Structural / Panel Bonding  Application on Mercedes CL500

Ready for bonding surface prepared with Teroson FL

Products:
Terokal 5045/5055
Teroson FL/FL+
Terofoam
Cartridge preheating box

Structural / Panel Bonding  Application on Mercedes CL500

1

2
1. Applying Terokal 5045/5055
on the frame and panel
1. Smoothing bead and spread it over
the bonding area

Structural / Panel Bonding  Application on Mercedes CL500

Wheel Housing

Terofoam

Terostat 9220

Elastics joints

Terokal 5055

Structural / Panel Bonding  Application on Mercedes CL500

1

fixing with Terokal 5055 and rivets

1. Fixing bonded side panel with

clamps & rivets
2. Glued and riveted side panel
ready to paint

Structural / Panel Bonding  Application on BMW 3 Series

Cut-out damaged area

Teroson tools

Prepared panel

Preparing the surface Teroson FL+

Applying Terokal 5045/5055

Smoothing the bead

Structural / Panel Bonding  Application on BMW 3 Series

Smoothing the bead also on frame

Ready for mounting

Using Terofoam

Mounting the panel

Fixing A/B-Pillar welding points

Welding B-Pillar frame

Structural / Panel Bonding  Application on BMW 3 Series

Bonding B-Pillar panel part

Bonding side panel part including acoustic part,

Structural / Panel Bonding  Application on BMW 3 Series

Fixing panel part

Curing over night

Next day preparing for paint

Last but not least cavity protection with Terotex HV 400

Structural / Panel Bonding  Panel Bonder

Terokal 5055
Two-part epoxy adhesive
High lap shear strength
Suitable at both low and high temperatures
Good adhesion on all surfaces used
in the repair shop (CRS,EGS, HDG, Al,
e-coat and organic coatings)
Excellent ageing properties
Mixing Ratio (by Volume and Weight) 1:1
Process Time at 23C
Pot Life Time: 80 minutes
Initial Strength at 23C: after 4 h
Final Strength at 23C: after 2 d
Lap Shear Strength (at 23C): 18 22 MPa
Final Strength at 100C: after 30 min
Lap Shear Strength (at elev. Temp.): > 20 MPa

Structural / Panel Bonding  Car Roof and other Repairs

Structural / Panel Bonding  Roof Repair on a VW

Laser brazed seam

Terostat 8597HMLC

Bond line Terokal 5055

Terokal 5055

Structural / Panel Bonding  Roof Repair on a Ford Mondeo

Laser brazed seam

Bond line Terokal 5055

Terokal 5055

Terostat 8597HMLC

Structural / Panel Bonding  Other Bonded Parts BMW

Structural / Panel Bonding

Bonding: Disassembled outer door panel on VW Golf V

Structural / Panel Bonding

Method 1: Pre-treatment of the assembly profile Golf V
1. Degreasing

Teroson FL / FL+

Flash off time 10 min

2. Priming

Primer 8519 P

Structural / Panel Bonding

Method 1: Bonding with DGX bonding material VW Golf V
Terostat 8597 HMLC

or
VW DH 009 100 03

Structural / Panel Bonding

Method 2: Bonding of the assembly profile with primerless Bonding material Golf V

1. Degreasing

Teroson FL / FL+

Flash off time 10 min

2. Primerless
bonding

Terostat 9000 PL

Structural / Panel Bonding

Bonded assembly profile on the outer door panel - VW Golf V

DGX bonding material

Structural / Panel Bonding

Door inner frame VW Golf V
Holes for clamping screws

Screws without final fixation, allows

adjusting the outer door panel in the final
exact position.

Outer panel

StructuralFoam
Acoustic
/ Panel Bonding
Restore OEM noise protection in the AAM with Acoustic foam
Our acoustic foams:
OES Terophon
AAM Terofoam

StructuralFoam
Acoustic
/ Panel Bonding
Sealing of Cavities
Co-injection parts

StructuralFoam
Acoustic
/ Panel Bonding
Line Application: Sealing of Cavities
Terophon part with plastic carrier before and after curing

StructuralFoam
Acoustic
/ Panel Bonding
Line Application: Sealing of Cavities
Terophon part with plastic carrier before curing

PA/TPN
for cast Al-pillar

Triple TPN with PA

Triple TPN with PA

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
2 component foam as automotive repair solution for filling gaps and cavities (A-, B-,
C- and D-pillars)

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
Two-part acoustic foam (aerosol can, ready to use)
Very good sag resistance
Long open / pot life time
Low water absorption
Excellent ageing properties
OEM specified
Major application areas: Filling and sealing of cavities
Application temperature: 10 35C (optimal: 18 23C)
Application time: 18 min
Cutting time: after 30 min
Cell structure: closed cells approx. 85%
Water absorption: approx. 2%
Density: 33kg/m3

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
Closed 2C foam

Open 1C foam

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
e.g. RENAULT ; B-pillar, C-pillar

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
e.g. JAGUAR ; B-pillar

StructuralFoam
Acoustic
/ Panel
 Bonding
Terofoam
e.g. AUDI; D-pillar, back-panel frame

Structural /Foam
PanelBonding
Terocore 1401
Some users:

Structural /Foam
PanelBonding
Terocore 1401
Some OEM users:

Structural /Foam
PanelBonding
Terocore 1401
Properties
Low density
High strength
High E-Modulus
High compression resistance
Excellent adhesion to body substrates
Advantages
Lightweight car body construction
Steel replacement
Reduced steel thickness
Safety increase
Deformation behaviour
Reduced intrusion
Enhancement of comfort
Body vibration
Driving stability

See under downloads

Terocore

Epoxy
Epoxyresin
resinsystem
system

Tailor-made
Tailor-madesolutions
solutions

Structural /Foam
PanelBonding
Terocore 1401
Drop tower test:

Test profile with reduced thickness (0,8 mm)

reinforced with polymer foam (total weight
approx. 1,2 kg)

Test profile (1,5 mm

thickness steel, not filled,
total weight approx. 1,2 kg)

Test profile (0,8 mm

thickness steel, not
filled, total weight
approx. 0,6 kg )

Videos DTT
(Drop Tower Test )
with/without Terocore

Structural /Foam
PanelBonding
Terocore 1401
Roof frame reinforcement

partially reinforced

Video Terocore: Van 360

Download Terocore OEM

Terocore 1401

Structural /Foam
PanelBonding
Terocore 1401
Preformed parts

Front Carrier

Rear Carrier

Front carrier reinforcement

Structural /Foam
PanelBonding
Terocore 1401
Line applications
Door frame reinforcement

Front Door

Rear Door

More information about TEROCORE 1401

2 component epoxy
Mixing Ratio
Process Time at 23C
Compressive Strength
Volume Change
Density (cured)
Water Absorption

(by Volume) 2:1

(Pot Life Time) 90 minutes
20 MPa
0 10 %
0,7 0.8 g/cm3
< 0,5 %

Structural /Foam
PanelBonding
Terocore 1401
Preformed parts
Suspension Reinforcement

Applications

TEROCORE 1401

crack

Structural / Panel Bonding  Tools and equipment

Tools and equipment
Preheating Box
Heating up to 72C
Automatic controlled, 220 V
40 x 31 x 14 cm
Keep the temperature for one hour (without connected)
For 6 x 310 ml cartridges or 4 x 570 ml foil packages
For 4 x 250 ml Terokal 5045 or Terocore 1401
due to 4-5 cartridges need within 15-20 min.

Teroson Staku Hand Cartridge Gun

Smooth action, long life
For use with 150 / 310 ml cartridges
No run-on
Easy to maintain and clean

Structural / Panel Bonding  Tools and equipment

Teroson Powerline II
Powerful tool for dispensing high viscose material
in single cartridge packaging
(2-component and 1-component)
Fine variable adjustment
Integrated pressure manometer

Cox Rechargeable Battery Gun

For dispensing high viscose material in single

cartridge packaging (2-component
and other 1-component)

Speed material flow is adjustable on all products

(from low to high viscosity)

Charger included

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