Canadian Finishing & Coatings Manufacturing Magazine November/December 2021 - 24

INDUSTRIAL FINISHING: AUTOMOTIVE COATINGS
additional width exactly matching the intended thickness of the
coating layer. The near-zero VOC coating is injected into this
cavity using a reaction injection molding (RIM) mixing head,
yielding a precision part with integrated coating in just two steps.
The resulting molded polyurethane part requires little rework
and offers high resistance to chemical and light exposure.
In another example of sustainability, primers with graphene
nanotubes offer a new solution for electrostatic painting of
automotive parts, says OCSiAl, producer of graphene nanotubes.
Conductive acrylic primers for polypropylene and SMC plastic
parts jointly developed by Turkish manufacturer Kanat Paints
& Coatings and OCSiAl demonstrate a stable, uniform level of
surface resistivity of around 105 Ω/sq. This makes it possible to
apply basecoat and other coating systems to automotive exterior
plastic parts via electrostatic application which is cost-effective
and sustainable.
" Our product line is flexible and adapts to match the request
of each specific customer, " says İlhan Demiral, Technical Sales
& Business Development Manager at Hayim Pinhas A.S., a
distributor of graphene nanotube solutions in Turkey. " What
is distinctive with the graphene nanotube solutions provided
by OCSiAl is their unprecedently low working threshold - the
required concentration starts at only 0.01 percent of nanotubes.
This is crucial for applications where the color and durability of a
final product are of great importance. "
The new primer demonstrates improved quality in comparison
to alternatives with other conductive additives, such as carbon
black, the companies say. High adhesion gives the ability to
assemble SMC parts coated with primer onto the metal body of
the vehicle at the beginning of the painting process and to apply
all required coating systems simultaneously to the metal and
plastic parts on the conveyor line via the electrostatic method.
" In addition, single wall carbon nanotubes make it possible
to produce light gray primers with a high L-value (greater than
70 percent) and high transfer efficiency. This leads to reduced
basecoat consumption in comparison with black primers and
potential cost reductions, " says Alper Kades, R&D Director,
Kanat.
OCSiAl adds, advanced nanotube primers are in the process
of receiving practical approval from several leading OEM
manufacturers.
LUXURIOUS INTERIORS
With increased vehicle usage comes the increased desire for an
aesthetic and comfortable interior. Luxury interior elements such
as soft, matte surfaces, unique designs, and increased electronic
integration such as interactive display screens all contribute to a
better occupant experience.
Not only do water-based textile coatings increase a vehicle's
green-factor, they also mimic the look and feel of luxury surfaces
- creating an elevated interior experience, says Covestro which
offers a variety of materials for soft-feel coatings that, when
applied on rigid substrates, allow automotive OEMs to achieve an
array of haptics and sensory surfaces within vehicles. Versatile
waterborne lamination adhesives allow for increased design
freedom and complex part geometries, it adds.
BASF recently disclosed results from the comprehensive
lifecycle assessment (LCA) of its synthetic leather solution,
Haptex. The LCA was based on a total value chain analysis of
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Basecoat application.
Haptex from its chemical production to the finished leather
goods. Factors such as cumulative energy demand and water
consumption figures were measured.
BASF says Haptex outperformed synthetic leathers from
solvent-based and waterborne-based synthetic leather
processes, in terms of carbon emissions. For instance, Haptex
was proven to produce 52 percent less greenhouse gas emissions
than conventional synthetic leather, with more than a 20 percent
reduction in energy consumption when using one kilogram of
chemicals for synthetic leather production. This is predominantly
due to eliminating the wet line from the production processes,
which reduces 30 percent of water usage compared to usual
solvent-based polyurethane production methods.
BASF says the results prove Haptex is a more sustainable
alternative for products made with synthetic leather, such as
automotive seating.
Haptex is a polyurethane solution for synthetic leather
production, which the company says possesses high peel strength,
anti-yellowing, and high abrasion performance properties.
Haptex also does not use any organotin catalysts or plasticizer.
" The report comes at a time when pressure mounts on brands
and OEMs to make stronger efforts toward sustainability
by choosing alternative and animal-free leather for their
products, " says Minli Zhao, Vice President, Consumer Industry,
Performance Materials Asia Pacific, BASF. " Therefore, we must
provide concrete information on environmental emissions and
how we are reducing the CO2 footprint to our customers. With
this study, Haptex has proven that it is more sustainable compared
to other conventional synthetic leather solutions, and at the same
time can fulfill the different conventional requirements from
OEMs and brands to produce products that are durable, stylish
and eco-conscious. "
PROCESS EFFICIENCY
We've come a long way from the invention of the assembly line,
but efficiency remains at the forefront of every smart business
plan. Process improvements such as the ability to paint all
substrates on one line, regardless of temperature sensitivity, and
increased cost savings per part through enable a faster and more
affordable production for automotive manufacturers, Covestro
says. Strides in process efficiency allow OEMs to reduce scrap
rate, hold less inventory, achieve a smaller footprint, and simplify
with fewer steps.
Low-temperature cure materials are one way Covestro looks
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Canadian Finishing & Coatings Manufacturing Magazine November/December 2021

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