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Sensor Products Inc

Main Office:
Sensor Products Inc
300 Madison Ave
Madison, NJ 07940

Arlene Gleicher
Phone: 1-973-884-1755 Fax: 1-973-884-1699
Web site: www.sensorprod.com Email: agleicher@sensorprod.com
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Established in 1990, Sensor Products Inc. USA is a world leader in the manufacture and distribution of tactile pressure sensing solutions. Their customized and off-the-shelf products are installed within all of the Fortune 500 industrial companies as well as thousands of smaller manufacturing firms. Their sensors are used in applications as diverse as tire testing to semiconductor manufacturing and from R&D labs to space missions. Additionally, Sensor Products provides in-house and on-site stress and pressure mapping analysis, as well as a variety of regional technical seminars.

Sensor film technology significantly reduces warped and rejected composite parts and has the ability to accurately map contact surface stress exposes inconsistencies and deformities.

Sensor Products Inc. presents Pressurex®, a thin Mylar-based sensor film that maps and measures the amount of interfacial stress exerted on honeycomb cores, composite lay-ups and bonded surfaces within composite structures. By using Pressurex® to see how surface stresses are distributed, an engineer can observe inconsistencies and misregistration in composite parts and thereby greatly reduce the yield defect rate. Other applications for Pressurex® include determination of press planarity in lamination processes, monitoring of vacuum bagging pressures, confirmation of pressure uniformity on wound filaments parts, and calibration of tools and equipment.

Pressurex® is available in sheets or rolls. When placed between contacting or mating surfaces, the film instantaneously and permanently changes color. This color change is a direct result of the amount of pressure applied. Comparison of color variations to a color correlation chart (conceptually similar to interpreting Litmus paper) can help determine precise pressure magnitude. Pressurex® can detect pressures from 2 to 43,200 PSI (.14 to 3,037 kg/cm2). Depending on the requirements of the project, additional graphical and statistical data can be retrieved from the film through Topaq®, an optical analysis system that can be bought or leased from Sensor Products Inc. or used by their staff.

In the aerospace industry, Pressurex® has been used to determine the exact amount of pressure causing cracks in the inner spars of a helicopter’s main rotor blade. A large sheet of Pressurex® was inserted into the bonding tool, bagged up, and pressurized in the autoclave. When the film was removed, the exact amount of pressure causing the crack was determined.

Pressurex sensor film also decreases resin content inconsistency in Prepreg and composite sheet manufacture. Prepreg and composite sheet manufacturers have a valuable tool to aid in producing consistent, high-quality products with uniform thicknesses. Pressurex® pressure indicating sensor film is ideal for preventing defects such as resin content inconsistency in the resin metering stage and off-spec fiber content in the press lamination stage. By revealing pressure variations between mating surfaces, it indicates corrective actions to take so that quality does not suffer and only top-quality prepreg and composite sheets are produced. Since prepreg is used in commercial and military aircraft, high modulus and strength must be attained.

In the process of manufacturing prepreg or composite sheets, precise resin metering onto the fibrous substrate is critical to success. Rollers need to be carefully aligned so that the meter resin that is applied to the substrate has uniform consistency and fabric wet-out (resin penetration into the fibrous substrate).

Pressurex® film in the resin metering stage exposes misalignment by measuring regions of high and low pressure between rollers. When placed between the two contacting rollers, the sensor film instantaneously and permanently changes color directly proportional to the actual pressure applied. Precise pressure magnitude is then easily determined by comparing color variation results to a color correlation chart (conceptually similar to interpreting Litmus paper). Variations in pressure that lead to defects can be quickly and accurately detected and corrected -- improving yield, decreasing scrap, and increasing productivity.

Following the resin metering step above, the web proceeds to the treater where heat and/or other curing processes (i.e. ultraviolet light cure) are used to attain the desired level of resin cure. While prepreg products are then wound up for processing into advanced composites, composite sheets require further consolidation and curing which is done by hydraulic presses. Precise alignment of the press platens is essential to produce sheets with consistent thicknesses since over time, press misalignment or deformation of the platens may occur from repeated exposure to high pressures and temperatures.

Pressure indicating sensor film placed into the press between the platens, indicates regions of high and low pressure, which if left uncorrected would lead to voids and/or regions of off-spec fiber content. Adjustments to the press to achieve uniform contact pressure across the entire platen area may then be made and final alignment verified with Pressurex®. This quality step is highly recommended to produce high-quality sheets of consistent thickness. It would be unfortunate to produce off-spec sheets that need to be discarded so near to the end of the manufacturing cycle after a large investment in materials and processing has been made.

Pressurex® records pressure from 2 - 43,200 PSI (0.14 - 3,000 kg/cm2). The film is thin and flexible (4 to 8 mils) which enables it to conform to curved surfaces. Since imprint is instantaneous, the film can be used at temperatures exceeding 200 Fº (93 Cº) for brief intervals. In addition, temperature shielding material for Pressurex® is available.

For a complimentary sample of Pressurex® in your desired range, contact Sensor Products Inc. at 1.973.884.1755 ( USA ), email info@sensorprod.com or visit their website at www.sensorprod.com/sample


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