The instrument panel assembly is a key component in the automotive interior and a component that users perceive most. Its appearance, design, and functional features directly influence their overall vehicle evaluation. It must combine comfort, aesthetics, decorative elements, and functionality. As the exposed component of the instrument panel structure, the selection of materials and processes plays a crucial role in the overall quality of the instrument panel.
Busman developed a TPO surface material for instrument panels. Based on the material properties and component structural characteristics, it optimized a suitable coating process and successfully applied the TPO surface to instrument panels, achieving mass production in mass-produced models.
TPO surfaces are primarily applied in automotive instrument panels using vacuum forming and hand coating processes. A performance comparison between vacuum forming and hand coating processes is shown in Table 4. This comparison shows that vacuum forming is more suitable for mass production, offering high production efficiency, greater product design flexibility, and efficient mold utilization. Hand coating is more suitable for high-end and luxury models, allowing for personalized design of different surface colors and textures.
According to the relevant standards for instrument panel product performance, the instrument panel cover was subjected to tests such as short-term heat resistance, long-term heat resistance, resistance to hot and cold cycles, and resistance to cold impact. The test results are shown in the table.
Performance of TPO skin instrument panel products |
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Project |
Standard Requirements |
Test Results |
| Short-term heat resistance | Abnormal phenomena such as surface wrinkles, cracks, breaks, whitening, peeling, swelling, gloss changes, fading, surface stickiness, softening and hardening, stains, etc. are not allowed. | Meet standard requirements |
| Long-term heat resistance | Meet standard requirements | |
| Resistant to hot and cold cycles | Meet standard requirements | |
| cold resistance | Abnormal phenomena such as surface wrinkles, cracks, breaks, whitening, peeling, and expansion are not allowed. | Meet standard requirements |
| Cold impact resistance | No deformation, cracks, breakage or other abnormal phenomena. | Meet standard requirements |
| Lightfastness | Abnormal grayscale level 3.0 phenomena such as cracks, breaks, whitening, peeling, expansion, surface stickiness, stains, etc. are not allowed, and the grayscale level is not less than level 4. | Meets standard requirements Grayscale level 3.0 |
| Chemical liquid resistant | Abnormal phenomena such as cracks, breaks, whitening, peeling, expansion, gloss changes, fading, surface stickiness, softening and hardening are not allowed | Meets standard requirements |
| Assembly Odor | <3.5 | 3.0 |
In line with the trend toward green environmental protection and energy conservation and emission reduction, TPO is a low-energy, low-emission, recyclable, and environmentally friendly surface material. Busman has successfully developed a TPO surface material for automotive instrument panels. Its lightweight, low-odor, and low-VOC advantages reduce weight and odor compared to traditional PVC surfaces. The successful development and application of TPO surface material provides an important reference for assemblies using skin materials such as consoles and door panels. Compared to PVC surface materials, this solution is lighter and more environmentally friendly.