聚氨酯树脂型材拉挤设备技术介绍.ppt
,热固性快速胶化聚氨酯的拉挤成型：加工过程和机械性能 Pultrusion of Fast-Gel Thermoset Polyurethanes: Processing Considerations and Mechanical Properties,Translation company :Beijing Jinghua Park polyurethane equipment Co., Ltd,热固性快速胶化聚氨酯的拉挤成型：加工过程和机械性能 Pultrusion of Fast-Gel Thermoset Polyurethanes: Processing Considerations and Mechanical Properties,背景：复合材料企业Background: the Composites Industry 实验策略Experimental Strategy -加工过程Processing -系统配置System Configuration -机械性能Mechanical Properties 结果Results -加工过程 Processing -机械性能Mechanical Properties -区域和人员监测器Area & Personnel Monitoring 结论Conclusions,什么是复合材料？ What is a Composite?,广泛定义：两种材料的结合，仅一种材料不能单独使用 Broad definition: a combination of two materials that can do things neither could do alone 工作定义：一种强韧的或坚硬的物质（经常是一种纤维）能够为基质（通常是树脂）提供重要的机械性能，从而保护纤维免受强度和环境的损坏。 Working definition: a strong or stiff reinforcement (usually a fiber) that provides key mechanical properties to a matrix (usually a resin) that in turn protects the fiber from stresses and environmental damage,工作定义覆盖了多样产品，如图所示 The Working Definition Covers a Huge Range of Products,市场数据： Market Statistics:,美国年度复合材料总量（2000年） U.S. Annual Composites Output(Year 2000),240亿美金 $24 Billion,39亿英镑（纤维和树脂） 3.9 Billion Pounds(Resin & Fiber),全球年度总量预计是美国的2.5倍（100亿英镑） Worldwide Annual Output is Estimated at 2.5 Times US (10 Billion Pounds),树脂消耗占总体的65%（美国25亿英镑，全球65英镑） Resin Consumption Accounts for 65% of Volume (2.5 Billion Pounds US/ 6.5 Billion Pounds Worldwide),信息来源：复合物品制造业协会 Source: Composites Fabricators Association,市场数据： Market Statistics：,历年复合材料市场增幅（如图所示） Historic Composites Market Growth,信息来源：复合物品制造业协会 Source: Composites Fabricators Association,市场数据： Market Statistics:,模具加工复合材料所占份额 Composites Production by Market Segment - 2001,信息来源：复合物品制造业协会 Source: Composites Fabricators Association,市场大小分析 Market Share by Size,50个大公司产量占35%,1200个中小公司产量占50%,4200个小公司产量占15%,信息来源：复合物品制造业协会 Source: Composites Fabricators Association,实验策略 Experimental Procedure,聚醚多元醇、异氰酸酯、催化剂和脱模剂的分类 Identification of candidate polyols, isocyanates, catalysts and mold releases 加工特点的两相评估 Two-phase evaluation of processing characteristics 单相，可工作的化学物质分类 Phase One: Identification of workable chemistries 两相 温度、加速包膜、化学计量学、脱模剂的开发 Phase Two: Exploration of temperature & speed envelopes, stoichiometry & mold releases 环境和工作的安全评估 Parallel environmental & workplace safety evaluation 机械性能特点 Mechanical properties characterization,实验策略 Experimental Procedure,聚醚多元醇、异氰酸酯、催化剂和脱模剂的分类 Identification of candidate polyols, isocyanates, catalysts and mold releases 加工特点的两相评估 Two-phase evaluation of processing characteristics 单相，可工作的化学物质分类 Phase One: Identification of workable chemistries 两相 温度、加速包膜、化学计量学、脱模剂的开发 Phase Two: Exploration of temperature & speed envelopes, stoichiometry & mold releases 环境和工作的安全评估 Parallel environmental & workplace safety evaluation 机械性能特点 Mechanical properties characterization,JHPK-G20 Pultrusion Machine(JHPK-G20拉挤成型设备),Pultrusion Machine(拉挤成型设备JHPK-G20系列),一、设备的基本介绍：可应用于新型聚氨酯型材的拉挤生产，产品可完全替代玻璃钢拉挤型材，包括聚氨酯门窗型材、聚氨酯导槽、聚氨酯管及其它成型件。 The general introduction and special function :applied in the new type polyurethane profile extruding production which can completely replace the fiberglass extruding profile, including the polyurethane profile of window and door, polyurethane guide groove, polyurethane pipe and other molding products. 二、注胶(拉挤成型）设备必要的几点功能 1、设备对于温度控制的精准性 The accurancy of temperature controlling 2、AB组分比例控制的的准确性 The accurancy of the ratio of the raw material 3、系统的稳定性：对与控制器及编程要求较高 The stability of the system : accompanying system 4、拉挤线速度的探测性：能精准的反馈拉挤速度，根据拉挤线速度控制原料输出的多、少、停止 The detectability of the speed : the accurancy of the speed feedback , high safety factor 4、自动上料：保证原料处于充足状态，确保连续生产。 Automatically supply raw materil,拉挤工艺介绍 the introduction of pultrusion technology,自动的连续的过程，通过拉着被树脂浸润的增强材料通过加热的模具来生产带一定横截面的复合材料的工艺。（牵引着被树脂浸润的增强材料通过加热的模具来生产带一定横截面的复合材料的工艺。 it's a automatic continuous process，through pulling the reinforcing materials that have been soaked with resin,then pass the heating moulds, in the end , produce some composites with transversal surface.it's such kind of crafts .,拉挤钢模和加热装置 Pultrusion Die and Heater Setup,90厘米钢模长度 90 cm die length,钢模出口冷却（持续流动的水） Die entrance cooling (continuous flow tap water),在3个区域中有6个独立的加热器，带有闭合回路的控制器。 Six independent resistance heaters in 3 zones with closed-loop controllers,25毫米空气隔阂 25 mm air gap,拉挤系统配置（根据聚氨酯变化） Pultrusion System Configuration (Changes for Polyurethane),树脂灌注，纤维润湿室 Resin injection/fiber wetting chamber 高密度聚乙烯（HDPE） Machined from HDPE 模具入口面板 Bolted/sealed to die entrance face 树脂计时和混合 Resin metering and mixing 商业计时和混合传动装置系统（车床喷涂设备）（螺旋缠绕喷涂设备） Commercial meter/mix gear pump system (truck-bed-liner spray equipment) 气动混合枪头带有一次性静态搅拌器（静态混合器） Air-actuated mix head with 30-element disposable static mixer,树脂灌注器和纤维润湿室 Resin Injector/Fiber Wetting Chamber,树脂灌注器和纤维润湿室 Entrance plate to reduce resin loss 入口设置：减少入口树脂损失 Exit matches shape and area of die entrance 长度：30厘米 Length: 30 cm 入口出口区域比例：6：1 Entrance/Exit area ratio = 6:1,机械性能特点 Mechanical Properties Characterization,一相：对于屏蔽材料使用树脂的可行性 Phase One: Screening materials for viability using resin-influenced and resin-dominated properties,单相（各项）机械性能测试协议（指标） Phase One Mechanical Properties Test Protocol,弹性强度测验用于实时监控 Flexural strength testing used for near real-time screening 1.样品准备 Fast sample preparation 2.样品在120（摄氏）度下45分钟固化。 Samples post-cured 45 min 120°C 3.最终的强度和延长性，相对于失败的数据 Ultimate strength and elongation to failure data used 用于最终树脂系统的选择-短梁切变强度测试 Short-beam shear strength test used for final resin system selection 更长的样品循环 Longer sample prep cycle needed 室内温度变化 Room temperature aging 树脂特性-最好的识别器 Resin-dominated property best discriminator,结果 Results,加工、处理 Processing 技术特性 Mechanical Properties 区域和人力监控 Area & Personnel Monitoring,处理结果 Processing Results,实现120到150厘米每分钟的速度和较低的拉力对工艺来说毫无困难 High speeds (120-150 cm/min) with low pull forces were achieved with little or no difficulty 机械的速度不会变慢 No deterioration of mechanicals with speed 在更高的速度限制方面有很大的潜力 Upper speed limit is undetermined 有机磷酸盐/有机脂模子能得到很好的释放 Organo-phosphate/organic ester mold releases produced excellent, glossy finish 树脂能够很好的加热 Resin is forgiving and heat-loving 只有一个crash系统，化学性能的改变在第二个阶段 Only one system crash chemistry modified for Phase Two 对温度和速度的改变有快速的反应 Benign response to extreme speed & temperature changes 增加中心区域的温度提高质量 Increased center zone temperature improved quality 长期的性能测试遇到的问题已经有解决方法，但是还未测试过 Problems encountered on long-term stability test runs Solutions have been developed but not yet tested,进口处区域温度的增高导致湿度的增加 ncreased Temperature in Entry Zone Caused Wetout to Deteriorate 湿度的增加影响机器的性能，在出口部分很容易被看出来 Wetout deterioration affected mechanical properties, and could be readily seen as the part exited the die,机器性能的描述 Mechanical Properties Characterization,双树脂系统进行下面两个测试 Two resin systems tested in Phase Two: 拜耳 STR 2000 体积比1：1系统 Baydur STR 2000 (1:1 by Volume System) 拜耳 STR 3000 标准系统 Baydur STR 3000 (Standard System),拜耳方法A的喷涂黏度测试结果 Results of Bayer Method A Paint Adhesion Testing,Method similar to ASTM D 3359 样品准备 Sample preparation: 商用喷涂部分-可用于丙烯腈纤维和聚氨酯的自动完成 Part painted with commercially-available 2-part acrylic-polyurethane automotive finish 在温度特定的房间里四天完成 Cured 4 days at room temperature 建造100平米的基层达到标准 Scratched through to substrate to create 100 squares 压力敏感的部分运用于水平的表面 Pressure-sensitive tape applied & pulled off parallel to surface 两个系统都标明为零损失 Both systems showed 0% loss,区域和人员检测器：标准 Area & Personnel Monitoring: Criteria 两相实验的测验展示 Testing conducted during Phase Two trials 客观性：决定MDI 在设备操作和工作领域的呼吸区域的气体浓度 Objective: determine airborne concentrations of MDI in breathing zone of machine operators and in the work area 允许数值： Permissible Levels ACGIH美国政府工业卫生学家会议规定(有害物）容许最高浓度 ACGIH Threshold Limit Value (TLV/TWA) 8小时工作日平均为10亿份（分）之5 5 parts per billion (ppb) averaged over 8-hour workday 职业安全与卫生条例可允许的暴露极限 OSHA Permissible Exposure Limit (PEL-C) 在一天中的任何时候不能超过10亿分之20 20 parts per billion (ppb) should not be exceeded during any part of the day,区域和人员检测器：结果 Area & Personnel Monitoring: Results 抽样方法：修正过的职业安全与卫生条例47 Sampling Method: modified OSHA 47 检测草案： Testing protocol 从3名操作者的呼吸领域抽取10个样本 Ten samples from breathing zones of 3 operators 在拉挤设备的5个地方抽取25个样本 Twenty-five samples from 5 locations around the pultrusion machine 结果： Results 呼吸领域的样本比较好，在TLV 条款下，从10亿分之0.2 到检测不到 Breathing zone samples were well below TLV values (0.2 ppb to non-detectable) 放在拉挤设备周围的区域样本，浓度从10亿分之18到检测不到 （在模具出口，通气罩下） Area samples, placed around pultrusion machine, ranged from 18 ppb (at die exit, under vent hood) to undetectable,拓展：不同树脂的优缺点 Expansion :the advantages and disadvantages about the resin,结论 Conclusions 双组份聚氨酯树脂看起来是现在使用材料的很好的替代品 Two-part polyurethane resins appear to be a very promising alternative to currently used materials -优越的机械性能 Superior mechanical properties -高产量的潜力 High productivity potential -相对容易的加工 Relatively easy processing -可控制的工作环境 Controllable workplace environment 进一步的检测要求建立多种适用范围 Further testing required to establish range of suitable applications -工作环境的暴露 Workplace exposure -化学物质的兼容性 Chemical compatibility,the application of pultrusion machine 拉挤设备的运用,the application of pultrusion machine 拉挤设备的运用,THANKS FOR YOUR ATTENTION,JHPK,
