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Strong, light parts from polyurethane
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Strong, light parts from polyurethane A STRONG, lightweight motorhome rear end has been developed by two German plastics firms. The motorhome part has been produced by Formtec PUR-Verarbeitungs GmbH of Dornstetten and Leverkusenbased firm Bayer MaterialScience AG. The motorhomes are manufactured by Hymer AG of Bad Waldsee, Germany. The part consists of a sandwich element comprising a core made of expanded polystyrene and two natural fibre facings joined together with Baypreg® polyurethane spray system. The element is made by impregnating the natural fibre mats with the spray and placing them in an open mould along with the core layer and another layer of impregnated natural fibre mat. Bayer says the polyurethane cures in ten minutes. Bayer says that a part using this type of natural fibre reinforced plastic can be very lightweight. The product measures 200 cm by 50 cm but weighs only 11 kg.
Bayer reports that using the Baypreg polyurethane spray system makes the process quicker when compared with epoxy resin systems by reducing the need for aftertreatment of the moulded part, and that the impact and torsional resistance are improved. The company also says that the system also eliminates the need for additional solvents and works at a lower processing temperature. According to Elke Springer who helped develop the part at Bayer, the system also allows greater design complexity. “The compression process allows a very high degree of design freedom,” she explains. “For instance, the rear end manufactured by Formtec has a tricky ‘L’ shape with exterior grooves and projections.” Various core materials, such as expanded polystyrene or rigid foams can be used with the system. Bayer MaterialScience AG; fax: +49-221-9902-160; website: www.bayermaterial-science.com.
The sandwich composite rear end of the motorhome.
June 2004
REINFORCEDplastics
7
Strong, light parts from polyurethane A STRONG, lightweight motorhome rear end has been developed by two German plastics firms. The motorhome part has been produced by Formtec PUR-Verarbeitungs GmbH of Dornstetten and Leverkusenbased firm Bayer MaterialScience AG. The motorhomes are manufactured by Hymer AG of Bad Waldsee, Germany. The part consists of a sandwich element comprising a core made of expanded polystyrene and two natural fibre facings joined together with Baypreg® polyurethane spray system. The element is made by impregnating the natural fibre mats with the spray and placing them in an open mould along with the core layer and another layer of impregnated natural fibre mat. Bayer says the polyurethane cures in ten minutes. Bayer says that a part using this type of natural fibre reinforced plastic can be very lightweight. The product measures 200 cm by 50 cm but weighs only 11 kg.
Bayer reports that using the Baypreg polyurethane spray system makes the process quicker when compared with epoxy resin systems by reducing the need for aftertreatment of the moulded part, and that the impact and torsional resistance are improved. The company also says that the system also eliminates the need for additional solvents and works at a lower processing temperature. According to Elke Springer who helped develop the part at Bayer, the system also allows greater design complexity. “The compression process allows a very high degree of design freedom,” she explains. “For instance, the rear end manufactured by Formtec has a tricky ‘L’ shape with exterior grooves and projections.” Various core materials, such as expanded polystyrene or rigid foams can be used with the system. Bayer MaterialScience AG; fax: +49-221-9902-160; website: www.bayermaterial-science.com.
The sandwich composite rear end of the motorhome.
June 2004
REINFORCEDplastics
7