# Presentation: 671382

## Development of an Insulation Responding to the FAR 25.856 by the Integration of Mica Flame Barrier  OCTOBER 2005, the 20th FAA PRESENTATION

-  Alain JACQUES 			(COGEBI)
-  Nicolas ORANCE 			(DAHER)

**Fire and Cabin Safety Research**

- ...................................
- .................................

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 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

## NEW Thermal/Acoustic Insulating Blanket

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

-  Aircraft Manufacturers

**NEW **Thermal/Acoustic Insulating **Blanket**
- or** Mica Paper Fire Barrier ****(Liner)**

- Weight : m < 75g/m2
- Process : respect the current process

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 2 - RAW MATERIAL

- High THERMAL
- resistance

_**MICA – Main Properties**_**     **

- CHEMICAL
-  inertness

- ELECTRICAL
- insulation

- MECHANICAL
- resistance

**2 - RAW MATERIAL**

- LAMELLAR
- (non-fibrous)

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 2 - RAW MATERIAL

- Due to its crystallographic structure, mica properties are anisotropic.
- The best behavior is exhibited perpendicularly to the cleavage.

_**COGEBI’s MICA PAPER**_

**2 - RAW MATERIAL**

- A pure Mica Paper of 25 g/m2 is an excellent _Flame Barrier_

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## 3 - DAHER BLANKET :Manufacturing and Installation

- 1 Glass wool automatic cutting

- 2 Film welding

_**PROCESS**_** :   5  steps  **

**3 - DAHER BLANKET :Manufacturing and Installation**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 3 - DAHER BLANKET :Manufacturing and Installation

- 3 Reinforcement

- 4 Control

**3 - DAHER BLANKET :Manufacturing and Installation**

- 5 Installation on aircrafts...
- (AIRBUS France assembly lines :
- A300, A320 and A340 families)

**20’000**
- Blankets per month !

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 	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.

- 	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.

***4-1 CogeBarrier ***

**4 - NEW PRODUCTS : CogeBarrier film and CoDaX****®**** blanket**

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

- Adhesion, when necessary

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## Aging

- _Specific products results_

**Properties**

**Unit**

**Test method**

**Target**

**RESULTS**

**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**

**Properties**

**Unit**

**Test method**

**Target**

**Mica-PVF1**

**% diminution of tensile **
**strenth**

- %

- Aircraft
- Manufacturer

-   25

**% diminution of seam **
**resistance - peeling**

- %

- Aircraft
- Manufacturer

-   30

**24**

**15**

**9**

**5**

**1000h/70°C**

**1000h/70°C/**
**/98%RH**

**Mica-PVF2**

**16**

- in progress

**14**

**1000h/70°C**

**1000h/70°C/**
**/98%RH**

**Mica-APK**

**7**

**15**

**1000h/70°C**

**1000h/70°C/**
**/98%RH**

**RESULTS**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

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

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

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

***4-2 Development and qualification tests on CogeBarrier ***

- _Specific products results_ :

**Flammability vertical 12 s**

**Unit**

**Requirement**

**Mica-PVF1**

**RESULTS**

**Burn length**

- mm

-  203

**After flame : burning time**

- s

-  15

**0**

**After flame : dripping time**

- s

-  5

**No drip**

**142 (*)**

**Unit**

**Requirement**

**Mica-PVF1**

**RESULTS**

**Flaming mode**

- -

-  100

**Non flaming mode**

- -

-  100

**0**

**0**

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

- Methods used for HF and HCl analysis : ionic chromatography

***4-2 Development and qualification tests on CogeBarrier ***

- _Specific products results_ :

**Gas**

**Unit**

**Target**

**Hydrogen fluoride (HF)**

- ppm

-  100

**Mica-PVF1**

**Non-flaming **
**mode**

** ****Flaming**
**mode**

**RESULTS**

**Hydrogen chloride (HCl)**

**Sulfur dioxide (H****2****S + SO****2****)**

**Hydrogen Cyanide (HCN)**

**Carbon monoxide (CO)**

**Nitrous gases (NO + NO****2**** )**

- ppm

-  150

- ppm

-  100

- ppm

-  150

- ppm

-  1000

- ppm

-  100

**0**

**0**

**0**

**0**

**0**

**0**

**< 10**

**0**

**0**

**0**

**63.3**

**0**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

##     Successful 

**BURNING BEHAVIOUR**

-  FAR25§853 (a) vertical test 12s

|  | Unit | Requirements | CoDaX® |
| --- | --- | --- | --- |
| Burn length  | mm | < 203 | 28.3 |
| After flame time | s | < 15 | 0 |
| After flame time of drips | s | < 5 | No drip |

-     Successful

| Radiant panel test | Unit | Requirements | CoDaX® |
| --- | --- | --- | --- |
| Flame time  | s | < 3 | 0 |
| Flame propagation distance | mm | < 51 | 0 |

- _New requirement_ : FAR25§856 (a) Flame propagation

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

##     Successful 

***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

| CoDaX® results: |  |
| --- | --- |
| No flame penetration (at least 5 min) |  |
| Backface calorimeters  | 0.89 and 0.58 W/cm2 |

-     Successful

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

##   CoDaX® Blanket		      	   CogeBarrier Film

**  ****CoDaX****®**** Blanket****	****	****      ****	****   CogeBarrier Film**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 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

## 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

## 5-2 Blanket new design concept : 

-  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 mechanical fixing part***
***is integrated on blanket***

***New fixation line ***
***(added on A/C skin or on stringers)***

- _FIELD_

***Mica protected face ***

- _FRAME_

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-3 Frame insulation principle 

***5-3 Frame insulation principle ***

- Mica protected
- face

- Mica protected
- face

- Possible ATA92
- interface
- (screwed “P-Clamps” or Combi)

- Possible ATA92
- interface
- (screwed “P-Clamps” or Combi)

***Fireproof ***
***fixation and removable safety part  ***

- WITHOUT FOAM RING

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-3 Frame insulation principle

- to separate blankets from
- direct structure contact, limiting condensation effect on cold parts.

- Possible ATA92
- interface
- (screwed “P-Clamps” or Combi)

- Possible ATA92
- interface
- (screwed “P-Clamps” or Combi)

***5-3 Frame insulation principle***

- Mica protected
- face

- Mica protected
- face

***Fireproof ***
***fixation and removable safety part  ***

- WITH FOAM RING

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-4 Frame insulation prototype

- OVERLAPPING ON FRAMES

- Frame pins

- Stringer pin

- Large overlapping to insure no leak to flame barrier

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-4 Frame insulation prototype

***5-4 Frame insulation prototype***

- ...under blankets : fixed brackets !

- After blanket installation, removable brackets are installed.

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-4 Frame insulation prototype

- ...or with standard clamps !

- with COMBIS electrical brackets...

- ELECTRICAL INTERFACES

***5-4 Frame insulation prototype***

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-5 Bilge and cargo floor insulation prototype

***CogeBarrier***

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 5-6 Cargo floor insulation

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

***5-6 Cargo floor insulation***

***Mica side**** *

***Phenolic side**** *

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 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

## 6 – CONCLUSION 

**Maintenance**
**Aging test**

**6 – CONCLUSION **
**(since last FAA conference in LISBOA november 2004)**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 6 – CONCLUSION 

**New Design principles**
**Prototype**
**Our back ground in installation**

**6 – CONCLUSION **
**(since last FAA conference in LISBOA november 2004)**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 6 – CONCLUSION 

**WORK WITH AIRCRAFT’S MANUFACTURERS AND AIRLINERS...**

**6 – CONCLUSION **
**(since last FAA conference in LISBOA november 2004)**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta

## 6 - CONCLUSION

*Innovative & Pertinent solution*

**6 - CONCLUSION**

- International Aircraft Materials Fire Test Working Group Meeting, Atlanta