JP2010201391A - Coating film smoothing method and coating film smoothing device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an easily automated coating film smoothing method and coating film smoothing device. <P>SOLUTION: The coating film smoothing device includes an irradiation means 130 for irradiating an uneven area 44 formed on the surface 42 of a coating film 40 with energy beam producing heat by the incidence to the surface 42 of the coating film 40, and a control means 160 for smoothing the uneven area 44 by melting the coating film 40 and making it flow by the heat produced by the energy beam with the control of the irradiation means 130. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a coating film smoothing method and a coating film smoothing apparatus.

  For example, since the painted surface of an automobile body is required to have high appearance quality, when a foreign object is found on the surface of the coating film, it is repaired and repaired. In the repair repair, for example, after removing foreign matter using sanding paper, the uneven area (foreign matter removal trace) is smoothed by a buffing machine.

  Since repair by buffing is difficult to automate, smoothing using a laser beam has been attempted (see, for example, Patent Document 1).

JP 2007-329271 A

  However, the concavo-convex region on the surface of the coating film has various concavo-convex shapes, but the laser beam removes the convex portion in the concavo-convex region and has a problem that the application range is narrow. Therefore, after all, finishing work by a buffing machine may be required, and automation is difficult.

  The present invention has been made in order to solve the problems associated with the above-described prior art, and an object thereof is to provide a coating film smoothing method and a coating film smoothing apparatus that can be easily automated.

  The uniform phase of the present invention for achieving the above object is a coating smoothing method. This coating film smoothing method irradiates an uneven area formed on the surface of the coating film with an energy beam that generates heat by being incident on the surface of the coating film, and the coating film is applied by the generated heat. It has the process of smoothing the said uneven | corrugated area | region by making it melt and flow.

  Another uniform phase of the present invention for achieving the above object is a coating film smoothing apparatus having irradiation means and control means. The said irradiation means irradiates the uneven | corrugated area | region currently formed in the surface of the said coating film with the energy beam which generate | occur | produces a heat by injecting into the surface of a coating film. The control unit controls the irradiation unit and smoothes the uneven region by melting and flowing the coating film with heat generated by the energy beam.

  According to the coating film smoothing method according to the present invention and the coating film smoothing apparatus according to another uniform phase, the uneven area on the surface of the coating is smoothed in a non-contact manner by the energy beam. Compared to a contact type such as polishing, automation is easier. In addition, since smoothing of the uneven area is caused by the flow of the molten coating film, it is effective not only for the convex part in the uneven area but also for the concave part, and can be applied to various uneven shapes. It is possible to suppress the occurrence of defective parts and avoid finishing operations that are difficult to automate, such as buffing, in a subsequent process. That is, it is possible to provide a coating film smoothing method and a coating film smoothing apparatus that can be easily automated.

It is the schematic for demonstrating the coating-film smoothing apparatus which concerns on Embodiment 1. FIG. It is a flowchart for demonstrating the coating process to which the coating-film smoothing method which concerns on Embodiment 1 is applied. It is sectional drawing for demonstrating the coating-film surface after the top-coat process shown by FIG. It is sectional drawing for demonstrating the coating-film surface after the foreign material removal process shown by FIG. It is a chart for demonstrating the coating-film surface shape after the smoothing process shown by FIG. It is a flowchart for demonstrating the coating process to which the coating-film smoothing method which concerns on Embodiment 2 is applied. It is the schematic for demonstrating the coating-film smoothing apparatus which concerns on Embodiment 2. FIG. It is a flowchart for demonstrating the coating process to which the coating-film smoothing method which concerns on Embodiment 3 is applied. It is a flowchart for demonstrating the coating process to which the coating-film smoothing method which concerns on Embodiment 4 is applied. It is sectional drawing for demonstrating the smoothing process shown by FIG.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic diagram for explaining a coating film smoothing apparatus according to Embodiment 1. FIG.

  The coating film smoothing apparatus 100 according to Embodiment 1 includes a vacuum chamber 110, a table unit 120, an electron gun (irradiation means) 130, a vacuum apparatus 140, and a controller (control means) 160. The uneven region 44 formed on the surface 42 of the coating film 40 is used to smooth the surface in a non-contact manner by an electron beam (energy beam). The object to be coated 10 is, for example, an automobile body.

  The uneven | corrugated | grooved area | region 44 consists of a minute rise | swell of the coating-film surface by the fine bubble which remained in the coating-film 40, or the foreign material mixed in or adhering to the coating-film 40, or a hollow. The foreign matter is airborne dust in the air, falling dust from the worker, fine solid matter in the paint, and the like.

  The vacuum chamber 110 has an openable door for carrying the article to be coated 10, and a table unit 120 and an electron gun 130 are disposed. The table unit 120 includes a holder 122 on which the article to be coated 10 is placed and a driving unit 124 for driving the holder 122. The drive unit 124 includes, for example, a linear motor, and is configured to be able to move the holder 122 along two horizontal axes.

  The electron gun 130 is used to irradiate an electron beam onto the coating film surface 42 of the workpiece 10 placed on the holder 122. The electron gun 130 includes an electron beam generator 132, an electron beam accelerator 134, and an electron lens system 136. Have. The electron beam generator 132 includes a filament and a cathode that generate thermoelectrons. The electron beam acceleration unit 134 has an anode for generating a strong electromagnetic field by applying a high voltage to the cathode of the electron beam generation unit 132. The electron lens system 136 includes a lens that adjusts the convergence angle, a convergence lens, a deflection lens, and the like. The number of electron beam irradiations is not particularly limited, and is repeated several times to several tens of times, for example, at intervals of about 10 s as necessary.

  The electron gun 130 is not particularly limited to the above-described configuration, and for example, a plasma electron gun that is filled with a low-pressure ionized gas and turned into plasma can be applied.

  The vacuum device 140 has a vacuum pump and the like, and is used to control the degree of vacuum of the vacuum chamber 110 when irradiating an electron beam.

  The controller 160 includes a programmable controller having a control unit 162 and a storage unit 164. The control unit 162 is a control circuit composed of a microprocessor or the like, and integrally controls the vacuum chamber 110, the table unit 120, the electron gun 130, and the vacuum device 140 according to a control program.

  The storage unit 164 includes a read-only storage device such as a ROM, a high-speed random access storage device such as a nonvolatile RAM, and a large-capacity random access storage device such as a hard disk drive, and stores a control program and various setting data. And a work area for executing the control program. The control program includes an electron gun so as to smooth the uneven area 44 of the coating surface 42 by melting and flowing the top coating film 40 by heat generated by the electron beam applied to the coating surface 42. A program for controlling 130 is included.

  In the coating film smoothing apparatus 100, as described above, the uneven area 44 formed on the coating film surface 42 is smoothed in a non-contact manner by an electron beam, and therefore, compared with a contact type such as buffing. Easy to automate. In addition, since the smoothing of the uneven area 44 is caused by the flow of the melted top coat film 40, it is effective not only for the convex portions in the uneven area 44 but also for the concave portions, and can be applied to various uneven shapes. Therefore, it is possible to suppress the occurrence of defective smoothing and to avoid a finishing operation that is difficult to be automated such as buffing in a subsequent process.

  An electron beam is preferable because it can be easily generated, propagated, concentrated and distributed, and deflected, and can easily cope with various irradiation conditions. Reference numerals 20 and 30 denote an undercoating film and an intermediate coating film.

  Next, a coating process to which the coating film smoothing method (smoothing step) according to Embodiment 1 is applied will be described.

  FIG. 2 is a flowchart for explaining a coating process to which the coating film smoothing method according to Embodiment 1 is applied, and FIG. 3 is a cross-sectional view for explaining the coating film surface after the top coating step shown in FIG. 4 and 4 are cross-sectional views for explaining the surface of the coating film after the foreign matter removing step shown in FIG.

  As shown in FIG. 2, the coating process according to the first embodiment includes a pretreatment process, an undercoating process, an intermediate coating process, an overcoating process, a foreign matter removing process, a carrying-in process, a smoothing process, and a removing process.

  In the pretreatment process, the object to be coated 10 made of an automobile body is subjected to degreasing and chemical conversion treatment by a dip method or a continuous spray method. The degreasing agent is, for example, an emulsion-based or alkaline degreasing agent. In the chemical conversion treatment, a zinc phosphate treatment solution having good compatibility with iron and zinc is applied to form a chemical conversion coating having a function of improving rust prevention and adhesion between the article 10 and the undercoat coating 20. To do. The zinc phosphate treatment liquid contains, for example, phosphoric acid and first zinc phosphate as main components, and includes an oxidizing agent (such as nitric acid, nitrite, and chlorate), a reducing agent, a metal salt, and the like as an accelerator.

  In the undercoating step, the undercoating film 20 is formed by electrodeposition coating or powder coating. The undercoat coating film 20 has a function of improving the adhesion between the article to be coated 10 and the coating film. The undercoat paint is, for example, a cation type electrodeposition paint or a powder paint having an epoxy resin or a polyester resin as a main resin.

  In the intermediate coating process, the intermediate coating film 30 is formed by air spray, airless spray, or electrostatic coating. The intermediate coating film 30 has a function of surface adjustment for making up for the appearance of the top coating finish while compensating for defects in the undercoat coating film. The intermediate coating is, for example, a solvent-type, water-based, non-aqueous, or high solid type paint.

  In the top coating step, the top coating film 40 is formed by air spray, airless spray, or electrostatic coating. The top coat film 40 has functions of imparting aesthetics and imparting environmental durability (such as weather resistance, chemical resistance, and wear resistance). The top-coat paint according to Embodiment 1 is made of a soft paint with improved scratch resistance, and includes self-healing clear # 200 manufactured by Sumitomo 3M Limited. As the top coat, a solid color paint, a metallic paint, a normal clear paint, or a combination thereof can be used. The coating film is not limited to a three-layer structure.

  In the foreign matter removing step, the foreign matter 50 (see FIG. 3) adhering to the coating film surface 42 after the completion of coating is removed using sanding paper. As a result, as shown in FIG. 4, an uneven region (repair site) 44 having a foreign matter removal trace remains. The particle size of the sanding paper is, for example, # 1500 to # 2500. The foreign matter 50 can be removed by, for example, a knife, and in this case, the foreign matter removal trace is a scratch formed by the knife.

  In the carrying-in process, the door of the vacuum chamber 110 in the atmosphere is opened, and the article 10 is placed on the holder 122. When the door is closed and sealed, the coating film smoothing apparatus 100 is controlled according to the control program. As a result, the vacuum device 140 operates and the inside of the vacuum chamber 110 is depressurized. The drive part 124 of the table part 120 is operated, and the holder 122 moves. Thereby, the uneven | corrugated area | region 44 located in the coating-film surface 42 of the to-be-coated article 10 mounted in the holder 122 is positioned in the irradiation position of an electron beam.

  In the smoothing step, the concavo-convex region 44 is smoothed by irradiating the concavo-convex region 44 formed on the coating film surface 42 with an electron beam, and melting and flowing the top coat film 40 with the generated heat. . At this time, the electron gun 130 is operated in accordance with the control program, and the electron beam generated and accelerated by the electron beam generating unit 132 and the electron beam accelerating unit 134 is irradiated to the coating film surface 42 via the electron lens system 136. . The number of times of irradiation with the electron beam is repeated several times to several tens of times as necessary, for example, at intervals of about 10 s.

  The electron beam is incident on the coating film surface 42 to generate heat, and the top coating film 40 is melted and fluidized by the heat to smooth the uneven area 44 that is a coating defect of the top coating film 40. . Thereby, the coating defect of the top coat film 40 is repaired.

  Moreover, since the uneven | corrugated | grooved area | region 44 of the coating-film surface 42 is smooth | blunted by an electron beam, it is easy to automate compared with a contact type like buffing. In addition, since the smoothing of the uneven area 44 is caused by the flow of the melted top coat film 40, it is effective not only for the convex portions in the uneven area 44 but also for the concave portions, and can be applied to various uneven shapes. Therefore, it is possible to suppress the occurrence of defective smoothing and to avoid a finishing operation that is difficult to be automated such as buffing in a subsequent process.

  Furthermore, since the top coat film 40 is made of a soft paint having improved scratch resistance, when the uneven area 44 is smoothed by buffing, the surface temperature of the paint film rises to 50 to 60 ° C. due to frictional heat. When the film is softened, the polishing property (polishing property) is lowered and the time required for smoothing becomes longer. On the other hand, in the first embodiment, since the coating film surface 42 is smoothed in a non-contact manner by the electron beam, the time required for smoothing is not affected.

  In the extraction step, when the smoothing by the electron beam irradiation is completed, the vacuum chamber 110 is opened to the atmosphere according to the control program, and the object to be coated 10 is extracted from the door of the vacuum chamber 110.

  FIG. 5 is a chart for explaining the coating surface shape after the smoothing step shown in FIG.

  The coating film surface shape after the smoothing process was measured for three types of coating films 1 to 3 having different surface conditions. In addition, regarding the height difference [μm] and the surface roughness (Ra) [μm] of the uneven area before the smoothing step, the coating film 1 is 0.02 to 0.05 and 0.005 to 0.010, and the coating film 2 is 0.65 to 0.90 and 0.1 to 0.3, and the coating film 3 is 1.0 to 1.5 and 0.3 to 0.5. The reason why the coating film 1 is smaller in height difference and surface roughness than the coating film 2 and the coating film 3 is that it is subjected to rough polishing after the foreign matter removing step.

  As shown in FIG. 5, in any of the three types of coating films 1 to 3 having different coating film surface shapes, a height difference of 0.01 or less and a surface roughness of 0.005 or less were obtained.

  As described above, according to the coating film smoothing method and the coating film smoothing apparatus according to Embodiment 1, the uneven area formed on the coating film surface is smoothed in a non-contact manner by the energy beam. Compared to a contact type such as buffing, automation is easier. In addition, since the smoothing of the uneven area is caused by the flow of the melted top coat film, it is effective not only for the convex part in the uneven area but also for the concave part, and can be applied to various uneven shapes. It is possible to suppress the occurrence of defective parts and to avoid finishing operations that are difficult to automate, such as buffing, in a subsequent process. That is, Embodiment 1 can provide a coating film smoothing method and a coating film smoothing apparatus that can be easily automated.

  In addition, the energy beam is an electron beam, and since generation, propagation, concentrated dispersion, and deflection are simple, it is easy to cope with various irradiation conditions.

  Furthermore, since the uneven | corrugated | grooved area | region of the coating-film surface smoothed is a foreign material removal trace of top coat film, this corrects the coating defect of top coat film 40.

  Next, a second embodiment will be described.

  FIG. 6 is a flowchart for explaining a coating process to which the coating film smoothing method according to the second embodiment is applied, and FIG. 7 is a schematic diagram for explaining the coating film smoothing apparatus according to the second embodiment. It is.

  The second embodiment is different from the first embodiment in that the electron beam irradiation conditions are adjusted according to the configuration of the uneven region, and as shown in FIG. 6, between the carry-in process and the smoothing process, It further has a three-dimensional shape detection step and an irradiation condition setting step.

  In addition, the coating-film smoothing apparatus 200 which concerns on Embodiment 2 has the measuring device 250 for measuring the three-dimensional shape of the uneven | corrugated area | region 44 in a non-contact type, as FIG. 7 shows. The measurement device 250 includes a light source for applying measurement illumination to the uneven region 44 and an imaging sensor that scans reflected light from the uneven region 44.

  Further, in the control program stored in the storage unit 264 of the controller 260 of the coating film smoothing apparatus 200, the image signal from the measuring apparatus 250 is processed, and the three-dimensional shape (including the position) of the uneven region 44 is processed. A program for detection and a program for determining the irradiation condition of the electron beam based on the detected three-dimensional shape are included. The irradiation conditions of the electron beam are, for example, an irradiation range, the number of irradiations, and an irradiation output. Reference numeral 262 denotes a control unit of the controller 260.

  Next, the three-dimensional shape detection step and the irradiation condition setting step will be described.

  In the three-dimensional shape detection step, the three-dimensional shape of the concavo-convex region 44 on the coating surface 42 of the object 10 is detected in a non-contact manner by the measuring device 250 controlled according to the control program. At this time, the measurement device 250 applies illumination for measurement to the uneven area 44 of the coating film surface 42 and scans the reflected light from the uneven area 44.

  In the irradiation condition setting step, the irradiation condition of the electron beam is determined based on the detected three-dimensional shape. Therefore, since the irradiation condition of the electron beam in the subsequent smoothing process is optimized, smoothing can be performed efficiently. The three-dimensional shape preferably includes at least the height difference and the surface roughness (Ra) of the uneven region 44. In this case, the irradiation condition of the electron beam can be optimized efficiently.

  As described above, according to the second embodiment, since the electron beam irradiation condition is determined based on the three-dimensional shape of the uneven region, the electron beam irradiation condition is optimized. Therefore, smoothing can be performed efficiently. Further, when the three-dimensional shape of the concavo-convex region includes at least the height difference of the concavo-convex region and the surface roughness (Ra), the irradiation condition of the electron beam can be optimized efficiently. Note that it is also preferable to consider the coating composition in determining the electron beam irradiation conditions.

  Next, a third embodiment will be described.

  FIG. 8 is a flowchart for explaining a coating process to which the coating film smoothing method according to the third embodiment is applied.

  The third embodiment is different from the second embodiment in that the quality of smoothing is determined. As shown in FIG. 8, the three-dimensional shape detection process and the quality determination process are performed between the smoothing process and the extraction process. Is arranged. The coating film smoothing apparatus according to the third embodiment is substantially the same as the coating film smoothing apparatus 200 according to the second embodiment, except that the quality determination program is included in the control program. Omitted to avoid duplication. The quality determination program is for determining whether the smoothed three-dimensional shape of the uneven area satisfies the quality.

  In the three-dimensional shape detection step, the three-dimensional shape of the uneven region 44 after smoothing is detected in a non-contact manner by the measuring device 250 controlled according to the control program. At this time, the measurement device 250 applies illumination for measurement to the uneven area 44 of the coating film surface 42 and scans the reflected light from the uneven area 44.

  In the quality determination step, it is determined whether or not the detected three-dimensional shape satisfies the quality. Thereby, it is easy to automate the final quality check, and the number of man-hours can be reduced. The quality is evaluated by, for example, the height difference of the uneven region 44 and the surface roughness (Ra). In addition, when quality is not satisfy | filled, it is also preferable to return to a smoothing process and smooth an uneven | corrugated area | region again.

  As described above, according to the third embodiment, it is easy to automate the final quality check, and the number of man-hours can be reduced.

  Next, a fourth embodiment will be described.

  FIG. 9 is a flowchart for explaining a coating process to which the coating film smoothing method according to Embodiment 4 is applied, and FIG. 10 is a cross-sectional view for explaining the smoothing step shown in FIG.

  The fourth embodiment is different from the first embodiment in that the object of smoothing is an intermediate coating film, and as shown in FIG. 9, a carry-in process and a smoothing process are performed between the intermediate coating process and the top coating process. The conversion process and the extraction process are arranged. In addition, since the coating-film smoothing apparatus 100 which concerns on Embodiment 1 is applied to the coating-film smoothing apparatus which concerns on Embodiment 4, the description is abbreviate | omitted in order to avoid duplication.

  In the carrying-in process, the door of the vacuum chamber 110 in the atmosphere is opened, and the article 10 on which the intermediate coating film 30 is formed is placed on the holder 122. When the door is closed and sealed, the coating film smoothing apparatus 100 is controlled according to the control program. As a result, the vacuum device 140 operates and the inside of the vacuum chamber 110 is depressurized. The drive part 124 of the table part 120 is operated, and the holder 122 moves. Thereby, the uneven | corrugated area | region 34 currently formed in the coating film surface 32 of the intermediate coating film 30 is positioned in the irradiation position of an electron beam. The concavo-convex area 34 is composed of minute bubbles remaining on the intermediate coating film 30, minute bulges or depressions on the coating film surface 32 due to foreign matter mixed in or attached to the intermediate coating film 30.

  In the smoothing step, as shown in FIG. 10, the electron gun 130 is operated according to the control program, the electron beam is irradiated onto the coating surface 32 of the intermediate coating film 30, and the coating film is formed by the generated heat. By melting and flowing, the uneven area 34 of the coating film surface 32 is smoothed.

  In the extraction step, when the smoothing by the electron beam irradiation is completed, the vacuum chamber 110 is opened to the atmosphere according to the control program, and the object to be coated 10 is extracted from the door of the vacuum chamber 110. The top coating film 40 is formed on the object to be coated 10 in the subsequent top coating process. At this time, since the coating film surface 32 of the intermediate coating film 30 is smoothed, the sharpness after the top coating is improved.

  In addition, the 3D shape detection process and the irradiation condition setting process according to Embodiment 2 are arranged before the smoothing process, or the 3D shape detection process and quality determination according to Embodiment 3 are performed after the smoothing process. It is also possible to arrange processes.

  As described above, according to Embodiment 4, since the surface of the intermediate coating film is smoothed, the sharpness after the top coating is improved.

  The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims. For example, the fourth embodiment can be additionally incorporated in the first to third embodiments. The object to be painted is not limited to the body of an automobile. As the coating film, a thermosetting type or a thermoplastic type can be applied. The energy beam is not limited to an electron beam.

10 Object 20 Undercoat film,
30 Intermediate coating film,
32 Coating surface,
34 Uneven region,
40 Top coat film,
42 Coating surface,
44 Uneven region,
50 foreign matter,
100 coating film smoothing device,
110 vacuum chamber,
120 table section,
122 holder,
124 drive unit,
130 electron gun (irradiation means),
132 electron beam generator,
134 Electron beam acceleration unit,
136 electron lens system,
140 vacuum equipment,
160 controller,
162 control unit,
164 storage unit,
200 coating film smoothing device,
250 measuring device,
260 controller (control means),
262 control unit,
H.264 storage unit.

Claims (8)

By irradiating an uneven region formed on the surface of the coating film with an energy beam that generates heat by being incident on the surface of the coating film, and by melting and flowing the coating film by the generated heat, A method of smoothing a coating film, comprising a step of smoothing an uneven region.   The coating film smoothing method according to claim 1, wherein the energy beam is an electron beam. The coating film is a top coating film,
The method for smoothing a coating film according to claim 1 or 2, wherein the uneven region is a repair site having a removal trace of foreign matter mixed in or adhering to the top coat film.   The coating film smoothing method according to claim 1, wherein the coating film is an intermediate coating film. Detecting the three-dimensional shape of the uneven region in a non-contact manner;
Determining an irradiation condition of the energy beam based on the detected three-dimensional shape;
The coating film smoothing method according to any one of claims 1 to 4, further comprising:   The coating film smoothing method according to claim 5, wherein the three-dimensional shape of the uneven region includes at least a height difference of the uneven region and a surface roughness (Ra). Detecting the smoothed three-dimensional shape of the uneven region in a non-contact manner;
Determining whether the detected three-dimensional shape satisfies quality;
The coating film smoothing method according to claim 1, further comprising: Irradiation means for irradiating an uneven region formed on the surface of the coating film with an energy beam that generates heat by being incident on the surface of the coating film;
Control means for smoothing the uneven area by controlling the irradiation means, and melting and flowing the coating film by heat generated by the energy beam;
The coating film smoothing apparatus characterized by having.

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