Features of electrostatic painting

Using electrical principles, electrostatic painting is an interesting and effective paint application technique. It employs electrically charged particles, as opposed to conventional painting methods, to produce a smooth, uniform coat with little waste. This technique is well-liked in sectors like furniture, appliance, and automotive manufacturing where a superior finish is crucial.

The paint particles are charged during the process as they are sprayed out of the applicator. To ensure a complete and even coating, these charged particles are then drawn to the grounded object being painted. This is an environmentally friendly option as it not only produces a superior finish but also uses less paint that misses the target.

The effectiveness of electrostatic painting is one of its most notable qualities. Less paint is required to cover an object completely because of the charged paint particles’ attraction to the object. This makes the process quicker and more economical than using traditional methods because it lowers expenses and speeds up drying times.

Furthermore, electrostatic painting is adaptable and works with a range of surfaces and forms. The method guarantees a consistent, long-lasting coat whether applied to a smooth plastic surface or a complicated metal framework. It is a favored option in many manufacturing and refurbishing applications due to its versatility.

All things considered, electrostatic painting has many advantages, such as better finish quality, financial savings, and environmental benefits. Industries can decide whether to integrate this cutting-edge method into their production processes by knowing its special characteristics and uses.

Technology

American inventor G. Runsburg used an electrostatic spray for the first time in 1941. The method suggested using electric fields to move charged paint particles. Paint is transmitted by a high-voltage negative charge (60-100 kW) as a result of interactions between liquid paint and varnish material and the pistol’s electrode. As charged particles exit the spray gun’s nozzle, they are directed toward the grounded product—to which the LKM is applied—along the lines of the electrostatic field.

The mutual repulsion of charged paint particles gives rise to the painting torch. The primary distinction between this technology and alternative approaches lies in the lack of a colorful fog being required because the particles are guided along predetermined lines. There is a range of 70 to 98 percent for the paint transfer coefficient. The product’s shape, the conductivity of the painted material, and other indirect factors all affect the transfer indicator.

LKM consumption can be decreased with the electrostatic method, and painting itself is made simpler. The traditional method of staining metal pipes requires turning the product multiple times. With an electrostatic pistol, the part does not need to be turned because the charged particles flow along the power lines and effortlessly encircle the obstructions. Because the paint in a processed area repels excess incoming material, staining is applied very evenly.

By using electrically charged particles to ensure paint adheres to surfaces evenly, reduces waste, and produces a smooth, long-lasting finish, electrostatic painting offers a superior coating technique. This method works particularly well for elaborate or large-scale projects because it can apply a consistent finish to even the most complicated shapes. It promises better coverage with less effort and material, which makes it a popular choice in both industrial and commercial settings thanks to its efficiency and high-quality results.

Types of spraying

There are two kinds of electrostatic spraying: cascading and classic. According to the classic, an electrostatic spray gun is fed a direct current at a high voltage via a high-voltage cable. There are several major problems with the traditional plan. We are first discussing the instability of the pistol electrode’s voltage. Furthermore, painting is a hassle, which limits the use of large cables, and switching off the power requires frequent trips to the transformer.

In the cascading technique, the pistol itself produces high voltage rather than the environment outside. Only 12 V is used to direct the voltage to the low-voltage cable that connects to the pistol; high voltage generation occurs within the apparatus. The change is implemented at the Kraskopolt cascade. Working with the applied cable is very convenient because it is thin and flexible.

With the cascading technique, you can adjust the voltage to a level that is appropriate for different kinds of materials and stop the flow of electricity regardless of the generator. Due to the voltage’s extreme stability, LCM consumption can be greatly decreased. The primary disadvantage of cascading spraying is the expensive equipment required. However, because this technology is so efficient, costs soon pay for themselves.

The following conditions impose some limitations on electrostatic spraying:

1. Properties of paintwork. In order for the paint to be charged correctly on the electrode, resistance is necessary at a level of at least 30 kOhm. Otherwise, the effectiveness of painting in an electrostatic field is radically reduced. As an example of a paintwork with a low level of resistance, compounds with significant additives of metal powder can be given (such are “metallic” -type enamels). Until recently, electrostatic staining was not used when applying water -soluble paints, since there was a high risk of short circuits due to the electro -conductivity of the liquid. The latest equipment for electrostatic staining equipment allow you to work with water -soluble LKM.
2. Properties of the material. It is difficult to color and wood, such as plastic and wood. The process can be facilitated using special conductive soils (in the case of plastic) or moisturizing (for wood).
3. The shape of the painted part. As mentioned above, the electrostatic method allows you to paint products of different shapes, however, in a closed conductive circuit, the voltage of the electrostatic field is zero. Therefore, there is no electric field in deep excavations, which is why particles of paint and varnishes do not fall into such areas. Moreover, without falling into all kinds of cavities, the paint is concentrated in other areas (for example, on the edges), which gives the formation of a too thick layer of coating. To avoid such problems (they are called the Faraday"s contour), staining inaccessible places is carried out by a conventional spray gun – airless or pneumatic.

Spensed "Star 3001"

We will examine the spray-reflector "Star 3001" as an illustration. The high voltage formation method utilized by this apparatus is cascading. Equipment modifications are made using both mechanical and automatic methods. Both versions are capable of operating with an air mixture as well as airless spraying.

There are additional modifications for paints based on solvent and water-soluble paints. The materials used in each model can vary greatly based on its intended use, and each model has unique design elements.

Because there is a large selection of equipment, you must choose how the electrostatic gun will be used before making a purchase. The "Star 3001" gadget is intended to operate on water-based systems. This indicates that because the design uses a unique material, the device is protected against a short circuit. However, "Star 3001" is not appropriate for use with organic solvents; instead, you must find a modification whose body is solvent-inert.

The power outage resolves the Faraday contrast issue in the spray of this model. When there is no nourishment, LKM can only be sprayed when pressure is applied. It’s very handy that the voltage control key is right on the spool case. Furthermore, you can manage the pressure with your hands by simply pressing the trigger. Additionally, the gun has memory, which allows it to retain three different electrostatic field configurations for every kind of paint.

Electrical resistance is a crucial characteristic of any varnish that is used. The probe that comes with the Star 3001 apparatus checks LKM for resistance and yields the most accurate indication of the electrostatic field.

Even with its sophisticated machinery, this type of spray is very low maintenance. After the case is simply disassembled, all of the mechanisms are visible to the naked eye. Any parts of the firearm are susceptible in the event of a breakdown. This situation enables us to lower the cost of repairs while also simplifying them.

It is noteworthy that the device weighs only 900 grams. Working with the device is physically challenging because of its lightweight, but it is also convenient because of its ergonomic handle.

A version of "Larius 2 Paint Systems" intended for industrial use has been created. Because of the double diaphragm used in this system, the paint is pumped at a low pressure.

Using the principles of attraction between oppositely charged particles, electrostatic painting is a highly effective technique that produces a durable and even finish. This method is environmentally friendly because it drastically cuts down on paint waste. After being charged, the paint particles are sprayed onto grounded surfaces, guaranteeing a smooth application with little overspray.

The ability of electrostatic painting to evenly coat intricate and difficult-to-reach areas is one of its most notable advantages. For painting metal surfaces, like those on machinery, fences, and cars, where conventional painting techniques might not work well, this makes it extremely helpful. A longer-lasting finish that is resistant to chipping and corrosion is the consequence of the strong bond that is formed between the paint and the surface.

Furthermore, electrostatic painting is a quick process. Industrial operations can complete projects more quickly thanks to the paint’s quick drying time. For many commercial and industrial applications, electrostatic painting is the preferred option due to its efficiency and superior finish.

All things considered, electrostatic painting is a flexible and powerful technique that has many benefits over traditional painting techniques. It is a great option for a variety of painting projects due to its capacity to produce a hard, consistent, and eco-friendly finish. Superior results that endure are produced by electrostatic painting, whether it is used for larger, more intricate projects or more general industrial use.

Video on the topic

Electrostatic sprayer of powder paint Pole-m. Polyus-m polymer paint spray

Powder painting at home. Do it yourself.

Graco Electrostatic painting – round spot

Electrostatic sprayer of powder paint Pole-m. Polyus-m polymer paint spray

Coloring with an electrostatic method. Graco Proxp60 pistol

Painting by an electrostatic field by the Ransburg 2 spray gun

Electrostatic coloring at an industrial enterprise