Coating process skills training materials

- Mar 05, 2019-

Coating process skills training materials

 

Coated glass used for building glass is generally coated film. We put the thickness of less than 1um film is called thin film, the thickness of more than 1um film is called thick film coating process is to use different materials on the surface of the substrate to form a new surface method. There are many methods of coating, such as vacuum evaporation, vacuum sputtering, chemical reduction, sol-gel method, etc. It requires the film to have a very strong adhesion, adhesion is not strong enough to call the cover. For strong adhesion, the glass surface must be cleaned.

 

Clean before coating

 

In prior to coating substrate must be clean, for coating, this is a small thing, but it is quite important for offline coating, but also more difficult to operate, for the coating of large area glass substrate completely clean is not possible, therefore, how to meet the requirements of coating must clean degree becomes very important. To maintain a high enough degree of cleanliness, if the degree of cleanliness is not enough, the film is easy to aging, or even take off the film and other phenomena. Different applications, different processing process of the film is not the same degree of cleanliness requirements, for the current production of our company's glass, low-e glass requirements of the glass cleanliness is not as high as the heat reflecting glass. At present, to prepare a large area of coated glass substrate for coating, a wet cleaning technology is mainly used, which includes three parts:

 

In prior to coating substrate must be clean, for coating, this is a small thing, but it is quite important for offline coating, but also more difficult to operate, for the coating of large area glass substrate completely clean is not possible, therefore, how to meet the requirements of coating must clean degree becomes very important. To maintain a high enough degree of cleanliness, if the degree of cleanliness is not enough, the film is easy to aging, or even take off the film and other phenomena. Different applications, different processing process of the film is not the same degree of cleanliness requirements, for the current production of our company's glass, low-e glass requirements of the glass cleanliness is not as high as the heat reflecting glass. At present, to prepare a large area of coated glass substrate for coating, a wet cleaning technology is mainly used, which includes three parts:

 

Loose glass surface impurities

 

Remove loose and separated impurities

 

Dry the cleaned glass surface

 

For loose impurity, we call this period of pre-cleaning, generally using the scrubbing method, the principle of scrubbing brush with wool is mechanical separation of dust on the surface of the glass, sprinkle clean water or other liquid recycle nozzle to glass to remove large particles of dust in the pre cleaning process, basic use hair brush cleaning more thick plate, multiple small brush connection on a bearing of a group, a washing machine has many set is in a clean, rotating disc brush itself, using the brush elastic loose impurity on the surface of the glass, connection about bearing translation at the same time, ensure clean to each parts of the glassIn this part, the commonly used tap water if glass substrate storage time is too long, or in damp environment for a long time, easy to moldy glass, moldy glass mould is difficult by general scrub clean off, are often used for polishing and polishing disc brush brush to thick, often adding cerium oxide or citric acid in polishing cerium oxide is a kind of viscous substances in the water tank, can increase the friction between the disk brushes and glass, citric acid can decompose organic matter appropriately using cerium oxide easy pollution cleaning machine table, not easy cleaning and maintenance cleaning machine, usually don't useA number of nozzles are installed between each group of disc brushes to spray tap water on the glass surface at a certain Angle and pressure to clean loose large impurities. Since tap water is used, tiny impurities cannot be removed.

 

Get rid of the separation of small particles impurities parts we call it a wash, the pre cleaning and cleaning part tend to have a space between, in this period, only water, no brush, is towards pre-cleaning section in the direction of the nozzle, the goal is to make larger particles in the process of the clean or dirty substance to the cleaning part, not conducive to the advantages of the maintenance. In the cleaning part, roller brushes are mostly used, and one or two sets of disk brushes are also used. Roller brushes can only clean impurities that have become loose or that are not firmly combined with the glass surface. In this part, roller brushes are used to further loosen impurities that are firmly combined, and then roller brushes are used to clean them. In the same way, the cleaning section also has a nozzle to spray water, the difference is that the cleaning section USES pure water, pure water is sprayed from the last row of nozzles to the glass surface, and then recycled to the water tank, and then the recycled low pure water is sprayed from the penultimate row to the glass surface, and so on.

 

Used in the actual mass production of coated glass production line is generally used for drying air knife glass substrate surface using compressed air through a slit nozzle blow it to the wet glass on the surface, the wind came out of the slit like blade, can immediately turn the water on the surface of the glass substrate membrane separation and make its atomization, the final out together with the air compressed air must be very clean, that is to say, it must pass a special filter for filtering air knife drying has many advantages.Which can quickly remove water film can also keep the glass substrate has been in a low temperature state, this reduces the effect of precipitation and precipitation cleaned the glass material will fall to the lowest point or stripe wind blade Angle and the wind blade is usually fixed, the size of the cannot be easily changed, so will not be able to easily remove during the maintenance, and internal always dirty air knife, lead to the pollution of glass in the dry, clean air knife when the maintenance is very important, and has the certain difficulty.

 

Coating operation

 

1. Upload operation

 

A. separate the air surface from the tin surface. The coated surface is the air surface. If there is no special case, all the equipment should be placed with the air face up. The difference between the air and tin surface can be irradiated by a purple lamp. The blurred light is on the tin surface and the clear light is on the air surface. In general, the placement can be in accordance with the tempered logo, special shaped glass must be placed in strict accordance with the drawings.

 

B. The coating debugging tablets are divided into: uniform 2400mm*800mm, semi-large 1000mm*800mm and small sample 400mm*800mm

 

C. the maximum size of the coating production line is 2540mm*4600mm, and the minimum size is 300mm*800mm. The length of the vertical production line must be greater than 800mm after slanting of all glass less than 300mm*800mm, otherwise it must be laminated. When glass is put, must assure to have a glass to press sensor, the glass that presses sensor must lead, lead commonly 50mm can. When placing small glass, the left and right spacing of glass can be appropriately enlarged (150mm~200mm), and the left and right spacing of large glass should be in accordance with the normal spacing (80mm~100mm). Small pieces of glass should be properly enlarged (150mm~200mm) before and after placement, while large pieces of glass should be normally spaced (100mm~150mm). If there is no special instructions from the engineer on duty, the way to put the film shall be strictly in accordance with this way.

 

D. When the first film code is finished immediately before production and the engineer on duty is on duty to debug the next film code, the upper supervisor shall timely count the number and placement of the glass to be produced as well as the drawings of special-shaped transforme glass, and pull one or several products to the plate table. If the quantity of glass is not enough or the position of the glass is not clear, report to the chief operator or the monitor in time and try to get the glass ready before production. At the same time, the upper supervisor should also pay attention to the size of the glass to see if it can be put together or need to be put into production. If you can put together the product, use two specifications, too many specifications with easy to be confused in the next film. If laminated glass is required, prepare scrap glass or sheet metal for laminating, double-sided tape, mask, clean gloves, etc. When the laminator is in charge of cleaning the glass, he/she should clean the site in time, put the waste paper into the garbage can and put the waste glass on the waste rack. In the remaining time, the supervisor and the film supervisor will combine some shelves that can be combined, so as to avoid excessive disorder of the site and waste of shelves.

 

E, can distinguish drawings, look at the chart

 

F, can distinguish the film code, to avoid mistakes. For example, 6C+12A+ 6ces11-82 #1 and 6ces11-82 #2+12A+6C are different products. The products with the film code #1 refer to the products that pay attention to the film surface, while the products with the film code #2 refer to the products that pay attention to the glass surface. The number before the film code indicates the thickness of glass. Products with the same film code but different thickness belong to the same kind of products and can be produced in one time. When producing the same kind of products, zero single patch should be placed first and the whole order should be placed last, in order to reduce the number of zero orders and facilitate subsequent processing. If there are multiple orders for the same kind of products, if there is no need to place the pieces together, the pieces shall be placed one by one, and there shall be no overlapping. If there is a patch, the patch shall be reported and filled in time, so as to ensure that at most the patch is generated in the last order.

 

G. During continuous production, the supervisor shall be responsible for pulling the glass to the front of the loading table, and the loading staff shall be responsible for continuous loading. The loading speed shall be fast and the position shall be accurate to ensure the continuity of production. At the same time, the laminator should pay attention to whether the glass has defects, and deal with the defective glass in time. If the glass cannot be dealt with, the laminator can first put the glass on other shelves, and the laminator can continue to be put on, so that the production cannot be interrupted. The supervisor should observe the quality of the glass washing machine after the first 3 POTS. If the cleaning quality is not good, the supervisor should deal with it in time. If the problem cannot be solved, the supervisor should inform the engineer on duty immediately. The glass that dozen slant puts must have one person to observe to clean the effect after cleaning machine, prevent glass to walk slant bump together. At the same time everyone should have a general idea of the order being produced.

 

H. In the process of glass patch production, first of all, the upper supervisor shall decide what kind of glass or steel plate to use according to the thickness and quantity of glass needed for the patch production. The total thickness of the patch shall not exceed 19mm, and the glass used for the patch shall be scrap glass as far as possible, and the number of times used shall not exceed 4, to prevent frequent use of broken glass in the cavity. When pasting, put the waste glass or steel plate on the turntable, stick 2 pieces of them with double-sided adhesive tape, and pat them with dirty gloves on the pasted double-sided adhesive tape for several times to prevent them from sticking too tightly and making it difficult to remove the glass when next pasting. The laminators put on clean white gloves and masks. The upper member from the cleaning machine entrance directly into the small glass into the cleaning machine, other people in the cleaning machine exit with both hands to hold the glass to come out of the position, to prevent the glass is too small from falling off the transmission table. Patch personnel try not to speak, to prevent saliva falling on the glass caused by water. The product shall be placed on the waste piece tightly, and the driving direction shall not exceed the waste piece, and the vertical driving direction shall be more than about 150mm, to prevent it from falling or hitting the door, and at the same time to facilitate the next piece.

 

I. the observation window after the coating cleaning machine should be closed in the normal production process to prevent dust or other substances from contaminating the cleaned glass. During the production of the order of capital airport, the observation window was not closed, which led to the snowfall from the ceiling onto the glass, and 9 pieces of waste glass, over 60 square meters.

 

J. The supervisor should take the initiative to observe the running state of the cleaning machine at work, including when to replace the filter cotton, whether there is abnormal running of the cleaning machine, and whether the water quality of the water tank of the cleaning machine is qualified, etc.

 

K. in the production of large plate glass, the hoisting box and unpacking must be completed in strict accordance with the safety operation rules. Before the formal production, it is necessary to test whether the sucker operates normally and whether the rotating a-frame moves normally. If it is normal, you can try to move the sucker glass onto the transmission table. If there is no problem, you can manually put the glass back into the box. If abnormal, timely repair, try not to affect the production time. At the beginning of production, attention must be paid to whether the suction of the first few pieces of glass is normal. It is better to suck the last 3~4 pieces of glass in each box by hand, because the glass will fall down most easily.

 

2. Take down slice operation

 

A. when low-e glass is produced, the water is blown dry by the rear cleaning machine to avoid water droplets falling on the glass to oxidize the low-e film. The low-e membrane has to be dusted. After the production of heat reflecting glass cleaning machine must be boiled water, cleaning machine to maintain clean, the height of the cleaning machine had better rise to the glass thickness and increase 1~2mm, to prevent the cleaning machine brush brush injury film surface. Large plate thermal reflective glass with online laminating machine, small pieces of thermal reflective glass with offline laminating machine laminating, laminating must be smooth without bubbles.

 

B. Wear a mask and clean gloves under low-e glass. The cutting speed should be fast. Try to change the glass for two people every 20 minutes when the world is hot, to prevent too hot, sweat drops on the glass glass oxidation glass, wipe the sweat with a towel do not use your hands to throw out the sweat.

 

C. The frame should be placed in the order required by the hollow. Paper covers should be placed between the glass and the glass. Try to align the glass edges to avoid cutting the plastic film when packing. The first piece of glass against the shelf must be turned over to ensure the glass surface contact with the shelf and prevent scratching the film surface during transportation

 

D. Cooperate with the quality inspector to put the waste glass on the waste rack, and carry the glass to be tested to the designated place

 

E, packaging low-e glass, first with a large enough plastic cloth spread to the shelf, plastic cloth to be clean without holes, not too large. After glass is put full frame undertake packaging, when packaging, cover glass octagonal with hard paper skin rise, prevent glass edge to cut plastic cloth. In the plastic bag into the desiccant, desiccant drying effect must be intact. When packing, the adhesive tape should be stuck flat without bubbles to prevent air from entering the oxidized glass. Use a knife to cut a 100mm hole in the packaged plastic bag. Vacuum up the air inside the plastic bag. Then fill the small hole with nitrogen gas and seal the small hole with transparent adhesive tape.

 

F and low-e packaging desiccant must be fresh or recycled. The recycled desiccant must be dried without failure. The following methods can be used to test whether the desiccant is invalid: open a package of new desiccant and a package of dried desiccant, and hold 30~40 desiccant in each hand. If both hands feel heat, it indicates that the desiccant is available after drying. If the desiccant is not hot, it cannot be used any more.

 

G. When packaging the heat-reflecting glass, apply the glass to the film, and the film shall be smooth without bubbles. The maximum thickness of the offline film sticking function is 12mm. For those who need to stick the Numbers on the glass, stick the Numbers on the glass surface and fix them in the same position as far as possible in the corner of the glass. Put one piece of plastic sheet in the box, enough to cover the whole box. Put the glass with good film into the packing box. The last piece and the first piece of glass face into the box. Pearly cotton is padded between the glass and the glass. Seal the packing plastic sheet with cellophane tape and then seal the box. Put the full box of glass into storage in time.

 

H. The packaging of large plate glass is similar to that of heat-reflecting glass box, except that the film is applied by online laminating machine. In addition, when the box is fixed on the large a-frame, the bottom height of the box should be paid attention to to ensure that the glass can be put in automatically. The suction cup should be tested manually before production. Don't wait for the vacuum chamber in the glass and find that there is something wrong with the suction cup and other equipment. It can't be boxed, which is easy to cause batch waste. In case of any failure in the production process, immediately notify the engineer on duty to stop putting the film, and the glass in the vacuum chamber will stop on the shelf after coming out. The lifting frame can lift 15 pot glass, and the maximum thickness of glass can be increased to 12mm.

 

I. If the scrap is found in the process of production, the patch should be made in time. If the report is deemed not to be wasted, the engineer on duty shall negotiate with the quality inspection on whether the patch is needed.

J. After the production of the order, clean up the site at the first time to ensure that the site is clean and tidy. Put the waste products on the waste rack, and put the products to be inspected separately. Each shift will be on duty during the garbage fork out to throw away, do not put shelves everywhere, each one or two glass, even take up the site is not beautiful.

K. Finished products should be placed neatly. Products of the same order should be placed together as far as possible.