REACh-compliant chrome coating on plastic

Cromatipic® coating proves itself as a fully industrialized chrome coating technology for plastic parts, completely without process emissions, i.e. REACh compliant for 2024 and beyond.

Thecoating system is based on UV lacquer and PVD coating and meets the most stringent industrial test criteria. Additional decorative and functional features create new attractive user benefits. Hauzer has been demonstrating the industrial maturity and expertise of Cromatipic® technology with a large coating plant in operation since 2017.

REACh Regulation 1907/2006 created the need to develop chrome coating processes for plastic components that meet the high requirements of the automotive industry but do not require hexavalent chromium substances. Hauzer has developed the Cromatipic® technology to provide a fully viable successor technology for the chrome plating of plastic parts.

The REACh Committee of the European Chemical Agency (ECHA) granted companies using chromium trioxide substances (_CrO3) for electrodeposition on plastics a maximum of 7 years to review the availability of safe alternatives or, if possible, to replace the substance earlier. After the sunset date of Sept. 21, 2017, the authorization to use hexavalent chromium substances will expire in about 4 years, on Sept. 21, 2024.

The rapidly approaching expiry triggers the need for the qualification of successor technologies for the chrome plating of plastic parts.

Figure 1a and 1b: Cromatipic® translucent - alternatively decorative chrome or illuminated area Figure 1a and 1b: Cromatipic® translucent coating - alternatively decorative chrome or illuminated area

Cromatipic® is a two-layer system consisting of UV lacquer and a PVD chrome coating, which does not require any chemicals containing chrome. It is a fully operational process that meets demanding test requirements. Cromatipic® is an industrialized technology which is continuously applied to automotive components and there are numerous passed validation processes of series applications in the automotive industry. At the same time, the cost efficiency is in line with current market prices for the chrome plating of plastic parts.

Cromatipic® not only complies with the REACh regulation, but is also a true zero-emission process. Both parts of the coating system, the UV coating and the PVD process, do not emit any environmental emissions. The coating process uses 100% solvent-free UV coating that does not contain any VOCs (volatile organic compounds). Conventional solvent-based paints require a downstream regenerative thermal oxidation (RTO) process to burn off harmful air pollutants. Such post-combustion processes are not necessary when using Cromatipic® technology UV coatings - which complies with local and international regulations. It is therefore easy to obtain a plant approval for a Cromatipic® system.

Fig. 2a and b: Cromatipic® "seamless" - Symbols appear seamless when not back-illuminated Figure 2a and b: Cromatipic® "seamless" - Symbols appear seamless when not back-illuminated

Automotive test specifications

Being a qualified future chrome coating technology for plastic parts means meeting the most stringent automotive test conditions. The gloss variant "Cromatipic® bright", was developed to meet the TL-226 and TL-528 standards, VW's test requirements for painted interior and exterior parts. For example, the hydrolysis test is part of TL-226 in which the coating is subjected to test conditions of 72h at
90 °C and 95 % relative humidity without any change in appearance, adhesion or scratch resistance. Another passed test from TL-226 is the 2000 stroke crock meter test.

Cost Efficiency

Cromatipic® is designed to be the number one successor technology for the electroplating of plastics on a large scale. This also applies to the cost aspect. Hauzer's Cromatipic® coating plant offers pricing that is common for CrIII electroplating. The facility near Barcelona is fully automated and set up for 3-shift operation. Customers can outsource contract plating there.

The coating line has sufficient capacity and is designed for part lengths of up to 1500 mm. Three-dimensional parts can be coated up to a maximum cross-sectional diameter of 200 mm. The process includes both stationary and continuous steps and allows part rotation or non-rotating positioning of substrates.

The color of the chrome layer is of interest to automotive designers. Cromatipic® coatings provide high process stability and high color fidelity, reliably delivering the same color from batch to batch. The color has been approved by automotive OEMs for numerous applications.

Additional decorative and functional features

Metallic colors can also be deposited that are clearly different from the chrome color. Shades of gray, anthracite, brown, brass, gold and black can be deposited using downstream PVD processes. The "gloss" or "matt" option is achieved by using various UV coatings.

Cromatipic® technology opens up a wide range of possibilities for designers. A new coating variant allows backlighting of coated surfaces. Parts can be used either as a light source - with backlighting - or as a decorative, non-backlit element. The lighting effect can be displayed as a line or symbol, or over the entire surface of the part.

The coating process is similar to the Cromatipic® coating on plastic. The luminous effect is achieved by using transparent plastic and UV lacquer as well as a semi-transparent chrome layer. The degree of translucency can be adjusted by the parameters of the PVD chrome coating process. Letters or symbols are applied using a laser etching process. The Cromatipic® translucent variant can be used as decorative light in the vehicle interior or for functional light in the exterior, such as on mirror housings with blinker function.

Cromatipic® also offers unprecedented geometric flexibility for coated parts. While galvanized frames - if they are delicate or thin-walled - can break during assembly, the paint-based Cromatipic® coating is highly flexible and does not break during assembly, which eliminates rejects late in the value chain.

Plant construction

With the coating plant near Barcelona, Hauzer is demonstrating the technical and commercial feasibility of Cromatipic® technology. In addition to operating the plant
Hauzer also offers complete turnkey coating systems. The engineers at Hauzer's headquarters in the Netherlands offer fully automated Cromatipic® coating lines, including^CO2 cleaning, UV coating and curing, PVD coating in a Hauzer Metalliner®, an in-line PVD system. The scope of delivery of a turnkey system is supplemented by all system components for the peripheral processes, such as transport system, paint supply, robot systems, ultra-pure air supply, power and paint supplies as well as racks, rack cleaning and more.

As a global PVD system manufacturer, Hauzer can use its service organization to ensure maintenance and servicing for the Cromatipic® system technology.

Hauzer is always ready to receive interested customers at its site near Barcelona who would like to find out more and visit the Cromatipic® coating process.

Fig 3: Cromatipic® coating performs vast elastic flexing, as shown on an ABS/PC dashboard frame Figure 3: Cromatipic® coating performs vast elastic flexing, as shown on an ABS/PC dashboard frame

Cromatipic® proves to be a fully industrialized PVD chrome plating technology for plastics components, with zero process emissions, compliant with REACh for the year past 2024 and beyond.

The coating system is based on UV-lacquer and PVD-coating which complies with the most challenging industrial test requirements. Added decorative and functional features open new and attractive user benefits. With a large coating line in operation since 2017, Hauzer proves the mature and industrialized capability of the Cromatipic® technology.

The REACh directive 1907/2006 has brought about the need to develop chrome coating processes for plastics components that fulfill high needs of the automotive industry, but work without hexavalent chrome substances. Hauzer developed Cromatipic® to be a fully capable successor technology for chrome plating on plastics.

The REACh Committee of the European Chemicals Agency (ECHA) decided to allow companies using chromium trioxide (_CrO3) substances in electroplating on plastic parts a maximum of 7 years to reassess the availability of safer alternatives or substitute the substance earlier when possible.

With the sunset date having passed on 21. Sept 2017, the authorization to use of hexavalent chrome solutions will therefore terminate in four years from now, on 21. Sept 2024.

The rapidly/shortly approaching date of the termination now triggers the need for the qualification of succeeding technologies for chrome plating on plastics.

Cromatipic® is a dual layer made of UV-lacquer and PVD chrome coating, completely free of chromium chemistry. It is a fully capable process that complies with challenging testing standards. Cromatipic® is an industrialized technology that is applied on automotive components on an ongoing basis. It has achieved numerous validation processes in long term automotive applications. At the same time, the cost efficiency is compliant with current market pricing for chrome plating on plastics parts.

Cromatipic® not only complies with REACh, but is a real zero emission process. Both Cromatipic® sub-layers, the UV-lacquer coating and the PVD process do not produce environmental emissions. The PVD chrome coating is performed under high vacuum, which does not emit any waste substances. And the lacquering process is using a solvent-free paint (100% solid content) that has no VOCs. Old solvent-paint technologies needed an added regenerative thermal oxidization (RTO) process to destroy hazardous air pollutants (HAPs) and volatile organic compounds (VOCs). Such added burning off process is not needed with lacquer used in Cromatipic® technology - which complies with local and international environment regulations about VOCs emission. Therefore, attaining operational approval for a Cromatipic® coating line is easy.