JP2001239609A - Method for preparing metal decorative sheet by transfer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for preparing a metal decorative sheet in which high level of design is possible and productivity is good in the method for preparing the metal decorative sheet which is used for a siding, etc. SOLUTION: After an embossing with an uneven pattern consisting of joint channel-like recessed parts and top face projected parts is performed by means of emboss rollers 1a and 1b, etc., on a metal base sheet 11, decoration is performed on the metal base sheet after embossing by transfer wherein a transfer sheet S is used and transfer pressure is provided thereon by a transfer roller 3 and in addition, a foamed resin layer is laminated on the opposite face side of the decorated face by means of a foamed resin lyer laminating apparatus 5, etc., to prepare the metal decorative sheet D. It may be possible that before the transfer pressure is applied, an adhesive is applied in advance on the metal base sheet by means of an adhesive applicator 2 and after transfer, a top coating layer is formed by coating by means of a top coat applicator 4, etc., The transfer decoration may be performed after the foamed resin layer is laminated. As the transfer pressure, solid particle collision pressure, etc., can be used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative metal plate used as metal siding or the like. In particular, the present invention relates to a method for manufacturing a decorative metal plate having high designability and excellent productivity.

[0002]

2. Description of the Related Art Conventionally, a metal decorative board made of a metal substrate has been used as a metal siding or the like. Also,
For example, in metal siding, the shape of the decorative metal plate is not a simple flat plate, but the design can be enhanced by forming a concave and convex surface at a portion or the like that is regarded as a joint groove. Like this,
As a method of manufacturing a metal decorative plate having an uneven surface, a decorative sheet obtained by performing pattern printing and embossing such as joint grooves on a resin sheet (see Japanese Patent Publication No. 58-14312) is attached to a metal substrate with an adhesive. However, in this case, the metal substrate remains a flat plate, it is impossible to emboss deeper than the thickness of the resin sheet laminated on its surface, and the design based on the unevenness is low. . Therefore, as a method of manufacturing a decorative metal plate in which a metal substrate itself is embossed, (1) a flat metal substrate is formed into a colored substrate which is colored by painting, and then the colored substrate is embossed to obtain a desired pattern. There was a method of forming unevenness. (2) Alternatively, after embossing the metal substrate, the convex portion excluding the concave portion such as the joint portion is selectively coated by a roll coating method or the like to be colored. That is, like the conventional metal decorative plate Da shown in the cross-sectional view of FIG.
A concave portion 21 and a convex portion 22 are formed by embossing, and the colored layer 19 is formed only on the convex portion 22 by coating. Note that the decorative metal plate Da of FIG. 2 also has a foamed resin layer 17 on the back side of the metal substrate 11. (3) Alternatively, as a method for producing a decorative metal plate having both a pattern and irregularities, as disclosed in Japanese Patent Application Laid-Open No. 9-60254, first, a brick is formed by transfer printing in a state where a metal substrate is flat. There has also been a method of forming a pattern pattern such as a key pattern, and then embossing a concave and convex pattern synchronized with the pattern pattern.

[0003]

However, in the manufacturing method of the above (1), the makeup can only be a design expression of only a single color with a uniform entire surface, and much less a pattern. In addition, the concave portion such as the joint portion and the other convex portions all have the same color, and the joint portion formed as the concave portion cannot be distinguished from the actual joint portion because of the difference in color. On the other hand, in the manufacturing method of the above (2), only a monochromatic design expression can be performed as in the case of (1), but the concave portion of the joint portion and the convex portion of the top surface are not made the same color and are different. It can be colored. Therefore, it is possible to emphasize the concave portion which looks like the joint portion by the difference in color. However, when the convex portion is applied, the colored coating liquid flows down to the concave portion, the coating liquid protrudes to the outer periphery of the convex portion, and bleeding (bleeding) E may occur as shown in FIG. As a result, the yield decreased and productivity was poor. In the manufacturing method (3), the positions of the picture pattern and the concavo-convex pattern are easily shifted due to thermal expansion of the metal substrate and deformation during embossing. In addition, since the metal substrate is hard, it applies tension to the base material to expand and contract the base material, as well as the transfer unit for the running base material, as in registering (synchronizing the pattern position) during multicolor printing of resin sheets. It is also difficult to correct the positional deviation by changing the path length between the head and the emboss unit.

Accordingly, an object of the present invention is to provide a method of manufacturing a decorative metal plate used as a metal siding or the like which has a high design and is excellent in productivity.

[0005]

In order to solve the above-mentioned problems, a method of manufacturing a decorative metal plate according to the present invention comprises embossing an uneven pattern formed of joint groove-shaped concave portions and a convex portion of a top surface on a metal substrate. After applying, painting is performed on the convex portion of the metal substrate after the embossing by transfer, and then a foamed resin layer is laminated on the opposite side of the transfer-painted surface of the metal substrate. did.

Alternatively, as a method for manufacturing a decorative metal plate according to the present invention, there is an embodiment in which the order of the steps of painting by transfer and laminating a foamed resin layer is reversed from the above method. That is, after the metal substrate is embossed with a concavo-convex pattern composed of joint groove-shaped concave portions and convex portions on the top surface, the non-transfer surface side of the metal substrate after the embossing is lined with a laminate of a foamed resin layer. After that, the projection on the metal substrate was painted by transfer.

As in any of the above methods, the metal substrate after embossing is painted by a transfer method,
Instead of a uniform monochromatic expression over the entire surface, a design expression using a picture becomes possible. In addition, since the uneven surface of the metal substrate that has been embossed in advance is painted by the transfer method, the top surface of the convex portion is located except for the concave portion serving as the joint portion among the unevenness formed by the embossing process. It is possible to paint reliably without misalignment (register misalignment). Therefore, the design feeling of the unevenness is higher due to the embossing process performed on the metal substrate, and the design feeling of the surface makeup is higher because the pattern can be expressed by painting by transfer. Then, the design feeling of these irregularities and the design feeling by painting make it possible to achieve a high design that was impossible in the past. In addition, since the painting is performed by the transfer method, there is no reduction in the yield due to bleeding of the colored coating solution protruding into the concave portions, which occurs when only the convex portions are coated and colored by the roll coating method or the like, and the production is excellent in productivity. Method. In addition, in the form in which the painting is performed after the lamination of the foamed resin layer, the deformation of the metal substrate due to the transfer pressure can be prevented by the foamed resin layer when the transfer pressure is large and the metal substrate is thin.

[0008] The method for producing a decorative metal plate of the present invention comprises:
In any of the above-described manufacturing methods, when performing painting by transfer, the collision pressure of solid particles is used as the transfer pressure. In this way, by using the solid particle collision pressure as the transfer pressure, complicated unevenness and deep fine unevenness that could not be transferred by the conventional roller transfer method using the transfer pressure by the elastic roller Even you can paint by transfer,
A more decorative metal decorative board can be manufactured.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a method for manufacturing a decorative metal plate according to the present invention will be described with reference to the drawings.

Overview: First, FIG. 1 is a conceptual diagram illustrating the method for manufacturing a decorative metal plate of the present invention in one embodiment. In the method shown in the figure, the metal substrate 11 is supplied in the form of a continuous strip, and the metal substrate 11 is first subjected to embossing by pressing the emboss rollers 1a and 1b. Groove-shaped concave portion 21 and convex portion 22 serving as a top surface
After forming a concavo-convex pattern consisting of the following, an adhesive for transfer is applied by an adhesive application device 2 such as roller coating to form an adhesive layer on at least the top surface of the metal substrate, and then transfer The transfer layer of the sheet S is transferred and painted by being pressed by the transfer roller 3 onto the convex portion 22 which is the top surface of the metal substrate after the embossing, and then the foamed resin layer laminating device 5 is used. Laminate a foamed resin layer. In the method illustrated in the figure, the metal sheet is further cut into sheets (sheets) by the cutting device 6 to obtain a metal decorative plate D. Further, in the method illustrated in the figure, the overcoat layer can be applied by the overcoating device 4 between the transfer painting and the foamed resin lamination, and further, the embossing rollers 1a and 1b and the adhesive coating device 2 In between, an accumulator is provided, and in embossing processing, the metal substrate is transported and processed by continuous feeding,
After the application of the adhesive such as transfer, overcoating, lamination of the foamed resin layer, and cutting, the metal substrate can be conveyed intermittently and processed in-line.

The adhesive coating and the overcoating performed by the method illustrated in FIG. 1 are appropriately performed as necessary, and may be omitted if unnecessary. The same applies to the accumulator. However, cutting by the cutting device 6 is normally performed. Alternatively, each of the steps may be performed off-line separately and independently, or in-line by connecting the preceding and following steps as appropriate.

Hereinafter, the method for producing a decorative metal plate by transfer of the present invention will be described in detail.

Metal substrate: The metal substrate 11 used is, for example, an aluminum alloy plate such as an aluminum plate or a duralumin plate, an iron or iron alloy plate such as a mild steel plate or a stainless steel plate, a copper plate, a brass plate, or the like. A metal substrate such as a titanium plate or a plate obtained by plating one or more of zinc, tin, lead, aluminum, copper, chromium, nickel and the like on them is used. The thickness of the substrate may be appropriately determined depending on the application, but is usually about 0.2 to 2 mm. In general, a metal substrate is used in the form of a continuous band as shown in FIG. 1 in terms of productivity, but a metal substrate cut into sheets (sheets) may be used after the first embossing. As a specific example of the metal substrate, for example, an aluminum plate having a thickness of 1 mm is used in a continuous band shape, and finally cut into a single-leaf metal decorative plate.

The metal substrate 11 may be provided with a resin layer on the painted surface side, the non-painted surface side, or both the front and back surfaces, as necessary, prior to the transfer processing. This resin layer is provided for surface protection such as corrosion prevention of the metal substrate, and for improving adhesion of the transfer layer at the time of transfer. The resin layer is provided by fusing the resin sheet by itself or bonding with an adhesive, or applying a coating liquid containing a resin. The resin layer is usually provided before embossing, but may be provided after embossing, particularly when the resin layer is formed by coating. As the resin of the resin layer, for example, a polyester resin, an acrylic resin, a vinyl chloride resin, a polyolefin resin, or the like is used as one type or a mixture of two or more types. Further, as an adhesive for bonding the resin sheet, for example, a urethane resin, an epoxy resin, a polyolefin-based resin, or the like may be used according to the resin of the resin layer.

Embossing: In the embodiment shown in FIG. 1, the embossing is performed by a rotary embossing method, and the metal substrate 11 is pressed by the embossing rollers 1a and 1b from the front and back to form an uneven pattern on the metal substrate itself. . As the embossing rollers 1a and 1b, rollers whose surface irregularities are of a male type and a female type are used. Both the emboss rollers 1a and 1b are made of metal such as iron or iron alloy. The embossing rollers 1a and 1b are preferably made of metal and hard, but have durability,
As long as the mechanical strength and the like are satisfied, ceramics can be used. The embossing may be performed by a known processing method such as a flat press embossing method.

The concavo-convex pattern formed on the metal substrate by embossing is basically arbitrary and is not particularly limited. For example,
For example, siding, brickwork, uneven pattern of joint groove by siding, etc., uneven pattern of spray painting surface such as stucco, lysine, etc. An uneven pattern, a leather squeeze, a texture, a character, a geometric pattern, or the like. In particular, in the production method of the present invention, unlike a metal decorative board in a form in which an embossed decorative sheet made of a resin sheet is laminated on a metal substrate, the unevenness due to embossing is also possible because deeper unevenness is possible. The design feeling can be higher. However, as a preferred specific example of the uneven pattern in the present invention, in the case of the decorative metal plate D illustrated in the cross-sectional view of FIG. 3, the concave portion 21 is a joint groove such as metal siding. For example, the joint groove has a joint width of 7 mm and a joint depth of about 2 mm. As a plan view shape of the joint groove-shaped concave portion,
FIG. 5 (A) shows a parallel line running in one direction.
As shown in FIG. 3B, the one running in two vertical and horizontal directions is typical. The shape shown in FIG. 5A reproduces the appearance of a siding panel, and the shape shown in FIG. 5B reproduces the appearance of brickwork or tiled. In addition,
When the joint groove or the like is provided, the convex portion 22 other than the joint groove becomes the top surface, and the convex portion 22 further has an uneven pattern such as stucco-like, ricin-like, etc. of the spray-painted surface as shown in FIG. Fine irregularities 23 such as a stone-like irregular pattern such as a granite cleavage plane and a wood-like irregular pattern such as a conduit groove may be provided.

Painting by transfer: In the painting process by transfer processing, usually, the transfer layer is transferred from the transfer sheet S onto the convex portion 22 of the metal substrate 11 after embossing. In the embodiment illustrated in FIG. 1, the transfer processing is performed by a roller transfer method using an elastic roller. Of course, a transfer method (a method of applying a transfer pressure) may be a method other than the roller transfer method, and is not particularly limited. The transfer method will be described later according to the concavo-convex shape of the metal substrate and the shapes of the transfer region and the non-transfer region of the metal substrate. A known method such as that described above may be appropriately employed. The transfer process may be performed in the state of the embossed metal substrate 11 alone, as shown in FIG. 2. In particular, when the metal substrate is thin or when the transfer pressure at the time of transfer is large, the transfer process is performed. In order to prevent deformation of the metal substrate, as shown in FIG. 6, a backing material such as a foamed resin layer 17 is preliminarily laminated on the back surface side (non-transfer surface side) of the metal substrate 11 and then subjected to transfer processing or a backing material. Is not used, a mounting table B (shown in FIG. 6) made of a material (carbon steel or the like) having a shape capable of fitting with the back surface of the embossed metal substrate 11 and having a rigidity that is not deformed by the transfer pressure. It is preferable that the embossed metal substrate 11 is placed on the metal substrate 11 and transfer pressure is applied in a state where the metal substrate 11 is fitted. Incidentally, in the transfer, as in the case of sublimation transfer, the entire transfer layer is
There is also a transfer in which only a transfer transfer substance such as a sublimable dye in the transfer layer transfers to the metal substrate side without transferring to the metal substrate side.

[Transfer Method] The cross-sectional view of FIG. 2 is a conceptual diagram conceptually showing how the roller transfer method is used to selectively transfer only to the convex portions particularly during transfer. That is, the transfer layer 13 is not transferred from the transfer sheet S including the support sheet 12 and the transfer layer 13 to the recess 21 serving as the non-transfer area by the transfer pressure generated by pressing the transfer roller 3. FIG. 4 is a view showing a state in which a transfer layer 13 is brought into contact with only a convex portion 22 to be transferred selectively. Note that, in the case of FIG.
An adhesive is applied in advance by roller coating or the like so that the adhesive layer 15
Is selectively formed, and the transfer layer 13 is adhered to the metal substrate 11 by heat-sealing the adhesive layer 15 or the like, so that the transfer layer 13 is selectively transferred only to the protrusions 22.

[Transfer Sheet] The transfer sheet S to be used is not particularly limited, and any known transfer sheet may be used depending on the application.

For example, the support sheet 12 of the transfer sheet S
For this, a sheet having releasability from the transfer layer 13 is used. Examples of such a support sheet include a resin sheet, paper, and metal foil. Above all, a resin sheet is typical. Further, the resin sheet can be used as a support sheet which can sufficiently impart moldability to the transfer sheet even when the transfer is performed while forming the transfer sheet using the solid particle collision pressure as the transfer pressure. As the resin sheet, for example, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, ethylene-isophthalate-terephthalate copolymer, thermoplastic polyester such as polyester-based thermoplastic elastomer, polypropylene, polyethylene, ethylene-propylene copolymer A single layer or a laminate of a resin such as a coalesced resin, a polyolefin resin such as an olefin thermoplastic elastomer, a polyamide resin such as nylon, or a vinyl chloride resin is used. The thickness of the support sheet is not particularly limited, but is usually about 20 to 100 μm. A specific example of the support sheet is a polyethylene terephthalate film having a thickness of 25 μm. Also, in consideration of environmental issues and the like, a polyolefin resin sheet (having a thickness of, for example, 100 μm) or the like is also suitable.

In the case where the above-mentioned resin sheet or paper does not have sufficient releasability from the transfer layer, a support sheet having a release layer on the transfer layer side may be used. As the release layer, for example, a coating material formed by adding a release agent such as a fluorine-based resin, wax, or silicone to a known vehicle made of an acrylic resin, a cellulose-based resin, a vinyl-based resin, or the like, is formed. , A resin such as a fluororesin, a silicone, a melamine resin, a polyolefin resin, an ionizing radiation crosslinkable polyfunctional acrylate, a polyester resin, an epoxy resin, or the like, or a melt extrusion coating. What is formed by coating may be used. The release layer is a component of the support sheet, and is separated from the transfer layer as a part of the support sheet when the support sheet is separated.

On the other hand, the transfer layer 13 is a layer provided with a decorative layer for expressing a pattern, an adhesive layer, a peeling layer, and other functional layers for imparting functionality.

For example, the decorative layer may be formed by a conventionally known method such as gravure printing, silk screen printing, offset printing, gravure offset printing, ink jet printing, a pattern layer obtained by printing a pattern with a material, aluminum, chrome,
A metal thin film layer or the like in which a metal such as gold, silver or the like is partially or entirely formed by using a known vapor deposition method or the like. The pattern is, for example, a wood pattern, a stone pattern, a squeezed pattern, a cloth pattern, a tiled pattern, a brick laminated pattern, a character, a geometric pattern, an abstract pattern, a solid pattern, or the like.

The ink for the picture layer is composed of a vehicle made of a resin binder and the like, a coloring agent such as a pigment and a dye, and various additives appropriately added thereto. A simple substance such as a vinyl chloride-vinyl acetate copolymer, a polyester resin, a cellulose resin, a urethane resin, or the like, or a mixture thereof is used. Examples of the colorant include inorganic pigments such as titanium white, carbon black, red iron oxide, graphite, and ultramarine blue; organic pigments such as aniline black, quinacridone yellow, isoindolinone red, and phthalocyanine blue; aluminum foil powder; and titanium dioxide coating. Glitter pigments such as mica foil powder or other dyes are used.

As the transfer layer, a release layer is brought into contact with the support sheet in order to adjust the releasability between the support sheet and the transfer layer, to protect the surface of the transfer layer after transfer and to improve the post-coating suitability. It may be provided as a layer. For the release layer, for example, a resin or the like used as a binder of the picture layer ink is used. Note that this release layer is a component of the transfer layer, and the transfer layer usually transfers to the metal substrate as a part of the transfer layer during transfer.

The functional layer is an antibacterial layer, an antifungal layer, a conductive layer, or the like. For example, the antibacterial layer is a layer in which a known antibacterial agent such as zeolite powder carrying silver ions is contained in a binder resin.

Here, as a specific example of the transfer layer, when the support sheet is a polyethylene terephthalate resin sheet, an acrylic resin and a vinyl chloride-vinyl acetate copolymer may be used as a release layer made of an acrylic resin and a binder resin. And a combination of a pattern layer (a pattern pattern layer and a concealing layer) using a mixture having a mass ratio of 8: 2.

[Adhesive] The adhesive is applied as an adhesive layer constituting the transfer layer of the transfer sheet or as an adhesive layer on the metal substrate, if necessary. For example, in the embodiment illustrated in FIG. 1, the coating is performed on the metal substrate side. Thus, the adhesive layer on the transfer layer side can be omitted. On the other hand, the adhesive layer in the transfer layer is provided when the transfer layer adheres to the metal substrate and is difficult to transfer without the adhesive layer. Therefore, when the adhesive layer is provided on the metal substrate side, or when the layer (decoration layer or the like) which is the rearmost surface of the transfer layer has the function of the adhesive layer, the adhesive layer as the transfer layer is omitted. Can also. In FIG. 1,
Although the example in which the adhesive is applied in-line by the adhesive coating device 2 immediately before the transfer pressure application is performed, the transfer pressure application and the adhesive application may be performed as an off-line process. The adhesive to be used may be appropriately selected depending on the application, required physical properties, and the like.

As described with reference to FIG. 2, the surface on which the adhesive is to be applied is selectively applied only to the convex portions 22 excluding the concave portions 21 of the metal substrate. Can be selectively transferred to Note that such selective transfer can also be performed without forming an adhesive layer on the metal substrate side in advance and using a transfer sheet on which an adhesive layer is formed as a transfer layer. However, in this case, depending on the transfer conditions such as the uneven shape of the metal substrate, the method of applying the transfer pressure, the strength of the transfer pressure, and the formability of the transfer sheet, when the transfer sheet enters the recess by the transfer pressure, When the transfer sheet comes into contact with the side surface from the convex portion to the concave portion, the transfer layer may be transferred to the transfer sheet. Therefore, it is preferable to appropriately use the adhesive layer formation target depending on the uneven shape and the transfer conditions.

As the adhesive to be used, a conventionally known resin may be used depending on the application. For example, thermoplastic urethane resin, thermoplastic polyester resin, polyamide resin,
Acrylic resin, thermoplastic resin such as vinyl chloride-vinyl acetate copolymer, thermosetting resin such as thermosetting urethane resin, melamine resin, epoxy resin, one-component curable resin such as moisture-curable urethane resin, or An adhesive made of a rubber-based or acrylic-based pressure-sensitive adhesive is used. The adhesive may be formed by applying a coating liquid (or ink) of the adhesive made of the above resin or the like by a known coating method (or printing method) such as roll coating. In order to form the metal substrate with deep irregularities over the entire irregular surface, a coating method such as spray coating, curtain coating, roll coating using a soft rubber roll, a sponge roll, or the like is preferable. The thickness of the adhesive layer is usually 1 to 100 μm
It is about. For example, a moisture-curable urethane resin adhesive is roll-coated to form an adhesive layer (at the time of drying) having a thickness of about 40 μm.

[Method of Applying Transfer Pressure: Transfer Method] The method of applying the transfer pressure is not particularly limited. For example, the following method may be used depending on the shape of the metal substrate and the transfer area, the application, and the like. A conventionally known transfer method may be adopted.

(1) Roller transfer method: This is the transfer method illustrated in FIG. The roller transfer method is described in, for example,
As described in JP-A-99550 and JP-A-8-286599, a conventional transfer method is used. In the roller transfer method, an elastic roller is usually used as a transfer roller. As the elastic roller, a roller in which the periphery of a rigid shaft made of iron or the like is covered with an elastic body is usually used. As the elastic body, silicone rubber, fluorine rubber, viton rubber, butadiene rubber, natural rubber or the like is used. The rubber hardness of the elastic roller is preferably set to 65 ° or less in order for the transfer sheet to follow the concave portion of the fine uneven pattern 23 formed on the convex portion of the top surface which is the transfer surface. The diameter of the elastic roller is usually about 5 to 20 cm. In addition, the elastic roller is usually heated by a heating source such as an internal electric heater or an external infrared radiation heater and used as a heating roller.

(2) Transfer method using solid particle collision pressure: Japanese Patent No. 2844424, Japanese Patent Laid-Open No. 10-193
No. 893 and the like. That is, as shown in FIG. 6, the transfer layer side of the transfer sheet S composed of the support sheet 12 and the transfer layer 13 is opposed to the transfer surface side of the transfer object (metal substrate 11). A large number of solid particles P collide against the sheet side, and the pressure of the collision is used to press the transfer sheet against the transfer surface of the transfer object. When the transfer layer is transferred to the transfer object side for transfer, the transfer sheet is adhered to the transfer object, and then the support sheet of the transfer sheet is peeled off to complete the transfer. This transfer method is particularly suitable when transferring to the surface of a complicated or deep fine uneven pattern 23 that cannot be performed by a roller transfer method or the like. As the solid particles P, nonmetallic inorganic particles such as ceramic beads and glass beads, metal particles such as zinc and iron, and organic particles such as resin beads such as nylon beads and crosslinked rubber beads are used. Particle size is usually 10-100
It is about 0 μm. The solid particles are ejected from the ejector toward the transfer sheet, and the collision pressure that collides with the transfer sheet becomes the transfer pressure. Typically, an impeller or a blowing nozzle is used for the ejector. The impeller accelerates the solid particles by its rotation, and the blowing nozzle accelerates the solid particles with a high-speed fluid flow.
Sandblasting, shot blasting, shot peening and the like used in the blasting field can be used for the impeller and the blowing nozzle. For example, a centrifugal blast device is used for the impeller, and a pressurized or suction blast device, a wet blast device, or the like is used for the blowing nozzle. The centrifugal blast device accelerates and ejects solid particles by the rotational force of the impeller. A pressurized blasting device ejects solid particles together with air while being mixed with compressed air. The suction-type blast device sucks solid particles into a negative pressure portion generated by a high-speed flow of compressed air, and ejects the solid particles together with the air. Wet blasting equipment
The solid particles are mixed with the liquid and ejected.

(3) Wrapping transfer method: JP-B-61-
As described in Japanese Patent Application Laid-Open No. 5895, JP-A-5-330013, etc., a transfer sheet is supplied in the major axis direction of a transfer target (metal substrate) having a columnar transfer surface such as a cylinder or a polygonal column. A transfer method using a so-called lapping method, in which a transfer sheet is transferred by pressing and bonding a transfer sheet to a plurality of side surfaces constituting a transfer object sequentially by a plurality of rollers having different directions. In this method, before or after the embossing, the flat metal substrate is bent into a column shape. The bending may be performed by a known processing method.

(4) Transfer method by vacuum forming: JP-B-56-4
No. 5768 (overlay method), Japanese Patent Publication No. 60-58
No. 014 (vacuum press method) and the like,
A transfer sheet is opposed or placed on a transfer object (metal substrate) having an uneven transfer surface, and a transfer layer of the transfer sheet is transferred to a base material by a pressure difference caused by vacuum suction from at least the transfer object side. Transfer method using vacuum forming lamination method. Since this method is performed in a decompression chamber and is a batch-type processing, the metal substrate is cut into a single sheet at least when the transfer pressure is increased. For example, it is cut after embossing.

[Cooperation between embossing and transfer processing] In addition, embossing and painting by transfer processing may be performed inline as a continuous process as shown in FIG. May be separated and performed offline.

Backside treatment step (lamination of foamed resin layer, etc.): As the backside treatment step, for example, a foamed resin layer or a glass fiber nonwoven fabric may be laminated as a backing material. In the present invention, at least the lamination of the foamed resin layer is performed. For example, on a metal decorative plate on which embossing and transfer painting have been completed, a foamed resin liquid is further applied to the metal substrate 11 side, which is the back side of the metal decorative plate, and the coated resin is further coated. When the liquid is in an unfoamed state, a glass fiber non-woven fabric is further laminated thereon as a backing paper.
After laminating with a roller or the like, the mixture is heated and foamed, and the foamed resin liquid is converted into a foamed resin layer. For example, in the case of the example shown in FIG. 1, in the back surface treatment, after the top coat is applied, the foamed resin layer is laminated by, for example, applying the foamed resin layer laminating apparatus 5 before cutting. When performed before cutting in this way, when the metal substrate after the top coat is in a continuous band shape, after rotating the metal substrate so that the transport direction of the metal substrate is in the opposite direction and turning the metal substrate upside down, Apply the foamed resin liquid to the upper side, which is the back side. Of course, it may be turned over after cutting. Further, after the back surface treatment, a top coat may be applied. The foamed resin layer laminating apparatus 5
For example, after applying a foamed resin liquid by a coating method such as roll coating or curtain flow coating, the foamed resin is heated and foamed in a heating furnace.

Incidentally, the decorative metal plate D illustrated in the cross-sectional view of FIG. 3 is an example in which a glass fiber nonwoven fabric is further laminated in addition to the lamination of the foamed resin layer as the back surface treatment. That is, the transfer layer 13 for painting on the metal substrate 11 is laminated only on the convex portion 22 via the adhesive layer 15 excluding the concave portion 21. Further, on the back side of the metal substrate 11, Foam resin layer 1
7 and a glass fiber nonwoven fabric 18 are laminated in this order.

The foamed resin layer 17 is provided to impart heat insulation and sound insulation to the decorative metal plate, and to prevent corrosion from the back surface of the metal substrate. Also, as mentioned above,
It may be provided for the purpose of preventing deformation of the metal substrate due to transfer pressure. As the foamed resin layer, a known polyurethane foam or the like can be used. Examples of the polyurethane foam include, for example, hard urethane which is cured and foamed by applying a foamed resin solution using a tolylene diisocyanate as a curing agent to a polyether polyol as a main component, and further using a foaming agent of a low boiling point solvent. A form or the like may be used. The thickness of the foamed resin layer is not particularly limited, but is not less than the degree that the back side of the embossed irregularities is flattened.

Further, the glass fiber nonwoven fabric 18 is
7 is provided for the purpose of covering and protecting the surface. The thickness of the glass fiber non-woven fabric is not particularly limited.
A nonwoven fabric of about g / m ² is used. As the backing paper, in addition to the glass fiber nonwoven fabric, a resin fiber nonwoven fabric of polyester or the like, paper, a resin sheet, or the like may be used. In the case of using a polyurethane foam which is cured and foamed after coating as described above, the backing paper is preferably laminated before curing and foaming to achieve good adhesion.

Other Steps : The method for producing a decorative metal plate by transfer of the present invention is a production method including at least the embossing process, the painting process by the transfer process, and the laminating process of the foamed resin layer. Other steps may be performed as necessary, such as performing the following surface treatment step and bending step.

[Surface Treatment Step] As a surface treatment step, an overcoat layer 16 (see FIG. 3) such as a transparent protective layer is formed on the surface of the transfer layer after the transfer by an overcoat device 4 or the like as illustrated in FIG. Is also good. The overcoat layer is provided to impart durability such as abrasion resistance, abrasion resistance, and weather resistance and a design feeling such as matting. Such an overcoat layer may be a layer according to use and required physical properties. For the overcoat layer, besides thermoplastic resins such as fluororesin and acrylic resin, curing of polyester resin, curable urethane resin, silicone resin, curable acrylic resin, ionizing radiation curable resin cured by ultraviolet rays or electron beams, etc. It is preferable to use a conductive resin or the like. The overcoat layer is made of one of these resins.
A coating liquid (or ink) having one or more kinds and optionally containing other additives may be formed by a known coating method or the like. In addition, as an additive, benzotriazole, an ultraviolet absorber such as ultrafine cerium oxide, a light stabilizer such as a hindered amine radical scavenger, abrasion comprising particles such as silica, spherical α-alumina, and flaky α-alumina. Agents, lubricants such as wax, coloring pigments, extender pigments and the like are used.
Coating may be performed by a known method such as spray coating, curtain coating, roll coating using a soft rubber roll, sponge roll, or the like, depending on the surface unevenness or the like. The thickness of the overcoat layer is about 1 to 100 μm. For example, a two-component curing type thermosetting urethane resin having a thickness of 10 μm
m may be spray-coated. The overcoat layer 16 may be formed on the entire surface of the metal substrate 11 including the concave portion 21 and the convex portion 22 as shown in FIG. 3, or only on the convex portion 22 (not shown).
May be formed.

[Bending process] As the bending process, for example, there is a process of bending the outer peripheral side surface of the metal substrate to the back side. In particular, when the above-mentioned foamed resin layer is provided, a weir for receiving the foamed resin liquid can be formed by this bending process. In addition, when a decorative metal plate is applied to an outer wall or the like by a bending process, it is also possible to form a joint (e.g., tenon, sane, etc.) for fitting the decorative metal plates together. The outer periphery to be bent by the bending process is usually two opposing sides (in the case of a continuous band, both sides in the width direction), but may be one or more arbitrary sides or the entire outer periphery. Note that the bending may be performed by a known method such as stepwise bending with a plurality of rollers. The right end portion of the decorative metal plate D in FIG. 3 is an example of a bent portion.

Use of the decorative metal plate: The use of the decorative metal plate obtained by the production method of the present invention is not particularly limited, and for example, it is used for interior materials of buildings such as walls and ceilings, siding materials, roof materials and the like. It is used for exterior materials of buildings, interior materials of vehicles such as cars, trains, ships, aircrafts, etc., fittings such as doors, window frames, door frames, building members such as skirting boards, rims, and partitions.

[0045]

According to the method for manufacturing a decorative metal plate of the present invention, a decorative metal plate having a high design can be obtained, and the productivity is excellent. That is, since the emboss is formed on the metal substrate, the design feeling due to the unevenness becomes deeper than the case where the embossed decorative sheet is laminated, and the design becomes high. In addition, since the decorative method for the metal substrate is such that embossing and painting are performed by the transfer method, it is possible to express a high-quality design using a picture instead of a uniform monochromatic expression over the entire surface. In addition, since the painting method is a transfer method, it is possible to paint only the convex portions, excluding the concave portions such as joints, of the irregularities formed by embossing. Therefore,
The sense of design by embossing the metal substrate itself and the sense of design by painting during transfer enable a high design that was not possible in the past. In addition, since the painting is performed by the transfer method, there is no reduction in the yield due to bleeding of the colored coating solution protruding into the concave portions, which occurs when only the convex portions are coated and colored by the roll coating method or the like, and the production is excellent in productivity. Method. In addition, in the form in which the painting is performed after the lamination of the foamed resin layer, the deformation of the metal substrate due to the transfer pressure can be prevented by the foamed resin layer when the transfer pressure is large and the metal substrate is thin. In addition, if solid particle collision pressure is used as the transfer pressure at the time of painting, complex irregularities and deep fine irregularities that could not be transferred by the conventional roller transfer method using the transfer pressure by the elastic roller are used. On the other hand, painting can be performed by transfer, and a decorative metal plate of higher design can be manufactured.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram illustrating a method for manufacturing a decorative metal plate of the present invention in one embodiment.

FIG. 2 is a conceptual diagram showing, in one embodiment, a painting step by transfer in the manufacturing method of the present invention.

FIG. 3 is a cross-sectional view showing one example of a decorative metal plate obtained by the present invention.

FIG. 4 is a cross-sectional view showing an example of a decorative metal plate obtained by a conventional manufacturing method and a defect thereof.

FIG. 5 is a plan view illustrating some of the joint-view groove-shaped concave portions in plan view.

FIG. 6 is a cross-sectional view conceptually showing a transfer method using a solid particle collision pressure and a measure for preventing deformation of a metal substrate by the transfer pressure.

[Explanation of symbols]

 1a Emboss Roller 1b Emboss Roller 2 Adhesive Coating Device 3 Transfer Roller 4 Top Coating Device 5 Foam Resin Layer Laminating Device 6 Cutting Device 11 Metal Substrate 12 Supporting Sheet 13 Transfer Layer (Picture Layer etc.) 15 Adhesive Layer 16 Top Coating Layer 17 Foamed resin layer 18 Glass fiber nonwoven fabric 19 Colored layer 21 Concave portion 22 Convex portion 23 Fine uneven pattern B Table D Metal decorative board Da Conventional metal decorative board E Nijimi (bleeding)

Claims (3)

[Claims] In a method of manufacturing a decorative metal plate, after embossing an uneven pattern formed of joint groove-shaped concave portions and convex portions of a top surface on a metal substrate, the metal substrate after the embossing is transferred by transfer. A method of transferring a decorative metal plate, in which painting is performed on the convex portion, and thereafter, a foamed resin layer is laminated on the opposite side of the transfer-painted surface of the metal substrate. 2. A method for manufacturing a decorative metal plate, comprising: embossing a metal substrate with a concavo-convex pattern including joint groove-shaped concave portions and convex portions on a top surface, and then performing non-transfer of the metal substrate after the embossing process. A method of transferring a decorative metal plate, in which the surface side is backed by laminating a foamed resin layer, and thereafter, the convex portion of the metal substrate is painted by transfer. 3. The method of transferring a decorative metal plate according to claim 1, wherein the transfer pressure is determined by using the collision pressure of solid particles as the transfer pressure.