“Thermoset Resins in Production Boatbuilding”

September 11, 2006

• Joe Parker• Product Manager, Pro-Set Inc.• PO Box 656• Bay City, MI 48707• 888-377-6738• parker@prosetepopxy.com

• Presented at a meeting of the Thermoset Resin Formulators Association at the Hyatt Regency Montreal in Montreal, Quebec, Canada, September 11 through 12, 2006.

• This paper is presented by invitation of TRFA. It is publicly distributed upon request by the TRFA to assist in the communication of information and viewpoints relevant to the thermoset industry. The paper and its contents have not been reviewed or evaluated by the TRFA and should not be construed as having been adopted or endorsed by the TRFA.”

Thermoset Resins in Production Boatbuilding

TRFA Fall 2006September 11, 2006

Joe ParkerGougeon Brothers Inc.

Abstract

• This presentation will provide an overview of the current manufacturing processes and polymer resins used in the marine industry. Historical perspective and trends looking forward are also included.

• Historical Perspective• Resin Types • Processes

• Transitional Phase• Driven by Regulation• Customer Performance Requirements• Resin Choices• Process Choices

Processes

• Contact Mold / Open Mold

• Vacuum Bag

• Resin Infusion

Resin Choices

• Polyester

• Vinylester

• Epoxy

Processes

• Contact Molding

• Wet Preg – Vacuum Bag

• Resin Infusion

Contact Moldingbucket and brush

• Advantages• Low cost • No new equipment• No additional training

necessary

• Disadvantages• minimal mechanical

properties gain• no control of resin

content• excess resin use /

cost• no labor savings

Closed Molding

• Vacuum Bagging

• Resin Infusion

• RTM

• RTM light

Vacuum Bagging(What is vacuum bagging ?)

• The process of using atmospheric pressure to consolidate or clamp a laminate

• A membrane is sealed to the mold, and air is evacuated from under membrane

• Atmospheric pressure presses on membrane, squeezing laminate between mold surface and membrane

Advantages of vacuum bagging

• Apply uniform pressure over entire laminate surface

• Remove excess resin

• Help remove entrapped air

• Contain any emissions

• Can conform to almost any shape

Vacuum Bag / Wet - PregImpregnator or roll coater wet - out

• Advantages• Saves labor• Good mechanical

properties in laminate• Excellent resin

content control• Good core bonding

• Disadvantages• Equipment cost• Equipment clean - up• Training required

Resin Infusion(how does it work)

• Dry laminate stack placed in mold

• Vacuum bag installed and checked for leaks

• Resin allowed to flow into laminate under bag using atmospheric pressure to push resin

Resin Infusion

• Advantages• Very good resin

content control• Good laminate

properties• Very clean / handle

dry fabrics & core• Can include

secondary structure

• Disadvantages• Training required• License may be

required• Some additional resin

waste• Additional disposable

materials

Resin Choices and Characteristics

• Polyester (PE)– Least expensive– Open Molding primary process– Resin infusion becoming popular– High VOC– Shrinkage is an issue– Toughness and Fatigue resistance in question

Resin Choices and Characteristics

• Vinylester (VE)– Higher price than PE – lower than Epoxy– Some contact molding– Used as skin coat resin with PE hulls– Resin Infusion most popular with VE– Better Fatigue resistance and Toughness– High VOC– Shrinkage

Resin Choices and Characteristics

• Epoxy– Most expensive Boatbuilding resin– Generally used in higher performance craft

• Often with carbon and S-glass

– Can be used for Resin Infusion– Best fatigue resistance and toughness– Vacuum bagged laminate creates lightest

structure

Summary

• Resin cost is small portion of part cost

• Cost of fibers and cores will continue to rise about equal to resin

• Closed molding here to stay and growing

• Customers demanding lighter, more durable boats