Manufacturing technologies
The following technologies may be used to produce TPO interior trim components:
Lamination
The production of interior trim components starts with the lamination of the TPO foil to the crosslinked polyolefin foam. As the TPO foil and the crosslinked polyolefin foam are from similar polymer families this can be done by using heat and pressure. A similar technology can be used with PP textiles as decorative materials.
Vacuumforming
1. Laminate (foam + foil/textile) Heating
2. Vacuumforming, Cooling & Trimming
Features:
- Well known global technology requiring relatively low investment
- Recycling of components possible in the case of TPO foil or PP textile/crosslinked PO foam/PP substrate
- Applications: door panels, door inserts, dashboards, seat backs, consoles
Low Pressure Injection Moulding
1. Injection of molten PP resin
a) melt strand application technology = strand of molten PP resin on the open mould
b) hot runner technology = injection of molten PP resin through channels in the open mould
2. Placing of laminate in mould
(also possible before step 1.)
3. Closing of moulds, moulding of complex & trimming
Features:
- Reduces production steps -> potential cost reduction
- Recycling of components possible in the case of TPO foil or PP textile/crosslinked PO foam/PP substrate
- Adhesive free technology
- Applications: door panels, dashboards
Compression Moulding onto Natural Fibre/PP Substrates
Technology
Natural fibres: E.g. flax, sisal, jute
| a) heating of substrate | b) placing of laminate and substrate in mould | c) pressforming of complex & trimming |
Features:
- Weight reduction
- Use of natural resources that can be re-grown
- Adhesive free technology
- Applications: door panels, door inserts
Reaction Injection Moulding
Technology
RIM = reaction injection moulding
a) (vacuum) form the laminate into a negative mould
b) pour/inject mix of liquid Polyol & Isocyanate components & cut glass fibres on treated foam side
c) remove mixing head
d) close moulds & wait for PUR reaction
e) cool & trim
Features:
- Weight reduction
- Possible reduction of production steps
- Applications: door panels, door inserts
Backfoaming with EPP (Expanded PP bead foam)
Technology
EPP = expanded polypropylene bead foam
a) pre-forming of laminate into negative mould
b) closing of mould
c) injection of EPP beads & steam on foam side
Features:
- Weight reduction
- Excellent energy absorption of components
- Recycling possible in the case of TPO foil or PP textile/crosslinked PO foam/EPP beads
- Adhesive free technology
- Applications: door panels, dashboards, pillar trim, door inserts, head rests
