KR20050011029A - Plastic mirror and Manufacturing method of plastic mirror - Google Patents

Abstract

PURPOSE: A plastic mirror and a method for manufacturing the plastic mirror are provided to enable automated production and manufacturing of large-sized plastic mirrors having enhanced durability and ensured user's safety by providing a uniformly reflective film formed by spraying a silver nitrate solution with a reducing agent on a transparent plastic substrate. CONSTITUTION: The method comprises: performing pre-treatment for removing foreign matter sticking to a surface of a plastic substrate using isopropyl alcohol(15); forming an adhesion layer by a spray method to increase adhesiveness between the substrate and a reflective film(10); primarily rinsing using pure water(11); forming an reflective film by spraying a silver nitrate solution and a reducing agent in the same amount using a two-head spray gun(20); secondly rinsing using pure water(21); primarily drying for removing water sprayed in the rinsing(22); forming a coating layer for preventing physical and chemical changes of the reflective film(30); and secondly drying for facilitating solidification of the coating layer(32).

Description

Plastic mirror manufacturing method and its products {Plastic mirror and Manufacturing method of plastic mirror}

The present invention relates to a method of manufacturing a plastic mirror, and more particularly, to a method of forming a reflective film by spraying a silver nitrate solution and a reducing agent solution on a transparent plastic substrate in a spray method.

In general, a mirror has a structure in which a reflective layer is formed on a substrate, which is a glass plate, to identify an object by reflection of the reflective layer, and quality is determined by a uniform thickness of the reflective layer, that is, flatness.

As a conventional method of forming a reflective layer, a method of dipping a substrate in a material having a metal salt and a method of depositing it in a vacuum space are used. However, the dipping method has a disadvantage in that the flatness of the reflective layer surface is lowered because the metal salt material is not uniformly adhered to the substrate, and the vacuum deposition method is excellent in forming the reflective layer uniformly, but there is a space limitation, thereby producing a large product. There is a disadvantage of low productivity which is not suitable for the following.

In addition, when the material of the substrate on which the reflective layer is formed is used as glass, the weight of the mirror itself is increased, and there is a weakness in impact, and there is a risk of injury to the user if broken.

Accordingly, the present invention has been made to solve the above conventional problems,

It is possible to manufacture a large mirror having a relatively uniform reflective layer by applying a spray spraying method to the reflective layer forming method, and a mirror manufacturing method considering the safety of the consumer such as improving the durability against impact by forming the material of the substrate into plastic and its To provide a product.

1 is a flow chart showing a manufacturing process of a preferred embodiment according to the present invention,

2 is a cross-sectional view of a plastic mirror manufactured by the manufacturing method of the present invention.

<Explanation of symbols for the main parts of the drawings>

10: adhesive layer forming step 11: the first washing step

15: pretreatment process 20: reflective layer forming step

21: 2nd washing step 22: 1st drying step

30: coating layer forming step 32: the second drying step

40: plastic substrate 50: adhesive layer

60: reflective layer 70: coating layer

Plastic mirror manufacturing method of the present invention for achieving the above object,

In the manufacturing method of the mirror, in order to improve adhesion to the reflective layer on the surface of the substrate after the pre-treatment process to remove the foreign matter on the surface of the plastic substrate using alcohol or iso-propyl alcohol (IPA) An adhesive layer forming step of forming a pressure-sensitive adhesive layer by spraying tin chloride (SnCl ₂ ), which is a surface modifier, in a spray method; A reflective layer forming step of forming a reflective layer by spraying silver nitrate and a reducing solution in a ratio of 1: 1 using a two-head spray gun to the adhesive layer formed in the adhesive layer forming step; In order to block the physical chemical change of the reflective layer formed in the reflective layer forming step, a coating layer forming step of forming a coating layer by coating or spraying a coating is included.

The spray gun is a device in which two jet holes are formed so that the silver nitrate and the reducing liquid, which are used to form the reflective layer, are sprayed into separate jet holes. In addition, the paint forming the coating layer is for protecting the reflective layer, and typically, urethane paint or the like is used.

In the pressure-sensitive adhesive layer forming step, tin chloride, which is a surface modifier, is sprayed in a drop shape without spraying tin chloride at a constant rate when the spraying pressure is lower than 1.0kg / cm ² , and when the spraying pressure is higher than 3.0kg / cm ^2. Since the spraying is not continuously performed and a blanking phenomenon occurs, the tin chloride layer applied becomes uneven, and the tin chloride is preferably sprayed at a pressure of 1.0 to 3.0 kg / cm ² .

In addition, when the spraying time is 3 seconds or less, the adhesive layer (tin chloride layer) is not uniformly formed on the substrate, and when the spraying time is 6 seconds or more, the adhesive layer is formed with an excessive thickness, so that it is sprayed for 3 to 6 seconds. desirable.

And, by adding a predetermined amount of fuel to the surface modifier can be expressed in the color of the mirror produced.

In addition, the injection pressure of the silver nitrate and the reducing liquid injected in the reflective layer forming step, when sprayed at a pressure of 1 or less and a pressure of 4 or more, as described above is not scattered or sprayed in the form of droplets, 1 ~ 4 kg Preference is given to spraying at a pressure of / cm ² .

In addition, it is preferable that the thickness of the reflective layer formed by the injection is excessively formed in a layer, or the layer is formed in a range of 0.2 to 0.5 μm in which the thickness is so thin that the reflection efficiency does not decrease.

On the other hand, the plastic mirror manufacturing method of the present invention in order to remove the residue of the tin chloride sprayed in the adhesive layer forming step, and the remaining substances reacted in the reflective layer forming step, pure water after the adhesive layer forming step and the reflective layer forming step The first washing step and the second washing step of spraying and cleaning are further performed.

In the water washing step, the pure spray pressure of the cleaning process is made for 3 to 6 seconds at a pressure of 1.0 ~ 2.5 kg / cm ² . This is less than the injection pressure of 1.0 kg / cm ² as described above, when purified water is reflective difficult to disperse injected in the front, is greater than 2.5 kg / cm ^2, due to the injection pressure to be peeled off the reflecting film (Eun Kyung film) formed on the reflective layer Because it can. In addition, the injection time is also preferably within the time that can sufficiently wash away the residual material within the range that is not excessively sprayed.

In addition, the first drying step and the second drying step to pass through the drying furnace after the second washing step and the coating layer forming step to promote the removal of water sprayed in the second washing step and the solidification of the coating layer formed in the coating layer forming step Is made more.

The drying process of the first drying step is made for 4 to 12 minutes in a drying furnace of 50 ~ 80 ℃, the drying process of the second drying step is made for 8 to 17 minutes in a drying furnace of 50 ~ 80 ℃. The drying is made of a silver hard film (reflective film) to form a reflective layer and the heat of the highest temperature that can prevent the coating material forming the coating layer from being deformed by heat during the time that the moisture removal and coating layer solidification can be completed completely, Preferably, in order to completely prevent thermal deformation within the above conditions, the first drying step is 5 to 10 minutes in a drying furnace of 60 ~ 70 ℃, the drying process of the second drying step is 10 ~ in a drying furnace of 60 ~ 70 ℃ It is drying for 15 minutes.

Hereinafter, a method of manufacturing a plastic mirror of the present invention and a product thereof will be described in detail with reference to the accompanying drawings.

1 is a flow chart showing a manufacturing process of a preferred embodiment according to the present invention, Figure 2 is a cross-sectional view of a plastic mirror manufactured by the manufacturing method of the present invention.

Plastic mirror manufacturing method of the present invention, as shown in Figure 1, the adhesive layer forming step 10, the first washing step 11, the reflective layer forming step 20, the second washing step 21, the first The drying step 22, the coating layer forming step 30, the second drying step (32) in order.

First, in the adhesive layer forming step 10, in order to improve the adhesion of the reflective layer 60 formed in the late process to the substrate 40 of plastic material, by spraying tin chloride, which is a surface modifier, on the surface of the substrate, the adhesive layer 50 To form. In this step, the pretreatment process 15 may be preceded by cleaning with alcohol or isopropyl alcohol to remove foreign matter (dust, oil, etc.) on the surface of the substrate.

The adhesive layer 50 has a first washing step 11 for spraying pure water in order to remove excess tin chloride.

The reflective layer 60 is formed by spraying silver nitrate and a reducing solution in a ratio of 1: 1 using a two-head spray gun on the surface of the cleaned adhesive layer 50.

In the reflective layer forming step 20, a second washing step 21 is performed in which a pure hard film (reflective film), which is the reflective layer 60, is formed and sprayed with pure water to wash away the remaining silver nitrate and the remaining material of the reducing liquid.

In addition, a first drying step 22 is performed on the reflective layer to remove moisture remaining on the surface of the reflective layer by using a drying furnace to smoothly form a coating to be described later.

In the coating layer forming step 30, an impermeable opaque paint is applied (sprayed) to the surface of the reflective layer from which moisture is removed, thereby preventing the reflective layer from coming into direct contact with the outside, thereby preventing chemical and physical deformation of the reflective layer. .

In addition, the second drying step 32 using a drying furnace is further made to promote the solidification of the paint, as shown in FIG. 2, the adhesive layer 50, the reflective layer 60 and the coating layer ( 70) is applied to the plastic mirror is applied in sequence.

Example

I. Preparation of the plastic mirror of the present invention

1) An adhesive layer was formed by spraying tin chloride, a surface regulator, at a pressure of 1.8 kg / cm ² for 5 seconds on a plastic substrate from which foreign substances on the surface were removed using alcohol or isopropyl alcohol.

2) Pure water was sprayed on the pressure-sensitive adhesive layer at a pressure of 1.8 kg / cm ² for 5 seconds to remove the tin chloride residue.

3) The two liquids were sprayed at a pressure of 2.5 kg / cm ² using a spray gun having two jet holes for spraying silver nitrate and a reducing solution on the surface of the cleaned adhesive layer to form a reflective layer having a thickness of 0.4 μm.

4) The pure water was sprayed on the reflective layer at a pressure of 1.8 kg / cm ² for 5 seconds to remove residual materials.

5) The substrate on which the reflective layer was formed was passed through a drying furnace at 65 ° C. for 8 minutes to evaporate moisture.

6) An impermeable urethane paint was applied to the reflective layer surface of the dried substrate to form a coating layer.

7) The substrate on which the coating layer was formed was passed through a drying furnace at 65 ° C. for 13 minutes to promote solidification of the paint.

II. Comparative table

1) Comparative Product

Plastic mirror of the present invention: A

Dipping manufactured glass mirror: B

Vacuum-deposited glass mirror: C

( ◎ : Very good, ○ : Good, △ : Normal, × : Bad)

As shown in Table 1, the present invention (A) has a better or similar flatness than the compared dipping products (B), and the flatness is somewhat lower than the mirror (C) manufactured by the vacuum deposition method It can be seen.

In addition, the present invention is somewhat better in the impact, it can be seen that the safety at the time of damage due to the impact is superior to the glass mirrors (B, C).

In addition, the dipped glass mirror (B) requires a large amount of solution that can hold the substrate in order to form a reflective film, and the vacuum-deposited glass mirror (C) is relatively limited due to the spatial limitation of vacuum forming the manufacturing space. Since the production of a large product is difficult, it can be seen that the plastic mirror of the present invention, which is formed by spraying an appropriate amount to form a reflective layer and has a limited size, is superior to the two comparative products in productivity.

Therefore, it can be seen that the plastic mirror according to the manufacturing method of the present invention is the same or superior product and manufacturing method than the two methods compared with reference to Table 1 in terms of flatness, impact properties, safety and productivity.

In addition, the above-mentioned example is only an example to demonstrate this invention. Therefore, it is obvious that the ordinary skilled in the art to which the present invention pertains uses the partial change with reference to the detailed description.

As described above, the plastic mirror manufacturing method of the present invention,

Most of the manufacturing process is made by spray injection method, which enables the automation of production. Since there is little space constraint, it is possible to manufacture a large mirror with a relatively uniform reflective layer. It is possible to provide a mirror manufacturing method and its product which have improved productivity and safety by improving durability and preventing accidents caused by breakage.

Claims (8)

In the manufacturing method of the mirror, After pretreatment to remove foreign substances on the surface of the plastic substrate using alcohol or iso-propyl alcohol (IPA), tin chloride (SnCl), a surface modifier, is used to improve adhesion with the reflective film on the surface of the substrate. ₂ ) a pressure-sensitive adhesive layer forming step of spraying the spray method to form a pressure-sensitive adhesive layer; A reflective layer forming step of forming a reflective layer by spraying silver nitrate and a reducing solution in a ratio of 1: 1 using a two-head spray gun to the adhesive layer formed in the adhesive layer forming step; And a coating layer forming step of forming a coating layer by spraying paint to block physical and chemical changes of the reflective layer formed in the reflective layer forming step. The method of claim 1, In order to remove the residue of tin chloride sprayed in the pressure-sensitive adhesive layer forming step and the remaining material reacted in the reflective layer forming step, the first washing step and the first step of cleaning by spraying pure water after the pressure-sensitive adhesive layer forming step and the reflective layer forming step Mirror washing method further comprises a washing step. The method of claim 2, The injection of tin chloride, the surface modifier of the pressure-sensitive adhesive layer forming step is a mirror manufacturing method, characterized in that made for 4 to 5 seconds at a pressure of 1.5 ~ 2.0 kg / cm ² . The method of claim 2, The injection pressure of the silver nitrate and the reducing liquid for forming the reflective layer in the reflective layer forming step is made of 2 ~ 3 kg / cm ² , the thickness of the reflective layer is characterized in that the mirror manufacturing method characterized in that formed in 0.3 ~ 0.4 ㎛. The method of claim 2, The first drying step and the second drying step of passing through a drying furnace after the second washing step and the coating layer forming step are further performed to promote the removal of water sprayed in the second washing step and the solidification of the coating layer formed in the coating layer forming step. Mirror manufacturing method, characterized in that made. The method of claim 5, The cleaning process in the first washing step and the second washing step is a mirror manufacturing method, characterized in that made for 4 to 5 seconds at a pressure of 1.5 ~ 2.0 kg / cm ² . The method of claim 5, The drying process of the first drying step is made for 5 to 10 minutes in a drying furnace of 60 ~ 70 ℃, the drying process of the second drying step is a mirror manufacturing method characterized in that it is made for 10 to 15 minutes in a drying furnace of 60 ~ 70 ℃ . A plastic mirror produced by the method of claim 1.