玻璃钢产品的生产工艺简介

-ThermosetFRPProcessing

玻璃钢产品的生产工艺简介Nov.

17,2010AtNCMofChina0Variations:

（不同形式）WetTransfer

(pre-wet&carry)DryTransferInputmaterials:

（增强材料）CSM,wovenroving,knits,veils,etc.短切毡，方格布，缝编毡，表面毡等ResinReinforcementsMoldHandLay-Up(HLU)

手糊工艺Definition-Theprocessofhandplacingsuccessivelayersofreinforcementandresinintoanopenmoldresultinginapartwithonefinishedsurface.Alsoknownascontactmolding.

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HandLayUp–Features

手糊工艺的特点Largeparts.

大尺寸部件Structuralparts.

结构件Lowtomediumvolumes.

中低产量订单Prototypingorproduction.

原型翻制TheHLUProcess

手糊过程MoldPreparation:模具准备typicallymadeofacompositewithatoolinggelcoatonthesurface,supportedbywoodormetalframing,oftenportable.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Cleanandapplymoldrelease(PVA,waxes,films).清洁模具，上脱模剂TheHLUProcessMaterialPreparation

材料准备mostreinforcementsforHLUcomeasrolledgoodswhichcanbeplacedonrackstounrollontocuttingtables.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multiplelayerscanbecutatthesametimeusingshears,utilityknifeorpowercutters.

使用切割工具，可以一次切多层reinforcementcanthenbestoreduntilneeded,butmuststaycleananddry.增强材料应当储存在干净，干燥的环境MaterialPreparationTheHLUProcessGelCoat

上胶衣ifasmooth,highqualitysurfaceisrequired,apigmentedgelcoatisapplied.如需要光滑，优质表面，可以采用彩胶thiscanbeflow-coatedorbrushed,butpreferablysprayedon.可以浇涂，刷涂但最好用喷涂Wherenogelcoatisused,thefirstlayershouldbeveiltoformaresinrichlayerforbetteraesthetics.

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GelcoatApplicationTheHLUProcessLaminating

层压thisistheprocessofcombiningthethermosetresinandreinforcementinthemold.是将树脂和增强材料糊制成型的步骤rollers,brushesorsqueegeesareusedtoconsolidatethelaminate;wettingallfibers,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TheHLUProcessLaminating

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LaminatingTheHLUProcessFinishing

结束afterconsolidationiscomplete,excessmaterialcanbetrimmedoffandthepartisallowedtocure,generallyatambienttemperature.

多余的材料可以切掉，在室温下固化Thepartcanthenberemovedusingwedges,grapplepointsorevencompressedair.脱模PartRemovalOCVProducts

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

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Compression

Molding模压工艺NA15

Application模压工艺的应用CompressionMolding

模压工艺Definition—Theprocessusingmatchedmetaldiesunderhighpressuretoformthereinforcementandresinintothefinishedpart.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ResinReinforcementWhatIsSMC?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:P204BMCOCVProducts979SMCAutoApplicationsExteriorClassAparts外饰件

Structuralparts

结构件Spray-Up

喷射

21Spray-Up

喷射Definition–Theprocessofsprayingchoppedfibersandresin,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-UpSteps2. Applygelcoat

上胶衣Spray-UpSteps3. Sprayonglass/resincombination

喷涂树脂纤维混合物Spray-UpSteps4. Rolloutglass/resinto:

辊压Consolidatelayers

加固Squeezeoutair

消泡Conformglassaroundradii，更好地贴模Spray-UpSteps5. Trimorgrindexcesslaminate

修边Spray-UpSteps6. Afterlaminatecures,removalfrommold andinspection.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TypicalMarketsPickupcabsandrunningboard

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

33FILAMENTWINDING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FILAMENTWINDINGAPPLICATIONFILAMENTWINDINGKeyTechnicalPoints

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Wetout–Efficiency

浸润快Visualappearance-Nostreaksinpart

外观–不起白条Easeofprocessing-Lowfuzzathighspeeds

工艺性–高速生产毛丝少OCVProductsSE2348: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

38PULTRUSION

拉挤Theprocessofcontinuouslypullingaresin-impregnatedreinforcementthroughadieintoit’sfinalshape.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