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EnglishHigh Edge Coverage Powder Coating
Industrial-grade protective coating solutions: environmentally friendly, durable, and cost-effective.
Intro to High Edge Coverage Powder Coating
High Edge Coverage Powder Coatings are formulations specifically designed to overcome the Faraday Cage Effect and improve the film thickness over sharp corners, welds, and cut edges. Standard liquid and powder coatings tend to pull back from sharp edges (known as edge thinness or 'picture framing'), leaving the most vulnerable areas exposed to corrosion. These specialty powders utilize specific rheology and surface tension modifiers to maintain a higher film thickness on edges and corners, ensuring a continuous, protective barrier in these high-corrosion-risk zones.
Rheology Control and Corrosion Defense
Sharp edges are the first points of failure for corrosion because the coating is at its thinnest point and is easily breached. The Faraday Cage Effect further impedes powder deposition on sharp internal corners and cutouts. High Edge Coverage powders address this by having controlled flow characteristics (rheology) in the molten state: the viscosity of the melted powder is optimized to prevent the film from pulling away from the sharp edge due to surface tension forces. This results in a film that is equal to or greater than the film thickness on the flat surface. This performance is critical for applications like pipes, railings, cut metal components, and complex welds where edges constitute the greatest corrosion vulnerability. Testing involves micro-measurement of the coating thickness at the tightest radii to confirm compliance with protective specifications.
Specifications
| Property | Standard High Edge Coverage Value |
| Primary Function | Corrosion Protection at Sharp Edges/Corners |
| Mechanism | Optimized Melt Flow and Rheology |
| Edge Coverage Ratio | >80% of Flat Surface Thickness (Target) |
| Target Areas | Sharp Edges, Welds, Cutouts, Inside Corners |
| Corrosion Vulnerability | Significantly Reduced |
| Chemical Base Options | Epoxy, Hybrid, or Polyester (Additive-based) |
| Film Integrity | Continuous, Consistent Thickness at Radii |
| Application Focus | High-Stress Corrosion Points |
Application Fields
- Pipe Coatings: Ensuring protection on the cut ends and weld seams.
- Automotive Frames and Underbody: Protecting cutouts, mounting brackets, and sharp corners.
- Railings and Fencing: Exposed edges and welds in exterior environments.
- Electrical Cabinets: Complex internal and external cut edges.
- Metal Furniture and Shelving: Welded joints and component edges requiring durability.
Key Characteristics
- Enhanced Corrosion Protection: Prevents premature corrosion failure that starts at thin-coated edges.
- Targeted Film Thickness: Maintains a consistent protective layer even on sharp radii and welds.
- Mitigates Edge Thinness: Overcomes the natural tendency of liquid and standard powder coatings to pull back.
- Improved Adhesion: The thicker edge film provides a more robust, stable bond.
- Regulatory Compliance: Meets coating specifications for minimum film thickness at high-stress points.
Comparison: High Edge Coverage vs. Standard Powder
| Feature | High Edge Coverage Powder | Standard Powder Coating |
| Edge Thickness | Thick, Continuous Layer | Thin, Recessed Layer (Picture Framing) |
| Risk of Edge Corrosion | Low | High |
| Rheology | Controlled Viscosity (Resists pull-back) | Standard Flow (Pulls back from sharp radii) |
| Cost | Medium to Higher (Specialty additives) | Standard |
| Long-Term Durability | Superior (Corrosion barrier maintained) | Compromised at edges |
Why choose us
Customization: We have a strong R&D team,and we can develop and produce products according to different requirement of customers.
Cost: We have our own raw material production center.So we can offer the most favourable price and good-quality products directly.
Quality: We have our own testing lab and the most advanced and complete inspection equipment, which can ensure the quality of our products.
Capacity: Our annual production capacity is over 30000 tons, we can meet the needs of different customers with diverse purchase quantity.
Service: We focus on developing high-quality products for top-end markets. Our products are in line with international standards, and are mainly exported to Europe, America, Southeast Asia, South America and other destinations around the world.
Shipment: We are only 200 kilometers away from the Shanghai Port and 230 kilometers to Ningbo port, it is very convenient and efficient to ship goods to any other countries.
Customization
Quality
Capacity
Service
Shipment
Frequently Asked Questions (FAQs)
- Q: Does high edge coverage powder solve Faraday Cage issues on inner corners?
- A: It helps by increasing the molten flow into recesses, but it cannot fully eliminate the initial coating deposition issue. Optimized gun settings and specialized low-Faraday powders may also be necessary for deep recesses.
- Q: **How is the edge coverage measured and verified?****
- A: Verification is typically done using cross-sectional micro-measurements on coated coupons with controlled sharp edges (e.g., 90∘ corners or specific radii) to compare the thickness at the apex to the flat surface.
- Q: Is this coating suitable for all chemistries (Epoxy, Polyester, etc.)?
- A: Yes. High Edge Coverage additives can be engineered into most powder chemistries, allowing the benefits to be applied to both corrosion-focused (Epoxy) and UV-stable (Polyester) applications.
Selection Guide: High Edge Coverage
Select High Edge Coverage Powder Coating when:
- The component has numerous sharp edges, welds, or complex cutouts that are highly prone to corrosion.
- The application is subject to a highly corrosive environment (e.g., exterior, coastal) where edge failure is common.
- The coating must comply with strict minimum film thickness requirements on all surfaces, including radii.
- The manufacturing process cannot easily adjust to increase the radius of sharp edges.
- The coating must act as a reliable, long-term barrier over the entire surface geometry.
