CN107685014A - 一种辐射固化印花建筑彩钢板及其制作工艺 - Google Patents

一种辐射固化印花建筑彩钢板及其制作工艺 Download PDF

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CN107685014A
CN107685014A CN201610640279.9A CN201610640279A CN107685014A CN 107685014 A CN107685014 A CN 107685014A CN 201610640279 A CN201610640279 A CN 201610640279A CN 107685014 A CN107685014 A CN 107685014A
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李新雄
张冬明
李时珍
周利
李东才
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Abstract

本发明公开了一种辐射固化印花建筑彩钢板及其制作工艺，其特征在于：它包括金属基板及设置在基板一面的涂覆层，所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED‑UV固化打印装饰层，LED‑UV固化打印装饰层外设置清漆层，还包括其制造方法。本发明具有极佳的耐候性、耐污及自清洁性，绿色环保，无光引发剂残留及分解，性价比高，装饰性、耐水性能优异，能耗低，固化速度快，生产过程无污染、无有害物质释放等优点。

Description

一种辐射固化印花建筑彩钢板及其制作工艺
技术领域
本发明涉及一种彩钢板，尤其涉及一种辐射固化印花建筑彩钢板及其制作工艺。
背景技术
彩钢板或彩涂钢板是指钢板经表面处理后涂覆有机涂层或复合有机薄膜，再经固化而成的产品，具有工艺灵活、强度高、易成型、轻便易安装、成本低廉等优异特性，在建筑领域得到了广泛应用，特别是用作公共建筑、厂房车间、活动板房及集成房屋的屋顶、屋面等。自20世纪90年代我国投建第一批彩涂钢板生产线以来，彩钢板在建筑业的用量逐年攀升，对生产效率及涂装质量提出了更高要求。常规“二涂二烘”及以上的施工工艺受表面涂层性能的影响，通常固化温度高、不环保且能源消耗量大；热转印及覆膜工艺过程繁琐、生产效率低下、花纹立体效果不明显、易褪色、不耐老化，不能满足高端市场的使用需求。现有彩钢板在环保性、耐污性及耐久性方面普遍存在不足，这些都是本领域急需解决的问题。
辐射固化涂料通过辐射能量引发液态低聚物或单体聚合，不含易挥发的有机溶剂，包括紫外光固化“UV固化”、电子束固化“EB固化”、红外光固化“IR固化”、γ射线固化和微波固化，其中UV固化技术应用最为广泛，其设备投入低，易于实现流水线生产，用于印花装饰层可提供饱满丰富的装饰效果。EB固化机理与UV固化有一定的相似性，相比而言，具有能量级别高、穿透力强、固化程度高，无需高昂的光引发剂，不存在引发剂残留和光分解产物迁移等特点，成本明显低于UV固化涂料。将EB固化涂料用于彩钢板涂装，可使EB固化涂层以下的其他辐射固化涂层得到二次固化，保证极佳的耐候性、耐污性及隔热反射功能等。EB固化的唯一缺陷在于设备投资高，随着技术的发展，EB固化设备的造价已明显降低，显示出极大的市场潜力。
发明内容
本发明的目的是克服现有技术的不足，提供一种具有极佳的耐候性、耐污及自清洁性，绿色环保，无光引发剂残留及分解，性价比高，装饰性、耐水性能优异，能耗低，固化速度快，生产过程无污染、无有害物质释放的辐射固化印花建筑彩钢板及其制作工艺。
为解决上述技术问题，本发明采用以下技术方案：
本发明包括金属基板及设置在基板一面的涂覆层，其特征在于：所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED-UV固化打印装饰层，LED-UV固化打印装饰层外设置清漆层。
作为以上技术方案的进一步改进：
所述金属基板为冷轧钢板、镀锌板、镀锌铝板、镀铝锌板、镀铝镁锌板、镀铝板、不锈钢板及铝合金板中的任意一种，其中对耐腐蚀性能要求较高时，优选镀铝锌板、镀铝镁锌板、镀铝板、铝合金板，所述金属基板的厚度为0.5-3mm。
所述金属基板的待涂覆面及其相反的一面涂布化学处理液。所述金属基板上与待涂覆面相反的一面涂布辐射固化弹性底漆层或辐射固化背漆层中的至少一种。
所述辐射固化弹性附着底、辐射固化实色中涂层、辐射固化弹性底漆层、辐射固化背漆层采用UV固化或LED-UV固化或EB固化。所述辐射固化实色中涂层采用辐射固化白色中涂层。
所述的清漆层采用EB固化普通清漆层或EB固化户外清漆层或EB固化隔热反射清漆层。对隔热效果要求较高时，优选EB固化隔热反射清漆层。
由于属于一个总的发明构思，本发明还公开了一种辐射固化印花建筑彩钢板的制备工艺：
本发明包括步骤1，对金属基板进行化学处理，并在金属基板的待涂覆面涂布辐射固化弹性附着底，涂布量为4-12g/m2；步骤2，在固化后的辐射固化弹性附着底上涂布辐射固化实色中涂层，涂布量为8-20g/m2；步骤3，在固化后的辐射固化实色中涂层上数码打印10-40g/m2的LED-UV固化打印装饰层；步骤4，在固化后的LED-UV固化打印装饰层上涂布8-45g/m2的EB固化普通清漆层，户外使用则涂布15-50g/m2的EB固化户外清漆层，对隔热效果要求较高时，在LED-UV固化打印装饰层上涂布15-50g/m2的EB固化隔热反射清漆层。
作为以上技术方案的进一步改进：
所述经过化学处理的金属基板上与待涂覆面相反的一面涂布有辐射固化弹性底漆层或辐射固化背漆层。所述EB固化的辐射剂量为20-150kGy，能量为100-300keV。
与现有技术相比，本发明的优点在于：
1、采用UV固化及EB固化技术制备一种印花建筑彩钢板，实现低温快速固化，具有能耗低、生产效率高、绿色环保的特点。
2、本发明中各类涂覆层为特殊开发的配套体系，保证优异的附着力、装饰效果、耐水性、抗污性及耐候性，且均为绿色环保材料，生产及使用过程中无污染、无有害物质排放。采用EB固化清漆作为最外层涂装，无残留光引发剂残留，漆膜固化程度高，性能可调，可使其以下的UV固化涂层实现后固化，保证优异的表观硬度和漆膜韧性。
3、本发明制得的彩钢板装饰效果丰富、性价比高，克服了单色板颜色单一的缺陷，解决了现有彩钢板在耐候及抗污等方面普遍存在的不足，且具有较好的隔热反射效果，可扩展彩钢板在建筑领域的应用，尤其是用作屋顶、屋面及室内外高档装饰材料。
具体实施方式
以下将结合具体实施例对本发明作进一步详细说明。
实施例1，一种辐射固化印花建筑彩钢板，包括金属基板及设置在基板一面的涂覆层，其特征在于：所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED-UV固化打印装饰层，LED-UV固化打印装饰层外设置清漆层。所述金属基板为0.6mm的镀锌板，镀锌板的待涂覆面及其相反的一面涂布化学处理液，镀锌板上与待涂覆面相反的一面涂布UV固化弹性底漆层和UV固化背漆层。所述辐射固化弹性附着底为UV固化弹性附着底，辐射固化实色中涂层为UV固化白色中涂层，清漆层为EB固化普通清漆层。
本发明的制备工艺包括：步骤1，对镀锌板进行化学处理，并在镀锌板的待涂覆面涂布UV固化弹性附着底，涂布量为6g/m2；步骤2，在固化后的UV固化弹性附着底上涂布10g/m2的UV固化白色中涂层；步骤3，在固化后的UV固化白色中涂层上数码打印12g/m2的LED-UV固化打印装饰层；步骤4，在固化后的LED-UV固化打印装饰层上涂布10g/m2的EB固化普通清漆层。所述经过化学处理的镀锌板上与待涂覆面相反的一面涂布有UV固化弹性底漆层和UV固化背漆层。所述EB固化的辐射剂量为75kGy，能量为150keV。
实施例2，一种辐射固化印花建筑彩钢板，包括金属基板及设置在基板一面的涂覆层，其特征在于：所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED-UV固化打印装饰层，LED-UV固化打印装饰层外设置清漆层。所述金属基板为0.8mm的镀铝板，镀铝板的待涂覆面及其相反的一面涂布化学处理液，镀铝板上与待涂覆面相反的一面涂布UV固化弹性底漆层和UV固化背漆层。所述辐射固化弹性附着底为UV固化弹性附着底，辐射固化实色中涂层为LED-UV固化白色中涂层，清漆层为EB固化户外清漆层。
本发明的制备工艺包括：步骤1，对镀铝板进行化学处理，并在镀铝板的待涂覆面涂布UV固化弹性附着底，涂布量为5g/m2；步骤2，在固化后的UV固化弹性附着底上涂布12g/m2的LED-UV固化白色中涂层；步骤3，在固化后的LED-UV固化白色中涂层上数码打印20g/m2的LED-UV固化打印装饰层；步骤4，在固化后的LED-UV固化打印装饰层上涂布15g/m2的EB固化户外清漆层。所述经过化学处理的镀铝板上与待涂覆面相反的一面涂布UV固化弹性底漆层和UV固化背漆层。所述EB固化的辐射剂量为60kGy，能量为200keV。
实施例3，一种辐射固化印花建筑彩钢板，包括金属基板及设置在基板一面的涂覆层，其特征在于：所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED-UV固化打印装饰层，LED-UV固化打印装饰层外设置清漆层。所述金属基板为1.2mm的镀铝镁锌板，镀铝镁锌板的待涂覆面及其相反的一面涂布化学处理液，镀铝镁锌板上与待涂覆面相反的一面涂布UV固化弹性底漆层和LED-UV固化背漆层。所述辐射固化弹性附着底为UV固化弹性附着底，辐射固化实色中涂层为UV固化白色中涂层，清漆层为EB固化隔热反射清漆层。
本发明的制备工艺包括：步骤1，对镀铝镁锌板进行化学处理，并在镀铝镁锌板的待涂覆面涂布UV固化弹性附着底，涂布量为4g/m2；步骤2，在固化后的UV固化弹性附着底上涂布11g/m2的UV固化白色中涂层；步骤3，在固化后的UV固化白色中涂层上数码打印15g/m2的LED-UV固化打印装饰层；步骤4，在固化后的LED-UV固化打印装饰层上涂布20g/m2的EB固化隔热反射清漆层。所述经过化学处理的镀铝镁锌板上与待涂覆面相反的一面涂布UV固化弹性底漆层和LED-UV固化背漆层。所述EB固化的辐射剂量为40kGy，能量为250keV。
下方提供针对本发明各个实施例的具体性能测试数据以供参考：
a起泡等级、脱落等级、变色等级、失光等级、锈点等级达到GB/T 1766规定的0级；
b粉化等级、起泡等级、脱落等级、变色等级、失光等级、锈点等级不次于GB/T 1766规定的1级。
c无粉化、起泡、脱落、开裂现象，失光等级、变色等级不次于GB/T 1766规定的1级。
上述只是本发明的较佳实施例，并非对本发明作任何形式上的限制。虽然本发明已以较佳实施例揭露如上，然而并非用以限定本发明。任何熟悉本领域的技术人员，在不脱离本发明技术方案范围的情况下，都可利用上述揭示的技术内容对本发明技术方案做出许多可能的变动和修饰，或修改为等同变化的等效实施例。因此，凡是未脱离本发明技术方案的内容，依据本发明技术实质对以上实施例所做的任何简单修改、等同变化及修饰，均应落在本发明技术方案保护的范围内。

Claims (8)

1.一种辐射固化印花建筑彩钢板，它包括金属基板及设置在基板一面的涂覆层，其特征在于：所述涂覆层与金属基板接触的一面为辐射固化弹性附着底，辐射固化弹性附着底外设置辐射固化实色中涂层，辐射固化实色中涂层外设置LED-UV固化打印装饰层，LED-UV固化打印装饰层外设置清漆层。
2.根据权利要求1所述的一种辐射固化印花建筑彩钢板，其特征在于：所述金属基板为冷轧钢板、镀锌板、镀锌铝板、镀铝锌板、镀铝镁锌板、镀铝板、不锈钢板及铝合金板中的任意一种，所述金属基板的厚度为0.5-3mm。
3.据权利要求1或2所述的一种辐射固化印花建筑彩钢板，其特征在于：所述金属基板的待涂覆面及其相反的一面涂布化学处理液。所述金属基板上与待涂覆面相反的一面涂布辐射固化弹性底漆层或辐射固化背漆层中的至少一种。
4.根据权利要求3所述的一种辐射固化印花建筑彩钢板，其特征在于：所述辐射固化弹性附着底、辐射固化实色中涂层、辐射固化弹性底漆层、辐射固化背漆层采用UV固化或LED-UV固化或EB固化。所述辐射固化实色中涂层采用辐射固化白色中涂层。
5.根据权利要求1所述的一种辐射固化印花建筑彩钢板，其特征在于：所述的清漆层采用EB固化普通清漆层或EB固化户外清漆层或EB固化隔热反射清漆层。
6.一种辐射固化印花建筑彩钢板的制作工艺，其特征在于：它包括步骤1，对金属基板进行化学处理，并在金属基板的待涂覆面涂布辐射固化弹性附着底，涂布量为4-12g/m2；步骤2，在固化后的辐射固化弹性附着底上涂布辐射固化实色中涂层，涂布量为8-20g/m2；步骤3，在固化后的辐射固化实色中涂层上数码打印10-40g/m2的LED-UV固化打印装饰层；步骤4，在固化后的LED-UV固化打印装饰层上涂布8-45g/m2的EB固化普通清漆层，户外使用则涂布15-50g/m2的EB固化户外清漆层，对隔热效果要求较高时，在LED-UV固化打印装饰层上涂布15-50g/m2的EB固化隔热反射清漆层。
7.根据权利要求6所述的一种辐射固化印花建筑彩钢板的制作工艺，其特征在于：所述经过化学处理的金属基板上与待涂覆面相反的一面涂布有辐射固化弹性底漆层或辐射固化背漆层。
8.根据权利要求6所述的一种辐射固化印花建筑彩钢板的制作工艺，其特征在于：所述EB固化的辐射剂量为20-150kGy，能量为100-300keV。
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