DEFORMABLE CLOSED MOULD

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DEFORMABLE CLOSED MOULD VACUUM INFUSION
REINFORCEMENT
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NON WOVEN CORE CONSTRUCTION

• STAPLE FIBRES
• CARDING
• CROSS LAPPING
• ADHESIVE SPRAY
• OVEN CURED

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NON WOVEN CORE CONSTRUCTION
PROPERTIES

• DESIGED PRIMARILY FOR UNFILLED RESINS.
• POTENTIAL RESISTANCE TO RESIN FLOW.
• A LOW COMPRESSION RESISTANCE.
• HIGH QUALITY SURFACE FINISH

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DESCRIPTION
POLYMAT HI-FLOW IS A MECHANICALLY STITCH
BONDED REINFORCEMENT CONSISTING OF A DEFORMABLE
ENGINEERED THERMOPLASTIC CORE SANDWICHED
BETWEEN TWO LAYERS OF CHOPPED STRAND GLASS
FIBRE. POLYMAT HI-FLOW IS PRIMARILY INTENDED
FOR USE IN CLOSED MOULD AND VACUUM INFUSION
PROCESSING AND IS AVAILABLE WITH DIFFERENT
WEIGHTS OF GLASS IN THE OUTER FACING.
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MANUFACTURING METHODS

• VACUUM INFUSION
• VACUUM ASSISTED RTM
• RTM (RESIN TRANSFER MOULDING)
• COLD PRESS MOULDING
• PRESSURE BAG MOULDING
• PRESS/ VAC MOULDING

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PROCESS FLOW

• CHOPPED GLASS
• LAID ONTO BELT
• POLYMAT CORE
• CHOPPED GLASS LAID ON TOP
• STICH BONDED

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CONSTRUCTION 3 LAYER LAMINATE

• TOP LAYER/ BOTTOM LAYER
• CHOPPED GLASS ROVINGS,
• STICH BONDED TO CORE

CORE ENGINEERED THERMOPLASTIC CORE (CORE WEIGHT
105 220GSM)

• LAMINATE WEIGHT 705 2220GSM
• CHOPPED GLASS ROVINGS,
• STICH BONDED TO CORE

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CORE OPTIONS

• MO1 - 220gsm x 4.5mm CORE
• MOST RESILIENT CORE FOR STABILITY IN
  CAVATIES FROM 3-7MM.
• EXCELLENT CONTROL OVER COMPRESSION.
• MO3 - 105gsm x 3mm CORE
• FOR USE IN 2-4MM CAVATIES AND
  WHERE COSMETIC FINISH IS IMPORTANT
• MO5 - 155gsm x 5mm CORE
• CORE FOR GENERAL USE IN 3-5MM
  CAVATIES WHERE FLEXIBILITY AND
  SURFACE FINISH ARE KEY ISSUES.

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MAIN BENEFITS

• 50 REDUCTION IN FILL TIME VERSUS RIVAL
  PRODUCTS.
• ABILITY TO HANDLE HIGHLY FILLED AND HIGH
  VISCOSITY RESINS.
• EASE OF FLOW AND FILL FOR VERY LARGE MOULDINGS.
• IMPROVED CONTROL OF FINISHED PART THICKNESS
  UNDER
• VACUUM FILM .
• ABILITY TO WITHSTAND HIGHER RTM PRESSURES.
• PREDICTABLE COMPRESSION AT A GIVEN PRESSURE.
• ELIMINATES PROBLEMS WITH CORNERS

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PROCESS BENEFITS

• REDUCE CYCLE TIMES.
• COMPLEXITY OF MOULDINGS CAN BE INCREASED.
• REDUCE RESIN REQUIREMENTS.
• SUPERIOR CORNER FILL.
• OUT PERFORMS EXISTING PRODUCTS.

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CASE 1 FLOW RATES

• FLAT PLATE COMPARISON AT DIFFERING PRESSURES
  AND VISCOSITIES

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CASE 2 FLOW RATES (1 MINUTE)

• POLYMAT HI-FLOW Vs LEADING COMPETITOR

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CASE 2 FLOW RATES (3 MINUTE)

• POLYMAT HI-FLOW Vs LEADING COMPETITOR

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CASE 2 FLOW RATES (5 MINUTE)

• POLYMAT HI-FLOW Vs LEADING COMPETITOR

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CASE 2 FLOW RATES (7 MINUTE)

• POLYMAT HI-FLOW Vs LEADING COMPETITOR

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CASE 2 FLOW COMPARISON

• POLYMAT HI-FLOW VS LEADING COMPETITOR
• 0.5 BAR UNDER VACUUM FILM. 1 POISE UNFILLED
  POLYESTER

HI-FLOW 450 COMPETITOR
450/5MM/450
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CASE 2 FLOW COMPARISON

• POLYMAT HI-FLOW VS LEADING COMPETITOR
• 0.5 BAR UNDER VACUUM FILM. 2 POISE 25 FILLED
  POLYESTER

HI-FLOW 450 COMPETITOR
450/5MM/450
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THICKNESS COMPARISON

• POLYMAT HI-FLOW VS LEADING COMPETITOR
• 1.0 BAR UNDER VACUUM FILM. 2.5 POISE UNFILLED
  POLYESTER

POLYMAT HI-FLOW LEADING COMPETITOR
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CASE 3
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CASE 3 9.5 MTR RACE BOAT HULL
INFUSION CRITERIA FOR MOVING TO CLOSED MOULD
DRAGON CLASS BOATS ALL NEED TO BE BUILT TO A
RACING SPEC - THAT CANNOT BE CHANGED (ONE
COMPANY TO THE NEXT). (CLOSED MOULD PROVED
PROBLEMATIC BECAUSE NO LAMINATE ADVANTAGES COULD
BE DESIGNED IN) THE BOAT HAD TO REMAIN SAME
IN LAMINATE THICKNESS, GLASS CONTENT AND
FLEXURAL PROPERTIES ON A ROUGH PAR WITH HAND LAY
CRAFT. BETTER CONTROL OVER LAMINATE AND
PRODUCTION EFFICIENCY.
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CASE 3 9.5 MTR RACE BOAT HULL INFUSION NEW
LAMINATE 2 X GEL COAT 2 X 300g/m² CHOP STAND
MAT gtgtgt HAND LAY BASE LAYERS 2 X 600g/m² BI-AX
/-45 CLOTHS 1 X 600/300g/m² BI-AX
COMBINATION PM/M300/M01/M300 POLYMAT 2 X
600/300g/m² BI-AX COMBINATIONS PEEL PLY
INFUSION MEMBRANE BAG
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CASE 3 9.5 MTR RACE BOAT HULL INFUSION TEST
TRACK
LAMINATE WITH POLYMAT HI-FLOW
HALF WAY MARK
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CASE 3 9.5 MTR RACE BOAT HULL INFUSION HULL
LAMINATE PRODUCT THE HULL INFUSES IN 25
MINUTES. APPROX. 9.5MTRS IN LENGTH.
COMPLETE INFUSION - FROM STATIC RESIN HEAD IN
BUCKET. APPROX. 8.5MM THICK VACUUM AT
0.6BAR.
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CASE 3 9.5 MTR RACE BOAT HULL
INFUSION LAMINATE EXPOSED FOR KEEL ATTACHMENT
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CASE 3 9.5 MTR RACE BOAT HULL
INFUSION BENEFITS OF POLYMAT HI-FLOW THE
ONLY TEST LAMINATE TO INFUSE EFFECTIVELY WHILE
MEETING SPEC THE ONLY MEANS OF MAINTAINING
SPECIFICATION THICKNESS UNDER BAG INFUSION
PRESSURE WHILE MAINTAINING SIMILIAR LAY-UP
THE ONLY MEDIUM THAT COULD BE USED AS PART OF
LAMINATE WITHOUT THE NECESSITY TO USE FURTHER
FLOW MEMBRANES THE ONLY MEDIUM TO DELIVER
CONSTANT LAMINATE THICKNESS AND STRENGTH SECURITY
WHILE BEING AN INTEGRAL PART OF THE LAMINATE
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CASE 4 FLOW RATES SEMI-RIGID TOOL DESIGN SET
AT 3MM CAVITY WITH 2 POISE UNFILLED POLYESTER
INJECTED AT 1.07 BAR.
TIME 30 SECONDS
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CASE 4 FLOW RATES SEMI-RIGID TOOL DESIGN SET
AT 3MM CAVITY WITH 2 POISE UNFILLED POLYESTER
INJECTED AT 1.07 BAR.
TIME 120 SECONDS
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CASE 4 FLOW RATES SEMI-RIGID TOOL DESIGN SET
AT 3MM CAVITY WITH 2 POISE UNFILLED POLYESTER
INJECTED AT 1.07 BAR.
TIME 200 SECONDS
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• CASE 4 FLOW ANALYSIS
• COMPARED WITH AN EQUIVALENT WEIGHT PRODUCT FROM A
  CURRENT MARKET LEADER, INJECTED UNDER IDENTICAL
  CONDITIONS, POLYMAT HI-FLOW PRODUCED THE
  FOLLOWING BENEFITS
• COMPLETE MOULD FILL IN HALF THE TIME.
• ERADICATION OF RESIN RICH EDGES DUE TO IMPROVED
  COMPRESSION RESISTANCE
• 20 RESIN SAVING.

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EXAMPLES OF CURRENT RTM LIGHT 1. SEPTIC
TANKS ADVANTAGE OF MOVING TO POLYMAT
HI-FLOW 6MM PART FILLED IN 5MIN (15-20MIN
SAVING). SAVED ENOUGH RESIN ACROSS 6 TANKS
TO MAKE ANOTHER TWO. COULD PRODUCE FURTHER
TWO IN A DAY DUE TO TIME SAVED.
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• EXAMPLES OF CURRENT RTM LIGHT
• 2. ARCHITECTURAL MOULDINGS
• MAIN BENEFITS GAINED FROM USING POLYMAT HI-FLOW
• ONLY PRODUCT THAT ALLOWED
• CONSTANT CONTROL OVER RESIN
• FLOW AT A THINNER WALL THICKNESS.
• ONLY PRODUCT TO ALLOW 25
• FILLED RESIN TO MOVE WITH EASE
• WITHOUT RESTRICTION.
• ONLY PRODUCT TO OFFER
• CONSISTENCY OF CORE PERFORMANCE
• FOR DEVELOPING VOLUME POSITION.

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• EXAMPLES OF CURRENT RTM LIGHT
• WHITEWATER COMPOSITES
• POLYMAT HI-FLOW ALLOWS WHITEWATER COMPOSITES
  TO INJECT FASTER, WITH SHORTER CYCLE TIMES, A
  CLASS A SURFACE PROFILE AND THE ABILITY TO INJECT
  HIGHLY FILLED RESINS FOR INCREASED COST SAVINGS.

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• CASE 5 FLOW RATES
• CRAY VALLEY ENCORE 30 RESIN FLOW RATE _at_ 0.8BAR,
  4MM CAVITY

FIXED CAVITY INFUSION POLYMAT HI-FLOW
450/MO1/450
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STRUCTURAL ANALYSIS FLEXURAL STRENGTH
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STRUCTURAL ANALYSIS FLEXURAL MODULUS
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STRUCTURAL ANALYSIS TENSILE STRENGTH
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STRUCTURAL ANALYSIS TENSILE MODULUS
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• PRODUCT OVERVIEW
• POLYMAT HI-FLOW SATISFIES THE REQUIREMENTS OF
  CLOSED MOULD AND VACUUM FILM PROCESSING, BEING A
  COLD FORMABLE LAMINATE WITH LOW RESISTANCE TO
  RESIN FLOW.
• POLYMAT HI-FLOW IS DESIGNED TO OVERCOME ALL OF
  THE EXISTING DRAWBACKS WITH CURRENTLY AVAILABLE
  MATERIALS, AND IS ENGINEERED TO ALLOW
  PRODUCTION OF NEXT GENERATION PRODUCTS.

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FEATURES BENEFITS
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• CHALLENGING QUESTIONS
• IF WE CAN OFFER A CLOSED MOULD REINFORCEMENT
  THAT
• FILLS THE PART FASTER
• USES LESS RESIN
• ALLOWS GREATER CHOICE OF RESIN
• PERMITS REALISTIC USE OF FILLERS
• IMPROVES QUALITY OF VACUUM BAG PARTS
• DECREASES STRESS IN YOUR MOULDS
• IMPROVES CORNER FILL
• INCREASES PROFITABILITY

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WHY WOULD YOU NOT WANT TO
USE
?