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D E S I G N U N L I M I T E D
B A Y D U R ® B A Y F L E X ®
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DE S I G N U N L IM I T E D | 3
Introduction
MULTI-FACETED BRANDS 5
Properties
GRADES WITH A UNIQUE PROFILE 7
Applications
DESIGN FREEDOM AND HIGH FUNCTIONALITY
Sports & leisure 9
House & home 11
Transportation & commercial vehicles 13
Medicine & technology 15
Electronics & entertainment 17
Composites
POWERFUL COMBINATIONS 19
Polyurethane production
ALWAYS THE RIGHT MIX 21
Polyurethane from BaySystems
ALL THE INGREDIENTS FOR SUCCESS 23
C O N T E N T S
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Following their invention by Dr. Otto Bayer in
1937, the polyurethanes’ success story con-
tinues to this day. Thanks to their incredible
versatility and adaptability, they have found
their way into virtually all areas of our daily
lives.
Two of this material’s product groups,
Baydur® and Bayflex®, reflect this success
story perfectly:
These polyurethane systems from Bayer
MaterialScience are the ideal choice in
countless applications. They provide alter-
natives to traditional materials such as wood
and metals, as well as to thermoplastic and
thermoset plastic materials. Sometimes they
are quite simply the only choice.
And here are just a few of the advantages of
Baydur® and Bayflex®:
- cost-effective production of large molded
parts
- variable wall thicknesses
- exceptionally accurate reproduction of sur-
face detail
- problem-free coatability
- strength and dimensional stability
- chemical resistance
- good combinability with other materials
- customizable properties
- relatively low investment in molds and
equipment
Key application areas for Baydur® and
Bayflex® include the electrical and machine
housing industry, medical equipment, farm
machinery, sports equipment, inward and
outward ventilation installations, sanitary
facilities, the furniture industry, waste water
technology, transportation, windows, build-
ing components, decorative trim and special-
purpose vehicles.
Baydur® and Bayflex® are long-established
brands that constantly inspire new applica-
tions.
DE S I G N U N L IM I T E D | 5
M U L T I - F A C E T E D B R A N D S
I N T R O D U C T I O N
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G R A D E S W I T H A U N I Q U E
P R O F I L E
DE S I G N U N L IM I T E D | 7
P R O P E R T I E S
BAYDUR® 20 – extra-light and dimension-
ally stable
Baydur® 20 is characterized by a low densi-
ty of 150–250 kg/m3 and a solid, hard-wear-
ing outer layer. Wall thicknesses of over
40 mm are possible. Baydur® 20 is not only
light but also impact-resistant and suitable
for cutting, nailing and bonding.
Main application areas: decorative trim
and elements, such as simulated plaster
BAYDUR® 40 – for complex shapes
Baydur® 40 has excellent flowability,
enabling easy production of large, complex-
shaped parts. This rigid integral skin foam
with a density range of 250–500 kg/m3 has
a robust, scratch-resistant surface.
Main application area: wood substitute for
use in furniture
BAYDUR® 60 – the versatile engineering
material
The design possibilities are virtually unlim-
ited. This product class is particularly useful
for large parts with widely varying wall
thicknesses. Baydur® 60 is light and strong
thanks to its integral skin structure and is
flame-retardant to UL94 V-0.
Main application areas: industrial hous-
ings, skis
BAYDUR® 110 – the specialist for thin-
walled and large molded parts
The microcellular, almost solid RIM material
can be cost-effectively processed thanks to
short demolding times of approx. 90 sec-
onds. Thin-walled molded parts can be pro-
duced with high inherent stiffness and
strength and excellent surface quality.
Main application areas: industrial housing
components, optical instruments, medical
housings, refrigerators, paneling/trim for
commercial vehicles
BAYDUR CSP ® – compact with simplified
processing
A compact material that requires only mini-
mal investment in machinery and molds. It
can also be processed in epoxy resin molds
and is suitable for manufacturing large, thin-
walled parts with excellent surface quality.
Main application areas: industrial hous-
ings, chairs
BAYDUR® GS – solid and robust
The solid casting system enables pressure-
less processing. Baydur® GS is wear- and rot-
proof and is frequently used as a long-last-
ing substitute for cast iron. The excellent
chemical resistance is often crucial.
Main application areas: sewage pumps,
manhole covers
BAYFLEX® INTEGRAL – tear-resistant and
elastic
Bayflex® integral is a flexible to semi-rigid
integral skin foam with a density range of
200–700 kg/m3. The surface hardness can
be varied as required (Shore A 30–85). The
tear-resistant and flexible foam has a closed
outer layer. The open-cell core has excellent
shock absorption when subjected to impact
stress. Bayflex® integral grips well and is
non-slip when studs or other surface struc-
tures are incorporated.
Main application areas: office furniture,
work mats, protective strips
BAYDUR® LMP – large molded parts
This new solid system is designed for large
molded parts and enables fast demolding
despite a long pot life. It exhibits high stiff-
ness and heat resistance combined with
high impact strength. Neither fillers nor
annealing processes are necessary.
Main application areas: paneling/trim for
commercial vehicles, housings for large
equipment
BAYFLEX® RIM – tough and elastic even at
temperatures below zero
Bayflex® RIM is a solid material that stands
out from the crowd, particularly because of
its excellent impact resistance even in
extremely cold conditions. Milled glass
fibers and other mineral reinforcing materi-
als can be added to achieve the required
stiffness.
Main application areas: sidebars, side
member moldings, bumpers and fenders for
cars and trucks, paneling/trim for snowmo-
biles, agricultural equipment and vehicles
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Safety and comfort, as well as design and
functionality, are especially important in the
sports and leisure industries. Every piece of
leisure equipment presents its own, specif-
ic challenges for the material.
For skis and snowboards, breaking strength
and flexibility are key factors. The ability to
form a durable bond with other materials is
a prerequisite for any state-of-the-art com-
posite structure. For bicycle seats, the key
factor on long distances is comfort through
ergonomic pressure distribution. Snow-
mobile hoods used in a freezing cold envi-
ronment require a product that withstands
impact unscathed. The fact that snowshoes
do not break even when subjected to
extreme stress can mean the difference
between life and death. Bumper car seats
and interior trim panels made from flexible,
tear-resistant polyurethane are not only
comfortable for funfair visitors, protecting
them from bruising, they are also ideal for
the ride operators, who prize the material’s
easy cleaning and durability.
Whatever the application needs, polyure-
thane has just the right answer.
Typical applications:
Baydur®
- Skis, snowboards
- Wakeboards, water skis
- Balls for bowling and skittles
- Motorbike trim
- Solariums
- Upper decks on speedboats
Bayflex®
- Bicycle saddles
- Snow shoes
- Snowmobile hoods
- Bumper car seats
- Rockers for children
- Safety padding for motorbike clothing
- Sparring helmets
DE S I G N U N L IM I T E D | 9
S P O R T S & L E I S U R E
D E S I G N F R E E D O M A N D H I G H F U N C T I O N A L I T Y
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The home and its furnishings offer design-
ers broad scope for creativity.
Furniture, bathroom fittings, lamps and
household appliances are available for all
tastes and in all styles. The variety of
designs is endless.
This calls for materials that allow designers
maximum freedom while at the same time
meeting the needs of durability and surface
quality.
The integral skin foam structure of Baydur®
gave the first cantilever chair, designed by
Verner Panton, the necessary stability.
The soft, rounded forms of the Zanussi OZ
refrigerator are no real challenge for
Baydur® – and yet would be virtually impos-
sible to produce using metal.
Bayflex®, with its flexible foam core, rounds
off the range. Chairs and stools that can be
foamed and coated in a single operation,
thanks to in-mold coating (IMC), provide
lasting comfort.
Also Baydur® parts can be finished in any
way desired. In addition to conventional
coating and IMC, the high-quality surface
enables back-foaming of thermoformed
films.
Baydur® and Bayflex® provide a host of visu-
al delights.
Typical applications
Baydur®
- Designer chairs
- Refrigerators
- Shower cabinets
- School chairs
- Bathroom stools
- Lamps
- Simulated stucco (decorative copings, roses)
- Cabinets
- Window frames
- Mirror frames
- Ornamentation on wooden furniture
- Doors
Bayflex®
- Designer chairs
- Table edging
- Armrests for office chairs
- Moldings for stair handrails
- Sheathing for solar modules
DE S I G N U N L IM I T E D | 1 1
H O U S E & H OM E
D E S I G N F R E E D O M A N D H I G H F U N C T I O N A L I T Y
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Trains and commercial vehicles are no
strangers to fashion either. Shapes are
adapted to the latest trends, with curved,
organic forms, for example, now in demand
in contrast to traditional square, angular
sheet metal designs. For these, designers
need products that not only give them the
necessary design freedom but can also face
up to the technical challenges. In particular,
reliability is essential, despite the high
stress placed on materials.
Strict regulations and standards, relating to
fire protection in trains for instance, must be
complied with. Whether for high-speed train
cockpits or excavator driver cabs, Baydur®
and Bayflex® offer a wide range of cus-
tomized systems for innovative solutions.
Typical applications:
Baydur®
- High-speed train cockpit interiors
- Forklift truck paneling
- Tractor hoods
- Body parts for agricultural machinery
- Ceiling paneling in track-bound vehicles
Bayflex®
- Excavator driver cabs
- Castors and wheels
- Steering wheels
- Headrests
- Protective moldings
- Body parts for agricultural machinery
- Seats
DE S I G N U N L IM I T E D | 1 3
T R A N S P O R TAT I O N &
COMM E R C I A L V E H I C L E S
D E S I G N F R E E D O M A N D H I G H F U N C T I O N A L I T Y
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In virtually no other field is research and
development so driven as in medicine. The
recovery process for humans (and animals)
depends to a significant extent on the perfect
functioning and development level of techni-
cal equipment. What was still cutting-edge
for medical equipment just a few years ago is
today often outdated. Outward appearances
also follow trends and help patients feel at
ease – an ideal domain for Baydur® and
Bayflex®.
Baydur® and Bayflex® offer a whole host of
application-related benefits for use in medi-
cine. The design freedom opened up by
these materials enables production of esthe-
tic and rounded forms. The easy cleaning of
the high-quality surfaces and their resistance
to chemicals and disinfectantsmake Baydur®
and Bayflex® ideal for use in medical practi-
ces and hospitals.
Typical applications:
Baydur®
- Computer tomograph housings
- Light therapy units
- Multifunctional hospital stretchers
- Heads and feet of hospital beds
- Housings for operating microscopes
- Housings for dialysis machines
- Spittoons
- Imitation bones for training surgeons
Bayflex®
- Wheels for wheelchairs
- Toilet seats
- Armrests and seats for wheelchairs
DE S I G N U N L IM I T E D | 1 5
M E D I C I N E & T E C H NO LO GY
D E S I G N F R E E D O M A N D H I G H F U N C T I O N A L I T Y
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The electronics and entertainment sectors
open up countless areas of application for
Baydur®. Its very special properties con-
stantly put it one step ahead of other mate-
rials, offering designers broad scope for
creativity.
Thanks to the outstanding acoustic features
of Baydur®, it is possible to produce partic-
ularly compact high-end hi-fi loudspeakers.
Even musical instruments, such as the
curved bodies of digital grand pianos, are
made using Baydur®.
A perfect surface is especially important for
high-quality equipment. And this is where
Baydur® has already repeatedly proven itself
as a material for housings for video projec-
tors, television sets and control consoles for
lighting effects. Compliance with the strin-
gent fire safety requirements to UL94 V-0 for
electrical equipment is ensured.
Typical applications for Baydur®
- TV cabinets
- Hi-fi loudspeakers
- Jukeboxes
- Bodies of digital grand pianos
- Projectors
- Precision sound sources for acoustic meas-
urements
DE S I G N U N L IM I T E D | 1 7
E L E C T R O N I C S &
E N T E R TA I NM E N T
D E S I G N F R E E D O M A N D H I G H F U N C T I O N A L I T Y
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DE S I G N U N L IM I T E D | 1 9
Polyurethanes all have one thing in com-
mon – they adhere well to most other mate-
rials. By harnessing this, polyurethanes’
already wide range of features can be
extended even further.
The possible combinations for Baydur® and
Bayflex® are virtually unlimited.
Whether with wood, metal or a whole range
of fiber materials and fillers, each combina-
tion of materials adds to the variety of
applications for these polyurethanes. The
property profile of the polyurethane com-
posite used can be manipulated depending
on the function, whether in combination
with fiber glass as a reinforcement for mois-
ture-resistant railway sleepers, as robust
sheathing for wooden planks for long-term
use in brick production, as insulating win-
dow profiles in combination with aluminum
or as impact-resistant, rust-free body parts
for commercial vehicles and public trans-
portation.
Typical applications:
Baydur®
- Base plates for producing bricks
- Railway sleepers
- Door leaves (with long glass fibers)
- Refrigerator doors (surface finished with
laminated foil)
- Window frames (composite with wood or
metal)
- Polymer concrete (mineral-filled, solid sys-
tems)
- Furniture (integration of functions by insert
molding)
Bayflex®
- Chairs (composite with metal)
- Automotive body parts reinforced with
fiber glass
P O W E R F U L C O M B I N A T I O N S
C O M P O S I T E S
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DE S I G N U N L IM I T E D | 2 1
The mold, temperature-controlled to approx.
60 °C, is held shut by a clamping force that
is adequate albeit low in comparison with
thermoplastic processing. The chemical
reaction of the raw material mixture in the
mold creates a polyurethane molded part
that can be produced in various wall thick-
nesses and densities.
This production method is known as the RIM
process (reaction injection molding).
Baydur® GS and Baydur® CSP occupy a spe-
cial position. They are suitable for simple,
pressureless casting equipment. Low-pres-
sure machines can also be used. Reactants
Baydur® and Bayflex® are formed by the
reaction of special-purpose polyols and iso-
cyanates. Production of these raw materials
is subject to strict quality controls and is
carefully monitored. The guidelines from
DIN ISO 9001, to which the Polyurethanes
Business Unit has been certified since 1995,
apply as a benchmark.
The liquid raw material components for pro-
cessing into molded parts are transported
to a mixing head using a high-pressure
pump metering unit. There they are mixed
intensively in the prescribed proportions
and metered into a preferably closed mold.
Stirrer motor
Polyol
Water outlet
Water intake
Stirrer motor
IsocyanateReturn circuit
Feed line
Plate-typeheat exchanger
Return circuit
Feed line
Mold lid
Mold
Mixing head
Axial piston pump
Axial piston pump
Water intakeWater outlet
are then metered using slow-running gear
pumps to a mechanical agitator, where mix-
ing takes place. These products also enable
cost-effective epoxy resin molds to be used
for smaller series.
Products made from polyurethane exhibit
excellent resilience and therefore make a
key contribution to the long service life of
the articles manufactured from them.
Polyurethane can be recycled if required.
Various recycling methods are available
depending on the situation – material recy-
cling, chemical recycling and energy recov-
ery.
A L W A Y S T H E R I G H T M I X
P O L Y U R E T H A N E P R O D U C T I O N
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The telephone book for the PU specialists
from BaySystems was attached here. If you
would also like to have it, just visit
www.bayer-baysystems.com
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BaySystems® is the new name of Bayer
MaterialScience’s worldwide network of
polyurethane systems houses. BaySystems®
is the ideal combination of polyurethane
expertise, service and local presence.
BaySystems® provides all polyurethane pro-
cessors with access to the extensive tech-
nology, research and support resources of
the world's largest manufacturer of polyu-
rethane raw materials.
Tell us your problem and we’ll provide the
solution. BaySystems® is always somewhere
near you, speaks your language, and offers
you fast, comprehensive support tailored to
your individual needs.
For more information, go to
www.bayer-baysystems.com
DE S I G N U N L IM I T E D | 2 3
A L L T H E I N G R E D I E N T S F O R
S U C C E S S
P O L Y U R E T H A N E F R O M B A Y S Y S T E M S
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Bayer MaterialScience AG
Business Unit Polyurethanes
51368 Leverkusen
Germany
www.bayer-baysystems.com
This information and our technical advice – whether verbal, in writing or by way of trials – is given in
good faith but without a warranty, and this also applies where proprietary rights of third parties are
involved. It does not release you from the obligation to test the products supplied by us as to their suit-
ability for the intended processes and uses. The application, use and processing of the products are
beyond our control and, therefore, entirely your own responsibility. Should, in spite of this, liability be
established for any damage, it will be limited to the value of the goods delivered by us and used by
you. We will, of course, provide products of consistent quality within the scope of our General
Conditions of Sale and Delivery.
Edition: 2008-09 · Order-No.: MS00040821 · Printed in Germany · E
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