E-Coat Seminar.

2008


A.
1.Neutralization ( )
2.Electro-deposition Reaction Mechanism
3.Electro Deposition Section
4. Parameter
5.ED Trends of Future
6. Trouble Shooting

1. Neutralization ( )

H
NNH
O
N
H
NN NNHH
CH
C
O
C
O
H
N
NH
N
H
NNH
2

H
NNH
O
N
H
NN NNH H
CH
C
O
C
O
H
N
NH
N
H
NNH
3

2.
2. Electro-deposition
Electro-deposition Reaction
Reaction


( ) ( )
Mechanism
Mechanism
(Electrolysis)
(Electrophoresis) (Electro deposition) (Electro endosmosis)

,
, H+, OH- .
,
.

( + )
.

.
OH- .
H+ OH- H2O
.
.

.

 (Electrochemical Reaction)

H 3N

N
H3N

O
H+

4 H3CH2C

H2N

H+

NH2
NH3

NH2

OH-

NH3

O C O
OH-

Paint Particles and

other positive ions

H+

Solublizing Acid and

OH-

other negative ions

H+

H2

N
H 2N

OH-

(Anode)

(Cathode)

- Electrolysis of water( )

- Electrolysis of water( )

2 HO

4 CH3COO-

4 H+
+

4 H+

- p H : 1 ~ 3

4 e-

4 CH3COOH

4 HO

4 e-

2 H

4 OH-

- Film deposition( )
4 RNH+

+ 4 OH-

- p H : 12 ~ 14

4 RN

+ 4 HO

3.
3. Electro
Electro Deposition
Deposition Section
Section ((

))

(Electro deposition, E-Coat, ELPO)

Bath .
,
. .

UF (Ultra Filtration Rinse Section)

. UF

.
Spray immersion .
UF #1 UF #2 UF #3 95%

(Deionized Water Rinse) (Cure)

UF ( )
.
,
.

4. Parameter

UF Module

/ /

Electrode
(Anode)

50%

/ P

Ripple 5%

Filter

pH

1 /

- UF
70% ~ 80%
Module .

1 /2

- Anolyte Flow .
- Anode ( SUS 316 L )
- Membrane .

Bath 28 ~ 34

- Max.

1 /

- Cartridge / Bag
Filter
- Bag : 2~3

Module : 1/2
Ion Change :2

- R/O Module / Ion Resin

4. Parameter

UF System (Ultra Filtration) :

Bath UF Module UF (Permeate)

UF Permeate UF Rinse (
) ,
, .
Bath
, UF Permeate
Bath fresh .
1 /min UF Permeate : 1.3L /min

UF Module Filter
- : Bag Filter Cartridge Filter
Module .

UF

UF Permeate Flux( )
- Bath Carry Over
- Bath p H ( pH Flow
)
- Membrane .
- (Filter Clog )/ . Permeate Back Pressure
- Parameter (NV, )

Foulant

Membrane

Membrane Support

4. Parameter

UF Module Type
UF Module Type

- Spiral Wound Type - Hollow Fiber Type- Multi Tubular Type - Plate
Type

UF Module Spiral Wound Type .

UF Module .
. UF Module 2.50.5 Kg.f/ ( P 2.0 Kg.f/ )
100 L/Min , : 35 .
Membrane PVDF (Polyvinylidene Fluoride) .
Molecular Weight Cut Off (MWCO) (NV, )

Spiral
Wound

Hollow
Fiber

Multi
Tubular

4. Parameter

Electrode (Anode : )
(+)
.
Box Cell Tubular Cell
1 4 ~ 6 .

(-) Fresh Bath

Electrode System Membrane Anode(SUS 316L) .
Membrane , Anode .
Electrode .
Anode , Anolyte( )
.
Anode 1 8L/min
Membrane Surface Resistance : Max. 25000.

4. Parameter

(Heat Exchange) : (30 2)

Pump . Pump

Bath .
Bath . 35

.

, Line .
34 .
IN Put - OUT Put (P )0.5 ~ 1.0 Kg.f/
.

:
:
:
:
:

(Rectifier)

/ 0V ~ 350V
Continues Type : (21 Amp.min/ / min)
UP-Down Program hoist Type : 75 A / m2
Ramp Time : 1sec ~ 60 sec
Ripple : Max. 5%

4. Parameter

(Deionized Water System)

Line Raw Material (Water) .

90% (Water) .
Material .
( ) Mineral
pH .
100
.

- (Conductivity : / ), ( Resistivity : . ) p H ( )
.

- p H 5.0 ~ 6.5 ,
- 10 / , ( 0.1 . )

1 / ( 1 . )

.

4. Parameter

,


R/O (Reverse Osmosis : )
EDI .

4. Parameter

Filtration

- Cartridge Filter

: , (2.0 Kg.f/ )

- Bag Filter

: , 1.0 Kg.f/
(Oil Magnetic Filter).

,SEED Cartridge Filter

Bag Filter .

Conveyor System
(Continuous) Type
- Conveyor Speed .
- Line Space .
- .(P & F Conveyor type)
Up-Down Type (Programmable hoist)
- .
- PARAMETER .
- Line . ( : min 45 sec)

 ED Zone Grounding
System

, Bath
Bath FRP Coating .
.
.
( Electro coat 2000 / Electrocoat for advanced users )

(wt %)

pH

(/)

15 ~ 20

5.9 ~ 6.3

1000 ~ 1800

30 2

- ,
( )
1 /1 .
- .
- p H .
p H (25% : ADJ-002)
.
p H

p H .
-

, UF Drain .
- .
36
34 .

 (%)

:
: BATH LEVEL

:
:
:

UF
RUPTURE VOLTAGE
( )

THROW POWER
ROUGH FILM
PHOSPHATE SENSITIVITY
UF (UF )

SYSTEM
BATH

P/B Ratio

PASTE

BINDER

Rough , DIRT
,UF
THROW POWER

CRATER

THROW POWER

PASTE BINDER

BINDER PASTE

pH

PASTE

Leak

DIRT
FILTER CLOG
T/POWER UF

, ,
Rough FILM


GAS PINHOLE

TANK
SYSTEM

%

BINDER

%
UF

Rough ( )
RUPTURE VOLTAGE
THROW POWER

Rough
THROW POWER

UF
( )
System

UF

5.
5. ED
ED Trends
Trends of
of
Future
Future of Economic Advantages (
Improvement

- Excellent Film Uniformity and Control ( )

- Low Applied Cost ( )
: Reduce Film density / Heat weight loss
: Low Temperature Cure
- Low Maintenance Cost ( )

Improvement of Environmental Advantages ( )

- VOC(Volatile Organic Compounds)& HAPs(Hazardous Air
Pollutants)
Free Formulations
- Lower BOD/COD in Waste Streams

5.
5. ED
ED Trends
Trends of
of
Future
Low P/BFuture
Ratio

Gen. 4

pigment = 33
binder

120 mg/h

= 100

Gen. 5

pigment = 17
binder

50 mg/h

= 100

Sedimentation
Velocity
Powercron 640

Gen.6 pigment = 12
binder

Reduced Pigment
- Lower Dry Film Density
- Improved Usage
- Lower Applied Cost

30 mg/h

= 100

Future

Powercron 648
Powercron 643
Powercron 6000CX
pigment = 4
binder

1 mg/h

= 100

Powercron 659
ElectroClear 2700

6.Introduction of New ED Products

Property

Powercron 659

Electroclear 2700

Epoxy

Acrylic

CR 659 - CP 506

CR 955

Solid (%)

18 ~ 22

11~ 13

P/B ratio

0.02 0.01

0.02 0.01

5.0 ~ 60

4.5 ~ 6.0

Conductivity

2100 ~ 2900

400 ~ 500

Bath
Temperature

30 2

30 2

Coat Volt / Time

225 V / 120 sec

60 V ~ 100 V / 60 sec

Bake schedule

121 20 Minutes
(Metal Temperature)

160 20 Minutes
(140 ~190 )

Resin Type

pH

6.Introduction of New ED Products

Property

Powercron 659

Electro Clear 2700

Black

Clear

0.4 - 1.2 Mils

0.4 - 1.2 Mils

55 75%

Full Gloss

2H Minimum

2H Minimum

100%

100%

Salt spray

500 Hours Minimum

500 Hours Minimum

Humidity

500 Hours Minimum

500 Hours Minimum

Water Soak

250 Hours Minimum

UV Durability

750 Hours Minimum

11 13 inches

Color
Film Thickness
Gloss - 60 Degree
Pencil Hardness
Crosshatch
Adhesion

Throw power


B.
1.
2.

1.
1.
(PRETREATMENT)
(PRETREATMENT)

~
.
,
.
,
.

(Hot Water Rinse)
(Degreasing)
(Rinse)
(Activation)
(Phosphates) (Rinse/Pure Water)
~ , , .

( , ) .

 (- :

- : Blaster )

~
.
.
Line Alkali .
, .

(Saponification) + , , ,
.
.

CH2-OOC-R - CH-OOC-R - CH2-OOC-R (fat) + 3NaOH (or KOH)
heated
CH2-OH -CH-OH - CH2-OH (glycerol) + 3 R-CO2-Na (soap)


~ .
, Alkali
.

.
. Ca,Mg
( )
.
Scale ( ) ,

120
. ~180ppm

40
ppm

40 ~ 80 ppm

180 ~ 300ppm

80 ~ 120 ppm

300ppm


~
.
Etching .
Etching

,
.

PO4-

Etching

OH-

Ti

PO4SO4-

SO4-

PO4Ti

Ti (PO) H2O

Ti

OH

SO4OH-

Ti

(Ti- Colloid)


~
Phosphophyllite [Zn2Me(PO2)4]
Hopeite [Zn3(PO2)4] Hopeite
Phosphophyllite Zn Mn, Ni
Tri cationic .
Tri cationic P/P+H Ratio (Phosphophyllite / Hopeite )
, , .

2Fe + 2H3PO4 Fe(H2PO4)2

+ H2

Fe(H2PO4)2 + [O]/(NaNO2) FePO4 (Sludge) + H3PO4 + H20

Zn + 2H3PO4 Zn(H2PO4)2

+ H2
Hopeite

3Zn(H2PO4)2+ 4H2O Zn3(PO4)2.4H2O Hopeite+ 4H3PO4

Fe(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Fe(PO4)2.4H2O

Phosphophyllite

Ni(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Ni(PO4)2.4H2O

Phosphonickelite

Mn(H2PO4)2 + 2Zn(H2PO4) + 4H2O Zn2Mn(PO4)2.4H2O

+ 4H3PO4
+ 4H3PO4

Phosphomangollite

+ 4H3PO4
Phosphophyllite




.


.

.

.
160 ~ 170
. : 1.5g ~ 3g/ ( 8% )

 SEM of Zinc
Phosphates
Before

After

Before

CRS

GA

 SEM of Zinc
Phosphates
Before

After

MG

2.

- ( )
-
-

- .
- .
- .

- :
-
-

- : CHECK.
- : CHECK
.( )

Sludge

- p H /

- .
- .
- Sludge .
.
- Sludge
Sludge Sludge
.( UF Module )

-p H : 5.0 ~ 7.0 ,- : Max 25 / .

 The Solubility of Zinc Phosphates

Phosphophyllite [Zn2Me(PO2)4] Hopeite[Zn3(PO2)4]

.
Phosphophyllite [Zn2Me(PO2)4] Hopeite [Zn3(PO2)4]
.
(Immersiong Type)
Phosphophyllite [Zn2Me(PO2)4] .
. ,

.

 pH
pH

pH

Zn

10.0

Al

10.0

Sn

11.0

Cu

11.5

Fe

13.0

(dm2) = (kg) (mm) x 2 x 100

Fe

7.876

Al

2.7

Zn

7.13

Mg

1.74

Mn

7.3

Bi

9.8

Sn

7.28

Pt

21.45