JP2004314463A

JP2004314463A - Composite steel plate reinforcer and its construction method

Info

Publication number: JP2004314463A
Application number: JP2003112330A
Authority: JP
Inventors: Tomohiro Kawase; 知洋川瀬; Takanori Shiose; 隆範塩瀬
Original assignee: Nihon Tokushu Toryo Co Ltd
Current assignee: Nihon Tokushu Toryo Co Ltd
Priority date: 2003-04-17
Filing date: 2003-04-17
Publication date: 2004-11-11
Anticipated expiration: 2023-04-17
Also published as: JP3849784B2

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the falling and deformation of a material even in washing with water as in case of a chemical treatment process etc., by using a coating material. <P>SOLUTION: In a composite steel plate reinforcer, a layer of the coating material is laminated on a steel plate, and a layer of a sheet material is laminated on the coating material layer. The coating material which is fusion-bonded/integrated to/with the sheet material by heating or without heating is used. The steel plate reinforcer can use at least one sheet material selected from a woven fabric, a nonwoven fabric, a glass cloth, resin-impregnated paper, resin-coated paper, a resin film, metal foil, and a metal fiber cloth. The steel plate reinforcer is constructed so that the coating material is applied at an optional position on the steel plate, the sheet material which is molded or cut to be a shape with the coating material applied in advance and an area approximately equal to or at least 80% of the area is laminated and stuck before the curing of the sheet material, and the steel plate, the coating material, and the sheet material are integrated by a sheet material curing process. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
本発明は、一例として自動車用の鋼板に使用される補強材、およびその施工方法に関する。
【０００２】
【従来の技術】
自動車工業における車両重量の軽減化は常に重要課題となっており、自動車に使用される鋼板も安全上、構造上の要求を満たす限界まで薄くされてきた。このため、特に自動車の外側を形成する鋼板には、鋼板補強材、通常デント材と呼ばれる材料が自動車の内側部分に貼着され、あるいは熱融着されて、鋼板の剛性の向上に寄与している。
【０００３】
これらの補強材は、ゴム系、瀝青系、アルキド樹脂、エポキシ樹脂、ウレタン樹脂、ユリア樹脂等の合成樹脂系材料に、適宜充填材、添加剤を配合して混合、混練りし、従来公知の加工方法によって所望の大きさ、形状に加工し、鋼板の必要部位に貼着されている。
【０００４】
その中で、成形物の補強材では貼着が困難な箇所への補強材の施工、あるいは、より軽量な補強材の開発等、需要者の要求に応えて、本出願人から、塗布型鋼板補強組成物に関する発明を特願平５−１１５２４３号、特願平１１−３５２８９２号、特願２００１−２０９６０４号として出願している。
【０００５】
【発明が解決しようとする課題】
上記発明では、塗布型にすることにより、必要な部位へ必要量のみの補強材の施工を可能にしたことで施工に無駄がなくなり、また、補強材の施工を塗装ロボットや自動塗装機で行なうことで、施工の省人化を実現している。
【０００６】
上記発明になる塗布型補強材は、加熱硬化型樹脂を使用しているため、自動車のプレス工程において塗布されてから、化成処理工程に至る過程においては未だ加熱を受けておらず、未硬化状態である。このため、補強材が塗布された自動車ボディが化成処理液に浸漬されると、未硬化の補強材から無機軽量充填材や体質顔料などが溶け出し、化成処理液を汚染するという問題を起こす可能性があった。この点を解決するべく、常温硬化型樹脂を使用した塗布型鋼板補強材に関する発明を、特願２００３−０４４２８２号として出願している。
しかしながら常温硬化型樹脂の場合、塗布してから硬化するまでの時間が短い樹脂系を採用した場合には、塗布作業現場において塗布材料や塗装機の管理を厳密に行なわないと、硬化可能状態に混合された塗布材料が配管や塗装機ホース中で固化し、配管やホースを塞栓させてしまう虞れがあり、一方硬化までの時間が長い樹脂系を採用した場合には、塗布材料の硬化時間が温度や湿度等の塗布環境に左右され易くなり、硬化が完了しない状態で化成処理工程へ移った場合には、上記した化成処理液の汚染が発生する可能性が残る、等の問題が指摘されていた。
そこで全く新たな視点より、シート型鋼板補強材と塗布型鋼板補強材の双方の長所を活かした複合型鋼板補強材の開発を目的とする。
【０００７】
【課題を解決するための手段】
かかる課題を解決せんとして、本発明者は鋭意研究の結果、次のような複合型鋼板補強材およびその施工方法を開発したものであり、その要旨は以下の通りである。
鋼板補強材であって、鋼板の上に塗布材料からなる層、更にその上にシート材料からなる層が積層一体化されてなることを特徴とする複合型鋼板補強材。
加熱により鋼板、およびシート材料に融着一体化する塗布材料を使用してなることを特徴とする上記に記載された複合型鋼板補強材。
常温において鋼板、およびシート材料に密着一体化する塗布材料を使用してなることを特徴とする上記に記載された複合型鋼板補強材。
織布、不織布、ガラスクロス、樹脂含浸紙、樹脂コート紙、樹脂フィルム、金属箔、金属繊維布から選ばれた１種以上のシート材料を使用してなることを特徴とする上記に記載された複合型鋼板補強材。
任意の鋼板上の位置に塗布材料を塗布し、予め塗布材料が塗布された形状・面積と略同一あるいは８０％以上の面積に成形または裁断されてなるシート材料を、塗布材料の硬化前に積層、貼付し、シート材料の硬化過程により鋼板と塗布材料、シート材料が一体化されてなることを特徴とする複合型鋼板補強材の施工方法。
以下に詳細に説明する。
【０００８】
本発明に使用される鋼板補強材は、塗布材料からなる層と、シート材料からなる層の２層よりなる複合型鋼板補強材である。
【０００９】
塗布材料としては、加熱により硬化し、剛性を発現することによって塗布した面の鋼板に密着し、補強すると同時に、塗布された面に積層貼付されるシート材料にも密着一体化する性質を有するものが使用できる。これらの塗布材料としては、アクリル樹脂系エマルション、酢酸ビニル系エマルション等の樹脂エマルション、ポリブタジエン等の液状ゴム、各種の水系樹脂、各種の溶剤系樹脂に適宜顔料、リン片状充填材、繊維状充填材等の充填材、添加剤を加えて混合分散したものが例示できる。
他の塗布材料としては、硬化のために加熱を必要とせず、塗布した後常温にて硬化し、剛性を発現することによって塗布した面の鋼板に密着し、補強すると同時に、塗布された面に積層貼付されるシート材料にも密着一体化する性質を有することものが使用できる。これらの塗布材料としては、二液混合による架橋硬化型ポリウレタン樹脂、湿気硬化型ポリウレタン樹脂、架橋硬化型エポキシ樹脂、重合反応型アルキッド樹脂、アクリル樹脂等の各種の常温硬化型樹脂に適宜顔料、リン片状充填材、繊維状充填材等の充填材、添加剤を加えて混合分散したものが例示できる。
【００１０】
なお、添加剤として発泡剤を加えることにより、塗布材料の硬化過程において同時に塗膜を発泡させることは、鋼板に歪が発生するのを防止するために有効である。また、本発明の鋼板補強材を自動車用として使用する場合には、塗布面である鋼板の表面には防錆のための油が付着している場合があるため、この様な状態の鋼板面にも付着する材料であることが望ましい。
【００１１】
本発明に使用する塗布材料は、従来公知の塗料用分散機を使用して製造することができる。即ち、ディゾルバー、プラネタリーミキサー、オープンニーダー、真空ニーダー、ロールミル、ボールミル、グレンミル等の分散機である。
【００１２】
上記の塗布材料は、従来公知の塗装方法により、任意の箇所に塗布することができる。刷毛塗り、ローラー塗装、エアスプレー塗装、エアレススプレー塗装、静電塗装、ロールコーター、カーテンフローコーター等が例示できる。工程の自動化を企図している場合には、コンピュータ制御による自動塗装機、塗装ロボットにより塗装させることも可能である。また、鋼板補強に必要な塗膜の膜厚を効率よく、しかも均一、確実に、硬化時に鋼板に歪が発生しない塗布方法を採用することが好ましく、これらの方法の例示として、塗装機のノズルチップにスリット型ノズルを採用する、あるいは旋回型ノズルを備えた塗装機を採用する等が挙げられる。
【００１３】
本発明に用いる塗布材料に積層するシート材料は、粘弾性を有する塗布材料の塗膜を拘束する働きをし、更に自動車の化成処理工程から水洗工程において鋼板に衝突する水流から、塗布材料の塗膜を保護する役割を有する。このため、剛性、強度、防水性、耐水性を有し、軽量で薄層であることが望ましい。更に、補強するべき鋼板面が常に平坦であるとは限らず、例えば自動車のアウタードアパネルの裏面に施工しようとする場合には、アウタードアパネルの曲面に合わせて塗布材料による塗布面が形成されるため、曲面に追従して密着一体化させる必要があるため、剛性と同時に、曲面に追従することができる程度の柔軟性が必要である場合も多い。織布、不織布、ガラスクロス、樹脂含浸紙、樹脂コート紙、金属箔、金属繊維布、ゴムシート、軟質樹脂シートから選ばれたシート材料が使用できる。
【００１４】
織布としては、天然、合成繊維を使用して織り込んだ各種の布、不織布としては、天然、合成繊維を使用してバインダー樹脂により繊維同士を接着し、シート状に加工したもの、ガラスクロスとしてはガラス繊維を不織布と同様にシート状に加工したもの、樹脂含浸紙としては、紙に液状の樹脂を含浸させ、乾燥させて強度、剛性を付与させたもの、樹脂コート紙も同様の目的で、紙の表面に液状樹脂をコーティングさせ、乾燥させたもの、金属箔としては、アルミニウム、アルミニウム合金等の展性、防錆性の高い金属の箔、金属繊維布としては、各種の金属繊維をシート状に加工したもの、ゴムシートとしては、天然、合成等各種のゴムを平板シート状に加工したもの、軟質樹脂シートとしては、塩化ビニル、酢酸ビニル、アルキッド、ポリエチレン、ポリウレタン、エポキシ、ユリア、フェノール等の各種の熱可塑性樹脂、熱硬化性樹脂に適宜可塑剤を加えて軟質化し、平板シート状に加工したものが使用できる。これらの各種のシート材料は、単独であっても、複数を積層して使用することも可能である。
【００１５】
シート材料は、予め塗布材料が塗布される面の面積、形状に合わせて略同一、あるいは塗布される面積の８０％以上の面積に成形、裁断等の加工が施されていることが望ましい。成形、裁断等の加工方法は、シート材料の材質に合わせた方法を適宜採用する。２以上の材質により複層のシート材料とする場合には、この形状裁断加工段階で、予め積層密着一体化加工を施しておいても良い。積層密着一体化は、感圧型接着剤、ホットメルト型接着剤等の接着剤塗布による密着、ステープル、クリップ等の物理的一体化、シート材料自身の接着能を利用しての圧着等、従来公知の方法が使用できる。
【００１６】
塗布材料が、加熱により硬化するタイプであっても、常温により硬化するタイプであっても、塗布材料を塗布後、シート材料を塗布材料の塗装箇所に合わせて載置積層し、塗布材料と一体化させる。単に載置したのみであると、塗布材料とシート材料との密着が不充分であるばかりか、両者の界面に隙間が発生し、シート材料による、塗布材料の拘束効果が期待できない可能性があるため、両者の界面には隙間が発生し無い様に密着させる必要がある。そのためには、シート材料を載置後、シート材料と略同一形状の圧迫器具によりシート材料の上層より圧力をかける、ローラーにより転圧する、空気圧をかける等の方法が挙げられる。圧力は、塗布材料のタック性、シート材料の剛性・柔軟性、材質等を考慮して決められるが、圧力が弱いと密着一体化が不充分となり、強すぎると塗布材料の塗膜が大きく変形し、シート材料の密着で塗布材料が剥離してしまうことがある。
【００１７】
シート材料を塗布材料に載置するには、作業員が手作業により貼付しても良いが、自動機、産業ロボットにより自動貼付を行なってもよい。自動機あるいはロボットによれば、所定の箇所にシート材料を貼付した後、連続作業により加圧密着を行なうことも容易である。自動機、あるいは産業ロボットは、缶やビンといった曲面にシールやラベルを自動貼付する機械が応用可能である。
【００１８】
塗布材料が加熱により硬化する材料である場合には、塗布材料にシート材料を貼付積層した段階では一体化したとは言えず、自動車のボディに施工した場合には、化成処理工程、電着塗装工程を経て、加熱乾燥炉を通過する際に、例えば１６０℃で１０〜２０分という加熱により、塗布材料が補強するべき鋼板、及びシート材料に熱融着し、一体化するものである。なお、塗布材料が常温により硬化する材料である場合には、鋼板及びシート材料との一体化に加熱が不要であることは、言うまでも無い。
また、本発明になる鋼板補強材は、自動車用鋼板に適用する場合を想定して詳細を説明したが、必要に応じて他の輸送機械、鉄道車両、船舶、航空機、あるいは土木・建築・構築物に使用されている鋼板に適用施工し、剛性を付与させることが可能であるのは、言うまでもない。
【００１９】
【発明の実施の形態】
本発明の理解に供するため、以下に実施例を記載する。いうまでもなく、本発明は以下の実施例に限定されるものではない。
【００２０】
【実施例１】
自動車用鋼板（厚さ０．８ｍｍ）にポリブタジエン、エポキシ樹脂、炭酸カルシウムからなる塗布材料１を厚さ平均１ｍｍ、幅２．５ｃｍ、長さ１５ｃｍの長方形の形状に塗布し、この形状と略同一のガラスクロスを積層し、ローラーにより転圧して密着させた。この試験片に水道水を衝突させた後、１７０℃で２５分の加熱を行ない補強材１とした。
【００２１】
【実施例２】
自動車用鋼板（厚さ０．８ｍｍ）にビスフェノールＡ型エポキシ樹脂にエポキシ樹脂反応性希釈剤、炭酸カルシウムを混合した主剤に、反応当量比の硬化剤を混合した塗布材料２を厚さ平均１ｍｍ、幅２．５ｃｍ、長さ１５ｃｍの長方形の形状に塗布し、この形状と略同一のガラスクロスを積層し、ローラーにより転圧して密着させた。この試験片に水道水を衝突させた後、１時間放置し、補強材２とした。
【００２２】
【実施例３】
自動車用鋼板（厚さ０．８ｍｍ）にポリブタジエン、エポキシ樹脂、炭酸カルシウムからなる塗布材料１を厚さ平均１ｍｍ、幅２．５ｃｍ、長さ１５ｃｍの長方形の形状に塗布し、この形状と略同一のアルミニウム箔を積層し、ローラーにより転圧して密着させた。この試験片に水道水を衝突させた後、１７０℃で２５分の加熱を行ない。冷却後に補強材３とした。
【００２３】
【比較例１】
厚さ３．２ｍｍの従来型ゴム系シート状鋼板補強材を裁断し補強材４とし、この片面に粘着剤を塗布し、この粘着剤塗布面を、実施例に使用した鋼板に貼着し補強材４とした。
【００２４】
【比較例２】
自動車用鋼板（厚さ０．８ｍｍ）にポリブタジエン、エポキシ樹脂、炭酸カルシウムからなる塗布材料１を厚さ平均３．２ｍｍ、幅２．５ｃｍ、長さ１５ｃｍの長方形の形状に塗布し、この試験片に水道水を衝突させた後、１６０℃で２０分の加熱を行ない、補強材５とした。
【００２５】
【比較例３】
自動車用鋼板（厚さ０．８ｍｍ）にビスフェノールＡ型エポキシ樹脂にマイカ、炭酸カルシウムを混合した主剤に、反応当量比の硬化剤を混合した塗布材料２を厚さ平均３．２ｍｍ、幅５ｃｍ、長さ２０ｃｍの長方形の形状に塗布し、この試験片に水道水を衝突させた後、１時間放置し、補強材６とした。
【００２６】
【試験方法】
（１）補強材の外観を観察し、形状の異常、脱落の有無を調べた。
（２）各試験片を、１ｍ^２あたりの質量を測定の上、補強性を測定した。補強性は引張試験機にて測定を行った。各試験片を、スパンが１００ｍｍの３点曲げタイプの変形測定ジグに載置し、圧縮速度２００ｍｍ／分で試験片を圧縮し、試験片の最大荷重を測定し、これに重力加速度を乗じて補強性とする。
【００２７】
【結果】
（１）外観
補強材１〜補強材４は外観に変形等の異常は見られなかった。補強材５には水道水の衝突箇所に変形が、補強材６には水道水の衝突箇所に変形・部分的脱落が発生しているのが観察された。
（２）補強性（単位はＮである）

【００２８】
【発明の効果】
本発明による複合型鋼板補強材では、本出願人により以前に出願された、塗布型の鋼板補強材における問題点、即ち、補強性の向上のために塗布材料を２層化し、上層を拘束層とした構造において、これらの材料に常温硬化型樹脂を採用してもなお、自動車塗装ラインにおける化成処理工程、これにつづく水洗、湯洗工程での水流衝突の衝撃による、材料の変形、脱落といった不具合を、塗布材料に積層貼付したシート材料により保護することで解決できた。
また、２層の塗布材料による塗膜を形成しようとすれば、塗装機が２組必要であり、自動塗装機、あるいは塗装ロボットを使用する様に意図した場合、設備投資額が大きなものになることは避けがたい。しかし、本発明では、高価な自動塗装機、若しくは塗装ロボットは１組で良く、拘束層は作業員による手貼り、あるいは、塗装ロボットよりはるかに安価なシート貼り装置を設置すればよいため、設備投資金額が抑制できる。
また、塗布材料のみの鋼板補強材と比較すると、塗布材料にシート材料を貼付し、適正な圧力で加圧するため、塗装面が均一、平滑となり、品質保証上、鋼板補強効果を均一とすることに役立つものである。[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a reinforcing material used for a steel plate for an automobile as an example, and a method for constructing the reinforcing material.
[0002]
[Prior art]
The reduction of vehicle weight in the automobile industry has always been an important issue, and the steel plates used in automobiles have also been reduced to the limit that meets safety and structural requirements. For this reason, especially on the steel sheet forming the outside of the automobile, a material called a steel sheet reinforcing material, usually called a dent material, is attached to the inside of the automobile or is heat-sealed, thereby contributing to the improvement of the rigidity of the steel sheet. I have.
[0003]
These reinforcing materials are rubber-based, bitumen-based, alkyd resin, epoxy resin, urethane resin, urea resin, and other synthetic resin-based materials, appropriately mixed with fillers and additives, mixed and kneaded. It is processed into a desired size and shape by a processing method, and is adhered to necessary parts of a steel plate.
[0004]
In response to the demands of consumers, such as the application of reinforcing materials to places where it is difficult to apply a reinforcing material for molded products, or the development of lighter reinforcing materials, the applicant of the present invention The inventions relating to the reinforcing composition have been filed as Japanese Patent Application Nos. 5-115243, 11-352892, and 2001-209604.
[0005]
[Problems to be solved by the invention]
In the above invention, by using a coating type, it is possible to apply only a necessary amount of reinforcing material to a necessary part, thereby eliminating waste in the construction, and performing the reinforcing material with a painting robot or an automatic painting machine. As a result, labor saving in construction is realized.
[0006]
Since the coating-type reinforcing material according to the invention uses a heat-curable resin, it is not yet heated in the process of being applied in the pressing step of an automobile and then reaching the chemical conversion step, and is in an uncured state. It is. For this reason, when the automobile body coated with the reinforcing material is immersed in the chemical conversion liquid, the inorganic lightweight filler and extender may be dissolved from the uncured reinforcing material, causing a problem that the chemical conversion liquid is contaminated. There was sex. In order to solve this problem, an invention relating to a coating-type steel plate reinforcing material using a cold-setting resin has been filed as Japanese Patent Application No. 2003-044282.
However, in the case of a room temperature curing resin, if a resin system that has a short time from application to curing is used, it must be possible to cure it if the application materials and coating machine are not strictly managed at the application site. There is a risk that the mixed coating material will solidify in the pipe or coating machine hose and plug the pipe or hose.On the other hand, if a resin system that takes a long time to cure is used, the curing time of the coating material Are likely to be affected by the application environment such as temperature and humidity, and if the process is shifted to the chemical conversion treatment process in a state where the curing is not completed, the above-mentioned problem of the possibility of the contamination of the chemical conversion treatment solution remains. It had been.
Therefore, from a completely new point of view, the purpose of the present invention is to develop a composite-type steel plate reinforcement that utilizes the advantages of both sheet-type steel plate reinforcement and coating-type steel plate reinforcement.
[0007]
[Means for Solving the Problems]
In order to solve such problems, the present inventor has developed the following composite steel plate reinforcing material and its construction method as a result of earnest research, and the gist thereof is as follows.
What is claimed is: 1. A composite steel plate reinforcing material, comprising: a layer made of a coating material on a steel plate; and a layer made of a sheet material further laminated and integrated on the steel plate.
The composite-type steel sheet reinforcing material as described above, characterized by using a coating material that is fused and integrated with a steel sheet and a sheet material by heating.
The composite-type steel plate reinforcing material as described above, characterized by using a coating material that is tightly integrated with a steel sheet and a sheet material at room temperature.
A woven fabric, a nonwoven fabric, a glass cloth, a resin-impregnated paper, a resin-coated paper, a resin film, a metal foil, and a metal fiber cloth, which are formed using one or more sheet materials selected from the above, characterized by the above-mentioned. Composite steel plate reinforcement.
A coating material is applied to a position on an arbitrary steel plate, and a sheet material formed or cut into an area approximately equal to or more than 80% of the shape and area to which the coating material has been previously applied is laminated before the coating material is cured. A method for constructing a composite-type steel plate reinforcing material, wherein a steel sheet, an application material and a sheet material are integrated by a process of curing and affixing the sheet material.
This will be described in detail below.
[0008]
The steel sheet reinforcement used in the present invention is a composite steel sheet reinforcement consisting of two layers, a layer made of a coating material and a layer made of a sheet material.
[0009]
The coating material has the property of being cured by heating and exhibiting rigidity, so that it adheres to and strengthens the steel plate on the coated surface, and at the same time, adheres and integrates with the sheet material laminated and attached to the coated surface. Can be used. These coating materials include resin emulsions such as acrylic resin-based emulsions and vinyl acetate-based emulsions, liquid rubbers such as polybutadiene, various water-based resins, various solvent-based resins, pigments, scaly fillers, and fibrous fillers. Examples thereof include those in which fillers such as materials and additives are added and mixed and dispersed.
As another coating material, it does not require heating for curing, it cures at room temperature after application, adheres to the applied steel plate by expressing rigidity, reinforces, and at the same time, It is possible to use a sheet material having a property of being closely adhered to and integrated with a sheet material to be laminated and attached. These coating materials include various room temperature curable resins such as a cross-linkable curable polyurethane resin by mixing two components, a moisture-curable polyurethane resin, a cross-linkable curable epoxy resin, a polymerization reaction type alkyd resin, and an acrylic resin. Examples thereof include fillers such as flake fillers and fibrous fillers, and additives that are mixed and dispersed with additives.
[0010]
It is effective to add a foaming agent as an additive to simultaneously foam the coating film in the process of curing the coating material in order to prevent the occurrence of distortion in the steel sheet. Further, when the steel sheet reinforcing material of the present invention is used for an automobile, oil for rust prevention may be attached to the surface of the steel sheet, which is the coated surface, so that the steel sheet surface in such a state may be used. It is desirable that the material also adheres to the surface.
[0011]
The coating material used in the present invention can be produced using a conventionally known coating disperser. That is, it is a disperser such as a dissolver, a planetary mixer, an open kneader, a vacuum kneader, a roll mill, a ball mill, and a Glen mill.
[0012]
The above-mentioned coating material can be applied to an arbitrary place by a conventionally known coating method. Examples include brush coating, roller coating, air spray coating, airless spray coating, electrostatic coating, roll coater, curtain flow coater, and the like. When the automation of the process is intended, it is also possible to perform the coating by an automatic coating machine or a coating robot under computer control. Further, it is preferable to adopt coating methods that efficiently, uniformly, and surely make the thickness of the coating film necessary for reinforcing the steel sheet so that no distortion occurs in the steel sheet during curing. As an example of these methods, a coating machine nozzle is used. For example, a slit type nozzle may be used for the chip, or a coating machine having a swirl type nozzle may be used.
[0013]
The sheet material to be laminated on the coating material used in the present invention acts to restrain the coating film of the coating material having viscoelasticity, and further, the coating material is coated from the water flow colliding with the steel sheet in the automobile chemical conversion process to the washing process. It has the role of protecting the membrane. For this reason, it is desirable to have rigidity, strength, waterproofness, and water resistance, and to be lightweight and a thin layer. Furthermore, the steel plate surface to be reinforced is not always flat. For example, when it is to be applied to the back surface of the outer door panel of an automobile, the coating surface of the coating material is formed according to the curved surface of the outer door panel. In addition, since it is necessary to closely follow and integrate a curved surface, it is often necessary to have rigidity and flexibility enough to follow a curved surface. Sheet materials selected from woven fabric, nonwoven fabric, glass cloth, resin-impregnated paper, resin-coated paper, metal foil, metal fiber cloth, rubber sheet, and soft resin sheet can be used.
[0014]
As woven fabric, various fabrics woven using natural and synthetic fibers, as nonwoven fabric, natural and synthetic fibers are used to bond fibers with binder resin and processed into sheet form, as glass cloth Is a glass fiber processed into a sheet in the same way as a non-woven fabric, as resin-impregnated paper, paper impregnated with a liquid resin and dried to impart strength and rigidity, and resin-coated paper is also used for the same purpose. The surface of the paper is coated with a liquid resin and dried, and as the metal foil, a metal foil with high malleability and rust-prevention properties such as aluminum and aluminum alloy, and as the metal fiber cloth, various metal fibers are used. Those processed into sheet form, rubber sheets include natural and synthetic rubbers processed into flat sheet form, and soft resin sheets include vinyl chloride, vinyl acetate, alkyd, Riechiren, polyurethane, epoxy, urea, various thermoplastic resins such as phenol, by adding an appropriate plasticizer to the thermosetting resin softened, which was processed into flat sheet can be used. These various sheet materials may be used alone or in a plurality of layers.
[0015]
The sheet material is desirably subjected to molding, cutting, or the like in advance to be substantially the same according to the area and shape of the surface on which the application material is applied, or to an area of 80% or more of the application area. As a processing method such as molding and cutting, a method suitable for the material of the sheet material is appropriately adopted. When a multi-layered sheet material is formed by two or more materials, lamination and adhesion integration may be performed in advance at this shape cutting step. Conventionally known lamination and adhesion integration includes adhesion by applying an adhesive such as a pressure-sensitive adhesive and a hot-melt adhesive, physical integration of staples and clips, and pressure bonding using the adhesive ability of the sheet material itself. Can be used.
[0016]
Regardless of the type of application material that cures by heating or the type that cures at room temperature, after applying the application material, the sheet material is placed and laminated according to the application location of the application material, and integrated with the application material To If simply placed, not only the adhesion between the coating material and the sheet material is insufficient, but also a gap is generated at the interface between the two, and the sheet material may not be able to expect the binding effect of the coating material. For this reason, it is necessary to make close contact so that no gap is generated at the interface between the two. For this purpose, there is a method in which after the sheet material is placed, pressure is applied from an upper layer of the sheet material by a compression device having substantially the same shape as the sheet material, rolling is performed by a roller, or air pressure is applied. The pressure is determined in consideration of the tackiness of the coating material, the rigidity and flexibility of the sheet material, the material, etc.If the pressure is too low, the adhesion and integration will be insufficient, and if it is too strong, the coating of the coating material will be greatly deformed However, the application material may be peeled off due to the close contact of the sheet material.
[0017]
In order to place the sheet material on the coating material, an operator may manually attach the sheet material, or an automatic machine or an industrial robot may perform automatic attaching. According to an automatic machine or a robot, it is easy to perform pressure contact by continuous work after sticking a sheet material to a predetermined location. As an automatic machine or an industrial robot, a machine that automatically applies a seal or label to a curved surface such as a can or a bottle is applicable.
[0018]
If the applied material is a material that cures by heating, it cannot be said that the material is integrated when the sheet material is applied and laminated on the applied material. After passing through the heating and drying furnace after the process, the coating material is thermally fused to the steel sheet and sheet material to be reinforced by, for example, heating at 160 ° C. for 10 to 20 minutes to be integrated. When the application material is a material that cures at room temperature, it goes without saying that heating is not necessary for integration with the steel sheet and sheet material.
In addition, the steel sheet reinforcing material according to the present invention has been described in detail assuming that it is applied to a steel sheet for automobiles. However, as necessary, other transport equipment, railway vehicles, ships, aircraft, or civil engineering / architecture / structures may be used. It is needless to say that it is possible to apply and construct the steel plate used for the steel sheet to impart rigidity.
[0019]
BEST MODE FOR CARRYING OUT THE INVENTION
Examples will be described below to facilitate understanding of the present invention. Needless to say, the present invention is not limited to the following examples.
[0020]
Embodiment 1
A coating material 1 made of polybutadiene, epoxy resin, and calcium carbonate is applied to a steel plate (thickness: 0.8 mm) in a rectangular shape having an average thickness of 1 mm, a width of 2.5 cm, and a length of 15 cm, and is substantially the same as this shape. Of glass cloth was rolled and pressed by a roller to make them adhere to each other. After colliding the test piece with tap water, heating was performed at 170 ° C. for 25 minutes to obtain a reinforcing material 1.
[0021]
Embodiment 2
A coating material 2 in which a base material obtained by mixing a bisphenol A type epoxy resin, an epoxy resin reactive diluent, and calcium carbonate with a steel plate (thickness 0.8 mm), a hardening agent having a reaction equivalent ratio of 1 mm, has an average thickness of 1 mm. It was applied in a rectangular shape having a width of 2.5 cm and a length of 15 cm, and a glass cloth having substantially the same shape as this shape was laminated and rolled by a roller to be closely adhered. After tap water was allowed to collide with the test piece, the test piece was allowed to stand for 1 hour to obtain a reinforcing material 2.
[0022]
Embodiment 3
A coating material 1 made of polybutadiene, epoxy resin, and calcium carbonate is applied to a steel plate (thickness: 0.8 mm) in a rectangular shape having an average thickness of 1 mm, a width of 2.5 cm, and a length of 15 cm, and is substantially the same as this shape. Of aluminum foil was rolled up and brought into close contact with each other by rolling with a roller. After the test piece was made to collide with tap water, heating was performed at 170 ° C. for 25 minutes. After cooling, the reinforcing material 3 was obtained.
[0023]
[Comparative Example 1]
A 3.2 mm-thick conventional rubber sheet-shaped steel sheet reinforcing material is cut to form a reinforcing material 4, an adhesive is applied to one surface thereof, and the adhesive applied surface is adhered to the steel sheet used in Examples to reinforce the steel sheet. Material 4 was used.
[0024]
[Comparative Example 2]
A coating material 1 composed of polybutadiene, epoxy resin, and calcium carbonate is applied to a steel plate for an automobile (0.8 mm in thickness) in a rectangular shape having an average thickness of 3.2 mm, a width of 2.5 cm, and a length of 15 cm. After tap water was made to impinge, heating was performed at 160 ° C. for 20 minutes to obtain a reinforcing material 5.
[0025]
[Comparative Example 3]
A coating material 2 in which a base material obtained by mixing bisphenol A type epoxy resin with mica and calcium carbonate in a steel plate (thickness of 0.8 mm), a curing agent having a reaction equivalent ratio of 3.2, and an average thickness of 3.2 mm, a width of 5 cm, The test piece was applied in a rectangular shape having a length of 20 cm, and the test piece was allowed to collide with tap water.
[0026]
【Test method】
(1) The appearance of the reinforcing material was observed, and abnormalities in the shape and the presence or absence of falling off were examined.
(2) Each test piece was measured for its mass per 1 m ² and then its reinforcing property was measured. The reinforcing property was measured by a tensile tester. Each test specimen was placed on a three-point bending type deformation measuring jig having a span of 100 mm, the test specimen was compressed at a compression speed of 200 mm / min, the maximum load of the test specimen was measured, and this was multiplied by the gravitational acceleration. Reinforcement is required.
[0027]
【result】
(1) The appearance reinforcing materials 1 to 4 did not show any abnormality such as deformation in the appearance. It was observed that the reinforcing member 5 was deformed at the tap water collision point, and the reinforcing member 6 was deformed and partially dropped at the tap water collision point.
(2) Reinforcement (unit is N)

[0028]
【The invention's effect】
In the composite-type steel sheet reinforcement according to the present invention, a problem in the application type steel sheet reinforcement previously filed by the present applicant, that is, the coating material is made into two layers to improve the reinforcing property, and the upper layer is made into a constraining layer Even with the use of a cold-setting resin for these materials, the impact of the impact of the water flow in the chemical conversion process, the subsequent water washing, and the hot water washing process in the automotive coating line may cause the material to deform and fall off. The problem could be solved by protecting the problem with a sheet material laminated and applied to the coating material.
In addition, two sets of coating machines are required to form a coating film with two layers of coating materials. If an intention is made to use an automatic coating machine or a coating robot, the amount of capital investment becomes large. That is inevitable. However, in the present invention, one set of an expensive automatic coating machine or coating robot may be used, and the constraining layer may be manually attached by an operator or a sheet attaching device that is much cheaper than the painting robot may be installed. Investment amount can be reduced.
In addition, when compared with a steel sheet reinforcement using only the coating material, since the sheet material is attached to the coating material and pressurized with an appropriate pressure, the coated surface becomes uniform and smooth, and the quality assurance of the steel sheet must be uniform. It is useful.

Claims

What is claimed is: 1. A composite steel plate reinforcing material comprising: a steel plate reinforcing material, wherein a layer made of a coating material is further laminated and integrated on a steel plate.

The composite steel plate reinforcing material according to claim 1, wherein a coating material that is fused and integrated with the steel sheet and the sheet material by heating is used.

The composite-type steel sheet reinforcing material according to claim 1, wherein a coating material that is tightly integrated with the steel sheet and the sheet material at room temperature is used.

It is characterized by using one or more sheet materials selected from woven fabric, nonwoven fabric, glass cloth, resin-impregnated paper, resin-coated paper, resin film, metal foil, metal fiber cloth, rubber sheet, and soft resin sheet. The composite-type steel plate reinforcing material according to claim 1.

A coating material is applied to a position on an arbitrary steel plate, and a sheet material formed or cut into an area approximately equal to or greater than 80% of the shape and area to which the coating material has been applied in advance is laminated before the coating material is cured. A method of constructing a composite-type steel sheet reinforcing material, wherein a steel sheet, a coating material, and a sheet material are integrated by a curing process of attaching and sticking the sheet material.