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  • 浅谈真空镀膜工艺的制程损耗率
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穷人赚钱门路For most customers who are first exposed to vacuum electroplating process, the loss rate of vacuum electroplating process has always been a psychological obstacle that cannot be easily overcome. Many new customers will feel a little high when they hear the 15% to 20% loss rate reported by the manufacturer. How much loss rate does vacuum electroplating industry need after all? Today from the perspective of vacuum plating process to briefly talk about the loss of the problem, hope to contact with the vacuum plating industry customers play a role in answering questions. Water have been known to wrest the attrition rate of plating industry is usually about 5% - 8%, therefore in the process of practical cooperation to negotiate, often have the customer take water plating the attrition rate of attrition rate to compare with the vacuum plating process, little imagine, electroplating and vacuum plating although both belong to the water surface electroplating processing industry, but the process is completely different, water is a more traditional electroplating processing surface electroplating processing technology, the principle of which is through chemical liquid soak, achieve in plastic surface in the form of chemical replacement add metal film layer to enhance the purpose of a metallic appearance, due to the limitation of process principle, Water electroplating products in environmental protection, color richness, reliability, signal penetration, light penetration, local cover plating and other aspects of natural defects, many demanding electronic industry products due to the above reasons and finally had to change the original design to give up the surface water electroplating processing; Vacuum plating technology arises at the historic moment, and then compared with water electroplating chemical displacement process, vacuum plating adopts pure physical way of vacuum evaporation coating to metal materials evaporation in the gaseous state uniform adsorption onto the surface of the plastic parts, and form a complete metal film layer after cooling, the perfect solved many disadvantages of the above water electroplating processing, combined with vacuum plating process in ROHS and environmental friendly aspects of excellence, has been more and more adopted by many senior design research and development personnel, widely used in all walks of life to improve the appearance of the products with metallic product. Vacuum plating processing attrition rate (scrap rate, SR) : as the name implies, is refers to the plastic material after vacuum coating process is processed into finished product in the process of electroplating, not meet customer quality requirement of semi-finished products and finished products of bad ratio, namely the total defective rate, attrition rate = calculated total bad present production process. Vacuum evaporation electroplating process has a certain particularity, the main processing process is roughly composed of the following parts: material into the factory -- assembly fixture -- spraying transparent UV primer -- coating curing -- vacuum coating film -- spraying UV finish paint -- coating curing -- rolling off the line to remove fixture -- full inspection packaging shipment; In electroplating process, according to the requirement of the process itself and the reliability test requirements of our clients, in addition to coating layer, often require two to three times the action, the application of UV coating UV coatings and UV curing coating, the coating on the surface state of liquid atomization spray to the product after need under special UV lamp light irradiation to achieve thorough drying curing condition, and once the UV coating curing to form permanent molecular chain structure, can't again on the original coating rework polishing spray or paint, often look bad for the only processing method is sorting out scrap directly. Vacuum plating UV coating is difference with traditional UV coating performance slightly, but the spraying process and the traditional principle of the UV coating process for the same traditional UV coating processing industry a spraying processing yield levels in about 80-85% is ideal vacuum plating process for contains two to three times the UV coating process, according to the traditional UV spraying the yield level of computing: 1×85%×85%×85%=61.4%, that is to say, if the final processing yield of vacuum electroplating process with three UV spraying processes reaches 61.4%, then the yield of each UV spraying has reached the average yield of traditional UV spraying --85%, and the loss rate is 1-61.4%=38.6%, which is obviously unacceptable to most customers. Therefore, the quality rate of a single UV spraying process in vacuum electroplating industry must be higher than the 85% yield level of traditional UV spraying industry, otherwise due to the superposition effect of the process, it will cause considerable material cost waste, which is unfavorable for customers and processing manufacturers. After numerous drilling and crucial vacuum plating industry professional and technical personnel, from the aspects of environmental purification, dust removal, process optimization for continuous improvement, try to keep the single UV spraying process of vacuum plating processing industry rate can achieve 90% above, without computing coating process and other loss situation, according to the general two UV vacuum plating coating, finished rty to: 1×90%×90%=81%, and the loss rate is 19%. If the normal loss rate of coating process is calculated again, such as 1%-2%, material test loss, first piece loss of each process, performance test loss, customer spare parts loss, and loss of line drop during processing, the loss rate of vacuum electroplating process of 25% is relatively scientific and reasonable. Generally speaking, the current standard of vacuum electroplating industry is 20%-25%, and the loss rate of large-size and complex parts is slightly higher, which may reach 30%-35%. After continuous process optimization and improvement of small size parts and small appearance parts, the process loss rate may be reduced to 15%-10% under ideal conditions, which is already quite remarkable for the vacuum electroplating industry. In addition to the above, the loss rate of vacuum electroplating process is also comprehensively related to the following six aspects: 1. The more complex the product shape, the more difficult it is to wipe and dust removal and the electrostatic air gun dust removal. The dust removal effect will be relatively poor, which will lead to the rise of the final defective rate and the rise of the loss rate. 2. The overall size of the product; The larger the size of the product, the larger the surface area, the higher the corresponding probability of appearance defects will be, the higher the loss rate will be; 3. Product appearance acceptance standards; The more strict the appearance acceptance standard of electroplating finished products, the lower the quality rate of vacuum electroplating will be, and the higher the corresponding loss rate will be. Therefore, the influence of reasonable quality requirements on the quality rate and loss rate of vacuum electroplating processing is very important. 4. Product reliability acceptance standards; The higher the requirement of reliability test for electroplating finished products, the more difficult the process is, and the higher the comprehensive loss rate of the whole vacuum coating process will be. 5. Matching status of electroplating fixture; Electroplating fixture directly affects the yield of the manufacturing process. If the fixture is not reasonable, it will have a great influence on the yield of vacuum electroplating process, and the loss rate will be high. 6. Employees' proficiency in products; In the first contact or trial production of the same product, the yield is often unable to reach the ideal state. However, after repeated exploration, summary, improvement and optimization of mass production, the yield of vacuum electroplating processing of the product will be significantly improved. To sum up, vacuum plating processing and processing technology of process attrition rate is influenced by various aspects comprehensive superposition, the result of the need to source from value products can production, product design and development, quality standards, fixture design, minimum purchase quantity, and so on factors will affect the yield of plating processing factory production processes, improve product rate, reduce the attrition rate is permanent pursuit of upstream and downstream manufacturing professionals, let's work hard and make progress together!


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