Aluminum electrophoresis white process technology introduction
[China Aluminum Network] Since its introduction for metal decoration and corrosion protection, electrophoresis technology has been widely adopted across various industries and material fields, especially in the automotive sector. Over time, this technique has seen rapid development. In particular, within the aluminum profile industry, Japan was among the first to develop electrophoresis technology for aluminum profiles in the 1960s, and it has since become a standard in the aluminum industry. China introduced electrophoresis equipment and technology around 20 years ago, and after more than two decades of growth, the application of electrophoretic aluminum materials has spread across all provinces and autonomous regions. These materials are now extensively used in construction and other sectors. Meanwhile, both colored and white aluminum materials have also experienced significant progress.
However, currently, white electrophoretic paint is mainly applied to aluminum materials using anode electrophoretic coatings, which are largely imported from abroad. This technology is dominated by foreign companies. After years of research and development, Wuhan Collier Chemical Co., Ltd. has successfully developed a high-performance aqueous polyurethane cathodic electrophoretic resin and obtained a national invention patent. Based on this innovation, they have created a white polyurethane cathodic electrophoretic paint. In Nanhai, Guangdong, China has established a cathode vertical and horizontal electrophoresis line specifically for this technology. After three months of trial operation, the system runs smoothly, with stable electrophoretic baths that are fully suitable for industrial production. Compared to traditional anode white electrophoretic coatings, this new method offers advantages in terms of process simplicity, energy efficiency, and environmental protection.
The white electrophoretic aluminum material produced by this process has a smooth film surface, high hardness, and excellent protective properties. It has been widely adopted in window decoration aluminum, aluminum profiles, and furniture materials, gaining recognition and respect from customers. The following discussion focuses on the white polyurethane electrophoretic paint process and the electrophoresis production line equipment developed by Wuhan Collier Chemical Co., Ltd.
Traditional Process: (Anode Acrylic White Electrophoretic Coating)
1. Degreasing → 2. Flow Washing → 3. Alkaline Etching → 4. Hot Water Washing → 5. Flow Washing → 6. Neutralization → 7. Flow Washing → 8. Flow Washing → 9. Oxidation → 10. Flow Washing → 11. Flow Washing → 12. Pure Water Washing → 13. Pure Water Washing → 14. Anode White Electrophoresis → 15. Pure Water Wash (Spray) → 16. Pure Water Wash → 17. Pure Water Wash → 18. Drying
New Process (Cathode Polyurethane White Electrophoretic Coating – Wuhan Collier Production Line as an Example):
1. Degreasing → 2. Flow Washing → 3. Flow Washing → 4. Pure Water Washing → 5. Pure Water Washing → 6. Pure Water Washing → 7. Cathode Polyurethane White Electrophoresis → 8. UF Water Washing (Spray) → 9. Pure Water Washing → 10. Pure Water Washing → 11. Drying
The new process significantly simplifies the workflow compared to the traditional one, making operations more convenient and efficient. For instance, this process is primarily used in aluminum profile door curtain tracks. The main equipment includes:
1. Electrophoresis Tank: Made of PVC, equipped with liquid circulation filtration, ultrafiltration, and cooling/heating systems. The coated workpiece should be 10–20 cm above the tank bottom, at least 15 cm away from the plate, and submerged 5–10 cm below the liquid surface. The tank surface flow rate should be around 0.2 m/s, with 4–6 cycles per hour.
2. Ultrafiltration Machine: Uses semi-permeable membranes to separate pigments, resins, solvents, and impurities from the bath solution. Common types include tube, roll, hollow fiber, and plate. Hollow fiber membranes, such as KL-Q04, are widely used, with a capacity of 200 L/h.
3. Pure Water Machine: Electrophoresis requires high-purity water. A R-1000 reverse osmosis unit is typically selected, producing 1 T/h of pure water.
4. Power Supply: Domestic electrophoretic power supplies are similar to global standards, featuring soft start/stop, automatic timing, voltage and current limits, and over-current protection.
5. Cooling and Heating Units: Use imported variable frequency compressors and electronic controls for temperature regulation, enabling multi-slot configurations.
6. Racks: Designed according to product specifications and process requirements. For example, degreasing uses Wuhan Collier’s K-301 acid degreaser at 5–8% concentration for 5–8 minutes at room temperature. Flow washing removes residual water and dirt, requiring pH ≥ 5.5 and conductivity ≤ 180 μS/cm, with each cycle lasting about one minute.
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