Press Information

Georg Kaufmann Formenbau AG
23. February 2007

Cost-efficient production of vehicle interior elements - Duo-Lamination – multiple in-mould decoration in just one injection moulding machine

Schematic diagram showing the different stages of the Duo Lamination process (see text for explanation) Source: Georg Kaufmann Formenbau, Busslingen/Switzerland

 

The basic decoration and the additional decoration on this prototype of an Audi A3 Sportback door panel trim developed by Peguform were back-moulded on one injection moulding machine using Duo Lamination technology. Photo: Peguform, Bötzingen

 

Busslingen, February 2007 –  With newly developed mould technology from Georg Kaufmann Formenbau AG, Busslingen/ Switzerland, it is now possible to mould parts with several differently decorated surfaces in just one injection moulding machine. The decisive features of the so-called Duo Lamination process are:

  • the innovative combination of two different mould halves for the moulding of the rear sides of the parts with a central rotating cube-shaped block with four identical cavities for the moulding of the front, decorated sides of the parts.
  • the use of pin and/or lug shaped contours for the reliable bonding of the polymers with which the different decorative materials are back-moulded in two separate injection operations.  This bonding technology is currently being patented by Georg Kaufmann Formenbau AG and Peguform GmbH, Bötzingen/Germany.

For this innovative process, the injection moulding machine must also be equipped with a rotary table mounted on a carriage and a second injection unit.  The in-mould decorated part is produced on this machine in four stages:
In stage 1, the basic decorative material (e.g. artificial leather) is inserted from one side of the machine into the vacant, readily accessible cavity of the cube-shaped block.  The rotary table then turns the block through an angle of 90°.  The reverse side of the decorative material in the cavity now faces the mould half on the stationary platen, where the part is then partially moulded (stage 2).  In stage 3, after a further turn through 90°, on the other side of the machine the cut-outs for the additional decorative materials are generated.  The prepared pre-cut parts are inserted into the cavity and located with the aid of the pins and lugs that were integrally moulded in stage 2. The rotary table again rotates the block through 90° so that the part now faces the mould half on the moving platen, where it is back-moulded by the second injection unit (stage 4).  A further turn through 90° brings the part back to its starting position, where it is removed from the mould and a new moulding cycle can commence.

The aforementioned integrally moulded pins and lugs are of central importance for the Duo Lamination process, for they serve as an exact means of positioning the additional decorative materials in the mould cavity in stage 3, thus avoiding wrinkles and creases during the subsequent back-moulding operation in stage 4.  What is more, these pins and lugs ensure a reliable, high-strength bond between the separately injected polymers (stages 2 and 4). 

The most important area of application for Duo Lamination is the production of vehicle interior elements, which today have to satisfy ever more exacting design and function requirements.  It is for this application in particular that the Duo Lamination system has been designed for a cycle time being compatible with normal mass production cycle times in the automotive industry. The process is also suitable for applications necessitating a lesser degree of automation, e.g. for the production of high-quality decorated parts in the furniture and related industries.


Further information – mould making:
Georg Kaufmann,  Georg Kaufmann Formenbau AG
Rugghölzli 3,  CH-5453 Busslingen/Switzerland
Tel.:  +41 (0) 56/485 65 00,  Fax:  +41 (0) 56/496 54 00
E-Mail:  gktool(at)gktool.ch, Internet:  www.gktool.ch

Further information – moulding process:
Yann Buchet,  Peguform GmbH
Schlossmattenstrasse 18,  D-79268 Bötzingen
Tel.:  +49 (0) 76 63/61-28 43,  Fax:  +49 (0) 76 63/61-24 75
E-Mail: y.buchet(at)peguform.de

Editorial contact and voucher copies:
Dr. Diether Burkhardt,  KONSENS Public Relations GmbH & Co. KG,
Hans-Kudlich-StraĂźe 25,  D-64823 GroĂź-Umstadt
Tel.:  +49 (0) 60 78/93 63-0,  Fax:  +49 (0) 60 78/93 63-20
E-Mail:  mail(at)konsens.de


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