Patent Grant
11236427
N/A
Certain steel vitreous enameling procedures require highly stress-relieved and extremely flat starting material in order to achieve a final coated product that has minimal deviation from flatness. One such enameling procedure is a two-step, two-fire porcelain enameling process. It is difficult to determine prior to the enameling whether a starting material has sufficient stress relief and flatness to achieve the desired minimal deviation. Historically, cold rolled commercial steel that has been batch annealed has produced coated products with deviations from flatness that have exceeded needs. The solution to this problem has historically been to source continuously-annealed steel, which comes at a significantly increased cost.
Typical methods for correcting a lack of flatness in batch-annealed steel include temper rolling, roller leveling, tension leveling, and stretch leveling.
Temper rolling is primarily aimed at hardening annealed steel and removing yield-point elongation (kinking), but it has the secondary benefit of correcting flatness. Temper rolling is not to be confused with tempering, which is an unrelated heat treatment process in hot forging that has a similar name. Temper rolling involves a 0.5-1.5% reduction in thickness using a single or double series of rolls to provide a small amount of cold work to the steel.
Roller leveling is the most inexpensive way to correct imperfections in flatness on batch annealed material. Roller leveling is typically installed at the start of the processing line. (i.e., the coating line). Roller leveling involves about 0.25-0.5% cold reduction through a series of small rolls in a cassette.
Tension leveling is another common approach to shape correction. Tension leveling is essentially roller leveling with an added tension applied. Tension leveling is typically installed as a stand-alone operation or part of a continuous annealing line. Tension leveling can achieve up to 1.5% cold reduction with fewer rolls by the addition of strip tension to the roller leveler configuration.
Stretch levelling is the least common but most effective method of shape correction. It is typically installed as a stand-alone operation and used in specialty steel and alloys. It can achieve up to 3% cold reduction with no rolls by using extremely high strip tension.
These means of correcting flatness are mentioned as potential solutions to the problem of lack of flatness in batch-annealed steel that is required for certain enameling processes. However, when attempted, these means of correcting flatness are insufficient to overcome the lack of flatness in batch-annealed steel. Conventional flattening processes are unpredictable in their ability to convert batch-annealed steel into a state suitable for certain enameled steels.
Accordingly, a need exists for systems and methods that allow cold-rolled, batch-annealed steel to be received at a manufacturing facility and coated with a two-step, two-fire enameling process to provide a product that has sufficient flatness.
The present disclosure provides systems and methods for in-line thermal flattening and enameling of steel sheets.
In an aspect, the present disclosure provides a method of producing an enameled steel sheet having an enamel coating on both sides. The method includes: a) in-line thermal flattening a feed stock steel sheet, thereby producing a thermally-flattened steel sheet; and b) subsequent to step a), enamel coating the thermally-flattened steel sheet on both sides, thereby producing the enameled steel sheet having the enamel coating on both sides, wherein executing the enamel coating of step b) directly to the feed stock steel sheet without the in-line thermal flattening of step a) produces a comparison enameled steel sheet having the enamel coating on both side, the comparison enameled steel sheet having a maximum deviation from flat of 0.5 mm or greater when a pressure of 20 kg/m2 is applied, the enameled steel sheet having a maximum deviation from flat of less than 0.5 mm when a pressure of 20 kg/m2 is applied.
In another aspect, the present disclosure provides a system. The system includes a source zone, an in-line thermal flatting zone, a two-side enameling zone, and a product removal zone. The source zone is for receiving a source produce to be processed. The in-line thermal flattening zone is downstream of the source zone. The two-side enameling zone is downstream of the in-line thermal flattening zone. The product removal zone is for removing finished products from the system and is downstream of the two-side enameling zone.
Before the present invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. The scope of the present invention will be limited only by the claims. As used herein, the singular forms “a”, “an”, and “the” include plural embodiments unless the context clearly dictates otherwise.
It should be apparent to those skilled in the art that many additional modifications beside those already described are possible without departing from the inventive concepts. In interpreting this disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. Variations of the term “comprising”, “including”, or “having” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, so the referenced elements, components, or steps may be combined with other elements, components, or steps that are not expressly referenced. Embodiments referenced as “comprising”, “including”, or “having” certain elements are also contemplated as “consisting essentially of” and “consisting of” those elements, unless the context clearly dictates otherwise. It should be appreciated that aspects of the disclosure that are described with respect to a system are applicable to the methods, and vice versa, unless the context explicitly dictates otherwise.
Numeric ranges disclosed herein are inclusive of their endpoints. For example, a numeric range of between 1 and 10 includes the values 1 and 10. When a series of numeric ranges are disclosed for a given value, the present disclosure expressly contemplates ranges including all combinations of the upper and lower bounds of those ranges. For example, a numeric range of between 1 and 10 or between 2 and 9 is intended to include the numeric ranges of between 1 and 9 and between 2 and 10.
The terms “upstream” and “downstream” refer to the direction of product movement through a system. If the product (i.e., steel sheet) interacts with a first component before interacting with a second component as it moves through a system, then the first component is upstream of the second component (and the second component is downstream of the first component).
Referring to
The source zone 12 can include components known to those having ordinary skill in the art to be useful for loading steel sheet into the system 10. For example, an arm for receiving a roll of cold-rolled steel can be present in the source zone 12.
Referring to
Referring to
The product removal zone 18 can include various cutting devices, rolling devices, stacking devices, and other means of manipulating the finished product to be suitable for transportation and sale.
Referring to
Referring to
Executing the enamel coating of process block 104 directly to the feed stock steel sheet without the in-line thermal flattening of process block 102 produces a comparison enameled steel sheet. The comparison enameled steel sheet has properties that are inferior to the product of the method 100.
As one example, the comparison enameled steel sheet has a maximum deviation from flat of 0.5 mm or greater when a pressure of 20 kg/m2 is applied. The enameled steel sheet produced by the method 100 has a maximum deviation from flat of less than 0.5 mm when a pressure of 20 kg/m2 is applied. In some cases, the enameled steel sheet produced by the method 100 has a maximum deviation from flat of less than 0.5 mm when a pressure of 10 kg/m2 is applied.
Maximum deviation can be measured by methods known to those having ordinary skill in the art. In one such method, the pressure is applied by setting a series of blocks having the proper weight to apply the desired force atop a sheet of interest that is itself resting on a flat surface. Once the blocks are placed, a point of greatest deviation from flat (or multiple points of greatest deviation if it is unclear which point is greater) are identified by human or automated visualization. The magnitude of that deviation is measured by distance measuring methods known to those having ordinary skill in the art (e.g., laser distance measurements, a ruler, a caliper, etc.).
The in-line thermal flattening of process block 102 includes heating the feed stock steel to a predetermined annealing temperature under a predetermined annealing tension. The predetermined annealing temperature can be between 300° C. and 700° C., including but not limited to, between 350° C. and 650° C. or between 400° C. and 600° C. The predetermined annealing tension can be between 20 MPa and 100 MPa, including but not limited to, between 25 MPa and 75 MPa, between 30 MPa and 50 MPa, or between 35 MPa and 40 MPa. The in-line thermal flattening of process block 102 can be done in a predetermined atmosphere. In some cases, the predetermined atmosphere can be air.
The enamel coating process of process block 104 can be a two-step, two-fire enameling process. The two-step, two-fire enameling process can include applying a ceramic slurry to both sides of a steel sheet and heating the sheet to predetermined enameling temperature while maintaining a substantially catenary position over a predetermined span distance at a predetermined lateral tension. This process is then repeated with application of the slurry to only one side of the steel sheet. The predetermined enameling temperature can be between 700° C. and 1000° C. The predetermined span distance can be between 1.0 m and 40 m, including but not limited to, between 2.5 m and 35 m, between 3.0 m and 30 m, between 4.0 and 25 m, or between 4.5 m and 20 m. In some cases, the predetermined span distance can be 4.5 m. The predetermined lateral tension can be between 2.0 MPa and 3.0 MPa, including 2.5 MPa. While one specific enamel coating process is described here in detail, it is contemplated that the method 100 can be suitable for use with other enamel coating processes known to those having ordinary skill in the porcelain enameling arts.
The feed stock steel sheet can be cold-rolled steel sheet. The cold-rolled steel sheet can be batch-annealed. The feed stock steel sheet can have a thickness of between 0.1 mm and 1.0 mm. The feed stock steel sheet can have a width of between 0.75 m and 2.0 m.
The resulting enamel coating can have a thickness of between 0.01 mm and 1.0 mm.
The feed stock steel sheet can be steel that meets the specifications of A242/A242M version 09a (Reapproved 2016) issued by ASTM International.
Process blocks 102 and 104 are performed in a single facility. Process block 102 and 104 can be performed in a single processing line.
The method 100 can further include cutting the enameled steel sheet into individual units. The cutting can be done by methods known to those having ordinary skill in the art.
While the above detailed description has shown, described, and pointed out novel features as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the devices or algorithms illustrated can be made without departing from the spirit of the disclosure. As will be recognized, certain embodiments of the disclosures described herein can be embodied within a form that does not provide all of the features and benefits set forth herein, as some features can be used or practiced separately from others. The scope of certain disclosures disclosed herein is indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims priority to U.S. Provisional Application No. 62/595,295, filed Dec. 6, 2017, which is incorporated by reference in its entirety.
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