Grantee Research Project Results
Final Report: Enabling Electrostatic Painting of Automotive Polymers With Low Cost Carbon Nanofibers
EPA Contract Number: EPD07080Title: Enabling Electrostatic Painting of Automotive Polymers With Low Cost Carbon Nanofibers
Investigators: Burton, David
Small Business: Applied Sciences, Inc.
EPA Contact: Richards, April
Phase: II
Project Period: May 1, 2007 through April 30, 2009
Project Amount: $224,988
RFA: Small Business Innovation Research (SBIR) - Phase II (2007) Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , SBIR - Pollution Prevention
Description:
In 2007, Federal Government regulations regarding the allowable emissions of volatile organic compounds (VOCs) forced automotive suppliers to pursue alternative painting techniques that do not rely on the heavy use of solvents. Additionally, automotive manufacturers constantly are seeking to reduce the weight of automobiles to increase fuel efficiency and eliminate corrosion from automotive parts and body panels while maintaining their capability to compete based upon cost, appearance, and performance. To meet those goals, manufacturers desire to use more polymer matrix composites, particularly in body panels.
Automotive suppliers prefer to use electrostatic painting (ESP) technology as it is an established process for generating parts with a Class A finish. Because polymers are inherently electrically insulating, suppliers of these types of components must apply an electrical conductive primer coat prior to ESP. The primer coat chemically bonds to the polymer and becomes the charge carrier for the part, whereby enabling the use of ESP. Primer coats require the extensive use of VOCs, which currently are released to the environment. The goal of this EPA SBIR Phase II was to eliminate the need for the conductive primer by incorporating low-cost, commercially available carbon nanofiber into the polymer to form an electrically conductive composite.
The production of polymer composites that can be electrostatically painted immediately after molding will remove a major barrier to the substitution of metal parts with composite parts on automobiles. The full development of this technology will increase the use of composite components in the automotive industry, which is in consonance with the efforts of the automotive industry to comply with environmental protection measures, as well as reduce the weight of transportation vehicles to increase fuel efficiency and eliminate corrosion while maintaining appearance, performance, and low-cost.
Incorporating carbon nanofiber (CNF) into polymers at low loadings has been reported to create composites that can carry electrical currents while simultaneously increasing mechanical properties.[1][2] Composites produced from a variety of large-scale, commercially available composite fabrication techniques (injection molding, compression molding, long-fiber thermoplastics processing, sprayable gelcoat), different automotive polymers (PP, PEEK, PC, PA66/ABS, HDPE), and several versions of carbon nanofiber were tested under this program.
In Phase I, the developed composites received the paint with no alterations in the painting process and behaved similarly to metal. The CNF did not affect the surface quality, nor did it impact the adhesion of the paint to the composite surface.
Overall, Applied Sciences was successful in demonstrating that composites made conductive with the addition of CNF can be electrostatically painted without the addition of a conductive primer coat. Elimination of the conductive primer will eliminate approximately 0.23 lbs of VOC emission per automobile, or about 18 percent of the total VOC emissions related to painting and finishing. ESP of polymers is estimated to reduce manufacturing costs by about $100 per vehicle. The net present value of this is conservatively estimated at $500 M for the industry during the next 15 years. Ultimate savings could reach $2 B annually.[3]
Conductive composites have further potential of being used in numerous under-the-hood applications and other areas where electrical conductivity is needed, and more widely as electronic enclosures, composite electrostatic precipitators, anti/de-icing heaters for aircraft, and anti-static flooring, countertops, and truck bed liners.
Despite the tremendous promise of these composite materials, their development and insertion into the marketplace has been slowed by the world-wide economic downturn. In particular, the efforts of ASI and its automotive supplier collaborator, INEOS, have been affected severely by the especially hard-hit automotive industry. These factors, along with the long qualification cycle of the automotive industry, have hampered the progress of this technology. However, ASI will continue to work with INEOS to advance the technology developed under this program.
References:
[1] Tibbetts GG, Lake ML, Strong KL, Rice BP. A review of the fabrication and properties of vapor-grown carbon nanofiber/polymer composites. to be published in: Composites Science and Technology.
[2] Boyce Components | K-Factor Advanced Composite Heating System Exit
[3] Pelsoci T. Advanced composite technologies with applications in automotive, petroleum, and civil infrastructure industries. Prepared for Economic Assessment Office, Advanced Technology Program, NIST.
Journal Articles on this Report : 1 Displayed | Download in RIS Format
Other project views: | All 2 publications | 2 publications in selected types | All 1 journal articles |
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Tibbetts GG, Lake ML, Strong KL, Rice BP. A review of the fabrication and properties of vapor-grown carbon nanofiber/polymer composites. Composites Science and Technology 2007;67(7-8):1709-1718. |
EPD07080 (Final) |
Exit Exit Exit |
Supplemental Keywords:
small business, SBIR, EPA, electrostatic painting, polymer composites, automotive polymers, carbon nanofibers, VOC emissions, air pollution control, , Sustainable Industry/Business, Scientific Discipline, RFA, Technology for Sustainable Environment, Sustainable Environment, Environmental Engineering, Environmental Chemistry, automotive coating, nanotechnology, electrostatic spray painting, nanofiber, alternative coatings, nanomaterials, RFA, Scientific Discipline, Sustainable Industry/Business, Environmental Chemistry, Sustainable Environment, Technology for Sustainable Environment, Environmental Engineering, automotive coating, electrostatic spray painting, nanotechnology, nanomaterials, alternative coatings, nanofiberSBIR Phase I:
Enabling Electrostatic Painting of Automotive Polymers with Low Cost Carbon Nanofibers | Final ReportThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.