vacuum forming and laminating technology

AUTOMOTIVE INDUSTRY
VACUUM FORMING
AND LAMINATING
TECHNOLOGY
power in plastics processing
KIEFEL
FORMING AND LAMINATING TECHNOLOGY
The needs of design and haptics require that interior trim components
be finished in a wide variety of decorative materials.
We use our decades of experience in the thermoforming of plastics
and the press-laminating of decorative materials such as textiles and
leather to plan, develop and manufacture machines and machine tools
designed to fulfil these requirements.
The high degree of automation of these units, along with a control
system designed for maximum ease and convenience, guarantees
optimum quality for the finished product, while taking cost efficiency
fully into account.
Door for BMW 5 with two-color-laminating
F orming and laminating
Typical areas of application
for forming and laminating
n Instrument panels
n Door and side trim elements
n Consoles and covering elements
n Door handles and armrests
n Storage shelves
n Inserts
n Map compartments
n Pillar liners
n Luggage-compartment liners
n External trim components
n Water-shielding and insulating elements
Door panel Saab 9-5, IMG laminated
Processes
n Vacuum laminating with PVC and TPO foil on substrates
n Vacuum forming of PVC and TPO foil
n Vacuum laminating using the in-mould graining (IMG) process
n Vacuum forming using the in-mould graining (IMG) process
Following manufacturing processes
Edge folding fixture for door panels
n Edge Folding
n Assembly
Riveting of a complete door lining using the ASC
riveting system.
KIEFEL
SINGLE STATION THERMOFORMING MACHINES
KL series
The KIEFEL Single-station-thermoforming
machines achieve a cycle time of 120 – 150
sec. (depending on machine equipment and
material combination). Due to this fact these
machines are suitable for small series.
Single station laminating machine
Technical Data
Range of small machines
KL 80/120*
KL 86/145
Range of large machines
KL 100/200
KL 100/240
Special sizes
Details on request
*Forming area
800 x 1200 mm
Forming tool for armrest
SINGLE STATION THERMOFORMING MACHINES
Basic configuration of
single station machine
n Frame, robust welded-steel structure,
individual elements bolted on
Options
n Enclosed and sealed pre-blow box
n Foil-winding system with manual foil inlet and cross-cutting
attachment
n Bottom table: Servomotor-driven via
four toothed racks with mechanical
synchronisation, two pneumatic valves
for additional function, water inlet for
tempering/cooling, 20 kN retaining force
n Top table: Servomotor-driven via
two toothed racks with mechanical
synchronisation, two pneumatic valves for
additional functions
n Heating station, pneumatically traversed,
consisting of: Lower heater with FS
elements; upper heater with FS elements
and pyrometer
n Table-in-table-function for top table
n Additional top table for contour punching
n Additional pyrometers
n Additional valves for the top and bottom table
n Vacuum on top platen
n Infrared pre-heating of substrate
n Roller gate instead of photoelectric barrier supplied by Sick
n IMG package (on request) Further options available on request
n Further options according to request
n Clamping frame (tool component); the
lower clamping frame is a fixed item
n Motor-actuated raising of upper clamping
frame
n Cooling via blower fans with adjustable
nozzles
n Vacuum system with vacuum pump and
reservoir
n Automatic pre-blow system controlled
automatically via photoelectric cell
n Siemens S7 control system, OP270
operator panel incl. process display
n Photoelectric barrier supplied by Sick,
operator protection on operation side
n Automatic tool change system
Door lining Saab 9-5
KIEFEL
INLINE VACUUM THERMOFORMING MACHINE
KLS series
Basic configuration of
Inline machine
Inline vacuum thermoforming machines can achieve cycle times
of > 38 sec., depending on configuration and the combination of
­material being handled. This makes Inline machines ideal for use on
large production runs.
n Complete frame design, robust weldedsteel structure; bolted single elements
n Enclosed and sealed pre-blow box
n Bottom table: servomotor-driven via four
toothed racks with mechanical synchronisation, two pneumatic valves for additional
function; water connection for tempering/
cooling, 30 kN holding force
n Top table: Servomotor-driven via two
toothed racks with mechanical synchronisation, two pneumatic valves for additional
functions
n Heating station: pneumatically moveable
heaters, consisting of:
- Lower heating element with FS heaters
and automatic lowering mechanism to
handle foil sag
- Upper heating element with FS heaters
and pyrometer
n Cooling via central blower unit and
­adjustable nozzles
n Vacuum system with vacuum pump and
reservoir, optimal form-vacuum by pump
n Pneumatic system
n Automatic pre-blow system operated via
photoelectric cell
n Foil unwinding system for one roll of foil
material
n Foil transported by means of chain-guide
conveyor system – motor-driven adjustable
n Centralised machine-lubrication system
n Siemens S7 control system, control panel
with 15“ touch screen incl. process security
n Personnel protection on operator’s side
with photoelectric barrier supplied by Sick
KLS Inline vacuum thermoforming machine
INLINE THERMOFORMING MACHINES
INLINE MACHINES
Option package
Top-table configurations
Bottom-table configurations
Rotating top table
Two- or four-up (KIEFEL-patented) For all forming/laminating
tasks, with contour and/or edge
folding cuts (e.g. I-panels, door
liners, knee protectors)
Single sliding table
Ergonomic loading and removal, cycle times of approx. 60
seconds (depending on article)
The advantages:
nO
ptimum freedom with
respect to auxiliary forming
aids, embossing cylinders
and cutting control
Turntable
Loading and removal while the
forming/ laminating process
is taking place, cycle times of
approx. 40 seconds (depending
on article), molded-parts with
large height (I-panel)
nR
eception of 4 tools ­possible,
also IMG-shells
Technical Data
Range of small
machines
KLS 76/125*
KLS 86/145
Range of large
machines
KLS 76/225
KLS 86/235
Special sizes
KLS 86/270
*Forming area
760 x 1250 mm
Table-in-table
For simpler forming and
laminating tasks with clamping
frame and/or rough cutting
(e.g. dashboards, glove compartment lids)
The advantages:
nA
uxiliary forming aid and
punching tool in one
nL
ow investment costs
Options
n Additional valves for the top and bottom
table
nP
ackage for the processing of 2-colored foil
n Infrared pre-heating of substrates
nA
utomatic part-handling (loading and unloading)
n Roller gate instead of photoelectric barrier
supplied by Sick
nA
utomatic tool change system
n In-mould graining (IMG) package
n Package for the processing of hot-melt
adhesive on foil
nF
oil storage unit for continuous production during tool change
nS
plit chain rail system, reduced foil consumption (patent KIEFEL)
nF
oil unwinding system with space for spare roll, foil station or
continuous foil magazine
KIEFEL
3-UP TURNTABLE THERMOFORMING MACHINES
Detail door-mounted armrest laminated using the
IMG process
Door-mounted armrest laminated using the IMG process
KIEFEL KDT-range turntable thermoforming
machines are used both for thermoforming/
laminating and press forming (male/female
moulding).
Typical fields of application include:
n Conventional thermoforming of foil materials and foil laminating on
substrates for vehicle interior trim
The foil material will be loaded as pre-cutted
parts into the turn-table.
n In-mould graining (IMG) applications such as door trim and vehicle
instrument panels
n Thermoforming of composite materials for use in the car industry
(e.g. bumper mountings)
The machines in the KDT range are characterised, as well as the
KIEFEL single station and Inline machines, by the use of servomotoractuated tables.
Depending on technical requirements (e.g. IMG applications), the top
table can be mechanically locked to operate in step with its bottom
counterpart.
The machine is fitted with an infrared substrate pre-heating station.
A handling device automatically separates and inserts the foil cuts into
the foil clamping frame.
The bottom table rotates through 90° towards the machine operator
for the purpose of ergonomically-efficient loading and unloading of the
machine.
TURNTABLE THERMOFORMING MACHINES
KIEFEL
TURNTABLE THERMOFORMING
MACHINES
Three-up turntable machine for IMG process and male/female thermoforming of
composite materials (with pressing force of up to 300 t)
KIEFEL turntable thermoforming machines are used both with foil and
material supplied in sheets, with
n Vacuum / compressed air
n Male / female tool with pressing force of up to 300 t.
Forming area: 1200 x 2000 mm
– Servomotoric driven top and bottom table, turntable – fast and
­dynamical move
– Automatic foil / sheet-insertion, locking mechanism
– Bridging/-Gliding frame – optimal foil stretching
– Additional top table for contour-punching and part handling
KIEFEL
VIDEO-CONTROL-SYSTEM
n PC with Celeron 850MHz, no fan required
n USB interface (bootable) for saving data and formulas, connection to
printer
n UPS unit to close Windows down correctly in the event of a power
failure
n Windows XP
n Language changeover with system running
n Overview provided by real image of system with main machine
values
Visualisierung mit 15“ Touchscreen
n Clear, station-orientated, menu-based management and target/
current settings
n Information displays for machine-operating and retooling procedures
n Password-protected access for authorised users
n Detailed fault diagnosis
– Alarm messages displayed on all screens
– Alarm display with “entry/exit” time
– Fault history can be saved for statistical purposes
n Special heating-unit program for the convenient adjustment of
radiators
n Multi-faceted trend analysis
– Activation temperature
– Vacuum curve
n Automatical control heating power
n Option: camera for a 2-dimensional temperature-display
n Online sequence-of-operation-diagram to optimize the process
n Logbook function: Real-time logging of all important events
n Production-data logging and reporting (format DBASE-compatible to
Excel) is possible by network
n Print function:
– Screenshots
– Entire formula (production settings)
– Error messages
– Trend curves
n Servicing and maintenance log
n SPC status information can be displayed for servicing purposes.
n Remote maintenance by modem or internet
K iefel – T H E A L L - R O U N D S U P P L I E R
KIEFEL – from Design to series production
As 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.
Your benefits
n Simulation of the forming process
n Optimisation of quality
n Reduction of film consumption
n Reduction of development time
n Cost savings in development phase and
series production
Process optimisation from concept phase to series production
Possible applications
n Vacuum forming tools with integrated edge trimmer
n Vacuum laminating tools with snap-type edge folder or edge trimmer
n IMG forming and lamination machines
n Press-laminating tools for use with various technologies
n High-frequency welding tools
n Substrate mounting element
n Vacuum forming tool for forming coated film materials
n Special devices for interior-trim components of all types
KIEFEL – with the power it takes
KIEFEL 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 Address
KIEFEL GmbH
Industriestraße 17–19
83395 Freilassing, Germany
PO Box 3125
83397 Freilassing, Germany
Tel.: +49 / 8654 / 78-0
Fax: +49 / 8654 / 78-490
e-mail: kiefel@kiefel.de
www.kiefel.de
The data supplied by Kiefel in this brochure are technically oriented. Should any doubt what­soever arise therefrom, said data
are to be considered as approximate and not binding. Any data are ­legally binding only when express reference is made thereto 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.
20/10 Z EN 2016
Printed in Germany.
Subject to technical modifications.