EP1398096A1 - Method for making integrated circuit aluminium panels - Google Patents

Abstract

Fabrication of a one side flat aluminum integrated circuit panel consists of preparing the surface of two aluminum alloy sheets, depositing on one of the sheets an anti-weld ink in reserved zones corresponding to the circuit design, roll-bonding the sheets and expanding the channels corresponding to the non-welded zones with a pressurized fluid. One of the sheets is made of series 1000 alloy and the other is made of an alloy of iron and manganese in which Fe+Mn is greater than 0.8 wt %, preferably greater than 1% or even 1.5%. An Independent claim is also included for the continuous fabrication of integrated circuit panels formed from at least three metal strips.

Description

Field of the invention

The invention relates to a method for manufacturing circuit aluminum panels. integrated, generally known as roll-bond, two-sided two-sided type deformed or single-sided or OSF (one side flat) with one flat side and one side distorted. These panels are made from two aluminum or alloy sheets of aluminum, one of which is coated, on the areas intended to become the circuit integrated, ink intended to prevent welding between the two sheets. Both sheets are then welded by co-laminating. Unwelded areas are then inflated hydraulically or pneumatically to form a circuit, the essential part of which is used as a heat exchanger, and in particular as a heating circuit cooling of household refrigerators.

State of the art

The book "Aluminum", volume 1 "Production - Properties - Alloys - Manufacturing semi-finished products - Annexed Fabrications ”, published by Editions Eyrolles, Paris 1964, pages 718 - 721, and the publication "Aluminum panels with integrated circuits: two complementary manufacturing lines for multiple products ”, published in the Aluminum Review, February 1982, describes the principle of the roll-bond process for the manufacture of two-sided type panels, and disclose the diagram of a line of continuous manufacturing, as well as the alloys usually used for the manufacturing of panels. In this continuous manufacturing line, the panels are formed from individual sheets (called "plates" in the book), which are transported manually or by mechanical conveyance through the different machines that make up the production line.

Patent FR 1 347 949 (Olin Mathieson) describes the principle of circuit panels integrated single-sided and offers to realize them from two resistance sheets different mechanics, one in 1100 alloy and the other in 1100 alloy with addition 0.12% zirconium.

Patent FR 2561368 (Cegedur Pechiney) discloses a manufacturing process in continuous single-sided roll-bond panels from two aluminum sheets or aluminum alloys.

The publication "High Performance Airgap Heat Shields Using Blow-Molded Roll-Bond Aluminum Technology "by V.J. Scott et al., Published in SAE Technical Paper Series (International Congress & Exposition, Detroit, Michigan, February 28-March 3, 1994), describes a production line for roll-bond panels which includes debranching and brushing of the two strips, application of the separating medium, preheating and rolling the strips to form a composite strip. This one is then subjected to coil annealing in a static oven.

This process is therefore not a continuous process. The use of a static oven allows more precise control of annealing conditions than processes using a passage, but the interruption represented by coil annealing presents disadvantages of an economic nature, decreases the response time of the chain production compared to commercial demand, and requires inventory management of intermediate products.

A particular problem in the roll-bond process is the quality and durability of channels formed. European patent EP 0 703 427 (Showa Aluminum) proposes a process which aims to reduce the number of defects during inflation (rupture of channels or local absence of deformation).

According to the Applicant's findings, the existing production lines do not not allow the manufacture of panels, and in particular single-sided panels, strong mechanical characteristics. Furthermore, it is desirable to guarantee that the panels formed, before inflation, are free from unacceptable defects.

The object of the invention is to provide a continuous manufacturing process for panels roll-bond, which is suitable for the manufacture of single-sided panels with strong mechanical characteristics and which allows, both for type panels single-sided and double-sided, early detection of faulty panels.

Subject of the invention

(a) l'alimentation de la chaíne de fabrication en deux bandes d'alliage d'aluminium A et B,

(b) optionnellement le décambrage des bandes A et B,

(c) le brossage des bandes A et B,

(d) l'application sur la bande A d'une encre anti-soudure,

(e) optionnellement le contrôle de la qualité de cette application,

(f) le préchauffage des bandes A et B,

(g) l'application à l'aide d'un laminoir de la bande B sur la surface de la bande A pour obtenir une bande composite,

(h) le recuit de la bande composite dans un four,

(i) le refroidissement de la bande composite,

(j) optionnellement, le planage de la bande composite,

(k) la découpe de la bande composite en panneaux,

(l) optionnellement un dispositif permettant l'élimination des panneaux comportant des défauts d'application de l'encre anti-soudure, détectés lors du contrôle à l'étape (e),

(m)le transfert des panneaux dans une presse de gonflage à plusieurs étages,

(n) le gonflage des canaux,

(o) la sortie des panneaux de la presse et leur empilage pour conditionnement.

The subject of the invention is a continuous process for manufacturing integrated circuit panels of aluminum alloy comprising the following steps:

(a) supplying the production line with two strips of aluminum alloy A and B,

(b) optionally descaling of bands A and B,

(c) brushing strips A and B,

(d) applying to the strip A an anti-welding ink,

(e) optionally controlling the quality of this application,

(f) preheating of bands A and B,

(g) applying with a rolling mill strip B to the surface of strip A to obtain a composite strip,

(h) annealing the composite strip in an oven,

(i) cooling the composite strip,

(j) optionally, leveling the composite strip,

(k) cutting the composite strip into panels,

(l) optionally a device allowing the elimination of the panels comprising defects in the application of the anti-welding ink, detected during the control in step (e),

(m) transferring the panels to a multi-stage inflation press,

(n) inflating the canals,

(o) the output of the press panels and their stacking for packaging.

Description of the invention

The invention relates to an improved manufacturing method for circuit panels. integrated in a two-sided or single-sided aluminum alloy. In the rest of the description we will designate by “strip A” the strip of aluminum or alloy aluminum to which the anti-welding ink is applied, "strip B" the strip in aluminum or aluminum alloy which is applied to strip A, "strip composite ”the strip formed from strips A and B, and by“ panels ”the panels formed by cutting the composite strip.

(a) l'alimentation de la chaíne de fabrication en bandes A et B,

(b) le décambrage des bandes A et B,

(c) optionnellement le brossage des bandes A et B,

(d) l'application de l'encre anti-soudure sur la bande A,

(e) le contrôle de la qualité de cette application,

(f) le préchauffage des bandes A et B,

(g) la création d'une bande composite par passage sous un laminoir de la bande A qui comporte l'encre, et de la bande B

(h) le recuit de la bande composite dans un four,

(i) le refroidissement de la bande composite,

(j) optionnellement, le planage de la bande composite,

(k) la découpe de la bande composite en panneaux,

(l) optionnellement l'élimination des panneaux comportant des défauts d'application du milieu séparateur, détectés lors du contrôle (e),

(m)le transfert des panneaux dans une presse de gonflage à plusieurs étages,

(n) le gonflage, de préférence simultané, des panneaux à tous les étages,

(o) la sortie des panneaux de la presse et leur empilage pour conditionnement.

The continuous process according to the invention comprises the following stages:

(a) feeding the production line with strips A and B,

(b) the descaling of bands A and B,

(c) optionally brushing the bands A and B,

(d) applying the anti-welding ink to the strip A,

(e) quality control of this application,

(f) preheating of bands A and B,

(g) the creation of a composite strip by passage under a rolling mill of the strip A which contains the ink, and of the strip B

(h) annealing the composite strip in an oven,

(i) cooling the composite strip,

(j) optionally, leveling the composite strip,

(k) cutting the composite strip into panels,

(l) optionally eliminating the panels comprising defects in the application of the separating medium, detected during the check,

(m) transferring the panels to a multi-stage inflation press,

(n) the inflation, preferably simultaneously, of the panels on all the floors,

(o) the output of the press panels and their stacking for packaging.

The bands A and B can be fed by two unwinders. In preferred embodiment of the invention, each of the two unwinders is provided with a mobile splicing device, allowing each band A and B to be changed without interrupting the running of the strips in the production line.

Before its introduction into the production line, it is advantageous to degrease the strips, for example by a flame method or any other known method of the skilled person.

It is advantageous to brush the surfaces of the strips A and B intended to enter into contact. Rotating brushes with steel wires are suitable for this purpose.

The application of the anti-welding ink on the strip A can be carried out by screen printing techniques known to those skilled in the art. Quality control of this screen printing can be done by a qualified operator. In a preferred embodiment of the invention, the quality of this application is preferably controlled by a automatic machine vision device capable of detecting faults unacceptable and identify the position of the faulty circuits on strip A. This device acquires the printed image and compares it to a reference deemed perfect. This system then eliminates the panels on the circuit before inflating which an unacceptable fault has been detected.

As a preheating oven, any continuous oven known to those skilled in the art loom can be used, for example a direct flame oven. In an achievement preferred of the invention, this oven allows temperature regulation so as to keep the temperature constant across the width of bands A and B in a interval between ± 10 ° C maximum, preferably between ± 7 ° C, and even more preferably in an interval between ± 5 ° C.

The application of band B on band A can be done in a traditional rolling mill and preferably in a quarto rolling mill. In a preferred embodiment of the invention, the two cylinders which come into contact with the strip are brushed with during rolling. The brushing device disclosed in the French patent FR 2568495 is suitable for this purpose.

For the annealing of the composite strip any continuous oven known to man of the trade can be used. In a preferred embodiment of the invention, this oven allows temperature regulation to keep the temperature constant over the entire width of the strip in an interval between ± 10 ° C, from preferably between ± 7 ° C, and even more preferably within a range between ± 5 ° C. The cooling of the composite strip can be done by spraying any refrigerant, liquid or gaseous, and preferably by spraying with water.

If it is necessary to level the composite strip at this stage, this leveling can be done for example mechanically by more or less nesting significant band between two layers of metal rollers.

The cutting of the composite strip into panels can be done using a shears fixed. In this case, it is necessary to add a tape accumulator which allows cut without interrupting the continuous running of the strip. In preferred embodiment of the invention, a flying shear is used, which makes superfluous the strip accumulator capable of inducing defects on the composite strip.

In a preferred embodiment of the invention, the panels are then eliminated whose circuits were detected as defective during the check, before transferring panels whose quality has been deemed acceptable in the inflation press. This transfer is advantageously done by loading the panels in an elevator.

Then the panels are transferred using a robot, for example by a robot to six axes, in the press.

The inflation press has several stages, preferably at least four stages, and even more preferably at least eight stages. In this press, the circuits are inflated using a pressurized fluid through a needle which is introduced into the inflation channel, between the two faces of each sign. The panels in the press can be inflated one after the other or, preferably, simultaneously. In a preferred embodiment of the invention, this press is of a construction such that it allows the inflation of single-sided panels, that is to say of panels comprising circuits inflated on one side only, the other face being flat, and of two-sided panels, that is to say of panels comprising inflated circuits on both sides. For the manufacture of single-sided panels, a back pressure is applied to the face opposite the planar face, according to the techniques known to those skilled in the art and described, for example, in the FR patent 2561368 cited above.

The press panels exit advantageously by a robot, by example a six-axis robot, which unloads the inflated panels from the press to a descender, which transfers the panels to a stacker making it possible to constitute stacks of panels ready to be packaged for shipment.

In a preferred variant of the invention, the bands A and B are centered and composite tape. For example, centering before entering the strip in the grip of the rolling mill is useful.

The invention as described above can be advantageously applied to the manufacture of all roll-bond panels for existing refrigerating appliances or for other heat exchange or transfer applications.

It can also be used for the manufacture of application panels structural, such as reinforcements for automobile bodywork. The plaintiff has found that in some cases it may be advantageous to use a panel composite made from more than two type A bands, which may contain a single circuit or several circuits, identical or not. In this case, by "Type A strip" means the strip or strips of aluminum or aluminum alloy on which (or which) is applied the anti-welding ink. By "band of type B "the strip (s) of aluminum or aluminum alloy which will be applied on the type A strip (s), and which do not include screen printing. As example, a roll-bond panel made up of three superimposed strips comprising two superimposed circuits consists of two type A bands and a band of type B. “Composite strip” means the strip formed from the strips of type A and type B, and by "panels" the panels formed by cutting the composite tape.

(a) l'alimentation de la chaíne de fabrication en deux bandes de type A et une de type B,

(b) le décambrage des bandes de type A et de type B,

(c) le brossage des bandes de type A et de type B,

(d) l'application du milieu séparateur sur les bandes de type A,

(e) optionnellement le contrôle de la qualité de cette application,

(f) le préchauffage des bandes de type A et de type B,

(g) la création d'une bande composite par passage sous un laminoir des bandes de type A qui comporte le milieu séparateur, et des bandes de type B,

(h) le recuit de la bande composite dans un four,

(i) le refroidissement de la bande composite,

(j) optionnellement, le planage de la bande composite,

(k) la découpe de la bande composite en panneaux,

(l) optionnellement l'élimination des panneaux comportant des défauts d'application de l'encre, détectés lors du contrôle (e),

(m)le transfert des panneaux dans une presse de gonflage à plusieurs étages,

(n) le gonflage, de préférence simultané, des panneaux à tous les étages,

(o) la sortie des panneaux de la presse et leur empilage pour conditionnement.

In this case, the continuous process according to the invention then comprises the following steps:

(a) supplying the production line with two strips of type A and one of type B,

(b) decambering type A and type B bands,

(c) brushing the type A and type B strips,

(d) applying the separating medium to the type A strips,

(e) optionally controlling the quality of this application,

(f) preheating of type A and type B strips,

(g) the creation of a composite strip by passing under strips of type A strips which comprises the separating medium, and of type B strips,

(h) annealing the composite strip in an oven,

(i) cooling the composite strip,

(j) optionally, leveling the composite strip,

(k) cutting the composite strip into panels,

(l) optionally eliminating the panels containing ink application defects, detected during the check (e),

(m) transferring the panels to a multi-stage inflation press,

(n) the inflation, preferably simultaneously, of the panels on all the floors,

(o) the output of the press panels and their stacking for packaging.

Example

The supply of the chain is done by a mobile splicing device allowing to change each of bands A and B without interrupting the scrolling of bands in the production line. This cart is equipped with mobile welders without input of metal to make the junction between the strips from two coils of metal.

The stripping of the strips A and B is done by a motorized roller stripper.

The surfaces A and B intended to come into contact are brushed by motorized metal brushes.

The stencil screen printing is done in a closed enclosure under pressure, allowing minimize dust deposits and the appearance of defects on the belt. Screens whose fabric structure and thread density are adjusted according to the print desired are used; screen printing is carried out by known techniques of the skilled person. The supply of non-stick ink on the canvas is automatic and allows a good homogeneity of the quantity of ink. The changing screens when changing series is done without stopping the line and is semi-automated. After screen printing, an additional ink stain is added to band A at the end of the patterns; said spot serves as marking during the cutting the composite strip into panels.

The quality of screen printing is controlled by an industrial vision device, fitted with line cameras. All patterns are acquired, processed and compared to a reference model image. This device makes it possible to check the functional dimensions patterns and spot any flaws (such as unnecessary spots, lack ink or imprecise edges). The position of the defective patterns is identified by the control computer to allow the panels which have these defective patterns before the inflation step.

The preheating oven is a pass-through gas oven. It is made up of two parts allowing to heat successively band B and band A. Its power is 1800 kW. The temperature of the strip in the oven is typically of the order of 400 ° C, but can go up to 500 ° C, depending on the alloys used. The oven has two heating zones twice. The temperature is kept constant à by a regulation system at ± 7 ° C.

The rolling mill used is a quarto rolling mill making it possible to achieve rolling of around 1400 tonnes, with the possibility of variable balancing.

The annealing furnace is a 1220 kW pass-through gas furnace. Temperature of the composite strip in the furnace is typically of the order of 400 ° C. but can go up to 500 ° C, depending on the alloys used. The oven has four zones of heating. The temperature is kept constant by a regulation system at ± 7 ° C.

The leveling of the composite strip is done by a leveler comprising 17 rollers variable nesting, known to those skilled in the art.

An ultrasonic sensor allows the detection of the ink stain deposited during the serigraphy and triggers the cutting of the composite strip into panels by a flying shears. The panels feed an elevator and are loaded in batches of eight in the inflation press using the six-axis robot.

The inflation press is a 2500-ton hydraulic press allowing the simultaneous inflation of the panels on all floors. Scheduled cycles allow online inflation of two-sided and single-sided panels. For panels single sided, back pressure is applied on all stages in addition to pressure inflation. The inflation cycles are controlled by a computer. The press is equipped with leak detection devices during inflation and allows elimination defective panels thus identified.

The panels whose channels have been inflated are discharged from the press by a second six-axis robot on a descender. The process parameters are adjusted in function of the scrolling speed measured at several points on the line. The speed of bands A and B can reach 15m / min. The speed of the composite tape can reach 30 m / min, for a rolling ratio of 2. The different settings for the line are managed automatically from a product database. The width of the strips used can reach 700 mm.

Claims (9)

Continuous process for manufacturing integrated circuit panels, comprising: (a) feeding the production line with strips A and B, (b) optionally descaling of bands A and B, (c) brushing strips A and B, (d) applying an anti-welding ink to the strip A, (e) optionally controlling the quality of this application, (f) preheating of bands A and B, (g) applying, with a rolling mill, strip B to the surface of strip A to obtain a composite strip, (h) annealing the composite strip in an oven, (i) cooling the composite strip, (j) optionally, leveling the composite strip, (k) cutting the composite strip into panels, (l) optionally eliminating the panels comprising ink application defects, detected during the control of step e, (m) transferring the panels to a multi-stage inflation press, (n) inflating the canals, (o) the output of the press panels and their stacking for packaging. Method according to claim 1, characterized in that the change of the bands A and B is carried out by splicing without interrupting the running of the composite band. Method according to one of claims 1 or 2, characterized in that the annealing of the composite strip in step h is done so that the temperature of said composite strip is maintained over its entire width in a range between ± 10 ° C, and preferably ± 5 ° C. Method according to one of claims 1 to 3, characterized in that the preheating of the strips A and B in step f is carried out so that the temperature of each of said strips is maintained over its entire width within a range included between ± 10 ° C, and preferably ± 5 ° C. Method according to one of claims 1 to 4, characterized in that the inflation press has at least 4 and preferably at least 8 stages. Method according to one of claims 1 to 5, characterized in that the cutting of the composite strip in step k is carried out using a flying shear. Method according to one of claims 1 to 6, characterized in that the rolling mill is a quarto rolling mill. Method according to one of claims 1 to 7, characterized in that the speed of the composite strip leaving the rolling mill is greater than 20 meters per minute. Continuous process for manufacturing integrated circuit panels formed from at least three metal strips, comprising: (a) supplying the production line with two strips of type A and one of type B, (b) decambering type A and type B bands, (c) brushing the type A and type B strips, (d) applying the anti-welding ink to the type A strips, (e) optionally controlling the quality of this application, (f) preheating of type A and type B strips, (g) the creation of a composite strip by passing under the rolling mill strips of type A and of strip of type B, (h) annealing the composite strip in an oven, (i) cooling the composite strip, (j) optionally, leveling the composite strip, (k) cutting the composite strip into panels, (l) optionally eliminating the panels containing ink application defects, detected during the check (e), (m) transferring the panels to a multi-stage inflation press, (n) the inflation, preferably simultaneously, of the panels on all the floors, (o) the output of the press panels and their stacking for packaging.