2016 SAE EBEAM TECHNOLOGIES PRESENTATION

ELECTRON BEAM TECHNOLOGY FOR AUTOMOTIVE APPLICATIONS

Anthony Carignano

Sales & Marketing Specialist

PCT Engineered Systems

EBEAM Division of Comet Group

SAE World Congress 2016

April 14, 2016

Detroit, MI

SAE INTERNATIONAL

EBEAM FOR AUTOMOTIVE APPLICATIONS:

COMET GROUP AT A GLANCE

Paper # (if applicable) 2

Worldwide leader in x-ray, RF, and EBEAM Technologies

IndustrialX-Ray

X-Ray Systems EBEAM

TechnologiesPlasma Control Technologies

OEM End-userOEM OEM

End-user

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TECHNOLOGY OVERVIEW


Sterilization

Environmental

Technology

Surface Curing

Crosslinking

Development Areas & Application Examples

FoodPharmaMedicine

Food SafetyBio-Refinery

FlexographyLithography

Gravure Digital Inkjet

Polymeric FilmsRubber Compounds

Hydrogels

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EBEAM FOR AUTOMOTIVE APPLICATIONS

EBEAM TECHNOLOGY


Brief History of Commercial Low Energy Electron Beam

Pioneered in 1950’s-60’s by W.R. Grace-Cryovac

BroadBeam systems developed in 1970’s

PCT’s Low Energy (LE) systems, 2008

Comet Sealed Lamps, 2010

Installed Base

> 1,000 low voltage EBEAM systems installed

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HOW EBEAM WORKS

• X-Ray Tube, EBEAM Lamp and CRT



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HOW EBEAM WORKS

• The anatomy of a low energy electron beam



Housing

Vacuum Chamber

Filament

Grid

Foil Window

Nitrogen Atmosphere

Substrate

Accelerated Electrons

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HOW EBEAM WORKS

• Electron Scattering



The distribution of energy absorbed by a material depends upon:

− Energy of electron

− Atomic number and density of materials

80 kV

80 mm

240 mm

160 mm

125 kV 150 kV0 mm

in air

Ti

Air

Monte Carlo simulation of point source EB scatter

Depth

Depth

Depth

DoseDose

Dose

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PROPAGATION

• in Water (Air Gap 10mm)

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ULTRAVIOLET VS. EBEAM TECHNOLOGY SELECTION


ULTRAVIOLET and ELECTRON BEAM:

- Are complementary, not competing technologies

- They have some similarities and fundamental differences

- Selection should be based on the best fit for the process and application. Best fit considerations may include:

• Enabling of end-use• Capital cost• Operating costs• End-use properties• Fitness for food packaging• Substrate considerations

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Ultraviolet Electron Beam

Photons Accelerated Electrons

Wavelength determines energy;

typically 250 to 450 nanometers

Accelerating voltage determines

energy; typically 80 to 180 kV

Energy unit conversion; 350nm

photon = 3.5eV

Typical electron energy at substrate;

70,000 eV

Total applied energy typically 0.1 to

0.5 J/cm@

Total applied energy typically

20 to 40 kilogray (kGy)

1 kGy = 1 J/gram

For 50 g/m2 layer = 0.1 to 0.2 J/cm2

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Increasing Wavelength

Non-Ionizing Radiation Ionizing

Radiation

Increasing Frequency/Energy

Ultraviolet energy insufficient to directly initiate polymerization

(non-ionizing)Photoinitiators Must be Used

Electron Beam: Will Ionize any

organic material.

No Photoinitiator Required

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Ultraviolet Electron Beam

- Depends on optical density of material - Depends on mass density of material

- Depends on peak irradiance (power and

focus) of UV source

- Controlled by acceleration potential

(voltage) of beam

- Good for clear materials, limited in

pigmented, filled, and opaque materials

- Easily penetrates into clear materials,

highly pigmented, filled, opaque materials

- Effective curing for thick coatings with

low pigment loadings

- Effective curing thick and/or heavily

pigmented or filled inks and coatings

- Lamination of clear materials - Enables lamination of opaque materials

Penetration

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CROSSLINKING


300kV down-fire low energy electron

beam system for crosslinking wear

liner of automotive tires.

Rubber

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CROSSLINKING


- Operationalized by Firestone in the 1980s.

- Now common practice among major tire makers.

- Provides green strength to tire for further processing

(Forms C-C chemical bonds and free radicals in vulcanized rubber macromolecules which

facilitate the formation of the grid with sulfur bridges)

Rubber

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CROSSLINKING


Key Performance Benefits:

- Provides pre-vulcanization tack and green strength in tire

manufacturing process

- Improves overall finish and shape of the tire.

- Improving the performance of the tread:

wear, temperature, solvent resistance

grip/traction of the tire

lower hysteresis loss on rolling

reduced fatigue of rubber components (carcass, breaker),

5-10% higher tire life

Rubber

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CROSSLINKING


Key Process Benefits:

- Reduces use of expensive synthetic/natural rubber compounding

materials/additives and lowers tire mass

- At 5Mrad (50KGry), produces premium quality tires in +10% less time

vs. non-irradiation tire making process.

- Reduce energy costs compared to 100% thermal methods

Rubber

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CROSSLINKING


PE/PP Foams

– Sekisui Softlon

– Toray TORAYPEF®

“ideal for automotive

lightweighting”

“replaces traditional foams

such as EPDM rubber,

polyurethane and PVC.”

“widely used for interior trim

applications because they

provide sealing against air,

moisture, noise and

temperature. “

Typical examples include:

door & side panels,

dashboard, headliners & ABC

pillars.

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History

EBEAM explored for automotive surface curing

applications since the 1960s.

“To capitalize on the opportunity for electron

beam coatings at Ford, PPG set-up the Radiation

Polymer Company (RPC), which subsequently

became an independent low-energy electron

beam company, RPC Industries.”

In the 1980s, Bill Burlant, PhD at the Ford Motor

Company, showed that electron beam cured

coatings on profiled and three dimensional metal

and plastic components could produce outputs

well over 750 times the speed of conventional

drying techniques.


SURFACE CURING


Photo: Ford Coatings Research circa 1985. Electron beam development

program for interior / exterior automotive parts.

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Coil Coating


SURFACE CURING


A flat inline metal coating process: the metal is unwound, cleaned, treated, primed,

cured, treated with a top coat, cured and rewound.

Converted substrate require chemical pretreatment and must be preheated to a target

activation temperature before solvent based coating chemistries can be applied.

Cooling zones are required to reduce metal temperature before additional coating

layers can be applied and prior to rewinding.

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EBEAM Coil Coating Advantages (Commercialized)


SURFACE CURING


+75% Lower energy consumption cost

More compact solution: floor space

Easy integration on existing lines

No solvents / 100% solids

- Higher coating coverage

- Greatly reduced carbon footprint (No emissions)

- No solvent incineration

- Non thermal: no CO2, no cooling , no water treatment

ELECTRON

BEAMCLEANING

BACKER

APPLICATIONREWIND

UNWIND

PRIMER

APPLICATION

TOP COAT

UV GLOSS

CONTROL

TOP COAT

APPLICATIONPRIMER

UV CURE

BACKER

UV CURE

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EBEAM Coil Coating Advantages


SURFACE CURING


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EBEAM Coil Coating Advantages


SURFACE CURING


- Energy savings (very low electrical consumption)

- Productivity (no PMT process window)

- Surface treatment (incorporated in primer function)

- Cooling water (no thermal process) and no water treatment

- No incineration of solvents

- Plant insurance (no risk of fire and explosion)

- Storage & handling (less coating consumption, one coating for

different gloss levels)

- Predictable taxes on emissions.

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EBEAM Coil Coated Li-Ion Batteries for Automotive:

Solvent-free compositions are possible

Solvent-free electrode compositions are rated as nonflammable,

which translates into lower insurance costs, less stringent

storage requirements and a reduction in handling hazards

Low emissions (VOC, etc.)

Conventional solvent or water-based processing requires high

drying energy and results in significant CO2 emissions

Compatible with heat-sensitive substrates

Conventional thermal drying of Li-Ion battery electrodes is

typically conducted using multiple temperature stages. EBEAM

curing can be conducted in a single step.


SURFACE CURING


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SURFACE CURING


EBEAM Coil Coated Lithium Ion Batteries for Automotive:

Key Attributes

• Ultra-high line speeds

– Estimated ≥ 600 m2/min throughput can be achieved based on ≥300 m/min (~980 fpm) line speed for roll widths up to 2 m (with machine footprint ~10 m2)

• Thicker electrodes – <200 μm can be achieved at throughputs mentioned above in a single pass with 300 kV system.

• Excellent energy efficiency – electrical efficiencies ≥ 60% are possible, including voltage transformer losses (i.e. ≥ 60% of electrical line energy is converted to productive EB energy)

• Environmentally friendly – EB processing requires no solvent and no initiator and has low emissions

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EBEAM curing of highly pigmented profiled automotive plastic parts


SURFACE CURING


Photo: Interior automotive ABS/PC

plastic trim plate support structure

coated with high gloss black mono

coat. Cured with COMET EBLab Unit.

Photo: ABS/PC button stock in EBLab

chamber immediately following surface

cure at room temperature using COMET

EBLAB Unit.

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SURFACE CURING


Measure

Current Thermal

Drying Line

200 kV EB Curing

Line

Parts/kWh 28 415

Plant Floor Space (ft2) 2400 1200

Yield (First Time Quality) 60% 90%

Productivity (parts/hour) 1080 3240

VOC Emissions (tons/year) 0.98 <0.047

Advantages:

- Excellent high gloss/matte appearance of dark

pigmented / highly loaded coating systems.

- When compared with UV cured systems similar

and or improved thermal shock, chemical, scratch

resistance

EBEAM curing of highly pigmented profiled automotive plastic parts

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EQUIPMENT CONFIGURATIONS


ELECTRON BEAM TECHNOLOGY FOR AUTOMOTIVE APPLICATIONS

Anthony Carignano

Sales & Marketing Specialist

E-Mail: [email protected]

Tel.: +1-563-949-9493

THANK YOU!

mailto:[email protected]

2016 SAE EBEAM TECHNOLOGIES PRESENTATION

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