JP4141641B2 - Embossing processing method and manufacturing method of decorative metal plate - Google Patents

Embossing processing method and manufacturing method of decorative metal plate Download PDF

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JP4141641B2
JP4141641B2 JP2000579665A JP2000579665A JP4141641B2 JP 4141641 B2 JP4141641 B2 JP 4141641B2 JP 2000579665 A JP2000579665 A JP 2000579665A JP 2000579665 A JP2000579665 A JP 2000579665A JP 4141641 B2 JP4141641 B2 JP 4141641B2
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resin
resin film
temperature
tma
tss
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寛之 岩下
幸治 田熊
義之 杉本
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Toyo Kohan Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • B32B15/04Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/0036Heat treatment
    • B32B38/004Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/06Embossing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/726Permeability to liquids, absorption
    • B32B2307/7265Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00Buildings or parts thereof

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Description

【技術分野】
【0001】
本発明はユニットバス等の耐水性を必要とする建材等に使用するエンボス加工性に優れた樹脂フィルム又はシート(以下、「樹脂フィルム」という。)のエンボス加工処理方法、及び化粧金属板の製造方法に関する。
【背景技術】
【0002】
化粧金属板はユニットバス等の耐水性を必要とする建材等に広く用いられている。この場合、樹脂フィルムを表面に被覆することは、素材の金属板に防食効果を付与することが主目的であるが、同時に化粧金属板に高級感を持たせるという目的もあり、従来からエンボス模様を付加することが広く行われてきた。
このような目的に使用される、エンボス模様を付加するフィルムの素材は、従来から、主としてエンボス加工が容易であること、低価格であること等の観点から、たとえば軟質塩化ビニル樹脂等が多く使用されてきた。
しかし、軟質塩化ビニル樹脂は成形を容易にするためにDBP(ジブチルフタレート)、DOP(ジオクチルフタレート)等のフタル酸類を可塑剤として添加、混合して軟質化している関係で、浴槽のような温度の高くなる箇所には使用し難く、またそれらを含む製品の廃棄には種々の問題がある。さらに、金属板にエンボス加工処理した樹脂フィルムを接着、ラミネート処理して使用する場合における製品の美感は、使用する金属板、金属板と樹脂との組合せ等によって異なる場合が少なくない。換言すれば、その用途の製品に使用する樹脂の種類とエンボス加工処理条件等によって、美感、特に高級感のような審美性的感性は左右され易いという問題があるために、エンボス加工処理は使用する樹脂との関係で最適条件で行うことが好ましい。
可塑剤を排除した硬質の塩化ビニル樹脂フィルムは、加工性が劣る上にエンボス加工処理が一般に困難であるほかに、エンボス処理によって得た樹脂の美観が得られ難いという問題がある。また塩化ビニル樹脂に代えて、オレフィン系樹脂のポリエチレン、ポリプロピレン樹脂等を使用する場合にはこれらの樹脂のエンボス加工性は良好であるものの、金属板上に積層した後に加工した場合に加工部分が白色化して美感を損なうという問題がある。
この問題を解決するために、ゴム成分を添加配合するという提案があるが、ゴム成分を添加するとポリエチレン樹脂は塩化ビニル樹脂同様の軟質樹脂に変性してしまうという問題が新たに発生する。また、ポリブチレンテレフタレート樹脂は耐水性及び水中に放置後の強度劣化が少ないという優れた特性を有するために、この分野の被覆材としては極めて有望であるが、通常の処理条件ではエンボス加工性が悪いためにこの目的のためには実用化されていなかった。
本発明は、上記、これらの課題を解決することを目的とし、従来の軟質塩化ビニル樹脂と同等以上のエンボス加工性に優れた樹脂フィルム及びその樹脂フィルムを被覆した高級感のある感性の豊かな化粧金属板を提供することを目的とする。
【発明の開示】
【0003】
本発明は以下の特徴を有する。
すなわち、
(A)
「下記(1)〜(3)のいずれかの樹脂フィルムの中から下記式で与えられるTMA(Thermo Mechanical Analysis)関係値が30以下である樹脂フィルムを選択して、
彫刻ロールによる圧下処理でエンボス処理加工を行う場合において、冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス加工処理することを特徴とするエンボス加工処理方法。
(1)固有粘度(IV)が1.0〜1.4のポリブチレンテレフタレート(PBT)樹脂フィルム、
(2)PBT樹脂30重量部とポリエチレンテレフタレート(PET)樹脂70重量部とのブレンド樹脂フィルム、
(3)PBT樹脂70重量部とポリカーボネート樹脂30重量部とのブレンド樹脂フィルム、
TMA関係値(℃)=Tse−Tss、
ここで、
軟化開始温度Tss(℃)は、TMAにより測定され、
2mmφで先端R=0.2以下(先端角60°)の針に荷重100gをかけ、10℃/minで昇温した時の針のフィルムへの進入深さをJIS−K−7196に準じて測定して得られた曲線における、
針が進入を始めるよりも低温側に認められる直線部分の高温側への延長と、
進入速度が最大となる部分の接線の低温側への延長との交点により求められる温度であり、
軟化終了温度Tse(℃)は、上記進入速度が最大となる部分の接線の高温側への延長と、
軟化終了後の高温側に認められる直線部分の低温側への延長との交点により求められる温度である。」
(B)
「下記(1)〜(3)のいずれかの樹脂フィルムの中から下記式で与えられるTMA(Thermo Mechanical Analysis)関係値が30以下である樹脂フィルムを選択して、
彫刻ロールによる圧下処理でエンボス処理加工を行う場合において、冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス加工処理し、
この樹脂フィルムを金属板に被覆することを特徴とする化粧金属板の製造方法。
(1)固有粘度(IV)が1.0〜1.4のポリブチレンテレフタレート(PBT)樹脂フィルム、
(2)PBT樹脂30重量部とポリエチレンテレフタレート(PET)樹脂70重量部とのブレンド樹脂フィルム、
(3)PBT樹脂70重量部とポリカーボネート樹脂30重量部とのブレンド樹脂フィルム、
ここで、
軟化開始温度Tss(℃)は、TMAにより測定され、
2mmφで先端R=0.2以下(先端角60°)の針に荷重100gをかけ、10℃/minで昇温した時の針のフィルムへの進入深さをJIS−K−7196に準じて測定して得られた曲線における、
針が進入を始めるよりも低温側に認められる直線部分の高温側への延長と、
進入速度が最大となる部分の接線の低温側への延長との交点により求められる温度であり、
軟化終了温度Tse(℃)は、上記進入速度が最大となる部分の接線の高温側への延長と、
軟化終了後の高温側に認められる直線部分の低温側への延長との交点により求められる温度である。」
【0004】
本発明の発明者等は樹脂フィルムの特性とエンボス加工性の関係について鋭意検討した結果、Thermo Mechanical Analysis(TMA)による軟化開始温度Tss(℃)と軟化終了温度Tse(℃)から計算されるTMA関係値である(Tse−Tss)の値が30以下の樹脂であり、樹脂フィルムとして、好ましくはポリブチレンテレフタレート樹脂を含有する樹脂フィルムを使用し、エンボス加工処理する冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、前記、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定することとした場合に、これらの樹脂フィルムのエンボス加工性が飛躍的に向上するとともに、そのエンボス処理したフィルムを化粧金属板に接着、ラミネート処理した場合に、製品に従来品以上の高級感を付与できることを見出した。
この結果、このような特性を有する樹脂フィルムを積層加工(ラミネート加工)し、折り曲げ等の加工を施した場合にも加工部分が白色化して意匠性を損なうという問題はなく、塩化ビニル樹脂と同等のエンボス加工性を向上させることができ、さらに耐水性及び水中に放置後の強度劣化が少ないという、ポリブチレンテレフタレート樹脂の優れた特性をそのまま維持することができた。
以下に本発明についてその内容を説明する。
【0005】
(使用する樹脂フィルム等)
樹脂フィルム等の厚さは特に限定しないが、例えば0.02〜0.30mm、好ましくは0.080〜0.150mmのポリブチレンテレフタレート(PBT)樹脂、PBTと他の樹脂との種々の割合のブレンド樹脂、たとえばポリエチレンテレフタレート(PET)樹脂、ポリカーボネート樹脂、アイオノマー樹脂等とのブレンド、又はこれらの3種以上の樹脂のブレンド、あるいはPBTと他の樹脂又は化合物との共重合体、たとえばイソフタル酸、アジピン酸との共重合体の樹脂フィルム等、さらに上記種々の樹脂フィルム等を異なる厚さの比率で積層した複合樹脂フィルム等を使用することができる。これらの樹脂フィルム等の中には着色樹脂等が入っていても差し支えない。2種以上のブレンド樹脂を使用する理由は、例えば衝撃強度には優れているが金属との接着性が劣る樹脂に対して、その接着性のみの改良を図るために金属との接着性の良好な樹脂をブレンドするようなケースであり、複合樹脂を使用するのは、金属との接着面に接着特性の優れた樹脂を使用するためである。
【0006】
これらの樹脂フィルムに使用する樹脂は、下記式で与えられるTMA関係値が30以下の範囲にあることが必要である。
TMA関係値(℃)=Tse−Tss ここで、Tss(℃)はTMAにより測定される軟化開始温度であり、またTse(℃)はTMAにより測定される軟化終了温度である。
このようなTMA関係値の樹脂フィルムを原料樹脂フィルムとし、彫刻ロールを使用して圧下エンボス加工処理する場合には、溶融樹脂が最初に接する冷却ロール表面の原料樹脂フィルムと接触している部分の温度を、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス処理加工することが必要である。
【0007】
樹脂のTMA関係値を30以下に限定する理由は、従来用いられていた塩化ビニル樹脂フィルムのエンボス加工後の平均表面粗度がRaで、4.0μmであったから、従来品との比較においてエンボス性を良好とする平均表面粗度基準をRaで4.0μmとしたためである。このようなTMA関係値の樹脂フィルム等を使用するとエンボス加工性が改良される理由は、軟化開始点から軟化終了点の範囲が比較的小さい樹脂を軟化開始点に近い一定の温度範囲内で処理した場合には、エンボス加工処理に伴って発生する圧縮エネルギーや摩擦エネルギーをこの温度範囲で樹脂が効果的に吸収することができるために、冷却後も樹脂が高度の歪みを維持できるからではないかと考えられる。
【0008】
また、このようなTMA関係値の樹脂フィルムを原料樹脂フィルムとし、彫刻ロールを使用して圧下エンボス加工処理する場合に、冷却ロールの表面が原料樹脂フィルムと接触している部分の温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲にする理由は、このような温度範囲でエンボス加工処理した樹脂フィルムを化粧金属板に接着、ラミネート処理した場合には、その製品の高級感がきわめて優れているからである。エンボス加工処理温度と、化粧金属板とのラミネート樹脂フィルムの有する感性の関係については、まだ不明な点が多いが、加工処理温度を樹脂の軟化温度近傍でコントロールすることにより、フィルムの粘着等も生じずに歪みを与えることが高級感の発生につながるのではないかと考えられる。
一般的に、TMA関係値と、樹脂フィルムのエンボス加工後の平均表面粗度Raの関係は逆相関関係となる傾向がある。この平均表面粗度Raは商品の意匠的価値(意匠性)と大きな関係があって、4以上の範囲が適正値であると考えられている。なお、この平均表面粗度Raのさらに好ましい範囲は5〜8である。
【0009】
(エンボス加工処理方法)
樹脂フィルム等のエンボス加工処理方法は、例えば複層フィルムを直接チルドロールの間に通す方法、ブラウンフィルムを加熱してチルドロールの間に通す方法、回転スクリーンロールに通して真空の力でエンボス加工する方法、複層フィルムをパーフォレーター(目打ち機)に通すホットニードルプロセス、刻印ロールを使用して圧縮する方法等の種々の方法があるが、本発明の場合はTダイから供給した樹脂フィルムを、Tss±10(℃)の温度範囲に調節した冷却ロールを使用して、又は冷却ロールと彫刻ロールで圧下する方法でエンボス加工処理される。エンボス形状としてはランダムマット、四角形、ダイヤモンド型、深絞り型、砂目等の種々の模様を、製品のニーズに応じて使用することができる。
【0010】
(エンボス性の良否判定)
本発明における樹脂フィルム等のエンボス性の良否はその樹脂フィルムのエンボス加工後の表面粗度Ra(μm)によって判断される。一般に良好なエンボス性とは樹脂の融点前後の温度で彫刻ロール等で圧下、エンボス加工したときに、容易にエンボス模様が樹脂フィルムの表面に形成され、かつその後、温度を上げた場合にも長時間、そのエンボス模様を維持していることをいう。
表面粗度の測定は、樹脂フィルムを室温に冷却した後、表面粗度Ra(μm)を東京精密社製SURFCOM表面粗さ計を用いて、JIS B0601に準拠して測定し、平均表面粗度が4.0以上をエンボス性良好とした。なお、この測定は、エンボス加工処理の終了した樹脂フィルムから、任意に5枚の樹脂試験片を採取して、その各試片について4個所の異なる場所の表面粗度を測定し、その平均値を計算して表面粗度Ra(μm)とした。
また、エンボス性の高級感の有無の判定をするためには、エンボス加工処理フィルムを化粧金属板上に貼付した後に水中に沈めて目視判定する。この場合に使用する金属板としては、鋼板、アルミニウム板、銅板等、広く金属板であれば用いることができる。鋼板としては、厚さ0.10〜1.20mmの普通鋼冷延鋼板が好ましい。中でも、厚さ0.10〜0.50mmの普通鋼冷延鋼板が好ましい。冷延製品の中でも低炭素又は極低炭素アルミキルド鋼板が好ましく使用されるが、Nb、Ti等を添加した非時効性鋼、3〜18wt%のクロムを含むクロム含有鋼板、種々の組成を有するステンレス鋼板等も使用することができる。これら圧延鋼板の表面は表面処理がされているものでも差し支えない。
表面処理方法としては、めっき処理、塗装処理等があり、めっき処理としては、例えば亜鉛めっき、亜鉛−アルミニウム合金めっき、亜鉛−コバルト−モリブデンめっき、錫めっき、ニッケルめっき、ニッケル・りんめっき、ニッケル・コバルトめっき、ニッケル・錫めっき等があり、また塗装処理としては種々の塗料をその性質に応じて焼き付け、塗装する方法で行われる。
【0011】
エンボス加工処理した樹脂フィルムを金属板上に被覆する場合には、エポキシ系、ポリエステル系、シアノアクリレート系等の接着剤を使用しても良いが、単にDSCにより測定した樹脂の融点Tmp(℃)以上に加熱しておいた金属板上に圧着する方法で接着しても良い。加熱圧着法で樹脂フィルムと金属板を接着させる場合には強固な接着力を得ることができるように金属板の表面を処理しておくことが好ましい。金属板の表面処理方法としては、電解クロム酸処理、接着プライマー処理等の方法を採用することができる。
TMA関係値の計算に必要な諸元の測定は以下の条件で行った。
理学電機(株)製のTMA、TAS−300を用いて、2mmφで先端R=0.2以下(先端角60°)の針に荷重100gをかけ、10℃/minで昇温した時の針のフィルムへの進入深さをJIS−K−7196に準じて測定した。図3にTMA関係値の測定曲線の一例を示す。ここで針の進入度は進入深さをフィルム厚みで割った値である。
軟化終了温度Tseは、図3に示すように進入度が急激に変化する曲線と、軟化終了後のベース線の接線交点により求められる温度である。同様に軟化開始温度Tssは、Tseで用いた曲線の接線と、その近傍のベース線の接線交点により求められる温度である。
また、DSCによるTmpの測定は以下の条件で行った。
パーキンエルマー社製の示差熱量計DSC−7を使用し、精秤した約5mgの試料を窒素ガス雰囲気下において20℃/分で昇温させ、吸熱ピークをDSCの融点Tmpとした。
実施例 以下に、実施例について本発明をさらに具体的に説明する。
【0012】
【実施例】
(実施例1)
図1に示すように、TMA関係値が7.2であって、その固有粘度(IV)が1.4のPBT(ポリブチレンテレフタレート)樹脂を溶融して、Tダイ(樹脂供給口)1からフィルム厚さが0.100mmになるように彫刻ロール3上に押し出した。フィルム状の溶融樹脂2を、彫刻ロール3と補助ロール5とで挟み、フィルム厚さ0.100mmにエンボス加工処理した固化フィルム6を製造した。この第1態様の処理方式は彫刻ロール(平均表面粗さRa=11μmの凹凸が付与された砂目ロール)3が冷却ロールを兼用している場合である。彫刻ロール3がフィルム状の樹脂と接する部分の表面温度は、使用した樹脂のTssが221.4℃であるため、ロール表面温度が215℃になるように彫刻ロール(冷却ロール)3内部に通水する冷却水温を調節・設定した。エンボス加工処理した同化フィルム6を、その後さらに室温まで冷却し、5枚の試片を間隔をおいて採取し、エンボス性の指標である表面粗度Raを測定して、その平均値を計算した結果、6.7μmであった。
【0013】
(実施例2)
図2に示すように、TMA関係値が3.3であって、その固有粘度(IV)が1.0のPBT樹脂を溶融して、Tダイ1からフィルム厚さが0.100mmになるように冷却ロール4上に押し出した。
フィルム状の溶融樹脂2を、彫刻ロール3と冷却ロール4とで挟み、フィルム厚さ0.100mmにエンボス加工処理した固化フィルム6を製造した。
この第2態様の方式は彫刻ロール(平均表面粗さRa=11μmの凹凸が付与されたSG目ロール)の3に対向するロールが冷却ロールとなっている場合である。冷却ロール4が樹脂と接する表面温度は、使用した樹脂のTssが220.5℃であるため、ロール表面温度が215℃になるように冷却ロール4内部に通水する冷却水温を調節・設定した。エンボス加工処理した固化フィルム6を、その後さらに室温まで冷却し、5枚の試片を間隔をおいて採取し、エンボス件の指標である表面粗度Raを測定して、その平均値を計算した結果、7.0μmであった。
【0014】
(実施例3〜10)
TMA関係値の異なる樹脂について、溶融樹脂をTダイから処理ロール上に押し出して、実施例1又は2の態様のエンボス加工方式で、0.100mmのフィルム厚さでエンボス加工処理した。この場合の冷却ロールが樹脂と接する表面温度Trはあらかじめ測定しておいた、使用樹脂のTMAによるTssに基づいてその都度、Tss±10(℃)以内に設定した。
実施例3はIV=1.0のPBT樹脂を使用して態様1で処理した場合、実施例4はIV=1.4のPBT樹脂を使用して態様2で処理した場合、実施例5と6はブレンド樹脂の場合で、実施例5はポリエチレンテレフタレート(PET)樹脂70重量部とPBT樹脂30重量部のブレンド、実施例6はPBT70重量部とポリカーボネート(PC)樹脂30重量部のブレンドの場合である。
実施例7は2層フィルムの例で、PBT樹脂フィルムとイソフタル酸の10モル%/PET樹脂の共重合樹脂フィルムの複合積層フィルム(厚さ比は4:1)、実施例8はPET樹脂単味の場合、実施例9はPC樹脂単味、実施例10はイソフタル酸とPET樹脂の共重合体の場合であり、その他の条件は表1に示した。
【0015】
(比較例1)
TMA関係値が30を超えている場合の例で、PBT樹脂とPET樹脂の等重量ブレンド樹脂を実施例1と同様の方法でエンボス加工処理し、その後さらに室温まで冷却し、5枚の試片を間隔をおいて採取し、エンボス性の指標である表面粗度Raを測定して、その平均値を計算した結果、3.2μmであった。
【0016】
(比較例2〜9)
比較例2〜8はTMA関係値は30以内であるが、冷却ロールの温度TrがTss±10(℃)の範囲を外れた場合で、このうち比較例2〜4は高位にずれた場合、比較例5〜7は低位に外れた場合である。比較例3はエンボス処理中に樹脂がロールに粘着してしまって試料を採取することはできなかった。比較例4の共重合体はイソフタル酸11モル%とPET樹脂の共重合体、比較例7はアジピン酸10モル%とPETの共重合体の場合である。また、比較例8と9は複層フィルムの場合で、比較例8はPBT樹脂フィルムとイソフタル酸の10モル%/PET樹脂の共重合樹脂フィルムの複合積層フィルム(厚さ比は4:1)、比較例9はPC樹脂フィルムとイソフタル酸の10モル%/PET樹脂の共重合樹脂フィルムの複合積層フィルム(厚さ比は4:1)で、TMA関係値が30を超えた場合である。なお、その他の条件は表2に示した。
【0017】
次に、このようにエンボス加工処理した樹脂フィルムについて、鋼板との組合せにおける高級感の有無を以下のようにして調べた。
まず、炭素分が0.030%のアルミキルド冷延鋼板であって厚さ0.50mmの鋼板に0.002mmの厚さに亜鉛めっき処理をし、この亜鉛めっき鋼板を30×20cmの大きさに切断する。この鋼板をDSCにより測定したTmp±10℃に加熱して、その表面上にエンボス加工した樹脂フィルムを貼付する。
このようなラミネート鋼板を3枚ずつ用意し、これを太陽光線の入らない室内のテーブル上に置き、試料の1m上から20Wの白色蛍光灯5本で照射する。年齢、性別の異なる5人の人に、観測場所及び角度を変えて以下のような評価点をつけてもらい、その評価点の平均値を求めて総合評価する。
評価点は、従来の塩ビラミネート鋼板と比較したときに、塩ビラミネート鋼板と同等以上の高級感がある場合を5点、塩ビラミネート鋼板より多少劣るがやや高級感の得られる場合を4点、塩ビラミネート鋼板に比較して安っぽいという感触の場合を3点とする。
このような評価をした場合、概ね表面粗度との関係があり、TMA関係値が30以下の樹脂フィルムを使用して、冷却ロール温度をTMAによるTss±10(℃)の温度範囲で処理した試料は、いずれも十分な高級感を有していた。これに対して、これらの要件にマッチしない比較例の試料の場合にはいずれも高級感は得られなかったり、不充分であった。これらの結果を表1、表2に示した。
【0018】
【表1】

Figure 0004141641
【0019】
【表2】
Figure 0004141641
【0020】
【産業上の利用可能性】
TMA関係値が30以下である樹脂フィルムを原料とし、冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス加工処理した場合には、従来の塩ビ樹脂と同等以上のエンボス面を得ることができ、高級感が得られる。
【0021】
【図面の簡単な説明】
図1は、実施例に係るエンボス処理加工方法の第1態様のロール配置図である。
図2は、実施例に係るエンボス処理加工方法の第2態様のロール配置図である。
図3は、TMA関係値の測定曲線の一例である。【Technical field】
[0001]
The present invention relates to a method for embossing a resin film or sheet (hereinafter referred to as “resin film”) excellent in embossing workability, which is used for building materials that require water resistance such as a unit bath, and the production of a decorative metal plate. Regarding the method.
[Background]
[0002]
The decorative metal plate is widely used for building materials that require water resistance such as a unit bath. In this case, the main purpose of coating the resin film on the surface is to give the material metal plate an anticorrosive effect, but at the same time it has the purpose of giving the decorative metal plate a high-class feeling, and the embossed pattern has been conventionally used. It has been widely performed.
Conventionally, the material of the film to which the embossed pattern is added is used mainly for such purposes, mainly from the viewpoint of easy embossing and low cost. It has been.
However, soft vinyl chloride resin is softened by adding and mixing phthalic acids such as DBP (dibutyl phthalate) and DOP (dioctyl phthalate) as a plasticizer in order to facilitate molding. It is difficult to use in places where the height is high, and there are various problems in disposal of products containing them. Furthermore, the aesthetics of the product when the embossed resin film is bonded and laminated to the metal plate is often used depending on the metal plate used, the combination of the metal plate and the resin, or the like. In other words, embossing treatment is used because there is a problem that aesthetics, especially high-grade aesthetic sensibility, are easily affected by the type of resin used in the product for that application and the embossing treatment conditions. It is preferable to carry out under optimum conditions in relation to the resin used.
A hard vinyl chloride resin film from which a plasticizer is excluded has problems in that the processability is inferior and the embossing treatment is generally difficult, and the aesthetic appearance of the resin obtained by the embossing treatment is difficult to obtain. In addition, when using olefin resin polyethylene, polypropylene resin, etc. instead of vinyl chloride resin, the embossability of these resins is good, but when processed after being laminated on a metal plate, the processed part is There is a problem of whitening and impairing aesthetics.
In order to solve this problem, there is a proposal of adding and blending a rubber component. However, when the rubber component is added, a new problem arises in that the polyethylene resin is modified into a soft resin similar to vinyl chloride resin. Polybutylene terephthalate resin is very promising as a coating material in this field because it has excellent properties such as water resistance and little deterioration in strength after standing in water. It was not put into practical use for this purpose because of its badness.
The present invention aims to solve the above-mentioned problems, and has a resin film excellent in embossing workability equal to or higher than that of a conventional soft vinyl chloride resin and a rich and high-quality sensibility coated with the resin film. An object is to provide a decorative metal plate.
DISCLOSURE OF THE INVENTION
[0003]
The present invention has the following features.
That is,
(A)
“A resin film having a TMA (Thermo Mechanical Analysis) relationship value given by the following formula is selected from the resin films of any of the following (1) to (3) :
When embossing processing is performed by a reduction process using an engraving roll, the surface temperature Tr of the portion where the cooling roll comes into contact with the resin film is defined as Tss ± 10 (° C.) based on Tss, which is the softening start temperature measured by TMA. The embossing processing method is characterized in that the embossing processing is performed by setting the range.
(1) a polybutylene terephthalate (PBT) resin film having an intrinsic viscosity (IV) of 1.0 to 1.4,
(2) a blend resin film of 30 parts by weight of PBT resin and 70 parts by weight of polyethylene terephthalate (PET) resin,
(3) Blend resin film of 70 parts by weight of PBT resin and 30 parts by weight of polycarbonate resin,
TMA-related value (° C.) = Tse−Tss,
here,
The softening start temperature Tss (° C.) is measured by TMA,
The penetration depth of the needle into the film when a load of 100 g is applied to a needle with a tip of R = 0.2 or less (tip angle 60 °) at 2 mmφ and the temperature is raised at 10 ° C./min according to JIS-K-7196. In the curve obtained by measurement,
The extension of the straight line portion that is recognized on the low temperature side from the start of the needle to the high temperature side,
It is the temperature obtained by the intersection with the extension of the tangent of the part where the approach speed is maximum to the low temperature side,
The softening end temperature Tse (° C.) is the extension of the tangential line where the entry speed is maximum to the high temperature side,
This is the temperature obtained by the intersection with the extension of the straight line portion observed on the high temperature side after the end of softening to the low temperature side. "
(B)
“A resin film having a TMA (Thermo Mechanical Analysis) relationship value given by the following formula is selected from the resin films of any of the following (1) to (3) :
When embossing processing is performed by a reduction process using an engraving roll, the surface temperature Tr of the portion where the cooling roll comes into contact with the resin film is defined as Tss ± 10 (° C.) based on Tss, which is the softening start temperature measured by TMA. Set to the range of embossing processing,
A method for producing a decorative metal plate, comprising coating a metal plate with the resin film.
(1) a polybutylene terephthalate (PBT) resin film having an intrinsic viscosity (IV) of 1.0 to 1.4,
(2) a blend resin film of 30 parts by weight of PBT resin and 70 parts by weight of polyethylene terephthalate (PET) resin,
(3) Blend resin film of 70 parts by weight of PBT resin and 30 parts by weight of polycarbonate resin,
here,
The softening start temperature Tss (° C.) is measured by TMA,
The penetration depth of the needle into the film when a load of 100 g is applied to a needle with a tip of R = 0.2 or less (tip angle 60 °) at 2 mmφ and the temperature is raised at 10 ° C./min according to JIS-K-7196. In the curve obtained by measurement,
The extension of the straight line portion that is recognized on the low temperature side from the start of the needle to the high temperature side,
It is the temperature obtained by the intersection with the extension of the tangent of the part where the approach speed is maximum to the low temperature side,
The softening end temperature Tse (° C.) is the extension of the tangential line where the entry speed is maximum to the high temperature side,
This is the temperature obtained by the intersection with the extension of the straight line portion observed on the high temperature side after the end of softening to the low temperature side. "
[0004]
As a result of intensive studies on the relationship between the properties of the resin film and the embossability, the inventors of the present invention, as a result, TMA calculated from the softening start temperature Tss (° C) and the softening end temperature Tse (° C) by Thermo Mechanical Analysis (TMA). The relational value (Tse-Tss) is a resin having a value of 30 or less, preferably a resin film containing polybutylene terephthalate resin is used as the resin film, and the cooling roll to be embossed is in contact with the resin film. When the surface temperature Tr of the portion is set to a range of Tss ± 10 (° C.) with reference to Tss, which is the softening start temperature measured by TMA, the embossability of these resin films is A dramatic improvement and embossed film on the decorative metal plate It has been found that a high-grade feeling can be imparted to a product when compared to conventional products.
As a result, even when a resin film having such characteristics is laminated (laminated) and subjected to processing such as bending, there is no problem that the processed portion is whitened and the design is not impaired, and is equivalent to vinyl chloride resin. It was possible to improve the embossability of the polybutylene terephthalate resin as it was, and to maintain the excellent properties of water resistance and strength deterioration after standing in water.
The contents of the present invention will be described below.
[0005]
(Resin film used)
The thickness of the resin film or the like is not particularly limited, but for example, 0.02 to 0.30 mm, preferably 0.080 to 0.150 mm of polybutylene terephthalate (PBT) resin, various ratios of PBT and other resins. Blend resins such as polyethylene terephthalate (PET) resins, polycarbonate resins, ionomer resins and the like, or blends of three or more of these resins, or copolymers of PBT with other resins or compounds, such as isophthalic acid, A resin film of a copolymer with adipic acid or the like, and a composite resin film obtained by laminating the above various resin films at different thickness ratios can be used. These resin films or the like may contain colored resins or the like. The reason for using two or more kinds of blended resins is that, for example, a resin having excellent impact strength but poor adhesion to metal has good adhesion to metal in order to improve only the adhesion. This is a case in which various resins are blended, and the composite resin is used because a resin having excellent adhesive properties is used for the adhesive surface with the metal.
[0006]
The resin used for these resin films is required to have a TMA-related value given by the following formula in the range of 30 or less.
TMA-related value (° C.) = Tse−Tss where Tss (° C.) is a softening start temperature measured by TMA, and Tse (° C.) is a softening end temperature measured by TMA.
When a resin film having such a TMA relation value is used as a raw material resin film and subjected to a rolling embossing process using an engraving roll, a portion of the part in contact with the raw material resin film on the surface of the cooling roll with which the molten resin comes into contact first. It is necessary to set the temperature to a range of Tss ± 10 (° C.) with respect to Tss, which is a softening start temperature measured by TMA, and perform embossing processing.
[0007]
The reason why the TMA-related value of the resin is limited to 30 or less is that the average surface roughness after embossing of the vinyl chloride resin film that has been used in the past was Ra, which was 4.0 μm. This is because the average surface roughness standard for improving the property is 4.0 μm in Ra. The reason why embossability is improved when using a resin film having such a TMA-related value is that a resin having a relatively small range from the softening start point to the softening end point is processed within a certain temperature range close to the softening start point. This is not because the resin can effectively absorb the compressive energy and frictional energy that accompany the embossing treatment in this temperature range, so that the resin can maintain a high degree of strain even after cooling. It is thought.
[0008]
In addition, when a resin film having such a TMA relation value is used as a raw material resin film and subjected to a rolling embossing process using an engraving roll, the temperature Tr of the portion where the surface of the cooling roll is in contact with the raw material resin film is The reason for setting Tss ± 10 (° C.) based on Tss, which is the softening start temperature measured by TMA, is that the resin film embossed in such a temperature range is bonded to a decorative metal plate and laminated. In some cases, the quality of the product is very good. There are still many unclear points regarding the embossing processing temperature and the sensitivity of the laminated resin film to the decorative metal plate, but by controlling the processing temperature in the vicinity of the softening temperature of the resin, film adhesion, etc. It is thought that imparting distortion without causing a high-class feeling.
In general, the relationship between the TMA relationship value and the average surface roughness Ra after embossing of the resin film tends to be inversely correlated. This average surface roughness Ra has a large relationship with the design value (designability) of the product, and a range of 4 or more is considered to be an appropriate value. In addition, the more preferable range of this average surface roughness Ra is 5-8.
[0009]
(Embossing processing method)
Embossing treatment method for resin film, etc., for example, a method of passing a multilayer film directly between chilled rolls, a method of heating a brown film between chilled rolls, a embossing with a rotating screen roll by vacuum force There are various methods such as a method of performing, a hot needle process in which a multilayer film is passed through a perforator (a perforator), and a method of compressing using a marking roll. In the present invention, a resin film supplied from a T die Is embossed using a cooling roll adjusted to a temperature range of Tss ± 10 (° C.) or by a method of rolling down with a cooling roll and an engraving roll. As the embossed shape, various patterns such as a random mat, a square shape, a diamond shape, a deep drawing shape, and a grain pattern can be used according to the needs of the product.
[0010]
(Embossing quality judgment)
The quality of the embossing property of the resin film or the like in the present invention is determined by the surface roughness Ra (μm) after the embossing of the resin film. In general, good embossability means that an embossed pattern is easily formed on the surface of a resin film when it is pressed and embossed with a sculpture roll at a temperature around the melting point of the resin. It means that the embossed pattern is maintained for a time.
The surface roughness is measured by cooling the resin film to room temperature, and then measuring the surface roughness Ra (μm) according to JIS B0601 using a SURFCOM surface roughness meter manufactured by Tokyo Seimitsu Co., Ltd. Of 4.0 or more was considered good embossing property. In this measurement, five resin test pieces are arbitrarily sampled from the resin film that has been subjected to the embossing treatment, and the surface roughness at four different locations is measured for each test piece. Was calculated as the surface roughness Ra (μm).
Moreover, in order to determine the presence or absence of embossed luxury, the embossed film is attached on a decorative metal plate, and then submerged in water for visual determination. As a metal plate used in this case, a wide metal plate such as a steel plate, an aluminum plate, or a copper plate can be used. As the steel plate, a plain steel cold-rolled steel plate having a thickness of 0.10 to 1.20 mm is preferable. Among these, a plain steel cold-rolled steel sheet having a thickness of 0.10 to 0.50 mm is preferable. Among cold-rolled products, low-carbon or ultra-low-carbon aluminum killed steel plates are preferably used, but non-aging steels added with Nb, Ti, etc., chromium-containing steel plates containing 3-18 wt% chromium, stainless steels having various compositions Steel plates and the like can also be used. The surface of these rolled steel plates may be surface-treated.
As the surface treatment method, there are plating treatment, coating treatment, and the like. As the plating treatment, for example, zinc plating, zinc-aluminum alloy plating, zinc-cobalt-molybdenum plating, tin plating, nickel plating, nickel / phosphorous plating, nickel There are cobalt plating, nickel / tin plating, and the coating process is performed by baking and coating various paints according to the properties.
[0011]
When coating an embossed resin film on a metal plate, an epoxy, polyester or cyanoacrylate adhesive may be used, but the resin melting point Tmp (° C) measured by DSC. You may adhere | attach by the method of crimping | bonding on the metal plate heated above. When the resin film and the metal plate are bonded by the thermocompression bonding method, it is preferable to treat the surface of the metal plate so that a strong adhesive force can be obtained. As the surface treatment method of the metal plate, methods such as electrolytic chromic acid treatment and adhesion primer treatment can be employed.
Measurements of specifications necessary for calculating TMA-related values were performed under the following conditions.
Using TMA and TAS-300 manufactured by Rigaku Denki Co., Ltd. Needle when a load of 100 g is applied to a needle with 2 mmφ and tip R = 0.2 or less (tip angle 60 °) and the temperature is raised at 10 ° C./min. The penetration depth into the film was measured according to JIS-K-7196. FIG. 3 shows an example of a measurement curve of TMA related values. Here, the penetration degree of the needle is a value obtained by dividing the penetration depth by the film thickness.
The softening end temperature Tse is a temperature obtained by a tangent intersection of a curve in which the degree of approach changes rapidly as shown in FIG. 3 and the base line after the softening ends. Similarly, the softening start temperature Tss is a temperature obtained from the tangent intersection of the tangent of the curve used in Tse and the base line in the vicinity thereof.
The Tmp measurement by DSC was performed under the following conditions.
A differential calorimeter DSC-7 manufactured by Perkin Elmer was used, and a precisely weighed sample of about 5 mg was heated at 20 ° C./min in a nitrogen gas atmosphere, and the endothermic peak was defined as the melting point Tmp of DSC.
Examples Hereinafter, the present invention will be described more specifically with reference to examples.
[0012]
【Example】
(Example 1)
As shown in FIG. 1, a PBT (polybutylene terephthalate) resin having a TMA relation value of 7.2 and an intrinsic viscosity (IV) of 1.4 is melted, and the T die (resin supply port) 1 The film was extruded onto the engraving roll 3 so that the film thickness was 0.100 mm. A film-like molten resin 2 was sandwiched between an engraving roll 3 and an auxiliary roll 5 to produce a solidified film 6 embossed to a film thickness of 0.100 mm. The processing method of the first aspect is a case where the engraving roll (a grain roll provided with irregularities with an average surface roughness Ra = 11 μm) 3 also serves as a cooling roll. The surface temperature of the part where the engraving roll 3 is in contact with the film-like resin is passed through the engraving roll (cooling roll) 3 so that the roll surface temperature is 215 ° C. because the Tss of the used resin is 221.4 ° C. Adjusted and set the cooling water temperature. The embossed assimilated film 6 was then further cooled to room temperature, 5 specimens were taken at intervals, the surface roughness Ra, which is an embossing index, was measured, and the average value was calculated. As a result, it was 6.7 μm.
[0013]
(Example 2)
As shown in FIG. 2, a PBT resin having a TMA-related value of 3.3 and an intrinsic viscosity (IV) of 1.0 is melted so that the film thickness from the T die 1 becomes 0.100 mm. And extruded onto the cooling roll 4.
A film-like molten resin 2 was sandwiched between an engraving roll 3 and a cooling roll 4 to produce a solidified film 6 embossed to a film thickness of 0.100 mm.
The system of this second aspect is a case where the roll opposite to 3 of the engraving roll (SG roll having an unevenness with an average surface roughness Ra = 11 μm) is a cooling roll. The surface temperature at which the cooling roll 4 is in contact with the resin was adjusted and set to the temperature of the cooling water passing through the cooling roll 4 so that the roll surface temperature was 215 ° C. because the Tss of the resin used was 220.5 ° C. . The embossed solidified film 6 was then further cooled to room temperature, 5 specimens were taken at intervals, the surface roughness Ra, which is an index of the embossing, was measured, and the average value was calculated. As a result, it was 7.0 μm.
[0014]
(Examples 3 to 10)
For resins having different TMA-related values, the molten resin was extruded from a T-die onto a treatment roll and embossed with a film thickness of 0.100 mm by the embossing method of the embodiment of Example 1 or 2. In this case, the surface temperature Tr at which the cooling roll is in contact with the resin was set within Tss ± 10 (° C.) each time based on the Tss measured by TMA of the resin used in advance.
Example 3 was treated with embodiment 1 using a PBT resin with IV = 1.0, Example 4 was treated with embodiment 5 when treated with embodiment 2 using a PBT resin with IV = 1.4. 6 is a blend resin, Example 5 is a blend of 70 parts by weight of polyethylene terephthalate (PET) resin and 30 parts by weight of PBT resin, and Example 6 is a blend of 70 parts by weight of PBT and 30 parts by weight of polycarbonate (PC) resin. It is.
Example 7 is an example of a two-layer film, and a composite laminated film (thickness ratio is 4: 1) of a PBT resin film and a copolymer resin film of 10 mol% of isophthalic acid / PET resin, and Example 8 is a single PET resin film. In the case of taste, Example 9 is a case of simple PC resin, Example 10 is a case of a copolymer of isophthalic acid and PET resin, and other conditions are shown in Table 1.
[0015]
(Comparative Example 1)
In the case where the TMA-related value exceeds 30, an equal weight blended resin of PBT resin and PET resin is embossed in the same manner as in Example 1, and then cooled to room temperature, and 5 specimens The surface roughness Ra, which is an embossing index, was measured and the average value was calculated. As a result, it was 3.2 μm.
[0016]
(Comparative Examples 2-9)
In Comparative Examples 2 to 8, the TMA-related value is 30 or less, but when the temperature Tr of the cooling roll is out of the range of Tss ± 10 (° C.), among these, Comparative Examples 2 to 4 are shifted to a high level. Comparative Examples 5 to 7 are cases in which they are out of the low range. In Comparative Example 3, the resin stuck to the roll during the embossing treatment, and a sample could not be collected. The copolymer of Comparative Example 4 is a copolymer of 11 mol% isophthalic acid and a PET resin, and Comparative Example 7 is a copolymer of 10 mol% adipic acid and PET. Comparative Examples 8 and 9 are multi-layer films, and Comparative Example 8 is a composite laminated film of PBT resin film and isophthalic acid 10 mol% / PET resin copolymer resin film (thickness ratio is 4: 1). Comparative Example 9 is a composite laminated film (thickness ratio is 4: 1) of a PC resin film and a copolymer resin film of 10 mol% of isophthalic acid / PET resin, with a TMA-related value exceeding 30. Other conditions are shown in Table 2.
[0017]
Next, the resin film thus embossed was examined for the presence or absence of a high-grade feeling in combination with a steel plate as follows.
First, an aluminum killed cold-rolled steel sheet having a carbon content of 0.030%, a 0.50 mm-thick steel sheet was galvanized to a thickness of 0.002 mm, and the galvanized steel sheet was sized to 30 × 20 cm. Disconnect. The steel sheet is heated to Tmp ± 10 ° C. measured by DSC, and an embossed resin film is stuck on the surface.
Three such laminated steel plates are prepared, placed on a table in a room where sunlight does not enter, and irradiated with five white fluorescent lamps of 20 W from 1 m above the sample. Five people with different ages and genders are given the following evaluation points by changing the observation place and angle, and the average value of the evaluation points is obtained and comprehensively evaluated.
The evaluation score is 5 points when there is a high-grade feeling equal to or higher than that of the conventional PVC-laminated steel sheet, 4 points when it is slightly inferior to the PVC-laminated steel sheet, but a slightly high-grade feeling is obtained. Three points are given for the feeling of being cheap compared to the laminated steel plate.
When such an evaluation was made, there was a general relationship with the surface roughness, and a TMA-related value of 30 or less was used, and the cooling roll temperature was processed in a temperature range of Tss ± 10 (° C.) by TMA. All the samples had a sufficient high-class feeling. On the other hand, in the case of the samples of the comparative examples that do not match these requirements, a high-class feeling was not obtained or was insufficient. These results are shown in Tables 1 and 2.
[0018]
[Table 1]
Figure 0004141641
[0019]
[Table 2]
Figure 0004141641
[0020]
[Industrial applicability]
Using a resin film having a TMA-related value of 30 or less as a raw material, the surface temperature Tr of the portion where the cooling roll is in contact with the resin film is Tss ± 10 (° C.) with reference to Tss, which is the softening start temperature measured by TMA When the embossing treatment is performed with this range set, it is possible to obtain an embossed surface equal to or higher than that of a conventional vinyl chloride resin, and a high-quality feeling can be obtained.
[0021]
[Brief description of the drawings]
FIG. 1 is a roll layout diagram of a first aspect of an embossing processing method according to an embodiment.
FIG. 2 is a roll layout diagram of a second aspect of the embossing processing method according to the embodiment.
FIG. 3 is an example of a measurement curve of TMA related values.

Claims (2)

下記(1)〜(3)のいずれかの樹脂フィルムの中から下記式で与えられるTMA(Thermo Mechanical Analysis)関係値が30以下である樹脂フィルムを選択して、
彫刻ロールによる圧下処理でエンボス処理加工を行う場合において、冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス加工処理することを特徴とするエンボス加工処理方法。
(1)固有粘度(IV)が1.0〜1.4のポリブチレンテレフタレート(PBT)樹脂フィルム、
(2)PBT樹脂30重量部とポリエチレンテレフタレート(PET)樹脂70重量部とのブレンド樹脂フィルム、
(3)PBT樹脂70重量部とポリカーボネート樹脂30重量部とのブレンド樹脂フィルム、
TMA関係値(℃)=Tse−Tss、
ここで、
軟化開始温度Tss(℃)は、TMAにより測定され、
2mmφで先端R=0.2以下(先端角60°)の針に荷重100gをかけ、10℃/minで昇温した時の針のフィルムへの進入深さをJIS−K−7196に準じて測定して得られた曲線における、
針が進入を始めるよりも低温側に認められる直線部分の高温側への延長と、
進入速度が最大となる部分の接線の低温側への延長との交点により求められる温度であり、
軟化終了温度Tse(℃)は、上記進入速度が最大となる部分の接線の高温側への延長と、
軟化終了後の高温側に認められる直線部分の低温側への延長との交点により求められる温度である。
A resin film having a TMA (Thermo Mechanical Analysis) relation value given by the following formula is selected from the following (1) to (3) :
When embossing processing is performed by a reduction process using an engraving roll, the surface temperature Tr of the portion where the cooling roll comes into contact with the resin film is defined as Tss ± 10 (° C.) based on Tss, which is the softening start temperature measured by TMA. The embossing processing method is characterized in that the embossing processing is performed by setting the range.
(1) a polybutylene terephthalate (PBT) resin film having an intrinsic viscosity (IV) of 1.0 to 1.4,
(2) a blend resin film of 30 parts by weight of PBT resin and 70 parts by weight of polyethylene terephthalate (PET) resin,
(3) Blend resin film of 70 parts by weight of PBT resin and 30 parts by weight of polycarbonate resin,
TMA-related value (° C.) = Tse−Tss,
here,
The softening start temperature Tss (° C.) is measured by TMA,
The penetration depth of the needle into the film when a load of 100 g is applied to a needle with a tip of R = 0.2 or less (tip angle 60 °) at 2 mmφ and the temperature is raised at 10 ° C./min according to JIS-K-7196. In the curve obtained by measurement,
The extension of the straight line portion that is recognized on the low temperature side from the start of the needle to the high temperature side,
It is the temperature obtained by the intersection with the extension of the tangent of the part where the approach speed is maximum to the low temperature side,
The softening end temperature Tse (° C.) is the extension of the tangential line where the entry speed is maximum to the high temperature side,
This is the temperature obtained by the intersection with the extension of the straight line portion observed on the high temperature side after the end of softening to the low temperature side.
下記(1)〜(3)のいずれかの樹脂フィルムの中から下記式で与えられるTMA(Thermo Mechanical Analysis)関係値が30以下である樹脂フィルムを選択して、
彫刻ロールによる圧下処理でエンボス処理加工を行う場合において、冷却ロールが樹脂フィルムと接触する部分の表面温度Trを、TMAにより測定される軟化開始温度であるTssを基準として、Tss±10(℃)の範囲に設定してエンボス加工処理し、
この樹脂フィルムを金属板に被覆することを特徴とする化粧金属板の製造方法。
(1)固有粘度(IV)が1.0〜1.4のポリブチレンテレフタレート(PBT)樹脂フィルム、
(2)PBT樹脂30重量部とポリエチレンテレフタレート(PET)樹脂70重量部とのブレンド樹脂フィルム、
(3)PBT樹脂70重量部とポリカーボネート樹脂30重量部とのブレンド樹脂フィルム、
ここで、
軟化開始温度Tss(℃)は、TMAにより測定され、
2mmφで先端R=0.2以下(先端角60°)の針に荷重100gをかけ、10℃/minで昇温した時の針のフィルムへの進入深さをJIS−K−7196に準じて測定して得られた曲線における、
針が進入を始めるよりも低温側に認められる直線部分の高温側への延長と、
進入速度が最大となる部分の接線の低温側への延長との交点により求められる温度であり、
軟化終了温度Tse(℃)は、上記進入速度が最大となる部分の接線の高温側への延長と、
軟化終了後の高温側に認められる直線部分の低温側への延長との交点により求められる温度である。
A resin film having a TMA (Thermo Mechanical Analysis) relation value given by the following formula is selected from the following (1) to (3) :
When embossing processing is performed by a reduction process using an engraving roll, the surface temperature Tr of the portion where the cooling roll comes into contact with the resin film is defined as Tss ± 10 (° C.) based on Tss, which is the softening start temperature measured by TMA. Set to the range of embossing processing,
A method for producing a decorative metal plate, comprising coating a metal plate with the resin film.
(1) a polybutylene terephthalate (PBT) resin film having an intrinsic viscosity (IV) of 1.0 to 1.4,
(2) a blend resin film of 30 parts by weight of PBT resin and 70 parts by weight of polyethylene terephthalate (PET) resin,
(3) Blend resin film of 70 parts by weight of PBT resin and 30 parts by weight of polycarbonate resin,
here,
The softening start temperature Tss (° C.) is measured by TMA,
The penetration depth of the needle into the film when a load of 100 g is applied to a needle with a tip of R = 0.2 or less (tip angle 60 °) at 2 mmφ and the temperature is raised at 10 ° C./min according to JIS-K-7196. In the curve obtained by measurement,
The extension of the straight line portion that is recognized on the low temperature side from the start of the needle to the high temperature side,
It is the temperature obtained by the intersection with the extension of the tangent of the part where the approach speed is maximum to the low temperature side,
The softening end temperature Tse (° C.) is the extension of the tangential line where the entry speed is maximum to the high temperature side,
This is the temperature obtained by the intersection with the extension of the straight line portion observed on the high temperature side after the end of softening to the low temperature side.
JP2000579665A 1998-10-29 1999-10-29 Embossing processing method and manufacturing method of decorative metal plate Expired - Fee Related JP4141641B2 (en)

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