CN101203328A - 涂料涂布或漆涂布可卷绕金属片材的设备和方法 - Google Patents

涂料涂布或漆涂布可卷绕金属片材的设备和方法 Download PDF

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CN101203328A
CN101203328A CNA2006800200251A CN200680020025A CN101203328A CN 101203328 A CN101203328 A CN 101203328A CN A2006800200251 A CNA2006800200251 A CN A2006800200251A CN 200680020025 A CN200680020025 A CN 200680020025A CN 101203328 A CN101203328 A CN 101203328A
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凯·K·O·巴尔
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Abstract

公开了一种涂料涂布或漆涂布可卷绕金属片材(106)的设备。所述设备正好包含一个有效地分配给第二卷轴座的驱动单元，基本上没有其它影响金属片材操作性能的装置。

Description

涂料涂布或漆涂布可卷绕金属片材的设备和方法
本发明涉及根据权利要求1或2的用于用涂料或漆涂布可卷绕、类似无端的金属表面部件的装置，以及根据权利要求11的相应方法。
类似无端的涂布的金属片材，尤其是钢板和铝板，大量加工用于汽车工业和制造家用电器(所谓的“白色家电”)，还用于制造航空和水运交通工具以及建筑物板材。钢板主要是金属裸露的、镀锌的或镀镍的片材，其厚度值为十分之几毫米到超过一毫米。作为用于随后漆涂布或塑料涂布的预处理，已经对这种卷绕片材(“卷材”)施涂了防腐蚀涂层和/或底漆。
这种涂层大多数在液态下涂布，偶尔也作为粉末涂层施涂，并且必须在施涂后以合理的方式干燥或交联以获得固体涂层。为此目的，已知的是将片材感应加热至约250℃或大于250℃的温度，由此所述涂层也被加热至200℃以上并因此干燥或交联。
这种方法需要大量能量，因为不仅主要的实际加工对象，即所施涂的涂层被加热，而且根本不需要加热的片材本身也被加热。相反地，片材的加热在某些情况下甚至不利，因为其可能改变在先前步骤中经过谨慎调整的热工艺而设定的片材的特定物理性质。就非常多吨的以这种方式干燥的已涂布片材而言，对金属片材的不必要加热造成的能量损失在国民经济中已经占相当比重。
已知方法的另一值得考虑的缺点在于，感应加热段的高生产成本。总的来说，前述缺点导致如今利用所谓“卷材涂布”法加工的片材价格仍相对较高，这在对汽车工业和消费品工业供应商增加的成本压力方面的不利表现得日益明显。
已知的卷材涂布法在单位时间内供应高生产量的高质量产品。然而，已经发现在重新卷绕具有已硬化涂层的已涂布片材时，会出现某些表面缺陷，比如细小裂纹和小的缺陷，这在某些情况下会严重损害其在随后使用过程中的有效性。具有这种缺陷的条带段在进一步加工时会产生质量差的产品，在某些情况下甚至不得不报废。
申请人为此以前已经提出过，干燥或交联步骤在所谓的辐射干燥器中通过利用高功率密度的近红外范围的电磁辐射照射表面部件的已涂布表面来实现，所述电磁辐射的基本有效部分在0.8～1.5μm的波长范围内；参见DE10106890A1。由DE10027444A1已知类似的方法和合适的粉浆。
至于它们的显著优点，这种使用NIR-干燥器的卷材涂布法已经同时广泛应用于大规模的工业钢铁处理。
已知采用感应或辐射干燥的大规模工业卷材涂布法的基本缺点在于，工艺控制和车间结构要适应巨大的生产量。对应的高功率装置占据空间，并且成本昂贵，而且只有在使用率较高时才更有效。对于应消费者特定要求的小定单不能利用这种方法和装置合理实现，因为在起动阶段直到达到稳定的工艺控制期间，以及在关闭装置这段时间，产生大量片材废料。由于批量很小，这更增加了本来已经很高的生产成本。
因此，本发明的目的是，提供基本改善了对小批量的适宜性的符合其类型的设备和符合其类型的方法，尤其是还可以直接在所述已涂布片材的消费者的住所处使用。
所述目的从设备角度，通过具有权利要求1和2的技术特征的设备实现，从方法角度，通过具有权利要求7的技术特征的方法来实现。相应从属权利要求的主题是本发明构思的有利改进。
本发明的基本考虑是使用结构和操作原理根据小批量加工进行调整的卷材涂布设备，尤其是在消费者住所处现场使用的设备。因此，根据本发明的基本观点提供结构紧凑的且轻便的装置，其不用长时间的起动或关闭阶段(在该阶段不输送有用产品)。
采用这种方案，即使少量的使用不同涂层材料的、不同颜色的表面部件也可以低成本地、以较快的施涂顺序、低的废品率和(由于所建议装置的相对低的制造成本导致的)低成本生产。例如，加工大约为20m卷材长度的定单，产生5m或更少的废卷材长度(达到工艺参数稳定的产量)。
根据本发明的第一个独立方面，在卷轴座上正好提供一个驱动器，并且实际上完全省去了影响操作性能的其它装置(幅面张力调节器等)，这使得结构紧凑。如果所述系统在输出端具有卷轴座，那么优选将所述驱动器分配给它。
根据本发明的其它基本的、相对独立的方面，所述系统作为相关联的可吊运组件(crane-capable block)构造在同一个承重结构上。因此，保证了快速和容易地将已涂布的片材或其它表面部件(格栅、网等)提供给消费者。
所述组件的外部尺寸优选为最大等于30英尺至50英尺的标准容器的外部尺寸。这确保了通过公路或铁路在相应的标准容器中的“整体”运送能力，以及在使用地点节约空间的装配。
所述紧凑结构基本上可以如下实现：辐射干燥器具有多个辐射体，其主要的有效部分在近红外或UV范围内，并且其尺寸在任何情况下在表面部件运送方向上小于5m，优选为500～2000mm，尤其是700～1500mm。另外的优点(结合适当的操作方式)是，随后安置的冷却段的特别紧凑的设计，尤其是高效率的水冷却段。
辐射干燥器的特别紧凑的结构基本上也可以如下实现：所述辐射干燥器在有效的水或空气冷却的整体反射器外壳内包含在2900K或更高的辐射器温度下工作的卤素灯丝灯和/或UV中压或高压灯。因此，合适的是使安置内部冷却流体通道的实心金属反射器的水冷却以适当方式与置于后面冷却段中的水冷却连接。与此组合，或者作为替代在特定操作条件下，可以采用空气进行反射器和辐射源(或尤其灯的末端)的冷却。还可以如此设计这种空气供给，使得其同时也用于排出涂层的溶剂组分。
特别有利的是，(根据本发明的其它相对独立方面)所述装置包含正好的一个用于操作能量和介质的介质接口，尤其是正好的一个电源电压接口和正好的一个清水(fresh water)接口。尤其是在可吊运容器设计的情况下，根据空间条件，在预期的操作位置，可以在容器壁上安置能量接口和介质接口，当然也可以采取其它构造。就此而论，要点是向所述设备内各个施用点的供给通过一个中心分配器进行，以便尽可能在操作位置只需要一个接口。
所提出的构造灵活适应不同的使用条件和要求，并且可以容易地以模块方式引入其它组分或替代组分。因此，对于需要迅速改变涂料种类或颜色的应用，可以提供第二涂布器，或者可以提供底漆涂布装置或其它预处理装置。可以在输出端集成用于所述已涂布和干燥的片材的后处理装置和/或不同类型的收集装置。
根据本发明的方法的特征在于涂布和干燥步骤的控制，其在表面部件输送开始和结束的时间制度方面明显不同于大规模工程卷材涂布法中涂布和干燥步骤的控制：在传统方法中，当片材基本达到预定的标称速度时才开始实施涂布和干燥步骤，而在根据本发明的方法中已经预先进行了涂布和干燥步骤，尤其是在达到标称速度的预定分率时自动进行。
一个优选的工艺控制的特征在于，将标称速度设定为3～30m/min，尤其是5～20m/min。这种运送速度大大低于工业装置的速度，然而，对于本发明的方案所针对的相对小的定单量来说足够了。低速度有助于使得可以进行不同的(和简化的)工艺，并且使得未涂布的或错误涂布的片材的废品率非常低。
一个优选的变化方案中，涂料涂布或漆涂布和干燥在过程开始后10秒内、优选5秒内起动。此外有利的是，在所提出的方案中，同时起动或停止涂料涂布或漆涂布和干燥，和/或在起动和停止之间在涂料或漆涂布工艺和干燥过程中没有其它主要的控制干扰。然而，在工业装置中，相应的控制命令通常由有资格和有经验的操作人员发出，所提出方法的简化控制还可以由不太有资格操作者来实现，并且操作者还能够同时完成其它任务。
本发明的优点和实用性另外在从属权利要求中和后面参照附图对两个优选变化方案的描述中给出。在图1和2中，分别以纵向剖面的方式示出根据本发明的设备实施方案的原理草图。
图1示出卷材涂布设备100，在同一个载板101上包括：用于待涂布板106的输入端卷105的第一输入端卷轴座103；辊式涂布器107；NIR干燥器109；水冷却单元111；以及用于已涂布片材的卷115的输出端持有物的第二输出端卷轴座113，和分配给第二卷轴座113的用于运送片材的驱动器(未显示)。总体上，所述设备是便携的，因为所有部件共同安装在载板101上。第一卷轴座103和第二卷轴座113之间的轴距l约10m，具体而言这通过NIR干燥器109的短的干燥器长度lT实现，总体上使得所述设备可以完整地安装在40英尺的标准容器中并通过铁路或公路运送到使用地点。
图1A示意性示出设备100的这种容器的变型，其中在此没有标出上面已提到的设备部件并且不再进行说明。设备100置于容器117中，在图中示出了底面117a，后壁117b，顶部封闭墙(顶篷)117c以及前门117d和后门117e。底面或安装板117a在部分长度上作为容纳介质基础结构的假底117f。
在面对操作者的一侧(在图中为前侧)，在涂布器107以及NIR干燥器109区域中设置观察窗119a或119b。在设备的相应区域上方，设置进气和出气处理单元121a、121b，它们通过进气和出气口(没有单独标出)与大气连接。所有基础结构接口都可以经过中央连接单元，所述中央连接单元连接至容器外部，例如在其后壁上，不能从图中辨别出来。另外，可以在平台上作为额外的单元设置用于指定的废气处理单元的电源和/或气体源以及废气处理单元本身。
图2示出另一结构紧凑的卷材涂布系统200，它具有与图1中系统100类似的结构。一致的部分基于图1的附图标记标明并且不再进行说明。主要区别在于，此处出口端没有(第二)卷轴座，而是具有转向单元214(只象征性地示出)，随后是片材剪切器216和用来容纳切割成尺寸206′的片材的堆放单元218。这些部件没有安置在同一个载板201上，而是在现场额外配置给所述装置。这使得基于上述尺寸，甚至可以在30英尺容器内容纳安置在载板201上的部件。
所提出的设备在垂直方向上的扩展不仅可以像图2中所示的变化方案那样，包括凹进到底面的额外设备，而且可以采用双层设计，这在实践中可以通过将一个容器放在另一个容器上面来实现，每个容器包含整体设备的一部分，例如第一个容器包含输入端卷轴座、第一涂布器(例如用于底漆的)和第一干燥段，第二个容器包含第二涂布器(例如用于面漆的)、指定的第二干燥段和输出端卷轴座或具有板储槽的切割单元等。
另外，在所述设备的基本构造中，可以故意安置可能以后插入的额外部件，例如额外的UV干燥器或用于(未涂布或已涂布的)卷材的机械加工单元。
应该注意，在本发明范围内，可以对上述实施例和方法方面做出各种修改，而不偏离本发明的保护范围。

Claims (19)

1.一种用涂料或漆涂布可卷绕、类似无端的表面部件，尤其是金属片材的设备，所述设备包括：
第一卷轴座，用于使第一所述表面部件的卷的输入端持有物转动，
位于所述第一卷轴座下游的涂布器，用于将所述涂料或漆施涂于所述表面部件上，
位于所述涂布器下游的辐射干燥器，用于在所述表面部件通过时干燥所述涂层，
位于所述辐射干燥器下游的第二卷轴座，用于使具有所述经干燥的涂料或漆涂层的第二所述表面部件的卷的输出端持有物转动，或者切割和堆放单元，用于切割和堆放具有经干燥的涂料或漆涂层的所述表面部件，和
至少一个驱动器，用于将所述表面部件以预定速度运送通过所述设备，
其特征在于，所述设备正好包含一个就其效果而言分配给所述第一或第二卷轴座的驱动器，其中基本上没有设置其它影响所述表面部件操作性能的装置。
2.一种用涂料或漆涂布可卷绕、类似无端的表面部件，尤其金属片材的设备，所述设备包括
第一卷轴座，用于使第一所述表面部件的卷的输入端持有物转动，
位于所述第一卷轴座下游的涂布器，用于将所述涂料或漆施涂于所述表面部件上，
位于所述涂布器下游的辐射干燥器，用于在所述表面部件通过时干燥所述涂层，
位于所述辐射干燥器下游的第二卷轴座，用于使具有所述经干燥的涂料或漆涂层的第二所述表面部件的卷的输出端持有物转动，或者切割和堆放单元，用于切割和堆放具有经干燥的涂料或漆涂层的所述表面部件，和
至少一个驱动器，用于将所述表面部件以预定速度运送通过所述设备，
其特征在于，所述组成部分的至少大多数作为相关联的可吊运组件构造在同一个承重结构上。
3.根据权利要求2的设备，其特征在于，所述组件的外部尺寸最大等于50英尺标准容器、尤其是30英尺标准容器的外部尺寸。
4.根据前述权利要求任一项的设备，其特征在于，所述辐射干燥器具有许多辐射体，其主要的有效辐射部分位于近红外或UV范围内，并且其在所述表面部件的所述运送方向上的尺寸为500～2000mm，尤其是700～1500mm。
5.根据权利要求4的设备，其特征在于，所述辐射干燥器在有效的水或空气冷却的整体反射器外壳内包含发射近红外范围内的射线的发射器，尤其是在2900K或更高的辐射器温度下工作的卤素灯丝灯，和/或发射UV范围内的射线的发射器，尤其是UV中压或高压灯。
6.根据前述权利要求任一项的设备，其特征在于，正好有一个介质接口用于操作能量和介质，尤其是正好有一个电源电压接口以及正好有一个清水接口。
7.根据前述权利要求任一项的设备，其特征在于，双层结构具有用于将所述卷从第一层运送到第二层的转向单元，尤其是用于使所述运送方向反转的转向单元。
8.根据前述权利要求任一项的设备，其特征在于，两个或多个前后排列的可选择性操作的涂布器，可以选择性地与单个辐射干燥器一起工作。
9.根据前述权利要求任一项的设备，其特征在于，两个或多个涂布器/辐射干燥器组合在所述运送方向上至少间接连续。
10.根据权利要求9的设备，其特征在于，所述辐射干燥器中至少一个装配有发射近红外范围射线的发射器，并且其它的装配有发射UV范围射线的发射器。
11.一种用于用涂料或漆涂布可卷绕、类似无端的表面部件，尤其是金属片材的方法，其中所述表面部件从第一个卷上抽出，并卷绕到第二个卷上或者被送到切割和堆放单元，其间，在所述表面部件通行过程中，为所述表面部件提供涂料或漆涂层并通过电磁辐射干燥，
其特征在于，在所述表面部件达到预定的恒定标称速度之前，开始所述方法，起动涂料或漆的涂布和干燥，和/或
在驱动器已关闭并且所述表面部件的所述速度已降至所述标称速度以下之后，结束所述方法，停止涂料或漆的涂布和干燥。
12.根据权利要求11的方法，其特征在于，在所述方法已开始之后10秒内、优选5秒内起动涂料或漆的涂布和干燥。
13.根据权利要求11或12的方法，其特征在于，同时起动或停止涂料或漆的涂布和干燥。
14.根据权利要求13的方法，其特征在于，在起动和停止之间，在涂料或漆的涂布和干燥中没有其它主要的控制干扰。
15.根据权利要求11～14任一项的方法，其特征在于，涂料或漆的涂布和干燥响应于对所述表面部件的所述实际速度达到其标称速度的预定分率的检测而自动起动。
16.根据权利要求11～15任一项的方法，其特征在于，标称速度设定为3～30m/min，尤其是5～20m/min。
17.根据权利要求11～16任一项的方法，其特征在于，通过分别的涂布器，将多种任选涂层中的一种选择性施涂到所述表面部件上，其中所有任选的涂层在同一干燥区域内干燥。
18.根据权利要求11～17任一项的方法，其特征在于，在所述表面部件上相继施涂至少两种涂层，并且其中每种涂层利用根据所述涂层材料的性质调整的干燥参数、尤其是利用经过调整的辐射波长来干燥或硬化。
19.根据权利要求18的方法，其特征在于，所述涂层中的一种利用近红外范围内的射线干燥或硬化，而其它涂层利用UV范围内的射线干燥或硬化。
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