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Latest News

Toyota adopts lightweight honeycomb solution based on EconCore’s ThermHex technology for latest hybrid model Prius PHV Japanese automotive OEM Toyota has adopted an interior part using unique honeycomb material solution for its new hybrid model Prius PHV launched earlier this year.

[view details]21-09-2017

Diehl Aircabin and EconCore combine to develop aircraft interior modules based on thermoplastic honeycomb Thermoplastic honeycomb technology specialist EconCore has joined forces with Diehl Aircabin to develop next- generation solutions for aircraft interior modules during a European Commission funded project.

[view details]07-09-2017

Armageddon Energy, EconCore and Dupont develop ultra-light photovoltaic panel based on polyamide honeycomb technology Armageddon Energy, EconCore and Dupont joined forces to create a new lightweight polymer solar panel, which is one-third the weight of a standard glass solar panel while being significantly more rugged and resistant to damage than standard panels.

[view details]15-06-2017

On 17 May, the TU/Ecomotive team (sponsored by EconCore) unveiled their fourth concept car: Lina! Lina is the world's first car made from bio composites.

[view details]18-05-2017

Smallest Cell Size Thermoplastic Honeycombs Ever Next to the 3mm cell sized PP honeycomb in a very low thickness of 3 - 3.5mm which has already been marked as a great commercial success, EconCore’s daughter company ThermHex Waben launched now two other configurations of the honeycomb:

[view details]16-05-2017

ThermHex

Folded honeycomb from a continuous thermoplastic sheet

Core material and process
The patented ThermHex honeycomb material and technology allows production from a single continuous thermoplastic sheet by successive in-line operations.

The ThermHex core is produced from a single sheet by a thermoforming,  a folding and a bonding operation. ThermHex honeycombs have closed skin strips, allowing perfect bonding of skins onto the core.

ThermHex technology enables the cost efficient production of honeycomb cores from a wide range of thermoplastic polymers with a large variation in cell size, density and thickness.

Production line

The ThermHex production technology enables the production of themoplastic honeycombs directly from the extruder or from a roll of material.

Inline postprocessing to panels and parts leads to further cost reductions by optimal process integration.

ThermHex Applications
EconCore technologies allow for production of ThermHex honeycomb cores from different thermoplastic polymers via a coil of film or by direct extrusion and enable a direct further processing in-line. The range of polymers include (but is not limited to) PP (Polypropylene), PE (Polyethylene), PS (Polystyrene), PET (Polyethylene terephthalate), PA (Polyamide), PC (Polycarbonate), ABS (Acrylonitrile-butadiene-styrene), PPS (Polyphenylene sulfide), PEI (Polyetherimide).   

In combination with different skin materials EconCore honeycombs offer a wide range of application possibilities. Low production costs of EconCore honeycombs enable substitution of other honeycomb cores and homogeneous panel materials. In development projects with our customers and licensees we develop panels and parts for packaging, graphical automotive, transportation, building & construction as well as furniture markets. 

ThermHex technologies for packaging & graphical applications

100% polypropylene (PP) ThermHex honeycomb boards are especially applicable to reusable plastic transportation boxes and solutions in the logistics sector, such us for example durable and hygienic plastic pallets. Layer pads, dividers, protection panels are complementary applications.

Same honeycomb panels are used in the applications in advertisement – PP boards are printable.

ThermHex PP honeycomb panels are a proven solution, realized by a number of EconCore’s licensees based all over the world, outperforming conventional corrugated plastic boards and PP cup shaped (bubble) panels. The advantages of ThermHex technology over these traditional solutions are very evident:

• bidirectional performance
• enhanced rigidity, flexural strength and compression strength and this at lower weight,
• cost savings due to lower material and energy use while the process is kept fast and continuous,
• very good thermal insulation.

 

ThermHex technologies for automotive interior parts

Lightweight sandwich panels may be produced directly in-line with the core production by direct in-line lamination of skins onto the ThermHex honeycomb core. Sandwich panels with thermoplastic skins and a ThermHex honeycomb core enable the very cost efficient forming of complex sandwich parts for automotive interior applications. In short, ThermHex technology is an answer to the critical needs of the industry: high performance combined with low weight and minimal cost!

Sandwich panels with ThermHex honeycomb cores are especially suitable for the following automotive interior components:

 

• luggage compartment floor and spare wheel covers
• door panels / door inserts
• seat back stiffeners and compartment dividers
• cabin floor and underfloor systems
• overhead systems (enhanced sounds absorption with an open cell honeycomb structure)

ThermHex technologies for applications in transportation

The continuously produced honeycomb sandwich panels offer a unique opportunity in the transportation segment, including applications such as delivery truck boxes, pick-up truck boxes, trailers, cladding panels in trucks and vans but also in the railway sector. Higher temperature resistant thermoplastic materials enable meeting the needs related to exterior applications while FST or fire resistant materials are suited for the use in mass transportation segment. Honeycomb panels with various  skin material types (thermoplastics, thermoplastic composites, GRP,  aluminium and steel) offer unbeatable performance and unique cost position.  

The relevant key features of ThermHex honeycomb technology and sandwich panels: 
high mechanical  performance due to the honeycomb structure of the sandwich core

• thermo-formability (complex shapes possible in one shot process, including over-molding options)
• thermal insulation (still air in the small honeycomb cells is a perfect insulator)
• enhanced damping performance
• weight reduction due to the honeycomb sandwich design
• cost reduction due to the in-line integrated, efficient production process


ThermHex technologies for building and construction  

ThermHex honeycombs with PP, steel or aluminium, CPL or HPL skins may be used for example in façade and inner cladding as well as furniture and visual communication applications. These material combinations enable cost efficient sandwich panels with outstanding weight-specific mechanical properties.
The direct in-line lamination of skins onto the continuously produced ThermHex honeycomb core allows for a very cost efficient production of panels for interior, furniture and cladding. The 100% PP panels can also be used as a temporary fencing and concrete casting panels.

PET nonwovens may be laminated onto the ThermHex core to enable processing with thermoset materials. 


 

econcore

ThermHex cores and production process

econcore

ThermHex cores and panels

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ThermHex panel production line
 

ThermHex PP container boxes


econcore

Examples of ThermHex panels with different skins for automotive applications


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ThermHex doorpanel

Truck boxes and cladding

Trailer

econcore

Examples of ThermHex sandwich panels for interior and furniture applications

Facade