How can intelligent surfaces provide more design freedom and functionality in car interiors and still be produced cost-effectively? Covestro investigated this important question together with a team of three industry partners: Votteler Lackfabrik GmbH & Co. KG, laser texture specialist Reichle Technology Center and Merck KGaA as a manufacturer of pearl effect pigments.
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With the help of Covestro's DirectCoating technology, automotive interior parts with seamless, smart surfaces can be produced quickly and effectively. |
The result is an effective concept for the production of interior parts with seamless, intelligent surfaces using Covestro's DirectCoating technology. The coated component is produced in two steps using a polyurethane reaction injection molding (PU-RIM) process.
Covestro will showcase the project during Digital Expo 2021 from September 14-16.
Multiple challenges
Car manufacturers and their suppliers face the challenge of integrating smart functions such as display and ambient lighting and touch control, in addition to a wide range of visual and haptic surface properties. Above all, the aim is to manufacture durable products as cost-effectively as possible in order to achieve broad acceptance in the industry. The goal is car interiors that can easily serve as a lounge, workspace and driver cockpit. In this way, an environment can be created in the car that combines comfort and infotainment with a feeling of safety.
PURIFLOW® paint systems from Votteler Lackfabrik GmbH & Co. KG enable outstanding surface properties such as good scratch resistance and a self-healing effect, but also a feel that ranges from soft leather to hard metal. These benefits, and the ability to create completely seamless surfaces, are thanks in part to polyurethane coating raw materials from Covestro.
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For the current development of dashboards for car interiors, Covestro collaborated with Votteler Lackfabrik, Reichle Technologiezentrum and Merck KGaA. |
In implementing the innovative solution, Votteler drew on the manufacturing expertise of Reichle Technologiezentrum GmbH, which operates Europe's largest laser texturing site. The company provided laser-textured PU-RIM molds for the project. Covestro supplied process technology know-how, coating raw materials from the Desmodur® and Desmophen® ranges without solvent additives, and Makrolon® and Bayblend® polycarbonate plastics, which proved to be a key to the project's success. Effect pigments from Merck® KGaA can be used to achieve various color and transparency effects.
DirectCoating: innovative technology for producing coated parts
In the DirectCoating process, the plastic substrate is first produced in an initial cavity by injection molding. The resulting part is then transferred to a second, minimally larger mold. The cavity between the substrate and the laser-engraved RIM mold corresponds exactly to the desired volume of the coating that is injected there. This creates a coated precision part in just two steps. It requires little rework and is highly resistant to chemicals and daylight. DirectCoating also offers advantages over conventional coating methods, including a shorter and faster process, no overspray and no need for a separate drying step.
