Design unlimited Baydur & Bayflex

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Design unlimited Baydur & Bayflex Publisher: Bayer MaterialScience AG Business Unit Polyurethanes 51368 Leverkusen Deutschland www.

com This information and our technical advice whether verbal, in writing or by way of trials is given in good faith but without a

It does not release you from the obligation to test the products supplied by us as to their suitability for the intended processes

1 Design unlimited Baydur & Bayflex Publisher: Bayer MaterialScience AG Business Unit Polyurethanes Leverkusen Deutschland This information and our technical advice whether verbal, in writing or by way of trials is given in good faith but without a warranty, and this also applies where proprietary rights of third parties are involved. It does not release you from the obligation to test the products supplied by us as to their suitability for the intended processes and uses. The application, use and processing of the products are beyond our control and, therefore, entirely your own responsibility. We will only sell our products on the basis of our General Terms and Conditions of Sale. Edition: Order-No.: MS MS Printed in Germany

2 Contents Introduction Multi-faceted brands 4 Properties Grades with a unique profile 6 Design freedom and high functionality Sports & leisure House & home Transportation & commercial vehicles Medicine & technology Electronics & entertainment Composites Powerful combinations 18 Polyurethane manufacturing Always the right mix 20 Polyurethanes from Bayer MaterialScience: innovative and sustainable 22 3

Introduction Multi-faceted brands Following their invention by Dr. Otto Bayer in 1937, polyurethanes became a success story that continues to this day.

Two of this material s product groups reflect this success story perfectly: Baydur and Bayflex.

They provide alternatives to traditional materials, such as wood and metal, as well as thermoplastics and thermoset plastic materials. Sometimes they are quite simply the only choice.

Easily coated Strength and dimensional stability Chemical resistance Easily combinable with other materials Individually adjustable properties Relatively low investment in molds and

3 Introduction Multi-faceted brands Following their invention by Dr. Otto Bayer in 1937, polyurethanes became a success story that continues to this day. Thanks to their incredible versatility and adaptability, they have found their way into virtually all areas of our daily lives. Two of this material s product groups reflect this success story perfectly: Baydur and Bayflex. These polyurethane (PU) systems from Bayer MaterialScience are the ideal choice in countless applications. They provide alternatives to traditional materials, such as wood and metal, as well as thermoplastics and thermoset plastic materials. Sometimes they are quite simply the only choice. These are only a few of the strengths of Baydur and Bayflex : Low-cost production of large molded parts Variable wall thicknesses Exceptionally accurate reproduction of surface detail Easily coated Strength and dimensional stability Chemical resistance Easily combinable with other materials Individually adjustable properties Relatively low investment in molds and equipment Key application areas for Baydur and Bayflex include the electrical and machine housing industry, medical equipment, farm machinery, athletic equipment, inward and outward ventilation systems, sanitary facilities, the furniture industry, waste water technology, transportation, windows, building components, decorative trim, specialpurpose vehicles and automobiles. Baydur and Bayflex are long-established brands that constantly inspire new applications. 5

Main application areas: Decorative trim and elements, such as simulated stucco BAYDUR 40 for complex shapes Baydur 40 has excellent flowability, enabling the simple production of large, complexly

Main application area: Wood substitute for use in furniture BAYDUR 60 the versatile engineering material The design possibilities are virtually unlimited.

Baydur 60 is light and strong thanks to its integral skin structure and is flame retardant to UL94 V-0.

4 Properties Grades with a unique profile BAYDUR 20 extra light and dimensionally stable Baydur 20 is characterized by a low density of kg/m 3 and a solid, hard-wearing outer layer. Wall thicknesses of over 40 mm are possible. Baydur 20 is not only light but also extremely impact resistant and suitable for cutting, nailing and bonding. Main application areas: Decorative trim and elements, such as simulated stucco BAYDUR 40 for complex shapes Baydur 40 has excellent flowability, enabling the simple production of large, complexly shaped parts. This rigid integral skin foam with a density range of kg/m 3 has a robust, scratch-resistant surface. Main application area: Wood substitute for use in furniture BAYDUR 60 the versatile engineering material The design possibilities are virtually unlimited. This product class is particularly advantageous for large parts with widely varying wall thicknesses. Baydur 60 is light and strong thanks to its integral skin structure and is flame retardant to UL94 V-0. Main application areas: Industrial housings, skis Baydur 110 the specialist material for thin-walled and large molded parts This microcellular, almost solid RIM material can be processed cost-effectively thanks to short demolding times of approx. 90 seconds. Thin-walled molded parts can be produced with high inherent stiffness and strength, and excellent surface quality. Main application areas: Industrial housing components, optical instruments, medical housings, refrigerators, paneling/trim for commercial vehicles BAYDUR CSP compact with simplified processing A compact material that requires only minimal investment in machinery and molds. It can also be processed in epoxy resin molds and is suitable for manufacturing large, thin-walled parts with excellent surface quality. Main application areas: Industrial housings, chairs BAYDUR GS solid and durable This solid casting system enables pressureless processing. Baydur GS is wear- and rot-proof and is frequently used as a long-lasting substitute for cast iron. Its excellent chemical resistance is often crucial. Main application areas: Sewage pumps, manhole covers BAYFLEX integral tear resistant and elastic Bayflex integral is a flexible to semirigid integral skin foam with a density range of kg/m 3. The surface hardness can be varied as required (Shore A 30 85). This tear-resistant and flexible foam has a closed outer layer. The open-cell core exhibits excellent shock absorption when subjected to impact stress. Bayflex integral grips well and is non-slip when napped or other surface structures are incorporated. Main application areas: Office furniture, work mats, protective strips BAYFLEX RIM tough and elastic even at sub-zero temperatures Bayflex RIM is a solid material that stands out from the crowd, particularly because of its excellent impact resistance even in extremely cold conditions. Short glass fibers and other mineral reinforcing materials are added to achieve the required stiffness. Main application areas: Side strips, side member moldings, bumpers and fenders for cars and trucks, paneling/trim for snowmobiles, agricultural equipment and vehicles 7

Design freedom and high functionality Sports & leisure Safety and comfort, as well as design and functionality, are especially important in the sports and leisure industries.

The ability to form a durable bond with other materials is a prerequisite for any state-of-the-art composite structure.

Snowmobile hoods used in a freezing cold environment require a product is impervious to impacts.

Bumper car seats and interior trim panels made from flexible, tearresistant polyurethane are not only comfortable for carnival visitors, protecting them from bruising, they are also

5 Design freedom and high functionality Sports & leisure Safety and comfort, as well as design and functionality, are especially important in the sports and leisure industries. Every piece of recreational equipment poses its own, specific challenges for a material. When it comes to skis and snowboards, breaking strength and flexibility are key factors. The ability to form a durable bond with other materials is a prerequisite for any state-of-the-art composite structure. The key factor with bicycle seats is comfort through ergonomic pressure distribution, particularly when riding long distances. Snowmobile hoods used in a freezing cold environment require a product is impervious to impacts. The fact that snowshoes do not break even when subjected to extreme stress can mean the difference between life and death. Bumper car seats and interior trim panels made from flexible, tearresistant polyurethane are not only comfortable for carnival visitors, protecting them from bruising, they are also ideal for the ride operators, who prize the material s easy cleaning and durability. Whatever the application needs, polyurethane has just the right answer. Typical applications: Baydur Skis, snowboards Wakeboards, water skis Balls for bowling and skittles Motorcycle cladding Tanning beds Upper decks on speedboats Bayflex Bicycle seats Snowshoes Snow mobile hoods Bumper car seats Rockers for children Safety padding for motorcycle clothing Sparring headgear 9

Design freedom and high functionality House & home The home and its furnishings offer designers broad scope for creativity.

This calls for materials that allow designers maximum freedom while at the same time meeting the needs of durability and surface quality.

The soft, rounded forms of the Zanussi OZ refrigerator are no real challenge for Baydur and yet would be virtually impossible to produce using metal.

Chairs and stools that can be foamed and coated in a single operation, thanks to in-mold coating (IMC), provide lasting comfort. Baydur parts can also be finished in any way desired.

6 Design freedom and high functionality House & home The home and its furnishings offer designers broad scope for creativity. Furniture, bathroom fittings, lamps and household appliances are available for all tastes and in all styles. The variety of deigns is endless. This calls for materials that allow designers maximum freedom while at the same time meeting the needs of durability and surface quality. The integral skin foam structure of Baydur gave the first cantilever chair, designed by Verner Panton, the necessary stability. The soft, rounded forms of the Zanussi OZ refrigerator are no real challenge for Baydur and yet would be virtually impossible to produce using metal. Bayflex, with its flexible foam core, rounds off the range. Chairs and stools that can be foamed and coated in a single operation, thanks to in-mold coating (IMC), provide lasting comfort. Baydur parts can also be finished in any way desired. In addition to conventional coating and IMC, the highquality surface also enables backfoaming of thermoformed films. Baydur and Bayflex provide a host of visual delights. Typical applications: Baydur Designer chairs Refrigerators Shower stalls School chairs Bathroom stools Lamps Simulated stucco (decorative copings, roses) Cabinets Window frames Mirror frames Ornamentation on wooden furniture Doors Bayflex Designer chairs Table edging Armrests for office chairs Moldings for stairway handrails Sheathing for solar modules 11

Design freedom and high functionality Transportation & commercial vehicles Trains and commercial vehicles are no strangers to fashion

Shapes are adapted to the latest trends, with curved, organic forms, for example, now in demand in contrast to traditional square, angular

For these applications, designers need products that not only give them the necessary design freedom, but can also face up to the technical

Strict regulations and standards, relating to fire protection in trains for instance, must be observed.

7 Design freedom and high functionality Transportation & commercial vehicles Trains and commercial vehicles are no strangers to fashion either. Shapes are adapted to the latest trends, with curved, organic forms, for example, now in demand in contrast to traditional square, angular sheet metal designs. For these applications, designers need products that not only give them the necessary design freedom, but can also face up to the technical challenges. Reliability despite the high stress placed on materials is particularly essential. Strict regulations and standards, relating to fire protection in trains for instance, must be observed. Whether for high-speed train cockpits or excavator cabs, Baydur and Bayflex offer a wide range of customized systems for innovative solutions. Typical applications: Baydur High-speed train cockpit interiors Forklift cladding Tractor hoods Body parts for agricultural machinery Roof panels in rail vehicles Bayflex Excavator cabs Castors and wheels Steering wheels Headrests Protective strips Body parts for agricultural machinery/trucks Seats Sills Front and rear spoilers 13

Design freedom and high functionality Medicine & technology In virtually no other field are research and development so driven as in medicine.

What was still cutting-edge for medical equipment just a few years ago is today often outdated.

Baydur and Bayflex offer a host of application-related benefits for use in medicine.

The easy cleaning of the highquality surfaces and their resistance to chemicals and disinfectants make Baydur and Bayflex ideal for use in medical

8 Design freedom and high functionality Medicine & technology In virtually no other field are research and development so driven as in medicine. The recovery process for humans and animals depends to a significant extent on the perfect functioning and development level of technical equipment. What was still cutting-edge for medical equipment just a few years ago is today often outdated. Outward appearances also follow trends and help patients feel at ease an ideal domain for Baydur and Bayflex. Baydur and Bayflex offer a host of application-related benefits for use in medicine. The design freedom opened up by these materials enables the production of aesthetic and rounded forms. The easy cleaning of the highquality surfaces and their resistance to chemicals and disinfectants make Baydur and Bayflex ideal for use in medical practices and hospitals. Typical applications: Baydur Computer tomograph housings Light therapy devices Multifunctional hospital stretchers Hospital bed head/foot components Housings for operating microscopes Housings for dialysis machines Cuspidors Imitation bones for training surgeons Bayflex Wheels for wheelchairs Toilet seats Armrests and seats for wheelchairs 15

Design freedom and high functionality Electronics & entertainment The electronics and entertainment sectors open up countless

Its very special properties constantly put it one step ahead of other materials, offering designers broad scope for creativity.

Even musical instruments, such as the curved bodies of digital grand pianos, are made of Baydur.

And this is where Baydur has already repeatedly proven itself as a material for the housings of video projectors, television sets

9 Design freedom and high functionality Electronics & entertainment The electronics and entertainment sectors open up countless areas of application for Baydur. Its very special properties constantly put it one step ahead of other materials, offering designers broad scope for creativity. Thanks to the outstanding acoustic features of Baydur, it can be used to produce particularly compact, highend hi-fi loudspeakers. Even musical instruments, such as the curved bodies of digital grand pianos, are made of Baydur. A perfect surface is particularly important for high-quality equipment. And this is where Baydur has already repeatedly proven itself as a material for the housings of video projectors, television sets and control consoles for lighting effects. The product complies with the stringent fire safety requirements for electrical equipment under UL94 V-0. Typical applications: Baydur TV housings Hi-fi loudspeakers Music boxes Bodies of digital concert pianos Video projectors Precision sound sources for acoustic measurements 17

Composites Powerful combinations Polyurethanes all have one thing in common: They adhere well to most other materials.

Whether with wood, metal or a whole range of fiber materials and fillers, each combination of materials adds to the variety of applications for these polyurethanes.

moisture-resistant railroad ties, as robust sheathing for wooden planks for long-term use in brick production, as insulating window profiles in combination with aluminum or

Typical applications: Baydur Base plates for making bricks Railroad ties Door leaves (with long glass fibers) Refrigerator doors (surface finished with laminated foil)

10 Composites Powerful combinations Polyurethanes all have one thing in common: They adhere well to most other materials. This can be used to expand the already wide range of properties of polyurethanes even further. The possible combinations with Baydur and Bayflex are virtually unlimited. Whether with wood, metal or a whole range of fiber materials and fillers, each combination of materials adds to the variety of applications for these polyurethanes. The property profile of the polyurethane composite used can be manipulated depending on the function, whether in combination with fiber glass as a reinforcement for moisture-resistant railroad ties, as robust sheathing for wooden planks for long-term use in brick production, as insulating window profiles in combination with aluminum or as impact-resistant, rustfree body parts for commercial vehicles and public transportation. Typical applications: Baydur Base plates for making bricks Railroad ties Door leaves (with long glass fibers) Refrigerator doors (surface finished with laminated foil) Window frames (composite with wood or metal) Polymer concrete (mineral-filled, solid systems) Furniture (integration of functions by insert molding) Bayflex Chairs (composite with metal) Table edging (composite with wood) Fiber-reinforced bodywork components Headrests (composite with metal) Steering wheels (composite with metal) 19

Polyurethane manufacturing Always the right mix Baydur and Bayflex are formed by the reaction of special-purpose polyols and isocyanates.

The DIN ISO 9001 guidelines, to which the Polyurethanes Business Unit has been certified since 1995, apply as a benchmark.

There they are mixed intensively in the prescribed proportions and metered into a preferably closed mold. The mold, temperature-controlled to approx.

The chemical reaction of the raw material mixture in the mold creates a polyurethane molded part that can be produced in various wall thicknesses and densities.

They are suitable for a simple, pressureless casting process, for which low-pressure machines can also be used.

11 Polyurethane manufacturing Always the right mix Baydur and Bayflex are formed by the reaction of special-purpose polyols and isocyanates. Production of these raw materials is subject to strict quality controls and is carefully monitored. The DIN ISO 9001 guidelines, to which the Polyurethanes Business Unit has been certified since 1995, apply as a benchmark. When producing moldings, a highpressure pump metering units transports the liquid raw material components to a mixing head. There they are mixed intensively in the prescribed proportions and metered into a preferably closed mold. The mold, temperature-controlled to approx. 60 C, is held shut by a clamping force that is adequate albeit low in comparison with thermoplastic processing. The chemical reaction of the raw material mixture in the mold creates a polyurethane molded part that can be produced in various wall thicknesses and densities. This production method is known as the RIM process (reaction injection molding). The two products Baydur GS and Baydur CSP play a special role. They are suitable for a simple, pressureless casting process, for which low-pressure machines can also be used. Reactants are then metered using slow-running gear pumps to a mechanical agitator, where mixing takes place. These products also enable cost-effective epoxy resin molds to be used for relatively small production runs. Products made from polyurethane exhibit excellent resilience and therefore make a key contribution to the long service life of the articles manufactured from them. Polyurethane can be recycled as necessary. Recycling can take various forms depending on the conditions: material recycling, chemical recycling or use as a source of energy. Agitator motor Water outlet Water outlet Water inlet Polyol Axial piston pump Water inlet Plate heat exchanger Feed line Agitator motor Return line Mold cover Isocyanate Return line Mixing head Axial piston pump Feed line Mold 21

12 Polyurethanes from Bayer MaterialScience: innovative and sustainable For your notes 23

Custom polyurethane foams: Uniquely versatile

Custom polyurethane foams: Uniquely versatile Custom polyurethane foams: Uniquely versatile Uniquely versatile No other foam system can rival polyurethane (PU) foams in terms of the variety of grades and