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

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

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
Examples of noise development from the field
• Door panel sliding against clear coat/paint
– Show video
• Armrest sliding against door panel insert
– Show video

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

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

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)

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

8
Anti-noise performance – report example
PRODUCT
Material pairing Paint vs. PVC foam 2.5 mm black
No
AFC
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
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
Impulse count 0 0
SHORT TEST – RT VDA 230-206

9
Anti-noise performance (short test, RT)
SHORT TEST ACCORDING TO VDA 230-206
PRODUCT
Material pairing Material pairing 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

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

11
Anti-noise performance (durability test, RT)
DURABILITY TEST BASED ON PARAMETERS OF VDA-230-206
PRODUCT
Material pairing Material pairing 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

12
PRODUCT
Material pairing PC-ABS vs. PVC foam 1 mm
No
AFC
variation
Cycles Characteristic
0-2,500/0-5,000
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
Impulse frequency [1/mm] 18.2 0.00 0.00
2,500-5,000/0-5,000
BI [noise rating]
No
need
8.5 8.5
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
Impulse count 0 0
Anti-noise performance (100K cycle durability test) –
PC-ABS vs. PVC foam foil 1 mm thick
DURABILITY TEST

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

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

15
DOOR PANEL SECTION
PRODUCT
Material pairing Paint vs. PVC foam 1 mm No AFC Anti-Friction Coating
0-5,000
RPZ [risk priority number] 10 1
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

16
Paint vs. PVC 1 mm foil –
panel section – no AFC
Video – no AFC

17
Paint vs. PVC 1 mm foil – panel section –
Video – AFC

18
DOOR PANEL SECTION
PRODUCT
Material pairing PC-ABS vs. PVC foam 1 mm No AFC Anti-Friction Coating
0-5,000
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

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

20
PC-ABS vs. PVC 1 mm foil – panel section –
Video – AFC

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

22
Customized version – aspect
Black version
UV version

23
PRODUCT
Material pairing Paint vs. PVC foam 1 mm Anti-Friction Coating (black) Anti-Friction Coating (UV)
0-5,000
Impulse count 0 0
5,000-10,000
Impulse count 0 0
Anti-noise data – paint vs. PVC 1 mm foil

24
PRODUCT
Material pairing PC-ABS vs. PVC foam 1 mm
No
AFC
Anti-Friction
Coating (black)
(UV)
0-5,000
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
Impulse frequency [1/mm] 18.2 0.00 0.00
5,000/10,000
BI [noise rating]
No
need
8.5 8.5
Impulse count 0 0
Anti-noise data – PVC 1 mm foil vs. PC-ABS

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

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

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

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

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

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.

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

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

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

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

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

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