母排、铜排、铝排 PVC 自动浸塑工艺，是针对电力系统中常用的母排（Busbar）、铜排（Copper Bar）、铝排（Aluminum Bar）等导电金属构件，采用自动化设备与 PVC（聚氯乙烯）粉末涂料，通过 “预处理 - 加热 - 浸塑 - 固化” 的连续流程，在金属表面形成均匀、致密、绝缘性能优异的 PVC 涂层的专业加工技术。该工艺突破传统手工涂覆的局限性，实现涂层厚度精准控制（0.2-2mm 可调）、绝缘等级稳定（可达到 Class 105 级及以上），同时具备抗腐蚀、耐老化、防电击等特性，广泛应用于高低压开关柜、配电箱、新能源汽车动力电池包、光伏逆变器等电力设备的导电连接部件防护。
The PVC automatic dipping process for busbars, copper bars, and aluminum bars is a professional processing technology for conductive metal components commonly used in power systems, such as busbars, copper bars, and aluminum bars. It uses automated equipment and PVC (polyvinyl chloride) powder coatings to form a uniform, dense, and excellent insulating PVC coating on the metal surface through a continuous process of "preprocessing-heating-dipping-curing". This process breaks through the limitations of traditional manual coating, achieving precise control of coating thickness (adjustable from 0.2 to 2mm) and stable insulation level (up to Class 105 and above). It also has characteristics such as corrosion resistance, aging resistance, and electric shock prevention, and is widely used in the protection of conductive connection components of power equipment such as high and low voltage switchgear, distribution boxes, new energy vehicle power battery packs, and photovoltaic inverters.
二、核心优势（Core Advantages）
卓越的绝缘与防护性能：PVC 涂层固化后形成紧密的高分子结构，体积电阻率可达 10¹⁴-10¹⁶Ω・cm，击穿电压≥20kV/mm，能有效隔绝金属构件与外界环境的接触，抵御潮湿、
粉尘、化学腐蚀（如酸碱雾）等因素影响，使金属排的使用寿命延长 5-8 年，大幅降低电力设备的维护成本。
Excellent insulation and protection performance: After curing, the PVC coating forms a dense polymer structure with a volume resistivity of 10¹⁴-10¹⁶Ω·cm and a breakdown voltage of ≥20kV/mm. It can effectively isolate metal components from the external environment, resist the influence of moisture, dust, chemical corrosion (such as acid-base fog), etc., extending the service life of metal bars by 5-8 years and significantly reducing the maintenance cost of power equipment.
高效稳定的自动化生产：采用全自动流水线作业，集成机械臂送料、连续式加热炉、精准浸塑槽及恒温固化箱，实现 24 小时不间断生产。单条生产线每小时可处理 100-200 根金属排（长度 1-3m），涂层厚度偏差控制在 ±0.05mm 内，产品一致性远超手工浸塑（传统手工偏差常达 ±0.2mm），合格率稳定在 99.5% 以上。
Efficient and stable automated production: Adopting fully automatic assembly line operation, integrating robotic arm feeding, continuous heating furnace, precise dipping tank, and constant temperature curing oven to achieve 24-hour uninterrupted production. A single production line can process 100-200 metal bars (length 1-3m) per hour, with the coating thickness deviation controlled within ±0.05mm. The product consistency is far better than manual dipping (traditional manual deviation often reaches ±0.2mm), and the qualification rate is stable above 99.5%.
环保节能与成本优化：采用无溶剂型 PVC 粉末涂料，无 VOCs 排放，符合国家环保标准；同时，自动化设备减少人工投入（1 条生产线仅需 2-3 人操作），且粉末回收率达 95% 以上（通过旋风分离 + 滤芯回收系统），综合生产成本较传统手工浸塑降低 30%-40%。
Environmental protection, energy saving and cost optimization: Using solvent-free PVC powder coatings, there is no VOCs emission, which meets national environmental protection standards; at the same time, automated equipment reduces labor input (only 2-3 people are needed to operate a single production line), and the powder recovery rate is over 95% (through cyclone separation + filter element recovery system). The comprehensive production cost is 30%-40% lower than that of traditional manual dipping.
灵活适配多规格金属排：通过更换专用夹具、调整浸塑时间（10-30s 可调）、加热温度（180-220℃可控）及粉末粒径（80-120 目可选），可适配不同材质（铜、铝、铜铝复合）、不同截面尺寸（10×1mm-120×15mm）及特殊形状（如折弯、打孔母排）的金属排加工，无需大规模改造生产线，满足多样化订单需求。
Flexible adaptation to multi-specification metal bars: By replacing special fixtures, adjusting dipping time (adjustable from 10 to 30s), heating temperature (controllable from 180 to 220℃), and powder particle size (optional 80-120 mesh), it can adapt to the processing of metal bars of different materials (copper, aluminum, copper-aluminum composite), different cross-sectional sizes (10×1mm-120×15mm), and special shapes (such as bent, perforated busbars). No large-scale transformation of the production line is required, meeting the needs of diverse orders.
三、主要设备构成（Main Equipment Composition）
自动化预处理系统：由超声波清洗槽、喷淋除锈装置、磷化处理槽及热风烘干炉组成。首先通过超声波清洗（频率 28-40kHz）去除金属排表面油污、粉尘；再针对氧化严重的金属排进行喷淋除锈（采用弱酸性除锈剂）；随后进行磷化处理（形成 5-10μm 磷化膜，增强涂层附着力）；最后经热风烘干（温度 80-120℃，时间 5-10min），确保金属排表面干燥无杂质，为后续浸塑奠定基础。
Automated preprocessing system: Composed of an ultrasonic cleaning tank, a spray derusting device, a phosphating tank, and a hot air drying oven. First, ultrasonic cleaning (frequency 28-40kHz) is used to remove oil and dust from the surface of metal bars; then, spray derusting (using weak acid derusting agent) is performed for metal bars with severe oxidation; then phosphating treatment is carried out (forming a 5-10μm phosphating film to enhance coating adhesion); finally, hot air drying (temperature 80-120℃, time 5-10min) is performed to ensure the surface of metal bars is dry and free of impurities, laying the foundation for subsequent dipping.
连续式加热系统：采用电加热式隧道炉，炉长 6-12m，分为预热区（温度 120-150℃）、恒温加热区（温度 180-220℃），通过 PLC 控制系统精准控制各区温度（温差 ±5℃）。金属排由链条输送机匀速送入炉内（输送速度 0.5-2m/min 可调），确保金属排整体温度均匀，达到 PVC 粉末熔融所需的 “热吸附” 温度（铜排因导热快，加热时间通常比铝排长 10%-15%）。
Continuous heating system: Adopting an electric heating tunnel furnace with a length of 6-12m, divided into a preheating zone (temperature 120-150℃) and a constant temperature heating zone (temperature 180-220℃). The temperature of each zone is precisely controlled by a PLC control system (temperature difference ±5℃). Metal bars are uniformly fed into the furnace by a chain conveyor (conveying speed adjustable from 0.5 to 2m/min), ensuring the overall temperature of the metal bars is uniform and reaches the "thermal adsorption" temperature required for PVC powder melting (copper bars have a heating time usually 10%-15% longer than aluminum bars due to fast heat conduction).
精准浸塑单元：包括 PVC 粉末储料罐、自动供粉系统、浸塑槽及升降机构。储料罐内的 PVC 粉末（常添加稳定剂、增塑剂以提升涂层性能）通过螺杆供粉机定量输送至浸塑槽；升降机构带动加热后的金属排匀速浸入粉末槽（浸入速度 50-100mm/s），根据涂层厚度需求控制浸塑时间；部分高端设备配备 “二次浸塑” 功能，可实现双层涂层（底层绝缘 + 表层耐磨），满足高防护需求。
Precise dipping unit: Including a PVC powder storage tank, an automatic powder supply system, a dipping tank, and a lifting mechanism. The PVC powder in the storage tank (stabilizers and plasticizers are often added to improve coating performance) is quantitatively transported to the dipping tank by a screw powder feeder; the lifting mechanism drives the heated metal bars to immerse into the powder tank at a constant speed (immersion speed 50-100mm/s), and the dipping time is controlled according to the coating thickness requirement; some high-end equipment is equipped with a "secondary dipping" function, which can realize double-layer coating (bottom layer insulation + surface layer wear resistance) to meet high protection requirements.
恒温固化系统：采用热风循环固化炉，炉内温度控制在 160-190℃，固化时间 15-30min（根据涂层厚度调整）。固化过程中，热风通过均流板均匀分布，确保金属排表面的 PVC 粉末充分熔融、流平并交联固化，形成光滑无气泡的涂层；炉体配备废气收集装置，将固化过程中少量挥发物（如增塑剂小分子）集中处理，避免环境污染。
Constant temperature curing system: Adopting a hot air circulation curing oven, the temperature inside the oven is controlled at 160-190℃, and the curing time is 15-30min (adjusted according to the coating thickness). During the curing process, the hot air is evenly distributed through the flow equalizing plate to ensure that the PVC powder on the surface of the metal bars is fully melted, leveled, cross-linked and cured to form a smooth and bubble-free coating; the furnace body is equipped with an exhaust gas collection device to centrally treat a small amount of volatiles (such as plasticizer small molecules) during the curing process to avoid environmental pollution.
后处理与检测系统：包含冷却输送线、外观检测台、厚度检测仪及绝缘性能测试装置。金属排固化后进入冷却线（采用风冷 + 水冷复合冷却，冷却时间 5-10min），降至室温后进行外观检测（人工或视觉相机检查涂层是否有划痕、针孔、流挂）；厚度检测仪（采用涡流测厚仪，精度 ±0.01mm）检测涂层厚度；绝缘性能测试装置通过耐压试验（施加 10-30kV 电压，持续 1min）验证涂层绝缘效果，确保产品符合行业标准（如 GB/T 1408.1、IEC 60243）。
Post-processing and inspection system: Including a cooling conveyor line, an appearance inspection table, a thickness detector, and an insulation performance test device. After curing, the metal bars enter the cooling line (using air cooling + water cooling composite cooling, cooling time 5-10min), and after cooling to room temperature, appearance inspection is carried out (manual or visual camera to check whether the coating has scratches, pinholes, sagging); the thickness detector (using an eddy current thickness gauge, accuracy ±0.01mm) detects the coating thickness; the insulation performance test device verifies the coating insulation effect through a voltage withstand test (applying 10-30kV voltage for 1min) to ensure the product meets industry standards (such as GB/T 1408.1, IEC 60243).
四、典型工艺流程（Typical Process Flow）
工件上料与预处理（Workpiece Loading and Preprocessing）：人工或机械臂将待加工的母排、铜排、铝排放入自动化输送线，依次经过超声波清洗（去除表面油污）→ 喷淋除锈（针对氧化金属排）→ 磷化处理（增强涂层附着力）→ 热风烘干（表面干燥），预处理后金属排表面粗糙度需控制在 Ra 1.6-3.2μm，确保粉末涂层能紧密附着。
Workpiece Loading and Preprocessing: Manually or by robotic arm, the busbars, copper bars, and aluminum bars to be processed are placed into the automated conveyor line, and sequentially undergo ultrasonic cleaning (removing surface oil) → spray derusting (for oxidized metal bars) → phosphating treatment (enhancing coating adhesion) → hot air drying (surface drying). After preprocessing, the surface roughness of the metal bars should be controlled at Ra 1.6-3.2μm to ensure that the powder coating can adhere tightly.
加热活化（Heating Activation）：预处理后的金属排由输送线送入连续式加热炉，在预热区逐步升温至 120-150℃，去除残留水分；随后进入恒温加热区，在 180-220℃下加热 5-15min（铜排加热时间约 12-15min，铝排约 8-10min），使金属排表面达到 “热吸附” 温度，为后续浸塑时 PVC 粉末的快速熔融奠定基础。
Heating Activation: The preprocessed metal bars are sent to the continuous heating furnace by the conveyor line, and gradually heated to 120-150℃ in the preheating zone to remove residual moisture; then enter the constant temperature heating zone, and heated at 180-220℃ for 5-15min (copper bars heating time is about 12-15min, aluminum bars about 8-10min), so that the surface of the metal bars reaches the "thermal adsorption" temperature, laying the foundation for the rapid melting of PVC powder during subsequent dipping.
PVC 浸塑（PVC Dipping）：加热后的金属排由升降机构抓取，匀速浸入装有 PVC 粉末的浸塑槽（浸入速度 50-100mm/s），根据预设涂层厚度（如 0.5mm 需浸塑 15-20s，1mm 需浸塑 25-30s）控制浸塑时间；金属排表面的高温使接触的 PVC 粉末迅速熔融、吸附，形成初步涂层；取出后，多余粉末通过振动筛回收至储料罐，实现循环利用。
PVC Dipping: The heated metal bars are grabbed by the lifting mechanism and evenly immersed into the dipping tank filled with PVC powder (immersion speed 50-100mm/s). The dipping time is controlled according to the preset coating thickness (such as 15-20s for 0.5mm, 25-30s for 1mm); the high temperature on the surface of the metal bars makes the contacted PVC powder melt and adsorb quickly, forming a preliminary coating; after taking out, the excess powder is recycled to the storage tank through a vibrating screen to realize recycling.
固化成型（Curing and Shaping）：浸塑后的金属排送入恒温固化炉，在 160-190℃下热风循环固化 15-30min；固化过程中，PVC 粉末充分熔融流平，形成均匀致密的涂层，同时发生交联反应，提升涂层的硬度（ Shore D 60-70）与耐候性；固化完成后，涂层与金属排的附着力达到 GB/T 9286 中的 1 级标准（划格试验无涂层脱落）。
Curing and Shaping: The dipped metal bars are sent to the constant temperature curing oven, and cured by hot air circulation at 160-190℃ for 15-30min; during the curing process, the PVC powder is fully melted and leveled to form a uniform and dense coating, and at the same time, cross-linking reaction occurs to improve the hardness (Shore D 60-70) and weather resistance of the coating; after curing, the adhesion between the coating and the metal bars meets the grade 1 standard in GB/T 9286 (no coating peeling in the cross-cut test).
冷却检测与成品（Cooling, Inspection and Finished Product）：固化后的金属排进入冷却输送线，先经风冷（温度降至 80-100℃），再通过水冷（温度降至室温），避免高温导致涂层变形；冷却后依次进行外观检测（无划痕、针孔）、厚度检测（符合设计要求）、绝缘性能测试（耐压试验合格）；合格产品进行标识、包装，不合格产品（如涂层厚度不达标）返回预处理环节重新加工。
Cooling, Inspection and Finished Product: The cured metal bars enter the cooling conveyor line, first through air cooling (temperature reduced to 80-100℃), then through water cooling (temperature reduced to room temperature) to avoid coating deformation caused by high temperature