The utilization of formable paint films in the implementation of in-mold decoration of composites manufactured by the resin infusion between double flexible tooling (RIDFT) process

Abstract

With the rapidly increasing deployment of polymer composites as the material of choice, environmentally benign methodologies for manufacturing and coating the resulting components are imperative. Several methodologies are currently in use to manufacture composites in 'closed' molds; however, the implementation of coatings is still for the most part, done using methods that provide for the release of harmful, volatile organic compounds (VOC) to the environment. The current work details the utilization of a thermoformable polycarbonate paint film for the in-mold decoration (1MD) of composite materials manufactured using the novel Resin Infusion between Double Flexible Tooling (RIDFT) process. RIDFT is a vacuum driven process where resin infusion is performed between two reinforcement-filled flexible diaphragms. Upon completion of infusion, the flexible diaphragms are vacuum formed over a one-sided tool, providing for the rapid cost effective manufacture of composite components. In this process, in-mold decoration is achieved by including a thermoformable polycarbonate paint film within the flexible diaphragms, over the reinforcing fabrics (fibers), prior to infusion. After infusion, the whole assembly (paint film, fibers and resin) is vacuum formed to the desired geometry, thus achieving IMD. This paper discusses the achievements and problems of this cost effective and environmentally friendly methodology. Formability of the fabric was made more difficult by the inclusion of the paint film. Assessment of the rheological properties of the paint film determined a radical improvement of formability at temperatures over 140°C; however, resin cure issues were prevalent well below the prescribed film forming temperature. A study was conducted to ascertain the appropriate resin-catalyst system to delay curing until complete forming of the polycarbonate film. Significant progress has been attained with the implementation of paint films in the RIDFT process, resulting in the successful manufacture of several IMD components.

Publication Title

Proceedings of the 12th U.S.-Japan Conference on Composite Materials

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