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product manual 2011

product manual 2011

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product manual 2011

Product catalog summary

Product Overview

Starlight: Composite panel with a transparent honeycomb core, available in variations such as Basic, Extra, Plus, Plus Floor, and Plus UVP.
Lightben: Composite panel with a clear Polycarbonate honeycomb core, available in Basic, Plus, Plus CC, and Plus UV variations.
Hexaben: Composite panel with an Aluminium honeycomb core, available in Small, Small Plus, Large, and Large Plus.
Ecoben: Composite panel with a recycled cardboard core, available as Ecoben Wave.

Handling and Storage

Panels should be stored in a sheltered location with temperatures between 10°C and +30°C. They should be handled vertically and stored horizontally on an even surface. Protective film should remain until installation.

Maintenance

Starlight and Lightben: Clean with lukewarm water and neutral detergent. Avoid direct sunlight and high temperatures during cleaning.
Hexaben: Similar cleaning procedures as Starlight and Lightben, avoiding abrasives and high alkaline detergents.

Products Processing

Avoid mechanical processing before 10 days from production. Use appropriate tool cooling systems and ensure adequate ventilation during processing to avoid toxic fumes.

Utilization Guidelines

Suitable for outdoor use in vertical partitions, roofs, and skylights.
Guidelines for raised floors and indoor humid environments.
Fire certifications and furniture component guidelines.

Troubleshooting

Solutions for scratches, tears, and condensation issues.

Safety Notes

Includes safety precautions and handling instructions.

Attachments

Technical data sheets, chemical resistance tables, adhesive compatibility, and safety data sheets.

Product Specifications

Specifications for Bencore panel products include:

Main clearance angle: 5° to 15°
Secondary clearance angle: 10° to 30°
Pitch/tooth spacing: 3 mm to 18 mm
Thickness: 3 mm to 4 mm
External diameter: 200 mm to 400 mm
Teeth material: Tungsten carbide
Cutting speed: 1800 m/min to 6000 m/min
Feed speed: 3 m/min to 6 m/min

Cutting and Drilling Procedures

Recommendations include adjusting cutting speeds and angles to prevent residue formation and ensure clean cuts. Use tungsten carbide or superfast steel for teeth material.

Milling and Edging

Milling involves using a router with automated panel feed systems. Edging can be done manually or by machine, with methods such as foil edging and T-profile edging.

Gluing and Assembling

Panels can be glued to each other or other materials. Reinforced joints can be made using polycarbonate foils. Adhesive compatibility is crucial to avoid damage.

Polishing

Polishing is recommended to restore gloss and finish surfaces. Specific instructions and materials are provided for both glossy and matte surfaces.

Thermoforming

Hot bending is possible with a recommended bending radius of 20-25 times the panel thickness. Consultation with Bencore’s Technical Office is advised.

Laser and Water-Jet Cutting

These processes are not recommended for STARLIGHT and LIGHTBEN panels.

Sealing Edges

Edges must be sealed with acid-free silicon in humid environments to prevent damage.

Guidelines for Use

Recommendations for outdoor use, raised floors, and humid environments are provided. Panels can be backlit with neon lamps or LEDs, but not with incandescent lamps.

Fire-Class Certifications

Fire certifications for various products are listed for Italy and Germany.

Furniture Components

Guidelines for making shelves and complex structures are provided, with load-bearing capacities and recommended materials.

Troubleshooting and Safety Notes

Solutions for common issues like scratches and delamination are provided. Safety precautions include using protective gear and ensuring proper ventilation during high-temperature processes.

Specifications

Detailed specifications for various Bencore products, including Starlight Plus, Lightben, and their variants. Key parameters include dimensions, load capacities, deflection values, and mechanical properties.

Load Capacity and Deflection

Tables outline the load capacity and deflection for different panel types under various conditions. For instance, Starlight Plus UVP panels show varying deflection based on support distance and load, with safety factors greater than 3.

Sun Elevation Angle and TSET Values

Data on solar transmittance (TSET values) at different sun elevation angles, indicating energy efficiency characteristics of the panels.

Chemical Resistance

Attachment 2 provides a chemical resistance table for Starlight Plus Class and Lightben Plus panels, categorizing resistance levels from optimal to insufficient against various chemicals.

Adhesives Compatibility

Attachment 3 lists compatible adhesives for bonding Bencore products, specifying manufacturers and trade names.

Safety Data Sheets

Attachment 4 includes safety information, first-aid measures, fire-fighting instructions, and handling guidelines. The products are non-hazardous, with specific recommendations for personal protective equipment during handling.

Environmental and Disposal Considerations

The document discusses ecological impacts, recycling options, and waste disposal methods, emphasizing the stability and inert nature of the materials.

Transport and Regulatory Information

The products are not classified as dangerous for transportation, and regulatory compliance is noted according to EEC directions.

Catalog excerpts

Product manual April 2011

Open the catalog to page 1

04 | Product manual | | Product manual | 05 1 . P RO D U C T D E S C R I P T I O N 1.1. STARLIGHT Composite panel made with a conic-cells transparent honeycomb core laminated with two layers of transparent/ coloured/satin-finished resin. Starlight is available in the following variations: STARLIGHT BASIC Standard entry-lever product. STARLIGHT EXTRA In comparison with Starlight Basic, has a stronger core: it is suitable for structural uses and when machining is needed ( like 45°cuts, milling etc.) STARLIGHT PLUS Panels with Fire Certification STARLIGHT PLUS FLOOR Panels specific for raised floors...

Open the catalog to page 3

06 | Product manual | | Product manual | 07 2. HANDLING AND STORAGE 3. MANTAINANCE 3.1. STARLIGHT - PLUS - LIGHTBEN - PLUS A plastic film protects STALIGHT, LIGHTBEN, HEXABEN and ECOBEN panels. It is advisable to keep the protective film in place for as long as possible, until panel installation. Storage must be carried out in a sheltered location (warehouse) with temperatures between 10°C and +30°C, avoiding direct sunlight, exposure to rain and snow, and presence of corrosive substances and/or solvents. Handling of a single panel must be done in a vertical position avoiding rubbing between...

Open the catalog to page 4

08 | Product manual | | Product manual | 09 3. MANTAINANCE 3.2. STARLIGHT, STARLIGHT-EXTRA, LIGHTBEN BASIC, HEXABEN SMALL/LARGE 3. MANTAINANCE 3.3. STARLIGHT - PLUS - UVP, LIGHTBEN - PLUS - UVP, STARLIGHT PLUS FLOOR PANELS - HEXABEN PLUS Dust and mill scale removal from edges and surfaces Edge cleaning: use compressed air to clean the edges. Surface cleaning: blow with compressed air and/or use an antistatic cloth wiping gently in order to avoid abrasions. Dust and mill scale removal from edges and surfaces Edge cleaning: use compressed air to clean the edges. Surface cleaning: blow with compressed...

Open the catalog to page 5

010 | Product manual | | Product manual | 011 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G TOOL GEOMETRIES AND RECOMMENDED PARAMETERS GENERAL PROCESSING RECOMMENDATIONS a) b) c) d) e) f) g) h) Do not undergo mechanical processing onto panels before 10 days’ from production. Avoid overheating the material: tools must be correctly sharpened, cleaned and not damaged. Use appropriate tool cooling systems (compressed air, water) in order to avoid material overheating which can cause formation of air light and chips, which are difficult to remove. Firmly anchor the pieces...

Open the catalog to page 6

012 | Product manual | | Product manual | 013 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G 4.1.2. CUTTING SPECIFICATIONS RECOMMENDED BY RAW MATERIAL MANUFACTURERS ALTERNATING SEMI-TRAPEZOIDAL SHAPE D Vd Va STARLIGHT- PLUS- UVP, LIGHTBEN- PLUS-UVP γ Secondary clearance angle (°) α 10÷-15 Pitch/tooth spacing (mm) t 8÷-18 Main clearance angle (°) t S 5÷15 Thickness (mm) s External diameter (mm) D Some recommended combinations external diameter / tooth number α Teeth material: Cutting speed (m/min) Vt Feed speed (m/min) Va 3÷4 200-400mm (larger diameters recommended)...

Open the catalog to page 7

014 | Product manual | | Product manual | 015 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G 4.2. DRILLING STARLIGHT, STARLIGHT-EXTRA, LIGHTBEN Tungsten carbide (recommended for a long lasting sharpening) Superfast steel (recommended for a better finishing of cut edges) Teeth material: Main clearance angle (°) γ Secondary clearance angle (°) 0 ÷ -5 SPECIFICATIONS SUPPLIED BY RAW MATERIAL PRODUCERS ϕ φ 10-15 (carbide teeth) 30-40 (carbide teeth) α α 10 (carbide teeth) 5 (carbide teeth) Pitch/tooth spacing (mm) t Thickness (mm) s 3-4 External diameter (mm) 200-400 mm...

Open the catalog to page 8

016 | Product manual | | Product manual | 017 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G 4.3. MILLING GEOMETRIES AND PROCESSING PARAMETERS FOR MILLING PERFORMANCE In the STARLIGHT, EXTRA STARLIGHT PLUS CLASS, STARLIGHT PLUS FLOOR, STARLIGHT PLUS UVP milling in the core can be performed so as to house the slip beading/edging (see paragraph 4.4) and profile joint (see par. 4.5.). In this type of processing a joinery machine “ROUTER” type (see scheme) with an automated panel feed system is recommended; recommended tools and cutting parameters are described below....

Open the catalog to page 9

018 | Product manual | | Product manual | 019 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G EDGING (MANUALLY OR BY MACHINE) “T” PROFILE EDGING HOUSED IN MILLED SLOT EDGING: EXTERNAL PROFILES MANUALLY EDGED PANEL bencore.it MACHINE EDGED PANEL bencore.it

Open the catalog to page 10

020 | Product manual | | Product manual | 021 4 . P RO D U C T S P RO C E S S I N G 4 . P RO D U C T S P RO C E S S I N G 4.5. GLUING AND ASSEMBLING The STARLIGHT (all types) and LIGHTBEN (all types) can be assembled one to the other and can be glued to other materials joining them at the covering sheets. Reinforced joints can be made inserting transparent polycarbonate foils inside spots milled (see par. 4.3) in the panel (STARLIGHT EXTRA, STARLIGHT PLUS CLASS, STARLIGHT PLUS FLOOR and STARLIGHT PLUS UVP only). EXAMPLES OF GLUED JOINTS WITH POLYCARBONATE STRENGTHENING (STARLIGHT EXTRA STARLIGHT...

Open the catalog to page 11

022 | Product manual | | Product manual | 023 4 . P RO D U C T S P RO C E S S I N G 4 . PA N E L P RO C E S S I N G 4.6. POLISHING STARLIGHT and LIGHTBEN surfaces can be polished proceeding as follows: • to restore original gloss of surfaces damaged by scratches or abrasions due to faulty repairs • to finish surfaces deriving from cutting/milling operations, giving them a look very similar to those of the external sheets of the panel; • to refine (give a final touch) after edging To choose the most suitable panels for the polishing operations, please consult the table below EXAMPLES OF THERMOFORMED...

Open the catalog to page 12

024 | Product manual | | Product manual | 025 4 . P RO C U C T S P RO C E S S I N G 4.8. LASER AND WATER-JET CUTTING Processings NOT RECOMMENDED for STARLIGHT and LIGHTBEN PANELS. 4.9. SEALING EDGES If panels are exposed to weather conditions or if they are placed in very humid environments (such as bathroom, saunas, etc.) edges MUST be sealed with acid-free silicon protecting surfaces near the edges with masking cellar tape. Some possible solutions are given below 5 . G U I D E L I N E S F O R T H E U S E O F PA N E L S 5.1. OUTDOOR USE (VERTICAL PARTITIONS, ROOFS AND SKYLIGHTS) Suggested materials...

Open the catalog to page 13

product manual 2011

product manual 2011

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