合理的反渗透设备流程是纯水
设备使用寿命的有力保证。只
有合理的流程才可以延长纯水
设备的寿命...
合理的反渗透设备流程是纯水
设备使用寿命的有力保证。只
有合理的流程才可以延长纯水
设备的寿命...
东莞鑫泽表面处理材料有限公司
地址：东莞市虎门镇金洲二区二排九栋六楼
联系人：张增参
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产品名称：电泳漆CNM-130
所属类别：德国低温阴极聚氨酯电泳漆CNM-130
产品简介：...
德国低温阴极聚氨酯电泳漆CNM-120浓缩液
产品说明：
主要成份：聚氨脂&&
固含量：55%
包装；20L&&&&&&&
产地：德国进口
价格：2元/L&&&
适用客户：高档箱包，饰品等 &&&&&&&
性能：低温固化，盐雾72小时，50%硝酸测试60S， &&&&&&&&
CNM-130是德国 进口聚氨酯体系的低温阴极电泳漆，适用于各种金属材料上的透明保护和彩色装饰。
一.【主要特点】
1)漆膜的外观均匀，光泽度高，流平性好，适用于透明涂装；
2)漆膜的固化温度低，适合于锌压铸件等各种金属材料上的电泳涂装；
3)提高固化可以提高性能，漆膜不会黄变；
4)电泳漆的性能稳定，易于管理。
二．原漆参数
操作条件】
过滤机3个循环每小时
用1~5μ棉芯过滤
固化条件】
三．漆配制和补充】
1)原漆的固体份为60%，用去离子水（5μS/cm以下）稀释到9~10%的固体份，即可进行电泳涂装。如配制10%固体份涂液原漆和去离
子水的比例为： 原漆∶去离子水＝1∶5
2)配制开始时先要到入少量去离子水，此时漆的黏度会提高，漫漫加水至涂料完全溶解。
3)补充漆时将固体份为20~30%的漆直接到入工作液，连续搅拌均匀后即可使用。
【日常管理维护】
（1）定期测定工作液的固体份进行补充和调节。
（2）出现漆膜不均匀，火山口等加入10%~20%的新涂料调整，固体份已偏高可补充10~20ml/L的溶剂IP。
（3）电泳漆的电导率过高、pH异常或外观有异常时测定涂料工作涂料的固体份，并超过滤1/3后，补加新漆。
（4）电泳漆长期放置后再使用由于涂膜变薄和老化，涂料每月用量不要低于开槽量的三分之一。
（5）漆膜上有细小颗粒，可用1微米的精密滤芯连续过滤。
四． &工艺流程： 电解脱脂→水洗→酸&& 洗→& 纯水洗→电泳涂装→回收→水洗→脱水→预干燥→固化 &。
五 常见故障及处理方案
可能产生的原因
提高电压、补新漆、提高槽温
离子污染，镀膜过厚
超滤，降低电压
清洗水污染
换清洗水，降低固含量
表面有油污
加强前处理
积油（缩边）
降低电压，减少时间
&上一个：没有了
下一个： 没有了
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备案号码：粤ICP备号 技术支持：电泳漆使用手册_甜梦文库
电泳漆使用手册
Automotive Electrocoat Reference Manual 阴极电泳漆涂装手册PPG INDUSTRIES, INC. 3800 W. 143rd Street Cleveland, OH 1-005011-3-97Ver1
Automotive Electrodeposition Reference ManualTable of Contents 目录1. INTRODUCTION TO ELECTROCOAT .................................................... 1-1简介 1.1. History of Electrocoat ..............................................................................................1-1 电泳涂装的历史 Why Electrocoat .......................................................................................................1-2 为什么要采用电泳电泳涂装 1.2.1. Advantages .................................................................................................1-2 优点 Limitations .................................................................................................1-4 局限性1.2.1.2.2.1.3.What is Electrocoat ..................................................................................................1-5 什么是电泳涂装 1.3.1. Anodic Versus Cathodic............................................................................1-5 阳极电泳和阴极电泳的区别1.4.Electrochemical Reactions ......................................................................................1-8 电化学反应 Components of Feed and Bath ................................................................................1-13 槽液及加料组份 Deionized Water .......................................................................................................1-14 去离子水 Membranes ...............................................................................................................1-16 膜 1.7.1. Ultrafilter Membranes ..............................................................................1-17 超滤膜 Anolyte Membranes ..................................................................................1-19 阳极膜1.5.1.6.1.7.1.7.2.1.8.Section Summary .....................................................................................................1-1911-3-97iVer 1Automotive Electrodeposition Reference Manual本节摘要2.DESIGN CONSIDERATIONS ...................................................................... 2-1设计要素 2.1. Introduction ..............................................................................................................2-1 介绍 General Design .........................................................................................................2-1 总体设计 2.2.1. Basic Requirements ...................................................................................2-1 基本要求 Sanitary Pans .............................................................................................2-2 滴漏盘 Carrier Design............................................................................................2-2 吊具设计2.2.2.2.2.2.2.3.2.3.Metal Preparation ....................................................................................................2-4 金属前处理 2.3.1. Body Shop Washer ....................................................................................2-4 车身清洗 Phosphating ................................................................................................2-4 磷化2.3.2.2.4.Electrocoat Tank ......................................................................................................2-6 电泳槽 2.4.1. Direction of Flow .......................................................................................2-6 流动方向 Adjustable Weir Plate ..............................................................................2-7 可调堰 Freeboard and Overflow ...........................................................................2-8 槽堰超出液面高度与溢流 Bottom Front End Filtration ....................................................................2-8 槽前段过滤2.4.2.2.4.3.2.4.4.11-3-97iiVer 1Automotive Electrodeposition Reference Manual2.4.5.Dimensions: Clearance ..............................................................................2-10 尺寸：间隙 Effective Coating Time..............................................................................2-11 电泳时间 Angle of Entry ............................................................................................2-11 入槽角度2.4.6.2.4.7.2.5.Materials of Construction .......................................................................................2-12 建槽材料 2.5.1. Dip Tanks ...................................................................................................2-12 浸槽 Tank Enclosure ..........................................................................................2-12 槽的间壁室 Tank Lining................................................................................................2-12 槽衬里2.5.2.2.5.3.2.6.Paint Circulation ......................................................................................................2-13 槽液循环 2.6.1. Surface Flow...............................................................................................2-14 表面液流 Pipe Velocity...............................................................................................2-14 管路内流速 Pumps .........................................................................................................2-14 泵 Piping ..........................................................................................................2-15 管路 Valves ..........................................................................................................2-17 阀 Pressure Gauges .........................................................................................2-18 压力表 Gasket Materials ........................................................................................2-19 垫圈材料2.6.2.2.6.3.2.6.42.6.5.2.6.6.2.6.7.11-3-97iiiVer 1Automotive Electrodeposition Reference Manual2.6.8.Filtration .....................................................................................................2-19 过滤 Paint Cooling ..............................................................................................2-19 槽液冷却2.6.9.2.7.Electrical ...................................................................................................................2-21 电气 2.7.1. Anodes ........................................................................................................2-21 阳极 Roof Anodes ...............................................................................................2-22 阳极顶盖 Anolyte Cells ..............................................................................................2-23 阳极隔膜系统 Power Supplies ...........................................................................................2-25 电源 Ultrafilters ..................................................................................................2-26 超滤器2.7.2.2.7.3.2.7.4.2.7.5.2.8.Rinses 淋洗 2.8.1. General Rinses ...........................................................................................2-27 概述 Over Tank Rinses ......................................................................................2-29 槽上冲洗 Recirculated Rinses #1 AND #2 ................................................................2-31 第一道和第二道冲洗 Drainage Between Rinses ..........................................................................2-33 各道冲洗之间的沥液 Dip Rinse ....................................................................................................2-33 浸洗 Recirculated D I Water Rinse...................................................................2-35 循环去离子水2.8.2.2.8.3.2.8.4.2.8.5.2.8.6.11-3-97ivVer 1Automotive Electrodeposition Reference Manual2.9.DI or RO Water .......................................................................................................2-36 去离子水或反渗透水 Temperature Protection ..........................................................................................2-37 温度防护 Line Stops .................................................................................................................2-38 停线 Baking .......................................................................................................................2-38 烘干 Paint Storage Tanks .................................................................................................2-39 涂料储备槽 Tank Feed .................................................................................................................2-40 槽液配置 2.14.1. Resin Component.......................................................................................2-40 树脂组分 2.14.2. Pigment Component ..................................................................................2-41 颜料浆组分 2.14.3. Acid Injection .............................................................................................2-43 加酸2.10.2.11.2.12.2.13.2.14.3.SYSTEM OPERATION.................................................................................. 3-1系统操作 3.1. Introduction ..............................................................................................................3-1 简介 Metal Cleaning And Phosphating ..........................................................................3-2 金属清洗及磷化 3.2.1. Precleaning .................................................................................................3-2 预清洗 Phosphating ................................................................................................3-2 磷化3.2.3.2.2.3.3.Tank Design and Construction ...............................................................................3-311-3-97vVer 1Automotive Electrodeposition Reference Manual槽的设计和结构 3.4. Paint Circulation ......................................................................................................3-5 槽液循环 Tank Electrification .................................................................................................3-6 电泳槽加电装置 3.5.1. Anodes ........................................................................................................3-6 阳极 Rectifiers .....................................................................................................3-7 整流器3.5.3.5.2.3.6.Ultrafiltration ...........................................................................................................3-7 超滤 Rinse Systems ...........................................................................................................3-9 清洗系统 Baking .......................................................................................................................3-10 烘干3.7.3.8.4.ANALYTICAL TESTS ................................................................................... 4-1分析试验 4.1. Electrocoat Solids (Non-Volatile) ...........................................................................4-2 电泳漆固体分（不挥发份） Electrocoat pH ..........................................................................................................4-3 电泳漆 pH 值 Electrocoat Conductivity .........................................................................................4-5 电泳漆的电导率 Panels and Panel Ratings ........................................................................................4-7 试板及试板评价 Measurement of Dry Film Thickness .....................................................................4-12 干膜厚度测量 Sandwich Compatibility Test ..................................................................................4-10 相容性试验4.2.4.3.4.4.4.5.4.6.11-3-97viVer 1Automotive Electrodeposition Reference Manual5.TERMINOLOGY ............................................................................................ 5-1专有名词11-3-97viiVer 1
Automotive Electrodeposition Reference Manual1.Introduction to Electrocoat 电泳漆简介 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 corrosion protection on hardto-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. Although dip coatings penetrated into the recessed areas, they were usually washed off by solvent vapors during baking. Thus, Dr. Brewer's 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 used 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。11-3-97Section 1-1Ver 1Automotive Electrodeposition Reference ManualAlthough 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 prim by 1970, ten of 100 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。Why Electrocoat 为什么要电泳涂装Because of the marked 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. 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。 1.1.1. Advantages 优点 Formation of protective films in highly recessed areas such as flanges and box sections provides critical corrosion protection. 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。 Transfer efficiencies of better than 95% result in reduced paint waste, especially when compared with spray-applied coatings. 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。 Use 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. 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11-3-97Section 1-2Ver 1Automotive Electrodeposition Reference Manual保设备费用。 The low paint bath viscosity (approximately equal to that of water) results in ease of pumping and allows drainage of the coated vehicle. 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。 Freshly-deposited paint is insoluble in water, permitting complete rinsing and recovery of dragged-out material. 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。 Uncured paint is dry enough to allow some handling. 未固化的漆膜不粘手，甚至可以作某些处理。 Unlike spray coatings, electrodeposited paint will not sag during baking. 不象喷涂的涂膜，电泳沉积的涂膜在烘干时不流臁 Unlike dip coatings, electrodeposited paint is not washed off in enclosed areas by hot vapors during curing. 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。 Since the process is automated, direct labor costs are markedly reduced. 由于生产过程自动化， 大大降低了直接劳动成本。 The deposited film is reproducible from part to part and from day to day. 电泳工艺稳定，可保证漆膜均一涂于工件上。 The electrochemical process of depositing paint appears, at first examination, however, it is actually more trouble-free than other paint application processes 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。 The large tank volume tends to minimize variations in paint or process. 槽的容量很大， 使涂料或工艺参数的波动减少到最小。 The operating parameters are well defined and are based on extensive experience.11-3-97Section 1-3Ver 1Automotive Electrodeposition Reference Manual操作工艺参数已有明确的规定，且是以丰富的经验为基础。 Samples from the tank, which are tested weekly at the PPG Electrocoat Laboratory, often predict problems before they appear on the line. 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 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。 A variety of metal substrates can be coated to permit extensive examination of differing conditions. 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。 Several tanks can be easily cross-compared. 可以容易的对几个槽进行相互比较。 Close anode-cathode distances in the coating tubes that are used in the electrocoat laboratory can be employed to magnify problems experienced in the field. 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。 1.1.2. Limitations 电泳涂装的局限性 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 electrocoat products. Thus, electrodeposition is used mainly for the application of prime coats. Application 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。11-3-97Section 1-4Ver 1Automotive Electrodeposition Reference ManualWhat is Electrocoat 什么是电泳涂装1.1.3. Anodic Versus Cathodic 阳极沉积法和阴极沉积法的区别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： The earlier resin technology was based on resins which contained acid groups. These could be neutralized to allow them to become soluble in water. 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。 When the solubilized resin was deposited, it regained its acidic function. This acidity permits ready crosslinking (curing) when the coating is baked. 当水溶性树脂沉积后，它可以恢复其酸性基团的功能。当此涂层被烘干时，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。 A method was needed to make alkaline polymers cure at temperatures low enough to ensure body integrity. 降低碱性聚合物固化的温度，同时还要确保漆膜的均一性。 The corrosivity of the bath solution had to be reduced. 必须降低槽液的腐蚀性。 The process of curing thermosetting resins is called &crosslinking&. During this process, which is driven by heat, the relatively small molecules deposited are chemically intertwined to form a single uniform film.11-3-97Section 1-5Ver 1Automotive Electrodeposition Reference Manual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 film's chemical environment. The 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. 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。 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 cathodic 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 urethane 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, solventresistant film. 虽然多种树脂都可以适用于电泳涂装，但最常见的是热固型的 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： It must be soluble or dispersible to form a stable solution even when subjected to a wide variety of production conditions.11-3-97Section 1-6Ver 1Automotive Electrodeposition Reference Manual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。 It must deposit onto an electrode to form a smooth, dense, insulating, wet film which also contains pigment. 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。 It must be able to coat a part which is complex in shape. 必须能够泳涂外形复杂的工件。 It must resist re-dissolution when rinsed. 必须在冲洗时不再被溶解掉。 It must become mechanically and chemically stable upon baking so that the resulting film can fulfill its protective and/or decorative requirements. 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。 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 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： It achieves corrosion resistance at low film thickness. 较低的膜厚具有良好的防腐蚀性。 It permits throwpower to interior surfaces without penalty of over-build on exterior surfaces. 保证工件内表面泳透力的同时，外表面上涂膜也不会过厚。 It achieves bimetallic joint corrosion resistance required by the increased use of galvanized metal. 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。 It possesses saponification resistance and long-term adhesion retention over an entire galvanized body panel. 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。11-3-97Section 1-7Ver 1Automotive Electrodeposition Reference ManualIt requires substantially less electrical consumption for deposition and, as a result, less refrigeration for cooling. 电泳本身耗电量少，从而用于冷却的冷量也少。 It achieves gloss and hold-out with and without spray primers. 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 reactions 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。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 &cationic& may be used as synonyms, they refer to two different aspects of the subject. 到此为止， 我们已经讨论了阳极漆和阴极漆，并且已使用了阳离子，阴离子等术语，虽 然阳极和阴离子可以作为同义词使用， 其实他们是用于表示一个事物的两个不同方面 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 opposites attract, the problem simplifies. The cathode is negative: thus, it repels negative charges and attracts positive charges. 带正电荷的电极称为阳极，带负电荷的电极成为阴极，水溶液中含有的带电粒子称为离 子，离子是带电荷的原子和分子，阴离子带负电荷，阳离子带正电荷，如果大家都明白异 性相吸的道理，问题就简单了，阴极带负电：所以它排斥负电荷而吸引正电荷。 The positively-charged ions in the solution are called cations, and the negatively-charged particles are called anions. Thus, by the principle of opposites attracting, the cations (positive11-3-97Section 1-8Ver 1Automotive Electrodeposition Reference Manualcharges) 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 called migration. 溶液中带正电荷的离子称为阳离子， 带负电荷的离子称为阴离子。这样，根据异性相吸 的原理，阳离子（带正电荷）与阴极（带负电荷）相互吸引，由于阴极位置相对固定，故 此阳离子便移向阴极，这种运动称为迁移。 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 negatively charged ions. 带负电荷的离子把带正电的树脂分子存在于阴极系统的溶液中。树脂的溶解性取决于阴， 阳离子的电平衡。 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 charge of the deposited paint. The two terms are often used interchangeably. 电泳漆沉积在阴极上时，此工艺称为阴极电泳，带正电荷的漆称为阳离子型电泳漆。故此 “阴极的”极“阳离子的”两个术语即分别表示漆的沉积对象及沉积漆的带电类型。这两 个术语常可互换使用。 The electrocoating process is known by several names: 电泳涂装工艺在英语中有以下几个名词： ? Elpo ? E-Coat ? Electropainting ? Electrodeposition ? 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 metallic ions whereas electrocoating deposits organic resin molecules. 跟电镀工艺相似，比如汽车保险杠度铬，电泳，电镀这两种工艺都是通过利用电流产生沉 积。不同之处在于，电镀时沉积金属离子，电泳时沉积有机树脂分子。 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 through 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.11-3-97Section 1-9Ver 1Automotive Electrodeposition Reference Manual阴极电泳涂装是一种将被涂件浸入水稀释的涂料中，进行类似电镀上漆的涂漆工艺，通过 在涂料中通直流电， 在阴极电泳涂装体系中， 被涂件作为阴极（带负电）。 油漆固体份 带正电荷， 因此被吸引到阴极。 Electrodeposition 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 processes taking place beneath the surface of the tank. 漆膜的电沉积过程同时包含有电泳，电解，电沉积，电渗等过程。对于电泳槽的操作人员 来说， 他们不一定要懂得这些原理，我们在此只是把在电泳槽中所发生的化学反应以及 工艺原理进行解释。 Electrolysis 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 best 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, sudden current surges should be avoided during deposition, and bath conductivity should be held within specified limits. These limits are set to control the conductivity of the paint only and do not consider the conductivity effects of ionizable contaminants which result from phosphate drag-in or poor quality deionized water. (The effects of these and other contaminants will be discussed later. 电解是靠通电使导电液体分解。水电解生成氢气和氧气是大家最熟悉的电解例子。 电解通常同时在一个或两个电极上析出气体。在电泳涂装过程中这种气体的析出却 是不利的。它对后面将要讨论的重要特性“泳透力”有影响。由于气体析出与电流 成正比，因此要避免在沉积过程中突然的电流波动，并且要将槽液电导率限制在特 定的范围之内。这种电导的限制只是对油漆电导率的控制， 并不考虑由于磷化液 的带入或去离子水质量差所导致的杂离子污染杂质离子物所产生的电导率作用（诸 如此类污染的作用将会在下文讨论） Electrophoresis is the migration of electrically charged colloidal particles in a conductive medium under the influence of an electrical potential (voltage). Examples of electrophoresis are the movements (migration) of pigment particles and colloidal resin particles which take place in the electrocoating process. Under the influence of an electrical potential, these particles will move towards the cathode by the process of electrophoresis. 电泳是在一电势电压作用下。导电介质中胶体离子的移动过程。例如，发生在电泳 涂装过程中电泳的是颜料粒子及胶体树脂粒子的运动(移动)，在这电势的作用下， 这些粒子靠电泳过程移向阴极。 Electrodeposition is the precipitation of paint particles at an electrode. Positively-charged11-3-97Section 1-10Ver 1Automotive Electrodeposition Reference Manualparticles will coagulate at the cathode, and negatively- charged particles will collect at the anode. Since these negatively-charged particles (called ions) help keep the positivelycharged resin in solution, they are sometimes referred to as counterions. 电沉积就是油漆粒子沉积在一个电极上。带正电的粒子将聚积在阴极上，带负电的 粒子会在阳极上聚集。由于这些带负电的粒子（称离子）使带正电的树脂保持在溶 液中，它们有时被叫做平衡离子。 The paint vehicle is usually cationic, and deposition takes place only at the cathode. It is an irreversible process. No coating can take place at the anode. 涂料的漆基一般为阳离子型，沉积只发生在阴极上，它是一个不可逆过程。在阳极 上不形成涂膜。 The first step in electrodeposition is the electrochemical decomposition of water (electrolysis). If the paint bath has a neutral pH, the primary reaction at the cathode is the formation of hydrogen gas and hydroxyl ions. This reaction causes a highly-alkaline boundary layer to form in the area of the cathode. Film deposition occurs when the cations (resin and pigment) react with the hydroxyl ions to become insoluble. This condition does not occur until the alkaline layer reaches a critical pH of about 12. 电沉积的第一步是水的电化学分解（电解）。如果漆液 PH 值呈中性， 在阴极上最 初的反应是产生氢气和氢氧根离子（OH-）,这个反应导致在阴极面上形成一高碱 性边界层。当阳离子树脂（树脂及颜料）与氢氧根离子反应，变为不溶于水时，这 就产生了沉积后的涂膜。但如果碱性边界层达不到大约 12 的临界 PH 值，将得不 到不溶于水的涂膜。 Electroendosmosis is the final process to be discussed. As paint solids are drawn to the cathode and precipitated, the film becomes semi-permeable. Water is driven from the vicinity of the cathode through the deposited film, causing the dehydration of the film. Such a film is relatively resistant to physical distortion. 电渗是要讨论的最后一个过程，当涂料固体份在阴极上沉积之后，此涂膜为半渗透 性。水份从阴极附近通过沉积过程排斥出来，引起涂膜脱水，这种涂膜已具有抗物 理变形性。 The water insolubility of the deposited coating permits rinsing with water to remove bath dragout. Drag-out consists of non-deposited paint which loosely adheres to the coated article as it is removed from the bath. To achieve good appearance for the deposited film, the drag-out must be rinsed away. 由于沉积涂膜的不溶于水性，允许用水清洗电泳板洗掉电泳带出的漆液。当被涂工件从电 泳槽中出来时，在其表面上附着一层未沉积的槽液，为了获得外观良好的电泳漆膜，必须11-3-97Section 1-11Ver 1Automotive Electrodeposition Reference Manual将带出的槽液洗掉。 In summary, the application of an electrical potential to two electrodes in a bath containing a conductive solution produces electrolysis of the solution and electrophoresis of the charged particles. Coagulation or deposition, occurs at the cathode. This process continues until a continuous and even film coats the entire surface of the cathode. 总之， 当加电压于装有导电溶液槽中的两个电极时，就产生溶液的电解和带电粒子的电 泳， 在阴极上发生聚积或沉积。这个过程一直持续到整个阴极表面被连续，均匀的涂膜 所覆盖。 Because the electrodeposited film has a relatively high electrical resistance at a given voltage, the process stops itself when the film is nearly equal on all surfaces and edges. The film thickness is directly proportional to the resistance of the deposited coating. 因为此电极沉积膜在既定的电压下具有一较高的电阻， 所以当所有表面及边缘被涂膜覆 盖时，电泳沉积过程会自己停止。涂膜的厚度直接与沉积涂层的电阻成正比关系。 Throwpower is a comparative function and is defined as the degree to which paint will coat recessed or hidden areas. Electrocoated films having a high electrical resistance exhibit good throwing power. 泳透力是一个比较性的参数。其定义是电泳涂料能使被涂装工件的凹深处或被隐密表面被 涂上的程度。 电泳漆膜电阻高，则泳透力就好。 Throwpower is one of the most critical aspects of the electrodeposition process. Without the ability to deposit corrosion-inhibiting films in areas which are impossible to reach by other painting methods, electrodeposition would remain a laboratory curiosity. Since Throwpower is so important, let us examine some of the critical variables involved. 泳透力是电泳工艺最重要的参数之一，如果电泳涂装不能将防腐涂膜涂覆在用其它涂漆法 所不可能达到的工件表面上，电泳涂装将永远仍是实验室研究的问题。 由于泳透力如此 重要， 让我们探讨一下一些影响泳透力的重要因素。 Variable 变量 ? Coating Time 电泳时间 ? Bath Solids 漆液固体份 ? Applied Voltage Relationship to Throwpower 与泳透力的关系 Varies Directly 直接成正比 Varies Directly 直接成正比 Varies Directly11-3-97Section 1-12Ver 1Automotive Electrodeposition Reference Manual电泳电压直接成正比Caution is necessary if voltage is increased to achieve higher Throwpower. Film build also increases as voltage increases and can result in rupture of the film. Rupture occurs when a high current density produces uncontrolled gassing at the electrode. Throwpower drops off as current is consumed in the production of gas and is not available to permit the covering of recessed areas. During rupture, the insulating properties of the film are also affected. 如果想获得较高的泳透力而增加电压则必须小心，此膜厚度也会由于电压的增加，导致漆 膜击穿。 当高电流密度引起电极上气体析出失控时，便会发生击穿。气体的产生消耗电 流引致泳透力下降，则不可能使隐蔽表面涂上漆。击穿过程也使漆膜绝缘性能受到影响。Components of Feed and Bath 槽液及加料组份Solids are consumed during the deposition process. The components used are referred to as feed. Feed consists of a concentrated pigment paste and low-viscosity, milky-colored resin. Feed is delivered to PPG customers as two components for two reasons: 固体份在电沉积过程中被消耗，用作补充的组份称为补加漆料， 补加漆料包括高 浓度的颜料浆和低粘度乳白色的树脂。PPG 公司向用户供应双组分补加漆料有以 下两个原因： The addition ratios of paste and resin can be varied to modify the coating characteristics required by local operating conditions. 颜料浆与树脂的加料比例可以根据用户的工艺操作所需及涂膜特性的特别要求而加 以调整。 Pigment paste is usually delivered at a higher viscosity than the resin. If the paste were pre-blended with resin, the local operator might experience difficulty with settling because of reduced viscosity caused by the resin. 颜料浆通常比树脂的粘度高， 如果颜料浆预先与树脂混合，由于加树脂后会导致 粘度降低而产生沉降， 会使操作者在使用过程中遇到困难。 The pigments used in electropaints must be carefully chosen. Those which are too water soluble or those which react with water should not be used. 用于电泳漆的颜料必须细心选择， 不能使用水溶性太强的或与水起反应的颜料。 A typical cathodic electropaint bath consists of four ingredients:11-3-97Section 1-13Ver 1Automotive Electrodeposition Reference Manual典型的阴极电泳漆由以下四种成分组成： An aqueous polymer solubilized with acid. 可与酸形成水溶性的聚合物。 Pigments which are wetted with a special solubilized resin. 被一种专用的水溶性树脂湿润的颜料。 Coalescing solvents. 混合溶剂。 Deionized water.去离子水。 The polymers and pigments have been discussed previously. Coalescing solvents are water-miscible glycol ethers which aid in the water-dispersibility of the resin and enhance coating uniformity. 聚合物和颜料在前面已经讨论过，混合溶剂是水溶性的乙二醇醚类， 它有助树脂 在水中的水分散和提高涂膜的均一性。 Coating uniformity is aided in two ways: 溶剂改善涂膜的均一性有两种途径： When the film is deposited, some coalescing (the flowing together of resin particles) takes place. This action helps build film resistance and permits the formation of uniform films. 当涂膜沉积时，发生某些聚结（树脂微粒聚到一起），这个作用有助于增强涂膜的 电阻及形成均一的涂膜。 During baking, the coalescing solvents enable the film to flow. 在烘干过程中， 混合溶剂有助于涂膜的流平。Deionized Water 去离子水Deionization is a process by which tap or raw water is made suitable for use in an electrocoat bath. Deionization is far more economical than distillation or reverse osmosis in commercial operations.11-3-97Section 1-14Ver 1Automotive Electrodeposition Reference Manual去离子水是一种将自来水或生水经处理后制成适合配电泳漆槽液用的水。 去离子 工艺在工业成本方面远比 蒸馏水或反渗透水经济得多。 Distillation is achieved by boiling and then recondensing water to remove in reverse osmosis uses a membrane separation process to accomplish the same purpose. 蒸馏是把水煮沸然后冷凝除去不溶性杂质；反渗透是使用膜分离工艺达到同样的目 的。 Deionization removes ionizable minerals from tap water by passing the water through ion-exchange beds. Both a strong acid cation bed and a strong base anion bed are required to remove all of the ions in the water. 去离子是使自来水通过离子交换柱除去可离子的矿物质。此工艺需同时使用一强酸 性阳离子交换柱和一强碱性阴离子交换柱以除去水中所有离子。 During the first step of the deionization process, cations (such as calcium, magnesium, and sodium) are exchanged for hydrogen ions. During the second step, the anions (such as chloride, sulphate, and silica) are exchanged for hydroxide ions. The hydrogen and hydroxl ions combine to form water (H2O). Factors such as the chemical composition of the incoming water, temperature, and operating pressure all play a role in determining how well the ions will exchange. 在去离子的第一步，阳离子（例如钙，镁，钠）被 H+（氢离子）置换， 第二步， 阴离子（例如氯化物， 硫酸盐，二氧化硅）都被 OH－（氢氧根离子）置换， H＋ 和 OH－结合生成水。（H２O）。进水的化学成分，温度，操作压力等因素是离子 交换工艺中的重要参数。 Over a period of years, a standard has been developeｄ regarding the required purity of water used in an electrocoat system. These standards have been mutually developed by the paint manufacturers and the end users. 多年前，关于电泳漆系统用水的纯度的标准已被定出，而这些标准是由油漆制造厂 和最终用户共同开发和订立的。 The standard water purity for present cationic paint systems is 10 micromhos or 100,000 ohms. The ohm is
the mho is a measure of conductance. (Mho is simply Ohm spelled backwards.) If the water quality rises above 25 micromhos, paint contamination may occur. Water that is less than 25 micromhos will cause no problem nor will it enhance the system operation.11-3-97Section 1-15Ver 1Automotive Electrodeposition Reference Manual目前，对阳离子漆（阴极电泳漆）系统的水纯度标准是 10 微姆欧或 100000 欧姆， 欧姆是一个电阻单位，姆欧是导电性的计量单位（姆欧是欧姆的简单倒拼）。如果 水质的电导率大于 25 微姆欧， 槽液可能被污染。 水质低于 25 微姆欧就不会引起 什么问题，但也不会提供系统的水平。 Deionized water is used in electrocoat tanks to prevent paint contamination. The presence of mineral contaminants causes two problems: 为了防止漆液被污染， 电泳槽中要用去离子水。无机杂质会引起两个问题： Minerals present during electrocoating affect appearance and corrosion resistance. 在电泳过程中无机物的存在会影响涂膜的外观和抗腐蚀性。 Disassociated minerals have an electrical charge. They migrate and consume current which could be used for paint deposition. Because pure water is a good solvent, it is used for bath make-up, for final rinsing of the electrocoat film, and after the phosphate machine to remove pretreatment contamination. 游离的无机物 带电荷，它们泳动并消耗用于涂漆的电能。 因为纯水是良好的溶 剂，所以被 用于电泳槽液的配制， 电泳涂膜的最终淋洗及磷化后除去前处理残留 物 The ability of a deionizer to exchange ions is reduced with continued operation, and a point is reached where it finally becomes exhausted. When this point is reached, it can be regenerated with strong acid and strong base. Hydrochloric acid (HCl) and liquid sodium hydroxide (NaOH) are the preferred materials for such use. Flake sodium hydroxide should not be used because it causes valve plugging. After the bed is regenerated, all acid and base (even trace amounts) must be flushed from the system. Any remaining acid or base materials will have a devastating effect on the electrocoat bath. 离子交换的能力会随连续运行而降低， 最后达到失效点。这时，可用强酸和强碱 再生。 为此， 盐酸（HCL）和氢氧化钠（NaOH）溶液是推荐选用的材料， 决不 能用片状 NaOH, 因为它会引起阀门堵塞。交换柱再生之后，必须将所有的酸，碱 （即使是微量）从系统中冲洗干净。 任何残留的酸碱，将对电泳槽液有破坏性影 响。Membranes 隔膜Membranes are selective barriers which allow particles or molecules of one kind to pass and exclude all others. This condition can be achieved by using size-exclusion11-3-97Section 1-16Ver 1Automotive Electrodeposition Reference Manualmembranes or by using anolyte (electrodialysis) membranes which operate in the presence of dense electric charges. 隔膜可以有选择性的允许一种粒子或一种分子通过，而挡住其它物质。使用特定尺 寸的隔膜或使用在高电荷密度下运行的阳极液（电渗析）隔膜， 可以达到这种状 况。 Two types of membranes are found in all electrocoat tanks: anolyte and ultrafilter membranes. The purpose of the anolyte membrane is to remove acid buildup which occurs when cationic resin is deposited upon a part. The purpose of the ultrafilter system is twofold: 在所有的电泳槽中泳用到两种隔膜， 阳极膜和超滤膜。阳极膜的作用是除去阳离 子树脂电泳到工件时产生的酸积聚。超滤膜的作用有两个： To provide a rinse solution to achieve the closed loop system, which will remove dragout, enabling high paint usage and resulting in clean coated products. 为闭路冲洗系统提供清洗液，冲洗掉由电泳槽中带出的浮漆，提高油漆利用率， 从而得到清洁的产品。 To remove water-soluble contaminants which might enter the tank through phosphate carry-in. 除去可能从磷化带入电泳槽中的水溶性污染物。 1.1.4. Ultrafilter Membranes 超滤膜 Ultrafilter membranes work on the principle of size exclusion. Dissolved molecules and particles are sorted out according to whether or not they are small enough to pass through the pores of the membrane. 超滤膜是利用筛分原理工作藉此把所需的并能通过隔膜微孔的物质与不能通过的溶解分子 颗粒分开。 In normal particulate filtration, liquid is forced under pressure through a porous medium. In ultrafiltration, similarly, liquid is forced under pressure through a porous medium. However, the pores are 1,000 times smaller. In fact, the membranes are so small that even some bacteria are unable to pass through. 一般的过滤是在压力作用下强行是液体通过多孔介质， 同样，在超滤中， 也实在压力下 强行通过多孔介质。然而，这孔径要小 1，000 倍， 实际上， 隔膜的孔径小得连有些细菌 都不能通过。11-3-97Section 1-17Ver 1Automotive Electrodeposition Reference ManualThe ultrafilter membrane will pass water, acid, some solvent, low-molecular- weight fractions of resin, and contaminating ions. When the bath is operating within the proper conductivity parameters, the ultrafiltrate is used to achieve the closed-loop rinse system. High conductivity is an indication of ion contamination. When this condition occurs, the ultrafiltrate is sent to drain, and deionized water is added to the rinses. 超滤膜可以通过水，酸，某些溶剂， 低分子量树脂及杂质离子。当电泳槽在正常的电导 率参数内运行时，使用超滤供封闭循环的清洗系统， 电导率高， 表明有离子污染， 当发 生这样情况时， 要排放超滤液， 加去离子水供清洗用。 Two forces oppose the production of ultrafiltrate: osmotic force and concentration polarization force: 阻碍超滤液的生成有两种力，渗透力和浓差极化力。 Osmotic force is the tendency of a solvent to equalize concentration throughout its volume. This force is overcome by applying pressure to the paint passing through the ultrafilter. 渗透力是一个溶剂在其容积内浓度不断平衡的趋势。 这个力靠施加压力使油漆通 过超滤装置来克服。 Concentration polarization force is the tendency for molecules to build up or concentrate at the membrane surface. Again, pressure may be applied, but a rapid movement of paint across the membrane is also important. At least four types of ultrafilters are available: 浓差极化力是分子在膜表面堆积或浓缩的趋势。仍然是要施加压力， 而且使油漆 快速通过膜表面， 来减少这个浓差极化力。超滤装置有四种类型中， 后面两种最 普及。 1. Plate and frame 板框式 2. Spiral wound 螺旋式 3. Open tube 开管式 4. Hollow fiber 中空纤维式11-3-97Section 1-18Ver 1Automotive Electrodeposition Reference Manual1.1.5. Anolyte Membranes 阳极液隔膜 These membranes work on the principle of electrodialysis. Unlike ultrafilters, they do not require pressure. The energy required is supplied by an electric field across the membrane. This membrane has a dense concentration of fixed charges and contains fine pores, permitting it to be selectively permeable to ions bearing the correct charge. 这类隔膜以电渗析原理工作， 与超滤器不同，他们不需要压力。 由穿过隔膜的两侧提供 所需的能量， 隔膜带有稠密的电荷密度及微孔。能有选择的允许带相应电荷的离子透 过。 When the resin deposits at the cathode, the counter ion which keeps the resin in solution accumulates. Since the counter ion is acidic, its buildup reduces the pH. However, the anolyte membrane permits the acid, but not the resin, to pass. Thus, the excess acid is removed, and the target pH of the bath is maintained. 当树脂在阴极上沉淀时，平衡树脂的离子在溶液中累积，由于这些平衡离子是酸性的，它 的累积使 pH 下降。然而，阳极液隔膜仅允许 酸通过， 但不允许 树脂通过。 这样，除去 多余的酸，来维持槽液的正常 pH 值。Section Summary 本节摘要Summary: Resin and pigment are deposited at the cathode in the cathodic system of electrocoating. This method is superior to the anodic method because of the greatly enhanced corrosion protection. 要点：在阴极电泳系统中，树脂和颜料沉积在阴极上， 因此大大地提高了防腐蚀 性，这个方法比阳极法优越。 The four reactions that occur as a car body is being coated are listed below. The key word from the definition follows in parentheses. 下面列出了涂装一台车身时发生的四个反应。定义的关键字写在括号中。 1 Electrolysis (decomposition) 电解（分解） 2 Electrophoresis (migration) 电泳（泳动，迁移）11-3-97Section 1-19Ver 1Automotive Electrodeposition Reference Manual3Electrodeposition (precipitation) 电沉积（析出）4Electroendosmosis (dehydration) 电渗（脱水）11-3-97Section 1-20Ver 1Automotive Electrodeposition Reference Manual2.Design Considerations 设计参数 Introduction 简介There has been a considerable amount of literature and discussion regarding equipment and controls which might be/are in use for cathodic electrodeposition products. Users, equipment suppliers, paint suppliers, and other concerned parties all have data, ideas and concepts which have merit. As a paint supplier deeply involved in electrodeposition operations, we have compiled the following design considerations. Many of these recommendations are being made as a result of our extensive experience in servicing and troubleshooting electrocoat systems. We feel that these items are either necessary or ideal for obtaining maximum utility of our cathodic products. 有关阴极电泳生产设备及控制的资料文章等很多。用户，设备供应厂家，油漆厂家 及其它有关部门都有一些有价值的数据，设想及概念等。作为油漆供应商与电泳操 作关系密切，我们整理出以下的一些关于在设计上需考虑的问题。这里的许多建议 都来自我们现场服务及电泳涂装系统的故障排除过程所积累的经验。我们认为这些 内容是必不可少的，并能令电泳漆在电泳系统中发挥最高的性能。 This does not mean that all of these items are essential for a satisfactory operation, but in our opinion they are desirable to obtain the highest quality of coating and surest system of operation. 这并不意味着这些内容是必须全部执行才可达到的令人满意的操作的，但我们的观 点是这是获得最高的涂层质量和最满意的系统操作所需要的。General Design 总体设计2.1.1. Basic Requirements 基本要求 No dead piping. 不能有没有回路的管道。11-3-97Section 2-1Ver 1Automotive Electrodeposition Reference ManualComplete drainage of tanks. Tank bottom should be pitched for complete drainage. Piping should be pitched for complete drainage and provided with low point drains. 电泳槽具有彻底的排空装置。为了完全排净，槽底应是倾斜的。管道也应是倾斜的 来提获得一个低的排出点。 No bare metal inside of paint tank. 电泳槽里面没有裸露的金属 Gravity overflow should be utilized in all rinses for permeate return. 溢流应在冲洗中被利用来回收超滤液。 2.1.2. Sanitary Pans 滴漏盘 Sanitary pans should be continuous throughout the entire phosphate and electrocoat system. Pans over the electrocoat tank protect the unit from chain oils and dirt. For greatest efficiency, the pans should be as wide as possible and should be designed so that they will not drain back into the electrocoat system. Sanitary pans within the rinse enclosure should protect the entire conveyor from rinses. 滴漏盘要连续走，随磷化和电泳生产线。电泳槽上方的防滴漏盘防止链油 及灰尘 等不落 在工件上。为使效果最佳， 滴漏盘要尽可能宽， 要设计得不致使赃物回流到电泳槽中。 在冲洗通廊间内的滴漏盘要保护整个运输链免受冲洗。 2.1.3. Carrier Design 吊具设计11-3-97Section 2-2Ver 1Automotive Electrodeposition Reference ManualThe body carrier should be designed so that no part of the carrier hangs over the unit. Areas on the production unit which are positioned so that the carriers directly overhead are very susceptible to phosphate contamination and water spotting. 车身的吊具要设计成没有任何的吊具部件在车身上方。如果吊具部件 在生产中处于工件的上方， 很容易使磷化污染物和水滴到工具的顶 上形成污染电泳槽的可能性。 A &C&-hook carrier which entirely cradles the production unit, or a pendulum type carrier work very well and are in use in a number of facilities. These designs also permit the best use of overhead anodes, a configuration which should result in significant paint savings. Box-type orFigure 111-3-97Section 2-3Ver 1Automotive Electrodeposition Reference Manualtubular design should be water-tight to prevent paint carryout, but must allow for a pressure relief hole above the liquid and spray level. The design must also provide for effective drainage of the production unit (see Figure 1). 整体支撑工件的“C”型吊具在许多车厂内采用，过滤效果均好。这种设计对使用顶部阳 极最好， 其结构能显著的节省油漆。 盒型或管型设计应为封闭式，以防止带出涂料，但 允许在液面及喷洗面上方开泄压孔。 设计还必须考虑工件沥液效果。（见图 1）Metal Preparation 金属前处理2.1.4. Body Shop Washer 车身车间清洗设备Effective body shop washers loosen and remove mill oils, pre-lubes, and stamping compounds from the body-in-white. Good pre-cleaning with high-pressure water and soap increases the effectiveness of the phosphating operation. Cleaning also reduces crater-causing contamination which is carried into the tank or which can blow out in the oven. The latter problem is most evident in the oil which collects in hem flanges. 有效的车身车间清洗设备应具有分散并除掉车身上矿物油，润滑剂及冲压拉延油。用高压 水及皂液进行良好的预清洗能提高磷化作业效果。清洗也可减少带入电泳槽的或电泳涂膜 烘干时发生缩孔的污染物。漆膜烘干时出现缩孔的问题在翻边及焊缝处最明显。 Pre-cleaning should include the removal of metal filings and weld splatter: both are potential sources for dirt in phosphate and electrocoat. Washing of the floor pan is an essential part of the pre-cleaning operation. 预清洗系统包括清除金属屑及焊渣， 它们是磷化和电泳槽内的污染物的来源。车底板亦 是预清洗操作的重点部位之一。。 2.1.5. Phosphating 磷化 Phosphating technology has been developed specifically for use with cathodic electrocoating. Phosphating products have unique characteristics based upon controlled crystal structures. The success of the phosphating operation depends entirely upon thorough body cleaning, uniformity of approved phosphate coating product, and low conductivity of the residual final DI rinse. 磷化技术的开发是为阴极电泳涂装而服务的。磷化材料的特性取决于可否控制晶体的结 构。成功的磷化操作完全取决于车身的清洁程度，磷化膜均匀与否以及最终残留的去离子11-3-97Section 2-4Ver 1Automotive Electrodeposition Reference Manual水电导率 是否低。 Thorough pre-cleaning includes removal of all oils and stamping compounds, metal filings and other particulate debris, and elimination of all phosphate sludge. The phosphate coating should be uniform, without streaks, patterns, or hashmarks. Crystal size should be small and dense, with a coating weight appropriate to the particular phosphate method. The recirculated DI rinse should be held below 100 micromhos and followed by a pure DI water rinse of less than 25 micromhos. Phosphated bodies should be uniformly wet or dry when they enter the phosphate bath. Nonuniform wetness can result in patterns or marks in the electrocoat film. A &camel-back& in the conveyor can aid in draining pockets which might hold rinse residues. 彻底的预清洗包括除去所有的油，冲压拉延剂，金属屑，其它碎屑颗粒及除掉所有的磷化 残渣。磷化膜应完全均匀，无条痕，花纹或染色斑痕。晶粒应小而致密，膜重与磷化方式 相称。水洗用循环去离子水的水质要保持在 10us/cm２ 以下，而随后的新鲜去离子水洗的 水质电导应低于 25us/cm２ 。磷化过的车身必须全湿或全干状态进入电泳槽。干湿不均匀 可导致电泳膜产生花纹或斑痕。运输链设一个驼峰有助于沥净冲洗水残液。 Accumulators, transfers, and delivery conveyors between phosphate and electrocoat should be tunneled to prevent body contamination from airborne dirt and oil. This enclosure should have adequate ventilation to prevent condensation and subsequent contamination of the production unit. Exposed accumulators should not travel alongside the phosphate machine, since airborne phosphate mist can cause craters or other blemishes in the electrocoat finish. Similar problems result from DI water regeneration tanks placed too close to unprotected car bodies. Phosphate mist and DI regeneration stations comprise, however, only two of several possible sources of contamination. 磷化和电泳之间的储存链，转移链及传送链要设封闭隧道，以防止悬浮于空气中的灰尘及 油对车身的污染。此封闭隧道要有充分的通风，防止凝结及对产品的再污染。外露的储存 链不能沿着磷化设备运行，因为空气中的磷化液雾可引起电泳漆膜产伸缩孔或其它缺陷。 去离子水再生槽的布置太靠近未加保护的车身也可引起类似的问题。磷化液雾和去离子水 再生仅仅是各种可能污染源的两种。 Removal of dirt by forced-air blow-off is not recommended because of the possibility of damage to the finish by air-driven contaminants. If a dry-off oven is used, the car body temperature should be cooled to paint-bath temperature. The warmer bodies also place a heavier load on paint-cooling equipment. 不推荐用压缩空气吹除灰尘。原因是空气所带的污染物对涂层仍有损害的可能性。如使用 加热烘设备时，车身温度要冷却到电泳槽液的温度。车身温度高也会增加油漆冷却设备的 负荷。11-3-97Section 2-5Ver 1Automotive Electrodeposition Reference ManualElectrocoat Tank 电泳槽2.1.6. Direction of Flow 流动方向 An electrocoat tank should be designed to move paint continuously in a circular path, with the surface moving in the same direction as the conveyor (see Figure 2). This design is experienceproven and results in the cleanest electrocoat body. Smooth fluid flow direction change (at the entrance end of the tank) is accomplished most effectively by using a radial lip. Paint headers direct paint up the entrance decline and help prevent pigment settling as the paint changes direction. Two variations of this design are currently being employed (see Figure 3). Bidirectional flow systems have also proved successful when incorporated with bottom center filtration. 电泳槽要设计成使油漆沿单一循环路线连续运动，液面运动方向与运输链运行方面相同 （见图 2），实际经验证明，这样的设计能得到最干净的电泳车身。平稳的流向变化（在 槽入口端）可考虑使用一“摇臂导向板”来实现。在工件入口端斜坡上喷头以引导漆液流 向入口端，漆液虽改变流向，以有助于防止颜料沉淀。现在这种设计的两种形式已被普遍 采用（见图 3）。另外，底部中央有抽出过滤装置的双向流动系统也已被证明是成功的。 A combination of floor headers and vertical side pipes with eductors provide effective tank agitation. If necessary, exit-end draft tubes can be added for enhanced circulation. Draft tubes are large volume agitator pump systems which move paint from the top surface and start it moving across the bottom surface. Floor headers should be supported approximately three inches (7-8 cm.) above the tank floor to permit free flow of paint along the bottom (see Figure 2). 槽底的喷射嘴与竖立式带喷头侧管相结合可提供有效的槽液搅拌。必要时，为加强循环， 可在出口端加引流管。引流管是大流量搅拌泵系统，它从液面使漆液运动，它使漆液做横 跨底表面运动。用引流管时，大量漆液不经过滤而返回，因此当采用引流管时会产生染质 污物和缩孔问题，就会延长问题存在的时间。槽底喷管要设在离槽底约 3 英寸（7-8cm） 处，这样可使漆液沿槽底自由流动（见图 2）。 Any area in the paint tank that is not properly agitated will permit pigment settling. Areas such as drains, sumps, pump wells, or dead paint lines may collect pigment. A paint return line with an eductor should be inserted into such areas to prevent such settling. 在漆槽中搅拌不彻底的任何区域都会引起颜料沉淀。象排出口，储槽，泵井或空油漆管路 等部位都会有颜料汇集。为防止此类沉淀，要在这些区域安设带喷射嘴的油漆返回管路。 Figure 211-3-97Section 2-6Ver 1Automotive Electrodeposition Reference ManualThe tank floor should be angled so that the main tank and weir will drain to permit maintenance. The holding tank may be used to contain inadvertent overflow from the dip tank. 槽底要有一定的坡度，这样主槽和溢流槽均可以完全排放，便于维修。也可以用电泳储存 槽来盛装工艺槽偶然溢出的槽液。Partial Radial Front EndFull Radial Front EndFigure 32.1.7. Adjustable Weir PlateAdjustable Weir可调堰An adjustable weir plate at the exit end of the tank is recommended to maintain tank level and to permit surface movement of the paint. The surface flow of the paint carries foam and dirt away from the entrance to the weir. Free fall of paint into the weir should be limited to less than 611-3-97Section 2-7Ver 1Automotive Electrodeposition Reference Manualinches (15 cm.) to prevent foaming. Sloped-bottom weir boxes with eductor agitation are recommended. Weir box configuration is dependent upon the type of pumps used for circulation (see Figure 4). 建议在电泳槽的出口端设可调的堰板以维持槽的液位并使槽液表面流动时会将泡沫和杂质 污物从电泳槽带入溢流槽，漆液到溢流槽的落差应保持在 6 英寸（15cm）以内来防止起 泡。建议在溢流槽底加喷嘴以保持搅拌。溢流槽的设计依使用的循环泵类型而定。（见图 4）2.1.8. Freeboard and Overflow 槽沿超出液面高度与溢流 To prevent the paint tank from overflowing in the event of material addition errors, the tank should be designed with approximately 9 inches (23 cm.) freeboard above the normal operating level. This margin should be sufficient to permit pumping of the first recirculated rinse tank back into the tank for easy cleaning of the rinse tank. An overflow pipe of at least 3 inches diameter should be installed near the top of the tank to drain into the dump tank to permit material recovery. This pipe should be located at least 9 inches above the normal operating level of the main tank. If the dump tank is installed below the main tank be certain that the building structure can support the additional weight of a full dump tank should it be filled completely. High level alarms should be installed to alert system operators and plant security should problems occur. 为防止漆液因偶然的加料失误而从槽中溢出，电泳槽应设计成其槽沿超出正常工作液面约 9 英迹23cm）。这个安全系数足以满足在清洗槽清理时，将第一循环冲洗槽液泵入电泳 槽的需要。在靠近槽顶处要装一个直径不小于 3 英寸的溢流管通向贮存槽，以便于材料回 收。此管应设在主槽正常工作液位置上至少 9 英寸的位置，无疑建筑结构要能支撑注满时 的总重量。要装高液位报警器及设备报警器，以保证系统安全进行，不发生事故。运输链 Figure 4 的接油盘也必须在适当的高度上，以防止在高液位情况下被淹没。 2.1.9. Bottom Front End Filtration 槽前端过滤11-3-97Section 2-8Ver 1Automotive Electrodeposition Reference ManualFiltering paint drawn from the floor of the tank at the bottom of the entrance decline has been proven essential to the removal of dirt from the paint. This concept is known as bottom front-end filtration. It is most effe}