Design and Analysis of 3D-MAPS: A Many-Core 3D Processor ...
ESC 3D-Core InfoEn11 Web
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1 FOAM IN NEW DIMENSIONS Seite 2 Examples of use 3 3D|CORE™ – Benefits and function 4 3D|CORE™ – Product range 5–6 Comparison of technical values 7–8 Comparison of cost and weight 9 Foam Core Navigator 10–11 Tips / Hints for application and processing 12 Application example “Dynamic” 13 Contact, general information
Transcript of ESC 3D-Core InfoEn11 Web
1
FOAMINNEWDIMENSIONS
Seite
2 Examplesofuse
3 3D|CORE™–Benefitsandfunction
4 3D|CORE™–Productrange
5–6 Comparisonoftechnicalvalues
7–8 Comparisonofcostandweight
9 FoamCoreNavigator
10–11 Tips/Hintsforapplicationandprocessing
12 Applicationexample“Dynamic”
13 Contact,generalinformation
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3D|CORE™ – ExamPLES Of uSE
Theimpressivestrengthofthefinalproduct,with3-Dflexibilityduringthemanufacturingprocess,isrecommendedforallapplicationswhereweightsavingisimportant:
Boatbuilding(deck) Boatbuilding(hull)
Carbodyconstruction Personalprotection
Airship(Zeppelinnose) Aviation(gliding)
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3D|CORE™ – BEnEfitS anD funCtiOn
Insearchofathree-dimensionallymouldabletechnicalfoamcoretheESCR&Dteamfound,throughcomprehensivesimulationsandtests,anewwaytocombinedrapebilityandreinforcementinoneproduct.Hexagonalfoambodiesconnectedthroughsmalljointsgaveaperfectsolution.
Thefirsttestsshowedthefollowingresults:
• Removalofthefoamfromthecavitiesandproducingtheconnectingjointsleavesathree-dimensionallymouldablefoamboard.
• Theresultantcavitiesproduceaperfectsystemofventingandfillingchannelsforvacuuminjection.
• Curingoftheresincreatesahoneycombstructurewiththewallsbeingsupportedbytheambientfoam.
• Theweightoftheresinisusedtobuildupa3-dimensionalreinforcingstructuremuchstrongerthanasinglefoamcore.
Comparingaclassicsandwich,i.e.anormalfoamcorewithouterlayers,witha3D|Coresandwich,anepoxyresinsystemwithacorethicknessof10mmwillprovidethefollowingincreasesintheparameters(forexamplePET):
Efficiencyinproduction +50%
Shearstrength +250%
Flexuralstrength +700%
Compressionstrength +1000%
Aftercheckingandconfirmingthesevaluesthroughadditionalmeasurements,ESCstartedplanninga3D|CORE™productionlineinJune2006.
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PRODuCt RangE
ESCdevelopsitsproductsinclosecooperationwithleadingfoamproducersoftheworld.Weonlyprocesspolymericfoamswhichhavepassedaverystrictcertificationproceduretoensurethebestpossibleresultforourcustomers.3D|CORE™isavailableinthefollowingfoamcores:
• E|XPS™ =FoamfromXPS(Extrudedpolystyrene)• E|PET™ =FoamfromPET(Polyethyleneterephthalate)• E|PUR™ =FoamfromPUR/PIR(Polyurethane)• E|PIR™ =NonflammablefoamfromPIR(Polyisocyanurate) withreduceddrapeability
3D|CORE™ PaCking
3D|CORE™isdeliveredinmodules,whichcanbeassembledtoendlessstructures.Inordertoachieveahomogeneousstructure,themodulesfeatureso-calledspacersontwoofthefoursides.Thesemeetthefacingsideofthefollowingmodulewithoutspacers.
Themodulesareavailableinfollowingmeasurements:540mm(21,26“)by370mm(14,57“).Longermodules,dependingonthefoamtype,onrequest.
Themodulesofthenextgenerationwillhaveawidthofaround600mm(23,62“)andalengthupto2940mm(115,75“).
Standardthicknessessuppliedexstockare3mm(0,12“),5mm(0,2“),7mm(0,28“),10mm(0,39“),12,7mm(0,5“)and15mm(0,59“).Otherthicknessesbetween3-15mmonrequest.
kitS / aSSEmBLy SEtS
Tobeproducedondemand.Thebasisofyourindividualkitisanengineeringdrawingwhichcanbeconvertedtoacuttingfile.Thewindingupfromyour3D-datawillbechargedindividually.
PaCkaging unitS
Thereisnominimumquantity.Inordertogetthelowestfreightratesforyouwestronglyrecommendamailingcarton(800x600x400mm)asthesmallestunitintheEuropeanfreightsystem.
Thestandardcontentofamailingboxarethefollowingquantities:in3mm(0,12“)=45sqm(484.38sqft)in5mm(0,2“)=30sqm(322.92sqft)in7mm(0,28“)=22sqm(236.81sqft)in10mm(0,39“)=15sqm(161.48sqft)in12,7mm(0,5“)=12sqm(129.17sqft)in15mm(0,59“)=10sqm(107.69sqft)
ShEEtS
Ofcoursewealsoprovidesheetsinseveralthicknesses.Pleasecontactus.
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FOAM IN NEWDIMENSIONS
ESC
for internal use only
8.230.84
10.971.27
10.380.82
14.770.47
0 2 4 6 8 10 12 14 16
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
1.44
0.58
1.77
1.11
1.460.66
1.8990.41
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
74.8
16.17
73.16
41.82
62.82
27.89
79.88
23.2
0 10 20 30 40 50 60 70 80 90
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
Compression strength Mpa
Shear stress τ Mpa
Flexural strength σ-fM Mpa
Material testing laboratory for materials and production technology of the University of Hannover
COMPARISION OF TECHNICAL DATA REGULAR FOAM CORES vs. 3D-CORE™ SAMPLES
The measurements were carried out by the
* 30 = Density / 0.7 = Cavity
* 30 = Density / 0.7 = Cavity
* 30 = Density / 0.7 = Cavity
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FOAM IN NEWDIMENSIONS
ESC
for internal use only
316.3321.35
269.9367.65
373.8239.28
518.2424.3
0 100 200 300 400 500 600
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
175.57718.83
913.366
771.59191.07
885.52372.87
170.72
0 100 200 300 400 500 600 700 800 900 1000
5298.642308.53
5041.594202.99
4573.722855.23
5335.423496.94
0 1000 2000 3000 4000 5000 6000
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
■ XPS 30 / 0 *■ 3D|CORE XPS 30 / 0.7 *
■ PUR 80 / 0■ 3D|CORE PUR 80 / 0.6
■ SAN 94 / 0■ 3D|CORE SAN 71 / 0.5
■ PET 115 / 0■ 3D|CORE PET 115 / 0.2
Laminate structureof the specimen
Resin – Epoxy Sicomin 8100/8822All specimen were produced using the vacuum injection method and cured at 80 °C
E Modulus MPa (shear strength)
E Modulus MPa (3 point bending test)
E Modulus MPa (compression strength)
COMPARISION OF TECHNICAL DATA REGULAR FOAM CORES vs. 3D-CORE™ SAMPLES
* 30 = Density / 0.7 = Cavity
* 30 = Density / 0.7 = Cavity
* 30 = Density / 0.7 = Cavity
1. Glassfibre Fabric Twill 110 g/m²2. Glassfibre Quadraxial Fabric 600 g/m² 3. 10 mm foam core4. Glassfibre Quadraxial Fabric 600 g/m² 5. Glassfibre Fabric Twill 110 g/m²
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FOAM IN NEWDIMENSIONS
ESC
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00 €
GRP Full laminate
Lantor Coremat Xi
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
Sphere Core
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
0 1 2 3 4 5 6 7 kg
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6*
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 €
GRP Full laminate
Lantor Coremat Xi
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
Sphere Core
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6*
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
0 1 2 3 4 5 6 kg
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 €
GRP Full laminate
Lantor Coremat Xi
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
Sphere Core
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6* n.a.
0 0.5 1 1.5 2 2.5 3 3.5 4 kg
4mm: weight kg/m2 €/m2
5mm: weight kg/m2 €/m2
3mm: weight kg/m2 €/m2
n.a. = Configuration not available * 80 = Density / 0.6 = CavitiesEpoxy resin 8 €/kg. Glass fibre 580 g/m² (size 0,64 mm) 3,22 € /m². Material price based on the regular market price per 100 m².
RELATIONSHIP BETWEEN COST AND WEIGHT OF PROCESSED CORE MATERIALS – VS. COMPETING PRODUCTS
for internal use only
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FOAM IN NEWDIMENSIONS
ESC
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 €
GRP Full laminate
Lantor Coremat Xi n.a.
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
Sphere Core
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
0 2 4 6 8 10 12 14 kg
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6*
0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 €
GRP Full laminate
Lantor Coremat Xi
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
Sphere Core
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
0 2 4 6 8 10 12 14 16 18 20 kg
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6*
0.00 10.00 20.00 30.00 40.00 50.00 60.00 €
GRP Full laminate
Lantor Coremat Xi
Lantor Coremat XM
Lantor Soric LRC
Lantor Soric TF
Lantor Soric XF
Lantor Soric SF
Sphere Tex /Ax
n.a.
n.a.
n.a.
n.a.
n.a.
n.a.
Sphere Core
0 1 2 3 4 5 6 7 8 kg
3D|CORE PET 100/0.2*
3D|CORE XPS 30/0.7*
3D|CORE PUR 80/0.6*
RELATIONSHIP BETWEEN COST AND WEIGHT OF PROCESSED CORE MATERIALS – VS. COMPETING PRODUCTS
10mm: weight kg/m2 €/m2
15mm: weight kg/m2 €/m2
6mm: weight kg/m2 €/m2
n.a. = Configuration not available * 80 = Density / 0.6 = CavitiesEpoxy resin 8 €/kg. Glass fibre 580 g/m² (size 0,64 mm) 3,22 € /m². Material price based on the regular market price per 100 m².
for internal use only
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xPS 30 PE t 100 PE t 150 PuR 80
Densities 30kg/m3 115kg/m3 150kg/m3 80kg/m3
Compatibility to resin
Epoxy good good good good
Polyester unsuitable good good good
Vinylester good good good good
Polyurethan good good good good
Phenolic good good good good
temperature
max. processing temperature
70°C 170°C 170°C 110°C
Compression strength for autoclave applications
max. pressure in mPa at 20°C
0,47 0,82 1,4 0,84
Drapeability good verygood verygood satisfactory
application
Vacuum infusion verygood verygood verygood verygood
Rtm satisfactory satisfactory good good
hand lay-up laminate
satisfactory good good satisfactory
autoclave (Pre preg applications)
unsuitable satisfactory satisfactory unsuitable
Rim unsuitable good verygood verygood
available thicknesses
3mm–15mm 3mm–15mm 3mm–15mm 5mm–15mm
DnV Cert.gL Cert.
EXTENDED STRUCTURED COMPOSITES GMBH & CO KG · OSTSTRASSE 70 · 32051 HERFORD WWW.ESCOMPOSITE.CO M · TELEPHONE +4 9 5221 9363-0 · FAX +4 9 5221 9363-71
AbdeckerAdresse
fOam CORE naVigatOR
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tiPS fOR aPPLiCatiOn anD PROCESSing Of 3D|CORE™
general information
3D|CORE™isespeciallysuitableforvacuuminjection.Thematrixfacilitatestheinfusionoftheresinintothelaminate.Thebasisoftheprocessalwaysisawellventedresinsystemwithappropriatecuringtime.
Verygoodresultsarealsoachievedusingthehandlay-uptechnique.ManyfoamsarealsosuitableforothermethodslikeRTM,RTM-light,RIM,etc.
Basis of calculation
InmostcasesthedesignofthelaminateiscalculatedwithCLTbasedonstandardvalues.ESCprovidesabasisofstandardvaluesforcoresof10mm.Thesestandardcoreshavethefollowingcomposition(valuesofotherstrengthsondemand):
3D|CORE™coveredwithtwolayersofcertified110g/m2twillglassfabricand600g/m2quadraxialglassfabricontopandbottom.ThiscoreisfilledwithastandardizedepoxyresinsystemfromtheFrenchproducerSicomin.
Thedesignerusesthevaluesasfixedparametersforavirtual“homogenous”materialinordertoavoidverycomplexFEMcalculations.Howeverwestronglyrecommendtoprepareyourowntestpanelsandperformowntestings.
Foryourspecialresinsystem,wecandeterminethesevalues,too.Pleaserequestourkeenestoffer.
Cutting
Alldescribedtypesoffoamcanbeeasilycuttothedesiredshapeusinggoodbladesandstandardtoolsforwoodprocessing.Themodulesshouldbefixedwithasteelrulerorsimilarinordertopreventbreakingawayofsinglefoambodies.
Assemblykitscanbeproducedondemand.
3D|COREinpressuretest
3D|COREinsheartest
3D|COREinflexuraltest
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PLaCing in thE mOuLD/ fixatiOn
Pleasenotethefollowing:
• Thejointsoftheindividualhexagonalbodiesarenotcentredsothatthemoduleswilleasilyfollowthecontourofthemould(drawing1).
• Therearejointsasspacersontwooutsidesofthemodule.Thesespacershavetobeorientatedinthesamedirectiononallmodules(drawing2).
• Thefollowingmoduleshavetobeinsertedsothattheconnectingjointsmeetoutsideswithoutspacers(drawing3).
• Themodulesshouldbeconnectedtogetherinordertopreventslipping.Wehavehadpositiveexperiencesinusingmedicaltapefromcelluloseacetatewithrubber-freeadhesive.Goodresultshavealsobeenachievedwithpolymerstaples.(drawing4).
• Theresinshouldbeproperlyventedbeforeinfusion.
• Theresinshouldbeinjectedintothestructureandnotontheouterlayers(drawing5).
• Attentionmustbepaidtotherightconsistencyofthehandlay-uplaminateresin.
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2
3
4
5
Hand lay-up laminate
Vacuum Infusion
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3D|CORE™ – aPPLiCatiOn ExamPLE “DynamiC”
The“Dynamic”with3D|CORE™ascorematerialshowsanexampleofeconomicefficiencyinlightweightconstruction.
Highlightofthefair:Thehullofthe”Dynamic“ 3D|CORE™ascorematerial
Hull-deckconnection
Thedeckisproducedusingthevacuuminfusionmethod Finished“Dynamic”onthewater
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COntaCt
Forcurrentcontactdetails,pleaserefertoourwebsitewww.escomposite.com
gEnERaL infORmatiOn
1. Manufactureranddistributorsstronglyrecommendthatcustomersestablishtheirowntestpanelsandconducttestswiththematerialssuppliedtoensurethattheyaresuitablefortheintendeduse.
2. Thetechnicalinformationcontainvaluesforthenominaldensity.Thesemaybeundershotorexceededduetodensityfluctuations.Minimumvaluesforthedesignofcomponentsareprovidedonrequest.Likewise,thedimensionsintherangeofthicknessmayvaryby+/-0.5mminlengthandby+/-10mminlengthandwidthperlinearmetre.Closertolerancesareonlyavailableonthebasisofawrittenagreement.
3. Thetechnicaldetailsinthispublicationcomplywiththemanufacturer‘sspecificationsandthecurrentstateofknowledge.Fortheaccuracyoftheinformationandtheresultsarisingfromtheiruseandfromtheproductsdescribedherein,noguaranteecanbegiven.
4. Manufactureranddistributorsexpresslyexcludeanywarranty.Thisappliesinparticularforthesuitabilityofproductsselectedbythecustomerforhisapplication.
5. Manufactureranddistributorsacceptnoliabilityforaccidentsandconsequentialdamageresultingfromtheuseandapplicationofproducts.
6. Nocontentofthisbrochureandthewebsiteofthemanufacturerorthedistributorisintendedtoinfringeexistingpatentsortorecommendapatentinfringement.
Herford,01Juli2009
