HIGH-FLYING POLYMERS · PPSU or PC for light-scattering effects. The relevant fire regulations are verified as part of the development process, and also during classifi-cation if

HIGH-FLYING POLYMERSSolutions for the aviation industry

2

EDITORIAL

UNLIMITED POLYMER SOLUTIONSNew standards in the aviation industry

Our mission is to constantly redefine the limits of the possible and to be present as a leading innovator in the construction, automotive and industrial sectors. REHAU secures long-term competitive advantages and a high degree of reliability through outstanding innovation. Industry-specific expertise from the three business divisions is brought together to develop new materials, formulations and products, and to advance these through to series production. Our structure, as an independent, family-owned company with an international outlook, gives us flexibility and our 127 sales offices, 42 production sites and 16 administrative offices ensure we are always right where our customers need us. High performance in every respect.

3

CONTENTS

1 Expertise in every area 41.1 An innovative development partner for many

types of aircraft 51.2 Materials and formulations from REHAU production sites 61.3 Professional solutions for the aviation industry 8

2 Energy efficiency made easy 102.1 RAU-FLIGHT – the material innovation 11

3 REHAU flies high 133.1 Profiles 133.1.1 Seat track covers 143.1.2 Bumper system 153.1.3 Cover profiles 163.1.4 Lighting covers 183.2 Systems 213.2.1 Handrails 213.2.2 PSU intermediate rail 223.2.3 Air ducts 233.3 Mouldings 243.3.1 Edge protector 243.3.2 Overhead locker brackets 253.4 Fibre-composite components 263.4.1 Retainers and slide guides for window systems 263.4.2 Clamping rails for side wall panels 283.4.3 Guide rails for side wall panels 293.5 Silicone profiles 303.5.1 Standard ABS components 303.5.2 Interior area seals 333.6 Silicone hoses 353.6.1 RTM hose 35

4

REHAU aviation1 EXPERTISE IN EVERY AREA

5

REHAU has been a recognised partner of the aviation industry since 1980 and works con-stantly to drive forward developments.

The innovative new material RAU-FLIGHT is significant for the indus-try, offering customers improved cost efficiency and energy balance.

References: - Airbus S.A.S. - Airbus Operations GmbH - Fokker Aircraft - ATR - FACC - Diehl Aircabin - Zodiac - Diehl Comfort Modules - Lufthansa Technik - Airbus Helicopters - Ruag - Decorative Products - P3 Group - STELIA Aerospace - B/E Aerospace

AN INNOVATIVE DEVELOPMENT PARTNER1.1for many types of aircraft

7

EXPERTISE IN EVERY AREA

Development of its own materials has been a cornerstone of REHAU’s engineering success since the company was founded. Top priority is always given to quality, reliability and benefit for the customer. With several thousand formulations for the various sectors, REHAU now possess-es one of the largest material portfolios worldwide.

The object of REHAU’s material, process and prod-uct developers is sustainable managementof valuable resources and low-waste production through active recycling concepts. Thus, particular attention is paid to the processing characteristics of materials in REHAU’s production works.

With more than 40 production sites worldwide, our researchers and developers have the perfect base to ensure their materials are fit for production and the market. Consequently, this yields synergies for the premium products that represent REHAU on the market.

MATERIALS AND FORMULATIONS1.2from REHAU production sites

Impact strength testPlant Port Elizabeth, ZA

9

REHAU’s development engineers and technicians accompany the product from the initial idea to development, installation and final use. They are at the custom-er’s side to provide advice and support, allowing easy implementation of special requirements and innovative solutions.

Our production and process engineering de-partments offer a host of solutions to meet any requirement, from one-off production to series production, and they work to optimise manufactur-ing processes.

In reworking, REHAU relies on various options, such as painting, surface finishing and fabrication, in order to implement the various product properties.

REHAU’s in-house material developmentdepartment provides cost-effective and beneficial solutions, even for customised applications.

In the logistics department, REHAU provides optimal conditions and made-to-measure solutions rightthrough to just-in-time deliveries.

PROFESSIONAL SOLUTIONS1.3for the aviation industry

Process expertise Details Material expertise: RAU-SIK, RAU-FLIGHT, RAU-FLIGHT PA Production processes: Extrusion, injection moulding, extrusion blow moulding, thermo forming Design: CATIA V5, FEM calculation, moldflow simulation Material development: RAU-FLIGHT Processing: 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 aeronautial- approved painting systems

Bending test Abrasion test

EXPERTISE IN EVERY AREA

10

In the aviation industry, every gram counts. Lightweight construction has always been a significant factor in aviation, not least because of flight physics. In addition to lightweight structures, light innovative materials also make a vital contribution. The use of these materials reduces energy consumption, thus improving cost efficiency, and also makes a sustainable environmental contribution.

made easy with RAU-FLIGHT 2 ENERGY EFFICIENCY

Improved cost efficiency with consistent properties

Through the use of intelligent polymer solutions, REHAU is able to provide customers with tailored solutions that not only have a positive impact on the energy balance but also meet engineeringand design requirements. The RAU-FLIGHT material family was specially developed for the aviation industry and achieves a weight reduction of up to 10%.

The challenge was to maintain themechanical properties of the approved basic mate-

rials and the technical feasibility to produce an end product suitable for series production. Fabrication operations, such as milling, painting, bonding etc., are still possible in accordance with the original material properties.

The new material RAU-FLIGHT can becustomised to meet specific customer require-ments; e.g. high-temperature applications with PPSU or PC for light-scattering effects.

The relevant fire regulations are verified as part of the development process, and also during classifi-cation if necessary.

Magnified 300 times Magnified 3,000 times

RAU-FLIGHT, the unique material principle:‘glass bubbles’ embedded in the polymer

matrix

11

RAU-FLIGHT THE MATERIAL INNOVATION2.1

For an A320, AIRBUS estimates an annual aviation fuel saving of 1,970 litres per 10 kg of saving in unloaded weight. Kerosene savings are achieved thanks to a weight reduction of up to 10% in existing polymer components with an assumed total weight of 100 kg per MSN.

© AIRBUS S.A.S. 2012 – photo by S. Ramadier

≈ 4,500,000 litres≈ 30,000 litres≈ 2,000 litres

Effect per fleet of 150 aircraft in a machine usage time of 15 years

Effect per aircraft in a machine usage time of 15 years

Effect per aircraft in a machine usage time of 1 year

ENERGY EFFICIENCY MADE EASY

13

In the polyamide sector, REHAU has succeeded in creating a perfect RAU-FLIGHT PA formulation. This material has been approved by AIRBUS in accordance with AIMS 04-01-025 and by BOEING in accordance with BMS8-270.

RAU-FLIGHT PA sets completely new standards in terms of ap-pearance and feel. It completely eliminates the surface treatment of dyed PA profiles normally carried out afterwards in order to prevent the material-specific lustre.

The surface can be created by the extrusion die, which gives the profile a consistent, matt and uniform appearance.

Surface marks that are typical of the process,such as extrusion drag lines, or marks caused by subsequent treatment, are a thing of the past. During this process, these surfaces can also be combined with and matched to additional components.

A sophisticated structural design makes it possible to produce thinner walled components in com-parison with other polyamides, which makes an additional contribution to weight optimisation but does not restrict the load-bearing capacity.

ENERGY EFFICIENCY MADE EASY

3.1.1

3.1.1

3.1.2

3.1.4

3.1.4

3.2.1

3.2.2

3.2.3

3.3.1

3.3.2

3.4.1

3.4.2

3.5

3.5

3.5

3.6

3.5

3.4.3

Seat rail coversThe safe connection point between passen-ger and aircraft.

Bumper systemThe bodyguard for lightweight structures.

Cover profilesThe clever transition between different floor coverings.

Lighting coversElegant design with sophisticated functional details.

HandrailsErgonomic and functional safety.

PSU intermediate railThe elegant connection between operating unit and overhead locker. 3.1.1

3.1.1

3.1.3

3.1.4

3.2.2

3.2.3

3.3.1

3.3.2

3.5

3.6

3.5

3.5

3.1.1

3.1.2

3.1.3

3.1.4

3.2.1

3.2.2

Air ductsFor a pleasant and hygienic atmosphere in the aircraft.

3.2.3

3 REHAU FLIES HIGH Our products for the aviation industry

15

Silicone profilesThe professionals for sealing, fixing and covering.

RAUSILAM hoseSilicone hoses for production of fibre-reinforced components.

Edge protectorSafely covered, both in the overhead locker and on the handrails.

Overhead locker bracketsThe reliable support in the overhead locker.

Retainers and slide guides for window systemsPermanent fixing of interior elements.

3.5

3.3.1

3.3.2

3.4.1

3.4.2 Guide rails for side wall panels The custom-fit connection between wall panels.

3.4.3

3.6

3 REHAU FLIES HIGH Our products for the aviation industry

Clamping rails for side wall panelsFixation between side walls panels and the fuselage.

3 REHAU FLIES HIGH Our products

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3.1 Profiles3.1.1 Seat rail covers Function The seats inside the cabin are mounted on aluminium

rails. The positions and spacings are variable. The alu-minium rails are covered with seat rail covers between the attachment points of the seats.

Surface Brushed uniform mattMaterial Polyamide 12 (RAU-PA), flame-retardant, coloured,

brushed matt RAUFLIGHT PA, flame-retardant, coloured Process Extrusion

3.1.1

17

3.1.2 Bumper system

Function Protection of lightweight structures, cable routing

Surface Uniform mattMaterial Polyamide 12 (RAU-PA), flame-retardant, coloured, brushed matt RAUFLIGHT PA, flame-retardant, colouredProcess Extrusion (retainer and cover profiles),

injection moulding (end caps)

3.1.2

94.

9

52

3

5

Printing

34.7

Adhesive tape

12.2

8.6

31

Printing

4.4

5.1

50

5.5

12.5

12.2

33

Printing

Stamping

12.350.4

13

20

Printing

18

3.1.3 Cover profiles

Function Decorative profiles to cover gapsSurface Partially brushedMaterial Flame-retardant materials approved for aircraft use; e.g. polyamide 12 (RAU-PA), polycarbonate (RAU-PC), etc.Process Extrusion

ABS 5759

Material: RAU-PA 592

Mat. no. 1953952

ABS 5786 AAA


Mat. no. 1953058

ABS 5786 ABA


Mat. no. 1953068

3.1.3

ABS 0317 AA


Mat. no. 1954731

ABS 5790 AB


Mat. no. 1954912

ABS 0318


Mat. no. 1954721

12.812.8

8.5

8.5

12.812.8

13.4

13.4

10.410.4

1515

48.6

34.8

2.9

11.7

7.4

31.5

Printing

37

5

11

3.4

14.5

9

19


Mat. no. 1954745

Material: RAU-PC 440

Mat. no. 1909721


Mat. no. 1909715


Mat. no. 1954635

Material: ABS 143

Mat. no. 1957940


Mat. no. 1959180

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3.1.4 Lighting covers Translucent cover profiles

Function Translucent lighting coverMaterial Polycarbonate (RAU-PC), flame-retardant, transparent,

UV-stabilisedProcess Extrusion

Material: RAU-PC 440 Co-extrusion with integrated SIK seal

Mat. no. 1903802, 1904162, 1834209

3.1.4

RAU-PC, coloured

RAU-PC, coloured

RAU-PC, transparent

Aluminium insert, 57 mm x 0.3 mmDue to the low wall thickness, an integrated layer of aluminium foil keeps some

product areas opaque.

Hinge

Profile

21

3.1.4 Lighting covers Coextruded lighting cover

Function Transparent lighting coverMaterial Polycarbonate (RAU-PC), flame-retardant, transparent,

UV-stabilised, polycarbonate (RAU-PC), flame-retardant, coloured, aluminium foil

Process Co-extrusion, mechanical processing (milling, cutting to length), assembly (clamp insertion)

3.1.4

22


Mat. no. 1956486


Mat. no. 1956476


Mat. no. 1909710

3.1.4

3.1.4 Lighting covers

Function Translucent lighting coverMaterial Polycarbonate (RAU-PC), flame-retardant, transparent,

UV-stabilisedProcess Extrusion,

mechanical processing (edge-milling)

23

Material: RAU-PEI 140

Mat. no. 1264162


Mat. no. 1264162

3.2.1

3.2 Systems 3.2.1 Handrails

Function HandrailMaterial Polyetherimide (RAU-PEI)Process Extrusion,

mechanical processing (milling, cutting to length), injection moulding, assembly

End cap

Rail

Holder

Silicone seal

24

3.2.2 PSU intermediate rail

Function Cover between PSU (Personal Service Unit) and over-head locker

Material Polyetherimide (RAU-PEI), silicone

Process Extrusion, mechanical processing (milling, cutting to length), injection moulding, painting, assembly

3.2.2


Mat. no. 1953293

Injection

Profile

Silicone seal

25

3.2.3 Air ducts

Function Air ductMaterial Polyetherimide (RAU-PEI),

silicone Process Extrusion,

mechanical processing (milling, cutting to length), injection moulding, painting, assembly

3.2.3


Mat. no. 1969770

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3.3 Mouldings3.3.1 Edge protector

Function Edge protection mouldings cover sandwich compo-nents, hiding gaps between two overhead lockers

Material Polycarbonate (RAU-PC), silicone

Process Injection moulding, extrusion, cutting to size and bonding silicone profiles


Mat. no. 1229913


Mat. no. 1229913

3.3.1

27

3.3.2 Overhead locker brackets

Function Provides support in overhead lockerMaterial 30% carbon-fibre reinforced polyphenyl sulphide (RAU-

PPS)Process Injection moulding,

mechanical finishing, painting, assembly

Material: RAU-PPS 150

Mat. no. -

3.3.2

28

3.4 Fibre-composite components3.4.1 Retainers and slide guides for win-

dow systems

Function Fixing for interior parts; e.g. in emergency exit areaMaterial Glass-fibre fabric with polyetherimide (RAU-PEI), carbon-fibre fabric with polyetherimide (RAU-PEI)Process Thermoforming consolidated panels, mechanical finishing

Material: RAU-TC 13307

Mat. no. -


Mat. no. 1766212


Mat. no. 1766152

Window

Assembly

Assembly of window funnel

29

Function Guide for window blindMaterial Polycarbonate (RAU-PC), glass-fibre fabric with polyetherimide (RAU-PEI)Process Injection moulding (window funnel), thermoforming of window blind guide


Mat. no. 1766523


Mat. no. 1291560


Mat. no. 1291570


Mat. no. 1766981

3.4.1

3.4.2 Tracks for side wall panels

Function Connecting rails for side wall panelsMaterial Glass fibre fabric with polyetherimide (RAU-PEI)Process Thermoforming consolidated panels, mechanical finishing

30

3.4.2 3.4.2


Mat. no. 1766104

3.4.3 Clamping rails for side wall panels

Function Fixes side wall panels to fuselageMaterial Carbon fibre fabric with polyetherimide (RAU-PEI)Process Thermoforming consolidated panels, mechanical finishing, assemblyNote: Prototype tool available. The rail has passed the AIRBUS static test.

Clip bonded to track

RailRetainingbracket

Screw, pane, safety pane

Blind rivet

31

3.4.3


Mat. no. -

3

16

Pressurisation

26

16

Pressurisation

12

12

32

3.5 Silicone profiles3.5.1 Standard ABS components

Product Standard profile (AIRBUS), gap hider for side wall panels and hatracks,

further standard profiles and developments on request

Function Sealing/hiding gaps/fixing elementsMaterial Silicone

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

Process Extrusion

ABS 5748 AA

Material: RAU-SIK 8968

Mat. no. 1834504

ABS 0306 B20


Mat. no. 1834584

ABS 5744 AA


Mat. no. 1834494

3.5.1

16

20.3

Printing

7.

7

8

Printing

22

2.5 Printing2.5 Printing

12

9.

8

10.6

Printing 3

25.4

33

ABS 5753 AA


Mat. no. 1834514

ABS 0307 AB


Mat. no. 1834003

DAN 262 CG


Mat. no. 1834604

ABS 0305 LB


Mat. no. 1802003

ABS 0305 LC


Mat. no. 1802013

ABS 0306 B01

ABS 0306 C01


RAU-SIK 8964

Mat. no. 1834013

3.5.1

3.5.1

Printing17

1514

.5

17

Printing

8.5

15

Printing

3 35

34

3.5.1 Standard ABS components

3.5.1

3.5.1

3.5.1

ABS 5748 AB


Mat. no. 1834594

ABS 0306 B02

ABS 0306 C02


RAU-SIK 8964

Mat. no. 1834023

ABS 0399 AA


Mat. no. 1834394

ABS 0398 A01


Mat. no. 1834384

3.5.23.5.2

3.5.2

3.5.2 Interior area seals

3.5.2

3.5.2

20.3

4

30.7

10.1

Printing

14.5

4

3

28

35

RAU-SIK 8968

Mat. no. 1834095

RAU-SIK 8968

Mat. no. 1834484

RAU-SIK 8968

Mat. no. 1850758

Fabrication: Water-jet cut

RAU-SIK 8325

Mat. no. 1825541

Fabrication: Compression

moulded part, slotted

RAU-SIK 8968

Mat. no. 1834354

RAU-SIK 8968

Mat. no. 1834085

3.5.2 Interior area seals7

11.8

20

4.8

18.8

23.5

Printing

451

15

11

3.2

25

18

34

3

3.9

26.5

47

50.8

1.5

7

36


Mat. no. 1834075

Fabrication: Adhesive tape application


Mat. no. 1834224

Fabrication: Punching + forming

bonding


Mat. no. 1834175

Fabrication: Punching + adhesive tape application


Mat. no. 1834274

Material: RAU-SIK

Mat. no. 1834314


Mat. no. 1834176Material: RAU-SIK 8968

Mat. no. 1834179


Mat. no. 1834074


Mat. no. 1834714


Mat. no. 1834178

3.6 Silicone hoses3.6.1 RTM hose

Product RAUSILAM FG 8 x 13.6dFunction Reinforced RAUSILAM hose for resin injection in resin

transfer moulding processMaterial SiliconeProcess Extrusion

3.6.1

Advantages of the RAUSILAM hose

- High safety, including temperature resistance up to 180°C for short periods of time- Resistant to heat and pressure- Plasticiser-free, in contrast to other flexible hose systems- Reduction of volatile compounds through annealing during production, thus almost no migration/contamination in the resin- Ensures good gliding properties without the use of talc- High flexibility thanks to PES filament reinforcement- Possible to check/monitor the burst pressure- Transparent solution without talc, thus no contamination of the resin and full monitoring of resin flow-related impurities, blistering and premature cross-linking- Product independently tested and used by the aviation industry

3.6.1

37


Mat. no. 1807388

© AIRBUS S.A.S. 2015 – photo by Master Films / P. Pigeyre

Quality is crucial to our success. By meeting the quality standards and requirements of our customers, we make a significant contribution to their satisfaction. At all REHAU locations, we work to worldwide-applicable quality principles and regulations.

This document is protected by copyright. All rights based on this are reserved. No part of this publication may be translated, reproduced or transmitted in any form or by any similar means, electronic or mechanical, photocopying, recording or otherwise, or stored in a data retrieval system.

Our verbal and written advice relating to technical applications is based on experience and is to the best of our knowledge correct but is given without obligation. The use of REHAU products in conditions that are beyond our control or for applications other than those specified releases us from any obligation in regard to claims made in respect of the products. We recommend that the suitability of any REHAU product for the intended application should be checked. Utilization and processing of our products are beyond our control and are therefore exclusively your responsibility. In the event that a liability is nevertheless considered, any compensation will be limited to the value of the goods supplied by us and used by you. Our warranty assumes consistent quality of our products in accordance with our specification and in accordance with our general conditions of sale.

© REHAU AG + Co Rheniumhaus 95111 Rehau

www.rehau.de

Subject to technical changes.IND716 EN 05.2018

EXPERTISE AND RELIABILITYREHAU stands for the highest professionalism and quality

We’re never far away.For locations, visit

www.rehau.de/standorte

Documents

HIGH-FLYING POLYMERS · PPSU or PC for light-scattering effects. The relevant fire regulations are verified as part of the development process, and also during classifi-cation if