Carbon Fiber Foam Sandwich Panel¹

Product Description 1.Product DescriptionManufactured using advanced technology, our High Strength Carbon fiber Foam Core Panel achieves the ultimate combination of strength, light weight and stunning appearance making the panel ideal for a wide range of uses from structural engineering applications through to exhibition systems and architectural use.This specially developed foam-cored carbon fiber panel is 6mm thick and uses a combination of genuine 2/2 twill 3k carbon fiber combined with a layer of woven E-glass either side of a light-weight 5mm closed-cell PVC foam core create a light-weight panel with excellent deflection strength. For maximum strength-to-weight ratio the sheets are manufactured without any gelcoat or surface coating but our propriety resin technology ensures a glossy, pin-hole free 'class-A' surface.Resin matrix is epoxy throughout with a high temperature post-cure for maximum mechanical performance.The panel has a smooth carbon fiber finish on both sides however the reverse side of the sheet is not designed to be a cosmetic face and as such some light scratches or imperfections from pressing, handling and cutting are to be expected. 2.Technical Data SheetWeight and DimensionsThickness6mmLength480mmWidth480mmWeight kg/m22.71kg/m2Product DataColourBlackAppearance2x2 Twill (Glossy)TypeSingle SidedResin MatrixEpoxyFabric Specificationfiber Orientation0, 90Mechanical PropertiesTg Onset (DMA)70°CCured Mechanical PropertiesTensile Modulus at 0/90°6610GPaTensile Modulus at 45°2060GPaTensile Strength at 0/90°71.4MPaTensile Strength at 45°36.7MPaElongation at Break at 0/90°2.64%Elongation at Break at 45°24.2 %Young's Modulus at 0/909.52GPaCompressive Strength1.33MPaCompressive Modulus72.5GPaCore Sheer Strength1.09MPaCore Sheer Modulus27.75MPaDensity0.452g/cm3Core Thermal Conductivity at RT0.033W/mKMaximum Water Absorption37.5g/m2General PropertiesGross Weight0.62kg 3.AdvantagesExceptional Formability into Compound CurvaturesNo Anticlastic or Buckling of Cell Walls in Curved ConditionsEquivalent Mechanicals as Hexagonal CoresCost Savings in Curved PanelsAlthough non-symmetric - W shear properties showed similar results regardless of shear direction Low DensityHigh Strength to Weight RatioHigh Surface area to Volume RatioIsotropic load responseControlled stress-strain CharacteristicsThe foam core allows us to make a panel of satisfactory thickness to be very stiff for the minimum possible weight. Conventional panels (made without a core material) are significantly heavier for the same deflection strength. 4.Typical UsesAvailable in sheet sizes up to 1980mm x 980mm sheet is suited to use a huge range of projects:Lightweight Structural/Engineering ProjectsVehicle Panelling / UndertraysUniversal Carbon fiber SplittersMarine PanellingExhibition Systems / DisplaysArchitectural Use5.Cutting, Shaping & FinishingAs with all carbon fiber and composites (like fiberglass, carbon Kevlar etc.) good results can be achieved for cutting, shaping and finishing this sheet using regular workshop tools like hacksaws, jigsaws and wet-and-dry. Specialist tools can, however, make lighter work of the job and produce better results.6.Shipping informationRestrictionsThis product is not classed as dangerous goods for transport and can be shipped to all destinations without restriction.Package SizeThere are no package size restrictions or surcharges for this product. ---------- FAQ ----------1.Do The Cut Edges Need Sealing And, If So, What With?Whether or not cut edges would benefit from sealing really comes down to the application and environment where the sheet will be used, specifically, we're really talking about prolonged or permanent exposure to liquids like water, chemicals, oil etc. In an application where the cut edge of the sheet is going to be regularly or permanently exposed to liquids then it would be beneficial to seal the edge to prevent water ingress which, over enough time, can travel down the fibers and cause delamination.Based on the above, if edge sealing is deemed advantageous then it's best done using some epoxy resin which should be mixed(according to its accompanying instructions) and either be brushed or smeared on the cut edge, or the cut edge dipped in it. Although it's by no means critical, a particularly suitable resin would be our XCR Epoxy Coating Resin.2.What Weight Can The Sheet Take? Could You Walk Across It If It Covered A Hol e In The Floor?It's not possible to give an exact weight because it would depend on many things (how the sheet is supported, what the span in, how the weight it loaded, whether the sheet is a 'free span'(i. e. not bonded/fixed) or bonded or fixed (so you get a 'drum skin' effect). That said, you could be confident that a sheet slid over a hole such that the sheet is supported on all sides would support the weight of an average person quite easily.3.What Are The Properties Of The Skins And Foam?The properties for the carbon fiber and glass used in the sheet we don't currently have data for but we are having mechanical property testing done on the finished foam core panel for which the data should be available soon.4.On The Foam Cored Carbon fiber Panels, How Do You Fasten Them In Place Without Crushing The Foam Core? Are There Special 'Top-Hat' Bushes Used Or Anything? If So, Do You Stock Them?Hi David, as you suggest, the key when fitting to a cored panel like this is not crushing the core with force that's too localised. This can be done using machined fittings, like a top-hat section, or it can be done by removing the foam and filling the cavity with solid material(usually epoxy resin). I'm afraid we don't have fitting bushes because there's too much variation in what dimensions (bush diameter, thread size, flange diameter) that may be required, if required, these would usually be machined to spec.Removing and solid filling the core can be very effective though and is easily done. You drill through the inside skin, then remove any remaining core material (you can even go a bit wider than the diameter of the drill hole) and then fill the cavity with a mix of epoxy resin. This creates an uncrushable core section that's bonded to the inside of the outer skin(and potentially to some of the inside of the inner skin too). Depending on what you're fixing the panel to, you could use a pan washer to spread the load onto the inside skin,bond on a sp reader plate or leave it as it is (especially if you've been able to remove core underneath the inside skin too).5.If The Panels Are Used So That The Foam Is Visible, How Can I Cover These With The Same Finish As The Carbon?What's the intended final use of the panel?... If it's something along the lines of a splitter then you can add rubber tri m around the leading edge, this is easy to do, will leave a neat finish and protect the vulnerable foam of the panel.If you really want to extend the same woven carbon fiber finish around the edge of the panel then this would be incredi bly difficult and pretty much the only way to do it would be to make a moulded part,i. e. start with a mould and then laminate a new part where the carbon fabric followed the contour of the moulded lip. A more realistic 'half-way option would be to fill the edge with a carbon filler; this can look very neat, matches the colour of the carbon fabric, and will provide strength and protection for the exposed edge.To do this, you would remove about 3mmof the foam core, all the way around. Once it's cured, you can flat and polish it to a high quality finish.6.Hello How Thick Is The Carbon fiber Skin Kind Regards Pete?Each skin on both the 6mm and 11mm panels, is approximately 0.5mmthick7.Is The Foam Closed Cell Or Open Cell? Do You Know The Make Up Of The Foam?The foam used in these panels is our LK 75 Closed cell PVC foam in either 5mmor 10mm thickness.8.What Is The Max Working Temperature For This Foam Core Sheet?The maximum working temperature for this sheet is 70C.9.Which Is Stiffer, The Foam Core Panel Or 3mmResin Infused Sheet?The Foam core panel is fractionally stiffer than the 3mmre sin infused sheet. It is also significantly lighter in weight and easier to cut.However, the 3mmresin infused sheet, being solid laminate, is much tougher and impact resistant than the foam cored panel.10.Would It Be Possible To Water Jet Cut This Sheet?Water jet cutting will cut the foam core panel easily and quickly. As with most composites, adjustment of the water j et settings may be necessary for the cut to remain clean and not chip or delaminate the edge of the sheet.11.Is It Possible To 'Cut And Fold' This Sheet?For example, I want to route out one skin and bend the other to create a 90deg bend. Also because the main loading will be shearIintend to cut out my parts at 45deg to the panel edges.No, not around a 90 degree bend. The problem would be the carbon sheet on the outer skin which would not be able to be bent around a 90 degree(or even 45 degree) corner without having a significant radius. If the bend was around a tight radius then the sheet is likely to fracture. 

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