7. infusion, process and moulding.ppt-process-and-moulding.pdf · reduced resin spillage and...
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DSM Composite ResinsInfusion, April 2008
1
Infusion
DSM Composite ResinsInfusion, April 2008
2Program
• Vacuum injection by using a bag or sheet• Strategy + cases• Resins • Temperature in the workshop• Viscosity of the resin• Equipment• Pictures
DSM Composite ResinsInfusion, April 2008
When Infusion
Wishes and/or requirements
Large dimensions Piece to piece reproducibiliy Targeted strengthening Low styrene emission Less product losses
DSM Composite ResinsInfusion, April 2008
4Resin infusion
What do you need for Resin Infusion?
Standard HLU mould with extra flange
Flex. ( foil ) top mould
Vacuum pump for resin transport
Temperature : 20-40°C
DSM Composite ResinsInfusion, April 2008
5Strategy with vacuum foil application
Which flow material ? (net, balsa, foam, glass)
Strategy ?
Reinforcement ?(glass, carbon,core material, aramid)
Seals ?
How to dose the peroxide ?
DSM Composite ResinsInfusion, April 2008
6UP Resins
•DCPD•Volume shrinkage ± 6%
•Orthophthalic•Volume shrinkage ± 8%
•Isophtalic•Volume shrinkage ± 7.5%
•Vinylester•Volume shrinkage ± 5%
DSM Composite ResinsInfusion, April 2008
7Temperature in the workshop
•Gel time•1 degree difference = 10% difference
•Viscosity•1 degree difference = 5-10% difference
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
9Viscosity
• Lower viscosity = faster injection
• Too low = bad wetting (and-or air)
Lower viscosity means more styrene, causes more shrinkage
DSM Composite ResinsInfusion, April 2008
10Curing systems
• Which peroxide ?• Buatanox M50 (MEKP)• Trigonox 44B (AAP)• Trigonox 51 (mix)
• Peak tmperature ?• As low as possible
• Gel time ?• Injection time plus 25%
• Postcure ?
DSM Composite ResinsInfusion, April 2008
Source: AKZO Nobel
DSM Composite ResinsInfusion, April 2008
Source: AKZO Nobel
DSM Composite ResinsInfusion, April 2008
13Equipment
• Mould with wide flange (resin channel) • Wax• Reinforcement: glass and/or carbon fibres• Flow material• Hoses (inlet , outlet, runner)• Tacky tape• Foil• Vacuum pump (resin trap!)• Clamps• Optional: Injection machine (to mix the resin with peroxide)
DSM Composite ResinsInfusion, April 2008
Helical tubes for
Air/ resin transport
Sealant tape forVacuum closure
Resin flow guides (Bleeders
Standard Handlay-up/Spray-up tool can be used
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Gelcoat and/or Topcoat:
Coloured layer providing surface aesthetics and osmosis protection (non-reinforced)
Barrier Coat:Coloured layer for optimizing the surface smoothness and hydrolytic stability
Skin Laminate:High quality reinforced layer, improving surface strength and hydrolytic stability.
Construction Laminate:Reinforced laminate providing structural strength and stiffness to the construction.
Loading package
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Laminate and resin inlet.
Peelply
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Point injection
Peripheral injection
Filling time ± 10 min.
Filling time ± 1 min.
Resin
Vacuum
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
The foil has to be styrene resistant and flexibleTensile elongation of foil: 300-600 %Translucent allowing observation of the flow front during fillingThickness of the foil: 50 micron.Recyclable material (due to one time use)Free of pin holes.Nylon basedWide enough to cover the whole part.
– Splicing of foils should be avoided, as this can often cause vacuum leakage.
Requirements vacuum foil
DSM Composite ResinsInfusion, April 2008
The foil has to be styrene resistant and flexibleTensile elongation of foil: 300-600 %Translucent allowing observation of the flow front during fillingThickness of the foil: 50 micron.Recyclable material (due to one time use)Free of pin holes.Nylon basedWide enough to cover the whole part.
– Splicing of foils should be avoided, as this can often cause vacuum leakage.
Requirements vacuum foil
DSM Composite ResinsInfusion, April 2008
Conclusions:Vacuum Foil Infusion:
– The first step for the entrepreneur to consider when moving from an open process to a closed process
– Reduced styrene emission
– Improved laminate mechanical properties
– Good reproducibility
– Cleaner process
Therfore a good alternative for Hand lay up and Spray up
DSM Composite ResinsInfusion, April 2008
Advantages DetailsLow mould/ tool investments Only small modifications are required to existing open
moulds
Improved laminate mechanical properties Higher density laminates with increased glass content
Good reproducibility: reduced dependence on workmanship
As long as process parameters and reinforcement package design are kept constant
Large products can be made in a closed process Highly effective for components with large surface area
Very low styrene exposures and emissions Reduced ventilation cost possible
Cleaner production More pleasant work environment
Reduced material waste compared to spray-up processes
Reduced resin spillage and reinforcement edge trimmings
Reduced cycle times possible For more complex products, thicker laminates, sandwich constructions and large products
Low cost for large, simple products
Liquid Resin Infusion
Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Source: Reichhold
Liquid Resin Infusion
DSM Composite ResinsInfusion, April 2008 Source: Reichhold
DSM Composite ResinsInfusion, April 2008
Source: Reichhold
DSM Composite ResinsInfusion, April 2008 Source: Reichhold
DSM Composite ResinsInfusion, April 2008
27Good to know
Keep permeability in line !Make enough flange areaWait 10 min. after peroxide dosing by hand.(5 min. with peroxide machine)Do not change the vacuum level too quickly !Not two glass overlaps on one placeKeep foam sheets close togetherUse resin stopper on flange !Use large resins inlet runners !
DSM Composite ResinsInfusion, April 2008
Plascore PP Honeycomb
DSM Composite ResinsInfusion, April 2008
Corporate Headquarters
Plascore Incorporated
615 N. Fairview St.
Zeeland, MI 49464-0170
USA
Phone (616) 772-1220
Toll Free (800) 630-9257
Fax (616) 772-1289
Web www.plascore.com
Email [email protected]
DSM Composite ResinsInfusion, April 2008
Pictures of an infusion session
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
DSM Composite ResinsInfusion, April 2008
Infusion trials
When we take in account the long injection time and the high inlet pressure (2 bar) we needed yesterday, it has (in my opinion) no sence to start infusion trials if we have not a:
Workshop temperature between 20 and 30°C
Resin viscosity between 80 – 150 mPa.s