How do Anti-Friction Coatings based on Binder Systems eliminate noise in automotive interiors?

Applications of Anti-

Friction Coatings based on

Binder Systems

Manfred Jungk - Vittorio Clerici

January 12th 2016

2

Introduction

• Modern passenger cars are equipped with sophisticated

measures to avoid propagation of noise from the engine

and gearboxes into the passenger compartment

• This creates a very comfortable environment for car

occupants

• On the other hand, this enables “new noises” to become

audible – particularly those generated by the sliding of

plastic components made of thermoplastics having poor

affinity under the tribological aspect

2016 All Rights reserved

3

Examples of noise development from the field

• Door panel sliding against clear coat/paint

– Show video

• Armrest sliding against door panel insert

– Show video


4

Proven solution

• Apply a surface treatment to the tribological contact

areas of the mating parts generating noise or in

suspect of producing it

Application of a dry-film lubricant = anti-friction coating

SOLUTION


5

Product requirement profile

• Noise elimination for a wide array of material combinations

used in interiors

• Friction reduction of mating surfaces; more important

constancy of a defined level (no stick-slip formation)

• Service life performance

• Good adhesion to plastic materials

• Compatibility with plastic materials (stress cracking)

• Transparent

• Water-based

• Air-curing (max drying temperature = 60°C)

• Easy industrialization – easy integration of application in

existing production processes/lines


6

Technology description

• Anti-Friction coating:

– Organic binder system

– Solid lubricants

– Solvent = water

wet film

substrate

Drying& curing

dry film = 10/12 µm

substrate

Solvent (water)


7

Anti-noise tester – overview

Sliding guideSpecimen

holder with

strain gages

for friction

force and load

measurement

and with

acceleration

detector for

stick-slip

measurement

Stick-slip intermittent movement


8

Anti-noise performance – report example

PRODUCT

Material pairing Paint vs. PVC foam 2.5 mm black No

AFC Anti-Friction Coating

Anti-Friction Coating variation

Load [N] Characteristic

5

BI [noise rating] 8.5 8.5

RPN [risk priority number] 1 1

COF static [µ] 0.64 0.47

COF dynamic [µ] 0.35 0.24

Max. acceleration [g] 0.07 0.06

Impulse frequency [1/mm] 0.00 0

Impulse count 0 0

10







Impulse count 0 0

20

BI [noise rating] 4.0 8.1 8.5

RPN [risk priority number] 10 1 1

COF static [µ] 1.43 0.36 0.3

COF dynamic [µ] 0.92 0.25 0.18

Max. acceleration [g] 4.53 0.07 0.06

Impulse frequency [1/mm] 1.86 0.00 0

Impulse count 17 0 0

30







Impulse count 0 0

SHORT TEST – RT VDA 230-206


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Anti-noise performance (short test, RT)

SHORT TEST ACCORDING TO VDA 230-206

PRODUCT

Material pairing Material pairing Anti-Friction Coating Anti-Friction Coating

variation

Paint PVC 1 mm

PVC 1 mm PVC 1 mm

Paint PVC 2.5 mm beige

Paint PVC 2.5 mm black

Paint TPO 1 mm

Paint Leather black

Leather black Leather black

PC-ABS Leather black

PC-ABS PVC 1 mm

Green = very

suitable


10

Anti-noise performance (short test, climatic cond.)

Paint FF99-0141 PVC 1 mm Paint ApO Leather PVC 1 mm

PVC 1 mm PVC 1 mm Leather Leather PC-ABS

Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating

Load [N] Climatic

conditions Max. acc.

[g] µ max.

Max. acc. [g]

µ max. Max. acc.

[g] µ max.

Max. acc. [g]

µ max. Max. acc.

[g] µ max.

5

23°C – 50% 0.0 0.2 0.0 0.2 0.0 - 0.0 0.8 0.0 0.5

40°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.8 0.0 0.6

80°C – 30% 0.0 0.5 0.0 0.1 0.0 - 0.0 0.8 0.1 0.6

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.7 0.0 0.6

10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.5

-30 °C 0.1 0.1 0.1 0.1 0.0 - 0.1 0.1 0.0 0.1

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.5

10

23°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.0 0.4 0.0 0.3

40°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.4 0.0 0.3

80°C – 30% 0.0 0.5 0.0 0.1 0.0 - 0.0 0.4 0.0 0.3

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.4 0.0 0.3

10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.3

-30 °C 0.0 0.1 0.0 0.1 0.0 - 0.1 0.1 0.0 0.1

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.3

20

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.3 0.0 0.2

40°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.1 0.3 0.0 0.2

80°C – 30% 0.1 0.4 0.0 0.1 0.0 - 0.0 0.3 0.0 0.2

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.2 0.0 0.2

10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2

-30 °C 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2

30

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.2

40°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.1 0.2 0.0 0.2

80°C – 30% 0.0 0.4 0.0 0.1 0.0 - 0.0 0.2 0.0 0.2

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.2 0.0 0.1

10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1

-30 °C 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1

23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2

SHORT TEST VDA 230-206


11

Anti-noise performance (durability test, RT)

DURABILITY TEST BASED ON PARAMETERS OF VDA-230-206

PRODUCT

Material pairing Material pairing Anti-Friction Coating Anti-Friction Coating

variation

Paint PVC 1 mm

PVC 1 mm PVC 1 mm

Paint PVC 2.5 mm beige

Paint PVC 2.5 mm black

Paint TPO 1 mm

Paint Leather black

Leather black Leather black

PC-ABS Leather black

PC-ABS PVC 1 mm 100K cycles 100K cycles

10,000 cycles or

as indicated

Green = very

suitable


12

PRODUCT

Material pairing PC-ABS vs. PVC foam 1 mm No

AFC Anti-Friction Coating

Anti-Friction Coating variation

Cycles Characteristic

0-2,500/0-5,000


RPN [risk priority number] 10 1 1

COF static [µ] 1.33 0.30 0.23

COF dynamic [µ] 0.97 0.14 0.16


Impulse frequency [1/mm] 18.2 0.00 0.00


2,500-5,000/0-5,000

BI [noise rating]

No need

8.5 8.5





Impulse frequency [1/mm] 0.00 0.00

Impulse count 0 0

95,000-100,000

BI [noise rating]

No need

8.5 8.5






Impulse count 0 0

Anti-noise performance (100K cycle durability test) –

PC-ABS vs. PVC foam foil 1 mm thickDURABILITY TEST


13

Anti-noise performance (100K cycle durability test)

– PC-ABS vs. PVC foam foil 1 mm thick

PVC 1 mm foil uncoated Before durability test

No wear, no

adhesion loss

After 100,000 cycle durability test


14

Modified anti-noise testing setup

• Instead of the common plastic

holder for the foil material, a cut-out

section of the door panel edge is

fixed in the testing machine

• Higher flexibility between machine

holder and tribological contact

enhances the sensitivity to stick-slip

formation

• Setup more similar to real

application


15

DOOR PANEL SECTION

PRODUCT

Material pairing Paint vs. PVC foam 1 mm No AFC Anti-Friction Coating


0-5,000


RPZ [risk priority number] 10 1





Impulse count 9 0

5,000-10,000

BI [noise rating]

No n

eed

8.5

RPZ [risk priority number] 1

COF static [µ] 0.73

COF dynamic [µ] 0.45

Max. acceleration [g] 0.06

Impulse frequency [1/mm] 0.00

Impulse count 0

Paint vs. PVC 1 mm foil – panel section

DURABILITY TEST LOAD = 20 N


16

Paint vs. PVC 1 mm foil –

panel section – no AFC

Video – no AFC


17

Paint vs. PVC 1 mm foil – panel section –

Anti-Friction Coating

Video – AFC


18

DOOR PANEL SECTION

PRODUCT

Material pairing PC-ABS vs. PVC foam 1 mm No AFC Anti-Friction Coating


0-5,000







Impulse count 366 0

5,000-10,000

BI [noise rating]

No

ne

ed

8.5

RPZ [risk priority number] 1

COF static [µ] 0.87

COF dynamic [µ] 0.50

Max. acceleration [g] 0.19

Impulse frequency [1/mm] 0.00

Impulse count 0

PC-ABS vs. PVC 1 mm foil – panel section



19

PC-ABS vs. PVC 1 mm foil –

panel section – no AFC

Video – no AFC


20

PC-ABS vs. PVC 1 mm foil – panel section –


Video – AFC


21

Customized versions

• Depending on the application (part) and substrate material

and/or color, the dry film of the applied anti-friction coating

may not be easily detectable (transparency)

• Black pigments and/or UV tracers can be added to the basic

formulation without infringing on the physical properties and

anti-noise performance


22

Customized version – aspect



Black version


UV version

23

PRODUCT

Material pairing Paint vs. PVC foam 1 mm Anti-Friction Coating (black) Anti-Friction Coating (UV)


0-5,000







Impulse count 0 0

5,000-10,000







Impulse count 0 0

Anti-noise data – paint vs. PVC 1 mm foil



24

PRODUCT

Material pairing PC-ABS vs. PVC foam 1 mm No

AFC Anti-Friction

Coating (black) Anti-Friction Coating

(UV)


0-5,000


RPZ [risk priority number] 10 1 1

COF static [µ] 1.33 0.28 0.27

COF dynamic [µ] 0.97 0.15 0.15


Impulse frequency [1/mm] 18.2 0.00 0.00


5,000/10,000

BI [noise rating]

No need

8.5 8.5






Impulse count 0 0

Anti-noise data – PVC 1 mm foil vs. PC-ABS



25

Temperature resistance - COF

• Application of the AFC on metal

Q-Panels

• After curing at proper conditions:

conditioning of the coated Q-

Panels under following conditions:

– RT as reference

– 4 h @ -40°C

– 4 h @ 100°C

– 4 h @ 150°C

– 4 h @ 200°C

• After conditioning the following

tests were carried out:

– Bending and cross-cut

– COF evaluation on oscillating

polymer tester

0.000

0.050

0.100

0.150

0.200

0.250

0.300

none 4 h @ -40°C

4 h @100°C

4 h @150°C

4 h @200°C

COF dyn

COF static


26

Ball/plate oscillating test machine

Test conditions:

Substrate = AFC coated Q-Panel

Ball = POM

Load = 2 N

Speed = 1 cm/s

Time = 1 and/or 8 h

Room temperature (23°C) and

40% rel. humidity

COF = mean coefficient of friction

measured during test


27

Temperature resistance – bending test

after 4 h @ -40°C after 4 h @ 100°C

after 4 h @ 150°C after 4 h @ 200°C

No peeling no

cracks formation

ASTM-D 1737


28

Temperature resistance – cross-cut test

after 4 h @ -40°C after 4 h @ 100°C

after 4 h @ 150°C after 4 h @ 200°C

No peeling no

cracks formation

ASTM-D 3359B


29

Summary

• Anti-friction coatings are a proven

solution that can provide the following

advantages for automotive interior

components:

– Excellent anti-squeak characteristics

– Long-term noise protection

– Low coefficient of friction

– Transparent; water-based

– Compatible with typical plastic

materials used in interiors

– Easy to integrate into

existing production lines


30

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upon the information. DOW CORNING DOES NOT MAKE ANY WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED,

WITH RESPECT TO THE UTILITY OR COMPLETENESS OF THE INFORMATION AND DISCLAIMS THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. DOW CORNING DISCLAIMS

LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.


31

Application process

• Anti-friction coatings can

be applied with traditional

painting equipment

• For interior components,

the most established

process is spraying


32

Application process

• Process can be fully

automated (robot spraying)

– Adv. for parts of

complicated geometry

• Specific automatic plants

are available on the market


33

Process integration

• Possible integration into existing production lines:

– Water-based system (no flash point, no emissions)

• Processability:

– Drying time: Water elimination; can be reduced to 2 min with 60°C

hot air; coated area touch dry

– Curing time: Fully cured after 2 hours (application of intended max.

load)

• Aspect after drying/curing:

– Dry film adhering to substrate

– Transparent if applied at recommended film thickness (10-12 µm)

– Dry film changes the gloss of the coated surface

– Not suitable for visible areas


34

Processability

• Spraying application

generally carried out

with 0.5 or 0.3 mm

nozzles

• Sedimentation/clogging

can be critical: High

stability is required

After 1 day After 6 months @ 40°C


How do Anti-Friction Coatings based on Binder Systems eliminate noise in automotive interiors?

Automotive

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