CoreLite - CoreLite Blog #Bonding

CoreLite Unveils Next-Generation PC11 Pro Coating for BALSASUD® Core

Fri, 02 Mar 2018 08:11:24 +0000

BALSASUD Core Coated CoreLite will unveil the next-generation PC11 Pro coating system at the JEC World 2018 in Paris during March 6 to March 8. The PC11 Pro coating system was engineered to significantly reduce resin uptake during the lamination process by sealing the pores in the end-grain balsa wood sheet more effectively than the standard PC11 coating system.

Balsa core resin uptake was compared between the standard PC11 formulation, and the newly developed PC11 Pro formulation against non-coated balsa. The balsa core was coated using the latest UV technology and then vacuum infused. The results show as expected: the new PC11 Pro formulation achieves significantly lower resin uptake compared to the standard PC11 coating formulation.

A typical balsa sheet of non-coated balsa wood core will absorb roughly 1900 grams of resin per square meter (177 grams of resin per square foot) during infusion. The standard PC11 formulation was able to reduce the resin uptake by up to 46% to 1020 grams per square meter (95 grams per square foot) of resin uptake. The new PC11 Pro formulation is completely revolutionary as it reduces resin uptake by up to 76% to only 450 grams per square meter (42 grams of resin per square foot).

After several months of Research & Development, we are glad to release the most advanced coating technology for balsa wood core in the market, which can provide incredible resin cost savings to our customers and significantly decrease the weight of the final composite structure” said Ms. Elsa Axelsdottir, Innovation Manager at CoreLite.

This new coating solution will be a key component to make structures lighter and more cost effective without losing the unique mechanical properties of balsa core. It can be used in wind, marine, rail, automotive, aerospace, defense and industrial applications. And can be used with different lamination processes including hand lay-up, vacuum bagging and infusion.

About CoreLite

CoreLite is a manufacturer of advanced balsa & foam core materials for high performance composites applications. CoreLite specializes in producing sustainable materials and delivering customized composite solutions with agile turnarounds.

For more information about CoreLite visit: www.corelitecomposites.com

CoreLite Introduces PC11 Coating for BALSASUD Balsa Core

Mon, 06 Jan 2014 19:14:16 +0000

CoreLite, Inc., Miami, FL, announced the introduction of BALSASUD PC11, a new balsa core product with a proprietary surface coating engineered for resin infusion, vacuum bagging, pre-pregs, and wet layup.

The proprietary polymer coating, under development for over a year, reduces resin absorption in the core while improving resin adhesion and bond strength in sandwich construction. PC11 is compatible with polyester, vinyl ester, and epoxy resin systems.

The increased bond strength comes with substantial resin and labor savings. By sealing the surface of the balsa core, PC11 eliminates the need to pre-wet, or “prime” the core with resin prior to laminating, reducing resin use and labor costs. The sealed surface also promotes more efficient resin flow in vacuum bagging and infusion processes.

PC11 joins BALSASUD SG (Standard Grade,) PG (Pith Grade,)and CoreLite Board in the CoreLite product line.

CoreLite Board is a cost-effective, closed-cell PVC foam specially formulated to provide high physical properties. It is engineered to meet the physical demands required for use in transoms, attachment points, floors, bulkheads, stringers, local reinforcement points, molds and tooling. CoreLite Board is a stand-alone product and can be used with our without composite skins as a direct replacement for wood and plywood. It has excellent fastener pullout strength and high flexural strength and stiffness and is 27% lighter than plywood.

BALSASUD balsa is grown, harvested and milled in Ecuador. The BALSASUD product line is vertically integrated– they own their own plantations and control production from harvesting to final processing. The BALSASUD S.A.facility in Ecuador has been FSC™ (Forest Stewardship Council™) certified by the Rainforest Alliance according to FSC Chain of Custody standards.

Final processing into finished core materials is done atCoreLite’s Miami facility, the newest balsa production facility in NorthAmerica. New coating equipment has been installed to apply PC11 coating. Controlling production from forest to end-user assures BALSASUD customers the highest quality balsa core products available today.

6 Steps to Test a New Adhesive on Core Materials

Fri, 25 Oct 2013 20:43:11 +0000

In the composites the world, almost all of us use some sort of adhesive or resin in our manufacturing process. Due to this, there is a huge variety of adhesive/resin options available to us.

When desiring to use a different adhesive product on core materials, it is very important to do proper testing before using that new adhesive on the entire process. For this purpose, we provide 6 brief steps to properly test the possible use of a new resin(s) in your manufacturing process:

Proper Technical Analysis: This applies material properties analysis applies to both; the resins (old and new) and the core material that will be bonded. This step is crucial as it provides you with materials' compatibility pre-analysis and possible chemical reactions that are necessary to ensure safety and reliability. We want to make sure that the new resin will bond the materials in a strong and proper manner for the long-term, so any previous history of material compatibility will be useful in this analysis.
Bonding Test: Apply some of the new resin to be used on a small area of the core material. The small are could be 4” x 4” or 6” x 6” (you can also apply it to a full piece). The goal here is to see if the new adhesive strongly bonds the core material and observe possible resin absorption issues (to reduce resin absorption, balsa wood core can come in the coated configuration). You can opt to wait for up to 72 hours in this step or next step to see if the bonding was done as intended.
Environmental Test: Once the product has been bonded properly with the new resin, it is important to test in all the environmental conditions your product could possibly be used. This will give you a better picture on how effective the new resin actually is for your particular application. For example, some resins may not perform well when exposed to water. Some resins may increase the rigidity of the structure, while others increase flexibility. It all comes down to the point of what is the purpose of your application and where will it be exposed.
Wait 72 Hours (optional): This should be done in case you have had no experience or previous history with the new resin that is being tested and want to observe any possible change or reaction that may not occur immediately; but further on.
Performance Comparison: This needs to be done between the old and new resin(s) that are being tested. The following questions will help you summarize what needs to be taken into consideration for the sake of comparing what is the most effective resin for you:

What is the cost difference of the both resins?
How much resin was used for the same bonding purpose for each resin?
How strong was the core material bond with each resin?
How long does it take to cure?
Was there a difference in performance in different testing environments?
Last, but not least, multiply the cost of the resins being compared, by the amount of resin needed for the same bonding area and purpose to see which one is lower.

Decision: If the new intended adhesive performed well on the testing, then it means it is usable. However, if the new proposed adhesive performed even better than previous one and will save you money; it is a no-brainer.

This brief guide should be helpful in your analysis of switching the resin used in your manufacturing process with core materials, considering safety, performance and cost.