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07-10-2008

Polyurethane system Baydur 110

Complex Molded Components in a Single Step

Polyurethane system Baydur 110

The trend towards substituting sheet steel with high-grade plastics for body parts in the automotive and commercial vehicles field continues unbroken. In addition to the well-known advantages such as design freedom and low weight, increasing importance is being attached to the economic production of the components. Present developments are currently focused on producing increasingly larger parts in one shot. As a result, and together with the possibility of integrating additional functions and components in the mold, extra costs and time-consuming work procedures can be eliminated. On the materials side, highly reproducible results are obtained by the use of very low-viscosity plastic materials that fill even the smallest cavity in the mold. Customized polyurethane systems permit very large moldings with complex structures such as undercuts and ribbing to be produced in a single shot without the need for expensive rework.

A recent example from the agricultural field involves the two side panels and tailgate of the Jaguar Green Eye forage harvester from Claas KGaA mbH in Harsewinkel, Germany. All three molded parts are made by Pestel PUR-Kunststofftechnik GmbH, Chemnitz, Germany, in a single shot. Hereby, the flame-retardant, microcellular polyurethane system Baydur 110 from Bayer MaterialScience supplied by BaySystems BÜFA is used. Thanks to the outstanding flow characteristics and low cavity pressure, there are virtually no restrictions on the geometric design of the molded parts, especially in the edge and interior areas. For example, undercuts, cutouts opposite the demolding direction, and slider-in-slider designs are possible. Each of the large side panels has dimensions of 4m x 2m and weighs about 40 kg. The tailgate has external dimensions of 1,7m x 1,6m and weighs some 30kg. All three components have complex structures such as undercuts, ribbing and different wall thicknesses. Inexpensive aluminum molds are used for production. Metal bushings and other inserts are integrated into the molding process.

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