BAYPREG Brosch GB neu_A4.fh11 - BaySystems - customized ...

– NO LIMIT – A TOUGH LIGHTWEIGHT FOR COMPOSITE PRODUCTION

THE PU COMPOSITE SYSTEM FOR
THE SPORTS AND LEISURE INDUSTRY
Customers of up-market sports and leisure equipment
tend to be very well informed. They know exactly
what performance they expect from their equipment
and they want a design that suits their lifestyle.
TOUGH AND LIGHTWEIGHT FOR COMPOSITE PRODUCTION
When they buy something, they send a clear
message to the manufacturers about the quality
and durability they want from the products
and about the desired level of innovation.
The key factors for the equipment manufacturers
are the versatility of the polyurethane components
used to make the products and an optimum
production process. Criteria such as environmental
protection and customization are also becoming
increasingly important.
The BAYPREG ® 2-component polyurethane system
satisfies all these requirements. Its outstanding
versatility sets completely new standards both
in industrial-scale production and in small-scale
customized manufacture.

CONTENTS
4 Baypreg ®
, the future-proof alternative
6 An extremely versatile material
8 Manufacturers hold the trump cards
10 Unbeatable processing advantages
12 Facts and figures
14 Everything is possible...
16 An alliance with nature – A successful partnership
18 Your contacts: All you need to know

4
Rear section of camper van
with a core of expanded polystyrene
THE FUTURE-PROOF
ALTERNATIVE
...to conventional epoxy resins.
Baypreg ® has been successfully used for the production of
composite polyurethane parts since 1990. Over the years, the
product range has been extended from the original core
business of water sports and now covers the entire leisure
segment. Key applications are in the camping, skiing and
snowboarding segments. Many leading manufacturers of
high-strength moldings see Baypreg ® as a convincing alternative
to conventional epoxy resins. The arguments for using
Baypreg ® are indeed persuasive, because Baypreg ®
- is solvent-free
- is suitable for all compression molding processes
- is compatible with almost any core materials such as
polystyrene, wood, plastics, PU, aluminum and paper
honeycomb
- can be processed with many reinforcing fiber materials
(e.g. glass, carbon and natural fibers)

Baypreg ® , in this case Baypreg ® F, a grade developed espe-
cially for automotive applications – has been used in the automotive
industry for many years in fully automated processes.
Paper honeycomb structures are generally used as the core
material in combination with natural fibers or glass fibers for
surface reinforcement.
Sailing boat with
glass fiber reinforcement
Wakeboard with
glass fiber reinforcement
Baypreg ® is also the product of choice when parts cannot be
produced on automated production lines due to their complicated
shape or complex design. By modifying the system
to make it react more slowly, Baypreg ® provides an easy-touse,
economical solution for prototypes, small production
runs or special customized products. This is especially useful
for medium-sized companies.
Natural fiber composites
5

6
BAYPREG ®
GLASS-FIBER
COMPOSITES
•
AN EXTREMELY
VERSATILE MATERIAL
Baypreg ® parts made of glass fiber-reinforced boast a range
of truly outstanding properties including very high impact
strength and torsional rigidity even at low temperatures.
Typical applications include sandwich elements for the sports
and leisure sector, such as snowboards, wakeboards and
skis, where maximum demands are made on the material's
properties.
• Rescue board – Manufacturer:
Karl Niedersüss, Rohrbach, Austria

Baypreg ® parts reinforced with natural fibers have
extra stability and are especially light in weight.
Baypreg ® has an extremely wide range of applications.
It is used, for example, to manufacture steps and rear
sections for recreational vehicles (RVs), trunk floors,
tables and wall panels, floors and walls for stage
building, and ultra-light rescue boards for use in
accidents and emergencies.
Glass fiber mat
•
BAYPREG ®
NATURAL FIBER COMPOSITES
•• Table made of Baypreg ® – Manufacturer:
Triple-E Meubilair B. V., Winsum (F.R.), NL
••
Natural fiber mat
7

Glass fiber – impregnated with BAYPREG ®
Natural fiber – impregnated with BAYPREG ®
Aramid fiber – impregnated with BAYPREG ®
MANUFACTURERS
HOLD THE TRUMP CARDS
Baypreg ® is available in two versions:
– As a resin for sandwich structures where an optimum
bond between the individual elements is essential.
The material is also suitable for bonding decorative
surfaces.
– As a resin incorporating a release agent for molded
articles without decorative facings, for example structural
components in interior applications.

A MATERIAL WITH
MANY FACES
Baypreg ® can be readily processed with all kinds of
conventional fiber materials such as glass carbon
and natural fibers. Because of the relatively low
viscosity of BAYPREG ® , outstanding wetting and
saturation of the fiber materials is ensured.
Baypreg ® provides an excellent bond to many core
materials such as polyurethane, polystyrene, wood
and various honeycomb structures. It can be processed
at a wide range of mold temperatures,
extending from 120 °C down to just 65 °C. This means
that BAYPREG ® can also be used in combination
with heat-sensitive inserts and decorative films.
• Step for a camper van – Manufacturer:
Formtec, PUR-Verarbeitungs GmbH, Dornstetten, D
•
Carbon fiber mat
9
Core materials

10
UNBEATABLE
PROCESSING ADVANTAGES
Long potlife
Once the two components have been mixed together in a
cup, it takes 3 – 10 minutes for the initial thermal reaction
to start. The actual chemical reaction begins after 10 – 20
minutes and ends with solidification after a further 3 – 5
minutes (all figures are approximate). This means the
mixture can be processed by hand for up to 25 minutes at
ambient temperatures of between 20 and 23 °C.
Compression mold
Spray head
Long open time for the impregnated fiber
After application of the reactive mix using a 2-component
spray machine, the impregnated fiber has an open time of
up to 45 minutes at room temperature (20 – 23 °C). This
means that the fiber can be further processed in this period
without any loss of quality.
Short mold residence time
Introducing the impregnated fiber material into the heated
mold triggers the controlled reaction of the 2-component
system. The reaction is soon completed and the part cures
very quickly.
Low mold temperatures
Under normal circumstances, a mold temperature of 80 °C
is enough to ensure rapid, economical curing. However,
because temperatures of up to 120 °C are also possible,
the mold residence times can be shortened considerably
if desired. In special cases – if, for example, heat-sensitive
inserts or decorative films are being used – the mold
temperature can be reduced to 65 °C, although the parts
will then naturally have to spend longer in the mold in
order to achieve top-quality results.
No post-curing necessary
Following removal from the mold and subsequent cooling,
the composite part attains its final strength without any
need for annealing. As a result, energy costs can be lowered.
These energy savings, in combination with the shorter
production cycles made possible by the reduced mold
residence times, make an important contribution to costeffective
production.

Free of solvents
Because Baypreg ® is solvent-free, it presents few problems
in terms of safety and toxicology when processed
by compression molding. Nevertheless, the safety precautions
listed in the EU directives must be observed during
processing.
A TOUGH LIGHTWEIGHT FOR COMPOSITE PRODUCTION
Outstanding mechanical properties
The composite materials have high tensile and flexural
strength despite their low weight per unit area. The glass
transition temperature (approx. 100 °C) is also superior
to that of many comparable materials.
High impact strength
Glass fiber composites are noted for their extremely high
impact strength even at very low temperatures.
Unlimited design freedom
Baypreg ® can also be used to make parts with complex
geometries. Fasteners, fixing devices or stabilizers can be
directly integrated, and subsequent machining is also
possible.
... but that's not all
If short cycle times and high productivity are imperative,
ultra-fast Baypreg ® F systems developed specifically for
the automotive industry by Bayer MaterialScience are the
answer.
11

•
12
Baypreg ® sheets
without fiber mats
••
Baypreg ® laminate
with 65% glass fiber
• Camper van steps, load test
•• Fracture under load
force > 4,000 N
Flexural tests
Flex modulus (N/mm 2 )
Flexural stress (N/mm 2 )
Outer fiber strain (%)
Tensile tests
Tensile E-modulus (MPa)
Tensile stress (MPa)
Impact test
Impact strength (kJ/m2 )
Torsion pendulum test
Glass transition temp. (Tg °C)
Viscosity D48/s 25°C
Flexural tests
Flex modulus (N/mm2)
Flexural stress (N/mm2)
Outer fiber strain (%)
Tensile tests
Tensile E-modulus (MPa)
Tensile stress (MPa)
Torsion pendulum test
Glass transition temp. (Tg °C)
FACTS AND FIGURES
Baypreg ®
2872
98
4,63
3106
64
18,27
90
Baypreg ®
with internal
release agent
1400
24500
690
3,35
22200
450
90
Baypreg ®
with internal
release agent
2625
94
5,36
2684
59
22,83
90
Baypreg ®
low viscosity
2100
21200
650
3,35
26800
450
90
Baypreg ®
high viscosity
5400
27700
756
3,42
27500
480
105

10 4
8
6
4
2
10 3
8
6
4
2
10 2
8
6
4
2
10 1
8
6
4
2
0
SPECIALIST INFORMATION:
GLASS TRANSITION TEMPERATURE
Torsion pendulum process DIN EN ISO 6721-2 B
Material: Baypreg ® VP PU 60BV 11
w: 7,96 mm / h: 1,22mm / L: 50 mm
10 0
10 -1
10
Torsion storage modulus G’ to
Damping tan �
Elongation �
°C -100 -80 -60 -40 -20 0 20 40 60 80 100 120 140 160 180 200 220 240 °C
13

14
2-comp. metering/spraying unit
- Baypreg ® systems are normally processed with fiber
materials by compression molding. This requires a heatable
mold made of aluminum or steel, capable of resisting a
clamping pressure of 5 bar.
Spraying Compression molding
EVERYTHING IS
POSSIBLE...
- The BAYPREG ® components can be metered and mixed
manually or processed on an industrial scale on 2-component
polyurethane machines. The ready-to-use polyurethane
system is then applied to one or both sides of the fiber
material by pouring or spraying.

Opening
- The fiber material is cut to size and placed in the mold,
which may be treated with release agent.
- If the fiber mat is treated outside the heated mold, open
times of up to 45 minutes at room temperature (20 – 23 °C)
are possible. Closing the heated mold triggers the forming
and curing process.
THE VARIABLE POLYURETHANE
COMPOSITE SYSTEM
Compression molding time as
a function of temperature
Formtemperatur (°C)
120
100
80
65
Molding time (min)
2 - 3
4 - 5
6 - 8
12 - 13
Further processing
15

16
• Trunk floor
•• Composite component
••• Trunk lid
TOUGH AND LIGHTWEIGHT FOR COMPOSITE PRODUCTION
• ••
AN ALLIANCE WITH NATURE –
A SUCCESSFUL PARTNERSHIP
In modern-day industrial production, natural fibers like hemp,
flax and sisal are making an unexpected comeback. In combination
with natural fibers, Bayer MaterialScience's Baypreg ®
polyurethane system produces high-quality, hard-wearing,
break-resistant and lightweight composite parts that can resist
even severe mechanical stresses and long-term vibrations.
•••

•
AN ALLIANCE WITH NATURE –
FOR THE SAKE OF THE ENVIRONMENT
Combining Baypreg ® with an ecologically friendly core material
such as a honeycomb made of recycled paper results in a
modern, innovative system for the manufacture of high-tech
products using renewable raw materials. It is also entirely
free of solvents. The use of annual plants like hemp, sisal and
flax as renewable resources encourages their cultivation.
•• •••
By virtue of their rapid growth, the plants reduce the content
of carbon dioxide (CO2 ) in the environment. On incineration
of the solvent-free parts at the end of their useful life, the
CO2 originally bound by the plant is released back into the
natural cycle.
• Klapptisch
•• Flachssamen
••• Hanfgewebematte
17

18
YOUR CONTACTS:
ALL YOU NEED TO KNOW
Would you like to find out more about Baypreg ® ?
We have all the information you need.
Just give us a call.
TOUGH AND LIGHTWEIGHT FOR COMPOSITE PRODUCTION
Elke Springer
Bayer MaterialScience AG
BaySystems Elastomers
Spraying & Reinforcement
51368 Leverkusen
Tel. ++49 – 214 30 2 67 17
Fax ++49 – 214 30 2 62 93
elke.springer@ bayerbms.com
Dr. Dirk Wegener
Bayer MaterialScience AG
BaySystems Elastomers
Spraying & Reinforcement
51368 Leverkusen
Tel. ++49 – 214 30 3 12 03
Fax ++49 – 214 30 2 62 93
dirk.wegener@ bayerbms.com

This information and our technical advice – whether verbal, in writing or by way of trials – are given in good faith but without warranty,
and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify
the information currently provided – especially that contained in our safety data and technical information sheets – and to test our
products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products
manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our
products are sold in accordance with the current version of our General Conditions of Sale and Delivery.
Edition: 2007-02 · Order no.: MS005090 · Printed in Germany · E
Bayer MaterialScience AG
51368 Leverkusen, Deutschland
www.bayermaterialscience.de