A coated scratch-proof film that can be formed without damaging the coating has been developed by Bayer MaterialScience. The Makrofol TP 278 polycarbonate film produces 3D component surfaces with a deep-gloss finish and abrasion resistance and is the first member of the new Makrofol HF product family of scratchproof-coated, formable films. Bayer says it has been developed in response to the recent more stringent specifications concerning the scratch resistance of printed and decorated 3D film components used, for example, in car interiors, household appliances and IT equipment.
     Conventionally, making decorated 3D film components scratch-resistant after production has usually needed a separate coating line with its associated investment and maintenance costs. It is easier to start with films that have already been given a scratch-proof coating and to back-print, form, trim and, if necessary, back-inject them with a thermoplastic by the film insert moulding process. The problem, says Bayer, was that before now, there were virtually no scratch-resistant coatings available that could withstand the forming stage without suffering damage. It has solved this problem with its DualCure scratchproof coatings. These are pre-cured coatings, which can be formed together with the film and are then finally cured using conventional UV lamps.
     Makrofol TP 278 has a DualCure coating which enables it to be used for producing narrow radii and a high depth of draw. Films can be cold formed using high pressure forming and also thermoformed. The cured film has abrasion and scratch resistance, and achieves a "1H" rating in the pencil hardness test, ISO 15184, 500 g. Another of the film's strengths is its resistance to everyday chemicals such as grease, fat and cleaning agents. Potential applications include housings for all kinds of consumer electronics, high-gloss cell phone housings and keypads, control elements of washing machines and dishwashers, and decorative 3D facings for car interiors such as the trim around the centre console.
     Other types will be added to the Makrofol HF product family in cooperation with customers. There are plans, for example, to develop formable scratch-resistant films for car interiors that produce a matte finish. Another target is to produce UV-stable hard-coat films for large add-on bodywork parts.

Picture shows how Albrecht Jung uses Makrofol TP 278 for the display of its new KNX room control system.