1. Evalith® Honeycombs
In Thermoset Infusion Process

2. A New Generation of Honeycombs Based on Polyester Spunbond
for Thermoset Applications
Johns Manville 2015©

3. Introduction of Johns Manville‘s spunbond
Introduction into Evalith® honeycombs
Impregnation of Evalith® honeycombs
Performance of Evalith® honeycombs
Application examples of Evalith® honeycombs
Johns Manville 2015©

4. Johns Manville Johns Manville
Major fiber glass manufacturer in North America and Europe.
Over 150 years of proud history ; A Berkshire Hathaway company since 2001.
Leader in key markets
Johns Manville Engineered Products
Glass Fibers
Glass fibers for composite reinforcement, glass nonwovens, and wallboard reinforcement
Nonwovens
Glass and polyester nonwovens for roofing, flooring, filtration, and etc.
The Engineered Products Europe/Asia business includes three areas of focus: Nonwovens, Fibers, and Glass Textiles.
In addition to glass fibers and glass and polyester nonwovens, we also produce basalt nonwovens. Basalt is solidified volcanic lava. It has a very high melting temperature (~ 1450 degrees Celsius) and shows excellent chemical resistance. JM basalt nonwovens are used in automotive headliners.
The Glass Textiles business manufactures glass textile wall coverings used primarily in commercial settings, such as hospitals, museums and office and apartment buildings.
Johns Manville 2015©

5. Spunbond
Johns Manville produces polyester (PET) spunbond nonwoven fabrics for the following market applications:
Commercial Roofing
Carrier material in bitumen based roofing products for flat roofs and underslating for pitched roofs
Filtration
Automotive – cabin air
Liquid filtration – pool & spa, coolant oils
Air filtration – industrial baghouse filtration
Specialty – cover stock for HVAC and HEPA filter medias, support for PTFE lamination
Reinforcements
Carpet
Geotextile
Specialty
Johns Manville 2015©

6. Spunbond Process Overview
Spin pack
Polyester Filaments
Quench air
Stretch nozzle
Rotary plate
Compressed
air
Lay belt
Johns Manville 2015©

7. Spunbond Process Overiew
chips hopper
extruder
spinneret
filaments
accumulator
binder
needle loom
dryer
winder
conveyor belt
Johns Manville 2015©

8. Spunbond Filaments Filament Structure ← Regular Polyester
Heterofil Polyester ←
Core
Sheath
Johns Manville 2015©

9. Introduction of Johns Manville‘s spunbond
Introduction into Evalith® honeycombs
Impregnation of Evalith® honeycombs
Performance of Evalith® honeycombs
Application examples of Evalith® honeycombs
Johns Manville 2015©

10. Introduction into NW Honeycombs
Honeycombs are used in various applications to reduce weight and increase mechanical performance
Typically honeycombs cores are used between two layers of reinforced material (e.g. FRP panels)
Honeycombs can be based on paper, thermoplastic resin, Nomex, Aluminium…
Evalith® spunbond honeycombs offer higher end performance honeycombs at reasonable cost
Foam filled honeycombs allow thermal insulation in dynamic applications at reasonable cost
Johns Manville 2015©

11. Evalith® Honeycomb Process
Honeycomb Welding Process:
Evalith® spunbond is continuously inserted into honeycomb process
Welding process: Nonwoven layers are sequentially
heat-melted -> compressed -> impregnated and joined
Expansion process: The material stack is
reheated to softening temperature -> extended -> cooled and fixed
Johns Manville 2015©

12. Evalith® Honeycombs Advantages
Sustainability: Through innovative welding process no need for auxiliary (glueing) materials
Economics: Fast and economic process
Versatility: Infusion resins include foams and thermoset systems
Optimization: Nonwoven honeycombs are breathable and porous –
For excellent infusion processes
For excellent mechanical bonding of skin and core
Amount of porosity and depth can be tailored
Porous area
Solid area
Porous area
Microscopic cross sectional view of a honeycomb wall
Microscopic view of a honeycomb wall surface
Johns Manville 2015©

13. Phenolic / Sat PET / Epoxy / PU resin
Dazzling Array of Evalith® Honeycombs
Resin impregnated
Phenolic / Sat PET / Epoxy / PU resin
compressive: > 8 80 kg/m³
compressive: > lb/ft³
Foam filled
Thermoformable
Low friability
High compressive (impregnated)
Thermal conduction: 0,03 85 kg/m³
100% thermoplastic PET
Compressive : 0,9 50 kg/m³
Temperature resist. (short): > 200° C
Johns Manville 2015©

14. Evalith® Honeycombs Performance
Evalith® honeycombs for a unique variety of requirements and processes:
Lightweight:
Honeycombs offer high mechanical performance at low weights
(e.g. >0,8 50 kg/m³,
up to 8MPa compression load for thermoset impregnated honeycombs)
Outstanding impact and shear resistance:
Honeycombs impregnated with thermoset resin
Offer optimized bonding between skin and core
Johns Manville 2015©
Johns Manville ©2014

15. Evalith® Honeycombs Performance
Evalith® honeycombs for a unique variety of requirements and processes:
Improved material bonding:
good bonding of thermoplastic polyester fibers to filling materials like foams and resins
Complex shaping:
Honeycombs offer very good thermoforming performance
Johns Manville 2015©
Johns Manville ©2014

16. Introduction of Johns Manville‘s spunbond
Introduction into Evalith® honeycombs
Impregnation of Evalith® honeycombs
Performance of Evalith® honeycombs
Application examples of Evalith® honeycombs
Johns Manville 2015©

17. Evalith® Honeycombs Impregnation Process
Honeycombs between two structural composite sheets
Wall structures can be impregnated with same resin as skin and cured in one shot
Honeycomb walls will take up resin from skin layer prepregs (capillary effect)
=> Optimized bonding from honeycomb structures to skin layers can be achieved in all cases
Johns Manville 2015©

18. Evalith® Honeycombs Impregnation Process
Process requirements:
Time for impregnation of honeycombs: ~ 20 sec 1 inch width)
Resin take up: approx. 50 – 60% of honeycomb weight added by resin (weight of honeycomb: ~ 50 kg/m³
panel of 1 inch adds ~ 1 kg/m² of resin into honeycomb walls)
One shot impregnation of skin and core enhances shear resistance
Johns Manville 2015©

19. Introduction of Johns Manville‘s spunbond
Introduction into Evalith® honeycombs
Impregnation of Evalith® honeycombs
Performance of Evalith® honeycombs
Application examples of Evalith® honeycombs
Johns Manville 2015©

20. Compression test plate
Evalith® Honeycombs Performance
 compressive test
According to ISO 14126
Compression test plate
max. load
max load
impression depth
mm2 N
N/mm2 mm
Floor panel: FRP/underliner/honeycomb/FRP, 30 mm
3600
21.705
6,03
1,54
Side wall
FRP/honeycomb/FRP, 20 mm
23.083
6,41
1,40
Front wall
FRP/honeycomb/FRP, 26 mm
22.271
6,19
1,22
PU foam panel
Foam filled honeycomb, 23 mm
2500
20.000
8.00
1,70
 compressive test
According to ISO 14126
Weight / specific
max. load
working load
specific load
Kg / kg/m² N
N/kg
Customer evaluation floor panel: FRP/underliner/honeycomb/FRP, 35 mm
1,76 / 9,8
21.000
16.500
9.375
3 point bending test
According to ISO 14125
Sample size
max. load
Flexural stress
Flexural strain εf mm N
MPa
Floor panel: FRP/underliner/honeycomb/FRP, 30 mm
200,0
10.298
27,9
8,8
Side wall
FRP/honeycomb/FRP, 20 mm
6.414,5
39,5
9,6
Front wall
FRP/honeycomb/FRP, 26 mm
>12.000
>40
Johns Manville 2015©

21. Impregnated: mechanical stability
Transportation / construction floor panels:
Value proposition
cost of ownership (life cycle)
ease of repair
lightweight
Insulation Panels
Renewable Energy
Filled:
Foam impregnated
Value proposition
shear resistance
insulation
Formed:
forming processes
Transportation interior trim
Value proposition
good thermoforming process
vibration / noise dampening
Johns Manville 2015©

22. Introduction of Johns Manville‘s spunbond
Introduction into Evalith® honeycombs
Impregnation of Evalith® honeycombs
Performance of Evalith® honeycombs
Application examples of Evalith® honeycombs
Johns Manville 2015©

23. Evalith® Honeycombs Value Chain
Spunbond
Honeycomb
Polyiso Foam
Process
Impregnation &
composite manufacturing
Sandwich Panel
Application
Johns Manville 2015©

24. Application Examples Thermoset Resin Impregnated: mechanical stability
fire resistance
Automotive
PU Foam Filled:
Foam impregnated
Shear resistance
Johns Manville 2015©

25. Evalith® Honeycombs Properties
Johns Manville 2015©

26. Evalith® Honeycombs Properties vs Paper
Johns Manville 2015©

27. Evalith® Honeycombs Properties vs PP
Johns Manville 2015©

28. Evalith® Honeycombs Properties vs Alu
Johns Manville 2015©

29. Evalith® Honeycombs
For further information we would be delighted to assist!
Julia Moegel
Business Development Manager Nonwovens Europe Johns Manville Europe GmbH
Max-Fischer-Str. 11 | Bobingen | Germany
P: | M:
F: | |
Johns Manville 2015©