Title: Development of an Insulation Responding to the FAR 25.856 by the Integration of Mica Flame Barrier OCTOBER 2005, the 20th FAA PRESENTATION
1Development of an Insulation Responding to the
FAR 25.856 by the Integration of Mica Flame
Barrier OCTOBER 2005, the 20th FAA
PRESENTATION
Fire and Cabin Safety Research
- Alain JACQUES (COGEBI)
- Nicolas ORANCE (DAHER)
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2TABLE 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
31 - PROBLEMATICS
? FAR25856 (b) Burnthrough on Thermal/Acoustic
Insulation
NEW Thermal/Acoustic Insulating Blanket or Mica
Paper Fire Barrier (Liner)
? Aircraft Manufacturers
Weight ?m lt 75g/m² Process respect the
current process
42 - RAW MATERIAL
MICA Main Properties
High THERMAL resistance
CHEMICAL inertness
ELECTRICAL insulation
MECHANICAL resistance
LAMELLAR (non-fibrous)
52 - RAW MATERIAL
COGEBIs 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
63 - DAHER BLANKET Manufacturing and Installation
PROCESS 5 steps
1 Glass wool automatic cutting
2 Film welding
73 - DAHER BLANKET Manufacturing and Installation
3 Reinforcement
4 Control
20000 Blankets per month !
5 Installation on aircrafts... (AIRBUS France
assembly lines A300, A320 and A340 families)
84 - NEW PRODUCTS CogeBarrier film and CoDaX
blanket
4-1 CogeBarrier
- 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.
Adhesion, when necessary
The mica-film colaminate, CogeBarrier, available
in rolls, is used to produce with the same
process the final blanket CoDaX
94-2 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/70C
1000h/70C/ /98RH
1000h/70C
1000h/70C/ /98RH
1000h/70C
1000h/70C/ /98RH
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
104-2 Development and qualification tests on
CogeBarrier
Specific products results
- Burning behaviour FAR 25853 Appendix F part I
(a) (I) (ii)
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 FAR25853 Appendix F, part V (d)
RESULTS
Unit
Requirement
Mica-PVF1
Flaming mode
-
? 100
0
Non flaming mode
-
? 100
0
114-2 Development and qualification tests on
CogeBarrier
Specific products results
- Concentration of smoke gas components after 4 min
test method AITM 3.0005
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
lt 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
124-3 CoDaX BLANKET qualification
BURNING BEHAVIOUR
? FAR25853 (a) vertical test 12s
Unit Requirements CoDaX
Burn length mm lt 203 28.3
After flame time s lt 15 0
After flame time of drips s lt 5 No drip
New requirement FAR25856 (a) Flame propagation
Radiant panel test Unit Requirements CoDaX
Flame time s lt 3 0
Flame propagation distance mm lt 51 0
? Successful
134-3 CoDaX qualification
New requirements FAR25856 (b)
- No burnthrough within 4 min of exposure -
Maximum flux measured behind 305mm from the front
surface of the test rig 2.27W/cm²
CoDaX results CoDaX results
No flame penetration (at least 5 min) No flame penetration (at least 5 min)
Backface calorimeters 0.89 and 0.58 W/cm²
? Successful
144-4 TWO WAYS
CoDaX Blanket CogeBarrier Film
155 - INSTALLATION DESIGN PRINCIPLES
5-1 FAR 25856 (b) problematic
FAR 25.856 A
FAR 25.856 AB
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.
165 - INSTALLATION DESIGN PRINCIPLES
5-1 FAR 25856 (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
175-2 Blanket new design concept
FIELD
FRAME
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)
185-3 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
195-3 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
205-4 Frame insulation prototype
Frame pins
OVERLAPPING ON FRAMES
Large overlapping to insure no leak to flame
barrier
Stringer pin
215-4 Frame insulation prototype
FIXED BRACKETS FOR SYSTEMS
After blanket installation, removable brackets
are installed.
...under blankets fixed brackets !
225-4 Frame insulation prototype
ELECTRICAL INTERFACES
with COMBIS electrical brackets...
...or with standard clamps !
235-5 Bilge and cargo floor insulation prototype
CogeBarrier
245-6 Cargo floor insulation
DAHER has developed and qualified fireproof
composites using MICA paper for fire bulkheads
applications (qualified per FAR 251191 1100C
/ 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
256 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
266 CONCLUSION (since last FAA conference in
LISBOA november 2004)
QUALIFICATION TEST PLAN in progress Maintenance
Aging test
276 CONCLUSION (since last FAA conference in
LISBOA november 2004)
DEVELOPMENT FOR A GLOBAL PROTECTION New Design
principles Prototype Our back ground in
installation
286 CONCLUSION (since last FAA conference in
LISBOA november 2004)
THE FUTURE OF CODAX OR COGEBARRIER REQUIRES
COLLABORATIVE WORK WITH AIRCRAFTS MANUFACTURERS
AND AIRLINERS...
296 - CONCLUSION
CoDaX / CogeBarrier Innovative
Pertinent solution