WO2010147506A2

WO2010147506A2 - Metal structure with developed surface (variants), and method for manufacturing said metal structure

Info

Publication number: WO2010147506A2
Application number: PCT/RU2010/000313
Authority: WO
Inventors: Андрей Виленович ЛЮБОМИРСКИЙ
Original assignee: Lyubomirskiy Andrey Vilenovich
Priority date: 2009-06-19
Filing date: 2010-06-15
Publication date: 2010-12-23
Also published as: RU2009123286A; WO2010147506A3

Abstract

The invention pertains to the production of finishing panels and can be used for producing finishing materials used for the external or internal finishing of buildings and premises, in particular for public or industrial purposes. The metal structure comprises two layers. The first layer is made of a corrosion-resistant alloy or metal and has straight or ark-shaped hairlines formed thereon. The second layer is made of a material selected from the group comprising an iron-carbon alloy, aluminium and aluminium alloys. A layer of adhesive may be applied between said layers.

Description

A metal structure with a developed surface (options) and a method for manufacturing a metal structure.

The invention relates to the production of building materials, namely decorative panels, and can be used in the manufacture of decorative materials used for both exterior and interior decoration of buildings and premises, mainly for communal and industrial purposes.

Known (RU, patent 2016912) is a two-layer high-strength corrosion-resistant steel consisting of a base layer containing carbon, silicon, manganese, chromium, nickel, copper, phosphorus, sulfur, iron and a cladding layer containing carbon, silicon, manganese, chromium, nickel, iron, and the main layer additionally contains molybdenum, aluminum and niobium.

Known technical solution is intended for the manufacture of loaded welded structures operating in a wide temperature range (up to -6O ⁰ C) in conditions of increased corrosion wear under the influence of sea water and other aggressive environments. One of the areas of use is the manufacture of containers - storages for transportation and storage of aggressive liquids. It is completely unsuitable for the creation of decorative finishing materials, including due to the high cost.

Known (RU, patent 2102688) is a two-layer metal structure containing a substrate of high-strength structural alloyed steel, while a plate of medium-strength or high-strength titanium alloy is additionally placed on said substrate with a thickness ratio plates of titanium alloy (A) and the thickness of the steel substrate (B), component A / B 0.5 1.0. In a preferred embodiment, the steel substrate is made of high-strength structural torsion steel with a thickness of 4.3 ÷ 5.3 mm, and the titanium plate placed on its outer side is made of a titanium alloy with a thickness of 2.5 ÷ 4.0 mm.

Known metal construction is applicable for the creation of protective devices (armor protection) and is not intended for the manufacture of decorative finishing materials due to the high cost and significant mass of a unit area sample, which will require additional costs to create a fastening of such a plate to the wall of a room or building.

Known (RU, patent 2215655) is a two-layer metal structure, which is intended for use as anti-corrosion coatings of equipment in installations for the production of chemical products, consisting of a first layer in the form of a stainless steel metal plate and a second layer welded onto the first, and the metal plate has a thickness of 2-30 mm and a surface area exceeding 0.1 m ² , and the welded layer has a thickness of 0.5-6 mm from a metal or alloy of stainless steel metals intended for chemical installations sky production.

Known (RU, patent 2225793) clad corrosion-resistant steel, consisting of a base layer of carbon or low alloy steel and at least one cladding layer of corrosion-resistant chrome steel, with adhesion layers not lower than the strength of the steel of the base layer, different in that corrosion-resistant clad steel the layer contains carbon, manganese, silicon, chromium, sulfur, phosphorus, iron and inevitable impurities. The thickness of the resulting plate is approximately 10 mm.

Known (RU, patent 66383) is a metal cladding panel containing a metal base with decorative elements on its front surface, characterized in that the base is made of stainless steel, and decorative elements are in the form of recesses on its front surface, which are flush to the level, located no more than 0.14 mm from the plane of the front surface, filled with a method of manufacturing powder coatings with paint of the corresponding color.

A disadvantage of the known facing panel can be recognized as its rather high cost, due to the use of a significant amount of expensive stainless steel. In addition, on the front surface of the known metal cladding panel, the visible defects are visible in the form of scratches and dents, as well as dirt in the form of fingerprints. This leads to an increase in production costs and subsequent maintenance of the installed metal cladding panel.

The technical problem, solved by means of the developed technical solution, consists in developing a new type of metal finishing panels used for facing the interior of industrial and communal types.

The technical result obtained as a result of the implementation of the developed design is to reduce the cost of production of metal cladding panels and labor costs when servicing metal finishing panels after their installation while maintaining their consumer properties. To achieve the specified technical result according to the first embodiment, it is proposed to use a two-layer metal structure, the first layer being made of a material selected from the group consisting of iron-chromium, iron-nickel, iron-nickel-chromium, iron-nickel-aluminum alloys -aluminum, iron-vanadium, aluminum-chromium, aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, as well as aluminum and its alloys with a thickness of 30 to 1000 microns, and the second layer is made of material selected from the group containing an alloy of iron-carbon, aluminum and its alloys, with a thickness of 200 to 2000 μm and a width of 80 - 2000 mm, while risks are arranged parallel to the outer surface of the first layer, preferably with a depth of 0, l-20 μm and a distance between them of up to 2 mm. Risks can be made straight or arched. However, other forms of scratches may be used. Layers can be joined in various ways. In particular, the layers can be joined by deposition, co-rolling and diffusion annealing in a furnace, or in bulk and subsequent co-rolling. The specified list does not limit the possible options for connecting the layers. Risks on the surface of the first layer are preferably applied before joining it with the second layer, however, it is possible that the surface is applied to the surface of the first layer after the first layer is connected to the second layer.

To achieve the specified technical result according to the second embodiment, it is proposed to use the metal structure, which is made two-layer, and the first layer is made of a material selected from the group consisting of alloys iron-chromium, iron-nickel, iron-nickel-chromium, iron-nickel-aluminum, iron-aluminum, iron-vanadium, aluminum-chromium , aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, as well as aluminum and its alloys with a thickness of 30 to 1500 microns, and the second layer is made of a material selected from the group consisting of an alloy of iron carbon, aluminum and its alloys, with a thickness of 0.2 to 2.0 mm, while the layers are connected by means of an adhesive joint with a metal structure width from 80 to 2000 mm, while parallel risks are applied on the outer surface of the first layer, preferably with a depth of 0, l-20 μm and a distance between them of up to 2 mm. Risks can be made straight or arched. However, it is not excluded the use of notches of a different shape. The adhesive bonding can be made on the basis of epoxy resins, polyester resins, polyurethane, structural acrylic adhesives such as Premambomd, cyanoacrylate adhesives such as Kosmofep. The specified list does not limit the possible options for the adhesives used. The thickness of the adhesive layer depends on the type of adhesive used, as well as on the method of its application. Risks on the surface of the first layer are preferably applied before joining it with the second layer, however, it is possible that the surface is applied to the surface of the first layer after the first layer is connected to the second layer.

For the manufacture of metal structures according to the second embodiment, the joined surfaces of the metal layers are degreased beforehand, at least one of them is applied to the adhesive layer and the surfaces to be bonded are connected, moreover the adhesive layer is applied with the original thickness, which provides an adhesive layer between the joined layers with a thickness of 0.002-2 mm. Degreasing is carried out by any method known in the art that is suitable for a given use case. The type of glue is selected based on the subsequent use of metal structures. The glue is applied by any method known in the art (brush, roller, spray, rollers, etc.).

As indicated above, in order to achieve the indicated technical result according to the first embodiment, it is proposed to use a two-layer metal structure, the first layer being made of a material selected from the group consisting of iron-chromium, iron-nickel, iron-nickel-chromium, iron-nickel - aluminum, iron-aluminum, iron-vanadium, aluminum-chromium, aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, as well as aluminum and its alloys with a thickness of 30 to 1500 microns, and the second layer is made of alloy selected o from the group containing an alloy of iron-carbon, aluminum and its alloys, with a thickness of 200 to 2000 microns and a width of 80 - 2000 mm. The metal structure is a two-layer structure, the outer layer of which having mainly a decorative function is made of corrosion-resistant material - various types of stainless steel, various aluminum alloys, as well as titanium, and the second - from medium-carbon steel or aluminum and its alloys. The ratio of the thicknesses of the layers shows that the main part of the facing panel is a material with low cost, and its external part, made of expensive material, makes up a small part of the panel and, therefore, slightly increases its cost. During development design it was experimentally established that the minimum thickness of the first layer should be at least 30 microns. At the specified minimum thickness of the first layer, its strength is sufficient to maintain the integrity of the layer. The indicated maximum thickness of the first layer is determined, on the one hand, by the method of reducing the consumption of expensive material, reducing the mass of the first layer, so as to be able to use weaker and, therefore, cheaper, fastening, both between the layers and the entire metal structure to the base, but with this, on the other hand, to maintain such consumer quality as the durability of the metal structure. In addition, it is necessary to take into account the manufacturability of the operation of joining two layers. It was experimentally established that the thickness of the first layer that meets the listed conditions should be no more than 1000 microns. Since the manufactured metal structures are intended for wide and long-term use, a necessary condition for their use is significant mechanical stability, including the ability to withstand intentional and unintentional mechanical damage, as well as the possibility of repairing damaged metal structures. In the process of operation as a facing panel, the metal structure may experience adverse natural influences, technogenic effects and adverse effects due to the human factor. Moreover, it is desirable for the consumer to be able to bring the mechanically damaged panel to its previous state without dismantling it. The main types of mechanical damage are scratches and dents from exposure to mechanical objects, which can abrasive particles (including dust), as well as solids that came into contact with the surface of the first layer of metalwork by chance due to improper installation of elements located next to the metalwork or by the evil will of a person (vandals), can be classified. In addition, it was noted that on the surface of the first layer, fatty contaminants, in particular fingerprints, are clearly visible. However, applying to the front surface of the first layer of parallel scratches, resulting in a developed surface, allows, firstly, to make less visible both mechanical damage to the surface in the form of scratches and dents, and grease contamination, which allows to increase the intervals between operations to eliminate mechanical damage and the removal of fatty contaminants, and, secondly, to simplify and reduce the cost of the specified removal through the use of technology for grinding contaminants and mechanical damage using use of a hand tool at the panel mounting location and without dismantling it. Thus, the application of parallelly arranged scratches, on the one hand, makes dirt and minor defects on the panel surface less noticeable, and, on the other hand, does not prevent the elimination of defects on the panel surface using hand tools and without dismantling the panel. Therefore, the reduction of labor costs and the cost of restoring the appearance of the surface of the panel is due to the use of camouflage properties developed by applying the panel panel. As well as providing the ability to dismantle the surface without dismantling. In the case of a smooth surface of the panel with the necessary local surface treatment (removal of small scratches and dents, as well as grease stains) it is necessary to process the entire surface of the panel, which makes it necessary to dismantle it and use complex and expensive equipment. The presence of a developed surface makes it possible, due to the peculiarities of human vision, to distinguish a local section of the panel from its total area, to process only the indicated local area.

It was experimentally established that with a thickness of 1500 μm, the possibility of rupture of the first layer with exposure of the second layer is practically excluded. The specified thickness, according to experimental data, guarantees the operation of metal for at least 10 years.

The second layer performs the function of the base, designed both for fastening the first layer and for stiffening the entire structure. When choosing its geometrical dimensions, it is necessary to take into account the following factors: on the one hand, the second layer should be thick enough to give the metalwork the necessary rigidity, on the other hand, it should be minimally thick to reduce the weight of the entire metal structure and simplify the fastening of the metal structure to the base. Since the cost of materials used as the material of the second layer is relatively not high compared to the cost of materials of the first layer, this factor can be neglected. Based on the above factors, it was experimentally established that the minimum thickness of the second layer is 200 microns, and the maximum thickness of 2000 microns. A thin layer of 200 μm is due to the ability of this sheet to keep its shape without bending under its own weight. These materials should be lightweight, as they will be used for production false ceilings to make them not dangerous for people if they fall on their heads. At the same time, the limiting values of the width of the metal structure were experimentally determined. With a width of the metal structure performing the cladding panel of less than 80 mm, the production of metal structures becomes unprofitable due to the rather high cost of a single section of the metal structure area, and with a metal structure width of more than 2000 mm it is difficult to fix such a metal structure on a vertical support, therefore, the consumer characteristics of the metal structure deteriorated. The first and second layers can be connected by any method known in metalworking. In particular, the layers can be joined by welding, co-rolling and diffusion annealing in a furnace or in bulk. The specified list does not limit the possible options for connecting the layers.

The metal construction according to the first embodiment of the developed technical solution can be made as follows.

Initially, a titanium tape, the width of which is from 80 to 2000 mm, and the thickness - from 30 to 1500 microns, used to obtain the first layer, is cleaned of mechanical impurities and degreased. Then the tape is passed along a set of rotating hard brushes, and the movement of the tape is carried out with the possibility of applying parallel marks on the surface of the titanium tape.

A sheet of medium-carbon steel of the same width is degreased, the surface of the sheet of medium-carbon steel is combined with the back of the titanium tape, and diffusion annealing is performed in the furnace. Then, the resulting semi-finished product is cut into facing panels in size and packaged.

As indicated above, in order to achieve the indicated technical result according to the second embodiment, it is proposed to use a metal structure that is made of two layers, the first layer being made of an alloy selected from the group consisting of iron-chromium, iron-nickel, iron-nickel-chromium, and iron- nickel-aluminum, iron-aluminum, iron-vanadium, aluminum-chromium, aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, aluminum with a thickness of 30 to 1000 microns, and the second layer is made of alloy selected from the group of iron glerod, aluminum and its alloys, of a thickness of 0.2 to 2.0 mm, wherein the layers are joined by adhesive bonding with a width of metal 80 to 2000mm. The requirements put forward to the first and second sheet of metal construction are similar to the requirements attached to the same sheets in the previous embodiment. The requirement for the adhesive used is to ensure the strength of the adhesive after hardening of the adhesive layer. Fast curing speed is also desirable.

Adhesive bonding can be made on the basis of epoxy resins, polyester resins, polyurethane, silicone, structural acrylic adhesives such as Premambomd, cyanoacrylate adhesives such as Kosmofep. The specified list does not limit the possible options for the adhesives used. The thickness of the adhesive layer depends on the type of adhesive used, as well as on the method of its application. For the manufacture of metal structures according to the second embodiment, the joined surfaces of the metal layers are degreased beforehand, at least one of them is applied to the adhesive layer and connected by glued surfaces, the adhesive layer being applied with the original thickness, which provides an adhesive layer between the joined layers with a thickness of 0.002-2 mm . Degreasing is carried out by any method known in the art that is suitable for a given use case. The type of glue is selected based on the subsequent use of metal structures. The glue is applied by any method known in the art (brush, roller, spray, etc.). Risks are applied to the surface of the first sheet by any method known in the art.

The developed technical solution can be illustrated by the following implementation examples. 1. The metal structure with a width of 80 mm contains two layers, the first layer being made of an iron-chromium alloy 30 microns thick, the second layer is made of an iron-carbon alloy 200 microns thick. The layers are joined by hot co-rolling. The first layer has rectilinear risks 0.1 mm deep and 0.2 mm between them. The product has a fairly low cost (about 65 - 68% of the cost of the metal structure used as the closest analogue) and operational characteristics (durability, corrosion resistance, resistance to mechanical damage and damage from natural factors, etc.), not inferior to operational characteristics of the metal structure used as the closest analogue. At the same time, labor costs and operating costs were reduced by 42 and 29%, respectively.

2. The metal product is made according to example 1, but the thickness of the second layer is 2000 μm. The depth of the grooves is 0.15mm.

The technical result obtained corresponds to the technical result of example 1.

3. The metal product is made according to example 1, but the thickness of the first layer is 1500 microns. Risks are performed by arcs.

The compound of the layers was obtained by diffusion thermal annealing. The second layer is made of aluminum alloy. The technical result obtained corresponds to the technical result of example 1.

4. The metal product is made according to example 1, but its width is 2000 mm The first layer is made of titanium. The technical result obtained corresponds to the technical result of example 1.

5. The metal product is made according to example 1, but the thickness of the first layer is 25 μm. The cost of metal construction corresponds to the cost of the product according to example 1, but the durability and resistance to mechanical damage are not sufficient. b. The metal product is made according to example 1, but its width is 70 mm The cost of the product is approximately 135 -

140% of the cost of metal construction - prototype.

7. The metal product is made according to example 1, but its width is 1800 mm The cost of the product is approximately 155

- 170% of the cost of metal construction - prototype.

8. The metal structure is made according to example 1, but the layers are connected by gluing with epoxy glue with a layer thickness of 0.4 mm The technical result obtained is similar to the technical result obtained in example 1.

The use of adhesive joints in the embodiments of the developed metal structure according to examples 2 to 7 leads to similar technical results.

Claims

Claim.

1. Metal construction, characterized in that it is made of two layers, the first layer being made of a material selected from the group consisting of iron-chromium, iron-nickel, iron-nickel-chromium, iron-nickel-aluminum, iron-aluminum, iron alloys - vanadium, aluminum-chromium, aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, as well as aluminum and its alloys, with a thickness of 30 to 1500 microns, and the second layer is made of a material selected from groups containing an alloy of iron-carbon, aluminum and its alloys, with a thickness of 200 to 2000 microns with irina 80 - 2000 mm, while on the outer surface of the first layer are applied parallel risks,

2. The metal structure according to claim 1, characterized in that the risks are performed with a depth of 0, l-20 μm with a distance between them of up to 2 mm.

3. The metal structure according to claim 1, characterized in that the layers are joined by welding.

4. The metalloconstruction according to claim 1, characterized in that the layers are joined by joint rolling and diffusion annealing in a furnace.

5. The metal structure according to claim 1, characterized in that the layers are connected in bulk and subsequent joint rolling.

6. Metal construction, characterized in that it is made of two layers, the first layer being made of a material selected from the group consisting of alloys iron-chromium, iron-nickel, iron-nickel-chromium, iron-nickel-aluminum, iron-aluminum, iron - vanadium, aluminum-chromium, aluminum-chromium-magnesium, aluminum-silicon, aluminum-titanium, aluminum-zinc, titanium, as well as aluminum and its alloys, from 30 to 1500 μm thick, and the second layer is made of a material selected from the group consisting of iron-carbon alloy, aluminum and its alloys , with a thickness of 0.2 to 2.0 mm, while the layers are connected by adhesive bonding with a metal structure width of 80-2000 mm, while parallel risks are applied to the outer surface of the first layer,

7. The metal structure according to claim 6, characterized in that the risks are performed with a depth of 0, l-20 μm with a distance between them of up to 2 mm.

8. A method of manufacturing a metal structure according to claim 6, characterized in that the surfaces of the metal layers used in the metal structure are degreased, at least one of them is coated with an adhesive layer and connected with glued surfaces, the adhesive layer being applied with the original thickness, which provides an adhesive layer between the connected layers with a thickness of 0.002-2mm.