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Increased driving comfort and safety are important development targets for automotive manufacturers. One approach is to reduce the roll movement when cornering. RAPA, one of the leading providers of solutions for driving comfort, uses DELO adhesives for their roll stabilizers.
Mechatronic systems such as controllable air suspension and dampers or roll stabilization are becoming more and more prevalent in automotive applications. Pneumatic and hydraulic valves at central points of the chassis ensure smooth operation. When driving along sharp bends, roll stabilization not only prevents phenomena such as body roll, but also balances stress loads caused by bumps.
In these electrohydraulic systems, control valves regulate the pressure generated by a pump, thus minimizing or completely offsetting roll movements when cornering. So far, they have been used mainly in luxury vehicles, sports cars, and SUVs.
The magnet head is the control unit and a key component in roll stabilization systems. It drives the control and shift valves that modulate oil flow within the system. Depending on the application and vehicle type, up to five magnet heads per block are used, with one or two blocks fitted per vehicle.
To ensure permanent compliance of magnet heads with automotive requirements, automotive supplier RAPA protects two points of the magnet heads using adhesives and potting compounds. This is done by potting the electronics, which consist of a coil and magnets, inside the cylinder using a two-component room-temperature-curing polyurethane adhesive. This material must exhibit very low viscosity to completely cast the cavities and the gap. However, due to its low viscosity, it can leak from the housing joint and the spot-welded transition joints between the housing and the base plate. This is why these points have to also be sealed before applying the polyurethane adhesive. To find a suitable material, RAPA specified their specific requirements. These include:
With these requirements in mind, RAPA contacted DELO and agreed to use a dual-curing methacrylate. This product group not only enables light fixation within seconds—thus immediately processing components onward without waiting for parts to cool—but also offers the required reliability for automotive applications. Based on the promising results of laboratory tests, the decision was made relatively quickly to move forward with DELO-ML DB136. This product can be used within a temperature range of –40 °C to +150 °C and is resistant to motor oil, fuel, and road salts. Testing shows it is guaranteed not to come undone during operation, crucial given its application site close to the chassis undercarriage. It also complies with the requirements outlined in the IP6K9K standard, which low-viscosity polyurethane pottings must adhere to.
DELO-ML DB136 also has a second curing mechanism, which allows it to fully cure under oxygen deprivation in shadowed areas where the housing is joined and welded, and the adhesive is not reached by light. This is important given the risk of corrosion that exists when combining uncured material and galvanized steel. In addition to choosing the adhesive, DELO also helped RAPA with integrating the process into their production and worked with the equipment manufacturer during testing. The process was set up so that, in the first step, magnet heads are placed in a holder and a camera checks their position. Next, the adhesive is applied from a 600-gram cartridge using a fully automated diaphragm valve with the option to modulate the application by its fluorescence. The adhesive is then cured in less than ten seconds by means of the DELOLUX 80 / 400 LED small area lamp.
In the automotive sector, it is common practice to reserve product innovations such as driver assistance systems or exterior and interior lighting technology for premium segments only before rolling them out on volume sellers some years later. Therefore, we can expect for roll stabilizers to be available in the mainstream automotive sector soon. With this said, with rapid curing and short cycle times, DELO adhesives have RAPA well-equipped to meet this projected rise in demand.
Are you also interested in a partnership with DELO and our innovative adhesive solutions? Take advantage of our non-binding project consultation!
About DELO: DELO is a leading provider of high-tech adhesives, offering solutions for automotive, electronics, and semiconductor industries for over 25 years. Our innovative technologies set industry standards. Companies like Bosch, Huawei, and Siemens trust DELO for superior adhesive technologies.
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![[Translate to German:] Magnets in an electric motor are being fixed using light and high-temperature adhesive, with DELO equipment visible.](/fileadmin/_processed_/e/3/csm_Automotive_light-fixation-magnet-electric-motor_production_content_1413x942_edff39efce.webp)
