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Bayflex - PUR - Covestro Deutschland AG
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Kunststoffe international, 2005-11-21, Economical Production of PU Parts
... time, and tough flash, and a high tolerance to fluctuations in environmental and process conditions. To meet this range of requirements, the chemical reaction must be largely completed at the time of demoulding. This was achieved by converting the Bayflex 110 "one-shot" systems to the Bayflex 180 prepolymer system (Fig. 4). When Bayflex 110 was used, two reactions had to take place in the mould virtually simultaneously. The long-chain, relatively slowreacting polyethers and the short-ch...
Kunststoffe international, 2005-11-21, Functionality is the Key Factor
...rements involved in the processes, its physiological inertness, its conformity to FDA/BGA and USP Class VI, its chemical resistance and its NMR compatibility [12]. Because of their specific application advantages, polyurethanes (grades: Baydur and Bayflex, manufacturer: Bayer) are used for a wide variety of medical products, in particular for housing sections for large pieces of equipment in clinics and hospitals such as mammography apparatus and computer tomographs (title picture; source: Bayer...
Kunststoffe international, 2005-11-21, Low Manufacturing Costs: Plastics Encapsulation for Solar Modules
..., e.g., for reasons of cost, is made entirely of relatively simple endless profiles. On the other hand, the assembly of the aluminium frame is difficult and expensive to automate for large modules. An inexpensive alternative is therefore sought. The Bayflex polyurethane elastomer has been used for years to frame automotive windscreens, and represents a technology for framing modules of similar size to solar modules. The module, i.e. the glass pane, is inserted in a suitable injection mould, whic...
Kunststoffe international, 2005-11-21, Low-Pressure Mixing Technology in PUR Processing
...crew diameter has a nominal size of 25 mm; the screw rotates at a maximum rotary frequency of 300 s-1, and the maximum throughput is 60 g/s. Experimental Material The PUR used in the series of experiments is a polyester formulation with a polyol (Bayflex VPPU 2003E), a crosslinking agent (Bayflex VPPU 0689) and an isocyanate (Desmodur VPPU 0926, all components from Bayer, Leverkusen). The crosslinking agent is added to the polyol in a ratio of 100 : 6.3 before processing. This mixture is proce...
Kunststoffe international, 2005-11-21, Pedestrian Safety
...r below the bumper. Alternatively, airbags can be installed above and below the bumper. Engineering thermoplastics, such as the PC+ABS blend (grade: Bayblend) or the polyester Pocan for the trim, and polyurethanes — in the form of Bayflex for the trim and Bayfill for the absorber foam — are ideal construction materials for such passive bumper systems. The trims — both thermoplastic and PU-RIM — can be produced with optimised weight and in short cycle times by thin-wall technology. Advantages of ...
Kunststoffe international, 2005-11-21, Polyurethane Gel: High-tech Gel Relieves the Back
... MaterialScience AG (BMS) was represented at this fair in Cologne/Germany for the first time as an exhibitor and showed visitors to Interzum its very wide range of flexible and structural foams made from the polyurethane systems, Bayfit, Baydur and Bayflex. The main focus of attention, however, was not a foam but Technogel, a gel-like high-performance material with exceptional tactile properties, which BMS exhibited in conjunction with Technogel Italia s.r.l. Better Living with Polyurethanes Ac...
Kunststoffe international, 2005-11-21, Polyurethanes Every Step of the Way
...brasion resistant or long-term flex resistant.How is a large manufacturer like Bayer AG responding to these challenges? At Simac 2001, the world's biggest shoe fair, the company presented not only new products but an entirely new concept for the Bayflex brand. Until now, the product range covered by this name was organised according to the basic chemical properties of the system components. In their day-to-day practice, however, shoe manufacturers place most importance on applications proper...
Kunststoffe international, 2005-11-21, Polyurethanes: Diversity in PU
...ing developed into a décor material for the automotive interior in partnership with Geba Kunststoffcompounds GmbH. An instrument panel produced by blow moulding rather than the customary powder-slush process was displayed at K2004. Thieme uses Bayflex EA in safety elements for the automotive interior and exterior. These deform under load but, thanks to their structure, regain their original shape again. Elements of this type provide head, pelvic, knee and lateral crash protection in models produ...
Kunststoffe international, 2005-11-21, Possibilities with Plastics: Sports Applications
... offer in the modern sports arena. Jörn Korte Sports shoes can be adapted to individual needs and kind of sport thanks to the use of polymer materials. Dimensionally stable and hydrolysis resistant intermediate soles made of polyurethane such as Bayflex with high impact damping give “active shock absorption”, which preserves the joints and the spinal column. Running soles made of similar polyurethane materials make a weight reduction of over 40% possible compared to conventional sole materials....
Kunststoffe international, 2005-11-21, PUR Composite Spray Moulding (PUR-CSM): Open to Many Different Applications
PUR Processing Open to Many Different Applications PUR Composite Spray Moulding (PUR-CSM). A new system variant of polyurethane spray technology involves the use of an isocyanate plus a fast- and a slow-reacting polyol. Depending on requirements, various additives, such as colour components, blowing agents or chopped reinforcing fibres, can be incorporated. For the production of moulded parts, only one mould half is required and no mould carrier. Ingo Kleba Thomas Kirsten In processing a rea...
Kunststoffe international, 2006-10-30, Investment: Node in the Global Production Network
...Polycarbonate production plant in Caojing, Shanghai/China for an initial 100000 tons a year. Fig. 2. The MDI splitter can produce up to 80000 tons of monomeric and polymeric MDI. Fig. 3. Polyester polyurethane (trade name: Bayflex Longlast) is particularly suited for the production of soles for safety shoes that undergo extreme environmental conditions.
Kunststoffe international, 2007-11-21, The "Vitreous" Car
...t trends in automotive design, too. This is true, for instance, for Makrolon polycarbonate which is now an established material for use in vehicle window panes and transparent roof modules. To quote more examples, the reinforced Bayflex 180/190 polyurethane should be mentioned, which is a lightweight material used for spoilers and side panels. Moreover, there are special types of the Makrofol PC film and of the Bayblend polycarbonate blend, enabling innovative metering instruments in displays. T...
Kunststoffe international, 2007-12-17, Unlimited Versatility and Design
...the most stringent of solutions in terms of its accurate fit and surface finish, in particular. The development partners of Bayer MaterialScience, Wayand, Quarzwerke and Audi have together worked out a solution on the basis of Bayflex 180 which suitably matches the complex requirements profile. One special feature of the material grade employed – Bayflex 180 – is the reinforcing material of Tremin 939-304 from Quarzwerke. This contributes towards ensuring that the part surface attains its high t...
Kunststoffe international, 2008-09-23, Noise Abatement through Use of a Foam-Filled Ballast Layer
...ugustin, both Germany, has developed the innovative, permanently flexible Durflex system for upper ballast layers. With this approach, the voids between the ballast rocks in the rail bed are filled completely with a flexible polyurethane system (Bayflex) from Bayer MaterialScience. Shifting of the ballast rock as a consequence of the dynamics forces introduced by the passing rail traffic is thus prevented. The durability of the upper ballast layer is increased several fold and the solid-...
Kunststoffe international, 2008-10-17, Polyurethanes (PU)
...the upper layer of the rail bed that was developed by Frenzel-Bau with the assistance of Bayer MaterialScience and Hennecke. In this application, the voids between the gravel in the rail bed are completely filled with Bayflex flexible PU foam (Fig. 8). Shifting of the gravel in response to the dynamic forces that arise as trains pass is prevented in this way. This extends the life expectancy of the upper layer of the rail bed several fold, maintenance and repair costs. In addition, solid...
Kunststoffe international, 2009-01-26, Polyurethane Systems in Rail Traffic
... Sankt Augustin, Germany, has developed the innovative and permanently flexible Durflex rail bed system (Title photo). In this approach, the cavities between the ballast rocks in the rail bed are completely filled with the elastic Bayflex PU system from Bayer MaterialScience (Fig. 2). The system can be used when constructing new rail beds as well as for existing stretches of track. The PU foam system prevents the ballast rock from shifting in response to the dynamic forces genera...
Kunststoffe international, 2009-02-17, Looking to Long-Term Success
...road track maintenance intervals and appreciably reduces the noise experienced by nearby residents. The cavities between the ballast stones in the track bed are completely filled with the polyurethane foam system based on Bayflex. This prevents the movement of the ballast stones, which occurs when a train passes over them. What’s more, the structure- borne noise is absorbed at source. The system can be used on all existing and new sections of track. This “whispering ballast” is now proving its c...
Kunststoffe international, 2010-09-24, A Material Unlimited
...polycarbonate film and Platilon thermoplastic polyurethane (TPU). In a second step, flexible photovoltaic modules are created from these cells. The Solon Black 160/05 in-roof module with an “intelligent” system frame based on Bayflex PU foam has already been introduced to the market (Fig. 5). The Multitec PU spray system from BaySystems, Bayer Material-Science”s system department, provides an efficient solution for manufacturing light-weight noise-insulating housings. They exhibit high weather r...
Kunststoffe international, 2012-01-30, Sustainable Way of Walking
... primary materials based on renewable raw materials. Bayer MaterialScience has thus developed polyester-based PU systems currently containing a 30 % share of renewable raw materials. They were customized to fit Bayflex LightWeight technology, which has been a proven method in the production of light soles for some time, and was designed for direct soling. This low-pressure technology is suited for PU systems based on polyether and polyester, which are foamed with a mixture of water and CO2 as a ...
Kunststoffe international, 2014-03-21, Novel Material Concepts: Sustainability and Design
...The surfaces produced are “mold-generated”, making it possible to create highgloss, matte and/or textured regions simultaneously on one part. The comfortable coatings for the interior come from the Bayflex product line with a variety of softness values and are available in various colors. The drawer in the cockpit of a production sedan is produced with a natural leather appearance and feel by means of the DirectSkinning process (Fig. 6) with such a polyurethane system. Many components (Desmophen...
Kunststoffe international, 2014-10-10, Polyurethanes (PU)
...tions. Semi-rigid integral-skin PU foams are used to cushion instrument panels and interior trim panels. Armrests and seat cushions are the domain of flexible integral-skin PU foams. Rigid integral-skin foams simplify lightweight designs. Bayflex Lightweight from Bayer MaterialScience is an innovative development for lightweight parts, e. g. in cars, trucks and buses. The PU system for reinforced reaction injection molding applications (RRIM) was honored in 2012 with the Materialica Design + Tec...
Kunststoffe international, 2016-03-08, Lightweight Material with Class A Surface
...elastomer system with a density lower than that of water (less than 0.9 g/cm3) is used for the first time in serial production. For comparison, the density values of steel and aluminum are around 8 and 3 g/cm3 respectively. The lightweight material, Bayflex Lightweight, has been developed by Covestro Deutschland AG, Leverkusen, Germany, formerly Bayer MaterialScience, in close collaboration with 3M Deutschland GmbH, Neuss, Germany, and the processor, Polytec Car Styling, Hörsching, Austria (Fig....
Kunststoffe international, 2018-09-19, Plastics for the Mobility of Tomorrow
...partners [1]. The PVC slush skin with which VW has been setting benchmarks for quality for more than ten years is being replaced by an IMC spray skin. PU’s lower density compared to PVC-P enables additional weight savings of 5 to 10 %. Bayflex spray skin can, like the classic spray skin of Recticel N. V., be produced in two tones by a masking technique. However, the use of an isocyanate crosslinking agent in the 2-component in mold coating lacquer from iSL-Chemie GmbH & Co. KG of Kürten, Germany...
... time, and tough flash, and a high tolerance to fluctuations in environmental and process conditions. To meet this range of requirements, the chemical reaction must be largely completed at the time of demoulding. This was achieved by converting the Bayflex 110 "one-shot" systems to the Bayflex 180 prepolymer system (Fig. 4). When Bayflex 110 was used, two reactions had to take place in the mould virtually simultaneously. The long-chain, relatively slowreacting polyethers and the short-ch...
Kunststoffe international, 2005-11-21, Functionality is the Key Factor
...rements involved in the processes, its physiological inertness, its conformity to FDA/BGA and USP Class VI, its chemical resistance and its NMR compatibility [12]. Because of their specific application advantages, polyurethanes (grades: Baydur and Bayflex, manufacturer: Bayer) are used for a wide variety of medical products, in particular for housing sections for large pieces of equipment in clinics and hospitals such as mammography apparatus and computer tomographs (title picture; source: Bayer...
Kunststoffe international, 2005-11-21, Low Manufacturing Costs: Plastics Encapsulation for Solar Modules
..., e.g., for reasons of cost, is made entirely of relatively simple endless profiles. On the other hand, the assembly of the aluminium frame is difficult and expensive to automate for large modules. An inexpensive alternative is therefore sought. The Bayflex polyurethane elastomer has been used for years to frame automotive windscreens, and represents a technology for framing modules of similar size to solar modules. The module, i.e. the glass pane, is inserted in a suitable injection mould, whic...
Kunststoffe international, 2005-11-21, Low-Pressure Mixing Technology in PUR Processing
...crew diameter has a nominal size of 25 mm; the screw rotates at a maximum rotary frequency of 300 s-1, and the maximum throughput is 60 g/s. Experimental Material The PUR used in the series of experiments is a polyester formulation with a polyol (Bayflex VPPU 2003E), a crosslinking agent (Bayflex VPPU 0689) and an isocyanate (Desmodur VPPU 0926, all components from Bayer, Leverkusen). The crosslinking agent is added to the polyol in a ratio of 100 : 6.3 before processing. This mixture is proce...
Kunststoffe international, 2005-11-21, Pedestrian Safety
...r below the bumper. Alternatively, airbags can be installed above and below the bumper. Engineering thermoplastics, such as the PC+ABS blend (grade: Bayblend) or the polyester Pocan for the trim, and polyurethanes — in the form of Bayflex for the trim and Bayfill for the absorber foam — are ideal construction materials for such passive bumper systems. The trims — both thermoplastic and PU-RIM — can be produced with optimised weight and in short cycle times by thin-wall technology. Advantages of ...
Kunststoffe international, 2005-11-21, Polyurethane Gel: High-tech Gel Relieves the Back
... MaterialScience AG (BMS) was represented at this fair in Cologne/Germany for the first time as an exhibitor and showed visitors to Interzum its very wide range of flexible and structural foams made from the polyurethane systems, Bayfit, Baydur and Bayflex. The main focus of attention, however, was not a foam but Technogel, a gel-like high-performance material with exceptional tactile properties, which BMS exhibited in conjunction with Technogel Italia s.r.l. Better Living with Polyurethanes Ac...
Kunststoffe international, 2005-11-21, Polyurethanes Every Step of the Way
...brasion resistant or long-term flex resistant.How is a large manufacturer like Bayer AG responding to these challenges? At Simac 2001, the world's biggest shoe fair, the company presented not only new products but an entirely new concept for the Bayflex brand. Until now, the product range covered by this name was organised according to the basic chemical properties of the system components. In their day-to-day practice, however, shoe manufacturers place most importance on applications proper...
Kunststoffe international, 2005-11-21, Polyurethanes: Diversity in PU
...ing developed into a décor material for the automotive interior in partnership with Geba Kunststoffcompounds GmbH. An instrument panel produced by blow moulding rather than the customary powder-slush process was displayed at K2004. Thieme uses Bayflex EA in safety elements for the automotive interior and exterior. These deform under load but, thanks to their structure, regain their original shape again. Elements of this type provide head, pelvic, knee and lateral crash protection in models produ...
Kunststoffe international, 2005-11-21, Possibilities with Plastics: Sports Applications
... offer in the modern sports arena. Jörn Korte Sports shoes can be adapted to individual needs and kind of sport thanks to the use of polymer materials. Dimensionally stable and hydrolysis resistant intermediate soles made of polyurethane such as Bayflex with high impact damping give “active shock absorption”, which preserves the joints and the spinal column. Running soles made of similar polyurethane materials make a weight reduction of over 40% possible compared to conventional sole materials....
Kunststoffe international, 2005-11-21, PUR Composite Spray Moulding (PUR-CSM): Open to Many Different Applications
PUR Processing Open to Many Different Applications PUR Composite Spray Moulding (PUR-CSM). A new system variant of polyurethane spray technology involves the use of an isocyanate plus a fast- and a slow-reacting polyol. Depending on requirements, various additives, such as colour components, blowing agents or chopped reinforcing fibres, can be incorporated. For the production of moulded parts, only one mould half is required and no mould carrier. Ingo Kleba Thomas Kirsten In processing a rea...
Kunststoffe international, 2006-10-30, Investment: Node in the Global Production Network
...Polycarbonate production plant in Caojing, Shanghai/China for an initial 100000 tons a year. Fig. 2. The MDI splitter can produce up to 80000 tons of monomeric and polymeric MDI. Fig. 3. Polyester polyurethane (trade name: Bayflex Longlast) is particularly suited for the production of soles for safety shoes that undergo extreme environmental conditions.
Kunststoffe international, 2007-11-21, The "Vitreous" Car
...t trends in automotive design, too. This is true, for instance, for Makrolon polycarbonate which is now an established material for use in vehicle window panes and transparent roof modules. To quote more examples, the reinforced Bayflex 180/190 polyurethane should be mentioned, which is a lightweight material used for spoilers and side panels. Moreover, there are special types of the Makrofol PC film and of the Bayblend polycarbonate blend, enabling innovative metering instruments in displays. T...
Kunststoffe international, 2007-12-17, Unlimited Versatility and Design
...the most stringent of solutions in terms of its accurate fit and surface finish, in particular. The development partners of Bayer MaterialScience, Wayand, Quarzwerke and Audi have together worked out a solution on the basis of Bayflex 180 which suitably matches the complex requirements profile. One special feature of the material grade employed – Bayflex 180 – is the reinforcing material of Tremin 939-304 from Quarzwerke. This contributes towards ensuring that the part surface attains its high t...
Kunststoffe international, 2008-09-23, Noise Abatement through Use of a Foam-Filled Ballast Layer
...ugustin, both Germany, has developed the innovative, permanently flexible Durflex system for upper ballast layers. With this approach, the voids between the ballast rocks in the rail bed are filled completely with a flexible polyurethane system (Bayflex) from Bayer MaterialScience. Shifting of the ballast rock as a consequence of the dynamics forces introduced by the passing rail traffic is thus prevented. The durability of the upper ballast layer is increased several fold and the solid-...
Kunststoffe international, 2008-10-17, Polyurethanes (PU)
...the upper layer of the rail bed that was developed by Frenzel-Bau with the assistance of Bayer MaterialScience and Hennecke. In this application, the voids between the gravel in the rail bed are completely filled with Bayflex flexible PU foam (Fig. 8). Shifting of the gravel in response to the dynamic forces that arise as trains pass is prevented in this way. This extends the life expectancy of the upper layer of the rail bed several fold, maintenance and repair costs. In addition, solid...
Kunststoffe international, 2009-01-26, Polyurethane Systems in Rail Traffic
... Sankt Augustin, Germany, has developed the innovative and permanently flexible Durflex rail bed system (Title photo). In this approach, the cavities between the ballast rocks in the rail bed are completely filled with the elastic Bayflex PU system from Bayer MaterialScience (Fig. 2). The system can be used when constructing new rail beds as well as for existing stretches of track. The PU foam system prevents the ballast rock from shifting in response to the dynamic forces genera...
Kunststoffe international, 2009-02-17, Looking to Long-Term Success
...road track maintenance intervals and appreciably reduces the noise experienced by nearby residents. The cavities between the ballast stones in the track bed are completely filled with the polyurethane foam system based on Bayflex. This prevents the movement of the ballast stones, which occurs when a train passes over them. What’s more, the structure- borne noise is absorbed at source. The system can be used on all existing and new sections of track. This “whispering ballast” is now proving its c...
Kunststoffe international, 2010-09-24, A Material Unlimited
...polycarbonate film and Platilon thermoplastic polyurethane (TPU). In a second step, flexible photovoltaic modules are created from these cells. The Solon Black 160/05 in-roof module with an “intelligent” system frame based on Bayflex PU foam has already been introduced to the market (Fig. 5). The Multitec PU spray system from BaySystems, Bayer Material-Science”s system department, provides an efficient solution for manufacturing light-weight noise-insulating housings. They exhibit high weather r...
Kunststoffe international, 2012-01-30, Sustainable Way of Walking
... primary materials based on renewable raw materials. Bayer MaterialScience has thus developed polyester-based PU systems currently containing a 30 % share of renewable raw materials. They were customized to fit Bayflex LightWeight technology, which has been a proven method in the production of light soles for some time, and was designed for direct soling. This low-pressure technology is suited for PU systems based on polyether and polyester, which are foamed with a mixture of water and CO2 as a ...
Kunststoffe international, 2014-03-21, Novel Material Concepts: Sustainability and Design
...The surfaces produced are “mold-generated”, making it possible to create highgloss, matte and/or textured regions simultaneously on one part. The comfortable coatings for the interior come from the Bayflex product line with a variety of softness values and are available in various colors. The drawer in the cockpit of a production sedan is produced with a natural leather appearance and feel by means of the DirectSkinning process (Fig. 6) with such a polyurethane system. Many components (Desmophen...
Kunststoffe international, 2014-10-10, Polyurethanes (PU)
...tions. Semi-rigid integral-skin PU foams are used to cushion instrument panels and interior trim panels. Armrests and seat cushions are the domain of flexible integral-skin PU foams. Rigid integral-skin foams simplify lightweight designs. Bayflex Lightweight from Bayer MaterialScience is an innovative development for lightweight parts, e. g. in cars, trucks and buses. The PU system for reinforced reaction injection molding applications (RRIM) was honored in 2012 with the Materialica Design + Tec...
Kunststoffe international, 2016-03-08, Lightweight Material with Class A Surface
...elastomer system with a density lower than that of water (less than 0.9 g/cm3) is used for the first time in serial production. For comparison, the density values of steel and aluminum are around 8 and 3 g/cm3 respectively. The lightweight material, Bayflex Lightweight, has been developed by Covestro Deutschland AG, Leverkusen, Germany, formerly Bayer MaterialScience, in close collaboration with 3M Deutschland GmbH, Neuss, Germany, and the processor, Polytec Car Styling, Hörsching, Austria (Fig....
Kunststoffe international, 2018-09-19, Plastics for the Mobility of Tomorrow
...partners [1]. The PVC slush skin with which VW has been setting benchmarks for quality for more than ten years is being replaced by an IMC spray skin. PU’s lower density compared to PVC-P enables additional weight savings of 5 to 10 %. Bayflex spray skin can, like the classic spray skin of Recticel N. V., be produced in two tones by a masking technique. However, the use of an isocyanate crosslinking agent in the 2-component in mold coating lacquer from iSL-Chemie GmbH & Co. KG of Kürten, Germany...
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