Close Connection – Sealing Systems and Door Modules
Moisture outside the car is OK, but inside it‘s a no go. That is why vehicles must be reliably sealed. In door modules, high-performance sealing foams from RAMPF Polymer Solutions fulfil this important tasks realiably and in the long term.
When driving in wet conditions, the water should always run off the car and not finds its way through the car door into the interior. In modern cars, this can be taken for granted; however, the processes that prevent this scenario from happening are complex. High-performance sealing foams based on polyurethane and silicone from RAMPF Polymer Solutions play a central role in keeping cars dry.
In recent years, the variety of car doors and door modules has greatly increased, and with it their complexity. The reason for this is the growing number of integrated systems, such as door locks, window regulators, and loudspeakers. In the manufacturing process, these elements are connected to a door assembly carrier and then form the internal part of a car door as a module. The door modules, also known as door assemblies, are usually made of aluminum or long glass reinforced polypropylene plastic.
Depending on the composition and design of the door module, different material formulations (liquid or paste) and application processes (2D, 3D) are required. To protect the sensitive electronic components of a door module from dust, moisture, and water, it must be efficiently sealed. This demanding task is mastered by two-component polyurethane sealing foams of the RAKU® PUR brand.
Albert Schmid, Key Technology Manager Sealing Systems at RAMPF Polymer Solutions:
Only the optimum combination of material and process technology ensures perfect sealing and guarantees reliable and long-term protection from moisture and chemical influences as well as various environmental impacts.
However, the sealing foam not only protects the door module from external influences, it also ensures compliance with the Noise Vibration Harshness (NHV) standards that are widely used in the automotive industry. NVH refers to all perceptible or audible vibrations in an automobile that could impair driving comfort. The polyurethane-based, two-component sealing foam from RAMPF Polymer Solutions makes a significant contribution to keeping the occurring vibrations as low as possible.
Advantages of 2K-RAKU® PUR sealing foam:
- Maximum functional reliability: very good properties with regards to sealing behavior, resilience, compressibility, ageing, and hydrolysis resistance
- High efficiency: fast curing, in-line production, and availability of parts
- Uncomplicated compensation of high manufacturing tolerances: low assembly forces and soft material
- Customized development: range of variation for polyurethane sealing material
- Inexpensive sealing material combined with cost-effective seal production
- Compliance with NVH standards
- Sustainable materials – cure at room temperature and can be recycled at RAMPF
Applying the polyurethane sealing foam
The sealing foams are applied using the FIPFG method (Formed-In-Place Foam Gasket). The seals are applied in-situ (on the spot) to the sealing groove of the door module. The two components of the sealing foam are first mixed together on a two-component mixing and dispensing system. The subsequent foaming is achieved by the chemical reaction of MDI isocyanate with water. After the liquid or paste-like sealing foam has been applied to the door module, the reaction begins shortly thereafter, and the foam expands.
One-stop solution provider – RAMPF Polymer Solutions and RAMPF Production Systems
Particularly for high volumes, as is common in the automotive industry, FIPFG technology has prevailed over other application options for door modules. When selecting the mixing and dispensing system, one should rely on a manufacturer with many years of experience and sophisticated machine technology.
For this reason, RAMPF Polymer Solutions works closely with RAMPF Production Systems, a leading international developer and manufacturer of mixing and dispensing systems. For the customer, this offers the key benefit of obtaining material and machine from a single source.
Furthermore, RAMPF supports customers from development to series production.
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