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Polypropylene Honeycomb
By using specific manufacturing methods benefits can be engineered directly
into the polypropylene honeycomb panel. Bonding method, method of
manufacture, facing selection, width and length of panel and composite and
thickness of the core material can be altered to provide optimum benefits
for the intended application – from heavy industrial use to art restoration,
to avionics.
Facing Materials
The facing material carries the bending loads while the core transmits or
carries shear loads. A variety of facing materials can be used to finish
polypropylene honeycomb panels with esthetic considerations in mind, or to
match an existing structure. Skin materials range from aluminum alloy, to
woven or unidirectional glass or carbon fiber reinforced epoxy resin and can
be used in combinations with a variety of inner and outer facings to suit
specific applications. Engineering processes enable identical matching to an
existing structure where the panel/s are used as replacements.
Bonding & Fabrication
Bonding and fabrication methods used to produce the polypropylene
honeycomb panel vary depending on whether volume production is the
objective, or whether the panel is being engineered for low strength or
structural and non-structural applications. Each material and process brings
with it a unique set of characteristics and qualities.
Complex structures are manufactured using the 'cut and fold' technique – a
process designed especially for composite panel production. Here a strip of
material is removed from the inner skin and the panels are bent or folded to
specified angles and the joint bonded. Reinforcing materials can be added at
the joints for additional strength.
Panels are cut and trimmed to size and, if necessary, edges are finished
with edge filler, extrusions or tape. Panels can be joined to form larger
flat sheets or fitted using extrusions or tongue-and-groove joints to create
bonded assemblies.
Polypropylene Honeycomb Core
polypropylene honeycomb is designed to possess optimal mechanical
properties and can be engineered in a large range of cell sizes and
densities. Generally, the smaller the core size the higher the panel
strength thus providing greater resistance to impact. All polypropylene
honeycomb cores have differing properties covering a wide range of
applications – stiffness, flexural strength and weight all increase to
varying degrees with increased core thickness.
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