Fuerth and Duesseldorf, 24 October 2007: The stamping foil manufacturer Kurz has further developed its foil feeding units for the in-mold decoration (IMD) process. The new IMD-MK/S series for processing single-image designs offers a substantially increased foil-advance speed. Whereas the previous machine series allowed a foil advance of up to 270 mm/s, the new unit allows - depending on the particular application, part geometry and the foil used - a maximum advance speed of up to 500 mm/s. This can signficantly reduce the injection-molding cycle times and the time required to produce the finished, decorated part.

Equally precise positioning of the foil IMD-MK/S is the next generation of the IMD-MK/P series of single-image, foil-processing units that can achieve a highly

precise orientation of the foil both in the feed and lateral directions. Despite the substantial increase in achievable advance speeds, the IMD-MK/S retains the previously high positioning accuracy of +/- 0.07mm in the x and y directions.

Kurz does however point out that, to achieve precise positioning of single images in a mold cavity, a suitably accurate injection mold, very low pressure tolerance of the foil being processed, and precise registration marks are required. Kurz foils and tools are matched to these requirements so that the desired positioning reliability can be achieved without difficulty.

Inline corrections provide additional time savings

The IMD-MK/S units are equipped with a programmable logic controller (PLC) that guarantees precise foil positioning when setting up a mold and monitors the positional accuracy of the designs during production. Should inaccuracies arise as a result of process fluctuations, the positioning can be adjusted while decoration is in progress either manually or automatically via an optional vision system linked to

the foil feeding unit. Realignment of the foil occurs without interruption to the injection-molding cycle, further increasing productivity.

Precision ensures higher part yields

Efficient Inmold decoration is not only achieved by the high advance speed but also the positioning precision of Kurz foil feeding units. The foil can be so precisely positioned in the mold that it is even possible to produce the injectionmolded

parts in a four-cavity mold. This advantage is being used often in the telecommunications industry. In the area of cell phone displays, Kurz feed units are used in conjunction with four-cavity molds in series production.

Process reliability with extensive standard equipment

According to Kurz, IMD-MK/S foil feeding units are not only characterized by their foil-advance speeds and positioning accuracy but also their high functional reliability. A large number of sensors monitor the correct passage of the foil from the foil-supply reel to the foil take-up reel. These sensors recognize foil tears, detect foil-adhesion points when using continuous designs, monitor the foil take-up and check that pinch and transport roller pairs are in the correct state. The status of the unit is also displayed on a three-way signal lamp. Trouble-free Inmold decoration is assured with foil feeding units configured in this manner.

Compact design

IMD-MK/S is even easier to operate than the previous model, has an especially compact design and can be easily integrated into various injection-molding machines. Kurz can supply machine-mounting plates that are exactly tailored to

individual customer requirements. The foil feeding units in the IMD-MK/S series are available in widths of 200, 300 and 400mm. Accessories like additional foil-cleaning stations at the foil take-up, round out overall product offerings.

Optimized product line for continuous-design foils

Kurz's product range of foil feeding units is complemented by a product line for processing continuous foils which have also been improved. The new IMD-W product line is based on the IMD-MK/S product line and comes with almost all

the same equipment features and functions (apart from the ability to process single-image designs). The product line is easy to use, especially because the process parameters can now be set via a cable remote with a clearly laid out

display. In addition, all connections between the control cabinet and the foil feeding unit can now be plugged in at either end.

The IMD-W units are also available in standard widths of 200, 300 and 400mm. Kurz also offers custom solutions, and "TWIN versions” for processing two foil tracks. 

Data sheets on the IMD-MK/S and IMD-W units, providing all the relevant technical details, are available from Kurz.

You can also find out more by visiting www.kurz.de . The foil feeding units can be seen in action at K 2007 at the Kurz Stand A 19/Hall 5.