Monique Buch, Chief Commercial Officer at Covestro: "The chemical industry and many of its key customer industries face profound transformations – on the path to circular economy, through AI and digitalization, or due to geopolitics and the realignment of global markets. With our expertise in high-performance materials, process and application development, we remain part of the solution and support our customers in achieving their goals."

The solutions presented at "K" are organized across the booth in the areas of Automotive, Electronics, Healthcare, Sports and Leisure, as well as Sustainable Future. They showcase "The Material Effect" in application across various industries and underline the company's long-term vision of a complete alignment with the circular economy. This vision remains the North Star for Covestro and the industry – despite short-term challenges and overlapping crises that require resilience and adaptability.

Materials with Impact: "The Material Effect" in Practice

Jochen Hardt, Booth Manager and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro: "At our booth, visitors can experience first-hand how 'The Material Effect' becomes reality in concrete applications. We deliberately present not only materials and products but showcase well-designed system solutions that offer real added value to our customers. My team and I at Covestro look forward to engaging with visitors throughout the fair!"

Sustainable Future

In the "Sustainable Future" area, Covestro demonstrates its comprehensive commitment to the circular economy. This includes the "CQ" portfolio, which marks products containing at least 25% alternative raw materials. Another example is the technology developed by Covestro and partners for producing plant-based aniline. Also featured are several car-to-car recycling projects that advance circularity in the automotive industry. For example, the NALYSES project, where Covestro works together with partners like HELLA and BMW on the circularity of headlights. Or a pilot program with NIO, VW, and GIZ for recycling polycarbonate parts. For the latter, visitors will find materials labeled "RE", "RP", and "R" at the booth – these are partly made from alternative raw materials.

Automotive

Highlight in the automotive area: The SUE "People Mover" – a prototype vehicle for public transportation. The autonomous e-shuttle was designed and developed by UE | STUDIOS. It features large-scale, curved 3D polycarbonate glazing as well as seamless integration of driver assistance systems and sensors, also using polycarbonate. The lightweight, highly durable monomaterial Arfinio® is used in the interior, along with a recyclable TPU monomaterial seat. The IMAGIO® tool for digital, photorealistic material twins will also be on display. It is now implemented in Autodesk VRED and makes design processes faster and more efficient.

Electronics

In the electronics area, Covestro showcases innovative NIA-PFAS (not intentionally added PFAS) polycarbonates with flame retardancy for laptop covers and IoT device housings. Additionally, a recyclable antenna housing made of Makrolon® monomaterial will be on display, combining optimal signal transmission with weight reduction.

Healthcare

In the healthcare booth area, Covestro presents material solutions that combine sustainability with performance and reliability: From medication delivery with particularly thin-walled, more easily recyclable monomaterial injectors to resistant housings for diagnostic devices that withstand disinfectants. Such devices can furthermore be made with NIA-PFAS material types for flame retardancy, and support the seamless integration of functionality such as touch operation and signaling in an attractive design.

Sports and Leisure

In the sports and leisure area, visitors will find applications such as the e-surfboard by Awake. Covestro materials can be found, for example, in the easily and quickly replaceable battery, with thermally conductive and flame-retardant polycarbonate for improved battery performance. Durable TPU-based materials on the grip of the replaceable battery additionally provide pleasant haptics and comfort.

Press Tour for Media Representatives

Media representatives are cordially invited to experience Covestro's exhibition booth at K 2025 in person. A press tour will take place on the first day of the fair, October 8, 2025, at 3:00 p.m. at booth A75 in Hall 6.

The tour offers a comprehensive overview of all focus areas as well as the opportunity for discussions with technical experts about "The Material Effect" and the implementation of the circular economy strategy in concrete applications. There will also be opportunities for individual interviews.

For more information about Covestro at K 2025, please visit Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

"This investment in our U.S. compounding plant is an important component of our 'Sustainable Growth' strategy. With this expansion, we can meet our customers' growing demand for specialized polycarbonate materials, grow together with our customers, and strengthen our position as a leading provider of polycarbonate materials in North America," says CTO Thorsten Dreier. "The move also aligns with our strategy to produce in the region for the region, to manufacture close to our customers and ensure reliable supply."

The capacity expansion is an important step to meet the growing demand for high-quality materials for the automotive, electronics, and healthcare industries in North America. "To be successful in these markets, you need the right portfolio, consistent quality, and supply reliability, as well as solution-oriented technical expertise,” says Lily Wang, head of the Engineering Plastics Business Entity. "The expanded production capacity for differentiated polycarbonates enables us to better serve our customers' complex needs for high-quality, high-tech materials with individualized properties.”

Covestro already has an established R&D center in Pittsburgh and is now doubling down on its U.S.-based compounding capability. In the future, both facilities will work even more closely together to drive the technology transfer from lab to industrial production to support major transformation processes, such as the electrification and automation of mobility, sustainable developments and digitalization.

“This investment, which follows our recent announcement of an almost 40 million Euro investment in our R&D capabilities in Pittsburgh, underscores how critical our U.S. sites and the U.S. market are to Covestro’s global strategy,” says Samir Hifri, chairman and president of Covestro LLC. “The expanded capacity of our polycarbonate compounding capabilities in Ohio will both help us better supply our customers as well as represent a commitment to our employees at the site, the Hebron, Ohio community, and the U.S. market as a whole.”

Construction of the new production lines is scheduled to begin in 2025, with operations starting by the end of 2026.

Baypreg® STM employs the Spray-Transfer-Molding process, where PU resins are sprayed onto glass fibers and molded into battery covers, enabling efficient production of composite components. Developed in collaboration with Liyang Shanhu Industrial Co., Ltd., a Tier 1 supplier of automotive parts and battery packs to Chinese and international OEMs, this solution represents a significant advancement that is also cost-effective.

Solution for lighter and high-performance battery covers

This PU solution reduces battery cover weight by more than half compared to traditional steel shell materials. As a non-metallic material, the Baypreg® battery cover inherently offers superior anti-corrosion and insulation properties, effectively preventing electric arcing. When compared with non-metallic options, it outperforms in terms of surface smoothness and airtightness. It also demonstrates high strength meeting tough requirements from OEMs.

“As the inventor of polyurethanes, Covestro brings decades of expertise in the automotive industry, with PU solutions enhancing both driving and riding experiences in automotive interiors and exteriors. We can now extend this expertise to NEVs as well,” said Akhil Singhania, Global Head of PU Specialties at Tailored Urethanes, Covestro. “The Baypreg® STM solution showcases Covestro’s ability to deeply understand evolving market needs and rapidly innovate cutting-edge material solutions. Our goal is to deliver lighter, more efficient, and sustainable solutions through continuous technological innovation.”

The NEV industry has witnessed rapid growth in recent years. According to the China Passenger Car Association, NEV sales accounted for 51 percent of total passenger car deliveries in China in July 2024, outnumbering those of internal combustion engine vehicles for the first time.

Diverse applications for Covestro’s PU composites

At the CCE, Covestro will also showcase its PU composite solutions across various sectors. For instance, PU composites are widely utilized in photovoltaic (PV) modules to enhance efficiency and quality. Specifically, PU frames combined with coatings solutions from Covestro offer superior corrosion and weather resistance for PV modules, PU profiles excel in insulation and mechanical performance in energy storage batteries, and transparent front sheets based on composites enable high light transmittance while demonstrating exceptional strength for solar panels. 

Additionally, in construction, PU windows and doors are ideal for nearly zero-energy buildings due to their excellent insulation. In infrastructure projects, PU composites are widely used in power poles, railway sleepers and cable trays for their durability, weather resistance and low maintenance costs.

To learn more about Covestro's PU composite applications at the China Composites Expo, visit the company’s booth 7R19 in Hall 7.1 at the National Exhibition and Convention Center (Shanghai) from September 2 to 4, 2024.

The façade of the Texoversum is just one example of a brand new technology that could completely revolutionize the construction industry. The sophisticated structure was designed on the computer and is based on carbon fibers wound by robots. Similar to networks in nature, for example in spider webs, beetle wings or palm leaves, the fiber structures are also very lightweight, but at the same time highly resilient, and require very little material. This not only saves resources, but also facilitates transport and assembly of the components.

The co-inventor of the innovative technology is architect Prof. Moritz Dörstelmann, whose company FibR also realized the façade of the Texoversum: "In contrast to conventional steel and concrete structures, we are able to get by with a minimum of material, because the robots only process as many fibers as are needed for the strength of the respective structure. As a result, we also save large amounts of CO₂ emissions." Dörstelmann also sees advantageous applications for the technology in roof structures, supports and, not least, interior fittings.

The necessary strength and durability of the composite is provided by Covestro's aliphatic polyurethane resin system Desmocomp^®, in which the fibers are embedded as if in a matrix. "The resin is highly resistant to weathering and the sun's high-energy UV radiation, making it very suitable for outdoor applications," explains Pejman Norastehfar, architect and specialist for construction applications in Covestro's Coatings and Adhesives segment. “Other plus points in the construction sector are its excellent chemical and flame resistance.”

In the Texoversum, the spun façade performs several important functions at once: it gives the building a unique look and stabilizes the surrounding balconies. It also serves as a railing and provides the necessary shade for the glass front behind it.

The building provides approximately 3,000 square meters of space for workshops, laboratories, a textile collection, think tank space and classrooms. The costs for the construction of the Texoversum amounting to 18.5 million euros were borne by the employers' association Südwesttextil, whose members include FibR GmbH in Kernen, east of Stuttgart.

Covestro will showcase various PU composite solutions at the 2023 China Composites EXPO Shenzhen, held from March 23-25 at Booth 1201 in Hall 2 at the Shenzhen Convention and Exhibition Center. These solutions, created in partnership with other companies, include pultruded profiles for windows and solar frames, rotor blade sections for wind turbines, top covers for new energy vehicle (NEV) battery packs, power distribution poles, and facade brackets. These products are made using a range of composite processes such as PU pultrusion, high-pressure resin transfer molding (HP-RTM), infusion, and filament winding.

Baydur^® Pultrusion window frame

The Baydur^® Pultrusion window frame is designed to reduce the energy consumption of buildings by providing exceptional heat insulation and mechanical properties. These frames are made of fiberglass reinforced polyurethane composites, with a waterborne polyurethane coating on the surface. Compared to conventional aluminum alloy or PVC windows, these composites have a smaller environmental impact and lower carbon emissions due to their superior insulation performance.

Baydur^® Pultrusion solar module frame

The Baydur^® Pultrusion solar module frame is a non-metal solution that combines a PU pultrusion composite with a PU waterborne coating. It has excellent mechanical properties and can resist strong chemical erosion, making it ideal for high humidity and high salt fog areas. Unlike aluminum alloy frames, Baydur^® frames don’t require grounding, and can improve energy generation efficiency of solar panels. It is a cost-effective solution for solar parks and Building Integrated Photovoltaic applications.

Baydur^® HP-RTM top cover for NEV battery packs

The Baydur^® HP-RTM top cover for NEV battery packs is a key application of PU in new energy vehicles. It is lightweight and can be as thin as 0.8mm, thus reducing total carbon emissions. The cover is also flame-retardant to ensure safe protection for vehicle batteries. Additionally, the HP-RTM process significantly improves manufacturing efficiency and reduces operational costs with its “one-drives-two” design, enabling one injection machine to service two press machines simultaneously.

Power distribution poles and telecommunication towers

Power distribution poles and telecommunication towers using Baydur^® and Desmocomp^® were developed to meet the needs of vast areas, regardless of the environment or terrain. These solutions are only one-eighth the weight of conventional concrete poles, generating substantially fewer CO₂ emissions during manufacturing and transport processes. They can also be effectively transported and installed even in difficult terrains. Furthermore, their inherent structural differences make them more resilient in extreme conditions such as typhoons, lightning storms, and corrosive environments, providing a stable lifespan of over 40 years with significantly lower maintenance costs over time.

Covestro also offers low-carbon versions of these polyurethane solutions containing alternative raw materials, such as mass-balanced polyurethanes certified by ISCC PLUS and partial bio-based products, to help customers along the value chain transition to a circular economy.

Covestro started working in the field of continuous fiber-reinforced thermoplastic composites in 2015 with the acquisition of TCG Thermoplast Composite GmbH. Following the strategic decision to discontinue the Maezio^® product line after almost eight years, Covestro searched intensively for a buyer for the Markt Bibart site. As this attempt was ultimately not successful, Covestro decided to close the site later this year. Most recently, 48 of the approximately 7,600 employees in Germany were employed there. “We have initiated an extensive sales process, which, unfortunately, was not successful. Our focus on the ground is now on providing the best possible support to all colleagues. To this end, we will be working closely with the local employee representatives to find fair solutions for all those affected and to ensure that the closure process is socially responsible,” emphasizes Site Manager John Bauer.

A focus on core business

Thermoplastic fiber composites are a highly specialized and competitive niche business. Covestro has invested in building up the business since taking over the site in 2015 and has made very good technical progress in production. Nevertheless, the company has not succeed to scale business with sufficient success in the market. There are only a few synergies with the core business of the Engineering Plastics business entity and the vast majority of key account business. In addition, the typical customers for thermoplastic composites only order on the basis of joint, complex and time-consuming technical application development, and then only in very small quantities. This is in marked contrast to the far predominant distribution model and key account business in the Covestro Group.

Covestro is thus sharpening its focus on its core Engineering Plastics business by discontinuing the Maezio^® products. Major customers in the automotive, electronics and healthcare divisions, among others, use these high-quality polycarbonates for further processing in a wide range of products.

PU in wind-blade production is a transformative innovation delivered by Covestro teams around the globe. With better mechanical properties, an efficient production process, and a more cost-effective production solution than conventional fiberglass-reinforced epoxy blades, PU blades are opening a new chapter in the wind blade industry.

Commercial success

Covestro and TMT signed a memorandum of cooperation about a year ago, based on which significant commercialization results have been achieved. PU wind turbines are now being used in commercial wind farms throughout China.

Dr. Binbin Hou, General Manager of Wind Business at TMT, said, "PU wind blades cater to the growing demand for longer wind blade designs. We hope to further collaborate with Covestro to improve the competitiveness of wind energy through continuous technology innovation."

"We are very pleased to reach the important milestone of the launch of the 1000th blade with TMT," said Christine Bryant, Global Head of the Tailored Urethanes Business Entity at Covestro. "We believe that industrial collaboration is fundamental to addressing global warming and energy shortage issues, and it is also an important part of Covestro’s commitment to a circular economy."

TMT produces PU wind blades ranging from 59.5 meters to 94 meters in length with different blade designs and layup structures to meet the growing demand for longer and larger wind blades. The 94-meter wind turbine blade, capable of generating 8 MW of energy, is the largest PU application for Covestro so far. Multiple TMT factories manufacture these blades under different temperatures, humidity, and altitude, proving the wide applicability of PU resin in the manufacturing process.

Dr. Xuebin Feng, R&D Director of Wind Business at TMT, said, "We overcame many technical challenges to accelerate the production process of large polyurethane resin wind blades and achieve mass production."

Further collaboration

In addition to wind turbine development, Covestro and TMT have jointly developed PU railway sleepers, which are more durable and cost-effective in maintenance than traditional wood and concrete sleepers. Covestro, an integrated PU solution provider, will cooperate with TMT to provide various PU resins, coatings, and PU machinery solutions.

Covestro is presenting the advanced solutions for automotive interiors unveiled at the K 2022 plastics trade show to the advanced solutions for automotive interiors now at this year's Automotive Interiors Expo in Stuttgart, Germany, November 8-10, 2022. At booth 3312 in Hall 3, the company will showcase a range of smart and sustainable material solutions that keep pace with the latest trends in automotive interior design.

Shaping the driving experience with new technologies

Makrolon^® Ai polycarbonate offers a special edge-lit composite color that can range from transparent to translucent, providing various options for ambient and dynamic automotive interior lighting. The combination of this material with the lightweight composite Maezio^®, which offers tremendous design freedom and is made partly from post-industrial recycled materials, allows occupants to sit back and enjoy the ride.

Functional integration through back-injection of polycarbonate

Covestro has developed the first material that is shrinkage-free and highly dimensionally stable, transparent and heat-resistant: Makroblend^® OM 845G, a polycarbonate blend with 20 percent glass fibers. This material can be back-injected and back-lit to create textured and 3D shapes.

Soft-touch coatings create surprising textures

Covestro offers a versatile range of hard to flexible aqueous 2-component (2K) polyurethane dispersions that allow a high degree of design freedom (from soft to hard). By combining this 2K polyurethane technology with edge-lit and high-tech Makrolon® Ai materials, it is possible to create a wide range of innovative textures.

Innovative coatings and adhesives for instrument panels and door 
trims

Together with designer Miika Heikkinen, Covestro's Coatings & Adhesives and Engineering Plastics segments have developed a door panel concept with new material solutions. The prototype contains a waterborne coating with innovative INSQIN^® technology in combination with an adhesive based on a Dispercoll^® U dispersion – two waterborne polyurethane (PU) solutions with low levels of volatile organic components (VOCs). Specially developed to provide cost-effective and sustainable applications for future automotive interior requirements, they provide translucent appearance, coating adhesion and deep color effects in door panels. As a vegan solution, the lower CO₂ emissions and reduced energy consumption of INSQIN^® can reduce the overall CO₂ footprint of plastics by up to 45 percent while providing virtually odor-free indoor air quality. The carbon footprint can be further improved by using an Impranil^® CQ DLU PU dispersion, which consists of approximately 35 percent renewable carbon by weight. In addition, the application also includes a partially biobased water-based soft-touch coating with up to 33 percent renewable carbon in the final formulation.

Lighting and heating integrated into the sunroof

Panoramic sunroofs and moonroofs are very popular in modern vehicles. Covestro, in collaboration with Loomia, has developed a roll-up sunroof shade concept that combines the sun-reflecting properties of Platilon^® TPU film during daylight hours with integrated fabric circuits for lighting and heating at night and in cold weather. To help passengers get the most out of the interior, we bonded the textile surface and electronics layer using our thin and flexible Platilon^® polyurethane film. It is tough enough to withstand repeated rolling without compromising performance.

Makrolon^® and Makrofol^® films for smart surfaces

Covestro and TactoTek^® have teamed up again to showcase the endless, more sustainable design possibilities of IMSE^® technology: Together, they developed demonstrators that showcase functional electronics while integrating control surfaces, computers and displays. The final design consists of a Raspberry Pi computer, an OLED display, all necessary circuitry and electronic components, and inks for coloring and decorating – all embedded in a Makrolon^® resin between two layers of Makrofol^® film. With this, we are showcasing powerful new material solutions for consumer electronics with a mono-material design where the plastic can be recovered at will and converted into new raw materials.

"Covestro takes the award as an honor but also as a responsibilty to deliver on its Circular Economy vision. Enabling growth for the global wind industry is one of the company’s major goals," said Dirk Soontjens, External Representative for Covestro in the Polyurethanes Wind Segment, at the award ceremony. "The productivity and good mechanical properties of the resin system also provide the opportunity to design longer and more durable blades to achieve higher annual energy production and lower energy costs, while removing roadblocks that the industry faces."

More efficient production of rotor blades

The processing and mechanical properties of Covestro's PU were studied through prototyping and advanced computer simulations. Thanks to their low viscosity at room temperature and high reactivity at elevated temperatures, they enable rapid infusion and curing. Compared with epoxy resins, this leads to significantly shorter rotor blade production cycles. Together with the potential for weight savings and their resistance, the PU resins reduce total cost of ownership by increasing energy efficiency and lowering manufacturing and maintenance costs.

In addition, several Covestro coating solutions for offshore wind turbines were included in the case presented for the JEC Innovation Award. These include a solvent-free gelcoat, a waterborne 2-component topcoat and a polyaspartic-based leading edge protection coating. The systems feature excellent adhesion properties on PU composites and were successfully tested under simulated offshore conditions. They facilitate the manufacturing process for rotor blades and thus improve the productivity of wind turbines.

"We are very excited about this joint solution, as we cannot process the materials ourselves for technical reasons," explains Lisa Ketelsen, Head of Thermoplastic Composites at Covestro. "By recycling according to type at our partner's plant, the raw materials can be converted back into valuable products with similarly good properties as those characteristic of virgin materials. The recycling of materials makes it possible to use them again in other products. In this way, we save raw material resources and contribute to the focus on the circular economy."

"Our company has many years of experience in recycling carbon fiber-reinforced thermoplastics and has the necessary plant technologies to process such waste. We were therefore the partner of choice for this task," says Tim Rademacker, general manager at Mitsubishi Chemical Advanced Materials and responsible for the carbon fiber recycling business. "From the processed waste, we produce high-quality new compounds of carbon fiber-reinforced polycarbonate for Covestro at CarboNXT^®."

Demand for such recycled products is high because they are valuable raw materials, but also because more and more industrial customers and consumers are looking for more sustainable products. The project will now be further developed to market maturity by Covestro, Mitsubishi Chemical Advanced Materials and possibly other partners. It is part of a global strategic program with which Covestro is focusing all its energy on the circular economy.

FISCO GmbH was able to implement the idea of the Dutch construction supplier fischer Benelux B.V. for a completely new force-bearing fixture through the already installed insulation material: The ThermoBracket fastening element was specially developed for rear-ventilated facades with very efficient thermal insulation. It is based on the aliphatic polyurethane (PU) composite Desmocomp^® from Covestro and is easy to install.

“Our composite material is highly resistant to UV radiation, making it ideal for long-term outdoor use,” explains Andreas Hecking, an Aliphatic Composites Specialist at Covestro. “It also meets the high flame retardancy requirements for this application, making it attractive to the construction industry.”

Desmocomp^® has a similar mechanical strength to aluminum, but its thermal conductivity is 1,000 times lower than with the standard metallic product. Therefore, even a low layer thickness of the composite material is sufficient to achieve good insulating performance. This both leads to a gain in the usable surface area on the building and contributes to the saving of CO₂ emissions and material – and thus to the conservation of resources.

Maezio^® is a brand of continuous fiber-reinforced thermoplastic composites that enable high-performance components for the footwear industry, among many other applications. These strong and lightweight materials provide superior stiffness without adding much weight to shoe parts, such as the midsole, toe kick and shank. The shank is a supporting structure in the shoe that runs beneath the arch of the foot.

“The excellent properties of carbon fiber composites can significantly improve the torsional stiffness of basketball shoes and help smooth the transition from heel to toe,” says Anson Zheng, senior director of Anta’s basketball category and designer of KT6. “The carbon fiber shank, together with the highly responsive midsole and shock-absorbing module on the heel, makes the KT6 a truly high-performance kick on the court.”

Versatile material for a sports icon

Since reaching an endorsement deal in 2015 with Klay Thompson, the Golden State Warriors shooting guard, Anta has released six generations of the KT line in a wide variety of colors and many playoff editions. They became instant hits and topped the charts in China among all Anta basketball lines – with growth continuing as the NBA star becomes increasingly popular in China.

In this latest KT silhouette, the X-shaped shank must be very thin to meet the weight specifications, but also strong enough to fulfill the torsional requirements. Maezio^® composites offer not only stiffness at low density, but also a great deal of design freedom – It can be stacked layer by layer at different angles to form sheets that are tailored to specific performance and mechanical criteria. For the design of the Anta shank, the orientation of the carbon fiber has been optimized to provide high stability, while the thickness is limited to just 1-millimeter to achieve a lightweight feel.

Thompson is expected to wear the KT6 in the upcoming 2020-21 NBA season, which is not expected to start before Christmas due to the coronavirus pandemic.

Designed for scale and sustainability

The KT6 is expected to be the top-selling product in the KT series. For this reason, Anta requires a carbon fiber composite material that is easy and efficient to process even on a larger scale. As thermoplastics, Maezio^® composites can be thermoformed efficiently at high yield rates and low cycle times, which is associated with cost reductions for millions of parts per year. The principle recyclability of the material, thanks to its thermoplastic matrix, offers added value for footwear brands that want to focus more on sustainability.

Strong collaboration

Covestro has been collaborating with Anta even before the development of the KT6. The team supported the sporting goods company in the design of carbon fiber midsoles for a running and another basketball shoe, which Anta developed as part of its product range in the run-up to the world-wide athletic competition in 2022.

“We’re very excited to support Anta in the design and development of its brand-new atheletic shoes by contributing our material expertise in composites,” says Lisa Ketelsen, head of the thermoplastic composites business of Covestro. “We see Maezio^® as a material that enables efficient mass production of high-performance parts in a diverse range of applications, including footwear. Another advantage is that the material can be adapted to the desired performance and different production sizes, and offers great value creation across industries.”

Anta owns a number of world-leading brands through frequent acquisitions. A consortium led by the company completed the purchase of Finnish sporting goods company Amer Sports in 2019, making Anta a globally leading sportswear maker by revenue.

Plastics and technologies will play a vital role in the future car cockpit. In collaboration with industry partners, Covestro has developed a premium concept for the car interior of the future. High-tech materials open up a vast array of new possibilities for many different components. The company is presenting the concept at the Car Smart Interior Conference in the form of two presentations and in the virtual showroom. The concept car can now also be discovered in an augmented reality app that can be downloaded from the Android and iOS stores.

Increasing demands on materials

"The interior design of the future will be characterized first and foremost by functionality, comfort and design, but also by efficiency and light weight. We intend to meet the resulting increasing demands with our material concept and are in a leading position here," explains Jochen Hardt, Vice President Global Marketing Mobility, in his presentation. “In particular, a high-quality and individual design has considerable influence on consumers' buying decisions while providing car manufacturers with opportunities for brand differentiation.“

The focus of the concept is on multi-sensor infotainment systems, innovative seating concepts, smart surfaces and personalized lighting. One particular highlight is a seamlessly integrated, three-dimensional multi-functional display. It presents a large-format visual experience for the user, enabled by the good optical quality of Makrolon^® Ai polycarbonate and Makrofol^® polycarbonate film.

Another key area of focus is the design of surfaces using colors, aesthetic appeal and haptics, with light effects and functions. Lightweight and durable materials such as Makrolon^® polycarbonate and Bayblend^® and Makroblend^® polycarbonate blends are particularly suitable for a host of design solutions, featuring glass-like surfaces, a wide range of colors and possibilities for integrating displays, sensors and cameras. Combined with wafer-thin surface layers of natural materials such as wood or marble, they can create a pleasant sense of wellbeing. With lighting, the effects can be enhanced even further. A further benefit is the good transparency of polycarbonate.

Lightweight construction concept for seat backs

In the program section on auto seating, Florian Dorin from Industrial Marketing Composites Automotive at Covestro reports on an application of Maezio^® composites in seat shells of the new electric concept car ENO.146. In the vehicle of the Chinese Guangzhou Automobile Group Co. (GAC), the recycled version of the continuous fiber-reinforced thermoplastic composite Maezio^® was used primarily for aesthetic reasons. According to the manufacturer, weight savings of up to 50 percent can be achieved compared to conventional seat concepts. Lightweight materials and an aerodynamic design make this car one of the most aerodynamically efficient vehicles in the world.

"Through component integration, our material can reduce the complexity of the overall component and thus simplify assembly. To this end, functional structures are incorporated into the mold, which reduces the number of parts and materials compared with metal backrests," says Florian Dorin. "We were also able to fulfill GAC's wishes with regard to the CMF categories of color, material and surface. The seat backs fit in well with the car manufacturer's nature-inspired design, which is based on a lake with lotus leaves." Another advantage is the principle recyclability of Maezio^® composites.

The logo consists of the two letters N and L of the country code, each one meter high. The main frame of the figures is made of polycarbonate, which contains recycled materials from waste sources such as used water bottles. It has been 3D printed using innovative large format technology. This finished part is strong and durable and is suitable for both indoor and outdoor applications. Covestro is already working with Chinese partners in the value chain to transform used polycarbonate water bottles into high-performance recycled plastics for the electronics, household appliances and automotive industries.

The facade of the logo is made from recycled Maezio^® composite sheets, which are made from processing waste. This material is not only light, strong and durable, but also corrosion resistant to meet the demanding requirements of outdoor installations. Its thermoplastic matrix makes it possible to completely recycle the material from both industrial waste and end-of-life products.

With open innovation to recycling management

"Circular economy must become the new guiding principle and that’s why we are working with the Consulate General of the Kingdom of the Netherlands in Guangzhou and partners in the value chain to design and produce this creative logo," said Holly Lei, President of Covestro China. "Through open innovation, we are striving to integrate the industrial chain and involve the end users to achieve a fully circular economy."

Michiel Bierkens, the Consul General of the Kingdom of the Netherlands in Guangzhou, said: "We are happy to be working with Covestro to enhance our new logo, as such cooperation will underscore our joint efforts to create a circular and sustainable world. We expect to promote this concept locally and globally by using it in our events so that more people can see this initiative and contribute their own efforts."

Covestro is on the way to fully aligning its entire production and product range, and in the long term all areas, to a new circular concept. The initiative to anchor circularity in a holistic approach focuses on four priorities: an increased use of alternative raw materials, innovative recycling processes, renewable energies and joint solutions.

"The partnership with NANOxARCH and the Dutch Consulate for the new logo is just another concrete example of how our open-innovation collaborations in China can drive solid progress towards the future, especially in a circular economy," said Dr. Michael Schmidt, Covestro's Head of Innovation for Asia Pacific. "For us, this is just the beginning, as we and our partners are working on numerous concrete measures and projects along the value chain for improved recycling and reusing plastics."

The Covestro products used in the logo include an aqueous polyurethane dispersion for adhesives that bond the main frame and facade securely, easily and efficiently, and raw materials for aqueous polyurethane coatings that offer good adhesion to the recycled polycarbonates, flexible surface design, anti-stain and durability. Both waterborne systems are also characterized by very low VOC emissions.

Covestro takes things one step further by using a continuous fiber-reinforced thermoplastic composite (CFRTP). Its Maezio^® material is extremely robust and lightweight, while also providing outstanding opportunities for high-quality and aesthetic design. One such current example of what is possible is a space-saving, modular table concept for autonomous vehicles. Covestro has developed it in cooperation with the mechanical and process technology provider Engel Austria and Dr. Schneider Unternehmensgruppe as a direct supplier to the automotive industry.

The objective was to construct a normal-sized table that is as thin as an Ultrabook, and can be stowed just as easily, for instance between the back seats, but is mechanically extremely durable. This table measures 41 cm in length and 32 cm in width, with its thickness increasing from 5 mm on the outer edge towards the inside to 10 mm – which is less than half the thickness of conventional car tables. The later fitting of hinges, already accounted for in the molding process, and ready-molded trays for pen and tablet reduce the number of components and save weight.

Light and robust sandwich construction

An initial version featuring a sandwich construction is shown in the interior concept. The upper and lower sides each consist of 1 millimeter thin layers of the polycarbonate composite material. The sandwich core is a rigid low-density polyurethane (PU) integral skin foam based on Baydur^® 20. Weighing just 690 grams, the table is twice the size of a conventional one and can even be loaded with 50 kg instead of 5 kg.

The manufacturing process was developed with partners at the LIT Factory of the Linz Institute of Technology (LIT) at Johannes Kepler University (JKU) in Linz, Austria. Here, with the help of digitalization, potentials ranging from product development to reuse can be optimally identified and leveraged.

The second step of the project aims at enabling a smooth and economic large-scale production of the table with series-proven processes and to transfer the know-how gained to other applications of CFRTP composites.

Not just for the automotive industry

The polycarbonate composite Maezio^® is not only a highly interesting material because of its low weight and moldability. With its noble carbon look, it is also ideal as a surface material for optically appealing surfaces for housings of laptops, smartphones or tablets, but also for sporting goods and other articles. In addition, thanks to their carbon look, clear coatings but also opaque coatings enable the production of durable products with unique surface properties that meet customers´ high demands in terms of design.

Our Presskit

Find more information on the topic in our press kit!

Press Releases:

• Design variety in the car interior of the future
• Modular table concept for the car of the future
• Innovative lightweight construction concept for seat backs

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The car interior will develop into a multifunctional living and working space. "This will result in completely new user expectations of the materials used," explains Jochen Hardt, who heads Global Marketing Mobility at Covestro, in a plenary lecture on the first day of the congress. Covestro presented a premium interior concept for this at the K 2019 plastics trade fair. The prototype developed together with partners will also be shown at the VDI Congress.

Multifunctional interior

"At the same time, the concept offers new opportunities for differentiation for the automotive industry," says Jochen Hardt, who is also a member of the expert committee for the VDI Congress. The comprehensive approach is equally concerned with functionality, comfort and design, but also with efficiency and light weighting. Highlights include multi-sensory infotainment systems, innovative seating concepts, smart surfaces and personalized lighting.

Of particular importance is a continuous fiber-reinforced thermoplastic composite material which Covestro offers under the name Maezio^®. It is extremely robust and lightweight and offers a great deal of design freedom. In the interior it is used in the seat shells and in a new space-saving table concept. The material also proves its versatility in the recently published compendium "Car Design Review 7", whose cover is made of CFRTP material. It is a leading resource for car designers worldwide and also includes an interview with Jochen Hardt on the interior concept.

New safety concept for the battery

A lithium-ion battery is the heart of the electric and hybrid car of the future. In its design, it is not only a question of high performance, which largely determines the range of the vehicle, but also of the greatest possible safety, for example in the event of an accident: On impact, the battery modules or cells could be damaged or cracked and possibly overheat or even catch fire.

Covestro has recognized this danger and developed a new concept for a battery housing based on the Baydur^® PUL polyurethane system in combination with pultrusion technology. This is a continuous process for the efficient production of fiber-reinforced plastic parts.

In a presentation on the first day of the congress, Galen Greene will report on the special mechanical stability of this material combined with its low weight. "We would like to make our contribution to making electromobility safer, more economical and therefore more attractive with such developments and the associated tests," the Covestro battery expert explains. "To this end, we are also seeking partners for the further optimization of this promising battery concept."

In focus: plastic recyclates in cars

Jochen Hardt is also a panelist in a discussion on the subject of “Recyclates – opportunities and general conditions for the use of plastics in the vehicle of the future" on the first day of the congress. Covestro is strongly committed to the recycling of plastics and the use of alternative raw materials. With a long-term program, the company wants to focus strongly on the circular economy and to be a shaping force for the plastics industry. The company is also showing developments on these topics at its virtual trade fair stand.

Covestro has been using bio-based raw materials and CO₂ in production for years. Recently, a strategic cooperation was also agreed with the Finnish chemical company Neste on the supply of material from renewable sources. It is intended to replace an important part of the fossil raw materials previously used for the production of polycarbonates.

Covestro is currently working with partners to develop innovative technologies for recycling plastics. The company is also a member of the Circularize Plastics project group. Its aim is to establish a new standard for the traceability of plastics back to the raw material to facilitate effective recycling.

The new model features a creative multi-material design concept: The structural frame in the center is made of aluminum and magnesium alloy, while the front and back shells have been given the highly-coveted look of carbon fibers. It is also designed with an advanced lock system featuring the absence of rivets and screws, giving it a smooth, minimalist finish.

Despite the dramatic decrease in travel due to the corona crisis, TUPLUS believes the travel industry will bounce back steadily as travel restrictions are eased in China and the world. “People haven’t changed in that they still want to travel, but we need to adapt to the new times ahead and to the new needs of tourists to feel safer,” says Catherine Jiang, President & CEO of TUPLUS. “High-quality materials are always at the heart of our design concept because we know our customers rely on them for travel safety and security. Covestro’s Maezio® composites have allowed us to take advantage of the superior strength and premium value of carbon fiber, to offer our customers enhanced protection and an entirely new travel experience.”

Performance meets design

On and off airplanes, in and out of car trunks, natural wear and tear – luggage needs to be robust. Maezio® thermoplastic composites are based on a polycarbonate matrix system. The intrinsic toughness of polycarbonate has made it a staple material for hard-shell suitcases for decades. Carbon fiber reinforced polycarbonate composites take stiffness and impact resistance to a new level. They can reduce the risk of damage and deformation, even when compared to metal, without adding weight.

Rigorous safety tests ranging from drop and tumble tests to falling ball impact tests have shown better impact resistance of composite shells compared to aluminum. This means the material can better protect articles in the luggage against perils, in particular sensitive equipment like cameras and high-end electronics.

A suitcase built to last also needs to look good. With a natural, unidirectional carbon fiber appearance, Maezio® composites break away from the traditional woven look of carbon fiber, while striking a chord with natural materials like wood in its looks and aesthetics. The simplicity and authenticity of that visual language is a good source of inspiration for designers.

Designed for scale

Performance and design are only the starting points for luggage manufacturers however, as they need to integrate new materials which can also be manufactured cost-efficiently at scale. Despite its popularity, carbon fiber luggage is known to be laboriously hand-crafted, driving up costs and making them difficult to scale.

Maezio® materials on the other hand, are thermoplastic composites, which can be thermoformed efficiently at high yield rates and low cycle times, making them ideal for mass production. Not all carbon fiber suitcases need to be thermoformed however – the unique design of the front and back shell structures of TUPLUS luggage allows composite sheets to be integrated directly into the production line and assembled after proper cutting and coating. This design approach is unique to expedite the scaling of carbon fiber suitcases.

“We believe our thermoplastic composite solutions will accelerate the adoption of carbon fiber composites in luggage thanks to their unique performance, aesthetic and production advantages,” says Lisa Ketelsen, Head of the thermoplastic composites business of Covestro. “Meanwhile, we’re also working on thermoformed, 3D luggage cover solutions to make composites available for a wide range of suitcases and allow more and more consumers to enjoy the performance and lifestyle benefits of composites.”

Based on its innovation leadership, Covestro was chosen as partner by Toyota Boshoku Corporation, a car component manufacturer of the Japanese Toyota Group, for jointly developing a new polyurethane composite material for the new electric concept car “LQ” developed by Toyota Motor Corporation. The material is based on a combination of Covestro's advanced Baypreg^® F NF technology and Toyota Boshoku's expertise in using kenaf fibers, and offers a lightweight and sustainable solution. In the “LQ”, the new product is used in door trims, where it makes its world premiere in a car model of this manufacturer.

Kenaf is a member of the hibiscus genus and is growing in regions such as South East Asia, Bangladesh, India and Africa. The fiber is obtained from bast fibers of the kenaf plant and has recently attracted increasing attention as a cost-effective raw material with good mechanical properties. In the automotive industry, the plant fiber is also attracting increasing interest as an alternative raw material.

Light and stiff

The kenaf fiber-reinforced polyurethane foam composite is characterized by a very low area density of less than 1 kg/m² and high strength, making the door trim made of the fiber-reinforced kenaf polyurethane foam 30 percent lighter than that produced from conventional materials. The lighter the material, the further the car can travel on a single gas or battery charge.

The new composite material was developed in close cooperation between Toyota Boshoku and Covestro's recently renovated Japanese Innovation Center. “Our joint development makes an important contribution to the design of particularly lightweight and sustainable vehicles,” says Hiroaki Ido, Head of Polyurethanes Application Development for Transportation at Covestro's Japanese Innovation Center. “It is also a good example of our company's focus on using alternative raw materials and establishing a circular economy.”

During the JEC World 2020 trade fair in Paris from March 3-5, Covestro will be presenting innovative and sustainable material solutions for various industries at Booth K6 in Hall 5. One important application is lightweight and robust components for vehicles that reduce fuel consumption and CO₂ emissions or increase the range of electric cars. With such products, Covestro is also contributing to the fulfillment of the UN goals for sustainable development (UN-SDGs).

In cooperation with customers and partners and through own developments, the range of applications for Covestro composites has again been expanded in comparison to the previous year. The range extends from pultruded profiles and facade mounting elements to large rotor blades for wind turbines, miniaturized electronic components and sports articles produced in large quantities with short cycle times.  

Robust, lightweight, aesthetic – thermoplastic composites in focus

Covestro has developed a new composite technology that facilitates the industrial-scale production of particularly thin, lightweight, high-strength yet aesthetic parts. It is based on Continuous Fiber-Reinforced Thermoplastic Polymers (CFRTP) and is marketed under the name Maezio™. Thermoplastics like polycarbonate are used as substrate material, and carbon or glass fibers are used for reinforcement.

One current example of an application is the redesigned wheels of the ES8 and ES6 SUVs of the Chinese electric car start-up NIO. At the K 2019 plastics trade fair, Covestro presented decorative wheel blades made of CFRTP composites with which the wheels can be optionally equipped. The benefits mentioned above, including aesthetics, play an important role here.

Another project is the design of an ultra-thin but very robust table as part of a new car interior concept, which Covestro developed together with partners and presented at K 2019. The table requires minimal design space and impresses with its high aesthetic and surface finish.

In addition to the innovative thermoplastic composites, Covestro is also presenting a particle foam made of expanded polycarbonate (EPC) at the JEC World 2020, which is characterized by very good mechanical properties over a wide temperature range, excellent impact strength and good fire protection. The material can be used in high-quality lightweight construction applications and is also recyclable.

High-strength, effective, durable – focus on thermoset composites

Polyurethane (PU) composites have also long been one of Covestro's core competencies. Together with partners along the value chain, the company is pushing ahead with the development of industrial production of these composites using the effective pultrusion process.

The highly reactive and aromatic PU matrix Baydur^® PUL is noted in various applications by outstanding mechanical properties and good wetting of the reinforcing glass or carbon fibers. At the JEC World 2020, Covestro will be exhibiting an example of a chassis component for light commercial vehicles developed and manufactured by Carbon Truck & Trailer GmbH using pultrusion.

The same material can be used to produce profiles for the lower part of the battery box of electric vehicles, for example. These profiles show their highest strength in the longitudinal direction and hold battery modules securely in shape, as has been proven in standard industrial tests for side impact protection. At the same time, the components can be produced efficiently and cost-effectively and can be easily combined with other materials.

The aliphatic PU system Desmocomp^® AP is particularly recommended for outdoor pultrusion applications due to its unique UV and weather resistance. One of Covestro's customers, Fisco GmbH, has used it to produce pultruded mounting elements for exterior facades that are not only weather-resistant but also inherently flame-retardant and mechanically robust. In addition to these elements, Fisco GmbH is able to fulfill the strict thermal efficiency requirements of this application. This property combination is well achieved with Covestros matrix material Desmocomp^®.

Efficient production of rotor blades

The expansion of renewable energies, especially wind power, plays a decisive role in effective climate protection. More intensive use in this area will require more cost-effective production of wind turbines with even longer rotors and thus even greater power output.

A polyurethane resin developed by Covestro allows lighter, longer and more robust rotor blades than the established systems used so far. This is the finding of a recent study by WINDnovation Engineering Solutions GmbH, a leading company in rotor blade design. In combination with glass fiber mats and an efficient vacuum infusion process, the resin can be used to achieve short cycle times in production and thus achieve significant cost savings.

PU dispersions to optimize the sizing of fiber reinforcement

Covestro's wide range of products exhibited at the JEC World 2020 also includes aqueous PU dispersions. They are used as film formers and crosslinkers in the formulation of sizings for glass, carbon, basalt, natural or other types of fibers. Baybond^®, the front-runner in the fiber sizing portfolio, is highly suitable for both thermoplastic and thermoset matrixes.

Attendees at Pharmapack, February 5-6, in Paris, can visit the Covestro booth (K46) to learn more about the company’s polycarbonate materials for the healthcare industry. Covestro will also highlight its materials at booth #2221 during MD&M West Conference and Exposition, February 11-13, in Anaheim, California.

Smooth delivery with low-friction polycarbonate

More and more, patients are using autoinjectors and injection pens to self-administer therapeutics from the comfort of their own home or on the go. These devices are expected to operate consistently every time, and utilize low-friction components to ensure injections are reliable and smooth.

To meet challenging low-friction requirements, Covestro is launching three new medical-grade polycarbonates: Makrolon^® M204 LF, Makrolon^® M402 LF and Makrolon^® M404 LF. Featuring reduced coefficients of friction, these grades deliver the excellent dimensional and mechanical properties of polycarbonate while eliminating the need for external lubricants.

The new low-friction Makrolon^® polycarbonates offer the following benefits to drug delivery devices:

• • Lower deployment forces
  • Durability and biocompatibility according to ISO 10993-1
  • Sterilizable with various methods, including autoclave, ethylene oxide and radiation (e-Beam, gamma)

“We built on the superior performance of polycarbonate to formulate low-friction grades that offer consistency and versatility which, in turn, help OEMs design devices that address emerging drug delivery trends,” said Doug Hamilton, global healthcare marketing leader, Covestro LLC.

Superior strength with glass-filled polycarbonate

Covestro also developed new glass-filled polycarbonates for surgical and drug delivery applications that demand stiffness and strength, such as load-bearing internal components for drug delivery devices and handles for minimally invasive or laparoscopic surgical tools.

These grades are divided into two series with varying levels of reinforcement. The high-performance series includes Makrolon^® M810 GF, Makrolon^® M820 GF and Makrolon^® M830 GF polycarbonate. In the high-flow series, Makrolon^® M410 GF, Makrolon^® M420 GF and Makrolon^® M430 GF polycarbonate are used for filling larger or thinner parts with improved productivity.

Additional advantages of Makrolon^® GF polycarbonates include:

• Biocompatibility according to ISO 10993-1 for applications less than 30 days
• Superior rigidity and strength
• High-gloss surface achievable with rapid heat cycle molding
• Higher tensile modulus and tensile strength, and improved dimensional stability under stress when compared to unfilled polycarbonate

“Our expanded materials offering gives healthcare OEMs access to a wide range of glass-filled polycarbonate products that deliver performance tailored to fit their applications,” said Hamilton.

GAC describes the ENO.146 as one of the most aerodynamically efficient vehicles in the world, thanks to a drag coefficient of only 0.146 (hence the name) and a NEDC (New European Driving Cycle) range of 1,000 kilometers. While a fully aerodynamic design is key to achieving such performance goals, the GAC R&D Center also uses lightweight and sustainable materials to reduce the weight of the car while raising the bar for sustainability. Covestro’s Maezio™ thermoplastic composite material is one of them.

“Mobility trends such as electrification and autonomous driving are redefining the role and function of car interiors,” says Zhang Fan, Vice President of the GAC R&D Center. “There is a growing need for material solutions that are lightweight and sustainable while opening up ways to create new user experiences ranging from visual to tactile feedback.”

Beyond weight savings

The backrests of the two front seats of the concept car are made of Maezio™ CFRTP, the reinforced thermoplastic composite material from Covestro. It is estimated that the composite seat backrest can save up to 50 percent in weight compared to typical metal constructions.

“Seats in the passenger compartment are an ideal target for weight savings, as they are among the heaviest parts there,” says Lisa Ketelsen, head of Covestro's thermoplastic composites business. “Fibre reinforced composites are the ideal material for lightweight automotive construction, but Maezio™ can further simplify molding and streamline the manufacturing process.”

In the case of a seat with a metal backrest, fittings and other attachments add to the complexity of production and assembly. Since Maezio™ is a thermoplastic material, parts and functions can be consolidated by injection molding processing. Functional structures are incorporated into the mould for shaping the backrest, reducing the number of parts and materials.  

Sustainable material

From the CMF (Color, Material, Finish) perspective, the design of the vehicle interior in ENO.146 was inspired by nature. According to Stephen Chen, chief designer in Advanced Design, GAC R&D Center, the choice of green color and various sustainable materials is intended to recreate the ambience of a lake with lotus flowers. The surface pattern of the front of the seat, for example, is designed to resemble that of lotus leaves.

“The backrest must fit into this design concept as a visible component, so the material must have a natural look and feel and high aesthetic value, and it must also be recyclable,” says Stephen Chen.

And this is exactly where Maezio™ comes in. This thermoplastic composite material can be cut and shaped at will to be reused at the end of its service life, giving it a unique marble-like appearance and a high quality look and feel, making it a sustainable material choice that fits perfectly into the design concept of the vehicle.

This first distribution partnership in Europe for the thermoplastic composite business of Covestro is a response to the growing demand for materials that are designed for lightweight construction yet as robust as metal.

Best possible solutions for customers

“We’re super excited to introduce BÜFA as part of our distribution network around the globe,” says Lisa Ketelsen, head of the thermoplastic composites business of Covestro. “In the future we want to nurture our mutual exchanges on market trends and customer needs in order to find the best possible solutions for our customers.”

“We’re thrilled to add Maezio™ into our product portfolio,” says Dirk Punke, Managing Director of BÜFA Thermoplastic Composites. “The tapes can be made particularly thin, but have a high stability and are especially light at the same time, which enables the production of complex and three-dimensional components in a wide range of industries.”

Maezio™ UD tapes are based on a thermoplastic matrix such as polycarbonate, which is strengthened with strands of continuous, oriented carbon or glass fibers. The UD tapes can be laminated together at different angles to form sheets that can be tuned to specific performance targets.

Based in Oldenburg, Germany, BÜFA Thermoplastic Composites GmbH & Co. KG is a spin-off of the BÜFA Group and was founded in 2018. It specializes in the sale of raw materials and semi-finished products for the manufacture of components from long and continuous fiber-reinforced thermoplastics.

"The car of the future is fully networked and is seamlessly integrated into everyday life, where it provides the user with new experiences and the greatest possible autonomy," said Jochen Hardt from Global Marketing Mobility at Covestro. At the unveiling of the prototype, the project manager added: "Modern materials and technologies have paved the way for this. Covestro is a leading player here. In cooperation with partners, we keep pushing the boundaries of what is possible."

The concept focuses equally on functionality, comfort and design, but also on efficiency and light weight. The focus is on multi-sensor infotainment systems, innovative seating concepts, smart surfaces and personalized lighting. High-tech materials from Covestro open up a kaleidoscope of new possibilities for many different components. A selection of the developments is presented below.

The highlight: a large multifunctional display

Special emphasis is placed on a seamlessly integrated, three-dimensional multifunctional display – a large-format visual experience for the user, made possible by the high optical quality of Makrolon^® Ai polycarbonate and Makrofol^® polycarbonate film. A sophisticated combination of In Mold Decoration (IMD) and Film Insert Molding (FIM) provides for the surface design and durability. The latest Human-Machine Interfaces (HMI) support passenger communication with the car and the outside world. Such polycarbonate films may also serve as a moldable carrier for printed electronics, enabling the integration of additional functions.

In the car exhibit at K 2019, Covestro will also present functional surfaces with premium look and feel. In addition to the use of polycarbonates and the INSQIN^® technology for textile coating, the particular appeal lies in the combination of unusual materials such as wood, stone and aluminum.

New seating concepts for future mobility

As the classic function of the driver's seat is no longer required, the car interior can be given a new look and design. Not only should the seats be comfortable, they should also offer enough flexibility to expand the interior space. An integrated and individually configurable lighting system ensures comfort and safety and enables car manufacturers to differentiate their brands.

Here, too, Covestro materials are trailblazers for the properties and advantages mentioned, for example polycarbonate composites of the Maezio™ brand. In the seats, they provide a new aesthetic appeal and robust structure, while Makrofol^® films combine design and functionality. The vegan and waterbased INSQIN^® technology for textile coating offers the same attractive appearance as leather, but at lower cost and with reduced solvent emissions. Here, the possibility of allowing light to shine through the coated surface and creating a completely new type of ambient lighting is attractive.

Flexible table construction

Together with partners, Covestro has developed a lightweight table that is tailored to new usage habits in autonomous vehicles and offers a lot of flexibility. The prototype shown at K 2019 is made of Maezio™ composite material and convinces due to its thin-walled construction, aesthetics and stability. The table can be designed to be foldable so that it can be stowed between the rear seats to save space.

The new movable Privacy Dome is designed to protect users' privacy. A sound-absorbing acoustic foam based on the Baynat^® polyurethane system provides each passenger with individual peace and quiet, independent of other passengers and the outside world. In addition, passengers can enjoy relaxing sounds such as the soothing sound of waves on the beach.

In addition to digitalization, the UN goals for sustainable development will especially influence the economy and society in the coming years. Covestro is determined to realize these sustainability goals at many levels. Meeting them is not only a prerequisite for a better, cleaner and healthier world, but also has great long-term economic potential

Change to circular economy indispensable

“Megatrends such as climate protection and population growth require a fundamental rethink in lifestyle and consumer behavior, not to mention in global production,” CEO Dr. Markus Steilemann said to journalists. “We need a complete transition from a throwaway to a circular economy in order to handle limited resources more responsibly and protect the climate.”

Covestro is committed to establishing new material cycles throughout the entire process chain with a view to making a tangible contribution to achieving this major goal. “We have set up a comprehensive and long-term program which will also open up new opportunities for value creation,” Steilemann explained. “High-quality plastics are and will remain drivers for sustainability and for overcoming global challenges. However, it is crucial to decouple the economic growth achieved from the consumption of fossil resources such as crude oil.”

Turning away from crude oil

A key aspect for developing a circular economy in the plastics and chemical industry is the closure of the carbon cycle through the recycling of raw materials. “In the long term, we want to do as much as possible without fossil resources and use alternative sources such as waste, plants and CO₂ instead,” said Steilemann. “In particular, used plastics are a valuable resource. That's why we want to work with partners to intensively develop innovative recycling methods,” said the Covestro CEO. Under no circumstances should plastic waste be allowed to enter the environment uncontrolled for longer. The industry is working intensively worldwide for better waste management – for example in the Alliance to End Plastic Waste, of which Covestro is a member.

Given its importance, the company is dedicating a special Theme Day to Circular Economy at its booth on Wednesday, October 23. External and in-house experts present practical examples and discuss with visitors. At the Covestro booth, these will also find many examples of products and technologies that can help close material cycles in various industries.

Covestro is one of the pioneers in the use of the exhaust gas CO₂ as a new raw material. A team from Covestro and RWTH Aachen University is now in the final round of the German President´s Award for the development of a corresponding process. Exhibits based on this technology will be specially featured at the booth. With modern materials and technologies, the company also supports the supply of energy from renewable sources.

Digitalization as a growth driver

Another driving force for the development of the economy and society in the coming years is the ongoing digitalization. Covestro wants to take advantage of the resulting opportunities and has started a comprehensive strategic program, which focuses on the customer. To this end, the company is anchoring digital technologies and processes along the value chain – from the supply chain through production, research and all interfaces to customers to the development of new business models. Various developments and exhibits at K 2019 as well as a separate Theme Day on Tuesday, October 22, underscore the great importance of digitalization for Covestro and its customers.

A stage for visitors

“We cordially invite all visitors to K 2019 to our booth in hall 6,” says Booth Manager Dr. Ulrich Liman. “We will be providing them a stage for discussions on their themes and wishes. They will also find products and technologies for important key industries.”

“A special experience awaits visitors in our ‘Sample Parcours’,” explains Liman. “There they can get to know materials and patterns through their senses, through seeing, feeling and hearing, but also in a playful manner. For example, join our Life Cycle Wheel and learn more about the circular economy! Or test your knowledge of plastics on our Quiz Machine.”

Theme Days from Automotive to Science

On each of the eight days of the fair, visitors can experience how Covestro is pushing boundaries on a different main theme. Lectures and discussions with experts from industry and academia will serve to deepen the topic and promote personal exchange.

All journalists are cordially invited to visit Covestro's press center at the A 75 exhibition booth gallery in Hall 6. You will have the opportunity to talk about the innovations and topics on display and receive the Covestro press kit for K 2019. On request, we would also be happy to give tours of the booth or arrange interviews.

Automotive (October 16)

The highlight of Covestro's trade fair appearance is a comprehensive interior concept for future mobility: trends such as autonomous driving, electric drive and car sharing make the automobile a multifunctional, mobile living and working space. It's all about functionality, comfort and design, not least also about efficiency. Covestro has developed the concept together with important partners along the automotive value chain. The main features are newly designed surfaces, the integration of ambient lighting, the latest infotainment systems and forward-looking seating concepts. On Wednesday, 16 October, the company will dedicate a special Theme Day to the automotive industry.

Science Celebration (October 17)

The second day of K 2019 is dedicated to current and outstanding research findings in polymer science. The highlight will be the presentation of the Covestro Science Award to a professor in the presence of invited guests from the world of science. The prize consists of a three-year doctoral fellowship to promote young scientists in materials research at universities. In addition, a researcher from Covestro will be awarded the Covestro Science Medal for outstanding scientific developments.

Start-up Challenge (October 20)

With the Start-up Challenge, Covestro aims to promote the creativity and entrepreneurial thinking of its employees and find the best business idea of 2019. The winners of the first competition will be chosen at the trade fair: they will be able to work as founders, implement their ideas and test their marketability. In return, they will receive start-up financing of up to one million euros, be released from their jobs for up to one year and can work within the company as start-ups. The ideas of the six finalist teams are focused on the development of the circular economy.

Local talent search

At K 2019, Covestro also will be presenting itself as an attractive employer to students, junior employees and experienced professionals. Curious jobseekers will find the right person to answer all their questions at the Career Bar.

The shoes satisfy the wishes of athletically active people for a healthy lifestyle, improved performance and individuality. Various material solutions from Covestro are worked in a seamless design, exemplifying the individual benefits of each material: INSQIN^® water-based polyurethane (PU) textile coatings and adhesives, PU foams, textile fibers and films made of thermoplastic polyurethane (TPU) and Maezio™ continuous fiber-reinforced thermoplastic composites (CFRTP).

“For me new materials are one of the most powerful driving forces for creative shoe design and for exploring new possibilities,” says Axis Liu. “Therefore, I appreciate the know-how of the experts at Covestro and I will continue to benefit from this in the future.” The cooperation between Liu and the Covestro team resulted in athletic shoe concepts that set standards in many respects: they are highly sustainable and light, yet extremely durable. They provide increased foot stability and help to compensate for the forces acting on the feet, in order to achieve improved athletic performance.

Running shoe with 3D-printed midsole

For the design of the running shoe, Axis Liu was inspired by a traditional figure from Chinese arts and craft: the “Multilayer Carved Ball” which has a dynamic structure handmade up of several layers. On the running shoe, the dynamic, extraordinary structure of the midsole was produced by a 3D printer.

Because running shoes are often worn outdoors for several hours at a time, it is particularly important for the upper material to be water resistant and breathable. This functionality is achieved on the concept running shoes by using a special INSQIN^® coating.

Conventional adhesives based on Dispercoll^® U dispersions join together the individual athletic shoe components securely, easily and efficiently. This water-based adhesive technology helps conserve energy and resources. It also contributes to making athletic shoe production more sustainable.

Basketball shoe with good shock absorption

During development of the basketball shoe, however, the designer drew inspiration from the world of toys and the modular construction often found there. Of course, his designs also took into consideration that the feet and bodies of basketball players are strained in different ways than those of runners.

In accordance with the different requirements of both sports, there are also differences in the individual components of the materials used. For example, the midsole of the basketball shoe was made using in-mold foaming and contains expanding TPU (ETPU), which provides good shock absorption and at the same time features particularly high restoring forces. This enhances performance for the jumping and quick acceleration that are common in basketball.

Both shoes use the newly developed Maezio™ carbon fiber-reinforced TPU (CFRTP), which is very light, but also extremely stiff and torsion resistant. This unique material combination offers a high degree of design freedom and a strong aesthetic appeal with unique, unidirectional carbon fiber optics; in addition, it is recyclable.

Other materials and their function

Apart from that there are many similarities between the two concept athletic shoes:

• The uppers of both shoes contain TPU fibers. These are highly resistant to abrasion and tearing, yet they feel extremely comfortable.
• The running shoe upper is applied with screen printing. This is the printing solution using INSQIN^® technology which is now used by world-leading manufacturers and brand owners. It provides a visual-haptic effect and improves the performance of design and manufacture.
• The Shoe tongue label with Chinese Character “聚”(jù) is applied using a TPU hot-melt film with good printability. 聚” means gather together, it demonstrates how well films of brand names Dureflex^® and Platilon^® adhere to textile materials with soft surface feel.
• Insoles made of viscoelastic PU foam effectively absorb mechanical loads.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
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Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

The lightweight components also enable commercial vehicle manufacturers to meet the increasingly rigorous European Union limit values,” explains Gerret Kalkoffen, Chairman of the Board of CarbonTT. “Logistics companies can use the vehicle to transport larger loads and thus operate more efficiently. In electric mobility, the lightweight chassis compensates for the weight of the battery and at the same time features simpler assembly and superior crash performance.”

Continuous production from polyurethane resin

At K 2019 plastics trade fair from October 16 to 23, Covestro will showcase such a composite component. It can be produced continuously by pultrusion with a Baydur^® PUL polyurethane (PU) matrix system. “With this system, we are pushing boundaries by providing a number of advantages over conventional materials,” says Benedikt Kilian, Project Manager for Process Development in the Polyurethanes segment at Covestro. “The material properties of the end part also meet stringent OEM specifications while enabling a lighter structure. Within seconds, the Baydur^® PUL low-viscosity system penetrates millions of carbon fibers perfectly and enables CarbonTT to achieve significant productivity gains.”

The profile design of the composite part was developed and optimized by CarbonTT to meet the mechanical requirements, achieve maximum weight reduction and minimize costs. Covestro supports CarbonTT with its Baydur^® PUL system and with its expertise in optimal pultrusion processing. Pultrusion runs have been successfully performed to demonstrate the benefits of the PU system and are being expanded.

The pultrusion process is a continuous process that can be automated to a high degree and is currently in the process of achieving industrial application. This makes it possible to produce differentiated and complex composite parts extremely efficiently, especially if a suitable polyurethane resin is used.

Beneficial process properties

Compared with other resin systems used for pultrusion, Baydur^® PUL has superior component and processing qualities. The superior mechanical properties of parts with a PU matrix enable customers to develop thin profiles and, where possible, use less complex fiber reinforcement. The viscosity of the system is also very low with high reactivity, which allows customers to produce very efficiently at high throughput rates.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

New aesthetic, improved aerodynamics

The wheels feature aluminum rims with opt-in carbon fiber blade inserts, designed to lend the vehicle a high-end aesthetic appeal with a lightweight flavor and improved aerodynamics. What Maezio™ composites bring to the table is a combination of a unique appearance with unidirectional carbon fiber optics and a wide variety of finishing options. Further information on these products can be found here.

“Maezio™ composites are a very unique material because they kind of redefine how beauty is associated with carbon fibers,” says Yanbing Wang, Senior CMF designer from NIO. “They have set a new aesthetic direction with the unidirectional strands of fibers that remind me of the flowing shapes of rocks within the Antelope Canyon. It feels dynamic and full of energy.”

To achieve a high level of aesthetics, the choice of the resin system is crucial. Polycarbonates boast high surface quality and optical performance. Furthermore, polycarbonate-based composites are compatible with a wide range of coatings and decoration processes for designing unique surfaces. This makes it possible to develop a clear matt-coating system for the wheelblade that not only retains the beauty of the unidirectional fibers but also provides the needed protection – wheels are every vehicle’s touchpoints with the road, and as such, must perform flawlessly.

A technical breakthrough

Automotive exteriors exist in a harsh environment, and the requirements are demanding. Parts have to display high scratch-, weather-, ageing and chemical resistance properties. For wheel blades comes the additional requirement of high heat resistance during braking. So automotive exterior components not only have to look good after years of use but also perform on an everyday basis under tough conditions.

In combination with the coating system, the composite wheel blades have withstood rigorous safety and performance requirements, such as impact, chemical and weather resistance. The Makrolon^® polycarbonate on which Maezio™ is based displays high thermal stability qualities so the wheel blade insert can survive braking-induced temperatures of up to 150° C.

A seamless integration

For composites to be widely adopted in automotive they also need to be easily integrated with other materials in a multi-material system. Because of their thermoplastic matrix system, Maezio™ composites can be easily joined with functional components during processing, e.g., through back injection molding. In the case of the wheel blade inserts, they are joined with the aluminum spokes of the wheel through back-molded screw bosses made of polycarbonates. The common resin material makes it easy and secure to bond the two parts.

A second life

Car manufacturers are under pressure to make their vehicles less environmentally impactful. Electric vehicles are ahead of the curve, and so it’s natural that EV manufacturers are on the lookout for materials that are easy to recover and recycle.

Maezio™ composites can be cut and remelted for reuse at the end of life, or reground into short fiber compounds and used in an injection molding process, making them a sustainable material choice for EV manufacturers to further improve their sustainability scorecard.

“We have proved with this major breakthrough that Maezio™ composites are a technically and commercially viable material solution in automotive exterior applications,” says Lisa Ketelsen, head of the thermoplastic composite business of Covestro. “The end result is a newly defined aesthetic direction and benchmark for thermoplastic composites in automotive. We look forward to helping the automotive industry scale new heights with the benefits thermoplastic composites have to offer.”

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

Visitors to the world’s premier fair for the plastics and rubber industry will find many examples of this presented by Covestro at Booth A75 in Hall 6. From October 16–23, 2019, products and technologies for the automotive, construction and electronics industries will be on display, but also innovative and functional applications in the health, furniture, sports and leisure sectors.

“In addition to the advancing digitalization, the United Nations Sustainable Development Goals will be a driving force in society and the economy for the coming years,” said CEO Dr. Markus Steilemann to journalists. “Their fulfillment is not only imperative for a better, cleaner and healthier world, but also holds great economic potential in the long term,” explained the CEO. “Covestro is determined to realize the UN sustainability goals at many levels.”

Industry pioneer

Steilemann named the development of a functioning circular economy and improved management of limited fossil resources, primarily crude oil, as central points for increased sustainability. “These are goals that will impact society as a whole and Covestro wants to contribute to this. Within our company, we want to establish material cycles along the entire value chain, from suppliers, to production and logistics, to the use of our products and their reuse,” explained Steilemann.

When recycling used plastics, it will be important to be able to exhaust all technical possibilities. “The relatively new method of chemical recycling is also an option, which requires additional support,” said the CEO.

A key aspect for developing a circular economy in the plastics and chemical industry is closing the carbon cycle with recycled resources. Here, plant waste and increasingly CO₂ are worth considering as alternatives to fossil resources. Covestro has already achieved numerous successes in these areas. “We want to become a pioneer on the path toward a future without fossil-based resources and emphasize our claim to leadership in the industry,” stressed Steilemann.

Digitalization creates added value

Another driving force is the advancing digitalization. Covestro wants to take advantage of the resulting opportunities and has started a comprehensive program, which focuses on the customer. To accomplish this, the company is incorporating digital technologies and processes into production, the supply chain, research and development, at all customer contact points and in new business model development. Various topics and exhibits at K 2019 underline how important digitalization is for the company, which hopes to set standards in this field in the plastics and chemical industry.

The examples below give an impression of the wide range of developments that Covestro will present at K 2019.

Completely networked society

One important requirement for future mobility and the digitalization of all areas of life and business is the new transmission technology 5G. To build the infrastructure for it, Covestro is working together with Deutsche Telekom and the Umeå Institute of Design to develop innovative material solutions for base stations, antennas and other system components. Covestro is also working on a multi-layered film solution in conjunction with a new manufacturing process for the backs of smartphone bodies. Unlike conventional metal elements, these polycarbonate films are permeable to high-frequency radiation.

Auto interior of the future

The highlight of the trade show exhibit is a comprehensive interior concept for future mobility. In line with the latest trend, it intends to turn car interiors into multi-functional, mobile living and working spaces. “We developed the concept together with key industrial and academic partners,” explained Jochen Hardt, marketing expert at Covestro and head of the project. “It involves functionality, comfort and design in equal measure, as well as efficiency.” The car of the future is fully networked and is seamlessly integrated into everyday life. Key design features are surfaces with a decorative look and feel, integrated ambient lighting, the latest infotainment systems and cutting-edge seating concepts.

Textiles with CO₂

Together with partners such as RWTH Aachen University and various textile manufacturers, Covestro succeeded in producing elastic textile fibers from thermoplastic polyurethane with CO₂, and as a result partially replaced crude oil as the raw material. The starting point is an intermediate product called cardyon®, which is already used for the soft foam found in mattresses and the base layers of sports fields. The partners are currently working on developing production to industrial scale and want to introduce a material cycle that is based on sustainable resources to the textile and garment industry.

Renewable energies on the rise

In addition to promoting an efficient circular economy, Covestro is also committed to further expanding renewable energies, such as wind power. Cooperation with partners has led to the development of a polyurethane resin as well as a process technology, which makes it possible to manufacture wind turbine rotor blades efficiently and cost-effectively. The company just recently processed its first commercial order for this from China.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

For more information please see www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports. These reports are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to make them conform to future events or developments.

"Our comprehensive concept includes developments, which may become reality in a few years, but it also includes visionary ideas for the future," explains Jochen Hardt, Global Marketing Mobility at Covestro and project manager for the new concept. "We are particularly focused on the interior design, which can be both living and working space in an autonomous vehicle, offering customized experiences to the user. Future vehicle concepts for electromobility offer car manufacturers opportunities for completely new room concepts and additionally open up a new ground for brand differentiation.”

Smart materials in the future car interior

The interior is equally a matter of functionality, comfort and design, but also of efficiency. The focus is on optically and haptically designed surfaces, the integration of ambient lighting, latest infotainment systems and novel seating concepts. High-tech materials from Covestro open up a kaleidoscope of new possibilities for many different components.

For example, Makrolon^® polycarbonates and their blends will play an important role in the interior of the future thanks to their outstanding properties. They are notable for their maximum design freedom, mechanical stability and low weight. In addition, they provide good thermal and electrical insulation. Makrolon^® enables a range of glass-like surfaces and up to various functional colors. This is important for the integration of future innovative displays, sensors, cameras and ambient lighting systems.

Maezio™ continuous fiber-reinforced thermoplastic composites from Covestro constitute a special class of composites. They are based on polycarbonate, but more robust and lightweight, due to reinforcement with carbon fibers, and are suitable e.g. for an efficient production of particularly thin-walled parts.

New dimension of infotainment

Makrofol^® polycarbonate films are used, for example, for printed, even three-dimensional large-scale cover plates for the integration of displays. The films also serve as carrier for printed electronics in touchscreens. The number of such display surfaces and touchscreens in car interiors will increase drastically due to the progressing digitalization and networking (connectivity) as well as the trend towards autonomous driving. The seamless integration of displays is also supported by a new generation of Makrolon^® AI polycarbonate materials.

Covestro also offers a range of Platilon^® thermoplastic polyurethane (TPU) films. Among other things, they are used as hotmelt films for bonding different materials like textiles. The sustainable INSQIN^® technology is used for textile coating in the car interior; it is based on solvent-free, waterborne polyurethane dispersions. Its use for the manufacture of coated textiles is efficient and saves water and energy, compared to conventional production.

Classic jack-of-all-trades: Polyurethane

Polyurethane is a classic but extremely versatile material for car interiors. In the form of soft or molded foam, it creates the basis for comfortable and safe car seats. Polyurethane foams have also been used for a long time in instrument panels, upholstery, trim parts and roof linings and provide comfort in the interior. With TPU coatings, surfaces can be created as desired – from particularly soft to hard.

Polyurethane coatings are also geared towards high-quality surfaces with adjustable properties. Covestro develops raw materials for robust and abrasion-resistant coatings, which are available in various colors and surface structures that protect underlying substrates and create a pleasant feel when touched. The company is also a pioneer in the formulation of aqueous coatings with low organic solvent content. Raw materials for polyurethane adhesives for solid and durable adhesive bonds round off the range.

Trendy exterior design for electric cars

At K 2016, Covestro for the first time dedicated itself to the mobility of the future on a larger scale and presented an integrated concept for the outer shell of electric cars. It was developed in close cooperation with design students from the renowned Umeå Institute of Design in Sweden and the automotive supplier HELLA. The development went beyond existing boundaries and offers new approaches for the attractive design of comfortable, functional and energy-efficient cars. The core elements are integrated sensors and antennas, holographic lighting, large-format display elements, 360-degree all-round glazing and seamless, homogeneous surfaces.

Groundbreaking achievements time and again

More than 50 years ago, still under the umbrella of Bayer, Covestro presented the first car with a complete plastic body at the plastics trade fair in Düsseldorf: the K 67. Since then, the company has repeatedly overcome the limits of the possible with innovative material solutions. Later milestones included the introduction of headlamps and automotive glazing, both made of the transparent polycarbonate Makrolon^®. Covestro was also a pioneer in coating raw materials for waterborne automotive fillers and base coats as well as for low-solvent polyurethane clear coats.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

A recent Life Cycle Assessment (LCA) has found a laptop cover made of Maezio™ continuous fiber-reinforced thermoplastic composites from Covestro can significantly reduce the carbon footprint by more than 70 percent compared to one made from conventional aluminum-magnesium alloy.

Better environmental performance across all impact categories

The LCA study, conducted in line with ISO 14040/14044 standards and reviewed by an independent panel of LCA experts chaired by DEKRA Assurance Service GmbH, compared a comprehensive range of parameters to assess the environmental performance of a laptop A-cover made from the two materials which are typically used for premium laptops. In all impact categories and scenarios, the composite laptop A cover shows better environmental performance than the aluminum-magnesium alloy cover from the extraction of raw materials until the end of life.

Even after the implementation of current technology developments – use of low impact cover gas for aluminum-magnesium alloy and potential benefits of recycling for both materials – the composite carbon footprint is still more than 30 percent lower.

“Covestro is committed to the United Nations Sustainable Development Goals and is committed to sustainability as one of the pillars of its corporate strategy,” says Dr. Frank Buckel, responsible for sustainability at the Polycarbonates segment at Covestro. “The ecological impact of novel materials like Maezio™ during the complete lifecycle is assessed to ensure that these materials reduce the impact on the environment.”

Pushing boundaries

“Thermoplastic composites are ideally suited for producing thinner, lighter and more robust parts for IT devices that meet the needs of tomorrow,” says Lisa Ketelsen, head of the thermoplastic composites business at Covestro. “The fact that Maezio™ thermoplastics are not only mechanically competitive but also environmentally advantageous will provide the electronics industry and many other industries with a powerful solution for reducing carbon footprint and reaching their sustainability targets.”

Compared to aluminum-magnesium alloys, Maezio™ composites can also achieve weight reductions of approximately 15 percent, and the composite A cover exhibits a similar good bending and torsional rigidity compared to the metallic material. Moreover, the composite A cover meets the v-0 classification of Underwriters Laboratories' UL 94 standard.

Previously Covestro received a European Plastics Innovation Award for its composite “A-cover” for next-generation laptops in 2017. The development received the second prize in the “Best Lightweight Innovation” category.

The composite technology also enables fast and efficient production of electronic parts, by combining the three conventional steps of preheating, thermoforming and functional integration into a single process. There are two positive results: substantially lower costs and shorter cycle times.

Maezio™ composites are based on continuous carbon or glass fibers impregnated with polycarbonate, thermoplastic polyurethane (TPU) or other thermoplastic resins.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

The range of applications is correspondingly large: it includes wind turbines, photovoltaic systems and auto parts, but also small-scale consumer products such as miniaturized electronic parts and insoles, which are manufactured in large quantities with short cycle times.

At the JEC World 2019 trade fair from March 12–14th in Paris, Covestro will present itself as a solution provider for various industries and applications. At Booth L5 in Hall 5, the company will exhibit its innovative and sustainable developments, which often feature the combination of low weight and high strength. Some of these components help to reduce fuel consumption and CO₂ emissions in cars, and therefore also contribute to meeting the UN’s sustainability goals.

Fiber-reinforced composites for robust, thin-walled parts

Thanks to a new composite technology, extra-thin, lightweight, high-strength yet aesthetic parts can be manufactured on an industrial scale. The technology is based on continuous fiber-reinforced thermoplastic polymers (CFRTP) and is sold under the name Maezio™. The matrix materials used include polycarbonate, and carbon fibers are added for reinforcement. At its Markt Bibart location, Covestro uses these materials to manufacture unidirectionally reinforced tapes and panels, which are further processed by customers.

These intermediate products are particularly well-suited for producing extra-thin-walled but robust housing parts for laptops and mobile phones. In line with the current trend for thin-walled devices with a cool look, they can also be made with aesthetic surface structures. The single-stage manufacturing process enables shorter cycle times and significant cost savings.

Cooperation with EconCore

Polycarbonate and its blends, as well as CFRTPs, are the material of choice for producing lighter and more stable honeycomb panels for the interior furnishings in public buses and trains. For this application, the products must comply with specific FST (fire, smoke and toxicity) requirements.

Improving the FST performance of honeycomb panels is an important goal of the new cooperation between Covestro and EconCore N.V. It involves finding the right combination of polycarbonate types and composite materials, and adapting EconCore’s honeycomb technology to meet the requirements. The overall objective is to develop lightweight sandwich panels with higher productivity than conventional composite materials.

Efficient production of wind turbine rotor blades

A core objective of Covestro’s sustainability concept is to provide active support for climate protection. One key aspect will be promoting renewable energies, primarily wind power. More intensive use in this area will require more cost-effective production of wind turbines with even longer rotors and thus even greater power output.

To achieve this, Covestro has developed a PU resin that, in combination with glass fiber mats and an efficient vacuum infusion process, enables short cycle times and thus cost savings compared with the more commonly used epoxy resin. It is also more robust and should also be suitable for larger sheet lengths. Due to its outstanding mechanical properties, it should also be suitable to produce lighter-weight blades. Last year in China, the company installed its own wind turbines with rotor blades of nearly 60 meters, in order to test the operating capability and stability under practical conditions.

UV-resistant and robust PU material for exterior use

Desmocomp^® is another highly versatile polyurethane resin, which is ideal for outdoor applications due to its excellent weather and fire resistance. The system can be easily and effectively processed using the pultrusion process.

At JEC World 2019 Covestro will present a composite application with this product in the field of solar power: Fiber Profil S.L. intends to use this Desmocomp^® aliphatic material for the assembly of large-scale photovoltaic plants and solar thermal systems. For this purpose, the fastening elements must have outstanding mechanical properties, but also need to provide reliable protection against UV radiation.

Also, among Covestro’s wide product selection at JEC World 2019 are its Baybond^® water-based PU dispersions, which can be used as a film former in fiber sizings to increase the mechanical stability of composites.

About Covestro:

With 2017 sales of EUR 14.1 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,200 people (calculated as full-time equivalents) at the end of 2017.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

Covestro has developed and tested a wide range of polycarbonates and -blends with specific grades to meet the FST performance required by railway and aviation applications. Furthermore, the company is currently developing a range of lightweight thermoplastic composite solutions under the brand name Maezio™. EconCore has developed and patented a unique manufacturing process to produce ultra-light honeycomb structures in an economic way, with a high variety of material combinations that can be fine-tuned in order to meet customers’ needs.

Meeting different requirements

Goal of the two companies’ collaboration is to optimize the FST performance of honeycomb panels in order to meet different application requirements. This shall be achieved by selecting the right combination of polycarbonate grades and composites for the honeycomb core and skin and at the same time adapting the parameters within EconCore’s honeycomb technology.

The results of preliminary FST tests, carried out by an independent institute on semi-finished, laminated honeycomb panels, are very encouraging: already at this early stage of development, sandwich-panels with different material and technology combinations have been produced and evaluated, fulfilling critical tests of EN45545 or FAR25.853 standards for various applications. Currently, the positive results of the preliminary FST tests are being verified in detailed investigations of different material combinations.

Fully integrated, continuous production

Ultimate goal of the joint development is to provide sandwich panels that fulfill the technical requirements, offer weight advantages and show better economics compared with currently used composite or metal solutions. The manufacturing process developed and patented by EconCore offers significant cost saving potential due to a high-speed and fully integrated continuous production process, where thermoplastic polymers are directly converted into a honeycomb structure and where, in addition, the sandwich skin layers can be immediately laminated onto core.

“The outstanding manufacturing process of EconCore allows tailoring our materials into lightweight sandwich panel solutions for our customers,” said Klaus Kraner, responsible for mass transportation applications in the Polycarbonates segment at Covestro. “The sandwich technology of EconCore is especially interesting for lightweight applications Covestro is targeting with Maezio™,” added Arne Böttcher, responsible for market development of the Maezio™ brand in the EMEA region.

“After succeeding in other application domains, we have decided to address inquiries of the higher end markets. The process has been proven to work very well with a wide range of thermoplastic materials, including these with FST chemistry, while EconCore’s technology has demonstrated its capability of delivering high-performance sandwich panels at high efficiency and cost levels not achievable with conventional methods,” said Tomasz Czarnecki, COO of EconCore N.V.

Finished parts in one shot

Tomasz Czarnecki adds, “We look forward to this new development and to continuing the partnership with Covestro. The polycarbonate-portfolio of our partner, combined with the composite solutions of Maezio™, provides us with the variety and quality of materials needed to meet the high technical requirements in mass-transportation markets. This journey is not only about making thermoplastic honeycomb cores. Imagine the potential benefits for the aerospace industry, if it had the option to thermoform sandwich panels into finished parts in a one-shot operation. The industry, already inclining to monolithic thermoplastic composites, has not seen such a change for decades.”

You are cordially invited to visit Covestro (booth no. L5/H5) and EconCore (booth no. R83/H6) at the forthcoming JEC World 2019 exhibition for more information.

About Covestro:

With 2017 sales of EUR 14.1 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,200 people (calculated as full-time equivalents) at the end of 2017.

About EconCore:

EconCore provides technology for the continuous production of honeycomb sandwich materials. The fast, versatile, continuous ThermHex process allows users to produce sandwich materials for various applications including automotive, transportation, building and construction, industrial packaging, photovoltaics, furniture and many others at minimal cost, weight and environmental impact. Several licensees of EconCore over the world operate the honeycomb sandwich panel production technology supplying performing sandwich to different markets. For more information, please visit www.econcore.com.

Find more information at www.covestro.com.
Follow us on Twitter: www.twitter.com/Covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.