What are the advantages of vacuum resin introduction process?
Vacuum resin introduction process is a low-cost manufacturing process developed in the past 20 years, especially suitable for the manufacturing of large products. Its advantages are as follows:
(1) The product has excellent performance and high yield.
Compared with hand laid components, the strength, stiffness, and other physical properties of components formed by vacuum resin introduction process can be improved by more than 30% -50% with the same raw materials. After the process is stable, the yield can approach 100%.
(2) The product quality is stable and has good repeatability.
The product quality is less affected by operators, and there is a high degree of consistency between the same component and various components. The fiber dosage of the product has been placed in the mold according to the specified amount before injection of resin. The components have a relatively constant resin ratio, usually between 30% and 45%. Therefore, the uniformity and repeatability of product performance are much better than those of hand layup process products, and there are also much fewer defects.
(3) Improved fatigue resistance can reduce structural weight.
Due to the high fiber content, low porosity, and high product performance, especially the improvement of interlayer strength, the fatigue resistance of the product has been greatly improved. Under the same strength or stiffness requirements, products made using vacuum induction technology can reduce structural weight.
(4) Friendly environment.
The vacuum resin introduction process is a closed mold process, where volatile organic compounds and toxic air pollutants are limited to the vacuum bag. Only trace amounts of volatile matter are present when the vacuum pump is vented (filterable) and the resin barrel is opened. VOC emissions shall not exceed the standard of 5PPm. This also greatly improves the working environment for operators, stabilizes the workforce, and expands the range of available materials.
(5) The overall product is good.
The vacuum resin introduction process can simultaneously form reinforcing ribs, sandwich structures, and other embedded parts, improving the integrity of the product. Therefore, it can manufacture large products such as fan casings, ship hulls, and superstructure.
(6) Reduce the use of raw materials and labor.
When laying the same layer, the resin dosage is reduced by 30%. Less waste, resin loss rate less than 5%. High labor productivity, saving more than 50% of labor compared to hand layup process. Especially when forming large and complex geometric sandwich and reinforced structural components, the material and labor savings are more significant. In the vertical rudder manufacturing of the aviation industry, reducing the price of fasteners by 365 is 75% lower than traditional methods, and the product weight remains unchanged, resulting in better performance.
(7) Good product accuracy.
The dimensional accuracy (thickness) of vacuum resin import process products is better than that of hand laid products. Under the same layer, the thickness of vacuum resin diffusion technology products is generally 2/3 of that of hand laid products. The thickness deviation of the product is about ± 10%, while the hand layup process is generally ± 20%. The flatness of the product surface is better than that of hand laid products. The inner wall of the vacuum resin introduction process hood product is smooth, and the surface naturally forms a rich resin layer, without the need for additional topcoat. Reduced labor and materials required for polishing and painting processes.
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