integral skin foams versatile polyurethane … 18:18:… · additives: e.g. flame retardant´s, ......

Bayer AG

Geschäftsbereich Polyurethane

D-51368 LeverkusenBayer on the Internet: http://www.bayer.com

BAYDUR®/BAYFLEX®

VERSATILE POLYURETHANE INTEGRAL SKIN FOAMS

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Storage tank

Container Drum Drum Container

Storage tank

or or

PolyolDesmophenmachine tank

IsocyanateDesmodur

machine tank

Gas loading

Metering machine

Additives: e.g. flame retardant´s,colour pastes

Mould carrier

Moulded article

Mould

Mixing head

R

VERSATILITY WITH POLYURETHANESPOLYURETHANE SYSTEMS, PROVENOVER AND OVER AGAIN

2

ADVANTAGES OF BAYDUR®

AND BAYFLEX®:

Economical production of large

moulded parts

Variable wall thickness

Exceptionally accurate reproduction

of mould surface detail

Easy to paint

Strength and dimensional stability

Chemical resistance

Easy to combine with other materials

Individually adjustable properties

Relatively low investment in moulds

and plant

The most important areas of use for

Baydur and Bayflex include housings

for electrical goods, games and vend-

ing machines, medical equipment, agri-

cultural machinery, paper and printing

equipment, sports equipment, ventila-

tion systems, sanitary goods, the furni-

ture industry, sewerage engineering,

traffic and transport engineering, win-

dows, structural elements, decorative

mouldings and special-purpose vehicles.

THE ORIGIN OF MODERN

MATERIALS

Baydur and Bayflex consist of a polyol

(Desmophen®) and an isocyanate

(Desmodur®). The quality of these raw

materials is subject to permanent and

stringent in-house Bayer quality con-

trols and is carefully monitored. The

relevant standard is DIN ISO 9001 and

the Polyurethanes Business Group was

certified in accordance with this stan-

dard in 1995. During production, the

liquid raw materials are fed to a mixing

head by means of a high-pressure

pumping and metering unit. There, they

are intimately mixed in the correct pro-

Diagram of the RIM process for polyurethaneproduction:

portions and are metered, under re-

duced pressure, into a mould which is

preferably sealed. The mould, kept at a

constant temperature of 60 °C, is held

in a mould carrier with adequate locking

force. A chemical reaction is initiated in

the raw material mixture in the mould

and finally a generally stress-free struc-

tural moulded article is formed. This

method of production is called the RIM

process.

Polyurethanes can be recycled at the

end of their service life. A number of

recycling processes is available,

depending on the boundary conditions.

CONTENTSVERSATILITY WITH

POLYURETHANES

Baydur and Bayflex

Features and fields of application

Production by the RIM process 2/3

BAYDUR® 20

Main area of use:

Decorative elements 4/5

BAYDUR® 40

Main area of use:

Simulated wood, furniture 6/7

BAYDUR® 60

Main area of use:

Industrial housings 8/9

BAYDUR® 110

Main area of use:

Parts for industrial housings, optical

equipment, housings for medical

equipment, refrigerators 10/11

BAYDUR® GS

Main area of use:

Effluent/water treatment plant 12/13

BAYFLEX® 20/30

Main area of use:

Office furniture 14/15

BAYFLEX® RIM/RRIM

Main area of use:

Impact resistant cladding 16/17

PROSPECTS

FOR POLYURETHANES

Market outlook and

future developments 18/193

Bayer's two polyurethane integral skinfoam systems Baydur® and Bayflex®

have been used for years in many different fields of application. Thanks toa number of properties characteristic ofpolyurethane, the Baydur® and Bayflex®

systems offer a complete substitute fortraditional materials such as wood ormetal and thermoplastic or thermosetmaterials.

BAYDUR® 20 - TECHNICAL DATA

Density of moulded article1) 170 kg/m3

Flexural strength1) 5 MPa

Flexural modulus of elasticity1) 160 MPa

Tensile strength1) 3 MPa

Elongation at break1) 3%

Tensile modulus of elasticity1) 130 MPa

Compressive strength at 10 % compression2) 2 MPa

Shore A hardness3) 98

Shore D hardness3) 26

Moulding shrinkage approx. 0.3 %1)DIN 53432 2)DIN 53421 3)DIN 53505

BAYDUR® 20SUPER-LIGHT INTEGRALSKIN FOAM

Baydur® 20 is especially suitable for theproduction of decorative elements witha wall thickness of up to 25 mm, due toits low density of 150 -250 kg/m3.Baydur® 20 is not only light but alsodimensionally stable and thermallyinsulating, while it can also be cut,nailed and glued. Thus, using this inte-gral skin foam, sealed, easily paintedsurfaces can be produced which, ifrequired, can also achieve flammabilityrating B2 by adding flame retardants inaccordance with DIN 4102.

There are only a few DIN standards for

lightweight materials with a sandwich-

type structure. In other cases, the

physical properties are determined in

the same way as described in existing

regulations. The test specimens are cut

out of a 1,000 mm x 500 mm x 10 mm

sheet with solid edge zones on both

sides, machine-made in a temperature-

controlled aluminium mould (mould

temperature: 60 °C; demoulding time: 6

minutes).

APPLICATIONS OF

BAYDUR® 20:

Decorative mouldings and elements

such as simulated stucco

Air duct sections with a large surface

area

Decorative simulated stuccomade from Baydur 20.

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Density of moulded article1) 400 kg/m3


Flexural modulus of elasticityl1) 520 MPa

Impact strength1) 10 kJ/m2

Shore D hardness2) 58

Heat deflection temperature1) 90 °C

Moulding shrinkage approx. 0.4 %1)DIN 53432 2)DIN 53505

BAYDUR® 40FLOWING FORMS

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Rigid integral skin foam Baydur® 40 hasa density in the range 250- 500 kg/m3

and exceptionally good flow, whichmeans that large moulded articles caneasily be made. By adding a blowingpaste, a hard outer layer can be formedso that surface hardness, and thusscratch resistance, is increased.

specimens are cut out of a sheet with

solid edge zones on both sides which

has been machine-made in a tempera-

ture-controlled aluminium mould (1000

x 500 x 10 mm) (mould temperature:

60 °C; demoulding time: 6 minutes).

APPLICATIONS OF

BAYDUR® 40

Simulated wood (Finto legno)

Furniture

Cladding panels

Window frames

Only some lightweight sandwich mate-

rials are covered by DIN standards. In

all other cases, the physical values are

determined in the same way as de-

scribed in existing regulations. The test

Baydur 40: Simulated period furniture made from polyurethane.

BAYDUR® 60THE FOAM WITH A HIGH PROFILE

There are virtually no limits to the num-ber of structural design possibilitieswhen using Baydur® 60. Due to thesandwich structure - a solid outer layerand a foam core - the material can beprocessed in much the same way aswood. This material has proved particu-larly suitable for large moulded itemsbecause it`s good flow properties allowthe use of complicated mould geome-tries. This means that the internal pres-sure in the mould is low. For this rea-son, and because it has good adhesiveproperties, combinations with othermaterials pose no problems.

VERSATILE AND UP-TO-DATE

Thanks to the exceptionally accurate

reproduction of mould detail with

Baydur 60, structures of any type at all

can be produced in the mould and indi-

vidual colours can be applied with a

coat of paint. If colour is not so impor-

tant, a black, brown or orange colora-

tion can be produced by adding pig-

ment to the polyol component.

APPLICATIONS OF

BAYDUR® 60

Industrial housings, e.g. medical and

dental equipment

Cores for skis

Window frames

Housing for a juke-box made from Baydur 60.


Preferred wall thickness 4 - 20 mm

Mould draw 1°

Threaded inserts can be insert moulded or fitted later yes

Snap-fitting connections no

Moulding shrinkage 0.4 - 0.7 % (depending on the system)

Density of moulded articles1) 550 - 650 kg/m3

Flexural modulus of elasticity1) 600 - 1050 MPa at a density 500 - 600 kg/m3

Flexural strength1) 25 - 45 MPa at a density 500 - 600 kg/m3


Elongation at break1) 8 %

Impact strength1) 18 KJ/m2

Heat deflection temperature1) up to 118 °C

Compressive strength at 10 % compression2) 18 N/mm2

Shore D surface hardness3) 62 - 70

Coefficient of thermal expansion 73 x 10-6 K-1

Water absorption4) 24h/RT < 0.4 %

Fire performance according to UL test V-0 at 10 mm wall thickness*

Fire performance according to5) B2

Fire performance according to German Federal Railways test6) S4-SR2-ST2*

* with flame retardant1)DIN 53432 2)DIN 53421 3)DIN 53505 4)DIN 53495 5)DIN 4102 6)DIN 5510

Moulded components made from Baydur 60.

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BAYDUR® 110ECONOMICAL PRODUCTION BYTHE RIM PROCESS

Baydur® 110 is a microcellular, solidRIM material which is characterised inparticular by its economical production.Thanks to fast demoulding cycles ofabout 90 seconds, moulded articleswith a wall thickness of preferably 4 to6 mm, high intrinsic stiffness and highstrength can be produced. Aluminiummoulds are used during productionwhich means that no release agents areneeded, resulting in an environmentallyfriendly production process. If required,a flame retardant version of Baydur®

110 in accordance with a variety ofstandards can be supplied.

APPLICATIONS OF

BAYDUR® 110:

Filter frames

Industrial housings of all sorts, e.g.

housings for medical equipment,

automatic vending machines, re-

frigerators.

Outer cabinet of a refrigerator made from Baydur 110.

Cladding round a petrol pump.

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Mould draw 1°

Threaded inserts can be insert moulded or fitted later sometimes

Snap-fitting connections possible

Moulding shrinkage 0.5 - 0.8 %

Density of moulded articles1) 1,100 kg/m3

Flexural modulus of elasticity2) 2,000 N/mm2

Flexural strength3)

Tensile strength4) 53/43 MPa (FR grades)



Heat deflection temperature6) 115 °C method B

Shore D surface hardness 75 - 77

Coefficient of thermal expansion - at RT 90 x 10-6 K-1

- at 60 °C 105 x 10-6 K-1

Water absorption7) 24h/RT< 0.6 %

Fire performance according to UL test V-0 as from 3 mm wall thickness*


Fire performance according to German Federal Railways test9) S4-SR2-ST2*

* with flame retardant1)DIN 53479 2)DIN 53457 3)DIN 53452 4)DIN 53455 5)DIN 53453 6)DIN 53461 7)DIN 53495 8)DIN 4102 9)DIN 5510

Baydur® 110 is an especially economical

polyurethane product due to improved

production parameters such as high

reactivity (fast demould times), lack of

release agent (time-saving) and high

density (defect-free surfaces).

BAYDUR® GSSOLID CASTING SYSTEM

Baydur® GS is a solid casting system,enabling a simplified, pressurelesscasting process which permits the useof low-cost epoxy resin moulds forshort production runs.

Cost efficiency is ensured even when

producing walls up to 60 mm thick, due

to the fast demould times. Baydur® GS

is characterised by a versatile property

profile. Its resistance to wear, rot and

chemicals is setting new standards in

the polyurethanes market. Baydur® GS

can even be used without a coat of

paint, either with its intrinsic brown

colour or incorporating a black pig-

ment. If the economic viability or other

features of the material need to be opti-

mised, then fillers can easily be added

during processing. APPLICATIONS OF

BAYDUR® GS

Decorative elements/picture frames

Pump housings

Display mannequins

Bowling and skittle balls

Connecting elements (fittings,

sleeves)

Gutters

Rotors for effluents

Drainage gullies

Access shafts / shaft bottoms

Cable sleeves

Filter plates

Animal feeding troughs

Replacement flagstones

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BAYDUR® GS - TECHNICAL DATA


Mould draw 1.1 - 1.5°

Threaded inserts can be insert

moulded or fitted later yes

Snap-fitting connections no

Moulding shrinkage 1.2 - 2.9 %, depending on the system, fillers and wall thickness

Density of moulded articles1) 1,180 kg/m3

Flexural modulus of elasticity2) 1,300 MPa





Heat deflection temperature6) 110 °C

Shore D surface hardness7) 74

Coefficient of thermal expansion 110 x 10-6 K-1

Fire performance according to UL test V-0, only highly filled


Fire performance according to

German Federal Railways test9) S4-SR2-ST21)DIN 53479 2)DIN 53457 3)DIN 53452 4)DIN 53455 5)DIN 53453 6)DIN 53461 7)DIN 53505 8)DIN 4102 9)DIN 5510 with additives

Propeller for an agitator made from Baydur GS (blue-pigmented).

Cladding for a control valve.

Housing for a signalling lamp (black-pigmented).

BAYFLEX® 20/30SKIN-TOLERANT AND NON-SLIP

Bayflex 20/30 is one of Bayer's elasticintegral skin foam systems, with a den-sity in the range 200 - 700 kg/m3.

The surface hardness can be varied

over a wide range (Shore 30 - 85).

Bayflex 20/30 is tear resistant and elas-

tic and forms a continuous external skin.

The open-cell core structure achieves a

high degree of damping under impact

stress. Bayflex 20/30 is skin-tolerant,

has a pleasant “feel” and, when studs

or a variety of surface textures are

incorporated, is also non-skid.

The material requires minimum care

because it is scratch resistant and

greases, oil and alcohol can simply be

wiped off. Bayflex surfaces are not

tacky and the elastic properties are

unaffected by weathering. Due to its

exceptional adhesive properties,

Bayflex 20/30 can easily be combined

with materials such as wood or metal.

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Armrests and upholstery of a hairdresser'schair made from Bayflex 20/30.

Non-skid industrial mats.

APPLICATIONS OF

BAYFLEX® 20/30

Instrument panels, bumpers

Interior trim in cars

Armrests for office furniture

Inserts for tool boxes

Gear wheels

Hockey gloves

Knee pads

Safety helmets

Dentists' chairs

Seats for sports equipment

Safety screens

BAYFLEX® 20/30 - TECHNICAL DATA

For example, the CFC-free system Bayflex 50 IK 33

Density1) 400 kg/m3 600 kg/m3

Shore A hardness2) 35 50

Tensile strength3) 0.73 MPa 1.6 MPa

Elongation at break3) 85 % 90 %

Weather resistance4) 1.4 KN/m 2.2 KN/m

Compressive stress, 10 % deformation 123 KPa 248 KPa

Compression set (25 %/70 h, RT)5) 2.5 % 3.1 %1)DIN 53420 2)DIN 53505 3)DIN 53504 4)DIN 53515 5)DIN 53572

BAYFLEX® RIM/RRIMIMPACT RESISTANT EVEN IN A SEVERE FROST

Bayflex® RIM is a variant of microcellu-lar, solid polyurethane material which ischaracterised in particular by its highimpact resistance, even in an extremelycold environment. In order to increasethe stiffness, glass fibres may be incor-porated as reinforcement.

The Bayflex RRIM products include

Bayflex XGT (Extended Gel Time),

which has processing times of up to 10

seconds since it is cross-linked with

glycol. If, however, an amine is used for

cross-linking, improved properties and

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APPLICATIONS OF

BAYFLEX® RIM/RRIM

Snow-scooter hoods

Large panels for agricultural and

construction machinery

BAYFLEX® XGT - TECHNICAL DATA

Density1) 1,181 kg/m3

Flexural modulus of elasticity, ASTM-D790 981 MPa



Tensile modulus of elasticity3) 870 MPa

Tear propagation resistance4) 100 KN/m

Impact resistance5) no failure

Notched impact resistance5) 14 KJ/m3

HDT ISO-R-75/B 65 °C

Shore D hardness6) 691)DIN 53420 2)DIN 53571 3)DIN 53457 4)DIN 53515 5)DIN 53453 6)DIN 53505

BAYFLEX® 110 - 50/180 - TECHNICAL DATA

Bayflex® 110-50 + 15 parts by Bayflex® 180 + 20 parts

wt. glass fibres by wt. mineral fibres

Density 1,150 kg/m3 1,200 kg/m3

Flexural modulus 700 MPa 1,650 MPa

Tensile strength 20 MPa 23 MPa

Elongation at break 93 % 148 %

Impact resistance 432 J/m 200 J/m

Sag test 71 mm 10 mm

1 h 120 °C - 15 cm overhang

(values determined in direction of fibres)

Truck bonnet madefrom Bayflex 110.

very fast cycles of only a few seconds

can be achieved. This is the case with

Bayflex RRIM types Bayflex 110 and 180.

Whereas Bayflex 110-50 is guaranteed

in particular to have a high impact re-

sistance, Bayflex 180 has a high intrinsic

rigidity.

Bayer AG, Germany

Deltapur, ItalyBayer HispaniaIndustrial, S.A.

Bayer (Pty.) Ltd.,South Africa

Bayer Corporation,USA

Bayer de Mexico S.A. de C.V.

Bayer S.A., Brazil

Bayer de Venezuela S.A.

Bayer Argentina S.A.

SumitomoBayer UrethaneCo. Ltd., Japan

Bayer JinlingPolyurethane Co.Nanjing / Pec Ltd.

Bayer SingaporePte. Ltd.

Production plantsMarketing centresSales offices

PROSPECTS FOR POLYURETHANESUNTAPPED POTENTIAL STILL EXISTS

Although Baydur® and Bayflex® havealready been on the market for a con-siderable length of time, no end can beseen to the world-wide boom. Devel-opment of the full range of properties isnow complete, but all fields of use havenot yet been opened up. Since the prop-erties of the Baydur® and Bayflex®

systems can be specifically tailored toindividual applications, there are stillplenty of opportunities to be grasped.

18 19

World-wide production, marketing and sales; the short route to customers.

MARKET PROSPECTS FOR

THE FUTURE

Research and development in the

polyurethanes sector do not stand still

at Bayer. New objectives are being

vigorously pursued all the time:

Reducing unit costs in order to

improve cost efficiency for the user.

Using fillers and reinforcing materials

to open up new applications.

Developing systems which are stable

at high temperatures.

Adjusting the flame retardant pack-

ages to comply with different stan-

dards.

Providing design and application-ori-

ented support for new applications.

Do you need products with exceptional dynamic properties and high wear resistance?

Then we're the partners you're looking for! Give us a call!

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integral skin foams versatile polyurethane … 18:18:… · additives: e.g. flame retardant´s, ......

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