“Thermoset Resins in Production Boatbuilding”
September 11, 2006
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Joe Parker
Product Manager, Pro-Set Inc.
PO Box 656
Bay City, MI 48707
888-377-6738
[email protected]
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Presented at a meeting of the Thermoset Resin Formulators Association at the
Hyatt Regency Montreal in Montreal, Quebec, Canada, September 11 through
12, 2006.
This paper is presented by invitation of TRFA. It is publicly distributed upon
request by the TRFA to assist in the communication of information and
viewpoints relevant to the thermoset industry. The paper and its contents have
not been reviewed or evaluated by the TRFA and should not be construed as
having been adopted or endorsed by the TRFA.”
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Thermoset Resins in
Production Boatbuilding
TRFA Fall 2006
September 11, 2006
Joe Parker
Gougeon Brothers Inc.
Abstract
• This presentation will provide an overview
of the current manufacturing processes
and polymer resins used in the marine
industry. Historical perspective and trends
looking forward are also included.
• Historical Perspective
• Resin Types
• Processes
• Transitional Phase
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Driven by Regulation
Customer Performance Requirements
Resin Choices
Process Choices
Processes
• Contact Mold / Open Mold
• Vacuum Bag
• Resin Infusion
Resin Choices
• Polyester
• Vinylester
• Epoxy
Processes
• Contact Molding
• Wet Preg – Vacuum Bag
• Resin Infusion
Contact Molding
bucket and brush
• Advantages
• Disadvantages
• Low cost
• No new equipment
• No additional training
necessary
• minimal mechanical
properties gain
• no control of resin
content
• excess resin use /
cost
• no labor savings
Closed Molding
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Vacuum Bagging
Resin Infusion
RTM
RTM light
Vacuum Bagging
(What is vacuum bagging ?)
• The process of using atmospheric
pressure to consolidate or clamp a
laminate
• A membrane is sealed to the mold, and air is
evacuated from under membrane
• Atmospheric pressure presses on membrane,
squeezing laminate between mold surface and
membrane
Advantages of vacuum bagging
• Apply uniform pressure over entire
laminate surface
• Remove excess resin
• Help remove entrapped air
• Contain any emissions
• Can conform to almost any shape
Vacuum Bag / Wet - Preg
Impregnator or roll coater wet - out
• Advantages
• Disadvantages
• Saves labor
• Good mechanical
properties in laminate
• Excellent resin
content control
• Good core bonding
• Equipment cost
• Equipment clean - up
• Training required
Resin Infusion
(how does it work)
• Dry laminate stack placed in mold
• Vacuum bag installed and checked for
leaks
• Resin allowed to flow into laminate under
bag using atmospheric pressure to push
resin
Resin Infusion
• Advantages
• Disadvantages
• Very good resin
content control
• Good laminate
properties
• Very clean / handle
dry fabrics & core
• Can include
secondary structure
• Training required
• License may be
required
• Some additional resin
waste
• Additional disposable
materials
Resin Choices and Characteristics
• Polyester (PE)
– Least expensive
– Open Molding primary process
– Resin infusion becoming popular
– High VOC
– Shrinkage is an issue
– Toughness and Fatigue resistance in question
Resin Choices and Characteristics
• Vinylester (VE)
– Higher price than PE – lower than Epoxy
– Some contact molding
– Used as skin coat resin with PE hulls
– Resin Infusion most popular with VE
– Better Fatigue resistance and Toughness
– High VOC
– Shrinkage
Resin Choices and Characteristics
• Epoxy
– Most expensive Boatbuilding resin
– Generally used in higher performance craft
• Often with carbon and S-glass
– Can be used for Resin Infusion
– Best fatigue resistance and toughness
– Vacuum bagged laminate creates lightest
structure
Summary
• Resin cost is small portion of part cost
• Cost of fibers and cores will continue to
rise about equal to resin
• Closed molding here to stay and growing
• Customers demanding lighter, more
durable boats