Loss rate after coating objects with vacuum coating equipment
For most customers who are new to the vacuum electroplating process, when they hear the manufacturer's loss rate of 5%-20%, the reaction will be somewhat high; how much loss rate does the vacuum electroplating industry need? Today, from the perspective of vacuum electroplating process, I will briefly talk about the problem of loss, hoping to answer questions for customers who are new to the vacuum electroplating industry.
As we all know, the loss rate of the water electroplating industry is usually around 5%-8%. Therefore, in the actual cooperation negotiation process, customers often compare the loss rate of water electroplating and vacuum electroplating processes. As we all know, although both water electroplating and vacuum electroplating belong to the surface electroplating industry, the process is completely different. Water electroplating is a relatively traditional surface electroplating process. The principle is to add a layer of metal film on the surface of the plastic to enhance the metal texture of the external parts through chemical liquid immersion and chemical replacement. Due to the limitations of the process principle, the products processed by water electroplating have natural defects in environmental protection, color richness, reliability, signal penetration rate, light penetration rate, and local shadow plating. , and many products with higher requirements in the electronics industry have to change the original design plan to give up surface water electroplating for the above reasons. Vacuum plating came into being. Compared with the chemical replacement process of water electroplating, vacuum electroplating adopts a pure physical vacuum evaporation coating method, which uniformly adsorbs metal materials on the surface of plastic parts in gaseous evaporation state, and forms a complete metal film layer after cooling, which perfectly solves the above water electroplating process. of many disadvantages. In addition, the excellent performance and environmental protection of the ROHS vacuum plating process are increasingly adopted by many designers and R&D personnel, and are widely used in all walks of life to improve product quality with metallic texture.
Scrap rate (SR): As the name implies, it refers to the percentage of defective semi-finished products and finished products that cannot meet the quality requirements of customers during the process of processing plastic materials into electroplated finished products through the vacuum coating process, that is, the "total defective rate". Scrap rate = total number of defective operations ÷ total number of production.
The vacuum electroplating process has certain particularities. The main processing flow is roughly composed of the following parts: material entering the factory - assembling fixture - spraying transparent UV primer - coating curing - vacuum coating - spraying UV topcoat - coating curing - Offline removal of fixtures - full inspection, packaging, shipment; in the electroplating process, according to the requirements of the process itself and the customer's reliability test requirements, in addition to the coating, it is often necessary to spray the UV coating twice or three times. UV coating is also called ultraviolet curing coating. After spraying on the surface of the product in a liquid atomized state, it needs to be completely dried and cured under the irradiation of a special UV lamp. Moreover, the molecular chain structure formed by the UV coating cannot be reworked, polished or repainted or resprayed on the original coating, and the appearance of defective products cannot be handled.
Although the performance of vacuum plating UV coating is slightly different from traditional UV coating, the spraying process is the same as the traditional UV coating process. The yield of one-time spraying in the traditional UV coating industry is about 80-85%, which is ideal. Because the vacuum plating process includes two or three UV spraying processes, the yield of traditional UV spraying is calculated: 1×85%×85%×85%=61.4%. If the final processing yield of the vacuum plating process of the three UV spraying process reaches 61.4%, then the yield of each UV spraying has reached the average yield level of traditional UV spraying -85%, and the loss rate at this time is 1-61.4%= 38.6%, which is obviously unacceptable to most customers. Therefore, the yield of a single UV spraying process in the vacuum electroplating industry must be higher than the 85% yield level of the traditional UV spraying industry. Otherwise, due to the superposition effect of the processes, considerable material costs will be wasted, which is unfavorable to both customers and manufacturers.
After many professional and technical personnel in the vacuum electroplating industry have been researching and tackling key problems, they have continued to try to improve in terms of environmental purification, dust removal, and process optimization. At present, the yield rate of a single UV spraying process in the vacuum electroplating industry can reach more than 90%. Not counting the losses in the coating process and other processes, according to the general two-layer UV vacuum plating process, the first pass rate of the finished product is 1×90%×90%=81%. The loss rate is 19%. If the normal loss rate of the coating process is 1%-2%, the loss of material inspection and trial plating, the loss of the first piece of each process, the loss of performance test products, the loss of customer spare parts, the loss of dropped lines during processing, etc. The 25% loss rate of vacuum plating is more scientific and reasonable.
Generally speaking, the current loss rate standard in the vacuum plating industry is usually 20%-25%, and the loss rate of large-sized parts and complex parts is slightly higher, generally reaching 30%-35%. After continuous process optimization and improvement, under ideal conditions, the process loss rate of small-sized parts and small-sized parts may also drop to 15%-10%, which is a very significant first-time pass rate of finished products for the vacuum electroplating industry.
In addition to the above, the loss rate of the vacuum plating process is comprehensively related to the following six aspects:
1. The complexity of the product shape; the more complex the product shape, the more difficult it is to wipe and remove dust with an electrostatic air gun, and the dust removal effect will be relatively poor, resulting in an increase in the final defect rate and loss rate.
2. The size of the product's external dimensions; the larger the product size, the larger the appearance area, the higher the corresponding probability of poor appearance, and the higher the loss rate.
3. Appearance acceptance criteria of finished products; the stricter the appearance acceptance criteria of finished products, the lower the yield of vacuum electroplating and the higher the corresponding loss rate. Therefore, reasonable quality requirements have a very important impact on the yield and loss rate of vacuum electroplating.
4. Acceptance criteria for the reliability of finished products; the higher the reliability test requirements of electroplating products, the more processes usually meet the test requirements, which will also lead to an increase in the overall loss rate of the entire vacuum coating process.
5. The matching of electroplating fixtures; electroplating fixtures directly affect the yield of the process. When the fixture is unreasonable, it will have a great impact on the yield of the vacuum plating process, and the loss rate will become higher.
6. The proficiency of the employees on the product; the same product, in the second contact or trial production, its yield rate is often impossible to reach the ideal state. However, after several mass productions, the yield of vacuum electroplating will be significantly improved.
To sum up, the process loss rate of vacuum electroplating process is the result of the comprehensive superposition of many factors. Pay attention to the mass production of products from the source. Factors such as product design and development, quality standard formulation, fixture design, and minimum purchase quantity will affect the process yield of electroplating manufacturers. Improving the yield rate and reducing the wastage rate is the eternal pursuit of upstream and downstream employees in the manufacturing industry. Let us work together and make progress together!
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