玻璃钢产品的生产工艺简介.ppt

-ThermosetFRPProcessing玻璃钢产品的生产工艺简介,Nov.17,2010AtNCMofChina,Variations:（不同形式）WetTransfer(pre-wetwettingallfibers,releasingairandconformingtothemold.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,TheHLUProcess,Laminating层压additionalreinforcementlayersandresinarenextappliedtobuildupthethickness.可以继续铺层以达到需要的厚度cores,stiffeners,inserts,etc.canbemoldedinatthisstage.植入预埋件thepartshouldbeinspectedbeforeleavingitfordryspots,entrappedairandotherdefects.脱模前，检查部件的缺陷，如未浸透处，气泡等,Laminating,TheHLUProcess,Finishing结束afterconsolidationiscomplete,excessmaterialcanbetrimmedoffandthepartisallowedtocure,generallyatambienttemperature.多余的材料可以切掉，在室温下固化Thepartcanthenberemovedusingwedges,grapplepointsorevencompressedair.脱模,PartRemoval,OCVProducts应用,CSM(choppedstrandmat)短切毡M123,M123E:300gsm,380gsm,450gsm,600gsmM137,M137E:300gsm,380gsm,450gsm,600gsm,Applications应用,Marine:boats!,pleasureandcommercial商用和休闲娱乐的船舶,Consumergoods:trays,skis消费品：托盘、滑板,Industrial:housings,shroud,enclosures工业：机架、围栏、棚子,Corrosion:tanks,ducts,fittings防腐：罐、导管、管件,Transportation:truck,busparts交通运输：卡车，公共汽车部件,CompressionMolding模压工艺,NA,Application模压工艺的应用,CompressionMolding模压工艺,DefinitionTheprocessusingmatchedmetaldiesunderhighpressuretoformthereinforcementandresinintothefinishedpart.Thisprocessissuitableformolding,complex,highstrengthglassfiberreinforcedpartsusingpreforms,sheetmoldingcompound(SMC)orbulkmoldingcompound(BMC).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,Resin,Reinforcement,WhatIsSMC?,SMC=SheetMoldingCompound片状模塑料TypeofFRPconsistingof:包括组分Thermosettingresinsystem树脂Glassfiberreinforcement(roving)玻纤增强Fillers(CalciumCarbonate,AluminumTrihydrate)填料Lowprofileadditives(thermoplastic)低收缩助剂Cureinitiators(peroxidecatalyst)固化引发剂Thickeners(Magnesium/CalciumOxides)增稠剂Moldreleaseagents(CaSt,ZnSt)脱模剂OCVProducts:P204,BMC,OCVProducts979,SMCAutoApplications,ExteriorClassAparts外饰件,Structuralparts结构件,Spray-Up喷射,Spray-Up喷射,DefinitionTheprocessofsprayingchoppedfibersandresin,inplaceofmattypereinforcements,intoanopenmoldresultinginapartwithonefinishedsurface.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Lowmoldcost模具投资低Relativelylowstartupcosts启动成本相对低(butnotaslowashandlay-up)Shorttoolingleadtime,simpledesignchanges工具准备时间短，设计变动容易Virtuallynoproductsizerestrictions无产品尺寸限制Colorandsurfaceoptions可选不同颜色和表面Bettersuitedtocomplexshapes适用于复杂形状部件,Disadvantages缺点,Laborintensive(butnotaslaborintensiveashandlay-up)耗费人工Onlyonefinishedsurface只有一个光滑表面Qualityismoreoperatordependent质量依赖于人工Highervolatileemissions挥发较大Higherinvestmentthanhandlay-up投资高于手糊Somematerialwaste-minimisedbycontrolledsprayingtechniques物料浪费可通过控制喷射工艺来减轻浪费,Spray-UpSteps喷射步骤,1.Preparemoldbyapplyingwaxormoldrelease模具准备，上脱模剂,Spray-UpSteps,2.Applygelcoat上胶衣,Spray-UpSteps,3.Sprayonglass/resincombination喷涂树脂纤维混合物,Spray-UpSteps,4.Rolloutglass/resinto:辊压Consolidatelayers加固Squeezeoutair消泡Conformglassaroundradii，更好地贴模,Spray-UpSteps,5.Trimorgrindexcesslaminate修边,Spray-UpSteps,6.Afterlaminatecures,removalfrommoldandinspection.固化后脱模并检查,TypicalMarkets主要应用,Marine船舶Sanitaryware卫生设施Spas,HotTubs浴室SwimmingPools游泳池Undergroundutilityboxes地埋电线盒,TypicalMarkets,Pickupcabsandrunningboard校车，踏脚板Utilitytruckenclosures公用车车身Imitationrocks仿石材Heavytruckbonnets,airdeflectors,fenders,cabenclosures重卡的一些部件OCVProducts:P209,P243,FilamentWinding缠绕,FILAMENTWINDING缠绕,DefinitionofProcess:Theprocessofhelically(spring-like)wrappingreinforcementsandresinaroundapolarmandrel.将树脂和增强材料成螺旋形地绕在芯模上成型,FILAMENTWINDINGAPPLICATION,FILAMENTWINDINGKeyTechnicalPoints缠绕的主要技术要点,LaminateProperties-Burst,static,andcyclicpressure制品性能-爆破强度，抗静电，循环应力ResinCompatibility-Epoxy,Vinylester,Polyester树脂环氧，乙烯基，聚酯树脂ExcellentPackageRunout-Labor,Waste纱团包装易抽出减少人工和浪费WetoutEfficiency浸润快Visualappearance-Nostreaksinpart外观不起白条Easeofprocessing-Lowfuzzathighspeeds工艺性高速生产毛丝少,OCVProducts,SE2348: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,Theprocessofcontinuouslypullingaresin-impregnatedreinforcementthroughadieintoitsfinalshape.将浸过树脂的增强材料连续地拉过模具并成型的工艺,TYPICALPULTRUSIONAPPLICATION拉挤的主要应用,ToolHandles工具手柄LadderRails梯子CompositeRebarforConcrete复合材料钢筋FloorGrating地板格栅Tubing管ElectricalStand-OffRods绝缘棒CableTrays线槽StructuralBeams结构梁,OCVProducts,P192、366U528:continouesfilamentmat,ResinTransferMolding树脂传递模压,ClassicResinTransferMolding典型的RTM,ResinTransfer(HiPressure)树脂灌注（正压）,MaleTool阳模,FemaleTool阴模,Thickness(fixed)固定厚度,Reinforcement增强材料,Vent气孔,VARTM(VacuumAssistedRTM)真空辅助RTM,ResinTransfer(lowpressure)树脂灌注（低压）,CounterMold,Mold模具,Reinforcement增强材料,