JP3101068B2 - Manufacturing method of metal products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a metal workpiece which is capable of etching a predetermined portion with high accuracy and is excellent in mass productivity.

[0002]

2. Description of the Related Art Conventionally, a masking liquid composed of a polymer solution is applied and dried, then cured to form a coating on a non-processed part, and the coated part is coated with an etchant to etch the surface of a predetermined part of the metal part. There has been known a method of manufacturing a metal processed product which is removed to form a desired pattern for decorative purposes or the like (Japanese Patent Publication Nos. 48-2649 and 49-27024).

[0003] However, it is difficult to form a uniform coating film and it is easy to cause corrosion unevenness, and it is difficult to remove the coating film after the etching treatment. There are problems such as inferior problems, particularly in a case where a coating film is provided on a large area, remarkably inferior in production efficiency, and difficulty in controlling the adhesion of the coating film to a metal part. If the adhesive strength of the coating film to the metal component is too weak, the corrosive liquid penetrates from the masking edge to make it difficult to form a precise pattern, and if it is too strong, it becomes difficult to remove it after etching.

[0004]

SUMMARY OF THE INVENTION The present invention is capable of coating with a film thickness excellent in uniformity, hardly causes corrosion unevenness, and is easy to remove the coating film after the etching process. In this case, we will develop a method of manufacturing metal products that can be coated efficiently and have excellent manufacturing efficiency, and that can easily control the adhesion of the coating film to metal parts and have excellent anti-corrosion liquid penetration from the masking edge. Make it an issue.

[0005]

According to the present invention, a masking sheet provided with an adhesive layer on a corrosion-resistant film is sequentially pressed by a linear pressure of 1 to 30 kg / cm while heating at least the surface of a metal part. A method of manufacturing a metal product, comprising: forming a coating film on a non-processed portion of a metal component by bonding, and etching the same with a corrosive solution to remove the surface of the non-processed portion. It is.

[0006]

[Function] By using a masking sheet having an adhesive layer provided on a corrosion-resistant film, coating can be performed with a film thickness excellent in uniformity, corrosion unevenness does not easily occur, and the coating film after the etching treatment is easily removed. The required portion can be efficiently covered even if it has a large area, and the production efficiency is excellent, and the adhesive strength of the coating film to the metal component can be easily controlled based on the adhesive layer.

On the other hand, by adhering the metal parts at least by heating at least at the surface thereof by a sequential pressure bonding method with a linear pressure of 1 to 30 kg / cm, it is possible to suppress the incorporation of air bubbles even in the case of a large-area coating, and from the masking end. Can be prevented, the masking sheet can be prevented from peeling off during etching, and a precise pattern can be formed.

That is, in the above description, even if the metal parts such as a metal plate reflect light sufficiently, they are rarely mirror-finished and generally have irregularities on the surface. R _max is about 10 μm. Therefore, in the method of bonding the masking sheet to the entire surface at once, it is difficult to avoid the incorporation of air bubbles even if the adhesive treatment is performed carefully, especially when the bonding area is as large as 1 m × 2 m or more, the air bubbles are easily taken in. The bubbles may partially concentrate with time. In such a case, 8
During the etching process, which is usually performed by immersing in a corrosion liquid at 0 to 120 ° C. for 1 hour or more, the taken-in air bubbles are likely to cause peeling of the masking sheet and penetration of the corrosion liquid.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In a method of manufacturing a metal processed product according to the present invention, a masking sheet is sequentially bonded to a metal part having at least a heated surface by a pressure bonding method, a coating film is formed on a non-processed part, and then the surface of the non-coated part is formed. The etching process is performed with a corrosive liquid. FIG. 1 illustrates an example of the manufacturing process. 2 is a heating step, 3 is a coating step, and 4 is an etching step. 1
Is a washing step.

In the present invention, at least the surface of a metal component such as a metal plate is heated before the masking sheet is bonded. The heating temperature is preferably from 30 to 120C. If the heating temperature is lower than 30 ° C., the adhesive strength that resists the etching process may not be exhibited. If the heating temperature is higher than 120 ° C., the adhesive force may be too strong to make it difficult to remove the masking sheet after the etching process.

In the illustrated embodiment, a metal part 5 washed with a solvent such as toluene through a brush 6 or the like is conveyed to a heating step 2 through a conveyor 7 and is heated by a heating means 8 such as a hot air drying tower.
Heating through. Note that the heating step 2 in the embodiment also serves as a drying treatment of a cleaning liquid such as a solvent.
The cleaning step 1 for metal parts is intended to remove contaminants such as dust, dust, foreign matter, and oil, which are likely to cause the penetration of the corrosive liquid. In the present invention, it is desirable to provide a cleaning step. Note that a brush or the like may be used for the cleaning process.

Next, the metal component heated to a predetermined temperature is coated with a masking sheet. The bonding of the masking sheet is performed by a sequential pressure bonding method using a linear pressure of 1 to 30 kg / cm, particularly a linear pressure of 8 kg / cm or more. If the linear pressure is less than 1 kg / cm, it is easy to take in bubbles due to insufficient pressure bonding, it will be peeled off due to enormous increase due to the rise in temperature of the taken-in bubbles during etching, and it will be easy for penetration of corrosive liquid. If it exceeds 30 kg / cm, the adhesive strength will be too strong. This makes it difficult to remove the masking sheet after the etching process.

The sequential pressure bonding method using a predetermined linear pressure may be performed by an appropriate method such as a method using a pressing roll such as a laminator roll. The masking sheet to be bonded may be heated to activate the adhesive layer.

In the illustrated embodiment, the metal part 5 heated to a predetermined temperature is conveyed to the coating step 3 via a conveyor 7 and the surface of the metal part 5 is pressed through pressing rolls 11 arranged above and below the metal part 5. The masking sheet 10 is successively pressed on the back surface to cover it. Reference numeral 9 in the drawing denotes a roll around which the masking sheet 10 is wound.

The masking sheet used in the present invention has a corrosion-resistant film provided with an adhesive layer. As the corrosion-resistant film, an appropriate film that can withstand the etching treatment with a corrosive liquid can be used. Examples thereof include polyester, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, ABS resin and the like.

In particular, from the viewpoints of workability when cutting into a predetermined shape and workability when peeling from a metal part, polyethylene, ethylene-based copolymers or blends thereof, polypropylene and propylene-based copolymers Or a polyolefin-based film composed of a blend thereof or the like is preferably used.

The thickness of the corrosion-resistant film is 20 to 500 μm.
m, preferably 30 to 300 μm. If it is too thin, it tends to include defects such as insufficient strength and pinholes, and if it is too thick, poor workability at the time of bonding to metal parts and peeling of stress at the time of etching tend to occur. Corrosion resistant film is modified by surface oxidation treatment such as corona treatment, flame treatment, ozone treatment, etc. for the purpose of improving the adhesive strength with the adhesive layer and preventing transfer of the adhesive layer to the metal parts (adhesive residue). Processing can be performed.

For forming the adhesive layer, for example, styrene / butadiene copolymer system, polyethylene system, polyamide system,
An appropriate adhesive such as a vinyl-based, silicone-based, or epoxy-based adhesive can be used. From the viewpoint of obtaining a masking sheet that is unlikely to cause layer separation (adhesive residue) from the corrosion-resistant film during peeling even when immersed in a high-temperature corrosive solution for a long period of time, one having excellent cohesion at 80 ° C. or higher is preferred.

Above all, an adhesive using chloroprene rubber and / or nitrile rubber is preferably used from the viewpoint of smooth peelability after etching and prevention of penetration of corrosive liquid. Examples of such an adhesive include a chloroprene-based adhesive, a nitrile-based adhesive, a mixture of a chloroprene-based adhesive and a nitrile-based adhesive, a mixture of a chloroprene-based adhesive and a nitrile rubber, and a mixture of a nitrile-based adhesive and chloroprene rubber. And the like.

In particular, a highly adhesive type, a thermally activated type, particularly a chloroprene rubber having a low crystallinity, a blend of methyl methacrylate grafted products of a chloroprene rubber and a chlorinated butyl rubber, and a nitrile having a low nitrile content Those made of rubber are preferred. In addition, a chloroprene-based adhesive is preferable in terms of resistance to etching treatment with a corrosive liquid.

Generally used chloroprene-based adhesives or nitrile-based adhesives control adhesive strength by adding necessary compounding agents such as tackifying resins, fillers, softeners, and crosslinking agents to chloroprene rubber or nitrile rubber. It was done.
As the tackifying resin, typically, a phenolic resin, a terpene-modified phenolic resin, a rosin-modified phenolic resin,
Highly polar resins such as terpene resins, rosins, and cumarone resins are used.

Other fillers include, for example, calcium carbonate, clay, colloidal silica, etc., softeners include, for example, phthalic acid esters such as dioctyl phthalate and various oils, and cross-linking agents include, for example, various vulcanizing agents. , Zinc oxide and magnesium oxide for chloroprene rubber, nitrile rubber, especially polyfunctional isocyanates and melamine compounds for carboxy-modified nitrile rubber,
Epoxy compounds and the like are generally used. The thickness of the adhesive layer may be appropriately determined, but is generally 10 to 200 μm.
m.

The masking sheet which can be preferably used in the present invention has an adhesive force (180 ° peel, peeling speed 300 mm / min) to a metal component of 200 to 16 at 20 ° C.
It is formed so as to be 00 g / 20 mm, 300 g / 20 mm or more at 100 ° C., and to have a heat shrinkage rate of 0.5% or less during etching in each of the vertical and horizontal directions. As a result, it is possible to smoothly remove and remove the adhesive portion without exposing the etched portion, prevent the penetration of the corrosive liquid, prevent the exfoliation due to the heat shrinkage stress at the time of etching, and smoothly remove and remove the adhesive residue after the etching. Can be.

The heat shrinkage of the masking sheet can be adjusted, for example, by removing the heat shrinkage strain in advance at a temperature slightly higher than the etching temperature, or by using a corrosion resistant film from which the heat shrinkage strain has been removed. Can be done with

The coating film made of a masking sheet is provided on a portion to be prevented from being etched by contact with a corrosive liquid. Therefore, in the case of a metal plate or the like, the coating film can be formed only on the required portions on the front and back surfaces by leaving the side surface exposed with the metal ground because it can be easily removed by cutting the peripheral edge as necessary. .

The application of a coating film to a required portion of a metal part is performed as follows.
Appropriate methods such as a method of bonding a masking sheet formed in a predetermined covering shape in advance to a predetermined position, a method of bonding a masking sheet to the entire surface of a metal part, and then cutting out a masking sheet of a portion to be etched and exposing a metal ground. It can be done in a manner.

In the covering step 3 of the illustrated embodiment, a method is adopted in which the masking sheet 10 is adhered to the front and back surfaces of the metal component 5 and then the masking sheet to be etched is cut off to expose the metal ground.

The metal part having the coating film formed on the non-treated portion is then subjected to an etching treatment with a corrosive liquid to remove the surface of the non-coated portion. The etching treatment with the etchant may be performed by an appropriate method such as a conventional method. Therefore, as the corrosive liquid, for example, an appropriate liquid corresponding to the metal component to be processed, such as an alkali-based or acid-based liquid, can be used, and conditions such as a processing time and a processing temperature are set according to the etching thickness and the like. Good.

A general etching method is a method in which a metal component is immersed in a corrosive solution composed of a 2 to 40% by weight aqueous alkaline solution such as sodium hydroxide or potassium hydroxide. At that time, the etching solution is usually 80 to 12 in terms of processing efficiency.
It is heated to about 0 ° C., and the immersion time is usually 30 to 180 minutes.

In the etching step 4 of the illustrated embodiment,
The metal part 5 provided with the coating film 10 is immersed in a corrosive liquid 13 stored in a liquid storage tank 12. Note that the etching treatment can be performed by a spray method of a corrosive liquid or the like, and may be performed by an appropriate method. The above-described spray method has an advantage that the formation of a coating film on the back surface or the like where the spray liquid does not adhere can be omitted.

After the etching process with the corrosive liquid is completed, the metal parts are washed with water or the like as necessary, and then the coating film (masking sheet) is peeled off to obtain the target patterned metal parts. Metal processed product is obtained.

In the present invention, for example, aluminum,
Any metal part made of magnesium, titanium, steel, stainless steel, copper, or an alloy thereof such as duralumin can be subjected to the etching treatment. The form of the metal part is also arbitrary, such as a plate or a cylinder, and the present invention can be particularly advantageously applied to a large metal part such as a metal plate having a length and width exceeding 1 m × 2 m. The purpose of the etching process is arbitrary, for example, formation of a decorative pattern, thinning, surface treatment, unevenness processing, and the like.

Example 1 9 parts of polypropylene (parts by weight, the same applies hereinafter) and ethylene
Vinyl acetate copolymer (vinyl acetate content 12% by weight) 1
After a corona treatment was applied to one side of a corrosion-resistant film having a thickness of 60 μm, which was made of a blend with the above parts, a chloroprene-based adhesive was applied to the surface to provide an adhesive layer having a thickness of 50 μm to form a masking sheet. The composition of the chloroprene adhesive is 100 parts of chloroprene rubber, 5 parts of magnesium oxide.
Parts, zinc oxide 3 parts, phenol-based tackifying resin 5 parts, silica-based filler 5 parts, antioxidant 1 part, and carbon black 1 part.

Next, the front and back surfaces of the duralumin plate having a length of 2 m and a width of 1.5 m are washed with a brush using toluene, and then the duralumin plate is heated to 60 ° C. under drying, and immediately the masking sheet is dried. Are sequentially pressed from one end of the duralumin plate to the other end at a linear pressure of 5 kg / cm through a laminating roll, and thereafter, a predetermined portion of the masking sheet is cut off to expose the duralumin surface, and 15% by weight water heated to 100 ° C. The substrate was immersed in a sodium oxide-based aqueous solution for about 80 minutes to perform etching.

Then, the duralumin plate was taken out, washed with water, and the masking sheet was peeled off to obtain the desired duralumin plate. In the obtained duralumin plate, no peeling of the masking sheet and no trace of etching due to penetration of the corrosive liquid into the coated portion were observed, and the predetermined portion set in advance with the coating film was accurately etched. No adhesive residue was observed after the masking sheet was peeled off.

Example 2 100 parts of carboxy-modified nitrile rubber, 30 parts of novolak type phenolic tackifier resin, 5 parts of silica filler,
Except for using a masking sheet having an adhesive layer formed by using a nitrile-based adhesive composed of 2 parts of a polyfunctional isocyanate and 1 part of an antioxidant, a duralumin plate was etched according to Example 1. Obtained.

In the obtained duralumin plate, no peeling of the masking sheet and no trace of etching due to permeation of the corrosive liquid into the coating portion were observed, and the predetermined portion set in advance with the coating film was accurately etched. Was. No adhesive residue was observed after the masking sheet was peeled off.

Comparative Example 1 An etched duralumin plate was obtained in the same manner as in Example 1 except that a masking sheet was sequentially pressed on a duralumin plate whose surface temperature was lowered to about 20 ° C. In the obtained duralumin plate, the end of the masking sheet was peeled off, and traces of etching due to the penetration of the corrosive liquid into the coated portion were observed.

Comparative Example 2 An etching product of a duralumin plate was obtained in the same manner as in Example 2 except that a masking sheet was sequentially pressed on a duralumin plate whose surface temperature was lowered to about 20 ° C. In the obtained duralumin plate, the end of the masking sheet was peeled off, and traces of etching due to the penetration of the corrosive liquid into the coated portion were observed.

[0040]

According to the present invention, it is resistant to etching for a long time at a high temperature by a corrosive liquid, and has excellent anti-penetration properties of a corrosive liquid to a coating portion, anti-peeling properties, and smooth exfoliation with no adhesive residue. A metal workpiece having an accurate etching pattern can be formed. In addition, the sheet method eliminates the need for drying and hardening treatments, has no restrictions on pot life, and has excellent uniformity. Large-area mask processing can be performed easily, with good workability, and can be performed with high accuracy and efficient coating. It is possible to obtain a processed metal product having no corrosion unevenness with high production efficiency.

[Brief description of the drawings]

FIG. 1 is a cross-sectional explanatory view illustrating a manufacturing process.

[Explanation of symbols]

 2: Heating process 5: Metal parts 7: Conveyor 8: Heating means 3: Coating process 10: Masking sheet 11: Press roll 4: Etching process 13: Corrosion liquid

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) C23F 1/00

Claims (1)

(57) [Claims] 1. A non-treatment of a metal part by bonding a masking sheet comprising a corrosion-resistant film provided with an adhesive layer in a sequential pressure bonding method with a linear pressure of 1 to 30 kg / cm while heating at least the surface of the metal part. A method of manufacturing a metal workpiece, comprising: forming a coating film on a portion; and etching the coating film with a corrosive solution to remove the surface of the non-coated portion.