how unique is the frame of a deknudt mirror?
DESCRIPTION
Detailed survey of the different production steps a frame of a Deknudt Mirror has to go through before it can be used to assemble a decorative mirrorTRANSCRIPT
Mirror Manufactuirng
www.deknudtmirrors.com
Production of
PU frames
Mirror Manufactuirng
www.deknudtmirrors.com
Technichal info about maximum dimensions :
Size of the mould : maximum 1900 x 1200 mm
Density PU frames : +- 400 gr/dm³
Density security gates :+- 600 gr/dm³
PU frames of high density (= more than 350 gr/dm³) have the same processing possibilities as wood.
Little series are perfectly possible due to the relatively low mould cost. (depending on the size and the difficulty about 3000 - 5000 EURO).
PU frames are water resistent, can handle high and low temperatures without any problem and do not change form < == > Wood (shrinkage, swelling, bowing… wood lives)
Mirror Manufactuirng
www.deknudtmirrors.com
In house design team designs constantly new mirror models
Mirror Manufactuirng
www.deknudtmirrors.com
From an approved drawinga prototype is sculptured.Generally by hand in wood.
With the prototype a mould is made in epoxy.Both front and backside.Cfr. Waffle iron
Mirror Manufactuirng
www.deknudtmirrors.com
Opened mould irons
Cfr. Waffle irons
Step 1 : spraying loosener
(cfr. Greasing waffle iron) to prevent PU from sticking to the mould
Mirror Manufactuirng
www.deknudtmirrors.com
Step 3 : Injection of the PU foamIs injected from one side of the mould.Once the foam is coming out on the other side,the hole of the mould is slammed shut
Step 2 : close mould with a clip systemThe mould irons are shut with a clip.The expansion pressure of the PU foam would openthe mould
Mirror Manufactuirng
www.deknudtmirrors.com
Step 4 : let PU foam become hard
Depending on the design, about 15 to 20 minutesfor the PU foam to expand and harden.
During the expansion , exoterm reactions warms thePU to about 40 °C == > H2O cooling around the mould
Step 5 : Take the frame out of the mould andclean itRemove frame from mould.Clean mould for next round.
Mirror Manufactuirng
www.deknudtmirrors.com
Step 6 : stripping
PU burrs are stripped from the frame,little holes are filled, frame is cleaned for primingQuality control.
Mirror Manufactuirng
www.deknudtmirrors.com
Step 8 : Primer
Primer is sprayed on the frame.
Depending on the final decoration : ¤ in colour ¤ with glue for gold or silver leaf
Step 7 : Drying oven
PU frames are hung for at least 10 daysin an oven of about 40°C in order to drive out air and possible gasses.
Mirror Manufactuirng
www.deknudtmirrors.com
Step 9 : gold or silver leaf
Frame is covered with leafs of metal in gold, silver or cupper colour by hand
Mirror Manufactuirng
www.deknudtmirrors.com
Step 10 : Brushing off
Once covered, the frame is brushed to remove all the rest leafs and clean it up.
Mirror Manufactuirng
www.deknudtmirrors.com
Step 11 : Final decoration
Depending on the desired decoration, the gold- or silverleafed frame is finished with sand or oil patinas.
Mirror Manufactuirng
www.deknudtmirrors.com
Step 12 : After putting on a protecting varnish layer, the frames are thoroughly checked.