Shape memory polymers and automotive decorative films derived therefrom

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Transitioning the automotive sector away from the costly and environmentally questionable practice of paint has seen the emergence of a technology known as in-mold forming which applies decorative polymer films onto complex parts with comparable aesthetic finishes. The technology intends to offer an uncomplicated, one-step process for rapid production of high-quality parts with Class 'A' finishes or even complex textured appearances. However, the thermo-mechanical environment to which these films are subjected as they are stretched and heated places new demands on their construction and there is little fundamental understanding for guidance on how a film laminated metal or plastic sheet will stretch and form in this environment. A previous NSERC CRD, now in its final year of completion, has been studying the issues that arise for these films as they are formed into metal or plastic parts, highlighting the complexities of avoiding wrinkling, color/gloss losses, adhesive debonding and film crack propagation. The industrial sponsor feels that their new developments into a very interesting area of polymer architecture known as 'shape memory polymers' will bring forth the next generation of decorative films for commercial use, minimizing or avoiding the problems found in forming current generations of films. As this is a new direction for film chemistry, the multitude of variables affecting the molecular architecture of a shape memory polymer need to be put into context with the thermo-mechanical environment for their forming of new automotive parts. In this regards, the proposed project will study how controlled variables of the molecular architecture for said polymer relate to the formability of the generated films. In addition, the work will seek to gain deeper fundamental knowledge into the relationship which the adhesive layer plays in metal and plastics forming operations as shape memory films are heated and deformed. The project will supply to the workforce highly skilled persons trained in the forming technology and armed with knowledge of these new polymers, to help implement the findings of this work into automotive companies targeted for use of this process as well as help bolster the technical staff of the film producer itself.