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Railways

 
Railways

Today's rail technology requires lighter and stronger materials to enable the manufacturer to build structures that travel faster with reduced environmental impact.

HONYLITE has been a transportation panel specialist for several years. Built to your exact specifications, HONYLITE honeycomb panels meet the critical design demands for structural integrity, beauty and performance demanded by the public transportation industry. Our sandwich panels are used for many transit car applications including: floors, walls, ceilings, doors, seating, tables and specialty cabinetry.

Composites find major applications in passenger coaches for excellent structural properties and improved aesthetics. Indian Railways have already initiated actions for inducting composites especially in the coaches.






Marine

Marine

Lowering the center of gravity by reducing weight above the water line has always been a priority for marine architects, but it is becoming ever more important as the cost of fuel and the performance expectations of sailing vessels rises. Reducing weight up high decreases the need for underwater stabilization devices and increases efficiency and speed.

HONYLITE sandwich structures are making a big difference reducing weight above the water line, and they are well-suited to the challenging and corrosive marine environment. We have supplied solutions for cruising, racing and motor yachts, high-speed ferries, offshore and in-shore lifeboats, Coast Guard and Navy vessels and even rowing shells.

At HONYLITE our strength lies in our ability to specify and apply a range of sandwich structures and processes depending on the application. We have the expertise to employ the right materials for demanding marine applications.




Aviation & Aerospace

Aviation & Aerospace

Honeycomb cores were first used on aircraft in the 1940s to reduce weight and increase payload and flight distance. They were incorporated into the aircraft design to replace the heavier conventional sheet and stringer or beam support approach, and their incorporation into sandwich panels has been a basic structural concept in the aerospace industry since the 1950s. In 2000, virtually every commercial and military aircraft depends on the integrity and reliability offered by honeycomb cores. There are numerous substrate materials with the honeycomb category. Honeycomb cores can have a density as small as 16 kg/m3. Every multi-engine airplane flying today in the world has some honeycomb core parts.

The main use of honeycomb is in structural applications. This is because honeycomb sandwich panels are extremely efficient in stiffness-to-weight and strength-to-weight situations. Whenever light weight is a premium, honeycomb sandwich construction is very difficult to beat.

Reduction of mass has always presented a challenge to the Design Engineer. A typical example of this is in the Aircraft Industry, where every extra kilogram of structural mass costs the Airline operator a huge amount each year.

  • Civil Aircraft
    Civil aircraft continue to consume greater levels of composites, benefiting from their strength and stiffness, tolerance of temperature extremes, high resistance to corrosion and fatigue and the weight saving opportunities.
  • Defense Aircraft
    In their quest for superior performance, Defense aircraft designers were the first to experiment with new materials and to demonstrate the effectiveness of composites. Today, the requirement for optimized aircraft designs, enabling pilots to perform advanced acrobatic manoeuvres, has led to a greater use of composites than ever.
  • Helicopters
    Both Civil and Defense helicopters consume large quantities of honeycomb components. Many parts are manufactured from honeycomb, including the side walls, floor panels and main rotor components.
  • Space
    Space launching satellites into space creates the ultimate performance challenge for composite materials. In addition to the crucial weight savings, the materials also have to withstand extreme temperature fluctuations. The performance requirements can be accommodated by the wide range of composite materials available.




Cleanroom Systems

Cleanroom Systems

HONYLITE offers a wide range of lightweight, strong and stiff honeycomb cleanroom wall panels and cleanroom ceiling panels. These lightweight strong cleanroom wall panels and cleanroom ceiling panels consist of aluminum facings bonded with polyurethane adhesive to commercial grade aluminum honeycomb core. Front and back facings can be coated with a wide variety of Powder or Roll Coated finishes.

These panels withstand repeated cleaning and sanitizing with various chemicals to resists microbial and fungal growth. They tend to be the most popular wall panels chosen for microelectronics cleanrooms because of they are non-outgassing, non-particle shedding, and anti-static as well as lightweight and non-combustible. Modular wall panels made of FRP (reinforced plastic) and HPL (high pressure laminate) are also used most often in pharmaceutical and medical device cleanrooms.

HONYLITE aluminum honeycomb panel bonding process insures that all volatile organic materials are removed from the aluminum honeycomb panels during manufacture. Testing of the finished aluminum panels has shown no detectable outgassing from panel components.

Our design and engineering teams can work with you to specify the best wall panels for your application or we can utilize our in-house manufacturing capabilities to custom build wall panels for your specific requirements.




Construction

Construction

The materials, which are traditionally used in the construction sector and which are glued to structural sandwich panels, are opening the way to innovative architectural solutions in the building and construction industry. The use of honeycomb cores in sandwich panels makes it possible to significantly reduce the weight of structures while enhancing the mechanical specifications of the skin of the sandwich at the same time. Consequently, this combination is used to make load-bearing and self-supporting structures (floors, floors on pedestals, staircase steps, etc.) These vertically applied sandwich panels (partitions, outer walls, etc), which are as thick as traditional solutions and covered with a skin (granite, marble, wood, aluminum, stainless steel, plywood etc.) are much easier to move and handle given their very low weight. They have additional benefits such as the absorption of vibrations, shock resistance and good thermal insulation properties. Honeycomb cores are used in interior decoration for traditional or designer furniture and will be appreciated not only for their reduced weight, but also for the vast range of shapes and enhanced options available (thin slices of natural stone, wood, aluminum, etc.)




EMI Shielding

EMI Shielding

HONYLITE Aluminium Honeycomb Air Ventilation Panels consist of an aluminum honeycomb foil held in a rigid extruded aluminum mounting frame. The foil, formed and laminated into a series of honeycomb cells that are glued and perforated or laser welded at the join, ensures a conductive path at each join. Although the foil is conductive in all directions, to enhance EMI performance, two pieces of honeycomb polarised at 90º to each other are recommended. The honeycomb vent is series of tubes that acts as a waveguide, guiding electromagnetic waves into or out of the enclosure, but as the tubes are long enough then it attenuates those waves. Typically the tube should be at least 3 times as long as the diameter. Good practice is 4 times. Therefore a 3.2mm cell should be 12.7mm long. Honeycomb material is used because it offers high shielding performance, light weight and good airflow.

Ventilation panels are designed for use in electronic enclosures where good air flow is required for cooling and ventilation but where EMC compliance must be ensured. Typical applications are:
Electronic Enclosures.
Air Conditioning Units.
Fan housings.
EMC Racks.
Communication shelters

Ventilation panels can be supplied with a range of finishes including:
Painted.
Tin or nickel plating.
Hexavalent chromium (RoHS compliant)
HONYLITE standard finish for aluminum vent panels fully meets the RoHS directive.




Laminar Flow

Laminar Flow

Honeycomb has been used successfully for many years as means of straightening ad directing air flow or changing turbulent flow into laminar flow. The thin cell walls provide an array of straight passageways with a maximum percent open area (95-99%), which results in a very low pressure drop and reduced turbulence and noise.

Aluminum and nonmetallic honeycomb have found applications in front of fans in ducts, air conditioners and heaters. Air curtains for some frozen food display cases rely on honeycomb to provide a narrow stream of air flow in front of the case. Wind tunnels and even water tunnels have used honeycomb as turning vanes and flow straightening devices.

Honeycomb placed in front of the fan increases the downstream velocity as a result of its ability to redirect the air in a straight path and reduce vortices.

A similar effect happens with ducted fans. Although the duct itself straightens or contains the air flow, honeycomb immediately in front of the fan aids in removing vortices and swirls in the flow. Turbulence causes noise, particularly at high air velocities of 1500 – 4000 ft/min (457 – 1219 m/min). Straightening the air flow can be beneficial not only in reducing power requirements, but also in keeping down the noise




Energy Absorption

Energy Absorption

HONYLITE provides a full range of crushable core as well as custom honeycomb configurations for a wide array of energy absorption applications serving many industries.

The basic concept of energy absorption is to take a moving object’s kinetic energy and convert it into internal work. The distance it takes to stop the object is a function of the load to which the object will be subjected. The longer the crush stroke the lower is the load.

Honeycomb works well as an energy absorber as it crushes uniformly at a known load, has a very long stroke, and has the highest crush strength-to-weight ratio of all the energy absorption materials.

Aluminum honeycomb is the core mainly used in energy absorbing situations. Commercial grade Kraft paper core has been used successfully in pallets for military airdrops. In the Gulf War in 1991, cargo planes would fly in low and drop equipment which was mounted on thick Kraft paper core pallets. The honeycomb would crush and protect the equipment from damage. This allowed equipment to be delivered where there were no runways.

Fiberglass and Nomex honeycomb cores are not usually used for energy absorbers due to their costs, but they could be as they do crush well. In fact, the fiberglass core has the greatest stroke, crushing more than 80% of its initial thickness. Aluminum core has a crush stroke between 70% - 80% of its height, depending on its density (lower the density, longer is the stroke).

Our engineers can help you specify a core type to fit your crush strength requirements, or can provide a custom product for your unique application. We will work with you to provide an innovative solution for your energy absorbing material needs.




Wind Energy

Wind Energy

HONYLITE metallic honeycomb can be very useful in the manufacture of tooling for wind turbine blades.

The incorporation of drilled aluminum core allows a stiff and stable lighter-weight tooling to be constructed which facilitates the even distribution of heat throughout the tooling. This ensures a consistent even cure throughout the laminate and avoids the risk of localized areas of semi-cured prepreg.

HONYLITE Polypropylene honeycomb is very cost efficient compared with monolithic structural materials. Indeed, not only used as a structural core, polypropylene honeycomb enable to save GRP materials. Combined with modern working up techniques (lamination, RTM light or infusion processes), polypropylene honeycomb have become the ideal core material for wind-turbine nacelles: good vibration damping and acoustic insulation properties.




Acoustics

 
Acoustics
There are two acoustical phenomena of interest with regard to sandwich panels: sound transmission loss and sound absorption.

The first relates to the use of honeycomb sandwich as sound barrier that is to prevent sound from being transmitted, while the second refers to its capacity as a sound absorber; in other words, to cut down reflected sound inside the room.

Acoustic Requirements
Enclosure Transmission loss requirements Absorption requirements
Library High High
Auditorium High Low
Engine room High None
Isolated factory None High
Sounding board Low Low


A honeycomb panel is an excellent sound barrier for very low frequencies (the range of structural borne vibrations), is fair to poor at somewhat higher frequencies (the range of engine noise), and is very poor at still higher frequencies (aerodynamic noises and human speech).

A panel whose front facing is perforated and whose back skin is impervious will be a good absorber over a very narrow frequency band. The mechanism of absorption in this case is by the Helmholtz resonator effect. This has to do with the volume of trapped air in the cell and the size of the hole in the facing.
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