ADD-COAT-7954 Eastman cellulose esters in automotive ... · We officially have 13 grades of CAB but...
Transcript of ADD-COAT-7954 Eastman cellulose esters in automotive ... · We officially have 13 grades of CAB but...
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Automotive coatingsImproving efficiency, enhancing aesthetics
Eastman cellulose estersADD-COAT-7954
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Agenda
Cellulose esters overview
Desired attributes for automotive coatings
Improving application and appearance• Cellulose esters in basecoats
Conventional low/medium solids solventborne basecoats Higher solids solventborne basecoats
• Cellulose esters in clear and top coats High solids clear coats
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Introduction to cellulose esters
Produced from renewable sustainable raw materials
Eastman supplies free flowing powders
CAB/CAP solution
Eastman cellulose esters come from renewable sources and have unique properties that enhance the application and aesthetics of automotive coatings
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Cellulose esters
A product of the reaction between organic acids and anhydrides with cellulose:
• Acetic acid/anhydride• Butyric acid/anhydride• Propionic acid/anhydride
Cellulose acetate (CA)
Cellulose acetate butyrate (CAB)
Cellulose acetate propionate (CAP)
Eastman cellulose esters are available in a wide variety of formats and dispersions for versatility in use to achieve desired formulation and coatings attributes.
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Code designationExample Eastman cellulose acetate butyrate
CAB 38 1 0.1- -Cellulose
acetate butyrateApproximate butyrl
content at trimester stage (wt%)
Number ofOH-groups per fouranhydroglucose units
Falling-ball viscosity (s)
Use solubility and molecular weight details for effective formulation and solvent choices
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Chain packing CA vs. CAB
Acetate molecule Butyrate molecule
Understanding chain packing impacts solubility parameters and solvent choice
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R1,R2,R3 – Acetyl, butyryl/propyl or H
Eastman cellulose esters for coatings application
Celluloseacetate
Cellulose acetate propionate
Cellulose acetate butyrate
Pharmaceutical and other products
Automotive coatings:Cellulose esters enable high quality, compliant
systems with higher solids
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Segment Overview
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Needs in automotive applicationsImproving application and aesthetics
Automotive OEM needs Flow and leveling (gloss/smoothness) Metallic flake alignment (brightness) Reduced drying time (throughput)
Automotive refinish needs Improved atomization (uniformity) Reduced surface defects (1st pass yield) Rheology (application and appearance)
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Metallic basecoatsDetails and desired attributes
Designers use metallic paint and special effect pigments to enhance flow lines in body panels and other components.
Metallic basecoats allow the use of a mixture of materials on a vehicle which all have the same appearance.
• Body coloured plastic components – bumpers, wing mirrors, and more.• Coated alloy wheels or plastic wheel trims
Coated plastic components are generally cheaper, lighter, and more versatile than using actual metal components.
Coatings can be given different tactile qualities such as soft feel and visual effects such as matt/glossy appearance.
Consistent appearance across all vehicle components is crucial and can be impacted by ingredient and formulation choices
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Segment Challenges Addressed by CAB and CAP
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Viscosity of CAB permits application of heavy basecoat
As solvent evaporates, film shrinks, flake orientation begins
Aluminum pigment (flakes)
Clear coat
CAB prevents solvents in clear topcoat from redissolving basecoat
How CAB functions in metallic basecoats
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T1
With CAB
Time
Solution viscosity
T2
V
No CAB
Solution viscosity
With CAB, solution viscosity increases more rapidly
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Comparing metallic flake orientationCoatings with and without CAB
With Eastman CAB viscosity changes more quickly, allowing for better metallic flake
orientation at the right time of the drying process
Without Eastman CAB metallic flake orientation is
hindered based on less desirable viscosity during drying
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Improved flake orientationIndications of ideal flip flop
90°
45°
Highest coating brightness at direct view
With CAB Without CAB
Coating appears progressively darker at angle view
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Tuning the properties of coatings
What if… Attributes increase Attributes decrease
Butyryl content of cellulose esters increases?
Flexibility Chemical resistance
Solubility Grease resistance
Hydrocarbon tolerance Hardness
Compatibility ―
Hydroxyl content of cellulose esters increases?
Water tolerance Moisture resistance
Alcohol tolerance Alcohol resistance
Hardness ―
Reactivity ―
Cellulose ester viscosityincreases?
Melting point Compatibility (very slightly)
Toughness Solubility (slightly)
― Solution nonvolatile at fixed viscosity
Cellulose esters are versatile problem solvers that offer formulators many options to achieve desired application and coating attributes
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Results for cellulose esters in metallic base coats
Conventional solventborne basecoatsSolus 2300 in higher solids solventborne basecoatsCellulose esters in clear coat and topcoat systems
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Eastman cellulose acetate butyrate for conventional solventborne basecoats
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Component Weight Description Supplier
Alpate 7106 NS 61.0 Metallic pigment Toyal Europe
Butyl acetate 61.0
Xylene 35.5
Cerafak 106 120.0 Wax Byk Chemie
Setal 90173 SS-50 320.0 Polyester resin Nuplex Resins
Dow Corning 56 (10% in butyl acetate) 7.0 Flow aid Dow Corning
Byk P104 S 0.5 Wetting aid Byk Chemie
Eastman CAB 381-0.5 (20% in butyl acetate) 360.0 Eastman
Butyl acetate 35.0
Total 1000.0
Property Value Test method
Application viscosity at 23°C 16–18 sec DIN cup 4
Solids content 20%
Technical data
Typical refinish metallic basecoat formulation
Butyl acetate till application viscosity
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Ingredient Typical amount Function
Binder (polyester or acrylic) 40–60% of total solids Appearance, depth of image (DOI), physical properties
Cellulose ester 15–35% of total solids Flake orientation, fast drying, prevents re-dissolve by top coat
Melamine resin 15–30% of total solids Inter-coat adhesion
Polyethylene wax dispersion 5–10% of total solids Helps appearance, reduces mottling
Metallic flake (aluminium) 10–15% of total solids Metallic effect, substrate hiding
Solvent To application viscosity (20 Sec. DIN 4 flow cup)
Fluidity, regulates drying time; solids at application viscosity typically > 20%
Additives As needed Flow, levelling
Typical components of a basecoat explained
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Flake orientationConfocal microscopy
Without CAB
With CAB
With CAB, metallic flakes align flat and reflect more light, enhancing appearance
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Visual affect of metallic flake orientation
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Resistance to redissolve by clear coat
CAB in the basecoat allows wet on wet application of clear coat without redissolve, which can alter appearance
With CABNo color change
Without CABVisual color change
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Reducing redissolveSEM images of basecoat/clearcoat interphase
Clean interphase indicating lower redissolve of the basecoat layer
Redissolve can negatively impact appearance
Diffuse interphase due to solvent migration into the basecoat layer
Poorer alignment of Al flakes
Without CAB With CAB
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Effect of increasing the level of CABDelivers enhanced aesthetic properties
Improves appearance
Smoother, more uniform paint film
More consistent metallic flake orientation
Improved color consistency
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Solus 2300 for higher solid automotive solventborne basecoats
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Eastman Solus™ 2300 performance additiveAutomotive OEM basecoat performance
Generic OEM basecoat formulationFormulation Wt % Formulation/application data
Polyester polyol (60% NVa) 44.0 Solids as prepared (%) prior to reducing to spray viscosity 46.9
Melamine resin (70% NVa) 18.5 Application viscosity (#4 Ford cup), seconds 20.06
Solus™ 2300 (40% in n-butyl acetate) 9.4 Theoretical solids (%) 39.6
Wax dispersion (5% NVa) 19.8 Measured solids (%) at application 39.40
Flow additive 0.7 Density (lb/gal) 8.25
Aluminum flake (70% NVa) 6.6 Density (g/l) 989
Solvent blendb 1.0
Total: 100.0
Butyl acetate till application viscositya NV = Non-volatileb Solvent blend = xylene/aromatic (50/50)
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Automotive OEM basecoat With Solus 2300
Control
Avg RMS : 4.69 um FI : 7.1
Avg RMS = 2.36 umFI : 10.1
Avg RMS = 2.08 umFI : 13.4
Top view
Side view
Solus 2300 Solus 2300 / microgel
With Solus, metallic flakes align flat and reflect more light, enhancing appearance
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Eastman Solus 2300Additional benefits to basecoats
Helps in lowering volatile organic compounds (VOC)
Superior performance• Optimized flake control/face brightness• Enhanced distinctness of image (DOI)• Reduced dry-to-touch times• Improved re-dissolve/strike-in resistance• Smoother films
Greater productivity by enabling higher solids
Reduced defects during and after coatings application
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Cellulose esters in clear and top coat systems
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Automotive clear coat Desired application and appearance attributes
Application
Faster dry to touch Improved flow and leveling and sag resistance
Improved hardness development
Appearance
Improved distinctness of image (DOI) Reduced defects
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Refinish clear coat formulation
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%Ac
rylic
+10%
Cel
lulo
se e
ster
Solvent
Additives
Curing agent
Cellulose ester
Polyol
Control Novel approach
Acrylic resin (75% n-BA) 58.12 52.30
Solus 2100 (55% MIAK) - 7.92
n-Butyl acetate 6.44 7.90
MIAK 5.58 2.02
Catalyst (1% in n-BA) 2.18 2.18
Part A subtotal 72.32 72.32
HDI trimer (90% n-BA) 20.76 19.67
n-Butyl acetate 5.67 5.37
PM Acetate 3.72 3.53
Part B subtotal 30.15 28.57Thinner
(n-Butyl acetate/1-ethoxy-2-propanol acetate 60/40)
4.0 6.0
Total 106.47 106.89
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Enhanced drying performanceWith Solus 2100
010203040506070
Control Fast Drying Acrylic Fast Drying Acrylic+10% Cellulose Ester
Sand
free
dry
tim
e (m
ins)
Fast drying acrylicControl Fast drying acrylic+10% cellulose ester
Sand
free
dry
tim
e (m
in)
15 minute drying time reduction
Reducing trying time is significant and decreases the chance of airborne contaminants to settle on wet paint and negatively impact appearance
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Enhanced sagging performance With Solus 2100
40
45
50
55
60
65
Fast Drying Acrylic Fast Drying Acrylic+10% Cellulose Ester
Dry
film
thic
knes
s @
sag
poi
nt (µ
m)
Fast drying acrylic Fast drying acrylic+10% cellulose ester
With Solus, higher Tg and faster solvent release mean top coats can be applied in thicker films, improving appearance and productivity
Spray application
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Enhanced König hardness developmentWith Solus 2100
0
50
100
150
200
250
0.01 0.1 1 10 100 1000
Kon
ig s
econ
ds
Hardness of 2K clearcoat based after baking (60°C/30min)
Fast Drying Acrylic
Fast Drying Acrylic+10% Cellulose Ester
Time (hr)
Fast drying acrylic
Fast drying acrylic +10% cellulose ester
Solus can decrease drying time while achieving desired hardness, improving productivity
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0
20
40
60
80
100
120
140
Fast Drying Acrylic Fast Drying Acrylic+10% Cellulose Ester
Visc
osity
dou
ble
time
(min
s)
Fast drying acrylic Fast drying acrylic+10% cellulose ester
Increased pot life improves productivity and eliminates unnecessary waste of materials
Enhanced pot life With Solus 2100
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Minimal VOC impactWith Solus 2100
300
320
340
360
380
400
420
440
Fast Drying Acrylic Fast Drying Acrylic+10% Cellulose Ester
VOC
(g/l)
Fast drying acrylic Fast drying acrylic+10% cellulose ester
With Solus, productivity and appearance can be improved while also meeting stringent VOC limits
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80
81
82
83
84
85
86
87
88
89
90
Fast Drying Acrylic Fast Drying Acrylic+10% Cellulose Ester
Glo
ss20
°(%
)
Gloss
Fast drying acrylic Fast drying acrylic+10% cellulose ester
8988.6
With Solus, there is insignificant impact to gloss compared to control
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Appearance measured by Wavescan
0.0
2.0
4.0
6.0
8.0
10.0
12.0
du Wa Wb Wc Wd We
Horizontal (Wavescan profile)
Fast Drying Acrylic
Fast Drying Acrylic + 10%Cellulose Ester
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
SW LW
Horizontal(Short and long wave)
Fast drying acrylic
Fast drying acrylic +10% cellulose ester
With Solus, there is measurable appearance improvement
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Appearance
Acrylic
+10% cellulose ester
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Cellulose esters reduce coating defects
Substrate
Coating
Picture framing
Pin holeCrater
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Improved flow and leveling with CAB
With Eastman CAB-551-0.01Good flow / leveling
High reflection
Without CABPoor flow / leveling
Poor reflection
Pencil reflection in a coating
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CAB reduces flooding and floating in paint
Solvent evaporation leads to localized surface cooling
With CAB, rapid viscosity rise after application effectively locks pigments in position, delivering more even color and appearance
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Similar mechanism for silica matting aids
Silica particle
Light LightReflected Scattered
Silica particle
Without CAB Higher solids Lower film shrinkage Higher gloss
With CAB Lower solids Higher film shrinkage Lower gloss
With CAB, the performance of matting aids such as silica is increased due to higher film shrinkage
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60° Gloss 2K acrylic urethane coating With silica matting aid at different film thicknesses
0
5
10
15
20
25
30
0 10 20 30 40 50 60 70 80 90
Thickness(Microns)
Glo
ss
Acrylic control
1: 0.3 Acrylic: CAB
1: 0.8 Acrylic: CAB
With CAB, constant gloss levels are exhibited as dry film thickness increases.
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Conclusion
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Cellulose esters for automotive coatingsEnhancing application and appearance
Improves application
Faster drying time Increases solution viscosity faster
Improved hardness development
Improves appearance
Smoother, more uniform paint film
More consistent metallic flake orientation
Improved color consistency
Improved flow and leveling
Delivers compliance
No negative impact to VOC Derived from renewable sources
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As the world’s leading supplier of specialty cellulose esters for more than 85 years, Eastman has a long history of reliably supplying customers with consistently high-quality products manufactured using advanced processes and controls. Leveraging years of formulating experience and a diverse portfolio of more than 50 cellulose esters (CA, CAB, CAP, and C-A-P) for a variety of applications, our technical experts can provide guidance to help customers select the best cellulose ester or blend to achieve the specific performance desired for their unique application. Over the years, we’ve introduced innovative products that help meet customer needs and market demands, most recently Eastman Solus™ performance additive for high-solids coatings and Eastman membrane material products for membrane filtration. Eastman works with regulatory agencies and industry associations on behalf of our customers to advocate for policies that allow industries to thrive, enabling sustainable innovation. At Eastman, our goal is to enhance the quality of life in a material way.
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Disclaimer
Although the information and recommendations set forth herein are presented in good faith, Eastman Chemical Company makes no
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© 2019 Eastman Chemical Company. Eastman, Solus and The results of insight are trademarks of Eastman Chemical Company.