CN117940220A - 用于制造电气应用所用的钢带的过程和相关联的设备 - Google Patents
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Abstract
一种用于连续制造电气应用所用的涂覆有清漆的钢带S的涂覆设备(1)，该涂覆设备包括罐状件(2)、涂覆辊(3)和施加辊(4)，其中：‑所述罐状件(2)能够容纳清漆溶液，并且构造成使得所述涂覆辊(3)与所述清漆溶液接触，‑所述涂覆辊(3)构造成与所述施加辊(4)接触，并且沿钢带宽度方向将所述清漆均匀地转移到所述施加辊(4)上，‑所述施加辊(4)构造成与所述钢带S接触并且在所述钢带的宽度上均匀地涂覆所述钢带，并且所述施加辊的表面具有40肖氏A至60肖氏A的硬度。
Description
技术领域
本发明涉及用于连续制造电气应用所用的涂覆有均匀清漆层的钢带的设备和方法。
背景技术
术语“电气应用”涉及使用钢带来制造具有特定磁性能的物品，例如电动马达的定子和转子、变压器和风车的涡轮机。用于电气应用的钢也被称为电工钢并且通常包含0重量百分比至6重量百分比的硅。电工钢可以分为两类：无取向钢和取向钢。
电工钢通常涂覆有清漆以使钢绝缘，从而防止电流流动并减少涡流。该清漆通常为水基溶液，该水基溶液包含25重量百分比至75重量百分比的树脂和5重量百分比至15重量百分比的溶剂(比如乙醇)以及由水组成的余量。上清漆过程包括至少两个步骤：将清漆以湿膜的形式涂覆的第一步骤，以及将清漆固化以获得网状干膜的第二步骤。湿膜的厚度通常为1.5μm至15μm，以便获得0.8μm至5μm的干膜厚度。
在制造过程中，上清漆是在退火后进行的。根据生产线架构，上清漆工段可以与退火炉联接或者不联接。清漆工段与退火炉联接或者不联接的事实影响线速度。此外，清漆需要在峰值金属温度(PMT)下的干燥步骤中成网状，这也限制了最大速度线。因此，线速度可以从30m.min-1至300m.min-1变化。
US 6 277 196旨在以高速在电工钢带上一致地涂覆薄且均匀的绝缘漆层。该设备包括雕刻的拾取辊和施加辊，施加辊具有没有凹槽或其他凹痕的基本上平坦的表面。
EP 3 143 179公开了一种用钝化层均匀地涂覆包装钢的过程和设备。该设备包括腔式刮刀、涂覆辊和施加辊。
发明内容
本发明的目的是提供一种允许在较宽范围的线速度下对电工钢带均匀地上清漆的设备和方法。因此，钢上的清漆层不应呈现任何图案。事实上，大多数用于电工钢的涂覆设备都与退火炉联接，从而导致线速度发生变化。
这通过提供一种根据权利要求1至6中的任一项所述的设备来实现。这还通过提供一种根据权利要求7至14中的任一项所述的方法来实现。
其他特征和优点将从本发明的以下描述中变得明显。
附图说明
图1图示了本发明的实施方式。
图2图示了本发明的第二实施方式。
图3图示了施加辊的硬度和速度线对最大清漆厚度的影响。
具体实施方式
如图1中所示，本发明涉及一种用于连续制造电气应用所用的涂覆有清漆的钢带S的涂覆设备1，该涂覆设备1包括罐状件2、涂覆辊3和施加辊4，其中：
-所述罐状件2能够容纳清漆溶液并且构造成使得所述涂覆辊3与所述清漆溶液接触，
-所述涂覆辊3构造成与所述施加辊4接触并且沿钢带宽度方向将所述清漆均匀地转移到所述施加辊4上，
-所述施加辊4构造成与所述钢带S接触，并且在所述钢带的宽度上均匀地涂覆所述钢带，并且所述施加辊的表面具有40肖氏A至6肖氏A的硬度。
图2示出了钢带S沿着方向D前进通过上清漆装置。钢带首先行进通过涂覆设备1，其目的是施加清漆溶液，然后通过干燥单元5，其目的是消除清漆的水分，并且然后使清漆成网状。测量所涂覆的清漆的厚度的装置6可以位于涂覆设备1与干燥单元5之间，并且可以连接至涂覆设备1的控制单元9。
在图2中所图示的实施方式中，涂覆设备1能够同时涂覆钢带的两个面，但是在替代实施方式中，涂覆设备1可以仅由设备的左侧部分1A或右侧部分1B组成，使得涂覆设备仅涂覆钢带的单个面。
图1中图示了涂覆设备1的左侧部分1A的一个实施方式。右侧部分1B没有被描述，因为右侧部分1B与左侧部分1A关于钢带S对称。
如图1中所图示的，该装置由第一辊4组成，第一辊4为施加辊4。该施加辊4一方面与钢带S接触，并且另一方面与第二辊3接触，第二辊3为涂覆辊3。在制造过程期间，涂覆辊3旋转并且与罐状件2中容纳的待沉积在钢带S上的清漆溶液接触。施加辊与清漆溶液之间的接触可以通过将所述涂覆辊浸渍到所述清漆溶液中来实现。罐状件2优选地配备有擦拭装置，该擦拭装置将溶液挤压到涂覆辊3的表面上。
擦拭装置使得可以确保涂覆辊3涂覆有必要量的待沉积溶液，以获得所需的湿清漆厚度。该擦拭装置优选地配备有刮刀。该装置可以包括两个刀片，例如，第一刀片位于涂覆辊3进入罐状件2的点处，并且使得可以去除涂覆辊3先前通过罐状件2残留的残余清漆溶液，并且第二刀片位于涂覆辊3离开罐状件2的点处，并且使得可以去除多余的溶液。刀片可以由例如塑料、不锈钢或碳纤维制成。该装置还可以是位于涂覆辊3离开罐状件2的点处的单个刀片、例如由不锈钢制成的刀片。
如图1中所图示的，罐状件优选地为腔式刮刀。腔式刮刀系统使用两个刮刀以及封闭的清漆腔，以将清漆分配至涂覆辊。通常，第一刀片用作计量刀片并从涂覆辊上擦去多余的清漆，并且第二刀片用作捕获或容纳刀片并将清漆保持在室内。
该清漆溶液的粘度为20℃下2.5×10-2Pa.s至20℃下4.0×10-1Pa.s。在第一示例中，溶液包含30重量百分比至50重量百分比的由丙烯酸树脂和磷酸盐颜料组成的干提取物、5重量百分比至10重量百分比的共溶剂(乙醇)、以及由水组成的余量。在另一示例中，该溶液包含40重量百分比至60重量百分比的为聚氨酯树脂与铝和氧化硅的混合物的干提取物、5重量百分比至10重量百分比的共溶剂(乙醇)、以及由水组成的余量。
涂覆辊3是由表面被雕刻的陶瓷涂覆的辊。更准确地，涂覆辊3雕刻有任何图案或单元结构。例如，图案可以为60°或30°或70°的六边形单元、线条图案、眼镜蛇形图案。涂覆辊的单元充满清漆溶液。涂覆辊的表面可以由陶瓷制成。涂覆辊的单元可以借助于激光或机械工具进行蚀刻。
虽然涂覆辊雕刻有图案，但是涂覆辊构造成将清漆均匀地转移到施加辊上。这意味着没有图案被转移至施加辊。因此，清漆厚度在宽度方向上是均匀的。
在第一优选实施方式中，涂覆辊3具有多个60°的六边形单元，六边形单元的线数为每厘米50线至200线，并且六边形单元的体积为每平方米辊表面5×10-6m3至6×10-5m3，并且优选地为每平方米辊表面1×10-6m3至5×10-5m3。
在第二优选实施方式中，涂覆辊3具有单元体积为每平方米辊表面1×10-5m3至8×10-5m3的眼镜蛇形图案。
在第三优选实施方式中，涂覆辊3具有单元体积为每平方米辊表面1×10-5m3至4×10-5m3的四边形图案。
在通过罐状件2后，涂覆辊3的涂覆有清漆溶液的表面与施加辊4接触。涂覆辊3可以沿顺时针方向或沿相反方向旋转。施加辊4优选地本身沿与涂覆辊3的旋转方向相反的旋转方向被驱动。
施加辊4或至少其表面优选地由下述材料制成：该材料使得可以实现溶液的最佳转移、即最大程度地减小溶液的损失的转移，溶液的损失例如由于制成辊或辊的表面的材料的吸收、或者相反地通过溶液在辊表面上的过度滑移而造成。这种材料还可以表现出耐化学腐蚀性以及耐机械磨损性。优选地，施加辊3由弹性体制成。在第一优选示例中，施加辊由氯磺化聚乙烯制成。在第二优选实施方式中，施加辊由聚氨酯制成。
施加辊构造成在宽度方向上均匀地涂覆所述钢带。因此，所得到的经涂覆的钢带上不存在清漆图案。为了实现这种均匀的涂覆，施加辊表面是没有凹槽或其他凹痕的基本上平坦的表面。
优选地，施加辊3的粗糙度Ra为0.5μm至3.5μm。如果施加辊的粗糙度Ra大于3.5μm，则可能出现所涂覆的清漆的不均匀性。甚至更优选地，所述施加辊的粗糙度Ra为0.6μm至1.5μm。
施加辊具有40肖氏A至60肖氏A的硬度。硬度可以按照ASTM D2240标准进行测量。
如果硬度低于40肖氏A，则施加辊的使用寿命由于涂层工艺而严重缩短。优选地，施加辊3具有至少45肖氏A的硬度，这样的最小硬度提供了更好的使用寿命，并且仍然提供了辊的良好变形从而产生均匀涂覆。
如果硬度大于60肖氏A，则最大清漆湿厚度是非常有限的，特别是对于较小的线速度来说更是如此。优选地，施加辊3具有至多55肖氏A的硬度。
实际上，在图3中，根据速度线绘制了涂覆辊可以涂覆的最大清漆湿厚度。这是针对辊表面的几种硬度绘制的：40肖氏A和60肖氏A(根据本发明)以及80肖氏A。所有曲线都是针对施加至施加辊的每米钢带宽度3000N的总力和20℃下0.12Pa.s的粘度绘制的。
可以观察到，对于根据本发明的涂覆辊，针对至少30m.min-1的速度线，可以涂覆的最大湿厚度为至少15μm。
因此，所要求的施加辊的硬度范围在确保足够的耐用性的同时提供了较宽范围的清漆涂覆湿厚度。
本发明还涉及一种用于连续制造涂覆有清漆的钢带的方法，该方法借助于如前所述的设备来实施，
其中，清漆层沉积在所述钢带的面的至少一个面上，所述清漆层的湿厚度为1.5μm至15μm，并且所述清漆的粘度为20℃下2.5×10-2Pa.s至20℃下4.0×10-1Pa.s，并且
其中，所述涂覆辊通过与容纳在所述罐状件中的清漆接触而被供应清漆，并且所述施加辊与所述涂覆辊和所述钢带接触，并且所述钢带以至少30m.mim-1的速度运行。
优选地，所述钢带为电工钢带。甚至更优选地，所述钢带是无取向电工钢带。所述无取向电工钢带优选地包含1.5重量百分比至4重量百分比的硅。
优选地，钢带以30m.mim-1至500m.mim-1的速度运行。甚至更优选地，钢带以30m.mim-1至300m.mim-1的速度运行。
涂覆辊3与施加辊4之间的接触压力必须足以将清漆溶液从涂覆辊转移至施加辊，但是接触压力不能太大以致于导致飞溅，飞溅会导致溶液损失并且因此导致溶液的非最佳转移。例如，可以借助于安装在涂覆辊3上的气缸来施加所述两个辊之间的压力。施加至涂覆辊3的合力FRR优选地为每米钢带宽度500N至3000N。
在该接触之后，施加辊4被涂覆有待沉积在钢带S上的湿清漆溶液。
施加辊4与钢带之间的接触压力不能太大，否则有擦除过多沉积的湿清漆溶液膜的风险，也不能太低，否则有钢带未被溶液充分润湿的风险。此外，辊必须在钢带上施加最小的压力，以补偿钢带中潜在的平整度缺陷。例如，施加辊4与钢带S之间的该压力可以借助于安装在施加辊上的至少一个气缸来施加。施加至施加辊4的总力FTB优选地为每米钢带宽度2000N至6000N。
施加辊4和涂覆辊3的旋转速度可以与钢带的移位速度同步。
在本发明的一个实施方式中，借助于厚度测量装置6来测量所沉积的湿清漆厚度的厚度。
另外，或者在本发明的附加实施方式中，涂覆辊3的旋转速度可以由图1所图示的控制单元9控制。该控制单元9连接至测量湿清漆厚度的装置。如果厚度小于目标厚度，则增大涂覆辊3的速度，并且如果厚度大于目标厚度，则减小涂覆辊3的速度。
例如，可以借助于电磁辐射测量仪来测量厚度。这些测量仪优选地尽可能靠近涂覆设备1安装，因为水分从膜中蒸发得非常快，这可能引起测量结果的显着变化。
在沉积湿清漆层的步骤之后，钢带经受干燥步骤。该干燥步骤借助干燥装置5进行。
优选地，在该干燥阶段之后，干燥后沉积的清漆层的厚度为0.8μm至5μm。
该干燥单元5例如是配备有喷嘴的干燥隧道，该喷嘴在120℃与350℃之间的温度下向所涂覆的钢带的方向喷射空气。干燥单元也可以是将钢带的温度增高至PMT、优选地在220℃与290℃之间的感应器。
Claims (14)
1.一种用于连续制造电气应用所用的涂覆有清漆的钢带S的涂覆设备1，所述涂覆设备1包括罐状件2、涂覆辊3和施加辊4，其中：
-所述罐状件2能够容纳清漆溶液并且构造成使得所述涂覆辊3与所述清漆溶液接触，
-所述涂覆辊3构造成与所述施加辊4接触并且沿钢带宽度方向将所述清漆均匀地转移到所述施加辊4上，
-所述施加辊4构造成与所述钢带S接触，并且在所述钢带的宽度上均匀地涂覆所述钢带，并且所述施加辊的表面具有40肖氏A至60肖氏A的硬度。
2.根据权利要求1所述的设备，其中，所述施加辊的所述表面具有40肖氏A至55肖氏A的硬度。
3.根据权利要求1或2所述的设备，其中，所述施加辊的所述表面由弹性体制成。
4.根据权利要求3所述的设备，其中，所述施加辊的所述表面由聚氨酯制成。
5.根据前述权利要求中的任一项所述的设备，其中，所述罐状件为腔式刮刀。
6.根据前述权利要求中的任一项所述的设备，其中，所述罐状件配备有擦拭装置10。
7.一种用于连续制造涂覆有清漆的钢带的方法，所述方法借助于根据权利要求1至6中的任一项所述的设备来实施，
其中，清漆层沉积在所述钢带的面中的至少一个面上，所述清漆层的湿厚度为1.5μm至15μm，并且所述清漆的粘度为20℃下2.5×10-2Pa.s至20℃下4.0×10-1Pa.s，并且
其中，所述涂覆辊通过与容纳在所述罐状件中的清漆接触而被供应清漆，并且所述施加辊与所述涂覆辊和所述钢带接触，并且所述钢带以至少30m.min-1的速度运行。
8.根据权利要求7所述的方法，其中，所述钢带是电工钢。
9.根据权利要求8所述的方法，其中，所述钢带是无取向电工钢。
10.根据前述权利要求中的任一项所述的方法，其中，所述清漆是水基清漆。
11.根据前述权利要求中的任一项所述的方法，其中，施加在所述涂覆辊上以接触所述施加辊的总力为每米所涂覆钢带宽度500N至3000N。
12.根据前述权利要求中的任一项所述的方法，其中，施加在所述施加辊上以接触所述钢带的总力为每米所涂覆钢带宽度2000N至6000N。
13.根据前述权利要求中的任一项所述的方法，其中，在所述清漆沉积之后，所述钢带经受干燥步骤。
14.根据前述权利要求中的任一项所述的方法，其中，所沉积的所述清漆层在干燥后的厚度为0.8μm至5μm。
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| PCT/IB2021/059204 WO2023057796A1 (en) | 2021-10-07 | 2021-10-07 | Process and apparatus for manufacturing a steel strip for electrical applications |
| PCT/IB2022/059551 WO2023057948A1 (en) | 2021-10-07 | 2022-10-06 | Process for manufacturing a steel strip for electrical applications and associated apparatus |
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| GB9625122D0 (en) | 1996-12-03 | 1997-01-22 | Europ Electrical Steels | Coating apparatus |
| US6306098B1 (en) | 1996-12-19 | 2001-10-23 | Novametrix Medical Systems Inc. | Apparatus and method for non-invasively measuring cardiac output |
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