PROCESSING TECHNOLOGY
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`Lamination: Wide-ranging films portfolio
`for protective and adhesive functions
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`PC and TPU films can each be processed using various
`lamination techniques. Platilon® and Dureflex® TPU films are
`compatible with flame, adhesive, and hot-melt lamination.
`Makrofol® and Bayfol® PC films can be used with adhesive and
`adhesive-free lamination as well as masking.
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`Contact expert
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`Featured Brands
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`Bayfol®
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`Du reflex®
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`Engineering thermoplastic and specialized photopolymer f ilms
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`Polyurethane film made from aromatic and aliphatic polyester or
`polyether
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`Makrofol®
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`Thermoplastic p olycarbonate f ilms
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`Platilon®
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`Platilo n® TPU f ilms
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`Thermoplastic polyurethane (TPU) fi lms can be joined using t hree different lamination
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`met hods, each providing distinct advantages depending on the application. Flame
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`lamination employs an open f lame to bond film to soft polyurethane foams, w hich are
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`often subsequently processed by die-cutting. Adhesive lamination relies on hot-melt
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`adhesives for smooth, f lexible and tem perature-resistant adhesion. Hot-melt
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`lamination is idea l for bonding fi lms w it h woven, non-woven, and knitted fabrics, as
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`well as other substrates.
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`Polycarbonate films are also compatible with t hree different lamination techniques.
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`Masking films can be applied t o prot ect g lossy film surfaces f rom dirt or scratches
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`during t ra nsportation and handli ng. With adhesive-free lamination, a strong bond is
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`ClearCorrect Exhibit 1044, Page 1 of 5
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`formed that cannot be separated non-destructively. Adhesive lamination can be used
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`to join PC films w it h numerous materials such as non-woven or woven fabrics.
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`Flame lamination: Foam-to-film bonds for a variety of
`applications
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`Flame lamination creates a bond by passing soft polyurethane foam over an open
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`flame to produce a thin adhesive layer of molten polymer used to bond the foam to
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`TPU film. This technique is frequently emp loyed to create laminates that are
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`subsequently processed by die-cutting. Applications whe re Dureflex® and Platilon®
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`film may be f lame laminated include automotive seat ing and headrests, headliners,
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`sun visors, sound deadening const ructions, motor housing insulation and automotive
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`ca rpet backing as well as shoe inserts.
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`FIims
`Du reflex®
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`Platilon®
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`Adhesive lamination: For smooth, durable textile seams
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`Adhesive lamination uses TPU adhesives or moisture- curing PU hot-melt adhesives
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`which, after melting, are pumped out of a storage container and applied to textiles o r
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`films. After joining the subst rates, three fu rther st eps take place: adhesion, cooldown
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`and curing of t he adhesive. The advantage of this process is the smoot h, f lexible
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`adhesion of textiles and films. Textiles jo ined with cross-l inking adhesive systems can
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`be washed at temperat ures of 90°C. Applications where Dureflex® and Platilon® film
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`may be lam inated by adhesives include multilayer textile laminates, woven and non(cid:173)
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`woven fabrics, and breat hable c lot hing.
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`Hot-melt lamination: Bonds films with woven, non-woven,
`and knitted fabrics
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`ClearCorrect Exhibit 1044, Page 2 of 5
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`Hot-melt lamination can be used to combine our Dureflex® and Platilon® films with
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`woven, non-woven, and knitted fab rics, as well as other substrates, by applying heat
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`and pressure. The resulting laminates offer improved physical strength for resistance
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`to wear, punctures, and tearing, as wel l as excellent barrier properties for enhanced
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`water resistance and breathability. The finished laminat es possess the
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`complementary properties of fabrics and po lyurethane films.
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`Dureflex® and Platilon® films can also be used as flexible adhesives with significa nt
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`tensi le properties in order to bond numerous materials in a composite structure. Hot(cid:173)
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`melt laminat ion is compatible with these TPU films in applicat ions such as automotive
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`headliners, seam tapes, inflatable rafts, blood pressure cuffs, emblems, labels,
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`breathable apparel, ballistic vests, smart cards (e.g. cred it , debit, ID, etc.). radio
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`frequency identification (RFID) systems, conveyor and drive belting, and cured in(cid:173)
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`place pipe rehabilitation (GIPP).
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`Masking films: Protection for glossy polycarbonate film
`surfaces
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`Our high-gloss double-sided Makrofol® and Bayfol ® polycarbonate fi lms are supplied
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`with protective masking films as standard. These masking films protect glossy
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`surfaces from d irt and scratches during transportation and handling. In addition,
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`Makrofol® or Bayfol® films with precise mattings are suppl ied with special lam inating
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`films which adhere to matte surface structures.
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`l=iMii-1
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`Films
`Bayfol®
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`l=iMii-1
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`Films
`Makrofol®
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`Adhesive-free lamination: High-strength joining based
`solely on heat and pressure
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`Makrofol® or Bayfol® PC films can be laminated without the use of adhesives by
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`applying heat and pressure. This process does not permit non-destructive separat ion
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`of the film after bonding. One important requirement is that the film must be heated
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`above the softening point of polycarbonate (approximately 148°C), and subject to a
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`minimum pressure of 15 N/cm 2 for a num ber of minutes.
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`Adhesive lamination: Diverse applications rely on
`thermoplastic adhesives
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`The adhesive lamination of Makrofol® or Bayfol® PC films mainly uses thermoplast ic
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`adhesives - especially moisture-curing polyurethane hot-melt adhesives or adhesive
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`syst ems which react at temperatures abov e 60°C. This lamination process makes it
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`possible to join f ilms with numerous materials including non-woven or wov en fabrics.
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`Related brands and products
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`ClearCorrect Exhibit 1044, Page 3 of 5
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`l·iMii·&
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`Films
`Du reflex®
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`l·iMii·&
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`Platilon®
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`~ Films
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`Bayfol®
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`l·iMii·&
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`Films
`Makrofol®
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`Brochure
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`TPU hot melt adhesive films- only USA I Bayfol®, Platilon®
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`Related articles
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`Polycarbonates offer new design freedom
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`360° holographic display
`Together with Sony, we developed a 360
`degree holographic display that show(cid:173)
`cases high-tech solutions for AR
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`Night light demonstrator
`Covestro materials enable a new ult ra-slim
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`
`Related Technologies
`
`Autoclave processing
`Autoclave processing bonds rigid layers of
`material with f lexible adhesive int erlayers
`to create strong compos ites
`
`Welding
`PC and TPU f ilms can be joined using ultra(cid:173)
`sonic welding, heat sealing, high f requency
`welding, laser weld ing or impulse we lding
`
`High pressure forming &
`thermoforming
`High pressure for ming and thermoforming
`processes for shaping printed. semi-fin(cid:173)
`ished film into three-dimensional
`components
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`ClearCorrect Exhibit 1044, Page 4 of 5
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`Die-cutting/Punching
`Die-cutting, punching, and stamping are
`mechanical processes used t o fashion f ilm
`parts into predefined shapes o r sizes
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`Foam-in-place
`Whenever barriers are requ ired in foam-in(cid:173)
`place processes, our thermoplastic
`polyurethane fi lms provide an effective
`solution
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`Film insert molding (FIM)
`Film insert molding (FIM) enables one-step
`fabricat ion of p lastic components with a
`decorated o r functional surface
`
`FHM'i+ii
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`Contact Expert
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`ClearCorrect Exhibit 1044, Page 5 of 5
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