FABRICATION OF COMPRESSION MOLDED ECO-COMPOSITES: OPTIMAL PROCESS CONDITIONS INDUSTRISKO PROIZVODSTVO NA KOMPRESIONO PRESUVANI KOMPOZITI: OPTIMALNI PROCESNI USLOVI V.Srebrenkoska PROJECT Eco-Houses Based on Eco-Friendly Polymer Composite Construction Materials - ECO-PCCM

2 Composite materials, which are produced in “Kompozitna Oprema" Composite materials containing glass fabric as reinforcement and synthetic phenolic resin as matrix. Composite materials containing cotton fabric as reinforcement and synthetic phenolic resin as matrix. Composite materials containing cellulose paper as reinforcement and synthetic phenolic resin as matrix. Composite materials containing glass fabric as reinforcement and synthetic epoxyde resin as matrix.

3 The reinforcement material used in the composites is impregnated with a resin when a preform prepreg is obtained. With the impregnation process a complete wetting of fibers with the matrix is performed lake a transparent film. In the prepreg itself the resin is transformed from A to B stages that is form liquid and soluble phase into a solid, partly melt able phase suitable for processing. Basic parameters in the process of prepreg production are: content of matrix, uniformity of matrix along overall surface of reinforcement, gel time, matrix flow, moisture content and volatiles materials. PRODUCTION OF PREPREGS

4 PRODUCTION OF STRUCTURAL COMPOSITES All the composites are fabricated by thermo compression in an open mold on a semi - industrial press in “Kompozitna Oprema".

5 PRODUCTION OF STRUCTURAL COMPOSITES- Optimal process conditions t = a + bx a,b-coef. x-thickness of the composite Glass / epoxy resin - based prepreg T= O C Ps= MPa Paper / phenolic resin - based prepreg T= O C Ps= MPa Glass / phenolic resin - based prepreg T= O C Ps= MPa Cotton / phenolic resin - based prepreg Cotton / phenolic resin - based prepreg T= O C Ps= MPa

6 MATERIALS FOR PRODUCTION OF ECO- COMPOSITES KENAF FIBERS PREFORMS-SMC as reinforcement as matrix Kenaf as reinforcement / TP1 as matrix as reinforcement as matrix Kenaf as reinforcement / B3 as matrix Components: PELLETS as reinforcementas matrixas coupling agent RC as reinforcement / B3 as matrix / CA as coupling agent as reinforcementas matrixas coupling agent RC as reinforcement / TP1 as matrix / CA as coupling agent Components:

7 Hot plate Kenaf layers Press piston Press platen Polster Release foil Thermocouple PRODUCTION OF ECO-COMPOSITES: KENAF/TP1 Optimal Press Cycle: T=170 O C Ps = 185 bar t = 15 min

8 Hot plate Press piston Press platen Polster Release foil The panels are fabricated by thermo compression in a closed mold. Mold MANUFACTURING OF KENAF/B3 ECO COMPOSITES Closed mold and application of spacers Kenaf layers NOTE: Open mold panel B3 squeezed out The application of the same press cycle (open mold and high pressure) as the one for kenaf/TP1 composites was impossible because B3 was squeezed out of the fibers. Optimal Press Cycle: T=175 O C Pm = until closing on the spacers t = 20 min

9 MANUFACTURING OF KENAF/B3 ECO-COMPOSITES To solve the problem of the B3 squeeze out, a closed mold and 9.0 mm thick spacers were applied to prevent full closure of the mold and migration of PLA to the boundaries of the composite panel. kenaf/B3 layers spacers Mold in open position Mold in closed position kenaf/B3 composite

10 Kenaf based composites

11 PRODUCTION OF ECO-COMPOSITES FROM PELLETS Molding frame 120 x 120 mm Molding package Pellets Molding tool is required One panel only per cycle Molding line Thay have been molded by thermo compression at: T= 185 o C, t=10 min with increasing pressure up to pounds.

12 Molded panel RC based composites

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