October 2003, Linden introduces a new process to manufacture leather instrument panels and interior components to the North American automotive market. The technology was developed by ISOTHERM AG, a Swiss equipment manufacturer, and BASF Group, Elastogran GmbH and is currently patent pending.
The traditional method for manufacturing leather components is a multi-step process with high labor costs and reject rates. The first step is to prepare the leather by sealing the seams and coating the backside with foil. Next, the leather is positioned in the tool and PUR materials are poured onto the leather. The substrate is then added behind the liquid PUR and compressed to form the finished structural part. The typical problems that result in a high reject rate include the hardening/shrinking of the leather grain on direct contact with monomers (orange peel effect), penetration of PU material through seams, and adhesion problems.
With the new process developed by ISOTHERM AG and BASF, the leather is positioned in the mold, the substrate is sprayed with a layer of PU foam which is then compressed into the leather to produce the finished structural part. This eliminates the backside coating and potential for orange peel defects, eliminates seam sealing, and adhesion problems. Since backside coating and seam sealing are no longer required, operator labor is reduced and cycle time shortened. Another attractive feature is that the process utilizes existing tooling.
Under an agreement initiated October 2003, Linden Industries will provide sales and service of Isotherm AG RIM Molding equipment in Canada, Mexico and the US.
