BASF foam in the interior insulation of new Boeing aircraft

Citation

(2008), "BASF foam in the interior insulation of new Boeing aircraft", Aircraft Engineering and Aerospace Technology, Vol. 80 No. 1. https://doi.org/10.1108/aeat.2008.12780aad.028

BASF foam in the interior insulation of new Boeing aircraft

BASF foam in the interior insulation of new Boeing aircraft

American aircraft manufacturer Boeing is insulating its new aeroplane series, the Dreamliner 787, with Basotect, BASF's sound-absorbing and heat- insulating melamine resin foam. This is the first time that a BASF foam has been used in the mass production of acoustic insulation for aeroplane cabin walls and environmental ducting. The outcome of the close cooperation between the two companies is the development of Basotect UL (ultra light), which, at six grammes per litre, is 30 per cent lighter than the conventional Basotect. Boeing and BASF also developed new test methods for the use of this specialty foam in aviation.

According to Boeing, the lightweight BASF foam supports Boeing's efficiency targets and, thanks to its high sound-absorbing capacity and its good thermal-insulation properties, Basotect is also instrumental in Boeing's concept for the layout of the Dreamliner 787 series. The new aircraft is quieter than aircraft of a comparable size.

Pieces cut from the elastic melamine resin foam can reportedly be installed in the cabin walls easily and quickly. The foam is said to retain its flexibility even at extremely high temperatures as well as at very low temperatures without becoming brittle. In addition, the material is stated to be highly flame- retardant, so that Basotect also complies with the strict fire-protection standards stipulated by the aviation authorities.

The goal of the collaboration between Boeing and BASF was the use of Basotect as an insulating material for cabin walls. Since, reducing aircraft weight is of paramount importance, this cooperation ultimately led to the development of Basotect UL, which is 30 per cent lighter in weight than the classic Basotect, yet exhibits the same attractive combination of acoustic and mechanical properties. Randy Smith, Boeing's Interiors Design engineer explains: “We investigated several material combinations, and our testing and analysis determined that a laminate containing Basotect was the most weight-efficient system to reduce the interior noise in the forward fuselage of the 787. We will continue to work together with BASF to identify other uses of Basotect in the thermal and acoustic insulation for future 787 aeroplanes.”

Basotect, a thermoset foam, belongs to the PlasticsPlus product line of BASF's Styrenics Division. Owing to its favourable combination of properties such as temperature-resistance and flame-retardant behaviour, and also the fact that it is extraordinarily lightweight, flexible, sound-absorbing and heat-insulating, this foam has already been widely used in the sound insulation of buildings as well as for fireproof airplane seats, in automotive construction and, most recently, in the Ariane 5 launcher, which delivers satellites into space.

Details available from: BASF, web site: www.basotect.de