CELEBRATING 21 YEARS OF INNOVATION! February 2009
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Nida-Core Corp. locations
Nida-Core Corp.’s state of the art 6300 M2 Port St. Lucie, Florida Technology Center
Nida-Core Canada distribution center
Nida-Core Structiso headquarters in France
Nida-Core India Regional Office Building
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Nida-Core Team Administrative: President
- Damien J. Jacquinet
Business Development Manager - Tim Johnson National Sales Manager
- Nick Dan
Marketing Director
- Jack Lugus
Technical Director
- Jeff Bootz
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What is RIGID-ELASTIC TECHNOLOGY?
Providing solutions for composites industry for over 21 years
World leader in plastic honeycomb technology
Serving marine, transportation and architectural industries 4
WHY SANDWICH CONSTRUCTION?
I-Beam Principle
Reduced weight
Increased stiffness, impact strength, resiliency, insulation, puncture resistance
Reduced operating costs, higher payloads, better fuel economy
Noise & vibration dampening, thermal insulation 5
AVAILABLE CORE MATERIALS
Balsa Plywood Polyurethane-polyisocyanurate foams PVC Linear foams PVC Cross-linked foams SAN foams PET foams Paper honeycomb Aluminum honeycomb Plastic honeycomb 6
BALSA & PLYWOOD NEGATIVE
POSITIVE
Good mechanical properties in thin grades under ideal circumstances Relatively inexpensive
Subject to rot Unsatisfactory impact strength Catastrophic core failure past ultimate stress point. Moisture inhibition
ELASTICITY 20-30% 7
PVC CROSSLINKED and LINEAR FOAMS POSITIVE
NEGATIVE
Good impact resistance Expensive
Easily conforms to intricate shapes
Thermal
Good insulator
Difficult
resistance to 90 Degrees Celsius to process
Compromised
chemical resistance ELONGATION 30-50% 8
SAN(styrene acrylonitrile) FOAMS POSITIVE
Improved impact resistance Moderate temperature
NEGATIVE
tolerance(95 Degrees C)
Chemical resistance Good processability
Expensive Can be attacked by styrene Hard to detect core failure Catastrophic core failure beyond ultimate stress point Crack propagation Delamination
ELONGATION 60-80% 9
PET(Polyethylene teraphthalate) POSITIVE • Improved impact resistance • GREAT temperature tolerance(175 Degrees C) • Chemical resistance • Thermo formable • Environmentally friendly manufacture of foam
NEGATIVE • Expensive • Catastrophic core failure beyond ultimate stress point • Crack propagation • Unisotropic • Loses mechanical properties when heated • Available only in 100 kg/m3 and 150 kg/m3 densities
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PLASTIC STRUCTURAL HONEYCOMB NEGATIVE
Moderate insulator R=3.3 per 25 mm
POSITIVE
Inexpensive NO catastrophic failure Excellent impact, chemical, Beveled edge processing fatigue resistance Excellent sound attenuation Inserts required for screw (natural harmonic150 Hz) – retention up to 22dB reduction Thermo formable Excellent processabilty Good temperature ELONGATION up toresistance 200% up to 110 C
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ACOUSTICS Nida-Core ® honeycombs have excellent acoustical characteristics because of their composition of polypropylene, a viscoelastic material, ready to absorb vibrations. Damping properties Sound absorption properties Sound insulation properties 12
VIBRATION DAMPING The damping properties of a material are it’s capacity to lower the vibrations of either mechanical or acoustical origins. A material has good damping properties if it releases low vibration levels, consequently it has a low acoustical radiation. Conversely, a poor damping material easily starts to vibrate at the lowest stimulation applied upon it. The damping capacity is characterised by the loss factor η, with values generally between 0 and 1. The Young’s modulus of the material has an influence on this factor.
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Vibration Level on the Bulkheads for a Motor Boat versus Engine Rotation Speed RMS 1.4 1.2 1 0.8 0.6 0.4 0.2 0 1900
2100
2300
Sandwich panel containing 25mmof Nida-Core
Rotation Speed (rpm)
Sandwich panel with a 25mmwooden-based core Sandwich panel with a 25mmwooden-based core and a 900 g/m² viscoelastic damping sheet
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SOUND ABSORPTION The acoustic absorption is the property that prevents sound reflection. To have a good absorption level, the material must be able to trap the sound waves. This is true for porous materials and honeycombs as the sound wave reflection is limited. The acoustical absorption is characterized by the "Îą sabine" factor. This factor is between 0 and 1. It is higher as the absorption level is increasing. To have an efficient absorption level, the Nida-Core ÂŽ has to be covered on one side with an air porous facing. The sound waves get inside the cells and then are trapped as for an Helmoltz resonator: they rebound inside on the walls until they are completely absorbed. 15
Sabine values
Acoustic Absorption Factor versus Frequency
1.2 1 0.8 0.6 0.4 0.2 0 100
1000
Porous decorative glass fabric on a Nida-Core thickness 60mm Mineral granules glued with a resin over 40mm of Nida-Core
10000 Frequency (Hz)
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SOUND INSULATION The acoustic properties for an element dividing two rooms are defined by its ability to lower the noise released from one side and its perception on the other side. The insulation is characterized by the attenuation factor quoted R, which is the difference between the released and received intensities. This may range from a few decibels to several ten decibels (Decibels are calculated from a logarithmic scale. A 3dB decrease represents a decrease of half of the sound intensity).
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SOUND INSULATION It is important to differentiate two types of partition for the acoustic insulation analysis: ÂŞ If we consider a structure with a single homogenous partition, the only factor which increases sound insulation is the mass. The heavier is the partition, better is the insulation. ÂŞ If we consider a composite structure (mass/spring/mass), which means an alternation of heavy layers and damping layers, it is then more difficult to define the attenuation factor.
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SOUND INSULATION To simplify such a structure, the first "mass" vibrates and transmits the waves to the "spring". This "spring" then transmits the vibrations to the second "mass", but because of its composition, it damps them. Such a structure has a resonance frequency where its attenuation factor is low, but by modifying the mass for the partitions, it is possible to "choose" this resonance frequency. For example, an objective may be to achieve a structure resonance frequency under 90 Hz, which is the lower limit of the defined spectrum for the acoustics in the structure. The attenuation factor for a composite structure, as soon as we are above the resonance frequency, is in all cases above the value obtained with the heavy mass alone.
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SOUND INSULATION Nida-Core 速 honeycombs are used to achieve light structural sandwich panels. In these composite panels, the honeycomb functions as a spring as related above. The facings of the sandwich panels are the heavy mass of the structure. Thus, it is possible to have a very good attenuation factor for the sandwich structure made with Nida-Core 速. The acoustical properties for sandwich panels made with Nida-Core 速 are affected by many parameters (the facing types which cover the Nida-Core 速, the dimensions and fixation types, the acoustical waves and frequencies applied). It is not possible to detail all characteristics, but only provide indicative values with different facings and under various acoustical solicitations: 21
How is Nida-Core H8PP made? Polyester Scrim Cloth for 100% bonding surface Copolymer Polypropylene Extruded 0.005 mm Wall Thickness
Polypropylene plastic barrier film under scrim 50Âľ to 300Âľ for Infusion and RTM to limit resin consumption
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Nida-Core Structural Honeycomb Technology vs. PVC, SAN and PET foams
Nida-Core Corp. is a marine industry specialist for over 21 years. We do not abandon our customers for higher margin opportunities overseas. Nida-Core mechanical properties are largely derived from its honeycomb shape and are especially efficient in thicker grades, therefore it is not as
dependent on price of petroleum based
raw materials, unlike foams. Nida-Core Structural Honeycomb is made from one of the most chemically resistant materials, polypropylene, unaffected by styrene. Nida-Core can be vacuum bagged to intricate shapes in large sheets, eliminating need for scored core, and associated problems like print through issues and inter laminar water migration issues. Nida-Core’s reduced thermal efficiency, as compared to foams, results in lower laminate temperatures, increasing longevity of gel coat finish and preventing cosmetic defect relating to post curing of the laminates. Nida-Core Structural Honeycombs offer substantial cost savings as compared to any structural foams.
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Nida-Core Structural Honeycomb Technology vs. Balsawood core No need to over engineer laminates for adequate safety margins due to the NO CATASTROPHIC failure mode of Nida-Core Structural Sandwich composite. Reduced risk of delamination due to the low styrene levels of modern resins and moisture inhibition problems frequently experienced thereof. Stable supply and pricing. Over 2 million sq. ft in stock for immediate delivery and over 30% cost savings when compared to equivalent thickness balsawood. Availability of large sheets (1.2X2.4 m) and corresponding material and cost savings due to cutting and installing efficiency. Near perfect track record in 21 years in marine industry. Over 40,000 boats built with Nida-Core Structural Honeycomb in year 2007. (hulls, decks, bulkheads etc.) Substantial reduction in NVH levels as compared to balsawood due to the constrained layer damping effect of viscoelastic honeycomb. Customers demand lower maintenance, NO ROT, wood free boats. Core cost is < 1% of typical boat cost. Why take a chance?
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MATERIAL ELONGATION COMPARISON CHART in % 200 180 160 140 120 100 80 60 40 20
BALSA PU FOAM CL PVC LIN PVC SAN FOAM PAPER HC ALU HC PLASTIC HC PET
0
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NIDACORE FC 55 APPLICATION
Key Property
Fluid Movement
Separation, Fluid transport, Laminar flow
Panel
Structural, Separation, Light weight
Gravel Replacement
Ease of Use, Structural, Separation, Fluid transport
Flooring
Non absorbing underlay, Energy absorption, Separation
Erosion control
Structural, Separation , Fluid transport
Protection (sports, industrial)
Separation, Energy absorption
Seating
Engineered resilience, Structural, Separation
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CUSTOMERS
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Laminate Bulkers: Nida-Core Matline - why you can achieve higher mechanical properties with Matline Laminate Bulker ?
Most laminate bulkers available in the marketplace today are composed of polyester fiber and glass micro spheres. Only Nida-Core Matline has OMNIDIRECTIONAL fiber orientation. Compared to linear fiber orientation(like most other competitors) omni-directional fiber provides equal strength characteristics in both directions. Matline published thicknesses correspond to REAL thickness of material sold. 28
NIDA-CORE PANELS • Wet laminated vaccuum bagged composite panels up to 3X15 m size with optional gelcoat surface in 40 stock colors. Large inventory worldwide. •Choice of core: Structural Honeycombs in various cell sizes, Balsalite, Foamline and NidaFusion STO Triangulated pin. •Skins include 600 GSM Woven Roving, 1200 GSM Woven Roving, Biaxials, Luan, Okoume, High Pressure Laminates, Metals, Wood Veneers, Stone and Marble, ThermoPlastics. •250 ton Oil Zone Heated conveyorized press , pneumatic presses. CNC cut to size. Ideal for floor, sidewall, marine bulkhead and interior assembly. Fast turnaround times.
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• NidaBond CBC(Core Bonding Compound) •NidaBond RFC(Radius Filleting Compound) •NidaBond APC(All Purpose Compound) •NidaBond PTC (Pourable Transom Compound) 30
NidaBond Pourable Ceramic Transom Compound, with 7 X stronger compression strength than marine plywood. Fix it once, fix it right! From inside the hull, cut inside laminate around the outer perimeter of the transom. If possible, peel off the laminate in one piece, for later reuse, or to use as template for makingâ&#x20AC;? the dam.
Remove all rotted and damaged material , down to the outside hull laminate.
Reinstall the inside laminate piece, that you previously peeled, or place â&#x20AC;&#x153;dam â&#x20AC;&#x153;(fiberglass or plywood) in place, with desired spacing from the outside hull laminate. If you create a new dam, we strongly recommend you laminate the dam prior to installing it, outside the hull ,with desired laminate thickness. This will create a primary chemical and mechanical bond to the cured NidaBond Transom Compound. 31
Use fiberglass tape to fiberglass/seal the perimeter of the inside laminate, or dam.
Adequate bracing and reinforcement is necessary to withstand the hydrostatic pressure of the liquid material to be poured into the cavity.
Estimate the volume of your cavity and mix catalyst into the pails of NidaBond, pour into the cavity, preferably a continuous pour of all necessary material.
NidaBond is designed to de-gas and cure by itself without any further input necessary. If you used the DAM method, remove the dam now and laminate the inside of the transom. If you had used the laminated dam method, use fiberglass tape to seal 32 the perimeter of the transom from inside the hull.
Advancements in Closed Molding of Sandwich Structures AS Effekt-Scott Bader Scandinavia-Nida-Core Corp. 2009
Feb 5 , 2009, 10:00am, Tallinn,Estonia Jack Lugus Director of Marketing, Nida-Core Corporation
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NidaFusion STO STF
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The Sandwich Material with Triangulated Truss Network PRINCIPLE A 3-dimensional Fiberglass reinforced foam for fabrication of high-stiffness low-density structures either flat or highly shaped.
APPLICATIONS Shipbuilding Transportation & Freight Insulated Doors & Panels Wind Turbine Blades & Nacelles Industrial Components
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Configuration of NidaFusion STO and NidaFusion STF
Sandwich constructions are made of :
Closed cell foam core Fiberglass reinforcements on each side of the foam Fiberglass roving stitched through the 3 elements, thus forming Triangulated Truss Network
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Foam & Reinforcements
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Reinforcement Stitching
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Resin Infusion
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40
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NidaFusion STO and STF Two products perfectly adapted for closed molding processes:
STO For Single Sided Tooling and Vacuum Infusion With Rigid Foam to Support Vacuum Pressure
STF
for Closed Tooling and RTM-Lite With Flexible Foam for Conformity to Shape and Section
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Advantages of NidaFusion STF
Instantaneous cold forming Can be shaped in several directions Allows for variable sandwich thickness Reduces cycle time Can be cut with a pair of scissors or a knife.
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Structures with NidaFusion provide: Excellent Flexural Rigidity
The Glass Fiber Truss Network uses the same materials entrusted to skin laminates. They are not sensitive to a loss of properties at elevated working temperatures, as opposed to PP Honeycomb or PVC Foams.
Excellent Fatigue Resistance and Damage Tolerance
The Truss Network and the Skin Reinforcements of the structure are mechanically interlocked, and not dependent upon adhesive bonding and shear properties of an interface between skin and core. This results in a sandwich structure that is exceptionally resistance to delamination, providing superior damage tolerance and fatigue resistance.
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Surface Reinforcements: All Reinforcements Types may be used: Fiberglas, Aramid, Carbon, etc. Woven Fabrics, Mats, Non-Crimp Fabrics, NidaFusion is typically produced with only one layer of reinforcement on each side. This ensures that Triangulation Fibers are entrapped within the final laminate. Additional laminating reinforcements provide integrity across joints, determine complete properties and exterior finish.
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The Triangulations are Characterized by: Step Length
The distance between stitches, from 10 to 60 mm. Small Step Lengths increase triangulations and mechanical properties. Small Step Lengths increase weight and cost.
Angle
45 degrees â&#x20AC;&#x201C; For Maximum Shear Resistance 60 degrees â&#x20AC;&#x201C; For Increased Compression Resistance
Fiber Tex
2400 Tex - Used for Highest Mechanical Properties. 1200 Tex - Used for Best Surface Finish. 46
The Foams :
Closed Cell Foams to displace resin during molding. Two types of foam distinguish the products:
Rigid Foams for the STO: Polyurethane foams (PU) Excellent Thermal Insulation and Chemical Resistance, with low Friability.
Polyisocyanurate foams (PI) Good Fire Resistance Standard NF 92501 : M1 Standard DIN 4102 : B2
Standard B.S. 476 Part 7 : Class 1
Phenolic foams (PH) Improved Fire Resistance without Toxic Fumes. Standard NF 92501 : M1, F1 Standard DIN 4102 : B1 Standard B.S. 476 Part 6 : Class 0 47
The Foams : Flexible Foams for the STF: Polyethylene (PE)
Used for structures with a high thickness variation and/or complex shapes. In practice, these foams are chosen for the manufacturing of small parts.
Polypropylene (PP)
For Structures with a low thickness variation, this foam allows the manufacturing of larger parts with higher molding pressures, and tolerance of higher exotherms. The elasticity can be increased locally by compressing it mechanically where necessary. This foam can be shaped at room temperature, then have its shape memorized by heating to 90-100째C during forming.
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Load nose diameter: 50 mm Span length L: 440 mm L' = L/2= 220 mm Sample length: 550 mm Sample width: 50 mm Cross head speed: 2 mm/min
4 point bending test and typical Four-Point flexure results 49
Sample length: 100 mm Sample width: 100 mm Cross head speed: 2 mm/min 2 sensors diametrically opposite measure displacement of the plates.
Compression Test, parameters and behavior in flat-wise compression test 50
Sample length: 270 mm Sample width: 75 mm Cross head speed: 2 mm/min
Core shear test and parameters and typical core shear test results
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NIDAFLOW R Comparison of Competitive Product Offerings
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The Competition Tradename
Producer
Rovicore Multimat Molding Mat Combimat Polymat Flomat
Chomarat OCV OCV Ahlstrom Flemings FGI 55
Product Comparison The essential components are binderless chopped strand glass mat separated by a lofted material that pushes the mat toward the mold surfaces and facilitates rapid resin flow. The combination must permit high drape and maintain crosssection through compound curves. The products are stitched together by the same machine types used for multiaxial fabrics. Product offerings are generally based upon up to three thicknesses of â&#x20AC;&#x153;Coreâ&#x20AC;?, and three weights of Glass Mat typically balanced. Product Nomenclature generally follow the rule of designating the glass by weight, and the core either by letter code or according to weight or thickness. [Glass/Core/Glass]
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Product Comparison Rovicore by Chomarat is the original product of this type developed for closed molding. The â&#x20AC;&#x153;Coreâ&#x20AC;? material is typically made of PP Staple Fibers (Chopped and Crimped). Generally a blend of two fibers, a large diameter fiber to retain loft, and a small diameter fiber to maintain integrity. The Multimat product of Saint Gobain Technical Fabrics was developed by Syncoglass with a knitted Glass Fiber Core. 57
NIDA-Flow NIDAFlow Application For Different Part Thickness Mold Cavity, mm P300C300 P300D300 P450C450 P450D450 P600C600 P600D600 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
24 19 17 14 13
20 17 15 13 12
27 23 20 18 16
24 21 18 17 15
30 26 23 20 19
26 23 21 19 18
Low Compression, Easy to displace reinforcement inside the mold High Compression, Increased difficulty for Resin Flow % Glass Fiber Content, Recommended Mold Gap Example: For a 2,5mm part, P300C300 has a 19% glass content, and P300D300 has a 20%, P300C300 will flow better, while P300D300 will have better mechanical performance. 58
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60
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40 m film infusion Atmosphere
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Vacuum Space Vacuum 100 km (63 miles)
Atmosphere
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Benefits of Vacuum Eliminates
need for heavy reinforced molds Eliminates need for industrial press Provides economic tooling specification
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Weight of air on our planet AT
sea level 1 cubic metre of air weighs 1.3 kg 100 km column 1 cm² air is 1kg (1 bar) Provides mould clamping force of 10 tonnes per m²
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Light RTM LRTM
Growth exceeds all other closed mold processes Focus on optimising LRTM Process Control z Material Systems z Tooling Resins z
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Light RTM Light
RTM tooling uses matched faced composite molds Atmospheric pressure clamps the closed mold together. The light weight mold structure offers low cost and rapid fabrication, but little or no resistance to injection pressures above atmosphere. Similar to infusion but has reusable tool face on both sides. 67
Light RTM Light
RTM uses Resin Injection Pumps to meter catalyst and control resin supply. Tooling Resins have been developed for rapid fabrication permitting low part count components to economically use closed mold processing. Specialty reinforcement materials have been developed for filling the mold cavity while providing rapid resin flow and maximizing flexural stiffness. Specialty core materials have been developed to provide sandwich structures while respecting part contours and cross section variations. 68
Advancements in Closed Molding of Sandwich Structures
Process Technology improvements permit Closed Molding for increasingly large objects, as well as for smaller series part runs with more economical tooling. New types of core materials facilitate complex shapes and variable cross sections to be achieved without using molded or machined-to-fit cores. Inserts may be integrated to incorporate fastening hardware to avoid additional fabrication steps. Closed Molding is increasingly used for sandwich structures in a wide variety of applications.
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Advantages labor saving
regularity in production no physical contact with the resin styrene-free workshop environment lower tooling cost (profitable at +/-80 pieces) quick and easy mold and counter mould production various choice of resin interesting for large parts easy production of sandwich parts
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Universal Insert system
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Typical Light RTM mould for 4.5 M craft Atmosphere
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Optimisation needs Increase
speed of injection. Automated control of injection Increased permeability Shorter gel times Maintain low cost tooling
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Limitations 10
tons/m² is enough to hold molds closed Resin could be injected at more than 1 bar Restricts resin injection speed to maintain pressures at or below atmosphere Gel times are extended for safety
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Variables Gel
time - known Viscosity - known Temperature - controlled Injection flow – depends on pressure Injection pressure – depends on flow Atmospheric pressure – known Mould injection pressure - Measured 75
Solutions Â&#x2039; Provide
accurate injection pressure data Â&#x2039; Read atmospheric pressure and inject 10mb under for safe and optimum control (0.0147 PSI) 76
How to control the pressure ? Injection
pressure controlled from mold Inbuilt pressure sensor tells the machine when to slow down. Specially designed to survive FRP shops. Accuracy of 1 mb (0.0147psi) absolute.
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Mould sensor Application PTFE Electronic PVSensor - Sensitivity +/- 1 mb ( +/- 0.0147 PSI)
-Low cost -Robust
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PVSensor â&#x20AC;&#x201C; Inserted in flow channel
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Application Light RTM and Film Infusion
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Multiple sensors for control and data logging
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PVSensor Optimisation system
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Accurate injection pressure control- Is it enough? For
optimization there is still a need to increase speed. Flow lengths become a limiting factor Need to stage resin input Primarily peripheral. Subsequent new input points to reinstate optimum flow speeds 84
Automatic Resin delivery Old
method buckets and pipes New method Automatic injection Valve Turbo Autosprue ™
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Filling molds automatically and precisely
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Turbo Autosprue â&#x201E;˘ (TAS) with Locksert
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With optional electronic position sensors
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Operation principles
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Benefits using Autosprues ™ Eliminates
wasteful pipe consumables Eliminates valuable time needed to replace resin feed pipes each cycle. Eliminates contact with resin mixes in workshop Reduces risk of air in part. Allows full automation 90
Precise pressure control benefits Enable
tool build to the lightest construction Large molds can be left to inject automatically. Eliminates human error causing mold overfill. Saves resin consumption Provides consistent part thickness. Protects tooling from excessive exotherm 91
Further benefits Removes
guesswork and “ black art ” Prevents possible fibre wash. Provides accurate vacuum leak detection. Low density PU and PE foams can be used with confidence…………..example
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Small craft â&#x20AC;&#x201C; Deck and hull 148kg
16 weeks - designs, patterns and LRTM tooling, craft in the water. 93
Light weight rigid design Â&#x2039;
Â&#x2039;
3 main chamber hull to deck construction providing monocoque very rigid and sealed chamber profile NidaFusion STF provides substantial deck strength and keel thickness. 94
Â&#x2039; Structural
adhesive points
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Â&#x2039;
20 metres of Structural adhesive
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Light weight mould provides off line production steps Â&#x2039; Light
weight for efficient production Â&#x2039; -off line for ease, demould, release coat application, gel coating and fibre loading 97
Â&#x2039;
Example of NidaFusion STF located on a contra deck mold
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Â&#x2039; NidaFusion
STF adheres to counter mold
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Dynamic Seal
Solid V Seal 100
Dynamic Seal
Solid V Seal 101
Mould Flange
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Mould clamping
103
Vertical Flange Closing System
Mould Flange Mould Flange
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Machine speed adjusts automatically
PVSensor provides closed loop auto mould fill control Mould pressure sensor feeds back control signal
Mould edge fill pressure controlled 105
Universal Insert 106
Advantages of staged mold filling Provides
up to 40% increase in mold fill
speed. Faster resin gel times can be set . Higher daily production gained. Releases machine more quickly for other mould injection
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Fill Curve for Single Port Injection Mold full line
Time to fill mold using standard peripheral fill 108
Fill Curve for Phased Port Injection
Time saved
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Initial resin flow to first channel zone
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Second Autosprue opens to continue injection
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112
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Solution â&#x20AC;&#x201C;Central Keyhole flow
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Initial peripheral flow
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Initial back pressure LOW
Resin builds pressure as distance from edge increases. Resin flow substantially decreases after 1m flow length as pressure increases to atmospheric pressure
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Back pressure now at atmosphere
Strategically placed additional staged resin injection fill lines within mold cavity between
Additional Mould cavity injection lines
0.75 to 1.5 m from mold edge
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Resin diverted to new fill point nearer final fill zone Peripheral injection ceases
Back pressure again LOW
118
Concept of Progressive staged filling of Light RTM mold.
Resin continues to flow from deeper points in the mould
119
There still remains the need to control pressure.
As resin is automatically switched so too is the sensing point within the cavity 120
Injection Strategy High aspect ratio problem
Peripheral Fill Central Gate 121
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The vacuum pump Vacuum pump vaccuostat
Electrical regulator
Electrical panel Air filter
0.6
0.8
0.6
0.4 0.2
1.0
0.8
0.4 0.2
1.0
Vacuum gauge
Active carbon filter
Adjustable vacuum valve Max vacuum valve Casters
124
1 Closing of the mold 2 Resin injection
Presentation of the process TYPE RT 121
DANFOSS
3 Vacuum control in the
0.6
middle of the mould
0.8
0.6
0.4 0.2
1.0
0.8
0.4 0.2
1.0
3
4
0
6
1
5
3
4
0
6
1
5
Solvant
RĂŠsine
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The mold Critical place of the system Pot to recuperate resin overflow counter mould
Mould
Trolly
126
Detail of the technical flange Male mold
Female mold
Rovicore
127
Detail of the technical flange Male mold
Closing vacuum
Female mold
Rovicore
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Wing seal
Silicon seal
129
Production of the mould 1506
Skin 1
Skin 2
Dimensions in Dimensions in mm Inches Sandwich core
130
Dimensions of the technical flange 13/64 3/4 5 20
3/4 20
255 1/2
3/8 10 3/8 10
1 25
Dimensions mm Dimensions in in Inches All radii of 51/4 mm minimum
25/64 10 13/64 5
3/4 8
63/8 10
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Use of a profile
132
Cutting the profile Laminate profilesprofiles with Laminate with 3 layers of mat 1,5 3 coat of matoz/ft² 450 gr
Mould
Cross section
Mould border
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Use of a profile
1. Positioning of the calibrated wax 2. Positioning of the profile 3. Laminating of counter-mould with the profile 134
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136
137
138
139
140
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Fabrication of the technical flange
142
Fabrication of the technical flange
143
Fabrication of the technical flange
Calibrated wax according to thickness required
First layer of the calibrated wax
13/64 Inches calibrated wax required
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146
147
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Fabrication of the technical flange Silicone seal 25/64 x 13/64 Inches
149
150
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Super Glue
Made in France
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Positioning of the silicone seal
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Fabrication of the technical flange Foam cut to size covered With 2 layers of PVC tape
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Fabrication of the technical flange 3/64 inches calibrated wax 3 layers of Cork or calibrated wax 1/8 inches
Make radius with plasticine
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165
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Positioning of the accessories
167
Example of the resin flow with 1 injection point Injection Point
Location of the vacuum Point
Resin flow Rovicore
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Example of the resin flow with 2 injection point Injection Point
Location of the vacuum Point
Injection Point
Resin flow Rovicore
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Influence of the reinforcement 1st vacuum
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Resin injection
Resin Counter
0 1 0 2 0 5 8 5 % Influence of the reinforcement 1 vacuum st
Reset
End of injection and closing of the tube
Reset
2nd vacuum
Injection pressure Atmospheric pressure
Core spring back effect
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The injector PEPE ororPA x8 mm(10mm) tube tube PA 10 25/64 inches
PTFE part
Metal part
View from below 172
Silicone beetwen Injector & laminat
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The vacuum pot Female vacuum coupling Quick coupling Cover with seal
Overflow pot (metal)
Metal insert
"o" ring
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Distance of the resin flow during injection in classic RTM • The longer the distance of the resin flow, the higher the pressure inside the mold. • In RTM, as in injection in the middle of the mold, we have to reinforce the male mold to avoid deformation. •When injecting a closed mold, the more the form is flat the more it is necessary to reinforce it.
Vent
176
Distance of the resin flow during injection in Light RTM
• In Light RTM, injection of the resin around the mold and ables to reduce the resin flow distance. • As a result, we need less reinforcement in the mold then in RTM.
Vacuum cup
• It’s only after we reach a specified resin flow distance that we have to reinforce the molds. 177
Internal pressure during Light RTM injection Resin flow distance in inches
0
10
20
30
40
0,6
0,5
1,4
0,3
50
Resin flow speed in in/min
2,8 2,4 2,0 1,6 1,2 0,8 0,4 0 0,7
Injection resin debit in US gallons / min
0,2 178
Visualisation of internal pressure during the injection Resin flow distance in cm
0
10
20
30
40
50
60
21
Pressure in PSI
18 15
Atmospheric pressure
Pressure zone
12 9 6
Vacuum zone
3 0 179
Visualisation of internal pressure during the injection Resin flow distance in cm
0
10
20
30
40
50
60
21
Pressure in PSI
18 15
Atmospheric pressure
12 9 6 3 0 180
Visualisation of internal pressure during the injection Distance de fluage de la rĂŠsine en cm
0
10
20
30
40
50
60
21
Pressure in PSI
18 15
Atmospheric pressure
12 9 6 3 0 181
Large Light RTM mold
Injection of resin
Full vacuum
Medium vacuum
50 in
CP ½’’
+ pressure
0
-
No pressure
vacuum 182
Large Light RTM mold
plywood ½‘’ laminate 5/32’’ Balsa wood ¾’’ laminate 5/32’’
laminate 5/32’’ balsa wood ¾’’ laminate 5/32’’
laminate 5/32’’
183
Injection sequence
1st vacuum
184
Injection sequence Full vacuum
Medium vacuum
185
Injection sequence Full vacuum
Deflection zone of the male mold
Medium vacuum
186
Deflection zone of the male mold
Injection sequence 187
Injection sequence 188
Injection sequence 189
Injection sequence 190
Slow-down of the resin flow in the deflection zone of the male mold.
Injection sequence 191
Slow-down of the resin flow in the deflection zone of the male mold.
Injection sequence 192
Slow-down of the resin flow in the deflection zone of the male mold.
Injection sequence 193
Injection sequence 194
Injection sequence 195
Injection sequence 196
Injection sequence 197
Because of the male mold deflection around the vacuum point, the resin arrive at the same time in the vacuum cup.
Injection sequence 198
Injection sequence Resin injection
Resin counter
0 0 0 %
Full vacuum
Reset
Medium vacuum
Pression dâ&#x20AC;&#x2122;injection
199
Injection sequence Resin injection
Resin counter
0 0 5 0 %
Full vacuum
Reset
Medium vacuum
Pression dâ&#x20AC;&#x2122;injection
200
Injection sequence Resin injection
Resin counter
0 2 0 0 5 %
Full vacuum
Reset
Medium vacuum
Pression dâ&#x20AC;&#x2122;injection
201
Injection sequence Resin injection Full vacuum
Resin counter
0 5 0 0 2 5 % Reset
Medium vacuum
202
Injection sequence Resin injection
Resin counter
0 8 0 5 2 5 0 %
Full vacuum
Reset
Medium vacuum
Pression dâ&#x20AC;&#x2122;injection
203
Injection sequence Resin injection
Resin counter
0 1 0 2 0 5 8 5 %
Full vacuum
Reset
End of injection Medium vacuum
Injection pressure
204
Injection sequence Resin counter
0 1 0 2 0 5 8 5 %
Full vacuum
Reset
Medium vacuum
Atmospheric pressure Pression dâ&#x20AC;&#x2122;injection
205
Injection sequence Resin counter
0 1 0 2 0 5 8 5 %
Full vacuum
Reset
Medium vacuum
Atmospheric pressure Pression dâ&#x20AC;&#x2122;injection
Sping back effect of the NidaFlow 206
Injection sequence Resin counter
0 1 0 2 0 5 8 5 %
Full vacuum
Reset
Medium vacuum
Atmospheric pressure Pression d’injection
It’s the combination of the rigidity of the male mold and the spring back effect of the NidaFlow that enables the male mold to return to it’s original form.
Sping back effect of the NidaFlow 207
20’’
Deflection zone
208
Finally a few further examples
209
Equipment used for Jeanneau, France LRTM production 42 foot sailing vessel deck
210
Light RTM technology in use on many Wind energy large mouldings applications
211
Xeroplas Portugal LRTM cored mouldings
212
New European Bus exclusively LRTM Molded parts
213
“Street Car” a new concept in Urban Buses
214
Double impression LRTM tool For Malaysia client makes two 3 metre cable tray mouldings
215
In floor mounting Shower Trays with large section thickness changes
216
ÎMARCOPOLO PARADISO GIV- 1983
12% PERCENTAGE OF PLASTIC FOR BUSES (COST)
217
ÎMARCOPOLO PARADISO GV- 1992
16% PERCENTAGE OF PLASTIC FOR BUSES (COST)
218
ÎMARCOPOLO PARADISO G6- 2000
20% PERCENTAGE OF PLASTIC FOR BUSES (COST)
219
ÎPERCENTAGE OF PLASTIC FOR BUSES (COST) 1949
1983
2000
2006
0%
12%
18 %
22%
220
ÎHISTORY OF PROCESSES Î1996 Spray-Up / Hand Lay-Up
80%
RTM 0% Vacuum Bag
15%
Vacuum Forming 0% Injection 1% Î2006
PU
4%
Spray-Up / Hand Lay-Up
39%
RTM Vacuum Bag
38% 4%
Vacuum Forming Injection PU
8% 3% 8% 221
DEVELOPMENTS MVC BRASIL Â&#x2039;
1996: MVC Starts to produce a truck hood with high pressure RTM process.
222
DEVELOPMENTS MVC BRASIL
Steel Mold weights 80 tons:
223
DEVELOPMENTS MVC BRASIL Â&#x2039;
The hood is made of a 3.5mm skin and the structure is given by 11 reinforcements glued inside the hood.
224
DEVELOPMENTS MVC BRASIL
2004: New Development with RTM Integrated with NidaFusion STF
225
226
CASE HISTORY MVC BRASIL
ENGINE DOOR for Marcopolo Bus
227
CASE HISTORY MVC BRASIL ENGINE DOOR for Marcopolo Bus Initially manufactured by Spray-up , using two composites parts and one injected PU core, with the three parts adhesively bonded together. RTM reduced manufacturing time and improved overall quality of the part.
The new process uses NidaFusion STF with the following benefits: - Elimination of the PU injected core - Reduction of the steel inserts - Part is 30% lighter, 40% faster to produce and 8% lower cost - Increased mechanical resistance and estimated life cycle of the part - Reduced investment (one mold only compared to three previously)
228
ENGINE DOOR COMPARATIVE
19 kg
13 kg
355 min
215 min 8% less
229
DEVELOPMENTS MVC BRASIL STRUCTURAL ROOF for Marcopolo Bus Currently a bus roof is made of: - A steel frame - An outside fiberglass skin - An inside skin (fiberglass, formica, plasticâ&#x20AC;Ś) - Some inserts (steels, plastic, foam â&#x20AC;Ś)
Development consists of replacing all these elements by one RTM Integrated part using NidaFusion STF
230
DEVELOPMENTS MVC BRASIL STRUCTURAL ROOF for Marcopolo Bus
Test mold representing one section of a 6m minibus roof.
231
DEVELOPMENTS MVC BRASIL STRUCTURAL ROOF for Marcopolo Bus
Good Surface Finish
Light
Stiff 232
ÎLight RTM
233
ÎCURRENT APPLICATIONS
Wheel Flare
Wheel Flare
Front parts
Bathroom
234
ÎCURRENT APPLICATIONS
External roof
Internal parts
Back Cover
235
236
237
238
239
Thank you for attending ! Questions Jack Lugus Nida-Core Corporation
240