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 properties. As a systems house, we specialize in putting this versatility to work for customers. Our strong point is the development of innovative raw material systems for the four main classes of PU foams: Flexible foams Integral skin foams Rigid foams Footwear foams Unlimited options The properties of PU foams can be effectively controlled over a wide range by taking a building block approach, in other words, by skillfully selecting the raw materials and additives. This enables us to precisely adapt the chemistry of our PU systems to specifications based on customer needs. For example, we can individually adjust the hardness, density and reaction time or, using fillers, we can optimize the mechanical properties of a PU system. By adding reinforcing fillers, we can vary the stiffness of the foams, all the way up to highrigidity foams for structural automotive parts. Flame retardants improve the already good fire resistance of PU foams, and even help PU thermal insulation composites to achieve a low flammability classification (DIN EN 13823). Additives with an antistatic effect enable structural components to dissipate electrostatic charge, thereby preventing its buildup. We also have customized PU systems for processes such as manufacturing lightweight composites using LFI methods or honeycomb technology. The short cycle times, low mold costs and good demolding behavior associated with our PU systems promote efficient manufacturing. Thanks to the low viscosity of the PU raw materials, the foams can flawlessly render even thin or complex component geometries. Quick selection of foamed systems Range Reactivity Molding sizes Molding density Slow Fast Small Large <250 g / L >250 g / L Flexible foam flexible ++ ++ ++ ++ ++ - Flexible foam viscoelastic - ++ ++ + ++ + Flexible foam semi-rigid + ++ ++ ++ ++ + Integral skin semi-rigid ++ ++ ++ + + ++ Integral skin rigid ++ ++ ++ ++ + ++ Rigid foam RIM Baydur - ++ ++ + - ++ Rigid foam honeycomb technology Baypreg ++ ++ ++ ++ - ++ Rigid foam spray Multitec - ++ ++ ++ - ++ Rigid foam energy-absorbing + ++ ++ + ++ + Footwear system ether + ++ ++ + - ++ Footwear system ester + ++ ++ + - ++ ++ Highly recommended + Recommended - Not recommended 4

From a single source Innovation, quality and performance Covestro Oldenburg GmbH & Co. KG is a leading PU systems house in central Europe. We develop, produce and market material solutions for one of the most innovative PU markets worldwide. As a subsidiary of Covestro Deutschland AG, we are closely networked with its other PU systems houses in Europe. Our know-how, our services Working in partnership Our customers are our partners in shared success. We support them throughout the entire development process for a PU component with our tailored technical and business services. We have decades of experience with polyurethane at our site in Oldenburg. Our development department, working in close cooperation with customers, produces customized PU systems. We supply customers with any product volume they request, even small batches that we produce on special, semi-automatic machines. Furthermore, our Production department is well-equipped, for instance with reactors for manufacturing isocyanate prepolymers. In our Technical Service Center, we replicate the production systems of our customers on commonly used machines, such as low-pressure or highpressure metering systems, to study the processing behavior of new PU systems. Our Materials Testing Lab conducts the most critical types of testing in accordance with relevant standards, such as tension, flexural, compressive deformation and aging tests. On-site service and training We support our customers in their native language and offer them on-site technical service. And we train them in areas such as PU processing and the safe handling of PU raw materials. Reliable and flexible production Be it drum or tank delivery, our production department adapts flexibly to customer needs. We deliver the requested quantities promptly, reliably and on schedule. In-house development department Our development department specializes in innovative PU systems for new applications and markets. You benefit from the know-how that Covestro has acquired in its role as global market leader in PU and the inventor of polyurethane. Technical Service Center We know our customers processes, thanks to our Technical Service Center, where we replicate established PU processing methods to ensure optimum customer service. small lot filling station In-house Testing Lab Detailed knowledge of material behavior is indispensable when it comes to component modeling and development. At our Testing Lab, we therefore calculate the most critical parameters of PU systems for our customers.

An overview Our PU systems for foams PU foams formulated with our raw material systems cover a very wide range of properties that are exploited by a variety of industries, including the automotive, footwear, commercial vehicle, building, furniture, mining, agricultural, security, sports and recreation industries. We have therefore divided our product groups in this table into flexible, integral skin, rigid and footwear foams to give customers a quick overview of their different, typical characteristics. These include mechanical properties, such as the hardness or tear propagation resistance of the resulting foams, as well as processing behavior (mold temperature, blowing agent, etc.) and typical applications. Naturally, we fine tune our PU foam raw materials in close collaboration with customers to suit a given application. Flexible foam systems Range Integral skin foam systems Type Product group Flexible Bayfit Compressive strength at 40% deformation 2 15 kpa Viscoelastic Bayfit Compressive strength at 40% deformation 5 100 kpa Semi-rigid Bayfill Compressive strength at 40% deformation 20 60 kpa Semi-rigid Bayflex Shore A 20 80 Rigid Baydur Shore D 30 80 Hardness range Density range Properties 50 80 g / L Low emissions, permanently flexible, lightweight Low compression set 45 120 g / L Memory effect 100 200 g / L 250 900 g / L 150 900 g / L Low emissions, permanently flexible Good sound absorption Good haptics thanks to flexible foam core Decorative, abrasion-resistant surface thanks to compact, elastic skin Weather resistant Good skin formation High surface hardness, good skin formation Coatable, easy release High stiffness and strength at low density RIM, S-RIM Fiber Spray (LFI) Baydur Shore D 40 80 200 900 g / L High flexural modulus of elasticity, high HDT, density > 250 g / L Rigid foam systems Footwear systems Honeycomb technology Baypreg Shore D 60 80 Spray Multitec Shore D 50 80 Energyabsorbing Baysafe Compressive strength at 40% deformation 200 1400 kpa Ester Bayflex S Midsoles, outsoles, mono-soles Component dependent 300 1200 g / L 45 120 g / L Midsoles: 280 450 g / L Outsoles: 900 1100 g / L Mono-soles: 500 600 g / L Ether Bayflex S Mono-soles 450 600 g / L Rigid lightweight composite Easy release/minimal release agent required Sandwich structure with variable densities Optionally with chopped glass fibers Flexible and ductile Absorbs impact energy by deformation Optional antistatic formulation to ESD, high oil resistance, lightweight and durable Easy release and CO 2 lightweight technology available Good oil and gasoline resistance Very good hydrolysis resistance Good resistance to acids and alkali solutions Optional antistatic formulation 5

High performance foams for a wide spectrum of applications PU foams are resistant to even the extreme adverse influences they may be exposed to in a wide range of different applications; these include energy and shock impact, abrasion, and severe weather conditions and temperatures. Start time Required mold temperature Blowing agent Typical mechanical properties (hardness-dependent) Example applications 4 12 s 40 60 C Chemical Compression set 3 12% Seat cushions 4 6 s 40 60 C Chemical Recovery times between 5 and 20 s Comfort mattresses 6 11 s 50 65 C Chemical Thermally and hydrolytically stable Back-molding of automotive interior Sealing lips for filter systems 10 30 s 40 50 C Physical High tensile strength and tear propagation resistance Seats Armrests Edge protection sections Floor mats Headrests 12 35 s 45 65 C Chemical / physical High flexural modulus of elasticity at low density Premium housings and trim components for commercial vehicles Exterior 5 20 s 60 80 C Chemical High flexural modulus of elasticity Adjustable over a wide range depending on the process 60 120 C Chemical High flexural strength Overhead shelf Combine harvester hood Housing parts Reversible luggage compartment floors Sunroof frames Commercial vehicle interior < 10 s, adjustable 30 60 C Chemical High flexural modulus of elasticity Single-shell, large area trim components < 10 s 40 60 C Chemical High compression set Foam-filled bumpers, crash pads 5 10 s 45 55 C Chemical / physical Very good abrasion resistance 20 50 mm 3 Good long-term flexural strength Good hydrolysis resistance Two-layer soles for safety shoes Single-layer soles for safety and casual shoes 8 10 s 45 50 C Chemical / physical Good long-term flexural strength at low temperatures Clogs Single-layer soles for casual shoes Firefighter boots

Further information can be found under: covestro.com Covestro Oldenburg GmbH & Co. KG Mittelkamp 112 26125 Oldenburg Germany Phone: +49 441 9317-501 E-mail: info.oldenburg@covestro.com This information and our technical advice whether verbal, in writing or by ways of trial are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. The information is provided by Covestro Oldenburg GmbH & Co. KG or Covestro Deutschland AG without assumption of any liability. If any of the above mentioned regulations change after the date of declaration, this declaration is no longer valid. Covestro Oldenburg GmbH & Co. KG or Covestro Deutschland AG will strive to keep this information up-to-date. Our advice does not release you from the obligation to verify the information provided especially that contained in our safety data and technical information sheets, to check for updates of any information provided by us and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery of Covestro Deutschland AG. covestro.com Edition: 9-2015 Order No.: MS 00067462 Printed in Germany