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Azdel Superlite Sheet - Technical Guide Part 1.

IP.com Disclosure Number: IPCOM000009064D
Publication Date: 2002-Aug-05
Document File: 35 page(s) / 4M

Publishing Venue

The IP.com Prior Art Database

Abstract

SuperLite thermoplastic composite sheets, made by a modified paper making process, are a highly adaptable form of chopped glass reinforced resin that may be easily molded over a wide range of density to provide the required balance of properties for a host of applications. Relatively high glass fiber content is used to effect lofting, the tendency of the product to form a porous, low density structure with excellent insulating and flammability characteristics, depending on the particular resin, temperature and glass fiber content and molding pressure. Relatively high glass fiber content and low melt viscosity resin at the intended use or processing temperature are paired to maximize lofting. The resulting network tends to exhibit superior sound dampening properties, thermal insulation and fire performance without the use of halogen or heavy metal salts, while also providing high mechanical properties in a relatively easily moldable form. Resins such as polyetherimide (PEI) and polyphenylene sulphide (PPS) provide a superior balance of properties with outstanding flame resistance, stiffness, temperature capability and chemical resistance.

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Slide 1 of 35

AZDEL Thermoplastic Composites

SuperLite® - Technical Guide

Technology that Endures

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Sections

1. Overview

2. Properties

3. Design & Tooling

4. Processing

5. Secondary Operations

6. Troubleshooting

In as much as AZDEL, Inc. has no control over the use to which others may put this material, it does not guarantee that the same results as those described herein will be obtained. Nor does AZDEL, Inc. guarantee the effectiveness of safety of any possible or suggested design for articles of manufacture as illustrated. Each user of the material or design or both should make his/her own tests to determine the suitability of the material or any material for the design, as well as the suitability of the material or design or both for his/her own particular use. Statements concerning possible or suggested use of the materials or design are not to be construed as constituting a license under an AZDEL, Inc. patent covering such use or as recommendations for use of such materials or designs in the infringement of any patent.

AZDEL, Inc. proprietary information / All copyrights reserved

Version 1.0


Slide 3 of 35

AZDEL Thermoplastic Composites

SuperLite® - Technical Guide

Overview

Exit

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AZDEL SuperLite Long Glass Fiber Sheet

Low pressure, thermoformable, composite of thermoplastic resin matrix and long chopped fiber combined with outer layers as needed for the application. (e.g. adhesion film, barrier film, scrim, tough PP film, non-woven, reinforcement or just the bare surface.)

Why AZDEL SuperLite?

Light Weight

Superior Strength to Weight Ratio

Air Flow Elimination can be Engineered if Desired

Recyclable, Recycled Content

Simplified Manufacturing Process

Low System Costs

Broad Range of Product Weight and Stiffness

Low Coefficient of Thermal Expansion (CTE)

High Impact with Ductile Failure


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Material & Process Benefits

Light weight

Homogeneous distribution

Dimensionally stable

Meets/exceeds typical automotive interior temperature and humidity requirements

Low system cost per area

Recyclable

Sound deadening properties

Low pressure, fast cycle

Consistent weight/glass content control

Low mold & equipment costs

In mold decoration capable (carpet/fabric/foam/film)

Process provides range of weight in grams per square meter (GSM) and ash content to tailor stiffness and/or other properties

Very Favorable System Economics


Slide 6 of 35

Manufacturing Process

1. AZDEL SuperLite Manufacturing (paper making process)

2. Nip roll laminating process for applying film and scrim

1 Step Nip Roll laminating

Process with SuperLite Web

 

* optional

Nip point

Hot SuperLiteTM

Web from Dryer

Top Scrim*

Bottom Film*

Product Out

To sheeting

   
 

Resin

plus

Additives

Chopped

Glass

Resin/Glass

Slurry

Cut to customer length & width

NIP

Rolls

Hot Air Dryer

SuperLite

Web

Head Box

Vacuum

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