By Liz White, editor
Grafenberg, Germany - Rampf Group has convinced car manufacturers and suppliers to change to a new, very light sealing foam to protect particularly sensitive components in cars, such as the doors in the Golf 6.
Since Rampf also supplies the application and automation technology, users save time and money by getting material and machine from one source, said the company.
For the new Golf 6 project, three of Rampf's six companies are involved - Casting Resins, Dispensing Technology and Automation. They supply the two-component PU sealing foam, developed specially for the Golf 6, along with the matching application technology.
For this car model, the system is installed at Wirthwein AG, where the injection-moulded plastic parts are manufactured and foamed directly: the finished sealed door modules are then delivered to Brose Fahrzeugteile GmbH, on a "just-in-time" basis.
Starting in October 2008, the DR-CNC mixing and dispensing cell, with a round storage system will produce a door assembly carrier with polyurethane seal about every twelve seconds - or about 1.5 million parts annually.
"We have a high degree of capacity utilisation in our factories. We cannot afford losses or disharmony in production. This is why we buy our sealing foam and machines from the same supplier. That saves time and money," said Hartmut Herrmann, project manager at Wirthwein AG.
Another benefit is that the new sealing material - RAKU-PUR 32-5022 - has low water absorption and good sealing, but also high mechanical strength and a low specific gravity. "As the sealing foam is very light-weight, the user saves approximately 20 percent of starting materials compared to other commercial foams," commented Stefan Siegers, sales and marketing director at RAMPF Casting Resins.
Other models the product is likely to be used in include Volvo models C30 and C40, the Porsche Cayenne and the successor to the VW Touareg.
Siegers also reckons that the sealing foam is also suitable for stainless steels, where initial tests have already proved successful.