world leaders in polycarbonate film technology, … · bayer polycarbonate films offer the clarity,...
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World Leaders in Polycarbonate Film Technology, Performance, and Optics
Makrofol® and Bayfol® polycarbonate films are clearlythe right choice when product excellence is your goal.Produced from Bayer’s MAKROLON® polycarbonateresins, Makrofol and Bayfol are backed by theworldwide technological leadership of Bayer. Bayerfilms are manufactured to stringent quality standards in ISO-9001:2000 certified facilities. State-of-the-artextrusion lines provide the flexibility to provide customcolors, widths, lengths, and sheets. These high qualityfilms have the required UL ratings, meet FDA approval,and are available in an assortment of surface textures.
Bayer films offer the stability, consistency, and strengthto ensure excellent quality in a wide range of applica-tions. Many times stronger than acrylic, Makrofol andBayfol can be easily formed and much more dimen-sionally stable than polyester. These films form easier,deeper, and more consistently than other materials,making the graphics crisper and gloss more consistentfrom part to part. Lower stress levels allow for tighterregistration of printed graphics. The superior strengthof polycarbonate allows you to use thinner films andstill achieve the results you desire.
Clearly the Right ChoiceMakrofol and Bayfol polycarbonate films featureoutstanding clarity and transparency. They areproduced in a variety of thicknesses, surface textures,grades, and glosses. You can choose from a widerange of options, including transparent, translucent,opaque, and metallic. Custom colors and grades forlaser engraving are also available.
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Achieving Higher Levels of Innovation and Excellence in Film Applications with Makrofol®
and Bayfol® Polycarbonate Films
♦ Instrument Panel Overlays♦ Thermoformed Medical Packaging♦ Indoor/Outdoor Labels and Decals♦ Mousepads♦ Automotive Dials♦ Nameplates♦ Exhibit and Display Components♦ Floor Graphics♦ Automotive Control Panels♦ Keypads♦ Chip Packaging♦ Membrane Switch Overlays♦ Menu Boards♦ Film Insert Molding♦ Electrical Insulation
Typical applications
include:
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Outstanding Product Line Provides Creative Design Options for New Applications
Bayer polycarbonate films offer the clarity, variety ofsurface textures, and specific properties you need tomeet the most demanding application requirements.
Graphic Arts QualityMakrofol® DE and PC polycarbonate films are availablein a wide variety of surface textures, including glassclear with both sides gloss. These films offer high lighttransmittance, excellent surface uniformity, and ease of processing. All films use pure Bayer MAKROLON®
polycarbonate resin. Most meet FDA approval and havethe necessary UL ratings.
Chemical Resistant BlendsBayfol® CR film is a polycarbonate/polyester blend thatprovides improved mechanical and chemical resistantproperties.
Flame RetardantMakrofol® FR films have flame retardant properties andcan be easily fabricated or printed. They are ideal forelectrical insulation and are available in white and clear.
Light DiffusingMakrofol® LT and BL films have been speciallydeveloped to provide light diffusion capability whichsurpasses the capability of films that rely on surfacetexturing for light scattering. Makrofol® LT and BL areavailable in natural color and smoke tint. Smoke tint issuitable for “dead front panels”.
Specialty Films and CompositesSpecialty films have been developed to provideincreased weatherability and durability under harshconditions. Makrofol® EPC film is a special compositefilm that provides excellent first surface chemical andUV resistance. Bayfol® AS-A (black) film is suitable forantistatic packaging of sensitive electronic components.
New ProductsA variety of new products have been developed to meetcustomer special needs. Those products, designated byMakrofol/Bayfol DPF or TP names, offer special featuressuch as unique textures and colors, UV and flameresistance, high Vicat softening temperature, soft feel,metallic look, adhesive coating, low stress, etc.
...Clearly the Right Choice
4
ThermoformingThe primary advantage offered by thermoforming is theability to achieve deep draws on the formed appliqué.The process does suffer from registration problems onthe graphic appliqué. This can cause problems wherecritical graphic registration is required.
High Pressure Forming (HPF)Developed by Bayer AG, high pressure forming offersseveral advantages. Due to the uniform force applied tothe film, very little residual stress remains in the part.The inks used to print the film may be heated prior toforming, allowing the graphic to be formed withoutcracking the ink. Since the front surface of the film isonly contacted by the air injected into the tool, rejectsfrom contaminants are reduced. Automatic pressesbuilt for this process can be considerably faster thanother processes. They have cycle times of seven to tenseconds, depending on gauge.
HydroformingThe hydroforming process provides excellent regis-tration of the graphics to the molded part. However, itdoes not allow the films to be heated to increase theelongation of the graphic inks. It allows for fast toolsetup and changeover. Formed parts exhibit relativelylow stress. The main drawback is long cycle times.
Match Metal DiesThis process has been used for prototypes and lowvolume applications. One advantage is that tool halvescan be heated to improve ink elongation during theforming process. The primary limitation of the process is that metal tooling contacts the front surface of theformed appliqué. This can result in gloss variations and contaminants being forced into the film’s surface.
TrimmingThere are presently three methods being used topretrim inserts prior to molding. Die-cutting offers highquality, low cost trimming and is primarily used formedium to long production runs. Laser cutting is a low volume prototype method of trimming parts. Hardtooling is the choice for high quality, long run parts.
Other Key ParametersOther key parameters which affect the insert moldingprocess have to do with design of the injection moldingtool, the location of the film appliqué in the mold, and the process conditions related to molding the final assembly.
Bayer Polycarbonate Films and Advanced Molding Technology
Bayer has developed Film Insert Molding (FIM)technology that can satisfy “a designer’s wish list” for 3-dimensional parts. Bayer’s materials and processesfor insert molding polycarbonate-based films providethe features you need for quality parts...at reduced costs.
♦ Compound curves
♦ Complex geometrics
♦ Registered graphics
♦ Multiple colors
♦ Opaque or transparent
♦ Selectively textural
♦ Scratch resistant
♦ Long lasting finishes
Film insert molding consists of placing a decorated film,either flat or formed into the mold of an injectionmolding machine. Resin is shot behind the film, bondingthe film surface to the molding resin to form a finishedintegral part. The development of water-based and highheat polycarbonate inks, innovative forming methods,and precision registering equipment provide majoradvantages in part decoration by FIM.
♦ Unlimited decoration possibilities with precisely registered graphics
♦ Design flexibility including complex designs and simplified backlighting
♦ Cost savings via productivity improvements such as reduction in post-molding operations
Many different film and resin combinations are possibleusing FIM. Typically, the insert molding process incorpo-rates the use of polycarbonate or polycarbonate blendfilm substrates, allowing a wide variety of injectionmolded resins to be used. Key factors to consider inchoosing materials are: the need for heat and/orchemical resistance; impact resistance requirements;and aesthetic appearance. Designers must alsoconsider the compatibility of materials with thedecoration process and graphic construction with theinjection molding resin.
Several different forming methods are being used forinsert molding. Each forming process has its ownbenefits and limitations which must be considered inthe design phase.
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Makrofol and Bayfol can be screen printed using acrylicand PVC-based inks. Ink adhesion is excellent and nopretreatment of the film is required. Because of thefilm’s high heat resistance, printing inks can be quicklydried at high temperatures.
Makrofol can be easily die-cut with a variety of steelrule dies. For the best overall results in terms of cleancuts, precision and die longevity, side-bevel rule isrecommended. With this configuration, the long-bevelside should face the scrap material displacement ratherthan the short side bevel.
Makrofol can be thermoformed at a temperature of 190°C (374°F), with the mold temperature at 110°C(230°F). If the film is to be heated very rapidly, it should first be dried for 3 to 4 hours at 100°C (212°F).
Except for Makrofol LT and BL films, all Makrofol andBayfol films are suitable for cold forming and offerdimensional stability at high service temperatures up to 130°C (266°F) for Makrofol and 100°C (212°F) forBayfol films.
Substrates carrying printed information can be bondedusing transfer adhesives, double-sided adhesive tapes,screen printed adhesives or two-component adhesives.For film-to-film bonding, solvents such as methylenechloride are normally used.
Makrofol and Bayfol can be welded to certain otherthermoplastics such as PC and ABS using ultrasonicmethods.
Gauge: .005˝ to .030˝Width: up to 53˝Surface Finishes: Gloss, velvet, suede, matte, micro-matte, and combinations
In-line sheeting is done at the extruder; sheets arestacked flat and delivered flat eliminating roll set.
Standard trimmed and squared sheeting is available for tighter dimensional tolerances.
Masking of gloss surfaces is available for films 7 miland thicker. Choices of masking are cling or stick.
Fabrication
Printing
Die-Cutting
Thermoforming
Embossing
Bonding
Welding
Custom Extrusion Capabilities
Converting Services
...Clearly the Right Choice for Molded Part Decoration
6
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Bayer Polycarbonate Films and Advanced Molding Technology
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...Clearly the Right Choice for Molded Part Decoration
9
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10
Typi
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fol®
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fol®
Wea
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Film
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Typi
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Poly
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ly.
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prox
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lues
and
are
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par
t of
the
pro
duct
spe
cific
atio
ns.
11
245 New Park DriveBerlin, CT 06037866.659.9023 • Fax: 877.229.3702www.bayerfilms.comE-mail:[email protected]©Copyright, Bayer Films Americas, 2004 Rev 9/05 Printed in USA
BFCAPBRO9/05
The manner in which you use and the purpose to which you put and utilize our products, technical assistance and information (whether verbal, written or by way of productionevaluations), including any suggested formulations and recommendations are beyond our control. Therefore, it is imperative that you test our products, technical assistanceand information to determine to your own satisfaction whether they are suitable for your intended uses and applications. This application-specific analysis must at least includetesting to determine suitability from a technical as well as health, safety, and environmental standpoint. Such testing has not necessarily been done by us. Unless weotherwise agree in writing, all products are sold strictly pursuant to the terms of our standard conditions of sale. All information and technical assistance is given withoutwarranty or guarantee and is subject to change without notice. It is expressly understood and agreed that you assume and hereby expressly release us from all liability, in tort,contract or otherwise, incurred in connection with the use of our products, technical assistance, and information. Any statement or recommendation not contained herein isunauthorized and shall not bind us. Nothing herein shall be construed as a recommendation to use any product in conflict with patents covering any material or its use. No license is implied or in fact granted under the claims of any patent.
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“Clearly the Right Choice”