CN108103461A - 一种汽车车灯镀膜工艺 - Google Patents

一种汽车车灯镀膜工艺 Download PDF

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CN108103461A
CN108103461A CN201711452355.4A CN201711452355A CN108103461A CN 108103461 A CN108103461 A CN 108103461A CN 201711452355 A CN201711452355 A CN 201711452355A CN 108103461 A CN108103461 A CN 108103461A
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周建国
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Ocean Jiangsu Car Light Co Ltd
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Abstract

本发明涉及一种汽车车灯镀膜工艺，包括以下步骤：S1、预处理，S2、底层刘平处理，S3、静电除尘，S4、铝膜镀层，S5、保护膜镀层。本发明提供汽车车灯镀膜工艺能够有效避免因工件表面存在杂质降低膜层附着力的现象，同时保证车灯的反射率，保证车灯镀膜质量。

Description

一种汽车车灯镀膜工艺
技术领域
本发明涉及汽车灯具表面处理技术领域，尤其涉及一种汽车车灯镀膜工艺。
背景技术
机动车辆外照明主灯的聚光镜反光膜的性能直接反映了灯具性能，影响车辆照明效果和行驶的安全性。为此，国家标准对汽车照明灯具反射镜的光学性能、反射膜的附着力、耐候性等提出了明确要求，其中反光膜的制作是最为关键的工艺技术之一。现有灯具产品中常常因镀膜厚度不足，附着力、反射率达不到要求，产品合格率不高，质量得不到保证，导致生产成本无法控制。因此，急需一种能够保证镀膜质量的车灯镀膜工艺。
发明内容
为了解决上述技术问题，提供一种能够保证镀膜质量的汽车车灯镀膜工艺。
本发明提供以下技术方案：
一种汽车车灯镀膜工艺，其特征在于，包括以下步骤：
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为20-40Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；采用抗静电清洗液能够有效的将工件表面的机油、手印以及灰尘等杂质去除，提高后续镀膜处理的效果，提高车灯产品合格率，保证产品质量。
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在200-300℃条件下烘1-2h，使用磨砂轮进行表面打磨；使用磨砂轮打磨能够有效控制工件表面UV漆层厚度，避免出现厚度不均的现象；另外，采用磨砂轮打磨后增加UV漆层表面与镀铝膜的接触面积，增大了经底层流平处理后工件流平层和铝膜之间的附着力，避免降低镀膜的强度；
S3、静电除尘：真空箱中顶端设有静电消除器，在真空条件下将步骤S2得到的工件放入真空箱中，其待镀层的一侧面向静电消除器，停留时间为2-3h；由于底层流平处理后，工件在转运过程中依然会因空气尘埃、物理接触影响镀膜效果，采用静电消除器将工件表面的尘埃去除，避免了传统化学药剂清洗对操作人员身体的伤害，也提高了后续镀膜的效果；
S4、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在200-400℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S5、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
进一步的，所述步骤S1中的抗静电清洗液为NaOH、硅酸钠、甲基硅油、二鲸蜡基二甲基氯化铵和乙醇的混合物，所述NaOH、硅酸钠、甲基硅油、二鲸蜡基二甲基氯化铵和乙醇的比例为5:3:2:1:10。
进一步的，所述步骤S2中通过磨砂轮打磨后使UV漆层厚度小于1mm。UV漆层的厚度过大影响车灯的反射率，而厚度过小则无法填补工件表面的凹陷，影响后续镀膜质量。
本发明的有益效果在于：
本发明提供汽车车灯镀膜工艺能够有效避免因工件表面存在杂质降低膜层附着力的现象，同时保证车灯的反射率，保证车灯镀膜质量。
具体实施方式
实施例1
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为40Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在200℃条件下烘1.5h，使用磨砂轮进行表面打磨；
S3、静电除尘：真空箱中顶端设有静电消除器，在真空条件下将步骤S2得到的工件放入真空箱中，其待镀层的一侧面向静电消除器，停留时间为3h；
S4、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在3000℃、射频功率为20条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S5、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
实施例2
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为30Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在300℃条件下烘2h，使用磨砂轮进行表面打磨；
S3、静电除尘：真空箱中顶端设有静电消除器，在真空条件下将步骤S2得到的工件放入真空箱中，其待镀层的一侧面向静电消除器，停留时间为2-3h；
S4、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在300℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S5、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
实施例3
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为20Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在250℃条件下烘1h，使用磨砂轮进行表面打磨；
S3、静电除尘：真空箱中顶端设有静电消除器，在真空条件下将步骤S2得到的工件放入真空箱中，其待镀层的一侧面向静电消除器，停留时间为2-3h；
S4、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在400℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S5、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
对比例1
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为40Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在250℃条件下烘1h，使用磨砂轮进行表面打磨；
S3、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在300℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S4、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
对比例2
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为40Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在250℃条件下烘1h；
S3、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在300℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S4、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
分别按照实施例1-3和对比例1-2的工艺对工件进行镀膜处理，对镀膜后的车灯进行耐酸碱试验、反射率以及膜层附着力试验，试验结果如下表所示。
实验证明，在镀膜前采用静电除尘步骤的车灯镀膜工艺有效提高了车灯膜层的在车灯基材表面的排布的致密性，减少了因基材与镀层之间的杂质含量，提高了车灯的耐酸碱性以及膜层附着力，提高了镀膜的效果和质量，另外采用对比例1工艺的车灯反射率略低于采用实施例1-3工艺镀膜的车灯，也充分说明了镀膜前静电除尘能够有效去除转运过程中产生的杂质，保证了产品的质量；而对比例1和对比例2说明了在底层流平处理过程中，因使用磨砂轮进行打磨增加UV漆层表面与镀铝膜的接触面积，增大了经底层流平处理后工件流平层和铝膜之间的附着力，避免降低镀膜的强度。
以上述依据本发明理想实施例为启示，通过上述的说明内容，相关工作人员完全可以在不偏离本项发明技术思想的范围内，进行多样的变更以及修改。本项发明的技术性范围并不局限于说明书上的内容，必须要根据权利要求范围来确定其技术性范围。

Claims (3)

1.一种汽车车灯镀膜工艺，其特征在于，包括以下步骤：
S1、预处理：将工件通过喷砂处理后置于盛放常温抗静电清洗液的超声波清洗槽中，在频率为20-40Hz的条件下超声震荡30min，用清水清洗2-3遍后置于真空干燥箱中烘干；
S2、底层流平处理：将经过预处理的工件待镀面完全浸没在UV漆中，静置2-3s后取出，并用烘箱在200-300℃条件下烘1-2h，使用磨砂轮进行表面打磨；
S3、静电除尘：真空箱中顶端设有静电消除器，在真空条件下将步骤S2得到的工件放入真空箱中，其待镀层的一侧面向静电消除器，停留时间为2-3h；
S4、铝膜镀层：将工件置于镀膜室中，抽真空后充入混合气体，在200-400℃、射频功率为20-30W条件下电极板激发电子，使反应室气体成为等离子体与纯度≥99.8％的铝块在工件表面进行反应成为纳米晶粒进行镀膜；
S5、保护膜镀层：采用Al2O3作为保护膜基材，采用PECVD镀膜机进行镀膜，得到成品。
2.根据权利要求1所述的一种汽车车灯镀膜工艺，其特征在于：所述步骤S1中的抗静电清洗液为NaOH、硅酸钠、甲基硅油、二鲸蜡基二甲基氯化铵和乙醇的混合物，所述NaOH、硅酸钠、甲基硅油、二鲸蜡基二甲基氯化铵和乙醇的比例为5:3:2:1:10。
3.根据权利要求1所述的一种汽车车灯镀膜工艺，其特征在于：所述步骤S2中通过磨砂轮打磨后使UV漆层厚度小于1mm。
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CN108796502A (zh) * 2018-06-29 2018-11-13 中山市达尔科光学有限公司 一种改善反光杯性能的镀膜工艺
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