Multiple in-mould decoration

Georg Kaufmann Formenbau has developed a "duo-lamination" system which enables the multiple in-mould decoration of vehicle interior elements in just one injection moulding machine.

With newly developed mould technology from Georg Kaufmann Formenbau, Busslingen/ Switzerland, it is now possible to mould parts with several differently decorated surfaces in just one injection moulding machine enabling the cost-efficient production of vehicle interior elements.

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 , Botzingen/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 90deg.

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 90deg, 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 90deg 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 90deg 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.

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