In the realm of thermoplastic manufacturing, a significant challenge is the absence of a suitable inflatable bladder that can both meet the necessary temperature requirements as well as reliably produce geometrically complex and hollow components with high mechanical performance. This predicament has limited the efficiency and cost-effectiveness of the process. However, RCF Technologies has introduced a groundbreaking solution by developing a reusable, inflatable, high temp bladder made from Rishon® material. This innovative proprietary material, which can sustain operating temperatures up to 850ºF, is perfectly suited to function as an inflatable, reusable mandrel. This game-changing technology has the potential to revolutionize the future of thermoplastic production.
The Problem with Existing Thermoplastic Bladders
The problem with current elastomeric bladders is that they are limited to a temperature range of 500ºF and lower. And, while it is possible to find bladders capable of one-time use up to a maximum of 600ºF, they are difficult to source.
To produce an aerospace grade fiber reinforced thermoplastic tubular component today, the most common practice is to compression mold the tubes onto a male mandrel. This, however, is unreliable as applying force from the OD towards the ID often results in wrinkles. It is also slow, expensive, and requires significant capital equipment. Additionally, it can also be very challenging to extract the part from the mandrel.
Bladder molding is an attractive alternative because it allows for increased rate, reduces the effort required to create a preform, and applies force from the ID toward the OD, effectively tensioning the fibers during consolidation and thus avoiding wrinkling. Moreover, it provides a significant cost savings, especially if the bladder can withstand multiple cycles.
Introducing Rishon® Material
RCF Technologies has developed a game-changing solution by harnessing the capabilities of Rishon material. Rishon is a cutting-edge material that exhibits exceptional thermal properties, can withstand high temperatures and pressures, and is flexible and robust, thus making it an ideal candidate for manufacturing inflatable bladders. Unlike traditional methods and materials used during the thermoplastic manufacturing process, Rishon will meet the requirements without compromising its structural integrity.
The Functionality of the Rishon® Bladder
The Rishon bladder developed by RCF Technologies serves as a reusable inflatable mandrel for manufacturing thermoplastics. The bladder is inserted into the tool and then inflated to create the necessary pressure. Once inflated, the tool is heated under pressure, allowing the thermoplastic material to soften and reform. After the curing process is complete, the tool is cooled, and a vacuum is applied to pull the bladder. The Rishon bladder, having served its purpose as a mandrel, can be easily removed and reused for subsequent manufacturing cycles.
The Advantages of RCF Technologies’ Solution
The utilization of Rishon material as an inflatable bladder offers several key advantages:
Temperature Resistance:
Rishon material can withstand the high temperatures required during the curing process of thermoplastics, ensuring its longevity and reliability.
Reusability:
The Rishon bladder can be reused multiple times, reducing the need for frequent replacements and ultimately lowering manufacturing costs.
Enhanced Productivity:
By eliminating the limitations imposed by traditional manufacturing processes, RCF Technologies’ solution enables faster production cycles, leading to increased productivity and shorter lead times.
Improved Quality Control:
The use of a reliable and temperature-resistant bladder ensures consistent and precise manufacturing of thermoplastics, enhancing the overall quality control process.
A Leap Forward in Manufacturing Thermoplastics
The development of RCF Technologies’ reusable inflatable bladder made from Rishon material represents a significant leap forward in the manufacturing of thermoplastics. This groundbreaking solution addresses the temperature requirements that have plagued traditional thermoplastic bladders, offering improved efficiency, reduced costs, and enhanced reliability. As this technology continues to advance, it holds the potential to revolutionize the future of thermoplastic production, unlocking new possibilities in various industries and paving the way for exciting advancements in manufacturing processes.
Insulation is a critical factor in aircraft design. It is vital to ensure components like pipes and ducts utilized in high-temperature environments, wings, fuselage, airframe, and engine areas receive proper thermal protection. Selecting the best materials to provide the highest levels of thermal management, acoustic insulation, and fire safety is essential to keep the crew and passenSegers comfortable and safe while also keeping utility costs low and reducing energy consumption. Strict standards and specifications must be met regarding design, construction, installation, reliability, and safety.
Thermal insulation is the process of restricting and controlling the transfer of heat between one object and another. Proper thermal insulation for components utilized in high temperature environments is crucial for efficient performance. Insulation materials also support the structural integrity of various aerospace components. They provide strength and durability, ensuring the safety and longevity of the aircraft. Additionally, ample insulation serves to keep utility costs low and reduce energy consumption as well. Therefore, finding the most appropriate insulative materials is of paramount importance.
Acoustic Insulation
Acoustic insulation reduces noise transmission from one area to another. Not only does acoustic insulation make for a more pleasant flying experience, but the FAA also requires aircraft to include acoustic insulation as it guarantees that excessive noise created by the aircraft doesn’t interfere with communication.
Insulation as Fire Protection
In addition to insulating against heat, fire protection is also essential. Firewalls, fire blankets, and other fire protection for various components are necessary elements in the construction of any aircraft for obvious reasons. Clearly, the more flexible, easy to install, and light weight this fire protection can be, the better. Specifications for these materials are rigorous as there is much at stake.
Thermal Conductivity in Aerospace Insulation
The impact of thermal conductivity on aerospace insulation cannot be overstated. Low thermal conductivity is crucial in aerospace insulation ensuring optimal performance and safety. Insulation is one of the best means of restricting and controlling heat loss and heat transfer. This heat management will not only lessen thermal stress on critical systems, but will promote longevity, performance, efficiency, and reliability.
Where Insulation is Used
Common applications utilizing insulation include:
Aircraft appliance insulation
Aircraft heat shields
Cable wraps
Cryogenic insulation
Electronics fire protection
Engine blades
Engine gaskets
Fire protection
Fire walls / doors
Fuel tanks
Fuselage
Gaskets
Helicopter struts
Hydraulic / air lines
Nacelle insulation
Selecting Insulation Materials for Aerospace Applications
Selecting insulation materials for aerospace applications involves consideration of several factors:
Temperature Range
An understanding of the specific aerospace application’s temperature range and operating conditions is essential. Different insulation materials have varying temperature requirements and performance characteristics, so it is crucial to choose a material that can withstand the unique conditions of each particular aircraft and application.
Weight
Another important factor to consider is the weight and space constraints. Insulation materials used in aerospace applications must be lightweight and compact to minimize the impact on the overall weight of the aircraft. This is especially critical in the aviation industry, where every ounce and inch matter. In some situations, custom insulation solutions utilizing techniques like airgaps can be utilized to improve the insulative results while reducing additional weight.
Fire Resistance
Fire resistance requirements must also be evaluated. Aerospace applications demand adherence to FAA requirements which call for highly fire-resistant materials. This factor is critical to ensure the safety of passengers and crew in case of any fire incidents.
Acoustic Insulation
Eliminating all noise generated by an aircraft is certainly impossible, but mitigating noise is an important consideration. It is essential to reduce aircraft noise levels and provide travelers with a comfortable environment.
Chemical Compatibility
In some areas of an aircraft, insulation material will encounter various chemical fluids. Exposure to these fluids may cause the insulation material to react negatively leading to damage and deterioration. Selecting an insulation material that is chemically compatible is significant.
Standard Insulation Solutions
Standard insulation solutions span a broad range of material options. Some have been relied upon for decades and others are newer to the market. Common insulation materials include fiberglass, mineral wool, cellulose, polyurethane foam, polystyrene (EPS), and polyimide foam. Each of these materials is intended to control and mitigate heat conduction, convection, and radiation. There is however, a new and improved insulation material – RishonX™ Material.
RishonX material has an operating temperature range of -170°F to +850°F. Varying thicknesses provide different protections against various heat levels. For example: A 0.90” layer of RishonX material can provide temperature drops as great as 600°. Whether an operating environment is frigid, or components need protection from extreme heat, RishonX offers an ideal insulating material.
In addition to insulation from heat, RishonX also insulates against fire. Over a 15-minute burn, RishonX maintained the following backside temps:
Backside Temperature
Material Thickness
106° F
.225”
280° F
.050”
RishonX insulation material also shows no signs of deterioration following exposure to most chemical fluids found on aircraft.
Vibration is an inescapable variable in aerospace. Airplane parts can only handle so much fatigue before they begin to degrade or fail. The longevity of instruments and avionics, landing gear, baffling, engine mounts, and even the airframe itself can be drastically impacted by the presence of excess vibration.
When it comes to vibration in an aircraft, there are numerous potential causes:
Crankshaft unbalance
Bearing problems
Loose or worn components in the assembly
Defective crankshaft counterweights
Cracked airframe components
Changes in the operating environment
Overloading
Lengthened service and aging effects
If ignored, the consequences of vibration are only magnified. In essence, vibration shortens the service life of critical components and, in turn, pushes up costs – often unexpectedly and unpredictably.
Effects of Vibration
Even though some vibration is normal and expected in aviation, when aircraft vibration becomes excessive, the following problems may arise:
Cracked exhaust stacks and sheet metal
Higher than normal occurrence of oil leaks and light bulb failures
Physical movement of the airframe (buzz in the seat, yoke and rudder pedals)
Passenger complaints of noise in the cabin
Cutting Down on Vibration
While the elimination of vibration from aircraft is not achievable, reducing it as much as possible and managing its levels for optimum performance will make a noticeable difference and increase the longevity of the airframe and avionics.
Anti-vibration components and materials are a critical starting point on this journey. Careful consideration of characteristics such as deflection, static loading and alignment is crucial when making these selections. Specifying anti-vibration materials and components from the outset, rather than allowing vibration-related problems to become apparent during operation, will result in sustained performance and safety and lower costs.
Rishon® material from RCF Technologies, a low modulus material which absorbs both sound and vibration, is an excellent place to begin. For more information, contact us today.
Gaskets play a crucial role in maintaining a secure seal between connected parts or surfaces, preventing fluid leaks and energy transfer. However, when it comes to high temperature applications, gaskets face two primary challenges: compression set due to prolonged exposure to high temperatures and extrusion or blow out caused by high pressure. Below, we will explore these two common problems and introduce innovative solutions provided by RCF Technologies to overcome these challenges.
Problem 1 – Compression Set
Exposure to high temperature over an extended period can cause gaskets to experience compression set, where the material loses its ability to bounce back to its original shape, leading to leakage. Different gasket materials have varying temperature limits. While metallic and composite seals can withstand temperatures above 1000°F (537°C), elastomeric or rubber gaskets have a lower operating temperature of around 350°F (177°C). However, there is a solution that surpasses these limitations.
Rishon® Material for High Temperature Stability
RCF Technologies offers a revolutionary material called Rishon®, which is a combination of RCF’s proprietary silicone and fiberglass. This unique composite allows Rishon® to withstand temperatures from -170°F to +850°F (-112.2°C to +454.4°C) continuously. Not only does Rishon® excel in high-temperature applications, but it is also an FAA-approved fire barrier in thicknesses as low as .027″. By incorporating Rishon® gaskets, you can avoid compression set and ensure a reliable seal even in extreme temperature environments.
Problem 2 – Extrusion or Blow Out
Extrusion or blow out from high pressure presents another challenge for gaskets. This occurs when the pressure forces the gasket material to deform or dislodge, resulting in leaks and potential system failure. Overcoming this problem requires an innovative approach.
Solution: Rishon® Shim Gaskets for High-Pressure Applications
RCF Technologies has developed a solution to combat extrusion and blow out using Rishon® material together with unique design innovations. By utilizing a 1–10 mm shim faced with a single ply of Rishon® on either side, the gasket gains the strength of a metal gasket while retaining the excellent sealing properties of rubber. This unique design ensures that no extrusion or blow out occurs, even in applications with narrow gaps, high pressures, or multiple bolt holes. With Rishon® shim gaskets, you can achieve a secure and reliable seal under extreme pressure conditions.
Additional Custom Gasket Solutions by RCF Technologies
In addition to addressing the two most common problems with high-temperature gaskets, RCF Technologies offers a range of custom gasket solutions tailored to specific applications. One notable example is the single-fastener gasket used for plumbing firewalls. This gasket features an overlapped split design, providing a completely fireproof seal while allowing easy access to wire bundles or tubes. This innovative solution minimizes weight, reduces installation and removal labor, and ensures utmost safety.
RCF Technologies: Your Partner in Custom Gasket Solutions
When it comes to high-temperature gaskets, RCF Technologies is a leading provider of customized solutions. RCF offers gaskets in any thickness and configuration, with the option to bond them to metal plates or other materials, make them fireproof, or design them to be easily removable. Whether your application involves anti-icing, engine seals, thrust reversers, or plumbing firewalls, RCF Technologies can deliver tailored gasket solutions to meet your specific needs.
In Conclusion
High-temperature applications present unique challenges for gaskets, including compression set and extrusion or blow out. However, by leveraging the advanced Rishon® material and innovative designs offered by RCF Technologies, these problems can be effectively overcome. With Rishon® custom gaskets, you can ensure a reliable seal even in extreme temperature and pressure environments. For custom gasket solutions that address your specific requirements, RCF Technologies is your trusted partner. Contact RCF today to discover how their expertise can benefit your applications.
