Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
Epoxy is the family of basic components or cured end products of epoxy resins. Epoxy resins, also known as polyepoxides, are a class of reactive prepolymers and polymers which contain epoxide groups. The epoxide functional group is also collectively called epoxy. The IUPAC name for an epoxide group is an oxirane.
In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure, or mixing with a catalyst. Heat is not necessarily applied externally, but is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.
Fibre-reinforced plastic is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass, carbon, aramid, or basalt. Rarely, other fibres such as paper, wood, boron, or asbestos have been used. The polymer is usually an epoxy, vinyl ester, or polyester thermosetting plastic, though phenol formaldehyde resins are still in use.
Fiberglass molding is a process in which fiberglass reinforced resin plastics are formed into useful shapes.
Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike conventional liquid paint which is delivered via an evaporating solvent, powder coating is typically applied electrostatically and then cured under heat or with ultraviolet light. The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as household appliances, aluminium extrusions, drum hardware, automobiles, and bicycle frames. Advancements in powder coating technology like UV-curable powder coatings allow for other materials such as plastics, composites, carbon fiber, and MDF to be powder coated due to the minimum heat and oven dwell time required to process these components.
Filament winding is a fabrication technique mainly used for manufacturing open (cylinders) or closed end structures. This process involves winding filaments under tension over a rotating mandrel. The mandrel rotates around the spindle while a delivery eye on a carriage traverses horizontally in line with the axis of the rotating mandrel, laying down fibers in the desired pattern or angle to the rotational axis. The most common filaments are glass or carbon and are impregnated with resin by passing through a bath as they are wound onto the mandrel. Once the mandrel is completely covered to the desired thickness, the resin is cured. Depending on the resin system and its cure characteristics, often the mandrel is autoclaved or heated in an oven or rotated under radiant heaters until the part is cured. Once the resin has cured, the mandrel is removed or extracted, leaving the hollow final product. For some products such as gas bottles, the 'mandrel' is a permanent part of the finished product forming a liner to prevent gas leakage or as a barrier to protect the composite from the fluid to be stored.
An alkyd is a polyester resin modified by the addition of fatty acids and other components. Alkyds are derived from polyols and organic acids including dicarboxylic acids or carboxylic acid anhydride and triglyceride oils. The term alkyd is a modification of the original name "alcid", reflecting the fact that they are derived from alcohol and organic acids. The inclusion of a fatty acid confers a tendency to form flexible coatings. Alkyds are used in paints, varnishes and in moulds for casting. They are the dominant resin or binder in most commercial oil-based coatings. Approximately 200,000 tons of alkyd resins are produced each year. The original alkyds were compounds of glycerol and phthalic acid sold under the name Glyptal. These were sold as substitutes for the darker-colored copal resins, thus creating alkyd varnishes that were much paler in colour. From these, the alkyds that are known today were developed.
Synthetic resins are industrially produced resins, typically viscous substances that convert into rigid polymers by the process of curing. In order to undergo curing, resins typically contain reactive end groups, such as acrylates or epoxides. Some synthetic resins have properties similar to natural plant resins, but many do not.
Pultrusion is a continuous process for manufacture of fibre-reinforced plastics with constant cross-section. The term is a portmanteau word, combining "pull" and "extrusion". As opposed to extrusion, which pushes the material, pultrusion pulls the material.
Curing is a chemical process employed in polymer chemistry and process engineering that produces the toughening or hardening of a polymer material by cross-linking of polymer chains. Even if it is strongly associated with the production of thermosetting polymers, the term "curing" can be used for all the processes where a solid product is obtained from a liquid solution, such as with PVC plastisols.
Polyester resins are synthetic resins formed by the reaction of dibasic organic acids and polyhydric alcohols. Maleic anhydride is a commonly used raw material with diacid functionality in unsaturated polyester resins. Unsaturated polyester resins are used in sheet moulding compound, bulk moulding compound and the toner of laser printers. Wall panels fabricated from polyester resins reinforced with fiberglass—so-called fiberglass reinforced plastic (FRP)—are typically used in restaurants, kitchens, restrooms and other areas that require washable low-maintenance walls. They are also used extensively in cured-in-place pipe applications. Departments of Transportation in the USA also specify them for use as overlays on roads and bridges. In this application they are known AS Polyester Concrete Overlays (PCO). These are usually based on isophthalic acid and cut with styrene at high levels—usually up to 50%. Polyesters are also used in anchor bolt adhesives though epoxy based materials are also used. Many companies have and continue to introduce styrene free systems mainly due to odor issues, but also over concerns that styrene is a potential carcinogen. Drinking water applications also prefer styrene free. Most polyester resins are viscous, pale coloured liquids consisting of a solution of a polyester in a reactive diluent which is usually styrene, but can also include vinyl toluene and various acrylates.
Bulk moulding compound (BMC), bulk moulding composite, or dough moulding compound (DMC), is a ready-to-mold, glass-fiber reinforced thermoset polymer material primarily used in compression moulding, as well as in injection moulding and transfer moulding. Typical applications include demanding electrical applications, corrosion resistant needs, appliance, automotive, and transit.
Sheet moulding compound (SMC) or sheet moulding composite is a ready to mould glass-fibre reinforced polyester material primarily used in compression moulding. The sheet is provided in rolls weighing up to 1000 kg. Alternatively the resin and related materials may be mixed on site when a producer wants greater control over the chemistry and filler.
Spray-Up also known as chop method of creating fiberglass objects by spraying short strands of glass out of a pneumatic gun. This method is used often when one side of the finished product is not seen, or when large quantities of a product must be made cheaply and quickly with moderate strength requirements. Corvette fenders and boat dinghies are commonly manufactured this way.
Solid surface is a man-made material usually composed of a combination of alumina trihydrate (ATH), acrylic, epoxy or polyester resins and pigments. It is most frequently used for seamless countertop installations.
A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as glass-reinforced plastic radar domes on aircraft and graphite-epoxy payload bay doors on the Space Shuttle.
Glass-filled polymer, is a mouldable composite material. It comprises short glass fibers in a matrix of a polymer material. It is used to manufacture a wide range of structural components by injection or compression moulding. It is an ideal glass alternative that offers flexibility in the part, chemical resistance, shatter resistance and overall better durability.
CFSMC, or Carbon Fiber Sheet Molding Compound, is a ready to mold carbon fiber reinforced polymer composite material used in compression molding. While traditional SMC utilizes chopped glass fibers in a polymer resin, CFSMC utilizes chopped carbon fibers. The length and distribution of the carbon fibers is more regular, homogeneous, and constant than the standard glass SMC. CFSMC offers much higher stiffness and usually higher strength than standard SMC, but at a higher cost.
In materials science, a matrix is a constituent of a composite material.