玻璃钢产品的生产工艺简介

1、 - Thermoset FRP Processing 玻璃钢产品的生产工艺简介玻璃钢产品的生产工艺简介Nov. 17, 2010At NCM of China 2003 Owens Corning / Owens Corning Confidential InformationVariations: （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ResinReinforcementsMold

2、Hand Lay-Up (HLU) 手糊工艺手糊工艺nDefinition - The process of hand placing successive layers of reinforcement 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 2003 Owens Corning / Owens Corning Confidential Informat

3、ionHand Lay Up Features 手糊工艺的特点手糊工艺的特点n Large parts. 大尺寸部件n Structural parts. 结构件n Low to medium volumes. 中低产量订单n Prototyping or production. 原型翻制 2003 Owens Corning / Owens Corning Confidential InformationThe HLU Process 手糊过程手糊过程n Mold Preparation:模具准备 typically made of a composite with a tooling ge

4、lcoat 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 2003 Owens Corning / Owens Corning Confidential InformationThe HLU Processn Material Preparation 材料准备 most reinforcements for HLU come

5、 as rolled 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

6、境 2003 Owens Corning / Owens Corning Confidential InformationMaterial Preparation 2003 Owens Corning / Owens Corning Confidential InformationThe 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, b

7、ut 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 aesthetics. 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 2003 Owens Corning / Owens Corning Confidential InformationGelcoat Application 2003 Owens Corning / Owens Corning Confiden

8、tial InformationThe HLU Processn Laminating 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 conforming 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

9、透，与模具贴合并赶出气泡 2003 Owens Corning / Owens Corning Confidential InformationThe HLU Processn Laminating 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 inspecte

10、d before leaving it for dry spots, entrapped air and other defects.脱模前，检查部件的缺陷，如未浸透处，气泡等 2003 Owens Corning / Owens Corning Confidential InformationLaminating 2003 Owens Corning / Owens Corning Confidential InformationThe HLU Processn Finishing 结束 after consolidation is complete, excess material can

11、 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 points or even compressed air.脱模 2003 Owens Corning / Owens Corning Confidential InformationPart Removal 2003 Owens Corning / Owens Corning Confident

12、ial InformationOCV Products 应用应用nCSM ( chopped strand mat ) 短切毡nM123, M123E: 300gsm, 380gsm,450gsm,600gsmnM137,M137E :300gsm, 380gsm,450gsm,600gsm 2003 Owens Corning / Owens Corning Confidential InformationApplications 应用应用nMarine: boats!, pleasure and commercial 商用和休闲娱乐的船舶nConsumer goods: trays, sk

13、is 消费品：托盘、滑板nIndustrial: housings, shroud, enclosures 工业：机架、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模压工艺模压工艺NA 2003 Owens Corning / Owens Corning Confidential Information Application 模压工艺的应用模压工艺的应用 2003 Owens Corning / Owens

14、 Corning Confidential InformationCompression Molding 模压工艺nDefinition Definition The process using matched metal dies under The process using matched metal dies under high pressure to form the reinforcement and resin into the high pressure to form the reinforcement and resin into the finished part. T

15、his process is suitable for molding, finished part. This process is suitable for molding, complex, high strength glass fiber reinforced parts using complex, high strength glass fiber reinforced parts using preforms, sheet molding compound (SMC) or bulk molding preforms, sheet molding compound (SMC)

16、or bulk molding compound (BMC).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（用于复杂形状，高强度要求的部件；有预成型，片状模塑料（SMCSMC）和团状模塑料（）和团状模塑料（BMCBMC）等）等ResinReinforcement 2003 Owens Corning / Owens Corning Confidential InformationWhat Is ?SMC = Sheet Molding Compo

17、und 片状模塑料Type of FRP consisting 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

18、 (CaSt, ZnSt)脱模剂OCV Products:P204 2003 Owens Corning / Owens Corning Confidential InformationBMCn OCV Productsn 979 2003 Owens Corning / Owens Corning Confidential InformationSMC Auto ApplicationsExterior Class A parts外饰件外饰件 Structural parts 结构件结构件Spray-Up喷射喷射 2003 Owens Corning / Owens Corning Conf

19、idential InformationSpray-Up 喷射nDefinition 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 surface. 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。 2003 Owens Corning / Owens Corning Confidential InformationAdvantages

20、 优点n Simple 简单n Low mold cost 模具投资低n Relatively low start up costs 启动成本相对低 (but not as low as hand lay-up)n Short tooling lead time, simple design changes工具准备时间短，设计变动容易n Virtually no product size restrictions 无产品尺寸限制n Color and surface options 可选不同颜色和表面n Better suited to complex shapes 适用于复杂形状部件 200

21、3 Owens Corning / Owens Corning Confidential InformationDisadvantages 缺点n Labor intensive (but not as labor intensive as hand lay-up) 耗费人工n Only one finished surface 只有一个光滑表面n Quality is more operator dependent 质量依赖于人工n Higher volatile emissions 挥发较大n Higher investment than hand lay-up 投资高于手糊n Some

22、material waste - minimised by controlled spraying techniques 物料浪费 可通过控制喷射工艺来减轻浪费 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps 喷射步骤1.Prepare mold by applying wax or mold release 模具准备，上脱模剂 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps2.Apply gel

23、 coat 上胶衣上胶衣 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps3.Spray on glass/resin combination 喷涂树脂纤维混合物 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps4.Roll out glass/resin to: 辊压 Consolidate layers 加固 Squeeze out air 消泡 Conform glass around radi

24、i，更好地贴模 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps5.Trim or grind excess laminate 修边 2003 Owens Corning / Owens Corning Confidential InformationSpray-Up Steps6.After laminate cures, removal from mold and inspection.固化后脱模并检查 2003 Owens Corning / Owens Corning Confidenti

25、al InformationTypical Markets 主要应用主要应用nMarine 船舶nSanitary ware 卫生设施nSpas, Hot Tubs 浴室nSwimming Pools 游泳池nUnderground utility boxes 地埋电线盒 2003 Owens Corning / Owens Corning Confidential InformationTypical MarketsnPick up cabs and running board 校车，踏脚板nUtility truck enclosures 公用车车身nImitation rocks 仿石材

26、nHeavy truck bonnets, air deflectors, fenders, cab enclosures 重卡的一些部件OCV Products:P209,P243Filament Winding 缠绕缠绕 2003 Owens Corning / Owens Corning Confidential InformationFILAMENT WINDING 缠绕缠绕Definition of Process: The process of helically (spring-like) wrapping reinforcements and resin around a po

27、lar mandrel. 将树脂和增强材料成螺旋形地绕在芯模上成型 2003 Owens Corning / Owens Corning Confidential InformationFILAMENT WINDING APPLICATION 2003 Owens Corning / Owens Corning Confidential InformationFILAMENT WINDING Key Technical Points 缠绕的主要技术要点缠绕的主要技术要点n Laminate Properties - Burst, static, and cyclic pressure 制品性能

28、-爆破强度，抗静电，循环应力n Resin Compatibility - Epoxy, Vinyl ester, Polyester 树脂 环氧，乙烯基，聚酯树脂n Excellent Package Runout - Labor, Waste 纱团包装易抽出 减少人工和浪费n Wetout Efficiency 浸润快n Visual appearance - No streaks in part 外观 不起白条n Ease of processing - Low fuzz at high speeds 工艺性 高速生产毛丝少 2003 Owens Corning / Owens Corn

29、ing Confidential InformationOCV Productsn SE2348:用于环氧高压管道n SE2350:用于环氧高压管道 158B : CNG气瓶环氧缠绕n SE1200: 风力叶片,适用聚酯树脂,乙烯基树脂体系n SE1500: 风力叶片,适用环氧树脂体系Pultrusion拉挤拉挤 2003 Owens Corning / Owens Corning Confidential InformationPULTRUSION 拉挤拉挤The process of continuously pulling a resin-impregnatedreinforcement 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 2003 Owens Corning / Owens Corning Confidential InformationTYPICAL PULTRUSION APPLICATION 拉挤的主要应用拉挤的主要应用nTool Handles 工具手柄nLadder