《玻璃钢产品的生产工艺简介.ppt》由会员分享，可在线阅读，更多相关《玻璃钢产品的生产工艺简介.ppt（49页珍藏版）》请在三一办公上搜索。
1、-Thermoset FRP Processing 玻璃钢产品的生产工艺简介,Nov.17,2010At NCM of China,Variations:（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,Hand Lay-Up(HLU)手糊工艺,Definition-The process of hand placing successive layers of reinforcement and resin i
2、nto 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 Preparation:模具准备typic
3、ally 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 Process,Material Preparation 材料准备most reinforcements for HLU come as rolled goods which ca
4、n 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 Preparation,The HLU
5、 Process,Gel 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 aesthetics.如不用胶衣，需
6、要采用表面毡，在部件表面形成富树脂层，达到表面效果,Gelcoat Application,The HLU Process,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.
7、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 Process,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 inspected before leaving it for dry spots,entrapped
8、 air and other defects.脱模前，检查部件的缺陷，如未浸透处，气泡等,Laminating,The HLU Process,Finishing 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 points or even com
9、pressed air.脱模,Part Removal,OCV Products 应用,CSM(chopped strand mat)短切毡M123,M123E:300gsm,380gsm,450gsm,600gsmM137,M137E:300gsm,380gsm,450gsm,600gsm,Applications 应用,Marine:boats!,pleasure and commercial 商用和休闲娱乐的船舶,Consumer goods:trays,skis 消费品：托盘、滑板,Industrial:housings,shroud,enclosures 工业：机架、围栏、棚子,Co
10、rrosion:tanks,ducts,fittings防腐：罐、导管、管件,Transportation: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,Definition The process using matched metal dies under high pressure to form the reinforcement and resin into the finished part.This process is
11、suitable for molding,complex,high strength glass fiber reinforced parts using preforms,sheet molding compound(SMC)or bulk molding compound(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,What Is SMC?,SMC=Sheet Molding Compound 片状模塑料Type of FRP consisti
12、ng 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:P204,BMC,O
13、CV Products979,SMC Auto Applications,Exterior Class A parts外饰件,Structural parts 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 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
14、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 suited to complex shapes 适用于复杂形状部件,Disad
15、vantages 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 controlled spraying techniques 物料浪费 可通过控制喷射工艺来
16、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 Steps,2.Apply gel coat 上胶衣,Spray-Up Steps,3.Spray on glass/resin combination 喷涂树脂纤维混合物,Spray-Up Steps,4.Roll out glass/resin to:辊压Consolidate layers 加固Squeeze out air 消泡Conform glass around radii，更好地贴模,Spray-U
17、p Steps,5.Trim or grind excess laminate 修边,Spray-Up Steps,6.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 Markets,Pick up cabs and running board 校车，踏脚板Utility tr
18、uck 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,P243,Filament Winding 缠绕,FILAMENT WINDING 缠绕,Definition of Process:The process of helically(spring-like)wrapping reinforcements and resin around a polar mandrel.将树脂和增强材料成螺旋形地绕在芯模
19、上成型,FILAMENT WINDING APPLICATION,FILAMENT 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 减少人工和浪费Wetout Efficiency 浸润快Visual appear
20、ance-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 Products,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,The process of continuously pulling a resin-impregnatedreinforcement through a die
21、 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 Products,P192、366U528:continoues filament mat,Resin T
22、ransfer Molding树脂传递模压,Classic Resin Transfer Molding 典型的RTM,Resin Transfer(Hi Pressure)树脂灌注（正压）,Male Tool 阳模,Female Tool 阴模,Thickness(fixed)固定厚度,Reinforcement 增强材料,Vent气孔,VARTM(Vacuum Assisted RTM)真空辅助RTM,Resin Transfer(low pressure)树脂灌注（低压）,Counter Mold,Mold模具,Reinforcement增强材料,Low Vacuum(facilitates resin flow)抽真空,High Vacuum(mold clamping)高真空度（密封）,What Other Infusion Are?其他的灌注工艺,VIP,VARTM,CCBM,SCRIMP,RTM,Lite-RTM,Infusion Applications 灌注工艺的应用,OCV Products,U816:continuous filament mat,Use Lots Of OCV Glass Fiber.Well Make More!,
