US20010025407A1 - Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet - Google Patents

Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet Download PDF

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Publication number
US20010025407A1
US20010025407A1 US09/764,713 US76471301A US2001025407A1 US 20010025407 A1 US20010025407 A1 US 20010025407A1 US 76471301 A US76471301 A US 76471301A US 2001025407 A1 US2001025407 A1 US 2001025407A1
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US
United States
Prior art keywords
epoxy resin
intermediate layer
cover sheets
spots
double
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/764,713
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English (en)
Inventor
Gerd Hartmann
Thomas Flehmig
Cetin Nazikkol
Friedrich Behr
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ThyssenKrupp Steel Europe AG
Original Assignee
ThyssenKrupp Stahl AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ThyssenKrupp Stahl AG filed Critical ThyssenKrupp Stahl AG
Assigned to THYSSEN KRUPP STAHL AG reassignment THYSSEN KRUPP STAHL AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BEHR, FRIEDRICH, FLEHMIG, THOMAS, HARTMANN, GERD, NAZIKKOL, CETIN
Publication of US20010025407A1 publication Critical patent/US20010025407A1/en
Abandoned legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • C09J5/06—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers involving heating of the applied adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/74—Partially cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2363/00—Epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2463/00—Presence of epoxy resin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49906—Metal deforming with nonmetallic bonding

Definitions

  • the invention relates to a process for the production of a double-layer metal sheet having an intermediate layer of an epoxy resin in the form of a hot melt glued to its cover sheets.
  • shaped structural members for example, are shaped which can be used in the bodywork of motor vehicles. For this reason they must have as low a weight as possible per unit of surface, accompanied by high buckling strength.
  • the double-layer metal sheet must also be satisfactorily deformable, more particularly satisfactorily deep-drawable.
  • the shaped constructional member must not cause problems during lacquering, more particularly cathodic immersion lacquering, followed by the stoving of the lacquer.
  • shaped constructional members produced from such a double-layer metal sheet are unsuitable for stove enamelling, since the outer layers of the intermediate layer consist of a mixture of polyethylene and polypropylene i.e., thermoplastics—which become liquid at temperatures above 160° C.
  • thermoplastics which become liquid at temperatures above 160° C.
  • stove enamelling which is typically performed at temperatures of 180° C. and above for a duration of at least 30 minutes, such an intermediate layer would partly run out and the glued connection between the cover sheets and the intermediate layer, important for the buckling strength of the shaped constructional member, would be lost.
  • a double-layer metal sheet is also known (EP 0 598 428 A1) in which an intermediate layer of polypropylene is glued by an adhesive to the cover sheets.
  • Such a double-layer metal sheet is supposed to be suitable for cold working to give a shaped structural member.
  • the shaped constructional member is supposed to have a high dimensional stability after a heat treatment at at least 135° C. Since polypropylene is a thermoplastics which becomes liquid at temperatures above 160° C., the same thing applies to such a constructional member as to the previously-described constructional member, namely that with a treatment time of 30 minutes at a temperature of at least 180° C., as is customary in stove enamelling, the glued connection between the cover sheets and the intermediate layer is lost.
  • the double-layer metal sheet is further processed to give the more particularly stove-enamelled shaped constructional member by the following steps:
  • the selection of particular epoxy resins ensures on the one hand that the two cover sheets are satisfactorily fixed spatially in relation to one another, and on the other hand that in the deformation of the double-layer metal sheet to give the shaped constructional member, more particularly by deep drawing, due to its not yet crosslinked epoxy resin the large-area intermediate layer shares in the necessary deformations, as do the spots, due to the their almost negligible area in comparison with the intermediate layer and their still adequate deformability, even in the polymerised state, and the cover sheets are not impermissibly heavily loaded and/or the cover sheets do not become detached from the spots.
  • the epoxy resin melts without running out and polymerises, thus ensuring for the first time the final, whole-area firm gluing of the cover sheets to the intermediate layer and giving the shaped constructional member its optimum buckling strength after the epoxy resin has cooled.
  • the invention is not limited to the epoxy resins described, but other materials with a similar behaviour are also suitable for the invention. It is important that during the deformation process such materials should fix the as a rule galvanised cover sheets without tearing off, something which presumes a certain flexibility. They should have a curing temperature of approximately 25° C. to 150° C. and a curing time which is shorter than the time of passage through a furnace. Lastly, in the cured state the spots should have substantially the same compressive strength as the intermediate layer in the still uncured state. Substances which are suitable for the spots include, for example, flexibilised epoxy resin adhesives, polyurethane adhesives and rubber adhesives.
  • the intermediate layer is provided with suitable receiving spaces prior to the introduction of the spots. This can be done by using as the intermediate layer a perforate foil which is not yet polymerised.
  • an intermediate layer is introduced over its whole area between the cover sheets, preferably by the coil coating process.
  • the spots which take the form of to some extent compression-resistant bodies, are scattered in. Contact between the spots and the cover sheets is effected more particularly by the feature that during the introduction of the intermediate layer and the spots between the cover sheets, followed by joining, due to their higher compressive strength the spots are forced into contact with the cover sheets by the intermediate layer.
  • cover sheets can be fixed over the spots by the polymerisation of their epoxy resin in different manners. Inductive heating is suitable both in a continuous heating furnace and in steady conditions. A heating press which contacts the cover sheets is also suitable for steady heating. Continuous heating can be performed by means of heated rollers.
  • FIG. 2 phases V to VII of the production process shown in FIG. 1, and
  • FIG. 3 a process for the introduction of an intermediate layer and spots between ribbons as cover sheets in a manner different from phases I to VII of the production process shown in FIG. 1.
  • a foil 2 of a not yet polymerised epoxy resin is produced for an intermediate layer by an extruder 1 (phase I).
  • the foil 2 passes through a perforating apparatus 3 which produces in the foil 2 , distributed over its area, receiving spaces 4 for spots of a different epoxy resin from that of the foil 2 intended for the intermediate layer (phase II).
  • the foil 2 passes through shears 5 , which cut the foil 2 to the length format of intermediate layers 6 (phase III).
  • a flat cover sheet 10 is laid on which is supplied from a stack of sheets 11 (phase VI in FIG. 1 and central part of FIG. 2).
  • the resulting composite comprising the two cover sheets 7 , 10 and the intermediate layer 6 disposed therebetween, together with the epoxy resin present in the receiving spaces 4 , then passes to a heating press 12 (phase VII in FIG. 1 and top part of FIG. 2).
  • a heating press 12 phase VII in FIG. 1 and top part of FIG. 2
  • the epoxy resin polymerises in the receiving spaces 4 , possibly accompanied by foaming, so that the epoxy resin contacts the two cover sheets 7 , 10 and sticks thereto, while although the epoxy resin of the intermediate layer 6 also sticks to the cover sheets, it does not polymerise.
  • After cooling and curing the epoxy resin in the receiving spaces 4 forms the spots fixing the two cover sheets 7 , 10 spatially in relation to one another.
  • the double-layer metal sheet 13 produced in this manner is then supplied to a deep-drawing installation 14 and shaped into the required constructional member 15 (phase VIII).
  • the still adequately deformable spots 16 consisting of polymerised epoxy resin distributed over the surface and occupying only a very small proportion thereof make themselves noticeable in as much as they fix the cover sheets 7 , 10 spatially in relation to one another, but do not result in pressure marks in the cover sheets at the connecting places.
  • the constructional member 15 thus shaped can therefore also be used as the outer skin of a motor vehicle.
  • the constructional member thus shaped then passes to a lacquering installation 17 , more particularly a KTL immersion bath (phase IX). Then it is supplied to a furnace 18 in which the lacquer is stoved, the hitherto unpolymerised epoxy resin of the intermediate layer 6 being simultaneously polymerised (phase X).
  • a lacquering installation 17 more particularly a KTL immersion bath (phase IX).
  • the hitherto unpolymerised epoxy resin of the intermediate layer 6 being simultaneously polymerised (phase X).
  • FIG. 3 differs from that in FIG. 1 substantially by the way in which the intermediate layer and the spots are introduced between the cover sheets.
  • two cover sheets 20 , 21 in ribbon shape are guided over two heated rollers 22 , 23 .
  • Layers 26 , 27 of epoxy resin are applied by applicators 24 , 25 substantially at the apex of the rollers 22 , 23 for the intermediate layer.
  • the thickness of the layers 26 , 27 is adjusted by squeegees 28 , 29 .
  • Bodies 31 of epoxy resin are scattered, distributed over the width of the cover sheets 20 , 21 by means of a pouring channel 30 , into the gusset of the epoxy resin-coated, band-shaped cover sheets 20 , 21 .
  • the bodies 31 have greater compressive strength than the layers 26 , 27 and a thickness which is at least equal to the distance between the inner sides of the cover sheets 20 , 21 in the nip of the rollers 22 , 23 . This ensures that the bodies 31 press through the layers 26 , 27 of the softer epoxy resin and contact the cover sheets 20 , 21 . With adequate heating the epoxy resin of the bodies 31 polymerises and sticks to the inner sides of the cover sheets 20 , 21 , while the epoxy resin of the layers 26 , 27 forming the intermediate layer does not polymerise, but the layers 26 , 27 are bonded to one another. After cooling, the spots 32 formed by the bodies 31 and distributed over the area fix the cover sheets 20 , 21 spatially in relation to one another.
  • the diameter of the bodies 31 is of less importance. In that case the decisive factor is that the increased volume caused by foaming is large enough to contact the cover sheets 20 , 21 .
  • the double-layer metal sheet produced in this manner can then can be cut to length and further processed to give the stove enamelled shaped constructional members, in accordance with phases VIII to X in FIG. 1.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
US09/764,713 2000-03-23 2001-01-17 Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet Abandoned US20010025407A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10014017.3 2000-03-23
DE10014017A DE10014017C1 (de) 2000-03-23 2000-03-23 Verfahren zum Herstellen eines Doppellagenbleches sowie ein tiefziehfähiges Doppellagenblech

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US20010025407A1 true US20010025407A1 (en) 2001-10-04

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US09/764,713 Abandoned US20010025407A1 (en) 2000-03-23 2001-01-17 Process for the production of a double-layer metal sheet and a more particularly stove enamelled shaped constructional member shaped therefrom, and also a deep-drawable double-layer metal sheet

Country Status (3)

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US (1) US20010025407A1 (de)
EP (1) EP1136253A3 (de)
DE (1) DE10014017C1 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050019199A1 (en) * 2003-07-03 2005-01-27 Agency For Science, Technology And Research Double-layer metal sheet and method of fabricating the same
WO2012127185A1 (en) * 2011-03-18 2012-09-27 Aston Martin Lagonda Limited Method for forming bonded structures and bonded structures formed thereby
KR20190040281A (ko) * 2016-08-24 2019-04-17 잘쯔기터 플래시슈탈 게엠베하 향상된 성형성을 갖는 복합 재료 및 이러한 복합 재료를 제조하는 방법 및 그로부터 성형된 부품
US12000329B2 (en) 2018-12-17 2024-06-04 Aston Martin Lagonda Limited Assemblies for engines

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* Cited by examiner, † Cited by third party
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DE10120121A1 (de) * 2001-04-25 2002-10-31 Thyssenkrupp Stahl Ag Zu einem Formbauteil umformbare Blechplatine
JP4418182B2 (ja) * 2003-06-25 2010-02-17 ソマール株式会社 熱交換器形成用材料、これを用いた熱交換器の製造方法及び熱交換器
JP2005051055A (ja) * 2003-07-29 2005-02-24 Tokyo Electron Ltd 貼合せ方法および貼合せ装置

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CH582289A5 (de) * 1974-12-18 1976-11-30 Liguori Philippe N Di
US4313996A (en) * 1979-05-21 1982-02-02 The Dow Chemical Company Formable metal-plastic-metal structural laminates
US4594292A (en) * 1983-01-18 1986-06-10 Sumitomo Metal Industries, Ltd. Metal-resin-metal sandwich laminates suitable for use in press forming
US5030488A (en) * 1988-11-23 1991-07-09 Chemical And Polymer Technology, Inc. Laminates, panels and means for joining them
NL9201968A (nl) * 1992-11-11 1994-06-01 Hoogovens Hylite B V Aluminium-polypropyleen-aluminium laminaat.
DE19736839A1 (de) * 1997-08-23 1999-02-25 Volkswagen Ag Deformationsstruktur für den Insassenschutz in Fahrzeugen
DE19846533A1 (de) * 1998-10-09 2000-04-20 Thyssenkrupp Stahl Ag Verfahren zum Herstellen eines einbrennlackierten Formbauteils

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050019199A1 (en) * 2003-07-03 2005-01-27 Agency For Science, Technology And Research Double-layer metal sheet and method of fabricating the same
WO2012127185A1 (en) * 2011-03-18 2012-09-27 Aston Martin Lagonda Limited Method for forming bonded structures and bonded structures formed thereby
GB2507188A (en) * 2011-03-18 2014-04-23 Aston Martin Lagonda Ltd Method for forming bonded structures and bonded structures formed thereby
KR20190040281A (ko) * 2016-08-24 2019-04-17 잘쯔기터 플래시슈탈 게엠베하 향상된 성형성을 갖는 복합 재료 및 이러한 복합 재료를 제조하는 방법 및 그로부터 성형된 부품
US11338553B2 (en) * 2016-08-24 2022-05-24 Salzgitter Flachstahl Gmbh Composite material with improved shaping properties and method for producing such a composite material and a shaped component from it
KR102480413B1 (ko) * 2016-08-24 2022-12-21 잘쯔기터 플래시슈탈 게엠베하 향상된 성형성을 갖는 복합 재료 및 이러한 복합 재료를 제조하는 방법 및 그로부터 성형된 부품
US12000329B2 (en) 2018-12-17 2024-06-04 Aston Martin Lagonda Limited Assemblies for engines

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Publication number Publication date
DE10014017C1 (de) 2002-01-03
EP1136253A2 (de) 2001-09-26
EP1136253A3 (de) 2003-10-29

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AS Assignment

Owner name: THYSSEN KRUPP STAHL AG, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HARTMANN, GERD;FLEHMIG, THOMAS;NAZIKKOL, CETIN;AND OTHERS;REEL/FRAME:011773/0090;SIGNING DATES FROM 20010313 TO 20010315

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO PAY ISSUE FEE