【Abstract】Alone with the popular application of 2K coating, I’d like to share with you all here about the matter in use and notices from the direct customer and the requirement of technics equipment.

【关键词】双组份材料特性、喷涂时间、比例精度、多色兼容、换色时间

【Key words】2K coating characteristic, pot life, mix ratio accuracy, multicolor compatibility, color change time

【前言】随着我国工业化进程的飞速发展，作为工业美容师的涂装行业，就双、多组份涂料的应用越来越广泛。双组份涂料因其环保、耐候以及优异的综合物理和化学性能越来越多的得到各界业主充分肯定；汽车及零部件行业：被应用到整车罩光漆，保险杠、反光镜、仪表板、油箱、发动机护板等的涂装中；同样被应用于电子行业：终端机外壳、各类键盘等；以及等多行业：航空航天，木制品和家具、卡车和大客车，工程、农用机械机，通用金属制品等。

本文针对内饰件双组份油漆特性和应用特点作以下阐述：

双组份内饰漆的应用特性：

材料特性

涂料主要种类有：

1）常见的双组份中涂或底漆

2）常见的双组份面漆

涂装行业使用双、多组份材料，主要有以下优势：

1）符合环境保护的要求：利于控制挥发物和有害废料的排放；避免工人与有毒害材料的直接接触。

2）延长的产品寿命和良好的耐久性：涂膜光泽度、饱满度、鲜映性、机械耐久性、化学耐久性有优良表现；双组份聚氨酯涂膜受到外力破坏时，不易损伤，具备较好的综合机械性能，更好的韧性；涂膜暴露在恶劣环境中、化学腐蚀剂中，老化的寿命大大延长；

3）更经济的生产工艺：降低油漆、人工和能源的成本，提升产品利润；喷涂后可使用低温、短时间烘烤，烘干炉的能源大大节省；更低的VOC，减轻环保的经济压力。

4）更广泛涂料的应用：更高的固体份涂料、水性涂料。

5）装饰效果：双组份油漆保持了油漆易于流平，桔皮现象小的装饰效果，在一些场合其装饰性优于粉末涂料；

喷涂时间

喷涂时间（PotLife）对于双组份油漆用户来讲非常重要：因为双组份油漆的固化不是通过溶剂的蒸发而成膜，而是通过化学的交联反应完成固化，固化过程中会释放热量。喷涂时间是指混合后的油漆粘度会呈现幂次方速度上升的起始时间，此时的油漆会由液体状态迅速成为固态，直至完全固化。对于使用单组份喷涂设备喷涂双组份油漆的用户来讲，必须在喷涂时间以前，喷涂使用所有混合后的油漆，并将单组份设备清洗干净。

固化剂的储存和输送

固化剂（B剂）主要由如下类型组成：异氰酸盐、催化剂、触媒剂、硬化剂。

此类材料在生产、包装、运输、使用的环节中，有如下特殊要求：（以材料商提供的材料规格书为准）

例：

温度要求：保持25±2摄氏度

包装要求：完全密闭金属桶。

使用要求：因大多数材料具有适度敏感性，所以要求完全在隔绝空气

（通常使用氮气或者氩气）保护填充输送，输送至组份配比设备的压力范围通常0.2~0.4MPA。

多使用带有隔绝空气密封结构的气动或者液压泵持续输送（如左图所示，避免柱塞杆工作中带出固化剂与空气中水分反应固化，而破坏普通的动态密封），带回流循环设计的双组份配比设备中，固化剂的回流桶同样需要使用纯度99%以上的惰性气体（通常使用氮气或者氩气）保护。保护压力范围通常0.01~0.02MPA。

比例精度的影响

谈到比例精度会涉及到：质量比例和体积比例。双组份计量设备通过计量泵或流量计采用体积计量方式保证比例精度；而人工混合通常使用质量比计量方式。

每一种双组份内饰油漆材料都会有自己的比例精度要求，允差范围一般为2-5%，个别有到10%。比例精度的保证是实现材料自身最佳性能的前提：固化剂过多，通常会使固化时间变短，油漆成膜后韧性下降变脆，甚至发生龟裂，颜色偏黄等现象；固化剂过少，会使油漆难以固化，甚至无法固化。

比例精度得不到保证是双组份内饰油漆使用的大忌，严重影响喷涂油漆的质量，导致返工或产品报废。

在使用双组份设备时影响比例精度的因素有以下方面：1）A、B材料压力的匹配：2）黏度的匹配：3）是否合理的清洗程序；4）比例阀等机械部件的性能下降；

混合对固化的影响

双组份内饰油漆在使用前因其特性要求严格分离，使用时为实现材料特性，必须每点都要保证充分混合。

人工混合通常采用机械搅拌器完成，混合效果与搅拌桨叶形状和搅拌时间长短相关，并且不能完全预知结果。

使用电子配比的双组份设备通常配备预混和精混装置，精混装置多采用静态混合器，设备的流道设计和压力稳定会影响即时混合比例。即时混合比例不稳定，混出的油漆会发生与人工混合时间不足一样的结果。设备长期使用，清洗效果的好坏会影响到混合效果。

?塑料件的喷涂换色和清洗；

塑料件喷涂的特点是种类多，批量相对较小，换色与清洗更为频繁；电子配比的双组份油漆混合设备具有自动清洗功能，最大程度保证设备的安全。当电子配比设备检测到混合腔（通常体积不超过300CC）内被混合的材料接近实际喷涂固化时间后（该时间可人工自由设置），设备会自动对混合腔进行清洗。

多色兼容

为应对汽车整车颜色的多样化，零部件力争对应颜色，减少色差，使用双组份内饰油漆对喷涂设备的颜色兼容性提出了更高的要求。

电子配比设备最多可接纳24种主剂（A），3种固化剂（B），共计63种配方的使用。A、B剂和配方的使用，不相互影响。配方之间的切换，只需一键式操作即可完成。设备将自动执行换色及清洗程序，换色及清洗程序需要编写在控制柜内。设备分为自动合手动分类：

双多组份电子配比设备，大致构成如下：

在目前全球及国内内饰涂装行业使用最广泛，具有如下功能：

1）适用材料广泛：双组份溶剂型和水性的环氧类、聚氨酯及酸固化清漆。

2）一次性投资：后期使用，仅配比阀等少量的活塞密封件，会发生二次费用投入。

3）一键式操作盒、EASYKEY显示屏设计，实时流量和配比状况显示。

6）单色、多色功能选择可满足多种应用工艺。

7）可编程的清洗和填料程序可充分节省涂料的用量

8）固化时间监视及自动清洗程序，保证设备的使用安全

9）流体盘及操作盒的防爆设计，可安置于有防爆要求的喷房内。

10）涂料黏度范围广，可配比黏度为20~3000厘泊的涂料。

提高换色质量

换色质量意味着：原漆无颜色残

留，并导入合格的新颜色油漆。提高换色质量需要考虑如下方面：

1）换色阀内部结构流道设计尤为重要，力求平滑，无死角，特别是密封处利于清洗。

2）在A、B剂的输入前端配置过滤装置，避免材料颗粒对质量的影响；

3）保持CCV等机械部件的良好性能，做好设备保养；

4）使用尽量符合材料性质的换色和清洗程序，合理设置清洗时间，避免时间不足造成的清洗不良和时间过长造成的溶剂浪费。

减少换色时间

使用单组份设备喷涂双组份（2K）油漆换色时，需要操作者熟练的排空原色漆，并用高活性溶剂循环清洗整套设备（包括：供给加压泵，流体处理原件、管路和喷枪），用干净的溶剂将带有色浆的溶剂推出，并再次使用干净溶剂清洗整套设备（换色质量要求高时，会增加清洗次数和时间）。清洗过程大约需要20分钟以上时间（与操作熟练度有关）。

双组份油漆设备换色时，只需要清洗混合部分，专用的换色装置会大幅缩短换色时间至5分钟以内；在对换色时间有更高要求的场合，还可通过以下办法将换色时间缩至几十秒：提高清洗介质的供给流量和压力；增加吹扫的交替频率；缩短吹扫的单次时间；在能够清洗彻底的前提下，尽量缩短清洗空气、溶剂的吹扫总时间。

?应用的环保性

解决手工混合的遗洒

双组份电子对涂料浪费的量几乎为零，近似为理想的状况，这是手工配比所无法达到的。A、B剂量接入设备后，在被喷涂前，完全在密闭的流体盘内进行计量和分配。配比设备的单次配比容积25~100CC，待此容积的涂料被使用后，再开始下一体积的配比。使用双组份内饰油漆人工配比时，不可避免的遗洒问题，以及配漆量必须大于使用量的问题，得到彻底解决。

减少返修

目前在国内使用的电子配比设备混合精度可获得持续±0.5%以内，以及良好的混合效果，是手工配比难以实现的；最大程度避免了因为人为因素造成的混合不匀或比例超差，而导致的工件返修。

解决清洗质量和溶剂浪费的冲突

采用双组份内饰油漆人工混漆，使用单组份喷涂设备施工时，必须在有效喷涂时间前将喷涂器具清洗干净。为保证不让残留的混合后的双组份油漆固化在设备内需要大量的高活性溶剂进行泵体内部、管道和喷具的冲洗。

通常普通单组份喷涂设备的输送、加压泵的容积一般为数百cc至数千cc，而混合后的喷涂软管中通常容积为0.2-0.5升；使用的换色清洗溶剂会数倍于被清洗容积，达到数十升。清洗不净会直接影响高压柱塞泵喉部密封的使用寿命。

使用双组份喷涂设备，预混和精混装置容积不大于160cc，连带混合后的喷涂软管容积，通常不超过1000cc,换色清洗时因为导入辅助吹扫空气，大大减少清洗溶剂使用量；在能够满足清洗质量的前提下，改编换色和清洗程序，可进一步有效的减少换色溶剂的浪费。

综上所述，使用双组份油漆一定要选用相适合的双组份设备。在提高产品质量和生产效率的同时，减少材料浪费，并且可以兼顾物料的管理（通常双组份油漆和调漆溶剂的价格都会高于普通单组份油漆）。在了解油漆和溶剂的用量、单价的基础上，可以通过合理地投资回报分析，确认工艺设备的投入，现场管理（可以是供应商参与的）与企业收益的相互关系及把握重点；为企业提质、增效、降本提供了可选择的方法

Types of nozzles and sprays
Due to a wide range of nozzle shapes and sizes (tip size from 0.8mm to 2.5mm), the consistency of the paint can be varied. The shape of the workpiece and the desired paint consistency and pattern are important factors when choosing a nozzle. The three most common nozzles are 1.4mm / 1.7mm / 2.0mm in the shape of full cone, hollow cone, and flat stream. In a manual operation method the air-spray gun should be held by a skilled operator, about 6 to 10 inches (15–25 cm) from the object, and moved back and forth over the surface, each stroke overlapping the previous to ensure a continuous coat. In an automatic process the gun head is attached to a mounting block and delivers the stream of paint from that position. The object being painted is usually placed on rollers or a turntable to ensure overall equal coverage of all sides.

HVLP (High Volume Low Pressure) spray gun
This is similar to a conventional spray gun using a compressor to supply the air, but the spray gun itself requires a lower pressure (LP) for low overspray. A higher volume (HV) of air is used to propel the paint at lower air pressure. The result is a higher proportion of paint reaching the target surface with reduced overspray, materials consumption, and air pollution. A pressure regulator is often required so that the air pressure from a conventional compressor can be lowered for the HVLP spray gun. Alternatively a turbine unit (commonly containing a vacuum cleaner derived motor) can be used to propel the air without the need for an air line.
A rule of thumb puts two thirds of the coating on the substrate and one third in the air. True HVLP guns use 8–20 cfm (13.6–34 m3/hr), and an industrial compressor with a minimum of 5 horsepower (3.7 kW) output is required. HVLP spray systems are used in the automotive, marine, architectural coating, furniture finishing, scenic painting and cosmetic industries.

LVLP (Low Volume Low Pressure) spray guns
Like HVLP, these spray guns also operate at a lower pressure (LP), but they use a low volume (LV) of air when compared to conventional and HVLP equipment. This is a further effort at increasing the transfer efficiency (amount of coating that ends up on the target surface) of spray guns, while decreasing the amount of compressed air consumption.

LVMP (Low Volume Medium Pressure) spray guns
This is a new type spray gun which occured in the market in the recent years.
the LVMP medium pressure spray gun will generate better atomization than LVLP sprayer. but you have to attach it to one bigger horsepower compressor which would generate more compressed air for this spray gun

我们的无气喷涂机包括：电动无气喷涂机和空气辅助气动喷涂机，隔膜泵和柱塞泵，低压大流量双隔膜泵， 腻子喷涂机，等，这些可以满足您对各种不同喷涂工作的需求。而且产品通过CE认证。

无气喷涂机将会是建筑承包商、专业油漆工、居房装修、旧房翻新和大工程的最完美的选择，因为其不仅高效率，节省工钱，而且节省涂料，喷涂后的表面更整洁漂亮。我们无气喷枪的喷嘴包含了从311-0.011″至635-0.035″在所有型号，而且我们的无气过滤网也包含了30#60#100#150#和180#等

到目前为止我们的无气喷涂产品已远销法国、德国、意大利、波兰、俄罗斯、丹麦，英国，比利时，荷兰，奥地利，爱尔兰，西班牙，葡萄牙，希腊，土耳其，乌克兰，加拿大，印度，泰国，日本，韩国，澳大利亚，南非，智利，阿根廷，巴西，墨西哥等多个国家。现在就和我们联系，获取更多的详细信息。

所有的喷涂机运出前的测试。所有的机械都将经过严格的检测以确定性能是否稳定，电流、功率、温度是上升是否合理，电机是否运转正常，喷雾是否接受……

but for airless spraying, you just put the suction hose into the big bucket, and the pump machine will transfer the fluid into the spray gun which could be connected by 15meter, 30meters hose
that’s mean you could use your spray gun on 2nd floor, or 3rd floor, while the pump sprayer machine is on the ground floor.
you don’t need to change the pot, just spray it continuely till the job is finished.

so airless paint spraying is totally designed for big area painting jobs, from low viscosity to high viscosity, water-based, or oil-based, with or without grains, paint / stains / lacquer / filler / putty / plaster etc.

– Operating instructions
Mixing the paint
• Step 1: First measure the viscosity of
the paint. To do this, stir the paint well,
then dip the viscosity measurement
beaker (9) into the paint and fill to just
below the rim. Raise the beaker and
wait to see how long it takes until the
paint has drained completely (Fig. 5).
The maximum viscosity value for this
spray gun is 30 to 35 seconds.
• Step 2: Thinning the paint. If the
value is lower than 30 seconds, you
will not need to thin the paint. If the
value is greater than 35 seconds, the
paint must be thinned until a value of
between 30 and 35 is reached. Always
thin paint in small amounts using a
suitable thinner. When choosing a
thinner, observe the instructions from
the manufacturer in order to ensure
that * you are using the correct thinner
type and that the paint can be thinned.
Stir the paint thoroughly before and
after thinning. Do not thin the paint
beyond the recommendations of the
manufacturer.
• Step 3: Sieve the colour through a
fine metal sieve or nylon stocking in
order to remove any particles that
may block the gun.
• Step 4: To remove the paint
container (1) turn it anti-clockwise
(Fig. 6). Pour the paint into the
container. Only fill the container with
paint up to the point where it starts
to narrow, then screw the container
firmly to the spray gun (Fig. 6). Make
sure that the seal (6) in the lid and
the feed hose (2) are not damaged
and are fitted correctly.
Preparing the surfaces
• Good preparation is essential for
perfect results.
• Remove any old, flaking paint and
sand the surface. The surface must
be free from dirt and grease.

– Spraying instructions
Operating elements of the spray gun
1. Spray cap (5): Releasing the securing
ring allows the direction of the air to
be set. The horizontal setting is
recommended for spraying up and
down, the vertical setting for spraying
from side to side.
2. Paint quantity regulator (8): This
regulator controls the amount of paint
released when the trigger on the handle
is pushed. The paint quantity regulator
must be set before any painting work is
carried out. We recommend that you
start with a test area.
3. Handle (12) of the spray gun: As
soon as the compressor is switched
on, the spray gun is supplied with
compressed air. The paint only flows
when the trigger (a) on the handle is
actuated.
Handling the spray gun
Before you start spray painting, always
test the paint on a separate test surface.
Spray painting requires patience and
practice. You will always produce better
results if you follow these basic tips.
Holding the spray gun
Hold the gun between 150 and 200mm
from the surface (Fig. 8). If you hold the
gun too close to the surface or move
the gun too slowly the paint will run. Too
much paint will cause streaks, whilst not
enough paint will result in a thin, foggy
surface.
Operating the handle
Press the trigger on the handle to start
spraying and let go at the end of each
individual sweep. This will result in an
even surface.
General instructions for spray painting
Individual spraying movements should
always be carried out at a constant
speed. Always keep the gun at the same
distance to the surface. Avoid rocking or
circular movements. Hold the gun straight
and maintain an even distance.
Overlapping technique
When spray painting, the previous sweep
should be overlapped by about 1/3. We
recommend using a crossing pattern.
Start with horizontal sweeps and finish
with light vertical sweeps. When spray
painting larger surfaces, for example, a
fence, we recommend dividing the work
into sections of one metre. Make sure
you use the overlapping technique when
starting each new section.

其具有以下优点：

第一、极高的涂装效率。喷涂效率高达每小时500-1200平方米，是传统滚筒施工的10倍以上

第二、极佳的表面质量。喷涂涂层平整、光华、致密、无刷痕、滚痕、和颗粒。

第三、延长涂层使用寿命。高压无气喷涂能使涂料颗粒深入墙体空隙，使漆膜也墙面形成机械咬合，增强涂料附着力，延长使用寿命。

第四、轻而易举地攻克拐角、空隙和凹凸不平的难刷部位

第五、节省涂料。刷涂厚度极不均匀，一般在30-250微米，涂料利用率低，而无气喷涂很容易获得厚度为30微米的涂层，相对节省涂料20-30%。

2. Never aim the gun at any part of the body. Never allow a hand to be in front of the gun. Gloves will not provide protection against an injury. A high pressure stream of paint produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.

3. In case of skin injection, see physician immediately.
Operational Safety
1. Never use a spray gun which does not have a trigger lock or trigger guard in place and in working order.

2. Report any unsafe condition to a supervisor. Equipment which has obvious defects may not be used until it is repaired.

3. Paint hose can develop leaks from wear, kinking, abuse etc. A leak is capable of injecting material into the skin. The paint hose should be inspected before each use.

4. Always have the tip guard in place while spraying. The tip guard provides some protection against injection injuries but is mainly a warning device.

5. Always lock the gun trigger, shut fluid pump off and release all pressure before servicing, cleaning tip guard, changing tips, or leaving unattended. Simply turning off the pump motor will not release pressure in the system. The Prime Spray Valve must be turned to the pressure release position to relieve the pressure.

6. Always remove spray tip before flushing or cleaning the system.

Hazard of Explosion or Fire
Solvent and paint fumes can explode or ignite causing property damage and or severe injury.
Exposure or Fire Prevention
1. Work area must remain well ventilated.

2. Do not spray paints or other flammable fluids that have a flash point below 70 degree F (21 degree C).

3. Avoid all ignition sources such as static electricity sparks from connecting and disconnecting power cords and working light switches.

4. Fire extinguishing equipment must be present and in working order.

5. Keep the pump away from spray area to avoid solvent and paint fumes.

6. High velocity flow of material through equipment may develop static electricity. The equipment being used and objects in and around the spray area must be properly grounded to prevent static discharge and sparks.

7. Use only conductive or grounded high pressure fluid hoses for airless applications. Be sure that gun is grounded through hose connections.

8. Follow the material and solvent manufacturer’s safety precautions and warnings.

9. When flushing equipment use lowest possible pressure.

Hazards of Explosion Hazard Incompatible Materials
May cause property damage or severe injury
Explosion Hazard Incompatibility Materials Prevention
1. Halogenated hydrocarbon solvent such as methylene chloride and 1, 1, 1- Trichlorethane are not compatible with aluminum and may cause an explosion. If unsure of a material’s compatibility with aluminum, contact your coating’s supplier.

2. Some spray guns and accessories cannot be used with halogenated hydrocarbon solvent. Be certain of compatibility before use with halogenated hydrocarbon solvents.
3. The Spray Tech pump is not compatible for use with halogenated hydrocarbon solvents.

Hazardous Vapors
Paints, solvents, insecticides, and other materials may be harmful if inhaled causing severe nausea, fainting, or poisoning.
Hazardous Vapors Prevention
Use a respirator or mask whenever there is a chance that vapors may be inhaled.

Read all instructions with the mask to assure that it will provide the necessary protection against the inhalation of harmful vapors.

General Hazards
May cause property damage or severe injury.
General Hazards Prevention
1. Read all instructions and safety precautions before operating.

2. Comply with all appropriate local, state and national codes governing ventilation, fire protection.

3. This pump is designed to be used with authorized Spray Tech parts only. When using this pump with parts that do not comply with the minimum specifications and safety device of the pump manufacturer, the user assumes all risk and liabilities.

4. Before each use check all hoses for cuts, leaks, abrasion or bulging of cover or damage or movement of couplings. If any of these conditions exist, replace the hose immediately. Never attempt to repair a damaged or worn high-pressure paint hose. Replace it with another grounded hose.

Warnings
1. If a metal container is used, ground the gun by holding against the edge of the container, in order to ground the container while flushing. Failure to do so may lead to static electric discharge, which may cause a fire.

2. Be sure to follow the pressure relief procedure when shutting the unit down for any purpose including servicing or adjusting any part of the spray system, changing or cleaning spray tips, or preparing for clean up.