0 first ! best ! smart !electro-deposition. 1 background anode + cathode o2o2 a-a- r+r+ h2h2 -...

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First ! Best ! Smart !

Electro-DepositionElectro-Deposition

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First ! Best ! Smart !First ! Best ! Smart !

Background

Anode +

Cathode

O2

A-

R+

H2

-

<Cathode Reactions>Electrolysis of water :

H2 + 2OH-

-NR2 + H2O

<Anode Reaction>

Electrolysis of water :

4H+ + O2 + 4e-

Film deposition :

2H2O + 2e-

-NR2H+ + OH-

2H2O

H+ CH3COO- + CH3COOH

Electrodeposition

A term for a broad range of industrial processes which includes electrocoating, e-coating, cathodic electrodeposition, and electrophoretic coating, or lectrophoretic painting. A characteristic feature of this process is that colloidal particles suspended in a liquid medium migrate under the influence of an electric field (electrophoresis) and are deposited onto an electrode. All colloidal particles that can be used to form stable suspensions and that can carry a charge can be used in electrophoretic deposition. This includes materials such as polymers, pigments, dyes, ceramics and metals.

The process is useful for applying materials to any electrically conductive surface. The materials which are being deposited are the major determining factor in the actual processing conditions and equipment which may be used.

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Development of ED coating

1921920019319399

Latex rubber electrodeposited on glove forms.

1939-Electrodeposition of emulsions on the inside of steel food Containers.

195195

99

196196

33 19711971

19761976

Introduction of cathodic electrocoating technology to the automotiveand appliance industries.

Introduction of high-film-build cathodic technology.

First experiments on anodically electrodeposition paint by Dr. George E. F. Brewer at the Ford Motor Company.

First anodic electrocoating production facility, Ford Motor Co.

History

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ED coating

Development

ED coating

Development

1990199019801980

Main Main

19951995 20102010

GenerationGeneration

ProductsProducts

ApplicationApplication

20052005

Chara-cterChara-cter

DetailDetail

HMC 1, 2HMC 1, 2

Cationic, 1packCationic, 1pack

ED1700ED1700

2nd (Not available)2nd (Not available)3rd,Conventional(Available)

3rd,Conventional(Available)

1. Pb contains2. Low film build


2pack 2pack

1. Pb contains2. Yellowing / Non yellowing3. High film build

1. Pb contains2. Yellowing / Non yellowing3. High film build

Low bake typeLow bake type

1. Pb contains2. Non yellowing3. Medium film build

1. Pb contains2. Non yellowing3. Medium film build

Lead FreeLead Free

1. Pb Free2. Non yellowing3. Medium film build

1. Pb Free2. Non yellowing3. Medium film build

ED1800 / ED1900ED1800 / ED1900 ED2000ED2000 ED2100/ED2600ED2100/ED2600

HMC 3,4,5,Asan,DYKMCHMC 3,4,5,Asan,DYKMC HMC BUSHMC BUS

HMC5, BHMC, ZAZ, JAC, Izh-Avto

HMC5, BHMC, ZAZ, JAC, Izh-Avto

1st Gen.1st Gen.

2nd Gen.2nd Gen.

3rd Gen., Conventional3rd Gen., Conventional

3rd Gen., High Functional3rd Gen., High Functional

3rd, High-functional(Available)3rd, High-functional(Available)

High TP / High functionalHigh TP / High functional

1. High Throw power2. High Functional3. Weatherability 4. Sn free available

1. High Throw power2. High Functional3. Weatherability 4. Sn free available

ED3000/ ED7000 / ECOED3000/ ED7000 / ECO

HMC1~4 ,51,Asan,Jeonju, BHMC, DYKMC, HMI, PK(Iran),Jeonju S/Frame

HMC1~4 ,51,Asan,Jeonju, BHMC, DYKMC, HMI, PK(Iran),Jeonju S/Frame

20002000

1st (Not available)1st (Not available)

HMC 1HMC 1

Anionic, 1packAnionic, 1pack

ED1600ED1600



19851985

1st Gen.1st Gen.

History

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First ! Best ! Smart !

GLOBAL E-COAT SYSTEM

KCC1. Harmony with DuPont Europe & US ED technology

2. Optimization of domestic automotive technology

(Formulation / Process technology development)

3. Application of KCC technology & trouble shooting

DuPont (Europe)AQUA EC Technology1984 ~ 2004

DuPont(US)ElectroShield, CorMax Technology 2004 ~ 2022

Organization

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ED Dept. in Ulsan

1. Quality improvement of DuPont-KCC product 2. Manufacturing technology development 3. Co-Work with DuPont 4. Quality improvement of automotive plant

Central Research Institute

1. Establishment of KCC ED technology foundation 2. Development of high performance ED ( High throw power, weatherability) 3. Development of main binders and additives

Global sales & technical service Dept.

1. Technical service to Automotive plants 2. Support of coating facilities & factor control 3. Support of sales & technical development

E-Coat E-Coat OrganizationOrganizationE-Coat E-Coat OrganizationOrganization

Organization

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HMC 1, 2HMC Jeonju, Pilot 1,2

HMC 3

HMC 41, 42

HMC Asan

HMC 51, 52

: Accent, Click, Santafe, Avante

DomesticIn-Line : Avante

: Genesis coupe, Starex, Porter: Genesis, Equus, Tusan

: Grandeur, Sonata

: Bus, Truck, Pilot models

Bath number : 14, Bath Capacity : 2,832ton Customer list

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BHMC 1, 2

Pars Khodro, Iran Khodro Diesel

DYKMC 1, 2

HMI, HMMRIzh-Avto, ZAZ

HAOS

OverseasIn-Line

ChinaJAC, GO(2 Lines)

Bath number : 16, Bath Capacity : 3,297ton

DFML, SMT

Customer list

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Domestic(Ulsan, Gyeongnam)Overseas(excluding China)

Domestic(Daegu, Pohang)

Domestic(Jeonju, Gwangju)

Overseas(China)

Domestic(Chungcheong, Gyeongin)

Part Line

13 Lines, 392 tons

14 Lines, 151 tons

8 Lines, 417 tons13 Lines, 213 tons

11 Lines, 160 tons

8 Lines, 143 tons

Bath number : 72, Bath Capacity : 1,475ton Customer list

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20082007 2009 2010

Unit : million won

• overall sales increase (15%↑ vs 2007)

• overseas sales increase (123% vs 2007)

77,770

67,731

70,315

67,587 Reason of sales increase

• Increase paint amount for HMC

overseas plant

• Extension to the new overseas

plants

-. Pars Khodro

-. HMMR

-. ZAZ

-. Lots of Chinese plants

Sales

Domestic

Export

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NOW, KCC ED is UNDER SUBMISSION

NISSAN

IRAN KHODRO

AVTOVAZ

PROTON

GAZ

Promotion issues

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ED2100, ED2600, ED2800

ED3000

ED3100, ED3500, ED3600, ED3700

ECO1000, ECO1200, ECO2000

ED7000-BLACK

CommercializedCommercializedProductsProducts

Commercialized Products

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ProductProduct ED2100, ED2600, ED2800

HistoryHistory1999 : HMC Asan plant (The first Pb free ED paint at domestic automotive plant)2000 : Application to the all HMC plants2010 : HMC 5th plant, BHMC1st plant, ZAZ, Izh-Avto

-. Pb Free, Medium Build-. Curing condition : 160℃-. P/B : 0.25 ~ 0.35-. Mixing Ratio 1 : 3.4(P/B 0.3)-. PTA 52%, PTB 40%

FeatureFeature

ED 2100 Series

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ProductProduct ED3000HT-GREY(M), ED3000HT-GREY(S)

HistoryHistory

2005 : HMC 2nd plant (The first Sn Free ED paint at domestic automotive plant)2006 : Application to the all HMC plants2010 : HMC 1,2,3,41,42, Asan, HAOS(Feed Over From PPG)

-. High Throwing Power-. Pb/Sn Free, Pb Free, Medium Build-. Curing condition :160℃-. P/B : 0.20 ~ 0.30, Mixing Ratio 1 : 4.5(P/B 0.25)-. PTA 52%, PTB 36%

FeatureFeature

ED 3000 Series

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Application historyApplication historyApplication historyApplication history Tear DownTear DownTear DownTear DownApplication resultApplication resultApplication resultApplication result

1. 2005.12.5 Application to the

HMC 2nd plant

2. 2006.3 1) Feed Over (~ 3 Turn over) 2) Tear Down

1. 2005.12.5 Application to the

HMC 2nd plant

2. 2006.3 1) Feed Over (~ 3 Turn over) 2) Tear Down

1. T/power improvement 1) Hood /Otr. Inr. : 50% improve 2) Cowl Comp :36%

improve 3) S/Side : 44% improve 4) Wheel House Inr. Assy. : 81% improve

2. Appearance improvement

1. T/power improvement 1) Hood /Otr. Inr. : 50% improve 2) Cowl Comp :36%

improve 3) S/Side : 44% improve 4) Wheel House Inr. Assy. : 81% improve

2. Appearance improvement

Wheel House Inner Assy’

S/Side Otr Inner

ED 3000 Series

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ProductProduct ED3100, ED3500, ED3600, ED3700

HistorHistoryy

ED3100 : BHMC 2nd plantED3500 : HMI 2nd plantED3600 : DYKMC 1st, 2nd plantED3700 : Pars Khodro, Iran Khodro Diesel -> Renault-Nissan CKD line

-. High Throw Power E-coat-. Optimization to the overseas automotive plant facility condition-. Pb Free, Pb/Sn Free(ED3700), Medium Build-. Curing condition :160℃ or 165℃-. P/B : 0.25, 0.3

FeaturFeaturee

ED3100,3500,3600,3700

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ProductProduct ECO1000, ECO1200, ECO2000

HistoryHistory

2007 : HMC 51st plant2008 : HMC BUS plant (Jeonju)2009 : HMC TRUCK plant (Jeonju)2010 : HMMR (Russia)

FeatureFeature

-. KCC Technology of ED paint-. High Throwing Power-. Pb Free, Medium Build-. Curing condition : 160℃ -. P/B : 0.25

ECO1000 Series

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ProductProduct ED7000-BLACK

HistoryHistory 2006 : HMC Side Frame line (for truck) High Weatherability (UV Durable)

-. Pb Free, Medium Build Type-. Curing condition :173℃-. P/B : 0.15 ~ 0.25-. Mixing Ratio 1 : 4.4(P/B 0.2)-. PTA 44%, PTB 33%

FeatureFeature

ED7000-BLACK

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Major Researches

• Compatibility for ZrO2 pretreatment

① Improvement of Throw Power , Mapping, Film build ② Improvement of corrosion resistance

* Ultra high T/Power → Consumption reduction ≒ 20% (Otr/inr=16/11 ㎛ )* Low bake off, Low film density

* Pigment Zero → Dirt Zero, Cost reduction ① ASH = 1~2% ② Film density = 1.2

* One component system

Technical Researches

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TargetTarget

• Reduction of paint consumption through the Ultra High throw power property (Outer/Inner = 16/11 ㎛ )

• Low bake off, Low film density

ApproachApproach• Establishment of Throw Power Vs GA Gas pinhole

Balance

• Good Appearance

• Corrosion resistance at low film (below 16 ㎛ )

• Line simulation(2011), Mass production and application(2012)

PlanPlan

Ultra High Throw Power E-Coat

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Ultra High Throw Power E-Coat

CurrentE-coat

Ultra highThrow E-coat

film substrate

Ultra high throw

reduce exterior film build

Overall usage reduction

(15~20%)

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ZirconiumZirconiumpretreatmenpretreatmentt

ApproachApproach

1. feature 3. Mapping Problem

E-coat for Zirconium pretreatment

• Shorten line length (No use of surface conditioner) • Reduction of sludge• Free of heavy metals • Operates at ambient temperature

2. Weaker Throw Power

Phospate PT

Zirconium PT

Exterior 20um 19um

Interior 11.5um X

Difficulty of controllingappearance and DFT

• Improvement of Throw Power & Appearance

• Control of film build

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TargetTarget

• Extremely low Pigment

• One component system

• Bath Circulation reduce

ApproacApproachh

• Eliminates setting and

flocculation concerns

• Reduces operating cost

• Increases UF flux rate

• Ultra-low VOC

AdvantagAdvantagee

Study and development with DuPont

* ASH = 1~2% * Film density = 1.2

Paste

Resin

BathCirculation

Bath FiltrationPastePaste

ResinResin

BathCirculation

BathCirculation

BathBath FiltrationFiltration

Pigment Free E-Coat

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Submersible data acquisition unit

Checking of rectifier condition & real coating voltage during coatingat the ED bath

1 2

SEM + Electron Probe Micro Analyzer

Magnifying & analyzing defect area of ED film

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624 배율

1,570 배율

GA 도금층

Focused Ion Beam+SEM + EPMA

Magnifying & analyzing defect area of ED film

Practical technical supporting

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Data pack for Oven Temperature checking

Oven condition check &Real MPT check during the oven drying process

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Test Report for heavymetal analysis

Offer the test reportof heavy metals, PBBs, PBDEs of KCC paint


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Test of bacteria, yeast, fungi in the ED process

Finds and removes afactor

Trouble shooting

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Cyclic Corrosion Test (approved by GM)

Cyclic CorrosionTest (approved by GM)

CCT for GMECC for RenaultAnd so on..

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Salt Spray Test

Official institutionapproved by KOLAS


QUV, IR, ICP, GC, EPMA, NMR, EDS, SEM..

Lots of analysis instrument are available

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Lots of analysis Instrument is availablefor customers

0 first ! best ! smart !electro-deposition. 1 background anode + cathode o2o2 a-a- r+r+ h2h2 -...

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