CN107000380B - 半成品、半成品的制造方法及其用途 - Google Patents
半成品、半成品的制造方法及其用途 Download PDFInfo
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Abstract
本发明涉及一种平板或带状的半成品(7,7‘),包含至少一个第一金属层(8、8‘)和至少一个塑料层(10,10‘),第一金属层和塑料层彼此全面地连接成金属/塑料复合材料(7),其中金属层(8、8‘)的材料厚度最高为1.5mm并且塑料层(10,10‘)的材料厚度最小为0.2mm。本发明还涉及半成品的制造方法和应用。本发明的任务,即提供一种比现有技术中应用的半成品明显更轻的半成品,通过具有权利要求1所述特性的半成品实现。
Description
技术领域
本发明涉及一种平板或带状的半成品,包含至少一个第一金属层和至少一个塑料层,其彼此全面地连接成金属/塑料复合材料,其中金属层的材料厚度最高为1.5mm并且塑料层的材料厚度至少为0.2mm。本发明还涉及半成品的制造方法和应用。
背景技术
在现有技术中尤其金属/塑料/金属复合材料是已知的。申请人以商品名出售夹芯板,其由两片材料厚度在0.2至0.3mm间的钢板覆盖层和在两个钢板覆盖层之间设置的材料厚度至少为0.3mm的塑料芯组成,这些板非常适合作为载客汽车的外部和/或内部元件。
此外,在现有技术中已知尤其是用于例如商用车辆、尤其是挂车(拖车)的嵌板,尤其是由金属夹心镶板制成的用于冷藏运输的厢式结构。例如作为外表面应用两面热镀锌的卷材涂料钢板,作为内表面应用两面热镀锌并且具有食品耐久性的塑料的钢板并且其中放置由聚氨酯泡沫制成的芯层(Rohr商用汽车公司的“isoplus II Vario”产品信息)。为厢式结构应用的钢板具有至少0.6mm的材料厚度。为了确保足够的结构稳定性和由于在行驶期间出现的高负载,至少这类型的结构不能够进一步地减少给出的材料厚度。轻型结构潜能在这样的应用领域中没有充分利用。在其他的应用领域中,对于材料厚度最大3.0mm的卷材涂层板材的应用存在进一步消减重量的可能性,例如在车库大门领域。
此外在现有技术中,带状涂装在专业范围内又被称作“卷材涂料”。在链接http:// de.wikipedia.org/wiki/coil_coating中可以下载作为例子的涂层方法的信息。通常情况下带钢,尤其是热镀锌的钢带和材料厚度在0.4mm到3.0mm之间的铝带被涂层。材料厚度低于0.4mm在卷材涂料设备中的施加被证明是非常困难的,因为不能够确保在相对较薄的材料上的全面的、尤其是具有恒定的厚度的涂层。
发明内容
在现有技术的基础上,本发明的目的在于,提供比现有技术中应用的半成品明显轻的半成品,以及该半成品的制造方法和应用。
任务如此解决,即金属/塑料复合材料的金属层的可见的表面具有卷材涂料涂层。
发明人确定了由至少一个金属层和至少一个塑料层结合形成金属/塑料复合材料,与具有相同材料厚度的金属制成的实心的材料相比,其中金属层的厚度最高为1.5mm,尤其最高为1mm,优选最高为0.5毫米并且尤其优选最高为0.35mm并且塑料层的厚度最少为0.2mm,尤其最少为0.3mm,优选最少0.4毫米,一方面导致减少的质量并且另一方面在卷材涂料过程中能够在金属层厚度低于现有技术公开的最小厚度的情况下没有问题地涂层。
根据本发明的半成品的第一实施例,金属层由钢材形成。虽然钢材相对于其他金属,尤其是相对于轻金属材料略微重,然而能够低成本地获得并且轻松地加工,尤其是冷成型。尤其使用金属的、优选两面涂层的钢材。作为涂层考虑使用锌或铝基的系统,其中尤其优选使用镀锌的钢材,因为其能够低成本地制备。
根据本发明的半成品的另一个实施例,半成品包含第二金属层,该第二金属层与塑料层的自由的表面连接成金属/塑料/金属复合材料。作为夹心成型的半成品具有高的弯曲刚度和屈曲刚度,在减少重量的同时基本上以适应的厚度符合实心材料的弯曲刚度和屈曲刚度。为了确保轻型结构潜能,第二金属层的材料厚度最高为1.5mm,尤其最高为1mm,优选最高为0.5毫米并且尤其优选最高为0.35mm。根据卷材涂料涂层或者可选择地其他涂层系统,第二金属层能够优选地具有与第一金属层相同的特性。金属层还能根据应用领域形成不同的厚度。
根据本发明的半成品的另一个实施例,第一和/或第二金属层的可见的表面被纹理化。一方面纹理能够作为突起在卷材涂料施加到金属层的过程中分别地施加。此点能够例如借助相应的加工的施料辊实施。由于至少第一金属层具有减小的材料厚度,能够在材料中存在不平坦,根据使用,例如在大面积的建筑构件,尤其在不利的光线和观察条件下在嵌板部件中导致不良的外观。为了抵消这一缺点,突起能够以例如重复图案弥补不良的外观或者赋予更好的外观。可选择地或者累积地能够在卷材涂料之后分别地在烘烤操作后通过冲压成形到至少第一金属层中,例如借助压花辊。一方面优势在于,如在突起情况下重复图案给至少第一金属层赋予了更好的外观,但是另一方面还能够在金属层中产生轻微的加固作用。尤其压花力如此调节,不会导致塑料层在复合物中的流动和厚度的降低。
根据本发明的半成品的另一个实施方式,塑料层由温度稳定的塑料形成。这是具有优势的,因为金属/塑料复合材料或金属/塑料/金属复合材料在卷材涂覆过程中,尤其是在对例如之前施加的粘合促进剂(引物)和在金属层上施加的涂层的卷材涂料涂层的烘烤时,暂时地暴露在高温中。为了塑料不会分解或流动,优选使用在至少到200℃,尤其至少到220℃的温度下耐温的塑料。优选例如基于PA、PE和/或其混合物的体系的塑料。
为了提高半成品的刚度和/或强度或将半成品的承载功能转移到塑料层中,根据本发明的半成品的另一个实施例,能够使用纤维增强的塑料。优选考虑掺杂有玻璃、碳和/或天然纤维的,尤其是可生物降解的纤维的塑料系统,其中根据纤维类型,尤其是通过填充内容的比例能够影响塑料的强度和/或刚度大小。所用的纤维优选在至少到200℃,尤其至少到220℃的温度下是耐温的。
另一方面,本发明涉及一种用于制造至少单面被涂层的平板或带状的半成品的方法,该方法通过半成品的使用,半成品包含至少一个第一金属层和至少一个塑料层,第一金属层和塑料层彼此全面地连接成金属/塑料复合材料,其中金属层的材料厚度最高为1.5mm并且塑料层的材料厚度最小为0.2mm,其中金属/塑料复合材料的金属层的可见的表面在卷材涂料操作中被涂层。根据本发明的方法的一个实施例设置第二金属层,第二金属层全面地与塑料层的自由的表面连接成金属/塑料/金属复合材料,其中金属/塑料/金属复合材料的第二金属层的自由的表面在卷材涂料操作中被涂层。为避免重复,参考上述的,尤其是实施例涉及的根据本发明的半成品。
根据本发明的方法的另一个实施例中,烘烤温度,尤其是用于烘烤之前施加的粘合促进剂(引物)和用于烘烤分别在金属层上施加的涂层的卷材涂料涂层的烘烤温度由塑料如此确定,确保塑料的温度稳定性,其中调节温度尤其最高为220℃,优选最高为200℃。
根据本发明的方法的另一个实施例,第一和/或第二金属层的可见的表面被纹理化。这点一方面作为突起能够在卷材涂层的过程中施加到的至少第一和/或第二金属层上和/或另一方面能够通过冲压在卷材涂料之后分别地在烘烤操作后成形在金属层中。
另一方面,本发明涉及本发明的半成品作为建筑构件,尤其是作为例如商用车辆、挂车(拖车)或大型家用电器(家用电器)的嵌板部件的应用。为了避免重复,参考上面的陈述。
附图说明
接下来借助描述实施例的附图对本发明进行更详细地阐述。相同的部件设置有同样的附图标记。其中:
图1示出了在现有技术中用于冷藏运输的厢式结构的部分截面图,
图2a)示出了根据本发明的能够作为嵌板部件使用的半成品的第一实施例的截面,
图2b)示出了根据本发明的能够作为嵌板部件使用的半成品的第二实施例的截面,
图3示出了根据本发明的方法的第一实施例的步骤顺序的示意图。
具体实施方式
作为例子,在图1中描绘了如目前现有技术中所应用的、由金属夹心镶板构成的、用于冷藏运输的厢式结构的部分截面图。金属夹心镶板1具有例如在外侧A上设置的第一钢板2,在钢板2的两面设置有金属涂层3,尤其是锌涂层。在外侧A的可见的钢板2的表面上施加卷材涂料涂层4形式的另外的涂层。在金属夹心镶板的内侧I上设置第二钢板2‘,在第二钢板2‘的两面上设置金属的涂层3‘,尤其是锌涂层和在内侧I的食品耐久性的有机层5并且第二钢板具有例如与第一钢板2相同的材料厚度。在钢板2、2‘之间设置有塑料芯6,例如泡沫塑料,其使金属夹心镶板完整。钢板2、2‘的材料厚度,尤其是第一钢板2的材料厚度例如为0.6mm并且由于稳定性原因和在行驶过程中出现的高负荷不能够进一步降低材料厚度。
作为根据本发明的半成品的第一实施例,在图2a)描绘了一种金属/塑料复合材料形式的半成品7。半成品7包含优选由钢材制成的金属层8,其两面是金属的涂层9,尤其是镀锌的、优选是电解镀锌的、并且具有例如0.3mm的材料厚度。优选两面电解涂层的钢材8与塑料层10单面地完全地连接,塑料层是至少到200℃、尤其是至少到220℃耐温的、并且具有例如0.5mm的材料厚度。在与塑料层相对的面上,金属层8的可见面设置有卷材涂料涂层11。根据本发明地半成品7特别适合作为建筑构件,尤其是作为商业车辆或拖车的嵌板部件。虽然半成品7的材料厚度略微大于钢板2的材料厚度,但是在半成品例如作为嵌板部件用于冷藏运输的厢式结构的部分时,能够通过降低在根据本发明的半成品7中的金属的比例消减尺寸,并且相对较薄的金属层能够无问题地通过卷材涂料设备与塑料层组合为金属/塑料复合材料(在此未绘制)。在此同样没有绘制出,塑料层能够是纤维增强,其还能够提高半成品的刚度和/或强度。还能够在使用纤维增强塑料中,根据用途进一步减小金属层的材料厚度。
作为根据本发明的半成品的第二实施例,图2b)描绘了一种金属/塑料/金属复合材料形式的半成品7‘。区别于半成品7,半成品7‘包含优选由钢材制成的第二金属层8‘,其两面是金属的涂层9‘,尤其是镀锌的、优选是电解镀锌的、并且全面地与塑料层10‘的自由的表面连接。半成品7‘的各个材料厚度,第一和第二金属层8、8‘例如是0.2mm并且塑料层10‘例如是0.3mm。半成品7的优点也能够适用于半成品7‘。
没有绘制的是,至少第一金属层8的可见的表面能够有纹理,从而为根据本发明的半成品7、7‘的后续的应用给予更好的外观。
图3绘制了尤其是在卷材涂料设备中用于制造至少被单面涂层的平板或带状的半成品的示意性的步骤顺序。在步骤12中优先制备一种带状的卷材,其或者具有上述的金属/塑料复合材料,该金属/塑料复合材料在塑料面上优选地设置用于保护塑料表面和用于在卷取状态下避免与金属面粘附的、在接下来的步骤中脱离的保护膜,;或者具有金属/塑料/金属复合材料,其中金属层的厚度最高是0.5mm,尤其最高是0.4mm,优选最高是0.35mm并且尤其优选最高是0.3mm,其中金属层优选由钢材制成并且两面优选电解涂层,并且塑料层的厚度至少是0.2mm,尤其至少是0.3mm,优选至少是0.4mm,其中塑料在直至至少200℃,尤其至少220℃的温度下是耐温的。带状的卷材被开卷并且连续地输送到用于清洁至少第一金属层的步骤13。至少第一金属层的钝化/活化发生在步骤14中,从而接下来借助施料辊将粘合促进剂(引物)涂抹到至少第一金属层上(步骤15),根据塑料确定的温度下烘烤粘合促进剂(步骤16),从而确保在复合物中塑料的温度稳定性,其中设定温度尤其最大为220°,优选最大为200℃。在下一步骤17中借助施料辊将卷材涂料涂层涂抹到包含有已经烘烤的粘合促进剂的至少第一金属层上,卷材涂料涂层在基本上与步骤16对应的温度下再次烘烤(步骤18)。在步骤19中或者进行带状半成品的开卷,其中卷材涂料涂层设置有保护膜,或者进行平板形状的半成品的切割。
在这里没有绘制的是,至少第一金属层能够有纹理。一方面纹理能够作为突起在卷材涂覆过程中施加在至少第一金属层上,例如在步骤18中。这样能够例如通过相应的加工的施料辊实施。可选择地或者累积地能够在卷材涂覆过程之后分别地在烘烤操作后通过冲压成形到至少第一金属层中,例如借助压花辊在步骤19后完成,其中尤其如此设置压印力,不会导致在复合物中塑料层的流动或厚度的减少。金属层(8,8‘)的材料厚度最少为0.05mm,尤其最少为0.1mm,并且优选最少为0.15mm。塑料层(10,10‘)的材料厚度最高为3mm,尤其最高为2.5mm,优选最高为2.0mm。
本发明不局限于由附图描绘的实施例,更确切地说根据本发明的半成品能够应有于所有领域并且取代现有的解决方案(卷材涂料金属板),其中重量的减少起到很重要的作用,例如在门类领域,工业门、车库门等。应用不限于车辆制造或大型家用电器。
附图标记说明
1 金属夹心镶板
2,2 ‘钢板
3,3 ‘金属涂层
4 卷材涂料涂层
5 食品耐久性的有机层
6 塑料芯
7 金属/塑料复合材料,半成品
7 金属/塑料/金属复合材料,半成品
8,8 ‘金属层
9,9 ‘金属的涂层
10,10 ‘塑料层
11 卷材涂料涂层
12 带状卷材的制备
13 清洗
14 活化/钝化
15 粘附促进剂的施加
16 粘合促进剂的烘烤
17 卷材涂料涂层的施加
18 卷材涂料涂层的烘烤
19 卷曲/切割段
Claims (9)
1.制造至少单面被涂层的平板或带状的半成品的方法,
其特征在于,
提供一种带状的卷材,包含至少一个第一金属层和至少一个塑料层,所述第一金属层和塑料层彼此全面地连接成金属/塑料复合材料,其中该金属层的材料厚度最高为1.5mm并且塑料层的材料厚度最小为0.2mm,
带状的卷材被开卷,其中金属/塑料复合材料的金属层的可见的表面在卷材涂料操作中被涂层并且烘烤卷材涂料涂层,
卷曲带状半成品或者切割平板形状的半成品。
2.根据权利要求1所述的方法,
其特征在于,所述金属层由钢材构成。
3.根据权利要求2所述的方法,
其特征在于,所述金属层由两面金属涂层的钢材构成。
4.根据权利要求1所述的方法,
其特征在于,半成品包含第二金属层,所述第二金属层全面地与塑料层的自由的表面连接成金属/塑料/金属复合材料,其中所述第二金属层的材料厚度最高为1.5mm。
5.根据权利要求4所述的方法,
其特征在于,第二金属层设置为,所述第二金属层全面地与塑料层的自由的表面连接成金属/塑料/金属复合材料,其中所述金属/塑料/金属复合材料的所述第二金属层的可见的表面在卷材涂料操作中被涂层。
6.根据权利要求1所述的方法,
其特征在于,
烘烤温度是根据塑料确定的,从而确保所述塑料的温度稳定性。
7.根据权利要求6所述的方法,
其特征在于,
烘烤温度设定最大为220℃。
8.根据权利要求6所述的方法,
其特征在于,
烘烤温度设定最大为200℃。
9.根据权利要求1至8中的任一项所述的方法,
其特征在于,
所述第一和/或第二金属层的可见的表面是纹理化的。
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DE102014017492.1 | 2014-11-27 | ||
PCT/EP2015/075521 WO2016083083A1 (de) | 2014-11-27 | 2015-11-03 | Halbzeug, verfahren zum herstellen eines halbzeugs sowie dessen verwendung |
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US20170341343A1 (en) | 2017-11-30 |
US10315389B2 (en) | 2019-06-11 |
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