The document discusses future trends in automotive coatings. It describes the evolution of coating systems from the 1970s to present day and projections to 2020. Compact coating processes are highlighted as market drivers to reduce cost and improve durability, environment, and sustainability. Examples of waterborne compact processes using B1/B2 layering or 3C1B configurations are presented. The premium compact process is identified as a best practice approach, providing appearance of full systems while improving economy and ecology. The future of coatings is said to involve fusion layer substrates, alternative pretreatment technologies, and multi-substrate capabilities.

1. Future is here in Automotive coatings
7th Eurocar Congress, Barcelona

2. Typical OEM Coating System

3. Market Drivers
Appearance Appearance Appearance Appearance Appearance
Durability Durability Durability Durability
Environment Environment Environment
Chemical Etch Chemical Etch Chemical Etch
Scratch / Mar Scratch / Mar
Compact/Cost Compact/Cost
Multi‐substrate
Sustainability
1970 1980 1990 2000 2010 2020
Anodic EDP 1976 1st Cationic EDP Enviroprime TM
Enamels Solventborne EnvirobaseTM
Base/Clear OptiprimeTM
NCT™ II 7
Diamond Coat™
Enviracryl™

4. The Future is Here
Technologies that change
The layering standards

5. Deluge,
Pre-wipe
Clean Rinse Rinse
Dip Clean RinseDip Rinse
Conditioner Zircobond™
Zinc Phosphate
Shorter process D.I.lower cost Virgin D.I. Post Rinse
Virgin
City Water
Rinse – Recirc D.I.
Dip Recirc D.I.
No limitation of Aluminum Over 2.0MMDip Rinse
vehicles coated
Nickel & Phosphate Free with ZircobondTM Globally
Lower Waste
Thin film

6. Clean, Pretreated Body- Bake
Cool
in-White E-Coat Rinse Cycle
Sanding
Sealer + Gel Bake
Cool
Bake Primer
Flash or Pre-bake
Sanding Interior Basecoat
Inspection Cool Bake Clearcoat Pick-Up

7. Compact Process Layering
Conventional ‐ Silver 3C1B ‐ Silver B1:B2 ‐ Silver
CLEARCOAT 40µ CLEARCOAT
CLEARCOAT 40µ
BASECOAT 15µ BASECOAT
B2 15‐25µ
PRIMER 30 ‐40µ PRIMER
B1 15‐25µ
E‐COAT E‐COAT E‐COAT
20µ 20µ
STEEL
STEEL STEEL
STEEL STEEL
Core formulas can be adapted to most existing line processes
B2 can be used as Bumper coating
B2 Only possible dependant on hiding of color shade & chip performance
Process control critical for UV trans (filmbuilds)
Duraprime® enhances B2 only potential and provides fortified system to delamination
(process control)

8. Light Transmittance
Requirements UV Light
Topcoat
Electrocoat
Delamination
Topcoat
Oxidized surface of
electrocoat
Electrocoat
4

9. WB Compact Process Layouts
Waterborne FP Ambient Booth #1: Brownfield
P B1 B2
BC Interior 4-12 min.
r Exterior Exterior 2-3 min. 2 min.
Cut-in Application 180F/82C Heated
e
p Recommend 5 minutes
1 coat 1 coat Ambient
Flash
Cool WB B1:B2
10-18µ 10-15µ
Waterborne FP Ambient Booth #2: Brownfield or Greenfield
B2 B2
P Exterior Exterior
FP/B1 BC Interior 4-12min.
r 1 coat 1 coat 2-3 min. 2 min.
e
Exterior Cut-in Application
Option Ambient
180F/82C Heated
Cool WB B1:B2
p 10-25µ Recommend 5 minutes Flash
(30-90 sec)
10-25µ
Waterborne FP Heated Flash Booth: Greenfield WB 3C1B
P 3-6 min. BC Interior BC Exterior 3-6 min.
FP 2 2
r 2-3 min. 180F / 82C Cut-in Application 1- 2 coats (30-90) 2-3 min. 180F/82C
Exterior min min.
e Ambient Heated Minimum 5 minutes sec. Ambient Heated
p 20-30µ Cool Cool
Flash Body Temp B4 BC< 95F 10-25µ Flash
Currently all compact process layouts include a sealer gel oven
Co-bake sealers under development

10. Overview : Waterborne Compact
Process Applications - 2011
Europe Ambient Flash B1:B2 (Interior application before B1)
Ambient Flash B1:B2 (Interior application between B1 & B2)
Heated Flash 3C 1B
Toyota Woodstock , 2009
GM Orion, 2011
Hyundai Kwangju, 2006
VW Chattanooga, 2011
Honda, 2010
Toyota, MS, 2011
Toyota, 2007
BMW Spartanburg, 2010
Mazda ,2010
Nissan Kyushu ,2011
VW Puebla, 2006
VW Chengdu, 2011
PSA Tranva, 2011
DB Rastatt,
1998

11. Overview : Waterborne Compact
Process Applications - 2015
Europe Ambient Flash B1:B2 (Interior application before B1)
Ambient Flash B1:B2 (Interior application between B1 & B2)
Heated Flash 3C 1B
Toyota Woodstock , 2009
GM Orion, 2011 2012
2013 2013 Hyundai Kwangju, 2006
VW Chattanooga, 2011 2012
Honda, 2010
2012
Toyota, MS, 2011
2013 2013 2013
2012 Toyota, 2007
BMW Spartanburg, 2010 2012
2014 Mazda ,2010
2014
2014 2012 Nissan Kyushu ,2011
VW Puebla, 2006 2013
VW Foshan 2013
VW Chengdu, 2011
2012
2012 2014
2013
2014 2013 2014
2012
2012 2014
2012 PSA Tranva, 2011
2013
DB Rastatt,
1998
2014
2012
2013

12. Global Compact Process
Projections
63+ total plants forecasted to
be running WB Compact
42+ total plants converted to layouts
that will accommodate PPG’s B1:B2
2K is the CC technology choice
Calendar Year

13. Premium Compact
“Best Practice” in Compact Process
– Commercial experience since January 2010
– 4-5 B1 shades capable of 15 B2 colors
– Appearance capable of current full system process
– Ceramic Top Finish is recommended for optimized appearance
Economy &
Ecology
Without
Sacrificing
Performance

14. The Future
Fusion-Layer
Substrate
Standard UHP Clearcoat
UV, Ambient cure, multi-
substrate capabilities,
alternative PT

15. Summary
• Market Demands have driven the need for
innovative layering concepts to become reality
• Evolution of paint systems is no longer enough
to meet the ever increasing needs of the
market.
• The future is here and it’s here to stay.

16. Thank You for your attention !
In case of questions:
Dr. Chris Harrold
Director Product Management Europe
Telephone: +41.21.822.3087
charrold@ppg.com