Bayer AG
Geschäftsbereich Polyurethane
D-51368 LeverkusenBayer on the Internet: http://www.bayer.com
BAYDUR®/BAYFLEX®
VERSATILE POLYURETHANE INTEGRAL SKIN FOAMS
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Storage tank
Container Drum Drum Container
Storage tank
or or
PolyolDesmophenmachine tank
IsocyanateDesmodur
machine tank
Gas loading
Metering machine
Additives: e.g. flame retardant´s,colour pastes
Mould carrier
Moulded article
Mould
Mixing head
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VERSATILITY WITH POLYURETHANESPOLYURETHANE SYSTEMS, PROVENOVER AND OVER AGAIN
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ADVANTAGES OF BAYDUR®
AND BAYFLEX®:
Economical production of large
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
The most important areas of use for
Baydur and Bayflex include housings
for electrical goods, games and vend-
ing machines, medical equipment, agri-
cultural machinery, paper and printing
equipment, sports equipment, ventila-
tion systems, sanitary goods, the furni-
ture industry, sewerage engineering,
traffic and transport engineering, win-
dows, structural elements, decorative
mouldings and special-purpose vehicles.
THE ORIGIN OF MODERN
MATERIALS
Baydur and Bayflex consist of a polyol
(Desmophen®) and an isocyanate
(Desmodur®). The quality of these raw
materials is subject to permanent and
stringent in-house Bayer quality con-
trols and is carefully monitored. The
relevant standard is DIN ISO 9001 and
the Polyurethanes Business Group was
certified in accordance with this stan-
dard in 1995. During production, the
liquid raw materials are fed to a mixing
head by means of a high-pressure
pumping and metering unit. There, they
are intimately mixed in the correct pro-
Diagram of the RIM process for polyurethaneproduction:
portions and are metered, under re-
duced 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 struc-
tural moulded article is formed. This
method of production is called the RIM
process.
Polyurethanes can be recycled at the
end of their service life. A number of
recycling processes is available,
depending on the boundary conditions.
CONTENTSVERSATILITY WITH
POLYURETHANES
Baydur and Bayflex
Features and fields of application
Production by the RIM process 2/3
BAYDUR® 20
Main area of use:
Decorative elements 4/5
BAYDUR® 40
Main area of use:
Simulated wood, furniture 6/7
BAYDUR® 60
Main area of use:
Industrial housings 8/9
BAYDUR® 110
Main area of use:
Parts for industrial housings, optical
equipment, housings for medical
equipment, refrigerators 10/11
BAYDUR® GS
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
Market outlook and
future developments 18/193
Bayer's two polyurethane integral skinfoam systems Baydur® and Bayflex®
have been used for years in many different fields of application. Thanks toa number of properties characteristic ofpolyurethane, the Baydur® and Bayflex®
systems offer a complete substitute fortraditional materials such as wood ormetal and thermoplastic or thermosetmaterials.
BAYDUR® 20 - TECHNICAL DATA
Density of moulded article1) 170 kg/m3
Flexural strength1) 5 MPa
Flexural modulus of elasticity1) 160 MPa
Tensile strength1) 3 MPa
Elongation at break1) 3%
Tensile modulus of elasticity1) 130 MPa
Compressive strength at 10 % compression2) 2 MPa
Shore A hardness3) 98
Shore D hardness3) 26
Moulding shrinkage approx. 0.3 %1)DIN 53432 2)DIN 53421 3)DIN 53505
BAYDUR® 20SUPER-LIGHT INTEGRALSKIN FOAM
Baydur® 20 is especially suitable for theproduction of decorative elements witha wall thickness of up to 25 mm, due toits low density of 150 -250 kg/m3.Baydur® 20 is not only light but alsodimensionally stable and thermallyinsulating, while it can also be cut,nailed and glued. Thus, using this inte-gral skin foam, sealed, easily paintedsurfaces can be produced which, ifrequired, can also achieve flammabilityrating B2 by adding flame retardants inaccordance with DIN 4102.
There are only a few DIN standards for
lightweight materials with a sandwich-
type 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 temperature-
controlled aluminium mould (mould
temperature: 60 °C; demoulding time: 6
minutes).
APPLICATIONS OF
BAYDUR® 20:
Decorative mouldings and elements
such as simulated stucco
Air duct sections with a large surface
area
Decorative simulated stuccomade from Baydur 20.
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BAYDUR® 40 - TECHNICAL DATA
Density of moulded article1) 400 kg/m3
Flexural strength1) 20 MPa
Flexural modulus of elasticityl1) 520 MPa
Impact strength1) 10 kJ/m2
Shore D hardness2) 58
Heat deflection temperature1) 90 °C
Moulding shrinkage approx. 0.4 %1)DIN 53432 2)DIN 53505
BAYDUR® 40FLOWING FORMS
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Rigid integral skin foam Baydur® 40 hasa density in the range 250- 500 kg/m3
and exceptionally good flow, whichmeans that large moulded articles caneasily be made. By adding a blowingpaste, a hard outer layer can be formedso that surface hardness, and thusscratch resistance, is increased.
specimens are cut out of a sheet with
solid edge zones on both sides which
has been machine-made in a tempera-
ture-controlled aluminium mould (1000
x 500 x 10 mm) (mould temperature:
60 °C; demoulding time: 6 minutes).
APPLICATIONS OF
BAYDUR® 40
Simulated wood (Finto legno)
Furniture
Cladding panels
Window frames
Only some lightweight sandwich mate-
rials are covered by DIN standards. In
all other cases, the physical values are
determined in the same way as de-
scribed in existing regulations. The test
Baydur 40: Simulated period furniture made from polyurethane.
BAYDUR® 60THE FOAM WITH A HIGH PROFILE
There are virtually no limits to the num-ber of structural design possibilitieswhen using Baydur® 60. Due to thesandwich structure - a solid outer layerand a foam core - the material can beprocessed in much the same way aswood. This material has proved particu-larly suitable for large moulded itemsbecause it`s good flow properties allowthe use of complicated mould geome-tries. This means that the internal pres-sure in the mould is low. For this rea-son, and because it has good adhesiveproperties, combinations with othermaterials pose no problems.
VERSATILE AND UP-TO-DATE
Thanks to the exceptionally accurate
reproduction of mould detail with
Baydur 60, structures of any type at all
can be produced in the mould and indi-
vidual colours can be applied with a
coat of paint. If colour is not so impor-
tant, a black, brown or orange colora-
tion can be produced by adding pig-
ment to the polyol component.
APPLICATIONS OF
BAYDUR® 60
Industrial housings, e.g. medical and
dental equipment
Cores for skis
Window frames
Housing for a juke-box made from Baydur 60.
BAYDUR® 60 - TECHNICAL DATA
Preferred wall thickness 4 - 20 mm
Mould draw 1°
Threaded inserts can be insert moulded or fitted later yes
Snap-fitting connections no
Moulding shrinkage 0.4 - 0.7 % (depending on the system)
Density of moulded articles1) 550 - 650 kg/m3
Flexural modulus of elasticity1) 600 - 1050 MPa at a density 500 - 600 kg/m3
Flexural strength1) 25 - 45 MPa at a density 500 - 600 kg/m3
Tensile strength1) 20 MPa
Elongation at break1) 8 %
Impact strength1) 18 KJ/m2
Heat deflection temperature1) up to 118 °C
Compressive strength at 10 % compression2) 18 N/mm2
Shore D surface hardness3) 62 - 70
Coefficient of thermal expansion 73 x 10-6 K-1
Water absorption4) 24h/RT < 0.4 %
Fire performance according to UL test V-0 at 10 mm wall thickness*
Fire performance according to5) B2
Fire performance according to German Federal Railways test6) S4-SR2-ST2*
* with flame retardant1)DIN 53432 2)DIN 53421 3)DIN 53505 4)DIN 53495 5)DIN 4102 6)DIN 5510
Moulded components made from Baydur 60.
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BAYDUR® 110ECONOMICAL PRODUCTION BYTHE RIM PROCESS
Baydur® 110 is a microcellular, solidRIM material which is characterised inparticular by its economical production.Thanks to fast demoulding cycles ofabout 90 seconds, moulded articleswith a wall thickness of preferably 4 to6 mm, high intrinsic stiffness and highstrength can be produced. Aluminiummoulds are used during productionwhich means that no release agents areneeded, resulting in an environmentallyfriendly production process. If required,a flame retardant version of Baydur®
110 in accordance with a variety ofstandards can be supplied.
APPLICATIONS OF
BAYDUR® 110:
Filter frames
Industrial housings of all sorts, e.g.
housings for medical equipment,
automatic vending machines, re-
frigerators.
Outer cabinet of a refrigerator made from Baydur 110.
Cladding round a petrol pump.
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BAYDUR® 110 - TECHNICAL DATA
Preferred wall thickness 3 - 12 mm
Mould draw 1°
Threaded inserts can be insert moulded or fitted later sometimes
Snap-fitting connections possible
Moulding shrinkage 0.5 - 0.8 %
Density of moulded articles1) 1,100 kg/m3
Flexural modulus of elasticity2) 2,000 N/mm2
Flexural strength3)
Tensile strength4) 53/43 MPa (FR grades)
Elongation at break4) 14 %
Impact strength5) 45 KJ/m3
Heat deflection temperature6) 115 °C method B
Shore D surface hardness 75 - 77
Coefficient of thermal expansion - at RT 90 x 10-6 K-1
- at 60 °C 105 x 10-6 K-1
Water absorption7) 24h/RT< 0.6 %
Fire performance according to UL test V-0 as from 3 mm wall thickness*
Fire performance according to8) B2
Fire performance according to German Federal Railways test9) S4-SR2-ST2*
* with flame retardant1)DIN 53479 2)DIN 53457 3)DIN 53452 4)DIN 53455 5)DIN 53453 6)DIN 53461 7)DIN 53495 8)DIN 4102 9)DIN 5510
Baydur® 110 is an especially economical
polyurethane product due to improved
production parameters such as high
reactivity (fast demould times), lack of
release agent (time-saving) and high
density (defect-free surfaces).
BAYDUR® GSSOLID CASTING SYSTEM
Baydur® GS is a solid casting system,enabling a simplified, pressurelesscasting process which permits the useof low-cost epoxy resin moulds forshort 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 pig-
ment. If the economic viability or other
features of the material need to be opti-
mised, 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
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BAYDUR® GS - TECHNICAL DATA
Preferred wall thickness 4 - 30 mm
Mould draw 1.1 - 1.5°
Threaded inserts can be insert
moulded or fitted later yes
Snap-fitting connections no
Moulding shrinkage 1.2 - 2.9 %, depending on the system, fillers and wall thickness
Density of moulded articles1) 1,180 kg/m3
Flexural modulus of elasticity2) 1,300 MPa
Flexural strength3) 60 MPa
Tensile strength4) 43 MPa
Elongation at break4) 21 %
Impact strength5) 60 KJ/m2
Heat deflection temperature6) 110 °C
Shore D surface hardness7) 74
Coefficient of thermal expansion 110 x 10-6 K-1
Fire performance according to UL test V-0, only highly filled
Fire performance according to8) B2
Fire performance according to
German Federal Railways test9) S4-SR2-ST21)DIN 53479 2)DIN 53457 3)DIN 53452 4)DIN 53455 5)DIN 53453 6)DIN 53461 7)DIN 53505 8)DIN 4102 9)DIN 5510 with additives
Propeller for an agitator made from Baydur GS (blue-pigmented).
Cladding for a control valve.
Housing for a signalling lamp (black-pigmented).
BAYFLEX® 20/30SKIN-TOLERANT AND NON-SLIP
Bayflex 20/30 is one of Bayer's elasticintegral skin foam systems, with a den-sity 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 elas-
tic 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.
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.
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Armrests and upholstery of a hairdresser'schair made from Bayflex 20/30.
Non-skid industrial mats.
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
BAYFLEX® 20/30 - TECHNICAL DATA
For example, the CFC-free system Bayflex 50 IK 33
Density1) 400 kg/m3 600 kg/m3
Shore A hardness2) 35 50
Tensile strength3) 0.73 MPa 1.6 MPa
Elongation at break3) 85 % 90 %
Weather resistance4) 1.4 KN/m 2.2 KN/m
Compressive stress, 10 % deformation 123 KPa 248 KPa
Compression set (25 %/70 h, RT)5) 2.5 % 3.1 %1)DIN 53420 2)DIN 53505 3)DIN 53504 4)DIN 53515 5)DIN 53572
BAYFLEX® RIM/RRIMIMPACT RESISTANT EVEN IN A SEVERE FROST
Bayflex® RIM is a variant of microcellu-lar, solid polyurethane material which ischaracterised in particular by its highimpact resistance, even in an extremelycold environment. In order to increasethe stiffness, glass fibres may be incor-porated 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
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APPLICATIONS OF
BAYFLEX® RIM/RRIM
Snow-scooter hoods
Large panels for agricultural and
construction machinery
BAYFLEX® XGT - TECHNICAL DATA
Density1) 1,181 kg/m3
Flexural modulus of elasticity, ASTM-D790 981 MPa
Tensile strength2) 34 MPa
Elongation at break2) 135 %
Tensile modulus of elasticity3) 870 MPa
Tear propagation resistance4) 100 KN/m
Impact resistance5) no failure
Notched impact resistance5) 14 KJ/m3
HDT ISO-R-75/B 65 °C
Shore D hardness6) 691)DIN 53420 2)DIN 53571 3)DIN 53457 4)DIN 53515 5)DIN 53453 6)DIN 53505
BAYFLEX® 110 - 50/180 - TECHNICAL DATA
Bayflex® 110-50 + 15 parts by Bayflex® 180 + 20 parts
wt. glass fibres by wt. mineral fibres
Density 1,150 kg/m3 1,200 kg/m3
Flexural modulus 700 MPa 1,650 MPa
Tensile strength 20 MPa 23 MPa
Elongation at break 93 % 148 %
Impact resistance 432 J/m 200 J/m
Sag test 71 mm 10 mm
1 h 120 °C - 15 cm overhang
(values determined in direction of fibres)
Truck bonnet madefrom Bayflex 110.
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 re-
sistance, Bayflex 180 has a high intrinsic
rigidity.
Bayer AG, Germany
Deltapur, ItalyBayer HispaniaIndustrial, S.A.
Bayer (Pty.) Ltd.,South Africa
Bayer Corporation,USA
Bayer de Mexico S.A. de C.V.
Bayer S.A., Brazil
Bayer de Venezuela S.A.
Bayer Argentina S.A.
SumitomoBayer UrethaneCo. Ltd., Japan
Bayer JinlingPolyurethane Co.Nanjing / Pec Ltd.
Bayer SingaporePte. Ltd.
Production plantsMarketing centresSales offices
PROSPECTS FOR POLYURETHANESUNTAPPED POTENTIAL STILL EXISTS
Although Baydur® and Bayflex® havealready been on the market for a con-siderable length of time, no end can beseen to the world-wide boom. Devel-opment of the full range of properties isnow complete, but all fields of use havenot yet been opened up. Since the prop-erties of the Baydur® and Bayflex®
systems can be specifically tailored toindividual applications, there are stillplenty of opportunities to be grasped.
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World-wide production, marketing and sales; the short route to customers.
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 pack-
ages to comply with different stan-
dards.
Providing design and application-ori-
ented 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!
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