Bayfol® LR films: next-generation bonding for electronics

Processing of composite materials requires tough, high-quality adhesive films 

Composite materials are increasingly the go-to choice for a range of industries. Apart from providing solutions in manufacturing, medtech, aerospace, automotive and electronics, composites also play a key role in everyday products such as synthetic leather and mobile phone back covers. In all these applications, tough protective layers with high-performance bonding are essential. 

Often, different materials such as wood, metals, plastics, ceramics and textiles have to be bonded together. At the same time, high bond strength is a must in order to ensure that the relevant components and products function under robust operating conditions. In addition to the strong adhesive strength on a wide range of substrates, the strength and elasticity during cross-linking of the bond are also crucial. 

Easy handling, that enables quick and clean application with a uniform adhesive film thickness and a material-friendly adhesive film, which is applied at a low temperature, is often the decisive advantage over liquid wet adhesive systems.

The high-strength bonds in these composites allow for their use in demanding conditions. Temperature fluctuations, chemical exposure, dust, moisture, and general wear affect surfaces and components over time. Roughened surfaces can compromise durability and other critical properties in various applications such as automotive, and consumer electronics applications, particularly in bonded synthetic leather and fiber-reinforced housings that face daily stress.

Innovative thermoplastic and thermoset adhesive films play an important part in meeting these challenges. 

Bayfol® LR 5902: quick, tough low-temperature bonding for composite materials 

Our Bayfol® LR 5902 is a thermoset adhesive film that enables rapid and durable structural bonding on a wide range of substrates. This heat-activated film (HAF) adhesive is dry, i.e. non-tacky at room temperature, solvent-free, and forms cross-linked bonds between molecules after heat activation. 

Processing the material above 90°C (194°F) triggers a permanent chemical reaction that cannot be reversed. This creates an exceptionally strong compound that not only withstands low and high temperatures and abrasive chemicals. It is also resistant to the effects of decomposition, also known as hydrolysis, after prolonged exposure to water.

The film’s relatively low activation temperature and short curing time of 20 minutes at room temperature makes it convenient and efficient in the processing of composite materials. With low overflow and a negligible deviation in thickness, Bayfol® LR 5902 can be applied quickly and precisely to irregularly shaped and multidimensional as well as to curved surfaces and profiles. 

Activation at low temperatures also makes it suitable for sensitive materials such as glass, fabrics, synthetic leather, and magnetic surfaces. Since the film can be stored at moderate room temperature, no refrigeration is necessary. Above all, the solvent-free formulation reduces the impact on the environment. 

Versatile solution for a range of industries and consumer electronics

Easy handling, rapid, low-temperature bonding, and irreversible molecular crosslinking that facilitates high bond strength – all these properties together make Bayfol® LR 5902 a high-quality, convenient solution for demanding applications across multiple industries. 

It offers excellent protection against chemicals, ageing, and hydrolysis, even under the toughest conditions. In the electronics industry, Bayfol® LR 5902’s low activation temperature paves the way for new material alternatives. The polar chemistry also enables activation by radio frequencies or ultrasound. The flexibility of the cured film makes Bayfol® LR 5902 an ideal choice, for example, for smartwatches, protective covers or artificial PU leather surfaces.