Type of Document	Thesis
Author	Chiu, Posen
Author's Email Address	posen@eng.fsu.edu; lionsking@pchome.com.tw
URN	etd-06142004-170147
Title	In-Mold Coating of Composites Manufactured with the Resin Infusion between Double Flexible Tooling Process by Means of Co-Infusion
Degree	Master of Science
Department	Industrial and Manufacturing Engineering, Department of
Advisory Committee	Advisor Name Title Ben Wang Committee Member Chuck Zhang Committee Member Okenwa Okoli Committee Member Zhiyong Liang Committee Member
Keywords	Co-Infusion Paint In-Mold Coating Composites Painting RIDFT LCM
Date of Defense	2004-06-07
Availability	unrestricted
Abstract As composite materials gain wider acceptance within the transportation industry, it is pertinent to investigate the available coating processes with a view to reduce emissions and associated costs. Current painting processes are not only laborious and time consuming, but expensive and present safety issues. In-mold coating presents an avenue for eliminating on reducing theses problems. This work aims to determine the feasibility and develop a methodology for In-Mold Coating (IMC) components manufactured using the Resin Infusion between Double Flexible Tooling (RIDFT) process. Comparisons of the cost and efficiency between a component manufactured by RIDFT and then painted, and a component manufactured by RIDFT IMC process is given. It indicates a 46% savings in capital investment and 55% savings in time while using RIDFT IMC. The viability of in-mold coating RIDFTed components was investigated. This work-in-process, reports on successes and challenges presented, during the co-infusion of a polyurethane enamel paint (DuPont Imron 5000) and a vinyl ester resin (Derakane 470-45). In this thesis, RIDFT IMC is used to manufacture a double-layered structure consisting of a vinyl ester layer for structural function and a polyurethane enamel coating layer. The two liquids are either simultaneously or sequentially infused into a double flexible mold and are cured. Liquid separation is maintained by a separation layer. Twenty-four case studies have been made to determine the viability of the IMC process. Eight different separation layers were tested to find out the most promising separating material. The specification of the separation layer was made. Several test evaluations were conducted. A Differential Scanning Calorimeter (DSC) is used to test the cure cycle for the resin and the paint. Mechanical testing, Dynamic mechanical analysis (DMA) and tensile tests are used to evaluate the performance of the produced parts. An Environmental Scanning Electron Microscope (ESEM) was used to evaluate the microstructure of the components. In order to improve the flow of the fluids, several Flow Distribution Channels (FDCs) were made and tested to determine the best configuration. The experimental results demonstrate that in-mold coating by means of co-infusion may be a viable option for painting RIDFT components with determination of an appropriate separation layer. The paint used in this work dissolves the separation layer. Further work has been suggested to develop a paint formulation that will not dissolve the separation layer.
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