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Technology

Greiner Perfoam has modern production facilities at its disposal, which guarantee both cost-effective and efficient production. High flexibility and top quality go without saying here at Greiner Perfoam. We are able to restructure and continually optimize all of our production methods at any time thanks to our well-equipped technical center. Numerous patents and awards are proof of our innovation – and secure your technical advantage.

Production Methods

Welding and Assembly Technology

Friction and Ultrasonic Welding

With the help of friction and ultrasonic welding technologies, we are able to combine our pressed components with injection molded plastic parts. These technologies are put to use both in make-to-stock production and in sequencing.
 

Bonding

Bonding is a process widely used to join attachment parts (e.g. sound absorbers, plastic parts, reinforcing elements) with pressed parts. The type of adhesive and adhesive application used depends on the requirements and quantity of products.
 

Riveting

The use of rivets to join plastic components has greatly increased in recent years. This joining technique is utilized specifically for components which have a honeycomb core structure. Because of the variety of products which have already been attached with rivets, Greiner Perfoam can offer customers a lot of know-how and problem-solving skills in this area.

Covering

The process of covering involves attaching attractive decals (laminates) to a broad variety of component surfaces. This allows a wide range of different fabrics and surface weights to be attached to complex surfaces. The support parts and decal materials are bonded together using specially adapted adhesives. Our covering experts are able to cover difficult contours and tight radii in either a single step or with minimal reworking. This technique is used for parcel shelves, convertible soft tops, trunk covers and inserts.

PU

Our processes allow us to manufacture components that meet the highest standards in terms of rigidity and temperature resistance while still managing to save on weight. Typical applications include self-supporting parcel shelves, convertible top compartment covers for cabriolets, and trunk floors for SUVs and convertibles. The process involves spraying honeycomb boards and fiberglass with PU before pressing them together. Several production stages later, the result is an extremely rigid sandwich construction with maximum load-bearing capacity and a very low weight thanks to the honeycomb core. What’s more, these honeycomb boards also offer a higher level of dimensional stability in comparison to conventional systems.

Thermoforming

The thermoforming process involves producing visible parts for interiors and acoustic parts for the engine compartment. In the case of the visible parts for interiors, PUR recycled material, honeycomb boards, and natural and glass fibers are combined with thermoplastic or duroplastic materials and decorative fleeces. This technique is used for items such as parcel shelves, trunk components, and roller blind encapsulations.
Acoustic parts are made of either PUR foam or a combination of natural fiber, PUR foam, and duroplastic materials. This technique can be found in hood linings and encapsulation parts for engines and transmissions.

Composite Molding and Punching

This process involves molding PUR recycled material (foam cut-outs) with bonding agents using pressurized and heated tools.
The advantages of composite foam can be found in the complex (3D) shapes it is capable of forming, not to mention the cost benefits afforded by the use of secondary raw materials. What’s more, its open-cell structure usually means composite foam is a better option than more recently developed foam types when it comes to acoustic effectiveness.
Greiner uses punching to manufacture a wide range of different damping parts and absorbers. This process involves punching out preset shapes from soft or recycling foam boards.
These punched parts are often used as damping parts on parcel shelves.

Development

Our highly qualified employees work closely with our customers to develop new products and manufacturing technologies. Our strengths here lie in our ability to quickly implement very practical application-oriented ideas.
Due to our years of expertise in integrated product development, we are able to offer our customers cost-effective and innovative solutions, which guarantee reliable, lasting products at competitive prices.
Our research department works in close cooperation with national and international research centers and universities.

Lightweight Construction

A central topic in the automobile industry is weight reduction, since lighter cars usually consume less fuel and ultimately emit less CO2. For this reason, new vehicles are usually made lighter than previous models. In order to offer our customers a suitable weight advantage, we develop new lightweight construction concepts to ensure that our components contribute to the ultimate goal of a lighter car.

Thermal Management

With regard to the performance and fuel consumption of a car, the thermal management of a combustion engine or transmission is very important. Some examples of this are engines quickly reaching their ideal operating temperature and needing to maintain this temperature for as long as possible, or motor oil getting warmer more quickly and frictional loss being minimized in the transmission. This is why we develop special material structures aimed specifically at influencing the thermal management of engine and transmission components, and ultimately at reducing the CO2 emissions of cars.

Acoustics Management

Good acoustics in the passenger compartment are important, particularly for cars in the premium segment. Future cars should not only have good acoustics on the inside, but the entire car needs to be quieter. In order to meet these requirements, we are currently developing highly efficient acoustic insulation components for engines and transmissions, as well as absorption materials for the engine and passenger compartments. Close cooperation within the Greiner Group makes it possible for us to develop and test special material components for this intended application.

Advance Development/Prototype Construction

We are able to generate functional prototypes and preproduction parts with very short lead times in our very well-equipped technical center. Furthermore, material samples are made out of new materials and/or with new material components and are tested in our laboratory following legal, customer-specific, and/or internal test regulations and standards. New and innovative processes are first developed and tested in the technical center before they are put into standard-production use.

Logistics

As a classic automotive supplier, the logistics department is constantly pushing towards further development and meeting growing customer needs. Complex topics like JIS (Just-in-Sequence) supply are designed through coordination and development with customers, and subsequently made a reality by inter-departmental cooperation in our team.

We aim for high delivery reliability every day. We aim to please our customers while also observing the fundamental principles of logistics.