Manufacturing Automation – Polyurethane Metering
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Spray Urethane Headliner

Custom Spray Polyurethane Headliners

 

Konal has always led the industry in new and innovated processes. The spray polyurethane system was developed to cover the customers specific needs and costs. As with any product there is no one way to produce it and Konal offers different solutions as required by our customers.

This type of headliner is a spray urethane layered composite construction and is unique to Konal. It has a cycle time of 70- 80 seconds (depends on the chemical composition of the foam and its cure time).

The advantage of this construction is for deep draws, good rigidity and impact resistance. The cover material has to be bonded in a separate operation.

  • Lower scrim with barrier
  • Fiber glass
  • Sprayed liquid urethane
  • Fiber glass
  • Scrim with barrier

 

Spray Urethane Headliner System Steps

 

The scrim and fiber glass comes in roll form and is indexed using the lift and carry transfer system. The upper and lower layers are separated before coming into the press. The top layer comes from above to allow clearance for the spray robot.

As the transfer indexes, the materials are pulled into the press at the same time a robot sprays urethane in a liquid form onto the lower layer materials. The upper materials then come in contact with the lower materials as the press closes. The urethane then fills the closed mold and cures for the appropriate time. Since the upper and lower scrim have a barrier on them, it keeps the urethane from coming in contact with the surface of the tool. This means that there is no mold release required in the process.

After the part is cured the press opens and the transfer lifts the molded part out of the tool and indexes one space (the next part is sprayed at the same time).

The transfer lowers and holds the part for post curing. The transfer cycles again when the new part in the press is cured. The post cured part is lifted and indexed to a manual trim station. The part is cut from the rolled material and placed into a formed lower nest. The operator then used a pin roller to pierce the upper scrim barrier to release any gases that form during the curing process. This keeps the ballooning of the scrim.

The part may then be trimmed as needed for the marriage process. After trimming if needed the part is them put into a rack for a final cure (usually 24 hours).

The part is then removed from the rack and placed onto a marriage tool system also supplied by Konal.

The cover material with adhesive applied (normally a film) is automatically pulled off of roll(s), flaws are automatically removed, cut and placed over the substrate. The press closes and a heated upper tool then bonds the pieces together.

The part is unloaded and placed into a water jet nest for final trimming of the substrate and cover material. Any edge folding required of the cover material to the substrate is done after this, along with any additional assembly.

 

The molding system requires:

Urethane metering unit and appropriate bulk storage

Robot with mix head and hosing

Mezzanine to hold metering unit and chemical tanks and needed equipment

Mix head nozzle cleaning unit. The nozzle is ‘wiped’ after each part. There is also a canister for giving the head a short shot if idled for a long period of time

100 ton single acting forming press with die lifters in the lower to aid in tool changes

Optional tool change system

Optional tool heating system

Lift and carry transfer system (press station, post cure station, manual trim station)

All control cabinets with PLC and needed hardware and software for operating the system

Guarding and operator protection as required by the plant and OSHA

 

The bonding system requires:

100 ton (tonnage may be less if less is required) press with die lifters in the lower to aid in tool changes

Cover material roll stand

Pull and cut system for the cover material

Cover material transfer system
All control cabinets with PLC and needed hardware and software for operating the system

Guarding and operator protection as required by the plant and OSHA

Please contact us with any of you questions, we will arrange to have a salesman meet with you to discuss any of your questions or concerns and help to customize a system to the requirements needed for your product

Please contact us with any of your questions, we will arrange to have a salesman meet with you to discuss any of your questions or concerns and help to customize a system to the requirements needed for your product.