CN106460184A - 用于制造包装用钢带的方法和相关设备 - Google Patents

用于制造包装用钢带的方法和相关设备 Download PDF

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CN106460184A
CN106460184A CN201480078880.2A CN201480078880A CN106460184A CN 106460184 A CN106460184 A CN 106460184A CN 201480078880 A CN201480078880 A CN 201480078880A CN 106460184 A CN106460184 A CN 106460184A
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applicator roll
aqueous
roller
aforementioned
band
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CN106460184B (zh
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马蒂亚斯·斯托夫
大卫·格利赫尔
蒂埃里·马凯
纪尧姆·勒基普
蒂博·勒克莱尔
马克·弗里德里克
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ArcelorMittal SA
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Abstract

一种涂覆有钝化层的包装用钢带的连续制造方法，其中，在所述带的面中的一个面上沉积有含水钝化溶液层，该含水钝化溶液层的厚度小于3μm并且该层含水钝化溶液的粘度在20℃下小于1.5×10‑3Pa·s。沉积借助于转移辊来进行，该转移辊一方面与带接触而另一方面与涂覆辊接触，该涂覆辊的表面具有多个六边形形状的蜂窝状室，该蜂窝状室的行数为每厘米50行至200行，并且该蜂窝状室的总体积为每平方米辊表面5×10‑6m3至10×10‑6m3，所述涂覆辊通过浸渍在具有擦拭装置的槽中而被供给有含水钝化溶液并且所述带以大于或等于400m/分钟的速度移动。相关实施设备。

Description

用于制造包装用钢带的方法和相关设备
本发明涉及涂覆有钝化层的包装用钢带的连续的制造方法和使得可以实施该方法的设备。
术语“包装用钢”包括用于食品、饮料和工业非食品(例如气溶胶气体或油漆)的包装的所有基于钢的材料。
包装钢包括马口铁等，马口铁是被一层锡覆盖的具有低碳含量(通常小于0.08％)的钢。
在锡的沉积之后施加钝化层，且该钝化层使得可以限制氧化锡的形成等。可以通过沉积含水钝化溶液(例如磷化或镀铬溶液)或可溶性化合物的溶液(例如草酸钛、硫酸钛或硫酸锆)来完成钝化。首先以湿膜的形式施加沉积物，其中，溶液呈含水形式，然后使经涂覆产品干燥以获得干膜。通常通过使经涂覆带穿过装备有沿带的方向喷射热空气的喷嘴的通道来进行干燥。为了小于10nm的干钝化涂层厚度，所沉积的湿膜的厚度通常小于5μm。事实上，钝化涂层机械地弱，并且其厚度越大，内聚破裂的风险就越高。这种内聚破裂导致可能稍后施加的有机涂层(例如清漆或油漆)的分层或粘附的损失。
钝化层可以通过“喷/浸/挤压”方法来沉积，根据所述方法，待涂覆的表面通过喷涂或浸没而被设置为与含水钝化溶液接触，此后，过量的溶液借助于挤压辊来消除。该方法的缺点在于，所沉积的湿膜的厚度不取决于被设置为与带接触的溶液的量，而取决于涂布线的速度。借助于挤压辊移除的溶液的量显著地取决于带在这些辊之间行进的速度。因此，无论线的速度如何，通过这种方法都难以获得钝化层的均匀厚度。
用于沉积钝化层的另一方法包括将含水钝化溶液以由转盘产生的液滴的均匀流的形式喷涂在带上，然后借助于铺展辊(spreader roller)使钝化层平滑。该方法的优点在于，即使在线的速度变化的情况下，所沉积的湿膜的厚度仍可以通过调节由转盘喷涂的溶液的流量来保持恒定。然而，溶液的均匀铺展在很大程度上取决于液滴形成均匀液体流所需的时间以及铺展辊与带之间的接触力，其由于辊的磨损、带的平直度的变化和辊的几何形状的公差以及辊的对准而不易于控制。因此，在钝化层的厚度的均匀性方面存在对于包装应用来说不能接受的缺陷。
为了消除这些均匀性问题，可以增加由转盘喷涂的溶液的量，但是其导致湿膜的更高的平均厚度，这反过来又引起干燥问题。事实上，必须蒸发所增加的量的水，以实现钝化层的所需干燥厚度并且消除带上残留水分的存在。然后，一种可能性是通过使线减速来增大带穿过干燥装置所花费的时间，特别是对于通常以大于或等于400m/分钟的速度运行的这种类型的线来说，这造成生产率问题。另一解决方案可以是增大干燥单元的长度，但是该解决方案给线造成空间问题。另一种可能性包括增大沿带吹送的空气的温度，但是该增大导致能量消耗的增大和钝化溶液的劣化。
本发明的目的是提供一种没有上述缺点的方法。因此，本发明的目的特别是提供一种无论生产线的速度如何都允许沉积具有恒定厚度的钝化层的方法。
为此目的，本发明的目标是如权利要求1中所描述的制造方法。
该制造方法还可以包括权利要求2至10中所描述的特征，所述特征被单独地或组合地考虑。
本发明的另外的目标是一种用于实施如权利要求11中所描述的方法的设备。
该设备还可以包括权利要求12至15中所描述的特征，所述特征被单独地或组合地考虑。
下面更详细地描述本发明的附加特征和优点。
为了说明本发明，已经进行了测试，并且将通过非限制性示例、特别是参照附图来描述这些测试，在附图中：
图1示出了根据本发明的一个实施方案的用于包装用钢带的制造设备。
图2示出了根据本发明的一个实施方案的涂覆装置。
图3A和图3B是使用SIMS装置拍摄的分别使用现有技术的方法和根据本发明的方法沉积的钝化膜的照片。
图4是双重曲线图，第一曲线图示出了生产线随时间变化的速度，第二曲线图示出了湿钝化膜的随相同时间段变化的厚度。
图5是表示通过根据本发明的制造方法沉积的湿钝化膜在横向方向考虑的带的不同点处的厚度的曲线。
图1示出了沿着方向D行进穿过涂覆装置2的钢带1。带1首先穿过涂覆装置3，其目的是施加含水钝化溶液的湿膜，然后穿过干燥单元4，其目的是消除该湿膜中所含的水分。测量所沉积的湿膜厚度的装置5位于涂覆装置3和干燥单元4之间并且连接至涂覆装置3的控制单元6。
在图1中所示的实施方案中，涂覆装置3能够同时涂覆带的两个面，但是在一个替代性实施方案中，涂覆装置3可以仅由该装置的上半部3A或下半部3B构成以使得涂覆装置3仅涂覆带的单个面。
在图2中示出了涂覆装置3的上部部分3A的一个实施方案。由于下部部分3B与上部部分3A相对于带1对称，因此未描述下部部分3B。
该装置包含第一辊，其被称为转移辊7。该转移辊7一方面与带1接触而另一方面与第二辊接触，该第二辊被称为涂覆辊8。涂覆辊8与转移辊7接触且与槽9接触，槽9包含待沉积在带1上的含水钝化溶液。在图2中所示的实施方案中，槽9装备有将溶液挤压在涂覆辊8的表面上的装置10。
在制造过程期间，涂覆辊8处于旋转中并且浸渍在包含含水钝化溶液的槽9中。该水溶液的粘度与水的粘度接近，并且在20℃下小于1.5×10-3Pa·s。所讨论的溶液可以是例如硅烷、三价铬的水溶液或的水溶液。涂覆辊8可以沿顺时针方向或相反方向旋转。
根据本发明，涂覆辊8具有多个六边形的蜂窝状室，该蜂窝状室的行数为每厘米50行至200行，并且该蜂窝状室的体积为每平方米辊表面5×10-6m3至10×10-6m3，并且优选地为每平方米辊表面5×10-6m3至7×10-6m3。
涂覆辊8的这些蚀刻特征使得能够沉积所需量的含水钝化溶液以均匀地在带的整个表面上获得湿钝化膜的所需厚度。
涂覆辊8的蜂窝状室填充有含水钝化溶液。擦拭装置10使得能够确保辊8涂覆有必需量的待沉积的溶液以获得所需的湿膜厚度。该装置10可以由两个叶片构成，例如，第一叶片位于辊8进入槽9的点处并且使得能够除去由于辊8在前穿过槽9而剩下的残留水溶液，并且第二叶片位于辊8离开槽9的点处，使得能够除去过量的溶液。第一叶片可以由例如塑料制成，并且第二叶片可以由不锈钢或碳纤维制成。装置10还可以是单个叶片，例如位于辊8离开槽9的点处的由不锈钢制成的叶片。
涂覆辊8的表面可以由例如陶瓷制成，并且蜂窝状室可以借助于例如激光或机械工具来蚀刻。
在穿过槽9之后，涂覆有水溶液的涂覆辊8的表面与转移辊7接触，转移辊7沿与涂覆辊8的旋转方向相反的旋转方向被自身驱动。
转移辊7或至少其表面优选地由使得溶液的最佳转移成为可能的材料制成，溶液的最佳转移即，使溶液由于例如被制成辊或其表面的材料吸收的损失或相反地溶液在该辊的表面上的过度滑动而产生的损失最小化的转移。该材料还可以表现出耐化学腐蚀以及耐机械磨损。转移辊7由例如弹性体制成，并且优选地由氯磺化聚乙烯或制成。
涂覆辊8与转移辊7之间的接触压力必须足以将含水钝化溶液从涂覆辊8转移至转移辊7，但是该接触压力不能大到使得其引起可能导致溶液的损失以及由此溶液的非最佳转移的飞溅。两个辊7、8之间的这种压力可以例如借助于安装在涂覆辊8上的柱(未示出)来施加。施加至辊8的总力FRR优选地为1500N至3000N每米带1宽度。
在这种接触之后，用待沉积在带1上的含水钝化溶液涂覆转移辊7。
转移辊7与带1之间的接触压力不能太大(存在擦掉太多的所沉积的湿钝化溶液膜的风险)，也不能太小(存在用溶液不充分润湿带的风险)。此外，最小压力必须由辊施加在带上以补偿带中潜在的平整度缺陷。转移辊7与带1之间的该压力可以例如借助于安装在转移辊7上的至少一个柱(未示出)来施加。施加至辊7的总力FTB优选地为3000N至5000N每米带1宽度。
转移辊7和涂覆辊8的旋转速度可以与带1的位移速度同步。
在本发明的一个实施方案中，借助于厚度测量装置5来测量所沉积的钝化层的湿膜的厚度。如果所测量的厚度小于目标厚度，则增大槽9中的水溶液的浓度，反之亦然。
此外，或者在本发明的另外的实施方案中，涂覆辊8的旋转速度可以由图1中所示的控制单元6控制。该控制单元6连接至测量钝化涂层的湿膜厚度的装置5。如果厚度小于目标厚度，则增大涂覆辊8的速度，反之亦然。
厚度可以例如借助于电磁辐射仪(electromagnetic radiation gauge)来测量。这些仪表优选地尽可能靠近涂覆装置3安装，这是因为水分非常快速地从膜蒸发，这会导致测量值的显著变化。
所沉积的湿钝化膜的厚度大致小于3μm，优选地小于1.5μm。
在沉积含水钝化层的步骤之后，带经过干燥步骤。该干燥步骤借助于干燥装置4来进行。该装置4是例如装备有喷嘴的干燥通道，所述喷嘴在80℃至190℃的温度下沿经涂覆带的方向喷射空气。在优选地为80℃至150℃的温度下喷射空气并且该空气的水分含量小于15％。控制所喷射的空气的水分含量使得能够降低所用的空气的温度，这表示在用于加热空气的能量方面的节省以及在减小损坏钝化层的风险方面的优点。该控制可以例如借助于位于通道中的多个位置中的抽气喷嘴(extraction nozzle)来进行。
在该干燥阶段之后，干钝化膜的厚度通常小于15nm，优选地小于8nm。
在另一实施方案(未示出)中，带可以在干燥步骤之前经过预加热步骤而达到低于80℃的温度。该预加热步骤可以例如借助于感应加热器或红外辐射来进行。
图3A和图3B是使用二次电离质谱仪或SIMS拍摄的照片。
两张照片示出了1456水溶液在马口铁钢上的沉积。在两种情况下，线的速度、1456水溶液的浓度和干燥过程是相同的。在第一种情况下(照片3A)，1456已借助于如上所述的现有技术的转盘方法沉积。在第二种情况下(照片3B)，1456已通过根据本发明的方法沉积。
在这两张照片中，显著的是，区域越暗，1456的浓度越高以及因此所沉积的钝化涂层的厚度越高。图3A示出了试样的表面上的不均匀钝化涂层的暗区域特征，而在图3B中没有观察到此种区域。因此，根据本发明的方法使得能够获得钝化层的恒定厚度，用现有技术的方法则不然。
图4包括两个曲线图。第一曲线图示出了根据本发明的生产线随时间变化的速度。第二曲线图示出了在该线上所沉积的湿钝化膜随时间变化的厚度。
用于该测试的生产线包括允许将含水钝化溶液沉积在钢带的顶面上的涂覆装置。该涂覆装置由转移辊、涂覆辊构成，转移辊由制成，涂覆辊的表面由陶瓷制成并且包括以每厘米大约160行间隔开的多个六边形形状的蜂窝状室，蜂窝状室的总体积为每平方米辊表面7.5×10-6m3。该涂覆辊浸入包含1456水溶液的槽中，该水溶液的浓度按市售1456溶液的体积计为大约8％。槽装备有擦拭装置，该擦拭装置在该槽的入口处具有塑料叶片，在出口处具有不锈钢叶片。
如第一曲线图中所示出的，线的速度在180m/分钟至500m/分钟变化。第二曲线图示出了：不管该速度变化如何，所沉积的湿钝化膜的厚度都保持恒定在±0.3μm。所观察到的峰值对应于焊接两个连续带的步骤，且被忽略。
因此，根据本发明的方法使得能够获得钝化涂层的恒定厚度，而不管生产线的速度如何。
图5是示出了湿钝化膜在带上的不同点处的厚度的曲线图，该厚度是在带的横向方向上的不同位置中测得的。钝化膜是在与图4中所描述的条件相同的条件下沉积的1456的膜。
带的厚度在这里用每平方米表面钛的毫克来表示，这是因为1456的厚度与其按重量计的钛含量直接相关。
该曲线图表明，1456膜在干燥之前的厚度从带的一侧向另一侧在0.78mg/m2和0.88mg/m2之间变化。因此，本发明所要求保护的方法使得能够获得钝化涂层的恒定厚度，该恒定厚度为±0.15mg/m2Ti。

Claims (15)

1.一种涂覆有钝化层的包装用钢带的连续制造方法，其中，含水钝化溶液层，所述含水钝化溶液层的厚度小于3μm并且所述含水钝化溶液层的粘度在20℃下小于1.5×10-3Pa·s，其中，这种沉积借助于转移辊来进行，所述转移辊一方面与所述带接触而另一方面与第二涂覆辊接触，所述第二涂覆辊的表面具有多个六边形形状的蜂窝状室，所述蜂窝状室的行数为每厘米50行至200行，并且所述蜂窝状室的总体积为每平方米辊表面5×10-6m3至10×10-6m3，其中，所述涂覆辊通过浸入装备有擦拭装置的槽中而被供给有含水钝化溶液，并且其中，所述带以大于或等于400m/分钟的速度移动。
2.根据权利要求1所述的制造方法，其中，施加于所述涂覆辊以将所述涂覆辊设置为与所述转移辊接触的总力为每米经涂覆钢带宽度1500N至3000N。
3.根据权利要求1或2所述的制造方法，其中，施加于所述转移辊以将所述转移辊设置为与所述钢带接触的总力为每米经涂覆钢带宽度3000N至5000N。
4.根据前述权利要求中的任一项所述的制造方法，其中，所述涂覆辊与所述擦拭装置接触，从而使得在所述槽的出口处除去过量的含水钝化溶液。
5.根据前述权利要求中的任一项所述的制造方法，其中，在所述含水钝化溶液的沉积之后，使所述经涂覆带经历干燥步骤。
6.根据权利要求5所述的制造方法，其中，所述干燥步骤通过沿所述带的方向吹送空气来进行，其中，所吹送的空气具有80℃至150℃的温度和小于15％的水分含量。
7.根据权利要求5或6所述的制造方法，其中，在所述干燥阶段之前，使所述带经历预加热步骤而达到低于80℃的温度。
8.根据前述权利要求中的任一项所述的制造方法，其中，根据钝化膜在干燥之前的厚度的测量值来控制水溶液中的钝化成分的浓度。
9.根据前述权利要求中的任一项所述的制造方法，其中，所述含水钝化溶液是1456的水溶液，其中，溶液的浓度按市售1456溶液的体积计为5％至15％。
10.根据权利要求8所述的制造方法，其中，所沉积的1456层在干燥之后的厚度小于15nm。
11.一种用于实施根据前述权利要求中的任一项所述的方法的设备，所述设备包括：
-转移辊(7)，
-涂覆辊(8)，所述涂覆辊(8)接触所述转移辊(7)并且具有多个六边形形状的蜂窝状室，所述蜂窝状室的行数为每厘米50行至200行，并且所述蜂窝状室的体积为每平方米辊表面5×10-6m3至10×10-6m3；
-槽(9)，所述槽(9)包含含水钝化溶液并且其中浸有所述涂覆辊(8)。
12.根据前述权利要求所述的设备，其中，所述转移辊(7)由弹性体制成。
13.根据前述权利要求中的任一项所述的设备，其中，所述涂覆辊(8)包括经激光蚀刻的陶瓷涂层。
14.根据前述权利要求中的任一项所述的设备，其中，所述槽(9)包括具有至少一个叶片的擦拭装置(10)。
15.根据前述权利要求中的任一项所述的设备，还包括磁辐射仪(5)，所述磁辐射仪(5)能够测量含水钝化溶液膜在干燥之前的厚度。
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