CN104995325A - 表面涂覆钢板及其生产方法 - Google Patents

表面涂覆钢板及其生产方法 Download PDF

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CN104995325A
CN104995325A CN201380072653.4A CN201380072653A CN104995325A CN 104995325 A CN104995325 A CN 104995325A CN 201380072653 A CN201380072653 A CN 201380072653A CN 104995325 A CN104995325 A CN 104995325A
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layer
steel plate
metal level
metal layer
anticorrosive
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托尔斯滕·伯格尔
彼得·克劳克
阿纳斯塔西娅·许斯勒
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ThyssenKrupp Steel Europe AG
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/012—Layered products comprising a layer of metal all layers being exclusively metallic one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
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Abstract

本发明涉及由具有涂层的碳钢制造的表面成品钢板，该涂层是由至少一个金属防腐蚀层(1.1)和被施加有粘结到金属防腐蚀层的材料的至少一个另外的层(1.2)形成的。为了使这种钢板无需提供有机颜料的油漆涂料，为了传达高品质的外观并且也为了具有很高的抗紫外线，根据本发明的至少一个另外的层(1.2)是金属层或者是由金属层形成的，其中，该金属层(1.2)是基于不锈钢、含铬和/或含镍的合金、铜和/或铜合金。所述至少一个附加金属层(1.2)可以任选地被设置有透明层(1.3)。用于制造这样的表面成品钢板的方法也被描述并被请求保护。

Description

表面涂覆钢板及其生产方法
技术领域
本发明涉及由碳钢构成的表面涂层钢板并且具有涂层，该涂层是由至少一个金属防腐蚀层和被施加有粘结到金属防腐蚀层的材料的至少一个额外层。本发明进一步地涉及表面涂层钢板的生产工艺，其中至少一个金属防防腐蚀层被施加有粘结到由碳钢构成的板状产品的材料并且至少一个额外层被施加有粘合到至少一个金属防腐蚀层的材料。
背景技术
由于耐腐蚀性差，未涂覆的碳钢通常由锌涂层来防止腐蚀。为美观起见，通常为多层、着色的有机表面涂层被随后施加并且这进一步增加了耐腐蚀性。然而，化学物质存在于表面涂层系统和引物里，以确保抗抗腐蚀性并且该表面涂层的粘合性有时危害健康和环境，因为它们通常包括重金属如镍、Cr6和Cr3。
另外，着色的有机表面涂层遭受当暴露于强烈紫外光时它们或多或少很快变得漂白的问题。
作为镀锌碳钢板的替代品，也有不生锈的(non-rusting)不锈钢和铜板可用，但这些相对昂贵。在一般情况下，特别是不锈钢是相对昂贵的材料，由于其金属合金元素如铬、钛和镍。
WO 2012/030726 A1描述了碳钢构成的镀锌钢板，其意图是模仿不生锈的不锈钢板。为此目的，钢板的锌层被挤压并且纹理化，其纹理具有在从0.127至1.524微米(＝5至60微英寸)范围内的表面粗糙度。镀锌且纹理化的碳钢板还具有有机涂层，该有机涂层是额外的腐蚀保护并且通过该有机涂层，所述金属板的外观可根据其最终用途而变化。有机涂层可以由透明聚酯薄膜构成，其具有特别是是抗指纹的功能。然而，这种镀锌且纹理化的钢板就其美观效果而言是相当不理想的。
发明内容
本发明的目的是提供在开篇提及的钢板，其无需着色的有机表面涂层可以提供就美学效果而言的高品质外观，并且另外地具有非常高的抗紫外特性。
这个目的通过具有权利要求1特征的表面涂覆钢板和具有权利要求8特征的用于生产表面涂覆钢板的方法实现。本发明的钢板及其生产方法的优选且有利的实施例在从属权利要求中加以说明。
本发明的钢板是由碳钢制成并且被设置有涂层，该涂层是由至少一个金属防腐蚀层和被施加材料地结合到金属防腐蚀层的至少一个另外的层组成，其中所述至少一个另外的层是金属层或者是由金属层形成的，并且该金属层基于不生锈的不锈钢、铬和/或含镍合金、铜和/或铜合金。
本发明的方法相应的特征在于至少一个金属防腐蚀层被施加被粘合到由碳钢构成的板状产品的材料，并且至少一个金属层被施加作为另一层的被结合到防腐蚀层的材料，其中，该金属层是基于不生锈的不锈钢、铬和/或含镍合金，铜和/或铜合金。
本发明的优点是通过另一金属层所产生的颜色或美学效果。其结果是，复杂的表面涂覆系统，其经常含有对环境和健康有害的物质，可以被省略并且与此同时非常高的抗紫外线性能得以实现。具体地，看起来像常规的单层、不生锈的不锈钢板或铜板，并且适合于广泛的用途例如在建造和建筑、车辆构造、造船、在家具行业、家用电器工业和/或娱乐电子的板状材料可以通过施加不生锈的不锈钢、铜、或铬、镍和/或含铜合金到被设置有至少一个金属防腐蚀层的碳钢板而被提供。例如，用于楼宇外墙的覆盖件、轨道、盖板、模板件、厨房电器的壳体、蒸汽抽气罩壳体、卫浴用具、装饰件和具有设计要求的壳体和外壳可以由本发明的表面涂覆钢板进行制造。例如，黄铜或青铜层可以在镀锌碳钢板通过施加根据本发明的铜合金进行制造。与相应的不锈钢或铜板相比，即由不生锈的不锈钢或铜制造的单层板，本发明的钢板不仅提供成本优势，而且由于作为支撑件的钢板而改进机械稳定性也是可能的。此外，该至少一个金属防腐蚀层特别是保证了本发明的钢板的高耐腐蚀性。此外，锡(Sn)或含锡的铜合金的应用使得实现高耐腐蚀性的青铜合金作为在金属腐蚀层上的进一步金属层也是可能的。
由碳钢制成的板的厚度是例如在从0.05至30mm的范围，优选从0.5至5毫米的范围。
本发明的钢板的至少一个金属防腐蚀层优选基于锌和/或铝的防腐蚀层，例如锌(Z)、电解锌(ZE)、锌铝(ZA)、铝锌(AZ)、热浸镀铝(FAL)或锌镁(ZM)类型的防腐蚀层。该防腐蚀层被施加到通过熔融浸渍处理或电解处理的由碳钢制成的板材。它确保该板材一侧或两侧(宽面)的至少抗腐蚀性。然而，本发明的钢板的防腐蚀优选地也可以延伸到(被剪切)的边缘，其特别是在锌基涂层的情况下能够实现。
该至少一个金属层优选通过化学或物理气相沉积被施加到金属防腐蚀层。沉积优选在减压、惰性气体(例如氩气)或在反应性气氛(例如氧或空气)下进行，伴随着金属、金属氧化物、金属碳化物和/或金属氮化物层被沉积在金属防腐蚀层。被施加到防腐蚀层的金属层也可以具有多层结构。该至少一个金属层优选地以从1纳米到10微米范围内的厚度，特别优选在50至200纳米范围内的厚度，被施加到金属防腐蚀层。
在本发明的工艺方法中，从气相的物理沉积可以在真空条件下和/或具有另外的惰性气体，优选氩气下进行。另一方面，化学气相沉积在反应性气氛下例如除了氧气或空气外的氧化性条件下进行。在这种方式中，防腐蚀层上的一个或更多金属氧化物层的沉积可以被实现。这在被涂覆材料的耐腐蚀性，特别是对于所参与的金属和化合物的电化学序列(electrochemical series)，特别是当锌和不锈钢都存在时可以是有利的。
本发明的另一优选实施例的特征在于在施加至少一个另外的金属层之前，至少一个金属防腐蚀层被纹理化。纹理化是在宏观和/或微观范围内实施的，例如通过压花图案、敷料、刷涂或类似方式。在纹理化之，至少一个另外的金属层随后被施加。纹理可以改善或增强所需的光学效果。例如，拉丝不锈钢或铜板的特定图案或外观可以以这种方式来产生。
本发明的进一步优选的实施方案包括将至少一个透明层施加到至少一个另外的金属层。在目前情况下，术语透明层包括半透明层，特别是透视的着色层，例如赋予不锈钢的透明层产生淡蓝色壳体或淡红色壳体的设计效果。透明层可以特别是基于例如有机涂层材料的透明清漆或抗指纹涂层。此外，本发明的钢板的抗腐蚀可以通过这个可选的透明(或半透明)层被进一步地改善。
附图说明
本发明在示出了一些示例性实施例的辅助下在下文进行描述。该图示意性地示出：
图1示出用于实施本发明工艺的装置；
图2以截面图的方式示出了根据本发明的表面涂覆钢板的部分；以及
图3同样以截面图的方式示出了本发明的进一步示例性实施方式的表面涂覆钢板的部分。
具体实施方式
用于由碳钢(C型钢)组成的钢板进行表面涂布的系统在图1中示出。根据本发明的待涂覆的由C型钢组成的该板状产品1具有例如以下化学组分：
碳钢作为钢圈2优选被供给给钢厂。带状的C型钢1的厚度是例如在0.05mm到30mm的范围内。带状的C型钢片1在热和/或冷轧3之后进行第一表面涂覆，该涂层用于宽面的防腐蚀并且，取决于该涂覆系统，也用于钢带1的边缘。该表面涂层或锌涂层可以是例如火镀锌(Z)、电解锌涂层(ZE)、锌-铝涂层(ZA)、铝锌涂层(AZ)，火铝涂层(FAL)或锌镁涂层(ZM)。
钢带1优选在热镀工厂4里在其两侧被被涂覆锌或者被设置有防腐蚀涂层。钢带1在隧道炉5里预先被加热。6代表汽提装置(stripping devices)，例如吹塑喷嘴，通过该汽提装置，过量的腐蚀保护材料或镀锌材料被从钢带1上移除并且该金属防腐蚀层的理想厚度被设定。
至少一个另外的金属层随后通过第二表面涂层工艺被施加到设置有金属防腐蚀层的钢带1'的至少一个侧面，该金属层是基于不生锈的不锈钢、铬或含镍合金和/或铜合金。所述至少一个另外的金属层优选通过物理气相沉积(PVD)或化学气相沉积(CVD)被施加到防腐蚀钢带。该层厚度在1纳米到10微米的范围内，优选在50至200纳米的范围内。该另外的金属层也可以以一些子层的方式被施加到防腐蚀层。用于施加较薄的进一步金属层或用于执行蒸汽沉积的装置被表示为在图1中标记7。
该薄的进一步金属层的蒸汽沉积优选在真空条件下或具有惰性气体优选氩气引入下进行。在此，被施加到防腐蚀层的金属被转换成气态并冷凝在所述防腐蚀层上。为了转化金属为气态，例如其被加热直到它以合适的汽化速率蒸发。为了施加高品质的且非常均匀的金属层到防腐蚀层上，汽化器与待涂覆的基板1'之间的距离对于材料而言尽可能地自由是有利的，由于这个原因，沉积优选在真空条件下进行。除了热作用汽化器或者作为其的替代，要被施加到防腐蚀层的金属还可以通过离子轰击的方式产生气相。在该物理涂覆方法(也称为溅射沉积)中，要被施加的金属的块体8表面上颗粒，被称为靶材，通过离子轰击的方式被原子化并且由此从块体表面上被烧蚀出来。以这种方式所形成的气态金属随后被输送到已经被涂有防腐蚀层的钢板1'并且在那里被涂敷并且被冷凝。
作为减压下操作的替代，金属氧化物层的汽相沉积也可以在反应性气氛下特别是在引入氧气或空气的氧化条件下进行。这使得被涂覆的C型钢的抗腐蚀性的优点能够被实现，特别是参与的金属和化合物的电化学系列，特别是在锌和不锈钢存在时。
在上述方法之一中，已涂有防腐蚀层钢板1'根据本发明的被提供有至少一个另外的金属、金属氧化物、金属碳化物和/或金属氮化物层，其给钢板1'带来例如类似于不锈钢的外观的高品质外观。
作为附加的防腐蚀层，至少一个透明层可以随后被施加。这个透明层优选由有机涂层材料形成，例如透明清漆。该透明层也可以执行除了额外的防腐蚀功能外的防指纹功能。所述至少一个透明层的应用例如通过油漆转印辊9或喷嘴装置来实现。此外，该透明层也可以具有轻微的色调，例如具有淡的蓝色、红色绿色或黄色壳体，以便它任选还具有设计功能。
在至少一个另外的金属层生产或沉积以及至少一个透明层的可选的应用之后，该表面涂覆的钢带被卷绕起来以形成钢圈10或通过切割装置11切割为具有特定长度的多个板12。
在本发明的优选实施方案中，由不生锈的不锈钢构成的进一步的金属层被施加到由C型钢制造的板状制品的金属防腐蚀层。这可以例如使用合适的不锈钢(例如1.4301合金类型的)作为靶材8通过物理气相沉积来实现。作为替代地或另外地方案，也可以使用铬和/或含镍合金，被称为镍基合金，例如镍-铜、镍-铁、镍-铁-铬、镍-铬、镍-钼、镍-铬-钴和/或低合金的镍合金作为靶材8在物理气相沉积中以形成至少一个另外的金属层。当这样的靶材8被使用时，已涂有防腐蚀层的C型钢板1'被赋予不生锈的不锈钢板的外观或者类似于不锈钢的外观。
在本发明的另一个优选的实施方案中，由铜或铜合金构成的另外的金属层通过蒸汽沉积被施加到C型钢基板1'的金属防腐蚀层。装饰性铜、黄铜或青铜层通过使用铜或铜合金进行制造。含锡(Sn)的铜合金的使用使得高耐腐蚀性的青铜合金能够被沉积在C型钢基板1'的金属防腐蚀层的表面上。
在防腐蚀层施加后，被涂布的钢板1'的表面可以在宏观和/或微观范围里以压花、图案等方式被额外地纹理化。例如，至少一个敷料辊13和/或刷子装置被用于此目的。任选的另外的纹理化使得本发明的钢板的光学外观得到提高，例如拉丝不锈钢板的光学外观可以被特别密切仿制。
图2示出了根据本发明的钢板的截面，其具有由被设置在两侧上的C型钢制造的支撑层1，具有金属防腐蚀层1.1。该支撑层1的厚度例如在从0.05至30毫米，特别是在从0.1到3毫米的范围。该防腐蚀层1.1优选地是基于锌和/或铝的金属层。进一步的金属层1.2被施加有粘合到防腐蚀层1.1中的至少一个上的材料。该金属层1.2是基于不生锈的不锈钢、铜、铬和/或含镍合金和/或铜合金。高金属层1.2比较薄，其厚度在从约1纳米至10微米的范围内，优选在50至200纳米的范围内。该金属层1.2可选地设有透明的有机层1.3，例如透明清漆的稍微着色的透明层或防指纹涂料。
在图3中所示的本发明的钢板的示例性实施例不同于图2中所示的示例性实施例在于，在进一步的金属层1.2和可选的透明层1.3施加之前，该防腐蚀层1.1已经以浮雕(emboss ing)或小的突出区域1.4的方式被设置有表面纹理。该表面纹理也被复制到金属层1.2和可选的透明层1.3里。
然而，透明层1.3也可以作为透明清漆或半透明着色涂料被施加到结构化的金属层1.2。随后该结构基本上仅在涂层内呈现。在这种情况下，已完工的表面被涂覆的钢板从而在其面向纹理的一侧山具有基本上平坦的或光滑的表面，这从避免污垢沉积在钢板上的角度上看是有利的。
本发明并非被限定于附图所示的示例性实施方案。相反，设想利用在所附权利要求中限定的发明的甚至是不同于所描述的示例性实施例的许多变体是可能的。因此，本发明的碳钢板1例如也可以在具有由不生锈的不锈钢、铜、铬和/或含镍合金和/或铜合金构成的层1.2的两侧上进行涂覆。

Claims (14)

1.一种表面涂覆钢板，其由碳钢构成并且具有涂层，该涂层是由至少一种金属防腐蚀层(1.1)和被施加有粘结到该金属防腐蚀层的材料的至少一个另外的层(1.2)构成，其特征在于，所述至少一个另外的层(1.2)是金属层或者是由金属层形成的，其中，该金属层(1.2)是基于不生锈的不锈钢、铬和/或含镍合金、铜和/或铜合金形成的。
2.根据权利要求1所述的表面涂覆钢板，其特征在于，至少一个另外的金属层(1.2)通过化学或物理气相沉积已经被施加到金属防腐蚀层。
3.根据权利要求1或2所述的表面涂覆钢板，其特征在于，所述至少一个另外的金属层(1.2)具有在1纳米到10微米，优选50至200纳米范围内的厚度。
4.根据权利要求1至3中任意一项所述的表面涂覆钢板，其特征在于，所述至少一个金属防腐蚀层(1.1)被纹理化。
5.根据权利要求1至4中任意一项所述的表面涂覆钢板，其特征在于，至少一个透明层(1.3)已经被施加到所述至少一个另外的金属层(1.2)。
6.根据权利要求1至5中任意一项所述的表面涂覆钢板，其特征在于，所述至少一个金属防腐蚀层(1.1)是基于锌和/或铝的防腐蚀层。
7.根据权利要求1至6中任意一项所述的表面涂覆钢板，其特征在于，所述至少一个金属防腐蚀层(1.1)通过热浸工艺或者电解工艺已经被施加到由碳钢构成的钢板。
8.一种用于生产表面涂覆钢板的方法，其中至少一个金属防腐蚀层(1.1)被施加有粘结到由碳钢构成的板状产品(1)的材料，并且至少一个另外的层(1.2)被施加有粘结到所述至少一个金属防腐蚀层的材料，其特征在于，至少一个金属层被施加有粘结到所述至少一个金属防腐蚀层(1.1)的材料以作为另外的层(1.2)，其中，该金属层(1.2)是基于不生锈的不锈钢、铬和/或含镍合金、铜和/或铜合金。
9.根据权利要求8所述的方法，其特征在于，所述至少一个金属层(1.2)通过化学或物理气相沉积被施加到所述金属防腐蚀层(1.1)。
10.根据权利要求8或9所述的方法，其特征在于，所述至少一个金属层(1.2)以在1纳米至10微米，优选50至200纳米范围内的厚度被施加到所述金属防腐蚀层(1.1)。
11.根据权利要求8至10中任意一项所述的方法，其特征在于，所述至少一个金属防腐蚀层(1.1)被纹理化。
12.根据权利要求8至11中任意一项所述的方法，其特征在于，所述至少一个透明层(1.3)被施加到所述至少一个另外的金属层(1.2)。
13.根据权利要求8至12中任意一项所述的方法，其特征在于，所述至少一个金属防腐蚀层(1.1)是基于锌和/或铝的防腐蚀层。
14.根据权利要求8至13中任意一项所述的方法，其特征在于，所述防腐蚀层通过热浸镀工艺或电解工艺被施加到由碳钢构成的板状产品。
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