nanotechnologies and plastic materials for aesthetic...
TRANSCRIPT
HORIZON 2020 EUROPEAN UNION FUNDING FOR RESEARCH & INNOVATION
Nanotechnologies and plastic materials for aesthetic automotive components
6/22/2015
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INDEX
1. MONDRAGON
2. Presentation of MAIER
3. Approach to nanotechnology from the automotive industry
4. MAIER’s approach to nanotechnology
4.1 Bulk thermoplastic nanoreinforced compounds4.2 Surface properties: anti-scratch4.3 Surface properties: self-cleaning (NANOCLEAN)4.4 Surface properties: paintability improvement (P4F)
5 Conclusions
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MAIER is a member of the MONDRAGON corporation. The corporate values are:
• Co-operation. • Participation. • Social Responsibility. • Innovation.
The Corporation’s Mission combines the core goals of a business organisation competing on international markets with the use of democratic methods in its business organisation, the creation of jobs, the human and professional development of its workers and a pledge to development with its social environment.
Global sales 2012: 12.970 million €/ Workforce 2012: 80.324 employees
MONDRAGON
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Main Customers:
Integration of different technologies:
� PAINTING: Body colour finishing, soft and high gloss (UV).
� CHROME PLATING: EU Leader High gloss, satin, Black Chrome and trivalent.
� FINISHING: Screen-printing,Thermoprint,Tampoprint,In-mould decoration,Laser etching.
� ASSEMBLIES: Welding Vibration, Ultrasonic, Stake, Laser, Hot Plate, Glueing.
� INJECTION: Conventional, gas, Bi-material, co- injection.
Decoration
Novel Multi-technologies to give high aesthetic value to the product.
R+D department dedicated to innovating in new aesthetics and functions.
Mastery of Parts with a High Functional Complexity
ToolShop
Our own Toolshop: Moulds, Prototypes, Rapid Prototypingand models.
European leader in automotive decoration
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Automotive Exterior Parts Business
PRODUCTS
• Exterior Automotive Components.
• European leaders in Wheel Trims, Front Grilles, Chrome Plated Parts and Fuel Filter Flaps.
FULL CUSTOMER SERVICE
• Design, Development and Manufacturing.
• Technology Centre in Gernika, with more than 100 engineers.
• Toolshop.
• R&D+i activities.
salesMillions of euros
2012
153,7
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PRODUCTS
• Door Panel Components: door handles, speaker grilles and trims.
• Instrument Panel Components: fascia withdifferent finishings and trims.
FULL CUSTOMER SERVICE
• Design, Development and Manufacturing.
• Technology Centre in Gernika, with more than 100 engineers.
• Toolshop.
• R&D+i activities.
Millions of euros sales
2012
23,9
Automotive Interior Parts Business
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JAPAN
France. Versalles Maier France
Germany. GöppingenMaier Deutschland
JapanTokyo
Maier UK Sales
5. Maier Czech Rep.5
4
4. Maier UK
TURKEY
2. Maier Ferroplast
1. Maier Gernika
3. Maier Navarra
8. MTC
3
2BILBAO
VALLADOLID
ZARAGOZABARCELONA
BURGOS
VIGO
8 1
Sales Offices
Alliances
Production Sites
Technology Centre
6. Alpha Maier (India)6
57. Maier Cromoplastica
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International presence
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1. R&D+IDecorative Innovations
Technology ResearchPerformance Materials
7. Validation
5. Conception and manufacturing of:PrototypesMoulds
Mounting Tools
Control Tools
4. Structural and Rheological SimulationsPatran
Marc Dytran
Mold Flow
3. CAD definitionCatiaIdeas
Unigraphics
2. StyleIcem Surf
8. IndustrialisationInjectionFinishings
Decoration
Mounting
6. Initial Parts
MTC – Maier Technology Centre
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INN
OV
AT
ION
S IN
TH
E M
AR
KE
T !
!!
Durable High gloss aspect
UV VarnishColoured clear coat on chrome plating
Laser Marking on PaintingIs it possible to colour the colour?
Laser Marking on Plastic Substrates Give plastic a unique character!
Personalize it!
Innovation in Aesthetical Decorations
Turning design trends into industrial technologies
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The approach of the automotive industry to nanotechnology can be summarized in the following table:
Approach to nanotechnology from the automotive industry
Self-Cleaning
nano-paint
Nanoprene
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MAIER has taken into account this trends of automotive industry and is currently working on the following activities:
1.- Bulk thermoplastic nanoreinforced compounds.
- Substitution of current fillers to reduce the weight of automotive components.
2.- Nanotechnology applied to functionalise surface properties.
- Anti-scratch properties.
- Self-cleaning properties.
- Improvement of the paintability for low surface-energy thermoplastics.
MAIER’s approach to nanotechnology
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Goal of the activity:
Weight reduction is one of the main issues on the automotive industry nowadays because carmakers and
OEMs want to reduce the fuel consumption and CO2 emissions of vehicles.
Nanotechnology used:
Two kind of nano reinforcements have been used:
1. Compounding of montmorillonite in a thermoplastic matrix (PP-MNT5).
2. Compounding of wollastonite in a thermoplastic matrix (PP-WOL5).
Bulk thermoplastic nanoreinforced compounds
Montmorillonite SEM
WollastoniteSEM
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Results obtained so far:
• The weight reduction obtained has been of 14% for the PP-MNT5 and 9% for the PP-WOL5.
• The shrinkage and CLTE of the material is higher than current grades.
• The processability of both compounds is stable, similar to the conventional compounds.
• The addition of nanoreinforcements produce two surface defects: tiger stripes and aggregates.
Bulk thermoplastic nanoreinforced compounds
Tiger stripes
Aggregates
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Goal of the activity:
Improvement of scratch and abrasion resistance of automotive components is a highly sought after feature for
all carmakers, specially when it comes to parts with a high-gloss like B-pillars.
Nanotechnology used:
MAIER has worked on the addition and formulation of coatings with nanoparticles and they have competed
with other technologies that are not nano:
• Nanoparticle 1: Modified silica nano-particles (linear and non-polar)
• Nanoparticle 2: Modified silica nano-particles (linear non-polar)
• Nanoparticle 3: Modified silica nano-particles (linear with medium polarity)
Surface properties: anti-scratch
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72%
60%65%
60%
22%
0%
10%
20%
30%
40%
50%
60%
70%
80%
Current
coating
Nanoparticle
1
Nanoparticle
2
Nanoparticle
3
Alternative
process
Gloss loss (%)
Results obtained so far:
• The surface performance of the coatings has improved from the current coating.
• Depending on the type of nanoparticle, the improvement is different.
• The addition of nanoparticles is economically inexpensive (due to the small amount added).
• There are other technologies, like improving the chemistry of the coating or the curing process that have a
higher impact on the scratch and abrasion resistances.
Surface properties: anti-scratch
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Optimisation and upscaling of self-cleaning surfaces for the automotive sector by
combining tailored nanostructured machined injection tools and functional thermoplastic
nanocompounds
Goal of the project :
To develop an industrial production method for injection moulded products to obtain highly water
repelling (superhydrophobic) surfaces. This property results in self-cleaning surfaces for outdoor
applications, where rainwater washes off the dirt without leaving any traces.
Surface properties: self-cleaning (NANOCLEAN)
Nanotechnology used:
Replication of the nanostructured mould
that makes the surface superhydrophobic,
mimicking the behaviour of the lotus leaf.
Nanoclean project was funded by the European Commission
http://www.nanoclean-project.eu/
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Results obtained:
81
102
126
151
0
20
40
60
80
100
120
140
160
ASA PP
Contact angle (WCA) on injection moulded parts
Smooth surface
Nanotexture
Mould cavity surface
Injection moulded part surface (replica of the mould cavity)
http://www.nanoclean-project.eu/
Nanoclean project was funded by the European Commission
Surface properties: self-cleaning (NANOCLEAN)
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Injection moulding
Nanoclean project was funded by the European Commission
Surface properties: self-cleaning (NANOCLEAN)
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Injection moulding production technology for multi-functional nano-structured plastic
components enabled by NanoImprint Lithography
Goal of the project:
MAIER’s goal is to improve the paintability of materials with a low surface energy, such as PP, in
substitution of the activation processes currently used (plasma, corona and flaming).
Nanotechnology used:
The activation processes can be replaced through surface patterning of a mould cavity. The
surface patterning is engraved on the mould cavity, so no additional process or steps are
necessary and nothing is added from a life cycle assessment point of view.
Surface properties: paintability improvement (P4F)Plast4Future project is funded by the European Commission
http://www.plast4future.eu/
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Conclusions
• Nanotechnology has a huge potential and almost never-ending possibilities for the
automotive industry: components for fuel cells, additives for tyres to improve their lifetime,
self-cleaning paints,…
• Nanofillers reduce weight of the vehicle with similar performance to current fillers, even if
there are some technical and technological hurdles to overcome.
• Improved scratch resistances can be obtained by current state-of-the-art nano-particles,
even if other current industrial solutions are more efficient (by the moment).
• Surface functionalities can be achieved by replicating nanostructured mould surfaces by
using processes that are industrially stable and capable (such as injection moulding).
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Spain
UK
IT
CZ
Xabier Aparicio
Tel: +34 94 625 9261
e-mail: [email protected]
http://www.maier.es/EN/tabid/58/language/en-US/Default.aspx
Thank you for your attention