Joining dissimilar parts in automotive interior trim applications has been accomplished by utilizing mechanical fasteners, organic and water based adhesives, and more recently, thermoplastic polymers. Recent trends towards reducing solvent emissions and waste management problems, improving the consistency of adhesive application, integrating parts, lowering parts fabrication costs, and designing a specified bond level has increased the use of thermoplastic adhesive films as bonding agents in several applications.
Initial efforts began over fifteen years ago with Dow Adhesive Films (DAF) being designed for bonding interior trim fabrics to various substrates. Films have subsequently been designed to improve performance of many interior trim parts in many ways such as: improving water resistance, allowing the part to be molded before installation, imparting a slip surface to a part, and supporting a non-woven fabric. Recent developments include adhesive films which: have deeper draw characteristics, activate at faster machine cycle times, provide encapsulation to fiberglass insulation, or provide a barrier to liquid foam systems without the need for additional wet adhesives. This paper will describe the functions and applications of Dow Adhesive Films into integrated automotive interior parts, highlighting several of these applications.