CN108541236B - Method and device for producing a material composite and use thereof - Google Patents

Method and device for producing a material composite and use thereof Download PDF

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Publication number
CN108541236B
CN108541236B CN201780007618.2A CN201780007618A CN108541236B CN 108541236 B CN108541236 B CN 108541236B CN 201780007618 A CN201780007618 A CN 201780007618A CN 108541236 B CN108541236 B CN 108541236B
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China
Prior art keywords
coating
station
metal strip
unit
material composite
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Expired - Fee Related
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CN201780007618.2A
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Chinese (zh)
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CN108541236A (en
Inventor
杰罗尔德·拉斯普迪克
克莱门斯·黑尔曼
斯特拉·扬森
马库斯·鲁达克
约瑟夫·施耐德
克劳斯-彼得·科赫
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ThyssenKrupp Steel Europe AG
ThyssenKrupp AG
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ThyssenKrupp Steel Europe AG
ThyssenKrupp AG
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
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Abstract

The invention relates to a method and a device for producing a material composite (2) having at least two layers (3,4) made of a metallic material and at least one layer (5) made of a polymer matrix material arranged between the two layers, comprising the following steps: preparing two metal coil bundles (6, 7) and a coil bundle (8) with a polymer film, uncoiling the coil bundles and continuously conveying the metal strips (3,4) and the polymer film (5) to a preheating unit, respectively, preheating the metal strips (3,4) and the polymer film (5) in the preheating unit (9,10,11) and continuously conveying the metal strips (3,4) and the polymer film (5) to a coating-laminating-extruding unit (12) to produce a material composite under pressure and/or temperature, then conveying the composite (2) to at least one cooling unit (13) and/or at least one post-processing unit (14), then cutting the material composite to length into plates or coiling up the material composite into coil bundles, wherein the first and second metal strips (3,4) are respectively at a surface treatment station (16.1) between the uncoiling and preheating units (9,10,11), 17.1) is passed through at least one pretreatment unit and the surface-treated surfaces of the metal strips (3,4) are brought into contact with the polymer film (5) in a coating lamination extrusion unit (12) and connected to one another.

Description

Method and device for producing a material composite and use thereof
Technical Field
The invention relates to a method for producing a material composite having at least two layers made of a metallic material and at least one layer made of a polymer matrix material arranged between the two layers, comprising the following steps:
preparing a first material in the form of a metal strip wound on a bundle, a second material in the form of a metal strip wound on a bundle and a third material in the form of a polymer film wound on a bundle,
these bundles are unwound and the metal strip and the polymer film are fed continuously to a preheating unit respectively,
in which the metal strip and the polymer film are preheated at least to a preheating temperature respectively and continuously fed to a coating, laminating and extrusion unit for producing a material composite under pressure and/or temperature,
the composite is then continuously conveyed to at least one cooling unit and/or at least one post-treatment unit, and the material composite is cut to length into plates or rolled up into a bundle.
The invention further relates to a device for producing a material composite having at least two layers made of a metallic material and at least one layer made of a polymer matrix material arranged between the two layers, having:
means for unwinding the first and second metal strips wound on the bundle and the polymer film wound on the bundle,
a device for preheating a metal strip and a polymer film,
device for coating-laminating-pressing together a metal strip and a polymer film for producing a material composite under pressure and/or temperature,
a device for cooling and/or post-treating a material composite,
device for driving and/or guiding a metal strip, a plastic film and/or a material composite, and
a device for cutting to length or rolling up a material composite.
Furthermore, the invention relates to the use of the material composite.
Background
In international publication WO 2009/043777 a1 of the applicant, a method and an apparatus are disclosed for producing a sandwich composite material having at least two layers made of a metal material and at least one layer made of a polymer matrix material arranged between the two layers. In fig. 3, a first material in the form of a metal strip wound onto a coil, a second material in the form of a metal strip wound onto a coil and a third material in the form of a polymer film wound onto a coil are prepared, unwound and fed continuously to a preheating unit, in each case in which the metal strip and the plastic film are preheated at least to a preheating temperature and fed continuously to a coating unit (twin-strip extruder) in order to produce a material composite under pressure and/or temperature. The material composite is then continuously conveyed to at least one cooling unit and/or at least one post-treatment unit, and then cut to length into plates or rolled up into rolls. In order to improve the adhesion properties between the polymer matrix material and the one or more metal materials in the sandwich material, it is proposed to apply an adhesion lacquer on the metal sheets, which can be applied in a coating procedure. Thus, for the production of the material composite, a metal strip is provided which has been coated with an adhesive paint/adhesive layer.
This surface treatment is carried out outside the continuous coating process. The method and the device for producing the material composite can therefore be designed more economically and further optimized, wherein the degree of automation can be increased. Starting from this prior art, the object of the present invention is to provide a method and a device for producing a material composite, with which the economy and the production process can be further optimized and the degree of automation can be increased.
Disclosure of Invention
According to the method according to the invention, this object is achieved in that the first and second metal strips are each passed through at least one pretreatment unit between the uncoiling and preheating units, the first metal strip is surface-treated on at least one side in a surface treatment station of the first pretreatment unit, and the second metal strip is surface-treated on at least one side in a surface treatment station of the second pretreatment unit, and the respective surface-treated sides of the metal strips are brought into contact with the polymer film in the coating lamination extrusion unit and are connected to one another.
In the method according to the invention, it is no longer necessary to subject the metal strip separately to a surface treatment in an upstream process, wherein the formability and the flatness of the material composite can also be influenced positively in addition to the adhesive properties in the material composite. By integrating the surface treatment of the metal strip in a continuous coating, laminating and extrusion process for producing a material composite, the production process can be designed more economically and further optimized compared to the prior art and at the same time the degree of automation can be increased.
According to a first embodiment of the method according to the invention, the metal strip is coated with an adhesive and/or a gluing system and/or a surface treatment agent and/or activated chemically and/or physically, preferably by means of a plasma, in the surface treatment station by means of coating, in particular by means of spraying, by means of bar coating or in particular by means of coating. The coating of the metal strip with the adhesive and/or the gluing system and/or the surface treatment agent on at least one side during the coating process is particularly preferred, since the coating can be reproduced with small tolerances and can be applied economically. The coating thickness of the applied wet film is between 0.001 and 0.1mm, in particular between 0.001 and 0.05mm, preferably between 0.001 and 0.03mm, particularly preferably between 0.001 and 0.02 mm. The alternative or additional at least one-sided activation of the metal strip is preferably carried out by means of plasma in order to chemically, mechanically and/or physically adjust the adhesion properties and the forming properties and/or the flatness.
According to a further embodiment of the method according to the invention, the metal strip is passed through a drying station after the surface treatment station. After activation and/or preferably after coating of the metal strip with the adhesive and/or gluing system and/or surface treatment agent, the metal strip is passed through at least one drying station, in which the adhesive and/or bonding system and/or surface treatment agent, preferably applied usually in liquid form, is dried at a temperature between room temperature and a temperature preferably below the decomposition temperature of the adhesive and/or gluing system and/or surface treatment agent used, in order to ensure that the applied adhesive and/or gluing system and/or surface treatment agent remains on the metal strip, which can then be reliably transported to the subsequent processing steps. Drying may be omitted, for example, when plasma treatment is performed.
According to a further embodiment of the method according to the invention, the metal strip is passed through at least one straightening station, a cutting station and/or a cleaning station in the pretreatment unit before the surface treatment station. In the straightening station, which is arranged after the unwinding (unwinding station) of the metal strip, in particular as seen in the processing direction, the stresses which are contained in the metal strip and which can lead to waviness in the unwound state can be relieved or purposely straightened out by stretching and bending, whereby the metal strip can be conveyed to the subsequent processing step in a defined flat state. The metal strip can be continuously trimmed along its longitudinal edges in a cutting station in order to be able to convey the metal strip to a subsequent processing step with a defined width and/or a defined strip edge pattern. In the cleaning station, the surface of the metal strip, in particular of the metal strip, can be cleaned and/or degreased in order to be able to provide at least one clean surface for the activation and/or coating of the metal strip in the surface treatment station.
According to a further embodiment of the method according to the invention, the material composite is cooled in at least one cooling station, preferably two cooling stations, of the cooling unit after the coating, laminating and extrusion unit. In the at least one cooling station, the cooling can be effected actively by suitable means or passively, for example by means of open air sections. By cooling in the at least one cooling station, the material composite can be conveyed to a subsequent processing step, in particular to ensure that the other stations are not subjected to a thermal load, the temperature of the material composite leaving the cooling unit being less than 100 ℃.
According to a further embodiment of the method according to the invention, the material composite is passed in the post-processing unit through at least one cutting station, one straightening station and one investigation station and/or one coating station. The material composite can be continuously trimmed along its longitudinal edges in a cutting station in order to be able to impart a defined width and/or a defined strip edge pattern to the material composite. In the straightening station, the stresses occurring in the material composite as a result of the processing steps which are influenced by temperature and/or pressure can be eliminated by stretching and bending or straightened out in a targeted manner, so that a high dimensional accuracy and a high degree of straightness and/or flatness can be imparted to the material composite. In the investigation station, the material composite can be inspected for surface defects, flatness defects and/or geometry defects, so that, when corresponding defects occur, they can be automatically classified and recorded, for example by some means. In the coating station, the material composite can be coated, for example, with a protective layer, adhesive layer, lacquer layer and/or a shaping aid layer, preferably with an anti-corrosive oil, in order to be able to provide temporary anti-corrosive protection, at least up to the subsequent processing of the material composite.
According to a further embodiment of the method according to the invention, the continuous guidance of the first and/or second metal strip by the respective device at least between the surface treatment station and the coating lamination extrusion unit is preferably carried out in such a way that the side of the metal strip that is surface-treated, preferably coated with the adhesive and/or bonding system and/or surface treatment agent, is not in contact with the guidance device, in order to thereby exclude contamination of the device due to possible adhesion of the surface treatment components and contamination or damage of the surface-treated side of the metal strip due to partial detachment of the adhesive and/or bonding system and/or surface treatment agent.
According to a further embodiment of the method according to the invention, the metal strip and the polymer film are fed to a coating lamination extrusion unit having a coating lamination extrusion station with a pair of coating rollers forming a coating gap in order to produce the material composite in the coating lamination extrusion station.
According to an alternative embodiment of the method according to the invention, the metal strip and the polymer film are fed to a coating lamination and extrusion unit having a first coating lamination and extrusion station and a second coating lamination and extrusion station, the first coating lamination and extrusion station having a first coating roller pair forming a coating gap and the second coating lamination and extrusion station having a second coating roller pair forming a coating gap, in order to combine the second metal strip with the polymer film in the first coating lamination and extrusion station to form a metal-polymer composite and to combine the metal-polymer composite with the first metal strip in the second coating lamination and extrusion station to form a material composite, wherein the material composite is produced in two coating, laminating and extrusion stations.
According to a further embodiment of the method according to the invention, an aluminum, magnesium or steel material is used as the first and/or second metal strip and a thermosetting or thermoplastic polymer matrix is used as the polymer film, wherein the polymer matrix can be reinforced or filled. Preferred polymers may be, for example, systems based on PA, PE, PP and/or mixtures thereof and polyesters and/or polyacrylates. If a steel material is used, the steel material is coated, for example with an inorganic and/or organic coating. The metal corrosion protection layer is preferably provided as a coating, particularly preferably based on zinc, and/or a mixture with aluminum and/or magnesium, which is applied to the steel material by hot dip coating or particularly preferably by electrodeposition. As an alternative, for example, galvanized and/or chrome-plated steel strips are also possible. The material thickness of the first and/or second metal strip is at most 1.5mm, in particular at most 1.0mm, preferably at most 0.5mm and particularly preferably at most 0.35mm, and the material thickness of the polymer film is at most 20.0mm, in particular at most 15.0mm, preferably at most 10.0mm and particularly preferably at most 5.0 mm. The metal strips each have a material thickness of at least 0.05mm, preferably at least 0.1mm, and the polymer film has a material thickness of at least 0.02mm, in particular at least 0.05mm, preferably at least 0.1 mm.
According to a second aspect, the object is achieved with an apparatus such that the apparatus has an apparatus for the pretreatment of at least a first and a second metal strip, wherein the apparatus for the pretreatment comprises a first pretreatment unit having a first pretreatment station for the one-sided surface treatment of at least the first metal strip and a second pretreatment unit having a second pretreatment station for the one-sided surface treatment of at least the second metal strip.
In the device according to the invention, the surface treatment of the metal strip is integrated in a continuous coating, laminating and extrusion process for producing the material composite, as a result of which the production process can be designed more economically and further optimized and in particular the degree of automation can be increased.
According to a first embodiment of the device according to the invention, the surface treatment station has a device for applying a coating, in particular a device for spraying, bar coating or preferably a coating machine for applying an adhesive and/or a gluing system and/or a surface treatment agent and/or a device for activating chemically and/or physically, preferably by means of plasma. The coating machine can be used economically and reproducibly for the coating of at least one side of a metal strip. Alternatively or additionally, a plasma device can be used, which can be operated, for example, at atmospheric pressure and which activates the metal strip reliably and reproducibly at least on one side.
According to a further embodiment of the device according to the invention, the device has at least one drying station for the metal strips. The drying station, which is arranged in particular, as seen in the treatment direction, after the surface treatment station of the metal strip, comprises at least one heating device, for example a circulating air dryer, for drying the adhesive and/or the gluing system and/or the surface treatment agent, which is preferably applied in liquid form in the surface treatment station.
According to a further embodiment of the device according to the invention, the pretreatment unit comprises at least one straightening station, one cutting station and/or one cleaning station. The straightening station comprises at least one device for flattening the uncoiled metal strip, preferably a straightener. The cutting station comprises at least one device for trimming the longitudinal edges of the metal strip, for example an edge trimmer. The cleaning station comprises at least one device for cleaning and/or degreasing the metal strip, for example a brush for mechanical cleaning and/or an apparatus, preferably for chemical cleaning, having a device for applying a chemical solution to the metal strip or immersing the metal strip in a chemical solution, a rinsing device for rinsing the metal strip treated with the solution, and possibly a drying device for drying the rinsed metal strip.
According to a further embodiment of the device according to the invention, the cooling unit comprises at least one cooling station and/or the post-treatment unit comprises at least one cutting station, one straightening station, one investigation station and/or one coating station. The cooling station comprises at least one (active) device for cooling the material composite, for example an air cooler. Alternatively, passive cooling can also be carried out, for example, by means of an open cooling section. The cutting station comprises at least one device for trimming the longitudinal edges of the material composite, for example an edge trimmer. The straightening station comprises at least one device for flattening the material composite, for example a straightener. The investigation station comprises at least one device for inspecting the material composite for surface defects, flatness defects and/or geometry defects, for example a measuring system with an analysis unit. The coating station comprises at least one device for coating the material composition, for example an electrostatic coating system.
According to a further embodiment of the device according to the invention, the coating/laminating/extrusion unit comprises at least one coating/laminating/extrusion station, preferably two coating/laminating/extrusion stations. The at least first coating lamination extrusion station comprises at least one device for coating lamination extrusion of at least one metal strip and a polymer film, preferably a pair of coating rollers operating simultaneously. In each of the two coating/laminating/extrusion stations, the individual stations have at least one device for coating/laminating/extrusion, preferably a pair of coating rollers. The construction of the lay-up roller pair is compact and relatively simple to operate and more economical than using a twin-plate press.
According to a third aspect, the invention relates to the use of a material composite produced according to at least one embodiment of the method according to the invention for producing a component, in particular for vehicle construction, preferably as a vehicle body component, in particular as a part of a body component or as a chassis component of a vehicle, in particular as a part of a chassis component, particularly preferably for internal combustion and/or electric motor-driven passenger vehicles, commercial vehicles, trucks, utility vehicles, buses, but also for rail vehicles, for example city rails or passenger trains. Furthermore, the material composite produced according to the invention can be used as a component in the shipbuilding, aircraft construction, equipment construction, machine construction, household goods or construction sector.
Drawings
The invention will be further elucidated on the basis of the drawings showing embodiments. Like parts are designated with like reference numerals. In the figure:
figure 1 shows a schematic view of a first embodiment of an apparatus for producing a material composite,
figure 2 shows a schematic view of a second embodiment of an apparatus for producing a material composite,
fig. 3 shows a schematic view of a third embodiment of an apparatus for producing a material composite, an
Fig. 4 shows a schematic view of a fourth embodiment of an apparatus for producing a material composite.
Detailed Description
Fig. 1 shows a schematic view of a first exemplary embodiment of a device (1) according to the invention for producing a material composite (2). The material composite (2) comprises at least two layers made of a metal material and at least one layer made of a polymer matrix material arranged between the two metal layers. Aluminum, magnesium or steel is suitable for the first and/or second metal strip (3,4) and a thermosetting or, for example, thermoplastic based polymer matrix material, for example also filled and/or reinforced, can be used as the polymer film (5). Preferred polymers may be, for example, systems based on PA, PE, PP and/or mixtures thereof and polyesters and/or polyacrylates. Preferably, a steel with a zinc-based coating is used, which steel is for example electrolytically coated. Combinations of different metallic materials are also possible. A first material in the form of a first metal strip (3) wound on a coil, a second material in the form of a second metal strip (4) wound on a coil and a third material in the form of a polymer film (5) wound on a coil are prepared and fed into the production process through means (6,7,8) for continuously unwinding the first and second metal strips (3,4) wound on the coil and the polymer film (5) wound on the coil, respectively to a preheating unit (9,10,11) having means for preheating the metal strips (3,4) and the polymer film (5). The machine direction is shown by the arrow.
The preheating units (9,10,11) comprise devices such as induction radiators, conduction radiators, convection radiators and/or infrared/laser/LED radiators and are arranged in particular inside the housing, so that they act as tunnel furnaces. Alternatively, other heating systems are possible, for example systems driven by circulating air.
The preheating of the metal strips (3,4) is carried out, for example, in a tunnel furnace (9,10) at least to a preheating temperature, which can lie between room temperature and the decomposition temperature of the coating, in particular between 150 ℃ and 275 ℃ depending on the nature of the metal material used, and the preheating of the polymer film (5) is carried out, for example, in a tunnel furnace (11) at different preheating temperatures, for example, when using a mixture of PE and PA, at a preheating temperature between room temperature and 150 ℃, in particular between room temperature and 125 ℃, preferably between room temperature and 100 ℃, in order to provide a sufficient temperature for the subsequent coating-laminating-extrusion step, depending on the polymer matrix material used. After leaving the tunnel furnace (9,10,11), the preheated metal strips (3,4) and the preheated polymer film (5) are continuously conveyed to a coating, laminating and extruding unit (12) for producing a material composite (2). The device for coating metal strips (3,4) with a polymer film (5) for producing a material composite (2) under pressure and/or temperature comprises at least one coating/laminating/extrusion station (12.1) having a pair of coating rollers (12.11) forming a coating gap (12.12). The pair of laminating rollers (12.11), which can be driven by means not shown, receives the preheated metal strips (3,4) and the polymer film (5) added between the metal strips (3,4) and laminates or connects them to form a material composite (2). The rollers of the pair of laminating rollers (12.11) can be moved towards each other or away from each other, for example, by means not shown, as indicated by the double arrow shown, whereby the distance between the pair of laminating rollers (12.11) can be varied and whereby the internal clear width of the laminating gap (12.12) can be adjusted as required. In the cladding-laminating-extrusion process, the internal clear width of the cladding gap (12.12) corresponds at most to the sum of the respective thicknesses of the metal strips (3,4) and of the polymer film (5) in the delivered state, preferably to a lesser extent, in order to exert a predetermined pressure on the material composite to be produced for the cladding-laminating-extrusion. Instead of or in addition to the pressure applied for the coating lamination extrusion, the temperature required for joining the first metal strip (3) and the polymer film (5) and the second metal strip (4) is provided by preheating the metal strips (3,4) at least to a preheating temperature, in particular for activating the surface treatment, preferably the adhesive and/or adhesive system and/or surface treatment agent, and preheating the polymer film (5) at least to a preheating temperature, in particular for activating, wherein the material composite (2) is produced in the coating lamination extrusion station (12). If, for example, the temperatures required depending on the properties of the metal strip and the polymer film to be connected to one another are not available via the preheating unit, the pair of coating rollers can have a device for temperature regulation, not shown here, in order to be able to provide the required heat/temperature.
After leaving the coating, laminating and extrusion unit (12), the material composite (2) is continuously conveyed to a cooling unit (13) having at least one cooling station (13.1) having at least one device for cooling the material composite (2), for example an air cooler, which cools the material composite (2) in such a way that it is ensured in particular in a subsequent processing step that the other stations are not exposed to thermal stress. Alternatively, the cooling unit can also be formed as an open air section. The temperature of the material composite (2) leaving the cooling unit (13) is, for example, less than 100 ℃. It is known to the expert how devices for driving the metal strips (3,4), the polymer film (5) and/or the material composite (2) can be constructed, in particular taking into account at which points in the process chain, for example, so-called drives are required in order to be able to ensure a continuous process. At least one coating/laminating/extrusion station (12.1) can be provided as a drive, said station having an actively driven coating roller pair (12.11) as described above. The means for guiding are indicated by reference numeral (27), which serve in particular for redirecting the metal strips (3,4), wherein the units (6,7,8,12) already described can also be regarded as further means for guiding. Finally, the cooled material composite (2) is continuously conveyed to a device (14) for cutting the material composite (2) to length into plates, for example a long-tube shearer, or to a device (15) for rolling up the material composite (2) into a roll.
In order to design and further optimize the production process of the material composite (2) more economically and in particular to increase the degree of automation, according to the invention, the first and second metal strips (3,4) are each passed through at least one pretreatment unit (16,17) between the uncoiling and preheating units (9,10), wherein the first metal strip (3) is surface-treated on at least one side in a surface treatment station (16.1) in the first pretreatment unit (16) and the second metal strip (4) is surface-treated on at least one side in a surface treatment station (17.1) in the second pretreatment unit (17), and the surfaces of the metal strips which have been surface-treated in each case are brought into contact with the polymer film (5) in the coating-laminating-pressing unit (12) and connected to one another. These surface treatment stations (16.1,17.1) comprise means for applying a coating (16.11,17.11), in particular for spraying, bar coating or preferably a coating machine for coating with an adhesive and/or a gluing system and/or a surface treatment agent, and/or means for activating chemically and/or physically, preferably by means of plasma. The coating (16.11,17.11) of at least one side of the metal strips (3,4) with an adhesive and/or a gluing system and/or a surface treatment agent can be applied reproducibly and economically with low tolerances, particularly preferably by means of continuous coil coating. The coating thickness of the applied wet film is between 0.001 and 0.1mm, in particular between 0.001 and 0.05mm, preferably between 0.001 and 0.03mm, particularly preferably between 0.001 and 0.02 mm. Alternatively or additionally, the activation of at least one side of the metal strips (3,4) is preferably carried out by means of plasma in order to chemically and/or physically adjust the adhesion properties and the forming properties and/or the smoothness of the material composite (2).
Fig. 2 shows a schematic view of a second exemplary embodiment of a device (1') according to the invention for producing a material composite (2). The individual stations of the device (1) in the first embodiment are also present in the second embodiment, but with the difference that in the pretreatment unit (16,17) the metal strips (3,4) are passed before the surface treatment station (16.1,17.1) through in each case at least one straightening station (20,21), in which the stresses which are contained in the metal strips (3,4) and which can cause waviness in the uncoiled state can be eliminated or purposefully straightened out by the tension-bending load, as a result of which the metal strips (3,4) can be conveyed in the flattened state to the subsequent processing steps. After the straightening stations (20,21), the metal strips (3,4) are passed through cutting stations (22,23) in each case, in which the metal strips (3,4) are trimmed continuously along their longitudinal edges in order to be able to transport the metal strips (3,4) to a subsequent processing step with a defined width and/or a defined strip edge pattern. After the cutting stations (22,23), the metal strips (3,4) are passed through a cleaning station (24,25) in each case, in which the metal strips (3,4), in particular the surfaces of the metal strips (3,4), are cleaned and/or degreased in order to be able to provide at least one clean surface for the activation and/or coating of the metal strips (3,4) which takes place in the surface treatment station (16.1, 17.1). After activation and/or preferably after coating of the metal strips (3,4) with an adhesive and/or gluing system and/or surface treatment, the metal strips (3,4) are passed through at least one drying station (18,19) in which the adhesive and/or bonding system and/or surface treatment, preferably applied usually in liquid form, is dried at a temperature between room temperature and a temperature preferably below the decomposition temperature of the adhesive and/or gluing system and/or surface treatment used, in order to ensure that the applied adhesive and/or gluing system and/or surface treatment remains on the metal strips (3,4), which can then be reliably transported to subsequent processing steps, in particular to a preheating unit (9, 10). The preheated metal strips (3,4) and the preheated polymer film (5) are continuously conveyed to a coating, laminating and extrusion unit (12) for producing a material composite (2). The coating laminating extrusion unit (12 ') comprises at least one coating laminating extrusion station (12 '. 1) having a pair of coating rollers (12 '. 11) forming a coating gap (12 '. 12), the pair of coating rollers (12 '. 11) receiving the preheated metal strips (3,4) and the preheated polymer film (5) added between the metal strips (3,4) and coating them in such a way that the metal strips (3,4) form the outer metal layers of the material composite (2) and the polymer film (5) forms the core layer between the outer metal layers of the material composite (2). The coating/laminating/extrusion unit (12 ') furthermore comprises at least one device for reheating (12 '. 31,12 '. 32) and/or for post-coating (12 '. 41,12 '. 42), wherein after leaving the coating/laminating/extrusion station (12 '. 1), the material composite (2) is continuously conveyed to a first reheating station (12 '. 31) for reheating or completely heating the material composite (2) at least to a complete heating temperature which is higher than the preheating temperature of the polymer film (5), in particular between 100 ℃ and 300 ℃, in order to melt the core layer located between the outer metal layers. After leaving the reheating station (12 '. 31), the completely heated material composite (2) is continuously conveyed to a post-coating station (12'. 41) in order to adjust the high adhesion and/or shaping properties and/or smoothness and the desired thickness between the individual layers in the material composite (2) over the entire cross-section by targeted and defined pressure application. After leaving the post-coating station (12 '. 41), the process can be repeated as necessary, in particular to further improve the adhesion, by reheating the material composite (2) in the second reheating station (12 '. 31) and then continuously conveying it to the second post-coating station (12 '. 42), wherein the conditions can be substantially identical to those in the stations (12 '. 31,12 '. 41). The material composite (2) is then continuously conveyed to at least one cooling unit (13) having a first cooling station (13.1), for example an air cooler, in which the material composite (2) is cooled to a first temperature in a targeted manner, and a second cooling station (13.2), for example an air cooler, in which the material composite (2) is further cooled to a second temperature, which is lower than the first temperature, in a targeted manner. By active cooling in the cooling unit (13), the material composite (2) can be transported to subsequent processing steps, in particular to post-processing steps, in particular in order to ensure that further subsequent stations are not exposed to thermal loads. Conveying the cooled material composite (2) to a post-processing unit (26) comprising: at least one cutting station (26.1) comprising at least one device for trimming the longitudinal edge of the material composite (2), such as a trimmer; a straightening station (26.2) comprising at least one device for flattening the material composite (2), such as a straightener; a probing station (26.3) comprising at least one device for inspecting the material composite (2) for surface defects, flatness defects and/or geometry defects, for example a measuring system with an analysis unit; a coating station (26.4) comprising at least one device for coating the material composite (2), for example an electrostatic coating system. After passing through the post-processing unit (26), the material composite (2) can be divided into plates or rolled up into a bundle.
Fig. 3 shows a schematic view of a third embodiment of the device (1 ") according to the invention for producing a material composite (2). In this embodiment, the individual stations in the first and second embodiment are also present again, and therefore only the differences in particular compared to fig. 2 are discussed. The coating/laminating/extrusion unit (12 ") comprises, in addition to the stations already described in the second exemplary embodiment, a first coating/laminating/extrusion station (12". 1) and a second coating/laminating/extrusion station (12 ". 2). The preheated second metal strip (4) and the preheated polymer film (5) are continuously conveyed to a first coating lamination-extrusion station (12 ". 1) which has a first coating roller pair (12". 11) forming a coating gap (12 ". 12) and is coated or connected as a metal-polymer composite (2'). After the first coating, the metal-polymer composite (2 ') passes through a reheating station (12 ". 33) for reheating or completely heating the metal-polymer composite (2') at least to a complete heating temperature, which is higher than the preheating temperature of the polymer film (5), thereby preparing for a second coating-lamination-extrusion. The completely heated metal-polymer composite (2') and the preheated first metal strip (3) are continuously conveyed to a second coating lamination extrusion station (12 ". 2) which has a second coating roller pair (12". 21) forming a coating gap (12 ". 22) and is coated or connected as a material composite (2). The material composite (2) is produced in two coating, laminating and extrusion stations (12 '. 1, 12'. 2). The reheating stations (12 '. 41, 12'. 42) and the post-coating stations (12 '. 31, 12'. 32) can be omitted as required.
Fig. 4 shows a fourth embodiment of the device (1 "') according to the invention. Only a part of the device (1') is shown, which differs from the previous embodiment in that, in particular, the first metal strip (3) forming the upper metal outer layer during the production of the material composite (2) is passed between the uncoiling and preheating units (9) through a pretreatment unit (16), the metal strip (3) is surface-treated on at least one side in a surface treatment station (16.1) in the pretreatment unit (16), preferably coated with an adhesive and/or gluing system and/or a surface treatment agent, the metal strip (3) with the single-sided coating (16.11) is continuously conveyed to a drying station (18), in which the adhesive and/or gluing system and/or the surface treatment agent is dried, the metal strip (3) is heated in the preheating unit (9), then to a coating, laminating and extrusion unit (12 ') comprising at least one coating, laminating and extrusion station (12'.1). The continuous guidance of the metal strip (3) by the respective device (27) at least between the surface treatment station (16.1) and the coating/laminating/pressing unit (12') is preferably carried out in such a way that the side (16.11) of the metal strip (3) which is surface-treated, preferably coated with the adhesive and/or bonding system and/or surface treatment agent, is not in contact with the guiding device (27), in order to thereby exclude contamination of the device (27) by possible adhesion of the surface treatment components and contamination or damage to the surface-treated side (16.11) of the metal strip (3) by partial detachment of the adhesive and/or bonding system and/or surface treatment agent.
Reference numeral (28) shows a separating/threading station comprising means for completely separating the metal strip (3) and means for threading the separated metal strip (3). Auxiliary storage (intermediate storage) and/or distribution systems or the like can be provided in the separation/threading station. In particular, before the defined operating parameters are reached during the start-up, the surface treatment substance, preferably the applied adhesive and/or the applied gluing system and/or the applied surface treatment agent, is dried to a suitable extent or slightly dried, in particular in the pretreatment unit (16), by means of a dryer (18) and is first wound up on a device (29) for winding up, here shown in dashed lines. By a suitable degree of dryness is meant that the layers are not connected to each other or adhered or damaged when rolled up. The preheating in the preheating unit (9) is not carried out at this stage. If defined operating parameters are reached, the preheating unit (9) is switched on, the metal strip (3) is disconnected and fed in the process direction to the coating, laminating and pressing unit (12') by means of a feed-through auxiliary device. The coating-laminating-extrusion unit (12 "') can comprise a coating-laminating-extrusion station (12" '.1) with a pair of coating rollers (12 "'.11) with a coating gap (12" '.12) to which the preheated first metal strip (3), the preheated polymer film (5) and the preheated second metal strip (4), shown here in dashed lines, are continuously fed, or it comprises two coating stations, wherein in this case the preheated first metal strip (3) and the completely heated metal-polymer composite (2 ') are fed to the second coating station to produce the material composite (2), as described for fig. 3.
The invention is not limited to these embodiments, but may also comprise other designs. For example, the device according to the invention can also comprise further components, in particular in addition to the station described another unwinding station, a joining station, in particular a binding machine for joining a strip head to the end of a strip or a film head to the end of a film, at least one winding store for a metal strip, a polymer film and a material composite, respectively. The number of layers used for producing the material composite is also not limited to three, but the layer structure can be selected at will.
Description of the reference numerals
1, 1' device
2 Material composite
2' Metal-Polymer composite
3,4 metal strip
5 Polymer film
6,7,8 decoiler, decoiler unit
9,10,11 preheating unit
12, 12' cladding-laminating-extrusion unit
12.1,12 '. 1,12 ' 1,12 '. 2 cladding-laminating-extrusion station
12.11,12 '. 11,12 ' 11,12 '. 21 overlay roller pair
12.12,12 '. 12,12 '. 22,12 '. 12 cladding gap
12 '. 31, 12'. 32,12 '. 31, 12'. 32 reheating station
12 '. 41, 12'. 42,12 '. 41, 12'. 42 post-cladding station
13 cooling unit
13.1,13.2 Cooling stations
14 fixed-length cutting device
15,29 windup device
16,17 pretreatment unit
16.1,17.1 surface treatment station
16.11,17.11 unilateral surface treatment
18,19 drying station
20,21 straightening station
22,23 cutting station
24,25 cleaning station
26 post-processing unit
26.1 cutting station
26.2 alignment station
26.3 probing station
26.4 coating stations
27 guide device
28 separation/threading station

Claims (27)

1. Method for producing a material composite having at least two layers made of a metallic material and at least one layer made of a polymer matrix material arranged between the two layers, comprising the steps of:
-preparing a first material in the form of a metal strip wound on a coil, a second material in the form of a metal strip wound on a coil and a third material in the form of a polymer film wound on a coil,
-unwinding the bundles and continuously conveying the metal strip and the polymer film, respectively, to a preheating unit,
-preheating the metal strip and the polymer film in the preheating unit at least to a preheating temperature and continuously conveying to a coating-laminating-extrusion unit for producing a material composite under pressure and/or temperature,
-then continuously conveying the material composite to at least one cooling unit and/or at least one post-treatment unit,
-finally cutting the material composite to length into plates or rolling up the material composite into a bundle,
it is characterized in that the preparation method is characterized in that,
the first and second metal strips are each passed between the uncoiling and preheating units through at least one pretreatment unit, the first metal strip is surface-treated on at least one side in a surface treatment station of the first pretreatment unit, and the second metal strip is surface-treated on at least one side in a surface treatment station of the second pretreatment unit, and the surface-treated sides of the metal strips are brought into contact with the polymer film and connected to each other in a coating-laminating-extrusion unit, the metal strips are coated in the surface treatment station, the coating thickness is between 0.001mm and 0.1mm, and the metal strips are passed through at least one straightening station, a cutting station and/or a cleaning station in the pretreatment unit before the surface treatment station.
2. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
in the surface treatment station, the metal strip is coated by means of a coating gluing system and/or a surface treatment agent and/or is activated chemically and/or physically.
3. The method of claim 2, wherein the first and second light sources are selected from the group consisting of,
characterized in that the coating is a spray coating.
4. The method of claim 2, wherein the first and second light sources are selected from the group consisting of,
characterized in that the coating is a bar coating.
5. The method of claim 2, wherein the first and second light sources are selected from the group consisting of,
characterized in that the coating is by means of coating.
6. The method of claim 2, wherein the first and second light sources are selected from the group consisting of,
characterized in that the gluing system is an adhesive.
7. The method of claim 2, wherein the first and second light sources are selected from the group consisting of,
characterized in that the activation is by means of a plasma.
8. The method according to claim 1 or 2,
it is characterized in that the preparation method is characterized in that,
the metal strip passes through a drying station after the surface treatment station.
9. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
after the coating, laminating and extrusion unit, the material composite is cooled in at least one cooling station of a cooling unit.
10. The method of claim 9, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
after the coating, laminating and extrusion unit, the material composite is cooled in two cooling stations of a cooling unit.
11. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
in the post-processing unit, the material composite passes through at least one cutting station, one straightening station, one probing station and/or one coating station.
12. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
the continuous guidance of the first and/or second metal strip by the respective device at least between the surfacing station and the cladding-laminating-extrusion unit is carried out in such a way that the surfaced side of the metal strip is not in contact with the guiding device.
13. The method of claim 12, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
the side is the side coated with the gluing system.
14. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
the metal strip and the polymer film are fed to a coating laminating and extrusion unit having a coating laminating and extrusion station with a pair of coating rollers forming a coating gap in order to produce a material composite in the coating laminating and extrusion station.
15. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
the metal strip and the polymer film are conveyed to a coating-laminating-extrusion unit having a first coating-laminating-extrusion station with a first coating roller pair forming a coating gap and a second coating-laminating-extrusion station with a second coating roller pair forming a coating gap, in order to combine the second metal strip with the polymer film in the first coating-laminating-extrusion station as a metal-polymer composite and to combine the metal-polymer composite with the first metal strip in the second coating-laminating-extrusion station as a material composite.
16. The method of claim 1, wherein the first and second light sources are selected from the group consisting of,
it is characterized in that the preparation method is characterized in that,
aluminum, magnesium or steel material is used as the first and/or second metal strip and a thermosetting or thermoplastic polymer matrix is used as the polymer film.
17. Device (1,1 ', 1 ", 1"') for producing a material composite (2) having at least two layers made of a metallic material and at least one layer made of a polymer matrix material arranged between the two layers, using a method for producing a material composite according to any one of claims 1 to 16, the device having:
-unwinding means (6,7,8) of a first and a second metal strip (3,4) wound on a bundle and of a polymer film (5) wound on the bundle,
-preheating means (9,10,11) of said metal strips (3,4) and of the polymer film (5),
-a cladding-laminating-extrusion device (12, 12') for cladding-laminating-extruding the metal strips (3,4) and the polymer film (5) together to produce a material composite under pressure and/or temperature,
-cooling means (13) and/or post-treatment means (26) of the material composite (2),
-drive and/or guide means (27) of said metal strips (3,4), polymer film (5) and/or material composite (2), and
-a cut-to-length device (14) or a rolling-up device (15) of the material composite (2),
it is characterized in that the preparation method is characterized in that,
the device (1, 1') comprises a pretreatment device (16,17) for at least a first and a second metal strip (3,4), wherein the pretreatment device (16,17) comprises a first pretreatment unit (16) having a first pretreatment station (16.1) for the single-sided surface treatment (16.11) of at least the first metal strip (3) and a second pretreatment unit (17) having a second pretreatment station (17.1) for the single-sided surface treatment (17.11) of at least the second metal strip (4), wherein the pretreatment units (16,17) each comprise at least one straightening station (20,21), one cutting station (22,23) and/or one cleaning station (24, 25).
18. The apparatus as set forth in claim 17, wherein,
it is characterized in that the preparation method is characterized in that,
the surface treatment stations (16.1,17.1) have devices for applying coatings and/or devices for chemically and/or physically activating.
19. The apparatus of claim 18, wherein the first and second electrodes are disposed in a substantially cylindrical configuration,
characterized in that the means for applying the coating is a means for spraying or bar coating.
20. The apparatus of claim 18, wherein the first and second electrodes are disposed in a substantially cylindrical configuration,
characterized in that the device for applying a coating is a coater for applying a gluing system and/or a surface treatment agent.
21. The apparatus as set forth in claim 20, wherein,
characterized in that the gluing system is an adhesive.
22. The apparatus of claim 18, wherein the first and second electrodes are disposed in a substantially cylindrical configuration,
characterized in that the activation is by means of a plasma.
23. The apparatus as set forth in claim 17, wherein,
it is characterized in that the preparation method is characterized in that,
the devices (1 ', 1') each have at least one drying station (18,19) for the metal strips (3, 4).
24. The apparatus as set forth in claim 17, wherein,
it is characterized in that the preparation method is characterized in that,
the cooling unit (13) comprises at least one cooling station (13.1,13.2) and/or the post-treatment unit (26) comprises at least one cutting station (26.1), one straightening station (26.2), one probing station (26.3) and/or one coating station (26.4).
25. The apparatus of any one of claims 17 to 24,
it is characterized in that the preparation method is characterized in that,
the coating-laminating-extrusion unit (12, 12 ') comprises at least one coating-laminating-extrusion station (12.1, 12 '. 1,12 '. 1,12 '. 2,12 '. 2).
26. Use of a material composite (2) produced by a method according to any one of claims 1 to 16 for producing components for use in the field of mechanical manufacture, household goods or construction.
27. The use according to claim 26, wherein,
the method is characterized in that the mechanical manufacturing comprises shipbuilding and aircraft manufacturing.
CN201780007618.2A 2016-01-20 2017-01-04 Method and device for producing a material composite and use thereof Expired - Fee Related CN108541236B (en)

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