DIN2304 helps the bus industry achieve "zero-defect" bonding!

 [Introduction] Modern industrial adhesive is a high-tech product. If used correctly, it can guarantee a "zero-defect" product. However, a large number of adhesive joint failures are still common in buses, and this is usually caused by the incorrect use of adhesives. This is the core of the DIN2304 standard: strict supervision of the bonding-related processes and organizational management related to bonding quality assurance.

The quality issues of passenger cars and issues related to bonding are as follows:

The bonding process is distributed in multiple workstations in the body and assembly workshops, such as body skin bonding, body sealing, glass bonding and sealing, floor bonding, wiring hole sealing, interior and exterior decoration bonding and sealing, and floor leather. Bonding, etc. According to statistics on after-sales bonding problems, it was found that there are three main types of problems: bonding, sealing, and aging. The causes of bonding failure are complex and numerous, and are distributed in all aspects of bus production, such as design issues, process issues, Manufacturing issues, bonded product issues, etc.

For example: 1. The adhesive seal of the side window fails, causing rust and water to flow out of the side window, and even the glass becomes loose;

2. The skylight sealing strip has aged, causing the skylight to leak.

3. Bubbles appear on the surface of the window sealant, which affects the appearance and customer acceptance.

Problems related to the manufacturing process and bonding in the factory. In the bonding quality records of the on-site manufacturing process, they are mainly concentrated in poor appearance of the glue, poor operation, problems with the inspection and rain record, and personality problems, which are widely distributed.

Therefore, from the statistical analysis of bonding problems after sales and on-site, we can see that bonding failure modes are diverse, and the causes also cover the entire production and manufacturing process, involving many links, and are systemic problems. The occurrence of bonding problems increases after-sales maintenance costs and reduces customer satisfaction and market competitiveness.

If you can understand DIN2304 in advance and produce according to this standard, many bonding failure problems can be avoided. Adhesive users often subjectively believe that what they are doing is correct. Once a problem occurs, they blame the adhesive on the adhesive, believing that the failure of the bonding is due to the quality of the glue! But in fact, most of the failure problems of bonded joints are not due to insufficient strength of the adhesive itself, but due to lack of knowledge about the use of glue and operating errors.

  In fact, the bonding process, like the welding process, is defined as a "special process" in ISO 9001, that is, the process cannot be 100% tested without any defects through subsequent non-destructive testing methods. For this reason, it is necessary to implement "error prevention" for "special processes" through the implementation of a quality management system.

The new version of the DIN2304 standard specifies the requirements for the entire process chain from product development to production and repair/maintenance to ensure the production of qualified bonded joints, and specifies a common organizational structure, contract and technical guidelines for the production of bonded joints to assist in the management of the bonding process. Therefore, a complete bonding technology system is used to ensure the quality of the entire process of bonding using adhesives.

ISO9001 only stipulates the most basic requirements for a quality management system (QMS) and does not stipulate the technical content of related processes. Although it provides a basis for quality assurance, it is too general and cannot be used as a dedicated means of quality assurance. Therefore, it is necessary to refine it into specific technical specifications and specify the corresponding process organization structure to ensure the correct application of bonding technology.

Different from the broad quality management system of ISO9001, DIN2304 combines the technical specifications of bonding design, manufacturing, quality assurance and maintenance with a complete quality management system, and has the following three core elements:

- Classify bonded joints according to safety requirements

- Division of responsibilities for bonding supervision

- Verification of loads/stresses sustained by bonded joints throughout their life cycle

At this stage, DIN2304 has become the bonding guidance standard for the entire European industrial industry, and has been rapidly promoted in the fields of home appliances, automobiles, electronics, aviation and other fields. Like the bonding standard DIN6701 and the welding standard EN15085 for railway vehicles that have been successfully applied to rail vehicles and their parts, DIN2304 provides enterprises with detailed and feasible production standards.

in conclusion:

Those who win the standard win the world. China is undergoing a profound industrial change. The past extensive economic growth model that relied on "price wars" to compete is no longer applicable. As an indispensable process in industrial production, bonding has gained More and more companies pay attention to it. Many companies from home appliances, automobiles, ships, aviation, etc. have established their own technical advantages and industry thresholds through DIN2301 certification, and continue to promote the stability of internal bonding processes and the reliability of corresponding organizational management, thereby remaining invincible in the fierce corporate competition. land.

Note: Yifa Bonding and Composites Research Institute is the exclusive strategic partner of German Fraunhofer IFAM in China.

Conduct EN17460 and DIN2304 certification audits, project support and consulting in China; carry out three levels of bonding: EAE European Bonding Engineer, EAS European Bonding Technician, EAB European Bonding Operator (European Bonding Operator) certificated by Fraunhofer Training and examinations, as well as training and examinations for composite design Composite-D, manufacturing Composite-M, maintenance Composite-R, and technician Composite-S. Special training courses related to customized bonding and composite material applications are also provided.

As of October 2023, Yifa has trained more than 5,500 engineering and technical personnel at all levels with bonding qualifications at home and abroad. Assisted more than 300 customers to obtain EN17460 (formerly DIN6701) and DIN2304 qualification certificates issued by Fraunhofer IFAM.