Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • FINISHING
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • Classifieds
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
    • RESOURCES
      • Columns
        • Ask Joe Powder
        • Did you know?
        • Distribution Dive
        • Focus on Canada
        • Formulating With Mike
        • Innovation Insights
        • Moody's Coatings Conundrums
        • Powder Coating Perspectives
        • Target the Market
        • TiO2 Insider
      • Blogs
        • Editor's Viewpoint
        • Industry Insights
      • Coatings Supplier Handbook
      • Podcasts and Videos
        • COAT-IT! Podcast
        • Videos/PCI TV
      • PCI Store
      • Classifieds
      • eBooks
      • Sponsor Insights
      • White Papers
      • COATLE Word Game
    • EVENTS
      • Coatings Trends & Technologies Summit
      • Paint and Coatings Academy
      • Webinars
      • Calendar of Events
      • Lifetime Achievement Award
    • DIRECTORIES
      • Buyer's Guide
      • Equipment Directory
      • Materials Directory
    • EMAGAZINE
      • Current Issue
      • eMagazine Archive
      • China Issue Archive
      • Editorial Advisory Board
    • CONTACT
      • Contact Us
      • Advertise
      • Subscribe to eMagazine
      • Subscribe to eNewsletters

    Breaking the Performance Barrier in Automotive Interiors

    By Derrick Twene, Jim Bilancieri, Ad van Dorst, Rijoy Putatunda
    pci0310-DSM-lg.jpg
    March 1, 2010

    The polymers used to protect and beautify interior automotive plastic coatings need to be top performers.

    The U.S. automotive industry has gone through huge transformations in the past 30 years, starting with the structure of the industry, where the dominance of the Big Three has been challenged by global players. Improvements in on-the-road performance have made exponential step changes as well. The performance improvements cover multi-dimensional aspects like fuel efficiency, robustness, safety features and comforts to name a few (Table 1).

    Table 1 Click to enlarge

    Interior automotive design has also undergone broad changes to improve ergonomics, functionality and appeal. Not the least of these is the expanded use of durable plastic materials, which now account for the majority of the human-contact surfaces.

    In this article, we focus on the needs of interior car coatings. These coatings are driven by three criteria: look, feel and functionality. While look and feel are a function of fashion trends and are relatively short lived, the demands in functionality are usually step changes in terms of physical and chemical resistance properties which, in turn, are intended to preserve the look and feel of the coating.

    Automotive Interiors: A Pleasurable Ride

    Interior automotive surfaces like door trim panels, instrument panels, dashboards and center consoles are often exposed to a broad array of chemicals as a result of daily use. Just considering the ingredients found in food and personal care items, cleaners and dressings, deodorizers and pet products; interior surfaces must be resistant to chemicals, which can be oleophilic or hydrophilic; acidic or alkaline; and solvents like alcohols, glycol ethers and hydrocarbons. Chemicals particularly harsh to interior surfaces include sun tan lotion, mosquito repellant (DEET: N,N-diethyl-meta-toluamide) and the freshness fragrances that make driving a more pleasurable experience. Now let’s raise the degree of difficulty by requiring protection at sub-zero and elevated temperatures to 140 ºF!

    All global automotive players have defined standards for interior coatings so that they retain their look and feel in the face of these extreme conditions. For example, General Motors has developed the Global Approved Paint on Plastic Systems based on GM 14867 specification. These are usually one-component systems. On the other hand Volkswagen’s TL-226 specification has another set of stringent standards that typically use two-component systems in Europe.

    Defining the Innovation Need

    Coating suppliers to the interior automotive plastics market are often large multinational corporations or regional players who form global alliances in order to supply the OEMs across the planet. Local regulations and growing consumer sustainability awareness make the use of low-VOC waterborne systems a prerequisite for many of the surface protection coating systems. Subsequently, coatings need to have good atomization during application providing the “appearance” prescribed by the designer, high adhesion to ABS and PC-ABS plastics and protective properties to resist chemical and abrasion attack.

    The GM Global Specification and VW TL-226 specifications for interior automotive plastic coatings have particularly defined the need to address the DEET/sun lotion attack on the coating systems. Both require resistance to attack under 80 ºC temperatures. To meet these demands, this multinational team of developers chose a polyurethane-hybrid polymer system.

    Table 1 Click to enlarge

    For application areas where the requirements are at a high level, urethane polymer chemistry forms a good basis from which new performance barriers can be reached.

    Polymer Design

    Various synthesis routes for high-molecular-weight polyurethane dispersions are common practice. Best know are the acetone process, the melt dispersion process, the ketamine process and the prepolymer mixing process. The first synthesis step of all these processes is the same, being a well-known polyurethane reaction in which diols or polyols are reacted with diisocyanates (Figure 1). Reaction product is then dispersed in water.

    In the case of anionic polyurethane dispersions, the prepolymer chains contain carboxylic acid stabilizing groups provided, for example, by dimethylol propionic acid (DMPA). The prepolymer acidity is then neutralized and transferred to water, where spontaneous particle formation occurs. Chain extension is then carried out resulting in the formation of a high-molecular-weight waterborne polyurethane polymer dispersion. The very nature of the process results in the formation of a polymer colloid, which is significantly different from that of emulsion polymers. They differ in terms of their colloidal, morphological and application characteristics.

    Figure 2 Click to enlarge

    It is well understood that, in terms of particle and polymer morphology, polyurethane dispersions have a unique advantage over many other polymers in their ability to form coherent films. The degree of coalescence and the interpenetration of the polymer chains leading to further gradual coalescence of the particles are reported to be much higher for typical polyurethane than for a typical acrylic latex particle (Figure 2).

    Critical to the superior film formation are two factors. First is the presence of water within the particle. Moisture content of the particle plays the roll of plasticizer in that it softens the particle thus making it easier to coalesce, as shown in Figure 3.

    Figure 3 Click to enlarge

    The second critical factor involves the nano-particle size of most polyurethane dispersions. During the coalescing process, particles are driven together by the evaporation of water from the coating. This “hydrostatic vacuum” forces the particles together the same way evacuating air between two surfaces binds them. The effectiveness of this process is relative to the surface area of particles. For a given mass of dispersed polymer, smaller particles will result in a greater surface area and a greater driving force.

    Figure 4 Click to enlarge

    Moreover, polyurethanes “generate” performance enhancement due to their ability to form micro-phase morphology, where hard segments and soft segments (segment phase separation) are manipulated to achieve suitable polymer packing resulting in enhanced hydrogen bonding (Figures 4 and 5). In designing new polymers to meet the new performance criteria this performance enhancer is addressed with special care.

    Figure 5 Click to enlarge

    Additionally, the inclusion of a polyurethane-hybrid design provided benefits that a polyurethane homopolymer or physical blend of resins could not. It is well understood that many of the physical performance improvements found in a hybrid design over a physical blend can be attributed to the homogeneity of the dried films.

    The Atomic Force Microscopy (AFM) images, shown in Figure 6, are presented in the phase mode showing the hard and soft segment distribution of the polymer. The image on the left illustrates the incoherent phase distribution of two dissimilar polymers during film formation. The image on the right illustrates the homogeneous distribution of dissimilar polymer resulting from hybrid polymerization. A homogeneous distribution of these regions is important in maintaining the physical characteristics of the polyurethane. Nano-phase hybrid technology is regarded as an excellent way to reinforce coatings and improve their performance.

    Figure 6 Click to enlarge

    Meeting Performance Needs on Two Continents

    The GM World specification for interior automotive plastics (GMW14867) contains demanding performance requirements for adhesion, humidity and impact, but the most demanding requirement is the resistance to chemical attack at 80 ºC (Table 2). GMW14445 utilizes a chemical cocktail comprised of equal amounts of: DEET, octyl methoxycinnamate, octocrylene, and homosalate.

    Table 3 Click to enlarge

    Of equal difficulty is the VW TL-226 specification, which requires 24 h resistance to hand cream and sun block lotion at 80 ºC (Table 3).

    By means of intelligent raw material choices and proprietary polymerization techniques NeoRez R-4000 was developed to meet the resistance challenge of GMW 14867 and VW TL-226. NeoRez R-4000 is designed to be effective in both 1K and 2K coatings. Two-component coatings utilize a blend of hydrophilic and hydrophobic isocyanate adducts to achieve higher crosslink density that is required to meet the 24 h 80 ºC test. Performance test results are shown in Table 4.

    Table 4 Click to enlarge

    Formulation

    NeoRez R-4000 can be compounded to meet the appearance needs for clearcoats, solid colors with varying grades of gloss and, of course, metallic (silver being the most popular). Waterborne coatings also need a shelf life of about six months, which demands good compatibility of the binder with the pigment preparation and additive alike. Starting-point formulations are shown in Table 5.

    Table 5 Click to enlarge

    To ensure good compatibility, all formulations should be prepared using a high-speed dissolver with each additive being carefully incorporated to avoid shock or flocculation. For two-component formulations, a (1:1) ratio of hydrophobic combined with hydrophilic isocyanate was added to a set amount of the one-component finished formulation under agitation (Table 6).

    The final formula films where checked as drawdowns on glass for flocculation and incompatibility. The coatings were visually assessed then measured for gloss, haze and pigment float. The formulations were additionally stored at 50 ºC for 3 months and rechecked for quality and performance.

    Table 6 Click to enlarge

    Conclusion

    It is well known that the performance standards for interior automotive plastic coatings have dramatically changed since plastics first appeared in the automobile cockpit. The standards established by General Motors and Volkswagen are amongst the most difficult to meet. But considering the plethora of chemicals, food items and reagents that may be residing on a coated plastic surface during mid afternoon sun in Phoenix it stands to reason that the polymers used to protect and beautify these substrates need to be top performers. NeoRez R-4000 is a new and effective polymer to help the formulator meet this challenge. 

    Acknowledgements
    The authors convey thanks to Ilse Koks- van den Nouweland, Sandy Wheeler and Delia Kriticos for experimental application work, and Herman Ryborz and Stefan Geboers for contributing the numerous synthesis and not giving up.

    This paper was presented at the Coatings for Plastics Symposium sponsored by PCI Magazine, Chicago, 2009.

    Share This Story

    Looking for a reprint of this article?
    From high-res PDFs to custom plaques, order your copy today!

    DSM NeoResins, Wilmington, MA
    DSM NeoResins, Wilmington, MA
    DSM NeoResins, Wilmington, MA
    DSM NeoResins, Wilmington, MA

    Recommended Content

    JOIN TODAY
    to unlock your recommendations.

    Already have an account? Sign In

    • PCI-0724-Global10-Feature-1440.png

      2024 Global Top 10: Top Paint and Coatings Companies

      Who ranks on top? PCI’s annual ranking of the top 10...
      Paint and Coating Market Reports
      By: Courtney Bassett
    • PCI-0724-PCI25-Feature-1440.png

      2024 PCI 25: Top Paint and Coatings Companies

      PCI's annual ranking of the top 25 North American paint...
      Paint and Coating Market Reports
      By: Courtney Bassett
    • pci1022-Kinaltek-Lead-1170.jpg

      A Novel Pigment Production Technology

      Following an extensive R&D program that demonstrated...
      Paint and Coating Pigments
      By: Jawad Haidar and Nitin Soni
    You must login or register in order to post a comment.

    water based emulsion coatings as mosquito and insect repellance

    Mangat Vk kannan
    August 8, 2012
    Request for guidance for water based emulsion formulations with mosquito/ insect repellant compositions. Can these products be extended? Please give a feed back.

    Report Abusive Comment

    Manage My Account
    • eMagazine
    • eNewsletter
    • Online Registration
    • Subscription Customer Service

    The Coatings Minute: Why Industry News Matters More Than Ever

    The Coatings Minute: Why Industry News Matters More Than Ever

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Your Inside Look at PCInnovations

    The Coatings Minute: Your Inside Look at PCInnovations

    CTT Registration Now Open

    CTT Registration Now Open

    More Videos

    Sponsored Content

    Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

    close
    • Modern arapartment complex painted in bright colors.
      Sponsored byEPS - Engineered Polymer Solutions

      Architectural Polymers Leading the Way in Coatings Innovation

    • paint sprayer in a workshop
      Sponsored byallnex

      Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

    Popular Stories

    No. 3 AkzoNobel

    AkzoNobel to Close Two Manufacturing Sites

    BASF SE Logo

    BASF Reportedly Eyes Exit from Coatings

    Modern living room interior with green plants, sofa and green wall

    Reimagining Architectural Paints with Plant-Based Acrylic Binders



    PCI Buyers Guide

    Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

    Start your RFP

    Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

    Find Suppliers

    Events

    September 3, 2025

    Coatings Trends & Technologies Summit

    The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

    January 1, 2030

    Webinar Sponsorship Information

    For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

    View All Submit An Event

    Poll

    Longest-running laboratory experiment

    What is the longest-running laboratory experiment?
    View Results Poll Archive

    Products

    CTT Summit Short Courses (Live 9/3/25)

    Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

    See More Products
    pci  webinar april 2025

    PCI CASE EBOOK

    Related Articles

    • Waterborne Alkyds Break Through the Performance Barrier

      See More
    • Fortifying the Barrier Against Contaminants in Food Processing: A Coating That is Deadly for Microorganisms

      See More
    • Decorative Finishing Solutions for Automotive Interiors

      See More
    ×

    Keep the info flowing with our eNewsletters!

    Get the latest industry updates tailored your way.

    JOIN TODAY!
    • RESOURCES
      • Advertise
      • Contact Us
      • Directories
      • Store
      • Want More
    • SIGN UP TODAY
      • Create Account
      • eMagazine
      • eNewsletters
      • Customer Service
      • Manage Preferences
    • SERVICES
      • Marketing Services
      • Reprints
      • Market Research
      • List Rental
      • Survey & Sample
    • STAY CONNECTED
      • LinkedIn
      • Facebook
      • Youtube
      • X (Twitter)
    • PRIVACY
      • PRIVACY POLICY
      • TERMS & CONDITIONS
      • DO NOT SELL MY PERSONAL INFORMATION
      • PRIVACY REQUEST
      • ACCESSIBILITY

    Copyright ©2025. All Rights Reserved BNP Media.

    Design, CMS, Hosting & Web Development :: ePublishing

    Painting & Coating Industry (PCI) logo Powder coating summit logo
    search
    cart
    facebook twitter linkedin youtube
    • Sign In
    • Create Account
    • Sign Out
    • My Account
    Painting & Coating Industry (PCI) logo Powder coating summit logo
    • NEWS
      • Latest News
      • Market Trends & Reports
      • Price Alerts
      • Subscribe to eNewsletters
      • Global Top 10/ PCI 25
      • Weekly Featured Article
      • COATLE Word Game
    • PRODUCTS
      • Product News
      • Must See Products and Services
    • MATERIALS
      • Additives
      • Resins/Polymers
      • Pigments
      • Equipment
      • Distributors
    • TECHNOLOGIES
      • Adhesives
      • Architectural Coatings
      • Industrial Coatings
      • Nanotechnology
      • Powder Coatings
      • Solventborne
      • Special Purpose Coatings
      • Sustainability
      • UV Coatings
      • Waterborne
      • FINISHING
        • Finishing News
        • Finishing Technologies
        • Finishing Equipment
      • RESOURCES
        • Columns
          • Ask Joe Powder
          • Did you know?
          • Distribution Dive
          • Focus on Canada
          • Formulating With Mike
          • Innovation Insights
          • Moody's Coatings Conundrums
          • Powder Coating Perspectives
          • Target the Market
          • TiO2 Insider
        • Blogs
          • Editor's Viewpoint
          • Industry Insights
        • Coatings Supplier Handbook
        • Podcasts and Videos
          • COAT-IT! Podcast
          • Videos/PCI TV
        • PCI Store
        • Classifieds
        • eBooks
        • Sponsor Insights
        • White Papers
        • COATLE Word Game
      • EVENTS
        • Coatings Trends & Technologies Summit
        • Paint and Coatings Academy
        • Webinars
        • Calendar of Events
        • Lifetime Achievement Award
      • DIRECTORIES
        • Buyer's Guide
        • Equipment Directory
        • Materials Directory
      • EMAGAZINE
        • Current Issue
        • eMagazine Archive
        • China Issue Archive
        • Editorial Advisory Board
      • CONTACT
        • Contact Us
        • Advertise
        • Subscribe to eMagazine
        • Subscribe to eNewsletters