An isolation pad and its manufacturing method

Abstract

This invention provides an isolation pad and its manufacturing method. The isolation pad of this invention is used during aluminum coil processing, positioned between the aluminum coil and the support rack to isolate them. The isolation pad has a multi-layered structure, with each layer made of aluminum alloy. The pad includes at least two outer layers: a first outer layer on the side in contact with the support rack and a second outer layer on the side in contact with the aluminum coil. This invention solves the problem of annealing embossing on the outer layer of the aluminum coil caused by direct contact between the aluminum coil and the support rack. The isolation pad is suitable for aluminum coils of various weights and sizes, exhibits reliable strength and high-temperature resistance, and does not fail even when repeatedly annealed and cooled with the aluminum coil in and out of the annealing furnace.

Description

Technical Field

[0001] This invention relates to the technical field of aluminum coil processing and manufacturing, and more specifically, to a insulating pad for use in the aluminum coil processing process and a method for manufacturing the same. Background Technology

[0002] In the aluminum coil manufacturing industry, in some cases, aluminum strip is wound onto a mandrel to form an aluminum coil. The coil can then be suspended from a support by the mandrel for subsequent processing steps, such as annealing. However, in other cases, a mandrel is not used during the winding process (referred to as "coilless aluminum coil"). When performing operations such as annealing on this type of coil, it is not possible to suspend it from a support by the mandrel; instead, the coil must be placed directly on a rack. The rack is typically made of iron. When the coil is placed directly on the rack for annealing, it softens, and its hardness and strength are far lower than that of the iron rack. Therefore, under its own weight, indentations easily form at the ribs where the coil contacts the iron rack, requiring the outer layer of the coil to be peeled off and discarded. Depending on factors such as the thickness, weight, and outer curvature of the aluminum coil, the embossing can penetrate as deep as a dozen layers of the aluminum coil, thus requiring the removal of more than a dozen layers, which leads to serious material loss.

[0003] To address this issue, a common approach in the art is to install an isolation structure on the rack to prevent direct contact between the outer layer of the aluminum coil and the upper surface of the iron rack. Common isolation structures include cable nets or rubber pads; however, each has its drawbacks. Cable nets are typically installed on the rack with their two edges connected to the rack edges and the middle suspended, making them prone to breakage when the aluminum coil is heavy. Rubber pads, on the other hand, have poor high-temperature resistance and cannot be used during annealing operations.

[0004] Therefore, there is a need to provide a reliable and high-temperature resistant insulating pad for use as an isolation structure between the material rack and the aluminum coil to solve the problem of annealing and imprinting on the outer layer of the aluminum coil. Summary of the Invention

[0005] The purpose of this invention is to address the above-mentioned problems in the prior art by providing a reliable and high-temperature resistant insulating pad for placement between the material rack and the aluminum coil. This solves the problem of annealing imprinting on the outer layer of the aluminum coil caused by direct contact between the aluminum coil and the material rack. It is also applicable to aluminum coils of various weights and sizes, and ensures that the insulating pad will not fail when the aluminum coil is repeatedly annealed and cooled in and out of the annealing furnace.

[0006] On one hand, the present invention provides an isolation pad for use in the aluminum coil processing process between an aluminum coil and a material rack for carrying the aluminum coil, so as to isolate the aluminum coil and the material rack. The isolation pad has a multi-layer structure, each layer of which is made of aluminum alloy material. The isolation pad includes at least two outer layers, a first outer layer on the side in contact with the material rack and a second outer layer on the side in contact with the aluminum coil.

[0007] According to a preferred embodiment of the present invention, the aluminum coil processing includes an annealing operation.

[0008] According to a preferred embodiment of the present invention, the insulating pad further includes a core layer located between the outer layers.

[0009] According to a preferred embodiment of the present invention, the hardness of the core layer is greater than that of the first outer layer and the second outer layer, and the hardness of the second outer layer is closer to that of the aluminum coil and less than or equal to that of the aluminum coil.

[0010] According to a preferred embodiment of the present invention, the core layer has a strength greater than that of the first outer layer and the second outer layer, wherein the strength of the second outer layer is closer to that of the aluminum coil.

[0011] According to a preferred embodiment of the present invention, the first outer layer and the core layer contain magnesium and / or silicon, while the second outer layer does not contain magnesium.

[0012] According to a preferred embodiment of the present invention, the first outer layer is made of 4004 aluminum alloy; the second outer layer is made of 3003 aluminum alloy; and the core layer is made of 3005 aluminum alloy.

[0013] According to a preferred embodiment of the invention, the isolation pad is curved relative to the horizontal surface and matches the bearing surface of the rack that engages with the isolation pad.

[0014] According to a preferred embodiment of the present invention, the isolation pad has a thickness of 15-20 mm, a width of 1300-1500 mm, a length of 1700-1950 mm, and a bending angle of 16-18 degrees relative to the horizontal surface.

[0015] According to a preferred embodiment of the present invention, the thickness of the first outer layer accounts for 8%-12% of the total thickness of the isolation pad, the thickness of the second outer layer accounts for 17%-23% of the total thickness of the isolation pad, and the remaining portion is the core layer.

[0016] On the other hand, the present invention provides a method for manufacturing the aforementioned isolation pad, the method comprising the following steps:

[0017] Step (i) involves manufacturing a first outer layer, a second outer layer, and a core layer between the first outer layer and the second outer layer;

[0018] Step (ii) Welding: The first outer layer, the second outer layer and the core layer obtained in step (i) are stacked along the thickness direction and welded along the length direction to form a welded body;

[0019] Step (iii) Hot rolling: The welded body obtained by welding is hot rolled to form the isolation pad.

[0020] According to a preferred embodiment of the present invention, in step (i), the steps of manufacturing the first outer layer, the second outer layer, and the core layer include:

[0021] Melting, melting raw materials to form molten aluminum alloy;

[0022] Casting involves casting the molten aluminum alloy into an aluminum alloy block.

[0023] Milling: Milling is performed on the cast aluminum alloy block to obtain a milled aluminum alloy block.

[0024] Furthermore, the steps of manufacturing the first outer layer and the second outer layer further include:

[0025] Hot rolling involves hot rolling a milled aluminum alloy block to obtain an aluminum alloy sheet.

[0026] According to a preferred embodiment of the present invention, in step (ii), continuous argon arc welding is performed along the length direction.

[0027] According to a preferred embodiment of the present invention, the method further includes: step (iv) annealing, placing the isolation pad obtained by hot rolling in step (iii) on the material rack, placing the aluminum coil on the isolation pad, and loading the aluminum coil, the material rack, and the isolation pad between the aluminum coil and the material rack into an annealing furnace for at least one annealing operation, wherein after at least one annealing operation, the isolation pad is curved relative to the horizontal surface and matches the bearing surface of the isolation pad that is engaged with the material rack.

[0028] According to a preferred embodiment of the present invention, step (iii) includes: preheating the welded body obtained by welding to a temperature range of 470-480°C, holding it at that temperature for 2-5 hours, and then rolling the welded body along its length at a rolling speed of 80-120 mm / min into an isolation pad with a length of 1700-1950 mm, a width of 1300-1500 mm, and a thickness of 15-20 mm.

[0029] According to a preferred embodiment of the present invention, the annealing temperature in step (iv) is 200-550°C.

[0030] According to a preferred embodiment of the present invention, in step (i), the melting step for manufacturing the first outer layer includes: placing crystalline silicon at the bottom of the melting furnace, adding the original aluminum ingot, igniting and starting the melting process, and when the temperature of the aluminum liquid reaches the temperature range of 750-760°C, adding magnesium ingot and stirring evenly to obtain aluminum alloy liquid.

[0031] According to a preferred embodiment of the present invention, in step (i), the casting step for manufacturing the first outer layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 675-685°C, and using a flow rate of 110-130 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 45-47 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm.

[0032] According to a preferred embodiment of the present invention, in step (i), the milling step of manufacturing the first outer layer includes: milling off aluminum alloy strips 8-10 mm wide from both sides of the cast aluminum alloy block in the width direction.

[0033] According to a preferred embodiment of the present invention, in step (i), the hot rolling step of manufacturing the first outer layer includes: preheating the milled aluminum alloy block to a temperature range of 450-470°C, holding it at that temperature for 2-5 hours, and then rolling the milled aluminum alloy block along the length direction at a rolling speed of 140-150 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 58-62 mm.

[0034] According to a preferred embodiment of the present invention, in step (i), the melting step for manufacturing the second outer layer includes: adding primary aluminum ingots to a melting furnace, igniting and starting the melting process, and when the temperature reaches a temperature range of 750-760°C, adding iron powder, copper wire and aluminum-manganese alloy and stirring evenly to obtain aluminum alloy liquid.

[0035] According to a preferred embodiment of the present invention, in step (i), the casting step for manufacturing the second outer layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 690-700°C, and using a flow rate of 100-120 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 41-43 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm.

[0036] According to a preferred embodiment of the present invention, in step (i), the milling step of manufacturing the second outer layer includes: milling off aluminum alloy strips with a width of 8-10 mm from both sides of the cast aluminum alloy block in the width direction.

[0037] According to a preferred embodiment of the present invention, in step (i), the hot rolling step for manufacturing the second outer layer includes: preheating the milled aluminum alloy block to a temperature range of 480-500°C, holding it at that temperature for 2-5 hours, and then rolling the milled aluminum alloy block along the length direction at a rolling speed of 160-170 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 98-102 mm.

[0038] According to a preferred embodiment of the present invention, in step (i), the melting step for manufacturing the core layer includes: adding primary aluminum ingots to a melting furnace, igniting and starting the melting process, and when the temperature reaches a temperature range of 750-760°C, adding iron powder, magnesium ingots, copper wire and aluminum-manganese alloy and stirring evenly to obtain aluminum alloy liquid.

[0039] According to a preferred embodiment of the present invention, in step (i), the casting step for manufacturing the core layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 700-710°C, and using a flow rate of 90-100 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 38-40 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1320 mm, and a thickness of 310 mm.

[0040] According to a preferred embodiment of the present invention, in step (i), the milling step of manufacturing the core layer includes: milling off aluminum alloy strips with a width of 8-10 mm from both sides of the cast aluminum alloy block in the width direction.

[0041] According to the insulating pad and its manufacturing method provided by the present invention, since the insulating pad is made of aluminum alloy, it will not cause undesirable annealing indentations on the aluminum coil placed on it during the aluminum coil production process, especially during the annealing and cooling processes after annealing, due to its similar strength. Furthermore, the multi-layered structure, manufacturing method, and aluminum alloy material of the insulating pad of the present invention give it reliable strength and high-temperature resistance, thus ensuring it will not fail after repeated annealing and cooling processes with the aluminum coil in and out of the annealing furnace. Attached Figure Description

[0042] To better understand the above and other objects, features, advantages, and functions of the present invention, reference can be made to the preferred embodiments shown in the accompanying drawings. In the drawings, the same reference numerals refer to the same parts. Those skilled in the art should understand that the drawings are intended to schematically illustrate preferred embodiments of the invention and are not intended to limit the scope of the invention; the parts in the drawings are not drawn to scale.

[0043] Figure 1 This is a schematic diagram of existing technology where aluminum coils without sleeves are placed directly on the material rack.

[0044] Figure 2 The diagram shows a wire mesh used in the prior art as an isolation structure between a material rack and an aluminum coil.

[0045] Figure 3 A perspective view of an isolation pad according to a preferred embodiment of the present invention is shown.

[0046] Figure 4 A perspective view of a rack according to a preferred embodiment of the present invention is shown.

[0047] Figure 5 The steps for manufacturing the insulating pad according to a preferred embodiment of the present invention are shown.

[0048] Figure 6 The steps for manufacturing the first outer layer and / or second outer layer of the insulating pad according to a preferred embodiment of the present invention are shown.

[0049] Figure 7 The steps for manufacturing the core layer of the insulating pad according to a preferred embodiment of the present invention are shown.

[0050] Figure 8 This is a schematic diagram of pressing an isolation pad using an aluminum coil of the largest diameter according to a preferred embodiment of the present invention.

[0051] Figure 9 This is a schematic diagram of a preferred embodiment of the present invention, in which a smaller diameter aluminum coil is placed on the isolation pad after the isolation pad is pressed and bent using an aluminum coil of the largest diameter. Detailed Implementation

[0052] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The embodiments described herein are merely preferred embodiments of the present invention; those skilled in the art can conceive of other ways to implement the present invention based on these preferred embodiments, and such other ways also fall within the scope of the present invention.

[0053] During the annealing process and post-annealing cooling of aluminum coils, the sleeveless aluminum coils, lacking the innermost core sleeve, cannot be suspended on a support and therefore need to be placed on a rack (such as...). Figure 1 (As shown). However, because the material rack is made of iron, its hardness and strength are much greater than that of the aluminum coil, which softens at high temperatures during the annealing process and subsequent cooling. Therefore, it easily leaves annealing indentations on the surface of the aluminum coil. Existing technologies mostly use wire mesh (such as...). Figure 2 As shown, the wire mesh serves as an isolation structure to separate the material rack from the aluminum coil, thus addressing the issue of annealing and embossing on the aluminum coil surface. However, the wire mesh is typically installed on the material rack with its two side edges attached to the edges and its center suspended. Due to the large weight of the aluminum coil and this suspended configuration, the installation area of ​​the wire mesh is not strong enough and is prone to breakage, requiring frequent replacement, which causes inconvenience and significant material waste.

[0054] This invention provides an isolation pad, different from the aforementioned wire mesh and other isolation structures, as well as a method for manufacturing the isolation pad. The isolation pad of this invention can be used as an isolation structure to separate the aluminum coil from the material rack during aluminum coil processing, such as during annealing and subsequent cooling, to prevent the aluminum coil from directly contacting the material rack and leaving annealing marks. Furthermore, the isolation pad of this invention has reliable strength, is suitable for various aluminum coils of different weights and sizes, and can withstand repeated annealing and cooling operations with different aluminum coils without failure, thus solving the aforementioned problems in the prior art. The isolation pad and its manufacturing method according to this invention will be described in detail below with reference to the accompanying drawings. In this context, directional terms such as "upper," "middle," and "lower" are used based on the isolation pad being positioned between the aluminum coil and the material rack in a normal placement state.

[0055] Figure 3 An isolation pad 1 according to a preferred embodiment of the present invention is shown. During aluminum coil processing, particularly during the aluminum coil annealing process and the cooling process after annealing, the isolation pad 1 is disposed on the aluminum coil and, as... Figure 4 The material rack 2 shown is used to separate the aluminum coil from the material rack 2. The material rack 2 is made of iron and is used to support the aluminum coil so that the unwound aluminum coil that is not wound on the core sleeve can be placed on the material rack 2 after the winding operation is completed for subsequent operations.

[0056] The isolation pad 1 has a multi-layer structure, with each layer made of aluminum alloy. This multi-layer structure includes a first outer layer on the lower side that contacts the material rack 2, a second outer layer on the upper side that contacts the aluminum coil, and a core layer located between the first and second outer layers. It is understood that the multi-layer structure of the isolation pad is not limited to the structure described above, which includes a first outer layer, a second outer layer, and a core layer; it can include more core layers depending on actual needs.

[0057] Furthermore, the first outer layer contains silicon, and the core layer contains magnesium. In this way, the magnesium in the core layer can combine with the silicon in the first outer layer to form a silicon-magnesium age-strengthening effect. This allows the insulation pad to maintain its strength even after repeated annealing and cooling operations with the aluminum coil in and out of the annealing furnace, thus avoiding the problem of insulation pad failure and ensuring reliable strength.

[0058] It is understood that the insulating pad of the present invention may also contain magnesium in the first outer layer and silicon in the core layer; or the first outer layer may contain both silicon and magnesium, and the core layer may contain magnesium, etc. Those skilled in the art can select the composition of the first outer layer and the core layer as needed, as long as the first outer layer and the core layer contain magnesium and / or silicon to achieve the silicon-magnesium aging strengthening effect.

[0059] Furthermore, the second outer layer of the insulating pad 1 is made of an aluminum alloy material with the same or similar composition as the aluminum alloy material used to manufacture the aluminum coil. "Same" here means that the elements contained in the second outer layer material and the content of each element are the same as those in the aluminum coil material; and "similar" means that the main elements (e.g., manganese) contained in the second outer layer material, excluding aluminum, are the same as those in the aluminum coil material, and / or the element content differs only slightly. Preferably, both the second outer layer and the aluminum coil are made of an aluminum-manganese alloy, and the main element (excluding aluminum) in both is manganese. Preferably, the percentage difference in manganese content (by weight) between the second outer layer and the aluminum coil is within 20%. Preferably, the manganese content (by weight) in the second outer layer is 1.1%-1.2%, and preferably, the manganese content (by weight) in the aluminum coil is 1.1%-1.3%. It should be noted that impurities contained in the material are not within the scope of the above discussion regarding elements.

[0060] Specifically, the second outer layer does not contain magnesium. This is because if the second outer layer of the insulating pad contains magnesium, the surface of the aluminum coil in direct contact with it is easily contaminated by the easily diffused and oxidized magnesium. Therefore, the absence of magnesium in the second outer layer can prevent this from happening.

[0061] Preferably, the first outer layer is made of 4004 aluminum alloy, the core layer is made of 3005 aluminum alloy, and the second outer layer is made of 3003 aluminum alloy.

[0062] Furthermore, the core layer has a higher hardness than the first and second outer layers, and the second outer layer has a hardness closer to that of the aluminum coil but less than or equal to it. For example, the core layer has a hardness of 38-42 HB, the first outer layer has a hardness of 32-36 HB, the second outer layer has a hardness of 28-30 HB, and the aluminum coil in most products has a hardness of 30-34 HB. In this way, because the second outer layer, which is in contact with the aluminum coil, has a lower hardness, no indentation is formed on the surface of the aluminum coil during operation due to pressure from the contact surface. At the same time, the core layer in the middle has a higher hardness, ensuring that the overall hardness of the insulating pad is sufficient.

[0063] Furthermore, the core layer has a greater strength than the first and second outer layers, with the strength of the second outer layer being closer to that of the aluminum coil. "Strength" as used herein refers to the tensile strength of each layer of the insulating pad and / or the aluminum coil when heated to a soft state by high-temperature annealing. Preferably, the soft tensile strength of the second outer layer differs from that of the aluminum coil by no more than 20%; and preferably, the soft tensile strength of the core layer is 20%-50% higher than that of the second outer layer; and preferably, the soft tensile strength of the first outer layer differs from that of the second outer layer by no more than 15%. More preferably, the soft tensile strength of the first outer layer is 105-115 MPa, the soft tensile strength of the second outer layer is 110-120 MPa, the soft tensile strength of the core layer is 150-160 MPa, and the soft tensile strength of the aluminum coil is 110-130 MPa. In this way, since the second outer layer has the same or similar strength as the aluminum coil, no indentation will occur at the contact point between the aluminum coil and the second outer layer due to the weight and strength difference of the aluminum coil during annealing or post-annealing cooling, thus ensuring the smoothness of the outer layer of the aluminum coil. Meanwhile, the first outer layer is far from the aluminum coil during annealing and pressing; therefore, to ensure sufficient deformation, its soft tensile strength is set to be close to, or slightly less than, the soft tensile strength of the aluminum coil and the second outer layer. Furthermore, the soft tensile strength of the core layer is greater than that of the other layers, thereby ensuring the overall strength and reliability of the insulating pad.

[0064] As described above, this sandwich structure of the isolation pad can both ensure that no indentation occurs on the surface of the aluminum pad by utilizing the lower strength and hardness of the second outer layer in contact with the aluminum pad, and at the same time, ensure the overall strength and hardness reliability of the isolation pad by utilizing the core layer and / or the first outer layer.

[0065] Furthermore, the isolation pad 1 is curved relative to the horizontal surface and matches the generally V-shaped bearing surface of the rack 2 that engages with the isolation pad 1. This is to accommodate the cylindrical shape of the aluminum coil. Specifically, as... Figure 4As shown, the generally V-shaped bearing surface of the rack 2 has inclined surfaces 21 and 23 at an angle to the horizontal plane, and a bottom surface 22 parallel to the horizontal plane connecting the inclined surfaces 21 and 23. The inclined surfaces 21 and 23 and the bottom surface 22 together define a generally V-shaped receiving space for receiving the isolation pad 1, and thus supporting the aluminum coil. When the downwardly bent isolation pad 1 is placed on the rack 2, the bent surface of the isolation pad 1 is tangential to or in contact with the inclined surfaces 21 and 23 of the rack 2, thereby allowing the isolation pad 1 to match the generally V-shaped bearing surface of the rack 2.

[0066] Preferably, such as Figure 3 As shown, the thickness D of the isolation pad 1 is 15-20mm, the width W is 1300-1500mm, the length L is 1700-1950mm, and its bending angle relative to the ground is 16-18 degrees. It should be understood that the dimensions of the isolation pad are not limited to the above values. Those skilled in the art can select appropriate isolation pad dimensions based on different aluminum coil weights, aluminum coil sizes, material rack sizes, and other conditions.

[0067] Preferably, the thickness of the first outer layer of the insulating pad accounts for 8-12% of the total thickness of the insulating pad, more preferably 10%, and the thickness of the second outer layer accounts for 17-23% of the total thickness of the insulating pad, more preferably 20%, with the remaining thickness being the core layer. It should be understood that the thickness percentage of each layer in the insulating pad is not limited to the above numerical ranges, and those skilled in the art can design the thickness percentage of each layer according to strength and other requirements.

[0068] The following is for reference Figure 5-9 The method for manufacturing the isolation pad of the present invention will be described in detail.

[0069] like Figure 5 As shown, according to a preferred embodiment of the present invention, the method for manufacturing the insulating pad of the present invention mainly includes the following steps:

[0070] Step (i) involves fabricating a first outer layer, a second outer layer, and a core layer between the first and second outer layers.

[0071] Step (ii) Welding: The first outer layer, the second outer layer and the core layer obtained in step (i) are stacked along the thickness direction and welded along the length direction to form a welded body;

[0072] Step (iii) Hot rolling: The welded body obtained by welding is hot rolled to form a spacer pad;

[0073] Step (iv) Annealing: The isolation pad obtained by hot rolling in step (iii) is placed on the rack, the aluminum coil is placed on the isolation pad, and the aluminum coil, the rack, and the isolation pad between the aluminum coil and the rack are put into the annealing furnace for at least one annealing operation. After at least one annealing operation, the isolation pad is curved relative to the horizontal surface and matches the bearing surface of the connecting isolation pad of the rack.

[0074] Furthermore, such as Figure 6 As shown, according to a preferred embodiment of the present invention, in step (i), manufacturing the first outer layer and / or the second outer layer includes the following steps:

[0075] Melting, melting raw materials to form molten aluminum alloy;

[0076] Casting involves casting the molten aluminum alloy into an aluminum alloy block.

[0077] Milling: Milling the surface of a cast aluminum alloy block to obtain a milled aluminum alloy block.

[0078] Hot rolling involves hot rolling a milled aluminum alloy block to obtain an aluminum alloy sheet.

[0079] Preferably, in manufacturing the first outer layer, in the melting step, crystalline silicon is placed at the bottom of the melting furnace, primary aluminum ingots are added, and ignition begins. When the temperature of the molten aluminum reaches 750-760°C, magnesium ingots are added and stirred evenly to obtain molten aluminum alloy. Then, in the casting step, the temperature of the molten aluminum alloy is maintained within the range of 675-685°C, and a flow rate of 110-130 m³ / h is used. 3 The aluminum alloy molten metal is cooled with cooling water at a rate of 45-47 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm. In the milling step, aluminum alloy strips with a width of 8-10 mm are milled off both sides of the cast aluminum alloy block to obtain a milled aluminum alloy block. Finally, in the hot rolling step, the milled aluminum alloy block is preheated to a temperature range of 450-470℃ and held for 2-5 hours. Then, the milled aluminum alloy block is rolled along the length direction at a rolling speed of 140-150 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 58-62 mm.

[0080] Preferably, in manufacturing the second outer layer, firstly, in the melting step, primary aluminum ingots are added to the melting furnace, and ignition begins. When the temperature reaches 750-760℃, iron powder, copper wire, and aluminum-manganese alloy are added and stirred evenly to obtain a liquid aluminum alloy. Then, in the casting step, the temperature of the molten aluminum alloy is maintained within the range of 690-700℃, and a flow rate of 100-120 m³ / h is used. 3 The aluminum alloy molten metal is cooled with cooling water at a rate of 41-43 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm. In the milling step, aluminum alloy strips with a width of 8-10 mm are milled off both sides of the cast aluminum alloy block in the width direction to obtain a milled aluminum alloy block. Finally, in the hot rolling step, the milled aluminum alloy block is preheated to a temperature range of 480-500℃ and held for 2-5 hours. Then, the milled aluminum alloy block is rolled along the length direction at a rolling speed of 160-170 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 98-102 mm.

[0081] Further, in step (i), as Figure 7 As shown, according to a preferred embodiment of the present invention, manufacturing the core layer includes the following steps:

[0082] Melting, melting raw materials to form molten aluminum alloy;

[0083] Casting involves casting the molten aluminum alloy into an aluminum alloy block.

[0084] Milling is performed on the cast aluminum alloy block to obtain a milled aluminum alloy block.

[0085] Preferably, in the core layer manufacturing process, firstly, in the melting step, primary aluminum ingots are added to the melting furnace, and ignition begins. When the temperature reaches 750-760℃, iron powder, magnesium ingots, copper wire, and aluminum-manganese alloy are added and stirred evenly to obtain a liquid aluminum alloy. Then, in the casting step, the temperature of the molten aluminum alloy is maintained within the range of 700-710℃, and a flow rate of 90-100 m³ / h is used. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 38-40 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1320 mm, and a thickness of 310 mm. Finally, in the milling step, aluminum alloy strips with a width of 8-10 mm are milled off both sides of the cast aluminum alloy block in the width direction to obtain a milled aluminum alloy block.

[0086] Furthermore, in step (ii), argon arc welding is preferably performed continuously along the length direction.

[0087] Further, in step (iii), it is preferable to preheat the welded body to a temperature range of 470-480°C, hold it at that temperature for 2-5 hours, and then roll the welded body along its length at a rolling speed of 80-120 mm / min into a spacer pad with a length of 1700-1950 mm, a width of 1300-1500 mm, and a thickness of 15-20 mm.

[0088] Furthermore, in step (iv), it is preferable to use as follows Figure 8 The largest diameter aluminum coil shown is placed on a separator pad and then annealed in the furnace to soften it. Because the largest diameter aluminum coil covers the entire separator pad, the entire separator pad is pressed to form all aluminum coils with diameters smaller than that of the largest diameter aluminum coil (e.g., ...). Figure 9 The small-diameter aluminum coil shown has a curved shape that matches the bearing surface of the rack. In actual production, those skilled in the art can determine the size of the maximum diameter aluminum coil according to actual production needs. More preferably, the spacer pad does not need to be fixed to the rack by welding or other operations. This is because the aluminum coil typically weighs 8-10 tons. When the aluminum coil is placed on the spacer pad for various operations, the spacer pad located between the rack and the aluminum coil usually does not shift under the weight of the aluminum coil. Furthermore, the aluminum coil is usually loaded and unloaded by a hoisting device, and this loading and unloading operation usually does not cause the spacer pad to shift. Therefore, this non-welded fixing design can save processes and reduce material and labor costs while ensuring that the spacer pad does not shift. And preferably, the annealing temperature in step (iv) is 200-550°C.

[0089] It should be noted that in the methods for manufacturing the insulating pad of the present invention discussed above, the values ​​and / or ranges of various parameters such as temperature, size, duration, and rate described are all preferred embodiments. Those skilled in the art can select different values ​​and / or ranges according to actual conditions or needs. Furthermore, it should be noted that the temperatures discussed in the above steps refer to the temperature of the material itself, not the set temperature within the annealing apparatus or the furnace gas temperature.

[0090] The scope of protection of this invention is defined only by the claims. Thanks to the teachings of this invention, those skilled in the art will readily recognize that alternative structures and / or methods disclosed in this invention can be used as feasible alternative implementations, and that the implementations disclosed in this invention can be combined to produce new implementations, which also fall within the scope of the appended claims.

Claims

1. An isolation pad, characterized in that, The isolation pad is used to be placed between the aluminum coil and the rack for carrying the aluminum coil during the aluminum coil processing process to isolate the aluminum coil and the rack. The isolation pad has a multi-layer structure, each layer of which is made of aluminum alloy material. The isolation pad includes at least two outer layers: a first outer layer on the side in contact with the rack and a second outer layer on the side in contact with the aluminum coil. The isolation pad has a shape that is bent relative to the horizontal surface toward the rack to adapt to the cylindrical shape of the aluminum coil, and the isolation pad matches the bearing surface of the rack and the isolation pad. The insulating pad further includes a core layer located between the outer layers; The hardness of the core layer is greater than that of the first outer layer and the second outer layer, and the hardness of the second outer layer is closer to that of the aluminum coil and less than or equal to that of the aluminum coil. And / or the strength of the core layer is greater than the strength of the first outer layer and the second outer layer, wherein the strength of the second outer layer is closer to the strength of the aluminum coil.

2. The isolation pad according to claim 1, characterized in that, The aluminum coil processing includes an annealing operation.

3. The isolation pad according to claim 1, characterized in that, The first outer layer and the core layer contain magnesium and / or silicon, while the second outer layer does not contain magnesium.

4. The isolation pad according to claim 1, characterized in that, The isolation pad has a thickness of 15-20mm, a width of 1300-1500mm, a length of 1700-1950mm, and a bending angle of 16-18 degrees relative to the horizontal surface.

5. The isolation pad according to claim 1, characterized in that, The thickness of the first outer layer accounts for 8%-12% of the total thickness of the isolation pad, the thickness of the second outer layer accounts for 17%-23% of the total thickness of the isolation pad, and the remaining part is the core layer.

6. A method for manufacturing an isolation pad as described in any one of claims 1 to 5, characterized in that, The method includes the following steps: Step (i) involves manufacturing a first outer layer, a second outer layer, and a core layer between the first outer layer and the second outer layer; Step (ii) Welding: The first outer layer, the second outer layer and the core layer obtained in step (i) are stacked along the thickness direction and welded along the length direction to form a welded body; Step (iii) Hot rolling: The welded body obtained by welding is hot rolled to form the isolation pad; Step (iv) Annealing: The isolation pad obtained by hot rolling in step (iii) is placed on the material rack, the aluminum coil is placed on the isolation pad, and the aluminum coil, the material rack, and the isolation pad between the aluminum coil and the material rack are put into an annealing furnace for at least one annealing operation. After at least one annealing operation, the isolation pad is curved relative to the horizontal surface and matches the bearing surface of the isolation pad that is engaged with the material rack.

7. The method according to claim 6, characterized in that, In step (i), the steps of manufacturing the first outer layer, the second outer layer, and the core layer include: Melting, melting raw materials to form molten aluminum alloy; Casting involves casting the molten aluminum alloy into an aluminum alloy block. Milling is performed on the cast aluminum alloy block to obtain a milled aluminum alloy block. The steps of manufacturing the first outer layer and the second outer layer further include: Hot rolling involves hot rolling a milled aluminum alloy block to obtain an aluminum alloy sheet.

8. The method according to claim 6, characterized in that, In step (ii), continuous argon arc welding is performed along the length direction.

9. The method according to claim 6, characterized in that, Step (iii) includes: preheating the welded body to a temperature range of 470-480°C, holding it at that temperature for 2-5 hours, and then rolling the welded body along its length at a rolling speed of 80-120 mm / min into a spacer pad with a length of 1700-1950 mm, a width of 1300-1500 mm, and a thickness of 15-20 mm.

10. The method according to claim 6, characterized in that, The annealing temperature in step (iv) is 200-550℃.

11. The method according to claim 7, characterized in that, In step (i), the melting step for manufacturing the first outer layer includes: placing crystalline silicon at the bottom of the melting furnace, adding original aluminum ingots, igniting and starting the melting process, and when the temperature of the aluminum liquid reaches the temperature range of 750-760°C, adding magnesium ingots and stirring evenly to obtain aluminum alloy liquid.

12. The method according to claim 7, characterized in that, In step (i), the casting step for manufacturing the first outer layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 675-685°C, and using a flow rate of 110-130 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 45-47 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm.

13. The method according to claim 7, characterized in that, In step (i), the milling step of manufacturing the first outer layer includes: milling off 8-10 mm wide aluminum alloy strips from both sides of the cast aluminum alloy block in the width direction.

14. The method according to claim 7, characterized in that, In step (i), the hot rolling step for manufacturing the first outer layer includes: preheating the milled aluminum alloy block to a temperature range of 450-470°C, holding it at that temperature for 2-5 hours, and then rolling the milled aluminum alloy block along the length direction at a rolling speed of 140-150 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 58-62 mm.

15. The method according to claim 7, characterized in that, In step (i), the melting step for manufacturing the second outer layer includes: adding the original aluminum ingot to the melting furnace, igniting and starting the melting process, and when the temperature reaches the range of 750-760°C, adding iron powder, copper wire and aluminum-manganese alloy and stirring evenly to obtain aluminum alloy liquid.

16. The method according to claim 7, characterized in that, In step (i), the casting step for manufacturing the second outer layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 690-700°C, and using a flow rate of 100-120 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 41-43 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1270 mm, and a thickness of 415 mm.

17. The method according to claim 7, characterized in that, In step (i), the milling step of manufacturing the second outer layer includes: milling off aluminum alloy strips with a width of 8-10 mm from both sides of the cast aluminum alloy block in the width direction.

18. The method according to claim 7, characterized in that, In step (i), the hot rolling step for manufacturing the second outer layer includes: preheating the milled aluminum alloy block to a temperature range of 480-500°C, holding it at that temperature for 2-5 hours, and then rolling the milled aluminum alloy block along its length at a rolling speed of 160-170 mm / min into an aluminum alloy plate with a length of 4800-5000 mm, a width of 1280-1320 mm, and a thickness of 98-102 mm.

19. The method according to claim 7, characterized in that, In step (i), the melting step for manufacturing the core layer includes: adding primary aluminum ingots to the melting furnace, igniting and starting the melting process, and when the temperature reaches the range of 750-760°C, adding iron powder, magnesium ingots, copper wire and aluminum-manganese alloy and stirring evenly to obtain aluminum alloy liquid.

20. The method according to claim 7, characterized in that, In step (i), the casting step for manufacturing the core layer includes: maintaining the temperature of the molten aluminum alloy liquid within a temperature range of 700-710°C, and using a flow rate of 90-100 m³ / h. 3 The aluminum alloy liquid is cooled by cooling water at a rate of 38-40 mm / min and cast into an aluminum alloy block with a length of 5200 mm, a width of 1320 mm, and a thickness of 310 mm.

21. The method according to claim 7, characterized in that, In step (i), the milling step of manufacturing the core layer includes: milling off aluminum alloy strips with a width of 8-10 mm from both sides of the cast aluminum alloy block in the width direction.

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