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TRANSCRIPT
Eastman Solus™
Cellulose based additives
for automotive coatings
Dr Damiano Beccaria
European Coatings Conference
Automotive Coatings
Düsseldorf, 12 & 13 November 2013
Cellulose esters, innovation from renewable resources
Market trends in automotive coatings
Novel approach in formulating: High solid basecoats
High solid clear coat
Life cycle assessment
Conclusions
2
Agenda
4
Cellulosic technology…
…a core competency for
the past 70 years
up to 60% of cellulose
(most abundant naturally
occurring bio-polymer)
A sustainable feedstock
alternative to petroleum-
based materials
Cellulose esters Innovation from renewable resources
Flow and leveling (gloss / smoothness)
Reduced surface defects (1st pass yield)
Reduced drying time (throughput)
Metallic flake alignment (brightness)
Improved atomization (uniformity)
Rheology (application & appearance)
6
Cellulose esters for coating applications
Five key innovation drivers for OEM automotive coatings
Productivity Environment
Globalization
Systems cost savings
Rebalancing global economy
Innovative approaches that lead to practical solutions
Automotive OEM coating development
Trends
Coating process
Conventional 3C2B process → 3C1B or CPP
• Lower overall film build
• Compact process
Clearcoat formulation
• Improve appearance especially
over a WB BC for CPP
• Increase application solids
• Improve scratch resistance
Basecoat
• Shift from Conventional SB to WB and Higher Solids SB is continuing
• Challenge to maintain brightness at high solids
Requires improved strike-in
resistance and flow / leveling
Having the right
rheology is key
9
Bio-based raw
material from well
managed forests
Manufactured using energy efficient resources
Color control /
flake alignment
Reduced energy
(with HS systems)
Productivity (in emerging markets)
Sustainable solutions in HS OEM basecoats
“Working with Eastman, working with BASF
on a project that drove the end needs for Ford
and yet still delivered to our end customer was
on the cutting edge side of what we do.”
- Tim Weingartz, Ford Motor Co.
• Clean interphase indicating lower redissolve of the basecoat layer
• Diffuse interphase due to solvent migration into the basecoat layer
• Poorer alignment of Al flakes
Control 15 % microgel
Novel chemistry 8% of cellulose ester
Cellulose esters improve appearance
11
Control
Avg RMS : 4.69 um; FI : 7.1
Top view
Avg RMS = 2.36 um; FI : 10.1
Novel solution 10% of Cellulose ester
Side view
Images: Courtesy of NIST
Cellulose esters improve appearance Better flake orientation & lower roughness
12
Sustainable solutions in OEM clear coats
AP
PE
AR
AN
CE
VALUE
Cellulose esters could create a new appearance standard
for 1K clear coat …
1K
2K
… and enable a new standard for 1K CPP
13
0
10
20
30
40
50
60
du Wa Wb Wc Wd We
Control: 48% solids, 30 sec.
Novel Chemistry: 53% solids, 42 sec.
… even at higher solids and spray viscosity
Wave Scan Profile BYK WAVESCAN DUAL
Ap
pe
ara
nce In
dex B
est
Results: enhancing appearance
14
Commercial clearcoat
Clearcoats with
novel chemistry
Results: balancing sag and appearance
15
Rapid viscosity build
0 10 20 30
Co
mp
lex
vis
co
sit
y
ŋ*
Time (min)
Control
Novel
Chemistry
Maintaining sag resistance …
… while improving clarity and stability
Sa
g r
esis
tan
ce
B
est
Commercial clear coat
Novel chemistry
Achieving improved film smoothness…
… with better filling properties
Results: reducing telegraphing
0
5
10
15
20
25
30
High film build Low film build
Sh
ort
wa
ve
Control
Novel Chemistry
16
Ap
pe
ara
nce In
dex B
est
Cellulose esters improve appearance,
even at low DFT
15,1
20,2
6,0
19,2
26,2
5,5
0,0
5,0
10,0
15,0
20,0
25,0
30,0
Longwave Shortwave Rating
Primed substrate 30 μm (Vert)
Modified rheology package
Control (28.3% SCA)
9,1
19,1
7,1
13,1
21,2
6,3
0,0
5,0
10,0
15,0
20,0
25,0
30,0
Longwave Shortwave Rating
Primed substrate 30 µm (Horiz)
Modified rheology package
Control (28.3% SCA)
11,4
17,5
6,6
10,9
20,4
6,7
0,0
5,0
10,0
15,0
20,0
25,0
30,0
Longwave Shortwave Rating
Primed substrate 40 μm (Vert)
Modified rheology package
Control (28.3% SCA)
4,6
17,0
8,6 8,7
18,4
7,2
0,0
5,0
10,0
15,0
20,0
25,0
30,0
Longwave Shortwave Rating
Primed substrate 40 μm (Horiz)
Modified rheology package
Control (28.3% SCA)
Appearance vs. DFT (vertical bake) – LW and CF
5
8
11
14
17
20
23
26
29
20 25 30 35 40 45 50
Lon
g W
ave
CC DFT
LW vs. CC DFT
Appearance vs. DFT (vertical bake) – LW and CF
5
8
11
14
17
20
23
26
29
20 25 30 35 40 45 50
Lon
g W
ave
CC DFT
LW vs. CC DFT
Modified rheology packageControl (28.3% SCA)
0
2
4
6
8
KonigHardness
Acid etch
Xyleneresistance
ScratchCar wash
Stone chip - 30 μm
DFT
Stone chip - 40 μm
DFT
Control: 28.3% SCA
Modified rheology package
Selected film property testing results
Improving appearance while providing overall superior environmental
performance
When considering an overall environmental balance, compact processes based on modern high-solids solventborne basecoats outperform waterborne systems
Previous studies have shown that VOC emissions from high-solids solventborne systems are similar to modern waterborne systems, but at reduced electricity and natural gas usage(1)
Energy reductions can lead to reductions in GHG gases
Eastman worked with IHS to collect additional automotive paint shop LCA data. Analysis adds additional support to previous studies
(1)Ford Motor Company, “Sustainable Painting Processes: Global Alternatives.” National Center for
Manufacturing Sciences Sustainable Designs and Manufacturing Roundtable, June 2012.
Eastman Solus™ performance additives
21
Paint Shop GHG emissions
Source: Eastman/IHS Life Cycle Assessment Study
-
50
100
150
200
250
300
350
400
3C2B-WB+ 1K CC
3C2B-WB+ 2K CC
3C2B-LowSolids SB+2K CC
3C1B-HighSolids SB+ 1K CC
3C1B -WB+ 2K CC
kg
CO
2e p
er
car
bo
dy
Carbon Footprint for OEM Automotive Coatings (BiW-to-gate, excluding materials)
Other
Abatement
Decks/Repair/Wax/Building
Bake & Cool
Heated Flash
Spray booths
Pretreat, E-coat, Seal
Excellent alignment with
published values
(1)Ford Motor Company, “Sustainable Painting Processes: Global Alternatives.” NCMS Sustainable Designs and Manufacturing Roundtable, June 2012 (2) Durr and BASF. “Eco-Efficiency Analysis of Global Coating Processes” Presented at Strategies in Car Body Painting 2012
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
3C2B-WB-1K 3C2B-WB-2K 3C2B-LSSB-1K 3C1B-SB-1K 3C1B-WB-2K
No
rmalized
kg
CO
2eq
/ c
ar
co
ati
ng
GHG Footprint Relative Comparison
EMN
Ford
BASF/Dürr
Summary
24
Renewable raw materials offer unique properties
New innovation … help create a new appearance standard:
• High Solid Base coats
• 1K clear coat systems with a vision towards enabling 1K in WB CPP’s
Our technical evaluations demonstrate improved performances with
Cellulosic based solutions
Cellulose esters can enable improved high-solids systems with superior
environmental performance compared to modern waterborne systems
Market alignment … collaboration will be required to bring innovation to
the marketplace
Let our sustainable materials
help driving your growth!