Covestro: Economical lightweight building composites

     Covestro has been working on the development of composite materials for many years. Whether it's small electronics, insulated facades, wind power plants, energy and resource-saving composites, and efficient manufacturing technologies, they are a core part of Covestro's sustainability philosophy.

At the International Composites Fair in Paris from March 6th to 8th, 2018, the company will showcase its lightweight and aesthetic materials and efficient production processes at Booth C28 in Hall 5.

New high-tech materials

Covestro has developed a new composite technology for the efficient production of particularly lightweight, hard, and aesthetically pleasing parts. It utilizes a continuous fiber reinforced thermoplastic composite (CFRTP) made of polycarbonate. Covestro produces tapes and sheets for further processing for customers, and has significantly expanded its production capacity at Markt Bibart to supply products worldwide.

Especially in the electronics industry, the trend is ultra-thin casing for laptops and smartphones. The laptop cover can be produced from CFRTP sheets, reducing cycle times and cost. Compared with magnesium alloy, it is about 15% lighter and has an beautiful external structure.

Wind power rotor blades are nearly 60 meters long

Renewable energy such as wind energy continues to develop. More intensive use requires fans to be more cost effective.

Covestro developed a special polyurethane impregnating resin for rotor blades. Combined with reinforced fiberglass and an efficient vacuum manufacturing process, cycle times can be reduced, resulting in lower costs. The resin developed in China has obtained DNV-GL certification – this is a prerequisite for entering the Chinese wind power industry.

In China, a new prototype of rotor blades with a blade length of 59.5 meters has been produced. Covestro expects to produce more blades and even longer blade lengths to make more efficient use of wind energy.

Composite material for exterior wall insulation

In the Benelux region, building envelope specifications strictly improve thermal efficiency. Curtain venting doors are very common, especially in offices and industrial buildings. In today's material solutions, only thicker insulating materials can be used or not at all.

In response to local conditions, FISCO Composite Solutions, in Tusmarshausen, Germany, together with other partners, has developed a new wall mount that meets the requirements and greatly facilitates the assembly process. The system installation is part of the lower structure of the curtain ventilated curtain wall and consists of two different components: a core made of fiberglass reinforced plastic, carrying gravity and wind from the surface into the masonry, and a package GFRP Core cylindrical heat shield for improved thermal insulation.

Fireproof polyurethane material

Due to its excellent fire resistance and good mechanical properties, FISCO uses Covestro's Desmocomp® material as the base material for GFRP core materials. Aliphatic polyurethane resins are mainly used in outdoor applications because of their good weatherability. One-component systems can be easily processed using a pultrusion process.

Aqueous polyurethane dispersions from the Baybond® line are used as glass and carbon fiber size film formers for thermoplastic composites. The dispersion has very good film forming properties, elasticity, adhesion and yellowing stability, and ensures good mechanical stability of the composite. More importantly, some Baybond® products are also approved for food contact. Covestro is also developing new products for thermoset applications.

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