Light RTM (LRTM) Moulding
Master Model
Master Model Orientation
Lounger pattern Flange
Flange/seal rules
Primary and secondary seals may follow different paths
Corner radii restriction must be observed
Other Flange examples
Master Model -Pinch off detail
Inserts in the first mould flange
Location of inserts on master pattern
Injection port on Face tool
Inserts illustrated
General mould cross section
Typical VM mould production set up
Location - Dowelling
Peripheral Fill
Flow path built into Mould flange
4m² small craft VM mould - filling
Reality
More Flow shots
Face tool Lay up
Calibration of first mould
Seals and flow channel profiles
Seals and profiles
Resin Runner Profile
Resin runner position
Two vacuum levels
Air driven vacuum control
Accuracy is the Key – Vacuum lock during LRTM Mould build
Total Cost of moulds
High Volume VM up to 800/ day!
VM will mould Small to Large Parts
LRTM can go big and complicated
Wind Turbine housing – approx. 100 m2 surface area
“RTM” and complimentary “LRTM” closed moulding for composites
Moulding Speed
“RTM” and complimentary “LRTM” closed moulding for composites
Moulding Accuracy
“RTM” and complimentary “LRTM” closed moulding for composites
Equipment requirements
Low pressure LRTM Machine
More Application examples
Sunlounger
Pacific Composites - Australia
Invalid Bath
10mm thick 80kg VE resin
VM can go big and complicated
Other VM applications
Conclusions
Heating /Temperature control
10.70M
Категория: ПромышленностьПромышленность

Light RTM (LRTM) Moulding “Mould build technology"

1. Light RTM (LRTM) Moulding

“Mould build technology"
Presented By
Alan Harper, Managing Director, Plastech TT. UK.
Plastech TT Ltd.,
1

2. Master Model

Orientation
Flange
Surface
Draft
angle
Release agent
Plastech TT Ltd.,
2

3. Master Model Orientation

Plastech TT Ltd.,
3

4. Lounger pattern Flange

Dual level flanging
Simple flange
Plastech TT Ltd.,
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5. Flange/seal rules

Plastech TT Ltd.,
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6. Primary and secondary seals may follow different paths

Plastech TT Ltd.,
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7. Corner radii restriction must be observed

Seals
placed on
pattern to
simulate
paths
Plastech TT Ltd.,
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8. Other Flange examples

130 mm +/- 5mm
Flange direction
change
Plastech TT Ltd.,
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9. Master Model -Pinch off detail

Plastech TT Ltd.,
9

10. Inserts in the first mould flange

Flange
vacuum
Injection port
Alternatives
Autosprue
10mm pipe
Plastech TT Ltd.,
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11. Location of inserts on master pattern

Plastech TT Ltd.,
11

12. Injection port on Face tool

Plastech TT Ltd.,
12

13. Inserts illustrated

Flange vacuum
insert
Autosprue
insert
Plastech TT Ltd.,
13

14. General mould cross section

Plastech TT Ltd.,
14

15. Typical VM mould production set up

Plastech TT Ltd.,
15

16. Location - Dowelling

X
and y location
Plastech TT Ltd.,
16

17. Peripheral Fill

Resin
mould flow designed to find initial
easy path around cavity.
Ideal - path fills before cavity starts to fill.
Theory to practise example………
Plastech TT Ltd.,
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18. Flow path built into Mould flange

Plastech TT Ltd.,
18

19.

Plastech TT Ltd.,
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20. 4m² small craft VM mould - filling

Plastech TT Ltd.,
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21. Reality

Plastech TT Ltd.,
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22. More Flow shots

Plastech TT Ltd.,
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23. Face tool Lay up

Release
agent
Tooling gel coat VE
Tissue + VE
First layer 450 g/m² CSM + VE
Second 3 x 450 g/m² CSM + LP
Frame – wood or light steel
Plastech TT Ltd.,
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24. Calibration of first mould

Plastech TT Ltd.,
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25. Seals and flow channel profiles

Plastech TT Ltd.,
25

26. Seals and profiles

Plastech TT Ltd.,
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27. Resin Runner Profile

In face
mould
or
contra
mould
Plastech TT Ltd.,
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28. Resin runner position

Plastech TT Ltd.,
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29. Two vacuum levels

Vacuum
1 to clamp mould flange.
At least 85% providing 1 tonne/linear m.
Vacuum 2 to clamp cavity and assist fill.
55% provides 0.55kg/cm ² clamping.
Plastech TT Ltd.,
29

30. Air driven vacuum control

Plastech TT Ltd.,
30

31. Accuracy is the Key – Vacuum lock during LRTM Mould build

Plastech TT Ltd.,
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32. Total Cost of moulds

Mould material costs £340 / m²
Labour costs average 30 hrs /m²
Comparison, LRTM tooling is less than
50% the cost of conventional RTM
tooling
Plastech TT Ltd.,
32

33. High Volume VM up to 800/ day!

Plastech TT Ltd.,
33

34. VM will mould Small to Large Parts

Plastech TT Ltd.,
34

35. LRTM can go big and complicated

Plastech TT Ltd.,
35

36. Wind Turbine housing – approx. 100 m2 surface area

Plastech TT Ltd.,
36

37.

Plastech TT Ltd.,
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38.

Difference between RTM and LRTM
Moulding Speed
Moulding accuracy
Equipment requirements
Plastech TT Ltd.,
38

39. “RTM” and complimentary “LRTM” closed moulding for composites

Difference between RTM and LRTM
Moulding Speed
Plastech TT Ltd.,
39

40. Moulding Speed

LRTM
injects the fibre pack at
approximately 1/3 the speed of RTM
LRTM cannot be speeded up by using
higher injection pressure
RTM is able to inject 2 to 4 times faster
Optimised RTM 6 times faster
Plastech TT Ltd.,
40

41. “RTM” and complimentary “LRTM” closed moulding for composites

Difference between RTM and LRTM
Moulding Speed
Moulding accuracy
Plastech TT Ltd.,
41

42. Moulding Accuracy

moulds within +/- 0.025”at best
RTM moulds within +/- 0.002” at best
LRTM mould accuracy governed by fibre
pack and vacuum level- unpredictable
RTM mould set accuracy controlled by
design - predictable
LRTM
Plastech TT Ltd.,
42

43. “RTM” and complimentary “LRTM” closed moulding for composites

Difference between RTM and LRTM
Moulding Speed
Moulding accuracy
Equipment requirements
Plastech TT Ltd.,
43

44. Equipment requirements

RTM
needs a low pressure meter mix
machine and tool manipulator.
LRTM needs a VERY low pressure meter
mix machine and two vacuum sources
Plastech TT Ltd.,
44

45. Low pressure LRTM Machine

Mould
Pressure
Guard
Regulates
speed of
pump to
achieve safe
low pressure
Plastech TT Ltd.,
45

46. More Application examples

Plastech TT Ltd.,
46

47. Sunlounger

Plastech TT Ltd.,
47

48. Pacific Composites - Australia

Pacific
Composites Australia
Plastech TT Ltd.,
48

49. Invalid Bath

Plastech TT Ltd.,
49

50. 10mm thick 80kg VE resin

Plastech TT Ltd.,
50

51.

Plastech TT Ltd.,
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52.

Plastech TT Ltd.,
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53. VM can go big and complicated

Plastech TT Ltd.,
53

54.

Plastech TT Ltd.,
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55.

Plastech TT Ltd.,
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56. Other VM applications

Plastech TT Ltd.,
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57. Conclusions

LRTM
is a viable lower cost system
complimentary to RTM.
Tooling manufacture must be accurate
Material selection, resin, fibre critical.
Operating procedures must be
consistent for success.
Plastech TT Ltd.,
57

58. Heating /Temperature control

Plastech TT Ltd.,
58

59.

Electrical Heater-Cloth Application.
Plastech TT Ltd.,
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