p. 1



# OAR Box 1394 Prepped by Ollie Stewart



## Document

Number: 

# 49 ) ll-C-1 9 Docket Number: 

# A-94-5 2

Printed 7/3/20087:52:01 AM

Sheet 49of 56P. 2 

# A44- &

»* t 0 Sr < » 

### UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENCY ^•«-r ^ „ , Offic e o f Ai rQualit y Plannin g an d Standard s -VlV-

- / Researc h Triangl e Park , Nort h Carolin a 2771 1 o 

# J U L 2 1 iS9 5

REINFORCE D PLASTI C COMPOSITE S PRE-MAC T MEETIN G Dea r Pre-MAC T Teamand/o r Wor k Grou p Member : Thi s memorandu

m serve s a s a reminde r o f th e upcomin g pre-MAC T teleconferenc e o n Monday , Jul y31 , 1995 , a t 1:00-4:0 0 pm

EDT . Th e meetin g wil l b e hel d a t th e EPA/Mutua l Buildin g i n Durham , NC . Fo r tea mmember s wh o canno t atten d i n person , th e call-i n phon e numbe r i s (919 ) 541-1591 . Enclose d wit h thi s mem o i s a brie f agend a fo r th e meeting

. Madelein e Stru

man d Jorda n Spoone r wil l conduc t th e meeting

. A presentatio n wil l b e give n byResearc h Triangl e Institut e (RTI ) o n th e pollutio n preventio n proces s assessmen t studie s sponsore d byEPA' s Offic e o f Researc h an d Development , an

d b yCoo k Compos

ite s & Polymers , Reichhol d Chemicals , an d Magnu m Industrie s o n th e product s supplie d t o RT I fo r testin g purposes . Tw o vendor s o f equipmen t technologie s fo r reducin g styren e emission s wil l b e availabl e t o discus s thes e proces s change s and answe r questions

. Hardcor e Composites , Ltd . wil l giv e a presentatio n o n th e SCRIM P proces s an d Liqui d Contro l Corp . wil l giv e a presentatio n o n th e Resi n Transfe r Moldin g (RTM ) process . Bot h o f thes e processe s ar e pollutio n preventio n alternatives

. Als o enclose d i s technica l materia l o n th e processe s an d equipmen t tha t wil l b e discussed

. I f anyon e beside s th e vendor s woul d lik e t o reserv e a spo t o n th e agend a t o mak e a presentation , expres s a view , etc. , pleas e notif yGre g LaFla mo r Jeffre yBes t a t PE S a t (919 ) 941-0333 . I f yo u hav e an yquestion s prio r t o th e meeting , pleas e contac t Madelein e Stru ma t (919 ) 541-2383 . Sincerely ,

Madelein e Stru

m Projec t Leade r Coating s an

d Consume r Product s Grou p Enclosure s 

# !•'. ! . £ 

# !(¥• ? 

# \?. R

• CY

5 *••

•• - \ mhi't

mP. 3



## ADDRESSEES : Moha n Balagopalan , SCAQM D Bo b Burmark , Washingto n DO E Jan e Caldwell , OAQPS/AQSS D (MD-15 ) Leonard o Ceron , Regio n I V Lis a Conner , OAQPS/AQSS D (MD-15 ) Patrici a Embrey , OG C (2344 ) Bo b Fegley , OR D (8105 ) Chuc k French , OAQPS/AQSS D (MD-15 ) Christin e McPhee , Ohi o EPA Lind a Herring , EPA/ES D (MD-13 ) Nor mKaplan , EPA/OR D (MD-61 ) Kare n Levy , OPA

R (6103 ) Mari a Malave , OEC A(2223A ) Hail e Mariam , OS W (5302W ) Crai g Matthiessen , OSWE R (5101 ) Stev e McNally , Composit e Fabricator s Assoc . Arnol d Medbery , OSDB U (12 3 0-C ) Richar d Nielson , Clar k County , N V Carlo s Nunez , OR D (MD-61 ) Be n Pamar , Sierr a Clu b Nanc yPate , OAQPS/ITPI D Solomo n Ricks , OAQPS/EMA D (MD-19 ) Ro n Ryan , OAQPS/EMA D (MD-14 ) Joh n Schweitzer , Composite s Institut e Jorda n Spooner , OPPT/PP D (7409 ) Jer i Weiss , Regio n I Vendor s Mar k Callicut , Reichhol d Chemical s To mHedger , Magnu

m Industrie s Mar k Hollenbech , Coo k Composite s &.Polymer s Kennet h Jacobs , Liqui d Contro l Corp . Georg e Tunis , Hardcor e Composites , Ltd . Mar k Bahner , RT I (Contractor ) Gre g LaFlam , PE S (Contractor )



## XP. 4



## REINFORCE D PLASTI C COMPOSITE S PRE-MAC T MEETING # 3

POLLUTIO NPREVENTIONTECHNOLOGIE S EP AMutua l Bldg. , Durham , N C Jul y31 , 199 5 1:0 0 p mED T

Call-i n #(919 ) 541-159 1



## * AGEND A*

1 . Introduction s & Genera l Discussio n 1:0 0 2 . Pollutio n Preventio n Stud yan d Proces s Technologie s 1:3 0 3 . Vendo r Presentation s 1:4 5 A . Mr . Mar k Bahne r Researc h Triangl e Institut e (RTI ) (Result s o f th e pollutio n preventio n testin g sponsore d b yEPA' s Offic e o f Researc h an d Development ) B . Mr . Mar k Hollenbec h Coo k Composite s & Polymer s (Supplie r o f gelcoat s use d byRT I i n th e tests ) C . Mr . Mar k Callicu t Reichhol d Chemicals , Inc . (Supplie r o f resin s use d b yRT I i n th e tests ) D . Mr . To mHedge r Magnu mIndustrie s (Supplie r o f applicatio n equipmen t use d byRT I i n th e tests ) E . Mr . Georg e Tuni s Hardcor e Composites , Ltd . (SCRIMP process ) F . Mr . Kennet h Jacob s Liqui d Contro l Corp . (RT M moldin g equipmen t an d process ) 4 . Additiona l Presentation s a s Requeste d 3:0 0 5 . Genera l Discussio n 3:3 0 Nex t Step s



## ° ?P. 5

07/21/S 5 10 3 1 2 "0*91 9 54 1 715 5 KT1 - Ul A lgJUU 2



## RESEARC H TRIANGL E INSTITUT E 

# /RT I mmLmmmm



# EP A OFFIC E O F RESEARC H AND DEVELOPMEN T (ORD ) INVESTIGATIO N OF POLLUTIO N PREVENTIO N TECHNIQUE S

T O REDUC E STYRENE EMISSION S FRO M OPEN-MOL D REINFORCED PLASTI C COMPOSITE S

FABRICATIO N

JUNE-JULY , 199 5

ACKNOWLEDGEMENTS :

REICHHOLD CHEMICALS , INCORPORATED

• MAGNU M INDUSTRIE S

• COO K COMPOSITE S AND POLYMER S



# JUL Y 31,199 5

4PJ L

07/21/9 5 16:1 2 ??919 54 1 715 5 RTI - CE A |fi00 3



## OBJECTIVE S GENERA L 1 . COMPAR

E MASS-BALANCE-BASE D EMISSIO

N MEASUREMENT S WIT H EP A METHO

D 25 A (TOTAL HYDROCARBO N ANALYZER

) EMISSIO N MEASUREMENTS . 2 . ESTABUSH "BASEUNE " RESULT S (USING AIRLESS-AIR-ASSIS T GU N AND METHYL ETHY

L KETON

E PEROXID

E "CATALYST" ) T

O COMPAR

E WIT H RESULT S FRO

M VARIOUS POTENTIA L POLLUTION PREVENTION MEASURES . 3 . DETERMIN

E TH E EMISSION REDUCTION S ACHIEVE

D B Y TH E FOLLOWING : PILO T TESTIN G A . LOWERING AH

< VELOCIT

Y I N TH E APPLICATION AREA , B . IMPROVE

D OPERATO

RSPRAYIN

G TECHNIQUES , GEL COA T TESTING C . HIGH-VOLUME-LOW-PRESSUR E (HVLP ) EXTERNAL MT

X SPRA Y GUN , D . HIGH-VOLUME-LOW-PRESSUR E (HVLP ) INTERNAL MT

X SPRAY GUN , E . LOWER-STYREN E CONTEN

T GE L COA T RESIN TESTIN G F . FLO

W COATE

R(NON-SPRAYING TECHNIQUE) , G . PRESSURE-FE

D ROLLE

R(NON-SPRAYING TECHNIQUE) , H . LOWER-STYREN E CONTEN

T RESm , L STYRENE-SUPPRESSE D RESIN , J . STYRENE-SUPPRESSE D RESI N PLU S ADDITIONA L WAX , K . BENZOYL-PEROXID E (BPO)-CATALYZE

D RESIN , AN

D L . WATER-EMULSIFICATION-TECHNOLOG Y (W.E.T. ) RESIN...NO T AVAILABLE .

$PJ_ 07/21/9 5 16:1 3 'OT91 9 54 1 715 5 K11 - UU A iajou »



## PROCEDURE S

1 . SPRA

Y BOOT H SERVIN

G A S TOTA

L TEMPORAR

Y ENCLOSURE. 2 . ISOLATE

D FRO M OT H E RVOLATIL

E ORGANI

C COMPOUN

D SOURCES . 3 . RANDOMIZE

D TESTIN

G SEQUENCE. 4 . TRIPLICAT

E TESTIN

G FO RPOTENTIA

L POLLUTIO

N PREVENTIO

N TECHNIQUES , SI

X TEST S FORBASELIN

E CONDITIONS . 5 . APPROXIMATEL Y THRE E RUNS PE

RDA Y (55 RUNS , OVE

RA PERIO

D O F FIV E WEEKS) .

&07/21/9 5 16:1 3 ©91 9 54 1 715 5 RTI - CE A P. 8 14)005

Emissio n an d Ai r Ro w Rat e Monitorin g Locatio n 2n d Floo r Makeu p Ai r Duc t

Ground-Floo r 

### 7'x6 ' (W ) Doubl e Doo

r

Applicatio n Equipmen t (Coul d b e Place d Insid e o r Outsid e th e Enclosure ) 

### Figure 1-2 . Sid e vie

wof th e Reichhol d Chemical s spra y boot h I n a permanen t tota l enclosur e (19' H x 12'W x 15'L)



# 1P. 9

uf/ii/s o 10:1 1 TQ-ai s &4 1 via a KT1 - Ufc. A IfljUU b

2 ' Rang e surroundin g th e botto m o f th e mol d t o eas e par

t remova l

Figur e 1-3 . Sketc h o f a mal e mold .



# 1P 1 0

lH/il/» 0 10:1 1 -Q*S1 » 34 1 /io o KH - UK A lg)UU 7



## EQUIPMEN

T

1 . TOTA L HYDROCARBO N ANALYZE

RWIT H A FLAM

E IONIZATIO N DETECTO R(FDD)

. 2 . SARTORIU S SCALES , ACCURAT E TO 1 GRA

M I N IS O KILOGRAMS . 3 . KRAF T PAPER, FIBERGLAS S VEILS . 4 . MAL E MOLD , APPROXIMATEL Y 2 5 SQUARE-FOO T TOTA L SURFAC E AREA . 5 . MAGNU M INDUSTRIE S APPLICATTO N EQUIPMENT : A . GE L COA T SPRA Y SYSTE M 1 . AIRLES S AIR-ASSIS T SPRA Y GUN , EXTERNAL MIX . 2 . HVL

P SPRA Y GUN , INTERNA

L MIX . 3 . HVL

P SPRA Y GUN , EXTERNA

L MK . B . RESIN SPRA

Y SYSTEM(S ) 1 . AIRLES S AIR-ASSIS T SPRA Y GUN , EXTERNAL MIX . 2 . AIRLES S AIR-ASSIS T SPRA Y GUN , EXTERNAL MIX , FO RBPO CATALYZE

D RESINS . C . RESIN NON-SPRA Y SYSTEMS 1 . FLOW-COATE

R(NON-ATOMIZE

D SPRAYING TECHNIQUE) . 2 . PRESSURE-FE

D ROLLE

R(NON-SPRA

Y SYSTEM) . 6 . COO KCOMPOSITES AN D POLYMER

S (CCP) GE

L COAT S A . "REGULAR " GE L COA T (APPROXIMATEL

Y 39 % STYRENE) . B . "LOW"-VO C GE L COA T (APPROXIMATEL

Y 25 % STYRENE) . 7 . REICHHOLD RESINS A . "REGULAR"-STYREN E (APPROXIMATEL

Y 40 % STYRENE , MEKP CATALYZED) . B . "LOW"-STYREN E (APPROXIMATEL

Y 35 % STYRENE) . C . STYRENE-SUPPRESSE D RESI N (APPROXIMATEL

Y 43 % STYRENE) . D . STYRENE-SUPPRESSED-PLUS-ADDITIONAL-WA X RESIN (APPROXIMATEL

Y 43 % STYRENE) . E . BPO-CATALYZE D RESI N (APPROXIMATEL

Y 43 % STYRENE) .P.1 1

07/21/9 5 16:1 5 ©91 9 54 1 715 5 RTI - CE A 12)00 8



### PRELIMINAR Y SUMMARY O F EP A OFFIC KO F RESEARC H AN D DEVELOPMEN T POLLUTIO N PREVENTIO N TESTIN G RESULT S (CONDUCTE D B Y RT I A T REICHHOL D CHEMICAL S FRO M JUN E T O JULY , 1995 )

GENERA L RESULT S O N AVERAGE , TOTAL HYDROCARBO N ANALYZERAN D MAS S BALANC E MEASUREMENT S WER E I N GOO D AGREEMENT .

• "BASELINE " EMISSION S WER E COMPATIBL

E WIT H RECEN

T TESTIN G B Y EP A AN D OTHER

S (IE. , HIGHE

RTHA N AP-42) . INDIVIDUA L EMISSION REDUCTIO N TECHNIQUE S REDUCED EMISSION S B Y U P T O APPROXIMATEL Y 4 0 PERCENT . PILO T TESTIN G RESULT S VELOCIT Y NO T FOUN D T O HAVE SIGNIFICANT EFFECT ON EMISSIONS , OVER TH E VELOCIT Y RANG E TESTED . OPERATO RSPRAY TECHNIQU E FOUN D TO HAVE A N EFFECT . GE L COA T TESTIN G RESULT S LOW-STYREN E GE

L COA T FOUN D T O SIGNIFICANTL

Y REDUC E EMISSIONS , BU T SOME APPLICATIO N PROBLEM

S WER E EXPERIENCED . N O SIGNIFICAN T DIFFERENC E I N EMISSION S BETWEE N TH E THREE GU N TYPE S TESTE D (AIRLES S AIR-ASSIST/EXTERNA L MTX , HVLP/EXTERNA L MIX , HVLP/INTERNA L MIX) . RESI N TESTIN G RESULT S FLO W COATERAN D PRESSURE-FE D ROLLE

RSIGNIFICANTL

Y REDUC E EMISSION S COMPARE D T O SPRAYING . LO W STYRENE RESIN , STYRENE-SUPPRESSE D RESIN , AND STYRENE SUPPRESSE D RESI N WIT H ADDITIONAL WA X AL L REDUCE EMISSION S COMPARED T O REGULA RRESIN . THE BENZOY L PEROXIDE-CATALYZE D RESIN THA T WA S TESTE D WA S NO T FOUN D T O SIGNIFICANTL Y REDUCE EMISSION S COMPARE D T O THE MEKP CATALYZE D RESI N TESTED .



# 10P.1 2 

## 07/2 0 '9 5 14:0 9 ID-CC P RESEARC H FPX.816-391-602 6 PAG E 2

v • • , r 

# CC P POLYCO R / STYPO L SSBSSS

S

962-WA-19 6 LO W VOC/BUFFBACK * WHIT E GE L COA T

DESCRIPTION ; Thi s ge l coa ti s a hig h performance ^ ISO/NPG* * produc twhic h ha

s lo w volatil e organi c compoun d properties , an d BUFFBACK * characteristics . Thes e qualitie s ar e demonstrate d as :

» Reduce d monome r lossek into th e air » Superio r weatherin g propertie s (compare d t o conventiona l ge l coats )

• Bliste r resistanc e acceptabl e fo r marin e application s

• High-glos s BUFFBACKj * characteristics .

- Cure d fil m thicknes s car tb e 5 - 15 % more tha

n othe r ge l coat s • Les s odo r • Smoothe r sprayed fil m (les s orang e peel )

Whil e offerin g thes e benefits , 962-WA-19 6 has retained th e importan tconstructio n applicatio n qualitie s yo u hav e com e j to expec ti n Coo k Composite an d Polymer s ge l coats , suc h a s resistanc e t o porosity , tearing , and colo r separation ; sa g resistance ; consisten tliqui d properties ; goo d patchability ; an d iriore . Thes e al l ad

d up t o highe r qualit

y appeal i n FRP part s mad e fro m CCP' s 962-WA-196 . j 

### 962-WA-19 6 resist s weatherin g and.blisterin g becaus e iti s formulated to giv e hig h perfonnanc e agains twate r an d certai n chemicals . 962-WA-19 6 i s mad e wit h NEOPENTY L GLYCO L and wa s primarily develope d fo r sanitar y an d quaUt y marine applications ; howeve ritshoul d b e use d i n an y Fljl P applicatio n where high performanc e characteristic s ar e desired . 962-WA-19 6 utilize s thi s uniqu e glyco l t o provid e a ge l coa twhic h surpasse s previou s commercia l ge l coat s i n its . resistanc e t o blistering . I

tals o contain s Isophthali c aci d a s a co-componen trathe r tha n Orthophthali c acid . Th e Is o i s used , (rathe r tha n th e Ortho ) t

o complemen tth e NP G fo r bette r end ! us e properties . Thi s ge l coa tprovide s durable , reduce d maintenanc e products .

*NP G i s a registere d trademar k o f Eastman Koda

k Company .

Copyright 'I99 » b

y Cook Composite

s nn d Polymer

s Co . COO KCDMP0SPEE 3 AN D POLYMER S P.O . Bo s 1*1938 9 Kansa s City . M O 64141-638 9 (816)391-600 0 F«x : (616 ) 391*621 5P.13

_ 

### 07/2 0 '9 5 14=1 0 1D-CC P RESEARC H FAX:816-391-602 6 PAGE 3
062-WA-I9 6 Piiy e 2 o f 6 

### 050 4 

### CCP' s ISO/NP G ge l coat s hav e enable d customers t o mee tan

d surpas s al

l requirement

s o f the America n National Standar d fo r plasti c bat

h tubs , showe r receptors an d showe r stalls . ANSIZ124.1 , . 2 an

d .3 .

962-WA-19 6 require s onl y th e additio n o f th e proper amoun

to f th e appropriat

e Methyl Ethyl Keton e Peroxid e to cure . TYPICA L PROPERT Y fat77'f r Thes e value s may o r ma y no tb e a manufacturing contro l criteria ; the y ar e liste d fo r a referenc e guid e only . Particula r batche s wil l notconfor m exactl y t

o th e number s liste d becaus e storag e conditions , temperature changes , age , testin g equipment(typ e an d procedure ) ca n eac h hav e a significan teffec to n th e tes tresults. Ge l coats outsid e o f these , reading s can perfor m acceptably . Fina l suitability i s i n th e end us e performance . Viscosity , Brookfiel d RV F # 4 a t4 rp m 10,00 0 -13,00 0 cp s Thi x Inde x (2/20 ) 4.2-5. 0 Flashpoin t82° F Non-Volatil e Material 74.5 % Weight/Gallo n 11. 5 lbs . Ge l Tim e at7 7 ° F wit h 1.8 % THERMACURE * IT S 1 4 - 1 7 minute s Lay-u p Tim e 4 5 -9 0 minute s Sa g Resistanc e Goo d at2 0 mil s Hid e Complete a t1 0 mil s

VO C dat a a s compare d to 952-W-A40 :

962-WA--19 6 952-W-A4 0 Volatil e materia l B y weigh t3. 0 lbs . pe r gallo n 4. 0 lbs . pe r gallo n * B y volum e .4 0 pe r gallo n .5 2 pe r gallo n Rul e 1162 * 90.2 0 gram s pe r meter2 

### 132.6 0 grams pe r meter 2



### 'SCAQM D procedur e (Sout h Coas tAi r Qualit

y ManagementDistrict' ) Copyrigh t199 4 b y Coo k Composite

s an d Polymer s Co .P. M 

### 07/2 0 '9 5 14:1 0

- 

### ID:CC P RESEARC H

... . . . j .



## i FAX:816-391-602 6 PAGE 4

%2-WA-l % l';ig e 3 ol'f i 05/9 4 

### APPLICATION ; Althoug h 962-WA-19 6 i s formulated a s a lo w VO C product , i tshoul d b e note d tha thig h atomizatio n o f

a ge l coatmeans more | volatizatio n (more overspray. . mor e monome r an d solid s loss , mor e odor) . I ti s important, then , t

o striv e for goo d atomizatio n (goo d fa n pattern , n o finger s o r tails , unifor m particl e siz e o f

about1/16" ) whil e maintainin g lowes t pum p an d atomizin g pressure s as practical . 962-WA-19 6 i s formulate d fo r airles s a s wel l as conventional spra y application . Brushin g o r rollin g i s no trecommended . Refe r t p PB-1 6 (Applicatio n Guide ) an d PB- 3 (Equipmen t Selection ) Bulletin s fo r additiona l specifi c recommendations . W e recommen d a ge l coa tdeliver y r^t e o f n o more tha

n 2. 5 pound s pe r minute, wit h conventiona l ai r atomize d equipment, ; an d n o mor e dia n 4 pound s pe r minute wjt h airles s equipment . 

# i Batc h mixin g i s recommende d to achiev e th e bes tcatalys tmi x an d cure , becaus e eve n with di e equipmen tproperl y calibrated , potential problem s ca n occu r du e to poorl y atomize d catalyst ; surgin g problem s (ge l coa to rcatalyst) ; poo r ti p alignmen t(catalys tt o ge l coa tmix) ; contamination ; an d poo r applicatio n procedures , whic h wil l quickl y negat e al l benefit s o f calibration . Th e equipmen t(an d applicatio n procedures ) mus tb e monitore d o n a routin e basi s t o ensur e prope r applicatio n an d cur e o f the ge l coat . Inquire o f an d adher e t o al l equipmen tmanufacturers ' recommendations . Fo rbes toveral l en d performance properties , a we tfil m thicknes s o f 1 8 ± 2 mil s i s recommende d a s ideal . Film s les s than 1 2 mil s may no tcur e properly , ma y b e har d t o patch , hav e mor e print-through , an d are mor e susceptibl e to wate r blisters . Film s abov e 2 4 mil s ma y pre-release , tra p porosity , crac k and are mor e subjec tto weatherin g discoloration . If wate rblister s are o f

a greatconcent

i (boathulls) , 2 0 t

o 2 4 mil s woul d perform bette r tha n a thinne rfilm , bu

tsag , porosit

y an d ^racking resistanc e coul d suffer . I f weatherin g (yellowin g fro m sunlight , decks ) i s o f grea tconcern , the n thinne r film s (1 2 t o 1 6 mils ) woul d perfor

m better , butpatchability , print-throug h an d bliste r resistanc e coul d suffer . I n additio n t o di e lo w VO C chemistry o f 962-WA-19 6 , di e lowe r viscosit y an d Thi x Inde x resul ti n both les s overspray an d les s jmonomer loss , bu tdi e total fil m thicknes s shoul d b e spraye d i n multipl e passe s (a tleas t3 a

t1 8 mils , 4 a

t2 0 to 2 4 mils) . Mor e rapid fil m buil d coul d resul ti n som e sag . |

t 

### Prope r mol d maintenanc e i s importanjt . Althoug h 962-WA-19 6 ha s excellen tpatchin g properties , minimal repai r wor k i s alway s desirable . Sandin g an d compoundin g ca n haste n th e chalkin g and los s o f gloss o f al l ge l coats . Avoi d overspra y settlin g o n mol d surface s b y beginnin g spray pattern closes tt o th e vapor/ai r exhaus tan d progressin g t o di e opposite mol d end . Maintai n recommende d spra y distance s from th e mol d surface .

Copyright199 4 fyy Coo k Composite s Md Polymer s Co .P.1 5 

### 07/2 0 '9 5 14:1 1 ID=CC P RESEARC H FAX:816-391-602 6 PAG E 5

• • . i

, i .* ' ' I ; %2-WA.|>.)f i Paye 4 or" 6 

### | * 05' ^ CURE : 

### I ti s recommende d tha

tge l time b e checked i

n the customer' s plant , becaus e age , temperature , humidity , an d catalys twil l produc

e varied ge l times . Gel time/cur e dat a refers specificall y t o THERMACURE * JTS J catalyst . Recommende d catalys tto b e use d with thi s produc ti s JTS . THERMACURE * Regula r EX , Nora c MEKP-925 , Witc o HP-9 0 an d Luperso l DHD- 9 can als o b e used , bu tthe y may giv e slightl y shorte r ge l an d cur e times . Th e catalys tleve l shoul d no texcee d 3 % o r fal l belo w 1.2 % fo r proper cure . Recommende d rang e i s 1.2 % to 3.0% , wid i 1.8 % a t77° F bein g ideal . Normally , th e ge l coa tfilm i s ready fo rlaminatio n i n 4 5 to 8 0 minutes . This time elemen ti s dependento n di e material temperature , roo m temperature , humidity , ai r movement , an

d catalys tconcentration . Note : ISO/NP G film s hav e a tendenc y to air dr

y an d lay-u p time s ma

y b e deceiving. . I f

lay-u p tim e i s checke d b y th e finge r method , sligh tpressure an d rubbing shoul d b e used . „ i t 

### Specia l fast-cur e version s ar e availabl e bu

tmus tb e requested . Thes e products offe r lay-u p time s o f 3 0 minute s o r less , depending o n ge l times . Fas tcure product s hav e shone r stabilit

y an d shoul d no tb e inventorie d ove r 4 5 days . Thes e products (standar d o r fas tcure ) should no tb e use d whe n temperatur e condition s ar

e belo w 60°F , a s curin g ma y b e adversel y affected . 

## EXPOSUR E DATA ; Preliminary accelerate d (QUV-340 ) an d Soud i Florid a exposur e indicate s mat962-WA-19 6 ha s superio rglos s retentio n ove r standar d ge l coats . CAUTION : ISO/NP G Ge l Coats ar

e no tcompatibl e in th e liqui d stat e wid i 94 4 IS O Ge l Coat s o r IS O resins . Spra

y an d pumpin g equipmentmus tb e completel y clea n o f thes e ge l coat s befor e 962-WA-19 6 ca n b e used . D o no tovenni x ge l coats . Overmixig g break s dow n ge l coa tviscosity , increasin g tendencie s t o sag , and cause s styren e loss , whic h coul d contribut e t o porosity . Gel coat s shoul d b e mixe d onc e a da

y fo r 1 0 minutes . The ge l coa tshoul d b e mixin g to the sides in d botto m o f di e containe rwit h th e leas tamoun to f turbulence possible . Ai r bubblin g shoul d no tb e use d fo rmixing . I ti s no teffectiv e an d only serve s a s a potential for wate r o r oi l contamination . D o no tadd an y material' , othe r tha n a recommended Methyl Ethyl"Keton e Peroxide , t o dii s productwidiou tdi e advic e of a representative o f the Cook Composite s an d Polymer s Co . Unde rn o circumstance s should glyceri n be adde d t o mi s product .



## I Copyrigh t199 4 b y Coo k Composite

s an d Polymer s Co.P.1 6 

### 07/20*9 5 14:1 1 ID:CC P RESEARC H FAX:816-391-602 6 PAGE 6

%2-WA-l % i Pny c 5 ol * 6 05/9 4 

### STORAP. E UMTTATIONS : Uncaialyzc d 962-WA-19 6 has a usag e lif e o f three month s from dal e o f manufacture whe n store d a t7 3 ° F o r below , i n a closed , factor y sealed , opaqu e container , and outo f direc t sunlight . Fas tcur e ge l coat s are stabl e fo r 4 5 days . Th e usag e lif e i s cu ti n hal f

fo r ever y 20° F ove r7 3 °F . Tote s o f produc tda n hav e eve n shorte r usag e lif e - 66% o f

tha tfo r drums . j 

### SHIPPTNfl ; Shippin g i s normall y i n ope n head 5^-gallo n drums .

Copyrigh t199 4 jb y Coo k Composite

s an d Polymer s Co.P.1 7 

### 07/2 0 '9 5 14:1 1 ID:CC P RESEARC

H FAX:816-391-602 6 PAG E 7

962->WA-IV 6 vPage C ol " 6 i 05/9 4 

## i POLYESTE RSAFET V INFORMATIO N

(Revise d OVM ) .1 1 saL- i o f products manufacture d b y th e Coo k Composite s an d Polymer s Co . an

d describe d herein ar

e mad e solel y on conditio n tlio i ourcustomer s compl y wit h applicabl e coli h an d safel y laws , regulation s an d order s relatin g t o th e handlin g o f ourproduct

s i n th e workplace . Befor e using , read th e followin g informatio n an d bot h di e product •be i and Matcrio l Safel y Dat a Shee tpertainin g l o eae h product . Mos tpolyeste rproduct s contai n styrene . Styren e ca n caus e eye . ski n an d respiratory "ac l irritation . Avoi d -iniae twit h eyes , ski n on d clothing . Impermeabl e gloves , safety eyewea ran d protectiv e clothin g shoul d b c wor n durin g us e t o avoi d ski n an d ey e contact . Was h thoroughl y ite ruse . i • tyren e i s a solven tan d ma y b e harmful i f inhaled . Repor o hav e nssocialted repeated in d prolonge d occupationa l ovenxposur e t o solven u wit h permanentbrtl n an d nervou s •siem damage . Extende d exposur e t o styren e a tconcentration s abov e th e recommende d exposur e limit s may caus e centra l nervou s syste m depressio n causin g dizziness , hoadache s ' nause a an

d i f overexposur e i s continue d indefinitely , los s o f consciousness , live ran

d kidne y damage . o notbreath e o rInges tvapor , spra y mist s an d dujt i cause d b y applyin g sanding , grindin g an d sawin g polyeste rproducts . Weara n appropriat

e NIOSWMSH A approved , operl y fitted , respirato rdurin g applicatio n an d us e o f thes e products until vapors , mls u and dusts ar e exhausted , unles s ai rmonitorin g demonstrate s vapors , min tand dusts e belo w applicabl e exposur e limits . Follo w respirato rmanufacturer' s direction s for respirato rus* . KInternationa

l Agenc y Fo rResearc h o n Cance r(IARC ) ha s reclassified styren e a s Crou p 2 B "possibl y carcinogeni c t o humans* . Thi s ne w classificatio n I s no tbase d o n no w alt h da u relating u eithe rhuman s o ranimals , buto n a chang e i n th e (AR C classificatio n system . Th e Styren e Infonnatio n and Researc h Cente rdoe i no tagre e wit h th e falsificatio n an d ha s publishe d th e followin g statement . 'Recend y publishe d studie s tracin g 50.00 0 worker s expose d t o hig h occupationa l level s o f styren e ove ra perio d o f yea n showe d n o associatio n betwee n styren e an d cancer , n o inaeas e I n cance ramon g styren e wvke n (a s oppose d t o th e averag e amon g al l workers) , an d n o increas e i n -tnalit y relate d t o styrene .
rrene i s classifie d b y OSH A an d th e Departmen to f Transportatio n a s a flammable liquid . Flammabl e polyeste rproduct s shoul d b e kep i awa y from heat , sparks , an d flame , gluin g and othe relectrica l system s i n th e wor k plac e shoul d b e vapor-proo f an d protecte d (rem breakage . ipo n fro m styren e ma y caus e flash tire . Styren e vapor s ar e heavie rtha

n airan d may concentrate fatth e lowe rlevel s o f mold s and th e wor k area . General du n ai rdilutio n loca l exhaus tventilatio n shoul d b e provide d I n volum e an d paise m t o kee p vapo n wel l belo w th e lowe rexplosio n limi tan d al l ai rcontaminant s (vapor , mls u an d dusts ) belo w : curren tpermissibl e exposur e limit s m th e mixing , application , curing'en d repai rareas . -h e labe l o rMaterial Safet y Dat a Shee tindicate s lea d o rlea d chroma u I s present , d o no tus e o n ays , furnitur e o rsurfeee s thatmigh tb e chawe d b y children . Wash hand s •roughl y afterusin g n d before smokin g o rciting . Long-ter m overexposur e b y inhalatio n o ringestio n o f mist s an d dusts from products containin g lea d compound s and lea d -ornat e ca n caus e harmfu l effect s t o th e urinary , blood , reproductiv e end . nervou s syste m an d ma y create risk o f cancer . Us e a respirato ra s explaine d i n Paragrap h 4 o f th ' brmation Shee t

•n e polyeste rproducts ma y contai n additiona l hazardou s Ingredients . T o determin e th e hazardou s Ingredients present , thei rapplicabl e exposur e limit s and othe rsafet y jrmition , read th e Materia l Safet y Dat a Shee tfer eac h product(identifie d b y produc tnumber) before using . I f

unavailable , thes e ca n b e obtained , free o f charge , from you r o k representative o rfrom: Coo k Composite s an d Polymers Co. , P.O . Bo x 419389 , Kansa s City , M O 64)4]<6389 , (116 ) 391*4003 . 1ST AID : I n eaa e o f

ey e contact , fluah immediatel y -wit h plenty o f wat^ rfer atleas t1 5 minute s an d ge tmedica l attention ; for skin , was h thoroughl y wit h soa p and water - (fleeted b y inhalatio n o f

vapor s o rspra y mist , remove t o fresh air . I f swallowed , ga tmedica l attention . yeste rproducts hav e a tleas ttw o component s thatmus tb c mixe d befor e use . An y mixture o f component s wil l hav e hazard * o f al l components . Befor e openin g th e packages , i all warnin g labels . Observ e al l precautions .

• p polyeste rcontainer ! close d whe n no ti n use . I n cas e o f spillage , absor

b with iner tmateria l an d dispos e o f

in accordanc e wit h applicabl e regulations. Emptie d container s / retain hazardou s residue . D o no tcut , punctur e o rwel d o o o rnea rthes e containers . Follo w containe rlabe l warning s unti l container s ar e thoroughl y cleane d ordestroyed . FO RINDUSTRIA L US E AN D PROFESSIONA L APPUCATIO N ONLY . KEE POU T O F REAC H O F CHILDREN . DISCLAIMER ' AN D UMITATIO N o rUABIUT Y

(03/19 ) i h e bes to f ou rknowledge , th e informatio n containe d herei n i s accurate . TH E WARRANT Y DESCRIBE D HEREIN SHAL L B E I N LIEU O F AN Y OTHE RWARRANTO . •RES S O RIMPLIED . INCLUDIN G BU T NO T LIMITE D TO . AN Y IMPLIE D WARRANT Y O F MERCHANTABILIT Y O RFITNES S FO RA PARTICULA RPURPOS E •R E AR E N O WARRANTIE S THA T EXTEN D BEYON D TH E DESCRIPTIO N O N TH E FAC E HEREOF . Th e Buyer' s sol e an d exclusiv e remed y agains tSelle rshal l ** rth e replacementofth e produet s o rrefun d n f di e purchas e pric e i n tha

i even tdie ta defectiv e eoedltio o ofth e product s shoul d b a foun d t o exist . N O OTHE RREMED Y nUDINO , BU T NO T UMITE D TO . INCIDENTA L O RCONSEQUENTIA L DAMAGE S FO RLOS T PROFITS . LOS T SALES . INJUR Y T O PERSO N O RPROPERTY . AN Y OTHE RINCIDENTA L O RCONSEQUENTIA L LOSS ) SHAL L P E AVAILABL E T O TH E BUYER . Tha sol e purpos e ofthi s exclusiv e remed y shal l b e t o provid e e rwith replacemen tofth e product s o rrefund ofth e purchas e pric e o f th e products If

an y defec ti n material s o rworkmanshi p i s foun d t o exist . Thi s exclusiv e remed y shal l x deeme d t o hav e felled i u essentia l purpos e s o lon g a s Selle ri s willin g and abl e t o replac e th e defectiv e produet s o rreftmd th e purchas e price . Buye rmus tgiv e Selle r : e I n writin g o f

an y allege d defec tcovere d b y thi s warrant y (togethe rwith all identifyin g details , includin g th e Produc tCode(s) , descriptio n an

d date o f purchase ) withi n y (30 ) day s o f

th e discover y ol " suc h defect . Final determinatio n o f lh e suitability o f

lh e materia

l fo rth e us e contemplated , th e manne ro f us e an d wlt-rilic rth e suggest * infringe s nny p-ucm s i s th e sol e responsibility o f th e buyer . , R S 0J/9 J i 

### I i Copyrigh t199 4 b y Coo k Composite s and Polymer s Co . Ib07/19/9 5 17:5 2 ©20 2 26 0 017 8 EP A PP D 14)002 P.1 8

SCRIMP" : Cos t affectiv e material s combine d mor e effectivel y SCRIM P i s th e acrony m fo r th o Seeman n Composit e Resi n Infusio n Moldin g Process . Develope d a s th e resul t of yesr s o f researc h o n th e sho p floor an d i n th e lab , th e proces s ha s prove n t o b e e superio r metho d fo r producin g hig h qualit y composit e part s mad e fro m a wid e rang e o f fibe r an d resi n combinations . Al l commercia l fibers , cor e material s an d an y resi n I n th e rang e o f 5 0 cp s t o 100 0 cp s wil l "SCRIMP 1 ' wit h outstandin g results . T o cove r th e wid e rang e o f availabl e resi n systems , th e process ca n b e ru n a t roo m o r elevate d temperatures . Simila r i n concep

t t o RTM , bu t requirin g onl y on e too l sid e sn d a simpl e vacuu m bag , * SCRIM P routinel y produce s larg e (200 0 sq . ft. ) parts , usin g bot h singl e aki n en d core d eonatruetlon , sn d highl y comple x 3- D trusse d port s weighin g u p t o 300 0 lis . I n a H cases , th » resultin g composit e meterle l propertie s directl y compar e t o propertie s the t tied ; onl y beetr - ochlevabl e I n highl y controlled , expensiv e autoclav e processes . ' . . SCRIMP : Ultimat e Composit e Qualit y Incontras tt o mostcomposit

e processes , the SCRIM

P proces s i s inherentl

y repeatable . Once equilibriu m resin content is achieved (55 % t o 60 % fibe rvolume , depending o n fabri

c architecture

) the proces s stops . Aerospace grad e qualit y i s ensure d b y firs teliminating al

l ai r void s befor e th e resin i s infused , enabling th e fabri c pre-for m t o ac ta s a neffective breathe rlayer . A s th e resin i s infused , i t travels i n controlled waves tha twor k t o completel y wetoutth

ereinforcin

g fiber s andeliminat

e an y voids tha

tcoul d b e create d b y theVOC' s emitte

d by th e resin durin g the cur e cycle . The proces s ha s been use d t

o infus e laminate s u p t o 6" thic k wit h th e sam e hig h qualit y result s a s a simpl e 1/8 " laminate. The Navy ha

s extensivel y tested SCRIM P laminates an

dha s conclude d tha

tth e void contentcannotb e detected wit h standar d - AST M methods . Wit

h orwithoutagel coat, composite s produced usin g SCRIM P exhibi tpinhol e free surfaces .

Moi d — — k>S»5 x 

# m\\ \ ^ ^ ^ Y\\ \ 

# • 1 • 1 ^ W m 

# LMs ^ 

# Hgj g

WWXw^ ^^^^^^^^^^^^^^^^^ 1 Ba g 

# a

•% 

# 1 \ , 

## • a •i



### •i

* * % 

# • 4

• Jul ^••E-J-Sw l



### . : 

### .' «

\

. . .\"* v 

### RESI N



# nP.1 9

07/19/9 5 17:5 3 ©20 2 26 0 017 8 EP A PP D Iffl 00 3

SCRIMP : Reduc e Labo r an d Sav e Material s SCRIM P allows an

y license d fabricato

rt o perfectl y produc e the part s the y hav e designed . Controlle

d bagging o f

dr y pre fomis , coupled wit

h repeatable resin . infusio n results i n hig h qualit y precisio n parts . Compare

d wit h prepreg, SCRIM

P eliminate s th e following : th

e nee d for refriaenite d storage , th

e need fo rtime consumin g debulking , expensive breathers , bleeder s an d porou s releases, an

d th e scra p causing phenomeno

n of bridg,ing .

Mediu m SCRIMP , muc h lik e RTM, offer

s th e benefi tof pre-foimin

g part s using dr y fabric s an d cores . However, unlik

e RTM , SCRIM P doe s no trequir e a two side d hig

h pressur e mold ora press . Part

s molde d using th e SCRIM P technology only requir

e a on e sided vacuu

m tightsurface. Standar

d FRP , mas s cas to r meta

l toolin g al

l function well .

. A tconstan tstress levels , superio

r mechanica

l propertie

s mea n les s materia

l cu tb e used t

o achiev e the same results . Perfec tsurfac e qualit y eliminate s th

e need fo rpinhol e filleri

n painte d applications , an d wher e ge l coat s ar e used , SCRIM

P eliminates "eg

g shells " tha

tcaus e expensive rework. Drive n solel y by vacuu m pressur e an d utilizin g th

e patente d SCRIM P resin distribution system , resin wil l we tou t laminates completely . Wit h bot h singl e skin orcore d construction , th

e entir e laminat e i s we ti n on e infusion step , eliminatin g weake rsecondar

y bonds an

d th e time an

d mes s tha taccompan

y them . Ver

y thic k fabrics , knit

s an d mat s (up t o 20 0 o z pe

rsq . yd. ) and cores ' ca

n b e use d t

o greatl y spee d th e lay-u p process . A s a result, a SCRIM P factor y look s mor

e lik e a n upholster

y o r carpeting operation tha

n a classi c FR

P o r composite shop . Cleanin g solvents an d th e associate d too l cleanin g tim e ar e als o completel y eliminated . 

### I



# mm

Vacuu m Pum p

^P.2 0

07/19/9 5 17:5 3 ©20 2 26 0 017 8 EP A PP D l£]UU 4

SCRIMP" : Application s i SCRIM Pha s finall y unlocke d th e ful l potentia l o f

composit e material s b y allowin g fo rth e manufactur e o f ver y larg e part s i n a hig h quality , environmentall y soun d fashio n withou tlarg e capita l investments . Today , manufacturer s license d t o us e th e SCRIM PSyste m ar e producin g part s fo rapplication s rangin g fro m sailboat s t o bridg e structures . SCRIM P laminate s ar

e use d t o sto p bullet s an d fen d ships . Train s buil tusin g "SCRIMPed " laminate s are lighter , bette rinsulate d an d mor e fatigu e an d corrosio n resistanttha n simila rstrucmre s buil tfrom conventional materials . Eve n structure s tha trequire th

e ultimat e material propertie s fo rdefens e purpose s utiliz e SCRIM Pbecaus e it perform s bette rtha n mor e expensiv e alternatives .

Offshor e Rei l

Trsnsportetlo n Marin e Infrastructur e 

# i f .P.2 1

07/19/9 5 17:5 4 ©20 2 26 0 017 8 EP A PP D Iff l 00 5

SCRIMP" : Perforin s Laborator y testin g has confirmed tha t SCRIM P produces composite s wit h th e qualit y an d performanc

e o f substantiall

y mor e expensiv e materials an

d manufacturin

g processes . Th e attache

d dat a i s summarized fro

m a comprehensive testin g progra

m complete d b y the Nava l Surfac e Warfar e Centert o evaluat e th e us e o f SCRIMP fo rprimar

y hull structur

e o f futur e combatan

tvessels . A s a resulto f

th e study, the Navy, conclude d tha tSCRIM P used wit h cost-effectiv e fibe

ran d resin combinations gave composit e performanc

e equivalento rsuperiort o more expensiv e materials processe d usin g costl y an d siz e limitin g aerospace processes . SCRIMP : Environmentall y •Responsibl e SCRIM P i s a completel y close d system tha ttrap s VOC' s instead o f

jus tsendin g the m u p th e stack . Reduce d nee d fo r solvent s couple d wit

h th e close d SCRIM

P SYSTE M wil l reduce styrene level s t o wel l belo w th e mos tstringen

tcurren tor proposed standards . Worke rexposur e t o wetresins durin

g the lay-u p proces s i s completel y eliminated . Rea l worl d sho p dat

a take n fro m SCRIM

P license d facilitie s ha

s shown tha

tthe combinatio n o f

SCRIM P an d environmentally responsible solvents ca n reduce VO C emission s b y a s muc h as 90 % ove rcorren

tope n moldin g practices . SCRIM P wil l fundamentall

y change your business . I

f yo u ar e a custome ro f composite material . SCRIM P wil l ensur

e yo u the bes tperformin

g produc ta tth e lowes tpossibl e price . I

f yo u ar e a fabricatoro f

composite material . SCRIM P wil l minimiz e o r eliminate you r environmenta

l problems and ope n ne

w door s t o large , repeatable, composite products . 

### • • m n m H
a s a o a 1 0 

### • CMIt-KSSN N | ^ H MAMUVU P A Compariso n of Composit e Propertie s

Fro m Lo wCost fabricatio n Method s

MXU M *fl-KM N '

• • towtstasYMwai a •r+.-gtm

— Tir-^^^H—

-tR-mtvo u "BBBJBB J (CAM P

Scrim p elose d proces s resin Infusio n o f e 6 8 foo tsailboa

thul l (Infusio n time : 3 5 minute* ) 

# <v>P.2 2

07/19/9 5 17:5 5 ©20 2 26 0 017 8 EP A PP D IfflOOt i 

# Resin-transfe r molding : A cost-effectiv e alternativ e

B y E d Galli , Easter n edito r 

## Thi s GRP process occupies the large gap in part cost and rate of output between open molding and compression molding. It's a cost-effective alternative forintermediate-volume production runs. Th e par tdesigner wh o makes glass * t/2~P- reinforced polyeste r th e material , o f choic e mus

tthe n make a choic e o

f pro duction methods . Eithe

r on e o f th e open-moldin g technique s (sprayu p and layup) o r els e compression moldin g i s usuall y selected . Ope n moldin

g carrie s a hig h per-piec e cost ; compressio n moldin g ca n reduc e tha

tcost , bu tonl y wit h volume s suffiden

tt o sprea

d ou t th e hig h cos to f th e matched-meta

l dies . Ther e i s another GR

P proces s tha

t ha s bee n quietl

y workin g the spaciou s ga p betwee n thes e two methods fo r som e year s bu tha s only recentl

y see n a surg e in interest . It' s resin-transfe r moldin g (RTM), sometime s called resin injection, an d i

toffer s man y advantages ^ t o th e compan

y ma tseek s productio

n o f roughl y 10 0 to 10.00 0 parte ! " Designer s wil l fin d th e proces s at tractive. RTM-molde

d part s have tw o finishe d sides , rathe rtha n th e one-Side d 

### produc to f ope n moldinq . Clas s A gel coate d finishes ar

e availabl e rightouto

f th e mold . Various type s o f glas s rein forcementar

e used , wit

h typ e and amoun tclosely tailore

d to th e part' s physical requirements . I n addition , cores , stif f eners an d other material

s can b e encapsulated i

n th e par twit h muc h greate r eas e tha n i n ope n moldin

g (thi s can' tb e don e a

tal l i n compression molding) . RT M is a low-pressur

e moldin g pro cess : th e us e o f lightweight

, otass-reinforce d polueste r o r epoxy •»n u 

### '*

* »lmr>«t t universal . Tha

tmeans , o

f course , tha

t lead tim

e fo r th e tooling i s shor

tand cos t i s moderate , a s compared t o meta l 'molds . Far

tdesign I s affecte d b y th e specifi c capabilitie

s an d limitation

s o f ttie process . Mos

timportant

, th e cos t an d qualirjTo

f th e part s depen d o n th e quafit y o f th e tooling . N o othertech niqu e i n plastic s moldin g exhibit s suc h dependence , excep tperhaps th e RI M process.. . an d RT

M migh tb e though

t o f a s RI M a ta leisurel y pace . RT M wil l entertai n th e moldin

g o f part s throughou

tth e GR P spectrum. RT M housings an

d shroud s have foun

d appftcatio n i n electronics , recreationa

l .vehicle s and consume r products. . Marine us e o

f th e proces s I

s widespread RT M part s ar e see n I n corrosion-resUtan tequipment, container

s o f al l sorts , seating an

d furniture

, protectiv e gea r an d sportin g goods . Th e curren

tRTMpar troste rals o indude s sanitar

y ware , poo l sides , caskets , cherry-picke rbuckets an d sola r collectors . On e o f th e mostelegant—as wel

l as growing—user

s o f RT M part s i s th e cus tom-buil tExcalibu rautomobile (Figur

e 1) . Presiden

tDavi d Steven s say s tha

t th e automotive company wa s attracte d especiall y t o th e toleranc

e control an

d two-sided smoothnes s o

f th e process . Majo r interio r part s o f th e Excalibu

rnow i n RT M indud e seatbacks , duc twork , th e consol e over the transmissio n runnel an d th e dashboard . Th e dashboard , wit h 90-de g return

s and othercomplex ities , wa s originall

y lai d up , requirin

g tha tthicknes s variations b e ground dow n i n orde r fo r instrumentatio

n to b e fixed i n place ; RT

M ha s eliminate

d tha t problem . Steven s is no w evaluatin g the benefit s o f replacin g exterior layu

p o f bodywork, a

n are a where RT

M can provid e sharpe r corners , whic

h hi s de signer s prefer. The doors ar

e th e first target , wit h th e interna

l structur e a s wel l

Figur e 1. Excaliburautomobtle Interiorwtth RTM dashboard

and otherparts. (Photo: Excalibur) 

# 1 MARCH / APRI L 198 2 PLASTIC S DESIG N FORU M 4 7

### .07/19/9 5 17:5 6 ©20 2 26 0 017 8 P.2 3 EP A PP D lg|UU 7

a s th e oute rshel l a candidat e fo rcon versio n t o one-piec e RT

M production . PROCES S CONSIDERATION S RT M i s carrie d ou ti n a close d mol d at ambien ttemperature ^ A geicoat , i f re quired , i s first*applie d t o on e o rbot h mol d halves . Cjias s reinforcemen tan d '^mmtmt-mt**tm^^mmtfmm an y othe rcomponent s ar e the n Lai d i n th e botto m half

. Th e mol d i s close d an d damped ; catalyze d resi n i s injecte d throug h a por tgeometricall y centere d i n th e to p mol d half

. (Additional port s ma y b e use d fo rlarge , comple x parts. ) Moldin g pressure s typicall y rang e betwee n 4 0 an d 8 0 psi . Thus , on e may . en)o y th e lowe rcost , lighte rweigh tan d faste rlea d tim e o f

"soft " tooling , fabri cate d fro m reinforce d polyeste rb r epoxy , usuall y wit h gelcoate d cavity surfaces . Rgur e 2 show s th e mol d "halve s an d th e RTM partmad e fro m i t

— a 42-lnc h housin g fo ra riding law n mower . Not e th e geicoa to n th e mol d halve s an d part . Th e auaht v o f

RT M tootin g deter mine s th e quality o f

th e par tan d ha s a maio r effec to n th e moldin g cycle . Moldmaker s differo n Jus tho w hefty

— an d thu s ho w expensiv e an d durable — th e toolin g shoul d be . A majo rconcer n fo r th e designe r i s contro l o f wal l thick ness . Kttie wall s of

th e cavitie s defie d unde rth e pressur e o f

th e resi n bein g pumpe d in , thicknes s tolerances will b e exceede d an d resi n wasted . Tha tprob- . le m ca n b e forestalle d b y well-rein force d tooling , o ra tleas ttoolin g sub stantial enoug h tha titca n b e clampe d i n a press . Us e o f

a press , usuall y th e pres sure-po d (pneumatic ) type , i s no twide spread ; bu tth e adde d cos tof th e pres s als o bring s bette rtoleranc e contro l an d faste rcycle s throug h semiautomation . (continued ) Figur e 2. Riding. iouinmoioe

r finis/ted por t(at left) and moi d halite s (below) .

Geicoa tI s first ap plied t o th e botto m moid half.

Both mold

halves ar e buil twtt h a gel coat/o r goo d part

surface finish. (Photos: Fiber Glass Toolin

g & Specialties) 

## Tabl e I . Comparativ e productio n cost s Productio n metho d Ope n mol d Cold mold RT M mold Matchedmeta l mol d P.rt./ mn bt , MnbUCnr-Vl / Tor tmoldsneede d 8-h r day da

y production ly r Sy r 4 4 7 3 2 16 0 . 8 8

1 2 1 2 1 1 Not* : Bawt

f o n productio

n o/30pon(/day . 6000paru/y«ar Source: Molded

FUxrGhu Cos. 1 5 1 0 1 0 1 Cost/mol d S 2.00 0 9,00 0 10,00 0 60.00 0 Tota

l mol d cost ly r5y r $16,00 0 S 30.00 0 18,00 0 90,00 0 20,00 0 100.00 0 60.00 0 60.00 0 Piec e price ,

cxdudlngtoo l amortizatio n $16.0 0 11.2 0 12.0 0 8.0 0 Tota

l piec e price ly r Sy r $186 7 $17.0 0 14.2 0 14.2 0 15.3 3 15.3 3 18.0 0 10.0 0

< • Di»«TtrsDESIGNfOPJJ M MARCH/APWLIW 2 

# 1-V Circl e 3 1 o n Reede r Service Car d

### J37/19/9 5 17:5 7 ©20 2 26 0 017 8 EP A PP D P.2 4 l£)00 8

Cycl e time varie s widely . Seat s fo r fast-foo d restaurant s ar e bein g molde d i n a 6-minut e cyde . Large , comple x parts ma y requir e overnigh tcure . Th e factor s tha taffec tcycl e lengt h ar e many : th e degre e o f

automatio n i n han dlin g th e molds , time t o plac e th e rein forcement , typ e o f

damping,.reactivit y o f resi n an d pumpin g speed . Th e labo rinvolve d i n pladn g (an d sometime s tailoring ) th e reinforcemen t ca n b c reduce d b y us e p f a preform ; highe rvolum e i s neede d t o offse tth e cos to f th e equipmen tneede d t o spra y u p th e prefor m o n a scree n patter n an d ove n cur e tt . I

f a geicoa tI

s require d o n on e side , tha tmol d half ca n b e dupli cate d t o spee d u p th e productio n line - adde d toolin g cos tfo ra shorte rcycle . A simpl e exampl e o f

ho w part-pro ductio n rates ca n var y i s offere d b y Joh n Plcssinger , presiden to f Desig n Evolutio n 4 o f

Lebanon , Ohio , a com pan y specializin g i n RTM design , tool in g an d low-volum e production . A too l fo ra 10-lnch-diameter , 6-inch-dee p partoriginall y manage d t o produc e 1 5 parts pe r8-hou r shift . Reinforcin g th e < too l fo rpres s mountin g double d th e rate ; a n additiona l 3 0 percen tincreas e wa s availabl e b y mountin g th e mal e too l i n th e pres s an d shuttlin g tw o femal e tool s (containin g th e reinforcement) I n an d out . (Eve n shorte rcycle s woul d hav e bee n availabl e ha d th e too l bee n builtwith temperatur e control. ) Th e exampl e i s presente d t o con vinc e designer s tha ti

tte Imperativ e t o kno w th e capabilitie s o f th e toolmake r an d th e method s o f

th e molder , be caus e o f th e impac to n par tquality an d cost ; th e dat a In Tabl e I ar e displayedi n th e sam e spirit . Th e cos tcompariso n wa s develope d b y Molde d Fibe rGlas s Cos. , Ashtabula , Ohio ; th e dat a de scrib e th e relativ e cost s o f fou rGR P method s an d ar e no tbase d o n a specific part . Th e one - an d five-yea rtota l par t costs , Includin g mol d amortization , sho w ho w th e relationshi p betwee n RT M an d matched-metal-di e moldin g (SMC ) change s a s th e lon g lif e o f th e stee l tooling take s effect . Whe n per-par t cost s ar e plotte d agains tvolum e fo rth e tw o methods , th e RT

M curv e crosse s th e SM C curv e at840 0 parts . Com pressio n moldin g i s usuall y considere d ' fo rapplication s i n th e neighborhoo d o f 

## Functional core s Core s I n RT M part s d o serve a s weight inducer s an d softeners ; bu

tVikin g Yach t 'Do. , Ne w Gretna , N . J „ build

s a rada r• «e h (se e photo ) tha

tdoe s more .

. Th e lightweigh

trtt-udtnenuat :wppcrtal50-bradarunitat4 G ' •dec-deration

. Mountin g stud s and . •.-•.'•

• condufoforwMng-mustbelntegMtotit t pert . Th e arc h i s molde d I n fourptocesf.i . tw o o f whic h ar e th e en d piece s -.-«

- -Y{ containin g th e mountin

g st^ds.-The:-W'- - cores o f th e two larg

e Identica l piece s tha

t for m th e arc h ar e molded bo m rigid "•••..

• urethan e foa m (114b/cu-f

tdensity ) - aroun d three aluminu

m condutt . Th e cove , wit

h glas s ma to n botii •>"*;V'.*7l3£ ?

rides. I s place d t n theRmn»Jdilfli| j otder t o producettds partbyliuin d la w wit h tw o fintehedsurfacss, KwoiiUp«( f been necessar

y to sandwic

h two { - * aroun d th e con , entailin

g i handfaisl-ilngdhhiii. Y.'-. - aohc«W«Mur«'tn'ser^".j'|| ^ •'"*••*< *

yach tradararc

h {topmos tpart , rooWun«rK»lpWureaV;aVoutlnfl show s cros s (Photo : VflrlngYaehtCo. ) •>•-•• * 

## Heavy-dut

y us e Trf e tfaee-plecefohouriit g for coolin g a n alternato

r o n 85-to n bucks was adapte d ho m tiie origina

l meta l design a t one-fourt h ofth e weight

. The molder, Sherwoo d Pattem , Hartviilc , Ohio , selecte d RT

M becaus e I

toffere d bette r dimensiona

l contro l tha n layup—th

e (a n operates withi

n V s Inc h o f th e housing. ' The RT M part s ar e mad e i n les s tha n hal f th e cyd e time require

d to la y u p th e prototypes . The housin

g consist s o f thre e piece s bolted together ; bo

h spacer s an d other hardwar e ar e Inserte d afte rmolding . Th e V«-lnch-thtc

k part s hav e Vt-inc h mountin g flanges , l«/a inche

s wide . Producin g thi s trick y change I n thickness is notabl e because the part

s ar e molde d to size ; the

y aren' ttrimmed. Th

e housing is 4 2 Inche s i n diameter

. Becaus e of th e sever e expecte d I n use , tn e assembled until ' ..•.._ T r | , 1 . wer e subjecte d to vfarptor

y testing . Mocl| ' tha n a hal f bUBo n cyde s faile

d t o destroy

1 ? ; thetategrttyofthehouslngs. - ' '*'•:•$? ;

.Fa n housing. (Photo: Liquid Contro l Corp. ) 

# 2 3

### 07/19/9 5 17:5 8 ®20 2 26 0 017 8 EP A PP D P.2 5 ifljuu a

10,00 0 parts , assumin g tha ttime i s availabl e fo rfabricatio n o f th e tooling . DESIG N CONSIDERATION S Th e followin g section s discus s material an d part-desig n consideration s i n gen era l terms . Spedfi c application s de scribe d i n th e accompanyin g boxe s sug ges tho w th e versatiUty'o f RT M permit s som e bendin g o f

th e rules . Th e uppe rpart-siz e limi ti s no t known : part s i n exces s ntKK l lb hav e bee n molded . Muc h large rparts hav e bee n produce d overseas—complet e boa tbulls , mor e tha n 3 0 ftlong . Materials . Mos tRT

M parts ar e molded wit h polyeste rresin ; epox y i s occasion ali y used . Specia l grade s fo rchemical , electrical , flame an d weatherin g re - ' quirement s ca n b e matche d to.perfor manc e criteria . Low-cos tfillers (da y an d caldu m carbonate ) ma y b e adde d t o th e resi n t o reduc e cost , improv e surfac e quality . minimiz e shrinkage an d crackin g i n resin-rich areas , an d inaeas e stiffening . Alumin a trihydrate als o add s flame re tardance . Low-profil e additives , a s .use d i n SMC , at e no teffectiv e becaus e the y requir e th e highe rprocessin g tem perature s o f

compressio n molding ; RT M version s ar e bein g sought . Par tweigh tma y b e reduce d b y foaming . Th e expansio n moldin g com pound s (EMC ) offere d b y Whitne y & Co. . Stratham , N.H. , ar e bein g use d in * severa l proprietary RT

M applications , wher e the y reduc e weigh tb y a s muc h a s 5 0 percent . A smal l reductio n i n modulu s i s als o experienced . I tca n b e nullifie d b y openin g th e mol d slightly t o inaeas e wal l thickness , thereb y allow in g additiona l foamin g t o tak e place ; n o additiona l resi n i s needed . Th e EM C additive s mus tb e use d with specia l resi n systems , a s thei rchemistr y i s complex . Uniroyal' s Celoge n XP-100 , intro duce d las tyear" fo runsaturate d polyes ters , i s suitabl e fo rRTM . Glas s reinforcemen ti s availabl e i n severa l forms . Continuous-stran d mat i s th e mos tpopula rmetho d of rein forcement , fo rformabilit y an d othe r reasons . Wove n rovin g an d glas s fabri c provid e th e highes tglas s conten tfo r adde d strength bu tare mor e difficul tt o form t o th e dimension s of th e par tan d mor e likely t o caus e strike-through o n 

# Tubs , etc . Tubs(conventionalandhot),showe r enclosures , whirlpools.. . i n short , sanitar y war e i s a n excellen tRT M appficatton

. The glossy gelroate

d auface come s rightou

to f th e mold . Unit

s ate lighte rfo r th e haule ran d wanne rfo r th e redlner, compare

d to meta L Bob Rldde

D o f Molde d Fibe r Glass Cos. , Ashtabula

, Ohio , put s the retai l cos tof RT M tubs a s lowe r tha n cast-iro n o r spcayup-backe

d aaytcmode b bu

thighe r tha n steal ; th e economy - minde

d remodeOe

r i s th e market . MFGbmoUtaga32-fc(Wmn*-ed ) bathtu b that , a s th e photo shows , Incorporate

s a sor to f S-shape d transvers e crass section ; additionally, the e side s have upwar

d flanges fo

r wal l mounting . Wa

B thickness Is0.l25t o 0.15 0 inch ; a prefor

m i tuse d fo

r rdnforesment

, ataajas s loadin

g o f 22t o 2 6 percent

. Th e resi n I s fiBed wit h S O percen tdut-nln a trihydrat e far flame retardanca.MFGaixpedstomaksa s . man

y a s 10,00 0 tubs , whic

h I s withi n SM C economics , bu

tth e compan

y selecte d RT

M fo r th e bette rgekoa t finish.

Bathtub wit

h gloss y gekoat

finish. (Photo : Molde

d FiberGianCos J 

# 100-pounder

s Desig n Evolutio n 4 , Lebanon, Ohio , mold s 1 2 sets o f three differen

tRT M part s tha tca n b e assemble

d t o ferm a 40 - ft-dlamete r solar-collecto

rdish . (Imagin

e tha tth e dis h I s cu tint o 1 2 wedges , and tha teach wedge I

s cu tconcentricall

y Int o the e pieces. ) The larges

tsegment s of the par tweig h 10 0 fc eac

h (se e photo) . Eac h section hasalV*tnc h end-grai n bals a core , wtthaglast-reinforced pdyeste r shi

m abou t0.08 0 Inc h thic k o n each side* . Th e part s ar e molded l n a pneumati

c press , wit h the resi n injecte d throug h a single port . Circumferentia

l tolerance s ar e held t o withi n 0.01 0 Inch

. Section of

40-ft-dk.mettrsolar-collector dish. (Photo: Desig

n Evolution 4)

th e surface . Choppe d strand ma ti s use d mainly fo rfla

tsurface s becaus e of its lo w formability . Surfac e veil s ca n b e adde d t o improv e surface finis h an d wea rresistance . Fo r mor e comple x parts , placemen t of th e reinforcemen ti s mor e labor-in tensive . Corner s ca n entai l intricat e cut tin g an d tuckin g maneuvers , sinc e over lap s caus e strike-through . Preforms offe r a solutio n fo r higher-volum e runs . Cor e material s suc h a s end-cu t balsa , matan d syntacti c foa m ca n b e place d I n th e mol d t o cu tcosts , stiffe n th e partan d reduc e resin-laye rthick nes s (an d thu s cur e time) . Ri b former s ah d othe rstructura

l Insert s ca n als o b e strategicall y locate d i n th e mold . Meta l inserts , preferabl y th e flanged type , ar e sometime s molde d in . • (continued).

r-rr^crXmCtviim MARCH/APRI L 198 2 

# Z4

# r 07/19/9 5 17:5 9 ©20 2 26 0 017 8 EP A PP D P.2 6 Ifl ] UI U

Gelcoat s provid e a smooth , gloss y colore d surfac e an d ca n b e formulate d fo r corrosio n resistanc e o rothe rpur poses . Resi n pigmentatio n wil l ofte n suffice forparts with les s stringen tcos metic*heeds , and , of

course , th e part

s ar e easil y painted . Par tdesign . A basi c desig n guid e fo r RT M parts TTyiw n i n Tdbt e U. Th e guid e provide s som e clea raistincoon s amon g severa l GR P processe s in term s o f design . Ther e ar e numerica l differ ence s i n matter s lik e draf tan d als o som e substantial difference s i n wha tca n an d canno tb e done—molded-i n holes , fo r instance . Carefu l consultatio n with molde r an d toolmake rca n lea d t o relaxatio n o f th e groun d mles . Fo rinstance , ribs an d bosse s ar e accounte d difficultt o em bod y i n RTM parts . The y ar e not , a s som e o f th e accompanyin g illustration s show , impossible . Thes e an d othe r geometrica l consideration s (suc h a s 

## Par tconsolidatio n Th e sea tback s fo r th e Excalibu

r wer e originall y lai d u p I n thre e piece s and assemble d wit h adhesive . Tha

t techniqu e encountered toleranc

e problems , creakin

g an d possibl e adhesion failur

e I n th e structure

, plus extensive labor

. Th e photo show s th e one-piec e RT

M conversion . Th e tooling, bul k b y RT M Corp. , Hardand

, Wis. , use s tw o tre e core s tha

thoo k Int o th e botto m mol d to fon n th e sc<ket

s fo nwunttn

g the sea tbac k o n tw o steel posts ; th e \ core s demol d wit

h th e part . Th e par tIs ' molde d to dimensions - n o trimmin g at th e partin g fine 1 s required . The thickness o

f th e sea tbac k tapers ; it' s thickes tatth e base . Thi

s produce s a Excalibu

rsea l backs . (Photo:R7MCorp. J somewha tflexibl e structur e tha t dampen s toa d Impacts. abruptchange s in thickness ) ar e con cerne d wit

h th e abilit

y o f th e glas s rein forcemen tt o resis tan y movemen t(or "wash, " i n th e parlance ) a s th e resi n i s pumpe d int o th e mold . Us e o f core s I n ribs an d bosses , togethe r wit h glass , wU

T 

## Tabl e U . Comparativ e desig n guide s for resin-transfer , ope n an d compressio n moldin g Desig n paramete r Minimu m Insid e radius . Inche

s Molded-l n hole s In-fnol d trimmin g Cor e pul l and slide s Undercut s

. Minimu m recommended draft , de g Minimu m practica

l thickness , inches Maximu m practica l thickness , inches Nonna l thickness variation, inche s Maximu m thickness buildup , heav y buildup , rati

o Corrugate d sections Meta l insert s Bosse s Rib s Ha tsection Raise d number s Finishe d surface s Source : OlMiu-Ccwnfn g Flbcrgt a Resin-transfer moldin g '/ • N o N o Difficul t Difficul t 2to 3 0.08 0 050 0 ±0.01 0 2: 1 Ye s Ye s Difficul t Difficul t Ye s Ye s Tw o Open

Sprayu p >/ « Larg e N o Difficul t Difficul t 0 0.06 0 . N o limi t ±0.02 0 A s require d Yes " Ye s Ye s N o Ye s Ye s On e moldin

g Hand layup 

## V « Larg e N o Difficul t Difficul t 0 0.06 0 N o limi t ±0.02 0 A s require d Ye s Ye s Ye s N o Ye s Yes On e Compressio n moldin g

Mat/Prefcn n »/ • Ye s Ye s N o No Shee tmolding compoun d

Via Ye s Ye s Ye s Ye s V s t o 6-Inc

h depth , It o 3 : abov e 6-Inc h depth , 3 o

ras require

d 0.03 0 0.50 0 ±0.00 8 2: 1 Ye s No trecommende

d Difficul t Difficul t Difficul t Ye s Tw o 0.05 0

1 ±0.00 5 A s require d Ye s Ye s Ye s Ye s N o Ye s Tw o



## ^ £

### .07/19/9 5 18:0 0 ©20 2 26 0 017 8 EP A PP D P.2 7 

### 1011



## Small-quantit

y prototypin g RT M Corp. . Hartland

, Wis. , has molde

d RT M prototype

s i n ver y lo w quantities

— a s fe w as five—fo

r part s destined fo

r SMC , BM C structura

l foa m an d eve n Injectio n molding . (WaU

s a s thi n a s Vi s inc h hav e bee n produced. ) th e compan y point s outtha teve n suc h lo w quantitie s ar e economica

l in term s o f the ' fas tstar tth e custome

rcan obtai

n fo r evaluatin g ne w designs . Th e thre e part s show n here , component

s fo r a slide projector, ar

c a goo d example . Th e prototypes ca n b e use d to prov

e ou tcomplex mechanica

l and optica l dimensiona

l relationships . Not e tha tth e larg e bas e uni trequire s a sk k cor e (fo

r th e to p o f th e par ta s see n hue) . A three-piec e mol d was use d t o produc e it . Productio

n part s ar e injectio n an d structural-foa

m molded .

Slide-projecto

rprototyp e parts . (Photo : RT M Corp. )



## Buildin g i n ribs Th e par tshown here—botto

m view , untrimmed—i

s on e o f five identica

l wedge-shaped piece s tha

tassemble to for m th e base , o r receptor , for a ftvehea d industria

l showerwit

h centra l plumbing . Rib s strengthe

n th e part . Thei r dimensions : 1V

5 Inche s deep , th e widt

h taperin g fro m l*/ « Inche s a tth e top t o a * weD-radiuse

d V«inch . Th e part

s ar e produce d a ta rat e o f 800 0 peryear . Core s hold th e glas s reinforcemen t I n place ; th e cores ar

e 1-inch-wid

e strip s - o f plywood . Sligh

tsin k mark s d o for m o n th e fla topposit e surface . Th e molder

/ toolmaker , FfcerGlassToollng & Specialties , Sheboyga

n Falls , Wis. , advises tha

tthe tooBn

g cos tfo r th e par t was one-sixteent

h tha to f matched-meta

l die s fo r SM C production. Eac

h 46-f c componen treplace s a 2500-t b concret e unit .

Botto m vie w of

untrimmed

Industrial showerbase. (Photo: FiberGlass Tootbi g & Specialties )

minimiz e wash , bu tther e i s th e likeli hoo d o f sin k o n th e opposit e surface . Large , fla texpanse s shoul d b e slightl y crowned , a s i s goo d GR P prac tice , perhap s V

* inc h o f crow n pe rfoot . .Th e molde d par

twil l flatte n ou tdurin g curing ; uncrowne d parts ma y dish . Raise d letterin g an d logo s ca n easil y b e molde d i n (provide d ther e i s enoug h draft) , a feature difficultt o obtai n i n ope n moldin g in term s o f gettin g glas s int o th e raise d areas . Althoug h RT M deliver s tw o finishe d surfaces , on e wil l contai n th e injectio n port . I f its .locatio n i s obtrusive , i

twil l hav e t o b e patche d o r masked . RT M part s conventionall y require

. trimming aroun d th e partin g line . Th e toolin g i s buil

twit h a flange d are a a tth e partin g line . Som e parts molde d t o ful l dimension s require onl y resi n deflash in g i n certai n cases ; proprietar y meth od s of handlin g th e reinforcemen telimi nat e resin-ric

h edges . All hole s mus tb e drilled an d larger opening s cu tout . forwhic h computer ize d equipmen tis available . It' s difficul tt o pi n dow n th e tightnes s o f toleranc e control i n RTM . th e matte r bein g s o dependen to n too l qualit y an d moldin g methods . Maintaining thick nes s tolerance s t o 0.01 0 inc h i s within th e capabilit y o f man y molders . Par

t shrinkag e ca n b e a s littl e a s 0.00 1 inch / inch . Th e strengt

h o f RTM parts , like othe rfacet s o f

th e process , fall s be twee n th e extreme s o f

ope n an d com pressio n molding . Th e amoun to f glas s loadin g i s obviousl y a factor . Loading s usuall y run betwee n 2 5 an d 3 5 percen t butca n b e muc h higher . Hoo d Mfg. , Sant a Clara , Calif. , fo rInstance , report s tha ta medica l cove rwith a Via-lnc h wall contain s 6 5 percen tglas s (continuous stran d mat) . On e o f

th e advantage s of RT M i s th e abilit

y t o plac e glas s an d othe rmaterial s with grea taccurac y pre cisel y wher e they'r e needed . RTM v s layup . On e o f

th e paper s a tthi s year' s SP I RP/ C Conference * pre sente d a rare compariso n o f ttie physi -

. ca tpropertie s o f

a par tmad e b y bot h layu p an d RTM . Th e parti s a commer da l generato rcover . A s Tabl e II I Indi cates , th e RT

M part , wit h a slightl y highe rglas s content , show s Improve men ti n a

D physica l properties . Thick nes s o f molde d part s vi a bot h processe s i s V< * inch . Part-remova l tim e l n RT M wa s 2 3 minutes , a s compare d t o 1 hou r fo rlayup . FUTUR E CONSIDERATION S I ti s th e curs e o f

intermediate-volum e processe s tha

tdevelopmen tmone y i s no tin generou s supply . Thus . RT M ha s grow n slowly . Bu tth e pac e i s quicken ing , an d mor e molder s hav e Joine d up . Th e resins , reinforcements , pumpin g equipmen tand , especially , toolin g ar e bein g Improved . Tw o majo r goals , ar e bein g pursued : largeTpart

s an d taste rcycles . RTM* s fu tur e will b e populate d with mor e auto mate d moldin g an d mor e sophisticate d tools . Som e meta l tool s ar e bein g use d now , forthos e Job s wit

h unusua l desig n requirements . Whil e RT M cycl e tim e won' tb e pare d t o tha to f compressio n molding , faste rcycle s will mak e larger run s mor e cos teffective . Encouragemen tt o expan d th e ca pabilitie s als o come s fro m overseas .

• "RT M - The Righ

tChoice /o r th e '80s." b

y N.E . Michael s (Fibe r Glas * Tooling tt

Specialties . She boyga n Falls, Wit. ) an

d J. Lot-e n and J. Bauer (Freema n Chemical

Corp. . Por

tWashington

. Wis.) . Presente

d af the 1982 SPI

RP/C Confer. ence . Washington

. O.C . , conl(l , u ,d ) 

# MP.2 8

07/19/9 5 18:0 1 ©20 2 26 0 017 8 EP A PP D IfflUI Z



### >

S o * » — o • - : sS 5 * . 8 « . U J > B • * • . . S .2 e e 

## ! I i l

• c ** • ^ • f S* S 5 J o n o o a • • ^ > - s

' C • V -* * 1 . 5

. 2 « e > > »

. - e « • - a ^ a - — ; J tn o 3 S • • "

< c £ "*<** • • O 3 O c "J , • * 2 * ° " 0 • « 5 5 < n• ; S 3 « | S . 3 • S c 3 

## i 5

—3 « * £ 3 . .

- I *

> £

O m. Cm « l mf •- 3 3 < X O - J 

## Tabl e III. Comparative physica l propertie s o f RT M an d sprayup Propert y Tensil e strength , ps i Tensile modulus , ps

i Tensil e elongation, % Impact , izod , unnotohed, ft-Ib/lnc

h Flexura l strength, ps

i Flexura l modulus , pr

i Barco l hardnes s Glass content, % RT M proces s 14,40 0 980,00 0 1.6 4 14.7 5 23,40 0 847,00 0 

### 4 8 2 8 Sprayu

p proces s 11.95 0 890,00 0 

### 1. 4 13. 9 22.00 0 830.00 0 

### 4 5 2 5 Source:N.E.Mfc-tos*(Fiber dm TooKr** Sftdalt^Sltebovgo-Fa^V^.lendJ . LnmnandJ. Bauer(Freeme n Chemical Corp. , Por tWathlngton, Wk.).



# ED P housings ED P cabinetr y put s man y demands o n th e designer . Thi

s highl y competitiv

e field place s a premiu

m o n movin

g fast — ah d RT M meet s tha tchalleng e wtt h fas t to d deliver

y and th e abilit

y t o mak e change s Inexpensively. Th e process ca

n b e use d fo r prototype an

d pceproductio

n part s a s -wel l a s for mediu

m volumes o

f th e man y specialt y product s i n th e medica l an d otherfklds . . . Th e bousing show

n her e wa s molde d by Risc o Inc. , Seattle , whic

h specialize

s in this area . Th

e compan y uses press mounting s fo r bes ttoleranc e contro l e s we U a s a numerica

l trimme rfo raccurat e cuttin g o f openings . Rib

s an d bosses ar

e molde d i n wit

h cores ; slot

s fo r car d rack s ca n b e routed ou

to f th e housing. Th

e company ha

s produce d severa l housing s wtthintegra

l EM I shieldin g b y incorporatin

g alumlnlxe

d glass ma twit h th e reinforcement

, Includin g th e on e shown .

Press-mounted , numerically trimmed EDP housing . (Photo: Risco Inc.).

Boa thull s ar e bein g buil tin England ; comple x mold s allo w RT M productio n o f no tonl y th e hull itsel

f butintegra

l stringers , bulkheads , moto rmount s an d othe rstructura

l members . I n th e automotive-parts area , Coli n Chapma n ha s refine d th e RT M proces s t o produc e bodywor k fo rseveral Lotu s model s an d ha s als o provide d technol og y fo rth e RT

M part s bein g use d in th e D e Lorean . Th e stainless-stee l skin of th e D e Lorea n i s applie d t o th e two piec e monocoqu e structura l bod y shel l produce d vi a RTM . Urethane-foa m beam s wrappe d wit

h glas s ma

tar e use d a s insert s l n th e shel l t o provid e addi tiona l impac tan d shoc k resistance . Automotiv e an d marine venture s i n RT M i n th e Unite d State s hav e no t reache d th e Britis

h levels , bu

tinteres ti s -z>7 •• high . Th e Excalibu r effort s hav e alread y bee n mentioned , an d Vikin g Yach tlas t yearbuil tth e femal e mol d fo rit s ne w 44-f tyach ts o thati

tcoul d b e converte d t o RT M fro m layu p a tsom e poin ti n th e future . Sinc e ittake s a layu p cre w fiv e day s t o produc e th e hull , th e prospect s o f RT M productio n l

n eve n hal

f tha t tim e ar e enticing . Certainl y man y layu p an d sprayu p lob s ar e *ju1n

ffi r-*)hl p tn **"> f

*-"* |, «' T W^* * improve d cosmetics , bette r propertie s "an d improve d workin g environmen tof Kf M . Molder s wh o effec tsuc h conver sion s ca n the n buil d u p thei r volum e un til the y fac e th e ultimate manifestatio n o f commercia l success : conversio n t o compressio n molding . Fo r information on res/n-trans/e r molding , circle 20 0 on the readerservice card.P.2 9

07/19/9 5 18:0 2 ©20 2 26 0 017 8 EP A PP D tfflu u 

# MAGNU M

INDUSTRIE S 

# TH E RESI N ROLLE R IMPREGNATO R Th e resi n rolle rimpregnato ri s on e o f ou r newes t developments

. I t was designe d fo r thos e doin g hand-lay-u p an d bucke t an d brus h we t out

. Th e resi n rolle rwa s als o designe d t b eliminat e al i spray-u p fumes , whic h i t does

. Thi s syste m wil l no t onl y eliminat e fume s bu t als o mixe s th e resi n an d catalys t intemall y blendin g th e catalyst an d resi n together

. Wid i thi s syste m wast e wil l b e cu t by 5 t o 10%

. Tim e i n lay-u p I s

. als o reduce d becaus e on e operato ri s wetting-ou t an d rollin g ou t a t th e sam e time

. • Th e weigh t o f you rproduc t ca n b e reduce d because whe n properl y used , th e rolle rwil l soa k

u p excess resi n an d thi s ca n the n b e use d wher e needed

. Glas s t o resi n rati o wil l b e constantl y main

tained

. I n fac t yo u wil l probabl y ge t a highe ramoun t o f glass t o resi n tha n achieve d eve rbefore

. Her e i s ho w th e syste m operates

. Catalys t an d resi n ar e pumpe d fro m th e mai n sourc e alread y metere d b y th e slav e pum p a s t o correc t percentage s ou t t o th e dispensin g block

. Whe n th e block , i s opene d catalys t ah d resi n the n flo w togethe ran d ar e mixe d i n th e stati c tube

. Afte rthe y ar e mixe d th e flow continue s dow n th e extensio n tub e an d ou t o f th e rolle rtube

. Th e catalyze d resi n flow s throug h th e rolle rtub e int o a n auge ran d ou t int o th e roller

. A t th e en d o f a day , simpl y tak e th e rolle rof f an d eithe rclea n o rdispose

. Then , flus h th e tub e whic h wil l tak e onl y seconds

. Thi s syste m ca n g o a s slo w o ra s fas t a s anyon e ca n handl e it , s o al l application s o f han d lay-u p o rbucke t an d brus h shoul d seriousl y tak e a clos e loo k a t thi s ne w system

. A specia l note , fo rthos e o f yo u plagued ' b y O.S.H.A

. an d th e E.P A I f you rproduc t wil l permi t th e us e o f a Resi n Rolle rImpregnator , yo u ca n reduce you rfume s t o tha t o f th e curin g resi n only . 1170 1 - 56t h Cou n Nort h Clearwater , F

L 34620 FA X 1 1-813-572-6895 Clearwater , F

L 1-813-573-295

5 Montreal

. Quebe

c 514-638-433

0 Standar d Features : I - BOS-3000-

6 Catalys t Slav e Syste m wit h AP 060

0 Resi n Pum

p I -MA-MR D Ai rManifol d I - CM-400

0 Catalys t Manifol d Syste

m I - MBA-100

0 Mixin g Bloc

k Assembl y I - MRD-100

0 RH D Rolle rHea

d Assembl y I - WMM-100

0 Wal l Mount Mas

t 1-MFP-IOOORushPo

t Optiona l Features : • Boom s 1 2 foot , 12 , 16, 18,20 , u p t o 3 4 foo t lon g • PC-200 0 Car t Assembl y • DC-100 0 Dru m Car

t Assembl y •FM-IOOORoo rMount • 3 foo t an

d 6 foot Rolle rExtension

s

RESI N ROLLE R IMPREGNATO R



# Z 8P.3 0

07/19/9 5 18:0 3 

### ©20 2 26 0 017 8 EP A PP D Ut I 01 4 

# MAGNU M

INDUSTRIE S 

# FLO-COATE R - WET-OU T SYSTE M I n today' s environmen t wit h ai r qualit y control s becomin g stricter , Magnu m Industrie s continue s t o figh t t o hel p F.R.P . manufacturer s mee t th e ne wcodes . I h ou r effort s t o d o thi s w e have no wcom e ou t wit h a ne wwa y o f applyin g resin. Th e Flo-Coater . Th e ke y t o efficien t wet-ou t i s t o reduc e over-spray , fuming , an d ai r entrapmen t whil e stil l gettin g goo d resi n penetration . Thi s ne wsyste m offer s severa l advantages t o th e F.R.P . sho p tha t uses han d lay-u p o r wet s ou t wit h a gun . Th e res m tha t come s throug h thes e hole s i s stream . Th e resultin g spra y patter n i s unique . Thi s pat ter n eliminate s over-spra y an d mistin g eve n a t hig h flo wrates . Usin g thi s resi n saturatin g syste m wil l reduc e styren e emissions , resi n waste , roll-ou t time , ah d shoul d increas e production . Don' t le t th e ne wcode s influenc e yo u int o buyin g som e elaborat e an d expensiv e ai r exhaustin g system . Fo r thos e o f yo u needin g t o reduc e styren e emission s o r jus t bokin g fo r a wa y t o sav e yoursel f som e money , a Magnu m Flo-Coate r o r a Resi n Rolle r Impregnato r i s th e answer . Thes e system s wil l reduc e th e styren e level s t o tha t o f th e curin g resin . Wha t mor e coul d yo u want !

Se e a demonstratio n today ! II70 1 - 56t h Cour t Norc h Clearvmer . F L 3462 0 FA X # 1-813-572-689 5 Clearwater . F L 1-813-573-295 5 Montreal , Quebe c 514-638-433 0 

### Standar d Features : Resi n Pum p 6: 1 Ratio , 4. 6 G.P.M . MRD-MS-IOI I Catalys

t Slav e Pump MRD-I000-BL K

Mixin g Block

Assy . Flo-Coa tNozzl e an

d Gu n MA-200 0 Ai r Manifol d CM-100 0 Catalys tManifold and Relie f Valve Optiona l Features : DC-100 0 Dru m Car

t BA-120 0 Boo m Assy

. WMM-100 0 Wal l Mount FM-1000 Floo r Mount Resin Pum p 11:1 Ratio , 4. 6 G.P.M . Longe r Hos e Length s

INTERNA L MI X FLOCOA T SYSTE M



# z ? FLOCOA T GU N