JP2004052270A

JP2004052270A - Joint design resin film, metallic plate covered with joint design resin film, and method of manufacturing them

Info

Publication number: JP2004052270A
Application number: JP2002208010A
Authority: JP
Inventors: Tokuaki Kakuma; 加隈　徳昭; Motohiro Tomomori; 友森　基裕; Koji Taguma; 田熊　幸治; Masanori Tanigami; 谷上　雅則; Takushi Nakamura; 中村　琢司
Original assignee: Toyo Kohan Co Ltd
Current assignee: Toyo Kohan Co Ltd
Priority date: 2002-07-17
Filing date: 2002-07-17
Publication date: 2004-02-19

Abstract

<P>PROBLEM TO BE SOLVED: To provide a joint design resin film superior in design, moisture resistance, durability and pollution resistance, a joint design resin film-covered metallic plate, and a manufacturing method therefor. <P>SOLUTION: This resin film is laminated on a metallic plate by forming a groove-shaped recessed part 7 and a bank-shaped projecting part 8 on both sides of the groove-shaped recessed part 7 on either surface of a double layer resin film for laminating a colored monolayer resin film 2 or a transparent resin film 4 for applying printing on a colored resin film or a colored resin film having an adhesive resin film on a lower layer, and is formed as the joint design resin film-covered metallic plate 10. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、表面に目地状の三次元的なデザインを付与した目地デザイン樹脂フィルム、それを金属板に積層した目地デザイン樹脂フィルム被覆金属板、およびそれらの製造方法に関する。
【０００２】
【従来の技術】
浴室、洗面所、トイレ、厨房など、建物のいわゆる水回りの部分は、耐水性を有するタイルをセメントや漆喰等を用いて貼り付けて壁、天井、あるいは床としていた。近年、特に集合住宅を中心として、これらの水回りの部分がユニット化され、壁材、天井材として、安価でかつ作業性に優れていることから、塩化ビニル樹脂フィルムなどの樹脂フィルムを鋼板などの金属板に積層して被覆した樹脂被覆金属板が用いられるようになってきている。しかし、これらの樹脂被覆金属板は平板状のまま用いられることが多く、三角形、四角形、六角形、八角形、円などの幾何学模様や、石材の断面を模した非幾何学模様などの目地部の模様や凹凸のあるタイルの壁や天井に比べて意匠性に乏しい。
【０００３】
【発明が解決しようとする課題】
本発明は、安価でかつ作業性に優れ、かつ意匠性、耐湿性、耐久性、耐汚染性にも優れた目地デザイン樹脂フィルム、目地デザイン樹脂フィルムを被覆してなる目地デザイン樹脂フィルム被覆金属板、およびそれらの製造方法を提供することを目的とする。
【０００４】
【課題を解決するための手段】
上記した問題を解決するために、本発明の目地デザイン樹脂フィルムは、
樹脂フィルムの表面に、溝状の凹部と、溝状凹部の両側に土手状の凸部が形成されてなることを特徴とし、また
溝状凹部の深さが２〜７０μｍであること、
土手状の凸部の高さが２〜７０μｍであること、
溝状凹部に有色の塗装が施されてなることを特徴とし、
さらに上記樹脂フィルムが
着色顔料を含有する有色樹脂フィルム、または、
着色顔料を含有する有色樹脂フィルムと透明樹脂フィルムとが積層されてなる複層樹脂フィルムであること、もしくは
着色顔料を含有する有色樹脂フィルムと片面に有色樹脂フィルムとは異なる色の印刷が施されてなる透明樹脂フィルムとが、印刷層が接するようにして積層されてなる複層樹脂フィルムであることを特徴とし、さらにまた
上記の有色樹脂フィルムが、着色顔料を含有するＰＢＴ、または上層の着色顔料を含有させてなるＰＢＴと下層のＥＴ／ＥＩの複層樹脂であることを特徴とし、またさらに
上記透明樹脂フィルムが、ＰＢＴまたはＰＥＴからなることを特徴とする。
【０００５】
また、本発明の目地デザイン樹脂フィルム被覆金属板は、上記のいずれかの目地デザイン樹脂フィルムを金属板に積層してなることを特徴とし、また
目地デザイン樹脂フィルムと金属板の間に接着剤を介在させて積層してなることを特徴とし、さらに
金属板が亜鉛の溶融めっき鋼板または９５％亜鉛−５％アルミニウム合金の溶融めっき鋼板であることを特徴とする。
【０００６】
さらに、本発明の目地デザイン樹脂フィルムの製造方法は、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成した後、溝状凹部内に有色の塗装を施すことを特徴とする。
【０００７】
さらに、本発明の目地デザイン樹脂フィルムの被覆金属板の製造方法は、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成し、溝状凹部内に有色の塗装を施してなる目地デザイン樹脂フィルムを、金属板に圧接して積層すること、または
金属板に接着剤を塗布し、接着剤塗布面に目地デザイン樹脂フィルムを当接して圧接して積層すること、または
金属板に接着剤を塗布し、接着剤塗布面に樹脂フィルムを当接して圧接して積層した後、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成し、溝状凹部内に有色の塗装を施すことを特徴とする。
【０００８】
【発明の実施の形態】
本発明の発明者等は、安価でかつ作業性に優れ、かつ意匠性、耐湿性、耐久性、耐汚染性にも優れた目地デザイン樹脂フィルム被覆金属板を鋭意検討した結果、金属板に被覆する前または後に、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧して、溝状の凹部と溝状凹部の両側に土手状の凸部を形成した目地デザインを設けることにより、目的とする目地デザイン樹脂フィルム被覆金属板が得られることを見出した。
すなわち、本発明によれば、有色の単層樹脂フィルム、または有色樹脂フィルム上もしくは下層に接着樹脂フィルムを有する有色樹脂フィルム上に印刷を施した透明樹脂フィルムを積層した複層樹脂フィルムのいずれかの表面に、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成した樹脂フィルムを金属板上に積層しているため、樹脂フィルム表面に形成した溝状の凹部と、溝状凹部の両側に土手状の凸部からなる目地部が明確でしかも立体感のある意匠効果が得られるとともに、耐湿性や耐久性、耐汚染性に優れた化粧金属板を提供することができ、さらにこの樹脂フィルム被覆金属板を安価にしかも優れた作業性によって提供できるものである。
以下、図面を参照しながら本発明を詳細に説明する。
【０００９】
図１、図２、および図３は、それぞれ本発明の目地デザイン樹脂フィルム被覆金属板の一例を示す概略断面図、図４は、本発明の目地デザイン樹脂フィルムの表面に形成した溝状の凹部と、溝状凹部の両側の土手状の凸部の一例を拡大して示す概略断面図である。本発明の目地デザイン樹脂フィルム被覆金属板１０は、図１に示すように、表面に溝状の凹部７とその両側に土手状の凸部８を形成させた着色顔料を含有する有色樹脂フィルム２を接着剤３を介してまたは介さずに直接積層し、溝状の凹部７内に有色の塗装９を施してなるか、または、図２に示すように、着色顔料を含有する有色樹脂フィルム２の上に、片面に接着剤としての機能も有する印刷層５を設け、他の片面に溝状の凹部７とその両側に土手状の凸部８を形成させた透明樹脂フィルム４を、印刷層５が有色樹脂フィルム２と接するようにして積層してなる複層樹脂フィルムを、接着剤３を介してまたは介さずに直接積層し、溝状の凹部７内に有色の塗装９を施してなるか、もしくは、図３に示すように、上層の着色顔料を含有する有色樹脂フィルム２と下層の接着樹脂フィルム６からなる複層樹脂フィルムの有色樹脂フィルム２の上に、片面に接着剤としての機能も有する印刷層５を設け他の片面に溝状の凹部７とその両側に土手状の凸部８を形成させた透明樹脂フィルム４を、印刷層５が有色樹脂フィルム２と接するようにして積層してなる複層樹脂フィルムを、接着剤３を介してまたは介さずに直接積層し、溝状の凹部７内に有色の塗装９を施してなる、いずれかの構成である。
【００１０】
本発明の目地デザイン樹脂フィルムを構成する、有色樹脂フィルム２、透明樹脂フィルム１、有色樹脂フィルム２の下層の接着樹脂フィルム６に用いる樹脂としては、ポリエステル樹脂であることが好ましい。ポリエステル樹脂としては、テレフタル酸、イソフタル酸、オルトフタル酸、２，５−ナフタレンジカルボン酸、２，６−ナフタレンジカルボン酸、１，４−ナフタレンジカルボン酸、１，５−ナフタレンジカルボン酸、ジフェニルカルボン酸、ジフェノキシエタンジカルボン酸、ジフェニルスルホンカルボン酸、アントラセンジカルボン酸、１，３−シクロペンタンジカルボン酸、１，３−シクロヘキサンジカルボン酸、１，４−シクロヘキサンジカルボン酸、ヘキサヒドロテレフタル酸、ヘキサヒドロイソフタル酸、マロン酸、ジメチルマロン酸、コハク酸、３，３−ジエチルコハク酸、グルタル酸、２，２−ジメチルグルタル酸、アジピン酸、２−メチルアジピン酸、トリメチルアジピン酸、ピメリン酸、アゼライン酸、ダイマー酸、セバシン酸、スベリン酸、ドデカジカルボン酸などのジカルボン酸と、エチレングリコール、プロピレングリコール、ヘキサメチレングリコール、ネオペンチルグリコール、１，２−シクロヘキサンジメタノール、１，４−シクロヘキサンジメタノール、デカメチレングリコール、１，３−プロパンジオール、１，４−ブタンジオール、１，５−ペンタンジオール、１，６−ヘキサジオール、２，２−ビス（４’−ヒドロキシフェニル）プロパン、ビス（４−ヒドロキシフェニル）スルホンなどのジオールを、それぞれ１種を重縮合してなるホモポリマー、またはジカルボン酸１種以上とジオール２種以上を重縮合してなる共重合体、あるいはジカルボン酸２種以上とジオールを１種以上を重縮合してなる共重合体、およびこれらのホモポリマーや共重合体を２種以上ブレンドしてなるブレンド樹脂のいずれかのポリエステル樹脂を挙げることができる。
【００１１】
有色樹脂フィルム２に用いるポリエステル樹脂としては、目地デザイン樹脂フィルム被覆金属板としての耐湿性、耐久性、および目地デザイン樹脂フィルムの最表面に設ける溝状の凹部７とその両側の土手状の凸部８を形成しやすくさせる観点から選択する。これらの観点から、有色樹脂フィルム２に用いるポリエステル樹脂として、結晶性の高いＰＢＴを用いることが好ましい。押出機を用いて樹脂フィルムに製膜する際に着色顔料を混練して有色樹脂フィルム２とする。着色する色としては、着色顔料として二酸化チタン、カーボンブラック、チタンイエロー、ベンガラ、群青、コバルトブルーなどの無機顔料やキナクリドンなどの有機顔料、あるいはその他の顔料を用い、白色系、黒色系、灰色系などの無彩色から、赤色系、青色系、黄色系、緑色系、茶色系などの彩色まで、使用する環境に合わせて選択することができる。有色樹脂フィルム２の厚さは、耐湿性、耐久性、および被覆下地となる金属板の隠蔽性の観点から３０〜１００μｍであることが好ましい。
【００１２】
しかし、結晶性の高いＰＢＴは金属板との接着性にやや乏しく、接着性が特に重要視される用途には、金属板との接着性に優れた結晶性の小さいＥＴ／ＥＩからなる接着樹脂フィルム６を有色樹脂フィルム２の下層に設けることが好ましい。接着性の観点から、ＥＴ／ＥＩはＥＴ（７５〜９５モル％）／ＥＩ（５〜２５モル％）のモル比の共重合体であることが好ましく、５〜２５μｍの厚さであることが好ましい。このような有色樹脂フィルム２の下層として接着樹脂フィルム６を設けた複層樹脂フィルムは共押出法を用いて作成することができる。
【００１３】
目地デザイン樹脂フィルム被覆金属板の製造方法としては、金属板に樹脂フィルムを当接して圧接して積層した後、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成して目地デザイン樹脂フィルム被覆金属板とする方法（以下、後加工法という）、および、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成した目地デザイン樹脂フィルムを金属板に圧接して積層する方法（以下、前加工法という）の２通りの製造方法がある。後加工法による場合は、有色樹脂フィルム２に用いる樹脂としてはＰＢＴ単独でも、図４に示す溝状の凹部７の深さｄやその両側の土手状の凸部８の高さｈを、目地模様が十分に際立つように形成させることができるが、前加工法による場合は、高結晶性のＰＢＴでは溝状の凹部７の深さｄやその両側の土手状の凸部８の高さｈを、目地模様が十分に際立つように形成させることが困難であることが多い。
【００１４】
それで、図４に示す溝状の凹部７の深さｄやその両側の土手状の凸部８の高さｈを好適範囲に調整して目地模様を際だたせるために、高結晶性のＰＢＴに低結晶性もしくは非晶性のポリエステル樹脂をブレンドして、有色樹脂フィルム２の加工性を調節する。低結晶性のポリエステル樹脂の例としては前記のＥＴ／ＥＩなど、非晶性のポリエステル樹脂の例としては、ＰＥＴのエチレングリコール成分を１，４−シクロヘキサンジメタノールで置換した変性体（代表例：イーストマンケミカル社製、商品名：ＰＥＴ−Ｇ）などを挙げることができる。
【００１５】
本発明の目地デザイン樹脂フィルム被覆金属板の最表面層は、上記の有色樹脂フィルム２に溝状の凹部７とその両側の土手状の凸部８からなる凹凸を有する目地模様を形成させたものであってもよいが、有色樹脂フィルム２の上に、凹凸を有する目地模様を形成させた透明樹脂フィルム４を積層することにより、立体感が増して意匠性を向上させることができる。さらに、凹凸を有する目地模様を形成させた透明樹脂フィルム４の有色樹脂フィルム２と接する面に大理石模様、石目模様、木目模様、幾何学模様などの印刷層５を形成させることにより、有色樹脂フィルム２の色と印刷層５の模様が透明樹脂フィルム４を透かして見えることに加えて、表面の凹凸を有する目地模様が組み合わされることにより、さらに意匠性を向上をさせることができる。
【００１６】
透明樹脂フィルム４は、上記のように優れた透明性や、溝状の凹部７とその両側の土手状の凸部８を形成しやすいことに加えて、本発明の目的とする用途である浴室、洗面所、トイレ、厨房など、建物の水回りの部分で使用に供された場合、水滴や水蒸気が付着するために耐湿性が必要とされる。また、黴や汚れを除去するためにアルカリ性の洗剤を散布されたり、洗剤を含ませた布やスポンジ等で拭われるため、耐アルカリ性も必要とされる。さらに、有色樹脂フィルム２と透明樹脂フィルム４の間に印刷層５が形成される場合は、疵付きや摩耗によって印刷層５が損傷したり消失しないよう、特に耐疵付き性や耐磨耗性のような耐久性も必要とされる。このような観点から、透明樹脂フィルム４に用いるポリエステル樹脂としては、ＰＢＴ、ＰＥＴ、ポリエチレンナフタレート（ＰＥＮ）、ＥＴ／ＥＩ、またはこれらの２種以上をブレンドしてなる樹脂が好適に適用することができる。これらの中でもＰＢＴおよびＰＥＴは特にこれらの目的に適っており、かつ比較的安価でありコスト的にも有利である。これらのポリエステル樹脂からなる透明樹脂フィルム４は、押出機を用いて樹脂フィルムに製膜するが、製膜に際して、１軸方向または縦方向と横方向の２軸方向に延伸加工して、延伸配向フィルムとしてもよい。延伸配向させることにより、耐湿性および耐アルカリ性をさらに向上させることができる。これらの透明樹脂フィルム４の厚さを５〜３０μｍとすることにより、凹凸を有する目地模様を形成させた際に立体感を有する良好な意匠性が得られる。
【００１７】
この透明樹脂フィルム４は有色樹脂フィルム２に積層されるが、透明樹脂フィルム４の片面に印刷層５を設ける場合は、印刷層５に接着剤としての機能も持たせることが好ましく、インキの顔料を保持させる樹脂として、ウレタン樹脂や塩酢ビ樹脂などを用いることが好ましい。さらに、透明樹脂フィルム４と着色樹脂フィルム２との接着性は、印刷層５にインキ顔料を含有しないウレタン樹脂や塩酢ビ樹脂などの接着剤層を０．２〜２μｍ程度の厚さで設けることにより、さらに向上させることができる。印刷層５を設けない場合は、印刷層５に変えて接着剤層を設けて有色樹脂フィルム２に積層することにより、優れた接着性が得られる。
【００１８】
有色樹脂フィルム２または透明樹脂フィルム４の表面に溝状の凹部７およびその両側に土手状の凸部８を形成させることにより、凹凸を有する目地模様とするが、目地模様は通常の縦、横、および縦横の格子状、斜線のバイアス状、直線や曲線を組み合わせた幾何学模様、および玉砂利を敷き詰めたような砂利模様の目地部分などを適宜選択する。目地模様の溝状の凹部７に施す有色の塗装９は、有色樹脂フィルム２の色調とは明らかに識別可能であることが必要であるので、有色樹脂フィルム２とは異なる色で塗装する。有色の塗装９の塗装幅は溝状の凹部７の幅未満となるように、かつ有色の塗装９が土手状の凸部８を超えてはみ出ないように塗装することが好ましい。この溝状の凹部７に施す有色の塗装９は、用途によっては施す必要がない場合もあり、塗装の実施の有無は用途により適宜選択する。
【００１９】
有色の塗装９に使用する塗料は、有色樹脂フィルム２または透明樹脂フィルム４との接着性に優れたものであることが好ましく、熱硬化型のポリエステル系塗料、エポキシ系塗料、アクリル系塗料、もしくはウレタン系塗料が好ましい。またこれらの塗料を塗布する場合はシルクスクリーン印刷により塗装することが好ましいが、粉体塗装や刷毛塗りなどの塗装方法を用いてもよい。これらの塗装方法を用いて塗装する場合は、非塗装部分を予めシールしてマスキングし、塗装後にマスキングシールを剥がすことにより、塗装部分が土手状の凸部８からはみ出ないように塗装することが可能である。
【００２０】
目地デザイン樹脂フィルムを積層する金属板１としては、鋼板、亜鉛または亜鉛−ニッケル、亜鉛−アルミニウム、亜鉛−コバルト−モリブデンなどの亜鉛合金などをめっきした亜鉛めっき鋼板、アルミニウムめっき鋼板、鋼板やこれらのめっき鋼板にリン酸処理、クロメート処理、リン酸クロメート処理などの化成処理を施した表面処理鋼板、アルミニウム合金板、ステンレス鋼板などを用いることができるが、価格や耐食性の観点から亜鉛の溶融めっき鋼板や９５％亜鉛−５％アルミニウム合金の溶融めっき鋼板、もしくはこれらの溶融めっき鋼板に上記の化成処理を施した表面処理鋼板を用いることが好ましい。また、これらの溶融めっき鋼板のめっき付着量は２０〜２００ｇ／ｍ^２であることが好ましい。めっき付着量が２０ｇ／ｍ^２未満であると耐食性が十分ではなく、一方、２００ｇ／ｍ^２を超えると表面の凹凸が増加し、外観が損なわれやすくなる。
【００２１】
次に、目地デザイン樹脂フィルム被覆金属板１０の製造方法について説明する。上記したように、目地デザイン樹脂フィルム被覆金属板１０は、下層のＥＴ／ＥＩからなる接着フィルム６を有する複層の有色樹脂フィルム２または単層の有色樹脂フィルム、もしくはこれらの有色樹脂フィルム２に印刷層５を有するまたは有さない透明樹脂フィルム４を積層してなる複層フィルムを金属板１に当接して圧接して積層した後、樹脂フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部７と、溝状凹部７の両側に土手状の凸部８を形成して目地デザイン樹脂フィルム被覆金属板とする後加工法、または、下層のＥＴ／ＥＩ接着フィルム６を有する複層の有色樹脂フィルム２または単層の有色樹脂フィルム、もしくはこれらの有色樹脂フィルム２に印刷層５を有するまたは有さない透明樹脂フィルム４を積層してなる複層フィルムの表面を目地模様を刻設したエンボスロールを用いて加圧し、溝状の凹部７と、溝状凹部７の両側に土手状の凸部８を形成した目地デザイン樹脂フィルムを金属板に圧接して積層する前加工法の２通りの方法を用いて製造することができる。
【００２２】
まず、後加工法を用いて製造する場合を説明する。まず、共押出法を用いて上層の有色樹脂フィルムと下層の接着フィルム６からなる複層の有色樹脂フィルム２を、または押出法を用いて単層の有色樹脂フィルム２を製膜する。
【００２３】
または、以下に述べる透明樹脂フィルム４をこれらの有色樹脂フィルム２に積層した複層フィルムを製膜する。透明樹脂フィルム４は押出法を用いて製膜する。透明樹脂フィルム４は延伸加工を施さない未延伸フィルムであってもよいし、１軸方向または縦横２軸方向に延伸加工を施した延伸配向フィルムであってもよい。また前記したように、透明樹脂フィルム４の片面に大理石模様、石目模様、木目模様、幾何学模様などの印刷層５を形成させてもよい。次いで上記の複層または単層の有色樹脂フィルム２と透明樹脂フィルム４を圧接して積層する。透明樹脂フィルム４の片面に印刷層５を設けた場合は、印刷層５が有色樹脂フィルム２と接するようにして積層する。この場合、印刷層５は接着剤としても機能する。また、印刷層５を設けない場合で、有色樹脂フィルム２と透明樹脂フィルム４の接着性が特に要求される場合は、透明樹脂フィルム４の片面に接着剤層を設け、接着剤層と有色樹脂フィルム２とが接するようにして積層することが好ましい。また、有色樹脂フィルム２の下層に接着フィルム６を設けてなる複層の有色樹脂フィルム２である場合は、その接着フィルム６を設けない側と、透明樹脂フィルム４の印刷層５または接着剤層とが接するようにして積層する。このようにして、金属板１に積層する多層樹脂フィルムが得られる。
【００２４】
次いで、この多層樹脂フィルムを金属板１に積層する。積層する方法は公知の熱接着法、接着剤を用いる方法、および両者を併用する方法もいずれを用いてもよいが、図１、図２、図３に示したように金属板１と多層樹脂フィルムの間に接着剤３を介して熱接着することがより好ましい。
【００２５】
以上のようにして得られた多層樹脂フィルム被覆金属板の樹脂表面を、通常の縦、横、および縦横の格子状、斜線のバイアス状、直線や曲線を組み合わせた幾何学模様、および玉砂利を敷き詰めたような砂利模様の目地部分などから適宜選択した目地模様を凸状に刻設したエンボスロールを用いて加圧し、溝状の凹部７と、溝状凹部７の両側に土手状の凸部８を形成させ、目地デザイン樹脂フィルム被覆金属板１０とする。
【００２６】
図５に、本発明の目地デザイン樹脂フィルムの溝状の凹部７とその両側に土手状の凸部８を形成させる、エンボスロールの一例の概略斜視図を示す。本図において、エンボスロール１１には円筒状のロール部１１ａの周面４箇所に、等間隔で長軸方向に凸部１１ｂが設けられている。このエンボスロール１１を一方とし、凸部を設けない通常の円筒状のロールを他の一方とするロール対を用いて、表面が加熱された多層樹脂フィルム被覆金属板を挟み付け、凸部を多層樹脂フィルム表面に圧入することにより、多層樹脂フィルム面上に横方向に等間隔で凹部および凹部両側に土手状の凸部が形成される。
【００２７】
多層樹脂フィルム面上の凹部および凹部両側の土手状の凸部の形成は次のようにして行う。すなわち、多層樹脂フィルムの表面を、多層樹脂フィルムを構成しているポリエステル樹脂の中の最も高いガラス転移温度以上の温度に加熱し、上記の目地模様を凸状に刻設したエンボスロールを一方のロールとする１対のエンボスロールを用いて多層樹脂フィルム被覆金属板を加圧する。このようにして、図４に示す溝状の凹部７と、溝状凹部７の両側に土手状の凸部８が形成される。溝状凹部７は、エンボスロールに刻設された目地模様の凸部を樹脂フィルム表面に圧入することにより形成されるが、溝状の凹部７は図４に示すように、特に幅方向の両端部で深く形成され、エンボスロール凸部を圧入することにより、樹脂が溝状凹部７の両端部から溝状凹部７の両外側にはみ出すことにより、溝状凹部７の両外部に土手状の凸部８が形成される。このようにして、樹脂フィルムの表面の溝状凸部７の幅方向の両端部においては、溝状凹部７の深さｄに土手状の凸部８の高さｈが加わった段差が形成されるので、極めて優れた立体感が視認できるようになる。なお、以下の記載において、深さｄは、樹脂が溝状凹部７の最も深い部分における深さを示す。
【００２８】
このようにして形成される溝状凹部７の深さｄは２〜７０μｍであることが好ましい。溝状凹部７の深さｄが２μｍ未満であると溝状凹部７の両側に形成される土手状の凸部８の高さｈが、十分な立体感が視認できるほどの高さに形成されない。一方、溝状凹部７の深さを７０μｍを超えて形成させることは多大な加圧力を必要とし、実用的ではない。
【００２９】
溝状凹部７と同時に形成される土手状の凸部８の高さｈは２〜７０μｍであることが好ましい。土手状の凸部８の高さｈが２μｍ未満であると十分な立体感が視認できない。一方、土手状の凸部８の高さｈを７０μｍを超えて形成させることは多大な加圧力を必要とし、実用的ではない。
【００３０】
上記の溝状凹部７の深さｄおよび土手状の凸部８の高さｈは、エンボスロールに刻設された目地模様の凸部の高さ、多層樹脂フィルム被覆金属板の樹脂表面の加熱温度、エンボスロールの加圧力を適宜選択することにより調整することができる。
【００３１】
また、上記の工程において、多層樹脂フィルムを金属板１に積層する際に同時にエンボス加工を施すことも可能である。すなわち、金属板１を、多層樹脂フィルムの金属板１と接するフィルム、すなわち有色樹脂フィルム２または接着樹脂フィルム６の融点±１０℃の温度に加熱し、多層樹脂フィルムを構成しているポリエステル樹脂の中の最も高いガラス転移温度以上の温度に予熱した多層樹脂フィルムを加熱された金属板１に当接し、目地模様を凸状に刻設したエンボスロールを一方のロールとする１対のエンボスロールを用いて多層樹脂フィルム被覆金属板を挟み付けて加圧する。このようにして、積層とエンボス加工を同時に行うことも可能である。
【００３２】
次いで、以上のようにして形成された溝状凹部７内に有色の塗装９を施す。この塗装９を施すことにより、目地模様を際立たせるので、有色の塗装９の色は有色樹脂フィルム２や印刷層５の色調とは明らかに識別できるように、有色樹脂フィルム２や印刷層５とは異なる色で塗装することが好ましい。しかし、用途によっては有色樹脂フィルム２や印刷層５と同一色調が好まれるものもあり、塗装９の色は用途により適宜選択する。また、塗装９は、用途によっては施す必要がない場合もあり、塗装の実施の有無は用途により適宜選択する。さらに、塗装９の塗装幅は溝状の凹部７の幅以下となるように、かつ塗装９が土手状の凸部からはみ出ないように塗装することが好ましい。
【００３３】
次に、前加工法を用いて製造する場合を説明する。まず、上記した後加工法の工程に従って、多層樹脂フィルムを作成する。次いで、この多層樹脂フィルムを多層樹脂フィルムを構成しているポリエステル樹脂の中の最も高いガラス転移温度以上の温度に加熱し、目地模様を凸状に刻設したエンボスロールを一方のロールとする１対のエンボスロールを用い、多層樹脂フィルムの最表面の樹脂フィルム、すなわち有色樹脂フィルム２または透明樹脂フィルム４が目地模様を凸状に刻設したエンボスロールと接するようにして挟み付け、多層樹脂フィルムの最表面に図４に示す溝状の凹部７と、溝状凹部７の両側に土手状の凸部８を形成させる。溝状凹部７の深さｄ、および土手状の凸部８の高さｈの好適範囲は、後加工法と同様に、エンボスロールに刻設された目地模様の凸部の高さ、多層樹脂フィルム被覆金属板の樹脂表面の加熱温度、エンボスロールの加圧力を適宜選択することにより調整することができる。
【００３４】
次いで、金属板１を、上記のエンボス加工を施した多層樹脂フィルムの金属板１と接するフィルム、すなわち有色樹脂フィルム２または接着樹脂フィルム６の融点±１０℃の温度に加熱し、多層樹脂フィルムを加熱された金属板１に当接し、１対のラミネートロールを用いて上記のエンボス加工を施した多層樹脂フィルムと金属板１を挟み付けて加圧して接着することにより、目地デザイン樹脂フィルム被覆金属板１０を得ることができる。金属板１と多層樹脂フィルムとの優れた接着性が必要な場合は、図１、図２、図３に示したように金属板１と多層樹脂フィルムの間に接着剤３を介して熱接着することが好ましい。
【００３５】
前加工法により形成された溝状凹部７内に有色の塗装９を施す場合は、後加工法と同様にして塗装９を施すが、前加工法においては多層樹脂フィルムにエンボス加工を施した後、またはエンボス加工を施した多層樹脂フィルムを金属板１に積層した後のいずれであっても差し支えない。
【００３６】
【実施例】
（試料番号１〜４）
着色顔料として二酸化チタン２０％と、カーボンブラック、チタンイエロー、およびベンガラをそれぞれ１％以下含有する、クリーム色のＰＢＴフィルム（厚さ６０μｍ、固有粘度１．０）に、片面にグレーの大理石模様の印刷（ウレタン系インキ）を施した無延伸の透明ＰＢＴフィルム（厚さ１５μｍ、固有粘度１．０）を、４００００Ｎの加圧力を負荷し、加熱温度８０℃の条件で積層した。次いで厚さ０．５ｍｍの亜鉛の溶融めっき鋼板（めっき量：１８０ｇ／ｍ^２）に塗布形クロメート処理を施し（Ｃｒとして４０ｍｇ／ｍ^２の皮膜量の化成処理皮膜を形成）、ポリエステル系接着剤を塗布して溶媒を乾燥除去した後、上記作成したフィルムを重ね合わせ、一対の加圧ロールを用いて挟み付け、加熱しながら加圧して積層接着した。積層接着に際しては、亜鉛の溶融めっき鋼板を２３０℃に加熱し、４００００Ｎの加圧力を負荷した。次いで、積層鋼板を２２０〜２３０℃に加熱し、幅３ｍｍ、高さ４０μｍの凸部をロール周方向に刻設したエンボスロールを一方とし、シリコン系ゴムをライニングした弾性ロールを他方とする１対のエンボスロールを用い、２００００〜１２００００Ｎの加圧力を負荷し、表１の試料番号１〜４に示す深さの溝状の凹部および高さを示す土手状の凸部を形成させた。次いで、溝状の凹部にシルクスクリーン印刷を用いて黒色のポリエステル系塗料を施し、さらに１００℃で５分間の加熱乾燥を行い、目地デザイン樹脂フィルム被覆金属板とした。
【００３７】
（試料番号５〜８）
厚さ０．５ｍｍの亜鉛の溶融めっき鋼板（めっき量：１８０ｇ／ｍ^２）に塗布形クロメート処理を施し（Ｃｒとして４０ｍｇ／ｍ^２の皮膜量の化成処理皮膜を形成）、ポリエステル系接着剤を塗布して溶媒を乾燥除去した後、共押出法により作成した、着色顔料として二酸化チタン１６％、チタンイエロー２％、コバルトブルー２％をそれぞれ含有する、緑色のＰＢＴ（厚さ７０μｍ、固有粘度１．０）と、９０モル％のエチレンテレフタレートと１０モル％のエチレンイソフタレートからなる透明のＥＴ／ＥＩ共重合体（厚さ１０μｍ、固有粘度０．６）からなる２層フィルムを重ね合わせ、一対の加圧ロールを用いて挟み付け、加熱しながら加圧して積層接着した。積層接着に際しては、亜鉛の溶融めっき鋼板を２３０℃に加熱し、４００００Ｎの加圧力を負荷した。次いで、積層鋼板を２３０〜２４０℃に加熱し、幅３ｍｍ、高さ６０μｍの凸部をロール周方向に刻設したエンボスロールを一方とし、シリコン系ゴムをライニングした弾性ロールを他方とする１対のエンボスロールを用い、２００００〜２４００００Ｎの加圧力を負荷し、表１の試料番号５〜８に示す深さの溝状の凹部および高さを示す土手状の凸部を形成させた。次いで、溝状の凹部にシルクスクリーン印刷を用いて白色のポリエステル系塗料を施し、さらに１００℃で５分間の加熱乾燥を行い、目地デザイン樹脂フィルム被覆金属板とした。
【００３８】
（試料番号９〜１２）
５０重量％のＰＢＴと５０重量％のＰＥＴのエチレングリコール成分を１，４−シクロヘキサンジメタノールで置換した変性体（イーストマンケミカル社製商品名ＰＥＴ−Ｇ）をブレンドしてなる樹脂にカーボンブラックを５％含有させた黒色フィルム（厚さ６０μｍ、固有粘度１．０）に、透明のウレタン系接着剤を塗布した透明の二軸延伸ＰＥＴフィルム（厚さ１５μｍ、固有粘度０．７）を、接着剤特面が黒色フィルムと接する用にして重ね合わせて８０〜１８０℃に加熱し、幅３ｍｍ、高さ４０μｍの凸部を刻設したエンボスロールを一方とし、シリコン系ゴムをライニングした弾性ロールを他方とする１対のエンボスロールを用い、エンボスロールが透明二軸延伸ＰＥＴフィルムに接するようにして、２００００〜１２００００Ｎの加圧力を負荷して両フィルムを加圧接着すると同時に、表１の試料番号９〜１２に示す深さの溝状の凹部および高さを示す土手状の凸部を形成させた。次いで厚さ０．５ｍｍの９５％亜鉛−５％アルミニウム合金の溶融めっき鋼板（めっき量：１８０ｇ／ｍ^２）に塗布形クロメート処理を施し（Ｃｒとして４０ｍｇ／ｍ^２の皮膜量の化成処理皮膜を形成）、ポリエステル系接着剤を塗布して溶媒を乾燥除去した後、上記作成したフィルムを重ね合わせ、一対の加圧ロールを用いて挟み付け、加熱しながら加圧して積層接着した。積層接着に際しては、上記合金の溶融めっき鋼板を２３０℃に加熱し、４００００Ｎの加圧力を負荷した。次いで、溝状の凹部にシルクスクリーン印刷を用いて白色のポリエステル系塗料を施し、さらに１００℃で５分間の加熱乾燥を行い、目地デザイン樹脂フィルム被覆金属板とした。
【００３９】
（試料番号１３〜１６）
厚さ０．５ｍｍの亜鉛の溶融めっき鋼板（めっき量：１８０ｇ／ｍ^２）に塗布形クロメート処理を施し（Ｃｒとして４０ｍｇ／ｍ^２の皮膜量の化成処理皮膜を形成）、ポリエステル系接着剤を塗布して溶媒を乾燥除去した後２２０〜２３０℃に加熱し、着色顔料として二酸化チタン１９％とカーボンブラック１％を含有する灰色のＰＢＴフィルム（厚さ８０μｍ、固有粘度１．０）を当接し、幅３ｍｍ、高さ４０μｍの凸部を刻設したエンボスロールを一方とし、シリコン系ゴムをライニングした弾性ロールを他方とする１対のエンボスロールを用い、２００００〜１２００００Ｎの加圧力を負荷して、樹脂フィルムを亜鉛の溶融めっき鋼板に積層接着させると同時に、表１の試料番号１３〜１６に示す深さの溝状の凹部および高さを示す土手状の凸部を形成させた。次いで、溝状の凹部にシルクスクリーン印刷を用いて白色のポリエステル系塗料を施し、さらに１００℃で５分間の加熱乾燥を行い、目地デザイン樹脂フィルム被覆金属板とした。
【００４０】
【表１】

【００４１】
（試料の特性評価）
作成した試料番号１〜１６の試料について、下記の特性を評価した。
［耐湿性］
試料を６０℃、９５％ＲＨの恒温恒湿雰囲気中で５００時間経時した後、粘着テープによる強制剥離試験を行い、下記の基準で耐湿性を評価した。
◎：剥離は全く認められない。
○：実用上問題とならない程度の僅かな剥離が認められる。
△：実用上問題となる程度の剥離が認められる。
×：全面剥離する。
［目地デザインの目視評価］
異なる７人により目地デザインを目視観察し、下記の基準で評価した。色の識別は試料板の正面より観察し、凹凸識別は試料板の斜め４５°方向より観察した。
◎：７人全員が識別可能と判定。
○：７人のうち４〜６人が識別可能と判定。
△：７人のうち１〜３人が識別可能と判定。
×：７人全員が識別不能と判定。
評価結果を表１に示す。
【００４２】
【発明の効果】
本発明の目地デザイン樹脂フィルム被覆金属板は、有色の単層樹脂フィルム、または有色樹脂フィルム上もしくは下層に接着樹脂フィルムを有する有色樹脂フィルム、有色樹脂フィルム上に印刷を施した透明樹脂フィルムを積層した複層樹脂フィルムのいずれかの表面に、溝状の凹部と、溝状凹部の両側に土手状の凸部を形成した樹脂フィルムを金属板上に積層しているので、樹脂フィルム表面に形成した溝状の凹部と、溝状凹部の両側に土手状の凸部からなる目地部が明確でしかも立体感のある意匠効果が得られるとともに、耐湿性にも優れており、浴室、洗面所、トイレ、厨房など、建物のいわゆる水回りの部分の壁材、天井材として好適に適用できる。
【図面の簡単な説明】
【図１】本発明の目地デザイン樹脂フィルム被覆金属板の一例を示す概略断　　　　　面図。
【図２】本発明の目地デザイン樹脂フィルム被覆金属板の他の一例を示す概　　　　　略断面図。
【図３】本発明の目地デザイン樹脂フィルム被覆金属板の他の一例を示す概　　　　　略断面図。
【図４】本発明の目地デザイン樹脂フィルムの表面に形成した溝状の凹部と、溝状凹部の両側の土手状の凸部の一例を拡大して示す概略断面図。
【図５】本発明の目地デザイン樹脂フィルムの表面に溝状の凹部と、溝状凹部の両側の土手状の凸部を形成させるエンボスロールの一例を示す概略斜視図。
【符号の説明】
１　：　金属板
２　：　有色樹脂　フィルム
３　：　接着剤
４　：　透明樹脂フィルム
５　：　印刷層
６　：　接着樹脂フィルム
７　：　溝状の凹部
８　：　土手状の凸部
９　：　有色の塗装
１０　：　目地デザイン樹脂フィルム被覆金属板
１１　：　エンボスロール
１１ａ：　円筒状のロール部
１１ｂ：　凸部
ｄ　：　溝状凹部の深さ
ｈ　：　土手状凸部の高さ[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a joint design resin film having a joint-shaped three-dimensional design on the surface, a joint design resin film-coated metal plate obtained by laminating the same on a metal plate, and a method for producing the same.
[0002]
[Prior art]
So-called water-around parts of buildings, such as bathrooms, washrooms, toilets, and kitchens, are made of walls, ceilings, or floors by attaching water-resistant tiles using cement, plaster, or the like. In recent years, these parts around the water have been unitized, especially in apartment buildings, and since they are inexpensive and have excellent workability as wall and ceiling materials, resin films such as vinyl chloride resin films have been used for steel plates, etc. A resin-coated metal plate that is laminated and coated on a metal plate described above has come to be used. However, these resin-coated metal plates are often used in the form of flat plates, and joints such as geometric patterns such as triangles, squares, hexagons, octagons, and circles, and non-geometric patterns that imitate the cross section of stone materials. Poor design compared to tiled walls or ceilings with uneven patterns or irregularities.
[0003]
[Problems to be solved by the invention]
The present invention provides a joint design resin film which is inexpensive and excellent in workability, and also has excellent design, moisture resistance, durability and stain resistance, and a joint design resin film-coated metal plate coated with the joint design resin film. , And a method for producing them.
[0004]
[Means for Solving the Problems]
To solve the above problems, the joint design resin film of the present invention,
On the surface of the resin film, a groove-shaped concave portion, characterized in that a bank-shaped convex portion is formed on both sides of the groove-shaped concave portion,
That the depth of the groove-shaped recess is 2 to 70 μm,
That the height of the bank-shaped protrusion is 2 to 70 μm,
It is characterized by colored coating on the groove-shaped recess,
Furthermore, the above resin film
Colored resin film containing a color pigment, or
Being a multilayer resin film in which a colored resin film containing a color pigment and a transparent resin film are laminated, or
A colored resin film containing a coloring pigment and a transparent resin film on which printing on a color different from the colored resin film on one side is applied, that the printed resin layer is in contact with the multilayer resin film that is laminated. Features and furthermore
The colored resin film is a PBT containing a color pigment, or a multilayer resin of a PBT containing an upper color pigment and a lower ET / EI, and further,
The transparent resin film is made of PBT or PET.
[0005]
Further, the joint design resin film-coated metal plate of the present invention is characterized in that any one of the joint design resin films described above is laminated on a metal plate,
Joint design It is characterized by being laminated by interposing an adhesive between the resin film and the metal plate.
The metal sheet is a hot-dip coated steel sheet of zinc or a hot-dip coated steel sheet of 95% zinc-5% aluminum alloy.
[0006]
Furthermore, the method for producing a joint design resin film of the present invention includes the steps of: pressing the surface of the resin film using an embossing roll engraved with a joint pattern, forming a groove-shaped concave portion, and a bank-shaped convex portion on both sides of the groove-shaped concave portion. Is formed, a colored coating is applied in the groove-shaped recess.
[0007]
Further, in the method for producing a metal plate coated with a joint design resin film of the present invention, the surface of the resin film is pressurized using an embossing roll having a joint pattern engraved thereon, and a groove-shaped concave portion and a bank formed on both sides of the groove-shaped concave portion. Forming a convex part of the shape, jointed design resin film obtained by applying a colored coating in the groove-shaped concave part, by pressing and laminating a metal plate, or
Applying an adhesive to the metal plate, abutting the joint design resin film on the adhesive applied surface and pressing and laminating, or
An adhesive is applied to a metal plate, and a resin film is brought into contact with the adhesive applied surface and pressed to be laminated. Then, the surface of the resin film is pressed using an embossing roll having a joint pattern engraved thereon to form a groove-shaped concave portion. And a bank-shaped convex portion is formed on both sides of the groove-shaped concave portion, and colored coating is applied in the groove-shaped concave portion.
[0008]
BEST MODE FOR CARRYING OUT THE INVENTION
The inventors of the present invention have studied the jointed resin film coated metal plate which is inexpensive and excellent in workability, and has excellent design, moisture resistance, durability, and stain resistance. Before or after, by pressing the surface of the resin film using an embossing roll engraved with a joint pattern, by providing a joint design in which a groove-like concave portion and a bank-like convex portion on both sides of the groove-like concave portion are formed. It has been found that a desired joint design resin film-coated metal plate can be obtained.
That is, according to the present invention, either a colored single-layer resin film, or a multilayer resin film obtained by laminating a transparent resin film printed on a colored resin film having an adhesive resin film on or below the colored resin film. On the surface of the resin film, a groove-shaped concave portion, and a resin film having bank-shaped convex portions formed on both sides of the groove-shaped concave portion are laminated on a metal plate, so that a groove-shaped concave portion formed on the resin film surface, It is possible to provide a decorative metal plate having a clear and three-dimensional design effect with joints formed of bank-shaped convex portions on both sides of the concave shape, and having excellent moisture resistance, durability, and stain resistance. Further, this resin film-coated metal plate can be provided at low cost and with excellent workability.
Hereinafter, the present invention will be described in detail with reference to the drawings.
[0009]
FIGS. 1, 2 and 3 are schematic cross-sectional views each showing an example of the joint design resin film-coated metal plate of the present invention, and FIG. 4 is a groove-like concave portion formed on the surface of the joint design resin film of the present invention. FIG. 4 is an enlarged schematic cross-sectional view showing an example of a bank-shaped convex portion on both sides of a groove-shaped concave portion. As shown in FIG. 1, the joint design resin film-coated metal plate 10 of the present invention is a colored resin film 2 containing a colored pigment having a groove-shaped concave portion 7 on the surface and a bank-shaped convex portion 8 on both sides thereof. Are directly laminated with or without an adhesive 3 and a colored coating 9 is applied in the groove-shaped recess 7 or, as shown in FIG. 2, a colored resin film 2 containing a colored pigment. A transparent resin film 4 having a printing layer 5 also having a function as an adhesive on one side and a groove-like recess 7 on one side and a bank-like projection 8 on both sides of the printing layer 5 5 is formed by directly laminating a multi-layer resin film laminated so as to be in contact with the colored resin film 2 with or without the adhesive 3, and applying a colored coating 9 in the groove-shaped recess 7. Alternatively, as shown in FIG. 3, the upper layer contains a color pigment. On the colored resin film 2 of a multilayer resin film composed of the resin film 2 and the lower adhesive resin film 6, a printed layer 5 also having a function as an adhesive is provided on one side, and a groove-shaped recess 7 is formed on the other side. A multilayer resin film formed by laminating a transparent resin film 4 having bank-shaped convex portions 8 formed on both sides such that a printed layer 5 is in contact with the colored resin film 2 is formed with or without an adhesive 3 interposed therebetween. , And a colored coating 9 is applied inside the groove-shaped recess 7.
[0010]
The resin used for the colored resin film 2, the transparent resin film 1, and the lower adhesive resin film 6 constituting the joint design resin film of the present invention is preferably a polyester resin. As the polyester resin, terephthalic acid, isophthalic acid, orthophthalic acid, 2,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, diphenylcarboxylic acid, Diphenoxyethane dicarboxylic acid, diphenyl sulfone carboxylic acid, anthracene dicarboxylic acid, 1,3-cyclopentane dicarboxylic acid, 1,3-cyclohexane dicarboxylic acid, 1,4-cyclohexane dicarboxylic acid, hexahydroterephthalic acid, hexahydroisophthalic acid, Malonic acid, dimethylmalonic acid, succinic acid, 3,3-diethylsuccinic acid, glutaric acid, 2,2-dimethylglutaric acid, adipic acid, 2-methyladipic acid, trimethyladipic acid, pimelic acid, azelaic acid, dimer acid , Dicarboxylic acids such as basic acid, suberic acid and dodecadicarboxylic acid, and ethylene glycol, propylene glycol, hexamethylene glycol, neopentyl glycol, 1,2-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, decamethyleneglycol, , 3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexadiol, 2,2-bis (4'-hydroxyphenyl) propane, bis (4-hydroxyphenyl) sulfone, etc. Is a homopolymer obtained by polycondensing one or more diols, or a copolymer obtained by polycondensing one or more dicarboxylic acids and two or more diols, or one or more dicarboxylic acids and one or more diols. Copolymers obtained by polycondensation and homopolymers thereof The or copolymer can include any of the polyester resin of two or more blend formed by blending resin.
[0011]
The polyester resin used for the colored resin film 2 includes moisture resistance and durability as a joint design resin film-coated metal plate, and a groove-like concave portion 7 provided on the outermost surface of the joint design resin film and bank-like convex portions on both sides thereof. 8 is selected from the viewpoint of facilitating formation. From these viewpoints, it is preferable to use highly crystalline PBT as the polyester resin used for the colored resin film 2. When a resin film is formed using an extruder, a colored pigment is kneaded to form a colored resin film 2. As the color to be colored, inorganic pigments such as titanium dioxide, carbon black, titanium yellow, red iron oxide, ultramarine, cobalt blue and the like, organic pigments such as quinacridone, or other pigments are used as coloring pigments, and white, black, and gray pigments are used. The color can be selected according to the environment to be used, from achromatic colors such as, to red, blue, yellow, green, and brown colors. The thickness of the colored resin film 2 is preferably 30 to 100 μm from the viewpoints of moisture resistance, durability, and concealment of a metal plate serving as a coating base.
[0012]
However, PBT having high crystallinity has a little poor adhesion to a metal plate, and in applications where adhesion is particularly important, an adhesive resin made of ET / EI having excellent adhesion to a metal plate and low crystallinity is used. It is preferable that the film 6 is provided below the colored resin film 2. From the viewpoint of adhesiveness, ET / EI is preferably a copolymer having a molar ratio of ET (75 to 95 mol%) / EI (5 to 25 mol%), and has a thickness of 5 to 25 μm. preferable. Such a multilayer resin film provided with the adhesive resin film 6 as a lower layer of the colored resin film 2 can be produced by using a co-extrusion method.
[0013]
As a method of manufacturing a jointed design resin film-coated metal plate, a resin film is brought into contact with a metal plate, pressed and laminated, and then the surface of the resin film is pressed using an embossing roll having a joint pattern engraved thereon to form a groove. And a method of forming a joint-shaped resin film coated metal plate by forming a bank-shaped convex portion on both sides of the groove-shaped concave portion (hereinafter referred to as a post-processing method), and engraving a joint pattern on the surface of the resin film. Pressurizing using the embossed roll, and pressing and laminating a groove-shaped concave portion and a joint design resin film having a bank-shaped convex portion formed on both sides of the groove-shaped concave portion with a metal plate (hereinafter referred to as a pre-processing method). )). In the case of the post-processing method, the depth d of the groove-shaped concave portion 7 shown in FIG. 4 and the height h of the bank-shaped convex portion 8 on both sides thereof are jointed even when PBT alone is used as the resin for the colored resin film 2. The pattern can be formed so as to be sufficiently prominent. However, in the case of the pre-working method, the depth d of the groove-shaped concave portion 7 and the height h of the bank-shaped convex portion 8 on both sides of the high-crystalline PBT are high. Is often difficult to form so that the joint pattern is sufficiently noticeable.
[0014]
Therefore, in order to adjust the depth d of the groove-shaped concave portion 7 shown in FIG. 4 and the height h of the bank-shaped convex portions 8 on both sides thereof to a suitable range to make the joint pattern stand out, a PBT having high crystallinity is used. The workability of the colored resin film 2 is adjusted by blending a low crystalline or amorphous polyester resin. Examples of the low-crystalline polyester resin include the above-mentioned ET / EI and the like. Examples of the amorphous polyester resin include a modified product obtained by replacing the ethylene glycol component of PET with 1,4-cyclohexanedimethanol (representative example: Eastman Chemical Company, trade name: PET-G).
[0015]
The outermost surface layer of the joint design resin film-coated metal plate of the present invention is obtained by forming the above-mentioned colored resin film 2 with a joint pattern having concaves and convexes formed by groove-shaped concave portions 7 and bank-shaped convex portions 8 on both sides thereof. However, by laminating the transparent resin film 4 on which the joint pattern having irregularities is formed on the colored resin film 2, the three-dimensional effect can be increased and the design property can be improved. Further, by forming a printed layer 5 such as a marble pattern, a stone pattern, a grain pattern, or a geometric pattern on the surface of the transparent resin film 4 having the joint pattern having irregularities formed thereon, the surface being in contact with the colored resin film 2. By combining the color of the film 2 and the pattern of the print layer 5 through the transparent resin film 4 and the joint pattern having surface irregularities, the design can be further improved.
[0016]
The transparent resin film 4 has excellent transparency as described above, and is easy to form the groove-shaped concave portion 7 and the bank-shaped convex portions 8 on both sides thereof. When used in water-related parts of buildings, such as toilets, toilets, and kitchens, moisture resistance is required because water droplets and water vapor adhere thereto. In addition, since alkaline detergent is sprayed to remove mold and dirt, or wiped with a cloth or sponge containing detergent, alkali resistance is also required. Further, when the printing layer 5 is formed between the colored resin film 2 and the transparent resin film 4, the printing layer 5 is prevented from being damaged or lost due to scratches or abrasion. Such durability is also required. From such a viewpoint, as the polyester resin used for the transparent resin film 4, PBT, PET, polyethylene naphthalate (PEN), ET / EI, or a resin obtained by blending two or more of these are preferably applied. Can be. Among them, PBT and PET are particularly suitable for these purposes, and are relatively inexpensive and advantageous in cost. The transparent resin film 4 made of these polyester resins is formed into a resin film by using an extruder. In forming the film, the film is stretched uniaxially or biaxially in a vertical direction and a horizontal direction, and stretched and oriented. It may be a film. By stretching and orienting, the moisture resistance and alkali resistance can be further improved. By setting the thickness of the transparent resin film 4 to 5 to 30 μm, a good design property having a three-dimensional effect can be obtained when a joint pattern having irregularities is formed.
[0017]
This transparent resin film 4 is laminated on the colored resin film 2. When the printing layer 5 is provided on one side of the transparent resin film 4, it is preferable that the printing layer 5 also has a function as an adhesive, It is preferable to use a urethane resin, a vinyl chloride-vinyl chloride resin, or the like as a resin for holding the resin. Further, the adhesiveness between the transparent resin film 4 and the colored resin film 2 is such that an adhesive layer such as a urethane resin or a polyvinyl chloride resin containing no ink pigment is provided on the print layer 5 with a thickness of about 0.2 to 2 μm. Thereby, it can be further improved. When the print layer 5 is not provided, an excellent adhesive property is obtained by providing an adhesive layer instead of the print layer 5 and laminating the colored resin film 2.
[0018]
By forming a groove-shaped concave portion 7 on the surface of the colored resin film 2 or the transparent resin film 4 and a bank-shaped convex portion 8 on both sides thereof, a joint pattern having irregularities is formed. , And vertical and horizontal lattices, diagonal biases, geometrical patterns combining straight lines and curves, and joints of gravel patterns such as scattered gravel are appropriately selected. The colored coating 9 applied to the joint-shaped groove-shaped concave portions 7 is required to be clearly distinguishable from the color tone of the colored resin film 2, and is therefore painted in a color different from that of the colored resin film 2. It is preferable to apply the colored coating 9 such that the coating width of the colored coating 9 is smaller than the width of the groove-shaped concave portion 7 and that the colored coating 9 does not protrude beyond the bank-shaped convex portion 8. The colored coating 9 to be applied to the groove-shaped concave portion 7 may not need to be applied depending on the application, and whether or not the coating is applied is appropriately selected depending on the application.
[0019]
The paint used for the colored coating 9 preferably has excellent adhesion to the colored resin film 2 or the transparent resin film 4, and is a thermosetting polyester-based paint, an epoxy-based paint, an acrylic-based paint, or Urethane-based paints are preferred. When these paints are applied, they are preferably applied by silk screen printing, but may be applied by a coating method such as powder coating or brush coating. When applying using these coating methods, the non-painted portion is sealed in advance and masked, and the masking seal is peeled off after painting so that the painted portion does not protrude from the bank-shaped convex portion 8. It is possible.
[0020]
Examples of the metal plate 1 on which the joint design resin film is laminated include a steel plate, a zinc-coated steel plate plated with zinc or a zinc alloy such as zinc-nickel, zinc-aluminum, zinc-cobalt-molybdenum, an aluminum-plated steel plate, a steel plate, and the like. Surface-treated steel sheets, aluminum alloy sheets, stainless steel sheets, etc., which have been subjected to chemical treatment such as phosphoric acid treatment, chromate treatment, phosphoric acid chromate treatment, etc. can be used for the plated steel sheet, but from the viewpoint of price and corrosion resistance, hot-dip coated zinc sheet It is preferable to use hot-dip steel sheets of 95% zinc-5% aluminum alloy or surface-treated steel sheets obtained by subjecting these hot-dip coated steel sheets to the above chemical conversion treatment. The coating weight of these hot-dip coated steel sheets is 20 to 200 g / m2. ² It is preferable that 20g / m plating weight ² If less than 200 g / m, the corrosion resistance is not sufficient. ² If it exceeds, the unevenness of the surface increases, and the appearance is easily impaired.
[0021]
Next, a method of manufacturing the joint design resin film-coated metal plate 10 will be described. As described above, the joint-design resin film-coated metal plate 10 is formed by a multi-layered colored resin film 2 or a single-layered colored resin film having the lower adhesive film 6 made of ET / EI, or a single-layered colored resin film. After a multilayer film formed by laminating the transparent resin film 4 with or without the printing layer 5 is pressed against the metal plate 1 and laminated, the embossing roll having the resin film engraved with a joint pattern is formed. Post-processing method of forming a groove-shaped concave portion 7 and a bank-shaped convex portion 8 on both sides of the groove-shaped concave portion 7 to form a jointed design resin film coated metal plate, or ET / EI bonding of a lower layer A multi-layered colored resin film 2 having a film 6 or a single-layered colored resin film, or a transparent resin film having or not having a printed layer 5 on these colored resin films 2 Joint surface design in which the surface of a multilayer film formed by laminating is pressurized using an embossing roll engraved with a joint pattern to form a groove-like concave portion 7 and bank-like convex portions 8 on both sides of the groove-like concave portion 7. It can be manufactured by using two methods of a pre-processing method in which a resin film is pressed against a metal plate and laminated.
[0022]
First, a case of manufacturing using a post-processing method will be described. First, a multi-layered colored resin film 2 composed of an upper colored resin film and a lower adhesive film 6 is formed by coextrusion, or a single-layered colored resin film 2 is formed by extrusion.
[0023]
Alternatively, a multilayer film in which a transparent resin film 4 described below is laminated on these colored resin films 2 is formed. The transparent resin film 4 is formed using an extrusion method. The transparent resin film 4 may be an unstretched film that has not been stretched, or may be a stretched oriented film that has been stretched in a uniaxial direction or a biaxial direction. Further, as described above, a printed layer 5 such as a marble pattern, a stone pattern, a grain pattern, or a geometric pattern may be formed on one surface of the transparent resin film 4. Next, the above-mentioned multilayer or single-layer colored resin film 2 and the transparent resin film 4 are pressed and laminated. When the printing layer 5 is provided on one side of the transparent resin film 4, the printing layer 5 is laminated so as to be in contact with the colored resin film 2. In this case, the printing layer 5 also functions as an adhesive. In the case where the printed layer 5 is not provided and the adhesive property between the colored resin film 2 and the transparent resin film 4 is particularly required, an adhesive layer is provided on one surface of the transparent resin film 4 and the adhesive layer and the colored resin It is preferable that the film 2 is laminated so as to be in contact with the film 2. In the case of a multi-layered colored resin film 2 in which an adhesive film 6 is provided below the colored resin film 2, the side on which the adhesive film 6 is not provided and the printed layer 5 or the adhesive layer of the transparent resin film 4 are provided. Are laminated so as to contact with each other. Thus, a multilayer resin film to be laminated on the metal plate 1 is obtained.
[0024]
Next, this multilayer resin film is laminated on the metal plate 1. As a method of laminating, any of a known heat bonding method, a method using an adhesive, and a method using both of them may be used. As shown in FIGS. 1, 2, and 3, the metal plate 1 and the multilayer resin are used. It is more preferable to thermally bond the films via the adhesive 3.
[0025]
The resin surface of the multilayer resin film-coated metal plate obtained as described above is laid with ordinary vertical, horizontal, and vertical and horizontal lattices, diagonal biases, geometric patterns combining straight lines and curves, and gravel. A joint pattern appropriately selected from such a joint part of a gravel pattern or the like is pressed using an embossing roll engraved in a convex shape to form a groove-shaped concave portion 7 and a bank-shaped convex portion 8 on both sides of the groove-shaped concave portion 7. To form a joint-design resin film-coated metal plate 10.
[0026]
FIG. 5 is a schematic perspective view of an example of an embossing roll for forming a groove-like concave portion 7 and a bank-like convex portion 8 on both sides of the joint design resin film of the present invention. In this figure, the embossing roll 11 is provided with convex portions 11b at four circumferential surfaces of a cylindrical roll portion 11a at regular intervals in the long axis direction. Using a pair of rolls having one embossing roll 11 and the other being a normal cylindrical roll having no convex portion, a multi-layer resin film-coated metal plate whose surface is heated is sandwiched, and the convex portion is multi-layered. By pressing into the surface of the resin film, the concave portions and the bank-shaped convex portions on both sides of the concave portions are formed at equal intervals in the horizontal direction on the surface of the multilayer resin film.
[0027]
The formation of the concave portions on the surface of the multilayer resin film and the bank-shaped convex portions on both sides of the concave portions are performed as follows. That is, the surface of the multilayer resin film is heated to a temperature equal to or higher than the highest glass transition temperature in the polyester resin constituting the multilayer resin film, and the embossing roll in which the joint pattern is engraved in a convex shape is used. A multilayer resin film-coated metal plate is pressed using a pair of embossing rolls. In this way, the groove-shaped concave portion 7 shown in FIG. 4 and the bank-shaped convex portions 8 on both sides of the groove-shaped concave portion 7 are formed. The groove-shaped recess 7 is formed by pressing a joint having a joint pattern engraved on an embossing roll into the surface of the resin film, and the groove-shaped recess 7 has, as shown in FIG. The embossing roll convex portion is press-fitted, and the resin protrudes from both ends of the groove-shaped concave portion 7 to both outsides of the groove-shaped concave portion 7. The part 8 is formed. In this way, at both ends in the width direction of the groove-shaped protrusions 7 on the surface of the resin film, a step is formed in which the height d of the bank-shaped protrusions 8 is added to the depth d of the groove-shaped recesses 7. Therefore, an extremely excellent three-dimensional effect can be visually recognized. In the following description, the depth d indicates the depth of the resin at the deepest portion of the groove-shaped recess 7.
[0028]
It is preferable that the depth d of the groove-shaped concave portion 7 formed in this way is 2 to 70 μm. If the depth d of the groove-shaped recess 7 is less than 2 μm, the height h of the bank-shaped protrusions 8 formed on both sides of the groove-shaped recess 7 is not formed high enough to allow a sufficient three-dimensional effect to be visually recognized. . On the other hand, it is not practical to form the groove-shaped concave portion 7 with a depth exceeding 70 μm, which requires a large pressing force.
[0029]
The height h of the bank-shaped projection 8 formed simultaneously with the groove-shaped recess 7 is preferably 2 to 70 μm. If the height h of the bank-shaped projections 8 is less than 2 μm, a sufficient three-dimensional effect cannot be visually recognized. On the other hand, forming the height h of the bank-shaped convex portion 8 to be more than 70 μm requires a large pressing force and is not practical.
[0030]
The depth d of the groove-shaped concave portion 7 and the height h of the bank-shaped convex portion 8 are determined by the height of the joint pattern engraved on the embossing roll and the heating of the resin surface of the multi-layer resin film-coated metal plate. It can be adjusted by appropriately selecting the temperature and the pressing force of the embossing roll.
[0031]
In the above process, it is also possible to perform embossing at the same time as laminating the multilayer resin film on the metal plate 1. That is, the metal plate 1 is heated to a temperature of the melting point of the film which is in contact with the metal plate 1 of the multilayer resin film 1, that is, the colored resin film 2 or the adhesive resin film 6 ± 10 ° C, and the polyester resin constituting the multilayer resin film is heated. A pair of embossing rolls in which a multilayer resin film preheated to a temperature equal to or higher than the highest glass transition temperature is brought into contact with the heated metal plate 1 and an embossing roll having a joint pattern engraved in a convex shape is used as one roll. And press with a metal sheet coated with a multilayer resin film. In this way, the lamination and the embossing can be performed simultaneously.
[0032]
Next, a colored coating 9 is applied to the inside of the groove-shaped recess 7 formed as described above. By applying this coating 9, the joint pattern is emphasized, so that the color of the colored coating 9 can be clearly distinguished from the color tone of the colored resin film 2 or the printed layer 5 so as to be distinguished from the colored resin film 2 or the printed layer 5. Are preferably painted in different colors. However, the same color tone as that of the colored resin film 2 or the printed layer 5 is preferred for some applications, and the color of the coating 9 is appropriately selected depending on the application. The coating 9 may not need to be applied depending on the application, and whether or not the coating is performed is appropriately selected depending on the application. Furthermore, it is preferable to apply the coating 9 such that the coating width of the coating 9 is equal to or less than the width of the groove-shaped concave portion 7 and the coating 9 does not protrude from the bank-shaped convex portion.
[0033]
Next, a case of manufacturing using a pre-processing method will be described. First, a multilayer resin film is prepared according to the steps of the post-processing method described above. Next, the multilayer resin film is heated to a temperature equal to or higher than the highest glass transition temperature of the polyester resin constituting the multilayer resin film, and an embossing roll having a joint pattern engraved in a convex shape is used as one roll. Using a pair of embossing rolls, the resin film on the outermost surface of the multilayer resin film, that is, the colored resin film 2 or the transparent resin film 4 is sandwiched so as to be in contact with the embossing roll in which the joint pattern is formed in a convex shape. A groove-shaped concave portion 7 shown in FIG. 4 and a bank-shaped convex portion 8 on both sides of the groove-shaped concave portion 7 are formed. The preferred ranges of the depth d of the groove-shaped concave portion 7 and the height h of the bank-shaped convex portion 8 are, similarly to the post-processing method, the height of the joint-shaped convex portion engraved on the embossing roll and the multilayer resin. It can be adjusted by appropriately selecting the heating temperature of the resin surface of the film-coated metal plate and the pressing force of the embossing roll.
[0034]
Then, the metal plate 1 is heated to a temperature of the melting point of the colored resin film 2 or the adhesive resin film 6 ± 10 ° C., that is, a film in contact with the metal plate 1 of the above-mentioned embossed multilayer resin film. The jointed design resin film coated metal is brought into contact with the heated metal plate 1 by sandwiching the metal plate 1 and the multilayer resin film subjected to the embossing using a pair of laminating rolls and pressing the metal plate 1 together. A plate 10 can be obtained. When excellent adhesion between the metal plate 1 and the multilayer resin film is required, as shown in FIGS. 1, 2 and 3, heat bonding is performed between the metal plate 1 and the multilayer resin film via the adhesive 3. Is preferred.
[0035]
When applying the colored coating 9 in the groove-shaped concave portion 7 formed by the pre-processing method, the coating 9 is applied in the same manner as the post-processing method, but in the pre-processing method, after the multilayer resin film is embossed. Or after the embossed multilayer resin film is laminated on the metal plate 1.
[0036]
【Example】
(Sample Nos. 1-4)
A cream-colored PBT film (thickness: 60 μm, intrinsic viscosity: 1.0) containing 20% of titanium dioxide as a coloring pigment and 1% or less of carbon black, titanium yellow, and red iron oxide on each side, and a gray marble pattern on one surface. A non-stretched transparent PBT film (thickness: 15 μm, intrinsic viscosity: 1.0) on which printing (urethane-based ink) was applied was laminated under a condition of applying a pressure of 40000 N and a heating temperature of 80 ° C. Next, a hot-dip galvanized steel sheet having a thickness of 0.5 mm (coating amount: 180 g / m2) ² ) Is subjected to a coating type chromate treatment (40 mg / m as Cr) ² After forming a chemical conversion coating with a coating amount of), applying a polyester adhesive and removing the solvent by drying, the above-prepared films are overlapped, sandwiched using a pair of pressure rolls, and pressed while heating. And laminated. At the time of lamination bonding, a hot-dip galvanized steel sheet was heated to 230 ° C. and a pressing force of 40000 N was applied. Next, the laminated steel sheet is heated to 220 to 230 ° C., and one pair of embossing rolls having a convex portion having a width of 3 mm and a height of 40 μm cut in the circumferential direction of the rolls and an elastic roll lined with silicone rubber as the other pair. The embossing roll was applied with a pressing force of 20,000 to 120,000 N to form a groove-shaped concave portion having a depth shown in Sample Nos. 1 to 4 in Table 1 and a bank-shaped convex portion having a height shown in Table 1. Next, a black polyester-based paint was applied to the groove-shaped concave portions using silk screen printing, and further heated and dried at 100 ° C. for 5 minutes to obtain a joint design resin film-coated metal plate.
[0037]
(Sample Nos. 5 to 8)
Hot-dip galvanized steel sheet with a thickness of 0.5 mm (coating amount: 180 g / m ² ) Is subjected to a coating type chromate treatment (40 mg / m as Cr) ² After forming a chemical conversion treatment film having a film amount of 3), a polyester-based adhesive was applied thereto, and the solvent was removed by drying. Then, 16% of titanium dioxide, 2% of titanium yellow, and 2% of cobalt blue were prepared as color pigments by a co-extrusion method. And a transparent ET / EI copolymer composed of 90 mol% of ethylene terephthalate and 10 mol% of ethylene isophthalate (thickness: 10 μm, thickness: 70 μm, intrinsic viscosity: 1.0). A two-layer film having an intrinsic viscosity of 0.6) was laminated, sandwiched using a pair of pressure rolls, and laminated while being pressed while heating. At the time of lamination bonding, a hot-dip galvanized steel sheet was heated to 230 ° C. and a pressing force of 40000 N was applied. Next, the laminated steel sheet is heated to 230 to 240 ° C., and one pair of embossing rolls having a protrusion of 3 mm in width and 60 μm in height engraved in the circumferential direction of the rolls, and an elastic roll lined with silicone rubber as the other pair. The embossing roll was applied with a pressing force of 20000 to 240000 N to form groove-shaped concave portions having a depth shown in Sample Nos. 5 to 8 of Table 1 and bank-shaped convex portions indicating the height. Next, a white polyester paint was applied to the groove-shaped concave portions using silk screen printing, and further heated and dried at 100 ° C. for 5 minutes to obtain a joint design resin film-coated metal plate.
[0038]
(Sample Nos. 9 to 12)
Carbon black is blended with a resin obtained by blending a modified product (trade name: PET-G, manufactured by Eastman Chemical Co.) in which the ethylene glycol component of 50% by weight of PBT and 50% by weight of PET is replaced with 1,4-cyclohexanedimethanol. A transparent biaxially stretched PET film (thickness 15 μm, intrinsic viscosity 0.7) coated with a transparent urethane adhesive is adhered to a black film (thickness 60 μm, intrinsic viscosity 1.0) containing 5%. An elastic roll lined with silicone rubber, with one embossed roll engraved with a convex part having a width of 3 mm and a height of 40 μm, heated to 80 to 180 ° C. with the special surface in contact with the black film and heated to 80 to 180 ° C. Using a pair of embossing rolls on the other side, the embossing rolls are in contact with the transparent biaxially stretched PET film, and the Simultaneously with pressure bonding both films loaded with pressure, to form a bank-like protrusions showing a groove-like recess and the height of the depth of that in samples 9-12 Table 1. Next, a hot-dip coated steel sheet of 95% zinc-5% aluminum alloy having a thickness of 0.5 mm (coating amount: 180 g / m2) ² ) Is subjected to a coating type chromate treatment (40 mg / m as Cr) ² After forming a chemical conversion treatment film with a film amount of), applying a polyester-based adhesive and drying and removing the solvent, the above-prepared films are overlapped, sandwiched using a pair of pressure rolls, and pressurized while heating. And laminated. At the time of lamination bonding, a hot-dip steel sheet of the above alloy was heated to 230 ° C. and a pressing force of 40000 N was applied. Next, a white polyester paint was applied to the groove-shaped concave portions using silk screen printing, and further heated and dried at 100 ° C. for 5 minutes to obtain a joint design resin film-coated metal plate.
[0039]
(Sample Nos. 13 to 16)
Hot-dip galvanized steel sheet with a thickness of 0.5 mm (coating amount: 180 g / m ² ) Is subjected to a coating type chromate treatment (40 mg / m as Cr) ² The coating is coated with a polyester-based adhesive and the solvent is dried and removed, and then heated to 220 to 230 ° C. to obtain a gray color containing 19% of titanium dioxide and 1% of carbon black as a color pigment. A pair of embossing rolls having a PBT film (thickness: 80 μm, intrinsic viscosity: 1.0) abutting thereon and having a protrusion of 3 mm in width and 40 μm in height engraved thereon, and an elastic roll lined with silicone rubber as the other pair. At the same time, a resin film is laminated and adhered to a hot-dip galvanized steel sheet of zinc by applying a pressing force of 20,000 to 120,000 N using the embossing roll, and at the same time, a groove-shaped concave portion having a depth shown in Sample Nos. 13 to 16 in Table 1 and A bank-shaped convex portion indicating the height was formed. Next, a white polyester paint was applied to the groove-shaped concave portions using silk screen printing, and further heated and dried at 100 ° C. for 5 minutes to obtain a joint design resin film-coated metal plate.
[0040]
[Table 1]

[0041]
(Evaluation of sample characteristics)
The following characteristics were evaluated for the prepared sample numbers 1 to 16.
[Moisture resistance]
After the sample was aged in a constant temperature and humidity atmosphere of 60 ° C. and 95% RH for 500 hours, a forced peel test was performed using an adhesive tape, and the moisture resistance was evaluated based on the following criteria.
◎: No peeling was observed at all.
：: Slight peeling that does not cause a problem in practical use is observed.
Δ: Peeling to a degree that is problematic in practical use is observed.
×: The entire surface is peeled.
[Visual evaluation of joint design]
The joint design was visually observed by seven different persons and evaluated according to the following criteria. The color was observed from the front of the sample plate, and the unevenness was observed from a 45 ° diagonal direction of the sample plate.
：: All seven persons were determined to be identifiable.
：: It is determined that 4 to 6 out of 7 persons can be identified.
B: It is determined that 1 to 3 persons among 7 persons can be identified.
×: All seven persons were determined to be indistinguishable.
Table 1 shows the evaluation results.
[0042]
【The invention's effect】
The joint design resin film-coated metal plate of the present invention is a colored single-layer resin film, or a colored resin film having an adhesive resin film on or below the colored resin film, and a laminated transparent resin film printed on the colored resin film. On one surface of the multilayer resin film, a resin film with a groove-like concave part and a bank-like convex part on both sides of the groove-like concave part is laminated on a metal plate. The groove-shaped recess and the joints formed by the bank-shaped protrusions on both sides of the groove-shaped recess provide a clear and three-dimensional design effect, and also have excellent moisture resistance, and are excellent in bathrooms, toilets, It can be suitably applied as a wall material or a ceiling material for a so-called water-around portion of a building such as a toilet or a kitchen.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing one example of a joint design resin film-coated metal plate of the present invention.
FIG. 2 is a schematic sectional view showing another example of the joint design resin film-coated metal plate of the present invention.
FIG. 3 is a schematic cross-sectional view showing another example of the joint design resin film-coated metal plate of the present invention.
FIG. 4 is an enlarged schematic cross-sectional view showing an example of a groove-shaped recess formed on the surface of the joint design resin film of the present invention and bank-shaped protrusions on both sides of the groove-shaped recess.
FIG. 5 is a schematic perspective view showing an example of an embossing roll for forming a groove-like concave portion and a bank-like convex portion on both sides of the groove-like concave portion on the surface of the joint design resin film of the present invention.
[Explanation of symbols]
1: metal plate
2: Colored resin film
3: Adhesive
4: Transparent resin film
5: Printing layer
6: Adhesive resin film
7: Groove-shaped recess
8: Bank-shaped convex part
9: Colored paint
10: Joint design resin film coated metal plate
11: Embossing roll
11a: cylindrical roll part
11b: convex part
d: Depth of groove-shaped recess
h: Height of bank-shaped protrusion

Claims

A joint design resin film, wherein a groove-shaped concave portion and a bank-shaped convex portion on both sides of the groove-shaped concave portion are formed on a surface of the resin film.

The joint design resin film according to claim 1, wherein the depth of the groove-shaped concave portion is 2 to 70 m.

The joint design resin film according to claim 1, wherein the height of the bank-shaped convex portions is 2 to 70 μm.

The joint design resin film according to claim 1, wherein a colored coating is applied to the groove-shaped concave portion.

The joint design resin film according to any one of claims 1 to 4, wherein the resin film is a colored resin film containing a coloring pigment.

The joint design resin film according to any one of claims 1 to 4, wherein the resin film is a multilayer resin film formed by laminating a colored resin film containing a color pigment and a transparent resin film.

A multilayer resin film in which a resin film is laminated with a colored resin film containing a color pigment and a transparent resin film on which printing of a color different from that of the colored resin film on one side is performed so that the printed layers are in contact with each other. The joint design resin film according to any one of claims 1 to 4, wherein

A colored resin film is made of polybutylene terephthalate (hereinafter, referred to as PBT) containing a color pigment, or PBT containing an upper color pigment and a lower ethylene terephthalate / ethylene isophthalate copolymer (hereinafter, referred to as ET / EI). The joint design resin film according to any one of claims 5 to 7, wherein the joint design resin film is made of a multilayer resin according to (1).

The joint design resin film according to claim 6, wherein the transparent resin film is made of PBT or polyethylene terephthalate (hereinafter, referred to as PET).

A joint design resin film-coated metal plate obtained by laminating the joint design resin film according to claim 1 on a metal plate.

The joint design resin film-coated metal plate according to claim 10, wherein the joint design resin film is laminated with an adhesive between the joint design resin film and the metal plate.

The joint design resin film-coated metal sheet according to claim 10 or 11, wherein the metal sheet is a hot-dip coated steel sheet of zinc or a hot-dip coated steel sheet of 95% zinc-5% aluminum alloy.

After pressurizing the surface of the resin film using an embossing roll engraved with a joint pattern, forming a groove-shaped concave portion and a bank-shaped convex portion on both sides of the groove-shaped concave portion, apply a colored coating in the groove-shaped concave portion. A method for producing a joint design resin film, wherein the method is performed.

The surface of the resin film is pressurized using an embossing roll engraved with a joint pattern, forming a groove-like concave part and a bank-like convex part on both sides of the groove-like concave part, and applying a colored coating in the groove-like concave part. A method for producing a joint-design resin film-coated metal plate, comprising: laminating a joint-design resin film comprising:

The method for producing a joint-design resin film-coated metal plate according to claim 14, wherein an adhesive is applied to the metal plate, and the joint design resin film is brought into contact with the adhesive-applied surface and pressed and laminated.

An adhesive is applied to a metal plate, and a resin film is brought into contact with the adhesive-coated surface by pressing and laminating. Then, the surface of the resin film is pressed using an embossing roll having an engraved joint pattern to form a groove-shaped recess. And forming a bank-like convex portion on both sides of the groove-shaped concave portion, and applying a colored coating in the groove-shaped concave portion.