Recoverable Polyolefin Foam Laminate Dent Resistance
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Solution Overview
Problem
Plastic film laminates used in vehicle interiors tend to form dents under stress, which remain visible due to lack of recovery behavior, posing a quality issue for both manufacturers and consumers.
Innovation Solution
A plastic film laminate comprising a top film with a modulus of elasticity of at least 150 N/mm² and a foam layer with compression hardness of 30 to 300 kPa, allowing for a pleasant tactile feel and rapid recovery from dents, while being processable through deep-drawing methods and achieving low gloss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a low density foamed layer is used, then weight reduction and pleasant pressure feel are achieved, but dent formation occurs under prolonged stress
Solution Approach 1:
The invention uses a composite structure consisting of a top film layer and a foamed polymer material layer. The top film provides high mechanical strength and dent resistance, while the foamed layer provides weight reduction and elastic comfort. This composite structure resolves the contradiction between weight reduction and dent resistance by combining materials with complementary properties.
Solution Approach 2:
The invention applies different material properties to different layers of the laminate. The top film has high mechanical strength and low elasticity to resist dents, while the foamed layer has low density and high elasticity for comfort. Each layer performs its specific function locally, resolving the contradiction between hardiness and softness.
2Ease of operation
If a soft foamed layer is used, then pleasant tactile feel is achieved, but recovery from dents is slow or incomplete
Solution Approach 1:
The composite laminate combines a soft, elastic foamed layer for tactile comfort with a rigid top film for structural support and dent resistance. The top film prevents permanent deformation while the foamed layer provides the desired soft feel, resolving the contradiction between softness and recovery speed.
Solution Approach 2:
The invention assigns different functional qualities to different layers: the foamed layer handles tactile comfort locally, while the top film handles structural integrity and recovery locally. This division of functional responsibilities resolves the contradiction between softness and rapid recovery.
3Reliability
If a high modulus of elasticity top film is used, then dent resistance is improved, but processing difficulty increases
Solution Approach 1:
The invention specifies a minimum modulus of elasticity threshold (150 N/mm²) for the top film to ensure adequate dent resistance. By defining this parameter threshold, the invention balances dent resistance requirements with manufacturability, as films meeting this threshold can still be processed using conventional methods while providing sufficient structural support.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The laminate exhibits excellent resilience, preventing dent formation and ensuring rapid recovery, thus maintaining a pleasant appearance and quality suitable for vehicle interior trim.
Implementation Method 1
a top film or a layer of this top film having a modulus of elasticity according to ISO 527-3 of at least 150 N/mm2
Implementation Method 2
the or a lower layer of the top film, in particular the compact top film, has a compression hardness according to ISO 3386-1 of 30 to 300 kPa
Data Source
AI summary
The invention relates to a plastic film laminate comprising a single-layer or multilayer top film and a foam layer, characterized in that the top film or layer of the top film has a modulus of elasticity of at least 150 N/mm², and the foam layer has a compression hardness of 30 to 300 kPa. The plastic film laminate and molded bodies comprising the same are suitable as synthetic leather and in particular for linings of motor vehicle internal spaces, e.g. door linings. The plastic film laminate is characterized by the fact that the plastic film laminate does not tend to form indentations and at the same time has a pleasant feel.