Success Of IML In Automotive Interior

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Success Of IML In Automotive Interior Domestic
Appliance Applications

• Richard Townsend Product Manager IML

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Overview

• Brief introduction to MacDermid Autotype
• IML definition
• Key features benefits of IML
• Automotive trends IML
• Domestic appliance trends IML

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About MacDermid Autotype

• Autotype History
• Producer of coated films and chemicals - founded
  in 1868
• Markets - printing, electronics, telecom,
  automotive appliance
• Sales 90million across 85 countries
• 9 acre manufacturing site in Wantage (UK)
• First company in the printing industry to attain
  ISO9001 in 1988
• ISO9001 (2000) in 2003, ISO14001 (BS7750) 1996
• MacDermid
• Acquired in June 2005 by MacDermid Inc
• Over 800 million turnover
• Global reach enhanced by MacDermid parent
• Enhanced ability to grow Film Insert Moulding
  business
• Existing MacDermid automotive businesses include
• Plating on Plastic
• Decorative metal coatings
• Anti-corrosion treatments

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MacDermid Autotype Locations
Global Headquarters, UK (Main Manufacturing
Centre)
Americas Sales Tech Support Centre
Asia Technical Centre, Suzhou, China
US Production Facility -Dry Film Resists
Asia Headquarters, Singapore
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What Do We Mean By IML?

• Also known as FIM (Film Insert Moulding)
• - Processing undertaken by our global customers

Print
Form
Mould
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• What Are The Key Features Benefits Of IML?

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Enhanced Durability For 3D Parts

• Conventional hardcoats brittle
• Cannot be formed without cracking
• MacDermid Autotype formable films
• Combine scratch resistance and chemical
  resistance with formability
• AutoForm
• HiForm
• XtraForm

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Cost Savings Component Integration

• Integrate windows and housings from one piece of
  film
• huge potential for cost down from
• tooling
• fewer moulding processes
• assembly
• gaskets/adhesives

Motorola C650
Lens and housing integrated using XtraForm
Courtesy of 3D Precolor
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Add Texture Effects

• Finishes can be enhanced by adding texture
  printing on first surface
• Aquatex FPH
• 4 textures
• Custom blending
• Selective printing

Super-matt
Gloss
Fine
Coarse
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Wide Range Of Decoration Effects

• Screen print cost per colour is small
• Complex designs can be economically introduced
• Wide range of effects
• metallics
• mirror
• aluminium
• woodgrain

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• What are the Automotive Trends opportunities
  for IML?

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Automotive Trends

• Switchgear
• High gloss black (piano lacquer)
• Back lit legends
• Ideal for FIM application
• But highly demanding of cosmetics
• Now similar needs to telecom lenses
• Scratch resistant coatings essential
• Major automotive adoption for XtraForm in
  Mercedes S Class
• Infotainment systems
• Opportunity for component integration
• High quality large format optical displays
• Antireflection needs

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Case Study Mercedes S Class

• Requirement
• Piano lacquer black
• High scratch resistance
• Solvent resistance
• Backlighting
• Super high quality cosmetic finish
• Small radius components for excellent fit
• 44 discrete components

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The Challenges

• No single applicator could handle the whole
  project
• Complex project management
• Ultra tight radius
• demanded extreme deep forming
• Registration on many parts critical
• Ultra low stress film needed
• New product for automotive market
• Pinhole free black printing critical
• Certainly the most challenging project yet

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The Response

• Project team involving all players
• 8 companies regularly engaged
• Weekly teleconference
• Regular on site process support
• Unprecedented open communication
• OEM project management instigated
• Custom product development to meet project needs

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Automotive Case Study

• Novel use of Clear Hard Coat Film
• With
• Real Wood Veneer
• for
• Interior Trim Applications

• Acknowledgements
• University of Warwick
• K. Makenji
• S. Buckley

A cooperative development with
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Wood Simulation

• Automotive interior design continues to demand
  wood trim
• FIM offers excellent routes to achieve this
• High resolution screen printing
• Flexography
• Lithography
• etc.
• However current fashion requires
• Truth in Materials
• If it looks like wood it should be wood!

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The Problem

• Maintain the use of real wood veneer
• a requirement for Premium Automotive Vehicles
• Eliminate wet spray lacquer
• High cost
• Environmental impact
• Rework to the surface
• Lengthy process time
• The Solution
• Use Clear Hard Coat film,
• AutoForm and HiForm G500
• Laminated to Real Wood Veneer

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The Development
Substrate Aluminium or Polymeric
Hot Emboss Heat Pressure Time
Wood Veneer
Hard Coat Film Autoform G500 Solvent Based
Adhesive

• Biggest Issues
• High bond strength
• Optical quality of adhesive
• Damage to film surface
• Dust and inclusions

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The Result

• Good optical quality of the veneer
• Good scuff / marr / Taber performance
• Passed automotive testing
• Adhesion integrity and environmental
• Estimated cost saving 20
• Robust process

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Anti-Reflection IML Films

• Anti-reflection properties for
• Instrument panels (IPs)
• Display windows
• Benefits
• Reduce sunlight reflection for driver
• Durability with scratch/chemical resistance
• Anti-smudge properties
• Easy to clean

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How Do Anti-Reflection Films Work?

• Achieves true antireflection
• Surface nano-embossing
• Motheye structure
• lt1 reflected light
• Excellent optical properties
• Coated onto FIM film inserts
• Highly cost effective

Simulated section through surface
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Motheye Anti-Reflection Films
Angle of Light
Film Surface
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• What are the Domestic Appliance trends
  opportunities for IML?

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Domestic Appliance Trends

• Extensive use of polyester membrane control
  panels
• Next step is the increasing use of polyester
  films combined with the IML process

• MAYTAG panel using MacDermid Autotype hardcoated
  polyester film

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Benefits using IML?

• Integrate Components
• Housings, window and switches combined

Courtesy Maf3, Italy
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Benefits of IML?

• European safety legislation driving component
  integration in this region
• Benefits influenced by material choice
• PET superior switch actuation life compared to PC
  10 million
• Maximum combination of actuation life and
  formability PET/PC blend (Bayfol CR)
• Hardcoated options

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Summary

• Significant potential for IML to reinforce OEMs
  brand image
• Cost advantages by integrating components
• Automotive trends favouring IML
• High gloss black
• Anti-reflection
• Info-tainment devices
• Domestic Appliance
• Cost advantages through component integration
• Enhanced switch life and panel durability

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• Thank you for your attention