A New In-Mould Decoration Process using Real Wood Veneer

Automotive manufacturers use real wood in interiors as a mark of premium car quality. The current manufacture of veneered components is costly, resource demanding and time consuming. An alternative in-mould decoration manufacturing technique is considered here, involving the injection moulding of polymers onto real wood veneer. Experimentation was carried out with two polymers; Polypropylene and Acrylonitrile Butadiene Styrene. These were injected onto three types of wood veneer in a simple geometry mould. All these samples moulded satisfactorily and good contact was achieved between the polymer and veneer. Adhesion integrity was carried out to DIN 53255. The testing resulted in a pass of the PP samples whilst the ABS samples failed. Scanning Electron Microscopy, imagery shows a high level of interaction at the interface with parts made from PP irrespective of veneer types. A high level of polymer penetration is present into the large and small voids of the veneer surface. The high level of penetration has secured a mechanical interlock condition. The samples produced from ABS showed a very poor level of polymer penetration.

Autorentext

Dr. Kylash Makenji is experienced in the field of injection moulding and polymer materials. He has numerous publications and conference papers, including book chapters and patents. He is based in WMG, The University of Warwick where he works on technology transfer from the Materials and Manufacturing theme group, into industry.