What is Airalite? I came across this name being a new material used for kayaks. In fact (expedition)-seakayaks are made from it.
Is Airalite a tecnique, a material are just a name? The fact is that every inquiry leads back to Perception, who probably adapted a new material in its building proces.
Looking at the details (see below) it is a promising material: strong with good charcteristics, but cheaper than glassfiber kayaks.
Looking at the information I found, I am just wondering how it works: It is described as a thermo-formed material. Being a packaging technologist I am thus forced to believe that the proces starts using a thick sheet of plastic that, after heating up, is sucked&blown into a mould.
That is of course a good idea because the production-time will be much shorter than with an glasfiber kayak; even shorter than a rotomolded kayak.
But thermoforming has also disadvantages: In the deepest parts of the kayak (most abrasive spots) the plastic sheet is stretched most and will also be thinner there. The same with sharp corners. So a kayakdesign demands special attention to the model (round shapes) thus preventing thinner spots. Also the qualitycontrol must focus on wallthicknesses.
Another disadvantage is that it will be deformed by heat (this is the result of a material being able to be formed this way, which means that the modelling-proces can also be reversed); the more heat applied to the kayak the more it is willing to go back to its original shape: the flat sheet of plastic.
And without a possibility of repair. But as the dangerous temperature is around 180°C, most situations in normal life are threatless. What to think of low temperatures? Perception tells us it will be more brittle then, but when not exagerating the use of the kayak, nothing will happen. We will see! What about the impact ice can have while paddling?
This thermoforming proces is suitable for most kayaks as the shape of a kayak is not very complicated when looking at two shells to be made: the hull and the deck.
But this is at the same moment a weak spot: how are these two shells connected to each other without the risk of separating under load or without the chance of leakage. This must be a very good glue: strong, durable with the characteristic of filling small holes at the spots both shells don´t have 100% contact with each other.
So my conclusion is that this is indeed a good idea to produce kayaks using the thermoform-proces, but I am curious if there are already some experiences with these Airalite-kayaks.
Who knows more about this?
================================================
A few details I found at the WWW:
Airalite is a thermo-formed material, stiff and light like traditional composite kayaks and with similar looks, but it costs considerably less.
-------------------
The same kayak in composite(66 pounds) weighs 54 pounds in Airalite.
-------------
revolutionary new material
-------------------
That's exactly what they did with their break-through Airalite™TM Technology. They've incorporated a material that's lighter and stiffer -- performing similar to fiberglass -- yet every bit as durable as plastic. It's priced like plastic too!
-------------------
Here at Perception,paddling is our life. And with that lifestyle comes the relentless challenge of making our kayaks better and better. Mile after paddling mile, we can’t help but ask ourselves, How can we make
a better boat? And, in the process, we’re not adverse to starting a revolution � or two. That’s exactly what we did with our break-though Airalite TM Technology. We’ve incorporated a material that’s lighter and stiffer �
performing similar to fiberglass � yet every bit as durable as plastic. It’s priced like plastic, too. This year we’re featuring Airalite TM Technology in two models � the Sonoma TM family � and there’s no telling where it will go from here.
Here’s the complete scoop on Airalite TM Technology.
Material:
Airalite TM kayaks are co-extruded high-impact acrylic over premium impact ABS. Airalite TM is the same materials as used in whirpools, spas, and some marine parts -- strong proof that it's a long-lasting material that will stand up to any type of water.
This material creates a kayak that's light and stiff like fiberglass with the durability and price of plastic. Airalite TM Technology perfectly meets the unique demands put upon the hull and deck.
Airalite TM is also forumlated with adhesives for additional flexibility and UV resistance.
Muscle:
Three times more stiff than polyethylene with the tensile strength that's 40 percent stronger. The trade-off is that the impact strength is lower compared to polyethylene. So don't take it off Bridal Veil Falls. Treat it like a fiberglass boat.
The kayak's adhesive is stronger than the Airalite TM material itself -- 5,000 pounds in lap shear. Therefore, overall boat strength is superior.
Weatherability & Durability:
Deck material has the highest rating for weatherability.
Hull material is engineered to provide a higher scuff resistance and impact strength.
Cleans up easily with mild soap. For tought spots, try alcohol.
Fire & Ice:
Heat deflection is 180 degrees, so don't get it too close to the campfire. You can't reshape it like polyethylene.
As with all plastics, tempuratures below 0 degrees reduce impact strength. Never the less, Airalite TM kayaks are good cold-water performers -- as long as you avoid sliding them off two-story igloos.
"Great Lookin' Kayak"
Airalite TM Technology imparts superior gloss, creating a shrine so brilliant it shouldn't be viewed by the naked eye.
Unlike some plastics, Airalite TM can be painted. so when you get the urge to show off your artistic talents, your only worry is the censorship board.
-------------------
our exclusive Airalite TM Technology.
Close to Kevlar and other composite materials in weight and stiffness, it provides composite-like performance but at a retail price thatis much closer to polyethylene.
----------
Made from light but tough Airalite, this ........ is as tough as rotomolded plastic, but enjoys the same stiffness and lightweight usually associated with fiberglass composite kayaks.
-------------------