Injection molded, extruded-in-color film fascia

摘要

A new multi-layer, co-extruded, in-color Ionomer film is developed to provide an alternative decoration process to replace paint on Dodge Neon Fascias. The Ionomer film provides a high-gloss, "class-A" surface in both non- metallic and metallic colors that match the car body paint finish. Using the Ionomer film to decorate fascias reduces cost; eliminates VOCs; increases manufacturing flexibility and improves performance (weatherability and durability). The molding process consists of thermoforming a film blank and injection-molding Polypropylene or TPO behind the film. The paper will include the background, the benefits, the technology development objectives, the film materials development, tooling optimization, film fascia processing (co-extrusion; thermoforming and injection molding) and validation testing of the film.