玻璃鋼產(chǎn)品的生產(chǎn)工藝簡介

-ThermosetFRPProcessing

玻璃鋼產(chǎn)品的生產(chǎn)工藝簡介Nov.

17,2010AtNCMofChina0Variations:

（不同形式）WetTransfer

(pre-wet&carry)DryTransferInputmaterials:

（增強材料）CSM,wovenroving,knits,veils,etc.短切氈，方格布，縫編氈，表面氈等ResinReinforcementsMoldHandLay-Up(HLU)

手糊工藝Definition-Theprocessofhandplacingsuccessivelayersofreinforcementandresinintoanopenmoldresultinginapartwithonefinishedsurface.Alsoknownascontactmolding.

采用手工方式將增強材料和樹脂鋪在開模中成型，獲取一面為光滑表面的部件HandLayUp–Features

手糊工藝的特點Largeparts.

大尺寸部件Structuralparts.

結構件Lowtomediumvolumes.

中低產(chǎn)量訂單Prototypingorproduction.

原型翻制TheHLUProcess

手糊過程MoldPreparation:模具準備typicallymadeofacompositewithatoolinggelcoatonthesurface,supportedbywoodormetalframing,oftenportable.通常在木架或金屬架上做一個玻璃鋼模具，使用模具膠衣，可以是移動式的Cleanandapplymoldrelease(PVA,waxes,films).清潔模具，上脫模劑TheHLUProcessMaterialPreparation

材料準備mostreinforcementsforHLUcomeasrolledgoodswhichcanbeplacedonrackstounrollontocuttingtables.大多用于手糊工藝的增強材料是成卷的，可以在工作臺上展開multiplelayerscanbecutatthesametimeusingshears,utilityknifeorpowercutters.

使用切割工具，可以一次切多層reinforcementcanthenbestoreduntilneeded,butmuststaycleananddry.增強材料應當儲存在干凈，干燥的環(huán)境MaterialPreparationTheHLUProcessGelCoat

上膠衣ifasmooth,highqualitysurfaceisrequired,apigmentedgelcoatisapplied.如需要光滑，優(yōu)質(zhì)表面，可以采用彩膠thiscanbeflow-coatedorbrushed,butpreferablysprayedon.可以澆涂，刷涂但最好用噴涂Wherenogelcoatisused,thefirstlayershouldbeveiltoformaresinrichlayerforbetteraesthetics.

如不用膠衣，需要采用表面氈，在部件表面形成富樹脂層，達到表面效果GelcoatApplicationTheHLUProcessLaminating

層壓thisistheprocessofcombiningthethermosetresinandreinforcementinthemold.是將樹脂和增強材料糊制成型的步驟rollers,brushesorsqueegeesareusedtoconsolidatethelaminate;wettingallfibers,releasingairandconformingtothemold.采用輥子，刷子或橡皮磙來層壓成型，使纖維被樹脂浸透，與模具貼合并趕出氣泡TheHLUProcessLaminating

層壓additionalreinforcementlayersandresinarenextappliedtobuildupthethickness.可以繼續(xù)鋪層以達到需要的厚度cores,stiffeners,inserts,etc.canbemoldedinatthisstage.植入預埋件thepartshouldbeinspectedbeforeleavingitfordryspots,entrappedairandotherdefects.脫模前，檢查部件的缺陷，如未浸透處，氣泡等LaminatingTheHLUProcessFinishing

結束afterconsolidationiscomplete,excessmaterialcanbetrimmedoffandthepartisallowedtocure,generallyatambienttemperature.

多余的材料可以切掉，在室溫下固化Thepartcanthenberemovedusingwedges,grapplepointsorevencompressedair.脫模PartRemovalOCVProducts

應用CSM(choppedstrandmat)短切氈M123,M123E:300gsm,380gsm,450gsm,600gsmM137,M137E:300gsm,380gsm,450gsm,600gsmApplications

應用Marine:boats!,pleasureandcommercial

商用和休閑娛樂的船舶Consumergoods:trays,skis

消費品：托盤、滑板Industrial:housings,shroud,enclosures

工業(yè)：機架、圍欄、棚子Corrosion:tanks,ducts,fittings防腐：罐、導管、管件Transportation:truck,busparts

交通運輸：卡車，公共汽車部件Compression

Molding模壓工藝NA15

Application模壓工藝的應用CompressionMolding

模壓工藝Definition—Theprocessusingmatchedmetaldiesunderhighpressuretoformthereinforcementandresinintothefinishedpart.Thisprocessissuitableformolding,complex,highstrengthglassfiberreinforcedpartsusingpreforms,sheetmoldingcompound(SMC)orbulkmoldingcompound(BMC).

該工藝采用金屬對模，用高壓將增強材料和樹脂壓制成型。適用于復雜形狀，高強度要求的部件；有預成型，片狀模塑料（SMC）和團狀模塑料（BMC）等ResinReinforcementWhatIsSMC?SMC=SheetMoldingCompound

片狀模塑料TypeofFRPconsistingof:包括組分Thermosettingresinsystem

樹脂Glassfiberreinforcement(roving)

玻纖增強Fillers(CalciumCarbonate,AluminumTrihydrate)填料Lowprofileadditives(thermoplastic)低收縮助劑Cureinitiators(peroxidecatalyst)

固化引發(fā)劑Thickeners(Magnesium/CalciumOxides)增稠劑Moldreleaseagents(CaSt,ZnSt)脫模劑OCVProducts:P204BMCOCVProducts979SMCAutoApplicationsExteriorClassAparts外飾件

Structuralparts

結構件Spray-Up

噴射

21Spray-Up

噴射Definition–Theprocessofsprayingchoppedfibersandresin,inplaceofmattypereinforcements,intoanopenmoldresultinginapartwithonefinishedsurface.

將短切的纖維（替代短切氈）和樹脂一起噴涂于開模上，形成一面光滑的部件。Advantages

優(yōu)點Simple

簡單Lowmoldcost

模具投資低Relativelylowstartupcosts

啟動成本相對低

(butnotaslowashandlay-up)Shorttoolingleadtime,simpledesignchanges工具準備時間短，設計變動容易Virtuallynoproductsizerestrictions

無產(chǎn)品尺寸限制Colorandsurfaceoptions

可選不同顏色和表面Bettersuitedtocomplexshapes

適用于復雜形狀部件Disadvantages

缺點Laborintensive(butnotaslaborintensiveashandlay-up)

耗費人工Onlyonefinishedsurface

只有一個光滑表面Qualityismoreoperatordependent

質(zhì)量依賴于人工Highervolatileemissions

揮發(fā)較大Higherinvestmentthanhandlay-up

投資高于手糊Somematerialwaste-minimisedbycontrolledsprayingtechniques

物料浪費–可通過控制噴射工藝來減輕浪費Spray-UpSteps

噴射步驟1. Preparemoldbyapplyingwaxormoldrelease

模具準備，上脫模劑Spray-UpSteps2. Applygelcoat

上膠衣Spray-UpSteps3. Sprayonglass/resincombination

噴涂樹脂纖維混合物Spray-UpSteps4. Rolloutglass/resinto:

輥壓Consolidatelayers

加固Squeezeoutair

消泡Conformglassaroundradii，更好地貼模Spray-UpSteps5. Trimorgrindexcesslaminate

修邊Spray-UpSteps6. Afterlaminatecures,removalfrommold andinspection.固化后脫模并檢查TypicalMarkets

主要應用Marine

船舶Sanitaryware

衛(wèi)生設施Spas,HotTubs

浴室SwimmingPools

游泳池Undergroundutilityboxes

地埋電線盒TypicalMarketsPickupcabsandrunningboard

校車，踏腳板Utilitytruckenclosures公用車車身Imitationrocks仿石材Heavytruckbonnets,airdeflectors,fenders,cabenclosures

重卡的一些部件OCVProducts:P209,P243 FilamentWinding

纏繞

33FILAMENTWINDING纏繞DefinitionofProcess:Theprocessofhelically(spring-like)wrappingreinforcementsandresinaroundapolarmandrel.將樹脂和增強材料成螺旋形地繞在芯模上成型FILAMENTWINDINGAPPLICATIONFILAMENTWINDINGKeyTechnicalPoints

纏繞的主要技術要點LaminateProperties-Burst,static,andcyclicpressure

制品性能-爆破強度，抗靜電，循環(huán)應力ResinCompatibility-Epoxy,Vinylester,Polyester樹脂–環(huán)氧，乙烯基，聚酯樹脂ExcellentPackageRunout-Labor,Waste

紗團包裝易抽出–減少人工和浪費Wetout–Efficiency

浸潤快Visualappearance-Nostreaksinpart

外觀–不起白條Easeofprocessing-Lowfuzzathighspeeds

工藝性–高速生產(chǎn)毛絲少OCVProductsSE2348:用于環(huán)氧高壓管道SE2350:用于環(huán)氧高壓管道158B:CNG氣瓶環(huán)氧纏繞SE1200:風力葉片,適用聚酯樹脂,乙烯基樹脂體系SE1500:風力葉片,適用環(huán)氧樹脂體系Pultrusion

拉擠

38PULTRUSION

拉擠Theprocessofcontinuouslypullingaresin-impregnatedreinforcementthroughadieintoit’sfinalshape.將浸過樹脂的增強材料連續(xù)地拉過模具并成型的工藝TYPICALPULTRUSIONAPPLICATION拉擠的主要應用ToolHandles

工具手柄LadderRails

梯子CompositeRebarforConcrete

復合材料鋼筋FloorGrating