technologies and solutions for the automotive...

Technologies and Solutionsfor the Automotive IndustryAdhesives and Sealants

» Assembly of stiff bodies with high load transmission

» High force transmission

» Prevents joint movement

» Low to medium load transmission

» High joint movement capabilities

» Good absorption of joint movement

» Sealing against moisture and agressive media

» Tolerates high movement of sealed joint due to high flexibility

» Excellent gap bridging properties

Structural Bonding Flexible Bonding Sealing

Metal Terokal 5074Terorehm 2100Terokal 9225 SFTerokal 221

Terostat MS 9360Terostat 8590 UHV/MTerostat 3208Terostat MS 9399Terostat 8593 HNL

Terostat MS 930Terostat 2469Terostat 9140Terostat 8595 M

Plastic Terostat 5197Purmelt QR 3511Purmelt QR 5210Terokal 225Loctite 3038Terokal 850

Terostat 8590 UHV/MTTerostat MS 9360Terorehm 1010Terostat 8599Terostat 8595 N/MT

Terostat 9120Terostat 1248 LVTerostat 2451Terolan 1102Terostat MS 935Terostat MS 939 FR

Glass Purmelt QR 3450 Terostat 9220Terostat 8590 UHV/MTerostat 8599Terostat 8593 HNLTerostat MS 9399

Terostat 9140Terostat PU 92Terostat 9320

Textile Terokal 1251Purmelt QR 6204-02Macromelt 2035Terokal 3944

Terostat MS 935Macromelt 6208

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A wide choice of solutions

To achieve the optimal bonding result, the following premises must be met:» Compatibility of the adhesive with the materials to be bonded.» Compatibility of the adhesive with the specified requirements.» Correct processing of the adhesive.

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Building “bridges”

Overview Structural Bonding

Structural bonding is a process in which two materials are solidly and permanently assembled using an adhesive. Adhesives build “bridges” between the surfaces of substrates to be joined.

Force transmission Elasticity Gap filling

The following key points should be considered for the design of bonded joints:

Preferred for thin sections. Simple design and good strength properties.

Single lap shear joint

Uniform stress distribution

Double lap shear joint

Frequently used to get smooth faces without extra preparatory work.

Single strap joint

Provides better strength than a single strap, but is more complicated.

Double strap joint

Offers excellent strength, but is very complicated to produce.

Hafted joint

Thin-walled pipe lap or strap joints which are sub-jected to torsion can reach the same strength as the metals involved.

Torsional loading

Benefits of adhesive bonding vs. conventional joining methods

Uniform stress distribution over the entire bonding surface: » Positive effect on the static and dynamic strength » Welding and riveting result in local stress peaksNo change in surface and texture of joined materials: » Welding temperatures change the texture and there-

fore the mechanical properties of materialsWeight saving: » Adhesives are perfect for light-weight constructions,

where thin-walled parts (wall thickness < 0.5 mm) must be joined

Adhesives also act as sealants: » Prevention from loss of pressure or liquids» Blocking the penetration of condensing water » Protection against corrosionJoining different materials: » Adhesive forms an insulating film » Prevention of contact corrosion» Electrical and thermal insulator

Compensation of different thermal material expansion

High resistance to peel forces High elongation recovery under shear or tensile stress

High vibration absorption High impact and shock absorption

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Stress distribution

Suitable sealants:» Prevent possible damage (e.g. by protecting against

unfavourable environmental influences, penetration or leakage of hazardous materials and gases, corrosion etc.).

» Allow simplified designs and provide a proper appear-ance.

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Safe, reliable, and trouble-free

Flexible Bonding Sealing

The safety and reliability of automotive modules often strongly depend on which components are joined together, on a reliable seal created between these parts and on the trouble-free, consistent performance of the sealants used.

Elastic adhesives combine the advantages of bon-ding and sealing in one single operation:» Prevent corrosive media entering or leaking from

assemblies, even in wider joints or gaps.» Create a friction-locked joint of mating parts by means

of adhesion to the substrates and inherent strength or cohesion within the adhesive itself.

Flexible bonding is a highly efficient and reliable technique for joining parts; it is widely accepted by automotive OEMs and suppliers.

» Flexible adhesives are selected for their capability of absorbing and/or compensating dynamic stresses.

» Henkel’s flexible adhesives exhibit a high inherent strength (cohesion) and a high modulus, achieving friction-locked joints which, at the same time, have elastic properties.

Sealing/filling of cut-outs

Surface sealing

Joint and overlap sealing

Potential application areas for sealants:

Seam sealing

Benefits of flexible bonding

» Simplified design by increasing strength to with-stand dynamic loads

» Prevents material fatigue and failure by achieving uniform transmission of the load and by maintain-ing the structural integrity (no thermal or mechani-cal weakening of parts).

» Saves production costs by replacing conventional mechanical fasteners (screws, rivets or welding).

» Allows the most varied substrate combinations, eg. metal/plastics, metal/glass, etc. and reduces and/or compensates stress caused by differential ther-mal expansion of joint substrates.

» Compensates the tolerances of the parts to be joined.

Sealants form a ”bridge“ between different part surfaces. The strength of a bond depends upon:» Adhesion of the sealant to the surface of the

substrate and cohesion (strength within the sealant itself).

» The physical and chemical properties of sealants depend to a large extent on the selected raw material basis.

» Elastic sealants have a high elongation of > 200%. » Reversible deformation with a high recovery rate

of > 70%. » Plastic sealants display only slight or no recovery

and low admissible total deformation (< 5%).

Benefits of sealing

Convincing qualities

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Metal Adhesives & Sealants

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Function Product Processing Mechanical Performance * Durability

Name Chemical Basis

No. of Components

ApplicationTemperature

Cure Temperature

Time Handling Strength

Shear Strength G-Modulus Elongation E-Modulus Max. Service Temp.

Structural Bonding Terokal 5074 Epoxy 1 40 – 50 °C 30 min/180°C after oven 26 MPa 570 MPa 13 % 1600 MPa 90 °C

Terorehm 2100 Epoxy 1 50 – 60 °C 30 min/180°C after oven 20 MPa 640 MPa 4 % 1800 MPa 90 °C

Terokal 9225 SF PUR 2 ambient ambient 0.5 – 1 h 16 MPa 1180 MPa 3 % 3300 MPa 90 °C

Terokal 221 Epoxy 2 ambient ambient 5 h 28 MPa 1000 MPa 3 % 3000 MPa 90 °C

Flexible Bonding Terostat MS 9360 MS-Polymer 1 ambient ambient 12 h 3.5 MPa 0.7 MPa 200 % 2 MPa 100 °C

Terostat 8590 UHV/M PUR 1 30 – 50 °C ambient 2 h 5 MPa 1.5 MPa 500 % 2 MPa 90 °C

Terostat 3208 Rubber 1 30 – 40 °C 30 min/180°C after oven 0.4 MPa 0.3 MPa 65 % 0.35 MPa 80 °C

Terostat MS 9399 MS-Polymer 2 ambient ambient 3 – 4 h 2 MPa 1.0 MPa 150 % 1.5 MPa 100 °C

Terostat 8593 HNL PUR 2 ambient ambient 1.5 h 4 MPa 3.0 MPa 250 % 8 MPa 90 °C

Sealing Terostat MS 930 MS-Polymer 1 ambient ambient 12 h 0.7 MPa 0.5 MPa 300 % 0.7 MPa 80 °C

Terostat 2469 Rubber 1 ambient no cure immediately 0.2 MPa n. a. n. a. n. a. 120 °C

Terostat 9140 Silicone 1 ambient ambient 12 h 1 MPa 0.7 MPa 500 % 1 MPa 200 °C

Terostat 8595 M PUR 1 ambient ambient 3 h 4 MPa 0.7 MPa 400 % 1.8 MPa 90 °C

Adhesives and sealants for metal bonding contri-bute to special properties. They improve e.g. the crash behavior by load transmission. Henkel pro-vides its customers with a wide range of special products for metal bonding.

Example for flexible metal bonding: hood components Example for metal sealing:

door hinge

*depends on joint design and test conditions

» High load transmission from structural until crash resistance

» Tolerates oily substrats (up to 3 g/sq.m.)

» For Terostat 8590 UHV/M and 8595 M promer recommended

» Excellent long-term stability and aging properties

Benefits of metal adhesives and sealants

Example for structural metal bonding: roof to b-pillar

Broad variety

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Plastic Adhesives & Sealants

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Name Chemical Basis

No. of Components


Cure Temperature



Structural Bonding Terostat 5197 Rubber 1 30 – 40 °C 30 min/180 °C after oven 14 MPa 180 MPa 12 % 260 MPa 90 °C

Purmelt QR 3511 PUR 1 120 °C ambient 1 min. 9 MPa n. a. 600 % 250 MPa 120 °C

Purmelt QR 5210 PUR 1 130 °C ambient 1 min. 10 MPa n. a. 500 % 600 MPa 150 °C

Terokal 9225 PUR 2 25 – 30 °C ambient 2 h 13 MPa 2200 MPa 3 % 3300 MPa 80 °C

Loctite 3038 Acrylic 2 ambient ambient 50 min 14 MPa 9 MPa 30 % 300 MPa 80 °C

Terokal 850 PUR 2 ambient ambient 2 – 3 h 20 MPa 19 MPa 60 % 600 MPa 90 °C

Flexible Bonding Terostat 8590 UHV/MT PUR 1 ambient ambient 3 h 5 MPa 1 MPa 400 % 2 MPa 90 °C

Terostat MS 9360 MS-Polymer 1 ambient ambient 4 h 3.5 MPa 0.7 MPa 200 % 2.4 MPa 100 °C

Terorehm 1010 PO 1 150 °C ambient 1 min 4 MPa n. a. 500 % 23 MPa 120 °C

Terostat 8599 PUR 1 50 – 60 °C ambient 5 min 5 MPa 2.5 MPa 250 % 5.0 MPa 90 °C

Terostat 8595 N/MT PUR 2 ambient ambient 1 – 3 h 4 MPa 0.7 MPa 400 % 1.5 MPa 90 °C

Sealing Terostat 9120 MS-Polymer 1 ambient ambient 12 h 2.6 MPa n. a. 250 % 1.6 MPa 100 °C

Terostat 1248 LV Rubber 1 ambient 30 min/180 °C after oven 1 MPa 20 MPa 40 % 30 MPa 90 °C

Terostat 2451 Rubber 1 ambient n. a. after oven 0.2 MPa n. a. n. a. n. a. 120 °C

Terolan 1102 PUR 1 ambient 85 – 95 °C 20 °C Obj. Temp. 3.5 MPa n. a. 200 % 3.2 MPa 80 °C

Terostat MS 935 MS-Polymer 1 ambient ambient 12 h 2.6 MPa n. a. 250 % 1.6 MPa 100 °C

Terostat MS 939 FR MS-Polymer 2 ambient ambient 1 h 2.8 MPa n. a. 250 % 12.1 MPa 100 °C

Various chemistries, as acrylics, polyurethanes, modified silanes or silicones are used in Henkel’s plastic adhesives and sealants product range. This variety ensures to deliver you with tailor-made products.

Example for plastic bonding: head lamps

Example for plastic sealing: interior fan

Example for flexible plastic bonding: cockpit

» Excellent gap bridging and long-term stability

» Increase of fatigue strength of assemblies

» Available also for PE and PP adhesion

» Most products are ambient curing and accelerated version available

Benefits of plastic adhesives and sealants


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Glass Adhesives & Sealants

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Name Chemical Basis

No. of Components


Cure Temperature



Structural Bonding Purmelt QR 3450 PUR 1 130 °C ambient 1 min 8 MPa n. a. 650 % 230 MPa 160 °C

Flexible Bonding Terostat 9220 MS-Polymer 1 ambient ambient 4 h 3.5 MPa 1.3 MPa 200 % 2.4 MPa 100 °C

Terostat 8590 UHV/M PUR 1 30 – 50 °C ambient 2 h 5 MPa 1.5 MPa 500 % 2 MPa 90 °C

Terostat 8599 PUR 1 50 °C ambient 0.5 h 5 MPa 2.5 MPa 250 % 5 MPa 90 °C

Terostat 8593 HNL PUR 2 ambient ambient 1.5 h 4 MPa 1.0 MPa 250 % 4 MPa 90 °C

Terostat 8593 HNL MS-Polymer 2 ambient ambient 1 – 2 h 2 MPa 1.5 MPa 150 % 2 MPa 100 °C

Sealing Terostat 9140 Silicone 1 ambient ambient 12 h 1 MPa n. a. 550 % 0.3 MPa 200 °C

Terostat PU 92 PUR 1 ambient ambient 6 h 1.5 MPa n. a. 500 % 0.9 MPa 90 °C

Terostat 9320 MS-Polymer 1 ambient ambient 0.5 h 0.5 MPa n. a. 80 % 2.4 MPa 90 °C

More comfort and safetyDirect glazing plays an important role in terms of visual design, ensuring vehicle stiffness and integ-rity and enhancing passenger comfort and safety. Our special glass product range contains a variety of features, e.g. primerless adhesion on glass.

Example for structural glass bonding: mirror boss

Example for flexible glass bonding: windshield

Example for glass sealing: moon roof

» All products moisture curing with-out any additional heat

» Excellent gap bridging and long-term stability as well as aging resistance

Benefits of glass adhesives and sealants


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Name Chemical Basis

No. of Components


Cure Temperature



Flexible Bonding Terokal 1251 Rubber 1 160 °C n. a. 1 min n. a. n. a. n. a. n. a. 80 °C

Purmelt QR 6204-02 PUR 1 130 °C ambient 1 min 25 MPa 2 MPa 500 % 5 MPa 130 °C

Macromelt 2035 PA 1 210 – 240 °C ambient 1 min 13 MPa n. a. 500 % n. a. 150 °C

Macromelt Q 5375 PO 1 160 – 200 °C ambient 1 min 0.9 MPa n. a. 400 % n. a. 90 °C

Terokal 3944 NBR 2 ambient ambient 2 – 4 h n. a. n. a. n. a. n. a. 110 °C

Sealing Terostat MS 935 MS-Polymer 1 ambient ambient 30 min 2.8 MPa 0.6 MPa 230 % 1.5 MPa 120 °C

Macromelt 6208 PA 1 180 – 230 °C ambient 1 min 3.5 MPa 0.25 MPa 600 % 0.6 MPa 130 °C

Textile Adhesives & Sealants

To each his ownEither bonding of roof liner, door panels or sun visors, high-tech textiles are typical substrates for automotive applications. We offer products with a broad adhesion spectrum to meet your special requirements.

Example for textile flexible bonding/sealing: sun visor Example for textile flexible

bonding/sealing: door panel

» Areal coating with low load trans-mission and very high flexibility

» Designed for fast processing with short time to handling strength

» Designed for car body interior applications with focus on low emission

Benefits of textile adhesives and sealants


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Tailor-made solutions

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Equipment

Teromix Hand GunFor use with Teromix-6700 twin cartridge

�K MS/Teromix Air Gun � x �10 ml For use with 310 ml cartridges Mixing 1:1Pressure ratio 1:1.5

Teromix Static Mixer Mixer element for Teromix-6700 2-component Vehicle Body Adhesive and Terokal-9225 Plastic Repair Adhesive

Softpress Hand Gun Handles all Presspack containers.

» Very rugged steel/ plastic design

» Smooth action

» Long life

» No run-on

» Easy to maintain and to clean

Teroson Multi-Press Telescopic Hand Gun For sprayable seamseal-ants/multi-functional seal-ants from 150/310 ml noz-zle cartridges.

» Excessive supply pres-sures will be automatical-ly reduced by means of a built-in reducing valve

» Telescopic piston en-sures smooth action, prevents trapped air bubbles

» Compact, short size: Slim and handy

�-Component MS Pistol Pneumatic alu pistol with piston and stamp.

» For 2-component sealants

» Ratio 10:1

» 2-component plastic cartridge

Telescopic Power Line Gun For dispensing car body sealants, adhesive seal-ants and direct glazing sealants.Engineering details:

» Telescopic piston does not wander, ensures smooth action, pre-vents trapped air bub-bles

» No run-on

» Cartridges are emptied 100%

Staku Hand Cartridge Gun Handles all 150 ml and 310 ml cartridges.

» Steel/plastic design with enclosed-type car-tridge skeleton frame

» Smooth action

» Long life

» No run-on

» Easy to maintain and to clean

An all-round package

Services

ConsultingExperience is our strength – our qualified Henkel-experts are looking forward to collaborating with you. Our consult-ing services encompass:» Set-up of line and cell layout» Trouble Shooting and tear-down analysis» Line audits and FMEA’s to gain process optimization» Prototype design in our Technology Center or on-site» Trending and Scouting

Henkel provides its customers with a wide range of services. These cover not only consulting and engineering, but also a wide range of chemical analysis by laborato-ries equipped with state-of-the-art instrumentation and individual training sessions. All activities contribute to the optimization of products and processes. According to

your requirements you can compile the different services together with your Henkel-expert. Thus you re-ceive an ideal and tailor-made consulting that varies from a separate analysis to an all-round package.

Chemical analysisAn extensive analysis is the foundation of performance validation and the subsequent measures of improvement. We offer:» Chromatography» Electro-chemical analysis» Volumetric analysis» Photometric analysis» Spectro-photometric analysis

Engineering and ValidationIn close cooperation with the customers Henkel shares experience. Henkel engineering services encompass:» Development or adjustment of adhesives, sealants on

customer demand» Validation with mechanical tests, chemical and mechani-

cal analysis including full specification approval follow-ing all major OEM specs

» Lifetime and service life prediction for lab test specimen and sub-assembly parts

» Preparation of experts reports, surveys and certificates

Trainings and seminarsEstablished knowledge is the basis for efficient working and precise troubleshooting. We offer comprehensive knowledge transfer in our trainings:» Technology and application training according to cus-

tomer requirements» P3 Cleaner College» Metal pretreatment seminar

For more information about the Henkel Automotive Value package, please have a look at www.henkel.com/automotive.services.

Our team is looking forward to assisting you in choosing individual elements of our service range, always tailor-made for your specific requirements.

Email: [email protected]

Henkel operates in three strategic business areas: Home Care, Personal Care and Adhesives, Sealants and Surface Treatments, which serves the transportation, electronics, aerospace, metal, durable goods, consumer goods, maintenance and repair and packaging industries, and offers a broad range of products for the craftsman and consumer.

More than 50,000 employees work for Henkel worldwide. People in 125 countries around the world trust in brands and technologies from Henkel.

Henkel AG & Co. KGaAHenkelstr. 67 40589 Düsseldorf Germanywww.henkel.com/automotive

Henkel – your worldwide automotive partner

Industrial adhesives and sealantsHenkel offers the world’s most extensive portfolio of adhesives and sealants for industrial applications. Each business unit can draw on all of the adhesives technologies available throughout the company. All customers, no matter what their sector, therefore benefit from Henkel’s comprehensive expertise and from its vast research facilities.

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