DNP Develops New Decorative Film with Texture Effect Compatible with Injection Molding Process
Provides expressions with real tactile sensations for use in automobile interiors
Dai Nippon Printing Co., Ltd. (DNP) has developed a new type of decorative film capable of expressing a variety of tactile sensations through a set of unique surface textures. The new decorative film adheres to the resin part, while it is being molded, by applying the thermal pressure generated by injection molding, in a process referred to as a simultaneous molding and decoration process. The new film will be marketed mainly for automobile interiors, aiming to capitalize on its unique visual and tactile effects.
DNP has positioned Living and Mobility as a business growth area, and is working to expand the automobile related business area. The Company offers decorative film as interior materials to auto makers in Japan and overseas. These include wood grain and metallic design features applicable with both simultaneous molding and decoration process and the methods used with decorative processing after injection molding. Demand for such interior materials from auto makers and consumers has been rising year by year. And, users have begun to call for a greater variety of design effects, including not only visual elements, but also a sense of luxury, comfort, touch and originality. In answer to these needs, DNP has developed a new decorative film based on the simultaneous molding and decoration process to provide not only a unique visual effect, but also a tactile sensation allowing users to confirm the texture by running their fingers over the surface.
[Features of the New Decorative Film]
- With currently used simultaneous molding and decoration process, the decorative film is pressed into a mold using heat and pressure. Doing so results in the loss of the surface texture, making it difficult to achieve any tactile sensation. Processing methods that provide for such sensations include vacuum pressure forming, which is capable of decorating the resin molded parts without applying a significant thermal pressure to the parts. In this latest development, however, DNP has successfully developed a decorative film capable of providing a tactile sensation using the simultaneous molding and decoration process that has become the mainstream process for producing interior materials for automobiles.
- By reviewing the film composition and providing a protective layer that absorbs the thermal pressure, it has been possible to maintain the surface texture even after the simultaneous molding and decoration process, to achieve a tactile sensation.
- The newly developed decorative film is compatible with existing simultaneous molding and decoration processes that are superior in terms of cost as a mainstream manufacturing method, and as a result, it is now possible to provide a tactile sensation at lower costs than before.
- Compared with methods that configure texture with a metal mold, it is possible to provide a variety of textures by changing the decorative film, improving pattern flexibility as a result.
DNP New Decorative Film
Cross Section Image
During the molding processes, the protective layer on the surface of the decorative film absorbs heat and pressure, and by removing that layer following completion of the molding, it is possible to achieve a molded product that maintains the textures of the film surface.
[Forward Looking Developments]
DNP will market the newly developed decorative film for mobility uses, such as automobiles, busses and aircraft, aiming for sales of 5.0 billion yen in FY 2020.