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Seeking topcoat solutions to prevent or mitigate electrodeposited epoxy coating's degradation after periods of UV light exposure

OPEN INNOVATION CHALLENGE BY

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The Electrophoretic coating process, also known as E-coat, consists of the immersion of parts in a paint emulsion. Once there is full immersion, an electrical current is applied that causes the paint to adhere to the surface in a uniform and homogenous layer. Electrodeposited epoxy coatings (E-coat) are prone to UV light degradation after direct or indirect sunlight exposure. We seek topcoats that, when deposited over E-coated automotive chassis frames, are capable to enhance both the resistance to photolysis and autoxidation and provide similar to higher corrosion resistance as the original E-coat. Emphasis is given to environmentally friendly technologies not formulated with heavy metals. Approximate annual volume starts at 750,000 ft^2.

The solution should be ready to scale, a commercially available topcoat or a solution soon to be in the market.

Typical Electrocoating Process Sequence

Desired Solution Criteria

Desired solution should fulfill the following criteria for UV degradation performance

  • 95% gloss retention after 2,500 hours of SAE J2527 or 95% gloss retention after 5 thermal cycles of Toyota’s TSH 1585G Method B, Xenon lamp testing.
  • 95% original E-coat thickness retention after the same testing requirements.

Desired solution should fulfill the following criteria for corrison and mechanical performance

  • Red rust rating of 7G or higher per ASTM D610 and a blistering rating of 9 per ASTM D714 after 120 cycles of SAE J2334.
  • Chip impact resistance of 8C or higher per SAE J400 (ambient temperature) or no peeling and rating 3 or higher per TSH 1553G.
  • Creepback from scribe should not exceed 2 mm in any direction from a 5 cm straight line after 120 cycles of SAE J2334.

Discarded Solutions

  • No reformulation of epoxy branded coatings; for example, no addition of non-absorptive binders or nanocomposites that change the original supplier's E-coat formulation.
  • No solutions that require a pre-treatment or a post topcoat application curing oven.

Technical Requirements

  • We seek solutions capable to be incorporated in a manufacturing line with restricted space (6 m^2) and no capability of a curing oven.
  • The cure state application must be suitable to store outdoors immediately after application.
  • Metal temperature right before application is in the range of 160 ºC (320 ºF) right after E-coat oven and down to 49 ºC (120 ºF).
  • Physical apperance should be black or a clearcoat with no drips or sags when cured.
  • The solution, when incorporated in line, should not negatively impact current cycle times.

Potential Solution Sources

Automotive paint developers.

Research laboratories developing paint solutions with advanced chemical formulas or Nanotechnology

Newcomers in the coatings industry seeking to scale up techical solutions for the automotive market.

Incentives

Submit your proposal/s for an opportunity of working together with Metalsa and be rewarded

Funding Awards

  • Relevant for research intensive companies (big and small), start-ups, research organisations and universities

  • Through partnership with Metalsa you would benefit from up to 22,000€ in funding, market accessibility.

Partnership and Research Collaboration

  • Metalsa Research Collaboration Model is suited to all academic (University) and private research organisations.

  • Metalsa will consider to fund up to 22,000€ for selected participants: whether to conduct a feasibility study; support on-going research; or enable applications for industry-focused research grants.

Timeline

Your journey starts here

25th October

Open innovation Challenge Launch

9th December

Deadline for submission

December 2022 to January 2023

Evaluation of candidates to meet Metalsa experts to refine their proposal

February 2023

Selection of the challenge winner

Contact us

Submit your comments or general inquiries regarding these challenges. We appreciate the opportunity to be of assistance.

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Eduardo Lira

Global strategy leader for technology exploration and intellectual property management.

Metalsa

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