How do Anti-Friction Coatings based on Binder Systems eliminate noise in automotive interiors?

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Information about How do Anti-Friction Coatings based on Binder Systems eliminate noise in...

Published on January 12, 2016

Author: molykotetl

Source: slideshare.net

1. Applications of Anti- Friction Coatings based on Binder Systems Manfred Jungk - Vittorio Clerici January 12th 2016

2. 2 Introduction • Modern passenger cars are equipped with sophisticated measures to avoid propagation of noise from the engine and gearboxes into the passenger compartment • This creates a very comfortable environment for car occupants • On the other hand, this enables “new noises” to become audible – particularly those generated by the sliding of plastic components made of thermoplastics having poor affinity under the tribological aspect 2016 All Rights reserved

3. 3 Examples of noise development from the field • Door panel sliding against clear coat/paint – Show video • Armrest sliding against door panel insert – Show video 2016 All Rights reserved

4. 4 Proven solution • Apply a surface treatment to the tribological contact areas of the mating parts generating noise or in suspect of producing it Application of a dry-film lubricant = anti-friction coating SOLUTION 2016 All Rights reserved

5. 5 Product requirement profile • Noise elimination for a wide array of material combinations used in interiors • Friction reduction of mating surfaces; more important constancy of a defined level (no stick-slip formation) • Service life performance • Good adhesion to plastic materials • Compatibility with plastic materials (stress cracking) • Transparent • Water-based • Air-curing (max drying temperature = 60°C) • Easy industrialization – easy integration of application in existing production processes/lines 2016 All Rights reserved

6. 6 Technology description • Anti-Friction coating: – Organic binder system – Solid lubricants – Solvent = water wet film substrate Drying & curing dry film = 10/12 µm substrate Solvent (water) 2016 All Rights reserved

7. 7 Anti-noise tester – overview Sliding guide Specimen holder with strain gages for friction force and load measurement and with acceleration detector for stick-slip measurement Stick-slip intermittent movement 2016 All Rights reserved

8. 8 Anti-noise performance – report example PRODUCT Material pairing Paint vs. PVC foam 2.5 mm black No AFC Anti-Friction Coating Anti-Friction Coating variation Load [N] Characteristic 5 BI [noise rating] 8.5 8.5 RPN [risk priority number] 1 1 COF static [µ] 0.64 0.47 COF dynamic [µ] 0.35 0.24 Max. acceleration [g] 0.07 0.06 Impulse frequency [1/mm] 0.00 0 Impulse count 0 0 10 BI [noise rating] 8.5 8.5 RPN [risk priority number] 1 1 COF static [µ] 0.47 0.37 COF dynamic [µ] 0.29 0.21 Max. acceleration [g] 0.06 0.06 Impulse frequency [1/mm] 0.00 0 Impulse count 0 0 20 BI [noise rating] 4.0 8.1 8.5 RPN [risk priority number] 10 1 1 COF static [µ] 1.43 0.36 0.3 COF dynamic [µ] 0.92 0.25 0.18 Max. acceleration [g] 4.53 0.07 0.06 Impulse frequency [1/mm] 1.86 0.00 0 Impulse count 17 0 0 30 BI [noise rating] 8.5 8.5 RPN [risk priority number] 1 1 COF static [µ] 0.31 0.26 COF dynamic [µ] 0.22 0.17 Max. acceleration [g] 0.06 0.06 Impulse frequency [1/mm] 0.00 0 Impulse count 0 0 SHORT TEST – RT VDA 230-206 2016 All Rights reserved

9. 9 Anti-noise performance (short test, RT) SHORT TEST ACCORDING TO VDA 230-206 PRODUCT Material pairing Material pairing Anti-Friction Coating Anti-Friction Coating variation Paint PVC 1 mm PVC 1 mm PVC 1 mm Paint PVC 2.5 mm beige Paint PVC 2.5 mm black Paint TPO 1 mm Paint Leather black Leather black Leather black PC-ABS Leather black PC-ABS PVC 1 mm Green = very suitable 2016 All Rights reserved

10. 10 Anti-noise performance (short test, climatic cond.) Paint FF99-0141 PVC 1 mm Paint ApO Leather PVC 1 mm PVC 1 mm PVC 1 mm Leather Leather PC-ABS Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating Anti-Friction Coating Load [N] Climatic conditions Max. acc. [g] µ max. Max. acc. [g] µ max. Max. acc. [g] µ max. Max. acc. [g] µ max. Max. acc. [g] µ max. 5 23°C – 50% 0.0 0.2 0.0 0.2 0.0 - 0.0 0.8 0.0 0.5 40°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.8 0.0 0.6 80°C – 30% 0.0 0.5 0.0 0.1 0.0 - 0.0 0.8 0.1 0.6 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.7 0.0 0.6 10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.5 -30 °C 0.1 0.1 0.1 0.1 0.0 - 0.1 0.1 0.0 0.1 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.5 10 23°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.0 0.4 0.0 0.3 40°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.4 0.0 0.3 80°C – 30% 0.0 0.5 0.0 0.1 0.0 - 0.0 0.4 0.0 0.3 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.4 0.0 0.3 10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.3 -30 °C 0.0 0.1 0.0 0.1 0.0 - 0.1 0.1 0.0 0.1 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.3 20 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.3 0.0 0.2 40°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.1 0.3 0.0 0.2 80°C – 30% 0.1 0.4 0.0 0.1 0.0 - 0.0 0.3 0.0 0.2 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.2 0.0 0.2 10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2 -30 °C 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2 30 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.2 0.0 0.2 40°C – 50% 0.0 0.2 0.0 0.1 0.0 - 0.1 0.2 0.0 0.2 80°C – 30% 0.0 0.4 0.0 0.1 0.0 - 0.0 0.2 0.0 0.2 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.1 0.2 0.0 0.1 10°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1 -30 °C 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.1 23°C – 50% 0.0 0.1 0.0 0.1 0.0 - 0.0 0.1 0.0 0.2 SHORT TEST VDA 230-206 2016 All Rights reserved

11. 11 Anti-noise performance (durability test, RT) DURABILITY TEST BASED ON PARAMETERS OF VDA-230-206 PRODUCT Material pairing Material pairing Anti-Friction Coating Anti-Friction Coating variation Paint PVC 1 mm PVC 1 mm PVC 1 mm Paint PVC 2.5 mm beige Paint PVC 2.5 mm black Paint TPO 1 mm Paint Leather black Leather black Leather black PC-ABS Leather black PC-ABS PVC 1 mm 100K cycles 100K cycles 10,000 cycles or as indicated Green = very suitable 2016 All Rights reserved

12. 12 PRODUCT Material pairing PC-ABS vs. PVC foam 1 mm No AFC Anti-Friction Coating Anti-Friction Coating variation Cycles Characteristic 0-2,500/0-5,000 BI [noise rating] 4.0 8.5 8.5 RPN [risk priority number] 10 1 1 COF static [µ] 1.33 0.30 0.23 COF dynamic [µ] 0.97 0.14 0.16 Max. acceleration [g] 6.2 0.23 0.06 Impulse frequency [1/mm] 18.2 0.00 0.00 Impulse count 168 0 0 2,500-5,000/0-5,000 BI [noise rating] No need 8.5 8.5 RPN [risk priority number] 1 1 COF static [µ] 0.28 0.22 COF dynamic [µ] 0.12 0.15 Max. acceleration [g] 0.46 0.07 Impulse frequency [1/mm] 0.00 0.00 Impulse count 0 0 95,000-100,000 BI [noise rating] No need 8.5 8.5 RPN [risk priority number] 1 1 COF static [µ] 0.24 0.19 COF dynamic [µ] 0.12 0.13 Max. acceleration [g] 0.13 0.05 Impulse frequency [1/mm] 0.00 0.00 Impulse count 0 0 Anti-noise performance (100K cycle durability test) – PC-ABS vs. PVC foam foil 1 mm thick DURABILITY TEST 2016 All Rights reserved

13. 13 Anti-noise performance (100K cycle durability test) – PC-ABS vs. PVC foam foil 1 mm thick PVC 1 mm foil uncoated Before durability test No wear, no adhesion loss After 100,000 cycle durability test 2016 All Rights reserved

14. 14 Modified anti-noise testing setup • Instead of the common plastic holder for the foil material, a cut-out section of the door panel edge is fixed in the testing machine • Higher flexibility between machine holder and tribological contact enhances the sensitivity to stick-slip formation • Setup more similar to real application 2016 All Rights reserved

15. 15 DOOR PANEL SECTION PRODUCT Material pairing Paint vs. PVC foam 1 mm No AFC Anti-Friction Coating Cycles Characteristic 0-5,000 BI [noise rating] 4.0 8.5 RPZ [risk priority number] 10 1 COF static [µ] 1.16 0.75 COF dynamic [µ] 0.72 0.47 Max. acceleration [g] 1.49 0.06 Impulse frequency [1/mm] 1.00 0.00 Impulse count 9 0 5,000-10,000 BI [noise rating] Noneed 8.5 RPZ [risk priority number] 1 COF static [µ] 0.73 COF dynamic [µ] 0.45 Max. acceleration [g] 0.06 Impulse frequency [1/mm] 0.00 Impulse count 0 Paint vs. PVC 1 mm foil – panel section DURABILITY TEST LOAD = 20 N 2016 All Rights reserved

16. 16 Paint vs. PVC 1 mm foil – panel section – no AFC Video – no AFC 2016 All Rights reserved

17. 17 Paint vs. PVC 1 mm foil – panel section – Anti-Friction Coating Video – AFC 2016 All Rights reserved

18. 18 DOOR PANEL SECTION PRODUCT Material pairing PC-ABS vs. PVC foam 1 mm No AFC Anti-Friction Coating Cycles Characteristic 0-5,000 BI [noise rating] 4.0 8.5 RPZ [risk priority number] 10 1 COF static [µ] 1.21 0.78 COF dynamic [µ] 0.66 0.44 Max. acceleration [g] 13.42 0.10 Impulse frequency [1/mm] 39.90 0.00 Impulse count 366 0 5,000-10,000 BI [noise rating] Noneed 8.5 RPZ [risk priority number] 1 COF static [µ] 0.87 COF dynamic [µ] 0.50 Max. acceleration [g] 0.19 Impulse frequency [1/mm] 0.00 Impulse count 0 PC-ABS vs. PVC 1 mm foil – panel section DURABILITY TEST LOAD = 20 N 2016 All Rights reserved

19. 19 PC-ABS vs. PVC 1 mm foil – panel section – no AFC Video – no AFC 2016 All Rights reserved

20. 20 PC-ABS vs. PVC 1 mm foil – panel section – Anti-Friction Coating Video – AFC 2016 All Rights reserved

21. 21 Customized versions • Depending on the application (part) and substrate material and/or color, the dry film of the applied anti-friction coating may not be easily detectable (transparency) • Black pigments and/or UV tracers can be added to the basic formulation without infringing on the physical properties and anti-noise performance 2016 All Rights reserved

22. 22 Customized version – aspect 2016 All Rights reserved Anti-Friction Coating Black version Anti-Friction Coating UV version

23. 23 PRODUCT Material pairing Paint vs. PVC foam 1 mm Anti-Friction Coating (black) Anti-Friction Coating (UV) Cycles Characteristic 0-5,000 BI [noise rating] 8.5 8.5 RPZ [risk priority number] 1 1 COF static [µ] 0.36 0.35 COF dynamic [µ] 0.22 0.22 Max. acceleration [g] 0.08 0.07 Impulse frequency [1/mm] 0.00 0.00 Impulse count 0 0 5,000-10,000 BI [noise rating] 8.5 8.5 RPZ [risk priority number] 1 1 COF static [µ] 0.26 0.27 COF dynamic [µ] 0.19 0.20 Max. acceleration [g] 0.08 0.07 Impulse frequency [1/mm] 0.00 0.00 Impulse count 0 0 Anti-noise data – paint vs. PVC 1 mm foil DURABILITY TEST LOAD = 20 N 2016 All Rights reserved

24. 24 PRODUCT Material pairing PC-ABS vs. PVC foam 1 mm No AFC Anti-Friction Coating (black) Anti-Friction Coating (UV) Cycles Characteristic 0-5,000 BI [noise rating] 4.0 8.5 8.5 RPZ [risk priority number] 10 1 1 COF static [µ] 1.33 0.28 0.27 COF dynamic [µ] 0.97 0.15 0.15 Max. acceleration [g] 6.2 0.06 0.07 Impulse frequency [1/mm] 18.2 0.00 0.00 Impulse count 168 0 0 5,000/10,000 BI [noise rating] No need 8.5 8.5 RPZ [risk priority number] 1 1 COF static [µ] 0.26 0.18 COF dynamic [µ] 0.13 0.12 Max. acceleration [g] 0.07 0.07 Impulse frequency [1/mm] 0.00 0.00 Impulse count 0 0 Anti-noise data – PVC 1 mm foil vs. PC-ABS DURABILITY TEST LOAD = 20 N 2016 All Rights reserved

25. 25 Temperature resistance - COF • Application of the AFC on metal Q-Panels • After curing at proper conditions: conditioning of the coated Q- Panels under following conditions: – RT as reference – 4 h @ -40°C – 4 h @ 100°C – 4 h @ 150°C – 4 h @ 200°C • After conditioning the following tests were carried out: – Bending and cross-cut – COF evaluation on oscillating polymer tester 0.000 0.050 0.100 0.150 0.200 0.250 0.300 none 4 h @ - 40°C 4 h @ 100°C 4 h @ 150°C 4 h @ 200°C COF dyn COF static 2016 All Rights reserved

26. 26 Ball/plate oscillating test machine Test conditions: Substrate = AFC coated Q-Panel Ball = POM Load = 2 N Speed = 1 cm/s Time = 1 and/or 8 h Room temperature (23°C) and 40% rel. humidity COF = mean coefficient of friction measured during test 2016 All Rights reserved

27. 27 Temperature resistance – bending test after 4 h @ -40°C after 4 h @ 100°C after 4 h @ 150°C after 4 h @ 200°C No peeling no cracks formation ASTM-D 1737 2016 All Rights reserved

28. 28 Temperature resistance – cross-cut test after 4 h @ -40°C after 4 h @ 100°C after 4 h @ 150°C after 4 h @ 200°C No peeling no cracks formation ASTM-D 3359B 2016 All Rights reserved

29. 29 Summary • Anti-friction coatings are a proven solution that can provide the following advantages for automotive interior components: – Excellent anti-squeak characteristics – Long-term noise protection – Low coefficient of friction – Transparent; water-based – Compatible with typical plastic materials used in interiors – Easy to integrate into existing production lines 2016 All Rights reserved

30. 30 The information contained in this communication does not constitute an offer, does not give rise to binding obligations, and is subject to change without notice to you. The creation of binding obligations will occur only if an agreement is signed by authorized representatives of Dow Corning and your company. Any reference to competitor materials contained in this communication is not an endorsement of those materials by Dow Corning or an endorsement by the competitor of Dow Corning materials. To the fullest extent permitted by applicable law, Dow Corning disclaims any and all liability with respect to your use or reliance upon the information. DOW CORNING DOES NOT MAKE ANY WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, WITH RESPECT TO THE UTILITY OR COMPLETENESS OF THE INFORMATION AND DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. DOW CORNING DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. 2016 All Rights reserved

31. 31 Application process • Anti-friction coatings can be applied with traditional painting equipment • For interior components, the most established process is spraying 2016 All Rights reserved

32. 32 Application process • Process can be fully automated (robot spraying) – Adv. for parts of complicated geometry • Specific automatic plants are available on the market 2016 All Rights reserved

33. 33 Process integration • Possible integration into existing production lines: – Water-based system (no flash point, no emissions) • Processability: – Drying time: Water elimination; can be reduced to 2 min with 60°C hot air; coated area touch dry – Curing time: Fully cured after 2 hours (application of intended max. load) • Aspect after drying/curing: – Dry film adhering to substrate – Transparent if applied at recommended film thickness (10-12 µm) – Dry film changes the gloss of the coated surface – Not suitable for visible areas 2016 All Rights reserved

34. 34 Processability • Spraying application generally carried out with 0.5 or 0.3 mm nozzles • Sedimentation/clogging can be critical: High stability is required After 1 day After 6 months @ 40°C 2016 All Rights reserved

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