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Makrolon - PC - Bayer MaterialScience

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Tradename: Makrolon
Family: PC
Producer: Bayer MaterialScience
183 hits in the material database
85 hits in the literature database
58 hits in the application database


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Kunststoffe international, Automotive Display: A Matter of Form
...e transfer film is now laid wrinkle-free in the mold under vacuum. When the two films have been positioned, the mold halves are closed and the films are backmolded with PC (grade: Makrolon Ai, supplier: Covestro) at up to 300 °C. Due to the high temperatures and pressures, the printed FIM and the transparent IMD protective coating become an integral part of the panel. To ensure that the subsequent panel has a uniformly high optical quality, the plastic is injected into the cavity while it is sti...

Kunststoffe international, Everything Keeps Flowing
...ing and HeatIn addition to structuring, the melt temperature TS, the mold surface temperature TW, the maximum injection pressure pE and the melt flow rate are varied (Table 1). The melt flow rate is changed by using two polycarbonates (type: Makrolon 2405 and Makrolon 2805; manufacturer: Covestro Deutschland AG, Leverkusen, Germany), which differ only in their molecular weight. The injection molding process is adjusted so that the filling of the cavity is pressure-controlled. This is contrary t...

Kunststoffe international, Present in a Multitude of Trends
...with high transparency, whose birefringence is reduced so that the passenger is able to see a very sharp image. For such highly integrated, large-scale 3D displays, Covestro has developed the Makrolon-Ai series, which makes it possible to create high-gloss surfaces with highest optical purity, and the formable, UV-curing films of the Makrofol HF series, which are designed for large-area components with deep gloss. The exterior of vehicles is also undergoing quite some changes. Electric vehicles...

Kunststoffe international, 2005-11-21, A Coater with a Clear Perspective
A Coater with a Clear Perspective KRD Sicherheitstechnik Cures Makrolon with Polysiloxane Lacquers Stefan Albus, Herne/Germany Despite their thermoformability, untreated crystal-clear polycarbonates make poor glass substitutes because they are not hard enough. However, applying speciality, non-scratch polysiloxane coatings by the appropriate method can rectify this deficiency. KRD Sicherheitstechnik, Geesthacht/Germany, specialises in non-scratch sealing of plasticised plastics. Since 19...

Kunststoffe international, 2005-11-21, Building: Trends with Polycarbonate Sheets
...gh mechanical stability and transparency of the sheets at the same time in addition to a low weight per unit area. This is be-cause they are sold by the square meter. Presently the first six layer multiwall sheets with thicknesses of 16 and 20mm (Makrolon multi UV, manufacturer: Bayer Sheet Europe) with different widths are on the market. They make an energy conservation of up to 25% for same thickness possible compared with standard multiwall sheets. For example the heat transfer coefficient (u...

Kunststoffe international, 2005-11-21, Case Study (5): Hot-Runner Solution for a Four-Gang Switch Plate
...ystem suitable for the application was chosen and prepared for frequent colour exchanges. Right from the first mould trials, it was possible to obtain high part quality and complete a colour change within 30 cycles. As plastic, a PC (grade: Makrolon, manufacturer: Bayer) was chosen, because it ensures high mechanical stability and high optical surface quality. The product specifications can be summarised as follows: - article: four-gang wall plate for Aquastar programme; - material: PC (grade: M...

Kunststoffe international, 2005-11-21, Comparative Study: Virtually Equal in Terms of Precision
...with mi-crostructure, produced over 50 cycles in each case, on machines in three different expansion stages from Battenfeld Spritzgießtechnik. The studies were conducted on two materials: a polystyrene 454 C natural from BASF AG and a polycarbonate Makrolon 2800 natural from Bayer AG. For the sake of simplicity, the discussion below concentrates on the result for the PC part, because it is more difficult to handle. Mould with Microstructure Insert The m2m (“micro to macro”) mould, shown in Fig....

Kunststoffe international, 2005-11-21, Component Design: Creep Resistance - A Characteristic Value for Creep Behaviour
... course in Plastics Technology of Aargau University of Applied Sciences in Brugg-Windisch in the subjects of Calculation and Design of Plastic Parts; jkunz@hsr.ch Fig. 1. Creep modulus curves for polycarbonate (grade: Makrolon 2808, manufacturer: Bayer) [3] Table 1. Creep resistance cC of selected plastics

Kunststoffe international, 2005-11-21, Designed for the Sun
...esign freedom for solar module constructions. These new solar modules are made up of three layers according to the sandwich principle. The upper layer is always a highly transparent solid sheet, generally made of 4 mm thick polycarbonate (PC; grade: Makrolon, manufacturer: Bayer). Depending on the particular application, the bottom layer can either be a transparent PC twin-wall sheet or another solid PC sheet, 2 to 3 millimetres thick which may be transparent, opaque, translucent or coloured (pa...

Kunststoffe international, 2005-11-21, Engineering Plastics: Products for Innovative Processes
... melting point of 225°C, while Pocan TP 710-003 has been specially developed for extrusion of profiles and sheets, which can then be further processed as circuit boards. The front section of the panorama roof on the smart forfour is produced from Makrolon 2067 polycarbonate manufactured by Bayer MaterialScience (Fig.3). This enables a 6kg weight saving to be made in comparison with a similar conventional glass component. As a result the vehicle’s centre of gravity is also lowered, which leads to...

Kunststoffe international, 2005-11-21, Escalators Made of Plastics
...cation. Blend technology in general makes it possible to generate a specific property profile from the individual properties of the blend components [2]. The best blend component for improving the shrinkage differential is PC. Polycarbonate (grade: Makrolon, manufacturer: Bayer AG) has an amorphous structure without any notable shrinkage differential (Table 2). In addition to this, moulded parts in PC are noted for their high dimensional accuracy (Figure 2) during production and their dimensiona...

Kunststoffe international, 2005-11-21, From Plastic to Branded Article
From Plastic to Branded Article A Raw Material Supplier's Marketing Strategy Johann Thim, Leverkusen/Germany Since its invention in the year 1953 Makrolon, the polycarbonate made by Bayer, has been the quality guarantor and jack of all trades among chemical materials. The plastic was previously known mainly to industry connoisseurs or plastics processors. Now Bayer wants to build up the Makrolon brand and make it popular with a broad public. Bayer, an international research-oriented ...

Kunststoffe international, 2005-11-21, Functionality is the Key Factor
...ost-saving form of therapy [9]. In the SpirosInhaler from Dura Pharmaceuticals Inc., key components like the thin-walled housing with integrated functional elements, the cap and the exchangeable drug cartridge are made of polycarbonate (PC; grade: Makrolon, manufacturer: Bayer). This material satisfies the very high mechanical requirements such as stiffness, dimensional stability and impact strength plus the high biocompatibility specifications. By opening and closing the cap, a dose of the powd...

Kunststoffe international, 2005-11-21, High Growth Rates: Polycarbonate (PC)
...6 already. One reason for this increase is the clearly improved extended service properties of PC bottles by comparison to their counterparts in glass, PVC and PET. In a test, it proved possible to refill water bottles in PC (Makrolon 1239) more than 100 times before they had to be withdrawn from service and recycled. Uli Franz, Klaus Horn, Hans-Joachim Laue and Holger Warth, Leverkusen Title photo. Olympic stadium in Athens: one of the two 78 m-high and 300 m-long metal arcs spanning the ...

Kunststoffe international, 2005-11-21, Injection Moulding Microstructured Functional Surfaces
...mittedly, the superior flow properties at elevated mould-wall temperature result in almost perfect structures, even at low holding pressure (Fig. 3). Injection moulding studies performed on a sawtooth structure with a standard polycarbonate (grade: Makrolon 2805, manufacturer: Bayer AG, Leverkusen/Germany) provide impressive confirmation of this tendency. The white-light-interferometer recording in Fig. 4 shows a cross-section of the structure. At a high melt temperature of 320°C, only a hig...

Kunststoffe international, 2005-11-21, Interview: Quo Vadis Polycarbonate Glazing?
...ion stage. Optimum parts production is only possible through close collaboration by all those involved in the process chain, i.e. raw materials supplier, machine and equipment maker, mould-maker, systems supplier, OEM and technology supplier. In Makrolon AG 2677, we have created the basis for producing panes of high optical quality. This grade of material was developed specifically for glazing and embodies the required properties, such as high purity, flow and toughness, and can be pigmented in ...

Kunststoffe international, 2005-11-21, Low Manufacturing Costs: Plastics Encapsulation for Solar Modules
...ch can splinter, is not desirable for some applications of modules, e.g. maritime applications, vandal-proof modules or curved modules for architectonic applications. Solid or double walled panels of a weathering-resistant polycarbonate (PC, grade: Makrolon) are suitable for these purposes. Since plastics and silicon have very different coefficients of thermal expansion, the solar cells must be protected with a soft encapsulant cast between the PC panels. Fig.4 shows some applications of PC-enca...

Kunststoffe international, 2005-11-21, Major Investment: Bayer Further Expands Production in China
...Wenning, Chairman of Bayer AG, underscored the raw materials manufacturer’s intention to further substantially expand its activities in China. Bayer is investing around USD 450 million in a dedicated polycarbonate production plant (trade name: Makrolon) at its Caojing location, 50 kilometres south of Shanghai. The plant is due to come on stream in the second quarter of 2006 and its overall capacity of 200000t/a will be gradually stepped up as the market grows. This will increase Bayer’s producti...

Kunststoffe international, 2005-11-21, Market & Profiles
...pilot plant for polycarbonate film at its Leverkusen facility. The new pilot plant provides better opportunities to examine application-related problems in the area of polycarbonates, to find solutions for customers and to develop new Makrolon-based films. The company’s erstwhile film centre at Dormagen was integrated into the new pilot plant. As part of this measure, old lines were updated and new equipment was installed. The main focus lies on a new screen printing line and on two Niebling hig...

Kunststoffe international, 2005-11-21, Materials with Multiple Functions
... developed new material types particularly for the thin-wall technique so that the housings have the necessary impact strength despite small wall thickness: acrylonitrile butadiene styrene copolymer (ABS; Novodur), polycarbonate (PC; Makrolon) or (PC+ABS) blend (Bayblend). These engineering thermoplastics have high impact strength and rigidity as well as thermal stability and dimensional accuracy. The industry’s increased requirements on decoration are fulfilled by use of engineering sheets made...

Kunststoffe international, 2005-11-21, Nano Injection Moulding
Nano Injection Moulding Calibration Structures for Scanning Probe Microscope Alessandro D'Amore, David Simoneta and Wolfgang Kaiser, Aarau/Switzerland, Helmut Schift, Villigen/Schweiz and Markus Gabriel, Muri/Switzerland Injection moulding is suitable for generating nanostructures with a replication fidelity of 25 nm. In a practical application, it was investigated how well nanostructures with special geometries can be replicated. The master forms (stampers) comprised silicon wafers. ...

Kunststoffe international, 2005-11-21, News
... the availability of polycarbonate on the global market. Financial details of the agreement were not revealed. Teijin Chemicals produces the polycarbonate Panlite in Japan and Singapore, while Bayer MaterialScience manufactures the polycarbonate Makrolon in Germany, Belgium, the USA and Thailand. Both companies are currently building new production plants for polycarbonate in China. Initially, Bayer and Teijin intend to supply each other in this market with polycarbonates for special application...

Kunststoffe international, 2005-11-21, Polycarbonate (PC)
...ng cycle times which were reduced from originally > 20 seconds to approximately 3 seconds. The production of DVDs which are made from two individual discs of 0.6 mm in 3 seconds required an ultra-light flowing polycarbonate. With its introduction of Makrolon DP1-1265 in 1995, Bayer provided this material for the first time. The next generation of storage discs with an even more compressed pit structure and laser diodes with increasingly shorter wave lengths will also use PC as a substrate materi...

Kunststoffe international, 2005-11-21, Polycarbonate instead of Glass: Large Car Windows from an Injection Moulding Machine
... and features two opposed horizontal injection units – the primary unit in the standard position and the secondary unit on the movable platen in place of the machine’s ejector (Fig. 1). The primary unit processes the glass-clear PC (grade: Makrolon 2607, manufacturer: Bayer MaterialScience) for the glazing and injects it into the injection compression mould; in a following step, the second injection unit overmoulds a stiffening and mounting frame in black PC (Makrolon 2405). Depending on part re...

Kunststoffe international, 2005-11-21, Polycarbonate Multiwall Panels: Transparency Coupled With Good Thermal Insulation
...the decision was the panels’ outstanding thermal insulation in addition to their high stability. Volker Benz In early 2003, Bayer Polymers Sheet Europe, known at that time as Makroform, launched new six-ply polycarbonate multiwall panels (grade: Makrolon) in thicknesses of 16 and 20 mm. The plastic-sheet manufacturer was reacting to the needs of the building trade where efficient thermal insulation – coupled with the thinnest possible structure – is playing an ever increasing role. Saving on f...

Kunststoffe international, 2005-11-21, Possibilities with Plastics: Sports Applications
...ed by their good connection to the upper shoe material and very high resistance to wear – thus preventing the golfer from leaving unwanted spike traces in the clubhouse. An important contribution to safety is made by polycarbonates such as Makrolon LQ for sports goggles and visors of all kinds (Fig.2). Apart from high transparency in highly transparent variants and also graded dyed variants above all the high impact strength pays for itself well. Thus Makrolon flats withstood a shot test of over...

Kunststoffe international, 2005-11-21, Preparation for Painting and Bonding: Inline Surface Modification During Injection Moulding
...ese long-chain compounds is that a single coupling location on the surface suffices to firmly bond a modifier chain with many functional (polar) groups (Fig.2). The experiments described in the following were performed on polycarbonate (grade: Makrolon 2803; manufacturer: Bayer MaterialScience AG) and on polyamide (grade: Durethan B 40 E; manufacturer: Lanxess Deutschland GmbH). Appropriate modifiers were selected by the Institute for Polymer Research in Dresden. Polyvinyl alcohol (PVOH) and pol...

Kunststoffe international, 2005-11-21, Process Technology: Plastic Automobile Windows
Special Plastic Automobile Windows Process Technology. Plastic is finding increasing use as a replacement for glass in automobile windows. An extremely dynamic market is developing, but one that places special requirements on materials, designs and production techniques. Success depends on an efficient logistical chain that addresses the product-specific requirements and the complex manufacturing processes. Christian Hopmann Sebastian Göbel Jan Forster With the introduction of the first Smar...

Kunststoffe international, 2005-11-21, Putting a Stop to Cracks
...an extruder. - during cooling, the greater volume shrinkage of the PP compared with PC (due to crystallisation) leads to the formation of microvoids around the dispersely-distributed PP particles. The main component used was a polycarbonate of grade Makrolon 2805, a colourless general-purpose polycarbonate grade produced by Bayer AG. The disperse phase was Hostalen 1080F produced by Targor GmbH (now Basell). Blends containing 0.5 to 5 % by weight PP were studied. The blends were compounded in a ...

Kunststoffe international, 2005-11-21, Reading by Laser
...ion, compared with over 20 s at the beginning of the eighties. The introduction of the DVD with half the substrate thickness and reduced pit structures led to a new challenge to polycarbonate manufacturers. Bayer was the first to respond, presenting Makrolon DP1-1265 in 1996, a product specially tailored to DVD production. It offers excellent flow properties, reduced birefringence compared with standard CD-grade polycarbonate, and a wide processing window. Depending on the machine and process, c...

Kunststoffe international, 2005-11-21, Roof Systems: A Concept Suitably-tailored to Plastics
...ploying multi-component injection moulding for a series-produced part of this size for the very first time. Using a swivel-platen machine with a clamping force of 4000t (manufacturer: Krauss-Maffei, Munich/Germany), coloured polycarbonate (type: Makrolon, manufacturer: Bayer) is first injected into the mould. The tinted pane obtained in this way benefits from low material stressing on account of the special breathing compression method which reduces the pressures in the mould. In a second stage,...

Kunststoffe international, 2005-11-21, Roofs of Light
...t arctic temperatures or when subject to sudden temperature changes. Extraordinary Properties Roofs flooded with light can be realised with solid sheets, corrugated sheets or multiwall sheets (manufacturer: Makroform GmbH) of polycarbonate (grade: Makrolon, manufacturer: Bayer AG) in a wide variety of geometries, and to custom sizes if required. The sheets may be colourless and crystal clear, coloured and transparent or translucent or opaque, as required by customers. In general all sheets for...

Kunststoffe international, 2005-11-21, Solar Modules: Plastics, Architecture and Photovoltaics
...cts, designers and engineers. The module’s sandwich structure always follows the same principle (Fig.1): the top layer is always formed by a massive, highly transparent panel (PMMA, grade: Plexiglas, manufacturer: Röhm, or PC, grade: Makrolon, manufacturer: Bayer). Depending on the application, there are various options for the lower layer: For example, a massive 3 to 4mm thick PMMA or PC panel (transparent, coloured or translucent) or a PMMA or PC double-skin sheet can be used. This provides sc...

Kunststoffe international, 2005-11-21, Sports Equipment: Plastics at all Events
...um was an important venue for the European Soccer Championships, EURO 2004. Here, the material is exposed to harsh weather conditions and intensive sunlight. The Olympic stadium in Athens has a sweeping roof construction made of Makrolon, the polycarbonate from Bayer MaterialScience (Fig. 6). Thanks to a special additive, it is able to reflect a large proportion of the heat. The Allianz Arena and other stadia chosen as venues for the Soccer World Cup in 2006 in Germany will be on show in the fo...

Kunststoffe international, 2005-11-21, Strong Upturn: Polycarbonate (PC)
... 50000t PC plant at the end of May this year in Jiaxing, in the eastern Chinese province of Zhejiang. Capacity is to have increased by a further 50000t by 2006. Bayer MaterialScience is currently erecting a world-scale production plant for its Makrolon brand of PC in Caojing; it will come on stream in 2006. Its capacity is to be ramped up in line with market requirements to a total of 200000t per annum The general trend worldwide is for PC manufacturers to successively adjust their capacity to ...

Kunststoffe international, 2005-12-07, Case Study (6): Hot-Runner Solution for a Light Guiding Optical Part
...6x296x125/S (Fig.5). Extensive electrical and dimensional tests were carried out on the hot half before it was delivered to the customer with extensive documentation. Preparations for Mass-Production Start-Up The material to be processed is Makrolon 6555 polycarbonate containing flame retardant (UL 94V0) (manufacturer: Bayer MaterialScience AG, Leverkusen/Germany). It is a high-viscosity product with an MFI of 7g/10min. The product parameters are: - article: light guiding optical part; - shape/...

Kunststoffe international, 2005-12-08, A Status Report (1): Versatility for Mass Production in MuCell Injection Moulding
...ing of the foaming gas into the thermoplastic melt (photos: Engel) Comparison of Charpy notched impact strength Fig. 1. Charpy notched impact strength acc. to ISO 179/1eA of unfoamed PC (grade: Makrolon 2805 FBL; manufacturer: Bayer MaterialScience AG) and microfoam. The DIN test specimens are take from the centre of 160mm x 20mm x 3.2 mm and 4mm test bars respectively, which were injection moulded on an Engel Victory 330H/80V/120 Combi. Fig. 2. MuCell process control integrated into the CC200...

Kunststoffe international, 2006-01-26, Structuring and Ablating: Manufacturing Medical Products with Laser Technology
...tion of light in the infrared (IR) range occurs by excitation of vibrations in molecules and, in the ultraviolet range (UV), by excitation of electrons. Figure 1 shows a typical transmission spectrum for a plastic, in this case polycarbonate (grade: Makrolon; manufacturer: Bayer). To an extent depending on the application, additional pigments and IR absorbers may be incorporated in order that transmission may be reduced in certain areas of the spectrum. A characteristic of all plastics is strong...

Kunststoffe international, 2006-02-23, Process Optimisation: Hot Embossing of Microstructures
...22MPa were applied. The trials involved various commodity and engineering plastics, including three amorphous, transparent polymers: - polymethylmethacrylate (PMMA, grade: Plexiglas 7H; manufacturer: Röhm GmbH, Darmstadt), - polycarbonate (PC) Makrolon 2805; manufacturer: Bayer MaterialScience AG, Leverkusen), - cycloolefin copolymer (COC, grade: Topas 6013; manufacturer: Ticona GmbH, Oberhausen), and two semi-crystalline, translucent polymers: - low-density polyethylene (PE-LD, grade: Lupolen 6...

Kunststoffe international, 2006-03-23, Stress Test: Ejection Without Damaging the Moulded Part
...ejection by means of four ejector pins positioned around the outside (configuration 1) stresses the part less than five ejector pins positioned inside (configuration 2). For the simulation, the material values for an amorphous polycarbonate (grade: Makrolon 2805; supplier: Bayer MaterialScience AG, Leverkusen) and a semi-crystalline polyamide (grade: Durethan B 30 S; supplier: Bayer MaterialScience AG, Leverkusen) were employed. Values for the mechanical and rheological characteristics were take...

Kunststoffe international, 2006-04-21, Dynamic Mechanical Analysis (DMA): Thermomechanical Application Limits for Plastics
...the isothermal test conditions, determination of temperature-dependent characteristics via hydropulsers is very involved. To determine the effect of various load levels on thermal application limits, the amorphous resin polycarbonate (PC; grade: Makrolon 2805, manufacturer: Bayer MaterialScience) and the two semi-crystalline resins polyamide 66 (PA66; grade: Ultramid A3K, dry, manufacturer: BASF) and polybutylene terephthalate (PBT; grade: Pocan B1501, manufacturer: Lanxess) were investigated i...

Kunststoffe international, 2006-10-30, Cleanroom Production: Tools for Routine Clinical Work
...focus. Greive produces hose connectors for a major manufacturer of dialysis systems. They have various 8-fold and 12-fold hot-runner moulds with interchangeable inserts to make the different hose diameters. The polycarbonate connectors (PC, type: Makrolon; manufacturer: Bayer MaterialScience AG, Leverkusen/Germany), with a part weight of approx. 0.5g, are manufactured around the clock, seven days a week on Boy 22 A and Boy 30 A injection moulding machines, which are connected to a centralised m...

Kunststoffe international, 2006-10-30, Material Development: Polycarbonate Lenses for LED Lighting
... focus light. With this procedure, not only are light energy losses kept low, the LED lamp can also have a very compact, simple and easily assembled design. Functional Integration and Higher Productivity. Transparent polycarbonates (PC), such as Makrolon by Bayer MaterialScience, provide an appropriate material for these lenses. Due to their high heat distortion temperature of maximum 130°C, they are capable of coping with maximal working temperatures inside an LED. In comparison with glass, in...

Kunststoffe international, 2007-01-22, Market Niches are Becoming ever Larger
... It is not directly perceptible by the customer. If, for example, we as Albis are producing under licence for Bayer or BASF this is done in accordance with their original formulations and in their packaging materials. This means that a Makrolon product, for example, that has been produced by Albis has the same specification, has exactly the same appearance and is packaged in exactly the same way as if it had come from Bayer. The speed of supply for the customer is also retained since the number ...

Kunststoffe international, 2007-02-13, Robust for Everyday Hospital Use
... of the technology is an adsorber, filled with a special material, which bonds the LDL cholesterol electrostatically, for example. A fracture-proof plastic was sought for the housing on the adsorber system. "The first choice was ultimately our Makrolon 2458", explains Markus Krieter, a medical technology expert in the Polycarbonates Business Unit at Bayer MaterialScience AG. "The polycarbonate is sufficiently tough and stiff, which means that the housing does not get damaged so easil...

Kunststoffe international, 2007-03-15, Promoting Innovations with a Focus
...bs and discharge lamps are that they consume less energy and have a longer service life. Lenses with free-form surfaces that have non-symmetrical geometries make particularly suitable optics for these LEDs. Transparent polycarbonates such as Makrolon make ideal materials for these collimator optics because, thanks to their high heat resistance of up to 130°C, they can cope with the maximum operating temperatures encountered in an LED. Micro Forceps and Scissors for Ophthalmic Surgery Alcon Gri...

Kunststoffe international, 2007-08-14, Vision Works – Today and Tomorrow
...wiss car pioneer Frank M. Rinderknecht has developed in close collaboration with BMS auto experts. Numerous developments by the plastics manufacturer can be found here, starting with lightweight body parts of the transparent polycarbonate Makrolon, headrest and armrest cushioning of the polyurethane gel Technogel, and cable sheathing of the flexible, abrasion-resistant and chemical resistant thermoplastic polyurethane Desmophan, to softfeel lacquers in the interior based on water-borne coating m...

Kunststoffe international, 2007-09-19, Energy Efficiency Taking on Increasing Importance
...urg, Germany. This is the first series application for a glass fiber reinforced thermoplastic in the Class-A zone of a heavy goods vehicle. According to Bayer MaterialScience AG, Leverkusen, Germany, the roof module of the smart fortwo (Fig.1) in Makrolon AG2677, which has an area of some 1.2 m2, is the biggest roof module to be made of polycarbonate to date. It is produced by two-component compression injection molding on an injection molding machine with a swivel platen, and then coated. The ...

Kunststoffe international, 2007-10-21, Polycarbonate (PC) and Polycarbonate Blends
...l capacity at the Jiaxing site in the Chinese province of Zhejiang by 50,000t to 100,000t. Following the construction of another production plant this should rise by 2009 to 160,000t/a. In 2008 Bayer MaterialScience AG will increase its capacity for Makrolon in Caojing near Shanghai from 100,000 to 200,000t/a. Chi Mei-Asahi and the Formosa Idemitsu Petrochemical Corp. (FIPC) are currently increasing the capacities of their plants in Taiwan by 75,000t/a in each case. LG-Dow is expanding its exist...

Kunststoffe international, 2007-11-21, Outer Body Skin with an Integrated Antenna
...(Fig.7). In line with the requirements placed on dimensional stability in heat and on the heat resistance of vehicle body materials, when a thermal calculation point of 110°C is employed, the supporting substrates of Bayblend T65 and Makrolon 2405 display a high and virtually equivalent stiffness in the order of magnitude of 1,850 to 2,000N/mm2. These two plastic substrates are additionally characterized by a relatively low coefficient of linear thermal expansion of around 80 to 90x10-6/°C at el...

Kunststoffe international, 2007-11-21, The "Vitreous" Car
...isionary Frank M. Rinderknecht, Rinspeed AG, Zumikon, Switzerland, together with vehicle experts at Bayer MaterialScience AG in Leverkusen, Germany. This car is designed as a cigar-shaped two-seater with its body and floor made of transparent Makrolon polycarbonate material. This enables an unobstructed view of i.e. details of the motor and the aluminum chassis. This transparency shall also represent the plastics manufacturer’s open-mindedness and preparedness to get into close co-operation with...

Kunststoffe international, 2007-12-17, Still Demand for Innovation Potential
...rity of supply on the other. Applications in this area are characterized by increasingly complex and often smaller structures, such as dosing systems, which must meet the additional requirements of high accuracy and reliability standards. Makrolon Rx1806 (PC) has been selected as the housing material for the RoweMiniPump from RoweMed AG, Parchim, Germany (Fig. 6). The various housing components are laser-welded together. However, the plastic can also be readily bonded to other materials by means...

Kunststoffe international, 2008-01-15, Better Dimensional Accuracy through High Pressure
...olume expansion coefficient, in this case illustrated with the example of different amorphous thermoplastics Fig. 4. Dependence of Thermal Conductivity: Pressure influences the thermal conductivity of PC (Makrolon 2805) in the solid, rubber elastic and molten states Fig. 5. Dependency of Viscosity: The viscosity of amorphous thermoplastics depends on the temperature. Frequency: 1Hz, plate geometry: plate-plate (25mm), strain: 0.2%, cooling rate: 3K/min, pressure: 1bar Fig. 6. Determination of th...

Kunststoffe international, 2008-02-29, Integrated Folding Transparency
...lement with which automobile manufacturers can style their compact cars within a corporate design. Against this background Bayer MaterialScience AG, Leverkusen, Germany, has developed a prototype of a highly integrated lightweight lamella roof using Makrolon AG2677, a special polycarbonate optimized for automobile glazing. The lamella modules in this prototype combine the functions of transparency, sealing as well as opening and closing in a single plastic part (title picture). The assembly is a...

Kunststoffe international, 2008-08-14, Growth through Change
...“BayVision” is the Concept Car i-mode, which was developed together with Hyundai and presented at the Geneva Autosalon 2008. It is provided with a total of eleven glazing parts, which are made from the high-performance polycarbonate Makrolon and would be difficult or impossible to produce from glass (Title photo). As the concept study shows, polycarbonate as glazing materials provides designers, in particular, with greater scope. Weight savings of up to 50% compared to glass additionally...

Kunststoffe international, 2008-10-17, Polycarbonate (PC)
.../a – as originally planned for the first quarter of 2009. By the end of 2008, Bayer MaterialScience will complete construction of a second production line at the integrated facility in Caojing near Shanghai that will increase the capacity for Makrolon by 100,000 to 200,000 t/a. Startup of this expansion stage depends on the market situation. This expansion increases the nameplate global PC capacity of the company to 1.3 million t/a. Mitsubishi Gas Chemical (MGC) has postponed star...

Kunststoffe international, 2008-11-20, The Future Has only just Begun
...ions that can compete with glass. A current example of this type of wet-coat is a system from Momentive Performance Materials GmbH, based on their AS 4700 top coat and their newly developed SHP 470 FT 2050 primer. Our own in-house testing with Makrolon AG2677 has shown that this system opens a wide processing window for the coating of glazing components with pronounced 3-D contours. Design Freedom – Weight Savings Included In comparison to glass polycarbonate offers much greater design freedom....

Kunststoffe international, 2009-02-17, Looking to Long-Term Success
... concept is that it is based on a combination of different technical solutions: The use of Bayer materials is playing an important role here, e.g. thermoplastic polyurethane for solar cells, a polycarbonate roof made from Makrolon and energy-efficient insulation materials based on polyurethane. Another environmentally relevant innovation introduced by Bayer was the permanently flexible Durflex railroad track superstructure system, which Bayer MaterialScience has developed with its partners Frenz...

Kunststoffe international, 2009-04-16, All Systems Go for White Light
...eans that there is absorption/extinction of light with short wavelengths. High Light Transmission over Long Paths Bayer MaterialScience has therefore extended its polycarbonate product range for demanding optical applications which also includes Makrolon LQ grades for glasses and visors. With the introduction of Makrolon LED 2245 and LED 2045 (Table 1) two new polycarbonate grades are now available that are particularly suitable for large wall thicknesses and light paths due to their high transm...

Kunststoffe international, 2010-04-20, Square Meters in CD Quality
...Leverkusen, Germany (Kunststoffe international 9/2009, p. 8). Thanks to innovative technology, it can produce up to 1.2m2-sized glazing parts – such as rear windows or panorama roof modules for the auto industry – made of Bayer’s polycarbonate Makrolon. They are manufactured with excellent optical quality under cleanroom conditions. Special requirements were not only placed on the injection molding machine (a 2,300 t two-component model from Engel), which is similar to a production machine, but ...

Kunststoffe international, 2010-08-19, Polycarbonate – How a High-tech Material Conquered the World and Continues to Do So
...matic polycarbonates. The enormous commercial potential of the polycarbonates was soon realized and industry, too, was enthusiastic after initial skepticism. Still in 1953, Bayer filed a patent application for the innovation – under the name Makrolon. A Plastic Conquers the Market In November 1958, the first polycarbonate production plant came on stream at Bayer's Uerdingen site. The monthly capacity was 40 t. In 1959, the plastic was presented to the trade public for the first time at the ...

Kunststoffe international, 2011-02-21, Science for a Better Life
...ir collectors for solar thermal energy with heat insulation included (center); Baytubes for larger rotor blades in wind turbines with higher effectiveness (right) Fig. 3. Energy saving: LED lenses made of Makrolon for the headlamps of cars are up to 50 % lighter than glass (left); polyurethane for thermal insulation on facades and window profiles as well as air and steam seals, energy savings in the refrigeration chain and nanofoams with doubled insulation performance (center); ultra-light mater...

Kunststoffe international, 2011-10-17, Polycarbonate (PC)
...ends as well as films produced from them. The increasing importance of public transport, such as buses and trains, is also making a contribution here. A prime example of a polycarbonate application in the mobility sector is auto glazing with Makrolon (Bayer MaterialScience). By offering a potential weight saving over glass of up to 50 %, this polycarbonate provides excellent opportunities for cutting vehicle weight and therefore CO2 emissions. Component costs can also be appreciably reduced thro...

Kunststoffe international, 2012-06-25, Virtual Demolding Forces
...the mechanical behavior of a material [1]. Preliminary studies have shown that strain rates of up to 20 s-1 can occur during demolding. For this reason, it is important to characterize the material employed – in this case a polycarbonate (grade: Makrolon 2805, manufacturer: Bayer MaterialScience AG, Leverkusen, Germany) – using the local strain rates and temperatures that will occur. In practice, it is difficult to conduct strain-rate-controlled tensile tests at high strain rates. The IKV theref...

Kunststoffe international, 2012-10-15, LED Lighting Technology in Vogue
... transparency, high impact strength, high heat resistance up to 120°C and inherently high flame resistance. Products for Transparent Optical Parts Mirroring the trend toward LEDs, Bayer MaterialScience AG, Leverkusen, Germany, has developed Makrolon LED, a new product family for making transparent optical components such as lenses, light guides, reflectors and diffusers by injection molding and extrusion (Fig. 1, E l e c t ronics SPEC I A L Table 1). The material formulations are available in co...

Kunststoffe international, 2012-11-26, Frequency-Dependent Behavior of Plastics
...eering method iteratively modifies the material parameters of the simulation until the latter matches the experiment as closely as possible. The method has been tested on and validated for different materials, including a polycarbonate (PC) (grade: Makrolon 2205;manufacturer:Bayer MaterialScience AG, Leverkusen, Germany) and a polyoxymethylene (POM) (grade: Hostaform C27021; manufacturer: Ticona GmbH, Sulzbach, Germany). The outcome of applying this method to a rectangular bar made of PC is illu...

Kunststoffe international, 2012-11-26, In-Mold Printing
...enge when selecting printing ink and printing parameters for this process. Reliable Replication of Printed Images Investigation of the fundamentals of the ink transfer process involved printing on injection molded plaques of polycarbonate (grade: Makrolon 2805, manufacturer: Bayer MaterialScience AG, Leverkusen, Germany). A pad-printing machine (model: TC 60T KH, manufacturer: Tamponcolor TC-Druckmaschinen GmbH, Neu-Isenburg, Germany) transferred the ink (type: Maramold MPC 980, manufacturer: Ma...

Kunststoffe international, 2012-11-26, Joining of Dissimilar Materials
...e plasma pretreatment of the joint surfaces even makes it possible to join amorphous and partially crystalline thermoplastics. This actually allowed the overall highest breaking force to be obtained for the bonding of PA6 and PC (grade: Makrolon 2405, manufacturer: Bayer AG, Leverkusen, Germany). A more specific adaptation of the parameters for the plasma treatment to the particular thermoplastic combination should make it possible in future to achieve a further improvement in the achievable bre...

Kunststoffe international, 2014-02-20, Composite Materials (Part 1): Self-Reinforced Thermoplastic Composites
...ure of the stretching zone is therefore set at 160 °C; the temperature is 150 °C in the preheating zone, and 90°C in the annealing zone. Figure 6 shows the stressstrain curves determined in the tensile test as per EN ISO 527-3 of a 200 μm-thick Makrolon 2805 PC film at different stretching ratios (SR). With monoaxial stretching, an increase in tensile strength to 183 MPa in the machine direction (MD) and to 91 MPa in the transverse direction (TD) can be obtained. The modulus of elasticity in the...

Kunststoffe international, 2014-02-20, The Insert Technology: Precise Prediction of the Deformation of Inserts
...rt deformation at the two measuring points M1 and M2, depending on several influencing factors. The trials were carried out using two transparent polycarbonate materials (manufacturer: Bayer MaterialScience AG, Leverkusen, Germany): a low-viscosity Makrolon 2205 (melt volume rate MVR = 34 cm3/10 min) and a high-viscosity Makrolon 2805 (MVR = 9 cm3/10 min). Because of the higher viscosity ofMakrolon 2805, a higher force is needed to maintain the melt flow, which acts on the insert due to an impul...

Kunststoffe international, 2014-03-21, Composite Materials (Part 2): Self-Reinforced Thermoplastic Composites
... numerical process for the simulation [3]. In addition, the distance between the two press plates, and thereby the flow range to be simulated, change during pressing. This can be illustrated with the following experiment: Polycarbonate (PC) (Makrolon 2805) is compressed at 300 °C between two circular plates by means of a predetermined lowering rate of the upper plate. The pressing force necessary for this process rises as a function of time. Figure 4, left shows the measured force in comparison ...

Kunststoffe international, 2014-03-21, Novel Material Concepts: Sustainability and Design
... RIM (Reaction Injection Molding) with Desmodur (isocyanate) and Desmophen (polyol) (figure: Bayer Material-Science) Fig. 7. Demonstrator of Bayblend, Makrolon (PC) and two PUA coatings from Panadur, produced live at the K-show in a fully automatic production cell by means of the ColorForm process (figure: Krauss-Maffei) Fig. 8. Comparison of the tendency to form sink marks between semi-crystalline, standard glassfilled PA and amorphous Grilamid TRV (figure: Ems)

Kunststoffe international, 2014-06-17, Plastic Optics in Multiple Layers
...assumed [6-9]. For the analysis of the composite strength, molding accuracy and optical performance a polymethyl methacrylate (PMMA, grade: Plexiglas 7N, manufacturer: Evonik Industries AG, Darmstadt, Germany) and a polycarbonate (PC, grade: Makrolon LED2445 HCC; manufacturer: Bayer MaterialScience AG, Leverkusen, Germany) were used. In the experiments, the cavity temperature and the temperature of the boundary surface were influenced systematically by a tempered slider.The results show that bon...

Kunststoffe international, 2014-07-22, Injection Embossing Extended
...es served as the test specimens, since these impose high standards of quality on the optical attributes and surface properties of the molded parts (Fig. 3). These lenses were manufactured from a polycarbonate with high light transmission (grade: LED Makrolon 2045, manufacturer: Bayer MaterialScience AG, Lever- kusen, Germany).Besides the pvT phase diagram, the effective temperature conductivity aeff and the glass transition temperature Tg must be mentioned, since they make it possible to calcula...

Kunststoffe international, 2014-10-10, Polycarbonate (PC)
...ter cooling and cycle times during injection molding.Many PC producers have reacted to the trend towards LED lighting technology. Bayer MaterialScience, for example, has developed a widely differentiated range of PC types named Makrolon LED. Also in thicker layers, the material exhibits a high transmittance, and guides white light even over large distances without significant losses. The product range meets a variety of demands, e. g. for industrial, construction, and traffic applications. It is...

Kunststoffe international, 2014-11-26, Does Size Matter?
...ickness, as long as the com-posite’s interface layer remains constant. Although this behavior was observed with two material combinations, opposing phenomena were also shown.For example, a PC+TPU combination (grade: Makrolon 2458; manufacturer: Bayer MaterialScience in Leverkusen, Germany, and Elastollan 1170 A Shore 40A; manufacturer: BASF Polyurethan GmbH in Lemförde, Germany) exhibited a peel force increase of 62 % after changing the thickness from 1mm to 2 mm. Both samples show a uniform pee...

Kunststoffe international, 2015-02-28, Laser-Based Dynamic Mold Temperature Control
...ed to the particular mold, since not only the geometry to be irradiated, but also the absorbance, is specific to the mold.To validate the laser-based plant technology, the reproduction of microstructures using polycarbonate (PC, type: Makrolon LED 2245; manufacturer: Bayer MaterialScience AG, Leverkusen, Germany) was investigated. The mold wall temperature was varied in three steps by increasing the laser power. This can delay a solidification of the melt in the edge region, and thereby achieve ...

Kunststoffe international, 2015-10-12, Lighting with a Future
... [5]. Many PC producers have also reacted to the trend towards LED light engineering. For example, Covestro AG (until 31 August 2015 Bayer MaterialScience AG), Leverkusen, Germany, has developed a broadly differentiated PC product series called Makrolon LED. It has high transmissivity even with larger coating thicknesses, and conducts white light without significant losses even over longer distances. The product range meets a vast array of demands, such as in industry or in construction engineer...

Kunststoffe international, 2016-04-08, Stress Cracking as Failure Criterion
...sed specimens. Once disorders, such as cracks, occur the tonal values rise locally strong due to reflections and scattering effects – the basis of the implemented crack detection routine.The stress crack formation of polycarbonate samples (grade: Makrolon 2658, manufacturer: Covestro AG, Leverkusen, Germany) was characterized by the modified plant technology. Specimens are produced by injection molding, using a variety of melt and mold temperatures, which are subjected to tests with deionized wa...

Kunststoffe international, 2016-10-17, Polycarbonate (PC)
...sheets make large-scale light applications possible, such as those required in offices. Components with multiple optical functions can be fabricated from the semi-finished products in keeping with current trends. With Makrolon SX Shark for instance, Covestro supplies a transparent solid PC sheet with curved micro-prism optics on one side and a glossy surface on the other. The sheet combines very high light transmission with precise light guidance for glare-free lighting. PC is firmly established...

Kunststoffe international, 2016-11-30, The Sound of Materials
...-reinforced plastics: Matrix failure, interface failure, and fiber breakage. By evaluating the recorded sound events, conclusions can be drawn about the nature of the damage.Glass-Fiber-Reinforced Polycarbonates under TestPolycarbonate (PC) (type: Makrolon, manufacturer: Covestro, Leverkusen, Germany) was used for the investigations. Hereby, an unfilled type as well as two types reinforced with short glass fibers (20 wt. % and 30 wt. %) and a type reinforced with long glass fibers (35 wt. %) wer...

Kunststoffe international, 2018-11-09, Droplets to the Beat of Milliseconds
...ized qualification process. Users can qualify their own materials or resort to Arburg’s material database. Standard granulates such as ABS (type: Terluran GP 35; manufacturer: Ineos Styrolution), PA10 (Grilamid TR XE 4010, Ems-Chemie), PC (Makrolon 2805, Covestro), TPE-U (Elastollan C78 A15, BASF) and PP (Braskem CP 393, Braskem), are documented therein. It also contains special plastics for specialized applications such as medical-grade PLLA (type: Purasorb PL18 and Resomer LR 708; manufacturer...

Kunststoffe international, 2018-12-19, Micropatterning by Friction Embossing
...ZMT 2 CC, manufacturer: Fischer Kunststoff-Schweisstechnik GmbH, Berkatal, Germany). A 500 µm thick polycarbonate (PC) film (type: Tecfilm TC 0010, manufacturer: Müller Ahlhorn) was placed on the tool and, over it, a 4 mm thick PC plate (type: Makrolon clear, manufacturer: Bayer) was clamped on the movable part of the machine. The radius of the circular movements was 650 µm and the process took 20 s from the beginning of the movements to the end of cooling down.The highest microstructure generat...

Kunststoffe international, 2019-07-04, New Illumination of Plastics
...Materials Used Typical plastics for optical components used in automotive engineering are polymethyl methacrylate (PMMA) (type: Plexiglas Resist zk5HC, manufacturer: Evonik Industries AG, Marl, Germany), polycarbonate (PC, type: Makrolon 2405, manufacturer: Covestro AG, Leverkusen, Germany), and liquid silicone rubber (LSR, type: Silopren LSR 7060, manufacturer: Momentive Performance Materials GmbH, Leverkusen). These plastic types also meet the necessary requirements for use in the construction...

Kunststoffe international, 2020-04-08, Protection and Attractive Design
...drop test of the housing itself from at least 1 m height. One material property which is related to the mechanical stability of the device is the notched impact strength at different temperatures. Materials such as Makrolon 2458 or Bayblend FR3010 do not break at 20 °C during this test and would be expected to satisfy this requirement at ambient conditions. Even more stringent impact requirements such as low-temperature multi-axial impact performance are more likely to require the impact perform...


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