This article mainly introduces the three major processes of bronzing process, welding process and printing process.
Hot Stamping Process
The bronzing process, simply put, is to imprint the bronzing paper on the surface of the product by heating and pressurizing the silicone plate, so that the product is branded with the corresponding font content.
According to the shape of the product, a reasonable fixture is designed, so that the content of the product does not shift, and the upper and lower color registration is accurate, in line with industry standards. For some irregular shaped products, several sets of tooling can be designed to shorten the time during the machine adjustment process, and to achieve accurate hot stamping and color registration. In terms of conical flasks, you can do a set of free swing angles to adjust.A set of universal fixtures are made for the hot method of special-shaped products, and the products can be rotated freely.For the hot stamping method of inlaid hot stamping, a set of 360° free rotating fixtures can be made.Several sets of fixtures can also be designed for other products that are difficult to locate.
In production, we should set the required process parameters according to the content and requirements of the product. Generally speaking, the higher the temperature of the bronzing plate, the shorter the bronzing time, and this time needs to be adjusted repeatedly. When the three items of time, pressure and temperature are in focus, the hot product will be bright and strong in adhesion.
Stamping steps: First of all, we need to carry out electrostatic dust blowing treatment on the surface of the product to ensure that no particles, flying silk and other dust are adsorbed on the surface of the semi-finished product. Secondly, after dedusting, we should put the semi-finished product into a jig that can be positioned for surface font bronzing
Ultrasonic welding is a high-tech technology for welding thermoplastic products. Various thermoplastic plastic parts can be processed by ultrasonic welding without adding solvents, adhesives or other auxiliary materials. The advantages are to increase productivity, reduce costs and improve product quality.
Ultrasonic tuning technicians must first be familiar with the principle of ultrasonic welding. It transmits ultrasonic energy to the welding area through the high-frequency vibration that reaches a certain amplitude. Due to the acoustic resistance at the welding area and the interface between the two welding large, so localized high temperatures will occur. In addition, due to the poor thermal conductivity of plastics, it cannot be dissipated in time for a while. The heat accumulates in the welding area and causes the contact surfaces of the two plastics to melt rapidly. After a certain pressure is applied, they are integrated into one. When the ultrasonic stops working, let the pressure continue for a few seconds to solidify and form, so as to form a strong joint and achieve the purpose of welding.
Ultrasonic plastic welding methods include welding method, implantation method, riveting method, spot welding method, forming method and cutting method.
Essential elements for ultrasonic tuning
The quality of ultrasonic plastic welding depends on the amplitude of the transducer welding head, the applied pressure, welding time, curing time and other factors.
Generally, the welding molds we install must be designed by professionals and must be matched with the product to ensure the welding fastness of the product and good stability during the production process. The mold installation must be tightened, the center alignment must be accurate, the base must be fixed firmly, and the mold temperature should be checked from time to time. As for burnout. In the production process, if the mold is found to be cracked or extremely hot, it should be removed immediately for inspection or replacement, otherwise it will affect the power effect of the transducer.
Matters needing attention in the production process: ultrasonic plastic welding parts should be electrostatically blown and then welded to ensure that the welded products are clean inside and out.
Screen printing is a printing method that uses screen printing for screen printing, which belongs to filter printing. First of all, starting with the mesh material and stretching the mesh, stretching the mesh on the frame is a very important link in printing. Various wire meshes have different tensions. The precision wire mesh needs to be pulled tightly, and it should not be pulled too hard. To make the tension of the mesh uniform, use a tensiometer to measure the tension of the mesh at any time. When the standard tension is reached, let the mesh stand still for 20 to 30 minutes to stabilize the tension.
Generally, there is a significant decrease in 48 hours after the mesh is glued, and the tension is completely stable for more than 6 days, and the plate can be used after 7 days, and the effect is better at this time. The choice of screen frame is very important, generally there are several kinds of wooden frame, aluminum frame and steel frame. At present, aluminum frame and steel frame are generally used. They have the advantages of high strength and small deformation. The aluminum frame is light in weight and adapts to the large-scale layout.
01 . How to stretch the net
The quality of the mesh is directly related to the effect of plate making and printing. Stretching is the basis for making good plates and printing high-quality prints.
The method of stretching the net is divided into two types: positive stretching and oblique stretching. The so-called positive stretch net is that the warp and weft lines of the net are perpendicular and parallel to the frame edge, which is the most commonly used standard stretch net method. The diagonally stretched net is stretched against the frame edge, and the direction of the wire and the frame edge is generally at an angle of 45°, but according to different purposes or in order to reduce the loss, the angle can also be adjusted appropriately. The advantage of the diagonal stretch method is that it can eliminate the jagged edges of the printed pattern.
02 . screen printing plate making
When making a plate, it should be determined in advance which printing method to use, such as flat-bed mechanical printing, mobile printing, that is to say, the direction of the printed product should be determined. According to these methods, determine the size of the screen frame and the position of the screen.
Generally speaking, the larger the width left around the positive film, the better the printing effect. Of course, it does not have to be placed in the middle of the screen frame, and sometimes it can be offset, as long as it is enough for the printing stroke.
The following is an example of printing process control: In order to ensure the best quality of printed fonts on the product, we first perform a discharge dust blowing treatment before the flame treatment to solve the dust, flying silk, etc. adsorbed on the product before the treatment, so as to avoid the flame after the flame. Sticking on the product, the purpose is to make the ink better adsorb on the product surface.After the treatment, we carry out electrostatic dust blowing treatment again. After blowing dust, UV ink printing is carried out immediately. After printing, the product is immediately placed on the UV machine tooling to enter ultraviolet curing. UV ink is quickly converted from liquid to solid after ultraviolet light.After passing the light, the staff will test the product fastness according to the QC standard. Technicians will accompany the quality control inspection, evaluation and confirmation before mass production. The inspectors will test the online products made once every 2 hours, and keep abreast of the control of the production process.
Of course, the flame treatment of PP products is the key. The quality of the treatment directly affects the fastness of the product, so the distance, height, and gas mixture from the flame to the product are more important. The adjustment of the flame must be checked by professional technicians, and the flame condition must be checked once an hour. At the same time, it is also necessary to check whether there is air leakage in each gas pipe to ensure safe production.
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