Continuous laminating process

Figure 35. Free rise, continuous lamination process (72).

Foaming Process of Resol-Type Foam. The foaming processes for phenolic foam of both the resol type and benzylic-ether type are the same as those for rigid polyurethane foams. The block-foaming process (slab foaming), pouring process, continuous-laminate process, and spray process are used. See Figure 57. 

Continuous-Laminate Process. This process is to foam continuously between two sheets of facing material, employing a laminator (double-belt conveyor). The productivity of this process is the highest, i.e., the yield of raw material is very good, and a high-quality product can be produced. The selection of material, foaming machine and laminator design are very important factors in this process. Excellent quality products have been manufactured by this process in the United States, Western Europe, and Japan. 

Unoriented Films. Unoriented multilayer films can be obtained by coextrusion of layers of 3GN and PET. Alternatively, multilayer films can be formed in a continuous lamination process using heat or optionally adhesive layers to bond the separate layers. Press lamination can also be used to form multilayer films by pressing layers of individual films at elevated temperature and pressure. Prior to film formation, the pol5miers are generally dried by heating to a temperature of 5°C below the crystallization temperature of the polymer under vacuum or inert atmosphere. The films can be rapidly cooled after extrusion to inhibit crystallization. ... 

In the continuous laminating process, roving is chopped onto a supporting cellophane (or other) carrier sheet film with the resin, which is doctored and passed first through... 

Over the years, continuous lamination processes have also been designed. Rather than cut the prepregs and foils into sheets, lay them up and press them as individual laminates, these processes use rolls of prepreg or bare fiberglass cloth and rolls of copper foil that are continuously unwound and fed together into a continuous horizontal press. One process starts with rolls of prepreg. Another starts with the bare, untreated fiber ass cloth, applies a resin to the cloth and is sandwiched with the copper foil as it is fed continuously into a horizontal press. At the back end of the press, sections of the continuous laminate can be cut into sheets, or with thin laminates, rolls of copper clad laminate can be manufactured. 

The cost of MEAs for applications up to 1 kW is commercially acceptable to the fuel cell industry today. The focus of MEAs for power applications greater then 1 kW, approaching 10-50 kW for stationary power (a typical space fuel cell is 15-30 kW and 75-100 kW for automotive fuel cells), is to drive the cost of the MEA lower by a factor of 10. This will be accomplished by developing the technology for manufacturing MEAs in a low cost, continuous lamination process and by finding alternate catalyst materials to platinum. 

Parallam, or laminated strand lumber (LSL) is a beam made by a continuous manufacturing process composed of bigger-size wood needles (very elongated wood particles) reassembled with a structural exterior grade adhesive, the favorite adhesive being isocyanates (pMDI) when heat-curing and PRFs when cold-curing. 

Phcnolics Good acid resistance, good electrical properties (except arc resistance), high heat resistance Compression molding, continuous lamination high pressure process... 

Hanak et al (9) presented a paper regarding the use of propoxylated Mannich adducts for the production of continuous laminates and fiberglass-reinforced molded rigid foam characterized by CFC reduction or elimination. Table 46 shows an example of the formulation and process conditions employed (9). 

Calendering is a popular method of rubber processing. It is also used in the production of films and in lamination of plastic film to substrates in a continuous web process. Hot-melt coating equipment is another version of calendering equipment used for production of plastic coated textile materials. 

This refers to many different fabricated RP processes such as contact/ low to high-pressure laminates, and continuous laminations. It usually identifies flat or curved panels using high pressure rather than contact or low pressure. It is a product made by bonding together two or more layers of laminate materials. The usual resins are TS such as epoxies, phenolics, melamines, and TS polyesters. A modification of this process uses TPs. The type of materials can be endless depending on market requirements. Included are one or more combinations of different woven and/or nonwoven fabrics, aluminum, steel, paper, plastic film, paper, etc. 

Unsaturated polyester thermoset systems use styrene as a reactive dilnent (sometimes along with substituted styrenes such as vinyl styrene or methyl methacrylate). Some of the styrene evaporates in the process (the emission factor is estimated at about 1-3% of the styrene for composites and a little higher for continuous lamination) and poses a threat as a hazardous air pollutant. The time-weighted average (TWA) for styrene is 50 ppm (or 213 mg/m ). In 1996 the Occupational Safety and Health Administration (OSHA) endorsed a proposal by the styrene industry to voluntarily adopt the 50-ppm exposure limit. 

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