Technical Process of Fiberglass Screen Manufacturing
The process of creating a fiberglass screen involves several detailed and technical steps, each critical to ensuring the final product’s quality and durability. Here’s a breakdown of the process:
1. Selected Raw Materials
The process begins with the selection of high-quality raw materials. Typically, this involves choosing a specific type of glass. The glass used is often soda-lime glass, chosen for its balance of clarity, durability, and cost-effectiveness. The glass is then melted at high temperatures, typically around 1400°C to 1600°C.
2. Drawn into Silk Thread
Once melted, the glass is drawn into fine silk threads. This is achieved by extruding the molten glass through tiny nozzles. The diameter of these threads usually ranges from 4 to 9 micrometers, a size that provides the ideal balance of strength and flexibility.
3. Twisted Yarn
These silk threads are then twisted into yarn. The twisting process adds strength and cohesiveness to the individual threads. The degree of twisting can vary, but it’s adjusted to ensure optimal strength for the screen’s intended use.
4. Coated Yarn
The twisted yarn is then coated. This coating, typically a PVC (polyvinyl chloride) layer, helps protect the yarn from environmental factors such as moisture and UV rays. The coating thickness can range from 0.35mm to 0.45mm, depending on the desired durability and stiffness.
5. Woven into a Net
Next, the coated yarn is woven into a net. This is done on specialized looms that interlace the yarns to form the screen mesh. The mesh size is typically measured in squares per inch, with common configurations ranging from 18×16 (standard) to 20×20 (finer mesh) squares per inch.
6. Gauze after Weaving
After weaving, the gauze is heat-set. This process involves heating the woven mesh to set the weave, ensuring it holds its shape and size. This heat setting is crucial for maintaining the screen’s structural integrity over time.
7. Product Quality Inspection
Quality inspection is a critical step. Each batch of screens undergoes rigorous testing to ensure it meets size, strength, and durability standards. This may involve tests for tensile strength, dimensional accuracy, and resistance to environmental factors.
8. Finished Product
Once approved, the screen is considered a finished product. It is then rolled onto spools or cut into sheets, depending on how it will be packaged and sold. The rolls can vary in width, commonly ranging from 0.5 meters to 3 meters, with lengths of up to 300 meters.
9. Product Packaging
Finally, the product is packaged for shipping. This often involves rolling the screens onto spools, wrapping them for protection, and then boxing them for transport. The packaging is designed to protect the screens from damage during transit and handling.
Each of these steps in the production of fiberglass screens is vital to ensure that the end product meets the high standards expected by consumers and industry regulations.