Technical Advantages of 3C1B Painting Process

Technical advantages of 3C1B painting process

3C1B technology, as a relatively mature coating process technology, has gradually become the mainstream technology transformation or design solution for automobile factories due to its ability to meet the development trend of energy conservation and emission reduction. Compared with traditional painting and painting processes, this technology integrates three coatings: intermediate coating, color coating, and clear coating, eliminating intermediate coating drying and polishing processes. It has the advantages of low investment and operating costs, low VOC (volatile organic compounds) and CO2 emissions Excellent appearance and performance of the coating.

3C1B process: energy conservation and emission reduction; Engineering intensification

Introduction

3C1B technology refers to three coatings that are baked once. By changing the coating properties, film thickness, and equipment parameters, the intermediate coating, color coating, and clear coating projects are intensive and only baked once to form a film. Compared with traditional processes, the intermediate coating drying and polishing processes are eliminated, as shown in Figure 1.

Advantages of 3C1B process

1.1 In terms of equipment investment

A set of intermediate coating drying furnace and strong cooling equipment, as well as the polishing chamber and related lighting and air supply and exhaust equipment, were saved. According to the design budget of the coating workshop of Huachen Zhonghua A Factory, the initial equipment investment was saved by about 11 million yuan. Saving approximately 160 meters of production line length, calculated based on a width of 3.4 meters, saves approximately 544 square meters of land area. Due to the shortened coating production line, investment can be reduced by 20%.

1.2 In terms of daily operating costs

(1) Reduce VOC emissions by approximately 35% (to below 45 g/m2); The application of efficient coating machines reduces VOC by 15%. Reduce CO2 emissions by 15%.

(2) In terms of electricity consumption, conventional drying and forced cooling equipment can consume 90 kW/h, and with an annual operating schedule of 250 working days and 16 h/d, it can save 360000 kW of electricity annually, approximately 360000 RMB (ignoring the electricity consumption of the middle coating polishing chamber).

(3) Natural gas consumption: The energy consumption of conventional drying and forced cooling equipment is 56 m3/h, and the annual energy consumption can be saved by 56 × sixteen × 250=224000 m3, converted to industrial gas consumption of 3.6 yuan/m3, can save 224000 yuan in annual costs × 3.6=806400 yuan.

(4) Polishing consumables, tools, and compressed air: Due to the fact that 3C1B technology does not require polishing after intermediate coating, it can save about 30% of materials such as sandpaper and adhesive cloth for polishing. Repair cost: Due to the fewer particles of the car body sprayed with 3C1B technology, the repair section can save about 25% of materials such as precision grinding discs, wool balls, polishing paste, and repair paint.

(5) Coating cost: Compared with 3C2B technology, the total film thickness of the topcoat sprayed with 3C1B technology is reduced by 20-25% μ m. The usage of paint has been reduced by about 20%.

1.3 Production efficiency

Due to the cancellation of the polishing process after intermediate coating by 3C1B technology, the source of most particles has been eliminated. After effectively controlling the cleanliness of the workshop, the particle count of the sprayed car body is reduced by about 20% compared to the car body sprayed with 3C2B technology.

Eight workers were eliminated from the intermediate coating and polishing station in a single shift, and two workers were removed from the cleaning station, resulting in a reduction of 20 workers in the total number of workshop workers.

1.4 In terms of process development

The 3C1B technology adopts a new "wet touch wet" coating process in the coating process, ensuring no mixing between coatings through precise coating interface control technology. Its film thickness control is different from traditional 3C2B technology.

Through precise coating interface control technology, including layered film thickness, coating solid content, and leveling time control, stable film formation between each coating is achieved to ensure that the appearance and performance meet the requirements of the indicators.

1.5 Production control aspects

Adopting "wet polishing process", introducing dust adsorption device, air humidification system, etc., to reduce the impact of dust in the painting workshop on the paint film and reduce the workload of repair.

1.6 In terms of coatings

In the 3C1B process, the thickness of the intermediate coating film is 17-23 μ m. Therefore, the insufficient coverage of the surface roughness of the electrophoretic paint by the intermediate coating results in the problem of orange peel. In the process of coating development, high solid resin is introduced into the intermediate and topcoat, and high solid clear varnish is introduced to reduce the shrinkage between coatings and solve the problem of orange peel.

For the problem of poor stone impact resistance in composite coatings, in the process of coating development, resin with good toughness is introduced into the intermediate coating, and a intermediate coating with decomposition impact energy is designed to reduce the probability of gravel hitting the substrate; Improve the hardness of the intermediate coating, enhance the adhesion between the intermediate coating and the electrophoretic layer, and reduce the degree of peeling between the electrophoretic layer and the intermediate coating.

Develop 3C1B process specific coatings by introducing high solid clear paint, medium solid color separation paint, and high solid intermediate coating to achieve good compatibility of composite coatings.

1.7 Actual effect achieved in the end

After adopting the "3C1B" process, the thickness, adhesion, hardness, impact resistance and other indicators of the paint film were tested, and the results all met the process standards.

2 Conclusion

In summary, with the rapid development of the national automotive industry, the automotive industry pays more attention to energy conservation, consumption reduction, and environmental protection. The equipment, materials, and processes used in the new automotive coating production line should be more inclined towards energy-saving and environmentally friendly. Therefore, the development and application of 3C1B technology will be the development trend for the renovation and upgrading of old coating production lines in the future. The implementation of 3C1B technology not only saves a lot of production costs, but also greatly reduces VOC and CO2 emissions, making a huge contribution to environmental protection. As a new technology that can save costs and protect the environment, 3C1B technology will definitely have broad application prospects.