production from glass to mirror
DESCRIPTION
To show how a plain glass plate is transformed to a cut to size mirror to be used in a decorative mirror, referred to as a interior jewel.TRANSCRIPT
Mirror Manufacturing
www.deknudtmirrors.com
Production from
glass to mirror
Mirror Manufacturing
www.deknudtmirrors.com
Mirrors made by Deknudt Mirror Works :
1. Quality of the glass: Usage of “fresh” glass coming out of the ovens of
the best European glass manufacturers
2. Silvering on own silver conveyor
3. Specialised in mirror (double sided, silk-screen printing, edge
finishing,…)
4. Respect for the environment (no lead, purification installations,…)
5. Completely conform all strict EU-norms (ISO 9001)
Mirror Manufacturing
www.deknudtmirrors.com
Technical info about maximum dimensions :
Thickness of the glass : maximum 8 mm dikte
Silver conveyor : maximum 1120 mm wide
Printing : glass size : max. 2040 x 1150 mm
plain printing : max. 2030 x 1065 mm
sandblasting : max. 1840 x 965 mm
quadri : max. 666 x 400 mm
Durorolls : maximum 1900 x 685 mm
Mirror Manufacturing
www.deknudtmirrors.com
Supply of fresh glass by glass manufacturers
Mirror Manufacturing
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Glass warehouse Deknudt Mirror WorksFresh DLF glass plates of 1e quality (321 x 255 cm)
Mirror Manufacturing
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Glass warehouse Deknudt Mirror WorksAlso coloured glass is processed
Mirror Manufacturing
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Glass cutting machine Deknudt Mirror WorksCutting of DLF glass plates (321 x 255 cm) to optimal working size
Mirror Manufacturing
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Waiting trolley of cut glassto silver conveyor
Mirror Manufacturing
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2e lacquer layer/glue layer
1e lacquer layer
passifation
silvering
activation
sensibilisation
glass
watching direction in mirror
Silvering : Different layers of a mirror
Mirror Manufacturing
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DLF glass (321 x 255 cm) cut to starting size (optimalisation)
Glass silvering
Mirror 1st protection
Drying
Mirror 2nd protection
Drying
Final cutting to size
Edge finishing :bevel, F- or C-edge
Normal mirror Double sided mirror
Glass silvering
Mirror 1st protection
Drying
Glue layer on mirror
Drying
Final cutting to size
Durorolls (back to back)
Edge finishing :bevelt, F- or C-edge
Mirror Manufacturing
www.deknudtmirrors.com
DLF glass (321 x 255 cm) cut to starting size (optimalisation)
Glass silvering
Mirror 1st protectionDrying
Mirror 2nd protection
Drying
Printing front side
Final cutting to size
Edge finishing :bevel, F- or C-edge
Printing back side of the glass
Silver printed glass
Glass silvering
Mirror 1st protectionDrying
Mirror 2nd protectionDrying
Final cutting to size
Edge finishing :bevel, F- or C-edge
Print front side Print back side
Mirror Manufacturing
www.deknudtmirrors.com
DLF glass (321 x 255 cm) cut to starting size (optimalisation)
Cover glass with tape(= transparent parts)
Silvering glass
double protection of mirrorDrying
Remove tape (= transparent again)
Possibly print again (sand blasting effect)
Final cutting to size
Edge finishing
Glass silvering(no protecting lacquer)
Mirror partially covered on the back side
(= printing what has to remain mirror)
Remove uncovered silver(= transparent again)
Possibly print again (sand blasting effect)
Final cutting to size
Edge finishing
Transparent / SandblastedVia silk-screen printing
Transparent / SandblastedVia covering with tape
Mirror Manufacturing
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Step 1. Glass preparation :
Clean with waterThorough rinsing and polishing with Cerium oxide9 Batteries with 12 turning brushes eachDrying and heating up to about 30 °C
Mirror Manufacturing
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Step 2. Sensibilisation and activation :
For a good attachment of the liquid silver on the glass surface.
Sensibilisation :A tin oxide solution is sprayed onA little further, it is rinsed off as well
Activation : Palladium Chloride solution on the surface a little further the surplus is sprayed off
Mirror Manufacturing
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Step 3. Silvering :
Liquid silver is equally divided over the glass surface by means of a spraying curtain. (1 micron = 1/1000 of 1 mm)
Mirror Manufacturing
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Step 4. End of precipitation reaction :
After 30 seconds the precipitation reacton of the liquid silver is finished.The surplus is sprayed off and the chemical reaction is stopped.
Mirror Manufacturing
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Step 5. Passification :
Silver layer is treated with a layer of tin chloride soluiton. Also that one is rinsed of a little furtherIn this way, the use of an environmentally unfriendly cupper layer can be avoided. = Green Mirror Deknudt !
Mirror Manufacturing
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Step 6. 1e pouring curtain of protection lacquer :
1st layer of protection lacquer on the silver layer (20 micron)
Mirror Manufacturing
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Step 7. 1e Drying oven :
Mirror runs through a 1st drying oven to let the protection lacquer slowly dryTemperature : 90°C - Duration: 4 minuten.
Mirror Manufacturing
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Step 8. 2nd pouring curtain of protecting or glueing layers :
2nd lacquer layer on top of 1st protection layer:Regular mirror : 2 x^protecting layerDouble sided mirror : glue lacquer (thermoplastic glue)
Mirror Manufacturing
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Step 9. 2nd drying oven :
The protected mirror runs through a 2nd drying oven to let the 2nd layer slowly dry.Temperature: 180°C - Duration : 4 minuten
Mirror Manufacturing
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10. Waiting trolleys in the production
After drying and quality control, the mirrors are put on waiting trolleys, in expectation of the next process and in the mean time cooling down
Mirror Manufacturing
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Silk screen printing :
Step 1 : Preparation :
Glass is put on the machine,
thoroughly rinsed and dried
Mirror Manufacturing
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Silk screen printing :
Step 2 : Printing :
Glass goes under screen
Paint is spread over the the sieve.
Paint only goes through tiny holes in the sieve .
Mirror Manufacturing
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Silk screen printing:
Step 3 : Oven :
Printed mirror goes through drying oven: 3 min. à 120°C
Mirror Manufacturing
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Silk screen printing :
Step 4 : Quality control printing quality :
Final check of the printing quality.Mirror put on waiting trolley for further processing.
Mirror Manufacturing
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Durorolls / Double sided mirror :
Step 1 : Preparation :Mirrors with thermoplastic glue in the upper lacquer layer are layed down back to back
Mirror Manufacturing
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Durorolls / Double sided mirror :
Step 2 : Through oven :Mirrors go through an oven of 110°C : both glue layers become plastic and get fixed to each other
Mirror Manufacturing
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Durorolls / Double sided mirror :
Step 3 : Pressing and cooling :Mirror plates are pressed together by 12 consequent pressing rolls. Cold water is poured through the rolls, which makes the mirrors cool down slowly and hardens the glue.
Mirror Manufacturing
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Durorolls / Double sided mirror :
Step 4 : End control :
Mirrors are now permanently glued to each other.
Quality control and putting them on a waiting trolly for further processing.
Mirror Manufacturing
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Cutting to final correct size
Drilling holes
Mirror Manufacturing
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Edge finishes :
ChamferGrinding the sharp corners
C-grinding mat of polished
Classic bevele.g. 25 mm on 7°
F-grindingmat of polished
Modern bevele.g. 7 mm on 30°
Mirror Manufacturing
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Edge finishes :
ChamferSharp corners removed
Unprocessed cut glass edge
Mirror Manufacturing
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Edge finishes :
C-grinding mat or polished
F-grindingmat or polished
Mirror Manufacturing
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Edge finishes :
Classic bevele.g. 25 mm on 7°
Modern bevele.g. 7 mm on 30°
Mirror Manufacturing
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Edge finishing machine (linear = 1 side at a time)
Mirror Manufacturing
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Edge finishing machine (double sided linear = 2 sides at a time) 2 sides horizontally and in the middle 90° turn for vertical sides== > 4 x quicker than linear edge finishing
Mirror Manufacturing
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Edge finishing machine (CNC)