CN115007425A - 一种tdx10彩色涂层板的生产工艺 - Google Patents
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Abstract
本发明公开了一种TDX10彩色涂层板的生产工艺，采用DX51D+Z的镀铝锌基板，聚酯面漆，来生产总膜厚9µm的超薄镀层薄涂层彩色涂层板；镀锌基板的镀层10/10g/m2，镀层采用铝锌镀层，锌含量不小于85%，锌层经过光整表面均匀，无锌粒、锌疤痕缺陷；依次经过下列工艺步骤进行生产，预处理工艺、底漆涂敷工艺、面漆涂敷工艺、固化工艺：机组速度50～70m/min，底漆炉工作温度分4段，第4段出口温度290～360℃；面漆炉工作温度分4段，第4段出口温度310～370℃，面漆炉板温225～232℃，水淬槽冷却后带温不大于45℃，通过短时高速低温来保证漆膜受热均匀性能稳定。
Description
技术领域
本发明涉及一种彩色涂层板的生产工艺，特别涉及一种TDX10彩色涂层板的生产工艺。
背景技术
目前国内彩涂产能过剩，彩涂板高额利润的时代宣告结束，竞争越来越激烈，只有提高产品质量，扩大产品市场份额，采取市场细分和差异化经营策略才能使彩涂板赢得市场竞争力。彩涂板的技术发展主要围绕涂层以及镀层的组合变化来满足不同的市场需求。
CN201210092782.7专利是一种彩涂板及其制备方法，发明提供一种彩涂板，同时还提供这种彩涂板的制备方法，所述的彩涂板包括基板，基板为具有冲压变形性能的钢板，基板表层依次设置底漆涂层和精涂层，底漆涂层和基板之间设置化学转化层，彩涂板制备方法为：1)彩涂板制备时，先对基板表面进行钝化处理，形成化学转化层；2)在化学转化层表面使用卷材涂料形成底漆涂层；3)再在形成底漆涂层的基板两面使用卷材涂料分别形成正面涂层和背面涂层。本发明的彩涂板及其制备方法，使得彩涂板在在彩涂生产线上生产冲压性能良好，同时能够解决彩涂板冲压时涂层易于裂纹或基材开裂问题。
CN201510086879.0专利是一种超高膜厚彩涂板的生产方法，预处理进行脱脂、表调和热水漂洗；钝化膜重控制在30～40mg/m2；底漆设计膜厚为15±5μm，采取偏上限控制；面漆设计膜厚25±3μm，采取偏下限控制；预混间控制搅拌速度和时间，固化工艺一、二段风速和温度设定值比一般彩涂板减少20～30％，冷却水采用除盐水，电导率为70μm/s，冷却处理时间为12～15s；板厚≤0.6mm，卷取机起始重量设置为1900～2100kg，结束重量设置为2900～3200kg，阶梯张力140％；板厚＞0.6mm，卷取机阶梯张力比设定为40000/基础张力。本发明可大批量稳定生产具有优异耐蚀、耐磨性能和较好性价比的膜厚40μm的超高膜厚彩涂板，成材率达到95％以上，是一种高附加值的彩涂板生产工艺。
彩涂基板镀层重量主要依据用途、环境腐蚀性、使用寿命和耐久性等因素进行选择。防腐是彩涂板的主要功能之一，镀层重量是影响彩涂板耐腐蚀性的主要因素。由于建筑用彩涂板通常直接暴露在大气环境中，因此通常选择耐腐蚀性好、镀层厚的热镀锌板或者热镀铝锌板等基板。耐腐蚀性通常随镀层重量的增加而提高，各类镀层钢板的耐蚀性基本与其镀层厚度成正比关系，因此可以通过增加镀层重量的方法提高彩涂板的耐腐蚀性。例如在工业污染严重和沿海潮湿地区，通常使用75/75-140/140 g/m2的热镀锌板，一般防腐要求的彩涂基板使用30/30-50/50 g/m2的热镀锌板或者热镀铝锌板。彩涂钢板的涂层一般上表面厚度在20-25微米左右，耐腐蚀性通常随涂层重量的增加而提高，由于涂膜具有耐擦洗、耐溶剂、耐污染、耐阳光、耐蚀性等保护作用，因此被广泛使用。这些涂层的作用都是来自涂料本身和良好的彩涂生产工艺。涂料的特性是影响涂层性能的重要部分。涂料是由树脂、颜料、添加剂、溶剂等四种原料所组成。树脂是涂料最主要的部分，在被涂物表面形成一张平滑且均匀的薄膜。优良的树脂须具备以下性质，能形成薄膜且对底材具有良好的结合力；对颜料有良好的分散性使色泽均匀。外观透明且色度低；对环境如阳光、空气与水份、酸雨、油脂与烟雾等有抵抗力；具备耐擦洗、耐磨擦、耐碰撞等性能。
结合新疆当地市场的需求现状，发展适合当地气候特征的彩涂板是一种发展方向；新疆地处大陆腹地，远离大海，气候常年干燥，对彩涂板的防腐要求不高，但现在市场上的彩涂板普遍涂层（20-25微米左右）和镀层（30/30-50/50 g/m2）偏厚，在新疆当地使用存在资源浪费，因此急需开发一种超薄镀层薄涂层彩色涂层板的生产工艺，生产出适合新疆气候的经济型彩色涂层板，来提升现有的生产技术。
发明内容
本发明的目的在于开发一种TDX10彩色涂层板的生产工艺，生产出适合新疆气候的经济型彩色涂层板。
本发明技术方案是：一种TDX10彩色涂层板的生产工艺，采用DX51D+Z的镀铝锌基板，聚酯面漆，来生产总膜厚9µm的超薄镀层薄涂层彩色涂层板；镀锌基板的镀层10/10g/m2，镀层采用铝锌镀层，锌含量不小于85%，锌层经过光整表面均匀，无锌粒、锌疤痕缺陷；
预处理工艺：脱脂液碱点7-10；温度65-75℃；钝化液铬点24±2，温度27±5℃，化涂PMT板温温度50-70℃，钝化膜膜重15-25mg/m2；
底漆涂敷工艺：底漆漆膜厚度3±1µm，聚酯背面漆上机粘度30-33秒，涂敷辊速度：机组速度二者的数值比为1.1～1.3：1，汲料辊速度：机组速度二者的数值比为0.3～0.5：1，涂料辊和汲料辊间压力≦1250kg；
面漆涂敷工艺：面漆漆膜厚度6±1µm，聚酯背面漆上机粘度30-35秒，涂敷辊速度：机组速度二者的数值比1.2～1.4：1，汲料辊速度：机组速度二者的数值比0.4～0.7：1，涂料辊和汲料辊间压力≦1350kg，通过提高辊速比和辊间压力来降低漆膜厚度且分布均匀；
固化工艺：机组速度50～70m/min，底漆炉工作温度分4段，第4段出口温度290～360℃；面漆炉工作温度分4段，第4段出口温度310～370℃，面漆炉板温225～232℃，水淬槽冷却后带温不大于45℃，通过短时高速低温来保证漆膜受热均匀性能稳定。
应用本发明的一种TDX10的超薄镀层薄涂层彩色涂层板生产工艺，可以较好的实现超薄镀层薄涂层彩色涂层板的生产，满足新疆本地以及西北地区的干旱气候的经济型彩涂板。采用本工艺可以传统冷轧镀铝锌彩涂产线的前提下在有限的设备精度下生产出满足下游用户防护要求的低成本彩涂钢卷，开辟了彩色涂层板的生产新途径。本发明适用于钢厂具有：连续热镀铝锌机组-连续彩涂机组的工装设备的钢铁生产企业。
具体实施方式
为达到上述目的，本发明的技术方案是，一种超薄镀层薄涂层彩色涂层板TDX10的生产工艺，其包括如下步骤：
1）原料准备：经过光整的镀铝锌基板，镀层采用铝锌镀层，锌含量不小于85%，镀层10/10g/m2，锌层表面均匀；
2）预处理工艺：脱脂液碱点7-10；温度65-75℃；钝化液铬点24±2，温度27±5℃，化涂PMT板温温度50-70℃，钝化膜膜重15-25mg/m2。
3）底漆涂敷工艺：底漆漆膜厚度3±1µm，聚酯背面漆上机粘度30-33秒，涂敷辊速度：机组速度（1.1～1.3）：1，汲料辊速度：机组速度（0.3～0.5）：1，涂料辊和汲料辊间压力≦1250kg。
4）面漆涂敷工艺：面漆漆膜厚度6±1µm，聚酯背面漆上机粘度30-35秒，涂敷辊速度：机组速度（1.2～1.4）：1，汲料辊速度：机组速度（0.4～0.7）：1，涂料辊和汲料辊间压力≦1350kg，通过提高辊速比和辊间压力来降低漆膜厚度且分布均匀。
5）面漆涂敷工艺：面漆漆膜厚度6-8µm，聚酯背面漆上机粘度30-40秒，涂敷辊速度：机组速度（1.2～1.8）：1，汲料辊速度：机组速度（0.3～0.7）：1，涂料辊和汲料辊间压力≦1500kg，漆膜厚度薄且分布均匀。
6）固化工艺：机组速度50～70m/min，底漆炉工作温度分4段，第4段出口温度290～360℃；面漆炉工作温度分4段，第4段出口温度310～370℃，面漆炉板温225～232℃，水淬槽冷却后带温不大于45℃，通过短时高速低温来保证漆膜受热均匀性能稳定。
Claims (1)
1.一种TDX10彩色涂层板的生产工艺，其特征在于采用DX51D+Z的镀铝锌基板，聚酯面漆，来生产总膜厚9µm的超薄镀层薄涂层彩色涂层板；镀锌基板的镀层10/10g/m2，镀层采用铝锌镀层，锌含量不小于85%，锌层经过光整表面均匀，无锌粒、锌疤痕缺陷；具体工艺步骤如下：
1）、预处理工艺：脱脂液碱点7-10；温度65-75℃；钝化液铬点24±2，温度27±5℃，化涂PMT板温温度50-70℃，钝化膜膜重15-25mg/m2；
2）、底漆涂敷工艺：底漆漆膜厚度3±1µm，聚酯背面漆上机粘度30-33秒，涂敷辊速度：机组速度二者的数值比为1.1～1.3：1，汲料辊速度：机组速度二者的数值比为0.3～0.5：1，涂料辊和汲料辊间压力≦1250kg；
3）、面漆涂敷工艺：面漆漆膜厚度6±1µm，聚酯背面漆上机粘度30-35秒，涂敷辊速度：机组速度二者的数值比1.2～1.4：1，汲料辊速度：机组速度二者的数值比0.4～0.7：1，涂料辊和汲料辊间压力≦1350kg，通过提高辊速比和辊间压力来降低漆膜厚度且分布均匀；
4）、固化工艺：机组速度50～70m/min，底漆炉工作温度分4段，第4段出口温度290～360℃；面漆炉工作温度分4段，第4段出口温度310～370℃，面漆炉板温225～232℃，水淬槽冷却后带温不大于45℃，通过短时高速低温来保证漆膜受热均匀性能稳定。
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