March 30, 2010 - Pittsburgh, PA - Use of a polyurethane system from BaySystems™ combined with the Long Fiber Injection (LFI) process is giving Cal Spas the ability to cost-effectively replace an outer spa cabinet while keeping the existing frame.
The outer spa cabinet is formed using the Baydur® 675 STR polyurethane system. The material not only contributes to an attractive appearance, but also offers significant production and processing advantages over traditional synthetic materials. Baydur® 675 STR polyurethane system is marketed under BaySystemsTM, the global polyurethane systems business of Bayer MaterialScience LLC.
The spa cabinet, manufactured by Romeo RIM, Inc., of Romeo, Mich., features a decorative finish with a unique wood grain texture that surrounds the spa. The material provides a luxurious finished cabinet. The materials technology also offers superior damage resistance without compromising design aesthetics.
“The spa cabinet’s striking finish is achieved during the molding process, in which the mold itself is textured with a realistic wood grain pattern, which is transferred onto the part,” said Matt Getty, applications engineer, Romeo RIM. “A secondary operation adds a colored finish coating that creates the rich wood-like appearance that is UV-resistant.”
Cal Spas selected LFI for its unprecedented strength-to-weight ratio, dimensional stability, as well as its impact, heat and chemical resistance. LFI also simplifies assembly by replacing traditional extruded polystyrene boards. Previously, multiple boards needed to be assembled using a tongue and groove feature to make one, large side panel for a spa cabinet. In contrast, LFI panels are molded as one side panel – eliminating the need for any extra wood ties, fasteners, glue, staples or other materials used in the manufacturing process. This results in a more efficient, cost-effective method for producing the panels.
In the LFI process, a robot is programmed to move over the open mold cavity while simultaneously dispensing both long glass fibers and the Baydur® 675 STR polyurethane system in an open-pour method. After the robot is finished pouring the material into the cavity, the mold is closed and the material cures. To achieve a durable surface for the finished LFI part, an in-mold coating is applied on the cavity tool prior to the material being poured into the cavity. This creates a polyurethane coating that chemically bonds itself to the LFI substrate, resulting in a surface that is extremely durable and scratch resistant.
“Using LFI the spa cabinet is designed to fit over an existing spa frame the way it is, which can also lead to additional cost savings for an OEM,” Getty said.
“The spa cabinet illustrates several benefits of the LFI process, including the ability to mold large, complex parts that are damage resistant and can withstand the elements,” said Craig Snyder, market channel representative, Bayer MaterialScience LLC. “The advantages of the LFI process provide Cal Spas the independence to produce spas that achieve superior durability and appearance while maintaining their luxury design aesthetics.”
Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with approximately 14,300 employees at 30 production sites around the world and 2009 sales of 7.5 billion euros. The company manufactures high-tech polymer materials and develops innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical, and sports and leisure industries. Sustainability is central to Bayer MaterialScience LLC’s business and is based around the key areas of innovation, product stewardship, excellence in corporate management, social responsibility and respect for the environment.
The outer spa cabinet is formed using the Baydur® 675 STR polyurethane system. The material not only contributes to an attractive appearance, but also offers significant production and processing advantages over traditional synthetic materials. Baydur® 675 STR polyurethane system is marketed under BaySystemsTM, the global polyurethane systems business of Bayer MaterialScience LLC.
The spa cabinet, manufactured by Romeo RIM, Inc., of Romeo, Mich., features a decorative finish with a unique wood grain texture that surrounds the spa. The material provides a luxurious finished cabinet. The materials technology also offers superior damage resistance without compromising design aesthetics.
“The spa cabinet’s striking finish is achieved during the molding process, in which the mold itself is textured with a realistic wood grain pattern, which is transferred onto the part,” said Matt Getty, applications engineer, Romeo RIM. “A secondary operation adds a colored finish coating that creates the rich wood-like appearance that is UV-resistant.”
Cal Spas selected LFI for its unprecedented strength-to-weight ratio, dimensional stability, as well as its impact, heat and chemical resistance. LFI also simplifies assembly by replacing traditional extruded polystyrene boards. Previously, multiple boards needed to be assembled using a tongue and groove feature to make one, large side panel for a spa cabinet. In contrast, LFI panels are molded as one side panel – eliminating the need for any extra wood ties, fasteners, glue, staples or other materials used in the manufacturing process. This results in a more efficient, cost-effective method for producing the panels.
In the LFI process, a robot is programmed to move over the open mold cavity while simultaneously dispensing both long glass fibers and the Baydur® 675 STR polyurethane system in an open-pour method. After the robot is finished pouring the material into the cavity, the mold is closed and the material cures. To achieve a durable surface for the finished LFI part, an in-mold coating is applied on the cavity tool prior to the material being poured into the cavity. This creates a polyurethane coating that chemically bonds itself to the LFI substrate, resulting in a surface that is extremely durable and scratch resistant.
“Using LFI the spa cabinet is designed to fit over an existing spa frame the way it is, which can also lead to additional cost savings for an OEM,” Getty said.
“The spa cabinet illustrates several benefits of the LFI process, including the ability to mold large, complex parts that are damage resistant and can withstand the elements,” said Craig Snyder, market channel representative, Bayer MaterialScience LLC. “The advantages of the LFI process provide Cal Spas the independence to produce spas that achieve superior durability and appearance while maintaining their luxury design aesthetics.”
Bayer MaterialScience LLC is one of the leading producers of polymers and high-performance plastics in North America and is part of the global Bayer MaterialScience business with approximately 14,300 employees at 30 production sites around the world and 2009 sales of 7.5 billion euros. The company manufactures high-tech polymer materials and develops innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction, medical, and sports and leisure industries. Sustainability is central to Bayer MaterialScience LLC’s business and is based around the key areas of innovation, product stewardship, excellence in corporate management, social responsibility and respect for the environment.
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