Henkel Unveils Breakthrough Polyurethane Foam Gasket to Revolutionize Door Module Efficiency

The fully automatic dosing application according to FIPFG technology is carried out with the CNC-controlled MK 825 PRO precision mixing head and the DM502 dosing system with high dosing accuracy.

(IN BRIEF) Henkel has unveiled its new 2-component polyurethane foam gasket system, specifically engineered for car door module production. This innovative system, named Sonderhoff Fermapor K31-A-5055-1-G / K31-B-4, enhances the deinking and sealing process by offering a unique combination of an extended pot life and rapid curing, which is critical in fully automated production. It is designed to meet strict mechanical, hydrolysis, and temperature stability requirements as specified by DBL 5452, ensuring that electronic and mechanical components within door modules are securely sealed against water, dust, and vibrations. The system also reduces material consumption by about 5% while maintaining optimal performance, thereby lowering costs. Henkel’s new foam gasket improves the overall tightness of the door module by evenly pressing the foam along the component contours and compensating for dimensional variances. This breakthrough technology promises to deliver significant efficiency gains with shorter cycle times, reduced material usage, and improved sustainability for door module manufacturing.

(PRESS RELEASE) DÜSSELDORF, 18-Mar-2025 — /EuropaWire/ — Henkel has introduced a revolutionary 2-component polyurethane foam gasket system designed to unlock significant efficiency gains in car door module production. Modern vehicles now integrate an increasing array of advanced technologies—from safety and infotainment systems to lighting and air conditioning—housed within door modules constructed of galvanized stamped sheet metal or glass-fiber reinforced plastic. These door modules not only support these electronic and mechanical components but also serve as a protective barrier, shielding the vehicle’s interior from weather conditions.

In the fully automated production process, a polyurethane sealing foam is applied to the contours of the door module using a CNC-controlled mixing head from the Sonderhoff dosing system. This sealing foam is critical, as it must not only provide effective water and dust resistance but also minimize driving-related vibrations, ensuring the secure installation of components such as electronic window regulators, door locks, and loudspeaker mounts.

Henkel’s new sealing system, designated as Sonderhoff Fermapor K31-A-5055-1-G / K31-B-4, has been developed to meet the demanding mechanical properties required by OEMs and suppliers. It boasts excellent hydrolysis and temperature stability in accordance with delivery specification DBL 5452. One of the standout features of this innovative foam gasket is its unique combination of a relatively long pot life with rapid curing once foaming begins—a balance that is essential for the high-speed, fully automated production of door modules. The foam remains workable long enough after application to ensure proper positioning, yet cures quickly to allow the door module to be processed and installed without delay.

This advancement not only cuts down on the need for intermediate storage and reduces overall curing time, but it also achieves approximately a 5% reduction in specific density without compromising performance. This means lower material consumption, translating to a more economical solution compared to current market alternatives. Moreover, the gasket’s low installation forces facilitate the seamless mounting of door modules within body-in-white assemblies and ensure that additional components, such as loudspeakers, window regulators, and locking systems, are sealed uniformly. The foam effectively compensates for any dimensional tolerances, delivering a consistently high level of tightness.

As a result, this new sealing foam system represents a groundbreaking innovation for door module manufacturers. It offers remarkable efficiency improvements through shortened cycle times and reduced material usage and weight, paving the way for large-scale production with significant cost savings.

Media contact:

Sebastian Hinz
Adhesive Technologies
Media Relations
Headquarters, Düsseldorf/Germany
+49-211-797-8594
press@henkel.com

SOURCE: HENKEL