Electrophoretic coatings have a specified film thickness standard. The thickness of cathodic electrophoretic coatings directly affects film performance and paint consumption costs. Excessively thick films increase paint usage, raise costs, and negatively impact product quality. Therefore, controlling the film thickness during electrophoretic coating is essential. However, improper operation or other factors can sometimes cause deviations in film thickness. So, how should we address excessively thick films? This article provides solutions to the problem of thick electrophoretic paint films.
Common Causes and Solutions for Thick Electrophoretic Films:
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Bath Temperature Too High Solution: Regularly clean the heat exchanger and check for blockages. Maintain bath temperature within the process range.
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Poor Bath Circulation Solution: Clean or repair clogged nozzles.
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High Solids Content in Bath Solution: Control feed material addition.
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High Solvent Content in Bath Solution: Discharge ultrafiltrate and replenish with deionized water.
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Excessively High Bath Conductivity Solution: Discharge ultrafiltrate and replenish with deionized water.
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Contamination by Impurity Ions in Bath Solution: Discharge ultrafiltrate, replenish with deionized water, and reduce impurity ions.
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Low Pigment-to-Binder (P/B) Ratio; Excess Emulsion Solution: Add color paste to increase the P/B ratio.
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Excessive Coating Time Solution: Reduce coating time.
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High Coating Voltage Solution: Lower coating voltage.
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Improper Cathode-to-Anode Ratio or Layout Solution: Adjust anode-to-cathode ratio and anode positioning.
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High Conductivity in Anode Liquid Solution: Discharge anode liquid and replenish with deionized water.
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Reduced Workpiece Surface Area Entering Bath Solution: Appropriately reduce voltage.
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Insufficient Bath Maturation Time Solution: Extend bath maturation time.
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Bacterial Growth in Bath Solution: Apply bactericide for sterilization.
The above summarizes the common causes and solutions for excessively thick electrophoretic paint films. Properly controlling film thickness ensures product quality while reducing paint consumption and production costs under quality-compliant conditions—a win-win outcome.