Treatment device and treatment method for pickling and phosphating metal parts

Abstract

A treatment device for single-stage treatment of a metal object to be treated by at least the steps of pickling and phosphating. The treatment device comprises at least the following: a treatment container for receiving the object to be treated and for receiving a flowable treatment substance; and a pump device for exchanging at least a fraction of the treatment substance. The treatment substance is flowable around at least one part of the object to be treated. The treatment substance comprises a phosphor- or phosphate-containing solution, in particular phosphoric acid. The phosphor- or phosphate-containing solution consists partly of water and partly of a reaction substance, and the reaction substance consists of phosphor or a phosphate and an additional treatment effect-improving substance. The proportion of the phosphor or phosphate in the reaction substance is at least 95%, and the reaction substance does not have a salt acid or sulfuric acid content.

Claims

1. A treatment device for the single-stage treatment of a metal object to be treated, wherein the treatment encompasses at least pickling and phosphating of the object to be treated, wherein the treatment device comprises: a treatment container for receiving the object to be treated and for receiving a flowable treatment substance; and a pump device for circulating at least a fraction of the treatment substance; wherein the treatment substance is flowable around at least one part of the object to be treated, wherein the treatment substance is a phosphor or phosphate-containing solution, wherein the phosphor or phosphate-containing solution comprises water and a reaction substance, wherein the reaction substance comprises phosphor or a phosphate and at least one additional treatment effect-improving substance, wherein the proportion of the phosphor or phosphate in the reaction substance measures at least 95%, wherein the reaction substance does not have a salt acid or sulfuric acid content, wherein the treatment container is separated by a wall from a collecting chamber for collecting treatment substance flowing over the wall, wherein the treatment substance collected in the collecting chamber can be conveyed back into the treatment container via a conveying line, wherein a filter device is provided for filtering the treatment substance to remove contaminants from the treatment substance that have accumulated in the treatment substance, wherein the pump device and filter device make up part of the conveying line, and the pump device is operable to convey the treatment substance through the filter device, wherein the conveying line is configured in such a way that the treatment substance conveyed back into the treatment container can generate a dam flow for discharging a portion of the treatment substance from the treatment container and into the collecting chamber.

2. The treatment device according to claim 1 further comprising a temperature control device for controlling temperature of the treatment substance that can be held in the treatment container, wherein the temperature control device can be used to definably set the temperature of the treatment substance.

3. The treatment device according to claim 1 wherein the water of the phosphor or phosphate-containing solution comprises fully decalcified water, the fully decalcified water comprises VE water, and the fraction of reaction substance relative to the fraction of fully decalcified water lies between 1:4 and 1:7.

4. The treatment device according to claim 3 wherein the fraction of reaction substance relative to the fraction of fully decalcified water measures 1:6 if the reaction substance is present in a solid state before mixed with the fully decalcified water or wherein the fraction of reaction substance relative to the fraction of fully decalcified water measures 1:5 if the reaction substance is present in a liquid state before mixed with the fully decalcified water.

5. The treatment device according to claim 1 wherein the reaction substance further exhibits no fractions of fluorine, chlorine, bromine, iodine, lead, mercury and selenium.

6. The treatment device according to claim 1 wherein the fraction of phosphor or phosphate in the reaction substance measures at least 97%.

7. The treatment device according to claim 1 wherein a pore-free protective layer that prevents hydrogen embrittlement while drying the treatment substance is generatable on the surface of the object to be treated by means of the treatment substance, wherein the protective layer exhibits a thickness of 2 m to 10 m.

8. The treatment device according to claim 1 wherein an additional substance for pickling and degreasing is added to the treatment substance, wherein the pickling and degreasing additive comprises an aqueous solution of non-ionogenic, biodegradable surfactants and inhibitors, and wherein the pickling and degreasing additive is added with a volume of 0.5% to 7% of the volume of the phosphor or phosphate-containing solution.

9. The treatment device according to claim 1 wherein an additional substance for defoaming is added to the treatment substance, wherein the defoaming additive preferably exhibits triisobutyl phosphate, and wherein the defoaming additive is added to the treatment substance with a volume of 0.01% to 5%, in particular with 0.2%, of the volume of the phosphor or phosphate-containing solution, or with a volume of 0.01% to 5%, in particular with 0.2%, of the volume of the phosphor or phosphate-containing solution reacted with the pickling and degreasing additive.

10. The treatment device according to claim 2 wherein the treatment container comprises a primary receiving chamber, into which the object to be treated can be introduced, and at least one first ancillary receiving chamber, wherein the primary receiving chamber and first ancillary receiving chamber are joined together in such a way that the treatment substance can flow out of the primary receiving chamber and into the first ancillary receiving chamber on the one hand, and can flow out of the first ancillary receiving chamber and into the primary receiving chamber on the other, wherein the primary receiving chamber and the first ancillary receiving chamber are separated from each other in such a way as to at least partially prevent the object to be treated from penetrating into the first ancillary receiving chamber, and wherein the primary receiving chamber is also coupled with a second ancillary receiving chamber, wherein the first ancillary receiving chamber is a buffer receiving chamber for receiving a specific quantity of the treatment substance, and wherein the second ancillary receiving chamber is a temperature control chamber, wherein the temperature control device is at least partially situated in the second ancillary receiving chamber.

11. The treatment device according to claim 2 further comprising a control device, wherein the control device is configured to control the temperature control device in such a way that the treatment substance is brought to a target temperature or target temperature progression and/or the control device is configured to control the pump device in such a way that the treatment substance is conveyed at a target flow rate or target flow characteristic, and/or the control device is configured to control the filter device in such a way that a filtered fraction of treatment substance exhibits a target purity, and/or the control device is configured to control a metering device in such a way that a target composition of the treatment substance can be set.

12. The treatment device according to claim 1 wherein the conveying line has an outlet opening located at an upper end of the treatment container.

13. A treatment method for at least pickling and phosphating a metal object to be treated, the method comprising: providing a treatment container for receiving at least one object to be treated and for receiving a flowable treatment substance; introducing the treatment substance into the treatment container, wherein no additional treatment container is used for pickling and phosphating; and introducing the object to be treated into the treatment container at least partially filled with the treatment substance to bring the object to be treated into contact with the treatment substance; wherein the contact between the treatment substance and object to be treated triggers at least a cleaning of the object to be treated, wherein the treatment substance is a phosphor or phosphate-containing solution, wherein the phosphor or phosphate-containing solution comprises water and a reaction substance, wherein the reaction substance comprises phosphor or a phosphate and an additional treatment effect-improving substance, wherein the fraction of phosphor or phosphate in the reaction substance measures at least 95%, wherein the reaction substance exhibits no fractions of salt acid and sulfuric acid, wherein the treatment container is separated by a wall from a collecting chamber for collecting treatment substance flowing over the wall, wherein the treatment substance collected in the collecting chamber can be conveyed back into the treatment container via a conveying line, wherein a filter device for filtering the treatment substance is provided, wherein filtration removes contaminants from the treatment substance that have accumulated in the treatment sub stance, wherein the pump device and filter device make up part of the conveying line, and the conveyed treatment substance is conveyed by the pump device through the filter device, wherein the conveying line is configured in such a way that the treatment substance conveyed back into the treatment container can generate a dam flow for discharging a portion of the treatment substance from the treatment container and into the collecting chamber.

14. The method according to claim 13 further comprising: adding an additional substance for pickling and degreasing to the treatment sub stance, wherein the pickling and degreasing additive comprises an aqueous solution of non-ionogenic, biodegradable surfactants and inhibitors, and wherein the pickling and degreasing additive is added with a volume of 0.5% to 7% of the volume of the phosphor or phosphate-containing solution.

15. The method according to claim 13 wherein an additional substance for defoaming is added to the treatment substance, wherein the defoaming additive comprises triisobutyl phosphate, and wherein the defoaming additive is added to the treatment substance with a volume of 0.01% to 5% of the volume of the treatment substance, or with a volume of 0.01% to 5% of the volume of the treatment substance reacted with the pickling and degreasing additive.

16. The method according to claim 13 wherein a pore-free protective layer that prevents hydrogen embrittlement after drying the treatment substance is generated on the surface of the object to be treated by means of the treatment substance, wherein the protective layer exhibits a thickness of 2 m to 10 m.

17. The method according to claim 13 wherein the phosphor or phosphate-containing solution comprises fully decalcified water and the reaction substance, wherein the fully decalcified water comprises VE water, and the fraction of reaction substance relative to the fraction of fully decalcified water lies between 1:4 and 1:7.

18. The method according to claim 13 wherein the fraction of phosphor or phosphate in the reaction substance measures at least 99%.

19. The method according to claim 13 wherein the treatment substance is brought to a definably set temperature by means of a temperature control device, and made to react with the object to be treated in the treatment container.

20. The method according to claim 13 wherein the reaction substance exhibits no fluorine, chlorine, bromine, iodine, lead, selenium and mercury.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a first view of a treatment device according to the invention in a passive state;

(2) FIG. 2 is a second view of a treatment device according to the invention in an active state;

(3) FIG. 3 is a perspective view of another treatment device according to the invention;

(4) FIG. 4 is a perspective view of yet another treatment device according to the invention;

(5) FIG. 5 is another perspective view of the treatment device according to the invention shown on FIG. 4;

(6) FIG. 6 is a perspective detailed view of part of the treatment device according to the invention shown on FIGS. 4 to 5;

(7) FIG. 7 is a first top view of the treatment device according to the invention shown on FIGS. 4 to 6;

(8) FIG. 8 is a second top view of the treatment device according to the invention shown on FIGS. 4 to 6;

(9) FIG. 9 is a perspective view of essentially the underside of the treatment device according to the invention shown on FIGS. 4 to 8;

(10) FIG. 10a is a first schematic side view of the treatment device according to the invention shown on FIGS. 4 to 9; and

(11) FIG. 10b is a second schematic side view of the treatment device according to the invention shown on FIGS. 4 to 9.

DETAILED DESCRIPTION

(12) FIG. 1 shows the treatment device 1 according to the invention. The treatment device 1 is used for treating, in particular degreasing, pickling, phosphating, descaling, preserving and derusting one or more objects to be treated 2. The object to be treated 2 is preferably introduced from above into a treatment container 4 of the treatment device 1. The treatment container 4 is here preferably at least partially and especially preferably completely filled with a treatment substance 6. In addition, a temperature control device 8 is preferably provided for controlling the temperature of the treatment substance 6, in particular heating it. Furthermore, at least one pump device 10 is preferably provided for circulating the treatment substance and/or generating a dam flow 20 and/or conveying treatment substance 6 discharged from the treatment container 4 back into the treatment container 4. The treatment container 6 is separated by a wall 12 from a collecting chamber. The flow generated in the treatment container 4 causes treatment fluid 6 to exit the treatment container 4 over the wall 12, so that it thereby gets into the collecting chamber 14. However, it is likewise possible that the treatment substance or fluid 6 be displaced in such a way by introducing the object to be treated 2 into the treatment chamber 4 that a portion of the treatment substance 6 exits the treatment container 4 over the wall 12. Reference number 16 denotes a conveying line that is used to convey the treatment substance 6 that exited the treatment container 4 back into the treatment container 4. A filter device 18 for filtering or preparing the treatment substance 6 is preferably situated in the area of the conveying line 16 or in the conveying line 16, or provided as part of the conveying line 16. It is here conceivable that the pump device 10 or another pump device (not shown) be located or formed in the progression of the conveying line 16. Furthermore, a pump/filter device can be provided, which either replaces a pump device and/or a filter device, or can be additionally provided. As may also be gleaned from the illustration, the treatment container 4 preferably exhibits at least one primary receiving chamber 22, a first ancillary receiving chamber 24 and a second ancillary receiving chamber 26. For example, the individual receiving chambers 22, 24, 26 are here separated from each other by grids 27, in particular by a respective single grate. The grid 27 here prevents the object to be treated 2 from being able to get into one of the ancillary receiving chambers 24, 26. Reference number 28 denotes a nozzle that can be used to generate a flow of the treatment substance 6.

(13) FIG. 2 shows the view known from FIG. 1, wherein the object to be treated 2 is situated in the treatment container 4 in this view, and thereby in contact with the treatment substance 6.

(14) FIG. 3 shows another configurational variant of a treatment device 1 according to the invention, in particular for wire coil treatment. The treatment device 1 depicted on FIG. 3 exemplarily exhibits a receiving rack 40, which preferably carries several wire coils 39 to be treated. The receiving rack 40 is here situated on a delivery point 41, wherein preferably several receiving racks 40 and several delivery points 41 are provided. In addition, the treatment device 1 preferably exhibits several, in particular 2, 3, 4, 5, 6, 7, 8 or more treatment baths 42. A plurality, in particular 2, 3, 4, 5, 6, 7, 8, 9 or more wire coils 39 can preferably be introduced into a treatment bath 42 for treatment, in particular simultaneously. Reference number 43 denotes a preferably purely optional device, specifically a fixation bath. It is here conceivable that several, in particular 2, 3, 4, 5, 6, 7, 8 or more, wire coils 39 can be simultaneously introduced into a fixation bath 43. It is further conceivable that several fixation baths 43 be provided. The treated wire coils 39 can be arranged at a removal point 44 for removal purposes. The treated wire coils 39 are preferably conveyed with a transport device 45, in particular a transport carriage or rail-guided portal crane, to the respective removal point 44. Several devices are further preferably provided for supplying, regulating and controlling the treatment device 1. For example, the depicted embodiment exhibits a pressure belt filter device 46, a metering device 47, a fully decalcified water preparation device 48, a control device 49, another pressure belt filter device 38, a storage tank for treatment basins 51 and several side channel compressors 52, in particular 8 of them. The metering device 47 is preferably automated, and especially preferably exhibits a buffer tank with a volume that preferably exceeds 5 m.sup.3, especially preferably exceeds 10 m.sup.3, and most preferably exceeds or precisely equals 20 m.sup.3.

(15) FIG. 4 shows a perspective view of a treatment device 1 according to the invention. The treatment device 1 is preferably L-shaped in design, i.e., it encompasses a treatment container 4, wherein the treatment container 4 exhibits a first interior portion that preferably extends at a right angle to a second interior portion. One interior portion is preferably longer than the other interior portion, wherein it is also conceivable that the interior portions are equally long or essentially equally long. For example, the structural design shown makes it possible to treat bent elements, such as pipes, carriers, claddings, etc. The treatment container 4 preferably exhibits at least or precisely one wall 12, wherein the wall 12 separates an area into which the objects to be treated are introduced from a collecting chamber 14. The collecting chamber 14 preferably serves to collect treatment substance that exits the treatment chamber over the wall 12.

(16) Reference number 10 denotes a pump device, in particular for generating a flow inside of the treatment substance to be introduced into the treatment chamber. Reference number 18 denotes a filter device 18 for filtering or preparing the treatment substance.

(17) The treatment substance is made to move or flow by means of nozzles 28a, 28b and 29a, 29b, 29c (see FIG. 5), from which the treatment substance conveyed via the pump device 10 is pumped into the treatment chamber.

(18) The enclosure 61 envelops or houses the nozzles 29a-29c. Preferably provided are three rows of 2 nozzles 28a, 28b and three rows of three nozzles 29a, 29b, 29c, with it also being conceivable that precisely or at least one nozzle 28 and/or 29 be provided. The nozzles 28 are especially preferably inclined relative to the nozzles 29, in particular at a right angle.

(19) Reference number 60 denotes a primary suction line, which is used to discharge, in particular siphon off, treatment substance from the treatment chamber via outlets 57a-57g (see FIG. 7). The discharged treatment substance is preferably prepared by means of the filter device 18, and conveyed back into the treatment chamber by means of the pump device 10 via the nozzles 28 and 29.

(20) The treatment device 1 can preferably be dimensioned in such a way that an installation surface of 5100 mm3800 mm is required. The treatment device 1 preferably encompasses a bath volume of essentially, up to, at least or precisely 14 cm.sup.3. The effective volume of the treatment device 1 according to the invention preferably measures 3400 mm3000 mm1500 mm, and the height of the overflow to the top edge preferably measures 200 mm.

(21) FIG. 5 shows another view of the aforementioned embodiment of the treatment device 1 according to the invention. As may be gleaned from this illustration, the nozzles 29a-29c or 33 nozzle array are accommodated in a pocket 61 in a wall of the treatment container 4, so as preferably not to disrupt or adversely impact the effective area. The nozzles 28a-28b are preferably likewise accommodated in a pocket in another wall of the treatment container 4, so as preferably not to disrupt or adversely impact the effective area. The pockets 61 are preferably provided with ram protection, so as to prevent damage to the built-in components.

(22) Further depicted is an additional filter device 19, wherein the additional filter device 19 is preferably designed as a coarse filter. The treatment substance to be prepared is especially preferably first siphoned out of the treatment container, then fed to the additional filter device 19, then guided through the pump 10, then guided through the filter device 18, which can preferably be designed as a bag filter, and then conveyed back into the treatment container via the nozzles 28, 29.

(23) The illustration further shows that the floor of the treatment container 4 exhibits surface portions 53, 54, 55, that are inclined relative to the horizontal. The surface portions 53-54 and 55-56 are each preferably arranged in such a way as to yield a linear contact area with each other in the region of a low point as viewed in a vertical direction. The contact area here preferably lies at a level below a contact area between the outer wall of the container extending in a vertical direction and the respective surface portion or floor portion 53, 54. As a consequence, the surface portions or floor portions 53, 54 and 55, 56 preferably form grooves, which guide the treatment substance and dirt particles to one or more outlets in a targeted manner. The surface portions 53-56 are preferably aligned relative to the horizontal with an inclination of 2 to 25, and especially preferably with an inclination of 6 to 15, and most preferably with an inclination of essentially or precisely 10.

(24) Reference number 8 denotes a preferably provided temperature control device. The temperature control device 8 preferably exhibits 8 electrical heating elements, in particular at 2 KW each. The heating elements are preferably likewise accommodated in the pocket 61 in the wall, so as not to disrupt or negatively impact the preferably required effective surface. The heating capacity configuration of the temperature control device can preferably be oriented toward a Wessling system (20 m.sup.3=20 KW heating capacity).

(25) In particular, FIG. 6 shows a detailed view of the pocket 61, in which the nozzles 29a-29c and temperature control device 8 are preferably situated.

(26) FIG. 7 shows the first portion of a groove 62 produced by the floor portions 53, 54 and 55, 56 of the treatment container that are inclined relative to each other, and the resultant second portion 63 of the groove. The groove preferably also extends into the collecting chamber 14. Outlets 57a-57f, in particular several outlets, are especially provided in the groove or in the area of the groove for discharging or siphoning the treatment substance out of the treatment chamber. Further preferably provided in the collecting chamber 14 is at least one outlet 57g for discharging or siphoning the treatment substance out of the collecting chamber 14. The outlets 57a-57g are preferably fluidly joined with the primary suction line 61 via connecting lines.

(27) Not shown is a grate, which is preferably horizontally aligned or aligned at a right angle to the lateral walls of the treatment container 4, and overlays the floor 53, 54, 55, 56 of the treatment chamber, wherein the grate is spaced apart from the floor, in particular by more than 20 mm, and preferably by more than 50 mm, and especially preferably by more than 100 mm, wherein the grate especially preferably is spaced apart from the floor of the treatment container by at most 500 mm. The grate preferably takes on the function of spacing an object to be treated that has been introduced into the treatment chamber apart from the floor of the treatment chamber, as a result of which particles that detached from the treated objects to be treated can accumulate under the object to be treated, so that these particles can always be siphoned out.

(28) FIG. 8 shows the primary suction line 60 and a portion of the connecting pipes 58a-58g, which join the outlets 57a-57g with the primary suction line 60. The overall suction line preferably comprised of at least the connecting pipes 58a-58g and the primary line 60 is preferably designed so that it can be dismantled. This is advantageous in particular for cleaning the individual parts of the overall suction line.

(29) FIG. 9 shows a perspective view of the underside of the treatment device 1 according to the invention. In particular the connecting pipes 58a-58g joined with the outlets and primary suction line can be derived from this illustration.

(30) FIGS. 10a and 10b show various side views of the treatment device 1 according to the invention depicted on FIGS. 4 to 9.

(31) The present invention relates to a treatment device 1 for the single-stage treatment of a metal object 2 to be treated, wherein the treatment encompasses at least the pickling and phosphating of the object 2 to be treated, wherein the treatment device 1 encompasses at least the devices mentioned below: a treatment container 4 for receiving the object 2 to be treated and for receiving a flowable treatment substance 6, and a pump device 10 for exchanging at least a fraction of the treatment substance 6, wherein the treatment substance 6 flows around at least one part of the object 2 to be treated, in particular the entire object 2 to be treated, wherein the treatment substance 6 is a phosphor or phosphate-containing solution, in particular phosphoric acid, wherein the phosphor or phosphate-containing solution consists partly of water and partly of a reaction substance, wherein the reaction substance consists of phosphor or a phosphate and an additional treatment effect-improving substance, wherein the proportion of the phosphor or phosphate in the reaction substance measures at least 95%, wherein the reaction substance in particular does not have a salt acid or sulfuric acid content.

REFERENCE LIST

(32) 1 Treatment device 2 Object to be treated 4 Treatment container 6 Treatment substance 8 Temperature control device 10 Pump device 12 Wall 14 Collecting chamber 16 Conveying line 18 Filter device 19 Additional filter device 20 Dam flow 22 Primary collecting chamber 24 First ancillary collecting chamber 26 Second ancillary collecting chamber 27 Grid 28 Nozzle 39 Wire coil 40 Treatment device for treating wire 41 Delivery point 42 Treatment bath 43 Fixation bath 44 Removal point 45 Transport device 46 Pressure belt filter device 47 Metering device 48 Fully decalcified water preparation device 49 Control device 50 Additional pressure belt filter device 51 Storage tank 52 Side channel compressor 53 First inclined floor portion 45 Second inclined floor portion 55 Third inclined floor portion 56 Fourth inclined floor portion 57 Outlet 58 Connecting pipe 60 Primary suction line 61 Pocket with nozzles 62 First portion of the groove 63 Second portion of the groove