novel monomer free vinyl hybrid resin for composite ... 2014 novel...radomes 5 functions • shield...
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Novel Monomer Free Vinyl Hybrid
Resin for Composite Radomes and
Aerospace Applications
Jim Bono JEC Paris March 12th, 2014
Background
• Advanced Material Market
• Styrenated Systems are Unacceptable
– Governmental Regulations
– Control Technologies Needed
– Minimize Capital Investment
• Development Need for Reactive Diluent Free Thermoset Resin Systems
– Cost Effective
– Improved Dry/ Wet Tg
– Improved Water Absorption
– Improved Production Rates- approach 3 minute cycle
Nomenclature
Styrene Free Resins
Reactive Diluent Free Alternative
Reactive
Diluents
VT
• Acrylates
• Others
Solids: “Pre-preg Monomer
Free Hot Melt Vinyl Hybrids”
Liquids: Reactive Oligomers
“Vinyl Hybrid Liquid Resins”
• ADVALITE™ – Monomer Free Hot Melts
• ADVALITE™ – Vinyl Hybrid Liquid Resins
Chemistry Description: Vinyl Hybrids
Radomes
5
Functions
• Shield microwave
antenna from adverse
environmental effects
• Minimal effect on
electrical performance
• Withstand Structural
Loads from pressure
differential
Material Property Considerations
• Water Absorption: Water absorbs transmission
energy and increases loss tangent
– Low water absorption is necessary for radomes
• Dielectric Constant: Determine the ability of
insulator to store electrical energy
– Low dielectric constant is necessary for radomes
• Loss Tangent: Ratio of input/output power
through material – Low loss tangent is necessary for radomes
Radome Resin Candidates
• Cyanate Esters
• Modified Epoxies (BisA Cyanate/Epoxy)
• Epoxy (Accelerated Dicyanamide, 120° C cure)
• ADVALITE™ Vinyl Hybrid
% Water Absorption Comparisons (64 Hour Boil)
0
0,5
1
1,5
2
2,5
3
3,5
Percent Water Absorption
Epoxy/DICY
X4833-60 (Vinyl Hybrid)
Modified Epoxy
Cyanate Ester
7
Dielectric Constant Comparison
2,5
2,6
2,7
2,8
2,9
3
3,1
Dry
Epoxy/DICY
X4833-60 (Vinyl Hybrid)
Modified Epoxy
Cyanate Ester
8
Dielectric Constant Comparisons
Dry vs. Wet
2.60
2.70
2.80
2.90
3.00
3.10
3.20
3.30
Epoxy/ DICY X4833-60
(Vinyl Hybrid)
X4622-47
(Vinyl Hybrid)
X4767-47
(Vinyl Hybrid)
X4759-06
(Vinyl Hybrid)
Die
lect
ric
Co
nst
ant
No Preconditioning 24 Hrs Boiling Water 64 Hrs Boiling Water
Dissipation Factor/Loss Tangent Comparison
0
0,005
0,01
0,015
0,02
0,025
Dry
Epoxy/DICY
X4833-60 (Vinyl Hybrid)
Modified Epoxy
Cyanate Ester
Comparison of Dissipation Factor/Loss Tangent
0,000
0,005
0,010
0,015
0,020
0,025
0,030
0,035
0,040
0,045
0,050
Epoxy/ DICY X4833-60(Vinyl Hybrid)
X4622-47(Vinyl Hybrid)
X4767-47(Vinyl Hybrid)
X4759-06(Vinyl Hybrid)
Loss T
an
gen
t
No Preconditioning 24 Hrs Boiling Water 64 Hrs Boiling Water
ADVALITE™ X4833-60 Radome Resin Clear Cast Mechanical Properties
Property Units ADVALITE™
X4833-60
Flexural Strength M Pa 78,7
Flexural Modulus G Pa 4,14
Tensile Strength M Pa 35,3
Tensile Modulus G Pa 3,54
HDT °C >200
Dry Tg °C 193
Wet Tg °C 172
Hand Lay-up (Prepreg)
Properties for Optimum Prepreg
• Optimum tack and drape
• Low volatile content
• Low temperature cure
• Long shelf-life
• Low heat of reaction
• Controlled flow
13
Hand Lay-up
• Heat of reaction of ADVALITE™
Vinyl Hybrids System is roughly half
of a standard 120 °C cure,
accelerated Dicyanamid Bis-A
epoxy, so parts with large cross-
sections can be cured with less risk
of exotherm and cracking
• ADVALITE™ Vinyl Hybrid Systems
offer cure times under 5 minute for
rapid part production
• ADVALITE™ Vinyl Hybrid Systems
are a peroxide-cure, lending itself
well to inline mixing for rapid
prepreg production
• Prepreg produced using
ADVALITE™ VINYL HYBRIDS
systems does not need to be frozen
or refrigerated, lowering the cost of
shipping and handling, and
minimizing scrap due to expired
shelf-life
Typical shelf-life @ 21°C for:
Cyanate ester 14 days
Cyanate/Epoxy 14 days
120 °C cure epoxy 4 to 8 weeks
ADVALITE™
Vinyl Hybrid> 1 year
14
Radome Resin
Typical Cost/Lb (Formulated)
$0
$10
$20
$30
$40
$50
$60
$70
$80
$90
$100
Cost per Lbs
Epoxy
X4833-60 (Vinyl Hybrid)
Modified Epoxy
Cyanate Ester
ADVALITE™ 35000-00 Vinyl Hybrid
FR Grade Hot Melt Prepreg Resin Prepreg Thermo-Mechanical Properties
Property Units
ADVALITE™
35000-00
RT
ADVALITE™
35000-00
RT, Wet
ADVALITE™
35000-00
120° C
Tensile Strength M Pa 73 69 51
Tensile Strength
Retention % 94% 70%
Tensile Modulus G Pa 4,6 4,7 4,3
Tensile Modulus
Retention % 102% 93%
Compression
Strength M Pa 64 58
Compression
Modulus G Pa 4,8 4,6
Flexural Strength M Pa 113 100.0 54.0
Flexural Strength
Retention % 89% 48%
ADVALITE™ Vinyl Hybrid Liquid Resins
Vacuum Infusion Process (VIP)
• Processing Conditions- resin factors
to consider: • Polymer structure
• Viscosity
• Degree of cure-part thickness
Critical to Filling Complex Geometries and Moldability:
• Optimize resin for low viscosity
and good fiber wetting while
retaining good physical properties
Vacuum Infusion Process
Infusion Flow Rates
0
2
4
6
8
10
12
14
0 20 40 60 80 100 120
Flo
w D
ista
nce
(in
)
Time (min)
Flow Distance vs Time
X4690-86
9102-75
1"
2"
3"
4"
5"
6"
7"
8"
9"
10"
11"
12"
13"
14"
15"
16"
17"
18"
Flow Media
Inlet Line
Laminate
Peel Ply
Vacuum Line
Record Time at
Distance Increments
Start Stopwatch
Vinyl Hybrid Infusion Trial
Deep vertical draw sections to
ensure proper resin flow rates
Thick section part- 12 mm
Used to study exotherm
conditions and glass wetting
Glass wetting acceptable throughout entire composite part Glass wetting acceptable
throughout entire composite
part
Mechanical Properties Comparison Neat Resin Clear Cast Results
Property Units ADVALITE™
35065-00 ADVALITE™
35060-00
ADVALITE™
X4830-27 ADVALITE™
X4759-06
Flexural Strength M Pa 159,3 116,9 74,6 117,3
Flexural Modulus G Pa 4,37 3,61 3,52 4,24
Tensile Strength M Pa 80,3 45,6 16,0 31,8
Tensile Modulus G Pa 3,83 3,77 3,63 4,14
Elongation % 2,8% 1,5% 0,5% 0,9%
HDT C 72 155 >200 >200
Dry Tg C 81 170 149 175
Wet Tg C 166
Water Absorption % 0,83% 0,57% 0,16%
Viscosity cps 625 1,200 400 1350
Conclusions
ADVALITE™ Vinyl Hybrid Systems offer resins capable to produce both prepreg and vacuum infusion molding systems for the Aerospace market which offer the following:
• Excellent retention of properties after exposure to water at elevated temperature
• Superior performance to epoxy regarding; Water Absorption, Dielectric Constant and Dissipation Factor
• Lower heat of reaction than epoxy for rapid cures of thick cross-section parts
• No need for refrigeration of prepreg
• Lower total cost for the manufacture of cost effective commercial radomes
Questions?
THANK YOU FOR YOUR ATTENTION!
Visit Reichhold at booth M48 – 7.3
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