Thermoset composite SMC for on-line painting of Automotive … · 2013-11-29 · 5 Transportation Weight Loss Diet Conference 2013, Stuttgart •Created in 2011, mergure composite

1

Thermoset composite SMC for

on-line painting of Automotive

Body Panels

Transportation Weight Loss Diet Conference 2013 , Stuttgart

Speakers :

Marie-Laure GUEGAN, R&D Manager, IDI Composites Europe

Guillaume CLEDAT, SMC Key market developer, CCP Composites

2

Outline of the presentation

Painting Process

SMC Supply Chain

SMC Thermoset Composite

E-coating SMC Grade development

Commercialization


3

Painting Process

Molder / Automotive TIER 1 OEM

Off-line Painting of SMC Parts:

Molding Class A SMC

Primer Step Painting Assembly

Molder / TIER 1 OEM

SMC e-coating Process :

Molding SMC e-coating

Assembly

Cataphoresis

Painting


4

Supply Chain

Raw materials and

equipments

manufacturers

Compounders Molders / TIER 1

suppliers OEMs

Glass fibers

Peroxides &

additives

Resins and

additives

Conversion Automotive

Truck, Bus

Agriculture

equipments

SMC formulation


5 Transportation Weight Loss Diet Conference 2013 , Stuttgart

•Created in 2011, mergure composite materials activities of Cray Valley,

CCP and Progress Plastics

•A company of Total group

•Unsaturated polyester and vinylester resin, low profile additive, gel coat

and bonding paste manufacturer

•950 employees 550 M $ turnover (2011)

•19 production sites on 4 continents

•10 % of staff dedicated to R&D and technical assistance

CCP Composites

Sao Paulo, Brazil

UPR, Gel Coats

Jeonju, South Korea

UPR, GelCoats, SMC, BMC, VE

Pasir Gudang, Malaysia

UPR, Gel Coats

Melbourne, Australia

Blend UPR ,Gel Coats

Stallingborough UK

UPR, Gel Coats

: CCP Plant

: Center of competence

Mississauga & Drummondville, Canada

Blend UPR , Gel Coats

Miranda Spain

UPR, Gel Coats

Drocourt, France

UPR, GelCoats, VE

Joinville & Caxias, Brazil

Gel Coats

USA 7 plants

UPR, Gel Coats

Boretto, Italy

Gel Coats

: Tolling/Operating Plant

Sao Paulo, Brazil

UPR, Gel Coats

Jeonju, South Korea



UPR, Gel Coats



Stallingborough UK

UPR, Gel Coats

: CCP Plant

: Center of competence

Mississauga & Drummondville, Canada

Blend UPR , Gel Coats

Miranda Spain

UPR, Gel Coats

Drocourt, France

UPR, GelCoats, VE


Gel Coats

USA 7 plants

UPR, Gel Coats

Boretto, Italy

Gel Coats


Sao Paulo, Brazil

UPR, Gel Coats

Jeonju, South Korea



UPR, Gel Coats



Stallingborough UK

UPR, Gel Coats

: CCP Plant

Miranda Spain

UPR, Gel Coats

Drocourt, France

UPR, GelCoats, VE


Gel Coats

Boretto, Italy

Gel Coats


Sao Paulo, Brazil

UPR, Gel Coats

Jeonju, South Korea



UPR, Gel Coats



Stallingborough UK

UPR, Gel Coats

: CCP Plant

Miranda Spain

UPR, Gel Coats

Drocourt, France

UPR, GelCoats, VE


Gel Coats

Boretto, Italy

Gel Coats



FRANCE Vineuil (41) (SMC/BMC/CIC/MMC)

IDI Composites Europe

Privately held family company with 6 independent facilities,

Global formulator of thermoset composites (SMC, BMC)

oriented to customers needs,

High Performance oriented product lines with product and

customer diversification,

Experienced management teams,

Unmatched capabilities with over 40 years experience

IDI Industrial Dielectrics, Inc.

IDI Composites International

7

General characteristics of SMC and BMC

Two main kinds of thermoset composite compounds :

SMC « Sheet moulding compound »

Compression molding, larger parts, longer glass fiber (25mm

and longer)

BMC « Bulk moulding compound »

Injection molding, smaller parts, complex parts, shorter glass

fiber, lower glass content (about 15 / 20%)

Typical composition and main properties:

Density : 1.3 to 2

Service temperature : - 30 to +200°C

Flexural strength : 120 to 625 MPa

Tensile strength : 65 to 440 MPa

Design

Recyclable

Glass fiber

Mineral

fillers

UP resin

LP additives


8 SIA / SFIP – Douai – 13/06/12 8 SFIP – Douai – 13/06/12 8

Production / Molding - SMC

Assemble

Painting


9

Main barriers to on-line painting were identified, five development

directions were followed up to achieve the required performances

Paint curing @ 200°C Resin chemistry

Higher thermal

stability

Painting process

« paint popping » issue Residual styrene

Minimization

Sealed surface

material

Curing

catalysis

Shrinkage control

Molding process

monitoring Material control

Conductivity SMC formulation

optimization Compatibility

with e-coating

Main barriers to on-line painting


10

Low profile or low shrink additives

Material microstructure

Optimization:

VOC emissions

Residual monomer migration

Release agent migration

Much improved paint surface quality

versus SMC cosmetic surface

properties MEB picture of cured UP resin with

PVAc (1) or PS (2) based additives

(1)

(2)

Shrinkage control mechanism

1

2


11

Thermal stability - TGA

Weight loss monitoring based on Thermal Gravimetry Analyzer

allows to simulate material behavior through the painting

process

Rise plateau total

Without 0,9 0,4 1,3

With 0,5 0,3 0,8

Without 0,6 0,4 0,9

With 0,4 0,2 0,6

Class A standard SMC

formulation

TGA (Weigth loss %)Initial cataphoris

simulation

- 35min @185°C

e-coating SMC Formulation


12

VOC Emissions – VDA 278

Reduction of organic compound emissions

Molding conditions : 120 sec @ 160/165°C / 2min

632

51

15

0

Standard class A

SMC formulation e-coating SMC

formulation


13

Solvent uptake

SMC solvent uptake after a

two hour contact

in a Maduri / Amocco test device

Solvent :

Butyl acetate / Xylene blend (60/40)

Maduri test

0,52%

0,11%

0,17%

0,34%

0,00%

0,10%

0,20%

0,30%

0,40%

0,50%

0,60%

% p

rise e

n m

asse

+cataphoresis simulation -35 min @ 185°C

Standard class A

SMC formulation e-coating SMC

formulation

Stainless

steel plate

Glass cell

Solvant

O-ring Coupon


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Painting process - Heuliez

Stage 1 : Cataphoresis line

10 min @ 160°C


Stage 2 : e-coating

Degreassing

Wiping

Primer : 30 to 35 µm thick

Curing : 20’ @ 150/160°C

Surface correction

Blowing

Wiping

Color base : 15 to 20 µm thick

Clear coat : 25 to 30 µm thick

Curing : 20’ @ 150/160°C

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Painting process - Heuliez

Primer

Base

+ clear coat

TEM analysis – Thickness

measurements

SMC


16

Failure mode analysis 1/3

Failure analysis of painted parts based on SEM and EDX

cartography

Painting failure

– agglomeration

Failure due to TIO2 agglomeration in the primer layer

SEM/EDX Analysis

IUT Blois – TOURS University


17



cartography

SMC failure – Cracks

SEM/EDX Analysis

IUT Blois - TOURS University


18



cartography

Handling issue

Cl- : NaCl - Sweat

Analyse MEB/EDX: LP additive

supplier Transportation Weight Loss Diet Conference 2013 , Stuttgart

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Surface smoothness

Improvement of edges

(poping suppression)

and

Long wave surface distortion

thanks to molding conditions

optimization

Surface smoothness measured

with BYK Wave Scan system

Byk Wave Scan LW SW DOI

Target LW < 8 10 <SW< 30 > 82

Std SMC + IMC 4,4 17,5 81,2

e-coating SMC 5,3 27,8 82,0


20

Commercialization

SMC e-coating :

March 2011 Serial Production,

Volume 155T 75.000 parts annually

Applications

Peugeot 807 Citroen C8


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Conclusion

Development of SMC e-coating

No cross contamination of the cataphoreses process between

metal and SMC parts

Conductive Material allows for electrostatic Painting Process

Compatible with metal high temperature painting process

Design flexibility of molded parts

Reduced part weight, for lighter vehicle weight over metal

Commercialization and on-line Painting

Reduced scrap rates and improved cycle time due to simplified

paint process

Colors Management

Reduced part costs to OEM's through improved processing,

improved cure, and reduced scrap



Contacts

IDI Composites Europe www.idicomposites.com

Marie-Laure GUEGAN

R&D manager

[email protected]

+ 33 (0) 685 037 918

Josy MANTET-GAY

Sales director

[email protected]

+ 33 (0) 630 552 457

CCP Composites www.ccpcomposites.com

Guillaume CLEDAT

SMC Key market developer

[email protected]

+ 33 (0) 680 11 29 28

Laurence MARECHAL

Marketing Director

[email protected]

+ 33 (0) 618 87 28 47

http://www.idicomposites.com/

mailto:[email protected]






http://www.ccpcomposites.com/



Documents

Thermoset composite SMC for on-line painting of Automotive … · 2013-11-29 · 5 Transportation Weight Loss Diet Conference 2013, Stuttgart •Created in 2011, mergure composite