Molded-In-Color 2003 Dodge Neon Film Fascia Using a Thermoformed multi-layer co-extruded Ionomer film withinjection molded Polypropylene substrate

摘要

A new multi-layer co-extruded in-color ionomer film is developed toprovide an alternative decoration process to replace paint on Neon Fascias.The ionomer film provides a high-gloss “class-A” surface in both nonmetallicand metallic colors that matches car body paint finish. Using theionomer film to decorate fascias reduces cost; eliminates VOCs; increasesmanufacturing flexibility and improves performance (weatherability anddurability). The molding process consists of thermoforming a film andinjection molding Polypropylene or TPO behind the film. The presentationwill include, the background, film materials development, co-extrusionprocess development, thermoforming of the film, injection molding andtrimming the final fascia, tooling optimization and testing of the film.