cornerstone application of composite

1

2016

900 E. Vienna Avenue, Milwaukee, WI 53212 P: 414-964-5200 www.cornerstonecomposites.com

Stronger Solutions

As a team of engineers, we believe that stronger solutions are always worth striving for. We help nimble, open-minded manufacturers advance their products by replacing metal and thermoplastic parts with higher performance, customized composite formulations.

Core Statement

Stronger Solutions

Stronger Solutions

Thermoset Composites

Thermoset composites often fill in the performance

region between common thermoplastics and metals.

PE ABS Nylon PC GFNylon PET PPS PEI PEEK Al Zinc Mg Mild Steel Hard Steel

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What are they?

• Mixtures of polymer resins, catalysts and reinforcements that react and cross-link when exposed to thermal energy, hence – “thermoset”.

• Close cousin to “chemical set” composites which cross-link at room temperature when mixed with a catalyst.

• As opposed to Thermoplastics, which can be melted, solidified and melted again with heat cycles, Thermosets are permanently solidified upon cross-linking.

• Thermoset materials get their unique properties from the formation of three-dimensional covalent bonds between the molecules – “cross-linking”.

• Different from Thermoplastics, whose molecule-to-molecule bonds are largely electrostatic attractions and entanglements.

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When should you use Thermoset?

High Stiffness Elevated Temperatures

High Strength Low Creep

Structural Aesthetics Dielectric Applications

Dimensional Stability Chemical Resistance

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Opposed to Thermoplastics

Opposed to Metals Mold to net shape – no machining Consolidate parts & functions

Chemical resistance Eliminate painting

Lower processing costs

Stiffer Stronger per $

Higher thermal performance Low shrink

Low residual stress Thermal Stability

Low creep

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• Phenolic • Wood, Cotton, Mineral, Glass, Graphite Filled

• Granular Polyester

• Bulk Molding Compound• Non Conductive, Conductive

• Sheet Molding Compound• Polyester, Vinyl Ester, High Glass, Low Density

• Rubber

• Thermoplastic

Material Formulations

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• Bulk Molding Compound (BMC)

• Viscous, putty-like compound for injection or compression molding

• Highly-filled and reinforced with short glass fibers

• Injection or compression-molded

• Glass reinforcement represents between 10% and 30%

• Mold in-color, or apply powder-coat or wet paint

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• Sheet Molding Compound (SMC)

• Similar chemistry to BMC

• Longer fiber length than BMC

• Glass reinforcement represents between 20% and 50%

• Sheathed top-and-bottom with carrier film

• Typically compression molded into complex shapes

• 400,000,000 lbs. used in automotive and heavy truck applications in 2006 (ACMA)

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• Use molded composite materials to replace cast, fabricated, extruded and stamped metal components:

•

• Reduce weight

• Reduce cost

• Manufacture to net shape

• Remove finishing operations• Painting• Machining

• Add molded-in features

• Consolidate components

Metal Replacement

Commercial Saw Table – replaced extruded aluminum

Base for a Commercial Food Slicer replaced cast aluminum for a savings of 50%

Molded composite Hopper for wood stove eliminated a complex and costly steel fabrication

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These materials retain their mechanical

properties at elevated temperatures well

beyond commercial thermoplastics.

Virtually no creep

Do not soften or melt

Very high ignition temperature

Are thermal insulators

High Temperature Performance

Oven Trays for Re-therm food preparation

Small Engine Valve Cover – low creep, maintains seal at elevated operating temperatures

Commercial Hot-Melt Glue Gun –operates at 350

Heated Products are a natural application for Thermoset Composites - with high temperature and low flammability requirements

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Dielectric Applications

Thermoset Composites are intrinsically dielectric: Maintain dielectric strength at

elevated temperatures Often used to replace ceramics –

less brittle Can be used to encapsulate

conductors

Welder Switch – high current load

Engine Block Connector – maintain dielectric strength at high temperature in oily, wet environment

Mass Transit “3rd Rail” Conductors – replaces ceramic in very tough environment.

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Lighting and Office

Lighting is a natural market for Thermoset Composites: High temperature exposure Non-yellowing High Dielectric Thermal insulator Can be metallized for reflectors

Keyboard Tray for Articulating Mechanism – replaced wood composite. Very flat. Very stiff.

Recessed Lighting Baffles

Stylized Florescent Baffle

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Food Preparation

Thermosets find a

natural home in the food

industry:

High thermal

capacity

FDA & NSF

compliance

Resistance to

chemical cleaning

products

Replaces Stainless

Steel and Aluminum

Base for Commercial Deli Slicer – replaced cast aluminum that required machining and polishing. Offers huge price savings.

Molded Composites make an attractive, cleanable, NSF-compliant surface for buffet service

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Unique Applications

Pack Frame – traditional material was fabricated aluminum

Commercial Flooring Nailer – provides toughness that aluminum could not

A polymer composite Heating Element –functions at 300?F. Molded from engineered phenolic composite.

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Mechanical Attributes of Thermosets

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80

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100M

od

ulu

s R

ete

nti

on

%

Temperature C

Modulus vs Temperature

Nylon (Crystalline TP) Phenolic (TS)

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20

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60

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100

120

Phenolic PPS Nylon 6/6 PBT PET

% D

ime

nsio

n R

eta

ine

d

Compressive Creep @ 150C

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Processing Molded Thermoset Composites

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• Andy Stroh • VP Sales & Marketing• astroh@cornerstonecomposites.com• 414-491-5948 (C)• 414-727-4221 (O)

• Boyd Miller• President• bmiller@cornerstonecomposites.com• 262-470-1379 (C)• 414-727-4227 (O)

• Bob Uhren• Technical Director• ruhren@cornerstonecomposites.com• 414-899-6279 (C)• 414-727-4241 (O)

• Erik Feller• Quality Engineer• efeller@cornerstonecomposites.com• 414-702-1124 ©• 414-727-4223 (O)

• Noah Brushel• VP Engineering• nbrushel@cornerstonecomposites.com• 414-305-7500 ©• 414-727-4222 (O)

• Tom Schueller• VP Operations• tschueller@cornerstonecomposites.co• 414-374-2132 ©• 414-727-4238 (O)