Production from glass to mirror

Mirror Manufacturing

www.deknudtmirrors.com

Production from

glass to mirror



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)



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



Supply of fresh glass by glass manufacturers



Glass warehouse Deknudt Mirror WorksFresh DLF glass plates of 1e quality (321 x 255 cm)



Glass warehouse Deknudt Mirror WorksAlso coloured glass is processed



Glass cutting machine Deknudt Mirror WorksCutting of DLF glass plates (321 x 255 cm) to optimal working size



Waiting trolley of cut glassto silver conveyor



2e lacquer layer/glue layer

1e lacquer layer

passifation

silvering

activation

sensibilisation

glass

watching direction in mirror

Silvering : Different layers of a mirror



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


Durorolls (back to back)

Edge finishing :bevelt, F- or C-edge




Glass silvering

Mirror 1st protectionDrying

Mirror 2nd protection

Drying

Printing front side



Printing back side of the glass

Silver printed glass

Glass silvering

Mirror 1st protectionDrying

Mirror 2nd protectionDrying



Print front side Print back side




Cover glass with tape(= transparent parts)

Silvering glass

double protection of mirrorDrying

Remove tape (= transparent again)

Possibly print again (sand blasting effect)


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)


Edge finishing

Transparent / SandblastedVia silk-screen printing

Transparent / SandblastedVia covering with tape



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



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



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)



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.



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 !



Step 6. 1e pouring curtain of protection lacquer :

1st layer of protection lacquer on the silver layer (20 micron)



Step 7. 1e Drying oven :

Mirror runs through a 1st drying oven to let the protection lacquer slowly dryTemperature : 90°C - Duration: 4 minuten.



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)



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



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



Silk screen printing :

Step 1 : Preparation :

Glass is put on the machine,

thoroughly rinsed and dried




Step 2 : Printing :

Glass goes under screen

Paint is spread over the the sieve.

Paint only goes through tiny holes in the sieve .



Silk screen printing:

Step 3 : Oven :

Printed mirror goes through drying oven: 3 min. à 120°C




Step 4 : Quality control printing quality :

Final check of the printing quality.Mirror put on waiting trolley for further processing.



Durorolls / Double sided mirror :

Step 1 : Preparation :Mirrors with thermoplastic glue in the upper lacquer layer are layed down back to back




Step 2 : Through oven :Mirrors go through an oven of 110°C : both glue layers become plastic and get fixed to each other




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.




Step 4 : End control :

Mirrors are now permanently glued to each other.

Quality control and putting them on a waiting trolly for further processing.



Cutting to final correct size

Drilling holes



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°



Edge finishes :

ChamferSharp corners removed

Unprocessed cut glass edge



Edge finishes :

C-grinding mat or polished

F-grindingmat or polished



Edge finishes :

Classic bevele.g. 25 mm on 7°

Modern bevele.g. 7 mm on 30°



Edge finishing machine (linear = 1 side at a time)



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



Edge finishing machine (CNC)

Production from glass to mirror

Education

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