cornerstone application of composite
TRANSCRIPT
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
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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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10
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60
70
80
90
100M
od
ulu
s R
ete
nti
on
%
Temperature C
Modulus vs Temperature
Nylon (Crystalline TP) Phenolic (TS)
0
20
40
60
80
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• [email protected]• 414-491-5948 (C)• 414-727-4221 (O)
• Boyd Miller• President• [email protected]• 262-470-1379 (C)• 414-727-4227 (O)
• Bob Uhren• Technical Director• [email protected]• 414-899-6279 (C)• 414-727-4241 (O)
• Erik Feller• Quality Engineer• [email protected]• 414-702-1124 ©• 414-727-4223 (O)
• Noah Brushel• VP Engineering• [email protected]• 414-305-7500 ©• 414-727-4222 (O)
• Tom Schueller• VP Operations• [email protected]• 414-374-2132 ©• 414-727-4238 (O)