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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 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


Glass bres

Glass wool

Glass balls

Talcum

Mineral stiffenersWood aggregate

ACM

AU

BR

CSM

CR

EPDM

ECO

FPM

MVQ

NBR

NR

SBR


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


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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

Documents

SSP_003_ru_Ремонт пластиковых деталей