Technical Bulletin IG018 Quanex Building Products

Transcription

1 Systems Unit Testing and QC Procedures for Dura Flexible Spacers Quality Control Tests I. Dew Point Determination for Flexible Spacer IG Units II. Quick Test or Ice Cube Test III. V-45 Initial Adhesion Test IV. Slosh Test I. Dew Point Determination for Flexible Spacer IG Units This Quality Control Test is conducted to ensure that the desiccant in the Flexible Spacer is active and capable of drying the hermetically sealed air space within the IG unit. Purpose: To measure the rate at which spacer desiccates a standard sized airspace. Required Materials 2 pieces of clean, dry clear float glass 5 (127mm) square Dew point apparatus. See Figure 1. A thermometer with a range of at least +32 to -100 F (0 to -73 C) Dry ice (solid carbon dioxide) -- powdered or pulverized Isopropyl alcohol A timing device with second indicating capability A sample of Flexible Spacer just removed from its packaging container. Procedure 1. Using the two small lites of clean, dry clear float glass and the Flexible Spacer sample, assemble a small IG unit. Compress the unit and seal the final corner. 2. Age the sample unit for 2 hours at 77 F (25 C). 3. Prepare the dew point apparatus with isopropyl alcohol and dry ice, and adjust the system to 0 F (-18 C). 4. Apply a film of alcohol to one face of the sample unit, and then place the brass section of the dew point apparatus in contact with this face for 3 minutes. Maintain the dew point apparatus at the desired test temperature by the addition of more dry ice as required for this 3-minute period. Technical Bulletin IG Remove the dew point apparatus after 3 minutes and apply another film of alcohol to the dew pointed area, and as quickly as possible, view the sample from above by means of a light transmitted through the sample from beneath. If condensation or frost has formed on the second surface of the top lite of glass, then the dew point of the sample is higher/warmer than the tested temperature. See Figure 1 for a configuration of the dew point test. Continued next page...

2 Technical Bulletin IG018 Unit Testing and QC Procedures for Dura Flexible Spacers 6. Repeat steps 1 to 5, adjusting the test temperature by 10 F (5 C) up or down as required, waiting 5-10 minutes between tests or until the condensation from the previous test has flashed off. 7. Repeat parts 1 to 5 after 24 hours aging at 77 F (25 C) starting at -40 F (-40 C) and adjusting the temperature up or down as required by 10 F (5 C). Figure 1: After removing the dew point apparatus, look for condensation or frosting on the inside surface of the glass as shown. Duraseal /Duralite /Decoseal /Edgetherm FS Performance Requirements 2 hour aged sample test should have a dew point of 20 F (-7 C) or lower. 24 hour aged sample test should have a dew point of -20 F (-29 C) or lower. Microseal DS Performance Requirements 4 hour aged sample test should have a dew point of <32 F (0 C). 24 hour aged sample test should have a dew point of 14 F (-10 C) or lower. In the event that the test sample does not meet the above requirements, immediately retest this packaging 4 wraps further down in the package. If additional stock is available set aside this drum and open another drum until the retest has been completed. In the event that the retest results do not meet the requirements, your Quanex Sales Representative should be contacted and this packaging should be set aside. See Notes 1-3 Note #1: For a comparison evaluation, a dew point run on a single lite of glass would show a deposit at a temperature of 32 F (0 C). See: Flexible Spacer Desiccant Dew Point Draw Down - Quick Test - (Ice cube test) Note #2: If the test lites of glass are not fully dried or if the samples are made during a high humidity period, the 2-hour results may not pass. A retest should be started with added care taken regarding the drying of the lites of glass. Note #3: Dew Point is recorded as the last boundary at which no condensation or frost is deposited on the 2nd surface of the top lite of glass, while with a 5 F (2.5 C) drop of the test temperature, a deposit is formed. Continued next page...

3 Unit Testing and QC Procedures for Dura Flexible Spacers II. Quick Test or Ice Cube Test This test is a quicker, yet less precise means of qualifying the dew point development of an IG unit than the Dew Point Draw Down Test detailed above. It requires no dry ice or frost point device. Its purpose, however, remains the same, and is to ensure that the desiccant in the Flexible Spacer is active and capable of drying out the hermetically sealed air space. Equipment and Supplies 2 pieces of clean, dry clear float glass 5 (127 mm) square Ice cubes with at least 1 flat side Water A timing device with second indicating capability A sample of Flexible Spacer just removed from its packaging container Procedure 1. Using the two 5 (127 mm) lites of clean, dry clear float glass and the sample to be tested of Flexible Spacer, assemble a small insulating glass unit. 2. Compress the unit and seal the final corner. 3. Age the sample unit for 2 hrs. for Duraseal/Duralite/Decoseal/Edgetherm FS, 4 hrs. for Microseal DS hours at 77 F (25 C). 4. Place a small amount of water on the top lite of the small sample unit and then hold the flat side of an ice cube (32 F / 0 C) in place on the sample unit for 3 minutes. 5. Remove the ice cube after 3 minutes and apply another film of water to the dew pointed area. Then as quickly as possible, view the sample from above by means of a light transmitted through the sample from beneath. If no condensation has formed on the second surface of the top lite of glass, then the dew point draw down on this Flexible Spacer would be considered good. If condensation formed, the desiccant activity of the spacer would be in question. If condensation is observed, redo the test. Technical Bulletin IG Hold the sample unit for 24 hours and repeat the dew point test, as well as associated production. Performance Requirements After 2 hours for Duraseal/Duralite/Decoseal/Edgetherm FS or 4 hours for Microseal DS there should be no condensation formed in the sample unit. If after these times, there is condensation formed, the test should be repeated and the first sample tested again after 24 hours aging at 25 C (77 F). If after 24 hours condensation still forms, the associated Flexible Spacer should not be used. Contact your Quanex Sales Representative. Continued next page...

4 Technical Bulletin IG018 Unit Testing and QC Procedures for Dura Flexible Spacers III. V45 Initial Adhesion Test This test is conducted to ensure adequate initial adhesion between clean, dry glass and Dura Flexible Spacer s bondline sealant; general use is in detecting unplanned glass or spacer contamination prior to IG unit release. Equipment and Supplies 2 pieces of clean, dry glass minimum thickness dsb/3 mm clear float, approximately 12 (305 mm) square Sample quantity of Flexible Spacer, just removed from packaging, but conditioned to F (21-25 C). Note: filler strips approximate length 5 (130 mm) Use of the production heated glass press Glass cutter Safety glasses, safety sleeves and gloves to safely handle glass Procedure 1. Apply the 12 (305 mm) sample of Flexible Spacer on two opposite edges (a) of the clean, dry pieces of clear float glass in the fashion used in production; on the other two adjacent sides (b), use pieces shorter than the glass (approximately 5 (130mm). Reference Fig.1. Figure 1: Assemble with fill strips Figure 2: Example V-45 rotation in test 2. Place the lite of glass on top of the applied spacer and slightly press by hand to set the unit, and then compress the unit to nominal using the production press. Press to the airspace dimension specific to the spacer used, , , being sure to achieve the correct exit temperature of 110 F-120 F (43 C-49 C). Continued next page...

5 Unit Testing and QC Procedures for Dura Flexible Spacers 3. Allow the assembly to cool to 75 F (24 C) for approximately 30 minutes after exiting the press. Then, wearing safety glasses gloves, and sleeves score the top lite with glass cutter (Ref. Figure 1 score lines) then press up on the score lines to break the glass. Reference Figure 2. Slowly hinge the unit by pulling up and rotating first one half of the fractured lite, opening it to 45 over a full 5 seconds. Check the bond line for adhesion by examining the black bond line adhesive and comparing it to the photos. 4. Figure 3 Acceptable, 4 not acceptable. Note: When you perform the V-45 test you may see an approximate.050 (1.3mm) adhesion loss to the interior of the test sample. This is the Top Coat area which is not part of the test requirement. Requirement is for >50% of bondline to remain adhered, as viewed through glass. 5. Repeat the procedure with the second half of the fractured top lite, also as shown in Figure 2. Performance Requirements To meet Acceptable standards as in Figure 3: If there are areas that exhibit a bondline shown in Figure 4. Not acceptable, verify that the glass used is completely clean and dry using the slosh test # IV, below. Retest by assembling another sample. Ensure that the applicator is not touching or otherwise contaminating the bond line when the Flexible Spacer is being applied. Ensure that the glass is opened slowly to 45 utilizing the full 5 seconds. If there is a second failure in this test, place this material on hold and contact your Quanex Technologies Sales or Technical Service Representative. Passing Pattern B: >50% adhesion area remaining adhesion loss bond line Top view from outside of glass, after timed flex of 45 adhesion loss bond line Failing Pattern A: <50% adhesion area remaining Technical Bulletin IG018 Figure 3 Figure 4 Continued next page...

6 Technical Bulletin IG018 IV. Slosh Test Unit Testing and QC Procedures for Dura Flexible Spacers The Slosh Test is an indicator of the cleanliness of glass used in the production of IG units. It is imperative that glass be free of contaminants-both particulate and chemical in order to produce high quality, durable units. Any contaminant can affect the long-term adhesive properties of IG seals. Detergents can be particularly insidious; an invisible layer of glass washer detergent that remains on the glass may cause premature failure of the IG unit. Detergents dissolved in water, will froth and produce suds when the liquid is agitated. This property can be exploited to test for glass cleanliness. Conduct the following frequently, such as at the beginning of each shift for example. Equipment and Supplies 2 pieces of clean, dry clear float glass for any production size Water A small, clean jar Procedure 1. Assemble a small (14 x 20 or other convenient size) Flexible Spacer IG unit. 2. After compression, leave the final corner open, and with the IG unit stood on end, pour clean tap water into the hole until it is about ¼ (6mm) deep. 3. By manipulating the IG unit, run the water all over (i.e. rinse) both interior surfaces of the glass. The purpose is to pick up any water-soluble contaminant and detergent residues that may have been deposited on the glass surfaces. 4. Slosh the water back and forth within the IG unit in an attempt to produce froth. Alternatively, transfer the rinse water to a clean jar that is easier to shake. If desired, a second jar can be filled with an equal amount of clean tap water and used as a control. 5. Bubbles in clean water will disappear when shaking stops providing an effective comparison, while detergent froth will remain visible when the agitation is stopped. 6. Also look for water that beads very sharply like water on a freshly waxed car. This indicates that while detergent made by rinsed, there may be contaminants that increase surface energy, also preventing good adhesion. Contaminants such as silicones, oils and waxes fall into this category. V. QC Records The following QC record sheets are included as IG 018 Appendix A: Dew point development Adhesion Unit rejects in house Receiving & stock Random finished unit inspection Note: These record sheets can be requested as Excel spreadsheets that can be modified for specific account needs.

7 Appendix A - Dew Point Development Technical Bulletin IG018

8 Technical Bulletin IG018 Appendix A - QC Finished Product Inspection by Exception

9 Appendix A - Record of Flexible Spacer Deliveries Technical Bulletin IG018

10 Technical Bulletin IG018 Appendix A - Daily Inspection of Flexible Spacer IG Units

11 Unit Testing and QC Procedures for Dura Flexible Spacers Rev. # Revisions Made Rev. Date 6 Corrected Truseal to Quanex Edits to page 5 (labeled drawings and reverse placement) Edits to pages 4 and SBU to Quanex, Formatting Formatting Reissue dates & Original Document created Technical Bulletin IG018 Quanex IG Systems 800 Cochran Avenue Cambridge, OH T F