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News

Rear projection monitors have housings made with flame-retardant polyurethane from Bayer MaterialScience

Bayer MaterialScience AG : 01 February, 2006  (New Product)
Rear projection monitors with high-definition picture quality promise DVD and video game fans a host of new possibilities. The housing for the model shown here was manufactured using the flame-retardant polyurethane integral skin foam Baydur 66 FR from Bayer MaterialScience.
While plasma and LCD screens are now a common sight in living rooms and at computer workstations, rear projection monitors with high-definition picture quality now promise DVD and video game fans a host of new possibilities. SIM 2 Multimedia S.p.A. in Pordenone, Italy, offers large-format high-end monitors equipped with state-of the-art Digital Light Processing technology and featuring a design that is both elegant and highly functional. The housings for the SIM 2 series DLP 45 and DLP 55 and the housing for Brionvega DLP 50 are produced by Tecnopol s.r.l. in Copiano, Italy. They contain the flame-retardant polyurethane integral skin foam Baydur 66 FR from Bayer MaterialScience AG, which Tecnopol sources from BaySystems Italia, Bayer MaterialScience’s Italian systems house.

Giorgio Revoldini was responsible for the top-quality design of the 45- and 55-inch units and Atelier Bellini designed the elegant 50-inch monitor. Both top designers were determined to produce an exceptional design that did not just follow current trends. “Challenges like this can only be met by using polyurethanes,” says Dr. Gloria Porta, operation manager at Tecnopol. “They offer almost unlimited design options and lend themselves to particularly cost-effective processing, especially in small and midsize series.”

In line with rear projection monitor design principles, the housing has a complex mold. It contains a total of 80 threaded bushings, incorporated in a single molding process. This is easily achieved thanks to the high flowability of the liquid reaction mixture. The base, with its greater wall thickness, is also molded at this stage. The whole housing of the 55-inch unit weighs only about 13 kilograms, thanks to the integral skin foam structure of the polyurethane, which ensures a high stiffness-to-weight ratio. As the tool is only exposed to low pressure, inexpensive aluminum molds can be deployed for cost-effective production.

The housings for rear projection monitors have been created by well-renowned Italian designers. Thanks to the high flowability of the liquid polyurethane reaction mixture, the complex mold could be realized very successfully. As the tool is only exposed to low pressure, inexpensive aluminum molds can be deployed for cost-effective production.

The high surface quality of the polyurethane material is also ideal for the subsequent coating of the housing section, as the surface needs to be very even with a high gloss finish to ensure optimum projection. A black coating with a gloss level of 0.3 is applied to the side panels inside the housing to prevent reflections. The mirror is located on the inside, at the top, and projects the DMD chip (Digital Micromirror Device) image signals outwards to the viewer. The lower section has a metallic coating which minimizes permeability to electromagnetic radiation. A black decorative coating is applied to the outside of the housing. The front section has panels made of Baydur FR 66 with control switches and sound grills. The material complies with the maximum classification V-0 of the strict US fire protection standard UL 94 from Underwriters Laboratories, Inc.
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