BPS240 format 1. Features. Related documents. Related products

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1 Cytec 1 of 5 BPS240 format 1 BPS240 format 1 BPS240 is a two ply, partially impregnated epoxy prepreg system designed for the manufacture of Body In White (BIW) panels with excellent surface quality from vacuum only processing at cure temperatures between 85 C and 150 C (185 F and 302 F). The first ply utilises Cytec s ZPREG partial impregnation technology, consisting of a structural fabric coupled to a surface scrim and a high performance resin system. The second ply combines low density syntactic core material and structural fabric to create significant panel rigidity in a rapid laminating format. The system is designed to be ready for painting without abrading or reworking; in many instances, paint can be applied directly to a degreased panel. Excellent environmental performance can be expected from panels painted in Hi Bake & Lo Bake paint systems. Features 7 to 30 days outlife at 21 C (70 F) 12 months storage at 18 C (0 F) Excellent physical and environmental performance in painted automotive applications Robust material format for consistent tack, excellent drape and form conformation Available, as standard, in carbon fibre and glass fibre variants, either in rolls or in pre cut kits Material architecture developed for reliable pin holefree finish, excellent panel flatness and rigidity Recommended for use with high quality composite or metallic tooling High performance resin systems designed for service temperatures up to 160 C (320 F) Flame retardant; self extinguishing when tested to ISO3795/FMVS302 Related documents Debulking guidelines (TDS1036) Oven vacuum bag processing lay up and bagging guidelines (TDS1041) BPS 240 format 1 recommendations (TDS1010) Related products BPS240 format 2 (PDS1260) VTF242FRB flame retarted epoxy surface ply (PDS1195) VTS243FR flame retardant syntactic core film (PDS1186)

2 Cytec 2 of 5 BPS240 format 1 Cure cycle Oven vacuum bag Vacuum bag pressure Recommended cure cycle Minimum of 980 mbar (29 Hg)* 1 to 3 C (1.8 to 5.4 F)/minute 1 hour at 120 C, +5/ 0 C (248 F, +9/ 0 F) Maximum of 3 C (5.4 F)/minute to 60 C (140 F) *This is the ideal vacuum level, however, it is recognised that it is not always possible to attain. If in doubt, please contact our technical support staff for advice. Autoclave cure Vacuum bag pressure Autoclave pressure Recommended cure cycle Minimum of 980 mbar (29 Hg)* 6.2bar (90psi) 1 to 3 C (1.8 to 5.4 F)/minute 1 hour at 120 C, +5/ 0 C (248 F, +9/ 0 F) Maximum of 3 C (5.4 F)/minute to 60 C (140 F) *This is the ideal vacuum level, however, it is recognised that it is not always possible to attain. If in doubt, please contact our technical support staff for advice. Alternative cure cycles Temperature 85 C (185 F) 100 C (212 F) 150 C (302 F) Duration 5 hours 2 hours 45 minutes Post cure In applications demanding maximum temperature for paint bake, it is essential that the component is post cured to fully develop the glass transition temperature. Post cure cycle 0.3 C (0.5 F)/minute 1 hour at 180 C 0/+5 C (356 F 0/+9 F)* 2 C (3.6 F)/minute to 60 C (140 F) * Temperature must be measured by the lagging thermocouple attached to the part. Notes: Parts may be loaded into a pre heated oven or heated at 3 C (5 F)/minute to the initial cure temperature. Large components should be adequately supported to avoid distortion.

3 Cytec 3 of 5 BPS240 format 1 Physical properties Test Sample conditions Results Cured resin VTF242FRB 1.23 g/cm 3 density VTS243FR g/cm 3 1 hour at 120 C (248 F) 118 C (244 F) DMA E onset Tg 1 hour at 120 C (248 F) + 1 hour at 180 C (356 F) 163 C (325 F) Carbon 0.067% 1 hour at 120 C (248 F) Shrinkage on Glass 0.088% cure Carbon 0.256% 1 hour at 120 C (248 F) + 1 hour at 180 C (356 F) Glass 0.275% Coefficient of thermal expansion (CTE) Post cured laminates tested from 30 to 100 C (86 to 212 F) Carbon Glass 4.2 x10 6 / C (2.3 x10 6 / F) 17.1 x10 6 / C (9.5 x10 6 / F) Tests carried out of complete systems, i.e. 2 ply laminates Weightsaving Potential Weight saving compared to panels of 1 Typical metallic panel thickness BPS240 Carbon (standard) BPS240 Carbon (skinny) BPS240 Glass 0.7mm Steel 1 70% 75% 65% 1.1mm Aluminium 1 42% 50% 35% 3.0mm SMC 2 68% 73% 65% 2.5mm Thermoplastic 3 44% 53% 37% 2 Typical Class A glassfibre SMC variant. Panel thickness is at, or near, minimum feasible. 3 Typical exterior panel variant. Panel thickness is at, or near, minimum feasible. Mechanical properties Material: Cure cycle: Test conditions: BPS240 1 hour at 120 C (248 F) Room temperature, dry Property Test Method Units BPS240 Carbon BPS240 Glass 0 Tensile strength MPa (ksi) (42.41) (23.49) 0 Tensile modulus ASTM D3039 GPa (msi) 38.0 (5.51) 13.9 (2.02) 0 Tensile poisson s ratio Compressive strength MPa (ksi) (53.75) (51.66) ASTM D695 0 Compressive modulus GPa (msi) 37.0 (5.37) 15.5 (2.25) (mod) 0 Compressive poisson s ratio ± In plane shear strength MPa (ksi) 55.5 (8.05) 52.7 (7.64) ASTM D3518 ± In plane shear modulus GPa (msi) 2.90 (0.42) 2.52 (0.37) 0 Flexural strength MPa (ksi) 598 (86.71) 403 (58.44) CRAG Flexural modulus GPa (msi) 34.1 (4.94) 16.0 (2.32) Note: It should be noted that the results given in the preceding table are for the specific systems described earlier and, therefore, for a precise thickness. Accordingly, the stress and modulus values cannot be directly applied in models of components at non standard thickness. Please contact our technical support staff for further advice and support in these cases.

4 Cytec 4 of 5 BPS240 format 1 Availability System BPS240 carbon Skinny BPS240 carbon BPS240 glass Surface Ply Bulk Ply VTF242FRB/GF1200/CF1100 VTS243FR/CF mm VTF242FRB/GF1200/CF1100 VTS243FR/CF mm VTF242FRB/GF1200/GF1100 VTS243FR/GF mm Approximate Cured Thickness Approximate Areal Weight 1.25mm 1.74kg/m mm 1.56 kg/m² 1.5mm 1.94kg/m 2 Rolls Surface and backing materials are supplied on separate rolls, usually ~25 linear metres in length. For automated processing, alternative roll lengths may be available upon request. Each roll will be supplied in a cardboard box or rolls may be grouped into larger stillages upon request. Pre cut Kits Cytec is pleased to offer a nesting and kit cutting service for BPS240 materials. The exact packaging details can be determined to suit each customer s needs. By receiving pre cut kits, the customer reduces waste handling requirements and can expect the maximum ease of handling. Engineering support is available to optimise kit templates for best material utilisation and component quality and consistency. Tooling System BPS240 has been developed for the manufacture of high quality, net shape components from composite or metallic tooling. Abrasing or reworking the cured component surface may be detrimental to the aesthetic quality and longevity of that surface once it has been painted and, it should, therefore, be avoided. Cytec has developed a considerable knowledge base regarding the application of composite body panel solutions. Additionally, the Group can offer a range of composite tooling solutions intended for high surface quality applications and will be pleased to offer further advice and support upon request. Storage Out life* at 21 C (70 F) Storage at 18 C (0 F) VTF242FRB 7 days VTS243FR 30 days VTF242FRB 12 months from date of manufacture VTS243FR 12 months from date of manufacture *Out life refers to accumulated time out of the freezer before the part is cured. Note: The actual freezer storage life and out life are dependent on a number of factors, including; fibre type, format and application. For certain formats, it may be possible for the storage life and out life to be longer than stated. Please contact our technical support staff for advice. Exotherm BPS240 system prepregs are reactive formulations which can undergo severe exothermic heat up during the initial curing process if incorrect curing procedures are followed. Great care must be taken to ensure that safe heating rates, dwell temperatures and lay up/bagging procedures are adhered to, especially when moulding solid laminates in excess of 5mm (0.20in) thickness. The risk of exotherm increases with lay up thickness and increasing cure temperature. It is strongly recommended that trials, representative of all the relevant circumstances, are carried out by the user to allow a safe cure cycle to be specified. It is also important to recognise that the model or tool material and its thermal mass, combined with the insulating effect of breather/bagging materials can affect the risk of exotherm in particular cases. Please contact our technical support staff for further information on exotherm behaviour of this prepreg.

5 Cytec 5 of 5 BPS240 format 1 Health & safety BPS240 contains epoxy resin which can cause allergic reaction on prolonged or repeated skin contact. Avoid contact with the skin. Gloves and protective clothing must be worn. Wash skin thoroughly with soap and water or resin removing cream after handling. Do not use solvents for cleaning the skin. Use mechanical exhaust ventilation when heat curing the resin system. Exhaust from vacuum pumps should be vented to external atmosphere and not into the work place. In the uncured state, ZPREG materials contain dry fibres. Small amounts of these fibres may be released into the atmosphere during cutting and handling. Skin contact with these fibres should be minimised, as should dispersal of the fibres into the workplace. Particular care should be taken when working with carbon fibre materials in the vicinity of electrical apparatus; such equipment should be made intrinsically safe. For further information, consult Cytec Safety Data Sheet number: VTF242FRB: VTS243FR: SDS415 SDS428 Attention The success application and longevity of anybody panel material is dependent upon many factors, including: component design, tooling quality, moulding process, paint application process, and lifetime environmental conditions. It is the responsibility of the user to demonstrate the fitness for purpose of BPS240 materials for their intended applications and processes. All statements, technical information and recommendations contained in this data sheet are given in good faith and are based on tests believed to be reliable, but their accuracy and completeness are not guaranteed. They do not constitute an offer to any person and shall not be deemed to form the basis of any subsequent contract. All products are sold subject to the Cytec s Standard Terms and conditions of Sale. Accordingly, the user shall determine the suitability of the products for their intended use prior to purchase and shall assume all risk and liability in connection therewith. It is the responsibility of those wishing to sell items made from or embodying the products to inform the user of the properties of the products and the purposes for which they may be suitable, together with all precautionary measures required in handling those products. The information contained herein is under constant review and liable to be modified from time to time. Copyright 2012 Cytec (Derby) Ltd. All rights reserved worldwide. All trademarks or registered trademarks are the property of their respective owners.