Eastman Solus Cellulose based additives for automotive coatings

Transcription

1 Eastman Solus Cellulose based additives for automotive coatings Dr Damiano Beccaria European Coatings Conference Automotive Coatings Düsseldorf, 12 & 13 November 2013

2 Agenda 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

3 Transportation: Innovative products 3

4 Cellulose esters Innovation from renewable resources 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 petroleumbased materials 4

5 Cellulose esters Innovation from renewable resources 5

6 Cellulose esters for coating applications Flow and leveling (gloss / smoothness) Metallic flake alignment (brightness) Reduced drying time (throughput) Improved atomization (uniformity) Reduced surface defects (1 st pass yield) Rheology (application & appearance) 6

7 Five key innovation drivers for OEM automotive coatings Systems cost savings Rebalancing global economy Globalization Environment Productivity Innovative approaches that lead to practical solutions

8 Compact vs Standard Process Saving energy and reducing cost 8

9 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 Requires improved strike-in resistance and flow / leveling Having the right rheology is key Basecoat Shift from Conventional SB to WB and Higher Solids SB is continuing Challenge to maintain brightness at high solids 9

10 Sustainable solutions in HS OEM basecoats Bio-based raw material from well managed forests Color control / flake alignment Manufactured using energy efficient resources Productivity (in emerging markets) 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. Reduced energy (with HS systems)

11 Cellulose esters improve appearance Control 15 % microgel Novel chemistry 8% of cellulose ester Diffuse interphase due to solvent migration into the basecoat layer Poorer alignment of Al flakes Clean interphase indicating lower redissolve of the basecoat layer 11

12 Cellulose esters improve appearance Better flake orientation & lower roughness Control Novel solution 10% of Cellulose ester Top view Avg RMS : 4.69 um; FI : 7.1 Avg RMS = 2.36 um; FI : 10.1 Side view Images: Courtesy of NIST 12

13 APPEARANCE Sustainable solutions in OEM clear coats Cellulose esters could create a new appearance standard for 1K clear coat 2K 1K VALUE and enable a new standard for 1K CPP 13

14 Results: enhancing appearance even at higher solids and spray viscosity Control: 48% solids, 30 sec. Novel Chemistry: 53% solids, 42 sec. Appearance Index Best 0 du Wa Wb Wc Wd We Wave Scan Profile BYK WAVESCAN DUAL 14

15 Complex viscosity ŋ* Sag resistance Best Results: balancing sag and appearance Commercial clearcoat Maintaining sag resistance Rapid viscosity build Novel Chemistry Clearcoats with novel chemistry Control Time (min) while improving clarity and stability 15

16 Shortwave Results: reducing telegraphing Commercial clear coat Achieving improved film smoothness 30 Novel chemistry Control Novel Chemistry Appearance Index Best 0 High film build Low film build with better filling properties 16

17 Cellulose esters improve appearance, even at low DFT 30,0 25,0 20,0 15,0 10,0 5,0 Modified rheology package Control (28.3% SCA) 21,2 19,1 9,1 Primed substrate 30 µm (Horiz) 13,1 7,1 6,3 30,0 25,0 20,0 15,0 10,0 5,0 15,1 Primed substrate 30 μm (Vert) Modified rheology package Control (28.3% SCA) 19,2 20,2 26,2 6,0 5,5 0,0 Longwave Shortwave Rating 0,0 Longwave Shortwave Rating 30,0 25,0 20,0 Primed substrate 40 μm (Horiz) Modified rheology package Control (28.3% SCA) 17,0 18,4 30,0 25,0 20,0 Primed substrate 40 μm (Vert) Modified rheology package Control (28.3% SCA) 20,4 17,5 15,0 10,0 5,0 4,6 8,7 8,6 7,2 15,0 10,0 5,0 11,4 10,9 6,6 6,7 0,0 Longwave Shortwave Rating 0,0 Longwave Shortwave Rating

18 Long Wave Appearance vs. DFT (vertical bake) LW and CF 29 LW vs. CC DFT CC DFT

19 Long Wave Appearance vs. DFT (vertical bake) LW and CF LW vs. CC DFT Modified rheology package Control (28.3% SCA) CC DFT

20 Selected film property testing results Stone chip - 40 μm DFT Stone chip - 30 μm DFT Konig Hardness Acid etch Control: 28.3% SCA Modified rheology package Xylene resistance Car wash Scratch

21 Eastman Solus performance additives 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

22 kg CO2e per car body Paint Shop GHG emissions 400 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 - 3C2B-WB + 1K CC 3C2B-WB + 2K CC 3C2B-Low Solids SB +2K CC 3C1B-High Solids SB + 1K CC 3C1B -WB + 2K CC Source: Eastman/IHS Life Cycle Assessment Study

23 Normalized kg CO2eq / car coating Excellent alignment with published values 80,0 GHG Footprint Relative Comparison 70,0 60,0 50,0 40,0 30,0 EMN Ford BASF/Dürr 20,0 10,0 0,0 3C2B-WB-1K 3C2B-WB-2K 3C2B-LSSB-1K 3C1B-SB-1K 3C1B-WB-2K (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

24 Summary 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! 24