Properties and Manufacturing of Sandwich Parts with Phenolic Foam Cores

Abstract

Phenolic resins are noted for their outstanding fire properties. Foams produced of this material combine these properties with other qualities such as low density and low thermal conductivity, a combination that makes them particularly attractive for aviation applications. With the further development of the foam systems, phenolic foams are nowadays available with acceptable mechanical properties, too. This paper looks at the property spectrum of these new foams in more detail. Taking the example of an overhead storage compartment door for a passenger aircraft, the article also shows how these foams are processed and what properties can be achieved and expected for such parts. The One Step Sandwich Moulding (OSSM) process is a technique that allows dry textiles to be impregnated with the foam system, giving a sandwich laminate with a foam core and a fabric skin in a single step.