb solutions. Fire-smoke-toxicity
(FST) compliant materials such as, for
instance, the FST version of polycarbon-

Folded honeycomb
The technology of so-called "folded honeycomb" is delivering products in different
geographies and serving the needs of different market segments. Beyond transportation and building & construction, four
licensors are running the process delivering
lightweight packaging solutions. No doubt
that the packaging market end is cost-sensitive and only the most efficient technolo-

104

Fig. 10: The new generation of hybrid metal-polymer composite panels

jec composites magazine / No103 March 2016

ate have proven to be convertible within
ThermHex honeycomb technology. Based
on preliminary test results, the product
shows competitive performance when
benchmarked to traditional phenolic
resin and aramid paper-based honeycomb
solutions. Further development of the
technology for the needs of the aircraft
industry is certainly very interesting but
the real interest of EconCore is to cover a
wider range of public transportation applications, including railway, where similar
FST requirements are present while high
production volumes fit much better to the
highly automated, high-speed production
process. ThermHex technology is universal
in its nature: various skin material types
may be applied onto a honeycomb core
made of basically any thermoplastic resin.
This makes it applicable in many different
market segments where the common need
is cost and weight reduction.

Multi-material options
Regarding multi-material options, one of
the most recent evolutions of ThermHex
technology users was the launch of a new
product by Tata Steel group, one of the
largest steel makers in the world. The new
product, a hybrid combining steel skins
and a thermoplastic honeycomb core, as
shown in figure 10, was presented at BlechExpo in Stuttgart, Germany, last November. The Coretinium® brand name relates
to the continuous production process and
endless length of the sandwich panel that
can be delivered by the new production
line. The product has all the means to set a
new standard in the industrial building segment, where aluminium composite panels
used to be very popular up to this moment.
Given that the steel-thermoplastic hybrid
provides a better rigidity-to-weight ratio
than aluminium solutions and at the same
time offers thermal insulation benefits,
Coretinium® is a first-line candidate for
the replacement of heavier counterparts
in transportation applications, including
truck, trailers, buses and rolling stock. n
More information:
www.econcore.com


http://www.econcore.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #103 - March 2016

Cover
Edito
Point of view : Lamborghini
Contents
COMPANY & BUSINESS
In brief
Acquisition
Agenda of Events
APPLICATIONS
Sports & leisure
Sustainable construction
MARKET
Global
Europe
SPECIAL JEC WORLD 2016
Conferences
End-users
Automotive
Awards
Basalt
Engineering
Performing
Strategy
RESEARCH & DEVELOPMENT
Joining
Testing
Impact resistance
TECHNOLOGY & INNOVATIONS
Wind
Software
Epoxy
Repair
Thermoplastic
Sandwich
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Cover
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 2
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Edito
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Point of view : Lamborghini
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 5
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Contents
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 7
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 8
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 9
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Ad1
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Ad2
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Ad3
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Ad4
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - In brief
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 11
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 12
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Acquisition
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 15
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 16
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Sports & leisure
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 18
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Sustainable construction
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 20
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Global
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 22
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 23
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Europe
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 25
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 26
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - SPECIAL JEC WORLD 2016
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 28
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Conferences
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 30
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 31
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 32
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 33
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 34
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 35
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 36
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 37
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - End-users
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 39
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Automotive
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 41
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 42
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Awards
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 44
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 45
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 46
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 47
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 48
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 49
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 50
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 51
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 52
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 53
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 54
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 55
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 56
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Basalt
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 58
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Engineering
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Performing
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 61
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 62
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 63
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Strategy
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 65
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 66
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 67
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 68
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 69
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - RESEARCH & DEVELOPMENT
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Joining
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 72
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 73
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 74
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 75
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Testing
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 77
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 78
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 79
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 80
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Impact resistance
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 82
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 83
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 84
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 85
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Wind
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 87
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Software
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 89
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 90
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Epoxy
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 92
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 93
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Repair
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 95
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Thermoplastic
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 97
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 98
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 99
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 100
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - Sandwich
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 102
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 103
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 104
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 105
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - In the world
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 107
JEC COMPOSITES MAGAZINE - Issue #103 - March 2016 - 108
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