PRODUCT DEVELOPMENTS Creating large format...

P R O D U C T D E V E L O P M E N T S

Creatinglarge format decorative glassArchitects and interior designers are rapidly changing the way interiors and exteriors of buildings look by incorporating decorative glass as a distinctive and important feature of their design. The use of decorative glass can afford reduction in construction costs, increased energy conservation and address long term environmental concerns. The aesthetic appeal of decorative glass is no longer exclusive to the exterior of a building, but has now expanded to wall coverings, room partitions, separations, stairways, balconies, kitchen backsplashes, as well as concealing areas in both residential and commercial applications.

35Glass-Technology International 3/2014

Although it was once considered unusual for an architect to specify decorative glass, today through the use of digital printing, screen printing, decorative lami-nates, etched and colored glass plus full coated span-drel sheets, many effects can be achieved. More and more exterior/interior doors, shower/bath enclo-sures, wall coverings, exte-rior façades, vanity tops, kitchen backsplashes and counters, elevators, floor tiles and more are recei-ving some type of decora-tive glass. Regardless of the function of the decorative glass, quality, colour con-sistency, colour uniformity and clarity are important, and have become cost-effective solutions to crea-te stunning effects that no other medium can provide. Digital printing has given glass decorators the ability to quickly create multiple

coloured patterns or repro-ductions of drawings, ima-ges, and photos onto glass in short run format. Screen printing allows for single colour laydown with the creation of multiple colours with sequential printing, being excellent for lon-ger production runs. With concerns for safety and weather related hazards, laminated glass can create images by incorporating digitally printed or screen printed products and ama-zing effects by laminating a printed film, fabric, metal screen, or other objects by encapsulating them between two layers of lamina-tion film and glass.

SCREEN PRINTINGScreen printing has the ability and versatility to give a monolithic flood coat, tints/transparencies from 10 to 90 per cent, selective patterns with texture and multiple colours through

sequential printing. When printing large format glass, the robustness of the ma-chine and the flatness of the print table are important to ensure complete and uni-form coverage. The me-chanical stress and desired quality demand from pro-cessing larger and heavier sheets of glass are signifi-cantly greater than those experienced in other flat glass printing applications. The mechanical stability of the screen printing process leads to predictable, repe-atable results for high vo-lume printing. Screens are required for each image to be printed. Typically the glass is washed and dried directly before printing. For quality print produc-tion, there are three general types of printers.A semi-automatic printer requires the operator to position the glass manual-ly against adjustable stops, with the glass either on

retractable ball rolls or an air floatation table. Once locked into position by vacuum on the table, the print cycle is automatic. A three-quarter automatic printer adds a conveyor thru the printer, allowing glass to enter and exit without operator intervention while maintaining the ma-nual registration process.A fully-automatic printer adds registration (squa-ring) for the glass to au-tomatically align the glass with the pattern to be prin-ted.Most systems are control-led via a PLC so that the operator can store recipes for quick recall and ma-chine setup. A robust print head and bridge hold the squeegee in proper posi-tion for a uniform print. Anti-drip systems are im-portant to prevent ink, par-ticularly tints/transparen-cies, from dripping onto the image area during the

P R O D U C T D E V E L O P M E N T S

36 Glass-Technology International 3/2014

the coating applied to the coating roll. Roll coaters can also be equipped with pattern print rolls to ap-ply continuous repeating patterns, dots, lines, and grids. Roll coaters are easy to maintain and clean. The most common applica-tion is spandrel glass used for obscuration panels, wall coverings and privacy partitions. Common inks include ceramic inks and silicone based inks.

DECORATIVELAMINATE Laminated glass, which originated for safety pur-poses, can create effects not possible with other techniques. Printed film, fabrics, metal mesh, and other objects that are open to the imagination can be laminated between layers of materials such as EVA or PVB. The thickness of the interlayer can be se-lected to mould around the thickness of the material being laminated. The inter-layer material may also be

bo. Print resolution is up to 720 dpi with edge-to-edge printing in a full selection of colours.

ROLL COATER A reverse roll coater ap-plies a full flood coating di-rectly onto an uncoated or pre-printed image. Power in-feed and out-feed con-veyors allow for easy inter-face with up- and down-stream components.A reverse roll coater typi-cally has three rolls: the bottom or backup roll, the coating roll which has a rubber surface that may or may not be grooved depen-ding on the wet thickness to be applied, and the metering (doctor) roll, to control the thickness of

art renditions, patterns, and textures in multicolor, providing excellent results when making short runs or when one-of-a-kind prints are desired. Print cycle time is significantly longer than a screen prin-ter, although it can deli-ver solid colours to four- colour processing in a sin-gle pass.Digital printing is begin-ning to provide products for light diffusion, light transmission, energy ef-ficiency, conductive sur-faces, anti-skid surfaces, and sun control. Digital printers use special formu-lations of ceramic inks that are suitable for both inte-rior and exterior projects with glass sizes up to jum-

flood stroke which applies the ink to the screen pri-or to the next print. High speed printers are capable of providing 120 and more prints per hour. Added fe-atures such as laser screen alignment, pneumatic scre-en clamping, and other op-tions help to shorten setup times. After printing the glass moves into a dryer, which for water miscible ceramic inks brings the ink to about 160°C. A cooling section may follow if the glass is to be offloaded or the glass can directly enter the tempering operation to fire the ink into the glass.

DIGITAL PRINTING Digital printers can re-produce images, photos,

37Glass-Technology International 3/2014

Casso-Solar Technologies

Casso Sola

506 Airport Executive Park

Nanuet, NY 10954

Tel.: 845-354-2010

Fax: 845-547-0328

sales@CassoSolarTechnologies.

com

www.cassosolartechnologies.com

belts, and cross bar con-veyors. The roll system with the spiral-wrap stainless steel rope is the most ro-bust and requires the least amount of maintenance. The stainless steel rope provides a cushion for the glass as well as thermally isolating the glass from the conveyor roll. Many belt materials wear over time and create residue that can end up in the coating on the glass. Exhaust is provided to remove the by-products evaporated during the pro-cess. A PLC controls the system allowing the ope-rator to setup a recipe for later recall, to automatically setup the heater temperatu-re zones, exhaust flow and conveyor speed.

with or without a combi-nation of heated air. Zones are provided in direction of travel to allow the creation of ramp/soak processing. Edge zones provide extra energy for product edge losses, providing a uni-formly heated product. For production requirements that have many widths of glass, cutoff zones can turn off unneeded heaters. The oven is fully insulated to re-tain the energy within with removable side panels and bottom panels for mainte-nance and cleaning. Com-mon conveyors included driven rolls spiral-wrapped with stainless steel rope, open weave Teflon coated fiberglass/Nomex (TM-DuPont) belts, wire mesh

ducing unique and specta-cular effects.

DRYER The dryer/curing oven con-sists of a conveyor system combined with medium wavelength infrared and convection for efficiency and flexibility of paint types. The dryer/curing oven should be suitable for water-miscible, pine oil, terpinol, and silicone inks as well as speciality inks like enamels, epoxy, and many others. The dryer/curing system is generally loca-ted outside a print/coating room so as not to generate heat back into these rooms. The dryer/curing oven may utilize flat panel or tubular quartz medium heaters,

direct printed and is avai-lable in a large selection of colours. One of the glass sheets can also be tem-pered to provide further strength to the product, so a combination of uni-que decorations and safety are characteristics of this product. Multiple layers of glass and decorative inter-layers are also possible. ETCHED GLASS Acid etched glass, either alone or with colour deco-rations, can provide spec-tacular wall and partition effects. Ceramic ink can create etch-like and colour effects. Spot etching can be complimented with colour applied either digitally or with a screen printer, pro-

COVERADVERTISERS INDEXAdelio LattuadaAyroxBando KikoBest MakinaBystronic glassCerionC.M.B. - BesanaCugher GlassForza G ItaliaGlassbuild AmericaGlasstec AsiaGlastonHeglaHelios ItalquartzIntermacItalcarrelliKeraglass - Emmegi GroupLandglass TechnologyLeybold OpticsLisec GroupMir SteklaOptimaRCN EngineeringRollmac - GeMaTaSofteco

CONTENTS - REGULAR FEATURESADVERTISERS INDEX &COMPANIES MENTIONEDOUR FAIRS CALENDAR 2014NEWS & PRODUCTSSUPPLIERS GUIDE - Yellow Pages in RussianSUBSCRIPTION SERVICE

CONTENTS - ARTICLESKeraglass and Emmegi Group: responding to the crisis and challengesof the global marketCasso-Solar Technologies: Creating large format decorative glassGeMaTa: important growth – more than 50per cent – in 2013Bohle: Clean process waterwith Bohle SedimentorSchott: celebrates BOROFLOAT®speciality glassLeybold Optics: leading the world in thin fi lm technologyOmni glassand paint: choosing theright fi re-ratedglass for your businessLightweight glazing unitsfor architectural purposesRuncorn Glass& Glazing: specialist inbespoke cuvedglass

SUPPLIERS GUIDE - Yellow Pages in Russian

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