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AZDEL Superlite Sheet - Technical Guide Part 2.

IP.com Disclosure Number: IPCOM000009065D
Publication Date: 2002-Aug-05
Document File: 31 page(s) / 4M

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The IP.com Prior Art Database

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IPCOM000009046D: IP.COM

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 31

AZDEL Thermoplastic Composites

SuperLite® - Technical Guide

Technology that Endures

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Slide 2 of 31

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 31

AZDEL Thermoplastic Composites

SuperLite® - Technical Guide

Processing

Exit

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Slide 4 of 31

General Characteristics

Process is characterized as "Thermo-stamping" or "Matched-mold Thermoforming".

Typical forming pressures to fully consolidate SuperLite are around 0.33 bar (~ 10 psi) and are unlikely to exceed 2 bar (30 psi).

Thickness of formed part is set by stops external to the mold.

For optimal structural performance, lofted material should not be fully compressed during molding.

Formed thickness from lofted material is inversely proportional to the depth of draw.

Usually, vacuum is not required when molding SuperLite, however, this might be necessary when using surface films (not adhesives.)

Thermoforming equipment is ideal for forming SuperLite, however, it can be formed on standard compression molding presses with the use of a frame to hold the sheet.


Slide 5 of 31

Characteristics of Forming Process (Minimum)

Single acting press (I.e.; only upper platen moves.)

Single-zone, radiant heat oven using either quartz or ceramic elements.

Material transport system that clamps/Pins SuperLite sheet on at least the two long edges, and keeps tension in sheet during heating and forming (the material is allowed to sag in the oven.)

Manual loading of SuperLite sheets onto material transport system.

Material transport system for cover stock that keeps tension in the material during processing.

Temperature control system to keep mold at constant temperature.


Slide 6 of 31

Characteristics of Forming Process (Optimum)

Double acting press (I.e.; both upper and lower platens move.)

Multi-oven, multi-zone, radiant heat ovens using either quartz or ceramic elements.

Material transport system that clamps SuperLite sheet on all f...