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Rogers has developed a proprietary technology to heat-laminate Victrex Aptiv film directly to metal foils or other materials in roll-to-roll and flat-panel laminate structures without adhesives.

Delamination caused by deteriorating adhesives that traditionally bond the layers of laminate structures can lead to premature product failure.

Adhesives often deteriorate when exposed to high temperatures, moisture or chemicals.

Rogers’ new technology, using Victrex Aptiv film, was developed to solve this problem.

Eliminating the use of adhesives has numerous benefits.

The first of these is the reduction of volatile organic compounds (VOCs) during production.

This makes the laminate structures more environmentally friendly.

Second, it reduces the amount of raw materials used compared to adhesive-based systems, creating the potential for an overall systems cost reduction.

Third, it creates increased laminate thermal conductivity by elimination of the insulating adhesive layers.

Fourth, it affords the ability to reduce laminate thickness, allowing for miniaturisation in smaller, thinner devices – as adhesives can add up to 50 per cent to the overall thickness and weight of a laminate structure.

Rogers states that it developed the proprietary process knowledge primarily for Aptiv films, which provide all the performance properties of Victrex PEEK polymer in a thin, flexible format.

To produce the adhesive-less laminates, Rogers installed a new line in its Belgium facility.

The production capability supports roll-to-roll laminate structures having a maximum roll length of 400m (1,312ft) and a maximum thickness of 0.25mm (0.10in).

When the rolls are panelised, a maximum width of 0.61m (24in) and length of 1.22m (48in) is achievable.

Rogers can also produce flat-press panels in two sizes – 0.61m (24in) wide x 0.46m (18in) long, or 0.46m (18in) wide x 1.22m (48in) long, with a maximum laminate thickness of 1.5mm (0.06in) in a press.

Both proprietary processes allow Aptiv film to be combined with metal foils like copper, brass, aluminium or other materials including aramid or glass-fibre fabrics.

The standard product is Aptiv film with either copper or aluminium foil on one or both sides, however, Rogers can laminate in a wide variety of configurations, such as with A-B, A-B-A and B-A-B structures.

The process is not limited to three layers of different materials, because Rogers tailor makes any adhesive-free laminate structure combining the required materials with Aptiv film customised to the customer’s end-use requirements.

Aptiv film has enabled Rogers to extend its market reach beyond high-frequency radar and telecommunications circuit applications.

The film allows Rogers to operate in high continuous-use temperature applications, including those with requirements up to 200C (392F), and can withstand lead-free solder processing temperatures, which can reach temperature extremes of 280C (536F).

Aptiv film has a unique combination of properties including high temperature and chemical resistance, low moisture absorption and excellent mechanical and electrical insulation properties enabling Rogers’ adhesive-less laminates to function in harsh environments such as those found in a variety of automotive under-the-hood, where longer part life leads to higher reliability; in down-hole oil and gas applications, where reliability and downtime avoidance are critical; and in aerospace applications, where adhesive-less laminates offer improved performance and weight reduction.

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