Manufacturing Automation – Polyurethane Metering
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Wet Urethane headliner

Wet Polyurethane Custom Headliner Systems

 

We have always led the industry in new and innovated processes. There are many variations of the wet urethane process that Konal manufactures. Each one was developed for a customer’s specific need. We are not limited to these and can manufacture a line for other required steps needed in your process and financial demands. This process has a cycle time of 45 to 65 seconds, depending on the foam core and adhesive forming time.

 

The wet headliner normally consists of the following:

  • Cover material
  • Adhesive film or webbing
  • Fiber glass
  • Catalyst
  • Foam core with urethane adhesive
  • Scrim (optional barrier film)

 

Wet urethane is the most economical headliner produced. It does have its limits on the depth of draw and amount of weight it can hold without creasing while being installed in the vehicle. It has good acoustical sound deadening.

 

Wet Urethane Header Production Process

 

The headliner is made on an in line machine, most if not all the components are in roll form. This type of construction also lends itself to having the water jet trimming process automatically loaded after molding. This eliminates the need for an additional operator.

The system consists of roll materials on spindles (mounted to roll carts below the work line or spindles mounted over the line.

The fiber glass can be in either roll form or chopped onto the scrim before the foam is applied.

There are lines that use sheet foam or rolled foam. Both types of foams are run through a roll coater to put the proper amount of adhesive on them. The sheet is then placed onto the lower layer of fiber glass.

Some adhesive require a catalyst be applied to the foam sheet. This can either be done after the roll coated or sprayed onto the fiber glass layer before the foam is loaded.

After the foam is loaded (catalyst may be applied if needed at this time) another layer of rolled or chopped fiber glass is added.

The adhesive film and cover material as placed upon the fiber glass. This is all done while the materials are being pulled to the set length. The material puller stops at the proper setting and all the layers are cut at the same time. The puller then positions the ‘sandwich’ to the proper index position.

The transfer then clamps onto the sides of the ‘sandwich’. Using a lift and carry motion the material is moved into the forming press. The mold in the press is heated in both the upper and lower halves. The press closes and the transfer then moves back to get the next ‘sandwich’.

When the press opens the molded part is raised and transferred to the water jet nest and lowered to the proper location. The part is then trimmed. If the water jet station is not included in the line the part is placed onto an unload table.

After the part is trimmed the operator unloads the part and any of the offal on the nest. the part is then loaded into a rack or moved to an assembly area if other parts are to be pre assembled before installation into the vehicle.

The system consists of the following:

Material roll carts and stands as needed

Adhesive roll coating system include automatic filling of adhesive and day tanks if required

Optional some customers prefer to spray the foam core with a water base adhesive instead of a roll coater. Konal can supply this also.

Catalyst spray system as needed

Material pull and cut system and flaw detect (for cover material)

Transfer system to move the part through the different stations

100 ton forming press (tonnage may differ depending on your specifications)

Optional tool change system

Optional tool heating 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

Water jet station (optional)

Depending on the volume of you product this system can also have manual operations and upgraded at a later date.

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.