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Composites. The High-performance Programme.

Tooling Resins

Blocks

Auxiliaries

Silicones


ebalta composite resins. For your strongest ideas. ebalta epoxy resin systems for composites have been specially developed for the manufacture of high-strength components reinforced with glass and carbon ďŹ bres. They are used, for example, in high-tech ďŹ elds such as racing, boatbuilding, the automotive industry, rail vehicle construction and wind turbines. Temperature range TG

80-90 °C

Resin

BIV Epoxy 800

Hardener

BIV Hardener 20

BLH Epoxy 200

BIV Hardener 800

K 25

100 : 30

Mixing ratio (p.b.w.) Pot life approx. [min] 200 g (20 °C) 18-22

LH 25

K 30

W 400

LH 25 Hardener

100 : 30

LH 25 L Hardener

100 : 15

270-310

20-25

25-30

270 Âą 310

50-60

70-90

Mixing viscosity [mPas] (25 °C)

450 Âą 90

220 Âą 30

650 Âą 200

450 Âą 100

330 Âą 80

950 Âą 100

950 Âą 100

Glass transition temperature TG

77

82

85

81

80

89

89

4-6 / 80

4-6 / 80

12-15 /

12-15 /

10-12 / 70

12-16 / 80

12-16 / 80

+ 50-80

+ 50-80

approx. [°C] after curing Curing [h / °C]

Properties and applications

s6ERYLOWVISCOSITYSYSTEMFOR

s,OWVISCOSITYSYSTEMFORHANDLAMINATING VACUUMBAGGINGANDINFUSION

VACUUMINFUSIONAND24s7ITH")6(ARDENER',

s7ITHHARDENER+AND7', APPROVALFORBOATBUILDINGAPPLICATIONS

APPROVALFORBOATBUILDING applications

s"YMIXINGTHEHARDENERSABOVE THE SYSTEMCANBEACCELERATED

s"YMIXINGTHEHARDENERSABOVE THESYSTEMCANBEACCELERATED

s(ARDENER+TRANSPARENT

Epoxy resin systems are our world. And composites the future. YEARSOFEXPERIENCEINTHEPRODUCTIONOFHIGH QUALITY TOOLINGRESINSnTHISWASTHEDRIVINGMOTIVATIONFOR ebaltaTODEVOTEITSELFTOTHEDEVELOPMENTOFlRST CLASS MATERIALSFORHIGH PERFORMANCECOMPOSITES4HERESULT ebaltaEPOXYRESINSYSTEMSIDEALFORTHEMANUFACTUREOF

2

s&LAMEPROOFLAMINATINGRESINFOR PRECISIONCOMPONENTS s#OMBUSTIBILITYCLASS3 SMOKE DEVELOPMENTCLASS32  sHARDENERVARIANTSWITHVARIOUSPOT LIVES s#OLOURWHITE

High quality and efďŹ cient: our composite resin systems and materials for composites %POXYRESINSYSTEMSWITH', APPROVAL LAMINATINGANDINFUSIONRESINS 2ESINSYSTEMSFORMOULDMAKINGLAMINATING ANDINFUSIONRESINS FORJOBLOTSANDSERIES

COMPOSITECOMPONENTSANDMOULDMAKING 3HOULDYOU

,AY UPPASTES BLOCKANDBOARDMATERIALS

HAVEANYSPECIlCQUESTIONSONPRODUCTSORTHEMANUFAC

#ONSUMABLESFORVACUUMINFUSIONPROCESSES

TURINGPROCESS JUSTCONTACTOURDISTRIBUTORS

!UXILIARIESANDADDITIONALPRODUCTS

Motorcylce cladding part


bis 100 °C AH 110 SR

up to 120 °C

up to 150 °C

up to 175 °C

up to 200 °C

AH 140

LH 26

LH 28-1

LH 30

LH 26 Hardener

TM

LH 30 Hardener

100 : 27

100 : 40

100 : 42

AH 140 TGL

LI 20

100 : 22

LI 60

LI 130

TC 60

100 : 35

TC 90

100 : 32

13-15

55-65

18-22

50-60

120-140

55-65

90-105

120-150

240-360

160-200

1850 ± 200

1000 ± 150

600 ± 75

600 ± 75

550 ± 75

600 ± 75

370 ± 75

400 ± 100

750 ± 100

2200 ± 500

100

102

83

95

103

114

114

150

182

200

12 / 80

12 / 80

4 / 60

4 / 60

4 / 60

4-6 / 60

4-6 / 60

Gradual postcuring

Gradual postcuring

Gradual postcuring

+ 6 / 80

+ 6 / 80

+ 6 / 80

+ 5-6 / 80 + 5-6 / 80

up to 180 °C

up to 160 °C

up to 180 °C

+ 4 / 120

+ 4 / 120

+ 4 / 120 s4EMPERATURE

s(IGH STRENGTHLAMINATING RESIN

s#URESTACKFREE s6ACUUMINFUSIONOFCARBON

s"ONDINGRESINFORlLLERS

ANDGLASSlBREPARTS

s4EMPERATURE RESISTANT WITH s(ANDLAY UPOFCARBON AND MEDIUMVISCOSITYSYSTEM

GLASSlBREPARTS

s(IGH TEMPERA-

s(IGH TEMPERA-

s(IGH TEMPERA-

RESISTANT LOW

TURERESISTANT

TURERESISTANT

TURERESISTANT

VISCOSITYSYSTEM

LOW VISCOSITY

SYSTEMFOR

LAMINATINGAND

FORCARBONlBRE

SYSTEMFOR

COMPONENTS

BONDINGRESIN

VISIBLEPARTS

COMPONENTS

ANDMOULDS

FORMOULDS

s(ARDENER32AND4',ALSO

s7ITHHARDENER4#

CUREWELLATROOMTEM

ALSOCURESWELLAT

PERATURE

ROOMTEMPERATURE

ANDMOULDS

Advantages of ebalta epoxy resins (IGH QUALITYebaltaEPOXYRESINSHAVENUMEROUSADVANTAGES COMPAREDTOPOLYESTERRESINS ,OWERCOMPONENTWEIGHTWITHIDENTICALSTRENGTH "ETTERMECHANICALPROPERTIES sTENSILESTRENGTH mEXURALSTRENGTHANDELONGATIONAT BREAKAREMUCHHIGHER sSHRINKAGEISMUCHLOWER 0ARTSAREOFAHIGHERQUALITYANDHAVEALONGERSERVICELIFE (IGHOSMOSISRESISTANCE

Motorcylcle fender

GL-approval as boatbuilding resins for BIV Epoxy 800 and BLH Epoxy 200

3


Vacuum infusion тАУ modern manufacturing for high-quality composite parts Special manufacturing methods are used for composite parts that have to provide a high level of strength and longevity. A higher ямБbre and lower resin content with an identical component weight is achieved by vacuum methods such as vacuum infusion.

5

7 6

4

8

3 1

$URINGVACUUMINFUSION RESINISSUCKEDINTOTHElBRE

2

THEPERFORATEDRELEASElLMAFTERCURINGOFTHERESIN

MATERIALBYAPPLYINGAVACUUM4HEMETHODWORKSAS

 4HEmOWMEDIUM ISNOWPLACEDINPOSITIONANDlXED

FOLLOWS

 4HERESINFEED ANDVACUUMHOSES AREATTACHED

 4HEVARIOUSFABRICS ARECUTTOSIZEANDPLACEDIN THETOOLSORMOULDSINDRYCONDITIONDEPENDINGON THEDESIREDWALLTHICKNESSANDSTRENGTH  4HEPEELPLY ISTHENPLACEDONTHEGLASSORCARBON lBREFABRICFOLLOWEDBYTHEPERFORATEDRELEASElLM 

ANDlXEDWITHANADHESIVETAPE  4HEVACUUMlLM ISTHENAPPLIEDANDSEALEDWITH THEAIDOFSEALANTTAPES   4HERESINISNOWSUCKEDINTHROUGHTHERESINFEEDAND ISDISTRIBUTEDOVERTHEENTIRECOMPONENT

&LOWMEDIUMANDHOSESCANBEEASILYREMOVEDTHROUGH

4

Rear hatch

Infusion resin ямВow


High ďŹ bre volume content for the highest requirements Wherever high quality is needed or large components are involved – vacuum infusion has crucial advantages compared to other manufacturing processes: an excellent cost-quality ratio, enormous strength and great progress towards occupational safety and efďŹ ciency. No matter which demanding manufacturing process you choose – ebalta offers the resin system that suits your needs.

Comparison of ďŹ bre volume contents of various manufacturing processes Vacuum infusion

40 - 66 %

Vacuum bagging

40 - 66 % 10 - 37 %

Hand laminating

50 - 70 %

Prepreg/Autoclave 25 - 66 %

RTM

Fibre volume content in %

0

20

40

60

80

100

Source: Institut fĂźr Kunststoffverarbeitung Aachen (Institute of Plastics Processing Aachen, Germany)

Advantages of vacuum infusion compared to hand laminating #LOSEDPROCESSANDCLEANWORKINGCONDITIONSlBRES AREINSERTEDINDRYCONDITIONGREATEROCCUPATIONAL

compared to prepreg/autoclave .OPROCUREMENTCOSTSFORAUTOCLAVE 4HICKLAMINATESCANBEPRODUCEDINONESTEPNODEBULKING NECESSARY

SAFETYSIGNIlCANTREDUCTIONOFEMISSIONLOAD ,OWERRESINCONTENTINCOMPONENT

compared to RTM (Resin Transfer Moulding)

,OWERWEIGHTWITHIDENTICALSTRENGTH

,OWERTOOLCOSTS

#ONSTANTQUALITYOFCOMPONENTSEVENANDBUBBLE

.OEXPENSIVEINJECTIONSYSTEM

FREESATURATION RESINCONTENTmUCTUATESBYLESS

24-ONLYBECOMESECONOMICALAROUNDPIECES

THAN ALMOSTNODIFFERENCESINTHICKNESS 4IMESAVINGS DECISIVEADVANTAGESABOVEALLFOR LARGERPARTSWITHCOREMATERIAL

compared to vacuum bagging ,OWERRESINREQUIREMENTFORLARGERPARTS "ETTERSURFACEQUALITYOFCOMPONENTS #LOSEDPROCESSANDCLEANWORKINGCONDITIONS

Radiator grill

5


Products for model, mould and tool making ebalta epoxy resin systems were developed especially for the production of moulds for highly resistant components strengthened with glass or carbon ďŹ bers. They are chemical and styrene-resistant, easily polishable and have a very dense surface.

Pot life

Product

Curing time

200 g/20 °C at RT

recommen-

Heat resistance

Hardener

Colour

Material properties

[min.]

[hrs.]

(HDT) ISO 75 [°C]

OH 4

32

WHITE

UNIVERSAL

15-20

3-5

82 Âą 3

OH 50

(ARDENER

BLACK

DENSESURFACE

12-18

16-24

93 Âą 3

OH 6-1

#( 

BLUE

VERYABRASIONRESISTANT

20-25

20-24

98 Âą 3

OH 35

#( 

BLACK

CHEMICALRESISTANT

20-30

16-24

98 Âą 3

OH 35

(-

BLACK

HEATRESISTANT

20-30

16-24

143 Âą 5

OH 82

4-

BLACK

HIGHHEATRESISTANT

220-260

24-48

175 Âą 5

OH 30

/((ARDENER WHITE

HIGHHEATRESISTANT

160-200

> 48

> 170

Coupling

KP 6

4',

GREY

ALUMINIUMlLLED

30-40

8-12

NA

LAYER

KP 7-1

4-

GREY

HEATRESISTANT

240-360

24-48

NA

"ACKlLLING

AH 110

4,

YELLOW

HIGHLYlLLABLE

85-95

24-28

100 Âą 3

STAMPING

+ alu grit

Method

dation

Build-up method 'ELCOATLAYER

TRANSPARENT

PS 06

4,

ALU GREY

HEATCONDUCTIVE

50-60

12-18

120 Âą 5

PS 07-1

4-

ALU GREY

HIGHHEATRESISTANCE

70-80

24-36

175 Âą 5

"ACKlLLING

BLH

+

GREEN LIKE

8-10

81 Âą 2

LAMINATING

Epoxy 200 AH 110

4,

YELLOW

GOODWETTINGPROPERTIES

20-25

', APPROVAL

G

HIGHSTRENGTH

85-95

24-28

100 Âą 3 147 Âą 2

TRANSPARENT

6

Interior door lining

LH 26

,((ARDENER BROWN TRANSPARENT HEATRESISTANT

120-150

10-16

LH 28-1

4-

BROWN TRANSPARENT HIGHHEATRESISTANCE

240-360

24-48

175 Âą 3

LH 30

,(

BROWN TRANSPARENT HIGHHEATRESISTANCE

160-200

> 48

181 Âą 5

PS 03-1

03 

BLUE GREY

40-50

16-24

68 Âą 2

PS 05

4,"

GREY

HEATRESISTANT

50-60

16-24

105 Âą 5

ebacryl L-1

ebacryl EM-1

LIGHT BEIGE

SHRINKAGEFREE

APPROX

8-12

NA

GLASSlBER lLLED

RTM mould of ebalta epoxy resin


Customised block material: with ebablockÂŽ, you receive a product that is manufactured individually according to your requirements allowing you to manufacture joint-free moulds and tools.

CoefďŹ cient of

Density at

(HDT) ISO 75

thermal expansi-

20 °C

recommendation

Colour

Material properties

[°C]

on [10ÂŻ6KÂŻ1]

[g/cm3]

ebaboard L-1

OCHRE

VERYEASYTOMACHINE

92 Âą 2

APPROX

¢

ebablockÂŽ P 185

BLUE

LOWTHERMALEXPANSION

115 Âą 5

APPROX

¢

ebablockÂŽ EP 138

MINT GREEN HEATRESISTANTUPTOÂŞ#

140 Âą 3

APPROX

¢

ebablockÂŽ EP 678

LIGHT BLUE

VERYlNESURFACE

119 Âą 3

¢

¢

P 25

RED BROWN

LOWDENSITY

50 Âą 2

CA

¢

P 26

RED BROWN

LAYERUPTOMM %0

54 Âą 2

APPROX

¢

P 27

GREY

HEATRESISTANT

86 Âą 3

50-52

¢

Product Method

Heat resistance

Milling

Further EP boards available on request

Production auxiliaries and additional products Consumables for vacuum infusion 0EELPLY

,EAVESANEVEN ROUGHANDDUST FREE

0ERFORATEDRELEASE

3EPARATESTHEmOWMEDIUMFROMTHE

SURFACEONTHELAMINATEAFTERREMOVAL

lLM

PEELPLY2ESINENTERSTHELAMINATE THROUGHTHEPERFORATIONS

/PTIMUMADHESIONOFSUBSEQUENTLAYERS EVENWITHOUTSANDING &LOWMEDIUM

&ORANEVENANDRAPIDmOWOFRESIN

6ACUUMBAGGINGlLM

DURINGVACUUMINFUSION

%NCLOSESTHEMOULDINAVACUUM)S APPLIEDATTHEENDANDBONDEDWITH SEALANTTAPE

3EALANTTAPEFOR

3EALTHEVACUUMBAGGINGlLM

3PIRALHOSE

VACUUMBAGGINGlLM

4OFEEDANDDISTRIBUTETHERESINAND EXTRACTTHEAIRBENEATHTHElLM

0LASTICHOSE

4OSUCKINTHERESIN

!DHESIVESPRAYFOR

4OlXTHEFABRICSANDVACUUMMATERIALS

FABRICS

#ONNECTORS

4 PIECESTOCONNECTTHEHOSES

-ULTIPACK

3TARTERKITWITHlLMS SEALANTAND

VACUUMINFUSION

ADHESIVETAPES PEELPLY mOWMEDIUM HOSES HOSECLIPS 4 CONNECTORS BUCKET INSTRUCTION FORANAREAOFABOUTM§

Additional products

ebacryl ,AMINATINGSYSTEM

0RODUCESVERYDIMENSIONALLYACCURATEMOULDS

FORMOULDMAKING

VERYSHORTPRODUCTIONTIME LOWCOEFlCIENT

NOHEALTHAND

OFTHERMALEXPANSION HARDLYmAMMABLE

SAFETYPROBLEMS

mAMMABLEMATERIALCLASS$). " 

-ATSANDFABRICS #OREMATERIALS

6ARIOUSWEAVESANDGRAMMES 6ARIOUSTEMPERATURERESISTANCES ANDDENSITIES

!REYOULOOKINGFORASPECIlCPRODUCT 3IMPLYGIVEUSACALLIFYOUCAN@TlNDWHATYOUARELOOKINGFOR0HONE  

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Tooling Resins

Blocks

Auxiliaries

Silicones

Composites Mould and tool making Design model making Foundry tooling Rapid prototyping Electrical encapsulation Further applications

ebalta Kunststoff GmbH Erlbacher StraĂ&#x;e 100 91541 Rothenburg ob der Tauber Germany

Tel.: +49 9861 7007-0 Fax: +49 9861 7007-77 info@ebalta.de www.ebalta.de

Stand 09/2011

We would be pleased to help you if you have any questions about our technology or products. Just call or make an appointment with your regional sales agent. We are looking forward to hearing from you!

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