Autoclave Process VS Compression Mold
The molding process uses the characteristics of each stage in the resin curing reaction to realizing the product molding, that is, the molding material plasticizes, flows, and fills the mold cavity, and the resin is cured.
In the process of filling the mold cavity with the molding material, not only the resin flows, but also the reinforcing material flows, Therefore, the molding pressure of the molding process is higher than that of other wet carbon vacuum processes, which belongs to high-pressure molding.
Therefore, it needs not only a hydraulic press that can control the pressure but also a metal die with high strength, high precision, and high-temperature resistance It is mainly used as structural parts, connecting parts, protective parts, and electrical insulating parts. It is widely used in the field of the composite industry.
Fortunately, jcsportline introduced a large number of molding equipment to make some columns of carbon fiber products in 2020, which has been highly praised by customers all over the world.
molding process
Advantages:
(1) quality defect(usually 2% ~ 5% defect rate ).
(2) The internal stress of the product is very low, the warpage deformation is also very small, and the mechanical properties are relatively stable.
(3) The wear of the die cavity is very small, and the maintenance cost of the die is low.
(4) The cost of molding equipment is low, its mold structure is simple, and the manufacturing cost is usually lower than that of injection mold or transfer molding mold.
(5) Large flat products can be formed. The size of the products that can be formed by molding is only determined by the clamping force of the existing molding machine and the size of the template.
(6) A mold with a large number of cavities can be placed on a given template, with high productivity.
(7) It can adapt to automatic feeding and automatic taking out of products.
(8) High production efficiency, easy to realize professional and automatic production.
(9) For the tail wing and other products, the problem of thick clamping line caused by the traditional process of clamping can be solved by molding
(10) Mass production, relatively low price. It solves the pain point of the low production capacity of carbon fiber products, and a mold can produce 8-16 products a day.
Disadvantages :
(1) The mold structure in the whole manufacturing process is complex, which is higher than the traditional carbon fiber mold
(2) It is not suitable for molding complex products with depressions, side slopes, or small holes.
(3) In the manufacturing process, it is difficult to fully fill the mold, and there are certain technical requirements
(4) For products with high dimensional accuracy requirements (especially for multi-cavity molds), the process is somewhat short.
(5) Finally, the flash of the product is thick, and the workload of removing flash is large. Inspection tools must be used
Autoclave
1. The method uses the pressure generated by the high-temperature compressed gas in the hot pressing tank to heat and pressurize the composite blank to complete the curing molding
The air source in the tank includes air, nitrogen, and carbon dioxide
2. Prepreg preparation – cutting – stacking – forming – post-curing
3. Forming – glue absorption in the tank, heat transfer with curing process, fiber compaction, resin curing, resin flow, bubble formation, and movement, residual stress, and deformation
advantages:
A. Uniform pressure in the tank: because compressed gas or inert gas or mixed gas is used to inflate and pressurize the hot pressing tank, the pressure acting on the normal of each point on the surface of the vacuum bag is the same, and the components are formed and solidified under uniform pressure
B. Uniform air temperature in the tank: the high-speed circulation of heating or cooling gas in the tank. The gas temperature at each point in the tank is basically the same. On the premise of reasonable die structure, it can ensure that the temperature difference at each point during the temperature rise and fall of components sealed on the die is small.
C. For carbon fiber products, it has high hardness, high-temperature resistance, and yellowing resistance. It is very light, but the cost is high. The price is about twice that of ordinary wet carbon. By the favor of OE, and brands, and other high-quality customers
D. Any complex product can be molded, and as long as the mold is made, the product can be produced.
Disadvantages :
A: Low efficiency, one mold can only produce one product a day, if you need high efficiency, only duplicating many molds
B: Extremely high power consumption and high equipment maintenance costs
C: Relative high mold cost
