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AEROSPACE COMPOSITES<br />
Product outline aerospace interiors<br />
<strong>TenCate</strong> Cetex System3<br />
Protective Fabrics<br />
Outdoor Fabrics<br />
Aerospace Composites<br />
Armour Composites<br />
Geosynthetics<br />
Industrial Fabrics<br />
Grass
TENCATE CETEX SYSTEM3<br />
Three thermoplastic products, one system, one solution<br />
<strong>TenCate</strong> Cetex ® System3 provides one stop solutions of interior<br />
panels. The product is ideally suited to fl at and single curvature parts<br />
where light weight high fi nish is required. The GE PEI based materials<br />
used for both skin and core, enable high quality parts to be produced<br />
in very short period of time.<br />
See the benefi ts:<br />
High quality pre fi nished skin materials<br />
Multiple texture fi nishes<br />
Very low OSU tox and fl ame<br />
Tough<br />
Base colour options<br />
Short manufacturing times timeline benefi ts<br />
Lightweight skin options without jeopardising skin quality<br />
Applicable manufacturing process:<br />
Thermo forming<br />
Cut and bend<br />
Hot bending<br />
Welding<br />
2<br />
AEROSPACE COMPOSITES
A thermoplastic technology driven system<br />
The unique properties of the <strong>TenCate</strong> Cetex ® System3 allows both<br />
traditional sandwich panel applications to be furnished using the<br />
panel system as well thermoforming of the system for single<br />
curvature parts. The pre-fi nished facings allow components to be<br />
manufactured and fi nished with little or no preparation, thus<br />
reducing or eliminating the amount of after work required with<br />
tradional thermoset technology.<br />
APPLICATIONS:<br />
Galley components<br />
Flooring<br />
Wardrobes and storage<br />
Overhead luggage bins<br />
Screen dividers<br />
Partitioning walls and bulkheads<br />
Dado rails<br />
Lavatories<br />
Seat components<br />
Plinths and pallets<br />
Trolley components<br />
Stairways and steps<br />
Decorative panels<br />
MATERIAL OPTIONS AND PROPERTIES<br />
Facing materials<br />
The <strong>TenCate</strong> Cetex ® facing sheets are produced using very high<br />
quality press technology allowing high standards of surface fi nish and<br />
property translation to be achieved. The sheets are produced in a<br />
variety of fi nishes and this is pressed into the surface so durability<br />
and consistency is assured.<br />
Finishes:<br />
High gloss<br />
Matt<br />
Enhanced bondable surface<br />
Textured fi nish<br />
Anti slip<br />
Along with surface fi nish the PEI polymer can be base coloured to<br />
enhance, reduce and in some cases eliminating fi nishing of surfaces<br />
of components. This is very useful when painting or covering<br />
components, as base colour matching the skins will greatly reduce<br />
the amount of paint one needs to apply. Along with this wear and<br />
scratch resistance of components is enhanced if base material colour<br />
is similar to the fi nal fi nished surface.<br />
Facing sheets<br />
A variety of reinforcements can be used to produce <strong>TenCate</strong> Cetex ®<br />
facing sheets, in general the main fabrics used are Glass, Carbon and<br />
Aramid yarns. The weights and fabric styles are many, and really<br />
there are no restrictions on which fabrics can be used to produce<br />
facing sheets. In general, for glass we have utilised both a 120 style<br />
glass and 7781 glass. Combinations of these plies allows us to<br />
produce skins from .005” 0.12mm in thickness upwards allowing<br />
lightweight panels to be produced through to heavyweight highly<br />
loaded panels. On the next page are some examples of laminate<br />
materials.<br />
Examples of laminate materials:<br />
Glass 8H (7781)/SS 0303/EC6 (BMS 8-353)<br />
Mass of fabric 300<br />
Mass of fabric + resin 448<br />
Resin content by volume (nominal) 50<br />
Resin content by weight (nominal) 33<br />
Moisture pick up 0.35<br />
Ply thickness 0.24<br />
Specifi c gravity 1.91<br />
Tg (DSC) (armorphous) 210<br />
Tm 310<br />
AEROSPACE COMPOSITES 3
TUBULAR HEADER CORE MATERIALS<br />
Sub<strong>header</strong><br />
<strong>TenCate</strong> Reet ut venim Cetex ad magna feu facillu mmodit lam zzriuscil del ex et, conOrting eum non henisci lisisim vulputat consequisit<br />
delenim digna con hent augait, sisl diam, vel et amcommo adit, quismolenit, quisl iurer susci tin ea alit prat adip eugiat<br />
loborem num ip ercilla dolese tat, suscilis ent dolorperil illum in utpat. Ed dio odiam, vulla faciliquatue alit inis eu faciduis<br />
dolortio dolor incipis duipit accum aliquisi. Agnis<br />
nonsecte dolorpe rcinci tie feu facin dolessim veriuscidunt<br />
et ut laorem velesequat ad feugue facilla feuissequis alis alit<br />
alit diamcom moluptat. Ut ad tin vel ipsum amefaccum ent nos nonsequi blaor alit dionsequat lor inim incing<br />
num vulluptate vel euissim illa ad er si euisl e, con Rserddeet<br />
ut venim ad magna feu facillu mmodit et amcommo loborem Erciliq uating elesequate consenisit iriusci nos am, vel utem<br />
num ercilla oreriurem dolese, mmodit suscilis ent dolorperil dolore facin ullamcor secte tatum euguero deliqui er iuscinc<br />
illum dolor incipis duipit accum er aliquisi.<br />
tisit vel ulput vuautat nis nullam zzrit praesecte velisl delis<br />
nim nos am, vel utem dolore facin ullamcor secte tatum<br />
Agnis alit diamcom moluptat. Ut ad tin vel ipsum ametums euguero deliqui er iuscinc consequis niatio con ullum dio<br />
andipsum adit vent nulputpat lamet lum ad magna faccum consendipisi exer susci tisit vel ulput vuautat nis nullam zzrit<br />
veraestrud ent num vulluptate vel euissim illa ad er si euisl praesecte velisl delis nim autat, quisi eugait<br />
® System3 incorporates the use of a thermoplastic core<br />
material (made by Tubus Bauer) the core is tubular in construction<br />
and can be supplied in many different core weights and primarily<br />
comes in 4 or 6 mm cell sizes. The core is cut to thickness and can be<br />
as thin as 3 mm. The unique properties of the core mean that there is<br />
no ribbon direction in the core. It is made from GE Ultem ® PEI polymer<br />
and this gives it excellent fi re properties.<br />
The concept behind <strong>TenCate</strong> Cetex ® System3 is three thermoplastic<br />
materials, one system. Combining the <strong>TenCate</strong> Cetex ® The thermoplastic adhesive SHARNET SN4275 gives excellent results<br />
when heated to 150<br />
facing skins<br />
with the Tubus tubular core with a thermoplastic fi lm adhesive allows<br />
structures to be manufactured quickly and effi ciently without altering<br />
the high level of surface fi nish already established in the skin material.<br />
This in itself allows for minimal preparation work later on if any in<br />
some instances.<br />
oC and this temperature is not suffi cient to alter<br />
the surface of the skin material. Bonding can be achieved in a matter<br />
of minutes compared to hours for thermosets and the peel numbers<br />
achieved are excellent. This process is utilised in the manufacture of<br />
premium aircraft fl ooring by WJ Tods and achieves very durable light<br />
weight fl ooring solutions for aircraft.<br />
4<br />
Core options<br />
AEROSPACE COMPOSITES<br />
PEI 4,0-48C PEI 4,0-75 C PEI 4,0-100 C PEI 4,0-120 C PEI 4,0-144 C<br />
Properties METRIC IMPERIAL METRIC IMPERIAL METRIC IMPERIAL METRIC IMPERIAL METRIC IMPERIAL<br />
Cell size 4.2 mm 1/8” 4.2 mm 1/8” 4.2 mm 1/8” 4.2 mm 1/8” 4.2 mm 1/8”<br />
Density<br />
Compressive strength<br />
Compressive modulus<br />
Shear strength<br />
Shear modulus<br />
48<br />
kg/m3 3 lb/ft3 75<br />
kg/m3 0.95<br />
mpa<br />
106<br />
mpa<br />
0.65<br />
mpa<br />
12.2<br />
mpa<br />
137 psi<br />
15.36 ksi<br />
94 psi<br />
2.95<br />
mpa<br />
178.5<br />
mpa<br />
1.3<br />
mpa<br />
4.6<br />
lb/ft 3<br />
100<br />
kg/m 3<br />
6.24<br />
lb/ft 3<br />
427 psi 4.6 mpa 603 psi<br />
25.8 ksi 222.8 mpa 32.3 ksi<br />
188 psi<br />
1.6<br />
mpa<br />
232 psi<br />
1.76 ksi 26 mpa 3.76 ksi 27 mpa 3.91 ksi<br />
120<br />
kg/m 3<br />
6.34<br />
mpa<br />
276.1<br />
mpa<br />
2.1<br />
mpa<br />
32<br />
mpa<br />
7.49<br />
lb/ft 3<br />
919 psi<br />
40 ksi<br />
Tubus-PEI core<br />
Thermoplastic<br />
adhesive 60 gsm<br />
144<br />
kg/m 3<br />
10.71<br />
mpa<br />
339.6<br />
mpa<br />
9 lb/ft 3<br />
1552 psi<br />
49.2 ksi<br />
304 psi 3.3 mpa 478 psi<br />
4.64 ksi<br />
40<br />
mpa<br />
5.79 ksi<br />
<strong>TenCate</strong> Cetex ® facing skins
TEST RESULTS<br />
Skins: GI 0303 002 1707 (E-glass)<br />
Core: PE: 4.0-75C 12 mm.<br />
Test Test method<br />
Areal weight EN 2329<br />
Thickness<br />
Specimen<br />
dimensions<br />
Length = 10 mm<br />
Width = 10 mm<br />
Length = 10 mm<br />
Width = 10 mm<br />
All specimen are conditioned at 23˚C / 50% RH and tested at 23˚C<br />
Test Test method<br />
Sandwich lexural<br />
strength<br />
(4 point bending)<br />
Climbing drum<br />
peel<br />
AITM 1.0018<br />
(Issue 1. March 1994)<br />
EN 2243-3<br />
(October 2005)<br />
Impact resistance AITM 1-0057<br />
Flammability<br />
(warp)<br />
12 sec. vertical<br />
Smoke density<br />
JAR/FAR 25. App.<br />
F part I<br />
&<br />
AITM 2.0002B<br />
JAR/FAR 25. App.<br />
F part V<br />
&<br />
AITM 2.0007<br />
Toxity AITM 3.0005<br />
Specimen<br />
dimensions<br />
Length = 400 ± 1 mm<br />
Width = 75 ± 0.1 mm<br />
Length = 300 ± 1 mm<br />
Width = 75 ± 0.5 mm<br />
Length = 305 ± 1 mm<br />
Width = 305 ± 1 mm<br />
Length = 300 mm<br />
Width = 75 mm<br />
Length = 75 mm<br />
Width = 75 mm<br />
Length = 75 mm<br />
Width = 75 mm<br />
# specimen<br />
# specimen avg. st dev. % var.<br />
3 2390 4.36 0.18<br />
3 12.64 0.01 0.08<br />
Results<br />
avg. st dev. % var.<br />
6 F max [N] 1382.5 46.1 3.3<br />
6<br />
3<br />
4<br />
4<br />
Force difference<br />
[N]<br />
Peel strength<br />
[N/mm]<br />
Mean failure<br />
energy [J]<br />
379.5 42.4 11.2<br />
5.07 0.56 11.1<br />
1.4 - -<br />
Measured (avg.)<br />
Airworthiness<br />
limit<br />
Burn length [mm] 55 203<br />
After fl ame time [s] 3 15<br />
After fl ame time of drips [s] 0 5<br />
Drips (yes/no) no<br />
Max. specifi c<br />
optical density<br />
4 Passed<br />
Measured (avg.)<br />
Airworthiness<br />
limit<br />
16 100<br />
AEROSPACE COMPOSITES 5
THERMOFORMING HEADER<br />
OF SINGLE CURVATURE PARTS<br />
Sub<strong>header</strong><br />
<strong>TenCate</strong> Reet ut venim Cetex ad magna feu facillu mmodit lam zzriuscil del ex et, conOrting eum non henisci lisisim vulputat consequisit<br />
delenim digna con hent augait, sisl diam, vel et amcommo adit, quismolenit, quisl iurer susci tin ea alit prat adip eugiat<br />
loborem num ip ercilla dolese tat, suscilis ent dolorperil illum in utpat. Ed dio odiam, vulla faciliquatue alit inis eu faciduis<br />
dolortio dolor incipis duipit accum aliquisi. Agnis<br />
nonsecte dolorpe rcinci tie feu facin dolessim veriuscidunt<br />
et ut laorem velesequat ad feugue facilla feuissequis alis alit<br />
alit diamcom moluptat. Ut ad tin vel ipsum amefaccum ent nos nonsequi blaor alit dionsequat lor inim incing<br />
num vulluptate vel euissim illa ad er si euisl e, con Rserddeet<br />
ut venim ad magna feu facillu mmodit et amcommo loborem Erciliq uating elesequate consenisit iriusci nos am, vel utem<br />
num ercilla oreriurem dolese, mmodit suscilis ent dolorperil dolore facin ullamcor secte tatum euguero deliqui er iuscinc<br />
illum dolor incipis duipit accum er aliquisi.<br />
tisit vel ulput vuautat nis nullam zzrit praesecte velisl delis<br />
nim nos am, vel utem dolore facin ullamcor secte tatum<br />
Agnis alit diamcom moluptat. Ut ad tin vel ipsum ametums euguero deliqui er iuscinc consequis niatio con ullum dio<br />
andipsum adit vent nulputpat lamet lum ad magna faccum consendipisi exer susci tisit vel ulput vuautat nis nullam zzrit<br />
veraestrud ent num vulluptate vel euissim illa ad er si euisl praesecte velisl delis nim autat, quisi eugait<br />
® System3 can be easily thermoformed into single<br />
and fi xing them to the core material again utilising the thermoplastic<br />
curvature parts and subsequently assembled without damage to the adhesive as the fi xing agent.<br />
high quality surface fi nish of the facing skins. To form shapes, a one This process takes minutes, not hours and again like the panel<br />
sided or match tooling philosophy can be applied and in some cases manufacture the fi nal parts need little of no fi nishing. This process<br />
tooling cost can be minimised to using sheet metal forms or MDF allows many interior profi les to be manufactured easily like the A340<br />
forms. The basis of the process is stress forming the surface skins lightweight overhead bin produced by AIM aviation.<br />
6<br />
AEROSPACE COMPOSITES<br />
Heat up<br />
Heat<br />
Heat<br />
Form<br />
Tool<br />
Tool
SEE THE BENEFITS IN THE FINISHING TIMELINE<br />
1 HR<br />
1 HR<br />
1 HR<br />
1 HR<br />
1 HR<br />
2 HRS<br />
Paint finish<br />
Primer<br />
Primer<br />
Sand and sweep<br />
Primer<br />
Primer<br />
Sand and sweep<br />
Moulding<br />
� Phenolic or Sytem 3 �<br />
7 Hours max.<br />
3 Hours max.<br />
Paint finish (opt.)<br />
Primer (opt.)<br />
Moulding<br />
Taking cost<br />
out System 3<br />
1 HR<br />
1 HR<br />
15 mins<br />
- HR<br />
AEROSPACE COMPOSITES 7
HEADER<br />
Sub<strong>header</strong><br />
North America<br />
South America<br />
www.tencate.com<br />
Europe<br />
Middle East<br />
Africa<br />
Asia<br />
Australia
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