VERSATILITY WITH POLYURETHANES POLYURETHANE SYSTEMS, PROVEN OVER AND OVER AGAIN
Bayer's two polyurethane integral skin foam systems Baydur and Bayflex have been used for years in many different fields of application. Thanks to a number of properties characteristic of polyurethane, the Baydur and Bayflex systems offer a complete substitute for traditional materials such as wood or metal and thermoplastic or thermoset materials.
THE ORIGIN OF MODERN MATERIALS Baydur and Bayflex consist of a polyol (Desmophen ) and an isocyanate portions and are metered, under reduced 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 structural moulded article is formed. This method of production is called the RIM process. BAYDUR 20 Main area of use: Decorative elements 4/5
CONTENTS
VERSATILITY WITH POLYURETHANES Baydur and Bayflex Features and fields of application Production by the RIM process 2/3
(Desmodur). The quality of these raw materials is subject to permanent and stringent in-house Bayer quality controls and is carefully monitored. The relevant standard is DIN ISO 9001 and the Polyurethanes Business Group was certified in accordance with this standard 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-
Polyurethanes can be recycled at the end of their service life. A number of recycling processes is available,
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
Industrial housings
8/9
BAYDUR 110 Main area of use: Parts for industrial housings, optical
Container Drum Drum Container
BAYDUR GS The most important areas of use for Baydur and Bayflex include housings for electrical goods, games and vending machines, medical equipment, agricultural machinery, paper and printing equipment, sports equipment, ventilation systems, sanitary goods, the furniture industry, sewerage engineering, traffic and transport engineering, windows, structural elements, decorative mouldings and special-purpose vehicles.
Additives: e.g. flame retardants, colour pastes Polyol Desmophen machine tank Gas loading Isocyanate Desmodur machine tank or or Metering machine
R R
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Mould carrier
Baydur 20 is especially suitable for the production of decorative elements with a wall thickness of up to 25 mm, due to its low density of 150 - 250 kg/m3. Baydur 20 is not only light but also dimensionally stable and thermally insulating, while it can also be cut, nailed and glued. Thus, using this integral skin foam, sealed, easily painted surfaces can be produced which, if required, can also achieve flammability rating B2 by adding flame retardants in accordance with DIN 4102.
There are only a few DIN standards for lightweight materials with a sandwichtype 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 temperaturecontrolled aluminium mould (mould temperature: 60 C; demoulding time: 6 minutes).
Elongation at break
3%
1) 2)
Shore D hardness
1)
DIN 53421
DIN 53505
APPLICATIONS OF BAYDUR 20: Decorative mouldings and elements such as simulated stucco Air duct sections with a large surface area
Rigid integral skin foam Baydur 40 has a density in the range 250- 500 kg/m3 and exceptionally good flow, which means that large moulded articles can easily be made. By adding a blowing paste, a hard outer layer can be formed so that surface hardness, and thus scratch resistance, is increased.
specimens are cut out of a sheet with solid edge zones on both sides which has been machine-made in a temperature-controlled aluminium mould (1000 x 500 x 10 mm) (mould temperature: 60 C; demoulding time: 6 minutes).
APPLICATIONS OF BAYDUR 40 Only some lightweight sandwich materials are covered by DIN standards. In all other cases, the physical values are determined in the same way as described in existing regulations. The test Simulated wood (Finto legno) Furniture Cladding panels Window frames
400 kg/m3
Flexural strength
20 MPa
1)
520 MPa
Impact strength
10 kJ/m2
2)
Shore D hardness
58
1)
90 C
Moulding shrinkage
1)
approx. 0.4 %
DIN 53432
2)
DIN 53505
There are virtually no limits to the number of structural design possibilities when using Baydur 60. Due to the sandwich structure - a solid outer layer and a foam core - the material can be processed in much the same way as wood. This material has proved particularly suitable for large moulded items because it`s good flow properties allow the use of complicated mould geometries. This means that the internal pressure in the mould is low. For this reason, and because it has good adhesive properties, combinations with other materials pose no problems.
VERSATILE AND UP-TO-DATE Thanks to the exceptionally accurate reproduction of mould detail with
vidual colours can be applied with a coat of paint. If colour is not so important, a black, brown or orange coloration can be produced by adding pigment to the polyol component.
APPLICATIONS OF BAYDUR 60 Industrial housings, e.g. medical and dental equipment Cores for skis Window frames
Baydur 60, structures of any type at all can be produced in the mould and indi-
BAYDUR 60 - TECHNICAL DATA Preferred wall thickness Mould draw Threaded inserts can be insert moulded or fitted later Snap-fitting connections Moulding shrinkage Density of moulded articles
1) 1) 1)
4 - 20 mm 1 yes no 0.4 - 0.7 % (depending on the system) 550 - 650 kg/m3 600 - 1050 MPa at a density 500 - 600 kg/m3 25 - 45 MPa at a density 500 - 600 kg/m3 20 MPa
8% 18 KJ/m2
1) 2)
up to 118 C 18 N/mm2 62 - 70 73 x 10
-6 -1
Fire performance according to German Federal Railways test * with flame retardant
1) 2) 3) 4)
S4-SR2-ST2*
5) 6)
DIN 53432
DIN 53421
DIN 53505
DIN 53495
DIN 4102
DIN 5510
Baydur 110 is a microcellular, solid RIM material which is characterised in particular by its economical production. Thanks to fast demoulding cycles of about 90 seconds, moulded articles with a wall thickness of preferably 4 to 6 mm, high intrinsic stiffness and high strength can be produced. Aluminium moulds are used during production which means that no release agents are needed, resulting in an environmentally friendly production process. If required, a flame retardant version of Baydur 110 in accordance with a variety of standards can be supplied.
APPLICATIONS OF BAYDUR 110: Filter frames Industrial housings of all sorts, e.g. housings for medical equipment, automatic vending machines, refrigerators.
Baydur 110 is an especially economical polyurethane product due to improved production parameters such as high reactivity (fast demould times), lack of
BAYDUR 110 - TECHNICAL DATA Preferred wall thickness Mould draw Threaded inserts can be insert moulded or fitted later Snap-fitting connections Moulding shrinkage Density of moulded articles
3) 1) 2)
115 C method B 75 - 77 - at RT - at 60 C 90 x 10
-6 -1 -1
105 x 10
-6
Water absorption
Fire performance according to German Federal Railways test * with flame retardant
1) 2) 9) 3) 4) 5)
S4-SR2-ST2*
6) 7)
DIN 53457
DIN 53452
DIN 53455
DIN 53453
DIN 53461
DIN 53495
8)
DIN 5510
Baydur GS is a solid casting system, enabling a simplified, pressureless casting process which permits the use of low-cost epoxy resin moulds for short 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 pigment. If the economic viability or other features of the material need to be optimised, 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
BAYDUR GS - TECHNICAL DATA Preferred wall thickness Mould draw Threaded inserts can be insert moulded or fitted later Snap-fitting connections Moulding shrinkage Density of moulded articles
3) 1) 2)
4 - 30 mm 1.1 - 1.5
yes no 1.2 - 2.9 %, depending on the system, fillers and wall thickness 1,180 kg/m3 1,300 MPa 60 MPa 43 MPa
21 % 60 KJ/m2
6)
110 C 74 110 x 10
-6 -1
Fire performance according to Fire performance according to German Federal Railways test
1)
8)
9) 4) 9)
2) 7)
DIN 53457
3)
DIN 53453
6)
DIN 53505
8)
Bayflex 20/30 is one of Bayer's elastic integral skin foam systems, with a density 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 elastic 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.
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
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.
BAYFLEX 20/30 - TECHNICAL DATA For example, the CFC-free system Density
1) 2)
Elongation at break
3) 4)
Weather resistance
15
DIN 53420
DIN 53505
DIN 53504
DIN 53515
DIN 53572
Bayflex RIM is a variant of microcellular, solid polyurethane material which is characterised in particular by its high impact resistance, even in an extremely cold environment. In order to increase the stiffness, glass fibres may be incorporated 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
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 resistance, Bayflex 180 has a high intrinsic rigidity.
BAYFLEX 110 - 50/180 - TECHNICAL DATA Bayflex 110 - 50 + 15 parts by wt. glass fibres Density Flexural modulus Tensile strength 1,150 kg/m3 700 MPa 20 MPa Bayflex 180 + 20 parts by wt. mineral fibres 1,200 kg/m3 1,650 MPa 23 MPa 148 % 200 J/m 10 mm
APPLICATIONS OF BAYFLEX RIM/RRIM Snow-scooter hoods Large panels for agricultural and construction machinery
1 h 120 C - 15 cm overhang
(values determined in direction of fibres)
Elongation at break
14 KJ/m3 65 C 69
DIN 53420
DIN 53571
3)
DIN 53457
4)
DIN 53515
5)
DIN 53453
6)
DIN 53505
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Bayer AG, Germany Bayer Corporation, USA Deltapur, Italy Bayer Hispania Industrial, S.A. Sumitomo Bayer Urethane Co. Ltd., Japan Bayer Jinling Polyurethane Co. Nanjing / Pec Ltd.
Bayer de Mexico S.A. de C.V. Bayer de Venezuela S.A. Bayer Singapore Pte. Ltd.
Bayer S.A., Brazil Bayer (Pty.) Ltd., South Africa Bayer Argentina S.A.
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