Download - SSP_003_ru_Ремонт пластиковых деталей
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Opravy plast jsou
tak snadn ...
p esv d te se sami!
Repairs of plastics are
so ease ... see for
yourself!
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Contents
Page
Introduction 4
Conditions of repairs 5
Classication of plastics 7
Identication 8
Marking of plastics 9
Marking of products from plastics 12
Welding 13
Components for sticking 15
Sticking 18
Summary 22
This textbook and worksheet cannot be used as a workshop manual!
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Introduction
With growing level of technology development, the
design of vehicles uses increasingly plastic parts,which are often combined with other materialsdue to design reasons. The area of their use cov-
ers in particular various surface parts of the car
body and its extension, panels and parts in the
interior.
The growth of proportion of plastic parts in the
total weight of the vehicle has not by far beenended and in view of the current trend in air tech-
nology it can be expected that plastic and
composite components will begin gradually to be
applied to a far larger extent as load-bearing
components.
A general rule is that plastics can be well repaired
thanks to their physical qualities. However, con-
servative tendencies survive in the vehicle repair
industry and repairs of plastic parts are made only
exceptionally.
Bumpers are the most frequent damaged plastic
parts in vehicles with up to 70% frequency ofdamaged plastic parts.
Although various alternatives of repairs exist,
repairs tend to be performed even in case of small
damage with the most convenient method, which
is in most cases replacement of the wholebumper. There are more causes of this, but proba-
bly the most signicant reason will be ignorance
of the latest state in the development and applica-
tion of adhesives and imperfect care for the clients
and their nancial resources.
This worksheet thus aims at making workers in
the service network acquainted with reasons and
possibilities of repairs of plastic parts; therefore,
the following 4 questions must be rst answered in
brief.
Introduction
The technology of repairs of plastic vehicle parts has a relatively short history. There-fore, the workshop repair practice always brings along repeating questions why, how,in what conditions and where to repair plastic parts.
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2. What to repair?
The most frequent repaired plastic parts on a
vehicle are the following:
- Bumpers (85%)- Spoilers- Covers and braces of headlamps- Front grid- Rear-view mirrors
1. Why to repair?
Conditions of repairs
Repairs of damaged plastic parts must be made
rst because repair is more advantageous thanthe mere replacement with a new part from nan-cial and environmental reasons. The change of
this state as against past was caused by the con-
tinuing development of adhesives used, by the
method of application of these adhesives, by the
general trend of growing prices of spare parts and
last but not least by the growth of costs of recy-cling of damaged plastic parts.
Another important nancial as well as time factor
is also the possibility of immediate repair without
necessity to have a part on stock or to wait for itssupply. In case of a minor damage to the bumper
it is not necessary even to make a complete
painting.
Insurance companies observe carefully the tech-
nological and price level of repair technologies.They set differentiated insurance premiums
according to costs of repairs for individual car
manufacturers. The amount of insurance premium
is also one of the factors inuencing decision of
clients to buy a specic brand.
The client will surely appreciate a high-quality, fast
and price favourable repair and will be loyal to the
brand SKODA in the future.
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We hold the sample at the edge of aame for max 10 sec.
The sample will extinguish afterremoval from ame
The sample burns on after removalfrom ame
The sampleburns with a yellow
ame
The sample burns
with a blue ame with
a yellow tip
The sample
burns with a blue
ame
The sample burns
with a blue ame with
a yellow tip
The sample burns
with a yellow ame
Positivereaction to
the Beilsein
test
Smell ofphenols
The sample dissolvesand drops- Smell of
burnt wool or hair
Smell offormaldehyde
The samplewill not
dissolve
The sampledissolves
and drops
Flocksof ash
Smell of
humidity
Smell of
burning
stuff
Not attacked
by tetra
Not attacked
by tetra
Floats on water
surfaceABS
Often
opaque
Opaque
PMMAPOMPA
PC
PC
PS
PVC
PP SB
Colour-
ing
bromide
water
Not col-
ouring
bromide
water
Mass
above
0.915g
Mass
less than
0.915g
PVC
PC
PA
POM
PMMA
PE
PP
PS
ABS
SB
- Polyvinylchloride
- Polycarbonate
- Polyamide
- Polyoxymethylene
- Acryl
- Polyethylene
- Polypropylene
- Polystyrene
- Acrylonibil - Butadiene - Styrene
- Shock-resistant polystyrene
Identication
Identication of the most common types of thermoplastics
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Codes (abbreviations) of the most common types of plastics
Table 1 - Examples of use of basic polymers (Thermoplastics and Duroplastics) which are oftenused in automotive industry
ABS
EP
PA6
PA11
PA12
PA66
PBTPES
PET
PC
PE
PF
PMMA
POM
PP
PPE
PPS
PTFE
PUR
PVC
SAN
Marking of plastics
Abbreviation Description
Acrylnitrite-Butadien-Styrol Copolymerisat
Epoxide
Polyamide with 6 atoms of monomer grid
Polyamide with 11 atoms of monomer grid
Polyamide with 12 atoms of monomer grid
Polyamide from 2 monomer grids with 6 atoms each
Polybutylene-terephthalatePolythersulphonide
Polyethylene-terephthalte
Polycarbonate
Polyethylene
Phenole-Formaldehyde
Polymethylmethacrylate (Acryl)
Polyoxymethylene, Polyacetal
Polypropylene
Polyphenylenether
Polyphenylesulde
Polytetrauorethylene
Polyurethane
Polyvinylchloride
Styrole/Acrylnitril-Copolymerisat
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Table 2 - Examples of use of lling and reinforcing materials often used in automotive industry
Table 3 - Examples of use of lling and reinforcing materials often used in automotive industry
GF
GM
GB
T
MWD
Abbreviation Description
Glass bres
Glass wool
Glass balls
Talcum
Mineral stiffenersWood aggregate
ACM
AU
BR
CSM
CR
EPDM
ECO
FPM
MVQ
NBR
NR
SBR
Abbreviation Description
Copolymer from ethylacrylate
Polyestherurethane-rubber
Butadiene-rubber
Chorosulphide polyethylene
Chloroprene-rubber
Terpolymer from ethylene
Copolymer from ethylenoxid (oxiran) and chlormethyloxiran
Rubber with uorine
Silicone rubber with matyl- and vinyl groups on polymer chain
Acrylnitril-butadiene-rubber
Isoprene-rubber (natural rubber)
Sterol-butadiene-rubber
Marking of plastics
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Marking of plastics
Examples of designation and use of plastics in SKODA vehicles:
Material FELICIA OCTAVIA
PP+EPDM Bumper Wheel housing
PP+EPDM+T Front panel Bumper
PP/PE+T Pillar and sill lining Pillar and sill lining, front panel
PP/PE Pull handles
other PP Fillings Fillings
PE Tank Tank
ABS Centre console, lamp body,ashtrays, ventilation slots, outermirrors
Mask, heating control, steeringlinkage cover, electric drive cover
PA6 Pull handles, outer handles,handle of pocket cover, clips
Outer handles, clips
PA66 Clips Clips, cable connectors
PC Ceiling lamp, third brake lamp
PPO Lining of pocket cover Instrument panel, ventilation slots,defrost grid
PBT Lamellas of ventilation slots, coversof wipers, plugs
ASA Registration number lightingledges, signs Outer mirrors, registration numberlighting ledge, mask, instrumentpanel foil
PC/ASA
Handle of 5
th
door
PC/ABS Rear lamps
APEC Cap in rear lamp
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Marking of products
a
b
c
d
f
e
01 02 03 04 05 06 07 08 09 10 11 12
97
98
99
00
01
02
03
04
05
96
Signicance of individual marks:
a) Logo of manufacturer
b) Part number
c) Code of manufacturer
d) Abbreviation of manufacturer
e) Code of material
f) Country of origin
Example of table with date of production ofa plastic part.
E.g. marking means the following:
- PP - polypropylene
- EPDM - modied elastomer
- T20 - reinforcing material
Example of marking of front bumper at OCTAVIA
The marking of plastics is standardised. It must be in the form of the so-called rubber stamp, which must
include prescribed data. The marking must be on each plastic product or component.
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Identication of plastic components
Before a plastic product is welded, it is necessary to detect material from which it has been manufac-
tured so a good quality connection is achieved. A connection can only occur if the basic and the additive
material are of the same type, which means that the product must contain the same additive substances.
- a heat test is the starting point of identication as the enclosed diagram includesreferences to other tests performed
- to identify or establish type of a plastic product, cut a small piece from the part to bewelded
Welding of plastic component
-
by hot air
-
by ultrasound
Welding
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Neu
new
neuv
eD007
700
D007700
Kunststoff-ReparatursetPlasticrepairsetSetdereparationpourplastic
1Set
Components for sticking
Set (D 007 700) for plastic repairs includes:
Set (D 007 700)
- - for repairs of plastics
2-component plastic adhesive (D 180 KU1 A1)
in double cartridge of 50 ml
- is applied to cleaned degreased surfacestreated with primer
Cleaner (D 195 850 A1) in a 100 ml bottle
- for cleaning and degreasing of bonded parts
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Primer (D 822 150 A1) - 150 ml spray
- applied to bonded parts as a substrate foradhesive itself
Reinforcing foil with textile
- lls in punched holes
Mixing tips
- enables easy blending of adhesive componentsand its spread
- are t directly on the cartridge with adhesive
- are intended for a one-time use
Components for sticking
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Components for sticking
Wiper
- - for spreading of adhesive
Metal stiffeners
- are put perpendicular to the bonded joint
Dosing gun (VAS 5155)
- is not part of the set
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Clean the plastic part completely and dry
thoroughly.
Clean the repaired part from both sides with a
detergent.
Wedge taper edges of the repaired spot(1-2 cm/grain size 120)
Remove cracks and ssures at their
ends by drilling with a small diameter
borer to prevent their expansion.
Roughen surface on both sides (grain size 120).
Sticking
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Sticking
Clean the repaired spot on both sides with a plas-
tics cleaner and air for about 10 minutes. Do nottouch the degreased surfaces or clean properly.
Spray the spot repaired from both sides properly
and air for at least 10 minutes. Do not touch thus
prepared spot in any case.
Spread adhesive on the inner (rear) part of therepaired spot (stick the metal stiffeners to cracks).
Secure the mutual position of damaged spots with
a suitable clamp.
Put the reinforcing textile (larger than the repaired
spot) on the inner side of the repaired spot,
spread adhesive all across the textile surface and
spread smoothly with a spatula.
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In case of extremely large cracks/holes or in order to
accelerate the process it is recommended to hardenthe adhesive by means of an infrared lamp (60C-70C/15 min).
Apply adhesive on the outer (front) side and spread
smoothly.
Harden with infrared radiation (60-70C/15 min).
After cooling and hardening, grind the redundantadhesive and remove dust. The hardened adhesive
can be ground, drilled and threaded.
Sticking
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Sticking
For better adhesion of the varnish, spray the
primer on the front side.
This completes the repair of the plastic part.
The upper surfaces are suitable for painting
according to guidelines from manufacturers of
varnishes after 1-4 hours.
The structure of upper surfaces can be renewedin a mixture with a paint hardener (e.g. D775 108 -
not part of supply).
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Some useful tips
An unmixed adhesive in an open double cartridge will endure about 8 months. Of course, applying tipswith hardened mixed preparation cannot be used. This is, however, a negligible quantity, which does not
mean any substantial loss or bad economy. A new tip will be used for the next repair.
Before new use of adhesive, do not x the tip on the double cartridge; instead rst remove the small bay-
onet closure and try with the dosing gun whether equal "beads" are leaving easily both cartridges,
otherwise it is necessary to clean both holes properly with a needle. After use, remove the tip from thedouble cartridge and x on the cartridge the bayonet closer that seals well. However, a tip with a hard-
ened preparation can be left on the cartridge as well. The cartridge is stored (suspended along with the
gun) in a position with the tip being roughly in perpendicular position.
Summary and prospects
In sum, it can be stated that tests performed so far prove feasibility of repairs and durability of bumpers
expertly repaired. The ofcial manufacturer and system supplier proves approval of such repairs with a
certicate issued by an authorised test laboratory. The certicate is also an important aid for experts and
insurance companies in establishing damages.
When deciding whether a repair and replacement with a new part is to be made it is always necessary to
keep always in mind an issue of economy. The aspect of repair adequacy to the age of the vehicle playsan important role.
Summary
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Notes