Glass fiber reinforced thermoplastic sheets

Figure 5.54 Processing sequence for compression stamping glass fiber reinforced thermoplastic sheets...

Reinforced Thermoplastic Sheet. This process uses precombined sheets of thermoplastic resin and glass fiber reinforcement, cut into blanks to fit the weight and size requirements of the part to be molded. The blanks, preheated to a specified temperature, are loaded into the metal mold and the material flows under mol ding pressure to fiU the mold. The mold is kept closed under pressure until the temperature of the part has been reduced, the resin solidified, and demolding is possible. Cycle time, as with thermosetting resins, depends on the thickness of the part and the heat distortion temperature of the resin. Mol ding pressures are similar to SMC, 10—21 MPa (1500—3000 psi), depending on the size and complexity of the part. 

Recendy, storm doors have been constmcted of advanced thermoplastic composites. Stampable, glass-mat reinforced polypropylene sheet is used to create a high strength outer skin. These compression molded skins are welded together using a friction or ultrasonic process then injection molded with a polyurethane foam core to produce an insulated structure. New technology for window frames incorporate the pultrusion of frame channels to produce a thermoset composite channel that can be filled with fiber glass for further insulation enhancement (12,31,33,34,48,49,54—56,60—67). 

The matrix can be either a thermoset or thermoplastic. The oldest and still widest used material for compression molded products is phenolic. The thermoset materials used to manufacture fiber reinforced compression molded articles is unsaturated polyester sheet or bulk, reinforced with glass fibers, known as sheet molding compound (SMC) or bulk molding compound (BMC). In SMC, the 25 mm long reinforcing fibers are randomly oriented in the plane of the sheet and make up for 20-30% of the molding compound s volume fraction. 

In use are stamping compression molding presses. Plastic used can be TS sheet molding compounds (SMCs) and stampable reinforced thermoplastic sheet (STX) material (STX is a registered tradename Azdel Inc., Shelby, NC). It is usually composed of a glass fiber-thermoplastic RTP (Chapter 15). 

Glass-mat reinforced thermoplastic (GMT) is similar to SMC and is available in sheet form, reinforced with random oriented fibers that may be continuous or discontinuous. It is manufactured on a double belt press where the glass fiber mats are sandwiched between layers of extruded molten polymer before it enters the press. The thermoplastic is usually about a few millimeters thick and thus stiff, and hence stored as fiat sheets. Another method involves deposition of a molten mixture of resin, chopped fibers, and additives over a moving belt where the water is driven off. The fiber volume fraction in this compound is usually 0.1-0.3 and fiber lengths are in the range of 10-30 mm, unless the reinforcement is continuous. 

Capacity for Making Fiber Glass-Reinforced Thermoplastic Sheet is Doubled by Azdel Inc., Shelby, NC, USA. Reinforced Plastics Newsletter 18 4, February 21, 1994. 

This glass fiber mat is impregnated by thermoplastic resin which is compounded with additives, under heat and pressure (Fig. 3.13). A double belt press is usually used to apply heat and pressure for the resin impregnation process. After the consolidation process, glass fiber reinforced sheets which have been conveyed through the double belt press, are cut into a desired size and stocked. 

Polypropylene sheet has been used most extensively however, thermoplastic polyester, polycarbonate, and nylon versions are available (see Elastomers, synthetic Polycarbonates). Continuous strand glass fiber mat is the typical reinforcement. The limited number of sheet suppHers reduces potential for competitive pricing. 

The resin matrix can be either thermosetting or thermoplastic. Thermosetting resins such as epoxy, polyimide, polyester, and phenolic are used in applications where physical properties are important. Polyester and epoxy composites make up the bulk of the thermoset composite market. Of these two, polyesters dominate by far. Reinforced with glass fiber, these are known as fiberglass-reinforced plastics (FRPs). FRPs are molded by layup and spray-up methods or by compression molding either a preform or sheet molding compound (SMC). 

Special types of glass fiber for specific processes (Chapters 4 and 5), such as sheet molding compound (SMC), pultrusion, and reinforcement of thermoplastics, is a marked trend in current development. Examples follow ... 

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