2009 Brochure

1February 2009February 2009

CELEBRATING 21 YEARS OF INNOVATION!

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Nida-Core Corp.’s state of the art 6300 M2 Port St. Lucie, Florida Technology Center

Nida-Core Structiso headquarters in FranceNida-Core Canada distribution center Nida-Core India Regional Office Building

Nida-Core Corp. locations

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Nida-Core Team

Administrative: President - Damien J. Jacquinet

Business Development Manager - Tim Johnson

National Sales Manager - Nick Dan

Marketing Director - Jack Lugus

Technical Director - Jeff Bootz

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Providing solutions for composites industry for over 21 years

World leader in plastic honeycomb technology

Serving marine, transportation and architectural industries

What is RIGID-ELASTIC TECHNOLOGY?

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WHY SANDWICH CONSTRUCTION?I-Beam Principle

Reduced weight

Increased stiffness, impact strength, resiliency, insulation, puncture resistance

Reduced operating costs, higher payloads, better fuel economy

Noise & vibration dampening, thermal insulation

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AVAILABLE CORE MATERIALSBalsaPlywoodPolyurethane-polyisocyanurate foamsPVC Linear foamsPVC Cross-linked foamsSAN foamsPET foamsPaper honeycombAluminum honeycombPlastic honeycomb

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BALSA & PLYWOOD

Good mechanical properties in thin grades under ideal circumstancesRelatively inexpensive

Subject to rotUnsatisfactory impact strengthCatastrophic core failure past ultimate stress point.Moisture inhibition

NEGATIVE POSITIVE

ELASTICITY 20-30%

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PVC CROSSLINKED and LINEAR FOAMS

Good impact resistance

Easily conforms to intricate shapes

Good insulator

Expensive

Thermal resistance to 90 Degrees Celsius

Difficult to process

Compromised chemical resistance

POSITIVE NEGATIVE

ELONGATION 30-50%

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SAN(styrene acrylonitrile) FOAMS

Improved impact resistanceModerate temperature tolerance(95 Degrees C)Chemical resistanceGood processability

ExpensiveCan be attacked by styreneHard to detect core failureCatastrophic core failure beyond ultimate stress pointCrack propagationDelamination

POSITIVE NEGATIVE

ELONGATION 60-80%

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PET(Polyethylene teraphthalate)POSITIVE NEGATIVE

• Improved impact resistance• GREAT temperature

tolerance(175 Degrees C)• Chemical resistance• Thermo formable• Environmentally friendly

manufacture of foam

• Expensive• Catastrophic core failure beyond

ultimate stress point• Crack propagation• Unisotropic• Loses mechanical properties

when heated • Available only in 100 kg/m3 and

150 kg/m3 densities

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PLASTIC STRUCTURAL HONEYCOMB

Moderate insulator R=3.3 per 25 mm

Beveled edge processing

Inserts required for screw retention

InexpensiveNO catastrophic failureExcellent impact, chemical, fatigue resistanceExcellent sound attenuation(natural harmonic150 Hz) –up to 22dB reductionThermo formableExcellent processabiltyGood temperature resistance up to 110 C

NEGATIVE POSITIVE

ELONGATION up to 200%

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ACOUSTICS

Nida-Core ® honeycombs have excellent acoustical characteristics because of their composition of polypropylene, a visco-elastic material, ready to absorb vibrations.Damping propertiesSound absorption propertiesSound insulation properties

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VIBRATION DAMPINGThe damping properties of a material are it’s capacity to

lower the vibrations of either mechanical or acoustical origins. A material has good damping properties if it releases low vibration levels, consequently it has a low acoustical radiation. Conversely, a poor damping material easily starts to vibrate at the lowest stimulation applied upon it.

The damping capacity is characterised by the loss factor η, with values generally between 0 and 1. The Young’s modulus of the material has an influence on this factor.

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0

0.2

0.4

0.6

0.8

1

1.2

1.4

RMS

1900 2100 2300 Rotation Speed(rpm)

Vibration Level on the Bulkheads for a Motor Boatversus Engine Rotation Speed

Sandwich panel containing 25mm of Nida-Core

Sandwich panel with a 25mm wooden-based core

Sandwich panel with a 25mm wooden-based coreand a 900 g/m² viscoelastic damping sheet

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SOUND ABSORPTIONThe acoustic absorption is the property that prevents sound

reflection. To have a good absorption level, the material must be able to trap the sound waves. This is true for porous materials and honeycombs as the sound wave reflection is limited. The acoustical absorption is characterized by the "α sabine" factor. This factor is between 0 and 1. It is higher as the absorption level is increasing.

To have an efficient absorption level, the Nida-Core ® has to be covered on one side with an air porous facing. The sound waves get inside the cells and then are trapped as for an Helmoltz resonator: they rebound inside on the walls until they are completely absorbed.

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Acoustic Absorption Factorversus Frequency

0

0.2

0.4

0.6

0.8

1

1.2

100 1000 10000

Frequency (Hz)

Sabine values

Porous decorative glass fabric on a Nida-Corethickness 60mmMineral granules glued with a resinover 40mm of Nida-Core

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SOUND INSULATIONThe acoustic properties for an element dividing two rooms

are defined by its ability to lower the noise released from one side and its perception on the other side.

The insulation is characterized by the attenuation factor quoted R, which is the difference between the released and received intensities.

This may range from a few decibels to several ten decibels (Decibels are calculated from a logarithmic scale. A 3dB decrease represents a decrease of half of the sound intensity).

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SOUND INSULATIONIt is important to differentiate two types of partition

for the acoustic insulation analysis:If we consider a structure with a single homogenous

partition, the only factor which increases sound insulation is the mass. The heavier is the partition, better is the insulation. If we consider a composite structure

(mass/spring/mass), which means an alternation of heavy layers and damping layers, it is then more difficult to define the attenuation factor.

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SOUND INSULATIONTo simplify such a structure, the first "mass" vibrates and transmits

the waves to the "spring". This "spring" then transmits the vibrations to the second "mass", but because of its composition, it damps them. Such a structure has a resonance frequency where itsattenuation factor is low, but by modifying the mass for the partitions, it is possible to "choose" this resonance frequency.

For example, an objective may be to achieve a structure resonance frequency under 90 Hz, which is the lower limit of the defined spectrum for the acoustics in the structure. The attenuation factor for a composite structure, as soon as we are above the resonancefrequency, is in all cases above the value obtained with the heavy mass alone.

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SOUND INSULATIONNida-Core ® honeycombs are used to achieve light structural

sandwich panels. In these composite panels, the honeycomb functions as a spring as related above. The facings of the sandwich panels are the heavy mass of the structure. Thus, it is possible to have a very good attenuation factor for the sandwich structure made with Nida-Core ®.

The acoustical properties for sandwich panels made with Nida-Core ® are affected by many parameters (the facing types which cover the Nida-Core ®, the dimensions and fixation types, the acoustical waves and frequencies applied). It is not possible to detail all characteristics, butonly provide indicative values with different facings and under various acoustical solicitations:

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Polyester Scrim Cloth for 100% bonding surface

Polypropylene plastic barrier film under scrim 50µ to 300µ for Infusion and RTM to limit resin consumption

Copolymer PolypropyleneExtruded 0.005 mm Wall Thickness

How is Nida-Core H8PP made?

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Nida-Core Structural Honeycomb Technology

vs. PVC, SAN and PET foamsNida-Core Corp. is a marine industry specialist for over 21

years. We do not abandon our customers for higher margin

opportunities overseas.

Nida-Core mechanical properties are largely derived from its

honeycomb shape and are especially efficient in thicker grades,

therefore it is not as dependent on price of petroleum based

raw materials, unlike foams.

Nida-Core Structural Honeycomb is made from one of the most

chemically resistant materials, polypropylene, unaffected by styrene.

Nida-Core can be vacuum bagged to intricate shapes in large

sheets, eliminating need for scored core, and associated

problems like print through issues and inter laminar water

migration issues.Nida-Core’s reduced thermal efficiency, as compared to foams,

results in lower laminate temperatures, increasing longevity of

gel coat finish and preventing cosmetic defect relating to post

curing of the laminates.

Nida-Core Structural Honeycombs offer substantial cost savings as compared to any structural foams.

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Nida-Core Structural Honeycomb Technology

vs. Balsawood core

No need to over engineer laminates for adequate safety margins due to the

NO CATASTROPHIC failure mode of Nida-Core Structural Sandwich composite.

Reduced risk of delamination due to the low styrene levels of modern resins

and moisture inhibition problems frequently experienced thereof.

Stable supply and pricing. Over 2 million sq. ft in stock for immediate

delivery and over 30% cost savings when compared to equivalent thickness

balsawood.

Availability of large sheets (1.2X2.4 m) and corresponding material and cost

savings due to cutting and installing efficiency.

Near perfect track record in 21 years in marine industry. Over 40,000 boats

built with Nida-Core Structural Honeycomb in year 2007. (hulls, decks,

bulkheads etc.)Substantial reduction in NVH levels as compared to balsawood due to the

constrained layer damping effect of viscoelastic honeycomb.

Customers demand lower maintenance, NO ROT, wood free boats.

Core cost is < 1% of typical boat cost. Why take a chance?

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MATERIAL ELONGATION COMPARISON CHART in %

020406080

100120140160180200

BALSAPU FOAMCL PVCLIN PVCSAN FOAMPAPER HCALU HCPLASTIC HCPET

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NIDACORE FC 55

Engineered resilience, Structural, SeparationSeating

Separation, Energy absorptionProtection (sports, industrial)

Structural, Separation , Fluid transportErosion control

Non absorbing underlay, Energy absorption, SeparationFlooring

Ease of Use, Structural, Separation, Fluid transportGravel Replacement

Structural, Separation, Light weightPanel

Separation, Fluid transport, Laminar flowFluid Movement

Key PropertyAPPLICATION

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CUSTOMERS

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Laminate Bulkers: Nida-Core Matline - why you can achieve higher mechanical properties with Matline Laminate Bulker ?

Most laminate bulkers available in the marketplace today are composed of polyester fiber and glass micro spheres. Only Nida-Core Matline has OMNI-DIRECTIONAL fiber orientation. Compared to linear fiber orientation(like most other competitors) omni-directional fiber provides equal strength characteristics in both directions. Matline published thicknesses correspond to REAL thickness of material sold.

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NIDA-CORE PANELS• Wet laminated vaccuum bagged composite panels up to 3X15 m size with optional gelcoat surface in 40 stock colors. Large inventory worldwide.

•Choice of core: Structural Honeycombs in various cell sizes, Balsalite, Foamline and NidaFusion STO Triangulated pin.

•Skins include 600 GSM Woven Roving, 1200 GSM Woven Roving, Biaxials, Luan, Okoume, High Pressure Laminates, Metals, Wood Veneers, Stone and Marble, ThermoPlastics.

•250 ton Oil Zone Heated conveyorized press , pneumatic presses. CNC cut to size. Ideal for floor, sidewall, marine bulkhead and interior assembly. Fast turnaround times.

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• NidaBond CBC(CoreBonding Compound)

•NidaBond RFC(RadiusFilleting Compound)

•NidaBond APC(All Purpose Compound)

•NidaBond PTC (Pourable Transom Compound)

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NidaBond Pourable Ceramic Transom Compound, with 7 X stronger compression strength than marine plywood. Fix it once, fix it right! From inside the hull, cut inside laminate around the outer perimeter of the transom. If possible, peel off the laminate in one piece, for later reuse, or to use as template for making” the dam.

Remove all rotted and damaged material , down to the outside hull laminate.

Reinstall the inside laminate piece, that you previously peeled, or place “dam “(fiberglass or plywood) in place, with desired spacing from the outside hull laminate. If you create a new dam, we strongly recommend you laminate the dam prior to installing it, outside the hull ,with desired laminate thickness. This will create a primary chemical and mechanical bond to the cured NidaBond Transom Compound.

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Use fiberglass tape to fiberglass/seal the perimeter of the inside laminate, or dam.

Adequate bracing and reinforcement is necessary to withstand the hydrostatic pressure of the liquid material to be poured into the cavity.

Estimate the volume of your cavity and mix catalyst into the pails of NidaBond, pour into the cavity, preferably a continuous pour of all necessary material.

NidaBond is designed to de-gas and cure by itself without any further input necessary. If you used the DAM method, remove the dam now and laminate the inside of the transom. If you had used the laminated dam method, use fiberglass tape to seal the perimeter of the transom from inside the hull.

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Advancements in Closed Molding of Sandwich Structures

AS Effekt-Scott Bader Scandinavia-Nida-Core Corp. 2009

Feb 5 , 2009, 10:00am, Tallinn,Estonia

Jack LugusDirector of Marketing, Nida-Core Corporation

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NidaFusion

STOSTF

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The Sandwich Material with Triangulated Truss Network

PRINCIPLEA 3-dimensional Fiberglass reinforced foam for fabrication of high-stiffness

low-density structures either flat or highly shaped.

APPLICATIONSShipbuildingTransportation & Freight Insulated Doors & PanelsWind Turbine Blades & NacellesIndustrial Components

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Configuration of NidaFusion STO and NidaFusion STF

Sandwich constructions are made of :

Closed cell foam coreFiberglass reinforcements on each side of the foamFiberglass roving stitched through the 3 elements, thus forming Triangulated Truss Network

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Foam & Reinforcements

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Reinforcement Stitching

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Resin Infusion

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NidaFusion STO and STF Two products perfectly adapted for closed molding processes:

STOFor Single Sided Tooling and Vacuum InfusionWith Rigid Foam to Support Vacuum Pressure

STFfor Closed Tooling and RTM-LiteWith Flexible Foam for Conformity to Shape and Section

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Advantages of NidaFusion STF

Instantaneous cold formingCan be shaped in several directionsAllows for variable sandwich thicknessReduces cycle timeCan be cut with a pair of scissors or a knife.

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Structures with NidaFusion provide:

Excellent Flexural RigidityThe Glass Fiber Truss Network uses the same materials entrusted to skin laminates. They are not sensitive to a loss of properties at elevated working temperatures, as opposed to PP Honeycomb or PVC Foams.

Excellent Fatigue Resistance and Damage ToleranceThe Truss Network and the Skin Reinforcements of the structure are mechanically interlocked, and not dependent upon adhesive bonding and shear properties of an interface between skin and core. This results in a sandwich structure that is exceptionally resistance to delamination, providing superior damage tolerance and fatigue resistance.

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Surface Reinforcements:

All Reinforcements Types may be used:Fiberglas, Aramid, Carbon, etc.Woven Fabrics, Mats, Non-Crimp Fabrics,

NidaFusion is typically produced with only one layer of reinforcement on each side. This ensures that Triangulation Fibers are entrapped within the final laminate. Additional laminating reinforcements provide integrity across joints, determine complete properties and exterior finish.

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The Triangulations are Characterized by:

Step LengthThe distance between stitches, from 10 to 60 mm. Small Step Lengths increase triangulations and mechanical properties. Small Step Lengths increase weight and cost.

Angle45 degrees – For Maximum Shear Resistance60 degrees – For Increased Compression Resistance

Fiber Tex2400 Tex - Used for Highest Mechanical Properties.1200 Tex - Used for Best Surface Finish.

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The Foams :Closed Cell Foams to displace resin during molding. Two types of foam

distinguish the products:

Rigid Foams for the STO:Polyurethane foams (PU)

Excellent Thermal Insulation and Chemical Resistance, with low Friability.

Polyisocyanurate foams (PI)Good Fire ResistanceStandard NF 92501 : M1Standard DIN 4102 : B2Standard B.S. 476 Part 7 : Class 1

Phenolic foams (PH)Improved Fire Resistance without Toxic Fumes.Standard NF 92501 : M1, F1Standard DIN 4102 : B1Standard B.S. 476 Part 6 : Class 0

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The Foams :Flexible Foams for the STF:

Polyethylene (PE)Used for structures with a high thickness variation and/or complex shapes.In practice, these foams are chosen for the manufacturing of small parts.

Polypropylene (PP)For Structures with a low thickness variation, this foam allows the manufacturing of larger parts with higher molding pressures, and tolerance of higher exotherms.The elasticity can be increased locally by compressing it mechanically where necessary. This foam can be shaped at room temperature, then have its shape memorized by heating to 90-100°C during forming.

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4 point bending test and typical Four-Point flexure results

Load nose diameter: 50 mmSpan length L: 440 mmL' = L/2= 220 mmSample length: 550 mmSample width: 50 mmCross head speed: 2 mm/min

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Sample length: 100 mmSample width: 100 mm

Cross head speed: 2 mm/min2 sensors diametrically opposite measure

displacement of the plates.

Compression Test, parameters and behavior in flat-wise compression test

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Sample length: 270 mmSample width: 75 mm

Cross head speed: 2 mm/min

Core shear test and parameters and typical core shear test results

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NIDAFLOW RComparison of Competitive Product

Offerings

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The Competition

Tradename Producer

Rovicore ChomaratMultimat OCVMolding Mat OCVCombimat AhlstromPolymat FlemingsFlomat FGI

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Product ComparisonThe essential components are binderless chopped strand glass

mat separated by a lofted material that pushes the mat toward the mold surfaces and facilitates rapid resin flow.

The combination must permit high drape and maintain cross-section through compound curves.

The products are stitched together by the same machine types used for multiaxial fabrics.

Product offerings are generally based upon up to three thicknesses of “Core”, and three weights of Glass Mat typically balanced.

Product Nomenclature generally follow the rule of designating the glass by weight, and the core either by letter code or according to weight or thickness. [Glass/Core/Glass]

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Product ComparisonRovicore by Chomarat is the original product of this

type developed for closed molding. The “Core” material is typically made of PP Staple

Fibers (Chopped and Crimped). Generally a blend of two fibers, a large diameter fiber to retain loft, and a small diameter fiber to maintain integrity.

The Multimat product of Saint Gobain Technical Fabrics was developed by Syncoglass with a knitted Glass Fiber Core.

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NIDA-Flow

Mold Cavity, mm P300C300 P300D300 P450C450 P450D450 P600C600 P600D6001.52.0 242.5 19 20 273.0 17 17 23 24 303.5 14 15 20 21 26 264.0 13 13 18 18 23 234.5 12 16 17 20 215.0 15 19 195.5 186.0

Low Compression, Easy to displace reinforcement inside the moldHigh Compression, Increased difficulty for Resin Flow% Glass Fiber Content, Recommended Mold Gap

Example: For a 2,5mm part, P300C300 has a 19% glass content, and P300D300 has a 20%,P300C300 will flow better, while P300D300 will have better mechanical performance.

NIDAFlow Application For Different Part Thickness

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40 m film infusion

Atmosphere

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VacuumSpace Vacuum

100 km (63 miles)

Atmosphere

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Benefits of Vacuum

Eliminates need for heavy reinforced moldsEliminates need for industrial pressProvides economic tooling specification

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Weight of air on our planet

AT sea level 1 cubic metre of air weighs 1.3 kg100 km column 1 cm² air is 1kg (1 bar)Provides mould clamping force of

10 tonnes per m²

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Light RTM

LRTM Growth exceeds all other closed mold processesFocus on optimising LRTM

Process ControlMaterial SystemsTooling Resins

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Light RTM

Light RTM tooling uses matched faced composite moldsAtmospheric pressure clamps the closed moldtogether.The light weight mold structure offers low cost and rapid fabrication, but little or no resistance to injection pressures above atmosphere.Similar to infusion but has reusable tool face on both sides.

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Light RTMLight RTM uses Resin Injection Pumps to meter catalyst and control resin supply.Tooling Resins have been developed for rapid fabrication permitting low part count components to economically use closed mold processing.Specialty reinforcement materials have been developed for filling the mold cavity while providing rapid resin flow and maximizing flexural stiffness.Specialty core materials have been developed to provide sandwich structures while respecting part contours and cross section variations.

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Advancements in Closed Molding of Sandwich Structures

Process Technology improvements permit Closed Molding for increasingly large objects, as well as for smaller series part runs with more economical tooling. New types of core materials facilitate complex shapes and variable cross sections to be achieved without using molded or machined-to-fit cores. Inserts may be integrated to incorporate fastening hardware to avoid additional fabrication steps. Closed Molding is increasingly used for sandwich structures in a wide variety of applications.

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Advantages

labor savingregularity in production no physical contact with the resinstyrene-free workshop environmentlower tooling cost (profitable at +/-80 pieces)quick and easy mold and counter mould productionvarious choice of resininteresting for large parts easy production of sandwich parts

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Universal Insert system

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Typical Light RTM mould for 4.5 M craft

Atmosphere

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Optimisation needs

Increase speed of injection.Automated control of injectionIncreased permeability Shorter gel timesMaintain low cost tooling

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Limitations

10 tons/m² is enough to hold molds closedResin could be injected at more than 1 barRestricts resin injection speed to maintain pressures at or below atmosphereGel times are extended for safety

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Variables

Gel time - knownViscosity - knownTemperature - controlledInjection flow – depends on pressureInjection pressure – depends on flowAtmospheric pressure – knownMould injection pressure - Measured

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Solutions

Provide accurate injection pressure dataRead atmospheric pressure and inject 10mb under for safe and optimum control (0.0147 PSI)

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How to control the pressure ?

Injection pressure controlled from moldInbuilt pressure sensor tells the machine when to slow down.Specially designed to survive FRP shops.Accuracy of 1 mb (0.0147psi) absolute.

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Mould sensor Application

PTFE Electronic PVSensor

- Sensitivity +/- 1 mb

( +/- 0.0147 PSI)

-Low cost

-Robust

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PVSensor – Inserted in flow channel

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Application Light RTM and Film Infusion

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Multiple sensors for control and data logging

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PVSensor Optimisation system

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Accurate injection pressure control-- Is it enough?

For optimization there is still a need to increase speed.Flow lengths become a limiting factorNeed to stage resin inputPrimarily peripheral.Subsequent new input points to reinstate optimum flow speeds

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Automatic Resin delivery

Old method buckets and pipesNew method Automatic injection ValveTurbo Autosprue ™

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Filling molds automatically and precisely

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Turbo Autosprue

™(TAS)with

Locksert

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With optional electronic position sensors

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Operation principles

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Benefits using Autosprues ™

Eliminates wasteful pipe consumablesEliminates valuable time needed to replaceresin feed pipes each cycle.Eliminates contact with resin mixes in workshopReduces risk of air in part.Allows full automation

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Precise pressure control benefits

Enable tool build to the lightest constructionLarge molds can be left to inject automatically.Eliminates human error causing moldoverfill.Saves resin consumptionProvides consistent part thickness.Protects tooling from excessive exotherm

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Further benefits

Removes guesswork and “ black art ”Prevents possible fibre wash.Provides accurate vacuum leak detection.Low density PU and PE foams can be used with confidence…………..example

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Small craft – Deck and hull 148kg

16 weeks - designs, patterns and LRTM tooling, craft in the water.

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Light weight rigid design3 main chamber hull to deck construction providing monocoquevery rigid and sealed chamber profileNidaFusionSTF provides substantial deck strength and keel thickness.

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Structural adhesive points

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20 metres of Structural adhesive

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Light weight mould provides off line production steps

Light weight for efficient production-off line for ease, de-mould, release coat application, gel coating and fibre loading

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Example ofNidaFusionSTF located on a contra deck mold

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NidaFusion STF adheres to counter mold

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Dynamic Seal

Solid V Seal

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Dynamic Seal

Solid V Seal

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Mould Flange

103

Mould clamping

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Mould Flange

Vertical Flange Closing System

Mould Flange

105

PVSensor provides closed loop auto mould fill control

Mould edge fill pressure controlled

Mould pressure sensor feeds back control signal

Machine speed adjusts

automatically

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Universal Insert

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Advantages of staged mold filling

Provides up to 40% increase in mold fill speed.Faster resin gel times can be set .Higher daily production gained.Releases machine more quickly for other mould injection

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Fill Curve for Single Port Injection

Time to fill mold using standard peripheral fill

Mold full line

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Fill Curve for Phased Port Injection

Time saved

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Initial resin flow to first channel zone

111

Second Autosprueopens to continue injection

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Solution –Central Keyhole flow

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Initial peripheral flow

116

Resin builds pressure as distance from edge increases.

Resin flow substantially decreases after 1m flow length as pressure increases to atmospheric pressure

Initial back pressure LOW

117

Strategically placed additional staged resin injection fill lines within moldcavity between

0.75 to 1.5 m from mold edge

Additional Mould cavity injection lines

Back pressure now at atmosphere

118

Peripheral injection ceases

Resin diverted to new fill point nearer final fill zone

Back pressure again LOW

119

Resin continues to flow from deeper points in the mould

Concept of Progressive staged filling of Light RTM mold.

120

There still remains the need to control pressure.

As resin is automatically switched so too is the sensing point within the cavity

121

Injection StrategyHigh aspect ratio problem

Peripheral Fill

Central Gate

124

The vacuum pump

Active carbon filter

Air filter

Electrical regulator

Vacuum pump

Electrical panel

Adjustable vacuum valve

Max vacuum valve

Vacuum gauge

vaccuostat

Casters

0.6

0.8

1.0

0.2

0.40.6

0.8

1.0

0.2

0.4

125

Presentation of the processTYPE RT 121

DANFOSS

0.6

0.8

1.0

0.2

0.40.6

0.8

1.0

0.2

0.4

3

1

0

5

4

6

3

1

0

5

4

6

Résine

Solvant

1 Closing of the mold

2 Resin injection

3 Vacuum control in the middle of the mould

126

The mold

Critical place of the system

Mould

counter mould

Pot to recuperate resin overflow

Trolly

127

Detail of the technical flange

Female mold

Rovicore

Male mold

128

Detail of the technical flange

Female mold

Rovicore

Closing vacuum Male mold

129

Wing seal

Silicon seal

130

Production of the mould

150

Dimensions in mm

Skin 1

Skin 2

Sandwich core

Dimensions in Inches

6

131

Dimensions of the technical flange

5 10 2555 102020

10 105

Dimensions in mm

8

All radii of 5 mm minimum

6

2 1/23/43/4

13/64

3/8 3/8 1

3/43/8

25/64

13/64

1/4

Dimensions in Inches

132

Use of a profile

133

Cutting the profile

Mould border

Cross section

Laminate profiles with 3 coat of mat 450 gr

Mould

Laminate profiles with3 layers of mat 1,5 oz/ft²

134

Use of a profile

1. Positioning of the calibrated wax2. Positioning of the profile3. Laminating of counter-mould with the profile

142

Fabrication of the technical flange

143


144


First layer of the calibrated wax

Calibrated wax accordingto thickness required

13/64 Inches calibrated wax required

149


Silicone seal 25/64 x 13/64 Inches

152

Super Glue

Made in France

153

Positioning of the silicone seal

156

Fabrication of the technical flangeFoam cut to size coveredWith 2 layers of PVC tape

160

Fabrication of the technical flange3/64 inches calibrated wax

3 layers of Cork or calibrated wax 1/8 inches

Make radius with plasticine

167

Positioning of the accessories

168

Example of the resin flow with 1 injection point

Injection Point Location of the vacuum Point

Resin flow

Rovicore

169

Example of the resin flow with 2 injection point

Injection Point Location of the vacuum Point

Resin flow

Rovicore

Injection Point

170

Influence of the reinforcement

1st vacuum

171

Influence of the reinforcement

2nd vacuum

Resin injection

1st vacuum

Injection pressure

End of injectionand closing of the tube

Atmospheric pressure

Core spring back effect

Resin Counter

0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

0 0 %1Reset Reset

172

The injectorPE or PA 10 x 8 mm tube

Metal part

PTFE part

View from below

PE or PA 25/64 inches (10mm) tube

173

Silicone beetwen Injector & laminat

174

The vacuum pot

Metal insert

Overflow pot (metal)

Cover with seal

Quick couplingFemale vacuum coupling

"o" ring

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• The longer the distance of theresin flow, the higher thepressure inside the mold.

• In RTM, as in injection in the middle of the mold, we have to reinforce the male mold to avoiddeformation.

•When injecting a closed mold, the more the form is flat the more it is necessary to reinforce it.

• The longer the distance of theresin flow, the higher thepressure inside the mold.

• In RTM, as in injection in the middle of the mold, we have to reinforce the male mold to avoiddeformation.

•When injecting a closed mold, the more the form is flat the more it is necessary to reinforce it.

Distance of the resin flow during injection in classic RTM

Distance of the resin flow during injection in classic RTM

Vent

177

Distance of the resin flow during injection in Light RTM

Distance of the resin flow during injection in Light RTM

• In Light RTM, injection of theresin around the mold and ables to reduce the resin flow distance.

• As a result, we need lessreinforcement in the mold then in RTM.

• It’s only after we reach a specified resin flow distance thatwe have to reinforce the molds.

• In Light RTM, injection of theresin around the mold and ables to reduce the resin flow distance.

• As a result, we need lessreinforcement in the mold then in RTM.

• It’s only after we reach a specified resin flow distance thatwe have to reinforce the molds.

Vacuum cup

178

Internal pressure during Light RTM injection

Internal pressure during Light RTM injection

0 10 20 30 40 50

Resin flow distance in inches

2,8

2,4

2,0

1,6

1,2

0,8

0,4

0

Res

in fl

owsp

eed

in i

n/m

in

0,7 0,6 0,5 1,4 0,2Injection resin debit in US gallons / min

0,3

179

0

3

6

9

12

15

18

21

0 10 20 30 40 50 60Resin flow distance in cm

Pressurezone

Vacuumzone


Visualisation of internal pressure during the injection


Pres

sure

in P

SI

180

0

3

6

9

12

15

18

21

0 10 20 30 40 50 60

Pres

sure

in P

SI

Resin flow distance in cm




181

0

3

6

9

12

15

18

21

0 10 20 30 40 50 60

Pres

sure

in P

SI

Distance de fluage de la résine en cm




182

pressure No pressure vacuum

50 in

-0+

Full vacuum Medium vacuum

Injection of resin

Large Light RTM mold

CP ½’’

183

laminate 5/32’’

laminate 5/32’’balsa wood ¾’’laminate 5/32’’

plywood ½‘’laminate 5/32’’Balsa wood ¾’’laminate 5/32’’

Large Light RTM mold

184

1st vacuum

Injection sequence

185

Medium vacuum

Full vacuum

Injection sequence

186

Medium vacuum

Full vacuum

Injection sequence

Deflection zoneof the male mold

187Injection sequence

Deflection zoneof the male mold


Slow-down of the resin flow in the deflection zone of the male mold.


Because of the male mold deflection around thevacuum point, the resin arrive at the same time in the vacuum cup.

199

Resin injection

Pression d’injection

Injection sequenceResin counter

0 0 %0Reset

Medium vacuum

Full vacuum

200

Resin injection



0 0 %0Reset

0 5 %0Reset

Medium vacuum

Full vacuum

201

Resin injection



0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

Medium vacuum

Full vacuum

202

Resin injection


0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

Medium vacuum

Full vacuum

203

Resin injection



0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

Medium vacuum

Full vacuum

204

Resin injection

Injection pressure

End of injection


0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

0 0 %1Reset

Medium vacuum

Full vacuum

205

Pression d’injectionAtmospheric pressure


0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

0 0 %1Reset

Medium vacuum

Full vacuum

206



0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

0 0 %1Reset

Medium vacuum

Full vacuum

Sping back effect of the NidaFlow

207

It’s the combination of the rigidity of the male mold and the spring back effect of the NidaFlow that enables the male mold to return to it’s original form.



0 0 %0Reset

0 5 %0Reset

2 0 %0Reset

5 0 %0Reset

8 5 %0Reset

0 0 %1Reset

Sping back effect of the NidaFlow

Medium vacuum

Full vacuum

208

20’’

Deflection zone

209

Finally a few further examples

210

Equipment used for Jeanneau, France LRTM production42 foot sailing vessel deck

211

Light RTM technology in use on many Wind energy large mouldings applications

212

Xeroplas Portugal LRTM cored mouldings

213

New European Bus exclusively LRTM Molded parts

214

“Street Car”a new concept in Urban Buses

215

DoubleimpressionLRTM toolFor Malaysia client makes two 3 metre cable traymouldings

216

In floor mounting Shower Trays with large section thickness changes

217

MARCOPOLO PARADISO GIV- 1983MARCOPOLO PARADISO GIV- 1983

12% PERCENTAGE OF PLASTIC FOR BUSES (COST)

218

MARCOPOLO PARADISO GV- 1992MARCOPOLO PARADISO GV- 1992


219

MARCOPOLO PARADISO G6- 2000MARCOPOLO PARADISO G6- 2000


220

1949

1983

2000

2006

0%

12%

18 %

22%

PERCENTAGE OF PLASTIC FOR BUSES (COST)

PERCENTAGE OF PLASTIC FOR BUSES (COST)

221

HISTORY OF PROCESSESHISTORY OF PROCESSES

Spray-Up / Hand Lay-Up

RTM

Vacuum Bag

Vacuum Forming

Injection

PU

Spray-Up / Hand Lay-Up

RTM

Vacuum Bag

Vacuum Forming

Injection

PU

19961996

20062006

80%

39%

0%

8%

1%

3%

4%

8%

38%

0%

15%

4%

222

DEVELOPMENTSMVC BRASIL

1996: MVC Starts to produce a truck hood with high pressure RTM process.

223


Steel Mold weights 80 tons:

224


The hood is made of a 3.5mm skin and the structure is given by 11 reinforcements glued inside the hood.

225

DEVELOPMENTS MVC BRASIL

2004: New Development with RTM Integrated with NidaFusion STF

227

CASE HISTORYMVC BRASIL

ENGINE DOOR for Marcopolo Bus

228

CASE HISTORYMVC BRASIL

ENGINE DOOR for Marcopolo Bus

Initially manufactured by Spray-up , using two composites parts and one injected PU core, with the three parts adhesively bonded together.

RTM reduced manufacturing time and improved overall quality of the part.

The new process uses NidaFusion STF with the following benefits:

- Elimination of the PU injected core- Reduction of the steel inserts- Part is 30% lighter, 40% faster to produce and 8% lower cost- Increased mechanical resistance and estimated life cycle of the part- Reduced investment (one mold only compared to three previously)

229

ENGINE DOOR COMPARATIVE

19 kg19 kg 13 kg13 kg

355 min355 min 215 min215 min

8% less

230


STRUCTURAL ROOF for Marcopolo Bus

Currently a bus roof is made of:- A steel frame- An outside fiberglass skin- An inside skin (fiberglass, formica, plastic…)- Some inserts (steels, plastic, foam …)

Development consists of replacing all these elements by one RTM Integrated part using NidaFusion STF

231



Test mold representing one section of a 6m minibus roof.

232



Good Surface Finish Light Stiff

233

Light RTMLight RTM

234

CURRENT APPLICATIONSCURRENT APPLICATIONS

Front parts BathroomWheel FlareWheel Flare

235

CURRENT APPLICATIONSCURRENT APPLICATIONS

Back CoverInternal parts External roof

240

Thank you for attending !

Questions

Jack LugusNida-Core Corporation

2009 Brochure

Documents

Transcript of 2009 Brochure