Baydur_Bayflex (1)

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: 2013-02-18 · Order-No.: MS MS00040081 · Printed in Germany

Design unlimitedBaydur® & Bayflex®

Publisher:Bayer MaterialScience AG Business Unit Polyurethanes51368 LeverkusenDeutschland

www.bayer-baysystems.com

IntroductionMulti-faceted brands

PropertiesGrades with a unique profile

Design freedom and high functionality Sports & leisure House & home Transportation & commercial vehicles Medicine & technology Electronics & entertainment

CompositesPowerful combinations

Polyurethane manufacturingAlways the right mix

Polyurethanes from Bayer MaterialScience: innovative and sustainable

Contents

4

6

8

10

12

14

16

18

20

22

3

Following their invention by Dr. Otto Bayer in 1937, polyurethanes became a success story that continues to this day. Thanks to their incredible versa-tility 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 poly-urethane (PU) systems from Bayer MaterialScience are the ideal choice in countless applications. They provi-de 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 ven-tilation systems, sanitary facilities, the furniture industry, waste water techno-logy, transportation, windows, building components, decorative trim, special-purpose vehicles and automobiles.

Baydur® and Bayflex® are long-esta-blished brands that constantly inspire new applications.

Introduction

Multi-faceted brands

5

BAYDUR® 20 – extra light anddimensionally stableBaydur® 20 is characterized by a low density of 150-250 kg/m3 and a solid, hard-wearing outer layer. Wall thick-nesses of over 40 mm are possible. Baydur® 20 is not only light but also extremely impact resistant and suita-ble for cutting, nailing and bonding. Main application areas: Decorative trim and elements, such as simula-ted 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 den-sity range of 250 – 500 kg/m3 has a robust, scratch-resistant surface. Main application area: Wood sub-stitute for use in furniture

BAYDUR® 60 – the versatile engi-neering material The design possibilities are virtually unlimited. This product class is parti-cularly 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 hou-sings, skis

BAYDUR® 110 – the specialist mate-rial for thin-walled and large molded partsThis microcellular, almost solid RIM material can be processed cost-effec-tively 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 ve-hicles

BAYDUR CSP® – compact with simplified processingA 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 hou-sings, chairs

BAYDUR® GS – solid and durable This solid casting system enables pressureless processing. Baydur® GS is wear- and rot-proof and is frequent-ly used as a long-lasting substitute for cast iron. Its excellent chemical resi-stance is often crucial. Main applica-tion areas: Sewage pumps, manhole covers

BAYFLEX® InTEGRAL – tear resi-stant and elastic Bayflex® integral is a flexible to semi-rigid integral skin foam with a density range of 200 – 700 kg/m3. 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 excel-lent shock absorption when subjected to impact stress. Bayflex® integral grips well and is non-slip when napped or other surface structures are incorpo-rated. 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, particu-larly 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 snowmo-biles, agricultural equipment and vehicles

Properties

Grades with a unique profile

7

When it comes to skis and snow-boards, breaking strength and flexibi-lity 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, par-ticularly 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, tear-resistant polyurethane are not only comfortable for carnival visitors, pro-tecting them from bruising, they are also ideal for the ride operators, who prize the material’s easy cleaning and durability.

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.

Whatever the application needs, poly-urethane 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

Design freedom and high functionality

Sports & leisure

9

The home and its furnishings offer designers broad scope for creativity. Furniture, bathroom fittings, lamps and household appliances are availa-ble for all tastes and in all styles. The variety of deigns is endless.

This calls for materials that allow desi-gners maximum freedom while at the same time meeting the needs of dura-bility 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 coa-ted 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 con-ventional coating and IMC, the high-quality surface also enables back-foaming 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


House & home

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 tradi-tional square, angular sheet metal designs. For these applications, desi-gners 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 particu-larly essential.

Strict regulations and standards, relating to fire protection in trains for instance, must be observed. Whether for high-speed train cockpits or exca-vator 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


Transportation & commercial vehicles

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 open-ed up by these materials enables the production of aesthetic and rounded forms. The easy cleaning of the high-quality surfaces and their resistance to chemicals and disinfectants make Baydur® and Bayflex® ideal for use in medical practices and hospitals.


• 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


Medicine & technology

15

Thanks to the outstanding acoustic features of Baydur®, it can be used to produce particularly compact, high-end hi-fi loudspeakers. Even musical instruments, such as the curved bodies of digital grand pianos, are made of Baydur®.

A perfect surface is particularly impor-tant 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 com-plies with the stringent fire safety requirements for electrical equipment under UL94 V-0.

The electronics and entertainment sectors open up countless areas of application for Baydur®. Its very spe-cial properties constantly put it one step ahead of other materials, offering designers broad scope for creativity.

Typical applications:Baydur® • TV housings• Hi-fi loudspeakers• Music boxes• Bodies of digital concert pianos• Video projectors• Precision sound sources for acoustic measurements


Electronics & entertainment

17

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 pro-perties 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 mate-rials adds to the variety of applica-tions 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, rust-free body parts for commercial vehi-cles and public transportation.


• 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)

Composites

Powerful combinations

19

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.

Baydur® and Bayflex® are formed by the reaction of special-purpose poly-ols and isocyanates. Production of these raw materials is subject to strict quality controls and is carefully moni-tored. The DIN ISO 9001 guidelines, to which the Polyurethanes Business Unit has been certified since 1995, apply as a benchmark.

When producing moldings, a high-pressure pump metering units trans-ports the liquid raw material compon-ents to a mixing head. There they are mixed intensively in the prescribed proportions and metered into a pre-ferably closed mold.

Agitator motor

Polyol

Water outlet

Water inlet

Agitator motor

IsocyanateReturn line

Feed line

Plate heat exchanger

Return line

Feed line

Mold cover

Mold

Mixing head

Axial piston pump

Axial piston pump

Water inletWater outlet

Reactants are then metered using slow-running gear pumps to a mecha-nical 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 the-refore make a key contribution to the long service life of the articles manuf-actured from them. Polyurethane can be recycled as necessary. Recycling can take various forms depending on the conditions: material recycling, che-mical recycling or use as a source of energy.

Polyurethane manufacturing

Always the right mix

21

Polyurethanes from Bayer MaterialScience:

innovative and sustainable

23

For your notes

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

……………………………………………………………………………………………………………………………………………………………

Documents

Baydur_Bayflex (1)