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  Clad material, method for manufacturing said clad material, and apparatus for manufacturing said clad materialUSPTO Application #: 20070272681Title: Clad material, method for manufacturing said clad material, and apparatus for manufacturing said clad material Abstract: A method for manufacturing a clad material in which a core material is cast and skin materials are pressure-bonded thereon aims to prevent deterioration of adhesiveness of the core material and the skin materials while keeping sufficient cooling rate of the core material, prevent thickness variation and/or breakage of the skin materials during the manufacturing process, and keep the surface property of the cooling rolls constant. The method for manufacturing a clad material (11) includes the steps of continuously supplying molten metal (M) into a gap between a pair of cooling rollers (2a) (2b) to cast a core material, and cladding skin materials (10a) (10b) on both surfaces of the core material with hot rolling by continuously supplying the skin materials on peripheral surfaces of the cooling rollers so that the skin materials prevent direct contact between the cooling rollers and the molten metal, wherein the skin materials are supplied so as to come into contact with the peripheral surfaces of the cooling rollers, and wherein a contact distance (L1) from a contact starting point (P1) where the skin material begins to come into contact with the cooling roller to a meeting point (P2) where the skin material begins to come into contact with the molten metal is set to 100 times or more of a thickness (t1) of the skin material. (end of abstract)
Agent: Oblon, Spivak, Mcclelland Maier & Neustadt, P.C. - Alexandria, VA, US Inventors: Tomoaki Yamanoi, Kazuhiko Minami USPTO Applicaton #: 20070272681 - Class: 219615000 (USPTO) Related Patent Categories: Electric Heating, Inductive Heating, Metal Working, Bonding, Brazing (e.g., Cladding, Etc.) The Patent Description & Claims data below is from USPTO Patent Application 20070272681. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001] Priority is claimed to Japanese Patent Application No. 2004-35186 filed on Feb. 12, 2004, and U.S. Provisional Application No. 60/545,530 filed on Feb. 19, 2004, the disclosure of which are incorporated by reference in their entireties. CROSS REFERENCE TO RELATED APPLICATIONS [0002] This application is an application filed under 35 U.S.C..sctn.111(a) claiming the benefit pursuant to 35 U.S.C..sctn.119(e)(1) of the filing date of U.S. Provisional Application No. 60/545,530 filed on Feb. 19, 2004, pursuant to 35 U.S.C..sctn.111(b). TECHNICAL FIELD [0003] The present invention relates to a clad material with skin materials laminated on both sides of a core material for giving, for example, brazing performance and corrosion resistance, especially, a clad material excellent in high-temperature strength, a method for manufacturing such clad material, and an apparatus for manufacturing such clad material. BACKGROUND ART [0004] The following description sets forth the inventor's knowledge of related art and problems therein and should not be construed as an admission of knowledge in the prior art. [0005] In recent years, in accordance with reduction in size and weight and improvement in performance of heat exchanges, the materials thereof are required to be thin in thickness and high in strength. Furthermore, for the purpose of decreasing environmental burden, a request of alternatives for chlorofluorocarbon has increased, and therefore a request of heat exchangers using CO.sub.2 as refrigerant has increased. Examples of such heat exchangers meeting the above demands include heat exchangers represented by radiators and heater cores, which use water as a principal component of refrigerant, heat exchangers represented by condensers and evaporators, which use fleon gas as refrigerant, and heat exchangers represented by gas coolers (evaporators), which use CO.sub.2 as refrigerant. [0006] As a component for use in these heat exchangers, a clad material consisting of an aluminum alloy core and an aluminum alloy skin material which gives brazing performance and corrosion prevention performance to the surface of the core and having sufficient strength even after brazing has been used. In a generally employed method for manufacturing such clad material, a pre-heated ingot is hot-rolled and then the surface thereof is scraped to obtain a core material having a thickness of 250 mm to 400 mm. The core material and a skin material having a thickness of 10 to 100 mm are placed one on another and then temporarily fixed with each other. Thereafter, the temporarily fixed members are subjected to hot-rolling, cold-rolling and, if necessary, intermediate annealing. [0007] As a material of the aforementioned aluminum alloy core material, there is an Al--Mn series alloy plate improved in high temperature strength by manufacturing under predetermined heat-treating conditions and rolling conditions. However, although these Al--Mn series alloy plates are excellent in characteristics as elementary substance, they can give simultaneously neither brazing performance nor corrosion prevention performance (Japanese Unexamined Laid-open Patent Publication No. 2000-104149 and Japanese Unexamined Laid-open Patent Publication No. 2002-241910). [0008] Moreover, as for the method for manufacturing a clad material, in place of the aforementioned hot-rolling method, various methods utilizing continuous casting of core materials have been proposed (Japanese Unexamined Laid-open Patent Publication No. H11-226699, Japanese Laid-open Patent Publication No. H8-509265 and Japanese Laid-open Patent Publication No. 2002-248599). [0009] Japanese Unexamined Laid-open Patent Publication No. H11-226699 discloses a method for continuously manufacturing a clad material in which a skin material is pressure-bonded to a core material which is being sent out from a cast rolling mill with pressure-bonding rolls disposed at the vicinity of the outlet side of the rolling mill. Also disclosed in FIGS. 11e and 11f of Japanese Laid-open Patent Publication No. H8-509265 is a method for continuously casting a core material and cladding of the core material and a skin material with pressure-bonding rolls disposed at the outlet side of the cooling rollers of the cast rolling mill. [0010] On the other hand, disclosed in FIGS. 11a, 11b and 11c of Japanese Laid-open Patent Publication No. H8-509265 is a method for manufacturing a clad material in which casting of a core material and pressure-bonding of the core material and the skin material are simultaneously performed by supplying the skin material at the inlet side of molten alloy with cooling rollers of the cast rolling apparatus. Also disclosed in Japanese Laid-open Patent Publication No. 2002-248599 is a method for supplying a skin material at the inlet side of cooling rollers for casting a core material when manufacturing a clad material in which the width of the skin material is wider than that of the core material and the skin material is embedded in the core material. [0011] However, there were the following problems in the manufacturing method of the aforementioned clad material. [0012] That is, according to the method in which pressure-bonding of the skin material to the core material is performed after the casting of the core material, since it is necessary to arrange a cast rolling mill and a pressure-bonding roll, the equipment becomes complicated in structure, and the production rate is restricted by the continuous casting rate of the core material. Furthermore, deterioration of adhesiveness of the skin material due to a segregation layer containing oxide formed on the surface at the time of continuous cast rolling and deterioration of corrosion characteristics at the interface cannot be suppressed. [0013] On the other hand, according to the method for simultaneously performing the casting of the core material and the pressure-bonding of the skin material to the core material, since the position where the skin material comes into contact with the molten metal (core material) at the inlet side of the cooling rollers becomes unstable, a part of the skin material may melt, or even may be broken. Furthermore, according to Japanese Laid-open Patent Publication No. 2002-248599, since the width of the core material is larger than that of the skin material and therefore the molten metal partially comes into contact with the cooling rollers, the roll surface property changes, resulting in difficulty in controlling the roll surface property for a long time. [0014] The description herein of advantages and disadvantages of various features, embodiments, methods, and apparatus disclosed in other publications is in no way intended to limit the present invention. Indeed, certain features of the invention may be capable of overcoming certain disadvantages, while still retaining some or all of the features, embodiments, methods, and apparatus disclosed therein. [0015] Other objects and advantages of the present invention will be apparent from the following preferred embodiments. DISCLOSURE OF INVENTION [0016] The preferred embodiments of the present invention have been developed in view of the above-mentioned and/or other problems in the related art. The preferred embodiments of the present invention can significantly improve upon existing methods and/or apparatuses. [0017] The present invention was made in view of the aforementioned problems, and aims to provide a method for manufacturing a clad material capable of keeping the surface property of cooling rollers constant while keeping high cooling rate of a core material, restraining deterioration of adhesiveness of a skin layer due to contamination of non-metallic inclusion such as an oxide film formed at the interface of the skin material and the core material, and restraining occurrence of thickness variation of the skin material after the cladding and/or breakage of the skin material during the manufacturing process. Furthermore, the present invention also aims to provide a clad material manufactured by the aforementioned method and an apparatus for manufacturing a clad material for executing the aforementioned method. [0018] The method for manufacturing a clad material according to the present invention has the following structures as recited in Items (1) to (11). [0019] (1) A method for manufacturing a clad material, comprising the steps of: [0020] continuously supplying molten metal into a gap between a pair of cooling rollers to cast a core material; and Continue reading... Full patent description for Clad material, method for manufacturing said clad material, and apparatus for manufacturing said clad material Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Clad material, method for manufacturing said clad material, and apparatus for manufacturing said clad material patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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