Leightweight A-60/A-0 Insulation System with high acoustical Performance

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Leightweight A-60/A-0 Insulation System

with high acoustical Performance

Rudy Czerny , R + D illbruck Insulation Systems

illbruck Production S.A. 2, Les Pales

CH-2950 Courgenay

Lecture for

17th International HISWA Symposium

on Yacht Design and Yacht Construction

18. + 19. November 2002

International Exhibition an Congress Centre

NL-Amsterdam

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• Introduction

• Innovative material selection

• From the base material to Composits

• Pre-Tests of Composits

• Acoustical Pre-Test

• Acoustical performance of A-0/A-60 insulation

• Test pieces for A-0/A-60 Test

• Insulation examples in yachts

• Upshot

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Introduction

The higher yacht building is the initiator of the lecture for this symposium . Today are usually for ship insulation as state of the art known: foams on polyurethane basis, heavy layer mats on basis polyolefine and mineral filled bitumen masses , as well as mineral fibres of glass and rock wool.

In the nineties for the first time thermoformed impedanz-absorbers with very good acoustical performance were used. On heavy layers and heavy layer elastomer material one did not want to give up however traditionally. In the course of the attempt for improvement of the acoustival effectiveness and the fire safety, as well as the weight reduction, heavy layers of any kind were not, however, anymore conceivable.

Heavy layers are often thermoplastic polyolefins with melting ranges of 70°C - 120°C and therefore pronounced unsuitable for fire-resistant applications.

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Introduction

The lightweight construction on basis sandwich constructions and Composits in many industries as "state of the art" should serve as an example. For the professional acoustician it is hardly conceivable that the noise damping, damping, insulation is without heavy layer. Until therefore all activities without heavy layer were designated than hardly not suitable.

What is introduced now as a final result of an innovative ship-insulation is the essence from numerous pretests, product designs and the courage to lead new ideas and procedures to production standard. With the passed examinations to IMO Resulotion A 754/18, A-0 and A-60 is created the basis, to go differing from the known insulation new ways in the insulation of ships. As a synergy effect for the future we hope for realizing this for all ship types.

Successfully a sailing yacht was insulated until now, a further one is at this time, in work and others in negociation.

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Innovative material selection

• Criterions

Performance efficiency and resistances

- not burnable

- heat resistant 280°C

- Hydrolysis resistant

- Media resistant, oil,petrol

- Thermoformable

- Compatible

- Able to bond

-Able to recycle

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Innovative material selection

Next to the performance potentials the fibre diameter field is a challenge to the typical nonwoven production methods.

Among other things the flame retardent of the fibre material in connection with the toxis behavior of the fume gas growth was assumption for the decision to melamine fibre.

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Innovative material selection

Production of volume nonwoven and needled nonwoven as a basis

for impedanz-absorbers of melamine fibre.

Biko-

Fibre material

Melamine fibre bale

Volume nonwoven processing Needled nonwoven processing

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Innovative material selection

Thermoformability of the semi-finished products

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Thermoforming results by §  Temperature §  Pressure §  Time Needled nonwoven Volume nonwoven Needled nonwoven

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Innovative material selection

Thermoformability of the semi-finished products to Impedanz-Absorbers

(illpedanz-absorbers) After removal from the tools the ready

done impedanz-absorbers were stored for cooling.

This is one example of a product application

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Innovative material selection

Acoustical comparison of melamine fibre to polyester fibre (PET)

absorber. Same weights per square inch were used as a starting point.

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Innovative material selection

A b s o r p ti o n s m e s s u n g i n d e r A l p h a - K a b i n e Illnowo N + V nichtbrennbare Absorber 0 0,2 0,4 0,6 0,8 1 1,2 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 Frequenz [H z ] A b so rp ti o ns ko e ff iz ie nt

Illno. T3x3 O b.+Un. Illnowo N 1/ 80-O H 1,58kg/ m² Illpedance Serienausführung 1,58kg/ m²

Acoustical effectiviness of the system components:

- Melamine fibre

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From Base material to Composit

Melamine foam:

volume weight ~10kg/m³

1m² Thickness: 100mm ~ 1kg

Foam finishing: hydrophobic

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From Base material to Composit

illtec (Melamine resin foam) is outline cut and for the insulation of frame

sections in the hull, as well as used in the constructions. The cover occurs

with illnowo N ( neddled nonwoven of melamine fibres).

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From Base material to Composit

• Ceramic fibres composits

•  

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Pre-Test of the composits

Production of different Composits and their pre-tests

according to IMO-Resulotion.

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Pre-Test of the composits

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Pre-Test of the composits

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Acoustical pre-test

The comfort-requirements in the yacht building receives new dimensions through the use of impedanz-absorbers in combination with melamine foam. The noise levels to be reduced lie for the drive and supply aggregates preferably at 125-500Hz.

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Acoustical pre-test

Transmission Loss Test

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Testing on tightness of the installation groove

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Acoustical performance from A-0/A-60 Insulations

Transmission Loss Test

Einfüg ung sdämmung g emessen im Fensterprüfstand Schiffsisolationen div. Aufbauten Fensterg röße 8 0 0 x 1 0 0 0 mm 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 200 250 315 400 500 630 800 ₁₀00 ₁₂50 ₁₆00 ₂₀00 ₂₅00 ₃₁50 ₄₀00 ₅₀00 ₆₃00 ₈₀00 10000 Frequenz [H z] Ei nf üg un g sd ä m m un g [ d B ] RH S - " Standart " A0 1 8 .0 1 .0 2 A6 0 1 8 .0 1 .0 2

These values have been realized with weights of appr. 3,8kg/m² for the A-0 system (System passed also the A-60 requirements), and appr. 7,0kg/m² for the A-60 engine room insulation.

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Acoustical performance of A-0 composit

Absorptionsmessung in der Alpha-Kabine

Plattenmaterial 1,2m² 0 0,2 0,4 0,6 0,8 1 1,2 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 F r e q u e n z [ H z ]

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Aluminium test piece for A-0/A-60 test

Test panel in the IMO resolution dimensions before insulation

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Insulation construction A-0 test

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Insulation construction A-0 test

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Insulation construction A-0 test

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Deck insulation

Bulkhead insulation

Test: A-0 + A-60 passed Test: A-0 + A-60 passed

Test according to IMO resolution A754/18 A-0 Test according to IMO resolution A754/18 A-0

Conditions Target actual Conditions Target actual Test piece size fullfilled 3120x2720mm Test piece size fullfilled 3020 x 2460mm

Area fullfilled 8,5m² Area fullfilled 7,5m²

Testing time 60 Min 63 Min Testing time 60 Min 61 Min Temperature on Aluminium-outside <180°C +RT°C T1= 99°C T2= 97°C T3= 98°C T4= 93°C T5= 99°C T6= 109°C T7= 107°C

Temperature on the backside testpiece insulation

Temperature of the

Aluminium-Panel after 60Min

<180°C + RT °C 180°C +RT °C T1 – T7 = 40-50°C <124°C Temperature in burning chamber: 960°C Temperature in burning chamber: 960°C

IMO-Resolution A 754/18 A-0 Test results

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IMO-Resolution A 754/18 A-60 Test results

Test at: TNO Fire and Burning Test-Center, NL-Delft

Deck insulation

Bulkhead insulation

Test according to IMO resolution A754/18 A60 Test according to IMO resolution A754/18 A60

Conditions Target actual Conditions Target actual Test piece size fullfilled 3120x2720mm Test piece size fullfilled 3020 x 2460mm

Area fullfilled 8,5m² Area fullfilled 7,5m²

Testing time 60 Min 66* Min Testing time 60 Min 67* Min Temperature on

Aluminium-outside <180°C +RT°C T1= 92,75°C T2= 88,77°C T3= 95,85°C T4= 103,5°C T5= 103,4°C

Temperature on the backside testpiece insulation

Temperature of the

Aluminium-Panel after 60Min

<180°C + RT °C 180°C +RT °C T1= 42,32°C T2= 32,72°C T3= 29,05°C T4= 31,38°C T5= 32,75°C Ca. 86°C *Interrupted after this time, the test pieces were all still intact

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Insulation Examples in Yachts

Still as a handcrafted model: the "Cecilie Marie" that as the first sailing yacht is equipped with the new illbruck ultralight performance insulation . Compared to other insulation materials we have accomplished a weight reduction of 20-50%.

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Leightweight A-60/A-0 Insulation System with high acoustical Performance