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Development of an Insulation Responding to the FAR 25.856 by the Integration of Mica Flame Barrier OCTOBER 2005, the 20 th FAA PRESENTATION. Alain JACQUES (COGEBI) Nicolas ORANCE (DAHER). Fire and Cabin Safety Research. ...................................

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alain jacques cogebi nicolas orance daher

Development of an Insulation Responding to the FAR 25.856 by the Integration of Mica Flame BarrierOCTOBER 2005, the 20thFAA PRESENTATION

Alain JACQUES (COGEBI)

Nicolas ORANCE (DAHER)

Fire and Cabin Safety Research

...................................

.................................

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide2

TABLE OF CONTENTS

1 – Problematics

2 – Raw material

3 – Blanket

4 – New products : CogeBarrier / CoDaX® - Qualification

5 – Installation on aircraft : CoDaX® specificities,design proposals

6 – Conclusion

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide3

1 - PROBLEMATICS

 FAR25§856 (b) : Burnthrough on Thermal/Acoustic Insulation

NEW Thermal/Acoustic Insulating Blanket

or Mica Paper Fire Barrier (Liner)

 Aircraft Manufacturers

Weight : m < 75g/m²

Process : respect the current process

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide4

2 - RAW MATERIAL

MICA – Main Properties

High THERMAL

resistance

ELECTRICAL

insulation

CHEMICAL

inertness

MECHANICAL

resistance

LAMELLAR

(non-fibrous)

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide5

2 - RAW MATERIAL

COGEBI’s MICA PAPER

Due to its crystallographic structure, mica properties are anisotropic.

The best behavior is exhibited perpendicularly to the cleavage.

A pure Mica Paper of 25 g/m² is an excellent Flame Barrier

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide6

3 - DAHER BLANKET :Manufacturing and Installation

PROCESS : 5 steps

1 Glass wool automatic cutting

2 Film welding

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide7

3 - DAHER BLANKET :Manufacturing and Installation

3 Reinforcement

4 Control

20’000

Blankets per month !

5 Installation on aircrafts...

(AIRBUS France assembly lines :

A300, A320 and A340 families)

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide8
For the Fuselage Burnthrough Resistance application, COGEBI and DAHER have developed a specific product.

The material consists in a layer of thin Mica paper coated with a Fluor-polymer and co-laminated with a film currently used as skin of the blanket responding to the part (a) of the FAR 25.856.

Fluor-polymer topcoat

Thin Mica paper 25 g/m²

PVF or APK film

Functionality

Chemic-physical protection

Flame barrier

Anti-tearing

Chemic-physical protection

4 - NEW PRODUCTS : CogeBarrier film and CoDaX® blanket

4-1 CogeBarrier

Adhesion, when necessary

The mica-film colaminate, CogeBarrier, available in rolls, is used to produce with the same process the final blanket : CoDaX®

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide9
Aging

4-2 Development and qualification tests on CogeBarrier

Specific products results

RESULTS

Properties

Unit

Test method

Target

Mica-PVF1

Mica-PVF2

Mica-APK

Square weight total

g/m²

EN 12127

-

67.0

73.4

63.1

Square weight flame barrier

g/m²

EN 12127

 75

37.0

42.4

41.1

Thickness

mm

-

-

0.10

0.13

0.10

Tensile strength

N/25mm

Aircraft Manufact.

 10

47.3

42.4

52.1

Penetration strength

N

Aircraft

Manufacturer

Ø10mm : 30

40.7

47.6

37.2

Ø20mm : 65

76.7

96.8

66.8

Peeling

N/25mm

Aircraft Manufact.

10

13.4

18.2

19.3

RESULTS

Mica-PVF1

Mica-PVF2

Mica-APK

Properties

Unit

Test method

Target

1000h/70°C

1000h/70°C/

/98%RH

1000h/70°C

1000h/70°C/

/98%RH

1000h/70°C

1000h/70°C/

/98%RH

% diminution of tensile

strenth

%

Aircraft

Manufacturer

 25

24

9

16

14

7

15

% diminution of seam

resistance - peeling

%

Aircraft

Manufacturer

30

15

5

in progress

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide10
Burning behaviour : FAR 25§853 Appendix F part I (a) (I) (ii)

4-2 Development and qualification tests on CogeBarrier

Specific products results :

RESULTS

Flammability vertical 12 s

Unit

Requirement

Mica-PVF1

Burn length

mm

 203

142 (*)

After flame : burning time

s

 15

0

After flame : dripping time

s

 5

No drip

(*): Only the film PVF burns, not mica

Maximal specific optical smoke density within 4 min : FAR25§853 Appendix F, part V(d)

RESULTS

Unit

Requirement

Mica-PVF1

Flaming mode

-

 100

0

Non flaming mode

-

 100

0

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide11
Concentration of smoke gas components after 4 min : test method AITM 3.0005

4-2 Development and qualification tests on CogeBarrier

Specific products results :

Methods used for HF and HCl analysis : ionic chromatography

RESULTS

Mica-PVF1

Gas

Unit

Target

Non-flaming

mode

Flaming

mode

Hydrogen fluoride (HF)

ppm

 100

0

< 10

Hydrogen chloride (HCl)

ppm

 150

0

0

Sulfur dioxide (H2S + SO2)

ppm

 100

0

0

Hydrogen Cyanide (HCN)

ppm

 150

0

0

Carbon monoxide (CO)

ppm

 1000

0

63.3

Nitrous gases (NO + NO2 )

ppm

 100

0

0

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide12

4-3 CoDaX® BLANKET qualification

BURNING BEHAVIOUR

 FAR25§853 (a) vertical test 12s

New requirement : FAR25§856 (a) Flame propagation

 Successful

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide13

4-3 CoDaX® qualification

  • New requirements :
  • FAR25§856 (b)

- No burnthrough within 4 min of exposure

- Maximum flux measured behind 305mm from the front surface of the test rig : 2.27W/cm²

 Successful

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide14

4-4TWO WAYS

CoDaX® Blanket CogeBarrier Film

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide15

5 - INSTALLATION DESIGN PRINCIPLES

5-1 FAR 25§856 (b) problematic

FAR 25.856 A

FAR 25.856 A+B

Bilge area : no blanket

Requirement is to protect the half lower part of fuselage, but there is usually no

blanket at the bottom (in bilge area) due to water condensation and draining.

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide16

5 - INSTALLATION DESIGN PRINCIPLES

5-1 FAR 25§856 (b) problematic

  • Development and concepts proposals for a global aircraft protection
  • improvement of the blanket
  • improvement of the frame insulation principle
  • test and prototype
  • improvement of the bilge and cargo floor prototype

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide17

5-2 Blanket new design concept :

FRAME

FIELD

New mechanical fixing part

is integrated on blanket

Mica protected face

Overlapping improvement

(to improve flame barrier efficiency – No leak !)

Mechanical fixations are implemented & increased

(to improve cohesion with primary structure... and also can be “FAR proof” !)

Blankets are simplified

(no more adhesive tapes or sewings : the fixations make local reinforcement !)

New fixation line

(added on A/C skin or on stringers)

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide18

5-3 Frame insulation principle

WITHOUT FOAM RING

Fireproof

fixation and removable safety part

Mica protected

face

Possible ATA92

interface

(screwed “P-Clamps” or Combi)

Possible ATA92

interface

(screwed “P-Clamps” or Combi)

Mica protected

face

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide19

5-3 Frame insulation principle

WITH FOAM RING

Fireproof

fixation and removable safety part

Mica protected

face

Possible ATA92

interface

(screwed “P-Clamps” or Combi)

Possible ATA92

interface

(screwed “P-Clamps” or Combi)

NOTE : foam ring is used

to separate blankets from

direct structure contact, limiting condensation effect on cold parts.

Mica protected

face

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide20

5-4 Frame insulation prototype

Frame pins

OVERLAPPING ON FRAMES

Large overlapping to insure no leak to flame barrier

Stringer pin

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide21

5-4 Frame insulation prototype

FIXED BRACKETS FOR SYSTEMS

After blanket installation, removable brackets are installed.

...under blankets : fixed brackets !

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide22

5-4 Frame insulation prototype

ELECTRICAL INTERFACES

with COMBIS electrical brackets...

...or with standard clamps !

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide23

5-5 Bilge and cargo floor insulation prototype

CogeBarrier

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide24

5-6 Cargo floor insulation

DAHER has developed and qualified fireproof composites using MICA paper for fire bulkheads applications (qualified per FAR 25§1191 : 1100°C / 15mn).

Such technology can easily be adapted to manufacture composite floor panels that INCLUDES an internal flame barrier (co-cured during manufacturing process) :

Mica side

Phenolic side

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide25

6 – CONCLUSION

(since last FAA conference in LISBOA november 2004)

MATERIALS and PROCESSES

TWO SOLUTIONS :

BLANKET : CODAX

Weight flame barrier: 40 g/m²

LINER : COGEBARRIER

Weight flame barrier: 65 g/m²

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide26

6 – CONCLUSION

(since last FAA conference in LISBOA november 2004)

QUALIFICATION TEST PLAN : in progress

Maintenance

Aging test

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide27

6 – CONCLUSION

(since last FAA conference in LISBOA november 2004)

DEVELOPMENT FOR A GLOBAL PROTECTION :

New Design principles

Prototype

Our back ground in installation

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide28

6 – CONCLUSION

(since last FAA conference in LISBOA november 2004)

THE FUTURE OF CODAX® OR COGEBARRIER REQUIRES COLLABORATIVE

WORK WITH AIRCRAFT’S MANUFACTURERS AND AIRLINERS...

International Aircraft Materials Fire Test Working Group Meeting, Atlanta

slide29

6 - CONCLUSION

CoDaX / CogeBarrier

Innovative & Pertinent solution

International Aircraft Materials Fire Test Working Group Meeting, Atlanta