One-step processing technology of anti-UV polyurethane material Leverkusen, October 2007 - Bright, light-stable surface finishes made of polyurethane materials are now ready for production through the Reaction Injection Molding (RIM) process. This is the result of close cooperation between Bayer MaterialScience and the Faurecia Group. Faurecia is mainly engaged in the production of large-volume surface decoration materials for medium and high-end automobiles. The two parties worked together to optimize the production process and the aliphatic polyurethane material system to produce high quality interior materials in pre-production molds. Gregor Murlowski, polyurethane surface material specialist at Bayer MaterialScience's Polyurethanes business unit, said: "As a polyurethane body material coating technology and in-mold coating RIM technology, this solution has a high cost performance. We have already anticipated the huge application of this material. Potential, especially as surface finish materials for automotive and commercial vehicle interior components such as instrument panels, armrests, center consoles and door trims.†Light-stabilized Bayflex® LS (light stable) is the new technology Made of polyurethane material. About BaySystems® About Bayer MaterialScience Bayer MaterialScience is one of the world's largest polymer producers with sales of 10.2 billion euros (continued) in 2006. Its business scope focuses on the development of high-tech polymer materials and innovative solutions for many areas of daily life. The industries served include: automotive, electronics and electrical, construction and sports and leisure. At the end of 2006, Bayer MaterialScience had 30 production sites and approximately 14,900 employees worldwide. Bayer MaterialScience is part of the Bayer Group.
Asbestos was added as an common ingredient to Brake Pads post-WWI, as car speeds began to increase, because research showed that its properties allowed it to absorb the heat (which can reach 500 °F) while still providing the friction necessary to stop a vehicle. However, as the serious health-related hazards of asbestos eventually started to become apparent, other materials had to be found. Asbestos brake pads have largely been replaced by non-asbestos organic (NAO) materials in first world countries. Today, brake pad materials are classified into one of four principal categories, as follows:
Non-metallic materials - these are made from a combination of various synthetic substances bonded into a composite, principally in the form of cellulose, aramid, PAN, and sintered glass. They are gentle on rotors, but produce a fair amount of dust, thus having a short service life.
Semi-metallic materials - synthetics mixed with varying proportions of flaked metals. These are harder than non-metallic pads, more fade-resistant and longer lasting, but at the cost of increased wear to the rotor/drum which then must be replaced sooner. They also require more actuating force than non-metallic pads in order to generate braking torque.
Fully metallic materials - these pads are used only in racing vehicles, and are composed of sintered steel without any synthetic additives. They are very long-lasting, but require more force to slow a vehicle while wearing off the rotors faster. They also tend to be very loud.
Ceramic materials - Composed of clay and porcelain bonded to copper flakes and filaments, these are a good compromise between the durability of the metal pads, grip and fade resistance of the synthetic variety. Their principal drawback, however, is that unlike the previous three types, despite the presence of the copper (which has a high thermal conductivity), ceramic pads generally do not dissipate heat well, which can eventually cause the pads or other components of the braking system to warp.However, because the ceramic materials causes the braking sound to be elevated beyond that of human hearing, they are exceptionally quiet.
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The light stable surface Decoration material in RIM technology has a short production cycle and good mold replication.
The aliphatic RIM surface material is produced in a one-step process and is therefore more cost-effective than the mold internal coating (IMC). In this method, the decorative coating is first sprayed into the mold, and the second step is the aromatic polyurethane material system by RIM technology. injection. However, despite the high quality of the polyurethane surface material produced by this method, the two-step processing cycle is longer, and the investment in molds and equipment is greater. These disadvantages must be considered.
The production of polyurethane surface spray materials in open molds also causes unnecessary material build-up, resulting in an irregular touch on the surface of the material.
“By comparing, even when the edge of the material is difficult to measure or the geometry is complex, the RIM process can accurately determine the thickness of the material wall when the nozzle cannot be accurately positioned. This prevents the material from accumulating,†explains Murlowski. This high degree of precision in determining the wall thickness of the material allows the seam connection of the concealed airbag to be accurate. The greater advantage of the RIM process is that it can reduce costs. Murlowski revealed: "Based on the parts in production, we expect this process to be 50% faster than polyurethane surface coating technology."
Compared to other materials, Bayflex® LS is based on UV-resistant aliphatic polyurethane materials, which means it can be painted in bright colors. The production of colored RIM surface materials has been optimized in terms of material flowability, depth of break, feel and scratch resistance. Bayflex® LS can be used to produce matte, dazzling surfaces.
Bayer MaterialScience offers more ideal materials for manufacturers of polyurethane surface finishes using the new RIM process. The company conducts rigorous surface material testing in accordance with OEM specifications such as heat aging, photoaging, volatility and tensile strength. Company services also include support for mold design processes and software to optimize flow and castability.
Since March 1, 2007, Bayer MaterialScience has incorporated its entire global polyurethane systems business under the umbrella of BaySystems®. This change involves not only existing brands in the industry, including Baytec® SPR, but also the global polyurethane system network and the company's support for customers in the global footwear industry. For more information on BaySystems®, please visit