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

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 (see attachment).

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.

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.

Possible solution areas

• 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.
• Metalsa will support grant applications by selected participants.
• Participants are encouraged to indicate the type of funding programs and their requirements in their submitted proposal.
• Metalsa will review funding request after the challenge ends and reach out to selected participants. Subject to availability of funding/grant calls and eligibility of the participants.

Cash Prizes

• The Innovation Challenge Winner will win 22,000€; the winning proposal must meet selection criteria and align with Metalsa business interest.
• Individual winner who qualify for the cash prize must be aged eighteen (18) years with full legal capacity at the time of registration and are not part of any Metalsa entity.
• Winner is solely responsible for the payment of taxes on their respective prizes.
• Prizes are not transferable. Unclaimed prizes will not be awarded and will be processed in a manner compliant with the law. If the prize cannot be awarded for whatever reason, Metalsa reserves the right to substitute the prize for another of equal value.

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.
• Metalsa global business network is available to amplify participants innovation for various regional markets. Accessibility is subject to Metalsa regional business focus and restrictions i.e. freedom to operate (FTO).
• Expertise and Facilities - Metalsa in-house experts will support participates from scientific R&D and application knowledge to business development along the entire value chain. This may include access to our global labs and facilities as appropriate.
• Three partnership models are considered in this challenge call. Joint-patent application will be considered if there is new intellectual property (IP), as well as, Metalsa support for IP generation:
• Research Collaboration – Metalsa will work together with universities or research institutes; within the framework of financing for undergraduate thesis, contract research, proposals for external funding or providing access to industry equipment.
• Joint-development – Metalsa and participant can work together to share technologies, develop or enhance their products, combine or integrate their technologies, or jointly commercialize a new product.
• Licensing – A business arrangement in which the participant can give Metalsa permission to manufacture its product for a specific payment (toll manufacturer).

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