With automated production to the optimum PU foam gasket
Consulting, prototyping, commissioning and contract manufacturing from a single source
Technology, material and component - these three factors must be optimally coordinated for the automated production of PU foam gaskets.
DOPAG and Stassen Industries GmbH advise customers together.
Foam gaskets made of polyurethane (PU) protect components from dirt, dust and moisture. They are applied, for example, to doors and ventilation grilles of switch cabinets, to loudspeakers and housings of control units in cars or as clear encapsulation on LED lights. Production is automated in many industries. However, there are still many companies that glue the foam gaskets in manually. The fact is: the automated application has less room for error compared to the manual application, but the process is demanding.
Technology, material and component must be precisely coordinated in order to optimise the production process. In any case, competent advice and support from experts is advisable here. This is offered jointly by the metering and mixing technology manufacturer DOPAG and the sealing and dispensing technology specialist Stassen Industries. The partnership focuses on advising customers on all aspects of gasketing, potting and adhesive applications in contract manufacturing, the production of prototypes and support in the integration and commissioning of the DOPAG dynamicLine, an automated gasketing system.
The advantages of automated application
PU foam gaskets are produced using the FIPFG process (formed-in-place foam gasket). A fully automated system is suitable for series production with high quantities. It enables easy handling of the components and meets all requirements in terms of process reliability and quality standards. Automated material application offers many advantages over manual application. High economic efficiency and a long service life can be achieved. More and higher quality foam gaskets can be produced in a shorter time. Thanks to the controlled overlap, there are no disadvantageous coupling points as with manual gluing. The start and end points of the foam bead merge into one another.
The dynamicLine from DOPAG was specially developed for gasketing applications. Its dynamic mixing system processes polymer reaction materials precisely and with a consistently high quality. In addition to sealign foams, this also includes adhesives and potting compounds. The material is automatically applied directly to the component using a linear robot. It is also possible to use an industrial robot to bring the component into position under the permanently mounted mixing head and to trace the geometry of the foam bead. The seal then cures at room temperature. The duration depends on various factors, including the material, the mixing ratio, the temperature in the room or the humidity. The control unit can store various metering and traversing programmes. Various parameters can thus be changed flexibly. For example, it is possible to switch between different components or material recipes, or different output rates with different seal widths or heights can be selected.
Combination of material and component decides
Stassen Industries GmbH produces PU foam gaskets at its production site in Remscheid, Germany. All employees are familiar with the DOPAG systems and know all production factors. PU foam gaskets are applied to component groups centrally in the value-added chain, across all industries. Speed, flexibility and reliability are required in production. What counts is experience in how the system works best in combination with the material and components to be processed. Stassen Industries is familiar with the equipment and material of all manufacturers as well as the customer's components and thus offers optimum advice and support. The all-inclusive service ranges from consulting and prototyping to contract manufacturing and the configuration and set-up of the DOPAG system at the customer's site. For example, customers can have PU foam gaskets applied to their components at Stassen Industries GmbH with the dynamicLine and thus gain experience. Erol Tamer (CTO) and Dennis Stassen (CEO) advise customers on gasketing, bonding and potting and can give the customer immediate feedback on what works and what doesn't based on their know-how and on tests in their own showroom. Based on years of expertise, the components are assessed and a solution approach is shown or suggestions for the material and the system configuration are made. The customer also receives support with the automation concept.
Later, the DOPAG system can be integrated into the customer's own production line - with the certainty that the application of the PU foam gaskets is already process-optimised. Together with DOPAG, Stassen Industries accompanies the customer from the very beginning and later also sets up the system on site at the customer's premises. The employees know the components and the process. The system is configured correctly straight away, so errors are avoided. If, for example, there are later peaks in production at the customer's site, Stassen Industries can immediately process subcontracted orders for the customer without much effort. In line with the two-supplier strategy, Stassen Industries GmbH thus provides the customer with a reliable backup solution.
Local value chain
Customers benefit above all from short transport routes and a fast response time when working together. The dynamicLine is manufactured at the DOPAG site in Mannheim, Germany. Through close cooperation, customers benefit from local support, comprehensive know-how and many years of industry experience directly through the experts in Mannheim or through the Stassen Industries site in Remscheid, Germany. Through direct exchange, users can familiarise themselves intensively with the dynamicLine and build up their own expert knowledge.
What are the advantages of PU foam gaskets compared to manually inserted seals?
Sealing possible in principle of all industrial components (also 3D) and shapes.
PU gaskets can be applied captive automated, they can adhere without additional adhesive tape.
Start and end points of the foam bead merge thanks to the controlled overlap programmed by DOPAG, no disadvantageous coupling points
No open joints or cuts
Parameters such as the width, height and hardness of the seal can be influenced
Less possibility of errors compared to manual application
High cost-effectiveness: The cost of the gasket is of higher quality and much lower compared to manually applied gaskets.
Short cycle times allow for efficient, automated production.
Sustainable: Compared to punched or cut gaskets, there is almost no waste.
Environmentally friendly rinsing of the system with water
Adhesive-free at room temperature after around four to 20 minutes, an oven for curing is not necessary
- One contact for the entire system solution
- All applications from one provider
- Implementation of specific requirements and automation
- Competent support from DOPAG experts
- A dedicated technical centre for testing and customer training
- Close collaboration with material manufacturers
- Decades of experience in metering and mixing technology
- Global distribution and service in over 40 countries
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