Bonding Sealing and Coating : an approach for a sustainable vehicle construction By Humbert Vidal

1. Bonding Sealing and Coating : an
approach for a sustainable vehicle
construction
Humbert Vidal
Technical Customer Service Manager Europe
Eurocar
Barcelona , November 2011

2. Content
1. Global development drivers
2. Sustainability and lightweighting
3. Modern paint shop sealing & coating technologies
Slide 2 Eurocar November 2011 Humbert Vidal

3. Content
1. Global development drivers
2. Sustainability and lightweighting
3. Modern paint shop sealing & coating technologies
Slide 3 Eurocar November 2011 Humbert Vidal

4. Global Development Drivers
Improve Fuel Efficiency
Increased Regulation Fuel Cost Environmental Concern
• US set to increase CAFE • Near historic per barrel high • Growth of urban centers
(Corporate Average Fuel • Difficulty renewing supply • Increased auto production
Economy) to 35 mpg by 2016 • Peak uncertainty • Rise in CO2 emissions
• Euro CO2 emission targets
120 g/km from 2012 to 2015
• Japan plans fuel efficiency
increase for 2015
Slide 4 Eurocar November 2011 Humbert Vidal

5. Global Development Drivers
Fuel Costs
Brent Crude: was up to $115 / barrel
• +35 % from 1 year ago
• at a 2½ year high on reports of
fighting near Libyan oil fields
‘Exxon Mobil Struggles to Find Oil’ –
The Wall Street Journal
• replaced only 95 barrels for
every 100 it has pumped in
the last decade
Uncertainty
• in supply chain
• in production,
did it peak in 2005?
Slide 5 Eurocar November 2011 Humbert Vidal

6. Global Development Drivers
Environmental Concern
• Growth in urban centers
1950 2008
Population in urban areas 30 % 50 %
Cities of more than 1,000,000 83 400
• Increased use of automobiles
• Production up 58 % from 1990
• Record volumes predicted for 2011
• Rise in CO2 production
• > 40 % increase since 1990
Slide 6 Eurocar November 2011 Humbert Vidal

7. Content
1. Global development drivers
2. Sustainability and lightweighting
3. Modern paint shop sealing & coating technologies
Slide 7 Eurocar November 2011 Humbert Vidal

8. Henkel Strategy for Sustainability
Five Focal Areas
Henkel Sustainability Report 2010
Energy consumption – 21 %
Water consumption – 26 %
Waste footprint – 24 %
Occupational accidents – 29 %
External recognition includes
5th time in a row „sector leader“
Dow Jones Sustainability World
Index (DJSI Europe)
Slide 8 Eurocar November 2011 Humbert Vidal

9. The Value of Weight Reduction for Sustainability
Comparable Absorption of CO2
According to The Conservation Fund, an
acre of trees containing 302 trees, will
sequester 361 tons of CO2 over its
lifetime of 100 years
• Each tree sequesters roughly 11 kg
of CO2 per year
• Reducing vehicle mass 5 kg
is equivalent to planting 1 tree
(20.000 km / year, - 5.5 % fuel consumption
@ - 10 % weight reduction)
Slide 9 Eurocar November 2011 Humbert Vidal

10. Contents
1. Global development drivers
2. Sustainability and Lightweigthing
3. Modern paint shop technologies
Slide 10 Eurocar November 2011 Humbert Vidal

11. Sustainability and Lightweighting
Transfer into Modern Paint Shops
Sustainability Light-
weighting • Ultra-light seam sealants
• Greener paint shop plastisols
light function
cracking integration • LASD coatings with higher
efficiency
greener raw do more
materials with less:
• Sealants and coatings for low
temperature paint shops
demateriali-
energy zation • Adhesives and sealants for
efficiency light weight hybrid car bodies
with CFRP
Slide 11 Eurocar November 2011 Humbert Vidal

12. Paint Shop Plastisols with Reduced Density
Material Concepts
1.6 g/cm3 1.4 g/cm3 1.2 g/cm3 1.0 g/cm3 0,8 g/cm3
high standard low ultra low
density density density density
Lightweighting
through
density reduction
- 2.5 kg / car
Slide 12 Eurocar November 2011 Humbert Vidal

13. Paint Shop Plastisols with Reduced Density
Product Portfolio
Terotex 3145: 1.3 g/cm3
Terotex 3160-60: 1.2 g/cm3
Terolan 3065: 1.05 g/cm3
New: Terolan 6078
• Density 0.85 g/cm3
• Tensile 1.7 MPa
• Elongation 180 %
• Appearance good paintability
• Application Flat stream
(picture: Technology
Center Heidelberg)
Slide 13 Eurocar November 2011 Humbert Vidal

14. Greener Paint Shop Plastisols
Development Drivers
Targets:
• Higher quality of car interior
atmosphere (e.g. ToxProof
requirements)
• Reduction of fogging
and VOC values (VDA 278)
• Lower risks for future safety label
requirements
• Use of raw materials from light cracking
as well as renewable sources
Slide 14 Eurocar November 2011 Humbert Vidal

15. Greener Paint Shop Plastisols
Technical Status
• Screening greener raw materials
completed with following benefits
- lower gelation temperatures
- improved adhesion on e-coat
- higher abrasion resistance
- good paintability
• VOC: ca. 33% lower compared to
standard PVC-plastisols
• Costs: slightly higher raw material costs
• Status: in approval testing with first OEM
Slide 15 Eurocar November 2011 Humbert Vidal

16. LASD Coatings with Higher Efficiency
Technical Background
Key criteria for LASD application:
• Weight reduction: 20 - 25 %
(vs. melt pads – based on same acoustic
performance)
• Automatic application
• Reduced shop complexity
• Constant material properties
Slide 16 Eurocar November 2011 Humbert Vidal

17. LASD Coatings with Higher Efficiency
Henkel Product Portfolio
Sustainable extension of Henkel’s
product portfolio for
LASD applications:
• 100 % Systems: Rubber LASD
Terophon 8271, 8273, 8275
Terophon 1161, 6142 (body shop)
• High Efficiency Acrylate LASD
Terophon 7150, 7151 W
NE
Slide 17 Eurocar November 2011 Humbert Vidal

18. LASD Coatings with Higher Efficiency
High performance acrylic systems
• Acoustic Performance
• High acoustic efficiency per area weight – broad damping curve
• Innovative latex technology: special microstructure for high damping
effects
• High quality & appearance of applied materials
• Constant process, comfortable application & less abrasion
Temperatur - °C
1,000
-30 -20 -10 0 10 20 30 40 50 60 70
EM
Verlustfaktor d
0,100
0,010
Trockendichte: 0,90 - 1,0 g/cm³
Flächengewicht: 3,0 kg/m²
0,001
Produkt- A Produkt- B Produkt- C
Slide 18 Eurocar November 2011 Humbert Vidal

19. Technology Transfer Bus & Truck to Cars
Systems for low temperature paint shops
Sustainable product portfolio extension
Epoxy
PVC Adhesives PU with new non-hazardous
Plastisols Sealants 1 K - or 2 K - SMP sealants & coatings
Acrylic
Rubber Coatings
Coatings
Flextec®
Slide 19 Eurocar November 2011 Humbert Vidal

20. Technology Transfer Bus & Truck to Cars
Systems for low temperature paint shops
Isocyanate-free technology in use for headlamp bonding and
sealing in bus and truck industry
Terostat 9320 UBC:
approval project with bus industry replacing
water-based UBC for oven-free paint lines
Industry drivers:
• „clean paint shop“ concepts
• oven-less processes
Slide 20 Eurocar November 2011 Humbert Vidal

21. Enabling Technologies for FRP Structures
Sealants for modern lightweight concepts
Source: McLaren Source: VW
Source: BMW
• Low temperature curing technologies for sealants and adhesives
and/or
Warm Cure Dual Cure
Technology 80°C Technology
80°C RT
Slide 21 Eurocar November 2011 Humbert Vidal

22. Summary
Tighter regulations, fuel availability and costs as
well as increasing public awareness for the
protection of the environment will lead to higher
demand of sustainable solutions for paint shops.
Henkel offers a broad portfolio of sustainable
paint shop solutions and strongly extends into
greener raw material concepts and ultra-
lightweight high efficiency systems.
Future focus will be directed into solutions for
substrate mix design with FRPs and for low
temperature or ovenless paint lines.
Slide 22 Eurocar November 2011 Humbert Vidal

23. Thank You!