烤漆知識簡介

塗裝流程以及塗裝知識簡介FoxconnBJcoatingintroduction2023.10北富塗裝廠內容簡介Content1.塗裝的根本原理Generalpaintingelements2.油漆的分類和組成Paintcompositionandtypes3.常見的噴塗不良Commonpaintdefects塗裝的根本原理

塗料是指塗布于物體外表,經過物理變化或化學反響而干結成膜的一種有機粘稠液體〔或粉末狀固體〕的總稱.塗裝生産(烤漆)即通過施工把塗料均勻地覆于工件外表並烘乾的過程.塗裝分爲刷涂,粉末噴涂,靜電噴涂,高壓無氣噴塗,電泳涂裝和空氣霧化噴涂〔目前北富所用的〕.爲什麼要噴塗(whytopaint)裝飾或標示功能(更美觀更有手感)——塑料噴漆後在顔色,光澤以及質地手感上有更多的選擇.噴漆後能遮住素材的缺陷和流線,得到更好的產品.Coatedplasticsofferchoiceofcolor,glossandtexture.Coatingmasksminorsurfacedefectsandflowlines,forabetter-finishedproduct.保護功能——塑料噴塗後能改善它的機械和化學組成,使塑件更耐用.Coatingplasticsimprovestheirmechanicalandchemicalproperties.Someplasticsneedacoatingforexteriordurability.其它特殊功能——

如導電等Otherspecialfunction:Suchasconductor.塗裝的根本原理噴塗漆膜成膜方式paintfilmformedby:1.溶劑揮發(fā)的成膜方式:塗料塗布後,本身不發(fā)生化學化學反應,只是塗料中的溶劑全部揮發(fā)即可凝結成膜.漆膜可在該溶劑中重新溶解.Physicaldrying:Dryingbysolventevaporationonly.Nochemicalreactionincreasingthemolecularweighttakesplace.OnlymoderateresistancepropertiesFastprocess.2.化學成膜:塗料中的樹脂分子與固化劑/(催化劑)發(fā)生化學反應而形成一層堅韌的漆膜.一般需加熱以促進反應而縮短反應時間。漆膜不能在該溶劑中重新溶解.

Chemicaldrying-Curing:DryingthroughsolventevaporationfollowedbyachemicalreactionSlowerthanphysicaldryingBetterresistanceproperties.Betterexteriordurability3.UV照射成膜:成膜的能量來自於紫外線,同樣是一種化學反應.漆膜不能在該溶劑中重新溶解.UV-curing–unsaturatedvinylcompoundswithinitiatoraddedreactwhenexposedtoUV-radiation.塗裝的根本原理

Elements油漆的組成和分類

Paintcompositionandtypes樹脂Binders溶劑Solvents顔料Pigments填料Fillers添加劑Additives樹脂是塗料中最主要的成分,它的性質對塗料的性能〔如塗料對底材的附著力、保護性能、物理化學性能等〕起主要作用.Thebinderisthemaincomponentofthepaint,Itdeterminestheprimarycharacteristicsofthepaintsuchasadhesiontothesubstrate,protectionandphysicalchemistry.塗料中樹脂的常用種類Commonbindersinthepaint:丙烯酸樹脂(Acrylics)環(huán)氧樹脂(Epoxies)聚氨酯樹脂(Urethanes)聚酯樹脂(Polyesters)醇酸樹脂(Alkyds)樹脂主要影響控制Bindersinfluence:烘乾機理及速度Dryingmechanismandspeed附著力Adhesion溶劑和化學抗性Solventandchemicalresistance光澤度Gloss耐候力Outdoordurability機械性能Mechanicalproperties油漆的組成和分類

Paintcompositionandtypes溶劑通常為能溶解成膜物的易揮發(fā)有機液體,溶劑只是用來改善塗料的可塗布性,幫助成膜物與顏料混合物轉移到被塗物外表上,從而形成均一的漆膜.Solventsareliquids,itsmaintaskistochangethesolidresin/pigmentmixtureintoaformwherebyitcanbeappliedinacontrolledwaytothesubstrateandformauniformfilm.溶劑主要影響控制Solventsinfluence:油漆粘度Paintviscosity揮發(fā)速度Evaporationrate對底材的潤濕及附著力Wetting/adhesiononthesubstrate噴塗效果Applicationanddevelopmentofeffect油漆的組成和分類

Paintcompositionandtypes顏料是存在於油漆中不能溶解的小粒子.主要分爲兩類,第一類是無機顔料,主要包括：金屬氧化物、碳、鋁以及雲母,另一類是有機顔料,包括多種烴類的混合物.Pigmentsconsistofsmallparticlesofdifferentcolorswhichdonotdissolveinthepaint.Pigmentsaredividedintotwomaingroups.Thefirstistheinorganicpigmentsandcomprisemetaloxides,carbon,aluminumandmica.Thesecondgroupistheorganicpigments,whichconsistofawidevarietyofhydrocarboncompounds.得到一種顔色一般要通過3~5種顔料的混合.Toproduceacolouryounormallyneed3-5pigments.選擇顔料的同時，還要考慮顔色以外的其它性能.例如,耐候性、耐高溫性、遮蓋能力以及價格.

Whenchoosingpigmentsyoualsohavetoconsiderotherpropertiesthancolour.Youmayforexamplehavetoconsideroutdoorresistance,temperatureresistance,hidingpowerandprice.油漆的組成和分類

Paintcompositionandtypes添加劑的含量非常小,通常小於5%.一種油漆爲了確保其性能通常包含幾種添加劑.Addedinsmallamounts,oftenlessthan1%.Apaintformulationnormallycomprisesoneorseveraldifferentadditives–alltoachievecertainpropertieseg.defoaming,pigmentorsurfacewetting,rheologycontroletc.幾種常見的添加劑及其作用CommonAdditivesanditsinfluence:分散劑:促進顔料/油漆/消光劑的混合擴散，保持擴散過程穩(wěn)定.Dispersants:Willfacilitatedispersionofpigments/fillers/mattingagentsandkeepthisdispersionmorestable潤滑劑:控制外表摩擦力，可以增強或減弱摩擦力.SlipAgents:Controlthefrictionofthesurface.Thefrictioncanbeincreasedordecreased流平添加劑:用於改變流平性能：防止流掛、增強流平.RheologyAdditives:Usedtomodifytherheology:preventsagging,increaseflow.外表活性劑:改善外表狀況、促進潤濕或是提供泡沫控制能力.Surfactants:Willchangethesurfacetensionandimprovewettingorprovidefoamcontrol.塑化劑:參加到油漆配方中目的在於增強彈性.Plasticizers:Addedtoaformulationinordertoincreasetheflexibility油漆的組成和分類

Paintcompositionandtypes幾種常用填料及其作用Commonfillersanditsinfluence:碳酸鹽:通過降低原料本錢從而降低產品價格Carbonates:Lowcostproductsforreducedrawmaterialcost矽酸鹽:改善機械性能Silicates:Improvemechanicalproperties粘土:常用于控制流平性能ChinaClays:Oftenusedforrheologycontrol此外,填料還可以Also,fillerscaninfluence:影響滲透性InfluencesPermeability促進粒化ImprovesSandability影響光澤度InfluencesGloss油漆的組成和分類

Paintcompositionandtypes塗料類型Primer:性能(吸附,防腐蝕,填充)Primers:togetadhesiononaspecificsubstrate.底漆:外觀(顏色)Basecoats:bringthedesiredcolor/effect面漆:機械性能和外觀(光澤)Topcoats:technicalperformanceandglossSofttouch：命名主要是由於它的觸感Characterisedbyitstactilefeeling絲綢漆:絲狀，平滑，感覺像絲綢Silk-like,asmoothfeelinglikesilk皮革漆:像羊皮，軟軟的如同觸摸皮革Suede,softlikethefeelingofleather橡膠漆:像橡膠，軟但是外表有很強的摩擦力Rubber-like,softbutwithahighfrictiontothesurfaceSofttouch一般都是雙組分的並且干膜厚度更高，這樣才能達到預期的觸感。橡膠漆產品都是低光澤的Theproductsarenormallytwo-packandneedtobeappliedatahigherdryfilmthicknessinordertogetthedesiredtactilefeelingSofttouchproductsalwayshavealowgloss油漆的組成和分類

Paintcompositionandtypes常見的噴塗不良

Commonpaintdefects附著力差adhesionloss氣泡blisters發(fā)白blushing火山口caters色差colormismatch開裂cracking光澤差glossvariations魚眼fisheye雜質impurity桔皮orangepeel針孔pinholes積漆或流掛runsorsags起皺wrinkling常見的噴塗不良-附著力差

Commonpaintdefects--Adhesionloss附著力差可能出現在:thecauseofadhesionloss:1.底材和油漆之間Betweenpaintandsubstrate素材自身問題、對素材的觸摸以及油漆的問題Thesubstrateitself,handingofsubstrateorthepaint’sproblem.2.油漆層之間Betweenpaintlayers兩個漆層中的一個出現問題或者對漆層的觸摸Oneoftwopaintlayersinvolvedorthehandingofthem解決的辦法solution:確保素材清潔乾燥makesurepartsarecleananddry維持精確正確的烘乾參數maintainaccurateandcorrectbakingparameters確保被噴塗的素材至少達到室溫，以防止?jié)穸冗^高時潮氣在素材外表聚集Makesurethepartsarebeingpaintedareatleastatroomtemperaturewhichcanpreventmoistureformingonthepartswhenthehumidityishigh常見的噴塗不良-附著力差

Commonpaintdefects--Adhesionloss氣泡通常形成于油漆和素材之間。Blisterarenormallyformedbetweenpaintandsubstrate氣泡通常由噴塗前就在漆膜下的水、水蒸氣、溶劑、油或者油污造成的。凃層中的氣泡是一種小的圓形凸起，包含或曾經包含上面所說的雜質。Blisteringisusuallycausedbywater,watervapors,solvent,oilorgreaseunderneaththepaintfilmpriortocoating.Ablisterinapaintfilmisasmalldomelikeraisedareathatcontains,oroncedidcontaintheabovecontaminantsAction：確認外表沒有雜質Checkthesurfaceisfreefromanycontaminants確保噴槍的供氣裝置清潔乾燥Ensurethegunairsupplyiscleananddry常見的噴塗不良-氣泡

Commonpaintdefects--Blisters火山口是噴塗過程中凃層中的氣泡破滅或者烘乾過程中溶劑的爆炸形成的.Cratersareformedwhenthebubblebreakwithoutleavingthepaintfilmorduringdryingthesolventpopping.解決辦法action：1.檢驗干膜膜厚是否超出範圍，確認流平時間符合供應商的推薦.checkDFTofthepaint

layersagainstSpcandmakesurethesuppliesrecommendationedonflashofftimeisfollowed.2.使用慢揮發(fā)稀釋劑。Useaslowerthinner

3.檢驗增加流平時間或是降低溫度能否解決問題。Checkifalongerflashofftimeorlowertemperaturesolverstheproblem常見的噴塗不良-火山口

Commonpaintdefects--Craters常見的噴塗不良-魚眼

Commonpaintdefects—fisheye魚眼是漆膜中特別的四周低中間高的不良。塗料沒有覆蓋到下層。有時可以在不良中部看到導致不良產生的雜質。FishEyeisadefectinapainfilmthatistypicallyrounddepressionswitharaisedmoundinthecenter.Thepaintisnotcoveringthelayerbeneath.SometimesanimpuritycausingthefisheyecanbeseeninthemiddleofthedefectCaused:魚眼通常由殘留在素材上的油、油脂或矽樹脂潤滑劑導致。油漆總是向遠離污點処流動。Fisheyesaremostcommonlycausedbyresidualoil,greaseandsiliconelubricantsonthesubstrate.Painttendsto“crawl〞awayfromspotsofthecontamination.Action:解決這類問題需要去除污染物。必須查明素材髒污的原因，防止再次發(fā)生.Thecontaminationneedstoberemovedtofixtheproblem.Itisimportanttounderstandhowthepartsbecamecontaminatedandtopreventthisfromhappeningagain常見的噴塗不良-桔皮

Commonpaintdefects—Orangepeel桔皮是一種類似桔子皮一樣的粗糙的不良。

OrangePeelcanbecharacterizedasatexturedeffectwhichresemblestheskinofanorange.桔皮產生的原因是噴塗過干。通常由於溶劑在噴塗過程中從漆霧中揮發(fā)過快，或是噴塗后揮發(fā)太快，導致流平和潤濕不充分Excessivedryspray.Thisoccurswhenexcessivesolventevaporatesfromtheatomizedpaintparticleswhileenroutetothetargetpartortooquicklyafterreachingthetargetpartcausingpoorflowoutorproperwetting.Action:1.用慢揮發(fā)稀釋劑Useaslowerthinner2.降低油漆黏度並且確保膜厚DecreasethepaintviscosityandmakesurethecorrectDFT

Caused:不良多發(fā)生在溶劑從溼膜中揮發(fā)過快時。這些不良多是由於溶劑在塗層內部揮發(fā)或上升至外表時留下的痕跡。PoppingandPinholesdefectsarisewhensolventislosttoorapidlyfromthewetpaintfilm.Thesedefectsareusuallycausedbysolventformingwithinthepaintfilmandescapingorrisingtosurfaceofthepaintfilm.常見的噴塗不良-氣泡和針孔

Commonpaintdefects—Poppingandpinhole主要的不良原因為：1.高溫固化前的流平時間缺乏.Insufficientflashtimepriortocuringinelevatedtemperatures.2.凃層過厚過溼.Toohigh,thickorexcessivewetfilmbuilds.3.顔料聚集.油漆的混合攪拌不充分會導致顔料聚集,進而束縛溶劑Pigmentclusters.Poormixingandagitationofpaintmayformpigmentclustersthatcantrapsolvent.4.溶劑揮發(fā)速度太快.Highsolventevaporationrates.5.溶劑揮發(fā)速度低會減少流平時的溶劑揮發(fā),使得烘乾固化時凃層中有過多的溶劑.Lowsolventevaporationratescanslowdownthesolventevaporationduringflashtimeswhichwillleaveexcessiveamountsofsolventinthepaintfilmwhilecuringorbaking.

常見的噴塗不良-積漆或流掛

Commonpaintdefects—Runsorsags積漆或流掛是噴塗于垂直外表的油漆,在通過固化烘乾進程成膜並停止流動之前,向下流動的速度與數量不同造成的代表性的結果RunsorSagsaretypicallytheresultofpaintbeingappliedonaverticalsurfacewherethepaintflowsdownwardatdifferentratesandinvariousamountsbeforethedryingorcuringprocesssolidifiesthefilmandstopstheflowofthepaint.造成積漆或流掛的主要原因是：凃層過溼過厚.Applicationofthecoatingfilmistoothickortoowet.噴塗設備或氣嘴髒污.裝置阻塞會導致噴幅變化,結果導致局部不平或過厚.Dirtyairpassagesinthesprayequipmentoraircap.Cloggedairpassagescancausedistortedspraypatternsresultinginunevenandheavyareas.操作員的技術或噴塗程式差.作用于復合零件的爛程式會導致局部的過厚.Pooroperatororprogrammedtechnique.Poorapplicationoncomplexpartscanresultinheavyareasonthepart.相鄰兩層閒的流平時間不夠，導致凃層過溼。Insufficientflashtimeinbetweencoatswhichleavesthecoatingtoowet.常見的噴塗不良-發(fā)白

Commonpaintdefects—Blushing發(fā)白就是被噴塗局部出現白色、乳白色區(qū)域Blushingistheappearanceofwhite,milkyareasonthepaintedpart.Cause:發(fā)白是由溼膜上的水珠〔露珠〕引起的.由於油漆和水不相溶，就形成了樹脂沉澱產生的乳白色區(qū)Blushingiscausedbywaterdroplets(dew)onthewetpaintfilm.Sincethepaintisnotcompatiblewithwater,amilkyareawithprecipitatedbinderisformed.Action：降低噴房相對濕度.Lowertherelativehumidityinthesprayingarea.使用供應商推薦的可以防止結露的稀釋劑.Useathinnerrecommendedbythepaintsupplierwhichcanabsorbthedewformed.降低稀釋劑揮發(fā)速度.Trytoslowdowntheevaporationrateofthethinner.降低噴槍的氣壓.Reduceairpressuretothegun常見的噴塗不良-色差

Commonpaintdefects—colormismatch顔色變化的原因可概括如下：Thecausesofcolorvariationcanincludethefollowing:1.混合攪拌不當導致顔料分配不均和外表顔色不勻.顔料在儲存運輸過程中會沉澱,使用時必須攪拌均勻.Impropermixingandagitationofthepaintcancauseunevenpigmentdistributionandunevencoloroverthesurface.Pigmentshaveatendencytosettleduringstorageandapplicationandmustbeproperlymixedandagitatedduringuse.2.膜厚變化可以引發(fā)顔色變化.膜厚與素材顔色共同決定最終顔色.Filmthicknessvariationscancausecolorvariations.Thefilmthicknesswilltogetherwiththesubstratecolorwilldecidethefinalcolor.乾濕程度會影響顔料在干膜中的分佈狀況,進而影響最終顔色.Wetordryapplicationwillinfluencehowthepigmentsaredistributedinthedrypaintfilmwhichhasaninfluenceonthefinalcolour.素材顔色的變化和素材的咬花會導致最終顔色的變化.Substratecolorvariationandthesubstratesurfacetexturecancausecolorvariationsofthefinalcoatingcolor.常見的噴塗不良-開裂

Commonpaintdefects—CrazingorCracking開裂〔CrazingorCracking〕不良是指凃層外表出現各種形狀的裂縫.CrazingorCrackingdefectsarelineswhichappearinthepaintfilm.Theselines開裂是一種外表缺陷，從凃層延伸至最初的素材外表。通常直綫的裂縫被認爲是Cracking，短而互相交聯的曲綫裂縫則被稱爲Crazing.Crazingorcheckingdefectsaresurfacedefectswhilecrackstypicallyextendthroughthepaintfilmtoprimarysurfacesubstrate.Checkingcanoftenbeidentifiedasstraightlinesandcrazingusuallyappearsasamassofinterconnected,shortwavylines.Cause:1.膜厚過厚,導致膜壓力大.膜厚過厚,會使烘乾時內層與外層的溫度不同,使膜的熱膨脹和收縮不同.在膜釋放應力的時候就會產生開裂.Highstressinthefilmcausedbythickfilmbuilds.Ifthefilmbuildisexcessivewhenbakingthetemperaturedifferencebetweenthetopandbottomthefilmcanbegreatcausingthefilmtothermallyexpandandcontractdifferently.Thiscouldresultincracks,crazingand/orcheckscausedbythefilmrelievetheinternalstress2.過烘也會造成這些不良,因爲凃層變脆.凃層失去彈性,不能承受加熱和機械壓力.Overbakedfilmscanalsoexhibitthesedefectsduetothefilmbecomingbrittle.Thefilmlosesflexibilityandcannotabsorbthermalormechanicalstress.常見的噴塗不良-髒污

Commonpaintdefects—Dirt髒污是指油漆中和噴塗外表的任何污染物.這些污染物包括但不局限于:空氣中的雜質與灰塵、毛絲、頭髮、未溶解的顔料、不粘附于外表的噴霧物質以及油漆殘渣.Dirtinpaintorinthepaintedsurfaceisdefinedasanyandallcontaminants.Thesecontaminantscouldinclude,butarenotlimitedto,airbornedirtanddust,lint,hair,improperlymixedpigment,oversprayandpaintdebris.Maincause:1.毛絲有幾個主要來源，包括包裝、抹布、遮蓋物和衣物.Lintfiberscanoriginatefromseveraltypesofsources.Thesecouldincludepackaging,shoprags,maskingmaterialsandclothes.2.油漆的過濾和輸送也能造成油漆中和噴塗外表出現髒污Fluidfiltrationandfluiddeliveryequipment