HIGH-FLYING POLYMERSebooks.rehau.com/.../Aircraft_opf_files/pdfs/Aircraft__.pdf · 2012-07-13 ·...

transcript

HIGH-FLYING POLYMERS SOLUTIONS FOR THE AERONAUTICS INDUSTRY

www.rehau.com ConstructionAutomotive

Industry

UNLIMITED POLYMER SOLUTIONS NEW STANDARDS IN AERONAUTICS

Our mission is to redefine the limits of the possible ever new and be a force for innovation in the construction, automotive and industry sectors. REHAU secures long-term competitive advantages by means of outstanding innovations and a high degree of reliability. 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 from every point of view.

CONTENTS

3. REHAU flies high

2. RAU-FLIGHT – the material innovation

1. Expertise in every area

Lightweight products for improved cost-efficiency . . . . . . . . 10

Innovative development partner – at home in many aircrafts . . . . . 4Materials and formulations from REHAU production sites . . . . . . 6Professional solutions for the aeronautics industry . . . . . . . . . 8

REHAU products for the aeronautics industry . . . . . . . . . . . 12

1 Profiles1.1 Seat Track Covers . . . . . . . . . . . . . . . . . . . . 141.2 Bumper System . . . . . . . . . . . . . . . . . . . . . . 151.3 Cover Profiles . . . . . . . . . . . . . . . . . . . . . . . 161.4 Light Covers . . . . . . . . . . . . . . . . . . . . . . . 182 Systems2.1 Handrails . . . . . . . . . . . . . . . . . . . . . . . . . 212.2 PSU Intermediate Rail . . . . . . . . . . . . . . . . . . . 222.3 Air Ducts . . . . . . . . . . . . . . . . . . . . . . . . . 233 Moldings3.1 Edge Protection Profiles . . . . . . . . . . . . . . . . . . 243.2 Luggage Compartment Brackets . . . . . . . . . . . . . . 254 Fiber composite components4.1 Retainer and Slide Guide for Window Systems . . . . . . . 264.2 Clamping Rails for Side Wall Panels . . . . . . . . . . . . 284.3 Tracks for Side Wall Panels . . . . . . . . . . . . . . . . 295 Silicone Profiles5.1 Standard Silicone Profiles . . . . . . . . . . . . . . . . . 30

Due to a system conversion to SAP in 2012 our article numbers will change to material numbers.The previous article numbers will become material numbers with 1 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.: 1123456Please note that in the system all quotations, order confirmations, dispatch notes and invoices will largely only be issued with the 7-digit number.

1 EXPERTISE IN EVERY AREA INNOVATIVE DEVELOPMENT PARTNER

AT HOME IN MANY AIRCRAFTS

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 - Sell - Dasell- Lufthansa Technik- Eurocopter- Ruag

RAU-FLIGHT, the new, innovative material, is crucial to the sector. It ensures the customer obtains better cost efficiency and a better energy balance.

RAU-FLIGHT: 40 kg

PEI 140: 46 kg

2 EXPERTISE IN EVERY AREA MATERIALS AND FORMULATIONS

FROM REHAU PRODUCTION SITES

Developing its own materials has been one of the cornerstones of REHAU’s technical success ever since the company was founded. Quality, reliability and products that benefit the customer have always been given utmost priority. With several thousand different formulations for the various business sectors, REHAU probably now has one of the largest material portfolios in the world to choose from.

A sustainable approach to using valuable resources and production methods that produce little waste and incorporate recycling concepts continue to be the mission of those who develop materials, pro-cesses and products at REHAU. This is why special attention is paid to the processing characteristics of materials in REHAU production facilities. With more than 40 such facilities worldwide, researchers and developers have a perfect basis upon which to make sure their materials are fit for production and for the market. In conclusion, this produces the synergies for the premium products for which REHAU is known.

Impact test

Port Elizabeth plant, South Africa

EXPERTISE IN EVERY AREAREHAU AS DEVELOPMENT PARTNER

REHAU development engineers and technicians concern them-selves with the product right from the idea stage, through the development and production processes and all the way to installation and use. They are there at the customer’s side to provide help and advice so that even special requirements can be worked on and innovative solutions found.

Our production and process engineering departments offer a host of solutions to meet any requirement, from single-piece production to series production and optimized manufacturing processes.

REHAU is an expert in all downstream processes such as painting, surface finishing and fabrication, to bring out the best from the various product characteristics.

Process expertise Details

Materials expertise. . . . . . . . . . . . . . . . . . RAU-SIK, RAU-FLIGHTProduction processes . . . . . . . . . . . . . . . . Extrusion, injection molding, extrusion blow molding, . . . . . . . . . . . . . . . . . . . . . . . . . . . thermoformingDesign . . . . . . . . . . . . . . . . . . . . . . . CATIA V5, FEM calculation, moldflow simulationMaterials development . . . . . . . . . . . . . . . . PPSU 10 % mineral filledProcessing . . . . . . . . . . . . . . . . . . . . . PC, PA6, PA66, PA12, PEI, PPSU, PPS, TPE and . . . . . . . . . . . . . . . . . . . . . . . . . . . silicone (Shore 50 and 70)Fabrication/finishing . . . . . . . . . . . . . . . . . Milling, grinding, CNC, drilling, bonding, painting Painting . . . . . . . . . . . . . . . . . . . . . . . Smooth and textured painting systems approved for . . . . . . . . . . . . . . . . . . . . . . . . . . . the aeronautics industry

REHAU’s expertise in developing its own materials provides solutions for special applications that are optimized in terms of both costs and benefits.

As regards logistics, REHAU has all the right answers plus made-to-measure solutions including just-in-time deliveries.

Bending test

Abrasion test

RAU-FLIGHT – THE MATERIAL INNOVATION LIGHTWEIGHT PRODUCTS FOR IMPROVED COST EFFICIENCY:10 TO 12.6 % WEIGHT REDUCTION WITH SAME MATERIAL

In the aviation industry, every gram counts. Lightweight construc-tion in aviation has always been crucial by virtue of the physics of flight. Along with light structures, lightweight innovative materials are also of decisive importance. The use of these materials reduces energy consumption and thus helps improve cost efficiency. It also makes its own contribution to sustainable environmental development.

Improved cost efficiency, same properties

Again and again, REHAU succeeds in providing customers with made-to-measure intelligent polymer solutions that save energy at the same time as they meet the most stringent requirements in terms of engineering and design.

RAU-FLIGHT, a material developed specially for the aviation industry which reduces weight by more than 10 %, is a shining example.

The challenge lay in maintaining the mechanical values of approved high-temperature thermo- plastics (PEI or PPSU) whilst producing an end product feasible for series production. Downstream operations, such as milling, painting, bonding etc., are all still possible without restriction.

New material RAU-FLIGHT can be specially custom-ized to meet specific customer needs.

The following example clearly highlights the benefits of RAU-FLIGHT:

A handrail system in an AIRBUS A-320 having a total weight of 48 kg would weigh more than 5 kg less if made of RAU-FLIGHT.

For an A-320, AIRBUS calculates annual fuel savings of 1,970 liters for every 10 kg of unladen weight spared.

Magnified 300 times

Magnified 3000 times

RAU-FLIGHT, the unique material

principle:

“Glass bubbles” embedded in the polymer

matrix.

RAU-FLIGHT product advantages:

- Lighter than

PEI: 10.0 %, PPSU: 12.6 %

- Identical mechanical properties

- Meets ABD031

RAU-FLIGHT: DLR Certificates ABD0031 and AITM 3.0005

7-1 Flammability . . . . . . . . . . . . . . . . . . FAR 25, App. F, Part 1 & AITM 2.0002A7-2 Heat Release . . . . . . . . . . . . . . . . . . FAR 25, App. F, Part IV & AITM 2.00067-3 Smoke Density . . . . . . . . . . . . . . . . . FAR 25, App. F, Part V & AITM 2.0007 7-4 Toxic Components . . . . . . . . . . . . . . . ABD 0031 & AITM 3.0005

≈ 4,500,000 liters ≈ 30,000 liters ≈ 2,000 liters

Kerosene savings achieved by RAU-FLIGHT PPSU versions (around 12.6 % lighter) of polymer components with an assumed weight of 100 kg per MSN.

Effect per fleet of 150 aircraft operating over a period of 15 years

Effect per aircraft operating over a period of 15 years

Effect per aircraft operating over a period of 1 year

REHAU FLIES HIGHREHAU PRODUCTS FOR THE AERONAUTICS INDUSTRY

Seat Track Covers The safe connection point between passenger and aircraft.

Bumper SystemThe bodyguard for lightweight structures.

Cover Profiles The clever transition between different floor coverings.

Light Covers Classy design with sophisticated function details.

Handrails Ergonomic and functional safety.

PSU Intermediate Rail The luxurious connection between operating unit and luggage compartment.

Air DuctsFor a pleasant and hygienic atmosphere in the aircraft.

Standard Silicone Profi les The professionals when it comes to sealing, fi xing and covering.

Edge Protector Safely covered, be it luggage compartment or handrails.

Luggage Compartment Brackets The reliable support in the luggage compartment.

Retainer and Slide Guide for Window SystemsPermanent fi xing of interior elements.

Clamping Rails for Side Wall Panels For fi xing side wall panels to fuselage.

Tracks for Side Wall Panels The perfectly fi tting connection between wall panels.

REHAU FLIES HIGHREHAU PRODUCTS FOR THE AERONAUTICS INDUSTRY

Bedruckung

Standard: ABS 0318

Material: RAU-PA 592

Mat.No. 1954721

Printing

Embossing

Printing

3.1 PROFILES3.1.1 SEAT TRACK COVERS

Function Aircraft seats are mounted on aluminum seat tracks. Seat position and distance are variable. Between the fi xation points the seat track is covered with cover profi les.

Surface Smooth matt brushedMaterial Polyamide12 (RAU-PA), fl ame resistant, colored Process Extrusion Standard: ABS 0317

Mat.No.

Standard: -

Mat.No. -

Printing

3.1 PROFILES3.1.2 BUMPER SYSTEM

Function Protection of honeycomb structures, Cover of electric cablesSurface Smooth matt brushed Material Polyamide 12 (RAU-PA), flame resistant, coloredProcess Extrusion (top and bottom profile), Injection molding (endcaps)

Standard: -

Mat. No. -

Standard: -

Mat. No. -

Standard: -

Mat. No. -

Standard: -

Mat. No. -

Standard: -

Mat. No. -

Printing

34.794.

Aluminum foil

3.1 PROFILES3.1.3 COVER PROFILES

Function Thin decorative profiles bonded to aluminum carrier profiles, covers the joint between carpet and plastic floor coverings, e.g. in galleys, toilets and other scree-ning profiles.

Surface BrushedMaterial Polyamide 12 (RAU-PA), flame resistant, colored, Adhesive tapeProcess Extrusion

Standard: ABS 5759

Mat.No. 1953952

Standard: ABS 5786 AAA

Mat.No. 1953058

Standard: ABS 5786 AAA

Mat.No. 1953069

Printing

Standard: -

Mat.No. -

Standard: -

Mat.No. -

Standard: -

Material: ABS 143

Mat.No. -

Standard: -

Material: RAU-PC 440

Mat.No. 1959180

Standard: -

Mat.No. -

Function Translucent light coverMaterial Polycarbonate (RAU-PC), fl ame resistant, transparent,

UV-stabilizedProcess Extrusion

3.1 PROFILES3.1.4 LIGHT COVERS TRANSLUCENT COVER PROFILES

Standard: -

Mat.No. -

3.1 PROFILES3.1.4 LIGHT COVERS COEXTRUDED LIGHT COVER

Function Transparent / opaque light coverMaterial Polycarbonate (PC), flame resistant, transparent,

UV-stabilized, Polycarbonate (RAU-PC), flame resistant, colored,

Aluminum foilProcess Coextrusion,

Mechanical processing (milling, cutting to length), Assembly (clamp insertion)

Standard: -

Mat.No. -

RAU-PC, colored

Profile

RAU-PC, transparent

Aluminum insert, 57 mm x 0.3 mm

Due to the slight wall thickness an aluminum foil is used to enhance the opaque

properties.

Function Translucent light coverMaterial Polycarbonate (RAU-PC), flame resistant, transparent,

UV-stabilizedProcess Extrusion,

Mechanical processing (edge milling)

Standard: -

Mat.No. -

Standard: -

Mat.No. -

3.1 PROFILES3.1.4 LIGHT COVERS

3.2 SYSTEMS3.2.1 HANDRAILS

Function HandrailMaterial Polyetherimide (RAU-PEI)Process Extrusion,

Mechanical processing (milling, cutting to length), Injection molding, Assembly

Standard: -

Material: RAU-PEI 140

Mat.No. -

Standard: -

Mat.No. -

End cap

Holder

Silicone seal

Function Cover between PSU (Personal Service Unit) and luggage compartment

Material Polyetherimide (RAU-PEI), Silicone

Process Extrusion, Mechanical processing (milling, cutting to length), Injection molding, Painting, Assembly

Standard: -

Mat.No. -

3.2 SYSTEMS3.2.2 PSU INTERMEDIATE RAIL

Injection molding

Profile

Silicone seal

3.2 SYSTEMS3.2.3 AIR DUCTS

Standard: -

Mat.No. -

Function VentilationMaterial Polyetherimide (RAU-PEI), Silicone Process Extrusion, Mechanical processing, Injection molding, Painting, Assembly

Function The moldings for protecting edges cover sandwich components and cover gaps between 2 luggage compartments

Material Polycarbonate (RAU-PC), SiliconeProcess Injection molding, Extrusion, Cutting and bonding of silicone profiles

Standard: -

Mat.No. -

Standard: -

Mat.No. -

3.3 MOLDINGS3.3.1 EDGE PROTECTION PROFILES

3.3 MOLDINGS3.3.2 LUGGAGE COMPARTMENT BRACKETS

Function Support in luggage compartmentMaterial 30 % carbon fiber reinforced polyphenyl sulfide (RAU-PPS)Process Injection molding, Mechanical processing, Painting, Assembly

Standard: -

Material: RAU-PPS 150

Mat.No. -

Function For fixing interior parts, e.g. overwing exit door coverMaterial Glass fabric reinforced polyetherimide (RAU-PEI), Carbon fabric reinforced polyetherimide (RAU-PEI)Process Thermoforming preconsolidated panels, Mechanical processing

Standard: -

Material: RAU-TC 13307

Mat.No. -

Standard: -

Mat.No. -

Standard: -

Mat.No. -

3.4 FIBER COMPOSITE COMPONENTS3.4.1 RETAINER AND SLIDE GUIDE FOR WINDOW SYSTEMS

Window

Assembly

Window funnel assembly

Function Guiding the window blindMaterial Polycarbonate (RAU-PC), Glass fiber fabric with polyetherimide (RAU-PEI)Process Injection molding (window funnel), Thermoforming of window blind guide

Standard: -

Mat.No. -

Standard: -

Mat.No. -

Standard: -

Mat.No. -

Standard: -

Mat.No. -

Function Rails for connecting side wall panelsMaterial Glass fiber fabric with polyetherimide (RAU-PEI)Process Thermoforming of preconsolidated panels, Mechanical processing

Standard: -

Mat.No. -

4.2 4.2

3.4 FIBER COMPOSITE COMPONENTS3.4.2 CLAMPING RAILS FOR SIDE WALL PANELS

Clip bonded to track

TrackRetaining bracket

Screw, pane, safety pane

Blind rivet

Function Fixing side wall panels to fuselageMaterial Carbon fiber fabric reinforced polyetherimide (RAU-PEI)Process Thermoforming of preconsolidated panels, Mechanical processing, Assembly,Remarks: Prototype tool available, Track passed AIRBUS static test

3.4 FIBER COMPOSITE COMPONENTS3.4.3 TRACKS FOR SIDE WALL PANELS

Standard: -

Mat.No. -

Printing

Product Standard profile (AIRBUS), Gap seal for side wall panels (ABS0306),

Profile (ABS0307), Other standard profiles and developments upon requestFunction Seals / gap covers / fixing elementsMaterial Silicone

DAN 1106 ∙ AIMS 04-07-003 ∙ RAU-SIK 8968 DAN 1107 ∙ AIMS 04-07-006 ∙ RAU-SIK 8964

Process Extrusion

3.5 SILICONE PROFILES3.5.1 STANDARD SILICONE PROFILES

Standard: ABS 5744 AA

Material: RAU-SIK 8968

Mat.No. 1834504

Standard: ABS 0306 B20

Mat.No. 1834584

Mat.No. 1834504

2.5 Printing

Printing

2.5 Printing

Printing

Mat.No. 1834023

Mat.No. 1834514

Standard: ABS 0307 AB

Mat.No. 1834003

Standard: DAN 262 CG

Mat.No. 1834604

Standard: ABS 0305 LB

Mat.No. 1802003

Standard: ABS 0399 A

Mat.No. 1834394

Standard: ABS 0305 LC

Mat.No. 1802013

Mat.No. -

Quality is crucial to our success. By meeting the quality standards and requirements of our customers we contribute greatly to their satisfaction. At every REHAU facility we work to quality principles and regulations applicable worldwide.

EXPERTISE AND RELIABILITYREHAU STANDS FOR ULTIMATE PROFESSIONALISM AND QUALITY

REHAU SALES OFFICES AE: Dubai, Phone: +9714 8835677, dubai@rehau.com AR: Buenos Aires, Phone: +54 11 489860-00, buenosaires@rehau.com AT: Linz, Phone: +43 732 381610-0, linz@rehau.com Vienna, Phone: +43 2236 24684, wien@rehau.com AU: Adelaide, Phone: +61 8 82990031, adelaide@rehau.com Brisbane, Phone: +61 7 38897522 brisbane@rehau.com Melbourne, Phone: +61 3 95875544, melbourne@rehau.com Perth, Phone: +61 8 94564311, perth@rehau.com Sydney, Phone: +61 2 87414500, sydney@rehau.com BA: Sarajevo, Phone: +387 33 475-500, sarajevo@rehau.com BE: Brussels, Phone: +32 16 3999-11, bruxelles@rehau.com BG: Sofia, Phone: +359 2 89204-71, sofia@rehau.com BR: Arapongas, Phone: +55 43 3152 2004, arapongas@rehau.com Belo Horizonte, Phone:+55 31 33097737, belohorizonte@rehau.com Caxias do Sul, Phone:+55 54 32146606, caxias@rehau.com Mirassol, Phone: +55 17 32535190, mirassol@rehau.com Sao Paulo, Phone: +55 11 461339- 22, saopaulo@rehau.com BY: Minsk, Phone: +375 17 2450209, minsk@rehau.com CA: Moncton, 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minneapolis@rehau.com ZA: Durban, Phone: +27 31 657447, durban@rehau.com Johannesburg, Phone: +27 11 201-1300, johannesburg@rehau.com

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 thereforeexclusively 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.

Englisch Profildruck Lieferprogramm

HIGH-FLYING POLYMERSebooks.rehau.com/.../Aircraft_opf_files/pdfs/Aircraft__.pdf · 2012-07-13 ·...

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