The FRP panel manufacturing process shared by Togloss
FRP panels are a new type of composite material made by combining glass fiber as the reinforcing material and synthetic resin as the matrix material through a specific process. Its production process mainly includes the following core steps:
I. Raw Material Preparation
Main Material Composition:
• Reinforcing Materials: Fiberglass cloth, fiberglass mat, fiberglass filaments, etc., different types and specifications are selected according to product performance requirements.
• Matrix Materials: Unsaturated polyester resin, epoxy resin, or vinyl ester resin, with good adhesion and chemical stability.
• Additives: Curing agents, accelerators, fillers (such as calcium carbonate, fumed silica), UV stabilizers, flame retardants, etc.
Typical Formulation:
• Gelcoat Layer: 40 parts gelcoat resin + 1.6-2.0 parts curing agent V388
• Reinforcing Layer: 100 parts unsaturated resin + 0.5-10.0 parts fumed silica + 3-10 parts calcium carbonate + 0.28-0.35 parts accelerator + 1-1.5 parts pigment paste
II. Production Process Flow
1. Mold Preparation
The mold design is determined based on the dimensions, thickness, strength, and appearance requirements of the flat plate. The surface must be smooth and flat and coated with a release agent to facilitate subsequent demolding.
2. Molding Processes
Hand Lay-up
• Suitable for: Small batches or medium-thickness products
• Process: Fiberglass material is laid layer by layer on the mold surface, resin is evenly applied to each layer, and air bubbles are removed by hand rolling to ensure full bonding between the fiber and resin.
Spray-up
• Suitable for: Large-area, complex-shaped products
• Process: Fiberglass and resin are simultaneously sprayed onto the mold surface using a spray gun, resulting in high production efficiency.
Vacuum Bagging
• Process: Resin is fully absorbed into the fiberglass through vacuum extraction, improving the quality and strength of the finished product.
Compression Molding
• Process: Pressure and heat are used to better bond the resin and fiberglass, suitable for producing high-strength, high-quality products.
3. Curing and Demolding
The molded FRP panel require curing, which can be done at room temperature or at high temperature. During curing, the resin undergoes a cross-linking reaction, enhancing the strength and stability of the sheet. After curing, careful demolding is necessary to ensure a smooth and flat surface.
4. Post-processing
The cured panel requires sanding, trimming, and surface coating. Sanding removes surface imperfections, while surface coating improves weather resistance and corrosion resistance.
III. Production Equipment
The FRP Panel production line mainly includes:
• Flattening System: Provides lateral external tension to achieve flattening.
• Feeding System: Oscillating feeding system with adjustable width.
• Coating System: Multi-point adjustable blade holder for precise thickness control.
• Impregnation Platform: Multi-channel independent temperature control to improve production speed.
• Heating and Curing System: Horizontal air duct supply for heating and precise temperature control.
• Cutting System: Horizontal cutting control for synchronous and stable operation.
Equipment Parameters:
• Production Speed: 2-8 meters/minute
• Sheet Width: ≤3000mm
• Sheet Thickness: 1.0-5.0mm
• Installed Power: 60-280KVA
IV. Key Points of Quality Control
Raw Material Control: Check the type, specifications, and moisture content of glass fiber; monitor resin viscosity, curing agent ratio, and mixing uniformity; ensure that fillers, release agents, etc., meet specifications.
Process Control: Control the molding environment temperature (20-30℃), humidity (50-70%), and ventilation; ensure the resin fully impregnates the fibers and eliminates air bubbles; strictly control curing time and temperature.
Finished Product Inspection: Inspect dimensions, strength, and surface quality; conduct performance tests such as tensile strength, flexural strength, and heat resistance.
FRP Panels are lightweight, high-strength, corrosion-resistant, have good insulation, and are highly designable, making them widely used in construction, chemical, power, and transportation industries.