RTM工藝的昨天，今天，和明天（上）

   艾倫•哈珀(Alan Harper)先生供職于美國(guó)MVP有限公司，是樹(shù)脂傳遞模塑（RTM）工藝領(lǐng)域的著名專家。本文是關(guān)于他對(duì)RTM工藝的起源，發(fā)展和應(yīng)用，以及對(duì)后來(lái)輕型樹(shù)脂傳遞模塑工藝（LRTM）的看法。

溯源RTM工藝

   RTM工藝應(yīng)用于復(fù)合材料行業(yè)已經(jīng)有50多年了。盡管關(guān)于RTM最初應(yīng)用的時(shí)間不是十分肯定，但是曾經(jīng)有過(guò)關(guān)于英國(guó)飛機(jī)公司在50年代末開(kāi)始應(yīng)用RTM工藝的相關(guān)報(bào)道。據(jù)艾倫•哈珀介紹，自1973年他在英國(guó)艾爾斯伯里公司（Aylesbury）工作就開(kāi)始接觸RTM工藝。當(dāng)時(shí)，他們從K&C模具公司買(mǎi)了一臺(tái)1:1泵機(jī)，制造了第一套R(shí)TM模具。

   回顧早期的模具工藝時(shí)，艾倫•哈珀用不堪回首形容。他說(shuō)，利用當(dāng)時(shí)的工藝在注射樹(shù)脂時(shí)只能通過(guò)模具中央的一個(gè)孔注入，直到看到模具的四個(gè)角落都流過(guò)樹(shù)脂時(shí)，人們才真正知道模具里是充滿樹(shù)脂的。因此你可以想像，經(jīng)過(guò)反復(fù)幾次生產(chǎn)后，模具的排氣口會(huì)堆著越積越厚、早已變干的、如石筍狀的樹(shù)脂，常年累月下來(lái)必然造成巨大的浪費(fèi)。

   雖然后來(lái)人們確實(shí)采取了更好的設(shè)計(jì)方案，比如將模腔封死，然后在其周圍鋪設(shè)導(dǎo)流管，直接將樹(shù)脂引流到外接到模具頂部的樹(shù)脂收集器中。但這么做仍然不能避免嚴(yán)重的浪費(fèi)，雖然模具是封閉的，模腔上的排氣口仍然會(huì)釋放些許苯乙烯廢氣，不僅需要定期清洗，而且每個(gè)周期后還需要重新更換。

   直到80年代中后期，樹(shù)脂注射工藝才開(kāi)始顯現(xiàn)出一些自動(dòng)化的跡象。當(dāng)時(shí)工藝的主要進(jìn)展在于，操作人員不必?cái)y帶著注射閥爬到模具上方，將注射頭插入模具的注入口中，同時(shí)在整個(gè)注射過(guò)程中緊緊抓住注射頭。待注射完成后將注射閥拔出，然后再迅速用塞子堵上模具的注入口，以防止樹(shù)脂倒流。當(dāng)談到早期的RTM工藝，人們可能會(huì)笑，但是在那個(gè)年代，這樣的工藝確實(shí)存在了許多年。

圖1：在早期的RTM工藝過(guò)程中，操作人員需要手持注射閥，將其插入模具的注入口中。

    而后，自動(dòng)注射閥（AutoSprue）的發(fā)明又將RTM自動(dòng)化的程度提高了一些，因?yàn)樗嫒斯⑵洳迦肽＞叩牟襟E。但是，對(duì)模腔中的樹(shù)脂仍然使用的是舊方法進(jìn)行管理。

    隨著RTM工藝的進(jìn)一步發(fā)展，出現(xiàn)了更為先進(jìn)的輕型樹(shù)脂傳遞模塑工藝—LRTM，該工藝的首次應(yīng)用是于1970年在德國(guó)。到1996年，法國(guó)Alwo公司主管讓•雅克（Jean Jacques Sick）將LRTM工藝介紹給美國(guó)MVP公司閉模工藝專家查爾斯•圖爾（Charles Tur）和法國(guó)國(guó)家成人職業(yè)協(xié)會(huì)（AFPA）復(fù)合材料講師讓•保羅（Jean Paul Galichet）。

    當(dāng)時(shí)，查爾斯•圖爾還有另一個(gè)身份是比利時(shí)原料供應(yīng)商Socomer的技術(shù)支持顧問(wèn)，他一直致力于推進(jìn)這項(xiàng)新工藝的進(jìn)展，并對(duì)他們的客戶進(jìn)行相關(guān)培訓(xùn)。AFPA講師讓•保羅則將這門(mén)新工藝作為技術(shù)培訓(xùn)教案教授給學(xué)生。

與此同時(shí)，肖馬拉復(fù)合材料公司（Chomarat Composites）也將混合氈—Rovicore推向市場(chǎng)，由于很好地迎合了低壓注塑樹(shù)脂滲透工藝的需求，一經(jīng)上市就廣受好評(píng)。到1998年，肖馬拉公司開(kāi)始奔走于世界各地，實(shí)地向客戶展示如何運(yùn)用LRTM新技術(shù)和模具制造Rovicore混合氈。

    同年，查爾斯•圖爾將LRTM介紹給Plastech公司（當(dāng)時(shí)是艾倫•哈珀的公司），一經(jīng)采納當(dāng)即看到了這項(xiàng)新工藝的真正優(yōu)勢(shì)和潛力。Plastech公司趁熱打鐵開(kāi)發(fā)了一套R(shí)TM設(shè)備和模具配件（如密封件等），為其客戶提供一個(gè)完整的LRTM工裝包。Plastech還將LRTM技術(shù)作為在其全球RTM的培訓(xùn)課程的內(nèi)容之一。

    因此，LRTM工藝在90年代一經(jīng)推出，立即給市場(chǎng)帶來(lái)了一個(gè)更清潔的樹(shù)脂注射系統(tǒng)。除了具有明顯的成本和輕量?jī)?yōu)勢(shì)，該工藝還降低接觸液體樹(shù)脂混合物的機(jī)會(huì)。LRTM的出現(xiàn)代表著整個(gè)閉模工藝發(fā)展的頂峰期，如今的用戶在操作上已經(jīng)變得越來(lái)越嫻熟，能按需精準(zhǔn)的建造模具。LRTM跟RTM很像，也是采取上下兩片閉合模具，但是比傳統(tǒng)RTM工藝的生產(chǎn)工作環(huán)境更清潔，而且浪費(fèi)率更低。與RTM相反，LRTM工藝是讓樹(shù)脂先流經(jīng)模具周邊，最后多余的樹(shù)脂從位于中央的出口流出。所有這些過(guò)程都在真空密封環(huán)境中進(jìn)行，因此揮發(fā)性有機(jī)化合物排放量幾乎為零。

英文原文：

RTM – past, present and future

Alan Harper

   Alan Harper, closed mould specialist at MVP Ltd, is a well-know expert in resin transfer moulding (RTM) technology. Reinforced Plastics asked him for his views on the future of this processing technique.

Reinforced Plastics: When was the RTM process first used?

   Alan Harper: To my knowledge RTM has been used for over 50 years. I became involved in RTM when working in Aylesbury, Bucks, UK, in 1973. We bought a 1:1 pump machine from K&C Mouldings and made our first RTM mould. Looking back, our mould technology was horrendous as when the resin was injected through a central mould hole, we only really knew it was full when resin poured from all four corners. Consequently you can imagine that after a few days of production we had huge wasteful stalagmites of harden resin on the floor growing daily towards the mould outlets. We did get better and designed the seals to run all around the mould cavity and installed pipes to direct the exiting resin into open cups balanced on the mould top. However, it was really wasteful, and although closed mould, the open vents still gave off styrene fumes and needed cleaning and renewing for each cycle.

   I cannot be sure of the original use of RTM but have read that a UK aircraft company started to apply a form of RTM in the late '50s.

Reinforced Plastics: How did the process develop in terms of automation and control?

   Alan Harper: It was not until the late mid '80s that a degree of automation in the actual injection of the resin started to appear. The main advance was to eliminate the need for the operator to climb onto the mould armed with an injection machine head, thrust it into the mould injection sprue port, and forcefully hold it down throughout the injection phase. After removing the nozzle a plug was quickly inserted manually to prevent resin back flowing. We laugh at this now but it really was like that for many years.

   An AutoSprue was developed whereby the machine could simply be plugged into the mould injection port allowing hands free injection and flushing. However exiting resin still had to be managed by the old method.

Reinforced Plastics: When did Light RTM (LRTM) first appear?

   Alan Harper: Light RTM technology was first developed in Germany in 1970. In 1996, Jean Jacques Sick, director of Alwo, France, introduced the Light RTM process to Charles Tur (currently closed mould specialist, MVP USA) and Jean Paul Galichet (composite teacher at AFPA, the French national association for adult vocational) through Alain Floret of Chomarat.

   Charles, who was working as a technical support for Socomer, a raw material supplier in Belgium, continued to develop the process and conducted training to help their customer base to make their own moulds. Jean Paul Galichet, teacher at the AFPA (French government training centre) included the technology in their composite training programmes.

   At the same time, Les Fils d'August Chomarat (Chomarat Composites) brought to the market their well known combination mat, Rovicore, which was ideally suited to the process by providing excellent permeability for the low pressure resin injection.

   In 1998, after several demonstration days with AFPA Laval and Socomer, Chomarat engaged Charles Tur to use his experience with the process, to travel the globe to demonstrate Rovicore to their clients using the new LRTM techniques and moulds.

   The same year, Charles Tur introduced the process to Plastech, the company I then owned, and we immediately saw the real advantages and potential of Light RTM. Plastech developed an RTM Machine and mould accessories, seals, etc. to provide a Light RTM package for their customer base. Plastech also combined Light RTM Technology to their existing worldwide RTM training courses.

   Thus the introduction of the Light RTM process, in the '90s, immediately brought about a much cleaner resin injection system. Apart from its advantage of utilising much lower cost lightweight moulds, the process eliminated any need for the operator to be exposed to liquid resin mixes. This led to an enormous upsurge in a truly closed mould application in our industry which continues today as more users become proficient with the prerequisite to build their own accurate closed moulds. We are not speaking here about film infusion, which could be called closed mould, as it has only one engineered moulded surface and usually requires a new 'B' surface film tool for each production cycle.

   Light RTM, like the original RTM method, produces two engineered moulded surfaces and far less wastage with considerably cleaner working environment over traditional RTM. Light RTM delivers the resin around the mould periphery and exits into a central catchpot. All this is under a modest vacuum level providing zero exposure to VOCs.