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Thermoset Resins in Production
BoatbuildingSeptember 11, 2006

• Joe Parker
• Product Manager, Pro-Set Inc.
• PO Box 656
• Bay City, MI 48707
• 888-377-6738
• parker_at_prosetepopxy.com
• 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.

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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.

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• Historical Perspective
• Resin Types
• Processes
• Transitional Phase
• Driven by Regulation
• Customer Performance Requirements
• Resin Choices
• Process Choices

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Processes

• Contact Mold / Open Mold
• Vacuum Bag
• Resin Infusion

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Resin Choices

• Polyester
• Vinylester
• Epoxy

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Processes

• Contact Molding
• Wet Preg Vacuum Bag
• Resin Infusion

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Contact Moldingbucket and brush

• Advantages
• Low cost
• No new equipment
• No additional training necessary

• Disadvantages
• minimal mechanical properties gain
• no control of resin content
• excess resin use / cost
• no labor savings

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Closed Molding

• Vacuum Bagging
• Resin Infusion
• RTM
• RTM light

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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

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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

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Vacuum Bag / Wet - PregImpregnator or roll
coater wet - out

• Advantages
• Saves labor
• Good mechanical properties in laminate
• Excellent resin content control
• Good core bonding

• Disadvantages
• Equipment cost
• Equipment clean - up
• Training required

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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

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Resin Infusion

• Advantages
• Very good resin content control
• Good laminate properties
• Very clean / handle dry fabrics core
• Can include secondary structure

• Disadvantages
• Training required
• License may be required
• Some additional resin waste
• Additional disposable materials

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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

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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

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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

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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