High-temperature uncoiling of metals

Abstract

To provide a system and a method for processing metal from a coil that may be uncoiled at homogenizing, annealing, or other elevated temperatures.SOLUTION: A method for heat-treating a metal coil 110 may include: heating in a furnace and elevating a temperature of the metal to be within a pre-heated temperature range, such as a homogenizing temperature range or an annealing temperature range; unwinding the metal coil 110 in a heated state in which the metal is within the pre-heated temperature range or before the metal has cooled past a threshold amount below the pre-heated temperature range; quenching an unwound portion 124 of the coil and reducing a temperature of the unwound portion to a within a quenched temperature range within a predetermined amount of time. The unwound portion 124 of the coil is manufactured in the unwinding step. A quenched portion 130 is manufactured in the quenching and reducing step.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit and priority of U.S. Provisional Application No. 63 / 005,014, titled "HOT UNCOILING OF METAL," filed on April 3, 2020, the content of which is hereby incorporated by reference in its entirety for all purposes.

[0002] The present disclosure generally relates to metal processing, and more specifically, to systems and methods for processing metal from coils that can be uncoiled at a homogenization temperature, annealing temperature, or other elevated temperature.

Background Art

[0003] To more easily transport a sheet of metal or other material, the material can be wound around a rotating mandrel. The resulting coil can generally be moved more easily than if the material were transported as one or more flat sheets instead. After being transported to an appropriate location, if the coil can be unwound and unspooled at a cut length, separated sheet material is available for further processing or use.

[0004] While convenient for transportation, the shape of a coil can be unsuitable for certain other processing tasks. For example, certain heat treatment processes involve raising the material to a considerable temperature and then rapidly quenching it. Such processes may not be practical to perform on a workpiece corresponding to a fully formed coil, for example, because the overall size of the coil tends to retain heat, hindering a sufficiently high heat extraction rate suitable for obtaining the desired results of the quenching process. Furthermore, various materials (such as metals) may be more susceptible to problems (such as scratching, stretching, or welding of overlapping windings) when handled at high temperatures while in coil form than when processed in individual layers of separate flat sheets. Therefore, if heat treatment is desired for a coiled material, the material is usually first removed from the coil by cutting it into separate strips before any heating operation of the heat treatment, and the heat treatment is then performed individually on the removed strips, i.e., each strip undergoes the appropriate heating and quenching operations of the heat treatment process. [Overview of the project]

[0005] The term "embodiment" and similar terms broadly refer to the subject matter of this disclosure and all of the following claims. Any statements containing these terms should be understood not to limit the subject matter described herein, nor to limit the meaning or scope of the following claims. The embodiments of this disclosure covered herein are defined by the following claims, not by the summary of the invention. The summary of the invention is a high-level summary of the various aspects of the disclosure and introduces some of the concepts further described in the sections on embodiments for carrying out the invention. The summary of the invention is not intended to identify any important or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by referring to the entire specification of this disclosure, any or all of the drawings, and the appropriate portions of each claim.

[0006] Specific examples herein address systems and methods for processing metal from coils that can be uncoiled at a homogenization temperature, annealing temperature, or other heating temperature. For example, an entire coil can be heated at once in a furnace and then uncoiled while still heated (e.g., while still in the furnace or immediately after being removed from the furnace). This may be more efficient and / or effective in terms of time, space, energy, and / or other criteria than processing a series of individual strips from the coil. The uncoiled portion of the coil may be cooled, quenched, and / or subjected to other forms of quenching systems by spraying air, water, or other coolant onto the uncoiled portion of the coil while still heated. Since the coil is not separated into individual cut lengths, a new coil can be formed by newly winding the quenched portion of the resulting coil. Thus, for example, a heat-treated coil can be obtained without the respective drawbacks that may be encountered in a process that, instead, involves individually heating and quenching the coil and then cutting it into lengths that are reattached to each other to form a continuous unit for forming a coil.

[0007] Various examples provide a method for heat-treating a metal coil. The method may include heating the metal coil in a furnace to raise the temperature of the metal to within a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range. The method may further include unwinding the metal coil while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount below the preheating temperature range. This unwinding can produce an unwinded portion of the coil. The method may further include quenching the unwinded portion of the coil to reduce the temperature of the unwinded portion to a quenched temperature range within a predetermined time. Quenching can produce a quenched portion.

[0008] In various examples, systems for heat-treating metal coils are provided. The system may include a furnace, which is sized to accommodate the metal coil and may be configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range. The system may further include a rewinding system, which may be operable to rewind at least a portion of the coil while the metal is heated to a preheating temperature range or before the metal cools beyond a threshold amount below the preheating temperature range. The system may further include a quenching system, which may be configured to receive the rewinded portion of the coil from the rewinding system and reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0009] In various examples, alternative systems for heat-treating metal coils can be provided. The system may include a furnace, which is sized to accommodate the metal coil and may be configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range. The system may further include a transport system, which may be configured to remove the coil from the furnace while the metal is heated and within the preheating temperature range, or before the metal cools beyond a threshold amount below the preheating temperature range. The system may further include a rewinding system, which is operable to rewind at least a portion of the heated coil at a rewinding position where the coil is being transported by the transport system. The system may further include a quenching system, which may be configured to receive the rewinded portion of the coil from the rewinding system and reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0010] In various examples, alternative systems for heat-treating metal coils can be provided. The system may include a furnace, which is sized to accommodate the metal coil and may be configured to raise the temperature of the metal to within a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range. The system may further include a rewinding system, which may include a rewinding mechanism operable on the coil to rewind at least a portion of the coil while the coil is in the furnace. The system may further include a quenching system, which may be configured to receive the rewinded portion of the coil from the furnace and reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0011] Other objectives and advantages will become apparent from the detailed description of the non-limiting embodiments below.

[0012] This specification refers to the attached figures below, and the use of similar reference numbers in different figures is intended to illustrate similar or analogous components. [Brief explanation of the drawing]

[0013] [Figure 1] This flowchart shows the process of heat-treating a metal coil according to various embodiments. [Figure 2] This is a side view of an example of a system that can be used to carry out the process of Figure 1 by various embodiments, showing the coil being uncoiled in the furnace. [Figure 3] This is a side view of components that can be used to carry out the process of Figure 1 according to various embodiments, showing an example of an option for transporting the coil to the unwinding position. [Modes for carrying out the invention]

[0014] Where used herein, the terms “invention,” “the invention,” “this invention,” and “this invention” are intended to broadly refer to the subject matter of this patent application and all of the following claims. It should be understood that any statements containing these terms do not limit the subject matter described herein, nor the meaning or scope of the following claims. While the subject matter of embodiments of the invention is described herein with specificity to satisfy statutory requirements, this description is not necessarily intended to limit the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be construed as meaning a particular order or arrangement among or between diverse steps or elements, unless the order of individual steps or arrangement of elements is explicitly described. Where used herein, the meanings of “a,” “an,” and “the” include singular and plural references unless otherwise explicitly indicated by context.

[0015] In material processing and manufacturing, coiled products can be obtained by continuous casting or rolling processes (such as hot rolling). Material processing may correspond to or include metalworking. For example, metalworking can produce coiled strips of materials such as conductive materials. As disclosed herein, conductive materials include, and may correspond to, materials that allow the flow of electric current in one or more directions, such as metallic materials. Suitable materials may include articles of any suitable thickness that can be coiled, such as metal sheets or metal shades. Coiled strips may have any suitable length or width. A coil may include, or correspond to, a coiled strip. For example, a metal coil may include a metal strip coiled around a spool and / or mandrel.

[0016] As used herein, a sheet typically refers to a product having a thickness of less than approximately 4 mm. For example, a sheet may have a thickness of less than approximately 4 mm, less than approximately 3 mm, less than approximately 2 mm, less than approximately 1 mm, less than approximately 0.5 mm, or less than approximately 0.3 mm (e.g., approximately 0.2 mm). As used herein, a plate generally has a thickness in the range of more than approximately 15 mm. For example, a plate may refer to an aluminum product having a thickness of more than approximately 15 mm, more than approximately 20 mm, more than approximately 25 mm, more than approximately 30 mm, more than approximately 35 mm, more than approximately 40 mm, more than approximately 45 mm, or more than approximately 50 mm. As used herein, a shade (also referred to as a sheet plate) generally has a thickness of approximately 4 mm to approximately 15 mm. For example, a shade may have a thickness of approximately 4 mm, approximately 5 mm, approximately 6 mm, approximately 7 mm, approximately 8 mm, approximately 9 mm, approximately 10 mm, approximately 11 mm, approximately 12 mm, approximately 13 mm, approximately 14 mm, or approximately 15 mm.

[0017] Certain aspects of this disclosure may be suitable for use with any type of material, such as metals, but certain aspects of this disclosure may be particularly suitable for use with aluminum. This description refers to alloys identified by aluminum industry designations such as “series” or “6xxx”. For an understanding of the most commonly used numbering system for naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingot” (both published by the Aluminum Association).

[0018] It should be understood that all ranges disclosed herein encompass all subranges contained therein. For example, the described range "1 to 10" should be considered to include all subranges between the minimum value "1" and the maximum value "10" (and including the endpoints), i.e., all subranges starting from a minimum value of 1 or greater (e.g., 1 to 6.1) and ending from a maximum value of 10 or less (e.g., 5.5 to 10).

[0019] The following embodiments are helpful in further illustrating the present invention, but at the same time, do not constitute any limitation thereof. Rather, various embodiments, modifications and equivalents thereof can be suggested to those skilled in the art without departing from the spirit of the invention after reading the description herein.

[0020] Figure 1 is a flowchart showing a process 10 for heat-treating a coil 110 according to various embodiments. The coil 110 can be made from a suitable material 112 such as a metal. In some examples, the metal is aluminum. The process 10 in Figure 1 includes the acts of manufacturing the coil 110 (act 20), inserting a mandrel (act 30), heating the coil 110 (act 40), unwinding the coil 110 (act 50), quenching (act 60), and cooling (act 70), but may include other acts further or alternatively and / or in other variations. In some embodiments, the process 10 may be performed such that the coil 110 can be maintained within a continuous band of material 112, without the band being cut and reconnected in any other way during the process of the process 10 between each act of the process 10.

[0021] In Act 20, step 10 may include manufacturing a coil 110. Manufacturing a coil in 20 may include, for example, obtaining a previously manufactured coil 110. Alternatively, manufacturing a coil 110 may include fabricating a coil 110. In some embodiments, the coil 110 may be manufactured by a hot rolling line and optionally by a cold rolling line. If the coil 110 is manufactured or obtained from a hot rolling line, the coil 110 can retain the heat applied by the hot rolling line, thereby reducing the amount of heat applied to reach a desired temperature for, for example, the heat treatment step 10.

[0022] The coil 110 can be formed around a spool 114. For example, the coil 110 can be formed by winding a sheet of material 112 around the spool 114 in a series of overlapping windings. In some embodiments, rotating the spool 114 can wind additional layers around the spool 114 to form the coil 110. The spool 114 may be tubular in shape. In some embodiments, the spool 114 may include an assembly of parts that allows the spool 114 to change its radial size in response to dimensional changes that may result from temperature changes during process 10, for example.

[0023] In act 30, step 10 can include inserting mandrel 116 into the coil. Mandrel 116 can engage spool 114 in a manner that facilitates subsequent rotation of spool 114 to rotate coil 110. In some embodiments, the expandability of spool 114 and / or mandrel 116 (e.g., as indicated by arrow 118) allows for radial expansion to accommodate changes in the inner diameter size of spool 114 that may result, for example, from heating of coil 110 during step 10. Although act 30 of inserting mandrel 116 is shown before act 40 of heating coil 110, in some embodiments, mandrel 116 may be inserted after coil 110 has been heated. In other words, act 30 of insertion can occur after, before, or during act 40 of heating coil 110.

[0024] To cause expansion of mandrel 116 and / or spool 114, various suitable mechanisms and structures can be used. Non-limiting examples include clam-like structures (with hinge halves and spring separators or other biasing mechanisms that allow the parts to be separated), tooth and pin arrangements, or nested tubes. In some examples, one or more components causing expansion may be commercially available components. The act of inserting mandrel 116 into spool 114 can be one that causes spool 114 to expand.

[0025] In act 40, coil 110 can be heated. For example, heating can correspond to applying heat 120 to coil 110 (e.g., as indicated by arrow 122) such that coil 110 is preheated to be within a specific preheating temperature range. To achieve heating in act 40, coil 110 can be maintained in a furnace or other heating environment for an appropriate time to allow the material 112 of coil 110 to reach a point within the specific preheating temperature range. In some embodiments, the preheating temperature range may be, for example, a homogenization temperature range. In some embodiments, the preheating temperature range may be, for example, an annealing temperature range.

[0026] In some embodiments, the homogenization temperature range is defined by endpoints selected within the range from 400°C to 600°C. In some embodiments, the endpoints are selected within the range from 450°C to 560°C. In some embodiments, the homogenization temperature range can be selected based on the type of alloy being processed. For example, 450°C to 500°C can be a suitable range for homogenizing 7xxx series alloys, and 530°C to 560°C can be a suitable range for homogenizing 6xxx series alloys.

[0027] More generally, the homogenization temperature range can correspond to a range suitable for homogenization. Homogenization can refer to a high-temperature process performed on a metal article to reduce the particle-level inhomogeneity of the as-cast microstructure. Homogenization is often performed at a temperature above the recrystallization temperature of the metal. For example, depending on the type of aluminum alloy, the recrystallization temperature of the metal can be about 300 - 400°C, and homogenization can be performed at a temperature of about 450 - 600°C. When heated within these temperature ranges (e.g., above the recrystallization temperature), the metallurgical microstructure of the metal article can become more homogeneous, thereby improving the formability and / or other metallurgical properties of the metal article. However, at these high temperatures, the metal article can be particularly prone to damage if handled incorrectly.

[0028] In some embodiments, the annealing temperature range is defined by endpoints selected within the range from 300°C to 500°C. In some embodiments, the endpoints are selected within a further range such as from 400°C to 500°C, from 300°C to 400°C, or from 350°C to 400°C, or from 300°C to 450°C. In some embodiments, the annealing temperature range can be selected independently of the type of alloy being processed. For example, 300°C to 450°C can be a suitable range for annealing, regardless of whether processing 7xxx series alloys, 6xxx series alloys, or other series of alloy systems.

[0029] More generally, the annealing temperature range may correspond to the range suitable for annealing. Annealing can refer to a high-temperature process performed on a metal article to achieve one of several effects. Without intending to limit the present disclosure, the purposes and parameters of annealing may include (1) releasing work hardening of the material to obtain formability, (2) recrystallizing or restoring the material without causing significant grain growth, (3) processing or transforming the texture to be suitable for formability and for reducing anisotropy during forming, and / or (4) avoiding coarsening of existing precipitated particles. Annealing can yield alloys in which the texture is improved and / or the anisotropy is reduced during forming operations such as stamping, rolling, or bending. By annealing, the texture can be controlled / designed during modified tempering to become more random and to reduce the components of those textures that can result in highly formable anisotropic textures (e.g., Goss, Goss-ND, or Cube-RD). This improved texture acts to reduce variations in properties across different directions, potentially reducing bending anisotropy and improving formability in forming processes involving rolling or perimeter stamping. However, at the high temperatures suitable for annealing, metal articles can become particularly susceptible to damage if handled improperly.

[0030] In some embodiments, heating in act 40 may include multiple steps, each having a temperature range and residence time. For example, in some embodiments, heating in act 40 may include one step of maintaining the coil 110 within a preheating temperature range suitable for annealing, and thereafter or before another step of maintaining the coil 110 within a preheating temperature range suitable for homogenization.

[0031] Heating in Act 40 can be provided at any suitable rate. For example, in some embodiments, heating may be carried out at a heating rate in the range of 20°C / hour to 100°C / hour. In some embodiments, slow heating (e.g., 20°C / hour to 40°C / hour) can be used to promote nucleation of the dispersed phase by using the dissolved precipitate as heterogeneous nucleation sites. This also ensures a uniform distribution of the solute within the matrix rather than initial melting at the interface between the precipitate and the matrix.

[0032] In Act 50, step 10 may include unwinding the coil 110. This unwinding may occur while the coil 110 is within a heating range (which may correspond to a different range, e.g., a preheating temperature range given by heating in Act 40, or a threshold amount below the preheating temperature range). For example, unwinding may occur while the coil 110 is in the furnace or while it is still heating after being removed from the furnace. In various embodiments, unwinding may occur while the coil is in a heated state where the metal is within the homogenization temperature range and / or before the coil cools beyond a threshold amount below the homogenization temperature range or other relevant preheating range (such as the annealing temperature range). In some embodiments, a suitable threshold amount may be 50°C or less. For example, the coil may be cooled to below 50°C from the temperature at which it was removed from the furnace before unwinding. In some embodiments, the threshold amount may be chosen to avoid a nose or drop along the continuous cooling transformation (CCT) curve and / or to avoid undesirable precipitation in the coil. The threshold amount can be selected based on the type of alloy being processed, such as whether it is a 7xxx series alloy, a 6xxx series alloy, or another series of alloys.

[0033] The unwinding at 50 may be a result of the rotation of the mandrel 116 and / or spool 114. This unwinding can produce an unwinded portion 124 of the coil 110. The unwinded portion 124 of the coil 110 may be processed by other acts in step 10.

[0034] In Act 60, step 10 may include quenching the unwinding portion 124 of the coil 110. For example, this can be achieved by subjecting the unwinding portion 124 to a quenching system 126. The quenching system 126 may have a suitable structure for conveying the quenching medium 128. For example, a jet is shown in Figure 1, but a tank or other conveying system for the quenching medium may be used. A suitable quenching medium may include, but is not limited to, air, water, or oil. Act 60 of quenching in step 10 can produce a quenched portion 130 of the coil 110.

[0035] Quenching at 60 may involve reducing the temperature within the unwinding portion 124 of the coil 110 to a quenched temperature range within a predetermined time. Quenching at 60 may include instantaneous quenching (e.g., within a few minutes or seconds, or within another short predetermined time) or prolonged cooling (e.g., within a few hours, or within another fairly long predetermined time). In some embodiments, quenching or the type thereof may be defined in terms of heat extraction rate, for example, instantaneous quenching may be associated with a heat extraction rate greater than 10°C / s, and / or prolonged cooling may be associated with a heat extraction rate less than 10°C / s.

[0036] However, quenching at 60 can be defined by any suitable parameter or combination of parameters in addition to, or instead of, the heat extraction rate. In a non-limiting example that may illustrate several possible relevant parameter types, coil 110, when heated to 525°C at act 40, can be cooled by an amount of approximately 25°C before quenching at act 60, reaching a temperature of approximately 500°C. For cooling, water (at room temperature (e.g., 20°C-22°C) or other temperatures within the range of 25°C-80°C) is used and sprayed through a series of jets over time intervals of approximately 1.5 to 15 seconds, thereby lowering the temperature of the material 112 of coil 110 to 350°C, and the quenching rate or heat extraction rate can be between 10°C / s and 100°C / s. However, other values ​​may be used.

[0037] For example, in some embodiments, the quenched temperature range may correspond to a range defined by endpoints selected within the range of 200°C to 500°C. In some embodiments, the quenched temperature range is defined by endpoints selected within a narrower range, such as 200°C to 350°C or 200°C to 250°C. In some examples, the lower limit of the range may correspond to 200°C or other temperatures below which, when high-solute alloys (e.g., alloys where the sum of solute systems, such as magnesium, silicon, copper, and / or zinc, exceeds 2.0 weight percent) are coiled, cold rolling may become difficult. In some embodiments, the quenched temperature range is selected for continuity with processes that achieve T6, T8, T9, or other specific tempering. In some embodiments, the quenched temperature range is selected to promote dispersion deposition or to homogenize the continuous casting material before subsequent cold working. In some embodiments, the quenching temperature range may be 300°C to 350°C, or other suitable ranges where the resulting material is soft enough for subsequent cold rolling but not too strong for further processing.

[0038] In some embodiments, quenching to reach a pre-quenched temperature range may result from exposing the unwinding portion 124 of the coil 110 to a quenching medium provided within the quenching temperature range (for example, the temperature of the medium may be referred to as the “quenching” temperature, and the temperature of the resulting metal may be referred to as the “quenched” temperature). In some embodiments, the quenching temperature range of the quenching medium may be defined by an endpoint selected within the range of 10°C to 350°C. In some embodiments, water can be used as the quenching medium and may be provided in liquid form at a temperature between 10°C and 100°C, for example. By providing water in liquid form, water can be provided at room temperature or with minimal heating or cooling above room temperature, and with significantly less energy consumption than when water is heated to convert it from a liquid state to a vapor. In some embodiments, water or other quenching medium may be provided at a temperature above 100°C or in other at least partially non-liquid forms. For example, in various scenarios, when water is used as a quenching medium, if the water is supplied at a temperature above 100°C, the water will turn into steam, which could lead to droplet entrainment of the material 112 in a way that could be harmful downstream of process 10, thus preventing condensation on the quenching portion 130.

[0039] In some embodiments, the quenching temperature range of the quenching medium can be defined by an endpoint selected within the range of 150°C to 200°C. For example, in various scenarios, a balance can be struck between providing a medium at a temperature within such a range to incorporate a suitable safety factor to ensure that the water temperature does not inadvertently drop to a range where condensation can occur, and at the same time providing a medium at a temperature low enough to result in a suitable heat extraction rate for quenching the material 112 within a given time.

[0040] In some embodiments, the appropriate quenching rate or heat extraction rate range may be defined by an endpoint selected, for example, within the range of 10°C / s to 100°C / s. The heat extraction rate can be selected based on the composition and / or other processing used. For example, different heat extraction rates can be used to convey different properties downstream. As an exemplary example, a heat extraction rate of 10°C / s may be suitable for situations in which subsequent cold working is performed, or a heat extraction rate of 100°C / s may be suitable for promoting the suppression of ludering in 5xxx alloys.

[0041] Non-limiting examples of a predetermined time may be less than 1 hour, less than 20 minutes, less than 2 minutes, less than 20 seconds, less than 2 seconds, or other suitable time frames. The predetermined time may be based on or dependent on a specific target heat extraction rate. In some embodiments, the unwinding speed of the coil 110 can be used as a system or measure that may influence or contribute to a suitable heat extraction rate. In some embodiments, a suitable heat extraction rate can be obtained, for example, by a range of unwinding speeds defined by endpoints selected within the range of 1 meter per minute to 100 meters per minute.

[0042] The quenching at 60 may include any suitable sequence of temperature decreases and / or increases. For example, the quenching at 60 may include a reheating step, or may be complemented by a reheating step. As an exemplary example, the unwinding portion 124 of the coil 110 may first be quenched to a lower temperature (e.g., below 200°C) to allow tension to be applied again or to enable other beneficial effects, and then reheated to a higher quenched temperature (e.g., between 200°C and 350°C) before being newly coiled at Act 70. Any suitable structure may be utilized to provide the relevant temperature rise, including, but not limited to, an additional dryer or oil or other heating medium provided in a suitable bath or through a nozzle (e.g., some nozzles or other structures of the quenching system 126 provide a quenching medium at a temperature selected to give heat transfer into the unwinding portion 124, and other examples of nozzles or structures of the quenching system 126 provide a quenching medium at a temperature selected to give heat transfer from the unwinding portion 124).

[0043] In Act 70, step 10 may include coiling the quenched portion 130. For example, if the quenched portion 130 is newly coiled or recoiled, a second coil 132 can be formed. This may provide the coil 110 with heat-treated and quenched material. By subjecting the coil to the heat treatment step 10 as described, a heat-treated coil 110 is provided, and preferred precipitants or other microstructures or properties of the coil 110 can be obtained.

[0044] Figure 2 is a side view of an example of a system 140 that can be used to carry out step 10 of Figure 1. The system 140 in Figure 2 is shown together with a furnace 142, a rewinding system 144, a quenching system 126, and a winding system 146, but other elements may be further or alternatively and / or in other modified forms.

[0045] The furnace 142 can be made to a size that accommodates the coil 110. The furnace 142 can be formed from one or more wall sections 150 that define an internal volume which can be heated by a burner or other suitable element. The furnace 142 may preheat the metal of the coil 110 or raise the temperature of the metal. For example, the furnace may preheat the metal or raise the temperature of the metal to a homogenization temperature range, annealing temperature range, or other specific heating temperature range, as described in Act 40 heating the coil 110 in Figure 1. In some embodiments, the interior of the furnace 142 may be an inert environment or otherwise controlled to prevent or reduce possible oxidation of the coil 110.

[0046] The unwinding system 144 may include components suitable for unwinding at least a portion of the coil 110. The unwinding system 144 can unwind a portion of the coil 110 while the coil 110 is still heating up (for example, as discussed in Act 50 of Figure 1). In some embodiments, the unwinding system 144 may include an unwinding mechanism 152 suitable for rotating the coil 110. In Figure 2, the unwinding mechanism 152 is shown as a motor with a belt operable to rotate the mandrel 116, but any other mechanism suitable for rotating the mandrel 116 and / or spool 114 that can engage and / or support the coil 110 may be used.

[0047] The furnace 142 in Figure 2 is shown with an opening 154. The opening 154 can be made sized to allow the unwinding portion 124 of the coil 110 to pass through. The furnace 142 may include a structure suitable for defining the size of the opening 154. In some examples, the size of the opening 154 can be varied. For example, the furnace 142 may include one or more doors 156, and these one or more doors may be adjustable by actuators or other components that give movement suitable for adjusting the size of the opening 154 defined by the doors 156 (for example, as indicated by arrow 158).

[0048] The quenching system 126 can receive the unwinding portion 124 of the coil 110 from the unwinding mechanism 152 and / or the furnace 142. Although the quenching system 126 in Figure 2 is shown as a series of jets for conveying the quenching medium 128, the quenching system 126 can accommodate other structures, including but not limited to those shown with respect to Figure 1 for the act 60 of quenching. Furthermore, although each pair of jets is shown in Figure 2, any number of jets or other structures can be used to convey the quenching medium 128. In some embodiments, the successive stages of the quenching system 126 may be provided with the quenching medium 128 at various (e.g., gradually decreasing) temperatures, so that the temperature can be gradually decreased over a particular profile or over a duration, for example, by allowing progression through multiple quenching stages and / or by allowing movement between the medium at various temperatures.

[0049] The initial roller 160 is shown downstream of the quenching system 126 in Figure 2. It may be advantageous to position the system 140 such that the material 112 from the coil 110 contacts the initial roller 160 only after it has already passed through the quenching system 126. For example, the initial roller 160 may be less likely to stretch or scratch the material 112 after it has been quenched than if the initial roller 160 were to come into contact with the material 112 before it has been cooled by the quenching system 126. By allowing the initial roller 160 to apply tension to the material in the coil 110, subsequent steps in the process can be facilitated, for example, when moving the material 112 through the system 140.

[0050] The coil 110 can be positioned in any orientation suitable for passing from the furnace 142 through the quenching system 126. While the material 112 leaves the furnace 142 and passes through the quenching system 126, it is shown in a vertical orientation by a solid line in Figure 2, but other orientations are also possible. An example of an alternative route is shown by a dashed line in Figure 2. For example, the material 112 can take on a catenary or other shape when routed.

[0051] A robotic arm 164 is also shown within the system 140 in Figure 2. The robotic arm 164 may be useful for handling the end or initial portion of the unwinding section 124 from the coil 110. For example, the robotic arm 164 may grasp the initial free end unwound from the coil 110 and orient it to a downstream position suitable for introduction into other elements within the system 140.

[0052] Other components may be included in the process line. For example, Figure 2 shows a bridle 166. The bridle 166 can be a magnetic bridle, which can propel and / or support the material 112 without physical contact with the material 112.

[0053] A lubrication system 168 is also shown in Figure 2. The lubrication system 168 may include nozzles and / or other suitable structures for applying lubricant to the material 112 passing by or through the lubrication system 168. A subsequent roller 170 is shown in Figure 2. The subsequent roller 170 may be used for tensioning or other suitable purposes.

[0054] As previously mentioned, system 140 may also include a winding system 146. The winding system 146 may recoil or newly coil material 112 received from other parts of system 140. For example, the winding system 146 may include another spool 114 and / or mandrel 116 that can be rotated to form a new or second coil 132 of the received material 112. The new or second coil 132 may correspond to material 112 that has been heat-treated by system 140.

[0055] Figure 3 is a side view of the components of a system 172 that may be used to carry out process 10. Figure 3 shows an example of options for transporting the coil 110 from the furnace 142 (e.g., either furnace 142A or 142B in Figure 3) to the unwinding position 174. At the unwinding position, for example, the coil 110 can be unwound while it remains heated and / or before a considerable cooling occurs relative to the preheating temperature provided by the furnace 142 (e.g., a cooling of 50°C or other threshold amounts, as discussed herein).

[0056] Various options for variations of different components are shown in Figure 3. For simplicity, examples of various components are shown on the left side of Figure 3, described first, and referred to by reference numbers ending in "A," while some variations of those components are then described on the right side of Figure 3, with the suffix "B" added to the components shown as examples.

[0057] The system 172 in Figure 3 is shown with a furnace 142A that can be removed from directly below or from below. The furnace 142A can be made to a size that accommodates a coil 110. The furnace 142A may include, or be associated with, a removal system 176A that allows the furnace 142A to be removed from the bottom side 178. The removal system 176A may include a hook 180 or other structure suitable for supporting the coil 110 and / or moving the coil 110. For example, the coil 110 may be supported by a spool 114 and / or mandrel 116, and the spool 114 and / or mandrel 116 may be supported within the furnace 142A by the hook 180 or other structure of the removal system 176A. The removal of the coil 110 from the furnace 142A can be facilitated by incorporating an actuator (not shown) suitable for allowing the movement of the hook 180 or other structure of the removal system 176A. As a non-limiting example, the hook 180 or other structure of the removal system 176A may be movable vertically (e.g., as indicated by arrow 182) and / or horizontally (e.g., including directions corresponding to the inside or outside of the page in Figure 3, as indicated by arrow 184, and / or directions corresponding to the left or right in the figure in Figure 3).

[0058] The furnace 142A may be accompanied by, or associated with, a transport system 186A. The transport system 186A may be able to move the coil 110 between the furnace 142A and the unwinding position 174, for example. The transport system 186A may include one or more carriers 188A. The carriers 188A may correspond to a cart, vehicle, mobile platform, or any other structure that can move the coil 110 from the furnace 142A to the unwinding position 174. Such transport allows the coil 110 to be unwound while it is still at the preheating temperature given by heating in the furnace 142A, or while it is heating within a threshold below the preheating temperature (for example, as discussed in Act 50 of Figure 1). In some embodiments, if the carrier 188A (or a portion thereof) can be preheated, the temperature difference between the coil 110 and the portion of the carrier 188A can be reduced in a way that reduces heat loss by the coil 110 during transport by the carrier 188A.

[0059] During operation, once the coil 110 reaches a suitable temperature due to heating from the furnace 142A, the removal system 176A can lower the coil 110 as indicated by the arrow 190. For example, the coil 110 can be lowered relative to the carrier 188A of the transport system 186A. For example, the coil 110 can be received by the carrier 188A so that the spool 114 and / or mandrel of the coil 110 are received and supported by the stand 192 (e.g., a fork or other support) of the carrier 188A. Elements of the removal system 176A can be moved in a direction suitable for releasing the coil 110 relative to the carrier 188A. For example, the hook 180 or other structure of the removal system 176A can move horizontally (e.g., as indicated by arrow 184) over the ends of the spool 114 and / or mandrel of the coil 110, and this movement can correspond to moving away from the carrier 188A, so that the carrier 188A can close, move away from the furnace 142A and / or perform other operations without interference from the elements of the removal system 176A.

[0060] In some embodiments, the elements of the removal system 176A may function as elements that can be loaded into the furnace 142A, or may be complemented by such elements. For example, the removal system 176A may be able to insert the coil 110 into the furnace 142A from the carrier 188A or other source by performing movements in the reverse order of those described for removal.

[0061] The carrier 188A may include an insulating enclosure 194A. The insulating enclosure 194A may at least partially enclose the coil 110. The insulating enclosure 194A may include an insulator 196 to reduce heat loss of the coil 110 during transport by the carrier 188A. For example, the insulator 196 may be included in the sides 198 and / or ends 200 of the insulating enclosure 194A. A non-limiting example of a suitable insulator 196 may include a fire-resistant material.

[0062] As used herein, the term “refractory material” may include any material that is relatively resistant to being attacked by molten metal and can maintain its strength at the high temperatures intended for the material in use. Such materials may include, but are not limited to, ceramic materials (inorganic nonmetallic solids and refractory glass) and nonmetals. A non-limiting list of materials suitable for insulator 196 includes the following: oxides of aluminum (alumina), silicon (silica, especially fused silica), magnesium (magnesia), calcium (lime), zirconium (zirconia), and boron (boron oxide); metal carbides, borides, nitrides, and silicides, e.g., silicon carbide, especially nitride-bonded silicon carbide (SiC / Si3N4), boron carbide, and boron nitride; aluminosilicates, e.g., calcium aluminum silicate; composite materials (e.g., composites of oxides and non-oxides); glass, including machinable glass; mineral wools, fibers or mixtures thereof; carbon or graphite, etc. As an illustrative example, in some situations, refractory materials can withstand temperatures up to 1200°C (for example, not suitable for steel, which tends to be processed at higher temperatures, even though other suitable refractory materials are available, but may be suitable for processing aluminum or copper), while in other situations, refractory materials suitable for processing aluminum and its alloys can be selected to withstand processing temperatures in a smaller range of 400 to 800°C.

[0063] The carrier 188A may include one or more releasably separable members 202A to facilitate the receiving and removal of the coil 110. While the carrier 188A is shown with two releasably separable members 202A in Figure 3, other numbers including one, two, or more than two are available; however, for simplicity, the hereafter specified description will primarily refer to a single member 202A. The separable member 202A may be movable between a closed configuration in which the coil 110 is at least partially enclosed by the insulator 196 and an open configuration in which the coil 110 is accessible for loading or removing from the carrier 188A.

[0064] As described above, during use, the coil 110 can be lowered toward the carrier 188A by the removal system 176A, as indicated by arrow 190. Once the coil 110 is received by the carrier 188A (for example, through the coil 100 supported by a stand 192 or other support structure within the carrier 188A using the spool 114 and / or mandrel 116), the detachable member 202 of the carrier 188A can be closed around the coil 110 (as indicated by arrow 204), thereby effectively insulating the coil 110 and preventing or reducing heat loss from the coil 110 while it is inside the carrier 188A.

[0065] The carrier 188A can transport the coil 110 away from the furnace, as indicated by arrow 206A. In some embodiments, the carrier 188A may be prepared to remove the coil 110 through an opening in a separable member 202A, as indicated by arrow 208A.

[0066] In some embodiments, the transfer system 210 can transfer the coil 110 from the carrier 188 and engage it with the rewinding mechanism 152 at the rewinding position 174 (for example, as indicated by arrow 212A). Although the transfer system 210 is shown as a robotic arm in Figure 3, it can correspond to any structure suitable for transferring the coil 110 from the carrier 188A to the rewinding mechanism 152. The rewinding mechanism 152 may include a motor or other device. If this motor or other device can rotate the spool 114 and / or mandrel 116, the coil 110 is rewound as it is formed around them.

[0067] The resulting unwinding portion 124 of the coil 110 can pass through the hardening system 126 to produce the hardened portion 130 of the coil 110. The hardening system 126 may correspond to (but not necessarily) components described elsewhere in this specification, and therefore the description will not be repeated. The hardened portion 130 after passing through the hardening system 126 may be re-coiled in a manner similar to the winding system 146 described with respect to Figure 2, thereby forming a new or second coil 132.

[0068] System 172 may include, in lieu of or further than, other components depicted and explained with respect to Figure 2, and may include other components. As an exemplary example of other elements not shown in Figure 2 (but which may be used with the system in Figure 2 as needed), the rewind position 174 of the rewind system 144 in Figure 3 is located at the rewind station 214. This rewind station also includes an insulator 216 (which may be similar to, for example, insulator 196) for heat retention during the rewind process. Also shown in Figure 3 is a biasing roller 218. The biasing roller 218 may be biased by a spring 220 or other biasing mechanism. In some embodiments, the biasing roller 218 may be biased alone or at least partially by its own weight. The biasing roller 218 can provide an appropriate amount of force to prevent one end or other part of the coil 110 near the biasing roller 218 from "spring-biased away" from the other wraps of the coil 110 during use. The biasing roller 218 may be pivotably mounted and / or otherwise repositioned so as to remain pressed against or otherwise engaged with the coil 110, so that contact with the coil is maintained even if the diameter of the coil 110 is reduced due to being unwound by the unwinding mechanism 152.

[0069] The components shown in system 172 in Figure 3 may be used as substitutes in system 140 in Figure 2, or vice versa. For example, the biasing roller 218 shown in Figure 3 is also not shown in Figure 2, but nevertheless the biasing roller 218 can be implemented in a suitable location in system 140 as described with respect to Figure 2. Similarly, the insulators 216 and / or 196 described with respect to Figure 3 can also be arranged in a manner relevant to system 140 in Figure 2.

[0070] Other variations are shown on the right side of Figure 3. For example, in some embodiments, the system 172 can mount the furnace 142B, which can be removed from the side and / or beside the furnace 142B. The removal system 176B may push or pull the coil 110 out of the furnace 142B horizontally, for example, in a direction substantially corresponding to the direction of exiting the page of Figure 3, as schematically shown by the bidirectional arrow 224. The removal system 176B may move the coil 110 further or alternatively vertically, for example, to a position where the structure of the carrier 188B is supported by the stand 192 or otherwise defined within the carrier 188B.

[0071] The carrier 188B and insulating housing 194B shown on the right side of Figure 3 differ from those shown on the left side of Figure 3. In the carrier 188B and insulating housing 194B on the right side of Figure 3, for example, the insulating housing 194B may include one or more releasably separable members 202B, which may be closed in a technique that can accommodate linear alignment of the tubular components (in contrast to, for example, the clamshell or hinged approach of the carrier 188A on the left side of Figure 3).

[0072] During use, the insulating housing 194B on the right side of Figure 3 may include a lid 226 or other elements which can be raised and / or lowered (as indicated by arrow 228) or otherwise moved and engage with other parts of the insulating housing 12B. The carrier 188B can move the coil 110 away from the furnace 142B (as shown by arrow 206B and similarly to arrow 206A). After a suitable distance has been traversed by the carrier 188B, the insulating housing 194B can be opened to allow access to the coil 110. For example, the lid 226 of the insulating housing 194B can be lifted as shown by arrow 208B.

[0073] For example, as indicated by arrow 212B, the coil 110 can be transported to the unwinding position 174 by the transfer system 210 in some embodiments. This allows the coil 110 to be unwound, hardened by the hardening system 126, and rewound by the winding system 146 in a manner similar to that described above with respect to the coil 110 provided from the left side of Figure 3.

[0074] In some embodiments, different types of removal systems 176 and / or transport systems 186 (including, for example, carriers 188 and / or associated components) may be used and suitable for different styles of furnaces 142. For example, a clamshell-type insulating housing 194A may be suitable for forming an upward-facing opening for receiving from a bottom-loading furnace 142A, and an insulating housing 194B with linearly aligned tubular components may be suitable for being lowered over a removal zone adjacent to a side-loading furnace 142B. Nevertheless, each type of furnace 142 is not limited to options such as those or the situations shown in Figure 3 as examples, and the elements (or their variations) in Figure 3 may be used with any other desired combination of elements.

[0075] Furthermore, any suitable combination of one-to-one, one-to-many, or many-to-many options is possible. For example, the arrangement on the right side of Figure 3 shows a single furnace 142 that can be loaded into individual carriers 188, but in some embodiments, a single carrier 188 can serve multiple furnaces 142 (for example, as shown on the left side of Figure 3, where individual carriers 188 are arranged to serve one of three different furnaces 142 shown above the carriers 188). In some embodiments, multiple carriers 188 can be used for individual furnaces 142, so for example, one carrier 188 may carry out a heated coil 110, and another carrier may position a new coil 110 to be loaded into the furnace 142 and heated. As an example, Figure 3 also shows that the unwinding position 174 can correspond to multiple carriers 188 and / or furnaces 142. By using the rewinding station 214 in combination with multiple furnaces 142, the use of the equipment can be made more efficient (for example, if the rewinding process is faster than the heating process, the start times between heating in different furnaces can be staggered, allowing the rewinding mechanism 152 to be used more frequently and reducing downtime between cycles). Furthermore or alternatively, the different furnaces 142 may be served by a single carrier 188, for example, to reduce the complexity and / or cost of the elements in the system 172.

[0076] In some embodiments, the coil 110 may be unwound at the unwinding position 174 without first being removed from the carrier 188. For example, the carrier 188 may include an aperture 230 (identified as 230A and 230B, respectively, in Figure 3) through which the unwinding portion 124 of the coil 110 can pass, allowing it to be routed to the hardening system 126 and / or to other parts of the process line or system 172. The aperture 230 may be sized to allow the coil 110 to be unwound and pass through the aperture 230 at the unwinding position 174. In some embodiments, the coil 110 can be unwound through the carrier 188 if the carrier 188 can engage with the unwinding mechanism 152 at the unwinding position 174. However, in some embodiments, the rewind mechanism 152 may include at least some parts that are built into or on the carrier 188, for example, which may provide further flexibility with respect to the position where the coil 110 can be rewound from within the carrier 188. Furthermore, in scenarios where the rewind mechanism 152 is at least partially built into or on the carrier 188, the transport system 210 and / or a separate rewind mechanism 152 may become unnecessary at the rewind position 174.

[0077] Exemplary embodiments In some embodiments, a device, system, or method is provided according to one or more of the following embodiments, or according to some combination of elements thereof. In some embodiments, the functionality of a device or system described in one or more of these embodiments may be utilized in a method described in one of the other embodiments, and vice versa.

[0078] Embodiment 1 is a method for heat-treating a metal coil, the method comprising: heating the metal coil to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range; unwinding the metal coil while the metal is in the preheating temperature range or before the metal cools beyond a threshold amount below the preheating temperature range, wherein the unwinding manufactures an unwinded portion of the coil; and quenching the unwinded portion of the coil to lower the temperature of the unwinded portion to a quenched temperature range within a predetermined time, wherein the quenching manufactures a quenched portion, wherein the quenching manufactures a quenched portion.

[0079] Embodiment 2 is the method of Embodiment 1 (or any other preceding or subsequent Embodiment, individually or in combination), wherein at least a portion of the unwinding of the coil is performed while the coil is maintained in the furnace, or between the heating of the coil and at least a portion of the unwinding of the coil, or the coil is transported between the furnace and the unwinding position.

[0080] Embodiment 3 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the heating, unwinding, and quenching are performed while the coil is maintained by a continuous band of material, without requiring the band to be cut and reconnected.

[0081] Embodiment 4 is the method of Embodiment 1 (or any of the other preceding or succeeding embodiments, individually or in combination), further comprising recoiling the hardened portion onto a second coil.

[0082] Embodiment 5 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), further comprising transporting the coil between the furnace in which the heating of the coil was performed and the unwinding position, between at least a portion of the heating of the coil and the unwinding of the coil.

[0083] Embodiment 6 is the method of Embodiment 5 (or any of the other preceding or subsequent embodiments, individually or in combination), further comprising removing the coil from the furnace from below or beside the furnace.

[0084] Embodiment 7 is the method of Embodiment 5 (or any of the other preceding or subsequent embodiments, individually or in combination), further comprising wrapping the coil at least partially with an insulating material to reduce heat loss of the coil during transport.

[0085] Embodiment 8 is the method of Embodiment 1 (or any of the other preceding or subsequent embodiments, individually or in combination), wherein at least a portion of the unwinding of the coil is performed while the coil is maintained in the furnace in which the heating of the coil was performed.

[0086] Embodiment 9 is the method of Embodiment 1 (or any of the other preceding or succeeding embodiments, individually or in combination), further comprising inserting a mandrel into a spool on which the coil is formed, and rotating the mandrel, wherein the unwinding of the coil is due to the rotation of the mandrel.

[0087] Embodiment 10 is the method of Embodiment 9 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the insertion of the mandrel occurs before the heating of the coil, and the mandrel is configured to expand radially to accommodate the change in the size of the inner diameter of the spool resulting from the heating of the coil.

[0088] Embodiment 11 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the metal includes aluminum.

[0089] Embodiment 12 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the preheating temperature range corresponds to a homogenization temperature range between 400°C and 600°C.

[0090] Embodiment 13 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the preheating temperature range corresponds to an annealing temperature range between 300°C and 500°C.

[0091] Embodiment 14 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, either individually or in combination), wherein the threshold amount is 50°C or less.

[0092] Embodiment 15 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the quenched temperature range resulting from the quenching is between 200°C and 500°C.

[0093] Embodiment 16 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the quenched temperature range resulting from the quenching is between 200°C and 350°C.

[0094] Embodiment 17 is the method of Embodiment 1 (or any of the other preceding or subsequent embodiments, individually or in combination), wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium given a quenching temperature range of 100°C to 250°C.

[0095] Embodiment 18 is the method of Embodiment 1 (or any of the other preceding or subsequent embodiments, individually or in combination), wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium given a quenching temperature range between 10°C and 200°C.

[0096] Embodiment 19 is the method of Embodiment 1 (or any of the other preceding or succeeding Embodiments, either individually or in combination), wherein the predetermined time is less than 20 seconds.

[0097] Embodiment 20 is the method of Embodiment 1 (or any of the other preceding or succeeding embodiments, individually or in combination), wherein the quenching corresponds to a heat extraction rate greater than 10°C / s.

[0098] Embodiment 21 is the method of Embodiment 1 (or any of the other preceding or succeeding embodiments, individually or in combination), wherein the quenching corresponds to a heat extraction rate of less than 100°C / s.

[0099] Embodiment 22 is a system for heat-treating a metal coil, the system comprising: a furnace made to a size to receive the metal coil and configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range; a rewinding system operable to rewind at least a portion of the coil while the metal is heated to the preheating temperature range or before the metal cools beyond a threshold amount below the preheating temperature range; and a quenching system configured to receive the rewinded portion of the coil from the rewinding system and to reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0100] Embodiment 23 is the system of Embodiment 22 (or any other preceding or succeeding Embodiment, individually or in combination), wherein the system further includes a transport system configured to move the coil between the furnace and the unwinding position of the unwinding system, or the unwinding system includes an unwinding mechanism configured to unwind the coil at least partially while the coil is located in the furnace to produce an unwinded portion of the coil.

[0101] Embodiment 24 is the system of Embodiment 22 (or any of the other preceding or succeeding Embodiments, individually or in combination), further comprising a winding system configured to receive the hardened portion from the hardening system and to recoil the hardened portion to form a second coil.

[0102] Embodiment 25 is the system of Embodiment 22 (or any of the other preceding or succeeding Embodiments, individually or in combination), further comprising a transport system configured to move the coil between the furnace and the rewinding position of the rewinding system.

[0103] Embodiment 26 is the system of Embodiment 25 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the transport system includes at least one carrier configured to receive the coil in the heated state and transport the coil to the unwinding position in the heated state.

[0104] Embodiment 27 is the system of Embodiment 26 (or any other preceding or succeeding Embodiment, individually or in combination), wherein the carrier is configured to receive an insulating housing around the coil.

[0105] Embodiment 28 is the system of Embodiment 27 (or any other preceding or succeeding Embodiment, individually or in combination), wherein the insulating housing includes at least one releasably separable member that is movable between a closed configuration in which the coil is at least partially enclosed by an insulator and an open configuration in which the coil can be accessed for loading or unloading into the carrier.

[0106] Embodiment 29 is the system of Embodiment 27 (or any other preceding or succeeding Embodiment, individually or in combination), wherein the insulating housing includes an aperture, the aperture being sized to allow the coil to be unwound and pass through the aperture at the unwound position.

[0107] Embodiment 30 is the system of Embodiment 26 (or any of the other preceding or succeeding Embodiments, individually or in combination), further comprising a transfer system configured to transfer the heated coil from the carrier to the rewinding mechanism at the rewinding position and engage with the rewinding mechanism.

[0108] Embodiment 31 is the system according to Embodiment 22 (or any of the other preceding or succeeding embodiments, individually or in combination), further comprising an insulator positioned relative to the rewinding position of the rewinding system to prevent or reduce heat loss from the coil when it is received at the rewinding position.

[0109] Embodiment 32 is the system of Embodiment 22 (or any of the other preceding or succeeding Embodiments, individually or in combination), wherein the unwinding system includes an unwinding mechanism configured to unwind the coil at least partially while the coil is located in the furnace, thereby producing an unwinded portion of the coil.

[0110] Embodiment 33 is the system of Embodiment 22 (or any other preceding or succeeding Embodiment, either individually or in combination), wherein the furnace includes an opening made to a size through which the unwinding portion of the coil passes.

[0111] Embodiment 34 is the system of Embodiment 33 (or any other preceding or succeeding Embodiment, individually or in combination), wherein the opening has the size defined by at least one door which is movable to adjust the size of the opening.

[0112] Embodiment 35 is a system for heat-treating a metal coil, the system comprising: a furnace made of metal sized to receive the coil and configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range; a transport system configured to remove the coil from the furnace while the metal is heated within the preheating temperature range or before the metal cools beyond a threshold amount below the preheating temperature range; a rewinding system operable to rewind at least a portion of the coil while it is heated at a rewinding position to which the coil has been transported by the transporting system; and a quenching system configured to receive the rewinded portion of the coil from the rewinding system and to reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0113] Embodiment 36 is a system for heat-treating a metal coil, the system comprising: a furnace made of the metal to a size that can accommodate the coil and configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range; a rewinding system having a rewinding mechanism operable on the coil to rewind at least a portion of the coil while the coil is placed in the furnace; and a quenching system configured to receive the rewinded portion of the coil from the furnace and to reduce the temperature of the rewinded portion to a quenched temperature range within a predetermined time.

[0114] All patents, publications, and abstracts cited above are incorporated herein by reference in their entirety. The foregoing description of embodiments, including the exemplary embodiments, is presented for illustrative and explanatory purposes only and is not intended to be exhaustive or to limit to the exact forms disclosed. Numerous modifications, adaptations, and their use will be apparent to those skilled in the art. Some embodiments of this disclosure are described in the following sections [1]-

[36] . [Item 1] A method for heat-treating a metal coil, The coil of the aforementioned metal is heated in a furnace to raise the temperature of the metal so that it is within a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range. The process of unwinding the coil of the metal while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount below the preheating temperature range, wherein the unwinding is the manufacture of the unwinded portion of the coil, and the unwinding is the manufacture of the unwinding portion. The process involves quenching the unwinding portion of the coil and reducing the temperature of the unwinding portion to the quenched temperature range within a predetermined time, wherein the quenching is the process of manufacturing the quenched portion, and the reduction is the process of reducing the temperature. The method, including the method described above. [Item 2] At least a portion of the unwinding of the coil is performed while the coil is maintained in the furnace, Between the heating of the coil and at least a portion of the unwinding of the coil, the coil is transported between the furnace and the unwinding position. The method described in item 1, which is one of the following. [Item 3] The method according to item 1 or 2, wherein the heating, unwinding, and quenching are performed while the coil is maintained by a continuous band of material, without requiring the band to be cut and reconnected. [Item 4] The method according to any one of items 1 to 3, further comprising recoiling the hardened portion onto a second coil. [Item 5] The method according to any one of items 1 to 4, further comprising transporting the coil between the furnace in which the heating of the coil was performed and the unwinding position between at least a portion of the heating of the coil and the unwinding of the coil. [Item 6] The method of item 5, further comprising removing the coil from the furnace from below or beside the furnace. [Item 7] The method according to item 5 or 6, further comprising wrapping the coil at least partially with an insulating material to reduce heat loss of the coil during transport. [Item 8] The method according to any one of items 1 to 4, wherein at least a portion of the unwinding of the coil is performed while the coil is maintained in the furnace in which the heating of the coil was performed. [Item 9] Inserting a mandrel into the spool in which the coil is formed, Rotating the mandrel, the unwinding of the coil is caused by rotating the mandrel, and the rotation The method described in any one of items 1 through 8, further including the method described in any one of items 1 through 8. [Item 10] The insertion of the mandrel occurs before the heating of the coil. The method according to item 9, wherein the mandrel is configured to expand radially to accommodate changes in the size of the inner diameter of the spool caused by the heating of the coil. [Item 11] The method according to any one of items 1 to 10, wherein the metal includes aluminum. [Item 12] The preheating temperature range corresponds to the homogenization temperature range between 400°C and 600°C, as described in any one of items 1 to 10. [Item 13] The preheating temperature range is the method described in any one of items 1 to 11, corresponding to an annealing temperature range between 300°C and 500°C. [Item 14] The method according to any one of items 1 to 13, wherein the threshold amount is 50°C or less. [Item 15] The method according to any one of items 1 to 14, wherein the quenched temperature range resulting from the quenching is between 200°C and 500°C. [Item 16] The method according to any one of items 1 to 15, wherein the quenched temperature range resulting from the quenching is between 200°C and 350°C. [Item 17] The method according to any one of items 1 to 16, wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium provided within a quenching temperature range of 100°C to 250°C. [Item 18] The method according to any one of items 1 to 17, wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium provided within a quenching temperature range of 10°C to 200°C. [Item 19] The method according to any one of items 1 to 18, wherein the predetermined time is less than 20 seconds. [Item 20] The quenching is performed according to any one of items 1 to 19, corresponding to a heat extraction rate greater than 10°C / s. [Item 21] The quenching is the method described in any one of items 1 to 20, corresponding to a heat extraction rate of less than 100°C / s. [Item 22] A system for heat-treating metal coils, A furnace made of the metal to a size that can accommodate the coil, and configured to raise the temperature of the metal to a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range, A rewinding system capable of unwinding at least a portion of the coil while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount below the preheating temperature range, A quenching system configured to receive the unwinding portion of the coil from the unwinding system and to reduce the temperature of the unwinding portion to a quenched temperature range within a predetermined time, The system including the above. [Item 23] The system further includes a transport system configured to move the coil between the furnace and the unwinding position of the unwinding system, The unwinding system includes an unwinding mechanism configured to unwind the coil at least partially while the coil is located in the furnace, thereby producing an unwinded portion of the coil, One of the systems described in item 22. [Item 24] The system according to item 22 or 23, further comprising a winding system configured to receive the hardened portion from the hardening system and recoil the hardened portion to form a second coil. [Item 25] The system according to any one of items 22 to 24, further comprising a transport system configured to move the coil between the furnace and the rewinding position of the rewinding system. [Item 26] The transport system according to item 25, comprising at least one carrier configured to receive the coil in the heated state and transport the coil to the unwinding position in the heated state. [Item 27] The system according to item 26, wherein the carrier is configured to receive an insulating housing around the coil. [Item 28] The system according to item 27, wherein the insulating housing includes at least one releasable and separable member that is movable between a closed configuration in which the coil is at least partially enclosed by an insulator and an open configuration in which the coil is accessible for loading into or removing from the carrier. [Item 29] The system according to item 27 or 28, wherein the insulating housing includes an aperture, the aperture being sized to allow the coil to be unwound and pass through the aperture at the unwound position. [Item 30] The system according to any one of items 26 to 29, further comprising a transfer system configured to transfer the heated coil from the carrier to a rewinding mechanism at the rewinding position and to engage with the rewinding mechanism. [Item 31] The system according to any one of items 22 to 30, further comprising an insulator, the insulator being positioned relative to the rewinding position of the rewinding system and, when received at the rewinding position, preventing or reducing heat loss from the coil. [Item 32] The unwinding system is the system according to any one of items 22 to 24, comprising a unwinding mechanism configured to unwind the coil at least partially while the coil is located in the furnace, thereby producing an unwinded portion of the coil. [Item 33] The system according to any one of items 22 to 24 or 32, wherein the furnace includes an opening made to a size for passing the unwinding portion of the coil. [Item 34] The system according to item 33, wherein the opening has the size defined by at least one door which is movable to adjust the size of the opening. [Item 35] A system for heat-treating metal coils, A furnace made of the metal to a size that can accommodate the coil, and configured to raise the temperature of the metal to a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range, A transport system configured to remove the coil from the furnace while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount below the preheating temperature range, A rewinding system that is operable to rewind at least a portion of the heated coil at a rewinding position where the coil is being transported by the transport system, A quenching system configured to receive the unwinding portion of the coil from the unwinding system and to reduce the temperature of the unwinding portion to a quenched temperature range within a predetermined time, The system including the above. [Item 36] A system for heat-treating metal coils, A furnace made of the metal to a size that can accommodate the coil, and configured to raise the temperature of the metal to a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range, A rewinding system having a rewinding mechanism operable on the coil to rewind at least a portion of the coil while the coil is located in the furnace, A quenching system configured to receive the unwinding portion of the coil from the furnace and to reduce the temperature of the unwinding portion to a quenched temperature range within a predetermined time, The system including the above.

Claims

1. A method for heat-treating a metal coil, The coil of the aforementioned metal is heated in the heating section of the furnace to raise the temperature of the metal so that it is within the preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range. The process involves unwinding the coil of the metal while the metal is heated within the preheating temperature range, or before the metal cools down by a threshold amount of 50°C or less from the preheating temperature range, wherein the unwinding is the manufacturing of the unwinded portion of the coil, and the unwinding is the manufacturing of the unwinding portion. Between the heating of the coil and at least a portion of the unwinding of the coil, the coil is transported between the heating section of the furnace that performed the heating and the unwinding position. The process involves quenching the unwinding portion of the coil and reducing the temperature of the unwinding portion to the quenched temperature range within a predetermined time of less than 20 seconds, wherein the quenching is the process of manufacturing the quenched portion, and the reduction is the process of reducing the temperature. The method, including the method described above.

2. The method according to claim 1, wherein the heating, unwinding, and quenching are performed while the coil is maintained by a continuous band of material, without requiring the band to be cut and reconnected.

3. The method according to claim 1 or 2, further comprising recoiling the hardened portion onto a second coil.

4. The method according to any one of claims 1 to 3, further comprising removing the coil from the furnace from below or beside the furnace.

5. The method according to any one of claims 1 to 4, further comprising wrapping the coil at least partially with an insulating material to reduce heat loss of the coil during transport.

6. Inserting a mandrel into a spool in which the coil is formed, wherein the insertion of the mandrel occurs before the heating of the coil, and the mandrel is configured to expand radially to accommodate the change in the size of the inner diameter of the spool caused by the heating of the coil; Rotating the mandrel, the unwinding of the coil is caused by rotating the mandrel, and the rotation The method according to any one of claims 1 to 5, further comprising:

7. The method according to any one of claims 1 to 6, wherein the metal includes aluminum.

8. The method according to any one of claims 1 to 7, wherein the preheating temperature range corresponds to a homogenization temperature range between 400°C and 600°C.

9. The method according to any one of claims 1 to 8, wherein the preheating temperature range corresponds to an annealing temperature range between 300°C and 500°C.

10. The method according to any one of claims 1 to 9, wherein the quenched temperature range resulting from the quenching is between 200°C and 500°C.

11. The method according to any one of claims 1 to 10, wherein the quenched temperature range resulting from the quenching is between 200°C and 350°C.

12. The method according to any one of claims 1 to 11, wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium provided within a quenching temperature range of 100°C to 250°C.

13. The method according to any one of claims 1 to 12, wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium provided within a quenching temperature range of 10°C to 200°C.

14. The quenching method according to any one of claims 1 to 13, wherein the quenching corresponds to a heat extraction rate of 10°C / s or higher.

15. The method according to any one of claims 1 to 14, wherein the quenching corresponds to a heat extraction rate of less than 100°C / s.

16. A system for heat-treating metal coils, A furnace comprising a heating section made of the metal to a size that can accommodate the coil, and configured to raise the temperature of the metal to a preheating temperature range corresponding to a homogenization temperature range or an annealing temperature range, A transport system configured to separate the coil from the heating section of the furnace while the metal is heated within the preheating temperature range, or before the metal cools down by a threshold amount of 50°C or less from the preheating temperature range, A rewinding system that is operable to rewind at least a portion of the heated coil at a rewinding position where the coil is being transported by the transport system, A quenching system configured to receive the unwinding portion of the coil from the unwinding system and to reduce the temperature of the unwinding portion to the quenched temperature range within a predetermined time of less than 20 seconds, The system including the above.

17. The system according to claim 16, further comprising a winding system configured to receive a hardened portion from the hardening system and to recoil the hardened portion to form a second coil.

18. The transport system according to claim 16 or 17, wherein the transport system includes at least one carrier configured to receive the coil in the heated state and transport the coil to the unwinding position in the heated state.

19. The system according to claim 18, wherein the carrier is configured to receive an insulating housing around the coil.

20. The system according to claim 19, wherein the insulating housing includes at least one releasable and separable member that is movable between a closed configuration in which the coil is at least partially enclosed by an insulator and an open configuration in which the coil is accessible for loading into or removing from the carrier.

21. The system according to claim 19 or 20, wherein the insulating housing includes an aperture, the aperture being sized to allow the coil to be unwound and pass through the aperture at the unwound position.

22. The system according to any one of claims 18 to 21, further comprising a transfer system configured to transfer the heated coil from the carrier to the rewinding mechanism at the rewinding position and to engage with the rewinding mechanism.

23. The system according to any one of claims 16 to 22, further comprising an insulator, the insulator being positioned relative to the rewinding position of the rewinding system and, when received at the rewinding position, preventing or reducing heat loss from the coil.

24. A method for heat-treating a metal coil, The aforementioned metal is aluminum or an aluminum alloy. The coil of the aforementioned metal is heated in a furnace to raise the temperature of the metal so that it is within a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range. The process of unwinding the coil of the metal while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount of 50°C or less from the preheating temperature range, wherein the unwinding manufactures the unwinded portion of the coil, and at least a portion of the unwinding of the coil is performed while the coil is maintained in the furnace that performed the heating of the coil. The process involves quenching the unwinding portion of the coil and reducing the temperature of the unwinding portion to the quenched temperature range within a predetermined time of less than 20 seconds, wherein the quenching is the process of manufacturing the quenched portion, and the reduction is the process of reducing the temperature. The method, including the method described above.

25. The method of claim 24, wherein the heating, unwinding, and quenching are performed while the coil is maintained by a continuous band of material, without requiring the band to be cut and reconnected.

26. The method according to claim 24 or 25, further comprising recoiling the hardened portion onto a second coil.

27. ​​Inserting a mandrel into the spool in which the coil is formed, Rotating the mandrel, the unwinding of the coil is caused by rotating the mandrel, and the rotation The method according to any one of claims 24 to 26, further comprising:

28. The insertion of the mandrel occurs before the heating of the coil, The method according to claim 27, wherein the mandrel is configured to expand radially to accommodate changes in the size of the inner diameter of the spool caused by the heating of the coil.

29. The method according to any one of claims 24 to 28, wherein the quenched temperature range resulting from the quenching is between 200°C and 500°C.

30. The method according to any one of claims 24 to 29, wherein the quenching comprises exposing the unwinding portion of the coil to a quenching medium provided within a quenching temperature range of 100°C to 250°C.

31. The method according to any one of claims 24 to 30, wherein the quenching corresponds to a heat extraction rate greater than 10°C / s, and / or the quenching corresponds to a heat extraction rate less than 100°C / s.

32. A system for heat-treating a metal coil, A furnace made of the metal to a size that can accommodate the coil, and configured to raise the temperature of the metal to a preheating temperature range corresponding to the homogenization temperature range or the annealing temperature range, A rewinding system operable to rewind at least a portion of the coil while the metal is heated within the preheating temperature range, or before the metal cools beyond a threshold amount of 50°C or less from the preheating temperature range, wherein the rewinding system includes a rewinding mechanism configured to rewind at least a portion of the coil while the coil is located in the furnace, thereby producing a rewinded portion of the coil. A quenching system configured to receive the unwinding portion of the coil from the unwinding system and to reduce the temperature of the unwinding portion to the quenched temperature range within a predetermined time of less than 20 seconds, The system including the above.

33. The system according to claim 32, further comprising a winding system configured to receive a hardened portion from the hardening system and recoil the hardened portion to form a second coil.

34. The system according to claim 32 or 33, wherein the furnace includes an opening made to a size for passing the unwinding portion of the coil, the opening having the size defined by at least one door which is movable to adjust the size of the opening.

35. The system according to any one of claims 32 to 34, further comprising a rewinding system having a rewinding mechanism operable on the coil to rewind at least a portion of the coil while the coil is located in the furnace.

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