JP4813772B2 - Method for producing resin-coated metal plate having rough surface portion - Google Patents
Method for producing resin-coated metal plate having rough surface portion Download PDFInfo
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- 229920005989 resin Polymers 0.000 title claims description 148
- 239000011347 resin Substances 0.000 title claims description 148
- 229910052751 metal Inorganic materials 0.000 title claims description 59
- 239000002184 metal Substances 0.000 title claims description 59
- 238000004519 manufacturing process Methods 0.000 title claims description 17
- 229920005992 thermoplastic resin Polymers 0.000 claims description 36
- 239000002245 particle Substances 0.000 claims description 23
- -1 polybutylene terephthalate Polymers 0.000 claims description 13
- 230000003746 surface roughness Effects 0.000 claims description 10
- 238000000576 coating method Methods 0.000 claims description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 7
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 7
- 229920001187 thermosetting polymer Polymers 0.000 claims description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 6
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 6
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 239000011324 bead Substances 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- 235000012239 silicon dioxide Nutrition 0.000 claims description 3
- 239000004408 titanium dioxide Substances 0.000 claims description 3
- 238000000034 method Methods 0.000 description 19
- 238000007493 shaping process Methods 0.000 description 17
- 239000006185 dispersion Substances 0.000 description 16
- 238000004049 embossing Methods 0.000 description 14
- 229910001335 Galvanized steel Inorganic materials 0.000 description 8
- 239000008397 galvanized steel Substances 0.000 description 8
- 238000007639 printing Methods 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000011282 treatment Methods 0.000 description 5
- 238000004804 winding Methods 0.000 description 5
- 238000007747 plating Methods 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 239000010960 cold rolled steel Substances 0.000 description 3
- 238000001723 curing Methods 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000000465 moulding Methods 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 238000007788 roughening Methods 0.000 description 3
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 238000010306 acid treatment Methods 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- KRVSOGSZCMJSLX-UHFFFAOYSA-L chromic acid Substances O[Cr](O)(=O)=O KRVSOGSZCMJSLX-UHFFFAOYSA-L 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- AWJWCTOOIBYHON-UHFFFAOYSA-N furo[3,4-b]pyrazine-5,7-dione Chemical compound C1=CN=C2C(=O)OC(=O)C2=N1 AWJWCTOOIBYHON-UHFFFAOYSA-N 0.000 description 2
- 238000009998 heat setting Methods 0.000 description 2
- 239000011256 inorganic filler Substances 0.000 description 2
- 229910003475 inorganic filler Inorganic materials 0.000 description 2
- 239000010954 inorganic particle Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000011146 organic particle Substances 0.000 description 2
- 239000002985 plastic film Substances 0.000 description 2
- 229920006267 polyester film Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011342 resin composition Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910000611 Zinc aluminium Inorganic materials 0.000 description 1
- 229910001297 Zn alloy Inorganic materials 0.000 description 1
- HXFVOUUOTHJFPX-UHFFFAOYSA-N alumane;zinc Chemical compound [AlH3].[Zn] HXFVOUUOTHJFPX-UHFFFAOYSA-N 0.000 description 1
- ZCDOYSPFYFSLEW-UHFFFAOYSA-N chromate(2-) Chemical compound [O-][Cr]([O-])(=O)=O ZCDOYSPFYFSLEW-UHFFFAOYSA-N 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- WMYWOWFOOVUPFY-UHFFFAOYSA-L dihydroxy(dioxo)chromium;phosphoric acid Chemical compound OP(O)(O)=O.O[Cr](O)(=O)=O WMYWOWFOOVUPFY-UHFFFAOYSA-L 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- PAJKBYQWGBVBPE-UHFFFAOYSA-N ethene;terephthalic acid Chemical compound C=C.C=C.C=C.OC(=O)C1=CC=C(C(O)=O)C=C1 PAJKBYQWGBVBPE-UHFFFAOYSA-N 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 238000005246 galvanizing Methods 0.000 description 1
- 238000007646 gravure printing Methods 0.000 description 1
- 238000013007 heat curing Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- QELJHCBNGDEXLD-UHFFFAOYSA-N nickel zinc Chemical compound [Ni].[Zn] QELJHCBNGDEXLD-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 239000012463 white pigment Substances 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
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Description
本発明は、粗面部を有する樹脂被覆金属板の製造方法に関する。 The present invention relates to a method for producing a resin-coated metal plate having a rough surface portion.
冷蔵庫、オーディオ機器などの家電製品用の扉やキャビネット、建築物の壁、天井、ドア部材などの内装材として、表面に目地模様などの凹凸部を形成させた樹脂を被覆してなる樹脂被覆金属板が用いられている。例えば、特開２００４−０５２２７０号公報には、樹脂フィルムの表面に、溝状の凹部と溝状の凹部の両側に土手状の凸部が形成された目地デザイン樹脂フィルム、およびその目地デザイン樹脂フィルムを金属板に被覆してなる目地デザイン樹脂フィルム被覆金属板が提案されている。この目地デザイン樹脂フィルムにおいては、金属製のロール表面に目地模様を刻設したエンボスロールを用いて樹脂フィルム表面を加圧して目地模様を転写している。このように、エンボスロールを用いて樹脂フィルム表面に凹凸模様を転写する場合、様々な凹凸模様を有する樹脂被覆金属板を得るにはそれぞれの凹凸模様を刻設したエンボスロールを準備しなくてはならないが、エンボスロールは高価であり、また製作に時間を要するなど、製品コストが高額化し生産性が低いという問題がある。また、金属製のエンボスロールは、樹脂フィルムに比べて熱伝導性が極めて大きく、エンボスロール表面の温度を厳密に一定範囲に制御しないと、鮮明なエンボス模様が得られない。すなわち、エンボスロール表面の温度が高すぎると樹脂フィルムが硬化しないために転写したエンボス凹部の部分が熱変形してエンボス模様のシャープさが失われる。一方、エンボスロール表面の温度が低すぎると樹脂被覆金属板の冷却速度が過大になり、金属板が破断しやすくなる。 Resin-coated metal that is coated with a resin with irregularities such as joints on the surface as interior materials such as doors and cabinets for household appliances such as refrigerators and audio equipment, building walls, ceilings, door members, etc. A board is used. For example, Japanese Patent Application Laid-Open No. 2004-052270 discloses a joint design resin film in which a groove-like recess and a bank-like projection are formed on both sides of the groove-like recess on the surface of the resin film, and the joint design resin film. A joint design resin film-coated metal plate is proposed in which a metal plate is coated. In this joint design resin film, the joint pattern is transferred by pressurizing the resin film surface using an embossing roll having a joint pattern engraved on the metal roll surface. Thus, when transferring an uneven pattern on the surface of a resin film using an emboss roll, in order to obtain a resin-coated metal plate having various uneven patterns, it is necessary to prepare an emboss roll engraved with each uneven pattern. However, the embossing roll is expensive and requires a long time to manufacture, resulting in high product costs and low productivity. Further, the metal embossing roll has extremely high thermal conductivity as compared with the resin film, and a sharp embossing pattern cannot be obtained unless the temperature of the embossing roll surface is strictly controlled within a certain range. That is, if the temperature of the embossing roll surface is too high, the resin film is not cured, so that the transferred embossed concave portion is thermally deformed and the embossed pattern becomes sharp. On the other hand, if the temperature of the embossing roll surface is too low, the cooling rate of the resin-coated metal plate becomes excessive, and the metal plate tends to break.
エンボスロールを用いずに、樹脂上に凹凸模様を転写する方法として、特開平０６−１１４９３２号公報には、粒径が０．１〜１．０μｍのフィラーを練り込んだ二軸延伸ポリエステルフィルムにプラスチックシートを重ねて両者を均一に加熱加圧した後、二軸延伸ポリエステルフィルムを剥離することにより、プラスチックシートにエンボス模様を転写するエンボス加工方法が提案されている。しかし、この方法によれば樹脂上に均一なエンボス模様を形成させることはできるが、目地デザイン模様などのような他の部分とは局部的に表面の凹凸状態が異なる部分を形成させることはできない。 As a method for transferring a concavo-convex pattern onto a resin without using an embossing roll, JP-A-06-114932 discloses a biaxially stretched polyester film kneaded with a filler having a particle size of 0.1 to 1.0 μm. An embossing method has been proposed in which an embossed pattern is transferred to a plastic sheet by peeling the biaxially stretched polyester film after the plastic sheets are stacked and heated and pressed uniformly. However, according to this method, it is possible to form a uniform embossed pattern on the resin, but it is not possible to form a part whose surface unevenness is locally different from other parts such as joint design patterns. .
樹脂などの成形体の表面に、他の部分とは局部的に表面の凹凸状態が異なる部分を形成させる技術として、特開平０５−０１６２２８号公報には、基材フィルム上に無機系フィラーとバインダー樹脂からなる樹脂組成物を塗布して全面に微細な凹凸層を形成させた後、微細な凹凸層上に部分的に樹脂を印刷して平坦層を形成させるか、または基材フィルム上に部分的に撥液性樹脂を塗布し、その上に無機系フィラーとバインダー樹脂からなる樹脂組成物を塗布することにより、微細な凹凸層と局部的な平坦層が混在したグロス−マット表面を形成してなる賦型フィルムが形成され、そしてこの賦型フィルムを用いて樹脂などの成形体の表面に賦型フィルムのグロス−マット表面を転写してスウェード調の表面とする技術が提案されている。しかし、この方法によれば、樹脂などの成形体表面の殆どの部分に微細な凹凸層が形成され、局部的に平坦層が形成されたスウェード調の表面状態が得られるが、平坦な樹脂フィルム上の一部に局部的に粗面部分を形成させたり、局部的にまたは全面に粗面化程度の異なる複数の粗面部を形成することはできない。 As a technique for forming a portion having a surface unevenness locally different from other portions on the surface of a molded body such as a resin, Japanese Patent Laid-Open No. 05-016228 discloses an inorganic filler and a binder on a base film. After applying a resin composition made of resin to form a fine concavo-convex layer on the entire surface, partially printing the resin on the fine concavo-convex layer to form a flat layer, or partially on the base film By applying a liquid repellent resin and applying a resin composition consisting of an inorganic filler and a binder resin on top of it, a gloss-matt surface in which a fine uneven layer and a local flat layer are mixed is formed. There has been proposed a technique for forming a suede-like surface by transferring the gloss-matt surface of the shaped film onto the surface of a molded body such as a resin using the shaped film. However, according to this method, a fine concavo-convex layer is formed on almost the entire surface of the molded body such as a resin, and a suede-like surface state in which a flat layer is locally formed can be obtained. A rough surface portion cannot be locally formed on a part of the upper surface, or a plurality of rough surface portions having different roughening levels cannot be formed locally or on the entire surface.
本発明に関する先行技術文献として以下のものがある。
本発明は、粗面賦型フィルムを用いて樹脂表面に局部的に粗面部を形成させてなる粗面部を有する樹脂被覆金属板の製造方法を提供することを目的とする。 The present invention aims to provide a method of manufacturing a resin-coated metal plate having a rough surface portion made by forming a locally rough surface on the resin surface using a coarse Menfu type film.
上記課題を解決する本発明の製造方法は、
金属板にポリブチレンテレフタレートからなる熱可塑性樹脂を被覆してなる樹脂被覆金属板を、オーブンにより該熱可塑性樹脂の軟化温度以上に加熱し、
軟化した該熱可塑性樹脂の表面に、ポリエチレンテレフタレートの二軸延伸フィルムの表面に、二酸化ケイ素、二酸化チタン、炭酸カルシウム、アクリルビーズから選ばれる耐熱性粒子を熱硬化性樹脂に分散した粒子分散樹脂層を形成することにより粗面化されてなる粗面賦型フィルムを、粗面形成面が接するようにして当接し、加圧ロールからなる挟圧手段を用いて加圧することにより、該熱可塑性樹脂の表面に該粗面賦型フィルムの粗面を転写した後、該粗面賦型フィルムを剥離することを特徴とする、粗面部を有する樹脂被覆金属板の製造方法である。
本発明の製造方法は、下記実施態様が好ましい。
（１） 前記粒子分散樹脂層が、前記二軸延伸フィルムの表面に模様を描くように局部的にまたは全面に形成されてなる製造方法。
（２） 前記粒子分散樹脂層が、表面粗さの異なる複数の粒子分散樹脂層を形成することによる、粗面化程度の異なる複数の粒子分散樹脂層である製造方法。
（３） 前記耐熱性粒子の粒径が０．１〜１００μｍである製造方法。
The manufacturing method of the present invention that solves the above problems is as follows.
The resin-coated metal plate made by coating a thermoplastic resin consisting of polybutylene terephthalate to the metal plate, heated above the softening temperature of the thermoplastic resin in an oven,
A particle-dispersed resin layer in which heat- resistant particles selected from silicon dioxide, titanium dioxide, calcium carbonate, and acrylic beads are dispersed in a thermosetting resin on the surface of the softened thermoplastic resin and on the surface of a biaxially stretched polyethylene terephthalate film The thermoplastic resin is obtained by abutting a rough surface-forming film that has been roughened by forming a rough surface-forming film so that the rough surface-forming surface comes into contact with each other, and pressurizing using a pressing means comprising a pressure roll. A method for producing a resin-coated metal plate having a rough surface portion, wherein the rough surface-shaped film is transferred to the surface of the rough surface-shaped film and then the rough surface-shaped film is peeled off.
The following embodiment is preferable for the production method of the present invention.
(1) The manufacturing method in which the particle-dispersed resin layer is formed locally or on the entire surface so as to draw a pattern on the surface of the biaxially stretched film.
(2) The production method, wherein the particle-dispersed resin layer is a plurality of particle-dispersed resin layers having different surface roughness levels by forming a plurality of particle-dispersed resin layers having different surface roughnesses.
(3) producing how the particle size is 0.1~100μm of the heat-resistant particles.
本発明においては、ポリエチレンテレフタレートの二軸延伸フィルム（以下“樹脂フィルム”ということがある）の表面に、粒径が０．１〜１００μｍの耐熱性粒子を分散してなる粒子分散樹脂層、または表面粗さの異なる複数の粒子分散樹脂層を印刷法などの塗布法を用いて局部的にまたは全面に形成して粗面賦型フィルムを構成し、この粗面賦型フィルムをポリブチレンテレフタレートからなる熱可塑性樹脂を被覆してなる樹脂被覆金属板の熱可塑性樹脂層に当接して挟圧して熱可塑性樹脂の表面に粗面賦型フィルムの粗面を転写した後、粗面賦型フィルムを剥離することを特徴としており、安価でかつ平易な方法で粗面賦型フィルムが利用できる。また、熱可塑性樹脂の軟化温度まで加熱された熱可塑性樹脂被覆金属板に、室温のままの粗面賦型フィルムを当接して挟圧するので、熱可塑性樹脂被覆金属板が急速に冷却され、かつ粗面賦型フィルムと熱可塑性樹脂被覆金属板が当接している時間を、熱可塑性樹脂が軟化温度以下になるまで充分に長く採れるので、エンボスロールを用いた場合よりもより鮮明なエンボス模様を得ることができる。さらに、粗面賦型フィルムは樹脂フィルム上に局部的にまたは全面に粗面化程度の異なる複数の粗面部を容易に形成させることができるので、この粗面賦型フィルムを用いると、熱可塑性樹脂被覆金属板の熱可塑性樹脂の表面に、局部的にまたは全面に粗面化程度の異なる複数の粗面部を形成させたソフィスティケートな外観を安価にかつ平易に得ることができる。
ポリブチレンテレフタレートからなる熱可塑性樹脂を被覆してなる樹脂被覆金属板を、以下単に“熱可塑性樹脂被覆金属板”と省略することがある。またポリブチレンテレフタレートを“熱可塑性樹脂”と省略することがある。
In the present invention, a particle-dispersed resin layer obtained by dispersing heat-resistant particles having a particle size of 0.1 to 100 μm on the surface of a biaxially stretched film of polyethylene terephthalate (hereinafter sometimes referred to as “resin film”) , or A plurality of particle-dispersed resin layers having different surface roughnesses are formed locally or on the entire surface using a coating method such as a printing method to form a rough surface-shaped film, and the rough surface-shaped film is formed from polybutylene terephthalate. After the rough surface of the rough surface-imparting film is transferred to the surface of the thermoplastic resin by contacting and sandwiching the thermoplastic resin layer of the resin-coated metal plate coated with the thermoplastic resin, the rough surface-shaped film is It is characterized by peeling, and a rough surface-shaped film can be used by an inexpensive and simple method. Further, the surface-roughened film is brought into contact with and sandwiched with the thermoplastic resin-coated metal plate heated to the softening temperature of the thermoplastic resin, so that the thermoplastic resin-coated metal plate is rapidly cooled, and Since the time for which the rough surface-imparting film and the thermoplastic resin-coated metal plate are in contact with each other can be taken long enough until the thermoplastic resin falls below the softening temperature, a clearer embossed pattern than when using an embossing roll is used. Obtainable. Furthermore, since the rough surface-shaped film can easily form a plurality of rough surface portions having different roughening levels locally or on the entire surface of the resin film, if this rough surface-shaped film is used, thermoplasticity A sophisticate appearance in which a plurality of rough surface portions having different roughening levels are formed locally or entirely on the surface of the thermoplastic resin of the resin-coated metal plate can be obtained inexpensively and easily.
Hereinafter, a resin-coated metal plate coated with a thermoplastic resin made of polybutylene terephthalate may be simply referred to as a “thermoplastic resin-coated metal plate”. Polybutylene terephthalate is sometimes abbreviated as “thermoplastic resin”.
以下、本発明を詳細に説明する。図１〜図３に本発明の粗面賦型フィルムの態様例を示す。図１において（１）は概略平面図、（２）は概略断面図、図２において（１）は概略平面図、（２）は概略断面図、図３において（１）は概略平面図、（２）は概略断面図
ある。図１は鏡面状の樹脂フィルム１の表面に、一種類の表面粗さのストライプ模様の粒子分散樹脂層２を局部的に設けてなる粗面賦型フィルム１０とした態様例である。この粗面賦型フィルムを用いて熱可塑性樹脂被覆金属板の樹脂層に粗面を転写すると、樹脂層の表面は平滑な面に粗面のストライプ模様が局部的に形成される。本図は樹脂フィルム１の長手方向に垂直なストライプ模様の粗面部２を設ける例であるが、ストライプ模様は樹脂フィルムの長手方向に平行に設けてもよいし、斜め方向に設けてもよい。また交差させた目地状のストライプ模様としてもよい。さらに、ストライプの幅も１種類ではなく複数の種類の幅としてもよい。また粗面部は直線状のパターン以外に円、正方形、三角形、多角形の幾何学模様やそれらを組み合わせた図形、または花や雲などの形状や抽象図形など任意の形で設けてよい。
Hereinafter, the present invention will be described in detail. The example of the aspect of the rough surface shaping film of this invention is shown in FIGS. In FIG. 1, (1) is a schematic plan view, (2) is a schematic cross-sectional view, FIG. 2 (1) is a schematic plan view, (2) is a schematic cross-sectional view, and in FIG. 2) is a schematic sectional view. FIG. 1 shows an example of a rough surface-
図２は粗面賦型フィルムの基材となる鏡面状の樹脂フィルム１の表面に、２ａ、２ｂ、２ｃの表面粗さの異なる３種類の分散樹脂層を、樹脂フィルムの長手方向に３種類の平行な分散樹脂層を並べた模様でフィルム全面に設けてなる粗面賦型フィルム１０とした態様例である。異なる表面粗さを得るには、分散樹脂層において分散粒子の粒径および樹脂中の含有量を異ならせることにより得られる。図２は樹脂フィルム１の全面に分散樹脂層を設ける例を示したが、局部的に分散樹脂層を形成させない平面部を残存させてもよい。たとえば分散樹脂層２ｃを形成させずに２ａ、および２ｂのみの分散樹脂層を設けてもよい。本図においては樹脂フィルムの長手方向に３種類の長方形の分散樹脂層を並べた模様を示したが、模様としては、上記のような任意の模様を選択できる。
FIG. 2 shows three types of dispersed
図３は鏡面状の樹脂フィルム１の表面に、局部的に長方形模様の分散樹脂層２ｅを設け、さらに分散樹脂層２ｅとは異なる表面粗さの長方形模様の分散樹脂層２ｆを分散樹脂層２ｅ上に局部的に重ねて設けてなる粗面賦型フィルム１０とした態様例である。本図においては長方形の分散樹脂層２ｆを局部的に設けた長方形模様の分散樹脂層２ｅを樹脂フィルムの長手方向に間隔を置いて並べた模様を示したが、模様としては、上記のような任意の模様を選択できる。
In FIG. 3, a rectangular resin
樹脂フィルムとしては、ポリエチレンテレフタレートの二軸延伸フィルムが使用される。ポリエチレンテレフタレートは安価であるとともに、融解温度が高く、二軸延伸して平滑面を有するフィルムとした後に高温で熱固定することにより、熱固定温度以下の温度で殆ど変形することのないフィルムとなるので、ポリエチレンテレフタレートの二軸延伸フィルムを用いた粗面賦型フィルムを加熱した熱可塑性樹脂被覆金属板に当接して狭圧しても変形することなく、熱可塑性樹脂被覆金属板の熱可塑性樹脂に鮮明な粗面を賦与することができるので、好適に用いられる。 A biaxially stretched film of polyethylene terephthalate is used as the resin film. With Po triethylene terephthalate is inexpensive, the melting temperature is high, by heat-set at a high temperature after the film having a smooth surface and biaxially oriented, the film not to hardly deformed at heat setting temperature below the temperature Therefore, the thermoplastic resin of the thermoplastic resin-coated metal plate is not deformed even if it is brought into contact with a heated thermoplastic resin-coated metal plate and narrowed by pressing a rough surface-formed film using a biaxially stretched film of polyethylene terephthalate. Since a clear rough surface can be imparted, it is preferably used.
上記の樹脂フィルム上に形成する分散樹脂層は、加熱した熱可塑性樹脂被覆金属板に当接して狭圧する際に変形することがないようにするため、樹脂部を構成する樹脂は熱硬化性樹脂であることが好ましい。熱硬化性樹脂としては、エポキシ樹脂、フェノール樹脂、メラミン樹脂、尿素樹脂、不飽和ポリエステル樹脂、ポリウレタン樹脂などを用いることができる。これらの熱硬化性樹脂に耐熱性粒子を分散させて樹脂フィルム上に塗布した後、加熱硬化させて分散樹脂層とする。 The resin constituting the resin portion is a thermosetting resin so that the dispersion resin layer formed on the resin film does not deform when pressed against a heated thermoplastic resin-coated metal plate. It is preferable that As the thermosetting resin, epoxy resin, phenol resin, melamine resin, urea resin, unsaturated polyester resin, polyurethane resin, or the like can be used. After heat-resistant particles are dispersed in these thermosetting resins and coated on a resin film, they are cured by heating to form a dispersed resin layer.
分散樹脂層中に分散させる耐熱性粒子としては、加熱した熱可塑性樹脂被覆金属板に当接して狭圧する際に変形することがない耐熱性を有する素材からなる粒子であれば特に制限が無く、無機質粒子であっても有機質粒子であってもよい。しかし熱安定性が高く、安価であり、粒度範囲が揃ったものとして入手が容易な二酸化ケイ素、二酸化チタン、炭酸カルシウムなどの無機質粒子や、アクリルビーズなどの有機質粒子を用いることが好ましい。これらの粒子径は形成する分散樹脂層により、０．１〜１００μｍの範囲で粒子径を揃えて分散樹脂層中に含有させる。また、分散樹脂層中に含有させる量としては樹脂に対して１〜３０重量％以下であることが好ましい。１重量％未満では分散樹脂層表面が殆ど粗面化しない。３０重量％を超えると印刷などによる塗布が困難になる。また、上記の粒子径の好適範囲内で微細粒子と粗大粒子を上記の好適含有量の範囲内で一定割合で混合して含有させてもよい。 The heat-resistant particles to be dispersed in the dispersed resin layer are not particularly limited as long as the particles are made of a material having heat resistance that does not deform when pressed against a heated thermoplastic resin-coated metal plate, It may be inorganic particles or organic particles. However, it is preferable to use inorganic particles such as silicon dioxide, titanium dioxide, calcium carbonate and the like, and organic particles such as acrylic beads, which have high thermal stability, are inexpensive, and are easily available as having a uniform particle size range. These particle diameters are contained in the dispersion resin layer with the same particle diameter in the range of 0.1 to 100 μm depending on the dispersion resin layer to be formed. Moreover, it is preferable that it is 1 to 30 weight% or less with respect to resin as an amount to contain in a dispersed resin layer. If it is less than 1% by weight, the surface of the dispersed resin layer is hardly roughened. If it exceeds 30% by weight, coating by printing or the like becomes difficult. In addition, fine particles and coarse particles may be mixed and contained at a constant ratio within the above-mentioned preferable content range within the above-mentioned preferable particle diameter range.
上記のようにして熱硬化性樹脂中に耐熱性粒子を分散させて樹脂フィルム上にグラビア印刷法、凹版印刷法、スクリーン印刷法などの印刷手段を用いて塗布する。塗布を容易に行えるように、熱硬化性樹脂中に耐熱性粒子を分散させる際に粘度を調整するために溶媒を用いてもよい。塗布した分散樹脂層が見かけ上硬化した後、使用した樹脂に応じたキュア温度に加熱して樹脂を加熱硬化させる。以上のようにして本発明の方法において使用する粗面賦型フィルムが得られる。 As described above, the heat-resistant particles are dispersed in the thermosetting resin and applied onto the resin film using a printing means such as gravure printing, intaglio printing, or screen printing. A solvent may be used to adjust the viscosity when the heat-resistant particles are dispersed in the thermosetting resin so that the coating can be easily performed. After the applied dispersed resin layer is apparently cured, the resin is heated and cured to a curing temperature corresponding to the resin used. As described above, the rough surface-shaped film used in the method of the present invention is obtained.
このようにして得られた粗面賦型フィルムを、加熱した熱可塑性樹脂被覆金属板の樹脂層に当接して挟圧して熱可塑性樹脂の表面に粗面賦型フィルムの粗面を転写した後、粗面賦型フィルムを剥離することにより、粗面部を有する樹脂被覆金属板が得られる。熱可塑性樹脂被覆金属板としては、冷延鋼板、冷延鋼板に電解めっき法を用いて亜鉛めっきしてなる電気亜鉛めっき鋼板や、亜鉛−ニッケル、亜鉛−アルミニウムなどの亜鉛合金めっきを溶融めっき法を用いてめっきしなる溶融亜鉛めっき鋼板、冷延鋼板に電解クロム酸処理、リン酸クロメート処理、塗布型クローメート処理、各種のノンクロム処理などの化成処理を施してなる表面処理鋼板、これらの亜鉛めっき鋼板にこれらの化成処理を施してなる表面処理亜鉛めっき鋼板、ステンレス鋼板、アルミニウム合金板のいずれかに、公知の積層方法を用いて熱可塑性樹脂を積層被覆してなるものを用いる。金属板上に積層被覆する熱可塑性樹脂としては、ポリブチレンテレフタレートが使用される。 After transferring the rough surface of the rough surface-imparted film to the surface of the thermoplastic resin by pressing the rough surface-shaped film thus obtained in contact with the resin layer of the heated thermoplastic resin-coated metal plate The resin-coated metal plate having a rough surface portion is obtained by peeling the rough surface-shaped film. Thermoplastic resin-coated metal sheets include cold-rolled steel sheets, electrogalvanized steel sheets obtained by galvanizing cold-rolled steel sheets using electrolytic plating, and zinc alloy plating such as zinc-nickel and zinc-aluminum. Hot-dip galvanized steel sheets that are plated using galvanized steel, surface-treated steel sheets that have undergone chemical conversion treatment such as electrolytic chromic acid treatment, phosphoric acid chromate treatment, coating-type chromate treatment, and various non-chromium treatments on these cold-rolled steel plates, and these zinc plating Any one of a surface-treated galvanized steel sheet, a stainless steel sheet, and an aluminum alloy sheet obtained by subjecting these steel sheets to a chemical conversion treatment is laminated with a thermoplastic resin using a known laminating method. Polybutylene terephthalate is used as the thermoplastic resin that is laminated and coated on the metal plate .
次に、本発明の粗面部を有する樹脂被覆金属板の製造方法について説明する。図４は本発明の粗面部を有する樹脂被覆金属板の製造方法の一態様例の模式図である。説明を簡略にするため、粗面賦型フィルム１０として、図１に示した樹脂フィルム１の長手方向に垂直なストライプ模様の粗面部２を設けたものを用いた場合を示す。図４において、金属板３上に熱可塑性樹脂４を積層してなり、コイル状に巻き取られた長尺帯状の樹脂被覆金属板２０ａは、アンコイラーなどの巻解手段３０ａから巻解かれ矢印方向に進行し、赤外線オーブンなどの加熱手段１５により、熱可塑性樹脂４の軟化温度以上の温度に加熱される。また、樹脂フィルム１の長手方向に垂直なストライプ模様の粗面部２が設けられ、コイル状に巻き取られた長尺帯状の粗面賦型フィルム１０は、アンコイラーなどの巻解手段３０ｂから巻解かれ矢印方向に進行する。矢印方向に進行した樹脂被覆金属板２０ａと粗面賦型フィルム１０は、樹脂被覆金属板２０ａの加熱された熱可塑性樹脂４と粗面賦型フィルム１０の粗面部２が当接するようにして対の加圧ロール４０ａと４０ｂからなる挟圧手段により挟み付けられて加圧され、熱可塑性樹脂４に粗面賦型フィルム１０の粗面部２が転写される。その後、合体した樹脂被覆金属板２０ａと粗面賦型フィルム１０は矢印方向に進行し、粗面賦型フィルム１０はデフレクターロール２５で進行方向を変更（図上で下方）され、樹脂被覆金属板は樹脂表面に粗面賦型フィルム１０の粗面部２が転写された凹部２ａ’を有する粗面部を有する樹脂被覆金属板２０ｂとして粗面賦型フィルム１０から剥離され、コイラーなどの巻取手段５０ａに巻き取られる。進行方向を変更された粗面賦型フィルム１０はコイラーなどの巻取手段５０ｂに巻き取られる。また、図４においてはデフレクターロール２５で粗面賦型フィルム１０と粗面部を有する樹脂被覆金属板２０ｂを剥離する例を示したが、粗面賦型フィルム１０と粗面部を有する樹脂被覆金属板２０ｂを剥離することなく巻取手段５０ａに巻き取ってもよい。この場合、粗面賦型フィルム１０は、粗面部を有する樹脂被覆金属板２０ｂがパネルなどの最終品に成形加工まで樹脂被覆金属板２０ｂの保護フィルムとして機能する。以上のようにして、本発明の粗面部を有する樹脂被覆金属板を得ることができる。
Next, the manufacturing method of the resin coating metal plate which has a rough surface part of this invention is demonstrated. FIG. 4 is a schematic view of an embodiment of a method for producing a resin-coated metal plate having a rough surface portion according to the present invention. In order to simplify the description, a case is shown in which a rough
図４では、長尺帯状の粗面賦型フィルムを用いて長尺帯状の樹脂被覆金属板の樹脂層に連続的に粗面部を形成させる態様例を示したが、切板状の樹脂被覆金属板に切板状の粗面賦型フィルムを載せ、プレス機を用いて加圧した後粗面賦型フィルムを剥離することにより、樹脂被覆金属板の樹脂表面に粗面賦型フィルムの粗面部を転写してもよい。 In FIG. 4, although the example of an aspect which forms a rough surface part continuously in the resin layer of a long strip-shaped resin-coated metal plate using a long strip-shaped rough surface shaping film was shown, a plate-shaped resin-coated metal A rough surface portion of the rough surface-shaped film is placed on the resin surface of the resin-coated metal plate by placing a cut-plate-shaped rough surface-shaped film on the plate, pressurizing it using a press, and then peeling the rough surface-shaped film. May be transferred.
以下、実施例にて本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail with reference to examples.
（実施例１）
[粗面賦型フィルムの作成]
エポキシ樹脂に二酸化ケイ素粉（平均粒子径：６．５μｍ）を２０重量％の量で分散してなる粒子分散液を作成し、ポリエチレンテレフタレートの二軸延伸フィルム（厚さ：３０μｍ、熱固定温度：２３０℃）の片面に、フィルム長手方向に垂直に幅８ｍｍ、間隔４０ｍｍ、樹脂硬化後の厚さが０．０７ｍｍとなるように、ロータリースクリーン印刷機を用いて図１に示すようなストライプ状に印刷塗布し、エポキシ樹脂が硬化した後、１５０℃で２分間加熱キュアを行い、粗面賦型フィルムとした。
(Example 1)
[Creation of rough surface film]
A particle dispersion obtained by dispersing 20% by weight of silicon dioxide powder (average particle size: 6.5 μm) in an epoxy resin is prepared, and a biaxially stretched film of polyethylene terephthalate (thickness: 30 μm, heat setting temperature: 230 ° C) on one side in a stripe shape as shown in FIG. 1 using a rotary screen printer so that the width is 8 mm perpendicular to the film longitudinal direction, the interval is 40 mm, and the thickness after resin curing is 0.07 mm. After printing and applying and curing of the epoxy resin, heat curing was performed at 150 ° C. for 2 minutes to obtain a rough surface shaping film.
[樹脂被覆亜鉛めっき鋼板の作成]
樹脂被覆金属板として、電気亜鉛めっき鋼板（板厚：０．２ｍｍ、めっき量：２０ｇ／ｍ２ 、めっき後に電解クロム酸処理を施し、クロムとして４０ｍｇ／ｍ２ 付着させた）の片面にポリエステルウレタン系の接着剤を１．５μｍの厚さに塗布し乾燥した。次いで接着剤を塗布した電気亜鉛めっき鋼板を２２５℃に加熱し、その接着剤塗布面に白色顔料を２０重量％含有するポリブチレンテレフタレートの未延伸フィルム（厚さ：２５μｍ、軟化温度：２２０℃）を当接し、１対の加圧ロールで両者を挟み付けて加圧し、樹脂被覆亜鉛めっき鋼板とした。
[Preparation of resin-coated galvanized steel sheet]
Polyester urethane on one side of an electrogalvanized steel sheet (plate thickness: 0.2 mm, plating amount: 20 g / m 2 , subjected to electrolytic chromic acid treatment after plating, and 40 mg / m 2 deposited as chromium) as a resin-coated metal plate The system adhesive was applied to a thickness of 1.5 μm and dried. Next, the electrogalvanized steel sheet coated with the adhesive was heated to 225 ° C., and an unstretched film of polybutylene terephthalate containing 20% by weight of a white pigment on the adhesive-coated surface (thickness: 25 μm, softening temperature: 220 ° C.) Were pressed between each other with a pair of pressure rolls to obtain a resin-coated galvanized steel sheet.
[粗面部を有する樹脂被覆金属板の作成]
上記の樹脂被覆亜鉛めっき鋼板を赤外線オーブンで２２５℃に加熱し、樹脂被覆亜鉛めっき鋼板の樹脂層に上記の粗面賦型フィルムのストライプ状の粗面部が接するようにして当接し、１対の挟圧ロールで両者を挟み付けて加圧し、粗面賦型フィルムのストライプ状の粗面を樹脂被覆亜鉛めっき鋼板の樹脂層に転写した。次いで粗面賦型フィルムを剥離し、表面に平滑な平面の一部にストライプ状の粗面部分が形成された、粗面部を有する樹脂被覆金属板（電気亜鉛めっき鋼板）を得た。
[Preparation of resin-coated metal plate with rough surface]
The resin-coated galvanized steel sheet is heated to 225 ° C. in an infrared oven, and is brought into contact with the resin layer of the resin-coated galvanized steel sheet so that the striped rough surface portion of the rough surface-shaped film is in contact therewith. Both of them were sandwiched and pressed by a pinching roll, and the striped rough surface of the rough surface-forming film was transferred to the resin layer of the resin-coated galvanized steel sheet. Subsequently, the rough surface shaping film was peeled off to obtain a resin-coated metal plate (electrogalvanized steel plate) having a rough surface portion in which a striped rough surface portion was formed on a part of a smooth flat surface.
本発明の方法は、樹脂フィルムの表面に、樹脂中に耐熱性粒子を分散してなる分散樹脂層を印刷法などの塗布法を用いて局部的にまたは全面に形成して粗面賦型フィルムを使用する。そのため金属製のエンボスロールに比べて、遙かに安価で平易に製造可能であり、粗面部を有する樹脂被覆金属板を安価に製造することができる。また、本発明の方法で使用する粗面賦型フィルムは、熱伝導性が低い樹脂フィルムからなる賦型フィルムを用いるため、エンボスロールによるエンボス加工におけるような、鮮明なエンボス模様を得るための厳密な温度管理が不要であり、平易に鮮明なエンボス模様が得られる。そのため、平坦な樹脂フィルム上の一部に局部的に粗面部分を形成させた目地模様やストライプ模様、さらに、局部的にまたは全面に粗面化程度の異なる複数の粗面部を形成させたソフィスティケートな外観を安価にかつ平易に得ることができる。 In the method of the present invention, a surface-imparted film is formed by forming a dispersed resin layer, in which heat-resistant particles are dispersed in a resin, on a surface of a resin film locally or entirely using a coating method such as a printing method. Is used. Therefore, compared to a metal embossing roll, an inexpensive and simple to manufacture available-a much, the resin-coated metal plate having a rough surface can be produced at low cost. Moreover, since the rough surface shaping film used in the method of the present invention uses a shaping film made of a resin film having low thermal conductivity, it is strictly necessary to obtain a sharp embossing pattern as in embossing with an embossing roll. Temperature control is not required, and a clear embossed pattern can be obtained easily. Therefore, joint patterns and stripe patterns with a rough surface part formed on a part of a flat resin film, and a sophisticate with a plurality of rough surface parts with different surface roughnesses formed locally or on the entire surface. A simple appearance can be obtained inexpensively and easily.
１ ：樹脂フィルム
２ ：粗面部２
２ａ ：分散樹脂層
２ａ’：凹部
２ｂ ：分散樹脂層
２ｃ ：分散樹脂層
２ｄ ：分散樹脂層
２ｅ ：分散樹脂層
２ｆ ：分散樹脂層
３ ：金属板
４ ：熱可塑性樹脂
１０ ：粗面賦型フィルム
１５ ：加熱手段
２０ａ：樹脂被覆金属板
２０ｂ：粗面部を有する樹脂被覆金属板
２５：デフレクターロール
３０ａ：巻解手段
３０ｂ：巻解手段
４０ａ：加圧ロール
４０ｂ：加圧ロール
５０ａ：巻取手段
５０ｂ：巻取手段
1: Resin film 2:
2a:
2d:
4: Thermoplastic resin 10: Rough surface shaping film 15: Heating means 20a: Resin-coated metal plate 20b: Resin-coated metal plate having a rough surface portion 25:
Claims (4)
軟化した該熱可塑性樹脂の表面に、ポリエチレンテレフタレートの二軸延伸フィルムの表面に、二酸化ケイ素、二酸化チタン、炭酸カルシウム、アクリルビーズから選ばれる耐熱性粒子を熱硬化性樹脂に分散した粒子分散樹脂層を形成することにより粗面化されてなる粗面賦型フィルムを、粗面形成面が接するようにして当接し、加圧ロールからなる挟圧手段を用いて加圧することにより、該熱可塑性樹脂の表面に該粗面賦型フィルムの粗面を転写した後、該粗面賦型フィルムを剥離することを特徴とする、粗面部を有する樹脂被覆金属板の製造方法。 The resin-coated metal plate made by coating a thermoplastic resin consisting of polybutylene terephthalate to the metal plate, heated above the softening temperature of the thermoplastic resin in an oven,
A particle-dispersed resin layer in which heat- resistant particles selected from silicon dioxide, titanium dioxide, calcium carbonate, and acrylic beads are dispersed in a thermosetting resin on the surface of the softened thermoplastic resin and on the surface of a biaxially stretched polyethylene terephthalate film The thermoplastic resin is obtained by abutting a rough surface-forming film that has been roughened by forming a rough surface-forming film so that the rough surface-forming surface comes into contact with each other, and pressurizing using a pressing means comprising a pressure roll. A method for producing a resin-coated metal sheet having a rough surface portion, wherein the rough surface-shaped film is peeled off after transferring the rough surface of the rough surface-shaped film to the surface.
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| Application Number | Priority Date | Filing Date | Title |
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| JP2004143386A JP4813772B2 (en) | 2004-05-13 | 2004-05-13 | Method for producing resin-coated metal plate having rough surface portion |
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| Application Number | Priority Date | Filing Date | Title |
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| JP2004143386A JP4813772B2 (en) | 2004-05-13 | 2004-05-13 | Method for producing resin-coated metal plate having rough surface portion |
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| JP2005324394A JP2005324394A (en) | 2005-11-24 |
| JP4813772B2 true JP4813772B2 (en) | 2011-11-09 |
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| JP2004143386A Expired - Fee Related JP4813772B2 (en) | 2004-05-13 | 2004-05-13 | Method for producing resin-coated metal plate having rough surface portion |
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| KR101138553B1 (en) | 2009-10-07 | 2012-05-11 | 김정식 | Flexible Laminate THEREON AND MANUFACTURING METHOD THEREOF |
| JP2012166475A (en) * | 2011-02-15 | 2012-09-06 | Ube Nitto Kasei Co Ltd | Method for producing molded article |
| JP6274731B2 (en) * | 2013-02-08 | 2018-02-07 | 東京応化工業株式会社 | Pattern forming device |
| CN109661862B (en) * | 2016-09-01 | 2021-08-31 | Ａｇｃ株式会社 | Metal laminate, method for producing the same, and method for producing a printed circuit board |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3045407B2 (en) * | 1991-04-15 | 2000-05-29 | 大日本印刷株式会社 | Molding film |
| JP3117031B2 (en) * | 1991-04-15 | 2000-12-11 | 大日本印刷株式会社 | Molded article having gloss-matte pattern |
| JP3164619B2 (en) * | 1991-11-19 | 2001-05-08 | 大日本印刷株式会社 | Matte transfer foil and decorative material |
| JPH0691835A (en) * | 1992-09-08 | 1994-04-05 | Dainippon Printing Co Ltd | Production of decorative metal plate |
| JP2002127688A (en) * | 2000-10-24 | 2002-05-08 | Tdk Corp | Transfer film and non-glare-treated substance |
| JP2004124064A (en) * | 2002-07-30 | 2004-04-22 | Toyo Kohan Co Ltd | Roughened surface resin film, metal plate coated therewith, method for making metal plate coated therewith, metal can with surface coated therewith and its making method |
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