1. 前处理：针对性清洁连接件铜排表面

• 打磨 / 去毛刺：重点处理连接件的孔洞边缘、拼接处，去除氧化层、油污和尖锐毛刺，避免涂层附着不均。

• 脱脂清洗：用碱性脱脂剂或环保清洗剂浸泡（5-10 分钟），或超声清洗，彻底去除加工残留油污和粉尘。

• 漂洗干燥：用清水冲洗残留清洗剂，再经 80-100℃低温烘干（10-15 分钟），确保孔洞、缝隙无水分残留。

2. 预热：适配连接件结构的均匀升温

• 将干燥后的连接件铜排放入烘箱，预热温度控制在 130-170℃。

• 预热时间根据连接件厚度和孔洞数量调整（8-20 分钟），确保铜排及孔洞内部温度一致。

• 目的是提升粉末熔融速度，避免因连接件结构复杂导致涂层附着力不足。

3. 浸塑：兼顾均匀性与结构适配性

• 选用适配的热塑性浸塑粉（如 PVC、PE 或阻燃型粉末），倒入浸塑槽并搅拌均匀。

• 手动或借助夹具固定连接件铜排，将其完全浸入粉末槽，停留 5-12 秒（孔洞较多时可适当延长）。

• 缓慢垂直提起，轻轻抖动去除多余粉末，确保涂层厚度均匀（常规 0.8-2.5mm），孔洞边缘无积粉。

4. 固化：确保复杂结构完全固化

• 将浸塑后的连接件铜排放入固化烘箱，升温至 185-230℃。

• 固化时间 20-35 分钟，根据涂层厚度和连接件复杂度调整，保证粉末完全熔融、流平并固化。

• 固化过程中避免堆叠，保持连接件间距，防止涂层粘连或破损。

5. 后处理：精准修整与质量检验

• 冷却：自然冷却至室温（或风冷加速），避免高温修整导致涂层变形。

• 修整：用专用工具清理孔洞内、边角处的多余积粉和飞边，确保连接件装配尺寸达标。

• 检验：检测涂层厚度、附着力（划格试验），检查是否有气泡、漏涂、裂纹等缺陷，合格后入库。

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1. Pretreatment: Targeted cleaning of the copper busbar surface of connectors

• Grinding/Deflashing: Focus on treating the hole edges and joints of connectors to remove oxide layers, oil stains and sharp burrs, avoiding uneven coating adhesion.

• Degreasing and Cleaning: Soak in alkaline degreaser or environmentally friendly cleaning agent for 5-10 minutes, or use ultrasonic cleaning to thoroughly remove residual oil stains and dust from processing.

• Rinsing and Drying: Rinse residual cleaning agent with clean water, then bake at a low temperature of 80-100℃ for 10-15 minutes to ensure no moisture remains in holes and gaps.

2. Preheating: Uniform temperature rise adapted to connector structure

• Put the dried connector copper busbars into an oven, with the preheating temperature controlled at 130-170℃.

• The preheating time is adjusted according to the thickness of connectors and the number of holes (8-20 minutes) to ensure consistent temperature inside the copper busbars and holes.

• The purpose is to increase the powder melting speed and avoid insufficient coating adhesion caused by the complex structure of connectors.

3. Dip Coating: Balancing uniformity and structural adaptability

• Select a suitable thermoplastic dip coating powder (such as PVC, PE or flame-retardant powder), pour it into the dip coating tank and stir evenly.

• Fix the connector copper busbars manually or with fixtures, completely immerse them in the powder tank, and stay for 5-12 seconds (the time can be appropriately extended for connectors with more holes).

• Lift vertically slowly and shake gently to remove excess powder, ensuring uniform coating thickness (conventional 0.8-2.5mm) and no powder accumulation on hole edges.

4. Curing: Ensuring complete curing of complex structures

• Put the dip-coated connector copper busbars into a curing oven and raise the temperature to 185-230℃.

• The curing time is 20-35 minutes, adjusted according to the coating thickness and connector complexity, to ensure the powder is completely melted, leveled and cured.

• Avoid stacking during the curing process and maintain spacing between connectors to prevent coating adhesion or damage.

5. Post-treatment: Precise trimming and quality inspection

• Cooling: Cool naturally to room temperature (or accelerate with air cooling) to avoid coating deformation caused by trimming at high temperature.

• Trimming: Use special tools to clean excess powder and flash inside holes and at corners to ensure the assembly dimensions of connectors meet the standards.

• Inspection: Test the coating thickness and adhesion (cross-cut test), check for defects such as bubbles, missing coating and cracks, and store the qualified products in the warehouse.