The car is our second home, and the air quality of the car interior texture is also very important. A healthy car environment not only improves driving safety, but also reduces the harm of the gas in the car. High perceived value, stylish appearance and comfortable touch are the main "soft" elements. These elements have become the minimum requirements for high-priced or high-end vehicles and appear on vehicles in the mid to low price range. The components and components of modern automotive interiors are becoming more and more complex, especially their shape and contours. The demand for three-dimensional is higher, which poses new challenges for thermoforming and vacuum lamination, as well as individual requirements for color, texture and materials.

The material performance requirement that semi-finished film manufacturers must first meet is that the surface of the part must have mechanical resistance, chemical resistance and weather resistance. In addition, the processing must also meet an increasing number of needs, such as the attachment of the trim and the frame. At the same time, they must meet all other requirements for automotive components and their manufacturing processes, including the technical capabilities of the components (eg crash performance, environmental impact and recyclability), maximum weight loss, quality consistency, process reliability and Economic.

Different methods

With extensive industry experience, Frimo systematically developed a range of process technologies and services related to thermoforming and vacuum lamination to meet the above-mentioned components and process requirements.

If all requirements are met, especially those related to cost, then close cooperation with OEMs or Tier 1 customers is an essential step in the early stages of component development. The cooperation between the two parties has enabled the joint development of custom solutions, which will be reflected in all aspects and innovative products below. Pre-design (including simulated thermoforming) helps ensure the reliability of the part production process. The thermoforming computer simulation was complemented by a film holder to show the simulated film on a real film sample. This not only enables the early inspection of possible dot texture distortion (texture stretching) and wall thickness changes, but also visually displays optical impressions such as gloss and scratch whitening.

Alternatives in the field of film

The decorative film market offers a range of innovative developments and advancements focused on weight reduction and texture optimization for thermoforming and vacuum lamination. The laminate film combines the unique feel of the PVC outer layer with the special elasticity and strength of the polyolefin foam, which is highly appreciated by some customers and original equipment manufacturers. They also greatly reduce weight.

They consist of a partially stretched or so-called partially foamed dense film with a weight-reducing effect and an improved feel and a tighter radius. Therefore, they are especially suitable for the production of geometrically complex parts such as instrument panels. Texture "zooming" during embossing provides a particularly clever way to partially compensate for a wide range of film stretches, especially in the key visible areas of the part. The "zoomed" texture exhibits only a small degree of distortion after stretching because "zooming" compensates for the stretching that occurs during thermoforming. During the in-mold embossing (IMG) process, the texture is transferred from the embossed shell mold (Fig. 2) to the film by a thermoforming process. TPO films are especially suitable for this method because they do not emit any corrosive substances when heated and have excellent release properties. As a result, IMG supports multiple designs and prevents texture distortion or loss in tight-area areas.