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In 1982 the introduction of Internal Mold Release systems revolutionized the Reaction Injection Molding (RIM) polyurethane fascia industry. IMR technology significantly reduced the frequency of spraying external mold release agents, making substantial increases in productivity possible. This technological gain has been industry proven and well documented. IMR technology can benefit the molding efficiency for RIM window encapsulation by reducing the need for spraying external mold release and by reducing the mold cleaning time. The unique requirements for manufacturing modular automotive windows mandated that the standard IMR systems, used for fascia, were not suitable for this application. New IMR systems were developed which improved storage stability and flowability, while providing excellent releasability, physical properties, adhesion, and processing.

Reaction Injection Molded (RIM) Polyurethanes are well-suited to automotive fascia applications. Their excellent impact resistance, paintability, and styling capabilities are well known. Efforts are underway in the automotive industry to improve the production economics associated with manufacturing RIM fascias. One method of reducing fascia material costs is to reduce the density of the polymer. This paper describes new experimental RIM systems that can be molded at a reduced density, yet still pass current OEM requirements, including on-car impact tests. These experimental RIM systems combine new filler technology and new resin formulations. The material cost for this system is competitive (based on molded part cost) with all other current methods of manufacturing fascias.

Modular window encapsulation of glass using Polyurethane RIM (Reaction Injection Molding) has been very popular in the automotive industry over the last 10 years. RIM offers many advantages in the design of modular windows including: flexibility to design complex shapes with variable wall thicknesses, molded-in attachment studs for easy assembly, and aerodynamic styling. The automotive industry is continually looking for new advancements in technology to increase productivity and decrease the costs of processing parts. A processing advancement using IMR (Internal Mold Release) was introduced into RIM bumper fascia in 1982 with great success. To this day, IMR is an important component for automotive fascia applications. Likewise, window encapsulation with the use of IMR in RIM systems has become a key component in reducing molding cost for automotive windows. The introduction of IMR in RIM for Window Encapsulation offers many potential benefits to the molders of these parts.