Bayer MaterialScience LLC

Bayer MaterialScience, Pittsburgh, will acquire the U.S. polycarbonate sheet business of Arkema Inc., Philadelphia.

WEB EXCLUSIVE: At the recent MD&M West show in Anaheim, Calif., Bayer MaterialScience introduced two Bayblend PC/ABS grades for medical equipment.

Process involves dipping the parts in an aqueous bath for a short period

WEB EXCLUSIVE: What’s described as a “premium” PC/PET alloy for horizontal automotive body panels is made from the “highest quality post-consumer and post-industrial recyclates,” according to Bayer MaterialScience, Pittsburgh.

WEB EXCLUSIVE: At October’s Fakuma 2011 show in Germany, BASF and Arburg teamed up in a demonstration of energy-efficient injection molding.

Going a step beyond the bullet-resistant security glazing familiar in banks and taxicabs, a new type of “structural envelope” based on a special polycarbonate sheet laminate from Bayer MaterialScience LLC, Pittsburgh, is said to establish a new level of bomb-blast resistance for building structures.

WEB EXCLUSIVE: Going a step beyond the bullet-resistant security glazing familiar in banks and taxicabs, a new type of “structural envelope” based on a special polycarbonate sheet laminate from Bayer MaterialScience LLC, Pittsburgh, is said to establish a new level of bomb-blast resistance for building structures.

WEB EXCLUSIVE: A high-flow polycarbonate and three TPUs have been introduced for medical applications by Bayer MaterialScience LLC, Pittsburgh.

 WEB EXCLUSIVE: One of two recent developments in polycarbonate films allows cost-effective integration of antennas into cell phones via printed electronics and film insert molding (FIM), also known as in-mold decorating (IMD). Bayer MateriaScience AG in Germany (U.S. office in Pittsburgh) has applied for a patent on a method of using printed electronics on PC films, which are then back-molded into cell-phone housings.

WEB EXCLUSIVE: The new Makrofol HF family of scratchproof, hard-coated polycarbonate films can be back-printed, 3D formed, trimmed, and then back-injected in a film insert molding process without damaging the coating.

WEB EXCLUSIVE: A new flame-retardant polycarbonate for LED lenses and covers allows these parts to be molded thinner than ever.

WEB EXCLUSIVE: The new Bugatti Veyron 16.4 Grand Sport combines the looks of an open-top roadster with the dynamics and safety of a closed vehicle.

Additives that render plastic compounds antistatic or electrically and/or thermally conductive are in hot demand.

WEB EXCLUSIVE: Two new developments from Bayer MaterialScience LLC, Pittsburgh, are said to provide new capabilities in LED lenses and lighting fixtures.

WEB EXCLUSIVE: Improved flow, lubricity, and release characteristics are claimed for new Makrolon Rx1851 medical-grade polycarbonate from Bayer MaterialScience LLC, Pittsburgh.

WEB EXCLUSIVE: Three new specialized grades of polycarbonate have been developed by Bayer MaterialScience LLC, Pittsburgh.

A new thermoplastic made by a polycondensation process similar to that used for polycarbonate offers high clarity, inherent flame resistance, and broad potential for copolymerization with PC and alloying with styrenics and polyesters.

As we reported in November and January, there is activity in blending polylactide (PLA) bioresins with engineering polymers for use in durable products such as laptops, cellphones, and auto parts.

A cylindrical high-pressure hydrogen tank in development for future automotive applications was made last year by Profile Composites Inc., Sidney, B.C., to prove out a new process (patent pending), funded by the National Center for Manufacturing Sciences in Ann Arbor, Mich.

Bayer MaterialScience AG in Germany (U.S. office in Pittsburgh) has started building a facility to produce carbon nanotubes (CNTs) in Leverkusen, Germany.

Photovoltaic markets are growing explosively, and so are opportunities for specialty film producers. Solar cell and module production, which was forecasted to grow at 50% a year for the next few years before the recession hit, is now expecting slightly more healthy 30% annual growth, according to DuPont, a major supplier of photovoltaic film materials. Solar cell and module manufacturers are expanding, and large numbers of new companies are entering the field.

Having received regulatory approval from the U.S.

Use of polyurethane resin is being pioneered for RTM and its vacuum-assisted variation (VARTM) by BaySystems, a Bayer MaterialScience company, Pittsburgh, as an alternative to unsaturated polyester, vinyl ester, or epoxy.

‘Zero-ODP’ is no longer enough. Now, PUR foamers are being asked to consider blowing agents with ‘low-GWP’ (global warming potential). Another environmental push is to expand use of bio-based polyols in rigid and flexible foams. Both were key topics at this year’s PUR conference.

A new PC/polyester blend from Bayer MaterialScience, Pittsburgh, meets the demands of thinwall overmolding onto metal for consumer electronic devices.

WEB EXCLUSIVE A line of polyurethane resin systems high glass-transition temperature (Tg) and low smoke and flame-spread ratings is newly available in North America for use in high-temperature composites.

A new low-gloss PC/ABS blend from Bayer MaterialScience, Pittsburgh, is aimed at glove-box doors, cup holders, door trim, knee bolsters, console bin doors, and overhead trim.

A new continuous roll-fed machine for high-precision forming and a flexible pressure former for prototyping were among the highlights of the recent 18th Annual SPE Thermoforming Conference in Minneapolis.

Bayer MaterialScience, Pittsburgh, has developed a new line of “eco-compliant” flame-retardant PC/polyester blends that contain no brominated or chlorinated FR additives or heavy metals.

Instead of extruding a colored cap layer onto sheet, profiles, or film, certain clear and opaque polymers can be dyed in a water bath, infusing color about 0.01 in. into the polymer and using a fraction as much colorant as would be used in melt compounding.

A new polycarbonate from Bayer MaterialScience, Pittsburgh, is designed for high-brightness LEDs.

To take advantage of the electrical conductivity and mechanical strength afforded by carbon nanotubes (CNT), Bayer MaterialScience AG in Germany (U.S. office in Pittsburgh) and Clariant Masterbatches (U.S. office in Winchester, Va.) signed a long-term cooperation agreement for development, production, and sales of CNT/thermoplastic compounds and masterbatches.

Bayer MaterialScience AG (U.S. office in Pittsburgh), which recently sold its share of the Exatec joint venture to partner SABIC Innovative Products (formerly GE Plastics), has created a new umbrella brand for its auto-glazing activities.

This first of two articles on directions in TPE development focuses on styrenic, copolyester, polyamide, and TP urethane elastomers. The following article covers olefinics—TPOs, TPVs, and POEs.

Polyurethane equipment at K 2007 in Dusseldorf showed incremental advances in cost-effectiveness and ability to handle a wide range of applications.

WEB EXCLUSIVE Two new antimicrobial PC grades from Bayer MaterialScience, Pittsburgh, use a silver-based inorganic additive to control growth of bacteria on the surface of medical devices.

A novel polyol is designed to produce high-support, high-resilience (HS-HR) flexible PUR slabstock for premium furniture and mattresses.

Two new lines of UV-cure and radiation-cure coating binders for plastics were recently unveiled by Bayer MaterialScience’s Coatings, Adhesives and Sealants business unit (U.S. office in Pittsburgh). Products in both lines can also be used for dual-cure applications.

WEB EXCLUSIVE Bayer MaterialScience, Pittsburgh, has bought intellectual property related to TPU slush molding from the former Collins & Aikman Corp.

Polycarbonate electroluminescent films can provide light in homes, cars, cellphones, and even inside ladies’ handbags.

A license agreement between Dow Chemical Co., Midland, Mich., and Germany's Bayer AG, allows Dow to produce polyether polyols using Bayer's patented Impact technology.

Custom backlighting with color-converting plastics and robotic extrusion of door seals won two categories of the 37th Innovation Awards presented in November by the SPE Automotive Div.

Bayer MaterialScience LLC, Pittsburgh, has added to its BaySystems North America LLC subsidiary by purchasing UCSC, Ltd. of Phoenix, Ariz., a leading supplier of rigid PUR spray foam roofing and wall insulation materials.

Novel polyol technology is designed to produce high-support and high-resilience (HS-HR) flexible PUR slabstock foam that offers excellent comfort and durability in premium furniture cushioning and mattresses.

The hot topic at this year’s PUR conference was rigid and flexible foams with increased biobased content. There was also news in one-component cast elastomers, surfactants, and TPUs.

A surprise announcement at last month’s K 2007 show in Dusseldorf was the sale of its Hennecke Group subsidiary by Bayer AG in Germany.

The last two months have seen several resin capacity announcements: BASF Corp., Engineering Plastics, Wyandotte, Mich., opened what it calls the world’s largest plant for nylon 6 in Freeport, Texas.

Bayer MaterialScience AG in Germany agreed to sell its 50% share in Exatec LLC, Wixom, Mich., to its jointventure partner, GE Plastics, Pittsfield, Mass., just prior to the sale of GE plastics to SABIC of Saudi Arabia.

A new ester-based TPU from Bayer MaterialScience, Pittsburgh, offers transparency, high hardness, and good extrudability for hose applications.

The major thrust in new materials at K is engineering thermoplastics for automotive, appliance, medical, and electrical/electronic parts.

At this year’s K show, look for the launch of fiberglass/polyurethane pultrusion into window frames, as well as several new high-efficiency mixing heads, MDI prepolymers for cast elastomers, and an energy-absorbing PUR foam for car bumpers. PUR pultruded windowsBayer MaterialScience will showcase polyurethane pultrusion technology, which recently has penetrated new applications.

A new version of in-mold decorating technology, developed initially for exterior auto body components, uses dual-cure coating technology to provide a paint film that is both stretchable for good thermoformability and also provides the high gloss and durability of conventional paints.

With capacity scale-ups driving prices down, the pace has picked up for commerical applications that boost electrical and thermal conductivity, structural strength, and thermal stability.

A new family of polyether TPUs is aimed at medical applications like catheters, thin-wall tubing, connectors, luers, stopcocks, films, and fabric coatings.

Is one type of resin dryer faster or more energy-efficient than another? That question prompts competing claims from suppliers—but very little concrete data. When one vendor performed controlled tests to get some answers, its results, published here for the first time, prompted further debate about the difficulties of making valid comparisons and the many complex issues involved in dryer selection.

New amine-cured MDI prepolymers are said to be the fi rst to allow casting MDI-based polyurethane-urea elastomers with superior mechanical properties.

The first medical-grade PC/ABS blends from Bayer MaterialScience, Pittsburgh, have been introduced for opaque parts such as surgical instruments, diagnostic devices, drug-delivery systems, and IV systems.

A proprietary elastomeric rigid foam formulation for polyurethane RIM has been used to produce an under-street valve box (similar to a manhole) to provide access to municipal and residential water lines.

Rigid microcellular polyurethane integral-skin foams produced with the RIM process are making inroads into larger parts than ever before.

A sprayed thick-fi lm coating system is designed for the demanding environment of industrial roofs.

New TPUs containing additives for laser marking are available from Bayer MaterialScience, Pittsburgh.

A sound-attenuating polyurethane elastomer system can be molded into one-piece floor coverings for cab interiors of heavy-duty and long-haul trucks and other heavy equipment.

Thermal insulation has become ‘eco-friendly,’ but now the challenge is to optimize economics, processing, and performance.

Bayer MaterialScience LLC, Pittsburgh, is aiming to restart its damaged TDI unit in Baytown, Texas, next month.

Injection molding of polycarbonate automotive window and roof glazing is an emerging market that offers weight savings up to 50%, greater styling freedom and potential for parts integration (ribs or brackets) that glass cannot match.

Bayer MaterialScience AG in Germany has invested $29 million to establish Lyttron Technology GmbH, a start-up company to produce electroluminescent films at Bayer’s headquarters site in Leverkusen.

A non-contact inspection system uses digital photography for accurate three-dimensional measurement of plastic parts.

Viscoelastic (VE) flexible urethane foams are growing in popularity for pillows, mattresses, and furniture due to their special properties.

Two new bonding and material technologies have been introduced to expand the use of hybrid plastic/metal composites for automotive applications.

Fewer thermoplastic materials suppliers will make the trip to Chicago this year.

Despite the small number of polyurethane and RIM exhibitors, you will find some interesting new materials and equipment technology.One highlight will be a novel aliphatic PUR cast elastomer technology said to enable production of highly transparent parts with unique property profiles.

Injection MoldingSimplified Hot Runners Save Time & CostA new lower-cost hot-runner alternative to valve gating is suited to less critical cosmetic applications where users need predictable and reliable gate opening but not sequential gate operation.

This emerging market promises to be big but challenging. Polycarbonate car windows require specialized machinery, high-end processing capability, premium polymers, advanced coating technologies, and innovative mold and runner designs.

High toughness, fast cure, and no styrene fumes are taking urethane composites beyond SRIM into pultrusion, filament winding, vacuum infusion, and spray-up.

A new polyether TP urethane from Bayer MaterialScience, Pittsburgh, features very high water-vapor permeability, suitable for film coatings on fabrics.

PUR lumber and utility poles challenge standard thermoplastic and thermoset composites. Other show news included ‘tool-less’ molding and new resins and equipment.

After nearly a decade of testing, roofing shakes of RIM polyurethane microcellular rigid foam are making a commercial push to compete with traditional cedar shakes.

A federal agency’s ruling has opened the way for a new polycarbonate window system to be used for all non-windshield glazing, provided it meets all existing auto glazing requirements.

Bayer MaterialScience in Germany and Pittsburgh is sampling customers with carbon nanotubes produced under the name Baytubes.

Ever wonder what it would be like to get tomorrow’s newspaper today? After reviewing the most important technical developments of the past 50 years in our October issue, we asked industry experts to help us imagine the biggest headlines in plastics from now to 2055. What we got was a mixture of predictions of what will happen and a wish list of what should happen.

Whether it was molding thermoplastic and polyurethane foam into one part in one machine, continuously foaming insulation between a metal pipe and thermoplastic skin, or pouring rigid foam behind a thermoplastic skin to replace steel refrigerator doors, there were plenty of novelties in PUR machinery and material among the exhibits at the K 2004 show in Dusseldorf last October.

A great deal of effort is going into formulating rigid and flexible foams for lower cost and better properties, despite the transition to "cleaner" blowing agents. Improving fire and smoke performance is another challenge.

Quite a few new polyolefins are being featured at this year’s show, with a particular emphasis on specialty PP and PE materials.

 New equipment at the K show will include several mixing heads for flexible foams and RIM, mixing/metering machines, a gas loading device for rigid integral-skin foaming, and a low-pressure potting unit for electrical components.New PUR materials include a new insulating foams for oil and gas pipelines, thermal encapsulation of car engines, and a steel/PUR composite for maritime and civil-engineering structures. New mixheads galoreKrauss-Maffei is unveiling new mixing heads for various PUR applications.

Usage of polyamides in U.S. under-hood parts could double in the next decade if nylon 6 and 66 follow European trends toward large panels that not only protect but beautify the engine compartment.

Bayer Polymers has developed a blow molding technology that is putting new bounce into shock-absorbent seating for motorcycles, snowmobiles, tractors and off-road vehicles.

There’s more to TP polyesters than you think. You may know PET, PBT, and PETG—but what about PCT, PCTG, PCTA, and PTT? If you’re not sure what they are, how their properties compare, and who sells them, we have the answers—and lots of new developments to report.

Injection molded, long-glass-reinforced polypropylene appears to be the staple of new automotive front-end systems (FES) designed with a high degree of parts integration.

Plastics are making new inroads in valve covers and air-intake manifolds on U.S.-built vehicles.

Wider adoption of in-mold decorating (IMD) for demanding industries like automotive, appliances, and consumer electronics will require thermoformers to have the right know-how and equipment.

Plastics processors are eyeing form able films as an economical, durable, and environmentally friendly means of producing fully decorated parts right out of the mold.

Plastic-metal hybrids are replacing all-steel structures in automotive front-end modules at an accelerated rate.

Food and consumer packaging was the focus of new developments in polyolefins and styrenics, while automotive was the main target for new engineering materials.

New materials at K 2001 are weighted heavily toward the engineering variety, especially nylons, acetals, and TP polyesters. A large handful of polypropylenes round out the major news.