Over the past ten years, due to the continuous development of energy saving works in buildings, the use of double-glazed windows has doubled from year to year. Hollow manufacturing has gradually developed from early manual production to modern semi-automatic or automatic production, and the production capacity, technical level and quality level have made significant progress. What are the production modes for the production of double-glazed windows? What are the specific manufacturing processes? How to produce quality products through effective quality control, let Ou Yade editor show you.
At present, the general production process of insulating glass units in China is as follows: stripping the film of the original low-e glass → cleaning and air drying → inspection of the observation deck → making spacer frames → molecular sieve cleaning → applying a layer of butyl glue → top frame → bonding (pressing) the sheet → sealing with two layers of structural adhesive.
The overall production and processing of insulating glass units is mainly controlled by materials and processes to achieve the goal of producing quality products. The original sheet, gasket, butyl rubber, desiccant and secondary structural adhesive are the main materials of the general insulating glass unit, and the quality of the materials must be checked before production.
The first step is to inspect the original film, check the dimensions, curvature, scratches, diagonals and other indicators of the original film, each indicator corresponds to a quality score. For example, the curvature of glass is usually controlled within 3mm. If the original glass sheet is bent beyond the standard, it will cause a number of problems such as scratches, cracks and springback after sealing, which will cause problems in the control of the production process. because of the raw material... Gasket inspection is mainly to select the same type as the processing order, select width specifications such as 6mm, 9mm, 12mm, and gasket types such as aluminum strips, strips with warm edges and stainless steel strips.
Quality control points
If the production process is followed, each process point has a corresponding quality control point, and each quality control point also reflects the operation of the hollow equipment, so if these quality control points are strictly checked, high-quality insulating glass products can be produced.
1. Deep film removal
Remove LOW-E first according to the compaction depth of the secondary structural adhesive. The main thing is to control the film removal width. From the beginning of film removal to the end of film removal, the film removal width error must be within 0.5mm. Otherwise, problems such as lamination width and whiteness will be caused at the top frame station. Secondly, to avoid problems such as unclean removal of the film glass, scratches on the surface of the film when touched, and damage to the glass by the film removal wheel.
2. Washing and drying
Second, when cleaning and drying glass, because the brush is used to spray water and the roller is used to clean the glass, the surface of the film often leaves scratches and water marks, and the surface of the film often leaves air knife marks. air drying section of the rear drive fan. Quality issues such as transmission wheel marks, belt marks and scratches. Therefore, the staff in this position must be serious and responsible.
3. Quality check
It is mainly to test the quality of film removal and cleaning, and identify quality problems in film removal and cleaning as early as possible with special quality inspection boxes. And finish the work on the top frame on the observation deck and weed out the unsuitable products.
4. Making a spatial frame
Process and produce gaskets for insulating glass units in accordance with the specifications, materials and sizes of gaskets indicated in the flow sheet. During the frame manufacturing process, quality issues such as poor frame manufacturing, bending and rounding of corners, spots on the gasket surface, improper connectors, deformation of the gasket interface, and large kerf burrs can occur. . Therefore, this process must strictly comply with the standard.
5. Gasket Fill Dryer
This technological process consists in filling the gasket with a molecular sieve. Generally, within 15 minutes, the separation bar filled with desiccant should be assembled to complete the insulating glass to prevent the failure of the molecular sieve. During the filling period, there will be latent quality hazards such as underfilling, insufficient adhesive blocking in the filling and filling holes, and deformation of the spacer bars by the filling machine. This link is the key to the quality of the whole insulating glass unit. .
6. Butyl rubber coating
In this link, we should pay attention to the quality of the butyl rubber coated on both sides of the gasket. Generally, the laminating quality of the laminating machine is used to judge the coating of the butyl rubber machine. The width of the butyl rubber after lamination should be greater than 5mm. When coating with a butyl rubber machine, you should also pay attention to the wave, tearing of the adhesive, and adhesive residue on the front of the gasket during coating, so that it does not mix with the insulating glass.
7. Top Frame
The manufacturing process of hollow glass is carried out together with the control inspection, and the glass and gasket that passed the inspection must be installed together. During this period, attention should be paid to the lamination and whiteness of the frame. If there are any problems, they should be reported to the first few stations in a timely manner, and they should be corrected immediately to prevent poor quality products. Therefore, all processes should cooperate closely.
This process consists of joining two or more separate pieces of glass with a spacer in the middle. After the incoming materials, which have been strictly inspected before, are combined, there will still be quality risks caused by the assembly station, such as gasket deformation after assembly, assembly displacement, butyl rubber width after pressing is less than 5mm, and butyl rubber is empty A number of problems with quality, such as scratches on the panel and joint. After assembly, the equipment must be adjusted in time according to the actual situation, so that it can meet the processing requirements of each glass size.
After a thorough inspection of the joint, seal the edge and apply a second sealant. Mix according to the ratio provided by the rubber factory to meet the specified requirements for use; work according to the rubber type and compaction depth required by the work plan, and control the mixing uniformity, compaction air line and compaction wave, etc. Quality issues. Be sure to strictly follow the requirements for using the original manufacturer, and if necessary, contact the original factory for technical support.
The above 9 requirements represent a simple process for the general production and processing of insulating glass units. Only in the process of strict and effective control of each quality point, do a good job of on-site management and supervision. And according to the correct implementation of the formal process, the risk and cost of quality control can be reduced in all aspects, and high-quality insulating glass units can be produced to satisfy customers. For the ingredients in the above process flow, it is recommended to use products from conventional manufacturers, such as aluminum strips and sealants, which seriously limit the quality and level of insulating glass units. Strict and consistent manufacturers can provide better service and quality.