BAYDUR/BAYFLEX VERSATILE POLYURETHANE INTEGRAL SKIN FOAMS

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Bayer AG Geschftsbereich Polyurethane D-51368 Leverkusen

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

ADVANTAGES OF BAYDUR AND BAYFLEX : Economical production of large

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,

BAYDUR 40 Main area of use: Simulated wood, furniture 6/7

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

depending on the boundary conditions. BAYDUR 60 Main area of use:

Diagram of the RIM process for polyurethane production:

Storage tank Storage tank

Industrial housings

8/9

BAYDUR 110 Main area of use: Parts for industrial housings, optical
Container Drum Drum Container

equipment, housings for medical equipment, refrigerators 10/11

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

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

Mixing head
2

Market outlook and future developments

Mould Moulded article

18/19

Mould carrier

BAYDUR 20 SUPER-LIGHT INTEGRAL SKIN FOAM

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).

BAYDUR 20 - TECHNICAL DATA Density of moulded article Flexural strength

1) 1) 1)

170 kg/m3 5 MPa 160 MPa 3 MPa

Flexural modulus of elasticity Tensile strength

1) 1)

Elongation at break

3%
1) 2)

Tensile modulus of elasticity

3) 3)

130 MPa 2 MPa 98 26 approx. 0.3 %

3)

Compressive strength at 10 % compression Shore A hardness

Shore D hardness
1)

Moulding shrinkage DIN 53432

2)

DIN 53421

DIN 53505

APPLICATIONS OF BAYDUR 20: Decorative mouldings and elements such as simulated stucco Air duct sections with a large surface area

Decorative simulated stucco made from Baydur 20.

BAYDUR 40 FLOWING FORMS

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

BAYDUR 40 - TECHNICAL DATA

1)

Density of moulded article

1)

400 kg/m3

Flexural strength

20 MPa
1)

Flexural modulus of elasticityl

1)

520 MPa

Impact strength

10 kJ/m2
2)

Shore D hardness

58
1)

Heat deflection temperature

90 C

Moulding shrinkage
1)

approx. 0.4 %

DIN 53432

2)

DIN 53505

Baydur 40: Simulated period furniture made from polyurethane.

Housing for a juke-box made from Baydur 60.

BAYDUR 60 THE FOAM WITH A HIGH PROFILE

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-

Moulded components made from Baydur 60.

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

Flexural modulus of elasticity Flexural strength Tensile strength

1) 1)

Elongation at break Impact strength

1)

8% 18 KJ/m2
1) 2)

Heat deflection temperature

3)

up to 118 C 18 N/mm2 62 - 70 73 x 10
-6 -1

Compressive strength at 10 % compression Shore D surface hardness

4)

Coefficient of thermal expansion Water absorption

24h/RT < 0.4 % V-0 at 10 mm wall thickness* B2

6) 5)

Fire performance according to UL test Fire performance according to

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 ECONOMICAL PRODUCTION BY THE RIM PROCESS

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.

release agent (time-saving) and high density (defect-free surfaces).

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

Cladding round a petrol pump.

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)

3 - 12 mm 1 sometimes possible 0.5 - 0.8 % 1,100 kg/m3 2,000 N/mm2

Flexural modulus of elasticity Flexural strength Tensile strength

4) 4)

53/43 MPa (FR grades) 14 % 45 KJ/m3

6)

Elongation at break Impact strength

5)

Heat deflection temperature Shore D surface hardness

115 C method B 75 - 77 - at RT - at 60 C 90 x 10
-6 -1 -1

Coefficient of thermal expansion

7)

105 x 10

-6

Water absorption

24h/RT< 0.6 % V-0 as from 3 mm wall thickness* B2

9) 8)

Fire performance according to UL test

10

Fire performance according to

Fire performance according to German Federal Railways test * with flame retardant
1) 2) 9) 3) 4) 5)

S4-SR2-ST2*
6) 7)

DIN 53479 DIN 4102

DIN 53457

DIN 53452

DIN 53455

DIN 53453

DIN 53461

DIN 53495

8)

DIN 5510

Outer cabinet of a refrigerator made from Baydur 110.

BAYDUR GS SOLID CASTING SYSTEM

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

Flexural modulus of elasticity Flexural strength Tensile strength

4) 4)

Elongation at break Impact strength

5)

21 % 60 KJ/m2
6)

Heat deflection temperature Shore D surface hardness

7)

110 C 74 110 x 10
-6 -1

Coefficient of thermal expansion Fire performance according to UL test

V-0, only highly filled B2

Cladding for a control valve.

Fire performance according to Fire performance according to German Federal Railways test
1)

8)

9) 4) 9)

S4-SR2-ST2 DIN 53455

5)

DIN 53479 DIN 53461

2) 7)

DIN 53457

3)

DIN 53452 DIN 4102

DIN 53453

6)

DIN 53505

8)

DIN 5510 with additives

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

Housing for a signalling lamp (black-pigmented).

12

BAYFLEX 20/30 SKIN-TOLERANT AND NON-SLIP

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

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.

Non-skid industrial mats.

BAYFLEX 20/30 - TECHNICAL DATA For example, the CFC-free system Density
1) 2)

Bayflex 400 kg/m3 35 0.73 MPa

50 IK 33 600 kg/m3 50 1.6 MPa 90 % 2.2 KN/m 248 KPa 3.1 %

4) 5)

Shore A hardness Tensile strength

3)

Elongation at break

3) 4)

85 % 1.4 KN/m 123 KPa 2.5 %

3) 5)

Weather resistance

Compressive stress, 10 % deformation Compression set (25 %/70 h, RT)

1) 2)

15

DIN 53420

DIN 53505

DIN 53504

DIN 53515

DIN 53572

BAYFLEX RIM/RRIM IMPACT RESISTANT EVEN IN A SEVERE FROST

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

Elongation at break 93 % Impact resistance Sag test 432 J/m 71 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)

Truck bonnet made from Bayflex 110.

BAYFLEX XGT - TECHNICAL DATA Density

1)

1,181 kg/m3 981 MPa 34 MPa

2) 3) 4) 2)

Flexural modulus of elasticity, ASTM-D790 Tensile strength

Elongation at break

135 % 870 MPa 100 KN/m no failure

5)

Tensile modulus of elasticity

5)

Tear propagation resistance Impact resistance

Notched impact resistance HDT ISO-R-75/B Shore D hardness

1) 6) 2)

14 KJ/m3 65 C 69

DIN 53420

DIN 53571

3)

DIN 53457

4)

DIN 53515

5)

DIN 53453

6)

DIN 53505

16

PROSPECTS FOR POLYURETHANES UNTAPPED POTENTIAL STILL EXISTS

Although Baydur and Bayflex have already been on the market for a considerable length of time, no end can be seen to the world-wide boom. Development of the full range of properties is now complete, but all fields of use have not yet been opened up. Since the properties of the Baydur and Bayflex systems can be specifically tailored to individual applications, there are still plenty of opportunities to be grasped.
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 packages to comply with different standards. Providing design and application-oriented 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!

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.
18 19

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