The Most Reliable Partner The Most Reliable Partner.
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Transcript of The Most Reliable Partner The Most Reliable Partner.
The Most
Reliable Partner
The Most
Reliable Partner
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First ! Best ! Smart !
IndexIndex
▷ C.R.I
▷ Automotive Coatings Technology
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History
C.R.I. View
C.R.I Development Item
Central Research Institute
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" Value creation through R&D technology innovation"
Central Research Institute Vision
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1979 Founded in Suwon City
1985 Commenced EMC R&D
1988 Relocated to Yongin City
1991 Branch Center established in YeoJu, UlSan
1992 Commenced Silicone R&D 1996 Certification from KOLAS (Korea Laboratory Accreditation Scheme)1997 Branch Center established in JunJu
2004 Organized Electronic Material R&D Division & Renewable Energy R&D Team
2006 Began Polysilicon R&D
CRI History
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Area : 16,000m2 (Research Building Area : 8,000m2)
Pilot : 5 buildings
Dormitory : 2 Places / Gymnasium : 1 Places
Human Resource Center : 1 buildings
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Major Research Area
: 356 researchers ( November. 2010)
Building SystemGlass
Building material
(Floor,PVC Door)
Inorganic Material
Fine ceramic
Ceramic composite
Metal composite
Special functional Resin
Epoxy Resin
UV curing Resin
Organic material
Silicone Material
Coupling agent / Oil /
Emulsion
Grease / Rubber / RTV
Special Functional Material Electronic Materials
(EMC / Adhesive / Film)
Renewable Material
(Solar Cell / Polysilicon)
1950s 1970s 1990s 2000s 2010s
1950s 1970s 1990s 2000s 2010s
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EMC / Electronic Materials
Display Materials
Powder CoatingsIndustrial Paints
DGU
Automotive Paints
Heavy-duty Protective Coatings
Paints
Industrial Materials
Organic Material Research Items
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Inorganic Material Research Items
System
Silicon Metal
Glass
Ceiling Panels
Gypsum Board
Ceramic Fiber
Window Profile
Fuel Cell
Decorative Floor Materials
Ceramic Materials for Electronics
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AUTOMOTIVE COATING AUTOMOTIVE COATING
TECHNOLOGYTECHNOLOGY
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Process ConsolidationUltra low cost
Appearance, ColorScratch, Durability
KCC‘s OEM Paint Driving Forces
Environmental protection
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Automotive coating Driving Forces
Higher Quality
Consistent Quality
Lower Cost
Growth in Asia
Class Distinctions( Mini -> Luxury)
Environment
Driving Forces
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Continuously Creative Support for Customer, WorldwideWorldwide
Meet the Global environment
Provide Low coat Idea
ContinuousDevelopingtechnology
Excellent Color Design &Style
Superior Appearance & Durability
Valuable Proposal for Customer
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PRIMER SURFACERPRIMER SURFACER
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Customer Needs & Trends for Primer Surfacer
Market Needs
Waterborne
SmoothSurface
Low cost
Chipping
HighSolid
CompactSystem
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Product Profile Primer Surfacer
Market needs, areas of differentiation
Lower cost
Improved chipping
good leveling / appearance , stability of w/b PS
Higher solids for high speed application
Market Situations
powder PS no new paint shops, PSA converting to EcoConcept(Primerless)
HS s/b PS = regional growth with car builds
W/b PS Toyota, Hyundai, China,… new lines using w/b
EcoConcept, 3 wet VW, Toyota, PSA, GM, Ford… trend to process consolidation
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•Good Chipping, Leveling• Low Coat• Multi color• High VOC• Hyundai (Korea, China, Russia, India..) Kia (Korea, China)
• Good Chipping• Lowest VOC• High Film build Cost• High Bake• Limited Color Change• PSA, GM, Chrysler
• Good Chipping, Leveling• Low Coat• Multi Color• Low Bake• Low VOC• Hyundai China, Kia China
Primer SurfacerPrimer Surfacer
Waterborne polyurethane Powder
Solvent primer polyurethane
Primer Surfacer characters
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* Rating : ++ > + > STD = O > - > --
Comparisons of Each System
Attribute SB Primer WB Primer(140°C)
WB PrimerSurfacer
PowderPrimer
Stonechip STD O O +
Appearance STD O - +
Application STD O/- - O
VOC’s STD + + ++
Color Capability STD O O/+ - -
Baking Requirements STD + + O/-
Recycling Potential STD + + ++
Material Cost STD -/O - -/O
Invest STD - - - -
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BASECOATBASECOAT
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Customer Needs & Trends for Basecoat
Market Needs
Extension WaterborneBasecoat
Low coatWide
ApplicationWindow
CompatibilityOf
Variety C/C
NewColor
CompactSystem
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Basecoat Technology Roadmap
HighPerformance
2007 2010 2015
Waterborne Basecoat (Old)
Solventborne Medium Solid /High Solid Basecoat
3 Wet
Current Future
Global Waterborne Basecoat (High solid, LCCC)
EcoConcept
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Product Profile Basecoat
Market needs, areas of differentiation
robustness: stable color position versus humidity/temperature, CC type, spray conditions, sandmarks, substrate
small batch / run in time, short lead time (espec. APC)
stable Tricoat process, bell/bell application, spot repair, new color effects
Low cost
Market
MS BC = regional growth in Russia, Asia with car builds
HS BC = mostly US, (1 line in China), 3 lines in Europe
W/b BC conversions from MS BC, most new paintshops
Ecoconcept, 3 wet
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CLEARCOATCLEARCOAT
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Customer Needs & Trends for Clearcoat
Market Needs
IncreaseH/S
DecreaseM/S
LowBake
Appearance
Anti Scratch
WideWorkability
DecreasePowdercoating
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Clear coat Technology Roadmap
High Performance
2007 2010 2015
Improved Appearance (1K, 2K)
High Performance Scratch C/C (1K,2K)
Current Future
Easy to Clean
Self healing Clear (2K,1K)
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Product Profile Clearcoat
Market needs, areas of differentiation
„best“ appearance, „no“ scratches, robust process window versus film build, spray conditions, application on hot substrate (BC flashoff), primerless windshield adhesion, easy repair (sanding), shorter baking/curing, higher solids, matt clearcoat
Lower cost
Market
MS CC = regional growth with car builds, conversion to HS
HS CC conversions from MS CC
w/b CC only Mercedes Rastatt, Opel moved to 1K s/b in 2010
PCC BMW only, BMW moved to 2K in 2010
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Scratch damaged
After 1week
Scratch reflow Clearcoat
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Self Healing Process
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Growing interest as California starts to limit car wash to conserve water
Customers (maybe) willing to pay premium
Current products have limited durability
Product Development started
Self Cleaning Clearcoat
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ConventionalConventionalCCCC
HYDROPHOBIC
Water insoluble pollutant material
Water soluble material
Drop of rain
Self CleaningSelf CleaningCC CC (lotus leaf effect)(lotus leaf effect)
HYDROPHILIC
Coating
Water insoluble and soluble material can be washed out
Rolling down
● ● Pollutant : Hydrophobic materialPollutant : Hydrophobic material
Si SiO O
OHOHOH OH
Maintenance Free (Suggested idea)
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Clear Coat Etch-Resistance
Mar-Resistance
Basecoats VOC Raw Material Cost
Standard Ac/MH O O/+ SB , WB O low
HPCC + + SB, WB O medium
Gen IV + + US SB,WB ++ medium
Supermar 2M + ++ SB, WB O medium
Epoxy Acid +++ O WB + medium
Oligomer HS / SHS + +++ US WB + high
PE/AC/SCA HDI ++ ++ WB ++ medium
PE/SCA HDI/IPDI 1:2 +++ - WB + medium/high
Powder +++ 0 WB +++ medium
* Rate : +++ > ++ > + > O > -
Comparison of Clearcoat
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Coating Process P / Code DFT ( ㎛ ) Baking Condition
SolventBorne
SurfacerConventional FU2240, FU2260 30-40 150℃×20mins
Low Bake FU2290, FU2245 30-40 140℃×20mins
Basecoat
1C1B Medium Solid TT662(x) 30-40 150℃×20mins
2C1B Medium Solid TT6631, TT666(x) 15-25 150℃×20mins
2C1B High Solid TT6820, TT6821 10-20 145℃×20mins
Clearcoat
Medium Solid TT6100, TT6200 35-45 150℃×20mins
High SolidTT6830, UT7000,
UT604235-45 145℃×20mins
WaterBorne
Surfacer 3C1B WU3090 30-40 150℃×20mins
Basecoat
Conventional -1 WT3060 15-20 150℃×20mins
Conventional -2 WT3069 10-20 150℃×20mins
3C1B WT3090 30-40 150℃×20mins
Clearcoat2C1B
TT6830, TT6831,UT6041
30-40 145℃×20mins
3C1B UT6090 30-40 150℃×20mins
KCC products
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CONSOLIDATION PROCESSCONSOLIDATION PROCESS
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Global Automotive Coatings Strategies
VW Paint shops mostly use waterborne primer, waterborne basecoat, solvent-
borne clearcoat (1K, 2K) New paint shops EcoConcept primerless
Toyota Converted all plants to waterborne basecoat Build new plants (convert some old) to 3-wet waterborne
GM Recent plants use waterborne basecoat, waterborne primer (China, Russia) New plants will go 3-wet waterborne using 2K CC
Ford Convert to standard high solids 3C2B and 3-wet high solids
Hyundai All recent plants waterborne basecoat, waterborne primer (EU, US, China,
India, Russia, Turkey) New plants may go 3-wet waterborne
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Advantages of consolidated Processes
Reduced investment for Green Field Paintshop
Facility footprint reduction / reduced line length
Energy reduction / Positive Life Cycle impact
Manpower reduction
Appearance and durability match current systems
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Consolidated Paint Processes
HS s/b 3 wet Introduced by Ford for global use (Mexico, Romania, China, US, India, Thailand)
MS s/b 3 wet In use by Mazda, Kia
Interest in Asia (e.g. Nissan, Tata)
w/b 3 wet In use by Toyota
Under development /introduction by HMC, Honda, GM globally (US, China, Brazil)
w/b primerless EcoConcept 2K BC, 2K CC approved and in use by VW, PSA
Development of system using 1K BC / 1K CC unsuccessfull attempts by NP, BASF, PPG
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Use of Clearcoat Technology with w/b consolidated System
• BMW, Mercedes, VW, PSA, GM use 2K CC
• Toyota, others use 1K CC
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Film Builds for Integrated waterborne Processes
Film
Th
ickn
ess,
µm
120
110
100
90
80
70
60
50
40
30
20
10
0
CED20 µm
Primer Surfacer35 µm
SolidWBBC
25 µm bell
Metallic WBBC7 µm air
7 µm bell
1K or 2K Clearcoat
40 µm 1K or 2K Clearcoat
40 µm
CED20 µm
Primer Surfacer25 µm
SolidWBBC
25 µm bell
Metallic WBBC7 µm bell
7 µm bell
1K or 2K Clearcoat
40 µm 1K or 2K Clearcoat
40 µm
CED20 µm
Solid2K WBBC25 µm bell
Metallic WBBC6 µm air
Metallic2K WBBC15 µm bell
2KClearcoat
40 µm
2KClearcoat
40 µm
3-Wet WB2K EcoConceptTraditional WB
CED20 µm
1K WBBC15 µm bell
1K WBBC15 µm bell
2KClearcoat
40 µm
1K EcoConcept
2
1
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Integrated Processes - Descriptions
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BC-2K1 coat
BC21 coat
BC1 coat
Heated
flash
2K CC1 coat
Bake
Integrated waterborne system – CompressedEcoConcept
BC1/Primer1 coat
BC21 coatBC2
2 coats
Heated
flash
CC – 1K or 2K1 coat
BakeHeated
flash
Integrated system – Non-compressed3-Wet
BC21 coat
BC2 coats
Heated
flash
CC – 1K or 2K2 coats
BakePrimer
1/2 coats
Bake
Traditional baked primer, waterborne system
PrimerSand Booth
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Non-Compressed Process – 3-Wet w/b
Non-Compressed Processes
3-Wet WB Advanced wbps for improved hold-out Rheology-enhanced wbbc to maintain appearance 1K or 2K clearcoat similar to current technology
Basic process requirements sealer gel oven is required BC1 / primer and BC2 heated flash: 3 - 5 minutes at 80 ºC Cooling for BC1 and BC2 = standard (body temperature at cc < 32ºC) Bake ramp is important (10 minute ramp to 110ºC, then normal 140ºC x 20 minutes)
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BC1/Primer1 coat
BC21 coatBC2
2 coats
Heated
flash CC – 1K or 2K1-2 coats
BakeHeated
flash
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Non-Compressed Process – 3-Wet Advantages
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Reduction of Paint Process Costs
Replace primer oven with heated flash ($1mio invest)
Reduction of paint shop footprint (40m oven, 100m sanding)
Reduced paint shop energy consumption (heated flash, no baking $500M/a)
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Compressed Process - EcoConcept
Compressed Processes
EcoConcept is 2K Eco: isocyanate mixed into BC1 in 1:10 ratio
Basic process requirements Sealer gel oven is required Heated flash = std wbbc/cc 3 - 8 minutes at 50 - 80 ºC Cooling = 0 - 2 minutes Bake = standard wbbc/cc
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BC-2K1 coat
BC21 coat
BC1 coat
Heated
flash
2K CC1 coat
Bake
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Compressed Process – EcoConcept Advantages46
Reduction of Paint Process Costs
Elimination of one spray booth and oven section
Elimination of primer application equipment circulation systems ($15 mio invest)
• No primer spraybooth, robots, applicators, circulation systems, paint mix, oven, ...
Reduction of paint shop footprint (50m spraybooth, 80m oven, 100m sanding)
Reduced paint shop energy consumption (eliminate primer spraybooth and oven, $2mio/a)
Reduced manpower requirements (eliminate primer sanding)
Reduced paint usage (1kg / car)
Reduced maintenance (one spray booth, one oven less to service)
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Energy Consumption in Paintshop (www.durr.com)
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Lifecycle Analysis for Consolidated Systems
0
500
1000
1500
2000
2500
3000
3500
4000
4500
w/b Standard 3 wet w/b EcoConcept
Pri
mary
En
erg
y M
J/c
ar
Use Phase
Finish, Repair
Clearcoat
Basecoat
Primer
22 % less energy
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Total Cost of Paintshop US $ / car
86 88 90
67 64 53
66 5956
5348
40
10
9
8
0
50
100
150
200
250
300
Standard 3 wet EcoConcept
Indirect MatlsEnergyLaborCapitalPaint
$ 282 $ 247(- $35)$ 268(- $14)
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Global Use of Consolidated Paint Processes
3C2BMS-SB
3C2BHS-SB
3C1BMS-SB
3C1BHS-SB
3C2BWB
3C1BWB
primerless/Compressed WB
OEM All GM, Ford
Mazda, Kia,Tata, Honda, Brilliance
(GM),Ford
All Toyota,Suzuki, HMC/Kia, GM,Daimler
Daimler, VW, PSA, BMW-Mini, (Mazda)
20092012Cars/a
>20Mio>20Mio
4 Mio4 Mio
1 Mio1 Mio
50.000>1Mio
>30Mio>40Mio
500.000>1Mio
700,000>2Mio
Region world USA Japan, India, China
Mexico, USA, India, Romania, Thailand, China
world Japan, Korea, Canada, USA, Brazil, India, China
Germany, Spain, Mexico, UK, France, Slovakia, USA, China, Brazil
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Commercial CarCommercial Car
▷ Bus & Truck
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Surfacer
Car Model of application
BUS
Good physical propertiesCharacteristicsExcellent Appearance
Cost High
FU2240P/CODE FU2290
STAREX, PORTERTRAJET,TRUCK
BUS
Saving Process cost
FU2241
Urethane Modified polyester / Melamine
ItemUrethane Modified polyester
/ Low MW polyester/ Urethane / Melamine
Wet on Wet forUrethane Modified
Polyester/Melamine
COMPARISON OF CHARACIERISTICS
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Top Basecoat
Car Model of application
STAREX, TRUCK,
BUS
TRUCK, BUS
TRUCK
P/CODE TT662(X) TT6620 TT6621
CharacteristicsConventional
(1C1B)
ExcellentAppearance
(1C1B)
Saving Process cost
(1C1B)
ItemMedium
SolidMedium
SolidPrimer less
TRAJET, STAREX,TRUCK
TUSON, TERRACAN
TT6631
WorkabilityMottles
(With Clear)
Semi HighSolid
COMPARISON OF CHARACIERISTICS
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Top Clearcoat
Car Model of application
PassengerCar
TRUCK,BUS
PassengerCar
PassengerCar
P/CODE TT6200 TT6100 UT6030 TT6830
Characteristics ConventionalChemical resistanceScratch resistance
Durability
For Water borneChmical resistanceScratch resistance
Durability
Low VOC Chmical resistanceScratch resistance
Durability
Item Conventional Functional-A Functional-B High solid
COMPARISON OF CHARACIERISTICS
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Wet on Wet System for Truck & Bus
Bake
Wet on Wet System
Traditional baking system
1K / 2K Bake
PrimerBake Primer
Sand Booth
CEDCEDBake
■ ‘2007. HMC Jeonju Plant Launched
FU2241Primer
TT6620Top coat
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Primer less for Truck & Bus
TT 6621Bake
Primer less System
Traditional baking system
1K / 2K Bake
PrimerBake Primer
Sand Booth
CEDCEDBake
■ November. 2010. HMC Jeonju Plant Launched
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ITEMCOATING
SYSTEMPRODUCT THINNER
D.F.T( ㎛ )(Film Thickness)
DRYINGCONDITION
SURFACER FU2240-GREY(P) 029S 30~40150℃*20 MIN
(MPT)
TOP COAT 1C1BTT6621
(Primer less)062 /
TH0254(N)30~40
140℃*20 MIN (MPT)
BASE COAT
2C1B
TT6631 TH0355 15~20140℃*20 MIN 150℃*20 MIN
(MPT)CLEAR COAT
TT6100 UT6042
063 / TH0254(N)
30~40
Baking System
RECOMMENDABLE COATING SYSTEM FOR TRUCK
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ITEMCOATING
SYSTEMPRODUCT THINNER
D.F.T( ㎛ )(Film Thickness)
DRYINGCONDITION
SURFACER
Wet on Wet FU2241-GREY 029S 20~25150℃*10 MIN
(MPT)
1C1B FU2290-GREY TH0254(N) 30~40150℃*10 MIN
(MPT)
TOP COAT 1C1B TT6620062 /
TH0254(N)30~40
150℃*20 MIN (MPT)
BASE COAT
2C1B
TT6631 TH0355 15~20140℃*20 MIN 150℃*20 MIN
(MPT)CLEAR COATTT6100 TT6200UT6042
063 / TH0254(N)
30~40
Baking System
RECOMMENDABLE COATING SYSTEM FOR TRUCK
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ITEM PRODUCT HARDNER THINNERRATIO (V%)
(Base : Hardener)
MIXED
VIS(sec)(at PaintTemp.)
D.F.T( ㎛ )(Film Thickness)
DRYING
CONDITION
WASH PRIMER
VP134-D/GREEN 934C.A 053 4 : 1 13~15 7~13
EPOXY
PRIMEREP330PTA-L/GREY EP330PTB TH0045K 4 : 1 13~15 30~35 70 *30 MIN℃
URETHANE
PRIMER SURFACER
E-PRASURFE-GREY E-PRASURFE C.A TH0045K 5 : 1 13~15 30~50 70 *30 MIN℃
URETHANE
TOP COATPRIMECOAT PRIMECOAT C.A TH0045K 2 : 1 13~15 40~60 70 *30 MIN℃
PUTTY PC2900(HQ)-GREY CA0926 -100/2 (wt
%)- -
Used to correct dented parts of sheet Used to correct dented parts of sheet metal, groove of damaged partsmetal, groove of damaged parts
Urethane System
COATING SYSTEM FOR TRUCK & BUS
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THANK YOUNext : Color Presentation