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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


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.


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


G R A D E S W I T H A U N I Q U E

P R O F I L E


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


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


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


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



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.


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


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



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.


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


M E D I C I N E & T E C H NO LO GY



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


E L E C T R O N I C S &

E N T E R TA I NM E N T




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.


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



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


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


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



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


Bayer MaterialScience AG

Business Unit Polyurethanes

51368 Leverkusen

Germany


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


design unlimited baydur bayflex - purmold · design unlimited baydur® bayflex ... and here are...

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