1、11-3-97 Ver1Automotive ElectrocoatReference Manual阴极 电泳漆涂装手册* INDUSTRIES, INC.Automotive Electrodeposition Reference Manual11-3-97 i Ver 1Table of Contents目录1. INTRODUCTION TO ELECTROCOAT. 2简介1.1. History of Electrocoat 2电泳涂装的历史1.2. Why Electrocoat. 2为什么要采用电泳涂装1.2.1. Advantages . 1-5优点1.2.2. Limitat
2、ions 2局限性1.3. What is Electrocoat 2什么是电泳涂装1.3.1. Anodic Versus Cathodic 2阳极电泳和阴极电泳的区别1.4. Electrochemical Reactions. 1-16电化学反应1.5. Components of Feed and Bath 1-18槽液及加料祖份1.6. Deionized Water. 1-21去离子水1.7. Membranes . 1-21隔膜1.7.1. Ultrafilter Membranes 1-23超率摸1.7.2. Anolyte Membranes. 1-23阳极膜1.8. Sec
3、tion Summary2本节 摘要2. DESIGN CONSIDERATIONS. 2设计 要素2.1. Introduction 2简介Automotive Electrodeposition Reference Manual11-3-97 ii Ver 12.2. General Design . 2总体 设计2.2.1. Basic Requirements . 2基本要求2.2.2. Sanitary Pans . 2滴漏盘2.2.3. Carrier Design 2-4吊具设计2.3. Metal Preparation 2-4金属预处 理2.3.1. Body Shop Wa
4、sher. 2-4车身清洗2.3.2. Phosphating 2-6磷化2.4. Electrocoat Tank 2-6电泳槽2.4.1. Direction of Flow2-6流动方向2.4.2. Adjustable Weir Plate.2-8可调堰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槽前端过滤2.4.5. Dimensions: Clearance 2-12尺寸：间隙2.4.6. Effective Coating Time 2-13电泳时间2.4.7
5、. Angle of Entry 2-13入槽角度2.5. Materials of Construction 2-14建槽材料2.5.1. Dip Tanks2-14浸槽Automotive Electrodeposition Reference Manual11-3-97 iii Ver 12.5.2. Tank Enclosure 2-14槽的间壁2.5.3. Tank Lining 2-15槽衬里2.6. Paint Circulation 2-15槽液循环2.6.1. Surface Flow. 2-16表面液流2.6.2. Pipe Velocity. 2-17管路内流速2.6.3
6、. Pumps 2-17泵2.6.4 Piping 2-18管路2.6.5. Valves 2-19阀2.6.6. Pressure Gauges. 2-21压力表2.6.7. Gasket Materials 2-21垫圈材料2.6.8. Filtration. 2-21过滤2.6.9. Paint Cooling 2-22槽液冷却2.7. Electrical . 2-23电器2.7.1. Anodes. 2-23阳极2.7.2. Roof Anodes . 2-24阳极顶盖2.7.3. Anolyte Cells. 2-26阳极隔膜系统2.7.4. Power Supplies. 2-2
7、8电源Automotive Electrodeposition Reference Manual11-3-97 iv Ver 12.7.5. Ultrafilters 2-30超滤器2.8. Rinses 2淋洗2.8.1. General Rinses . 2-31概述2.8.2. Over Tank Rinses. 2-33槽上冲洗2.8.3. Recirculated Rinses #1 AND #22-34第一道和第二道冲洗2.8.4. Drainage Between Rinses 2-37各道冲洗之间的沥液2.8.5. Dip Rinse. 2-37浸洗2.8.6. Recircu
8、lated D I Water Rinse.2-39循环去离子水2.9. DI or RO Water 2-40去离子水和渗透水2.10. Temperature Protection 2-42温度防护2.11. Line Stops 2-42停线2.12. Baking 2-43烘干2.13. Paint Storage Tanks. 2-44涂料储备 槽2.14. Tank Feed . 2-44槽液配制2.14.1. Resin Component. 2-45树脂组份2.14.2. Pigment Component 2-46颜料组份2.14.3. Acid Injection. 2-4
9、8加酸Automotive Electrodeposition Reference Manual11-3-97 v Ver 13. SYSTEM OPERATION 2系统 操作3.1. Introduction 2简介3.2. Metal Cleaning And Phosphating. 3-2金属清洗及磷化3.2.1. Precleaning . 3-2预清洗3.2.2. Phosphating 3-3磷化3.3. Tank Design and Construction3-4槽的设计 和 结构3.4. Paint Circulation 3-6槽液循环3.5. Tank Electri
10、fication . 3-8电泳槽加电 装置3.5.1. Anodes. 3-8阳极3.5.2. Rectifiers. 3-8整流器3.6. Ultrafiltration . 3-9超滤3.7. Rinse Systems . 3-11清洗系统3.8. Baking 3-12烘干4. ANALYTICAL TESTS . 2分析 试验4.1. Electrocoat Solids (Non-Volatile) 2电泳漆固体份（不挥发份）4.2. Electrocoat pH 4-5电泳漆 pH 值4.3. Electrocoat Conductivity . 4-9电泳漆的电导率Autom
11、otive Electrodeposition Reference Manual11-3-97 vi Ver 14.4. Panels and Panel Ratings. 4-13试板及试板 评价4.5. Measurement of Dry Film Thickness .4-16干膜厚度 测 量4.6. Sandwich Compatibility Test 4-18相容性试验5. TERMINOLOGY 2专有名词Automotive Electrodeposition Reference Manual11-3-97 Section 1 Ver 1 Introduction to El
12、ectrocoat电泳漆简介1.1. History of Electrocoat电泳涂装的历史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 corrosio
13、n protection on hard-to-reach parts of car bodies.在美国福特车厂 George Brewer 博士的 领导 下，福特汽车公司从 1957 年就着手研究 电 泳涂装。 这 个计划是开发一种改善车 身难涂部位防腐蚀性的方法。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. Alt
14、hough dip coatings penetrated into the recessed areas, 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.
15、汽车制造厂商们早已注意到汽车内部 隐蔽处的锈蚀 ，但暴露在外的平面部位， 如车顶却不易 锈蚀。虽然浸涂法能使涂料进 入汽车 内部，但是在烘干过程中，油漆因溶剂 蒸 发而被洗掉。于是 Brewer 博士领导小组努力去开发一种在施工过程中溶剂可以从涂膜中被排除掉的涂料，他们的工作开创了电泳涂装。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 u
16、sed anodic electrodeposition.福特公司的第一个用于车轮涂装的生产槽在 1961 年 7 月 4 日开始运行，用来涂装汽 车车身的 Wixom 槽建于1963 年， 这两个槽所用的均是阳极电泳漆。Although market growth for electrodeposition steadily increased immediately after introduction, not until 1973, when cathodic products were introduced, did the market literally “boom“. In 1
17、965, only one car in 100 was primed with electropaint; by 1970, ten of 100 were electropainted; now, almost 90% are primed with cathodic electrocoat.开发电泳涂装后，虽然市场的需求稳定增长，但直到 1973 年阴极电泳漆问 世时，市 场 需求才真正繁荣起来。1965 年只有 1%轿车用电泳底漆，到 1970 年增加到 10%，现在几乎 90%用电泳底漆。1.2. Why Electrocoat为什么要电 泳涂装Because of the mark
18、ed advantages of electrodeposition, the process has, during 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.Automotive Electrodeposition Reference Manual11-3-97 Section
19、 2 Ver 1由于电泳涂装具有明显的 优点， 此工艺在过去的 20 年中已成为汽车涂底漆的最主要方法。以下的电泳涂装优点清楚地说明了它获 得惊人成功的原因。1.2.1. Advantages优点1 Formation of protective films in highly recessed areas such as flanges and box sections provides critical corrosion protection.2 电泳漆在非常隐蔽的部位，如翻边 以及箱式 结构，仍能形成完整的保 护膜，从而得到较高的防腐 蚀性。3 Transfer efficiencie
20、s of better than 95% result in reduced paint waste, especially when compared with spray-applied coatings.4 尤其与喷涂法相比，涂料利用率能达到 95%以上，减少了涂料的浪 费。5 Use of water as practically the only carrier virtually eliminates fire hazard, materially reduces water and air pollution, and markedly reduces the cost of f
21、acilities for controlling these conditions.6 使用水做 载体，免除了火灾危险。 大大降低了水和空气的污染，明显地减少了 环保设备费用。7 The low paint bath viscosity (approximately equal to that of water) results in ease of pumping and allows drainage of the coated vehicle.8 槽液粘度低（大约等于水的粘度）， 泵送容易，也利于被涂车身的沥干。9 Freshly-deposited paint is insolubl
22、e in water, permitting complete rinsing and recovery of dragged-out material.10 刚 沉积电泳上的漆不溶于水， 允许彻底清洗， 且 可回收 带出的槽液。11 Uncured paint is dry enough to allow some handling.12 未固化的漆膜不粘手，甚至可以作某些处理。13 Unlike spray coatings, electrodeposited paint will not sag during baking.14 不象喷涂的涂膜， 电泳沉积的涂膜在烘干时 不 流掛。15
23、Unlike dip coatings, electrodeposited paint is not washed off in enclosed areas by hot vapors during curing.16 与浸法涂装不同，电泳沉积在内腔部位的涂 膜，在烘干过程中不会被 热蒸汽洗掉。17 Since the process is automated, direct labor costs are markedly reduced.18 由于生 产过程自动化， 大大降低了直接劳动成本。19 The deposited film is reproducible from part t
24、o part and from day to day.20 电泳工艺稳 定，可保 证漆膜均一涂于工件上。Automotive Electrodeposition Reference Manual11-3-97 Section 3 Ver 1 The electrochemical process of depositing paint appears, at first examination, quite complicated; however, it is actually more trouble-free than other paint application processes
25、for several reasons: 电泳涂装法 问世后，第一次考 验 是相当复 杂的，但由于下列几个理由，实际 上掌握它并不比其它涂装方法难。21 The large tank volume tends to minimize variations in paint or process.22 槽的容量很大， 使涂料或工艺 参数的波 动减少到最小。23 The operating parameters are well defined and are based on extensive experience.24 操作工艺参数已有明确的 规定，且是以丰富的经验为基础。25 Sample
26、s from the tank, which are tested weekly at the PPG Electrocoat Laboratory, often predict problems before they appear on the line.26 PPG 电泳漆实验 室每周从槽中取的样 品做实 验，常常是在生产线上出 现问题之前就能预报。Since the PPG Electrocoat Laboratory constitutes a controlled environment, the following controls permit close monitoring
27、 of the commercial-scale process:由于 PPG 电 泳漆实验 室 时监控实验室，可以实现以下 对工业规模的工艺过 程的严密控制。27 A variety of metal substrates can be coated to permit extensive examination of differing conditions. 28 可以涂装各种各 样的金属底材，且可进行不同 条件的严格考验。29 Several tanks can be easily cross-compared.30 可以容易的 对 几个槽进行相互比较。31 Close anode-c
28、athode distances in the coating tubes that are used in the electrocoat laboratory can be employed to magnify problems experienced in the field.32 在 电泳实验室使用的试验槽中，调近阳极 -阴极 间距可用来放大在这方面经常出现 的问题。1.2.2. Limitations电泳涂装的局限性Although the advantages of the electrodeposition process far outweigh disadvantages,
29、 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 electrocoat products. Thus, electrodeposition is used mainly for the application of prime coats. A
30、pplication of a variety of color coats requires separate dip tanks.虽然电泳的 优点比缺点多，但是还是有一些局限性。电泳工艺只能用在 导电的底材上；当涂装的物体烘干后。不可能进 行第二次电 泳涂装。因此，电泳涂装主要被用来涂底漆；涂不同的颜色涂膜要在不同的槽中进行。Automotive Electrodeposition Reference Manual11-3-97 Section 4 Ver 11.3. What is Electrocoat什么是电泳涂装1.3.1. Anodic Versus Cathodic阳极沉积法和
31、阴极沉积 法的区别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:基于沉积的 电泳方式，已经开发 了阳极电泳漆和阴极电泳漆两种类型的电泳漆阳极 电泳漆首先投入正式生产有两个原因：33 The earlier resin technology was based on resins which contained aci
32、d groups. These could be neutralized to allow them to become soluble in water.34 早期的树脂制造技术都是以含酸基团的 树脂为基础，中和后，他们可以溶于水。35 When the solubilized resin was deposited, it regained its acidic function. This acidity permits ready crosslinking (curing) when the coating is baked.36 当水溶性 树脂沉积后，它可以恢复其酸性基团的功能。当此
33、涂层被烘干时，这种酸性基团可使漆膜其迅速交联（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: 阴极电泳漆的树脂在 1975 年阳极型树脂商品化之前很长一段时间内就有能力制造了，但其正式投产之前要克服以下两个主要的问题。37 A method
34、 was needed to make alkaline polymers cure at temperatures low enough to ensure body integrity. 38 降低碱性聚合物固化的温度，同时还要确保漆膜的均一性。 39 The corrosivity of the bath solution had to be reduced.40 必须降低槽液的腐蚀性。 The process of curing thermosetting resins is called “crosslinking“. During this process, which is dr
35、iven by heat, the relatively small molecules deposited are chemically intertwined to form a single uniform film热固型树脂的固化过程称为交联， 这个过程是以热为动力，较小分子的沉积膜经 化学交联形成一个完整的表面。.The reactions involved in crosslinking deposited film depend upon the films chemical environment. The structures that are obtained by the
36、se curing reactions are essential for the practical value of the coating. Reaction conditions also determine bake time, temperature and, therefore, energy consumption.电泳漆膜交 联的反应取决于涂膜的化学反应环境，靠这些固化反应获得的涂膜结构，对其防腐性能 具有真正的实际价 值。反应的条件也决定了烘干时间及温度，以及消耗能源。Automotive Electrodeposition Reference Manual11-3-97
37、Section 5 Ver 1 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.阳极电泳槽液一般 pH 约为 9，可沉积涂层 却是高酸性。酸催化的交 联反应 比较容易进行。The situation is somewhat different for catho
38、dic materials. As 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.对阴极电泳就有所不同了，阳离子树脂的交联反 应可以在内部或外部进行，但因未固化阴离子涂膜具有碱性，所以外部交联反应较缓慢。Internal crosslinking is carried out by urethan
39、e groups mixed with 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.内部的交联 是靠与阳离子树脂混合的氨基甲酸脂基团进行的。这些交联
40、剂于正常槽液温度下在水中很稳定，但在固化温度下就变得活泼起来。通过采用一些特殊的处理工艺，确保这些交联剂不会在槽液温度起反应而引起槽液的不稳 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.虽然多种树 脂都可以适用于电泳涂装，但最常见
41、的是热固型的热固型的树 脂在烘干时融合或融化成 为一坚硬，均匀的耐溶剂涂膜。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:研发人员必 须确保树脂具
42、有硬度，柔韧性，附着力，耐水及化学品性，颜料湿润性及其它特性。用于制造 电泳漆的树脂 还必须 具备如下特性：41 It must be soluble or dispersible to form a stable solution even when subjected to a wide variety of production conditions.42 树 脂必须 可溶解或分散成一种 稳定的溶液，可以适应多种生产条件。43 It must deposit onto an electrode to form a smooth, dense, insulating, wet film w
43、hich also contains pigment. 44 树 脂必须 能沉 积 在一个电极上，形成一光滑，致密， 绝缘 ，并含有 颜 料的湿涂膜。45 It must be able to coat a part which is complex in shape. 46 必 须能够 泳涂外形复杂的工件。47 It must resist re-dissolution when rinsed.48 必须在冲洗时 不再被溶解掉。49 It must become mechanically and chemically stable upon baking so that the result
44、ing film can fulfill its protective and/or decorative requirements.50 经 烘干后的涂膜具有机械及化学稳 定性，以满足保护和（或）装饰的需要。Automotive Electrodeposition Reference Manual11-3-97 Section 6 Ver 1Although the principle of electrodeposition gained acceptance with the anodic systems, it was not until the cathodic method was
45、 developed that electrodeposition became the common method for priming automobiles. The cathodic method has the following advantages:虽然电泳涂装的原理是从阳极电泳系 统获得的， 但是直到开发 出了阴极电泳涂装法以后， 电泳涂装才成为汽车涂底漆普遍采用的方法。阴极 电泳漆有以下优点：51 It achieves corrosion resistance at low film thickness. 52 较低的膜厚具有良好的防腐蚀性。53 It permits t
46、hrowpower to interior surfaces without penalty of over-build on exterior surfaces.54 保 证工件内表面泳透力的同时，外表面上涂膜也不会过厚。55 It achieves bimetallic joint corrosion resistance required by the increased use of galvanized metal.56 双金属复合层也能获得良好的防腐蚀性， 可适 应日益扩大的镀锌钢板用量的需求。57 It possesses saponification resistance an
47、d long-term adhesion retention over an entire galvanized body panel.58 它具有耐皂化性， 在全镀锌的 车身板上可 长期保持其附着力。59 It requires substantially less electrical consumption for deposition and, as a result, less refrigeration for cooling. 60 电 泳本身耗电量少，从而用于冷却的冷量也少。61 It achieves gloss and hold-out with and without s
48、pray primers.62 本身具有足够的光泽度，可 喷 涂或不 喷涂中涂， 同时在没有中涂的情况下也不影响面漆的亮度。The prime advantage for cathodic systems, however, is superior corrosion protection. With anodic electrodeposition, metallic ions from the part being coated often become included in the deposited film. This condition results from anode re
49、actions when current is applied. The presence of the iron ion in the film provides a readily available site for rust to start. In addition, when deposited, cationic resins are alkaline in nature and tend to be natural corrosion inhibitors. 其实， 阴极 电泳的最主要 优点还是防腐蚀性非常优良。材用阳极电泳时 ，由于通电时的阳极反应从被涂工件上溶下的金属离子常常包含在漆膜中，。在漆膜中存在的铁离子就成了开始生锈的诱因。另外，沉积时，阳粒子树脂呈碱性， 这样就成为天然的 缓蚀剂 。1.4. Electrochemical Reactions电化学反应To this point, we have discussed anodic and cathodic paint and have used the terms anionic and cationic as well. Although the terms “cathodic“ and
