A variety of methods
The lamination techniques for the films portfolio of Covestro are diverse. Below please find an overview of the most common methods for Platilon® and Dureflex® and also for Makrofol® and Bayfol®.
TPU-Films - Dureflex® & Platilon®
Flame lamination creates a bond by passing soft foam over an open flame, producing a thin layer of molten polymer that becomes the adhesive for bonding polyurethane foam to polyurethane film. The foam lamination process is most frequently used to create laminates that are die cut into parts.Applications where Dureflex® & Platilon® film may be flame laminated include: automobile headrests, armrests, sound deadening constructions, motor housing insulation, automotive carpet backing, shoe inserts, automobile seating, headliners, and visors.
For the adhesive laminating process either thermoplastic adhesives or moisture-curing PU hot melt adhesives are broadly used which, after the melting, are pumped out of a storage container and applied onto textiles or films. After the joining of the substrates three further steps take place: the adhesion, cooling down and the curing of the adhesive. The clear advantage of this process is the smooth, and very flexible adhesion of textiles with films. Textiles which are adhered with cross-linking adhesive systems can be washed at temperatures of 90°C.
We differentiate between Screen print, Melt print and Spraying.
Applications where Dureflex® and Platilon® film may be laminated by adhesives include: multilayer textile laminates, breathable clothing.
Hot Melt Lamination
Hot melt lamination combines Dureflex® & Platilon® film with woven, non-woven, and knitted fabrics, as well as other substrates, by applying heat and pressure. These laminates have improved physical strength for wear, puncture, and tear resistance, and have excellent barrier properties that provide water resistance and breathability.The finished laminate possesses the complementary properties of both the polyurethane film and the fabric. Dureflex® & Platilon® film can also be used as a flexible adhesive with significant tensile properties, bonding numerous numbers of materials in a composite structure.
Applications where Dureflex® & Platilon® film may be hot melt laminated include: automobile cabin head liners, seam seal tapes, inflatable rafts, blood pressure cuffs, emblems, labels, breathable apparel, bullet resistant vests, smart cards (e.g., credit, debit, identification, etc.), radio frequency identification (RFID), conveyance belting, drive belting; and cured in-place pipe rehabilitation (CIPP).
PC-Films and PC blended Films – Makrofol® and Bayfol®
Laminating Films (Kaschierung)
Makrofol® and Bayfol® films with both-sided high glossy surfaces are as standard delivered to our customers with protective masking films. Masking films protect the glossy surfaces from dirt and scratches during transportation and handling. Furthermore Makrofol® or Bayfol® films with very precise mattings are also supplied with special laminating films, which adhere to the matte surface structures of the films.
Lamination without the use of adhesives
Makrofol® or Bayfol® films can be laminated without the use of adhesives. Thereby the films bond and cannot be separated non-destructively afterwards. The Requirement for this property is that the film is heated above the Softening Point of polycarbonate, approx. 148°C and a pressure of at least 15N/cm² for some minutes.
For the adhesive lamination of Makrofol® or Bayfol® films thermoplastic adhesives are mainly used especially moisture-curing polyurethane hot melt adhesives or adhesive systems which react at temperature above 60°C. By the use of this lamination process, the films can be joined with numerous materials like non-woven or woven fabrics.
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