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Covestro, EconCore in effort to develop FST-performing honeycomb cores and panels

Jolly Sunshine Limited | Updated: Feb 14, 2019

EconCore N.V. and Covestro are combining their technologies in order to produce strong and lightweight honeycomb panels with outstanding performance. One of the targeted key performance aspects is to comply with fire, smoke, toxicity (FST) requirements for public transportation applications, including railway and aerospace. Deck box and trading card sleeve and deck binders.

Covestro has developed and tested a wide range of polycarbonates and blends with specific grades to meet the FST performance required by railway and aviation applications. Furthermore, the company is currently developing a range of lightweight thermoplastic composite solutions under the brand name Maezio. EconCore has developed and patented a unique manufacturing process to produce ultra-light honeycomb structures in an economic way, with a high variety of material combinations that can be fine-tuned in order to meet customers’ needs. Deck box and trading card sleeve and deck binders.

The ultimate goal of the joint development is to provide sandwich panels that fulfill the technical requirements, offer weight advantages and show better economics compared with currently used composite or metal solutions. The manufacturing process developed and patented by EconCore offers significant cost saving potential due to a high-speed and fully integrated continuous production process, where thermoplastic polymers are directly converted into a honeycomb structure and where, in addition, the sandwich skin layers can be immediately laminated onto cores. Deck box and trading card sleeve and deck binders.

“The outstanding manufacturing process of EconCore allows tailoring our materials into lightweight sandwich panel solutions for our customers,” said Klaus Kraner, responsible for mass transportation applications in the Polycarbonates segment at Covestro. “The sandwich technology of EconCore is especially interesting for lightweight applications Covestro is targeting with Maezio,” added Arne Böttcher, responsible for market development of the Maezio brand in the EMEA region. Deck box and trading card sleeve and deck binders.

“After succeeding in other application domains, we have decided to address inquiries of the higher end markets. The process has been proven to work very well with a wide range of thermoplastic materials, including these with FST chemistry, while EconCore’s technology has demonstrated its capability of delivering high-performance sandwich panels at high efficiency and cost levels not achievable with conventional methods,” said Tomasz Czarnecki, COO of EconCore N.V. Deck box and trading card sleeve and deck binders.

Tomasz Czarnecki adds, “We look forward to this new development and to continuing the partnership with Covestro. The polycarbonate-portfolio of our partner, combined with the composite solutions of Maezio, provides us with the variety and quality of materials needed to meet the high technical requirements in mass-transportation markets. This journey is not only about making thermoplastic honeycomb cores. Imagine the potential benefits for the aerospace industry, if it had the option to thermoform sandwich panels into finished parts in a one-shot operation. The industry, already inclining to monolithic thermoplastic composites, has not seen such a change for decades.” Deck box and trading card sleeve and deck binders.