Curtain Wall Glass Panel Processing Flow (Glass Adhesion Subframe)
(1) Production Processing Order
1. Upon receiving the production processing order, it should be carefully reviewed. If the order is correct, it must be completed within the specified date with guaranteed quality and quantity.
2. If there are problems with the order, they should be promptly reported to the production department for proper handling before processing can continue.
3. Statistics, material calculation, and matching of processing orders must be completed.
(2) Raw Material Requisition
1. According to the statistical method above, determine the required material specifications, and then complete the material requisition procedures in the materials department.
2. When requisitioning raw materials, ensure they are stacked neatly.
3. Aluminum materials and glass finishes must not be scratched.
(3) Aluminum Material Cutting
1. Inspect machinery before use.
2. When handling large pieces of glass, three people must work in unison to prevent the glass from swaying violently and breaking. When using a gantry crane, check the charging status of the electric glass suction cup first and ensure the crane travels parallel to the ground.
3. The cutting error of aluminum materials should not exceed ±1mm.
4. Protect the decorative surface when cutting aluminum materials.
5. After cutting, stack the semi-finished products neatly for easy retrieval by the assembly team.
(4) Aluminum Material Hole Processing, Packaging, and Lamination
1. Before using the machine, check that it is functioning properly; otherwise, do not start the machine.
2. When processing holes in aluminum materials, ensure that the cut is smooth.
3. Before packaging aluminum materials, clean the surface thoroughly, and add 80mm–100mm of plastic film to each end.
4. Avoid excessive extension to prevent waste.
5. Before laminating aluminum materials, check that the laminating machine is functioning properly. Turn on the power, temperature, and conveyor. Lamination can begin only when the temperature reaches approximately 100°C.
6. After plastic coating, the aluminum material must have a smooth surface and must not have cracks or fissures.
(5) Aluminum Frame Assembly
1. Transport semi-finished products to the assembly area, taking special care to protect the decorative surface.
2. When assembling various aluminum products, ensure four key points: joints must be flat, aligned, tight, and secure.
3. When installing support blocks, the dimensions at both ends must be consistent.
(6) Toluene Cleaning of Aluminum Frame and Application of Adhesive Strips
1. When cleaning the aluminum frame with toluene, first wipe the area to be glued with a white cloth, then use the "dry-wet wiping method": wipe with toluene first, followed by a dry cloth.
2. When cleaning the glass with toluene, the same dry-wet wiping method must be used. The wiping area should be 40mm inward from the wide edge of the aluminum frame to avoid affecting the coated surface of the glass.
(7) Glass and Aluminum Frame Assembly
1. The aluminum frame and glass must be aligned around the edges to ensure perpendicularity of the glass to the aluminum frame.
2. Press the aluminum frame and glass evenly together.
3. After assembly, the diagonal error of the aluminum frame should not exceed ±1.5mm.
4. Before pressing the glass and aluminum frame together, ensure the double-sided adhesive strips are completely removed.
(8) Glue Injection and Collection
1. First, turn on the air compressor and check all valves of the glue injection machine to ensure proper function.
2. When injecting glue, ensure the structural adhesive is fully applied, and after collection, ensure the glue is flat, smooth, and the glass surface is clean.
3. When replacing structural adhesive, ensure all air is removed from the glue container before starting the glue injection gun.
4. Before leaving work, clean the glue injection gun until no black glue remains, then turn off the valves and the air compressor.
5. Maintain daily records for glue injection, panel calibration, butterfly tests, and tensile tests.
(9) Curing and Maintenance
1. Before the glue surface cures, the glued glass must be placed in the curing area.
2. Determine curing time based on the sample's curing status. The glued glass must be fully cured before removal from the warehouse.
(10) Finished Products Warehousing
1. Finished products must be approved by the quality inspection department before being stored in the warehouse.
2. They must be stacked neatly. After sealant application, the finished products should be stacked with the glass tilted at an angle of 10°–20° to the ground. No more than eight pieces of glass should be stacked.
Glass Sealant Application Process
Key points for each step of the glass sealant application process:
(1) Order Acceptance
1. After receiving the production task processing order, it must be fully reviewed, and the required component materials (such as aluminum frames and glass) must be clearly identified.
2.I f it is found that the glass and aluminum frame do not match, the production department should be notified immediately for appropriate handling.
(2) Material Requisition
1. Aluminum frames must be retrieved from the assembly group, and glass must be retrieved from the glass opening area or the cleaning group.
2. When handling materials, protect the coated surface of the glass and prevent loosening at the corners of the aluminum frame. If any problems are found, appropriate measures must be taken.
(3) Surface Treatment
1. Before cleaning the glass and aluminum frame with toluene, wipe the surrounding area with a white cloth to remove surface debris. Then, use the "dry-wet wiping method," which involves wiping with toluene first, followed by a dry cloth.
2. When cleaning the glass with toluene, the dry-wet wiping method must also be used. The wiping area should be 40mm inward from the wide edge of the aluminum frame to avoid affecting the quality of the glass's coated surface.
(4) Applying Double-Sided Adhesive
1. Ensure the adhesive strip is tightly against the inner edge of the aluminum frame to avoid gaps.
2. The applied adhesive strip should be even to ensure a good bond between the glass and aluminum frame.
(5) Glass and Aluminum Frame Assembly
1. Align the aluminum frame and glass on all sides to ensure the glass edge is perpendicular to the aluminum frame.
2. The diagonal error of the glass and aluminum frame assembly should not exceed 1mm. Then, remove the paper on both sides of the adhesive and press the aluminum frame and glass together evenly.
(6) Glue Injection and Finishing
1. Before injecting glue, record the temperature, humidity, time, amount of glue injected, specifications, and site name of the day in a valid record book.
2. After draining the water from the air compressor, start the air compressor and open all valves of the glue injection machine to check for normal operation.
3. After verifying that the equipment is normal, begin mixing the two components. Several principles must be followed before applying glue:
- Bow test to observe whether the two-component glue is mixed well.
- Tensile test to observe whether the two-component glue meets the requirements (in principle, it should be mixed at a ratio of 1:11 to 1:14).
4. Glue injection can only be carried out after the above principles are implemented.
5. During injection, ensure the structural glue is full. When finishing, the glass and aluminum frame surface must be flat, smooth, and clean.
6. When replacing structural adhesive, turn off the pressure valves for both black and white adhesives before raising the dispensing machine and removing empty cans (to prevent adhesive from entering the gun barrel and causing blockages).
7. Pay attention to the order in which new adhesive cans are replaced, ensuring all air is removed before starting the dispensing.
8. After dispensing or before leaving work, clean the dispensing gun according to two principles:
- Turn off the black adhesive extrusion tube switch to prevent black adhesive from entering the mixing pipe.
- Open the dispensing gun and expel all mixed adhesive until only white adhesive remains.
9. After cleaning the dispensing gun before leaving, turn off all valves and the air compressor.
10. For dispensing machine maintenance, ensure all lubrication points on the machine are adequately lubricated.
(7) Finished Product Curing and Stacking
1. After applying the adhesive, stack the finished products with the glass tilted at an angle of 10°–20° to the ground. No more than eight pieces of glass should be stacked at a time. Place them in the curing area before the surface begins to cure and do not move them until fully cured.
2. Ensure no gaps between glass pieces to prevent crushing.
(8) Finished Product Inspection and Warehousing
1. After quality inspection, verify that all products are processed according to the processing order and that each step meets the processing requirements. If any quality issues are found, the adhesive application team leader must be notified for rework and correction. If the quality problem is caused by human error, the responsible party shall bear corresponding responsibility.
2. Finished products must be stacked neatly in the warehouse.