In-mold film insert for plastic thermoforming process is structured to prevent air inclusions and /or shrink grooves forming in a product based on the film and thermoplastic molding material

摘要

The film insert(12) has a structured surface(18) with a depth which prevents forming of shrink grooves and/or significant air inclusions in a molded product comprising the film insert and one or more layers(11) of a molding material. The structured pattern is distributed uniformly over the film surface and has a depth of 10-100%, preferably 20-40%, of film thickness. Structuring of the film creates a degree of extension sufficient to compensate for shrinkage during a molding stage. The structure pattern comprises bulges and/or depressions designed to prevent air inclusions during joining of the film and plastic layers. Structuring has little or no closed areas and a mean depth of not less than1micron, preferably not less than5microns. The structured surface is either on the side of the film facing the plastic molding layer or on the molding layer facing the film and is produced by embossing or pressing. An independent claim is included for a molded product comprising a thermoplastic molding material layer(11) and a film insert(12). The interface(15) between the molding layer and film has a structure(18) which prevents air inclusions between the film and molded product and shrink grooves on the molded product.