Principles of Automotive OEM Coatings

Dr. Ulrike KUTTLER

ALLNEX AUSTRIA GmbH - Our R&D Center in Graz
 Allnex at a Glance
A 1.5 Billion $ private equity owned company with
Sales 2012 by Product Line
a strong market position in 4 different business lines:

 Liquid Resins and Additives (LRA)

 Radiation Curable Resins (RAD)
 Powder Resins (PCR)
 Crosslinkers (XLR)

Different market segments: Sales 2012 by Segment

 Automotive
 Industrial
 Packaging coatings and inks
 Protective
 Industrial plastics
 Specialty architectural
 Allnex – Our global footprint

2,000 people dedicated to Coating Resins

 Allnex – Our Technologies for Automotive OEM Coatings
RESYDROL® : Waterdilutable Alkyd- and modified Alkyd resins
Waterdilutable Polyester- and modified Polyester resins

DAOTAN ® : Waterdilutable Polyurethane dispersions

VIACRYL ® : Water- and solventdilutable Acrylic resins

MACRYNAL ® : Isocyanate crosslinkable Acrylic resins (s/b & w/b)

CYMEL ® : Melamine Aminoplast Crosslinkers (methylated, butylated as well as

mixed alcohols range)

CYCAT ® : Catalysts for Melamine Amino Crosslinkers

ADDITOL ® : Additives for

 Pigment wetting
 Stabilizing aluminum pigments in waterborne Basecoats
 Leveling & flow
 Substrate wetting
 Degassing & defoaming
Automotive OEM Layers
Clearcoat
DFT: approx. 50 - 60µm

Topcoat
DFT: approx. 50 - 60µm
Basecoat
DFT: approx. 10 - 30µm

Primer Surfacer
DFT: approx. 25 - 35µm

Cathodic Electrodeposition „CED“

DFT: approx. 20µm

Metal & Pretreatment

 Automotive OEM Layers - their main responsibilities

Cathodic Electrodeposition „CED“

Corrossion protection (together with pretreatment layer) of the car body

Primer Surfacer – the „damping- and preparation“ layer

Protection against mechanical impacts (stone chip protection )
Leveling of unevenness and irregularities (sanding marks, poor leveling / high
roughness of CED)

Basecoat – the „style / emotion“ layer

Providing color and effect – also of high importance for supporting the shape of
the car body

Clearcoat – the „appearance and protection“ layer

Appearance: Excellent leveling (smooth surface)
High gloss and body
Protection: UV radiation (causes degradation of the polymers)
Chemicals (gasoline, acids, tree gum, bird droppings,……)
Mechanical impacts (scratches, car wash brushes,…..)
Cathodic Electrodeposition
A short introduction
 CED

 History
 Basics
 Coating composition
 Tank
 Adjustments
 CED - History

 Anodic Electrodeposition
Since 1961 (FORD-Patent)
Heyday: 1965 till approx. 1978

 Cathodic Electrodeposition
Starting in 1975
State-of-the-art technology till today
 CED - Basics

What do we need for CED?

 A conductive object to be coated

(all kinds of metal or metalized substrates)

 Electric power (DC) generated by a rectifier

 The CED bath with anode cells as counter electrodes

 An oven (150 – 190°C) for the stoving process

 CED - Basics

Advantages of CED
 Fully automated
 No limitation for the shapes of objects
 Good penetration into holes (throwing power)
 No overspray and other losses (except loss of the isocyanate
blocking agent)
 Best corrosion resistance of all coating systems

Disadvantages
 Rather high investments for the coating line
 Curing temperature >140°C
 CED - Basics
Principle of CED

+ -

Water/e-Coat

Elektrolyse
Electrolysis Coagulation
Koagulation

Anode: Cathode:
Formation of H+-ions Formation of OH--Ions
(acid) (Base)
The resin coagulates by the pH-shift
 CED – The Coating Composition

1. Cationic resin dispersion (also containing the crosslinker)

2. Pigments
3. Cosolvents
4. Additives
5. Curing catalyst
6. Deionised Water
1. Cationic Resin Dispersion for Primer:

A. Backbone resin

OH OH H+ RCOO-
N Epoxy resin N Organic acids like
Formic, acetic, lactic,….

B. Crosslinker: blocked aromatic Isocyanates

C. Catalyst: metal catalyst

Cationic Resin Dispersion for Monocoats:

A. Backbone resin

OH
OH H+
N polyacrylate N RCOO-

OH

B. Crosslinker: blocked aliphatic Isocyanates

 Performance Comparison

Epoxy - CED Acrylic - CED

Corrosion resistance +++ -

UV - resistance --- ++

Feasible color range --- ++

Stoving temperature > 160°C > 170°C

 Salt Spray Test ASTM (500 hrs)

Infiltration
[mm]
6,5
aromatic
aliphatic
acrylic/30% EP
5
acrylic/15% EP
Epoxy
5 4

0
1 2 3 4 5
 240 hrs Accelerated Weathering (QUV - B)
Loss of 100
gloss
aromatic
100 aliphatic
acrylic/30% EP
acrylic/15% EP
68 epoxy

50

22
15

0
1 2 3 4 5
2. Colors/Pigments

 Epoxy CED for car bodies: grey

TiO2, carbon black, (extenders)

 Epoxy CED for small parts: black

Carbon black, extenders

 Acrylic CED for Monocoat systems: different colors

Organic pigments
2. Colors/Pigments

For the pigment grinding a separate grinding resin is used!

The CED system consists of 2 components

 the CED dispersion (clear, not pigmented)
 the pigment paste

Both components are fed into the tank separately

3. Role of the Cosolvents:
Influencing film forming:
The higher the solvent content, the softer the film in the
deposition stage:
 the lower the film resistance
 the higher the flow of electricity
 the higher the film build
 increase of the bath temperature has same effect
Well established cosolvents are Texanol, Hexylglycol,
Phenoxypropanol and Butylglycol (as carrier for the others)
4. Additives

 Anti crater agents (incompatible with the ecoat):

 Edge protection additives

 Zinc pinhole additives (use of cosolvents is also possible)

 Dispersing additive: for preparing the water dilutable catalyst

dispersion
5. Curing Catalysts

 Blocked aromatic isocyanates need a metal catalyst for

deblocking and crosslinking

 Catalysts in use are DBTO, DOTO, Bismuth compounds

 All catalysts need a special preparation to bring them into a

water dilutable form, which cannot be hydrolised in the
waterborne ecoat
E- Coat characteristics (CED)

Solids content 15 – 20 %
pH 4-6
Conductivity 800 – 1500 µSi
MEQ-value 25 - 40
(milliequivalent acid/
100 g solid resin)
Pigment binder ratio 0,15 : 1 (black)
< 0,1 : 1 (organic)
< 0,5 : 1 (grey)
General Parameters

1. Voltage 30 – 420 Volt DC

2. Current (Ampere) depending on film resistance
3. Deposition time (sec)
4. Bath temperature (°C)
5. Electric charge (As, Cb)
6. Deposition equivalent (Cb/g deposited ecoat)
 Minimum Coalescing Temperature MCT
(Constant voltage)

µm 40

35
irregular deposition regular deposition
30

25

20

15

10
20 22 24 26 28 30 32
Bath temperature °C

Cosolvent addition: moves the MCT and µm to the right

CED - Process:

 Deposition time 2 - 4 minutes

 Loss of solid material is compensated by addition

of new material (dispersion as well as pigment paste)

ANODE:

 Formation of the neutralisation acid (removed by the

anolyte)
 Formation of oxygen
CATHODE:
 Deposition, coating formation of hydrogen
Film Forming During the Electrodeposition

 The amount of deposited material decreases with the

time of deposition, as the film forms a layer with strongly
reduced conductivity
 Depending on the softness of the E- coat (Tg of the resin),
normal film thickness (15 – 25 µm) up to high film build
(25 – 50 µm) can be generated
 Throwing power: the ability of the E- coat to penetrate
into holes
 The film is almost dry after deposition (<2% water) after
rinsing
Circulation of Anolyte, Ultrafiltration:

 ANOLYTE = liquid phase in the anode, which absorbs the acid

which is generated by the deposition

 ULTRAFILTRATION = additional removal of waterborne

components from the coatings system.
Turnover

Is the time for full consumption of the material in the tank

 Depends on coated surface/time

 Typical turnover is 2-5 weeks, but can go up to 1 year
(stability challenge!)
 Tank size and turnover define the consumption of the
material; tank size can go up to 500 m³ (bigger cars,
buses)
Metal Substrates/Pretreatments
 Blank steel (only used for testing purposes)

 Iron phosphated steel (low end substrates)

 Zinc phosphated steel (most common substrates for

Automotive and GI, gives highest performance – depending
on dotation and rinsing; Cr free rinse is a must in EU)

 Sandblasted steel (very seldom)

 Other metal substrates Mg, Al, …. deliver different deposition

performance and have to be evaluated individually
Challenges:

 Cratering (external contaminations)

 Leveling
 Pinholes (MCT – behaviour)
 Coagulation in the tank
(too low neutralisation, bacteria ?)
 Redissolution (too low pH in CED)
 New metal pretreatments (e.g. Zirconium- based)
Primer Surfacer
A Short Introduction
 Primer Surfacer

 History
 Basics
 Coating composition
 Trends
 Primer Surfacer - History

 Only solventbased (s/b) chemistry till late 1980 / early

1990s

 Worldwide first waterborne (w/b) Primer Surfacer at

Opel in Germany early 1990s

 Other OEM‘s (VW- Group, Volvo, Daimler, BMW,…..)

followed within the next decade

 Today w/b Primer Surfacer is „state of the art“ but still a

high amount of s/b technology in use (Fiat, Renault, PSA,
OEM‘s in US and Asia,……)

36
 Technology Segmentation Primer Surfacer:
Development from 2004 to 2010

100% 100%

90% 90%

80% 80%

70% 70%

60% 60%

50% 50%

40% 40%

30% 30%
20% 20%

10% 10%

0% 0%
Europe Eastern&Central Americas Japan Asia Europe Eastern&Central Americas Japan Asia
E. E.

w/b Powder solvent w/b Powder solvent

Primer Europe East & Americas Japan Asia Primer Europe East & Americas Japan Asia
Surfacer 2004 Central 2004 2004 2004 Surfacer 2010 Central 2010 2010 2010
Europe (Outside Europe (Outside
2004 JP) 2010 JP)
WB 40% 10% 8% 10% 5% WB 70% 14% 11% 30% 10%
POWDER 2% 0% 51% POWDER 4% 0% 70%
SB 58% 90% 41% 90% 95% SB 26% 86% 19% 70% 90%
100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
 Primer Surfacer - Basics

 Application of the Primer Surfacer with ESTA (electrostatic

application) by means of high speed bells

 Dry film thickness (DFT) can vary from 20 – 35µm

 Standard baking conditions: 20min/165°C (at some OEMs

lower temperatures down to 145°C )

 Each OEM / OEM line has more or less different requirements

38
 Basics
Main Requirements for the Primer Surfacer

 Excellent Appearance (gloss, leveling, absolutely NO surface defects)

 Broad application window = high robustness of the Primer Surfacer
(temperature, humidity, application speed , baking conditions……) to
achieve high first run o.k. rates
 Excellent adhesion to different CED- and PVC qualities
 Excellent intercoat adhesion to a broad variety of Basecoats
 Excellent humidity resistance
 Excellent mechanical properties – tough elastic even at -20°C
 Shear & storage stability
 …….
 ......

39
 Primer Surfacer – The Coating Composition

s/b Primer Surfacer w/b Primer Surfacer

Polyester (mod. Alkyd) mod. Alkyd

Epoxy resin Polyester (PU- mod.)
Melamine Crosslinker Melamine Crosslinker
Benzoguanamine Crosslinker blocked Polyisocyanate
Pigments Pigments
Extenders Extenders
Additives Additives
Solvents (> 40%) Solvents (< 5%)

40
 Primer Surfacer – The Coating Composition

EPOXY Modifier Resin

Adhesion
Corrosion resistance
Pigment wetting

Basic Resin Polyester Modifier Resin

Levelling
Hardness
Economic efficiency

Stone chip resistance

IMPROVE
PU Modifier Resin

41
Trends / Challenges for the Primer Surfacer Layer:

 Further improved appearance (gloss, leveling)

 further broadening of application window („robustness“)

 Lower cost / higher productivity

 Low bake (< 120°C?)

 Elimination of Primer Surfacer layer in „Compact Paint

processes“

42
 Basecoat
A short introduction
 Basecoat

 History
 Basics
 Coating composition
 Trends
 Basecoat - History

 Only solventbased (s/b) chemistry till mid 1990s

 All German OEM‘s meanwhile use w/b Basecoat

 Today w/b Basecoat is „state of the art“ but still a high

amount of s/b technology in use (Fiat, Renault, PSA,
OEM‘s in US and Asia,……)

 Due to steadily increasing legislative pressure in China

w/b Basecoat technology is growing much quicker than
expected.

45
 w/b Basecoat in Global Car Production

90

80

70

60

50
Mio Cars

40

30

20

10

0
1997 1999 2001 2003 2005 2007 2009 2011 2013 2015

World (w/b) World (all)

 Conversion from s/b to w/b OEM Basecoat
% w/b BC
 Basecoat - Basics

 Application of the Basecoat with ESTA (electrostatic

application) by means of high speed bells or for metalic
Basecoats ins 2 runs (ESTA / pneumatic gun)

 Dry film thickness (DFT) can vary from 10 – 30µm (color

dependant!)

 Standard baking conditions: 10min/80°C, followed by

20min/145°C (together with Clearcoat)

 Due to the huge variety of colors and effects the most

sophisticated paint layer of the car. An advanced formulation
know how as well as carefull resin selection is key!

48
 Basecoat - Basics
Main Requirements for the Basecoat

 Excellent appearance (effect, leveling, absolutely NO surface defects)

 Excellent adhesion to different Primer Surfacer qualities
 Excellent intercoat adhesion to a broad variety of Clearcoats
 Excellent humidity resistance
 Excellent mechanical properties – tough elastic even at -20°C
 Shear & storage stability
 Robust in application
 …….
 ......

49
 Basecoat – The Coating Composition

s/b Basecoat w/b Basecoat

Polyester (PUD mod.) PUD, Polyester, Acrylic

CAB Thickener
Melamine Crosslinker Melamine Crosslinker
Pigments Pigments
Talcum Talcum
Additives Additives
Solvents (> 70%) Solvents (~ 10%)

50
 Basecoats – The Modular Approach

 Polyurethane dispersion (PUD)

Is providing adhesion, flexibility, appearance (flip flop effect in metallic BC) and stone chip
properties. Very important component in the formulation!
 Acrylic dispersion
Is providing hardness, physical drying, helps to fix the aluminum pigment and is decreasing
overall formulation cost
 Melamine resin
Is improving leveling, wetting of Clearcoat, and intercoat adhesion (BC/CC), increase open
time of BC
 Polyester
Can help to improve levelling, adhesion, flexibility and stone chip properties. Is also used in
pigment pastes.
 Thickener
Is providing the rheological properties for the BC. Very important in metallic BC to achieve a
perfect flip flop effect
 Structure of PU-Dispersions

In the synthesis of PU dispersions Polyisocyanates (hard segments) and

Polyols (soft segments) are co- reacted in a polyaddition reaction.

Soft - Segments Hard - Segments

OH-Polyester Polyisocyanate (TDI, IPDI,

OH-Alkyd TMXDI...)
OH-Polyether Diol
OH- Acrylate Dimethylolpropionic acid
OH- Polycarbonate (Amine)

52
 Typical Hard - Segments

Aliphatic / Cycloaliphatic (CH2)6 N C O

O N O
O C N (CH2)6 N C O
N N
O C N (CH2)6 (CH2)6 N C O
Hexamethylene diisocyanate (HDI) O
O Isocyanurate

O C N (CH2)6 N N (CH2)6 N C O

O (CH2)6 N C O
Urethdion H H
O C N (CH2)6 N N N (CH2)6 N C O

O O
Biuret
H3C CH3
O C N CH3 O C N N C O
N C O

Isophorone diisocyanate (IPDI) Dicyclohexylmethandiisocyanate (Desmodur W)

53
 Typical Hard - Segments

Aromatic

CH3
N C O CH3
O C N N C O

N C O Toluylene diisocyanate
(TDI)

N C O

O C N N C O
N C O

Diphenylmethane diisocyanate
(MDI)
54
 Schematic Production Process for PUDs

Soft-Segments Hard-Segments

Co-reacting Soft- and Hard-Segments

Neutralization
(amines or strong bases)

Dispersing in water

Chain elongation Chain stopping

55
 Different Production Procedures for PUDs

„ACETONE“ PROCESS

1. Polyaddition (i.e. co- reaction of soft segments with Polyisocyanates and a

hydrophilic acid component) as well as the chain extension step (with Di- oder
Polyamines) is run in Acetone (homogeneous phase)
(instead of Acetone solvents like e.g. MEK, MIBK, THF are also suitable)

2. After the neutralization- and dispersion step the Acetone is distilled off

Advantages:
• Very universal
• Viscosity during synthesis easy to control

Disadvantages:
• complex and expensive
• residual solvent in the resin
• Process not sustainable
• Unfavorable yield
 Different Production Procedures for PUDs

„MELT“ PROCESS

1. Polyaddition (i.e. co- reaction of soft segments with Polyisocyanates and a

hydrophilic acid component) is run WITHOUT any solvent (in a melt)

2. A potential chain extension step is run AFTER the neutralization and

dispersion step (i.e. in water)

Advantages:
• NO residual solvent
• Food yield
• No „solvent waste“

Disadvantages:
• Tricky process (very high viscosities)
• Process not suitable for all the different PUD- chemistries
 Different Production Procedures for PUDs

„SOLVENT“ PROCESS

1. Polyaddition (i.e. co- reaction of soft segments with Polyisocyanates and a

hydrophilic acid component) is run WITH solvent (NMP/NEP are the most
common ones)

2. A potential chain extension step is run AFTER the neutralization and

dispersion step (i.e. in water)

Advantages:
• very universal
• viscosity during synthesis easy to control

Disadvantages:
• Resin may contain quite high amounts of solvent
• Toxicology and price of NMP / NEP
 Different Production Procedures for PUDs
„MONOMER“ PROCESS

1. Polyaddition (i.e. co- reaction of soft segments with Polyisocyanates and a

hydrophilic acid component) is run in acrylic monomers (acrylic /methacrylic
acid and esters thereof) that act as „solvent“

2. A potential chain extension step is run AFTER the neutralization and dispersion
step (i.e. in water)

3. Radical polymerization of the acrylic monomers yields a solvent free, acrylic

modified PUD (graft polymer)

Advantages:
• NO residual solvent
• Good yield
• No „solvent waste“

Disadvantages:
• Smart but tricky process
• Only for acrylic modified PUDs (graft polymers)
 Film Morphology

Hard - Segment  „ net-points“

Soft - Segment  flexibility

Soft- and Hard- Segments within the polymer are leading to a

„structure of domains“.

This special stucture is creating the well known tough-elastic behaviour

of PUD based coatings (even at low temperatures!)

60
 PU Dispersions – Structure Properties

O O

R NH C NH R R NH C O R‘

Urea Urethane

Urea- as well as Urethane groups have a strong dipole moment.

This is causing strong interactions with the surface of substrates

excellent adhesion to “difficult substrates” like e.g. plastics

Moreover this dipole moment is causing strong intermolecular forces

(cohesion)

outstanding mechanical properties and elasticity

61
 PUD Basics – The „Take Aways“

1. PUD‘s are produced by a polyaddition- reaction of soft segments (OH- group

containing pre- polymers) with Polyisocyanates (hard segments) and a
hydrophilic acid component

2. The different production procedures for PUD- resins are tricky and complex

3. The majority of the hard segments (Polyisocyanates) as well as many soft

segments (OH- Polycarbonates, OH- Polyethers,….) are high price raw
materials leading to PUD‘s with elevated price level

4. The achieved properties like

• Adhesion to critical substrates

• Outstanding mechanical properties
• Excellent elasticity and abrasion resistance
• Tough elastic behaviour even at low temperatures

make PUD‘s a first choice for Automotive OEM Basecoat applications!

Polyurethane Dispersions

Structure – Property
Relationships
 PUDs – Soft Segments

Soft Segment Advantage Disadvantage

Very good appearance Hydrolytic stability
OH- Polyester
V. good mech. properties

Good body Yellowing, outdoor durability

OH- Alkyd
Good substrate penetration Hydrolytic stability

Low viscosity Poor light- and thermo

OH- Polyether
Hydrolytic stability stability

Quick drying Stability against oxidants

OH- Polyacrylate
Outdoor durability

Hydrolytic stability High Price

OH- Polycarbonate
Outdoor durability
 PUDs – The Molecular Weight

PUD‘s with low / medium molecular weight („chain stopped“ grades)

designed for crosslinking with Polyisocyanates or Amino resins

Advantages:
• Good leveling (due to slow physical drying)
• Good degassing
• Good pigment wetting
• Excellent chemical- and solvent resistance properties
• Excellent mechanical- and adhesion properties
• Can be formulated with little to no solvents

Disadvantages:
• Need crosslinker (Polyisocyanate or Amino resin)
• More complicated handling (valid only for 2K formulations)
• Potlife (valid only for 2K formulations)
• Price (expensive Polyisocyanate)
 PUDs – The Molecular Weight

PUDs with high / very high molecular weight („chain extended“ grades)

Designed for 1-pack applications (further crosslinking is possible)

Advantages:
• Quick physical drying
• Excellent orientation of metalic pigments (bright metalic effect!)
• Outstanding elasticity, adhesion and mechanical properties
• No need for crosslinker
• Easy handling (1 pack!)
• No potlife

Disadvantages:
• Weak pigment wetting
• Weak chemical- and solvent resistance properties
• Poor leveling (due to quick physical drying)
• Should be formulated with solvents
 PUDs – Preferred Fields of Application

SUBSTRATE LAYER MAIN BENEFIT

Plastic Primer Adhesion, mech. properties

Basecoat Adhesion, metalic effect,

Monocoat mech. properties

Metal Primer Surfacer Adhesion, stone chip properties

Basecoat Adhesion, metalic effect, mech.

properties
 Current Trends in the Base Coat Area

 Completely eliminate NMP/NEP from recipes (change in

legislation)

 „Lower cost“

 Further improved robustness i.e. stable color position regardless of

humidity / temperature conditions, spraying conditions, type of
Clearcoat, substrate,…….

 New color effects

 Bell / bell application

 Clearcoat
A short introduction
 Clearcoat

 Technology- and market overview

 Basics
 Coating composition
 Trends
 OEM Clearcoats – Technology Overview
Till 2010 the Clearcoat layer was the one with the broadest diversification.
Following technologies were in use:

Technology In use at

s/b 1K- Clearcoat Fiat, Peugeot, Renault,…

(Melamine crosslinked)

s/b 1K- Clearcoat Toyota and other Japanese OEM‘s

(Carboxy – Epoxy technology)

s/b 2K- Clearcoat VW, Audi, Mercedes, BMW,…….

(Polyisocyanate crosslinked)

w/b 1K- Clearcoat Opel (Eisenach plant only), Mercedes

(Melamine crosslinked) (Rastatt plant only)

Powder Clearcoat BMW (ONLY!!)

Technology Segmentation Clearcoat: Development from 2004 to 2010

100% 100%

90% 90%

80% 80%
70% 70%
60% 60%
50% 50%
40% 40%
30% 30%
20% 20%
10% 10%
0% 0%
Europe Eastern&Central Americas Japan Asia Europe Eastern&Central Americas Japan Asia
E. E.

w/b 1K s/b 2K s/b Carboxy-Epoxy Powder w/b 1K s/b 2K s/b Carboxy-Epoxy Powder

CLEAR Europe Middle/East/ Americas Japan Asia 2004 CLEAR Europe Middle/East/ Americas Japan Asia 2010
COAT 2004 Central 2004 2004 (Outside JP) COAT 2010 Central 2010 2010 (Outside JP)
EU2004 Europe 2010
WB 1.7% WB 4%
1K 70.0% 80% 60% 21% 58% 1K 54% 80% 57% 21% 62%
Melamine Melamine
2K 26.7% 20% 15% 30% 16%
1K_Acidcar 25% 49% 26% 2K 38% 20% 15% 30% 14%
boxy 1K_Acidcar 27% 49% 24%
boxy
Powder 1.6% Powder 4.6% 0.5% 0.3%
100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
 OEM Clearcoats – Technology Overview

Since 2010 a steady consolidation of Clearcoat technologies is ongoing:

 w/b 1K Clearcoat stopped at Opel Eisenach and Mercedes Rastatt ->

switch to s/b Clearcoat!

 BMW stopped powder Clearcoat -> switch to s/b 2K Clearcoat

 s/b 2K Clearcoat is increasing, but worldwide s/b 1K Clercoat still has

a share of approx. 80%
 Clearcoats – Basics

 Application of the Clearcoat with ESTA (electrostatic

application) by means of high speed bells

 Dry film thickness (DFT) in the range from 50 – 60µm

 Standard baking conditions: 20min/145°C

 The paint layer where majority of final properties is provided

by the resin technology. Carefull resin selection is key!

74
 Clearcoats – Basics
Main Requirements for the Clearcoat

 PREMIUM Appearance (gloss, leveling, absolutely NO surface

defects)
 Excellent adhesion to different Basecoat qualities
 Excellent outdoor durability, no yellowing
 Excellent humidity resistance
 Excellent mechanical properties – tough elastic even at -20°C
 Excellent chemical resistance (solvents, chemicals, acids, …….)
 Excellent scratch resistance (carwash!!)
 Robust in application
 Easy to repair by sanding or polishing
 ......

75
 s/b 1K Clearcoats

Basic components Properties

Outdoor durability, chemical

Acrylic resin
resistance and hardness

Body, leveling, adhesion, scratch

Polyester resin
resistance, outdoor durability

Sca mod. resins Antisagging and good flow/aspect

Melamine Crosslinker

Blocked Isocyanate Flexibility, chemical resistance

Catalyst Reactivity (if necessary)

 s/b 2K Clearcoats

Basic components Properties

Outdoor durability, chemical
Acrylic resin
resistance and hardness
Body, leveling, adhesion, scratch
Polyester resin
resistance, outdoor durability
Sca mod. resins Antisagging and good flow/aspect

Polyisocyanate Crosslinker

Melamine resin Additional crosslinking

 OEM Clearcoats – Technology Comparison

Technology PROS CONS

Price Formaldehyde release

s/b 1K Robustness Acid- / chemical resistance
(Melamine) Scratch resistance Film build
Easy handling (no 2K equipment!) Appearance , gloss
not for compact process

No Formaldehyde issue
Acid- / chemical resistance 2K equipment needed
s/b 2K
Film build Price
(Polyisocyanate)
Appearance Scratch resistance
Gloss
Suitable for compact process
 Current Trends for the Clearcoat

 Appearance, appearance, appearance

 „Lower cost“

 Further improved robustness (less rework!)

 Improved scratch resistance

 Higher solids content (due to more stringent legislation)

Contact Details:
Dr. Ulrike KUTTLER
Global Application Technology Manager, Automotive
Ulrike.Kuttler@allnex.com
Phone: +43 50399 1302
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