JP4304297B2 - Method for manufacturing anti-slip plate - Google Patents
Method for manufacturing anti-slip plate Download PDFInfo
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- JP4304297B2 JP4304297B2 JP2004162458A JP2004162458A JP4304297B2 JP 4304297 B2 JP4304297 B2 JP 4304297B2 JP 2004162458 A JP2004162458 A JP 2004162458A JP 2004162458 A JP2004162458 A JP 2004162458A JP 4304297 B2 JP4304297 B2 JP 4304297B2
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- 238000000034 method Methods 0.000 title claims description 29
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 239000000463 material Substances 0.000 claims description 52
- 238000005507 spraying Methods 0.000 claims description 32
- 238000007789 sealing Methods 0.000 claims description 29
- 230000000873 masking effect Effects 0.000 claims description 26
- 239000007921 spray Substances 0.000 claims description 21
- 238000007751 thermal spraying Methods 0.000 claims description 18
- 238000000576 coating method Methods 0.000 claims description 17
- 239000003795 chemical substances by application Substances 0.000 claims description 16
- 239000011248 coating agent Substances 0.000 claims description 15
- 239000003973 paint Substances 0.000 claims description 15
- 229910052751 metal Inorganic materials 0.000 claims description 12
- 239000002184 metal Substances 0.000 claims description 12
- 239000000758 substrate Substances 0.000 claims description 12
- 238000004040 coloring Methods 0.000 claims description 9
- 239000002904 solvent Substances 0.000 claims description 8
- 230000002265 prevention Effects 0.000 claims description 7
- 230000003746 surface roughness Effects 0.000 claims description 6
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 5
- 239000011701 zinc Substances 0.000 claims description 5
- 229910052725 zinc Inorganic materials 0.000 claims description 5
- 239000004593 Epoxy Substances 0.000 claims description 4
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 4
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 239000011737 fluorine Substances 0.000 claims description 3
- 229910052731 fluorine Inorganic materials 0.000 claims description 3
- 230000002452 interceptive effect Effects 0.000 claims description 3
- 238000004090 dissolution Methods 0.000 claims 1
- 229920001296 polysiloxane Polymers 0.000 claims 1
- 239000002245 particle Substances 0.000 description 6
- 239000000565 sealant Substances 0.000 description 6
- 239000000470 constituent Substances 0.000 description 4
- 238000010790 dilution Methods 0.000 description 4
- 239000012895 dilution Substances 0.000 description 4
- 239000012528 membrane Substances 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- 229910001220 stainless steel Inorganic materials 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 238000007865 diluting Methods 0.000 description 2
- 238000010285 flame spraying Methods 0.000 description 2
- 238000005554 pickling Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- -1 dipping Substances 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000005562 fading Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
- Coating By Spraying Or Casting (AREA)
Description
本発明は、基材表面に一層構造の溶射膜を形成してなる溶射膜形成部材であって、特に、膜表面に模様を形成することより装飾性を有するスリップ防止板として好適に使用される溶射膜形成部材の製造方法に関するものである。 The present invention relates to a thermally sprayed film forming member obtained by forming a sprayed film of a single layer structure on the substrate surface, in particular, suitably used as the slip prevention plate having a decorative than forming a pattern on the film surface a method for producing a sprayed film forming member to be.
従来から、金属板等の基材に金属やセラミックスの溶射膜を形成した溶射膜形成部材は、溶射膜表面の凹凸が摩擦機能や装飾機能を有するところから、種々の用途に使用されている。例えば、摩擦機能を重視する溶射膜形成部材（以下「摩擦機能部材」という）としては、工場の通路床板等として使用されるスリップ防止板や点字ブロック等として使用される誘導ブロックがあり、装飾機能を重視する溶射膜形成部材（以下「装飾機能部材」という）としては、建造物の内外壁として使用される化粧板やドア等の構成材として使用される各種建築用材がある。 Conventionally, a sprayed film forming member in which a metal or ceramic sprayed film is formed on a base material such as a metal plate has been used for various applications because the unevenness of the surface of the sprayed film has a friction function and a decoration function. For example, as a sprayed film forming member (hereinafter referred to as “friction function member”) that places importance on the friction function, there are an anti-slip plate used as a factory floor plate, a guide block used as a braille block, etc. Examples of the thermal spray film forming member (hereinafter referred to as “decorative function member”) that emphasizes the above are various building materials used as components such as decorative plates and doors used as inner and outer walls of buildings.
而して、装飾機能部材については勿論、摩擦機能部材についても、用途上の要求や需要者の要求により、溶射膜表面に模様を表出した装飾性が重視される場合があり、従来からも、複数種の溶射材を使用して溶射材固有の色（金属色等）による色分け模様を膜表面に形成するようにした溶射膜形成部材（例えば、特許文献１）が提案されている。
このように溶射材固有の色を利用して色分け模様を形成した溶射膜形成部材（以下「従来部材」という）は、塗装により模様を形成したもののように、膜表面の摩耗や溶射粒子の剥落により色落ちするようなことがなく、耐久性に富むものである。 In this way, the sprayed film forming member (hereinafter referred to as “conventional member”) in which a color-coded pattern is formed using the unique color of the sprayed material is worn on the surface of the film or the sprayed particles are peeled off like a pattern formed by coating. Therefore, there is no color fading and the durability is high.
しかし、従来部材は、色の異なる複数種の溶射材を使用して溶射工程を何度も繰り返すことによって溶射膜を形成するものであるから、製造工程が複雑となり、製造コスト、ひいては製品コストも高騰するといった問題がある。 However, since the conventional member forms a thermal spray film by repeating the thermal spraying process using a plurality of types of thermal spraying materials having different colors, the manufacturing process becomes complicated, and the manufacturing cost and thus the product cost are also increased. There is a problem of soaring.
本発明は、このような問題を生じることなく、耐久性に富み且つ安価な模様表出溶射膜を有する実用的なスリップ防止板の製造方法を提供することを目的とするものである。 An object of the present invention is to provide a practical method for producing an anti-slip plate having a durable and inexpensive pattern-sprayed sprayed film without causing such problems.
また、本発明は、基材の表面にこれから所定量離間した位置に配したマスキング部材の上方から当該基材表面へと溶射する一回の溶射工程を施して、当該基材表面に、溶射材がマスキング部材に干渉することなく溶射された部分とマスキング部材に干渉される部分とで溶射膜の膜厚ないし緻密度が異なることにより明度差による模様が表出する一層構造をなし且つ表面粗度をＲｍａｘ５０〜３０００μｍ（より好ましくはＲ ｍａｘ ５０〜２０００μｍ）とする溶射膜を形成するようにしたことを特徴とするスリップ防止板の製造方法を提案する。 Further, the present invention is subjected to a single spraying step of spraying from above the masking member arranged therefrom to the surface of the substrate to a predetermined amount spaced position to the substrate surface, on the substrate surface, more thermal spray film thickness to density of the sprayed coating in a portion that is interfering with the sprayed portion and the masking member without interfering with the masking member is exposed is patterned by Li Ming degree difference by the and different for Turkey (more preferably R max 50 to 2000 m) to and surface roughness without the structure Rmax50~3000μm proposes a method for producing a slip prevention plate being characterized in that so as to form forming a sprayed film and.
本発明の製造方法にあっては、前記一回の溶射工程において、基材表面とマスキング部材との距離を変更することによって、溶射膜における膜厚差ないし緻密度差を調整することができる。また、前記溶射膜に、これが金属溶射膜である場合において、金属溶解処理を施すことにより、更に粗い多孔質溶射膜を得るようにすることができる。更に、溶射膜を溶射材固有色以外の色とする場合には、溶射膜を着色封孔剤により着色，封孔処理しておくことができる。この場合、着色封孔剤としては、塗料を溶剤で希釈（一般に２５〜７５％に希釈）してなるものを使用することが好ましく、例えば、エポキシ系、アクリル系、ウレタン系、シリコン系、フッ素系又は亜鉛系の塗料を溶剤により５０％に希釈したものを使用するのが最適である。なお、本発明における基材の表面とは、溶射膜の形成に先駆けて表面処理（例えば、ブラスト処理やプライマ層（亜鉛等の犠牲金属やその他の溶射材による溶射膜等）を形成する処理）を行なう場合にあっては、当該表面処理後の基材表面をいうものとする。 In the manufacturing method of the present invention, the film thickness difference or the density difference in the sprayed film can be adjusted by changing the distance between the substrate surface and the masking member in the single spraying step. Further, when the sprayed film is a metal sprayed film, a more coarse porous sprayed film can be obtained by performing a metal dissolving process. Further, when the sprayed film is a color other than the color unique to the sprayed material, the sprayed film can be colored and sealed with a colored sealing agent. In this case, it is preferable to use a colored sealing agent obtained by diluting a paint with a solvent (generally diluted to 25 to 75%). For example, epoxy, acrylic, urethane, silicon, fluorine It is optimal to use a paint based on zinc or zinc based diluted to 50% with a solvent. In addition, the surface of the base material in the present invention is a surface treatment (for example, a treatment for forming a blast treatment or a primer layer (a thermal spray film with a sacrificial metal such as zinc or other thermal spray material) prior to the formation of the thermal spray film). In the case of performing the above, the surface of the base material after the surface treatment is meant.
本発明の方法によって製造される溶射膜形成部材は、一層構造の溶射膜を、部分的に、膜厚ないし緻密度が異なるようにすることによって、溶射膜表面に明度差による模様を形成するように構成したものであるから、装飾性及び耐久性に優れたものであり、スリップ防止板として好適に使用できる、極めて実用的価値の高いものである。 The sprayed film forming member manufactured by the method of the present invention forms a pattern due to a difference in brightness on the surface of the sprayed film by partially changing the thickness or density of the sprayed film having a single layer structure. Therefore, it has excellent decorativeness and durability, and can be suitably used as an anti-slip plate and has extremely high practical value.
また、本発明の製造方法によれば、一回の溶射工程（溶射膜の膜厚を確保するために基材表面への溶射作業を繰り返す場合を含むが、従来部材の溶射膜を形成する場合のように独立した溶射工程を繰り返す場合は含まない。）により模様を有する溶射膜を形成することができ、溶射膜形成部材の製造を効率良く且つ安価に行なうことができる。また、マスキング部材の形状及び基材表面からマスキング部材の距離を変更することによって、模様形態を任意に変更することができ、多様な模様を形成することができる。 Moreover, according to the manufacturing method of the present invention, a single thermal spraying step (including the case where the thermal spraying operation on the base material surface is repeated in order to ensure the film thickness of the thermal sprayed film, the case where the thermal sprayed film of the conventional member is formed. The thermal spray film having a pattern can be formed by repeating the independent thermal spraying process as described above, and the thermal spray film forming member can be manufactured efficiently and inexpensively. Also, by changing the shape of the masking member and the distance of the masking member from the substrate surface, the pattern form can be arbitrarily changed, and various patterns can be formed.
図１は本発明に係る製造方法によって得られたスリップ防止板１の表面形態（溶射膜表面における模様形態）を示す平面図であり、図２はその縦断面図（図１のＩＩ−ＩＩ線に沿う断面図）であるが、このスリップ防止板１は、図１及び図２に示す如く、基材２の表面に、膜厚ないし緻密度の異なる第１膜部分３ａと第２膜部分３ｂとを有する一層構造の溶射膜３を形成したものである。 FIG. 1 is a plan view showing the surface form (pattern form on the surface of the sprayed film) of the anti-slip plate 1 obtained by the manufacturing method according to the present invention, and FIG. 2 is a longitudinal sectional view thereof (II-II line in FIG. 1). As shown in FIGS. 1 and 2, the anti-slip plate 1 is formed on the surface of the base material 2 on the surface of the base material 2 with the first film portion 3a and the second film portion 3b having different film thicknesses or densities. A one-layer sprayed film 3 having the following structure is formed.
すなわち、溶射膜３は、格子状をなす第１膜部分３ａとこれによって区画された複数の方形部分たる第２膜部分３ｂとからなる。各第２膜部分３ｂは、図２に示す如く、第１膜部分３ａに比して、膜厚が厚く高緻密度のものとされている。したがって、第１膜部分３ａと各第２膜部分３ｂとでは、図１に示す如く、顕著な明度差が生じ、その結果、溶射膜３の表面においてかかる明度差による明瞭な模様（格子模様）が形成されている。 That is, the sprayed film 3 includes a first film portion 3a having a lattice shape and a second film portion 3b which is a plurality of rectangular portions partitioned by the first film portion 3a. As shown in FIG. 2, each second film portion 3b is thicker and has a higher density than the first film portion 3a. Therefore, as shown in FIG. 1, a remarkable brightness difference occurs between the first film portion 3a and each of the second film portions 3b. As a result, a clear pattern (lattice pattern) due to the brightness difference on the surface of the sprayed film 3 is generated. Is formed.
基材２の構成材及び形状や溶射膜３の構成材は、用途等に応じて任意に選定することができ、基材２及び溶射膜３の構成材として金属，セラミックス，プラスチックを使用することができる。また、基材２の形状は、板形状，ブロック形状等の単純形状の他、グレーチング等の複雑な立体形状ないし製品形状をなすものとできる。例えば、当該スリップ防止板１を工場の通路床等に使用するスリップ防止板として使用する場合には、基材２としてステンレス鋼鈑，鉄板，アルミ板等の金属板（ステンレス鋼鈑が最適する）を使用し、溶射膜３の構成材（溶射材）として、耐摩耗性等に優れたクロム鋼等（ＳＵＳ４２０Ｊ２（１３Ｃｒ），１７Ｃｒ，３１６，３１６Ｌ等）を使用することが好ましい（耐摩耗性に加えて安価である点からしてＳＵＳ４２０Ｊ２が最適する）。 The constituent material and shape of the base material 2 and the constituent material of the sprayed film 3 can be arbitrarily selected according to the application and the like, and metal, ceramics, and plastic are used as the constituent material of the base material 2 and the sprayed film 3. Can do. Moreover, the shape of the base material 2 can be a complicated three-dimensional shape such as a grating or a product shape in addition to a simple shape such as a plate shape or a block shape. For example, when the anti-slip plate 1 is used as an anti-slip plate used for a passage floor in a factory, a metal plate such as a stainless steel plate, an iron plate, an aluminum plate, etc. (stainless steel plate is most suitable) It is preferable to use chromium steel or the like (SUS420J2 (13Cr), 17Cr, 316, 316L, etc.) having excellent wear resistance as a constituent material (spraying material) of the sprayed film 3 (for wear resistance). In addition, SUS420J2 is optimal because it is inexpensive.
溶射膜３は、基材２の表面に周知の前処理（ブラスト等による基材表面の粗面化処理等）を施した上で、適宜の溶射材３ｃを溶射することによって形成されるが、上記した如く部分的に膜厚，緻密度に差を生じさせるために、図３及び図４に示す如く、基材２上に第１膜部分３ａに対応する形状（格子形状）のマスキング部材４を設置した状態で、溶射を行なう。 The thermal spray film 3 is formed by spraying an appropriate thermal spray material 3c after performing a known pretreatment (such as a roughening process of the base material surface by blasting) on the surface of the base material 2. In order to cause a difference in thickness and density partially as described above, a masking member 4 having a shape (lattice shape) corresponding to the first film portion 3a on the substrate 2 as shown in FIGS. Thermal spraying is performed with the installed.
すなわち、マスキング部材４を、基材表面から所定量離間させた状態で、基材１上に設置し、マスキング部材４上から溶射材３ｃを基材表面に溶射させる。 That is, the masking member 4 is placed on the base material 1 in a state of being separated from the base material surface by a predetermined amount, and the thermal spray material 3c is sprayed on the base material surface from the masking member 4.
而して、基材２の表面においては、マスキング部材４に直対向する部分（以下「第１被溶射面」という）２ａとこれ以外の部分（以下「第２被溶射面」という）２ｂとでは、溶射材３ｃの溶射形態が大きく異なる。すなわち、図４に示す如く、第２被溶射面２ｂにおいては、溶射材３ｃがマスキング部材４に干渉されることなく到達するため、溶射機からの溶射量に一致する量の溶射材３ｃが投射されるが、第１被溶射面２ａにおいては、溶射材３ｃがマスキング部材４に干渉して溶射材３ｃの当該被溶射面２ａへの投射量が大幅に減少することになる。したがって、第１被溶射面２ａにおいては、第２被溶射面２ｂに形成される溶射膜（第２膜部分）３ｂに比して、膜厚が小さく緻密度の低い溶射膜（第１膜部分）３ａが形成されることになる。この第１膜部分３ａの膜厚ないし緻密度は、第１被溶射面２ａからマスキング部材４までの距離（溶射方向における距離）によって異なり、当該距離が大きくなるに従って、マスキング部材４と第１被溶射面２ａとの間に飛散侵入する溶射材量が多くなり、膜厚ないし緻密度は高くなる。すなわち、当該距離を変更することによって、第１膜部分３ａの膜厚ないし緻密度を任意に調整することができ、第２膜部分３ｂとの間の膜厚差ないし緻密度差を調整することができる。なお、溶射膜３は一回の溶射工程によって形成される一層構造をなすものであるが、当該溶射工程における溶射材３ｃの溶射回数は一回に限らず、複数回繰り返される場合がある。すなわち、溶射は、溶射機の溶射口を基材表面に沿う一定距離だけ平行移動させつつ行なうが、かかる移動回数（溶射回数）は必要とする膜厚や溶射条件に応じて設定され、溶射回数が一回で足りる場合もあれば、複数回となる場合もある。 Thus, on the surface of the substrate 2, a portion (hereinafter referred to as “first sprayed surface”) 2 a directly facing the masking member 4 and a portion (hereinafter referred to as “second sprayed surface”) 2 b other than this portion Then, the thermal spraying form of the thermal spray material 3c is greatly different. That is, as shown in FIG. 4, since the sprayed material 3c reaches the second sprayed surface 2b without being interfered with the masking member 4, an amount of the sprayed material 3c corresponding to the sprayed amount from the sprayer is projected. However, on the first sprayed surface 2a, the sprayed material 3c interferes with the masking member 4 and the amount of projection of the sprayed material 3c onto the sprayed surface 2a is greatly reduced. Accordingly, in the first sprayed surface 2a, the sprayed film (first film portion) is smaller in thickness and lower in density than the sprayed film (second film portion) 3b formed on the second sprayed surface 2b. ) 3a is formed. The film thickness or density of the first film portion 3a differs depending on the distance (distance in the spraying direction) from the first sprayed surface 2a to the masking member 4, and as the distance increases, The amount of the thermal spray material that scatters and enters between the thermal spray surfaces 2a increases, and the film thickness or density increases. That is, by changing the distance, the film thickness or density of the first film part 3a can be arbitrarily adjusted, and the film thickness difference or density difference with the second film part 3b can be adjusted. Can do. The thermal spray film 3 has a single layer structure formed by a single thermal spraying process, but the thermal spraying frequency of the thermal spray material 3c in the thermal spraying process is not limited to one and may be repeated a plurality of times. In other words, the thermal spraying is performed while the spraying port of the thermal sprayer is translated by a certain distance along the surface of the substrate. The number of times of such movement (number of times of spraying) is set according to the required film thickness and spraying conditions. May be sufficient once, or multiple times.
ところで、溶射膜３は、用途等に応じて、基材２の表面全体又はその一部に形成されるが、当該スリップ防止板１にあっては、溶射条件を工夫することにより、図５に示す如く、一般的な溶射膜に比して、溶射粒子３ｄを大径とする粗面構造をなすものとして、膜表面の摩擦機能を増大させるようにしておくことが好ましい。溶射膜３の表面粗度をどの程度とするかは、当該スリップ防止板１の用途等に応じて決定されるが、膜表面の摩擦機能を重視するスリップ防止板として使用される場合、つまり靴等の履物との間に一定以上の摩擦力を確保する必要のある摩擦機能部材として使用する場合には、表面粗さがＲｍａｘ５００〜１５００μｍとなるように設定しておくことが好ましい。 By the way, the sprayed film 3 is formed on the entire surface of the base material 2 or a part of the surface of the base material 2 depending on the use or the like. In the anti-slip plate 1 , the spraying condition is devised in FIG. As shown in the drawing, it is preferable to increase the friction function of the film surface by using a rough surface structure in which the diameter of the sprayed particles 3d is larger than that of a general sprayed film. If either the surface roughness of the sprayed coating 3 and how, is determined in accordance with the slip prevention plate 1 applications and the like, which is used as the slip prevention plate that emphasizes friction function of the membrane surface, That is, when used as a friction functional member that needs to ensure a certain level of frictional force with footwear such as shoes, it is preferable to set the surface roughness to R max 500 to 1500 μm. .
溶射方法としては、溶射材の性状等に応じて、アーク溶射，プラズマ溶射，線爆溶射等の電気式溶射法や溶線式，溶棒式，粉末式フレーム溶射等のガス式溶射法等、周知，公知の溶射法を、任意に採用することができる。一般には、ガス式溶射に比して高い溶射量（フレーム溶射の２〜４倍）及び高い溶射膜密着強度が得られるアーク溶射を採用することが好ましい。上記した粗面構造の溶射膜３を得る場合には、アーク溶射条件（チップ，電圧，溶射距離等）を工夫することによって、一般的なアーク溶射条件による溶射膜より粗い溶射粒子３ｄが得られるように工夫しておく。なお、溶射条件を工夫することのみによっては溶射膜３の粗面度に限度があるが、要求される粗面度がかかる限度を超える場合には、溶射後の処理によって溶射膜３の粗面度を増大させることが可能である。例えば、金属溶射の場合、溶射後に酸洗い等の金属溶解処理を施して、溶射粒子３ｄの一部を溶解することによって、更に粗い多孔質溶射膜３となすことができる。勿論、かかる溶射後の処理を行なう場合にあっては、溶射条件を一般的な緻密質溶射膜と同様にして、その緻密質溶射膜を上記した酸洗い等により、摩擦機能部材として好適する粗面構造の多孔質溶射膜３を得るようにすることも可能である。 As the thermal spraying method, electric spraying methods such as arc spraying, plasma spraying, and wire explosion spraying, and gas spraying methods such as welding wire, welding rod, and powder flame spraying, etc. are well known depending on the properties of the spraying material. A known spraying method can be arbitrarily employed. In general, it is preferable to employ arc spraying that provides a high spraying amount (2-4 times that of flame spraying) and high adhesion strength of the sprayed film as compared with gas spraying. When the sprayed film 3 having the rough surface structure described above is obtained, by spraying the arc spraying conditions (chip, voltage, spraying distance, etc.), the sprayed particles 3d rougher than the sprayed film by general arc spraying conditions can be obtained. Be devised as follows. In addition, although there is a limit to the roughness of the sprayed film 3 only by devising the spraying conditions, when the required roughness exceeds the limit, the roughened surface of the sprayed film 3 is processed by the treatment after spraying. It is possible to increase the degree. For example, in the case of metal spraying, a more coarse porous sprayed film 3 can be obtained by performing a metal dissolving process such as pickling after spraying to dissolve a part of the sprayed particles 3d. Of course, in the case of performing the treatment after the thermal spraying, the thermal spraying conditions are the same as those of a general dense thermal sprayed film, and the dense thermal sprayed film is subjected to rough washing suitable as a friction functional member by the above-mentioned pickling. It is also possible to obtain a porous sprayed film 3 having a planar structure.
また、溶射膜３は、溶射材３ｃに固有の色を呈するが、膜厚差ないし緻密度差による明度差模様を溶射材固有色以外の色による場合には、例えば、図５に示す如く、溶射膜３に着色封孔剤５を使用した封孔処理を行なって、多孔質溶射膜３の封孔処理を行なうと共に溶射膜３の着色を行なうことが好ましい。この封孔処理は、多孔質溶射膜の気孔消失を目的とする一般的な封孔処理及び溶射膜の着色を目的とする一般的な塗装処理を兼ねるものであり、塗料を溶剤で希釈した着色封孔剤５を使用して、一般的な封孔処理と同様手法（刷毛塗り，浸漬，エアスプレー等）により行なう。 Further, the sprayed film 3 exhibits a color unique to the sprayed material 3c, but when the brightness difference pattern due to the film thickness difference or the density difference is based on a color other than the sprayed material specific color, for example, as shown in FIG. It is preferable to perform a sealing process using the colored sealing agent 5 on the sprayed film 3 to perform the sealing process of the porous sprayed film 3 and to color the sprayed film 3. This sealing treatment also serves as a general sealing treatment for the purpose of eliminating pores in the porous sprayed film and a general coating process for coloring the sprayed film. The sealing agent 5 is used, and a method (brush coating, dipping, air spraying, etc.) is performed in the same manner as general sealing processing.
塗料としては、スリップ防止板１の使用条件等に応じて、エポキシ系，ウレタン系，シリコン系，アクリル系，フッ素系，亜鉛系の塗料等が使用される。例えば、耐薬品性，密着性を重視する場合にはエポキシ系が好適であり、耐候性を重視する場合にはウレタン系や更に耐久性に優れるシリコン系が好適である。 As the coating material, an epoxy-based, urethane-based, silicon-based, acrylic-based, fluorine-based, zinc-based coating or the like is used depending on the use conditions of the anti-slip plate 1. For example, when emphasizing chemical resistance and adhesion, an epoxy system is suitable, and when emphasizing weather resistance, a urethane system or a silicon system having further excellent durability is suitable.
ところで、着色封孔剤５は、塗料をシンナー等の溶剤で希釈して得られるが、その粘度が必要以上に高い場合には、溶射膜３への浸透が十分に行なわれないし、溶射膜表面を被覆する封孔剤層が必要以上に厚くなって、溶射膜表面の表面粗度を低下させたり、極端な場合には、膜表面の凹凸を消失させてしまう虞れがある。逆に、着色封孔剤５の粘度が一定以下である場合（塗料の溶剤による希釈度が必要以上に高い場合）には、封孔処理による多孔質溶射膜３の強度向上が図れない（封孔処理する意義がない）ばかりか、塗料による着色が十分に行なわれない。したがって、着色封孔剤５の粘度、つまり塗料の溶剤による希釈度は、このような点を考慮して設定しておくことが必要であり、一般には、塗料をシンナー等の溶剤に２５〜７５％に希釈しておくことが好ましく、５０％に希釈しておくことが最適である。このような希釈度の着色封孔剤５によれば、図５に示す如く、一回の封孔処理（刷毛塗り等）により、封孔剤５を溶射膜３の内部へと十分に浸透させることができ、溶射膜３の表面を、所望する摩擦機能を発揮できる程度に粗く（Ｒｍａｘ５０〜３０００μｍ（より好ましくはＲｍａｘ５０〜２０００μｍ））しつつ、良好に着色することができる。 By the way, the colored sealant 5 is obtained by diluting the paint with a solvent such as thinner. However, if the viscosity is higher than necessary, the penetration to the sprayed film 3 is not sufficiently performed, and the surface of the sprayed film is not obtained. There is a possibility that the sealing agent layer covering the film becomes thicker than necessary, and the surface roughness of the sprayed film surface is lowered, or in an extreme case, the unevenness of the film surface is lost. On the contrary, when the viscosity of the colored sealing agent 5 is below a certain level (when the dilution of the paint with a solvent is higher than necessary), the strength of the porous sprayed film 3 cannot be improved by sealing treatment (sealing). In addition, there is no significance to the pore treatment), and coloring with paint is not sufficiently performed. Therefore, it is necessary to set the viscosity of the colored sealing agent 5, that is, the degree of dilution of the paint with a solvent in consideration of such points. It is preferable to dilute to 50%, and it is optimal to dilute to 50%. According to the colored sealing agent 5 having such a dilution, as shown in FIG. 5, the sealing agent 5 is sufficiently permeated into the sprayed film 3 by a single sealing process (brush coating or the like). The surface of the thermal sprayed film 3 can be satisfactorily colored while being rough enough to exhibit a desired friction function (R max 50 to 3000 μm (more preferably R max 50 to 2000 μm)).
以上のように構成されたスリップ防止板１は、従来部材のように異種溶射材による複数の溶射膜を独立して各別に形成したものと異なって、一種の溶射材による一層構造の溶射膜３を形成して膜表面に模様を表出させるものであるから、一回の溶射工程により効率良く且つ低コストで製造することができる。また、第１膜部分３ａと第２膜部分３ｂとの膜厚差によって摩擦機能が向上するため、スリップ防止板として好適する。特に、溶射膜３の表面粗さを、図５に示す如く、一般的な溶射膜に比して高くしておくことによって、摩擦機能の更なる向上を図ることができ、スリップ板として極めて優れるものとなすことができる。また、マスキング部材４の形状（特に、基材表面に平行する方向の大きさ）によっては、マスキング部材４のセット状態での溶射工程時において第１被溶射面２ａに十分な第１膜部分３ａが形成されない場合があるが、かかる場合には、マスキング部材４を取り外した上で、当該第１被溶射面２ａに十分な第１膜部分３ａを形成するための溶射工程を別途行なうようにしてもよい。また、着色封孔剤５による封孔処理を施しておくことにより、溶射材固有色と異なった色合いの明度差模様を得ることができ、模様の多様化を容易に図ることができる。しかも、着色封孔剤５が溶射膜３の内部に浸透していることから、仮に膜表面が摩耗したり溶射粒子が剥脱するようなことがあっても、色落ちすることがなく、溶射材固有色を利用する場合と同様に装飾機能（及び摩擦機能）が長期に亘って低下することがなく、耐久性に富む。また、一回の封孔処理によって封孔処理と着色処理とを同時に行なうことから、封孔処理及び着色工程を各別に行なう必要のある場合に比して、製作が容易であり、製品コストの低減を図ることができる。 The anti-slip plate 1 configured as described above is different from the case in which a plurality of sprayed films made of different kinds of sprayed materials are independently formed as in the conventional member, and a single-layered sprayed film 3 made of a kind of sprayed material. Since the pattern is exposed on the film surface, it can be manufactured efficiently and at low cost by a single thermal spraying process. Further, since the friction function is improved by the difference in film thickness between the first film portion 3a and the second film portion 3b, it is suitable as an anti-slip plate. In particular, the surface roughness of the sprayed coating 3, as shown in FIG. 5, by keeping higher than the typical thermal spray film, can further improve the friction function, as a slip plate It can be extremely excellent. Further, depending on the shape of the masking member 4 (particularly, the size in the direction parallel to the substrate surface), the first film portion 3a sufficient for the first sprayed surface 2a during the spraying process in the set state of the masking member 4 However, in such a case, after removing the masking member 4, a spraying process for forming a sufficient first film portion 3a on the first sprayed surface 2a is performed separately. Also good. Further, by performing a sealing treatment with the colored sealing agent 5, it is possible to obtain a lightness difference pattern having a hue different from the unique color of the thermal spray material, and to easily diversify the pattern. Moreover, since the colored sealing agent 5 penetrates into the sprayed film 3, even if the film surface is worn or the sprayed particles are peeled off, the sprayed material does not lose color. The decoration function (and the friction function) does not deteriorate over a long period of time as in the case of using the unique color, and the durability is high. In addition, since the sealing process and the coloring process are performed simultaneously by a single sealing process, the manufacturing process is easier and the product cost can be reduced compared to the case where the sealing process and the coloring process are required to be performed separately. Reduction can be achieved.
なお、本発明に係る製造方法は、上記した構成に限定されるものでなく、本発明の基本原理を逸脱しない範囲において適宜に改良，変形することが可能である。例えば、溶射膜３の表面に表出する明度差模様は、マスキング部材４の形状を変更することによって、自由に変更することができる。また、上記した例では、膜厚ないし緻密度が２段階に異なる第１及び第２膜部分３ａ，３ｂによって明度差模様を形成するようにしたが、マスキング部材４の形状及び溶射方法を工夫することによって、膜厚ないし緻密度が３段階以上に異なる溶射膜を形成することができる。また、複数のマスキング部材４を基材表面からの距離が異なるように設置しておくことによっても、膜厚ないし緻密度が３段階以上に異なる溶射膜を形成することが可能である。また、異色の着色封孔剤５を使用して、膜厚ないし緻密度が異なる膜部分毎に異なる着色を施しておくことができる。勿論、一部の膜部分のみに着色封孔剤５による着色を施しておくこともできる。また、着色封孔剤によっては膜表面の色彩が不十分である場合、着色封孔剤による膜表面の彩度を更に高めたい場合又は膜表面の性状向上（耐候性，耐食性等の向上）を図りたい場合等にあっては、着色封孔剤による着色，封孔処理を行った後に、膜表面に適宜の塗料（例えば、着色封孔剤と同色，同質のものであって溶剤による塗料の希釈度を着色封孔剤より高くした塗料や発色剤，クリヤ剤，性状向上塗料（耐候性塗料，耐食性塗料等），自己修復塗料等）を塗布するようにすることができる。この場合において、溶射膜の粗面構造を確保しておく必要があるときには、塗料により形成される塗膜の厚さを必要最小限の極く薄いものとして、当該塗膜の形成により溶射膜の粗面構造が消失しないように配慮する。 Note that the manufacturing method according to the present invention is not limited to the above-described configuration, and can be appropriately improved and modified without departing from the basic principle of the present invention. For example, the brightness difference pattern that appears on the surface of the sprayed film 3 can be freely changed by changing the shape of the masking member 4. In the above-described example, the lightness difference pattern is formed by the first and second film portions 3a and 3b having different thicknesses or densities in two stages. However, the shape of the masking member 4 and the thermal spraying method are devised. As a result, it is possible to form sprayed coatings having different film thicknesses or densities in three or more stages. Also, it is possible to form sprayed films having different film thicknesses or fine densities in three or more stages by installing a plurality of masking members 4 so that the distances from the substrate surface are different. Moreover, different coloring can be given for every film | membrane part from which a film thickness thru | or denseness differ using the colored sealing agent 5 of a different color. Of course, only a part of the film portion can be colored with the colored sealing agent 5. Also, depending on the color sealant, if the color of the film surface is insufficient, if you want to further increase the color saturation of the film surface with the color sealant, or improve the properties of the film surface (improvement of weather resistance, corrosion resistance, etc.) In the case where it is desired to paint, after coloring and sealing treatment with a coloring sealant, an appropriate paint (for example, the same color and the same color as the colored sealant, and the solvent coating) It is possible to apply paints, color formers, clearing agents, property-improving paints (weather-resistant paints, corrosion-resistant paints, etc.), self-healing paints, etc., which have a higher degree of dilution than colored sealants. In this case, when it is necessary to ensure the rough surface structure of the sprayed film, the thickness of the coating film formed by the coating is set to be a very thin minimum and the coating film is formed by forming the coating film. Consider not to lose the rough surface structure.
１…スリップ防止板、２…基材、２ａ…第１被溶射面、２ｂ…第２被溶射面、３…溶射膜、３ａ…第１膜部分、３ｂ…第２膜部分、３ｃ…溶射材、３ｄ…溶射粒子、４…マスキング部材、５…着色封孔剤。 DESCRIPTION OF SYMBOLS 1 ... Anti-slip board , 2 ... Base material, 2a ... 1st sprayed surface, 2b ... 2nd sprayed surface, 3 ... Sprayed film, 3a ... 1st film | membrane part, 3b ... 2nd film | membrane part, 3c ... Spraying material 3d ... spray particles, 4 ... masking member, 5 ... colored sealing agent.
Claims (6)
基材の表面にこれから所定量離間した位置に配したマスキング部材の上方から当該基材表面へと溶射する一回の溶射工程を施して、当該基材表面に、溶射材がマスキング部材に干渉することなく溶射された部分とマスキング部材に干渉される部分とで溶射膜の膜厚ないし緻密度が異なることにより明度差による模様が表出する一層構造をなし且つ表面粗度をＲｍａｘ５０〜３０００μｍとする溶射膜を形成するようにしたことを特徴とするスリップ防止板の製造方法。 In the manufacturing method of the anti-slip plate that is a friction function member that needs to ensure a certain level of friction force with the footwear and that uses the friction function due to the unevenness of the surface of the thermal spray film formed on the surface of the base material,
A single thermal spraying process is performed on the surface of the base material from the upper side of the masking member disposed at a predetermined distance from the masking surface to the base material surface, and the thermal spray material interferes with the masking member on the base material surface. A layer structure in which a pattern due to a difference in brightness appears due to a difference in film thickness or density of the sprayed film between a part sprayed without interference and a part interfering with the masking member, and the surface roughness is set to Rmax 50 to 3000 μm. A method for manufacturing an anti-slip plate, characterized in that a sprayed film is formed.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004162458A JP4304297B2 (en) | 2004-05-31 | 2004-05-31 | Method for manufacturing anti-slip plate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2004162458A JP4304297B2 (en) | 2004-05-31 | 2004-05-31 | Method for manufacturing anti-slip plate |
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| JP2005344139A JP2005344139A (en) | 2005-12-15 |
| JP4304297B2 true JP4304297B2 (en) | 2009-07-29 |
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| JP5835241B2 (en) | 2013-01-29 | 2015-12-24 | トヨタ自動車株式会社 | Thermal radiation member and method of manufacturing thermal radiation member |
| JP6387889B2 (en) * | 2015-04-15 | 2018-09-12 | トヨタ自動車株式会社 | Thermal spray coating formation method |
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