7. Infusion, process and moulding.ppt-process-and-moulding.pdf · Reduced resin spillage and...

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DSM Composite ResinsInfusion, April 2008

Infusion

2Program

• Vacuum injection by using a bag or sheet• Strategy + cases• Resins • Temperature in the workshop• Viscosity of the resin• Equipment• Pictures

When Infusion

Wishes and/or requirements

Large dimensions Piece to piece reproducibiliy Targeted strengthening Low styrene emission Less product losses

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

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 ?

6UP Resins

•DCPD•Volume shrinkage ± 6%

•Orthophthalic•Volume shrinkage ± 8%

•Isophtalic•Volume shrinkage ± 7.5%

•Vinylester•Volume shrinkage ± 5%

7Temperature in the workshop

•Gel time•1 degree difference = 10% difference

•Viscosity•1 degree difference = 5-10% difference

9Viscosity

• Lower viscosity = faster injection

• Too low = bad wetting (and-or air)

Lower viscosity means more styrene, causes more shrinkage

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 ?

Source: AKZO Nobel

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)

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

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

Laminate and resin inlet.

Peelply

Source: Reichhold

Point injection

Peripheral injection

Filling time ± 10 min.

Filling time ± 1 min.

Vacuum

Source: Reichhold

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

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

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

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

Liquid Resin Infusion

DSM Composite ResinsInfusion, April 2008 Source: Reichhold

Source: Reichhold

DSM Composite ResinsInfusion, April 2008 Source: Reichhold

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 !

Plascore PP Honeycomb

Corporate Headquarters

Plascore Incorporated

615 N. Fairview St.

Zeeland, MI 49464-0170

Phone (616) 772-1220

Toll Free (800) 630-9257

Fax (616) 772-1289

Web www.plascore.com

Email sales@plascore.com

Pictures of an infusion session

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

7. Infusion, process and moulding.ppt-process-and-moulding.pdf · Reduced resin spillage and...

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