Aerospace components manufacturer, Saint-Gobain Performance Plastics (SGPPL), based in Seattle, Washington, USA, has perfected a system for producing secondary structures such as lightweight, self-insulating air distribution ducts and panels for aircraft using Epibond epoxy adhesives, from Huntsman Advanced Materials. SGPPL use the most advanced materials available for all component manufacturing and use Epibond 1544-A82/D, a high performance, self-extinguishing adhesive, to seal and reinforce the air ducts. Epibond 1544-A82/D is particularly suited to fabricating aircraft parts that must meet the US Federal Aviation Administration Regulations (FAA FAR) 25.853 and O.S.U. Tests (heat release rate). The product is qualified to BMS 5-126, Type 4, Class 4, Grade B. SGPPL produces rigid foam ducts with fibreglass skins in sizes up to 3.9m long by 50cm in diameter; panels up to120cm square, and is a preferred supplier to aerospace manufacturers around the world.

Duct Fabricating - SGPPL moulds duct walls by casting rigid isocyanurate foam into tools lined with fibreglass material. The process produces air distribution ducts and panels with a fibreglass skin integrally moulded into the parts and accommodates the manufacture of a variety of complex shapes required for installation behind aircraft floors, walls and ceilings. To complete duct assemblies, the edges of the rigid foam structures are sealed using fibreglass soaked with Epibond 1544-A82/D epoxy adhesive. Edge sealing helps long term part durability by increasing strength and preventing moisture incursion. Seams and through-wall sections drilled for inserts are also reinforced with the fibreglass/epoxy combination. Epibond 1544-A82/D epoxy adhesive helps optimise manufacturing productivity because it is easy to apply, has a 20 minutes gel time and develops early green strength to accommodate handling of parts after four hours at room temperature. The semi-paste like epoxy is non-flowing even when applied to vertical surfaces and has a low density of 1.18g/cc to maintain the desired light weight of the ducts. Once cured, Epibond 1544-A82/D exhibits good mechanical properties with a range of substrates including phenolics, metals and ceramics. The adhesive can be used at temperatures of up to 93 oC.