With a focus on the reinforced plastics industry CCI works with producers of glass fiber, converted fiber products, resins, and releases (internal and external) who have a long-term commitment to the world wide composites market. With its partners, CCI, has a combined experience of over 60 years in the composites business and offers the ability to optimize product and product utilization based on user requirement.
PULTRUSION
One of the fastest growing and complex areas of GRP production, pultrusion is a sophisticated highly capital- intensive process for the continuous volume manufacture of close tolerance dimensioned profiles. Continuous reinforcements pre impregnated with resin by dip bath or injection are pulled through a heated die to cure to a strong, rigid section. Internal release agents are exclusively used as the release mechanism. Roving, knits, continuous filament mat are, in general, are the reinforcing products of choice for this process.
FILAMENT WINDING
Another capital-intensive process filament winding is the winding of continuous resin impregnated reinforcing fibers around a cylindrical form. Mainly for the production of pressure vessels, tubes and tanks because of the high hoop stress, which is often enhanced by cross winding at different angles. Externally applied release agents water based and washable preferably, are used to minimise contamination.
SMC/BMC
This is the ultimate GRP process, high volume, high cost tooling and process equipment with many varied applications in the electrical, construction and automotive industries.
A physically thickened compound (BMC) or chemically thickened compound (SMC) made from reinforcing fibers, resin, catalyst, pigment, filler and release agent is compression molded at temperatures in excess of 260 F in a matched steel tool.
Our European partner, CRC, is heavily involved in developing an alternative to group two metallic stearates commonly used, but with many disadvantages to post mold processing and product acceptability.
RESIN TRANSFER MOULDING/COLD PRESS
This process utilizes low to medium cost matched male and female tooling. Resin is either injected into the closed mould void pre filled with reinforcement, often with vacuum (RTM) or introduced prior to mould closure (cold press). Many of the reinforcing products are specifically designed for this process that has a number of process variations. Good productivity is achieved with Wuertz IMR grades specially formulated for gel coat and bulk resin allowing long runs between mould maintenance and consistent finish. Post mold operations such as painting and adhesive bonding are not affected. Marbocote external release compliments the IMR system perfectly in this application.
HAND LAY UP and SPRAY UP
Contact moulding is highly labor intensive. Reinforcing materials are applied as a mat or chopped glass fibers into a pre-catalyzed resin matrix in an open mold that is normally gel coated. This is then consolidated and de-aired by hand. Molds are normally wax coated. IMR’s are used with both gel coated and non-gel coated moldings to enhance external release agent performance and therefore increase productivity. We offer low cost solvent synthetic wax and fluorocarbon external release agents as well as water-based emulsions. Marbocote semi-permanent systems are increasingly replacing conventional external release agents.
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