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▷ C.R.I
▷ Automotive Coatings Technology
Index
1
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Central Research Institute
History
C.R.I. View
C.R.I Development Item
2
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Central Research Institute Vision
" Value creation through R&D technology innovation"
3
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CRI History
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
4
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Area : 16,000m2 (Research Building Area : 8,000m2)
Pilot : 5 buildings
Dormitory : 2 Places / Gymnasium : 1 Places
Human Resource Center : 1 buildings
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Major Research Area
1950s
1970s
1990s
2000s
2010s
: 356 researchers
( November. 2010)
Building System
Glass
Building material
(Floor,PVC Door)
Silicone
Material
Coupling agent / Oil /
Emulsion
Grease / Rubber / RTV
Inorganic Material
Fine ceramic
Ceramic composite
Metal composite
Organic material
Special functional Resin
Epoxy Resin
UV curing Resin
Special Functional Material
Electronic Materials
(EMC / Adhesive / Film)
Renewable Material
(Solar Cell / Polysilicon)
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Organic Material Research Items
Heavy-duty
Protective Coatings
Industrial
Materials
Automotive Paints
EMC / Electronic
Materials
Paints
Display Materials
DGU
Industrial Paints
Powder Coatings
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Inorganic Material Research Items
Ceramic Materials
for Electronics
Gypsum Board
Silicon Metal
Ceiling Panels
Fuel Cell
Ceramic Fiber
Window Profile
Glass
System
Decorative Floor
Materials
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AUTOMOTIVE COATING
TECHNOLOGY
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KCC‘s OEM Paint Driving Forces
Process
Consolidation
Ultra low cost
Appearance, Color
Scratch, Durability
Environmental
protection
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Automotive coating Driving Forces
Lower Cost
Consistent
Quality
Environment
Driving
Forces
Class
Distinctions
( Mini -> Luxury)
Higher Quality
Growth in Asia
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Valuable Proposal for Customer
Continuously Creative Support for Customer, Worldwide
Meet the
Global
environment
Continuous
Developing
technology
Provide
Low coat Idea
Excellent
Color Design &
Style
Superior
Appearance
& Durability
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PRIMER SURFACER
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 Customer Needs & Trends for Primer Surfacer
Chipping
Smooth
Surface
Waterborne
High
Solid
Compact
System
Low cost
Market Needs
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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
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 Primer Surfacer characters
Solvent primer polyurethane
• Good Chipping, Leveling
• Low Coat
• Multi color
• High VOC
• Hyundai (Korea, China, Russia, India..)
Kia (Korea, China)
Powder
Waterborne polyurethane
•
•
•
•
•
•
Good Chipping, Leveling
Low Coat
Multi Color
Low Bake
Low VOC
Hyundai China, Kia China
Primer Surfacer
•
•
•
•
•
•
Good Chipping
Lowest VOC
High Film build Cost
High Bake
Limited Color Change
PSA, GM, Chrysler
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 Comparisons of Each System
Attribute
SB Primer
WB Primer
(140°C)
WB Primer
Surfacer
Powder
Primer
Stonechip
STD
O
O
+
Appearance
STD
O
-
+
Application
STD
O/-
-
O
STD
+
+
++
Color Capability
STD
O
O/+
--
Baking Requirements
STD
+
+
O/-
Recycling Potential
STD
+
+
++
Material Cost
STD
-/O
-
-/O
Invest
STD
-
-
--
VOC’s
* Rating : ++ > + > STD = O > - > -19
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BASECOAT
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 Customer Needs & Trends for Basecoat
New
Color
Extension
Waterborne
Basecoat
Wide
Application
Window
Low coat
Compatibility
Of
Variety C/C
Market Needs
Compact
System
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 Basecoat Technology Roadmap
High
Performance
3 Wet
EcoConcept
Global Waterborne Basecoat (High solid, LCCC)
Solventborne Medium Solid /High Solid Basecoat
Waterborne Basecoat (Old)
2007
2010
2015
Current
Future
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Product Profile Basecoat
Market needs, areas of differentiation
 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 
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CLEARCOAT
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 Customer Needs & Trends for Clearcoat
Anti Scratch
Appearance
Wide
Workability
Low
Bake
Decrease
M/S
Increase
H/S
Market Needs
Decrease
Powder
coating
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 Clear coat Technology Roadmap
High
Performance
Easy to Clean
Self healing Clear (2K,1K)
High Performance Scratch C/C (1K,2K)
Improved Appearance (1K, 2K)
2007
2010
2015
Current
Future
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Product Profile Clearcoat
Market needs, areas of differentiation
 „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
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 Scratch reflow Clearcoat
Scratch damaged
After 1week
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 Self Healing Process
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 Self Cleaning Clearcoat
 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
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 Maintenance Free (Suggested idea)
● Pollutant : Hydrophobic material
Water insoluble pollutant material
Conventional
CC
Water soluble material
Coating
Self Cleaning
CC (lotus leaf effect)
H2O
OH
H2O
OH
H2O
OH
Ｓｉ
H2O
OH
Ｓｉ
O
O
H
Y
D
R
O
P
H
O
B
I
C
H
Y
D
R
O
P
H
I
L
I
C
Drop of rain
Rolling down
Water insoluble and soluble material can be washed out
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 Comparison of Clearcoat
Clear Coat
EtchResistance
MarResistance
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
+++
O
WB
+
medium
+
+++
US WB
+
high
PE/AC/SCA HDI
++
++
WB
++
medium
PE/SCA HDI/IPDI 1:2
+++
-
WB
+
medium/high
Powder
+++
0
WB
+++
medium
Epoxy Acid
Oligomer HS / SHS
* Rate : +++ > ++ > + > O > 32
<32>
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 KCC products
Coating Process
P / Code
DFT (㎛)
Baking Condition
Conventional
FU2240, FU2260
30-40
150℃×20mins
Low Bake
FU2290, FU2245
30-40
140℃×20mins
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
Medium Solid
TT6100, TT6200
35-45
150℃×20mins
TT6830, UT7000, UT6042
35-45
145℃×20mins
3C1B
WU3090
30-40
150℃×20mins
Conventional -1
WT3060
15-20
150℃×20mins
Conventional -2
WT3069
10-20
150℃×20mins
3C1B
WT3090
30-40
150℃×20mins
2C1B
TT6830, TT6831,UT6041
30-40
145℃×20mins
3C1B
UT6090
30-40
150℃×20mins
Surfacer
Solvent
Borne
Basecoat
Clearcoat
Surfacer
Water
Borne
Basecoat
Clearcoat
High Solid
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CONSOLIDATION PROCESS
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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
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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
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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
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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Film Builds for Integrated waterborne Processes
120
110
Film Thickness, µm
100
1K or 2K
Clearcoat
40 µm
90
1K or 2K
Clearcoat
40 µm
1K or 2K
Clearcoat
40 µm
80
70
60
Solid
WBBC
25 µm bell
Metallic WBBC
7 µm air
7 µm bell
2K
Clearcoat
40 µm
2K
Clearcoat
40 µm
2K
Clearcoat
40 µm
50
40
Metallic WBBC
7 µm bell
7 µm bell
Primer Surfacer
35 µm
30
20
10
Solid
WBBC
25 µm bell
1K or 2K
Clearcoat
40 µm
CED
20 µm
Solid
2K WBBC
25 µm bell
Metallic WBBC
6 µm air
Metallic
2K WBBC
15 µm bell
1K WBBC
2
15 µm bell
1K WBBC 1
15 µm bell
CED
20 µm
CED
20 µm
2K EcoConcept
1K EcoConcept
Primer Surfacer
25 µm
CED
20 µm
0
Traditional WB
3-Wet WB
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Integrated Processes - Descriptions
Traditional baked primer, waterborne system
Primer
1/2 coats
Bake
Primer
Sand
Booth
BC2
BC
12coat
coats
Heated
flash
CC – 1K or 2K
2 coats
Bake
Integrated system – Non-compressed
3-Wet
BC1/Primer
1 coat
Heated
flash
BC2
BC2
coat
21coats
Heated
flash
CC – 1K or 2K
1 coat
Bake
Integrated waterborne system – Compressed
EcoConcept
BC-2K
1 coat
BC BC2
1 coat
1 coat
Heated
flash
2K CC
1 coat
Bake
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41
Non-Compressed Process – 3-Wet w/b
Non-Compressed Processes
Heated
BC1/Primer
1 coat
flash
BC2
1BC2
coat
2 coats
Bake
Heated
flash
CC – 1K or 2K
1-2 coats
 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)
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Non-Compressed Process – 3-Wet Advantages
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)
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Compressed Process - EcoConcept
Compressed Processes
BC-2K
1 coat
BC BC2
1 coat
1 coat
Heated
flash
2K CC
1 coat
Bake
 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
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Compressed Process – EcoConcept Advantages
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)
45
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Energy Consumption in Paintshop (www.durr.com)
46
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Lifecycle Analysis for Consolidated Systems
4500
22 % less energy
4000
Primary Energy MJ/car
3500
3000
Use Phase
Finish, Repair
Clearcoat
Basecoat
Primer
2500
2000
1500
1000
500
0
w/b Standard
47
3 wet w/b
EcoConcept
47
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Total Cost of Paintshop
US $ / car
300
$ 282
$ 268 (- $14)
$ 247(- $35)
10
9
250
53
48
8
40
200
66
59
56
150
67
64
53
86
88
90
Standard
3 wet
EcoConcept
100
50
Indirect Matls
Energy
Labor
Capital
Paint
0
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Global Use of Consolidated Paint Processes
3C2B
MS-SB
3C2B
HS-SB
3C1B
MS-SB
3C1B
HS-SB
3C2B
WB
3C1B
WB
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)
2009
2012
Cars/a
>20Mio
>20Mio
4 Mio
4 Mio
1 Mio
1 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
52
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▷ Bus & Truck
Commercial Car
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COMPARISON OF CHARACIERISTICS
Surfacer
Item
Urethane Modified polyester
/ Melamine
Urethane Modified polyester
/ Low MW polyester
/ Urethane / Melamine
Wet on Wet for
Urethane Modified
Polyester/Melamine
Characteristics
Good physical properties
Excellent Appearance
Cost High
Saving
Process cost
P/CODE
FU2240
FU2290
FU2241
Car Model
of application
STAREX,
PORTER
TRAJET,
TRUCK
BUS
BUS
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COMPARISON OF CHARACIERISTICS
Top Basecoat
Item
Medium
Solid
Medium
Solid
Primer less
Semi High
Solid
Characteristics
Conventional
(1C1B)
Excellent
Appearance
(1C1B)
Saving
Process cost
(1C1B)
Workability
Mottles
(With Clear)
P/CODE
TT662(X)
TT6620
TT6621
TT6631
Car Model
of application
STAREX,
TRUCK,
BUS
TRUCK
TRAJET,
STAREX,TRUCK
TUSON,
TERRACAN
TRUCK,
BUS
55
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COMPARISON OF CHARACIERISTICS
Top Clearcoat
Item
Conventional
Functional-A
Functional-B
High solid
Characteristics
Conventional
Chemical resistance
Scratch resistance
Durability
For Water borne
Chmical resistance
Scratch resistance
Durability
Low VOC
Chmical resistance
Scratch resistance
Durability
P/CODE
TT6200
TT6100
UT6030
TT6830
Car Model
of application
Passenger
Car
TRUCK,
BUS
Passenger
Car
Passenger
Car
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Wet on Wet System for Truck & Bus
Traditional baking system
Bake
Primer
Bake
Primer
Sand
Booth
1K / 2K
Wet on Wet System
Bake
CED
FU2241
Primer
TT6620
Top coat
Bake
■ ‘2007. HMC Jeonju Plant Launched
57
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Primer less for Truck & Bus
Traditional baking system
Bake
Primer
Bake
Primer
Sand
Booth
1K / 2K
Primer less System
Bake
CED
TT 6621
Bake
■ November. 2010. HMC Jeonju Plant Launched
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RECOMMENDABLE COATING SYSTEM FOR TRUCK
Baking System
ITEM
COATING
SYSTEM
SURFACER
TOP COAT
1C1B
BASE COAT
PRODUCT
THINNER
D.F.T(㎛)
(Film Thickness)
DRYING
CONDITION
FU2240-GREY(P)
029S
30~40
150℃*20 MIN
(MPT)
TT6621
(Primer less)
062 /
TH0254(N)
30~40
140℃*20 MIN
(MPT)
TT6631
TH0355
15~20
TT6100
UT6042
063 /
TH0254(N)
30~40
2C1B
CLEAR COAT
140℃*20 MIN
150℃*20 MIN
(MPT)
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RECOMMENDABLE COATING SYSTEM FOR TRUCK
Baking System
ITEM
COATING
SYSTEM
PRODUCT
THINNER
D.F.T(㎛)
(Film Thickness)
DRYING
CONDITION
Wet on Wet
FU2241-GREY
029S
20~25
150℃*10 MIN
(MPT)
1C1B
FU2290-GREY
TH0254(N)
30~40
150℃*10 MIN
(MPT)
1C1B
TT6620
062 /
TH0254(N)
30~40
150℃*20 MIN
(MPT)
TT6631
TH0355
15~20
TT6100
TT6200
UT6042
063 /
TH0254(N)
30~40
SURFACER
TOP COAT
BASE COAT
2C1B
CLEAR COAT
140℃*20 MIN
150℃*20 MIN
(MPT)
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COATING SYSTEM FOR TRUCK & BUS
Urethane System
ITEM
PRODUCT
HARDNER
THINNER
RATIO
(V%)
MIXED
VIS(sec)
(Base : Hardener)
(at PaintTemp.)
D.F.T(㎛)
(Film Thickness)
DRYING
CONDITION
WASH
PRIMER
VP134-D/GREEN
934C.A
053
4:1
13~15
7~13
EPOXY
PRIMER
EP330PTA-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 COAT
PRIMECOAT
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 metal,
groove of damaged parts
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THANK YOU
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