Laminating Industry Brochure

power in plastics processingAUTOMOTIVEINDUSTRYMACHINES AND TECHNOLOGIES FOR THE2SluSh MouldingRiveting with ASC teChnologyAnd ultRASoniChF weldingPRe-FoRMing FoR bACkinjeCtionedge-FoldinglAMinAting oF FilMMAteRiAllAMinAting oFtextileS/leAtheR3KIEFELthe PARtneR oF the AutoMotive induStRy And the SuPPlying induStRyK I E F E L A U T O M O T I v E - S O L U T I O N Sn individual CoMPlete SolutionSn Maximum QuAlityn exellent eConoMiC eFFiCienCyn individual solutions: KIEFEL is one of the international market leaders wherever the processing of plastics for the automotive industry is concerned. Working in close cooperation with our customers, we plan and provide complete solutions for the production of interior trim components.n outstanding know-how: Our strength lies in our total mastery of the processing technologies involved, our engineering potential and our know-how as producers of industrial machines based on an experience for more than 50 years.n Maximum quality: In addition to developing the fundamental principles of plastic processing technology, our research labs work together with the customer – right from the prototype phase – to develop manufacturing techniques. Prototype components are pro-duced for pre-series vehicles. Production is carried out using KIEFEL machines and tools – delivering components that meet the high quality specifications of automobile manufacturers, with the very best in functionality,aesthetic appeal and haptics.n vacuum-laminating of substrates with PvC and TPO filmn Pre-forming of film for subsequent appli-cation to foam backing, back-injection or back-pressingn vacuum lamination and forming of film by the in-mold-graining process (IMG)n Slush mouldingA comprehensive RAnge oF teChnologyn Edge folding of film, textiles, leather and Alcantara, with and without adhesiven Press-laminating of textiles, leather and Alcantaran Riveting by means of ASC technique and/or ultrasonicn High-frequency weldingn Special procedures for gluing and assemblyContinual PRoCeSS SeQuenCen Consultation on the element designn Selecting the processing technologyn Feasibility studiesn Production of prototype partsn Industrializationn Process optimationn After-Sales CareDoor interior trim panel BMW, Series 5, bicolor, vacuum laminated4kieFelFoRMing And lAMinAting MAChineSConfigurations are available for all the forming and laminating tasks involved in the manufacture or finishing of interior- or exterior-trim components in various materials.Whether for door linings, A-, B-, and C-columns, shelves, consoles or coated film materials. Customers can count on optimised matching to their individual requirements.The forming and laminating machines are designedon a modular basis as:n Single stationn Inline orn Turntable machines.KLS 76/225 with bottom turntable and rotating top table5n Committed to the furture: The increasingly demanding require-ments of design and haptics mean that interior trim components must be finished in a wide variety of decorative materials. Our machines and tools meet these needs – thanks to our long experience in the thermo-forming of plastics.n individual solutions: Whether singlestation or inline machines, in combination tool and process-specific know-how, Kiefel covers the entire production spectrum. Our skills cover production-optimised design right up to the prototype phase and the industrial production. Thanks to innovative technologies and machinery concepts, our partners are well equipped to match the future. n optimised quality and cost-efficiency: A high degree of machine-ry automation, advanced control technology and outstanding ease of operation can of course be taken for granted. These factors are what guarantee the optimum quality and maximum cost-effectiveness of the products made using our systems.F O R M I N G A N D L A M I N A T I N G M A C H I N E SForming and laminating machinesoPtiMuM QuAlity And CoSt-eFFiCienCyn IInstrument panelsn Door- and side-trim elementsn Consoles and covering elementsn Door handles and armrestsn Storage shelvesn Insertsn Map pocketsn Pillar linersn Luggage-compartment linersn External trim componentsn Water-shielding and insulating elementsPossible applicationsInstrument panel BMW MiniDoor interior trim paneltechnologiesn vacuum forming and laminatingn vacuum forming and laminating with the In-Mold-Graining Process (IMG)n Integrated cutting and trimming solutions as well as edge folding on the laminated parts by collapsing stroke6kieFeledge-Folding MAChineSThe edges of the laminated, back-pressed or back-injected liner com-ponents used in the automotive interior-trim sector suppose special requirements with respect to the manufacturer. Exact quality specifica-tions require clean and blemish-free decorative finishes with precisely-folded edges. KIEFEL offers made-to-measure solutions: from single-station edge folding units up to complex multi-station edge-folding systems.Multi-station-edge-folding machine for door liner trim7E D G E - F O L D I N G U N I T Sn efficient: Edge-folding technology used with KIEFEL machines with individual BUS system-controlled pusher elements deliver outstanding results.n Individual solutions: KIEFEL offers several tried and tested technologies – all designed to meet various needs in an optimum way:n Edge-folding using the cold-tool technique and contact adhesive Edge-folding with adhesive activated by means of: • Hot air • Heated folding slide unit • High frequency • Infraredn Adhesive-free edge folding, with back-injected or back-pressed components for examplen Combination with cutting and trimming as well as assembly tasks, e.g. ASC rivetingn Machines with tool change for flexible processingedge-folding-machinesPReCiSe, eFFiCient, Flexiblen Door and side trim elementsn Upper door panelsn Textile insertsn Map compartmentsn Armrestsn Pillar linersn Consoles and covering elementsn Special applicationsPossible applications8kieFelSluSh-Moulding with inFRARed/ hot AiR teChnologyKIEFEL has developed a completely new heating process for heating up the the tools, the galvanos. A combination of the infrared heating technology with the hot air heating system ensures a homogeneous heating of the tools. The main heating capacity is supplied by the infra-red heaters and in the downstream air heating station the temperature is equalized. A large quantity of infrared heating elements which can individually been set guarantee a quick heating up to the particular hea-ting profile of each galvano . In the downstream temperature balancing station the air is supplied to the tool very fast by a nozzle system.With this combined procedure a very short cycle time at a homogene-ous temperature distribution in the tool could be achieved.Galvano in IR-preheating station Infrared heating station Galvano with slush-moulded skin at the removal stationInterior-trim components are increasingly being manufactured on a threedimensional basis. The increase in the design complexity of components – especially with respect to the reduced radius dimensions of component edges – along with requirements with regard to haptics, make the production of such complex components as instrument panels using the so-called “slush moulding process” (rotational sintering) absolutely necessary.9 S L U S H - M O U L D I N Gn Flexibility with design: Complex three-dimensional shapes and minimum gaps and radius dimensions are possible. Back-surface cuts can be carried out without problem during the production process. Large-depth items, such as instrument panels, can be handled.n high thermal stability: Does not create spring-back forces in the material. High thermal-load resistance prevents peeling and crackingn efficient: Inline machines with twin galvano systems can produce up to 1400 skins per day in three-shift operation.n high quality: Demanding quality requirements are met with high consistency of the forming quality for matching of surfaces for joined components. Slush-MouldingdeSign And hAPtiCS n Instrument panelsn Door and side trim elementsn Airbag and glovecompartment coversn various shelf elementsPossible applicationsInstrument panel BMW X3, bicolor Slush-moulded skin in the galvano (tool)Removed slush-moulded skinInstrument panel for BMW X5, bicolort-SiMASC Riveting MAChineSKnow-how, best quality and optimised flexibility these are values, which made us to an reliable partner of the automotive industry.FoRMing And lAMinAting MAChineShigh-FReQuenCy welding MAChineS10K I E F E L – T H E P A R T N E R O F T H E A U T O M O T I v E I N D U S T R YPReSS-lAMinAting MAChineSedge-Folding MAChineStheRMoFoRMing oF COATED FILM MATERIALSSluSh-Moulding WITH INFRARED/ HOT AIR TECHNOLOGYKnow-how, best quality and optimised flexibility these are values, which made us to an reliable partner of the automotive industry.1112kieFelASC Riveting MAChineSEver more demanding requirements with respect to technology and design are turning door linings into functional items with a variety of material finishes. Door linings can consist of over ten individual compo-nents, joined at up to 70 different points. KIEFEL’S ASC riveting system is an innovative, newly-developed, patented assembly technique for hard-wearing, robust, rattle-free joins.Kiefel ASC riveting units are working succuessfully and reliable in more than 100 applications.Riveting of a complete door lining using the ASC riveting system.13Door liningA S C - R I v E T I N G M A C H I N E SThe ASC (air supported contact) riveting process combines all the ad-vantages of the joining system used to date – in a highly efficient way.n no heat damage: The energy is transferred to the component only at the precise point required. This prevents the components from suffering heat damage.n Maximum strength: The slow and careful reshaping of the riveting pin leads to optimum forming of the rivet head, combined with maxi-mum rivet-head strength.n no shaking or rattling noise: The process rivets the components firmly together, without any play.n Maximum efficiency: Short startup time and standby control limit energy consumption to the duration of the riveting process.n optimised cycle time: A wide range of riveting systems is up to the cycle-time and ergonomic requirements, material-flow specifications and the complexity of the joining process.n Complete solutions: Complex assembly task can be tackled using a combination of the ASC riveting process with adhesive-based and ultrasonic welding technology.ASC Riveting machineshigh-QuAlity joining teChniQuewelding/riveting of:n Door and side trim elementsn Luggage-compartment linersn Instrument panelsn Consoles and diverse cover elementsn Special applicationsn The ASC technology may also be combined with edge folding, cutting and adhesion processes.Possible applications14kieFelPReSS-lAMinAting MAChineSDifferent machine systems are available for the press-laminating of textiles, imitation or genuine leather and Alcantara. Standardised singlestation or special machines are available to meet the individual customer requirements and cycle times. The press-laminating and edge-fold techniques can be combined, if required, to integrate the edge-fold into the press-laminating process.This is often realized by armrests covered with textile, synthetic leather or leather.Putting of adhesive can be integrated in the system by robots.Press-laminating machine15Door interior trim paneln Radiotor heating elements with single positionn 3-D heating elements for adhesive free laminatingn 3-D sliding frame for laminating without creasesn Processing of exact blances without rifinishingn Fast semiautomatic tool changen Integrated tool control for edge-foldingPress-laminating machinesMAxiMuM QuAlity:n Door insertsn Door-mounted armrestsn Consolesn Luggage-compartment linersn Wide range of cover elementsn Special applicationsPossible applicationsP R E S S - L A M I N A T I N G M A C H I N E SCovering elements16kieFelhigh-FReQuenCy welding MAChineSHigh-frequency welding is one of the original technology used by KIEFEL. This technology, together with the corresponding machinery engineering, has undergone continuous further development and improvement over recent decades.High-frequency welding machine for sun visors17n Rational: Multi-part turntable- or sliding-table machines with high-frequency welding presses permit rational production.n Flexible: various tools can be quickly changed. Depending on the article, automated component feeding or the integration of further manufacturing steps, including fully-automated production lines, are possible.n Maximum quality: Ultra-modern engineering, tooling and HF generator technology with individual power regulation and optional process control guarantee the production of high quality parts.high-frequency welding machineseFFiCient And FAStn Door and side-trim elements (two-tone)n Individual parts of an instrument panel (two-tone) n Textile insert (HF lamination)n Map pockets (HF lamination)n Reinforced-section welding on floor carpetsn Sun visorsn Convertible hoods and rear windowsn Sound-insulating matsn Joining of polyamide structural componentsn Special applicationsPossible applicationsH I G H - F R E Q U E N C Y W E L D I N G M A C H I N E STurntable machine with feed robot for the welding of reinforced sections onto floorcarpets.Sun visors18kieFeltheRMoFoRMing oF CoAted FilM MAteRiAlSThe goal is to create a top-class surface finish. This is done by using a positive highly-polished vacuum-capable thermoforming tool to form the components in clean-room conditions. The subsequent back-injection or back-pressing process provides the required dimensional stability.KIEFEL ensures optimum compatibility for the entire process sequence used in the thermoforming of coated film materials:n Tool configuration with shrinkage rate detectionn Thermoforming tooln Cleaning technology for film materialn Clean-room technologyn Thermoforming technologySeries KMD machine for forming the decorative trim elements.Highly-polished vacuum-capable forming tool.in the exterior:n Forming of roof modulesn Forming of wing elementsn Forming of various hood and cover elementsn Forming of bumper bars and other body elementsin the interior:n Automotive interiors increasingly incorporate designer-style decorative elements in doors and instrument panels. This involves the three-dimensional forming of thin ABS film with compressed-air support. Depending on the surface of the ABS film, it is possible to produce an aluminium or wood-look design. A subsequent back-injection process gives the component its dimensional stability.Possible applicationsIn addition to their use for interior items, plastics are increasingly being used on the outside of vehicles. Colour-coated film materi-als can be used to substitute complex coating processes. 19kieFel – FRoM deSign to SeRieS PRoduCtionAs a single-source supplier of machines for the processing of foil materials and textiles, KIEFEL boasts of several decades of experience in the area of tool building and special industrial equipment. KIEFEL applies the latest technology in design and manufacturing to the implementation of customer-specific requirements.All tools are thoroughly lab-tested and subjected to trials on the customer’s machinery before delivery and implementation in line production.Process optimisation from concept phase to series productionn vacuum forming tools with integrated edge trimmern vacuum laminating tools with snap-type edge folder or edge trimmern IMG forming and lamination machinesn Press-laminating tools for use with various technologiesn High-frequency welding toolsn Substrate mounting elementn vacuum forming tool for forming coated film materialsn Special devices for interior-trim components of all typesPossible applicationsK I E F E L – T H E A L L - R O U N D S U P P L I E Ryour benefitsn Simulation of the forming processn Optimisation of qualityn Reduction of film consumptionn Reduction of development timen Cost savings in development phase and series production10/10 Z EN 2015Printed in Germany.Subject to technical modifications.kieFel – with the power it takesKIEFEL is a world leader when it comes to the design and manufacture of machines used to process plastic film materials. The company offers core expertise in the fields of forming and joining technologies. As a supplier to reputable manufacturers in various sectors, KIEFEL GmbH services customers in the automotive, medical technology, refrigerator and packaging industries.The headquarters of KIEFEL GmbH is in Freilassing/Germany. The company also runs its own network of sales and service centres in the United States, France, the Netherlands, Russia, China, Brazil, Indonesia and India, and is represented by sales partners in more than 60 countries worldwide.Kiefel GmbH is a member of the German Brückner Group, a worldwide leading supplier of plastics machinery.KIEFEL is certified to DIN EN ISO 9001:2000 standards.Company AddressKIEFEL GmbH Industriestraße 17–19 83395 FREILASSING, GERMANYPO Box 3125 83397 FREILASSING, GERMANYTel.: +49 / 8654 / 78-0 Fax: +49 / 8654 / 78-490 e-mail: kiefel@kiefel.de www.kiefel.deThe data supplied by Kiefel in this brochure are technically oriented. Should any doubt what soever arise therefrom, said data are to be considered as approximate and not binding. Any data are legally binding only when express reference is made there-to on the contractual offers and acknowledgements of orders issued by Kiefel. Through the publication and/or presentation of any of its brochures or catalogues or any explanatory evidence or information supplied therein, Kiefel hereby legally assumes no consultative advisory obligation or liability whatsoever in as far as proprietorship of any Kiefel products is concerned and in connection with any specific aim or any technical or economical expectations by the user.