NOVEL POLYMER UPDATE-1/20/97-Reprinted from the post of Sri's
I am printing this article after getting permission from Cyclopss Corp. This gives more
insight into the Novel polymer that will soon be commercially available.
They are in the process of making available a RTM (Resin Transfer Moulding)
Processable, High-Temperature, Non Carcinogenic resin System for 600 Degrees
Fahrenheit Environments.
The Cyclopss Initiative and Industry need:
The aerospace industry is aggressively seeking low-cost, high temperature polumetric
composites
to lower weight and improve the performance of jet engines. Currently , PMR-15 is
the baseline polymetric matrix material used, but because it contains carcinogenic
methylene dianiline (MDA) and it is difficult to process, manufacturers and end users
would like to use a more processable, non carcinogenic/mutagenic resin that is low in
cost.
Foster-Miller Inc. in collaboration with Cyclopss Corporation has developed a solvent
less, resin transfer, mouldable (RTM) resin system that has thermal and mechanical
performance similar to PMR-15 ( May be superior). This material was developed as a
part of a NASA-Lewis SBIR grant incorporating an essential resin component ( The
Monomer, which is a building block for the resin)
manufactured exclusively by Cyclopss Biochemical Corporation. This novel resin
system is not carcinogenic or mutagenic components and is cost competetive with
respect to PMR-15.
The new resin system system is a modified version of NASA-Lewis's AMB-21 resin,
but has improved glass transition temperature (TG) and thermal oxidative stability
(TOS). The modifications do not appear to sacrifice its other desired high-temperature
properties. The Tg value of the resin system exceeds 650 deg. Fahrenheit resin matrix.
This is suitable for use as a true 600 deg. resin matrix.
This material was successfully demonstrated as a true RTM processable system.
Composite tubes and flat panels were fabricated, with the resin as the matrix, using
conventional RTM techniques without solvent assistance. Whereas traditional
high-temperature polymides, such as PMR-15 and AMB-21, typically have viscosities
in the 2000 cPs range at very high temperatures (400 deg.), This resin system has a
viscosity <= 800cPs at temperatures between 110 deg centigrade (230 deg.
fahrenheit) and 150 deg. Centigrade (302 deg. fahrenheit) with a good pot life.
Traditionally, 1000 cPs is considered the maximum viscosity for RTM techniques.
Cyclopss along with Foster-Miller believes that the technology developed can be
applied to other high-temperature resin systems to make them RTM processable.
Over the last five years a large percentage of the application for advanced composite
materials, have been realised by the RTM process. Due to its intrinsic economic
advantages, it has become an attractive substitute for traditional processes such as
autoclaving and compression moulding processes. An increasing number of companies
have generated significant cost savings from this substitution, through large reductions in
capital costs, energy costs, labour costs and prepreg storage costs.
However, two specific groups of potential users continue to be prevented from
realising the savings from the RTM process. Very large components and those with
high volume fibre fractions or integrated conductive membranes cannot currently be
manufactured by this process. The technical obstacles preventing the use of RTM in
these applications are almost all linked to the same two major deficiencies.
An absence of high performance resin systems able to be processed by RTM.
An absence of sufficiently high levels of control and speed of response of the bresin
injection systems. There is an urgent need for advanced forms of RTM process
equipment and materials able to cost
effectively and reliably manufacture these types of component.
Companies have to realise the massive cost savings associated with the RTM process
in applications where components possess very long flow lengths, complex sectional
changes and fragile membrane inclusions. It also allows existing RTM processors to
generate manufacturing cost savings from higher production rates and lower reject
rates as a result of generic improvement to the control of the injection process.
Resin Transfer Moulding:
Resin Transfer Moulding is a closed mould process that produces parts of high quality
with regards to thickness, surface finish and mechanical properties. The process
exhibits much lower cycle times compared to hand limitation or even vacuum bagging
methods, with production times of 15 minutes possible. This means that between 25 -
40 parts can be produces per day with a single tool. The process is environmentally
friendly and produces parts with two good surfaces. The tooling cost is more than
double that of hand laminating
tools and the equipment required is expensive (in the order of between R20 000 and
R120000). The number of parts produced per day, the fact that the process is not
labor intensive, and the quality aspects more than make up for this.
Challenges:
The development of tougher resin system able to maintain performance at high service
temperatures and possessing low processing viscosities. The development of a
mechatronic resin injection system providing accurate and rapid feedback of injection
flow rates and pressures producing real time adapting control, optimising mould filling.
The validation of the technology developed on new and existing components from
within the ranges of the industrial collaborators.
Benefits
Incredible uses in the Aero space Industry.
Thermoplastic Injection Moulding using Continuous Reinforcement Fibres
Flexible Tooling Technology for Low Cost Closed Mould Processing
Low Cost, Net Shape Preforming
Explosion Resistant Cladding Panels for Buildings
Resin Transfer Moulding for Interiors of Mass Transportation Vehicles
Resin Transfer Moulding for Structural Automotive Components
Foster-Miller ( Since this is their area of expertise ) are working with several major
aerospace end users to develop an extensive performance database on this material.
Currently, the resin system is unavailable commercially, but the goal is to make it
available in limited quantities in the near future. To Commercialize this Novel Polymer a
Limited liability Corporation has been formed by its share holders and co-developers,
Foster-Miller and Cyclopss Biochemical Corporation. This sector of Cyclopss is really
worth taking another look and warrants more DD. This area may be the largest profit
maker in the near future.
Regards,
Sri.
Thanks Sri...Jeff
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