The central issue in all polyurethane applications is the conversion from the past linear economy into a circular economy, and the use of sustainable raw materials in manufacturing. To do so, manufacturers are taking measures such as using bio-based raw materials, chemical recycling, and CO2 as a synthesis component. Digitalization, electromobility, autonomous driving and the construction industry are also driving PU development.

Polyurethane (PU)

Bauwesen

Bauchemie

Baustoffe

Automotive

Elektronik

Polyurethan-Schaumstoffe (PUR)

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Baubetrieb / Bauwirtschaft

Kunststoff Werkstoffe

Polyurethan

Windkraft

Energieerzeugung

Erneuerbare Energie

Kunststoff

Kunststoff-Recycling

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

Sustainable Growth

For a long time, chemical recycling was considered an unfinished addition to established material processes. In the meantime, however, some technologies are making the leap into large-scale industrial use: an overview of the various processes and providers.

Overview of the Various Processes and Suppliers

Recycling

Umweltmanagement

Polypropylen

Thermoplaste

What Is Happening in Chemical Recycling?

Thanks to new technologies and together with other chemical derivatives the greenhouse gas CO2 can be converted into plastic precursors. Covestro is developing sustainable insulating materials for the construction sector based on this raw material.

Dämmstoffe

Schaumstoffe und Vorprodukte

Using CO2 in Rigid Foam Insulation Boards

The new mobile communications standard 5G is advancing steadily. This development is also increasing the demand for materials that facilitate and ensure the high transmission rates for 5G signals. Plastics manufacturer Covestro has presented a corresponding thermoplastic polyurethane (TPU).

Cell Phone Covers Made from TPU

The process chain of the direct coating process has now been optimized. Self-healing, fast-curing PU casting coatings and polycarbonate compounds are now available for this manufacturing process.

Direct Coating with Polyurethane Coatings Creates Opportunities in Design and Functionality

Oberflächentechnik

Polycarbonat

Short Cycle Times and High Productivity for Smart Components

Tailored products for medical technology based on polyurethane raw materials have been developed by Bayer MaterialScience AG, Leverkusen, Germany. The latest developments include new materials in OP instruments through to wound care. One example is Bayblend M850XF, a polymer blend of polycarbonate and acrylonitrile butadiene styrene that is highly suitable for the production of housings for medical appliances. These include in particular surgical instruments, diagnostic appliances and drug dispensing systems. As with most of the other thermoplastics developed by Bayer MaterialScience for medical technology, this polymer blend is also characterized by good impact strength and rigidity, and satisfies the demands of certain biocompatibility tests to ISO 10933-1 and USP (United States Pharmacopeia) Plastics Class VI. 

From Operation Instrument Through to Wound Care 

Polyurethane 

It is the common goal of the auto industry and seat manufacturers to produce vehicle seats that ensure comfort and safety throughout the lifetime of the vehicle. To obtain a reliable basis for debating the assessment of the long-term properties of seat foam, a comparative study of the test methods and parameters was performed. 

Testing Technology: Accelerated Humid Aging of Polyurethane Moldings 

At the end of September, Frimo Group GmbH, a manufacturer of production systems for the international automotive industry, celebrated its 50th anniversary in Lotte, Germany. The fourth Frimo Forum was held at the same time. The talks and practically oriented technology exhibition provided an information and communications platform on topics of importance to the industry. 

Warmformen / Thermoformen

Stanzmaschinen, Kunststoff

PUR-Werkzeuge

PUR-Schäummaschinen

Falzen, Bördeln, Clinchen

Anniversary: From the Garage to a Hotbed of Technology 

With Loctite MAX 2, Henkel KgaA, Düsseldorf, Germany, has developed a polyurethane-based composite matrix resin that cures much faster than the epoxy resins normally used for resin transfer molding (RTM). This reduction in curing time is another breakthrough in the development of composite matrix resins for the production of lightweight components in the automotive industry. In addition, due to its low viscosity, Loctite MAX 2 penetrates and impregnates the fiber material much more easily and gently so that very short injection times can be achieved. 

Curing Time Reduced to a Minute 

Verbundwerkstoffe / Werkstoffverbunde

Composite matrix Loctite MAX 2 

In cooperation with partners in industry and academia, Bayer MaterialScience AG, Leverkusen, Germany, has developed an effective and cost-efficient seismic protection system for buildings. An extremely tear-resistant woven fabric is applied with a special adhesive directly to the wall, like wallpaper, forming a permanent bond. In the event of an earthquake, the “wallpaper” holds large areas of the masonry together and should keep it stable for some time. The objective is to delay or even prevent the collapse of the walls, giving the occupants time to flee the building to safety. The key component of the system is the adhesive formulated with Dispercoll U, a waterborne polyurethane dispersion from Bayer MaterialScience. Partners in the patent-pending development are the Karlsruhe Institute of Technology (KIT) and Kast, the manufacturer of the fabric, based in Sonthofen, Germany. 

Efficient and Affordable Seismic Protection 

Environment-Friendly Adhesive 

In a sandwich construction alongside fixing the glass fiber mats the PU matrix also binds the paper honeycomb core to the surface skin. Application of the material is a highly significant factor in this context. For this process Hennecke GmbH, Sankt Augustin, Germany, has developed their PU-CSM technology which allows a uniform and reproducible distribution of the polyurethane and fibers. This is necessary in respect of warpage and low material usage. 

Trunk Load Floors – Minimizing Warpage 

PU-CSM 

Plastics can also remember things. This is made clear by a new thermoplastic polyurethane. The shape memory polymer can be temporarily fixed in a deformed state and then converted back almost entirely into its original shape. Potential applications exist in trademark protection and mechanical engineering as well as in the textile, sports, leisure and toy industries. 

Thermoplastic Polyurethane: Programmed to Have a Keen Memory 

Previously unknown possibilities in terms of quality, economy, ergonomy, and robust processes have been opened up by new approaches and solutions for the manufacture of fiber composite components on a series scale. Moreover, such components can also be designed with filigree or even bionic surface structures in future – also with in-mold painting. 

Fiber Composite Components: Start of a New Era 

In the last three years, global consumption of polyurethane has been growing by approx. 5 % per year. In 2012, it reached a volume of 15.3 million t. This encouraging growth trend can be expected to continue in both the middle and long term. The global factors strongly contributing to this include increasing urbanization and mobility, the economic growth driven by rising living standards, mainly in threshold countries, and last but not least, worldwide measures for saving energy. 

Stable Growth: Polyurethane (PU) 

An innovative process makes it possible for the first time to recover polyol from production scrap generated in standard flexible polyurethane foam block manufacture. Thanks to this process, the production scrap is suitable for recycling back into flexible foam manufacture, so bringing ecological and economic advantages. 

PU Recycling: Flexible Stays Flexible 

Specialty Chemicals Company Launches Production Line

Lanxess put a new production line for the manufacture of water-based compounds into operation in Nantong, China.

Lanxess put a new production line for the manufacture of water-based compounds into operation in Nantong, China. The business belongs to the Urethane Systems (URE) business unit which is also producing polyurethane dispersions, an important ingredient of the compounds.

Under the Pellart brand these products are used in many functional coatings applications where high requirements in terms of haptics, chemical resistance, gloss level, temperature and abrasion resistance and, above all, the lowest possible content of volatile organic compounds (VOC) are required.

Typical areas of application are flat materials for automobile interiors, i.e. instrument panels, seats and door panels, but also decorative foils for consumers and industry.

Water-based and therefore environmentally friendly products are a strong trend globally. “As the automotive industry will continue to switch from solvent-based to environment-friendly water-based coatings, we see strong potential with attractive growth rates,” says Michael Timm, Head of Marketing & Development Cast Elastomers at URE.

With the new production line, the company will be able to supply customers in Asia with modern and environmentally friendly Pellart products. Fast developments and customer proximity are provided by the coupling with the application development center, which was opened by Lanxess in Shanghai in June 2021, as well as by the backward integration into its PU dispersions.

Lanxess produces polyurethanes and lubricants at its Nantong site, which covers over 100,000 m2. The urethanes products include hot-cast prepolymers, which are components of specialty polyurethanes that are used primarily in the construction, mining, oil, gas, athletic equipment and electronics industries. These polymers are used, for example, to manufacture rollers, tires and wheels, conveyor belts, screens, seals and so on.

LANXESS Deutschland GmbH  

The specialty chemicals company put a new production line for the manufacture of water-based compounds into operation

At its Nantong site, China, which covers over 100,000 m2, Lanxess produces urethanes and lubricants

2021-11-24 Lanxess

issue 08/2021

issue 07/2021

issue 06/2021

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