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IndexIndex

▷ C.R.I

▷ Automotive Coatings Technology

3


History

C.R.I. View

C.R.I Development Item

Central Research Institute

4


" Value creation through R&D technology innovation"

Central Research Institute Vision

5


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

6


Area : 16,000m2 (Research Building Area : 8,000m2)

Pilot : 5 buildings

Dormitory : 2 Places / Gymnasium : 1 Places

Human Resource Center : 1 buildings

7


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

8


EMC / Electronic Materials

Display Materials

Powder CoatingsIndustrial Paints

DGU

Automotive Paints

Heavy-duty Protective Coatings

Paints

Industrial Materials

Organic Material Research Items

9


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

10


AUTOMOTIVE COATING AUTOMOTIVE COATING

TECHNOLOGYTECHNOLOGY

11


Process ConsolidationUltra low cost

Appearance, ColorScratch, Durability

KCC‘s OEM Paint Driving Forces

Environmental protection

12


Automotive coating Driving Forces

Higher Quality

Consistent Quality

Lower Cost

Growth in Asia

Class Distinctions( Mini -> Luxury)

Environment

Driving Forces

13


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

14


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16


PRIMER SURFACERPRIMER SURFACER

17


Customer Needs & Trends for Primer Surfacer

Market Needs

Waterborne

SmoothSurface

Low cost

Chipping

HighSolid

CompactSystem

18


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

19


•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

20


* 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 - - - -

21


BASECOATBASECOAT

22


Customer Needs & Trends for Basecoat

Market Needs

Extension WaterborneBasecoat

Low coatWide

ApplicationWindow

CompatibilityOf

Variety C/C

NewColor

CompactSystem

23


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

24


Product Profile Basecoat


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

25


CLEARCOATCLEARCOAT

26


Customer Needs & Trends for Clearcoat

Market Needs

IncreaseH/S

DecreaseM/S

LowBake

Appearance

Anti Scratch

WideWorkability

DecreasePowdercoating

27


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)

28


Product Profile Clearcoat


„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

29


Scratch damaged

After 1week

Scratch reflow Clearcoat

30


Self Healing Process

31


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

32


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

ＳｉＳｉO O

OHOHOH OH

Maintenance Free (Suggested idea)

33


<33>

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

34

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

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

35


CONSOLIDATION PROCESSCONSOLIDATION PROCESS

36


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

37


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

37

38


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

38

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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First ! Best ! Smart !39

40


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

41


Integrated Processes - Descriptions

41

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

42


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)

42

BC1/Primer1 coat

BC21 coatBC2

2 coats

Heated

flash CC – 1K or 2K1-2 coats

BakeHeated

flash

43


Non-Compressed Process – 3-Wet Advantages

43

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)

44


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

44

BC-2K1 coat

BC21 coat

BC1 coat

Heated

flash

2K CC1 coat

Bake

45


46


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)

47


Energy Consumption in Paintshop (www.durr.com)

47

48


48

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

49


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)

50


51


52


53


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

54


Commercial CarCommercial Car

▷ Bus & Truck

55


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

56


Top Basecoat


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


57


Top Clearcoat


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


58


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

59


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

60


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

61


ITEMCOATING

SYSTEMPRODUCT THINNER


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

62


ITEM PRODUCT HARDNER THINNERRATIO (V%)

(Base : Hardener)

MIXED

VIS(sec)(at PaintTemp.)


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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