1、-Thermoset FRP Processing 玻璃钢产品的生产工艺简介Nov.17,2010At NCM of ChinaVariations:（不同形式）Wet Transfer(pre-wet&carry)Dry TransferInput materials:（增强材料）CSM,woven roving,knits,veils,etc.短切毡，方格布，缝编毡，表面毡等ResinReinforcementsMoldHand Lay-Up(HLU)手糊工艺Definition-The process of hand placing successive layers of reinfo
2、rcement and resin into an open mold resulting in a part with one finished surface.Also known as contact molding.采用手工方式将增强材料和树脂铺在开模中成型，获取一面为光滑表面的部件Hand Lay Up Features 手糊工艺的特点Large parts.大尺寸部件Structural parts.结构件Low to medium volumes.中低产量订单Prototyping or production.原型翻制The HLU Process 手糊过程Mold Prepar
3、ation:模具准备 typically made of a composite with a tooling gelcoat on the surface,supported by wood or metal framing,often portable.通常在木架或金属架上做一个玻璃钢模具，使用模具胶衣，可以是移动式的 Clean and apply mold release(PVA,waxes,films).清洁模具，上脱模剂The HLU ProcessMaterial Preparation 材料准备 most reinforcements for HLU come as rolle
4、d goods which can be placed on racks to unroll onto cutting tables.大多用于手糊工艺的增强材料是成卷的，可以在工作台上展开 multiple layers can be cut at the same time using shears,utility knife or power cutters.使用切割工具，可以一次切多层 reinforcement can then be stored until needed,but must stay clean and dry.增强材料应当储存在干净，干燥的环境Material Pr
5、eparationThe HLU ProcessGel Coat 上胶衣if a smooth,high quality surface is required,a pigmented gelcoat is applied.如需要光滑，优质表面，可以采用彩胶this can be flow-coated or brushed,but preferably sprayed on.可以浇涂，刷涂但最好用喷涂Where no gelcoat is used,the first layer should be veil to form a resin rich layer for better aes
6、thetics.如不用胶衣，需要采用表面毡，在部件表面形成富树脂层，达到表面效果Gelcoat ApplicationThe HLU ProcessLaminating 层压 this is the process of combining the thermoset resin and reinforcement in the mold.是将树脂和增强材料糊制成型的步骤 rollers,brushes or squeegees are used to consolidate the laminate;wetting all fibers,releasing air and conformin
7、g to the mold.采用辊子，刷子或橡皮磙来层压成型，使纤维被树脂浸透，与模具贴合并赶出气泡The HLU ProcessLaminating 层压 additional reinforcement layers and resin are next applied to build up the thickness.可以继续铺层以达到需要的厚度 cores,stiffeners,inserts,etc.can be molded in at this stage.植入预埋件 the part should be inspected before leaving it for dry
8、spots,entrapped air and other defects.脱模前，检查部件的缺陷，如未浸透处，气泡等LaminatingThe HLU ProcessFinishing 结束 after consolidation is complete,excess material can be trimmed off and the part is allowed to cure,generally at ambient temperature.多余的材料可以切掉，在室温下固化 The part can then be removed using wedges,grapple poin
9、ts or even compressed air.脱模Part RemovalOCV Products 应用CSM(chopped strand mat)短切毡M123,M123E:300gsm,380gsm,450gsm,600gsmM137,M137E:300gsm,380gsm,450gsm,600gsmApplications 应用Marine:boats!,pleasure and commercial 商用和休闲娱乐的船舶nConsumer goods:trays,skis 消费品：托盘、滑板nIndustrial:housings,shroud,enclosures 工业：机架
10、、围栏、棚子nCorrosion:tanks,ducts,fittings防腐：罐、导管、管件nTransportation:truck,bus parts 交通运输：卡车，公共汽车部件Compression Molding模压工艺NA Application 模压工艺的应用Compression Molding 模压工艺nDefinition The process using matched metal dies under high pressure to form the reinforcement and resin into the finished part.This proce
11、ss is suitable for molding,complex,high strength glass fiber reinforced parts using preforms,sheet molding compound(SMC)or bulk molding compound(BMC).n该工艺采用金属对模，用高压将增强材料和树脂压制成型。适用于复杂形状，高强度要求的部件；有预成型，片状模塑料（SMC）和团状模塑料（BMC）等ResinReinforcementWhat Is?SMC=Sheet Molding Compound 片状模塑料Type of FRP consistin
12、g of:包括组分Thermosetting resin system 树脂Glass fiber reinforcement(roving)玻纤增强Fillers(Calcium Carbonate,Aluminum Trihydrate)填料Low profile additives(thermoplastic)低收缩 助剂Cure initiators(peroxide catalyst)固化引发剂Thickeners(Magnesium/Calcium Oxides)增稠剂Mold release agents(CaSt,ZnSt)脱模剂OCV Products:P204BMCOCV
13、Products979SMC Auto ApplicationsExterior Class A partsExterior Class A parts外饰件外饰件 Structural Structural partsparts 结构件结构件Spray-Up喷射 Spray-Up 喷射Definition The process of spraying chopped fibers and resin,in place of mat type reinforcements,into an open mold resulting in a part with one finished surf
14、ace.将短切的纤维（替代短切毡）和树脂一起喷涂于开模上，形成一面光滑的部件。Advantages 优点 Simple 简单 Low mold cost 模具投资低 Relatively low start up costs 启动成本相对低(but not as low as hand lay-up)Short tooling lead time,simple design changes工具准备时间短，设计变动容易 Virtually no product size restrictions 无产品尺寸限制 Color and surface options 可选不同颜色和表面 Better
15、 suited to complex shapes 适用于复杂形状部件Disadvantages 缺点Labor intensive(but not as labor intensive as hand lay-up)耗费人工Only one finished surface 只有一个光滑表面Quality is more operator dependent 质量依赖于人工Higher volatile emissions 挥发较大Higher investment than hand lay-up 投资高于手糊Some material waste-minimised by control
16、led spraying techniques 物料浪费 可通过控制喷射工艺来减轻浪费Spray-Up Steps 喷射步骤1.Prepare mold by applying wax or mold release 模具准备，上脱模剂Spray-Up Steps2.2.Apply gel coatApply gel coat 上胶衣上胶衣Spray-Up Steps3.Spray on glass/resin combination 喷涂树脂纤维混合物Spray-Up Steps4.Roll out glass/resin to:辊压 Consolidate layers 加固 Squeez
17、e out air 消泡 Conform glass around radii，更好地贴模Spray-Up Steps5.Trim or grind excess laminate 修边Spray-Up Steps6.After laminate cures,removal from mold and inspection.固化后脱模并检查Typical Markets 主要应用Marine 船舶Sanitary ware 卫生设施Spas,Hot Tubs 浴室Swimming Pools 游泳池Underground utility boxes 地埋电线盒Typical MarketsPi
18、ck up cabs and running board 校车，踏脚板Utility truck enclosures 公用车车身Imitation rocks 仿石材Heavy truck bonnets,air deflectors,fenders,cab enclosures 重卡的一些部件OCV Products:P209,P243Filament Winding 缠绕 FILAMENT WINDING 缠绕Definition of Process:The process of helically(spring-like)wrapping reinforcements and res
19、in around a polar mandrel.将树脂和增强材料成螺旋形地绕在芯模上成型FILAMENT WINDING APPLICATIONFILAMENT WINDING Key Technical Points 缠绕的主要技术要点Laminate Properties-Burst,static,and cyclic pressure 制品性能-爆破强度，抗静电，循环应力Resin Compatibility-Epoxy,Vinyl ester,Polyester 树脂 环氧，乙烯基，聚酯树脂Excellent Package Runout-Labor,Waste 纱团包装易抽出 减
20、少人工和浪费Wetout Efficiency 浸润快Visual appearance-No streaks in part 外观 不起白条Ease of processing-Low fuzz at high speeds 工艺性 高速生产毛丝少OCV ProductsSE2348:用于环氧高压管道SE2350:用于环氧高压管道 158B:CNG气瓶环氧缠绕SE1200:风力叶片,适用聚酯树脂,乙烯基树脂体系SE1500:风力叶片,适用环氧树脂体系Pultrusion拉挤 PULTRUSION 拉挤The process of continuously pulling a resin-im
21、pregnatedreinforcement through a die into its final shape.将浸过树脂的增强材料连续地拉过模具并成型的工艺TYPICAL PULTRUSION APPLICATION 拉挤的主要应用Tool Handles 工具手柄Ladder Rails 梯子Composite Rebar for Concrete 复合材料钢筋 Floor Grating 地板格栅Tubing 管Electrical Stand-Off Rods 绝缘棒Cable Trays 线槽Structural Beams 结构梁OCV ProductsP192、366U528
22、:continoues filament matResin Transfer Molding树脂传递模压Classic Resin Transfer Molding 典型的RTMVARTM(Vacuum Assisted RTM)真空辅助RTMWhat Other Infusion Are?其他的灌注工艺VIP,VARTM,CCBM,SCRIMP,RTM,Lite-RTMInfusion Applications 灌注工艺的应用 OCV ProductsU816:continuous filament matUse Lots Of OCV Glass Fiber.Well Make More!感谢下感谢下载载
