Fur and flocking like innovative coating

The main modification shall regard the ventilation of the three cabins: the base-coat one, the colour one and the transparent one: - Before the change all the cabins were fed by only one air supply unit, then every cabin shall be fed independently by means of three different air-supply units - Filter-frame modifications - Installation of six air-veils (one at the enter and one at the exit of each cabin) - Installation of a switchboard to control the rpms of every motor connected with the ventilators by means of inverters and PLC systems. The main advantages in comparison with the current configuration that we will gain with these interventions will be: - The possibility to work by means of only the cabin we need, with a great energy saving; - The absolute independence of every cabin in regulating to the internal air-flow, optimising it on each component we paint (reducing in this way the scraps caused by over spray); - A better filtration of the air supplied. Now FFLIC partners are able to paint in 7 different configurations ¿flat¿ parts of a car cabin as door panels and we can test the equipment to new very important applications (think the ¿paint¿ surface in 4 door panels). Now at the end of the project we have studied and modified the cabins in order to obtain better flow air Balance-sheet in order to improve the part number quality.

The aim of this study was to optimise the acoustic response of the lid of the glove compartment located in the dashboard of the new car model in the event it is subjected to a ¿kick¿, i.e. e sudden blow. The impact simulates the kind of blow a passenger could accidentally deliver to the glove compartment mentioned above. Quite a substantial acoustic output at a frequency estimated at 150MHz to 250MHz is produced thanks to a volume of air, acting as a sound box, between the lid and the glove compartment itself. Given that a passenger can only produce a relatively minor blow by accident (a modulus of 15N was taken for this impact) and that such events occur under normal conditions of temperature, humidity and pressure. Furthermore the evaluation of the behaviour of this part (a door of a glove-box to be inserted in a car dashboard), with regard to its peculiar vibration modes and frequencies, under the hypothesis that it undergoes an impulsive knock was carried out. As example a similar knock it might be the one caused accidentally by the passenger. This analysis took in account the use of three different constructive materials, which were characterized by three different elastic modulus values; these materials were de-signed to be applied in automotive parts. For the glove box we had obtained the extension of a patent in France and in Spain. We had studied the noise attenuation in flat panels made by tpo and pa 6 + 66 with different contents of filler an air bag was studied as well as the attenuation due to a foam. The activity competences will be used for new planning and building glove boxes, door panels, dash boards in automotive branche, because different mould building and moulding technologies are known and available in Plastal. The result will offer to the market not only an optimisation of product ratio costs/benefits, but also environmental benefits inside a car cabins improving the health safety during the drive.

As basis for a new coating material with textile like appearance and respectively properties a special resin vehicle has been developed in order to carry effect carriers for the desired properties. The resin is a mixture of a hydroxy-functional polyurethane and a polyester polyol. It is the basis for a 2 component waterbased Polyurethane Coating, which will be equipped with special extenders to achieve the desired surface effect. The binder development had been finalized by end 2002. During the last quarter of 2003 EDAG carried out a complete Specification test and proved the final Coating OK.

The ECCS had to develop a new coating material to provide surface finishes with textile like, suede like or velvet like appearance and mechanic-acoustical properties correspondingly. The binder for the coating is developed by DuPont. Based on this binder composition ECCS has tested approximately 60 different effect carriers in the coating formulation. These effect carriers are tested in different sizes and several amounts. We can distinguish several types of effect carriers: e.g. powders, fibres and grinded rubber. We have now made a selection of the effect carriers with the best results on appearance and spray ability. Samples have been sent to several market partners to test the mechanic-acoustical properties. The potential use of the achievements are the use of the know-how in many branches. In daily life situations, many surfaces are with a non-smooth surface and some of those effects should be painted with an effect-carrier-paint. In industrial branches the producers of effect-carriers, especially those companies who produce many plastic waste products, which can be used for effects (e.g. rubber waste). The internal company strategy will be the use and implementation of knowledge in education activities and implementation of knowledge in consultancy in the use of effect carriers in paints.

DuPont had to develop a new coating material to provide surface finishes with textile like, suede like or velvet like appearance and mechanic-acoustical properties correspondingly. The binder for the coating was also developed by DuPont. Based on this binder composition ECCS has tested approximately 60 different effect carriers in the coating formulation. These effect carriers are tested in different sizes and several amounts. We can distinguish several types of effect carriers: e.g. powders, fibres and grinded rubber. We have now made a selection of the effect carriers with the best results on appearance and spray ability. Samples have been sent to several partners to test the mechanic-acoustical properties. Taking all test results into consideration, polyamide fibres had been chosen as the best option to give the textile like surface appearance. Based on these assumptions a paint / testing specification had been defined by DuPont and EDAG. This Specification combines elements both from painting and flocking requirements.

The definition and the optimization of a new methodology based on product simulation for achieving the TTM, costs reduction and better quality of the final product is the main result for the Carcerano. The simulation and the check of a new product during all the project development phases (from concept to engineering) involving new technologies and appropriate software and hardware, gave the possibility to reach this aim. Carcerano developed the technique to produce a reliable simulation tool for embossed and coated objects: by fabric, by flock and especially by the new products developed in FFLIC project. By the use and the development of virtual prototype, Carcerano S.r.l. reached a realistic perception feeling in the simulation and visualization of objects, finalized also to virtual clinic test, without making 3D physical prototypes. Besides, using the virtual prototype is possible to detect project errors or ergonomic problems before starting with the equipment production, avoiding committing errors on tools. This developed integrated methodology, aims also to quickly transfer the mathematical model in the different optimized simulation, checks an developing environments.

The carried out activities are in progress and the final goals are to replace the flocking technology with the new paint. For this reason the stress is given to noise attenuation, one of the most important request by car makers. The other stress are in testing and we are improving paint and moulding technologies, as we are confident in improving quality and saving costs. Plastal target is to offer samples of a dashboard and door panels with ¿Fflic¿ paint to customers and to start business. A complete report of the impact on health and tests routine was carried out. We think to reach the result to start direct dialogues with the R&D departments of car makers, but other business field will follow. Noise study involved the virtual impact of a knock in a cover of a glove-box and the influence of different technologies in noise attenuation: gas injection, variable thickness, temperature. A patent (no 2807371) was carried out by Plastal in France. Active noise control test are currently in progress and the aim is to obtain the paint layerable, to give a suitable noise attenuation. Other studies were carried out on air-bags, to improve the comfort inside the cabin. The main project results will be used and proposed to international car producers and designers for the direct use of the global noise reduction, above all regarding the internal car-cabin noise reduction, according to the progressive EU regulations on consumers health protection (in this case: hearing).

A numerical method based on Computational Fluid Dynamics has been set-up in order to predict spray deposition of paints. The method is based on the combination of a model for the impact of droplets onto a surface with a Lagrangian tracking of the spray. It has been developed by starting from experimental values of the flow field generated by a spray gun, but the use of CFD makes it possible to extrapolate the results to conditions for which experimental data are not available. The method has been used so far to simulate the amount of overspray from standard paint guns and to predict the thickness of the deposited paint layer on different geometries. Some bad operating conditions of spray guns have been simulated as well, in order to verify the effect on the deposited paint layer. The potential strategic use of computational fluid dynamics is focused on simulation and prediction of the distribution of sprayed paints to obtain more uniform deposition, required in higher quality coating. The predictive method will be used for further developments of new standard spray guns and could be easily extended to newer electro-paint plants. The experience gained could be used both for activity of consultancy in the field of paint deposition and for new joint researches for industrial companies and academic institutions.

Moulding process control was planned with the following targets that are currently in progress: - CAD simulation and integration with moulding process; - Remote control of the moulding in factory offices. The results will be a new informatics network able to offer improved quality control and cost saving. We have produced the first drafts for testing to support the moulding process control. We have introduced a closed loop in molting press+mold+software the first results are ok as the new software is able to follow rheological changes of the polymers offering the opportunity to improve the use of recycled polymers. The photoengraving study was started and also a comparison between nylon and polypropylene moulding process, including the start-up of the principal characteristic moulding measurements. The results could be used by the main European car makers for the integration in the production process of a better moulding process control, above all regarding the internal pollution reduction, according to the progressive EU regulations on health protection. Also the possibility of the developments in replacing metal with plastics will be used as market strategy.

To check the quality of the first developed basic lacquer samples were applied on different plastic substrate testpanels. Fundamentals for requirements technical properties are the test requirements of the automotive specifications. In preliminary tests the resistance against UV-radiation of some basic lacquer recipes (from ECCS, DuPont) without any fibres was performed to choose the best basic coat. The results were fine. In a first test loop, the lacquers were applied on different plastic substrates. Particular tests were performed to determine the influence of film thickness and plastic material to paint adhesion and the emission of condensable components. All results of adhesions, fogging condensates and abrasions were fine. In the second test loop the influence of different surface effect additives (different fibres, rubbers) were checked. EDAG examined the results of adhesion, abrasion and the fogging condensate. The adhesion on PC is fine, on ABS is marginal; the fogging results are all fine, the abrasion test for PA-powder-surface is fine. For Rubber-, Pelt-feel- and PU-Powder results are not very fine. After finishing the test procedures of Loop3 a modification of the lacquer formulation was necessary, because of process ability by automatically spray guns. The lacquer was optimized in consideration of the fiber length and Fiber concentration by DuPont. Therefore an new test loop was necessary! (i.e. Testloop 4) Because only the length of the fibers a no chemical modification was performed by DuPont, not all tests had to been performed. All odour-, fogging-, C-emission- and formaldehyde test were ignored. Reason: the length of fibers does not influence this measurement results. A typically climatic change test (VW PV 1200) and because the painted surface represents a borderline case between paint and textile an additional abrasion test (Taber) was added in the test matrix. Main result: the quality of this formulation is very close to these of test Loop3! Main achievement of the last two Testloops 3+4: the most requirements of the automotive industries will be complied by the FFLIC-painting system! At the same time the development project and the facilities of the new product was presented on the ¿International Motor Fait (IAA; Frankfurt, 09. -21. Sept. 2003). Feedback: the new lacquer will be a very interesting material with a high grade of technical application and design freedom. For the stylists the material will be more a alternative for felt than for flocking. The technological properties of the FFLIC-system meet the most requirements of the automotive industries. It will be a very interesting new material with a high grade of stylistic freedom. Also the very important fact of health is reached, that no single fibres will be emitting when the painted surface is by abrasion or scratching. The main project benefit and the potential use is represented by the capability of checking the development of new plastic and polymer products in respect with technical possibilities and properties, above all related to the stylists feedback to the surfaces appearance and optics. In fact there will be cooperation with EMTEC, Heidelberg, Germany, company specialized in electronic microscopy for the study of surface effects, quality of fibres in lacquer-matrix, analysis of surface damage effects after different function and abrasion tests, to develop a better synergy with the end user requirements.

Pilot painting equipment was completely internally redesigned and rebuilt in order to assure the independence of the painting cabins, splitting the working activities towards flexibility and efficacy. The flow air control, as the study of the dust inside the cabins, as well as the monitoring of temperature and humidity are reached using a specifically developed process software. This new integrated process control system ensure the complete and diffuse supervision and monitoring to all production managing levels. The main potential results are the evolution of a dedicated painting spray plant with new multi-components paint, with scrap reduction and quality improvement, a better pollution control, a great energy saving and a correct use of resources (painting overspray), that could be used for further applications and new similar projects. The main dissemination planning could regard the improvement of the comfort of inside cabins of the car, using the experience made with the geometry of components parts, polymers, superficial treatments, assembly system, in order to reduce the noise, with an optimized production plant.

We create a method in order to recycle the object painted with FFLIC paint. Our method is self-working, with a high safety for workers and environment; we define the method at laboratory scale and we draw two different plants at industrial level. In D15-16 there were the explanations of our method and the drawing.

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