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.17,2010AtNCMofChina©2003OwensCorning/OwensCorningConfidentialInformation–Variations:（不同形式）–WetTransfer(pre-wet&carry)–DryTransfer–Inputmaterials:（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©2003OwensCorning/OwensCorningConfidentialInformationHandLayUp–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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcess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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcessMaterialPreparation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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcess–GelCoat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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcessLaminating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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcess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©2003OwensCorning/OwensCorningConfidentialInformationTheHLUProcess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©2003OwensCorning/OwensCorningConfidentialInformationOCVProducts应用CSM(choppedstrandmat)短切毡M123,M123E:300gsm,380gsm,450gsm,600gsmM137,M137E:300gsm,380gsm,450gsm,600gsm©2003OwensCorning/OwensCorningConfidentialInformationApplications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©2003OwensCorning/OwensCorningConfidentialInformationCompressionMolding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ResinReinforcement©2003OwensCorning/OwensCorningConfidentialInformationWhatIsSMC?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©2003OwensCorning/OwensCorningConfidentialInformationBMCOCVProducts979©2003OwensCorning/OwensCorningConfidentialInformationSMCAutoApplicationsExteriorClassAparts外饰件Structuralparts结构件Spray-Up喷射©2003OwensCorning/OwensCorningConfidentialInformationSpray-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。©2003OwensCorning/OwensCorningConfidentialInformationAdvantages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©2003OwensCorning/OwensCorningConfidentialInformationDisadvantages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©2003OwensCorning/OwensCorningConfidentialInformationSpray-UpSteps喷射步骤1.Pr