1、精選優質文檔-傾情為你奉上專心-專注-專業Automotive Electrocoat Reference Manual陰極電泳漆涂裝手冊陰極電泳漆涂裝手冊* INDUSTRIES, INC. 精選優質文檔-傾情為你奉上專心-專注-專業Table of Contents目錄目錄1.INTRODUCTION TO ELECTROCOAT.2 簡介1.1.History of Electrocoat.2電泳涂裝的歷史1.2.Why Electrocoat.2為什么要采用電泳涂裝1.2.1.Advantages.1-5 優點1.2.2.Limitations.2 局限性1.3.What is Ele

2、ctrocoat.2什么是電泳涂裝1.3.1.Anodic Versus Cathodic.2 陽極電泳和陰極電泳的區別1.4.Electrochemical Reactions.1-16電化學反應1.5.Components of Feed and Bath.1-18槽液及加料祖份1.6.Deionized Water.1-21去離子水1.7.Membranes.1-21隔膜1.7.1.Ultrafilter Membranes .1-23 超率摸1.7.2.Anolyte Membranes.1-23 陽極膜1.8.Section Summary.2本節摘要2.DESIGN CONSIDE

3、RATIONS.2設計要素精選優質文檔-傾情為你奉上專心-專注-專業2.1.Introduction.2簡介2.2.General Design .2總體設計2.2.1.Basic Requirements.2 基本要求2.2.2.Sanitary Pans .2 滴漏盤2.2.3.Carrier Design.2-4 吊具設計2.3.Metal Preparation.2-4金屬預處理2.3.1.Body Shop Washer.2-4 車身清洗2.3.2.Phosphating.2-6 磷化2.4.Electrocoat Tank.2-6電泳槽2.4.1.Direction of Flow

4、.2-6 流動方向2.4.2.Adjustable Weir Plate.2-8 可調堰2.4.3.Freeboard and Overflow.2-8 槽堰超出液面高度和溢流2.4.4.Bottom Front End Filtration.2-9 槽前端過濾2.4.5.Dimensions: Clearance.2-12 尺寸：間隙2.4.6.Effective Coating Time.2-13 電泳時間2.4.7.Angle of Entry.2-13 入槽角度2.5.Materials of Construction.2-14精選優質文檔-傾情為你奉上專心-專注-專業建槽材料2.5.

5、1.Dip Tanks.2-14 浸槽2.5.2.Tank Enclosure.2-14 槽的間壁2.5.3.Tank Lining.2-15 槽襯里2.6.Paint Circulation.2-15槽液循環2.6.1.Surface Flow.2-16 表面液流2.6.2.Pipe Velocity.2-17 管路內流速2.6.3.Pumps.2-17 泵2.6.4Piping.2-18 管路2.6.5.Valves.2-19 閥2.6.6.Pressure Gauges.2-21 壓力表2.6.7.Gasket Materials.2-21 墊圈材料2.6.8.Filtration.2-

6、21 過濾2.6.9.Paint Cooling.2-22 槽液冷卻2.7.Electrical.2-23電器2.7.1.Anodes.2-23 陽極2.7.2.Roof Anodes .2-24精選優質文檔-傾情為你奉上專心-專注-專業 陽極頂蓋2.7.3.Anolyte Cells.2-26 陽極隔膜系統2.7.4.Power Supplies.2-28 電源2.7.5.Ultrafilters.2-30 超濾器2.8.Rinses 2淋洗2.8.1.General Rinses .2-31 概述2.8.2.Over Tank Rinses.2-33 槽上沖洗2.8.3.Recircula

7、ted Rinses #1 AND #2.2-34 第一道和第二道沖洗2.8.4.Drainage Between Rinses.2-37 各道沖洗之間的瀝液2.8.5.Dip Rinse.2-37 浸洗2.8.6.Recirculated D I Water Rinse.2-39 循環去離子水2.9.DI or RO Water.2-40去離子水和滲透水2.10.Temperature Protection .2-42溫度防護2.11.Line Stops.2-42停線2.12.Baking 2-43烘干2.13.Paint Storage Tanks.2-44涂料儲備槽2.14.Tank

8、Feed.2-44精選優質文檔-傾情為你奉上專心-專注-專業槽液配制2.14.1.Resin Component.2-45 樹脂組份2.14.2.Pigment Component.2-46 顏料組份2.14.3.Acid Injection.2-48 加酸3.SYSTEM OPERATION.2系統操作3.1.Introduction.2簡介3.2.Metal Cleaning And Phosphating.3-2金屬清洗及磷化3.2.1.Precleaning.3-2 預清洗3.2.2.Phosphating.3-3 磷化3.3.Tank Design and Construction.

9、3-4槽的設計和結構3.4.Paint Circulation.3-6槽液循環3.5.Tank Electrification.3-8電泳槽加電裝置3.5.1.Anodes.3-8 陽極3.5.2.Rectifiers.3-8 整流器3.6.Ultrafiltration.3-9超濾3.7.Rinse Systems .3-11清洗系統3.8.Baking 3-12精選優質文檔-傾情為你奉上專心-專注-專業烘干4.ANALYTICAL TESTS.2分析試驗4.1.Electrocoat Solids (Non-Volatile).2電泳漆固體份（不揮發份）4.2.Electrocoat pH

10、.4-5電泳漆 pH 值4.3.Electrocoat Conductivity.4-9電泳漆的電導率4.4.Panels and Panel Ratings.4-13試板及試板評價4.5.Measurement of Dry Film Thickness.4-16干膜厚度測量4.6.Sandwich Compatibility Test.4-18相容性試驗5.TERMINOLOGY.2專有名詞精選優質文檔-傾情為你奉上專心-專注-專業Introduction to Electrocoat 電泳漆簡介電泳漆簡介1.1. History of Electrocoat 電泳涂裝的歷史電泳涂裝的歷史

11、Research directed toward the development of a paint which could be deposited electrophoretically was begun in 1957 at the Ford Motor Company under the direction of Dr. George Brewer. This research was designed to develop a method for improving corrosion protection on hard-to-reach parts of car bodie

12、s.在美國福特車廠 George Brewer 博士的領導下，福特汽車公司從 1957 年就著手研究電泳涂裝。 這個計劃是開發一種改善車身難涂部位防腐蝕性的方法。Automobile manufacturers were well aware that rust occurred in interior recessed areas, also noting that flat exposed areas, such as roofs, were often rust free. Although dip coatings penetrated into the recessed areas,

13、 they were usually washed off by solvent vapors during baking. Thus, Dr. Brewers group strove to create a paint in which the solvents could be removed from the film during the application process. Their work led to the development of electrocoat.汽車制造廠商們早已注意到汽車內部隱蔽處的銹蝕，但暴露在外的平面部位， 如車頂卻不易銹蝕。雖然浸涂法能使涂料進

14、入汽車內部，但是在烘干過程中，油漆因溶劑蒸發而被洗掉。于是 Brewer 博士領導小組努力去開發一種在施工過程中溶劑可以從涂膜中被排除掉的涂料，他們的工作開創了電泳涂裝。The first Ford production tank began operation on July 4, 1961 to coat wheels. The Wixom tank for auto bodies was installed in 1963. Both of these tanks used anodic electrodeposition.福特公司的第一個用于車輪涂裝的生產槽在 1961 年 7 月 4

15、 日開始運行，用來涂裝汽車車身的 Wixom 槽建于1963 年， 這兩個槽所用的均是陽極電泳漆。Although market growth for electrodeposition steadily increased immediately after introduction, not until 1973, when cathodic products were introduced, did the market literally boom. In 1965, only one car in 100 was primed with electropaint; by 1970,

16、ten of 100 were electropainted; now, almost 90% are primed with cathodic electrocoat.開發電泳涂裝后，雖然市場的需求穩定增長，但直到 1973 年陰極電泳漆問世時，市場需求才真正繁榮起來。1965 年只有 1%轎車用電泳底漆，到 1970 年增加到 10%，現在幾乎 90%用電泳底漆。1.2. Why Electrocoat 為什么要電泳涂裝為什么要電泳涂裝Because of the marked advantages of electrodeposition, the process has, during

17、 the last two decades, become the dominant method for priming automobiles. A listing of the advantages of electrodeposition clearly explains the reasons for its spectacular success.精選優質文檔-傾情為你奉上專心-專注-專業由于電泳涂裝具有明顯的優點， 此工藝在過去的 20 年中已成為汽車涂底漆的最主要方法。以下的電泳涂裝優點清楚地說明了它獲得驚人成功的原因。1.2.1.Advantages 優點優點1Formati

18、on of protective films in highly recessed areas such as flanges and box sections provides critical corrosion protection.2 電泳漆在非常隱蔽的部位，如翻邊以及箱式結構，仍能形成完整的保護膜，從而得到較高的防腐蝕性。3Transfer efficiencies of better than 95% result in reduced paint waste, especially when compared with spray-applied coatings.4 尤其與噴涂

19、法相比，涂料利用率能達到 95%以上，減少了涂料的浪費。5Use of water as practically the only carrier virtually eliminates fire hazard, materially reduces water and air pollution, and markedly reduces the cost of facilities for controlling these conditions.6 使用水做載體，免除了火災危險。 大大降低了水和空氣的污染，明顯地減少了環保設備費用。7The low paint bath viscosi

20、ty (approximately equal to that of water) results in ease of pumping and allows drainage of the coated vehicle.8槽液粘度低（大約等于水的粘度），泵送容易，也利于被涂車身的瀝干。9Freshly-deposited paint is insoluble in water, permitting complete rinsing and recovery of dragged-out material.10剛沉積電泳上的漆不溶于水， 允許徹底清洗， 且 可回收帶出的槽液。11Uncure

21、d paint is dry enough to allow some handling.12 未固化的漆膜不粘手，甚至可以作某些處理。13Unlike spray coatings, electrodeposited paint will not sag during baking.14不象噴涂的涂膜，電泳沉積的涂膜在烘干時不 流掛。15Unlike dip coatings, electrodeposited paint is not washed off in enclosed areas by hot vapors during curing.16與浸法涂裝不同，電泳沉積在內腔部位的涂

22、 膜，在烘干過程中不會被熱蒸汽洗掉。17Since the process is automated, direct labor costs are markedly reduced.18由于生產過程自動化， 大大降低了直接勞動成本。19The deposited film is reproducible from part to part and from day to day.精選優質文檔-傾情為你奉上專心-專注-專業20 電泳工藝穩定，可保證漆膜均一涂于工件上。The electrochemical process of depositing paint appears, at firs

23、t examination, quite complicated; however, it is actually more trouble-free than other paint application processes for several reasons: 電泳涂裝法問世后，第一次考驗是相當復雜的，但由于下列幾個理由，實際上掌握它并不比其它涂裝方法難。21The large tank volume tends to minimize variations in paint or process.22槽的容量很大， 使涂料或工藝參數的波動減少到最小。23The operating

24、parameters are well defined and are based on extensive experience.24 操作工藝參數已有明確的規定，且是以豐富的經驗為基礎。25Samples from the tank, which are tested weekly at the PPG Electrocoat Laboratory, often predict problems before they appear on the line.26PPG 電泳漆實驗室每周從槽中取的樣品做實 驗，常常是在生產線上出現問題之前就能預報。Since the PPG Electroc

25、oat Laboratory constitutes a controlled environment, the following controls permit close monitoring of the commercial-scale process:由于 PPG 電泳漆實驗室時監控實驗室，可以實現以下對工業規模的工藝過程的嚴密控制。27A variety of metal substrates can be coated to permit extensive examination of differing conditions. 28可以涂裝各種各樣的金屬底材，且可進行不同

26、條件的嚴格考驗。29Several tanks can be easily cross-compared.30 可以容易的對幾個槽進行相互比較。31Close anode-cathode distances in the coating tubes that are used in the electrocoat laboratory can be employed to magnify problems experienced in the field.32在電泳實驗室使用的試驗槽中，調近陽極-陰極間距可用來放大在這方面經常出現的問題。1.2.2.Limitations 電泳涂裝的局限性電泳

27、涂裝的局限性Although the advantages of the electrodeposition process far outweigh disadvantages, some limitations exist. Electrodeposition can take place only on electrically-conductive substrates. When a unit is coated and baked, the electrodeposition of a second coat is impossible with standard electroc

28、oat products. Thus, electrodeposition is used mainly for the application of prime coats. Application of a variety of color coats requires separate dip tanks.雖然電泳的優點比缺點多，但是還是有一些局限性。電泳工藝只能用在導電的底材上；當涂裝的物體烘干后。 不可能進行第二次電泳涂裝。因此，電泳涂裝主要被用來涂底漆；涂不同的顏色涂膜要在不同的槽中進行。精選優質文檔-傾情為你奉上專心-專注-專業1.3. What is Electrocoat 什

29、么是電泳涂裝什么是電泳涂裝1.3.1.Anodic Versus Cathodic 陽極沉積法和陰極沉積法的區別Based upon the method of deposition, two types of electropaint have been developed: anodic and cathodic. The anodic types were commercialized first for two reasons:基于沉積的電泳方式，已經開發了陽極電泳漆和陰極電泳漆兩種類型的電泳漆陽極電泳漆首先投入正式生產有兩個原因：33The earlier resin technol

30、ogy was based on resins which contained acid groups. These could be neutralized to allow them to become soluble in water.34 早期的樹脂制造技術都是以含酸基團的樹脂為基礎，中和后，他們可以溶于水。35When the solubilized resin was deposited, it regained its acidic function. This acidity permits ready crosslinking (curing) when the coatin

31、g is baked.36 當水溶性樹脂沉積后，它可以恢復其酸性基團的功能。當此涂層被烘干時，這種酸性基團可使漆膜其迅速交聯（固化）。The ability to produce a cathodic-type resin was available long before the resins were introduced commercially in 1975. Two major problems had to be overcome before commercialization became possible: 陰極電泳漆的樹脂在 1975 年陽極型樹脂商品化之前很長一段時間內

32、就有能力制造了，但其正式投產之前要克服以下兩個主要的問題。37A method was needed to make alkaline polymers cure at temperatures low enough to ensure body integrity. 38 降低堿性聚合物固化的溫度，同時還要確保漆膜的均一性。 39The corrosivity of the bath solution had to be reduced.40 必須降低槽液的腐蝕性。 The process of curing thermosetting resins is called crosslinki

33、ng. During this process, which is driven by heat, the relatively small molecules deposited are chemically intertwined to form a single uniform film.熱固型樹脂的固化過程稱為交聯， 這個過程是以熱為動力，較小分子的沉積膜經化學交聯形成一個完整的表面。.The reactions involved in crosslinking deposited film depend upon the films chemical environment. The

34、 structures that are obtained by these curing reactions are essential for the practical value of the coating. Reaction conditions also determine bake time, temperature and, therefore, energy consumption.精選優質文檔-傾情為你奉上專心-專注-專業電泳漆膜交聯的反應取決于涂膜的化學反應環境，靠這些固化反應獲得的涂膜結構，對其防腐性能具有真正的實際價值。反應的條件也決定了烘干時間及溫度，以及消耗能源

35、。Anodic electrocoats usually have a pH of approximately 9.0; however, the deposited film is, in contrast, highly acidic. Acid catalyzed crosslinking reactions can be used with little difficulty.陽極電泳槽液一般 pH 約為 9，可沉積涂層卻是高酸性。酸催化的交聯反應比較容易進行。The situation is somewhat different for cathodic materials. As

36、with anodic resins, the crosslinking can be either internal or external. Because of the alkaline nature of the uncured cationic film, external linking reactions are sluggish.對陰極電泳就有所不同了，陽離子樹脂的交聯反應可以在內部或外部進行，但因未固化陰離子涂膜具有堿性，所以外部交聯反應較緩慢。Internal crosslinking is carried out by urethane groups mixed with

37、 the cathodic resin. These crosslinkers are stable in water at normal bath temperature but become reactive at curing temperatures. Special procedures are used to ensure that these crosslinkers will not react at bath temperature to cause instability.內部的交聯是靠與陽離子樹脂混合的氨基甲酸脂基團進行的。這些交聯劑于正常槽液溫度下在水中很穩定，但在固化

38、溫度下就變得活潑起來。通過采用一些特殊的處理工藝，確保這些交聯劑不會在槽液溫度起反應而引起槽液的不穩定性。Although numerous types of resins may be suitable for electrodeposition, the most common ones are thermosetting. Thermosetting resins fuse or melt when baked into a hard, uniform, solvent-resistant film.雖然多種樹脂都可以適用于電泳涂裝，但最常見的是熱固型的熱固型的樹脂在烘干時融合或融化成為

39、一堅硬，均勻的耐溶劑涂膜。Resin chemists must ensure that the resin has particular properties of hardness, flexibility, adhesion, water-and-chemical resistance, pigment wetting, and others. To be used as an electropaint, the resin must also have the following characteristics:研發人員必須確保樹脂具有硬度，柔韌性，附著力，耐水及化學品性，顏料濕潤性及

40、其它特性。用于制造電泳漆的樹脂還必須具備如下特性：41It must be soluble or dispersible to form a stable solution even when subjected to a wide variety of production conditions.42樹脂必須可溶解或分散成一種穩定的溶液，可以適應多種生產條件。43It must deposit onto an electrode to form a smooth, dense, insulating, wet film which also contains pigment. 44樹脂必須能

41、沉積在一個電極上，形成一光滑，致密，絕緣，并含有顏料的濕涂膜。45It must be able to coat a part which is complex in shape. 46必須能夠泳涂外形復雜的工件。47It must resist re-dissolution when rinsed.48 必須在沖洗時不再被溶解掉。49It must become mechanically and chemically stable upon baking so that the resulting film can fulfill its protective 精選優質文檔-傾情為你奉上專心

42、-專注-專業and/or decorative requirements.50經烘干后的涂膜具有機械及化學穩定性，以滿足保護和（或）裝飾的需要。Although the principle of electrodeposition gained acceptance with the anodic systems, it was not until the cathodic method was developed that electrodeposition became the common method for priming automobiles. The cathodic meth

43、od has the following advantages:雖然電泳涂裝的原理是從陽極電泳系統獲得的， 但是直到開發出了陰極電泳涂裝法以后， 電泳涂裝才成為汽車涂底漆普遍采用的方法。陰極電泳漆有以下優點：51It achieves corrosion resistance at low film thickness. 52 較低的膜厚具有良好的防腐蝕性。53It permits throwpower to interior surfaces without penalty of over-build on exterior surfaces.54保證工件內表面泳透力的同時，外表面上涂膜也不

44、會過厚。55It achieves bimetallic joint corrosion resistance required by the increased use of galvanized metal.56雙金屬復合層也能獲得良好的防腐蝕性， 可適應日益擴大的鍍鋅鋼板用量的需求。57It possesses saponification resistance and long-term adhesion retention over an entire galvanized body panel.58它具有耐皂化性， 在全鍍鋅的車身板上可長期保持其附著力。59It requires

45、substantially less electrical consumption for deposition and, as a result, less refrigeration for cooling. 60電泳本身耗電量少，從而用于冷卻的冷量也少。61It achieves gloss and hold-out with and without spray primers.62本身具有足夠的光澤度，可噴涂或不噴涂中涂， 同時在沒有中涂的情況下也不影響面漆的亮度。The prime advantage for cathodic systems, however, is superio

46、r corrosion protection. With anodic electrodeposition, metallic ions from the part being coated often become included in the deposited film. This condition results from anode reactions when current is applied. The presence of the iron ion in the film provides a readily available site for rust to sta

47、rt. In addition, when deposited, cationic resins are alkaline in nature and tend to be natural corrosion inhibitors. 其實， 陰極電泳的最主要優點還是防腐蝕性非常優良。材用陽極電泳時，由于通電時的陽極反應從被涂工件上溶下的金屬離子常常包含在漆膜中，。在漆膜中存在的鐵離子就成了開始生銹的誘因。另外，沉積時，陽粒子樹脂呈堿性， 這樣就成為天然的緩蝕劑。精選優質文檔-傾情為你奉上專心-專注-專業1.4. Electrochemical Reactions 電化學反應電化學反應To th

48、is point, we have discussed anodic and cathodic paint and have used the terms anionic and cationic as well. Although the terms cathodic and cationic may be used as synonyms, they refer to two different aspects of the subject.到此為止， 我們已經討論了陽極漆和陰極漆，并且已使用了陽離子，陰離子等術語，雖然陽極和陰離子可以作為同義詞使用， 其實他們是用于表示一個事物的兩個不同

49、方面的。Positively charged electrodes are called anodes while negatively charged ones are called cathodes. A water solution contains charged particles which are called ions. Ions are atoms or molecules with charges. Anions have negative charges, and cations have positive charges. If one remembers that o

50、pposites attract, the problem simplifies. The cathode is negative: thus, it repels negative charges and attracts positive charges.帶正電荷的電極稱為陽極，帶負電荷的電極成為陰極，水溶液中含有的帶電粒子稱為離子，離子是帶電荷的原子和分子，陰離子帶負電荷，陽離子帶正電荷，如果大家都明白異性相吸的道理，問題就簡單了，陰極帶負電：所以它排斥負電荷而吸引正電荷。The positively-charged ions in the solution are called cat

51、ions, and the negatively-charged particles are called anions. Thus, by the principle of opposites attracting, the cations (positive charges) are attracted to the cathode (which is negative in charge). Since the cathode is relatively fixed in position, the cations move toward it. This movement is cal

52、led migration.溶液中帶正電荷的離子稱為陽離子， 帶負電荷的離子稱為陰離子。這樣，根據異性相吸的原理，陽離子（帶正電荷）與陰極（帶負電荷）相互吸引，由于陰極位置相對固定，故此陽離子便移向陰極，這種運動稱為遷移。Negatively-charged ions keep the positively-charged resin molecules in a cathodic system in solution. The solubility of the resin depends on the critical balance of positively and negativel

53、y charged ions.帶負電荷的離子把帶正電的樹脂分子存在于陰極系統的溶液中。樹脂的溶解性取決于陰，陽離子的電平衡。When paint is deposited at the cathode, the process is called cathodic, and paint with a positive charge is called cationic paint. Thus, the terms cathodic and cationic refer, respectively, to where the paint is deposited and the type of

54、charge of the deposited paint. The two terms are often used interchangeably.電泳漆沉積在陰極上時，此工藝稱為陰極電泳，帶正電荷的漆稱為陽離子型電泳漆。故此“陰極的”極“陽離子的”兩個術語即分別表示漆的沉積對象及沉積漆的帶電類型。這兩個術語?？苫Q使用。The electrocoating process is known by several names: 電泳涂裝工藝在英語中有以下幾個名詞： Elpo E-Coat Electropainting Electrodeposition 精選優質文檔-傾情為你奉上專心-專

55、注-專業 Electrophoretic Painting Electrocoating is similar in process to that of electroplating, such as the application of chrome on automobile bumpers. The two processes are alike in that both use the passage of electric current for deposition. They differ, however, because electroplating deposits me

56、tallic ions whereas electrocoating deposits organic resin molecules.跟電鍍工藝相似，比如汽車保險杠度鉻，電泳，電鍍這兩種工藝都是通過利用電流產生沉積。不同之處在于，電鍍時沉積金屬離子，電泳時沉積有機樹脂分子。Cathodic electrocoating is a paint-plating type operation in which the object to be coated is dipped into a water-thinned paint. A direct current is then passed t

57、hrough the paint. In the cathodic system, the article to be coated is made the cathode ( is charged negatively). The paint solids are positively charged and are, therefore, attracted to the cathode.陰極電泳涂裝是一種將被涂件浸入水稀釋的涂料中，進行類似電鍍上漆的涂漆工藝，通過在涂料中通直流電， 在陰極電泳涂裝體系中， 被涂件作為陰極（帶負電）。 油漆固體份帶正電荷， 因此被吸引到陰極。Electro

58、deposition of paint films simultaneously involves electrophoresis, electrolysis, electrodeposition, and electroendosmosis. Although a thorough understanding of these principles is not necessary for one to understand the operation of an electrocoat tank, they are presented here to explain the process

59、es taking place beneath the surface of the tank.漆膜的電沉積過程同時包含有電泳，電解，電沉積，電滲等過程。對于電泳槽的操作人員來說， 他們不一定要懂得這些原理，我們在此只是把在電泳槽中所發生的化學反應以及工藝原理進行解釋。63Electrolysis is the decomposition of a conductive liquid by the passage of an electric current. The electrolysis of water into hydrogen and oxygen is perhaps the b

60、est known example of this process. Electrolysis is usually accompanied by gas evolution at one or both electrodes. Gassing is undesirable in the electrocoating process, limiting the throwing power, an important property which will be discussed later. Since gassing is proportional to current flow, su