Aviation & Aerospace

Both AZOTE®, more specifically Plastazote, and ZOTEK® F foams are used extensively in the aerospace civil, business and military aviation. They have closed cell structure, giving low water absorption and low water vapour permeability, excellent insulation characteristics and good durability, allowing both long life and flexibility when fabricating parts.

Being closed cell, ZOTEK F foams are being used increasingly to replace PVC Nitrile, Silicone and other foams, which are too heavy, don’t meet the radiant panel test requirements or are open cell and can potentially absorb moisture.

Special flame retarded grades of Plastazote foams are able to meet the requirements of FAR/CS 25.853(a) App F Pt I. Additionally, ZOTEK F grades, being inherently non flammable, are able to meet the Radiant Heat Panel test FAR 25.856 (a) App F Pt VI and have low smoke density, low toxic gas emission and low heat release. The new ZOTEK F grades designated ZOTEK F HT offer an additional operational temperature limit of 160°C, an improvement of +50°C over the current ZOTEK F range. They also offer enhanced chemical and solvent resistance, combined with higher levels of structural rigidity.

All of these closed cell foams can be converted easily using traditional foam fabrication techniques such as sawing, routing, gluing, laminating, welding and die-cutting. They can also be thermoformed into complex single component structures providing many benefits over multi-layer foam systems, such as weight and cost reduction.

Plastazote foams are used in many seating and soft trim areas. The low-density closed cell nature of these foams allows significant weight reduction in seat cushions. Additionally, they are used to provide buoyancy or support in crucial areas of seat cushions, improving both comfort and durability.

Plastazote foams are used to provide soft touch and energy management around seating areas. These include foam-backed fabrics used around superior seating, seat armrests and crash pads on the rear of headrests

ZOTEK F foams show very low heat-release values, (a requirement for cabin interiors) and may be used in conjunction with other materials, such as leathers, that generally exhibit higher OSU values where ‘average’ results for material combinations need to be achieved.

Applications for Plastazote and ZOTEK F foams in the galley area are diverse. From compact crew seats and beds, to thermal insulation in ovens and refrigerators, through to kit boxes, these versatile foams can be fabricated to suit many applications.

ZOTEK F and Plastazote foams are used in many areas of the airframe, primarily as thermal and acoustic insulation and damping materials. Applications include ducting and water pipe insulation, water diverters and insulation of the cockpit, window reveals, and insulation pads for cargo deck and doors. The nature of these foams makes them easy to fabricate into intricate shapes. The excellent UV resistance of ZOTEK F also lends itself to applications where there is regular exposure to radiation, such as in the cockpit.

The synergistic combination of structure and insulating properties of ZOTEK F 38HT and F 74 HT foams has provided engineers new flexibility and expanded the design envelope. Not only can they reduce the weight of the final part up to 30%, but they are also able to remove several manufacturing steps along the way, creating a more efficient process.

AZOTE foams have been widely used as transit packaging for many years and find application in both aerospace production areas, for tool control and part protection during transport, and on planes to produce safe compact storage for pieces of equipment such as defibrillator units.

More recently, ZOTEK F foams have found use as packaging where lightweight inherently flame retarded foams with high purity are required to protect high value components and equipment during transit in both aviation aerospace applications.

Plastazote and ZOTEK F foams are used in the manufacture of military airplane ejector seats, having light weight and excellent energy absorption. Other diverse applications include cavity fillers, to prevent water ingress, air ducting insulation and thermal & acoustic insulation in general.

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