Knowde Enhanced TDS
Identification & Functionality
- Chemical Family
- Polymer Name
- Composite Materials Functions
- Technologies
- Product Type
- UD tape to 610 mm (24”) wide
- Fabric prepreg to 1270 mm (50”) wide
Features & Benefits
- Product Highlights
- Minimum ambient work life of 4 weeks
- Excellent balance of mechanical properties, toughness, and modulus
- Formulated for compatibility with UHMWPE fiber for low dielectric Applicationss
- Flexible, robust range of process cycles
- Vacuum bag, autoclave, and press consolidation
- Excellent matrix for sandwich structure skins
Applications & Uses
- Applications
- Composites End Use
- Composites Processing Methods
- Recommended Applications
- Sport & Recreation
- Motorsport & Formula 1
- Automotive
- Energy
- Medical
- Consumer Electronics
- Aerostructures
- Industrial
- Marine structures
- Dielectric structures
- Processing Method
RS-1 is a toughened epoxy resin that has an excellent work life (minimum of 30 days at ambient conditions) yet cures at 80°C (176°F) in 12 hours or 93°C (200°F) in 3–6 hours (other alternative cure schedules can be furnished by Toray). The catalyst requires elevated temperature for initiation of the cure reaction. RS-1 reaches minimum viscosity at 65–71°C (150–160°F), yet cure reaction rate is minimal, providing excellent conditions for dwell and consolidation. Understanding the above processing characteristics and versatility of the RS-1 system provides users with excellent success in their own specific environments. Although RS-1 is a very flexible resin system with respect to processing, certain guidelines need to be followed in order to achieve optimal mechanical properties. Toray strongly recommends that sample/subscale work representative of the actual structure and process conditions be performed in the customer oven and shop environment with Toray technical input/assistance prior to using RS-1 on large structures.
- Apply full vacuum (minimum or 28 inHg) to the debulked laminate. Toray recommends a warm debulk if practical, but room temperature debulks can be effective (please contact Toray for debulk recommendations on large parts). It is critical that the prepreg plies are layed-up such that wrinkling and voids are minimized. Toray recommends use of Teflon® rollers or squeegees to remove air pockets during lay-up of the individual plies.Vacuum bag lay-up sequence is as follows:
- Tool with appropriate mold release or release film and debulked prepreg laminate
- 0.1 kg/m2 (3 oz/yd2 ) natural nylon peel ply, or equivalent
- Perforated film (“P3” type, or equivalent)
- 1.2 kg/m2 (4 oz/ft2 ) polyester breather cloth
- 121°C (250°F) rated nylon bagging film.
- Apply thermocouples to the part and oven every 1.8–2.4 m (6–8 feet). Toray recommends some thermocouples be placed inside the laminate (near an edge) if at all possible, not just on top of the laminate or outside the vacuum bag. Embedded thermocouples are extremely useful as they provide an understanding of the actual temperature profile achieved in each region of the entire part.
- Place a vacuum port every 0.7 m2 (8 ft2 ) or so over the part to ensure good vacuum and volatile egress over the entire part area.
- Ramp the oven at -17.2 – -13.8°C (1–7°F) per minute for thin laminates. The ramp rate may be adjusted, depending on the thickness of the part and the heating characteristics of the oven. For example, laminates greater than 50 plies will require a dwell at 71.0–76.6°C (160–170°F) for 3 hours using a slower ramp rate of -17.2 – -16.6°C (1–2°F) per minute. Always base the ramp rates and dwells on the “lagging” (i.e., the slowest) thermocouple.
- When the lagging thermocouple reaches 66–71°C (150–160°F) start the dwell, i.e.; leave the oven at this temperature for at least 30 minutes based on the thickness and number of plies of laminate as noted above. As a general rule, the thicker the laminate, the longer the dwell time. The goal is to achieve laminate consolidation, de-aeration, and compaction without too much cross-linking at this stage of the cure cycle. Again, always base the start of the dwell period on the lagging thermocouple
- At the end of the dwell, ramp the oven at -17.2 – -13.8°C (1–7°F) per minute to either 80–293°C (176–200°F) and dwell for the appropriate time (12 hours minimum at 80°C/176°F) or 3 hours minimum at 93°C/200°F). The dwell times are again based on the lagging thermocouple. Dwell time does not begin until the last thermocouple has reached the dwell temperature. The part cannot be over cured. In most cases, the longer cures mean better parts as long as the tool can take the longer cure time without distortion
- The HDT (heat deflection temperature, representing the amount of cure) will continue to advance the longer the part is cured and the higher the cure temperature, up to a final endpoint where it will no longer increase the HDT (again depending on part size and thickness). Thinner laminates and smaller parts tend to need less time, but it is important to achieve recommended minimums for temperatures and times
- Allow the part to cool in the oven under vacuum by simply turning off the heat source and continuing to run whatever fans or blowers have been used during the cure. Do not open the oven doors. It is best to remove the part when it can be touched comfortably (less than 43°C/110°F). This can take up to 7 hours or longer for large structures, so be patient. If the part is pulled directly from the oven when at a high temperature it can be thermally shocked and warpage, prerelease, or separations between prepreg plies or between prepreg and cores (“delaminations”) can occur.
Properties
- Physical Form
- Mechanical Properties
- Typical Properties
- Thermal Properties
| Value | Units | Test Method / Conditions | |
| Compressive Modulus | 2.9 (0.43) | Gpa (Msi) | — |
| Compressive Strength | 117 (17) | GPa (Ksi) | — |
| Tensile Modulus | 3.0 (0.44) | Gpa (Msi) | — |
| Tensile Strength | 79 (11.5) | MPa (Ksi) | — |
| Value | Units | Test Method / Conditions | |
| Density | 1.24 | g/cm3 | — |
| Viscosity 133,700 cps at 50°C (122°F) | 1550 | cps | — |
| Value | Units | Test Method / Conditions | |
| Coefficient of Thermal Expansion | 57.6 (32) | ppm/°C (ppm/°F) | — |
| Tg (by DSC) | 107 (225) | °C (°F) | — |
Storage & Handling
- Shelf Life
- Out Life: 30 days at 24°C (75°F)
- Frozen Storage Life: 6 months at -18°C (< 0°F)
Out life is the maximum time allowed at ambient temperature before cure.