JP4801991B2 - Building materials - Google Patents

Description

  The present invention relates to a monolithic extruded body with an aluminum core and a building member.

  Conventionally, as a method for producing a synthetic resin product with a core material, a synthetic resin product with a core material is obtained by lamination molding and / or extrusion molding with a synthetic resin using a metal core material having a resin adhesive applied to the surface. A method characterized by this is known (Patent Document 1). Specifically, a phenol-modified acrylic adhesive, a modified urethane adhesive, an adhesive composed of a silane coupling agent, etc. is applied to an aluminum core in advance, and the core is put into an extrusion molding machine to contain the core. A synthetic resin molding is obtained. However, in such a method, since it is necessary to apply an adhesive to the core in advance, the manufacturing is complicated and there is a problem in productivity.

Therefore, as a method with excellent productivity, in particular, as a method for manufacturing a plate material for construction, a metal plate having a predetermined thickness dimension, a width dimension, a longitudinal dimension, a uniform cross section in the longitudinal direction, and a corrugated plate shape is formed. Is a method of manufacturing a building plate material including a core material and a resin containing the core material, and a corrugated plate having a uniform cross section in the longitudinal direction, while transporting the metal strip material in the longitudinal direction. The first step of continuously forming the core material, the second step of continuously forming the resin molded product including the core material by the resin extrusion molding method, and the resin molded product formed in the second step have a predetermined length. And a third step of obtaining a unit plate material by cutting each unit (Patent Document 2). Specifically, composite extrusion molding (coextrusion molding) is performed on the surface of a corrugated core material having a thickness of about 0.3 to 1.0 mm together with a resin raw material. However, in such a method, the productivity is certainly improved, but since the synthetic resin is directly coated on the metal core material, the metal core material and the synthetic resin cause poor adhesion.
JP-A-62-13315 JP 2003-13543 A

In order to improve the adhesiveness, it is conceivable to emboss the surface of the metal core material in the technique of Patent Document 2. However, the processing is very complicated and it is extremely difficult to cope with an irregularly shaped core material other than a flat plate shape or a hollow core material.
In particular, when the core is made of aluminum, it may be possible to anodize the aluminum core to make the surface porous and improve the adhesion by using the core. In addition, the adhesion was not sufficient.

  An object of the present invention is to provide an integral extruded body and a building member having sufficient adhesion between a coating layer and a core material and excellent in productivity.

  In the present invention, a coating layer made of a synthetic resin is formed on a part or all of the outer surface of an aluminum core material along the longitudinal direction of the core material, and at least the outer surface of the core material is coated. The present invention relates to a monolithic extrusion-molded body characterized by having a groove having a depth of 0.03 to 1.0 mm along the longitudinal direction in a layer forming region, and a building member comprising the monolithic extrusion-molded body.

The longitudinal groove of the aluminum core material contained in the integrally extruded body of the present invention is more uniform and efficient than a groove in a direction substantially perpendicular to the longitudinal direction or unevenness provided by embossing. Good formation is possible. Therefore, it is excellent in productivity and has sufficient adhesion between the coating layer and the core material.
Since the longitudinal grooves of the core material can be formed at the same time when the aluminum core material is extruded, the productivity of the integrally extruded product is remarkably improved.
When the longitudinal grooves of the core material are formed at the same time as the extrusion of the aluminum core material, the groove depth and pitch become more effective and uniform, so that the adhesiveness is remarkably excellent.

  The integral extruded body of the present invention is formed by forming a coating layer made of a synthetic resin on the outer surface of an aluminum core material. Specifically, for example, as shown in FIGS. 1 and 2, the coating layer 1 is continuously formed in the longitudinal direction m of the core material 10. In the circumferential direction P of the cross-section of the core material 10, the coating layer 1 may be formed continuously in the entire circumferential direction P as shown in FIGS. 1 and 2, for example, or in the circumferential direction P It may be formed in part. FIG. 1 and FIG. 2 are schematic sketches showing an example of the integrally extruded product of the present invention.

  In this specification, the integral extrusion means that the resin for the coating layer is extruded and at the same time, the layer is sequentially coated and integrated with the fed core material, and formed by such a method. Is referred to as an integral extrusion.

  The core material used in the present invention only needs to have a groove on the outer surface at least in the coating layer forming region along the longitudinal direction. For example, the core material may have the groove only in the coating layer forming region, or The groove may also be provided in a region other than the layer formation region. From the viewpoint of adhesiveness with the coating layer, the core is preferably made of, for example, a circumferential direction and a longitudinal direction of the cross section of the core 10 on the entire outer surface of the core 10 as shown in FIGS. It is formed continuously in both directions of m. In the present invention, since the groove on the outer surface of the core material is along the longitudinal direction m of the core material, the groove in the direction substantially perpendicular to the longitudinal direction of the core material, unevenness provided by embossing, etc. Compared to the above, grooves can be formed simultaneously with the molding of the core material, and more uniform groove formation can be achieved efficiently. As a result, the productivity of the integrally extruded product is improved, and at the same time, sufficient adhesion between the coating layer and the core material can be ensured. For example, when the core has a groove on the outer surface that is only along a direction substantially perpendicular to the longitudinal direction of the core, particularly when the core has a rod shape, such a groove is post-processed. Therefore, the processing itself becomes difficult. Further, since the grooves are easily formed unevenly, the adhesiveness tends to be lowered. Even if it can be formed uniformly, it takes a relatively long time to form such a groove, which is inefficient. Further, for example, when the outer surface of the core material has only unevenness by embossing that is post-processing, such unevenness is extremely difficult to form uniformly, and one having a short pitch is extremely difficult to create.

  The present invention does not prevent the core material from having, for example, a groove in a direction substantially perpendicular to the longitudinal direction or unevenness due to embossing in addition to the groove in the longitudinal direction of the core material. It is preferable to have only longitudinal grooves. This is because it is possible to ensure good adhesion between the core material and the coating layer only by having the grooves in the longitudinal direction.

  The depth (Dp) of the groove 2 is 0.03 to 1.0 mm, preferably 0.05 to 0.35 mm. If the depth is too shallow, processing itself is extremely difficult, and adhesion to the coating layer is reduced. If the depth is too deep, the coating layer becomes thick and the coating itself becomes difficult, and the irregularities of the core material appear on the surface of the molded body, which may cause poor appearance.

  The pitch (P) of the grooves 2 (that is, the deepest part interval between adjacent grooves) is preferably 0.03 to 1.5 mm, and more preferably 0.05 to 1.0 mm. When the pitch is too large, the adhesiveness to the coating layer tends to decrease. If the pitch is too small, processing itself cannot be performed.

  The depth and pitch of the grooves are shown as average values of values measured at arbitrary three locations per 1 m in the longitudinal direction of the core material. The measurement method is not particularly limited, but a method using a micro gauge is simple. Further, the depth may be measured by irradiating a laser beam. The depth and pitch can also be measured by a method of confirming the cut section with a microscope.

  The shape of the groove is not particularly limited as long as the object of the present invention is achieved. For example, as shown in FIG. 3 and FIG. In addition, the shape may be such that the concave portions are continuous, or the shape may be such that the substantially arc-shaped convex portions and concave portions are continuous.

  The grooves are preferably formed uniformly from the viewpoint of adhesion to the coating layer. For example, the depth and pitch of the groove can be made very uniform by providing the groove during extrusion of the core material. For example, a core material having a very uniform groove can be obtained by giving a desired groove shape to an aluminum extrusion mold and extruding aluminum from the mold. Thereby, the adhesiveness between a coating layer and a core material can be improved notably.

  The core material has a hollow or solid shape made of aluminum or an aluminum alloy, and the overall shape thereof is not particularly limited, and may be, for example, a flat plate shape, a rod shape, or the like. Usually, the core material is formed by extrusion molding of aluminum or aluminum alloy. In particular, in various shapes of core materials such as hollow shapes, U-shapes, and L-shapes, it is very useful that the extrusion can be performed when it is difficult to provide grooves by normal post-processing. In the present invention, “made of aluminum” includes “made of aluminum alloy” in its category.

When the core material has a hollow form, the thickness of the aluminum portion is preferably 1.0 mm or more, particularly 1.1 to 5.0 mm.
Moreover, the whole dimension in case a core material has a hollow or solid form is not restrict | limited in particular, What is necessary is just to set suitably according to the use of the integral extrusion molding obtained.

  In particular, when the integral extruded body is used as a building member, the core material preferably has a bar shape as shown in FIGS. 3 and 4. In this case, the core material may have either a hollow shape or a solid shape, but is preferably hollow as shown in FIGS. 3 and 4 from the viewpoint of reducing the weight of the building member. .

  When the core has a bar shape, the cross-sectional shape is not particularly limited, and may be, for example, a substantially circular shape, a substantially elliptical shape, a substantially rectangular shape (for example, a substantially rectangular shape, a substantially square shape), or the like. From the viewpoint of handleability of the building member, a core material having a substantially circular, substantially elliptical or substantially rectangular cross-sectional shape, particularly a substantially elliptical or substantially rectangular cross-sectional shape is preferable. In particular, the hollow rectangular cross-sectional core material is prone to bend by the resin pressure during integral extrusion molding, and the adhesiveness tends to be lowered. Therefore, the provision of grooves according to the present invention is very effective. The cross-sectional shape of the core material means a cross-sectional shape perpendicular to the longitudinal direction of the core material.

  In the case where the core material has a hollow form, the core material may have a screw hole for attaching the integrally extruded body inside the hollow. The screw hole can be integrally formed at the same time when the core material is formed by extrusion molding.

  When the core material is formed by extrusion, a longitudinal groove can be formed at the same time. That is, at the time of extrusion molding of an aluminum core material, a predetermined longitudinal groove is formed on the outer surface of the core material by using, as an extrusion port, a mold having a convex portion corresponding to the predetermined longitudinal groove on the inner surface. It can be formed. Alternatively, a ready-made aluminum core material having no groove, a hole having the same shape as the cross section of the core material, and a convex portion corresponding to a predetermined longitudinal groove on the inner surface of the hole A ring-shaped groove forming member is prepared, and the groove forming member is fitted at one end of the core material, and in this state, the groove forming member is relatively passed to the other end of the core material to thereby obtain a predetermined longitudinal direction. Grooves can be formed on the outer surface of the core material. The core material cross section means a core material cross section in a direction perpendicular to the longitudinal direction of the core material. In any of these methods, uniform formation of the longitudinal grooves can be achieved in a relatively short time.

  If the longitudinal grooves are simultaneously formed when the aluminum core material is extruded, the grooves can be formed in a shorter time, and thus the productivity of the integrally extruded product is significantly improved. Moreover, the grooves are formed more uniformly and the adhesiveness is remarkably excellent.

  The core material in which the grooves in the longitudinal direction are formed may be anodized to form an alumite layer for the purpose of improving adhesion with the coating layer before the formation of the coating layer described later. Preferably it is not applied. This is because, in the present invention, the adhesiveness can be effectively improved without performing such alumite treatment.

  The coating layer 1 formed on the outer surface of the core material is made of a synthetic resin and has a so-called non-foamed body or a low foamed form with a foaming ratio of 5 times or less, particularly 2 times or less.

  Synthetic resins used for such coating layers include, for example, polyvinyl chloride resin (hereinafter referred to as PVC resin), acrylonitrile-butadiene-styrene copolymer resin (hereinafter referred to as ABS resin), and acrylonitrile-styrene-acrylic rubber copolymer. Resin (hereinafter referred to as ASA resin), polystyrene resin, high impact polystyrene resin, acrylonitrile-styrene copolymer resin (hereinafter referred to as AS resin), silicon-based composite rubber-modified acrylonitrile-styrene copolymer resin (hereinafter referred to as SAS resin), Modified polyphenylene ether resin, polyethylene resin, polypropylene resin, polymethyl methacrylate resin (hereinafter referred to as PMMA resin), methyl methacrylate-butyl acrylate copolymer resin, methyl methacrylate-styrene copolymer tree (Hereinafter referred to as MS resin) acrylic resin or polyester resin or a mixed resin or the like of these and the like. Particularly preferred from the viewpoints of moldability, toughness, and economy are PVC resin, ABS resin, SAS resin, AS resin, ASA resin, and PMMA resin, and these resins themselves are harder. These synthetic resins include fillers such as calcium carbonate, talc, mica, and shirasu balloons, lightweight materials, reinforcing materials such as glass fibers and cellulose fibers, flame retardants, other heat stabilizers, and synthetic resins such as lubricants. Various additives added to the molded body can be included.

  The coating layer may be composed of a single layer or may be composed of two or more synthetic resin layers, but is preferably composed of two or more layers, particularly 2 to 4 synthetic resin layers. When the coating layer is composed of two or more synthetic resin layers, the synthetic resin constituting each layer may be independently selected from the above synthetic resins.

  A preferred coating layer is composed of two or more synthetic resin layers, and the synthetic resin layer in contact with the core material is a polyester resin layer. This is because the adhesion between the coating layer and the core material is more effectively improved. When the coating layer is composed of two or more synthetic resin layers, the thickness of the layer in contact with the core material (so-called inner layer) needs to be at least thicker than the groove depth of the core material from the viewpoint of adhesiveness. Usually, it is 0.05-2 mm. For example, when the groove depth is 0.1 mm, at least the inner layer needs to have a thickness of 0.1 mm or more, and preferably 0.15 mm (0.05 mm or more thicker than the groove depth) or more as an average value. Particularly in the case of integral molding, the adhesive force is exhibited because it is in close contact with the core material by the resin pressure. At this time, the synthetic resin layer other than the polyester-based resin layer in contact with the core material is more preferably made of PVC resin, ABS resin, SAS resin, AS resin, ASA resin, PMMA resin, or the like. This is because the effect of improving the adhesion by the polyester resin layer is more effectively exhibited.

  When the coating layer is composed of two or more synthetic resin layers, the outermost surface layer preferably has a protective function for protecting the surface. It is preferable that the outermost surface layer having such a protective function is usually made of PMMA resin, SAS resin, AS resin, ASA resin, ABS resin, MS resin, or PVC resin among the synthetic resins. Among such synthetic resins, when the outermost surface layer is made of PMMA resin, ABS resin, MS resin, or AS resin, a transparent protective layer can be obtained.

A preferred configuration of the coating layer is shown below. However, it is not limited to the following configurations. In addition, the layer described at the beginning is a layer in contact with the core material, and shows a layer approaching the outermost surface layer in order, and the layer described at the end is the outermost surface layer;
(1) Adhesive layer made of polyester resin-transparent protective layer made of PMMA resin;
(2) Adhesive layer made of a polyester-based resin-surface decoration layer made of a colored SAS resin having a seed;
(3) Adhesive layer made of polyester-based resin-decorative layer made of colored PMMA resin having seed agent-surface layer made of PMMA resin;
(4) Adhesive layer made of polyester resin-translucent protective layer made of colored ABS resin;
(5) Adhesive layer made of a polyester-based resin-surface decoration layer made of a colored translucent MS resin having a seed;
(6) Adhesive layer made of a polyester-based resin-surface decorative layer made of a colored translucent PMMA resin having a decorative powder;
(7) Adhesive layer made of polyester-based resin-decorative layer made of colored PMMA resin having decorative powder-Transparent surface layer made of PMMA resin;

  The thickness of the coating layer is preferably 0.3 mm or more, more preferably 0.6 mm or more from the viewpoints of hardness, wearability, and production stability. When the coating layer is composed of two or more synthetic resin layers, the thickness of the layer in contact with the core material (so-called inner layer) is extremely preferably at least greater than the groove depth of the core material from the viewpoint of the adhesiveness. In addition, the total thickness of two or more layers should just be in the said range. In particular, when the coating layer thickness is 0.6 mm or more, stable decoration expression is possible when the surface decoration layer is formed. The upper limit of the thickness is not particularly limited, but is 3 mm or less, preferably 2 mm or less, in view of excessive resin pressure during integral molding, productivity and cost.

  The monolithic extruded product of the present invention is manufactured by a so-called monolithic extrusion method in which the coating layer is integrated with the core material simultaneously with the extrusion molding of the coating layer from the viewpoint of productivity, long product molding, and constant product characteristics. The In particular, in the case of producing an integrally extruded body having a coating layer composed of two or more synthetic resin layers, it is produced by a coextrusion type integral extruder as shown in FIG. Specifically, the resin extruded from each extruder (11, 12 in FIG. 5) for melting and kneading the resin forming each synthetic resin layer is laminated in one die 13, and at the same time, the layer is Then, the core material 14 having the fed longitudinal grooves is sequentially covered and integrated. Once integrated, it is usually cooled and cut to the desired dimensions. Although two extruders are used in FIG. 5, the present invention is not limited to this, and it may be appropriately installed according to the number of synthetic resin layers constituting the coating layer.

  The integral extruded body of the present invention does not need to cover the entire surface of the aluminum core with a synthetic resin. For example, as long as it has a substantially rectangular cross section as shown in FIG. 4, the upper and lower surfaces may be covered, and the side surfaces may be in a covered state where the core material is exposed. In addition, the present invention includes a case where only a portion that appears as an external appearance is covered if it is a building member.

[Core]
The following aluminum alloy core materials A to G manufactured by extrusion molding were used. In addition, at the time of extrusion molding of the core materials A to F, a die having a convex portion corresponding to the groove of each core material shown in Table 1 was used as the extrusion port. At the time of extrusion molding of the core material G, a die having no convex portion was used at the extrusion port. The core materials B to G were further subjected to alumite treatment. All the aluminum cores had a total length of 3 m.

[How to create an evaluation sample]
Example 1
An integrally extruded product was produced by a coextrusion type integral extruder shown in FIG. Specifically, the synthetic resin of the outer layer (outermost surface layer) and the inner layer (layer contacting the core material) are simultaneously extruded from the outer layer extruder 12 and the inner layer extruder 11, respectively, and the aluminum core material 10 ( The core material A) was laminated and coated to produce an integrally extruded body having a two-layer coating layer on the entire outer surface of the aluminum core material A in the circumferential direction. Extrusion conditions, extrusion resin, and core material conditions are as follows.
Outer layer extruder: 40φ, single screw extruder (extrusion temperature about 180 ° C)
Inner layer extruder: 40φ, single screw extruder (extrusion temperature about 150 ° C)
Inner layer resin: A polyester resin having a specific gravity of 1.26 and a melting point of 115 ° C. The inner layer thickness after cooling is 0.2 mm.
Outer layer resin: SAS resin (UMG Wood; manufactured by MG ABS Co., Ltd.). The outer layer thickness after cooling is 0.5 mm.
The aluminum core is preheated (about 100 ° C.) immediately before being inserted into the die.

(Examples 2 to 4 and Comparative Example 1)
An integrally extruded product was produced in the same manner as in Example 1 except that the core material shown in Table 2 was used as the aluminum core material.
(Example 5 and Comparative Example 2)
In the same manner as in Example 1, except that the core material shown in Table 2 was used as the aluminum core material, and the thickness of the inner layer resin was 0.4 mm and the thickness of the outer layer resin was 1.0 mm. Extruded bodies were produced.

[Evaluation methods]
-Adhesiveness First, the thermal cycle test was implemented with respect to the sample.
The thermal cycle test is to hold a sample repeatedly under low temperature and high temperature conditions. Specifically, the sample was held at −10 ° C. for 2 hours and held at 80 ° C. for 2 hours as one cycle for a total of 20 cycles. . After completion of the thermal cycle test, the surface was washed with water and dried in the shade for 24 hours.

Subsequently, an adhesion test was performed on the sample after completion of the test in accordance with the JISK5400: 1990 8.5.2 cross cut tape test. Specifically, a grid was created on the sample surface. The grids were created with a cutter knife, the interval between the cuts by the cutter knife was 2 mm, and the total number of grids was 100. The method of applying the tape and the method of removing the tape were performed according to the JIS method. In the evaluation results in the table, the numerator is the number of grids that did not peel, and the denominator is the total grid number.
The adhesion test was performed at the central portion in the longitudinal direction of the integrally extruded body. In addition, when there is even one peeling grid, the integral extruded product cannot be shipped as a whole.

  The integrally extruded body with an aluminum core material of the present invention is useful as a building material such as a decorative material for construction, a handrail for construction, a face grid for security, a deck material, and a balcony louver.

It is a general | schematic sketch showing an example of the integral extrusion molding of this invention. It is a general | schematic sketch showing an example of the integral extrusion molding of this invention. It is a general | schematic sketch showing an example of the core material which comprises the integral extrusion molding of this invention. It is a general | schematic sketch showing an example of the core material which comprises the integral extrusion molding of this invention. It is a schematic sectional drawing of the coextrusion type integral extrusion molding machine for manufacturing the integral extrusion molding of this invention.

Explanation of symbols

1: coating layer, 2: groove, 10:14: core material, 11:12: extruder, 13: die.

Claims (1)

A coating layer having a thickness of not less than 0.3 mm and not more than 3 mm made of synthetic resin is formed on a part or all of the outer surface of the aluminum core material along the longitudinal direction of the core material. A building member comprising a monolithic extruded body having a groove having a depth of 0.05 to 0.35 mm and a pitch of 0.05 to 1.0 mm along the longitudinal direction at least in the covering layer forming region,
The groove is formed when the core material is extruded,
The coating layer is composed of two or more synthetic resin layers formed on the outer surface of the core material by integral extrusion molding, and the synthetic resin layer in contact with the core material of the coating layer is a polyester resin layer, and is the outermost surface The synthetic resin layer is composed of polymethyl methacrylate resin, silicon composite rubber-modified acrylonitrile-styrene copolymer resin, acrylonitrile-styrene copolymer resin, acrylonitrile-styrene-acrylic rubber copolymer resin, acrylonitrile-butadiene-styrene copolymer resin, methyl A building member comprising a resin selected from the group consisting of a methacrylate-styrene copolymer resin and a polyvinyl chloride resin.

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