This paper describes the basic principles of non-sagging polyurethane compositions as well as a wide variety of applications for this technology. Applications for nonsagging polyurethanes include: structural adhesives for SMC, expandable caulkings and sealants, furniture edging, carpet seam sealants, and flexible, sandable patching compounds.

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Attachments are critical for the performance of sandwich composites in automotive components. In this paper, Bayer continues its investigation on attachments techniques and focus on a procedure to embed and test attachments for polyurethane-based sandwich composites. In developing reliable attachment techniques and methods for evaluation and design, Bayer opens new application possibilities for this family of composites in the automotive market.

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The implementation of metal stampings combined with injection molded 30% glass fiber reinforced polyamide type 6 (PA6-GF30%) for commercial passenger car and truck front end modules has grown in the automotive industry over the past five years. This patented Plastic-Metal Hybrid (PMH) design technology has proven its ability to enable the automotive original equipment manufacturer (OEM) to engage a flexible assembly strategy, decrease capital expenditures and reduce labor hours required to manufacture a vehicle. The roof module is an opportunity to further develop content by combining adhesives, coatings, film and reinforced polyurethane (PUR) composite materials with PMH technology. The powerful combination provides the OEM a component ready to assemble. This paper presents a roof module concept that utilizes PMH to create a roof frame welded to the body-in-white (BIW) structure that is capable of going though on-line electro-static coating (E-coat) processes. The frame becomes a common footprint upon which a variety of roof modules constructed with PUR composites protected by coating and film can be attached to the vehicle with adhesive.

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A variety of different materials have been considered and implemented for occupant protection in automotive head impact countermeasures since the beginning of the 5-year phase in of FMVSS 201 (Upper). This paper will show that polyurethane foams are superior at retaining their energy absorbing characteristics over the service temperature range of –30 to 85° C.

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This paper compares different types of polyurethane automotive seating foam in a variety of static and dynamic tests currently used in the automotive industry.

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This paper focuses on the polyurethane reinforced reaction injection molding RRIM process for the production of automotive body parts. Bayer examines the elimination of the postcure process in the manufacture of polyurethane RRIM composite automotive body panels and the significant savings that would reduce. The paper profiles Bayer's Bayflex 180 polyurethane RRIM system and Bayflex 190 polyurethane RRIM system.

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Bayer has developed a methodology to systematically evaluate different polyurethane foam technologies for automotive seating at constant density and hardness.

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This research presents information demonstrating the dependence of comfort properties, such as vibrational transmissivity and quasi-static hysteresis, on polyurethane foam thickness and foam chemistry in automotive seating.

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Natural fiber-reinforced polyurethanes are being used more and more in the automotive industry. This paper describes efficient process engineering for manufacturing automotive trim from a combination of a natural fiber mat and a polyurethane system.

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This slide presentation by Bayer MaterialScience discusses the applications, manufacturing processes and equipment for three Structural Reaction Injection Molding (SRIM) technologies - Low Density-SRIM Composites, High Density-SRIM Composites, and Polyurethane Natural Mat and Honeycomb Composites for use in a variety of automotive applications.

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Advanced composite technologies have become significant to use for interior applications in order to meet the market demands to produce lighter weight cars and trucks. Bayer has developed Baypreg F polyurethane systems that can be utilized with different combinations of reinforcing mats and honeycomb cores to manufacture interior composite parts.

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Bayer Corporation has been engaged in extensive development of high- density structural RIM (HDSRIM)materials during the past several years. This paper addresses HDSRIM technology from its infancy as bumper beams to its present maturity as full-size pick-up truck composite boxes and tailgates. This paper also discusses implementation of the HDSRIM technology to those areas beyond the present applications.

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Bayer Corporation has developed a PU foam system, which will be marketed by Orbseal to Automotive OEM’s. It expands to 5000% of its initial volume. The low-density foam resulting from the high expansion rate allows for a complete acoustic seal and provides material savings of up to 30% while still meeting OEM requirements on Insertion Loss.

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This presentation describes a new, promising method for simultaneously recycling combinations of polyurethane foam - polyurethane headliner foam scrap, scrap from the production of complete headliners and post-consumer scrap from the dismantling of ELVs.

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Bayer MaterialScience continues to develop new composite technologies combining a lightweight, lowdensity core together with fiber-reinforced polyurethane skins. The polyurethane chemical system, designated as Baypreg® F, is an integral part of this composite technology that produces parts with a high stiffness to weight ratio.

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Bayer MaterialScience has been engaged in extensive development of Structural RIM (SRIM) polyurethane materials for over two decades. Out of these developments two traditional technologies, plus another new one, have evolved. These afford the automotive designers as well as the engineers to capitalize on the composite advantages that are increasing with the demand for lighter weight cars and trucks. This paper discusses these three composite technologies.

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An HFC-245fa system for discontinuous metal panels has been developed. The system passed ASTM E-84 Class I* requirements of <25 flamespread and <450 smoke at 3.5 inches. Further development work at Bayer is focused on improving the firmness at demold and optimization of physical and processing properties.

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This paper describes a new Baytec® MAX (MDI amine crosslinked) prepolymer product line, consisting of novel polyester and polyether prepolymers produced from diphenylmethanediisocyanate. These prepolymers demonstrate reactivities similar to that of corresponding, free-monomer stripped 2,4- TDI prepolymers when extended with diamine co-reactants such as MbOCA and MCDEA, and produce polyurethaneurea elastomers with comparable physical properties.

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Segmented poly(urethane-urea)s have been synthesized, via a two-stage polymerization, with mixed soft segments of ultra-low monol content poly (propylene glycol) (PPG) and tri(propylene glycol) (TPG) which allows the fabrication of quality elastomers without crosslinking.

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Biomonitoring holds the promise of an integrative measure to estimate the total internal dose to an individual resulting from exposure to diisocyanate via different routes, such as inhalation and skin contact.

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New rules defining transportation, loading, unloading and storage incidental to transportation and accident/incident reporting procedures may have a drastic affect upon your shipping and receiving of hazardous materials.

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FOOTWEAR - A study of improved formulations for microcellular polyurethane foams used for footwear soling and other applications.

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The insulated pipe manufacturers in North America have traditionally used materials such as asbestos, calcium silicate, mineral wool and fiberglass to insulate pipes used for applications above 250°F. The insulating material is usually wrapped around and secured to the pipe. Rigid polyurethane foam can be molded around a pipe, cut from bunstock and secured to a pipe or sprayed on a rotating pipe.

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This paper describes a mid-infrared spectroscopic procedure for the determination of the poly(oxypropylene) polyol hydroxyl number.

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When using reaction injection molding (RIM), there is a body of laws, principles and recommendations derived from observations to follow for gate design and placement. Close consideration of these will improve the chances of a successful project.

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This paper will help fabricators in the composites industry understand how the RIM process works, the advantages of the RIM process and the key materials used with the RIM process, as well as new developments taking place in processing and materials.

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Low-density polyurethane composites offer significant advantages. The presentation will provide a primer on the following: Polyurethane foams; Reinforcing polyurethane foam with glass fibers; Applications; Comparison of properties and cost of low-density polyurethane composites to polyester FRP; Advantages.

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This paper focuses on exciting, new developments and innovations in reaction injection molding processing, materials and equipment. RIM is a premier plastics molding process that offers versatility in processing options and chemical systems used to produce high-quality, highly styled plastic products.

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The various mechanical recycling technologies presented as part of this technical paper have greatly contributed to improve the overall image regarding the recyclability of polyurethanes in recent years.

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