Research at Bayer

Research at Bayer MaterialScience

Investment in research and development at Bayer MaterialScience in 2007 came to EUR 209 million, not including the company’s joint development activities with customers. This was 8 percent of the Bayer Group’s R&D spending.

In the Polycarbonates business unit, for example, work is ongoing to further improve and fine-tune the melt polycarbonate process for the new polycarbonate production facility in Shanghai, China. There is also a major focus on the development of plastics with improved flame-retardant properties for the electrical and automotive industries (Bayblend® FR series and Makrolon®) and high-performance polycarbonate film (Makrofol®) for automotive interiors and cellphone housings.

New applications for high-tech materials

Waterborne 2K PU coating Meeting ecological requirements	Printable aliphatic Desmopan® films for improved mechanical properties and light stability
Aspartates for innovative corrosion protection	Multitec® Short Fiber Spraying – fast, efficient process
New Makroblend® product lines for use in automotive exterior parts – high toughness even at low temperatures	ETICS External thermal insulation composite system
Flame-resistant Bayblend® grades with Eco-label compliance	Bayflex® Lightweight Density reduction, excellent dynamic compression set performance
New scratch-resistant Makrolon® grades for automotive glazing

Examples of new product developments at Bayer MaterialScience:

Polycarbonates

In the Polycarbonates business unit, for example, work is ongoing to further improve and fine-tune the melt polycarbonate process for the new polycarbonate production plant in Caojing, China, which is being equipped with the very latest production processes. Examples of innovative product applications include the development of diffuser sheets that ensure even distribution of the light in the backlighting of flat LCD screens, and the development of plastics with improved flame retardance through nanoparticles.

Polyurethanes

In addition to the consistent improvement of existing processes for the production of aromatic isocyanates and polyethers, the Polyurethanes Business Unit also concentrates on the development of new products for new applications. In the advanced composites sector, in which polyurethanes play a key role, a new Baydur® formulation for exterior bodywork sections for large vehicles has been developed. The new formulation outperforms the material previously used in terms of both heat resistance and strength.

The Coatings, Adhesives, Specialties Business Unit is another example of our innovative capabilities. The focus here is on the development of raw materials for high-grade paints and coatings, adhesives, sealants and functional films. An important area of research is polyurethane raw materials for low-solvent or solvent-free – and thus more environmentally friendly – coatings systems. These water-based polyurethane dispersions have a high growth potential, because they are versatile enough to find application in virtually all areas of daily life. Applications include automotive interiors, and textile and leather coatings. Other typical fields of application are in industrial coating and the coating of wood, furniture and plastics.
With Baycusan® Bayer MaterialScience is breaking new ground in polyurethane chemistry: These new solvent-free, environmentally compatible raw materials offer significantly improved properties for hair- and skin-care products and decorative cosmetics.

Specialties

The 'Specialties' segment embraces a variety of research activities and innovative product developments that are still at the beginning of their life cycle. Developments in the field of nanotechnology research point the way to highly promising improvements in the performance characteristics of existing products. Innovative surface technologies hold out excellent prospects for new and improved applications in medical technology.

Functional films are films whose surfaces or structure can be given additional properties that enable the substrate to conduct electricity, light up, or serve as a storage device, for example, thus opening up previously undreamed-of possibilities. Take television sets, for example: In the past, viewers stared into the good old cathode ray tube, which has now been replaced by the LCD flatscreen. In the future, thanks to functional films, foldable TV screens will provide unprecedented picture quality. The technology can also be transferred to many other types of display, which opens up a huge market. Other examples include electroluminescent, three-dimensionally deformable films offering maximum design freedom to product developers and industrial designers in the automotive, telecommunications and home electronics sectors.
Thanks to their excellent mechanical properties, polycarbonate films provide an exceptionally high level of protection against forgery for security cards and driver’s licenses. Next-generation photovoltaic systems could conceivably no longer be made of complex silicon wafers, but instead be supplied as reels of paper-thin film. These and many other projects are expected to be realized in conjunction with partners along the value added chain.

To tap possible new areas of activity, the “New Business” unit studies and evaluates innovative technology and market trends. These are then implemented in the business units or in independent companies. Bayer MaterialScience also works closely with universities, institutes and start-ups throughout the world on research and development projects.