烤漆知识简介

1、塗裝流程以及塗裝知識簡介塗裝流程以及塗裝知識簡介Foxconn BJ coating introduction 北富塗裝廠北富塗裝廠内容簡介 Content塗裝的基本原理 Coated plastics offer choice of color, gloss and texture. Coating masks minor surface defects and flow lines,for a better-finished product.Coating plastics improves their mechanical and chemical properties. Some pl

2、astics need a coating for exterior durability.Other special function: Such as conductor塗裝的基本原理噴塗漆膜成膜方式 paint film formed by:Physical drying:Drying by solvent evaporation only.No chemical reaction increasing the molecular weight takes place .Only moderate resistance properties Fast process. Chemical

3、drying-Curing:Drying through solvent evaporation followed by a chemical reaction Slower than physical drying Better resistance properties. Better exterior durabilityUV-curing unsaturated vinyl compounds with initiator added react when exposed to UV-radiation.塗裝的基本原理 Elements油漆的組成和分類Paint composition

4、 and types樹脂Binders溶劑Solvents顔料Pigments填料Fillers添加劑Additives油漆的組成和分類Paint composition and types油漆的組成和分類Paint composition and types油漆的組成和分類Paint composition and types油漆的組成和分類Paint composition and types油漆的組成和分類Paint composition and types油漆的組成和分類Paint composition and types常見的噴塗不良 Common paint defectsq魚

5、眼 fish eyeq雜質impurityq桔皮 orange peelq針孔 pinholesq積漆或流挂runs or sagsq起皺wrinkling常見的噴塗不良-附著力差附著力差Common paint defects-Adhesion lossq確保素材清潔乾燥確保素材清潔乾燥 make sure parts are clean and dryq維持精確正確的烘乾參數維持精確正確的烘乾參數maintain accurate and correct baking parametersq確保被噴塗的素材至少達到室溫，以防止濕度過高時潮氣確保被噴塗的素材至少達到室溫，以防止濕度過高時潮氣

6、在素材表面聚集在素材表面聚集 Make sure the parts are being painted are at least at room temperature which can prevent moisture forming on the parts when the humidity is high常見的噴塗不良-附著力差附著力差Common paint defects-Adhesion loss氣泡通常形成于油漆和素材之間。Blister are normally formed between paint and substrate氣泡氣泡通常由噴塗前就在漆膜下的水、水蒸氣

7、、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。Blistering is usually caused by water ,water vapors,solvent,oil or grease underneath the paint film prior to coating.A blister in a paint film is a small domelike raised area that contains ,or once did contain the above contaminantsActionAction：確認表面沒有雜質 Ch

8、eck the surface is free from any contaminants確保噴槍的供氣裝置清潔乾燥 Ensure the gun air supply is clean and dry常見的噴塗不良-氣泡氣泡Common paint defects-Blisters火山口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.Craters are formed when the bubble break without leaving the paint film or during drying the solvent popping.解決辦法解決辦法 acti

9、on： 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.check DFT of the paint layers against Spc and make sure the supplies recommendationed on flashoff time is followed . 2.使用慢揮發稀釋劑。Use a slower thinner 3.檢驗增加流平時間或是降低溫度能否解決問題。Check if a longer flashoff time or lower temperature solvers the problem常見的噴塗不良-火山口火山口Common p

10、aint defects-Craters常見的噴塗不良-魚眼Common paint defectsfish eye魚眼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。Fish Eye is a defect in a pain film that is typically round depressions with a raised mound in the center.The paint is not covering the layer beneath .Sometimes an impurity causing the fishe

11、ye can be seen in the middle of the defectCaused: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。Fisheyes are most commonly caused by residual oil, grease and silicone lubricants on the substrate. Paint tends to “crawl” away from spots of the contamination.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，防止再次發生.The contamin

12、ation needs to be removed to fix the problem.It is important to understand how the parts became contaminated and to prevent this from happening again常見的噴塗不良-桔皮桔皮Common paint defectsOrange peel桔皮桔皮是一種類似桔子皮一樣的粗糙的不良。 Orange Peel can be characterized as a textured effect which resembles the skin of an o

13、range. 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過快，或是噴塗后揮發太快，導致流平和潤濕不充分Excessive dry spray. This occurs when excessive solvent evaporates from the atomized paint particles while en route to the target part or too quickly after reaching the target part causing poor flow out or proper wetting.Action:1.用慢揮發稀釋劑 U

14、se a slower thinner2.降低油漆黏度並且確保膜厚Decrease the paint viscosity and make sure the correct DFT 常見的噴塗不良-氣泡和針孔氣泡和針孔Common paint defectsPopping and pin hole主要的不良原因為：1.高溫固化前的流平時間不足. Insufficient flash time prior to curing in elevated temperatures.2. 凃層過厚過溼. Too high, thick or excessive wet film builds. 3.顔

15、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Pigment clusters. Poor mixing and agitation of paint may form pigment clusters that can trap solvent. 4.溶劑揮發速度太快. High solvent evaporation rates.5.溶劑揮發速度低會減少流平時的溶劑揮發,使得烘乾固化時凃層中有過多的溶劑. Low solvent evaporation rates can slow down the solvent evaporation during flash times w

16、hich will leave excessive amounts of solvent in the paint film while curing or baking. 常見的噴塗不良-積漆或流挂積漆或流挂Common paint defectsRuns or sags積漆或流挂積漆或流挂是噴塗于垂直表面的油漆,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Runs or Sags are typically the result of paint being applied on avertical surface where the paint flo

17、ws downward at different rates and in variousamounts before the drying or curing process solidifies the film and stops the flow of the paint.造成積漆或流挂的主要原因是：凃層過溼過厚. Application of the coating film is too thick or too wet.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. Dirty air passages in the spray equipment or a

18、ir cap. Clogged air passages can cause distorted spray patterns resulting in uneven and heavy areas.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. Poor operator or programmed technique. Poor application on complex parts can result in heavy areas on the part.相鄰兩層閒的流平時間不夠，導致凃層過溼。Insufficient flash time in between

19、coats which leaves the coating too wet.常見的噴塗不良-發白發白Common paint defectsBlushingCause:發白發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Blushing is caused by water droplets (dew) on the wet paint film. Since the paint is not compatible withwater, a milky area with precipitated binder is formed.Action： 降低噴

20、房相對濕度. Lower the relative humidity in the spraying area. 使用供應商推薦的可以避免結露的稀釋劑. Use a thinner recommended by the paint supplier which can absorb the dewformed. 降低稀釋劑揮發速度. Try to slow down the evaporation rate of the thinner. 降低噴槍的氣壓. Reduce air pressure to the gun常見的噴塗不良-色差色差Common paint defectscolor m

21、ismatch顔色變化的原因可概括如下：The causes of color variation can include the following:1.混合攪拌不當導致顔料分配不均和表面顔色不勻.顔料在儲存運輸過程中會沉澱,使用時必須攪拌均勻. Improper mixing and agitation of the paint can cause uneven pigment distribution and uneven color over the surface. Pigments have a tendency to settle during storage and appli

22、cation and must be properly mixed and agitated during use.2.膜厚變化可以引發顔色變化.膜厚與素材顔色共同決定最終顔色.Film thickness variations can cause color variations. The film thickness will together with the substrate color will decide the final color.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. Wet or dry application will influence how

23、the pigments are distributed in the dry paint film which has an influence on the final colour.素材顔色的變化和素材的咬花會導致最終顔色的變化. Substrate color variation and the substrate surface texture can cause color variations of the final coating color. 常見的噴塗不良-開裂開裂Common paint defectsCrazing or Cracking開裂開裂（Crazing or

24、 CrackingCrazing or Cracking）不良是指凃層表面出現各種形狀的裂縫. Crazing or Cracking defects are lines which appear in the paint film. These lines開裂是一種表面缺陷，從凃層延伸至最初的素材表面。通常直綫的裂縫被認爲是CrackingCracking，短而互相交聯的曲綫裂縫則被稱爲Crazing. Crazing. Crazing or checking defects are surface defects while cracks typically extend through

25、the paint film to primary surface substrate. Checking can often be identified as straight lines and crazing usually appears as a mass of interconnected, short wavy lines.Cause:1.膜厚過厚,導致膜壓力大.膜厚過厚,會使烘乾時内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. High stress in the film caused by thick film builds. If the

26、film build is excessive when baking the temperature difference between the top and bottom the film can be great causing the film to thermally expand and contract differently. This could result in cracks, crazing and/or checks caused by the film relieve the internal stress2.過烘也會造成這些不良,因爲凃層變脆.凃層失去彈性,不

27、能承受加熱和機械壓力. Over baked films can also exhibit these defects due to the film becoming brittle. The film loses flexibility and cannot absorb thermal or mechanical stress.常見的噴塗不良-髒污髒污Common paint defectsDirt髒污髒污是指油漆中和噴塗表面的任何污染物.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、不粘附于表面的噴霧物質以及油漆殘渣.Dirt in paint or in t

28、he painted surface is defined as any and all contaminants. These contaminants could include, but are not limited to, airborne dirtand dust, lint, hair,improperly mixed pigment, overspray and paint debris.Main cause:1.毛絲有幾個主要來源，包括包裝、抹布、遮蓋物和衣物. Lint fibers can originate from several types of sources.

29、These could include packaging, shop rags, masking materials and clothes.2.油漆的過濾和輸送也能造成油漆中和噴塗表面出現髒污Fluid filtration and fluid delivery equipment can cause dirt in the paint or painted surface.3.噴房風壓不穩. Improper system air balance or negative air flow in key areas of paint system.4.噴塗中,空氣未過濾,地板和設備髒會給空

30、氣中引入雜質和粉塵Airborne dirt and dust can be generated in the painting facility by many sources including unfiltered air, dirty floors and dirty equipment.5.積聚在輸送鏈、支架、噴槍和噴房的漆渣也可能附著在噴塗表面Overspray paint that accumulates on conveyors, racks, paint tooling and the paint booth can end up on the painted surface.常見的噴塗不良-起皺起皺Common paint defe