RCF Technologies’ Reusable Inflatable High Temp Bladder: The Future of Manufacturing Thermoplastics
Game Changing Technology
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.
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Selecting Insulation Solutions: Thermal, Acoustic, and Fire Protection
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
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.
An Improved Insulation Solution: RishonX Material
RCF Technologies provides an improvement on current insulation solutions utilizing proprietary 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.
RishonX insulation offers additional benefits, including:
- Fire resistance
- Chemical compatibility
- High temperature ranges
- Sound and vibration attenuation
- Electrical conductivity
- Vulcanization
- Low outgassing
Whether an operating environment is frigid, or components need protection from extreme heat, RishonX offers an ideal insulating material.
More information about our thermal insulation products and our proprietary RishonX material can be found at www.rcftechnologies.com.