JP2007268880A - Resin film coated steel sheet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a resin film coated steel sheet enhanced in the adhesion of a pressure-sensitive adhesive material, a sealing material, an adhesive material, etc. while keeping the anti-staining function possessed by a water repellent, and the resin film coated steel sheet. <P>SOLUTION: The manufacturing method of the resin film coated steel sheet comprises forming a water repellent layer on one side of a resin base material layer and forming a steel sheet on one side opposite to the resin base material layer. The method is composed of an air bubble mixing process for mixing fine air bubbles with a water repellent solution prepared by mixing the water repellent with a solvent, a coating process for coating one side of the resin base material layer with the water repellent solution, a first heating process for heating the water repellent solution in order to fix the same to the resin base material layer as the water repellent layer and a second heating process for heating the fixed water repellent solution at a temperature higher than that of the first heating process. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a resin-coated steel sheet and a resin-coated steel sheet manufacturing method, and more particularly to a resin-coated steel sheet and a resin-coated steel sheet manufacturing method having antifouling properties.

  As a wall panel that constitutes the wall surface of a bathroom unit, etc., the interior side surface is made of decorative steel plate, etc., and the backside material of the outdoor side is made of steel plate, etc., both of which are plasterboard, asbestos, glass wool except for the edges on both sides Such a type that is attached to and integrated with a core material 53 such as the above is widely performed.

  The indoor side surface is easily contaminated with scattered shower water, scales, and the like, and chemicals such as shampoos, soaps, and bathing agents also adhere to the indoor surface, so that it is desired to have antifouling properties and chemical resistance.

  In this respect, many materials having water repellency such as silicone compounds have excellent water repellency and chemical resistance, and it is preferable that they can be used for a coating layer of a decorative steel sheet.

In fact, by utilizing the excellent water repellency, chemical resistance, etc. possessed by the silicone compound, a resin coating film is formed on the metal body by powder coating, and a coating layer mainly composed of the silicone compound is formed on the resin coating film. A method of manufacturing a formed metal body is known (for example, see Patent Document 1).
JP-A-6-254492

  However, even if such a water-repellent agent is applied to the surface to improve the antifouling performance, this water-repellent layer can be used on the surface with an adhesive material such as tape, a sealing material typified by a caulking material, or in use. When some kind of adhesion is required, such as an adhesive such as a label that describes protection of equipment, household goods, or human bodies, there are cases where they are difficult to adhere, they are easy to peel off, and it is difficult to maintain the adhesion state. Or even if it was bonded at first, the adhesive force may decrease with the passage of time, and the bonded portion may peel off or may float.

  In particular, when used as a water-surrounding member such as a wall panel of a bathroom unit, a sealing material intended to prevent the penetration of liquid typified by water is difficult to adhere, and liquid leakage occurs due to peeling. It becomes a fatal problem that a member which is in trouble when wet becomes wet and becomes unusable.

  The present invention has been made in consideration of the above-described circumstances, and maintains the antifouling function of a water repellent, while improving the adhesion of adhesive materials, sealing materials, adhesives, and the like. It aims at providing a coated steel plate manufacturing method.

  In order to solve the above-described problem, the method for producing a resin-coated steel sheet according to the present invention forms a water-repellent layer on one surface of the resin base layer as described in claim 1 and is opposite to the resin base layer. In forming a steel plate on one side, a bubble mixing step of mixing fine air bubbles into a water-repellent aqueous solution containing a water repellent in a solvent, and a coating step of applying the water-repellent to one side of the base material layer And a first heating step for heating the water-repellent solution to fix the water-repellent layer on the resin substrate layer, and a second heating step for heating the fixed water-repellent layer at a higher temperature than the first heating step. Are provided.

  The main temperature of the first heating step is preferably a temperature at which the solvent is evaporated and the water repellent is oxidized to fix the water repellent layer, as described in claim 2. The main temperature is preferably lower than the melting point of the resin base material layer and higher than the main temperature of the first heating step.

  In addition, preferably, as described in claim 3, a room temperature process placed in a room temperature environment may be provided between the first heating process and the second heating process.

  On the other hand, in order to solve the above-described problem, the resin-coated steel sheet according to claim 5 is manufactured by the method according to any one of claims 1 to 3 described above.

  The resin base material layer preferably has a first resin layer bonded to the steel plate, a transparent second resin layer bonded to the water repellent layer, as described in claim 5, It is also possible to form a decorative layer sandwiched between them.

  According to the method for producing a resin-coated steel sheet according to the present invention, it is possible to improve the adhesion of an adhesive material, a sealing material, an adhesive material and the like while maintaining the antifouling function of the water repellent.

  An embodiment of a method for producing a resin-coated steel sheet according to the present invention will be described with reference to the accompanying drawings. FIG. 1 is a cross-sectional view of a resin-coated steel sheet 1 manufactured by the method for manufacturing a resin-coated steel sheet according to the present invention. The resin-coated steel plate 1 shown in this embodiment bonds the steel plate 2, the first resin layer 4, the decorative layer 6, the second resin layer 7, the water repellent layer 8, and the steel plate 2 and the first resin layer 4. The second resin layer 7 provided with the first adhesive layer 3 and the decorative layer 6 and the second adhesive layer that bonds the first resin layer 4, and a protective film 9 is attached to the surface of the water repellent layer 8. Is done.

  As the steel plate 2, for example, a hot dip galvanized steel plate having a thickness of about 450 μm is used.

  The first resin layer 4 is a thermoplastic resin, for example, a polyester film having a thickness of 75 to 80 μm, and may be colored to conceal the color of the underlying steel plate 2.

  The adhesive used for the first adhesive layer 3 for laminating the first resin layer 4 to the steel plate 2 is a heat generally used such as a polyester adhesive, a urethane adhesive, an epoxy adhesive, and an acrylic adhesive. It is a curable adhesive and is applied to the steel plate 2.

  Since the second resin layer 7 is a thermoplastic resin and needs to withstand the drying heat in the drying process after the water-repellent layer 8 is applied, the biaxially stretched PET (polyethylene having a thickness of 25 to 50 μm) Often formed by terephthalate). You may comprise this in two layers, 50 micrometers PET and 25 micrometers PET.

  The decorative layer 6 enhances the design by providing a pattern or the like on the surface of the resin-coated steel sheet 1, and is printed on the back surface of the second resin layer 7 by gravure printing, offset printing, screen printing, or the like.

  When the second resin layer 7 and the water repellent layer 8 are formed transparent and the first resin layer 4 is colored, the pattern printed on the decorative layer 6 is not affected by the color of the underlying steel plate 2. Since it can be seen as it is from the surface, the design is improved and the application of the resin-coated steel sheet is expanded.

  The adhesive used for doubling the first resin layer 4 and the second resin layer 7 printed with the decorative layer 6 to form the second adhesive layer 5 is a polyester-based adhesive, a urethane-based adhesive, or an epoxy-based adhesive. A thermosetting adhesive that is generally used, such as an acrylic adhesive, and is applied to the first resin layer 4.

  Here, the second resin layer 7 provided with the decorative layer 6 and the first resin layer 4 are bonded by the second adhesive layer 5 is called a doubling sheet 15, and the water repellent layer 8 is fixed to the doubling sheet 15. This is called a resin base sheet 10. By laminating the resin base sheet 10 on the steel plate 2, corrosion of the steel plate 2 is prevented.

  For the water repellent layer 8, a silicone resin compound is often used. It is desirable that the water repellent layer 8 has a contact angle of the silicone resin compound with water of 100 ° or more. This is because, when the contact angle is less than 100 °, sufficient contamination resistance may not be exhibited depending on the contamination component.

  The thickness of the water repellent layer 8 is preferably 0.01 to 10.0 μm, and more preferably 0.05 to 5 μm. When the thickness of the silicone resin compound is less than 0.01 μm, the effect of improving the stain resistance and oil resistance, which are surface characteristics, is not seen, and there are cases where the coating does not reach the whole and there are pores. is there. On the other hand, when it exceeds 10.0 μm, there arises a problem that the film causes blocking.

  A typical example of the silicone resin compound used in the water repellent layer 8 is a thermosetting silicone resin compound. A thermosetting silicone is a resin composed of a mixture composed of an alkyl siloxane having at least one carbon-carbon double bond and an alkyl siloxane having at least one silicon-hydrogen bond, either directly or diluted in a solvent. The silicone resin compound of the water repellent layer 8 is formed by applying to one surface of the base sheet 10 and thermosetting.

  As these silicone resins, those widely sold in general can be used. Moreover, as long as it has a water-repellent function and an antifouling function, a fluorine compound etc. may be sufficient and it is not limited to a silicone resin compound, for example.

  The water repellent layer 8 has a large number of fine pits formed on a smooth surface. With this smooth surface, the water repellency and antifouling properties inherent to the water repellent layer are maintained, and a large number of fine pits exert an anchor effect on the adhesive and the sealing material, thereby improving the adhesion.

  Accordingly, it is difficult to peel off the sealing material such as the adhesive on the back surface of the caution label describing the personal protection and household property protection methods, and the caulking material for preventing water leakage, thereby ensuring safety.

  The protective film 9 is a PP (polypropylene) sheet having a thickness of about 100 μm, and the surface of the resin-coated steel sheet 1 is processed when the resin-coated steel sheet 1 is conveyed, or until it is processed as a wall panel and attached to the site. It is a curing material to protect and does not constitute the resin-coated steel sheet 1.

  The resin-coated steel sheet 1 according to the present embodiment is configured as described above, and the manufacturing method thereof will be described below with reference to the flowchart of the manufacturing process shown in FIG.

  First, the printing manufacturer prints the second resin layer 7 to form the decorative layer 6 (step S1). As described above, this printing is performed by a known printing method such as gravure printing, offset printing, or screen printing.

  The second resin layer 7 to which the decorative layer 6 is added is doubled with the first resin layer 4 by the laminate manufacturer (step S2). As shown in FIG. 3A, doubling is performed while the first resin layer 4 is wound up, and an adhesive 5a to be the second adhesive layer 5 is applied, and the second resin layer 7 is applied to the applied surface. A doubling sheet 15 is formed by the roller 11. As shown in FIG. 3B, the doubling sheet 15 may be formed by thermal fusion using the heating furnace 12 without providing the second adhesive layer 5.

  In order to improve the adhesion of the silicone resin compound forming the water repellent layer 8 to the doubling sheet 15 on the surface of the doubling sheet 15 on which the water repellent layer 8 is formed, corona discharge treatment, flame (flame) treatment, etc. Surface treatment is performed (step S3).

  Then, after the corona treatment, aging is performed at 40 ° C. for about 24 hours (step S4).

  Next, a water repellent is applied by the coating manufacturer (step S5). As shown in FIG. 4, the water repellent coating is performed by applying the water repellent 8 a to the surface of the second resin layer 7 with the roller 11 while winding the doubling sheet 15, and placing it in the drying furnace 13. By forming the water repellent layer 8 on the sheet 15, the resin base sheet 10 is formed.

  The water repellent solution 8a uses toluene as a solvent to disperse a water repellent containing silicone, but is limited to toluene as long as it serves as a solvent for the water repellent. is not. Moreover, if the water repellent stock solution can be applied, a solvent is not necessary.

  Fine bubbles 8b are also mixed in the water repellent solution 8a. As shown in FIG. 5A, the fine bubbles 8 b can be mixed in the solvent by entraining air when the water repellent is stirred with the solvent and the stirrer 16. Alternatively, as shown in FIG. 5 (b), when the aqueous solution is applied, it may be mixed into the solvent by blowing air when the aqueous solution is in contact with the surface of the doubling sheet 15. However, if natural air can be entrained without blowing air, it does not matter.

  By putting the doubling sheet 15 coated with the water repellent solvent 8a into the drying furnace 13, curing of the water repellent and evaporation of the solvent are promoted. When the water-repellent solution 8a is obtained by dispersing a silicone compound in toluene, it is preferable that the drying furnace 13 is placed in the drying furnace 13 at a main temperature of about 120 ° C. for about 30 seconds. In the case of using an aqueous repellent solution made of other materials, the temperature and time to be placed in the drying furnace 13 are determined according to the material and conditions.

  Since the main temperature of the drying furnace 13 is relatively low, the fine bubbles 8b mixed in the water repellent solvent do not rupture even when expanded, and as shown in FIG. It remains encapsulated inside.

  Here, when the heating temperature by the drying furnace 13 is high to some extent, the fine bubbles 8b expand greatly and rupture as shown in FIG. 6 (b), and the recesses 8c are formed on the surface of the water repellent layer 8. The pits 8c may become larger than necessary, or may burst to fine bubbles 8b deep in the water-repellent layer 8 to generate a large number of pits 8c unnecessarily. The smoothness of the surface of the water layer 8 is impaired, and the water repellency may be lowered.

  Therefore, in order to form the water repellent layer 8, such a problem can be avoided by evaporating the solvent in which the water repellent is dispersed and setting the temperature at which the water repellent is cured. 8 leads to an increase in the efficiency of the formation time.

  Heating by the drying furnace 13 constitutes the first heating step of the present invention, and thereby a sufficient water repellent function can be obtained.

  After application of the water repellent, the resin substrate sheet 10 is aged at about 40 ° C. for 48 hours (step S6).

  Thereafter, the resin base sheet 10 is placed in a normal temperature state (step S7). As a result, the stability of the water-repellent layer 8 can be increased and the water-repellent performance is improved. At this point, the adhesive material for the label with precautions for personal protection and household property protection, and the prevention of water leakage Sealing materials such as caulking materials and adhesives hardly adhere. Even if they are bonded, they are easily peeled off or peeled off over time.

  In addition, as the room temperature process, in addition to what is intentionally left in the room temperature state, for example, the transport time to the manufacturer performing the next step may be considered.

  After passing through the room temperature process, the resin base sheet 10 is laminated on the steel plate 2 (step S8). As shown in FIG. 7, this steel plate laminate is first used on one surface of the steel plate 2 to which the resin base material sheet 10 is bonded using a generally used coating equipment such as reverse coat and kiss coater. The adhesive 3a is applied so as to have a thickness of about 2 to 10 μm.

  And the coating surface is dried and heated by the heating furnace 14 which consists of an infrared heater and / or a hot-air heating furnace, and the resin base material sheet 10 is immediately coat | covered and cooled using a laminator, and the resin-coated steel plate 1 is obtained.

  Since the melting point of the resin base sheet 10 is about 260 ° C., the main temperature of the heating furnace 14 is set so that the surface temperature of the steel plate 2 becomes a temperature of about 190 ° C. to 250 ° C. lower than this. If too much time is taken, the water repellent performance of the water repellent layer 8 deteriorates and affects the antifouling performance. Therefore, the main temperature is preferably within 1 minute.

  As shown in FIG. 6C, when heated at a temperature higher than the main temperature of the drying furnace 13 after the water repellent coating step, the water repellent layer 8 is almost completely cured at this stage. Near microbubbles 8b create pits 8c on the surface due to the expansion pressure of air. However, in the deep part of the water-repellent layer 8, since the periphery of the fine bubbles 8 b is covered with the hardened water repellent, the expansion of the deep micro-bubbles 8 b is suppressed and rarely ruptures. 8c does not occur.

  The smooth surface of the water repellent layer 8 maintains the original water repellency and antifouling properties of the water repellent layer 8, and the recesses 8c exert an anchor effect on the adhesive and the sealing material, thereby providing adhesion. Is increased.

  Accordingly, a safety label can be secured because it is difficult for a sealing material such as a caution label that describes a method for protecting people and household goods, a caulking material that prevents water leakage, and an adhesive to peel off.

  This steel plate laminating step is a step performed even in a normal decorative steel plate or the like that does not have the water repellent layer 8, and by using this step, the recesses 8c are formed on a part of the surface of the water repellent layer. . Therefore, it is not necessary to newly provide a recess forming process, and it is economical because it is not necessary to use a special manufacturing process.

  The heating by the heating furnace 14 constitutes the second heating step of the present invention. Thus, the method for producing the resin-coated steel sheet according to the present invention is the first heating step of fixing the water repellent layer 8 to the doubling sheet 15. And a second heating step for forming a recess 8c on the surface of the fixed water-repellent layer 8.

  However, as described above, the second heating step is also performed in a general steel sheet laminating step in which the water repellent layer 8 is not provided. Therefore, a step added to add the water repellent layer 8 is In essence, it is only the first heating step. On the other hand, since two or more heating steps are added to the water repellent layer 8, there is an advantage that the water repellent layer 8 can be cured more completely.

  The completed resin-coated steel sheet 1 is provided with a protective film for protecting the surface (step S9), transported to a panel maker, cut into a required size, provided with a fold at the end, a plaster board, etc. The core material is lined and molded into a panel (step S10).

  The embodiments described above are for illustrative purposes and do not limit the scope of the invention. Accordingly, those skilled in the art can employ embodiments in which each or all of these elements are replaced by equivalents thereof, but these embodiments are also included in the scope of the present invention.

  For example, in the present embodiment, doubling is performed in which the second resin layer 7 is bonded to the first resin layer 4 prior to the application of the water repellent layer 8, but the order is not limited to this, as shown in FIG. After applying the water repellent layer 8 to the second resin layer 7 (step S14), doubling may be performed (step S17). In this case, the room temperature process may be provided after doubling (see step S16).

Sectional drawing of embodiment of the resin film steel plate which concerns on this invention. The flowchart which shows the manufacturing process of the resin film steel plate shown by FIG. It is a figure explaining a doubling process, (a) is based on adhesion, (b) is a figure showing what is based on thermal fusion. The figure explaining a water repellent coating process. It is a figure explaining the method of mixing a fine bubble in a water-repellent solution, (a) is the method by stirring, (b) is the figure which shows the method by spraying. (A) is a view showing a water-repellent layer containing bubbles, (b) is a view showing a state in which bubbles are ruptured to form a recess, and (c) is a state of the water-repellent layer after the steel sheet laminating step. FIG. The figure explaining a steel plate lamination process. The flowchart which shows the other manufacturing process of a resin film steel plate.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Resin film steel plate 2 Steel plate 3 1st contact bonding layer 4 1st resin layer 5 2nd contact bonding layer 6 Makeup layer 7 2nd resin layer 8 Water repellent layer 8a Water repellent 8b Microbubble 8c Recess 9 Protective film 10 Resin base material Sheet 15 Doubling sheet

Claims (5)

In the method for producing a resin-coated steel sheet, a water repellent layer is formed on one surface of the resin base material layer, and a steel plate is formed on one surface opposite to the resin base material layer.
A bubble mixing process in which fine air bubbles are mixed into a water-repellent aqueous solution containing a water repellent in a solvent,
A coating step of coating the water-repellent solution on one surface of the base material layer;
A first heating step of heating the aqueous repellent to fix the resin base layer as the water repellent layer;
A second heating step of heating the fixed water-repellent layer at a higher temperature than the first heating step;
A method for producing a resin-coated steel sheet, comprising: The main temperature of the first heating step is a temperature at which the solvent is evaporated and the water repellent is cured to fix the water repellent layer.
The method for producing a resin-coated steel sheet according to claim 1, wherein the main temperature of the second heating step is lower than the melting point of the resin base material layer and higher than the main temperature of the first heating step. The method for producing a resin-coated steel sheet according to any one of claims 1 and 2, further comprising a room temperature step placed in a room temperature environment between the first heating step and the second heating step. A resin-coated steel sheet produced by the method according to claim 1. The resin base material layer is formed by forming a first resin layer bonded to the steel plate, a transparent second resin layer bonded to the water repellent layer, and a decorative layer sandwiched therebetween. The resin-coated steel sheet according to claim 5.

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