JP5203017B2 - Painted metal plate with excellent design and its manufacturing method - Google Patents

Description

  The present invention relates to a coated metal plate excellent in design and suitable for use in home appliances, indoor and outdoor building materials, and a method for producing the same.

  In a product using a metal plate, the outer plate touched by human eyes is mostly used with some coating applied for the purpose of improving the corrosion resistance and the design.

  Conventionally, such painting has been performed by an after-coating method in which painting is performed after completion of product assembly, but recently, the use of pre-painted metal sheets (pre-coated metal sheets) has been increasing.

  The percentage of use of coated metal plates is increasing: (1) can help customers skip processes, (2) can avoid complicated tasks such as degreasing and painting, (3) in urban areas In the case of home appliance factories that are located, it is difficult to renew the paint factory, (4) special functions can be added, and (5) design characteristics can be added.

  Among these reasons, a pattern-coated metal plate has been demanded particularly focusing on the design properties of the painted metal plate.

  Conventional techniques for pattern-coated metal plates include metallic coating metal plates that change the reflection direction of light and express patterns by adding scaly pigments to the top coat, and variations of metallic coating layer metal plates For example, a metal-coated metal plate having a hammer tone pattern (unevenness pattern as if struck with a hammer) is known.

  Since the metallic coated metal plate contains scaly pigments such as aluminum flakes in the top coat film, the reflection of light changes greatly depending on the orientation direction and the visual recognition direction of the scaly pigments, and a pattern appears. However, there is a problem that the roll eyes are very conspicuous due to the rib-like uneven pattern formed parallel to the coating direction. For this reason, it is made to suppress conspicuous roll eyes by using 3 roll coating or curtain roll coating.

  In addition, proposals have been made to suppress the noticeability of roll eyes without using 3-roll coating or curtain roll coating. For example, Patent Document 1 discloses a metallic material in which a scale-like substrate is coated with a metal such as an Fe-based alloy or an Ni-based alloy together with organic beads to develop a metallic view with no directivity. It is described that a painted metal plate can be obtained.

  On the other hand, there has been proposed a metallic-coated metal plate in which directivity is lost and cosmetics are imparted by combining spray coating with metallic coating. For example, in Patent Document 2, the top coat film is composed of a top coat base paint and a top clear paint, and the top coat base paint contains organic resin fine particles and a color pigment, and the top coat clear paint contains glitter powder. In addition, it is described that the top-coat clear paint is wet-on-wet before the base-coat colored base paint is dried. Further, in Patent Document 3, the top coat film is composed of a top coat base paint and a top clear paint, and the top coat base paint contains organic resin fine particles and a color pigment, and the top coat clear paint contains glitter powder. It is described that the shrink coating material contained is used, and the top clear coating material is wet-on-wet coated before the top coating colored base coating material is dried.

  Next, it has been proposed to produce a metallic coated metal plate having a hammer tone pattern (irregular pattern as if struck with a hammer) by spraying a solvent onto the wet metallic paint. For example, in Patent Document 4, an undercoat paint is applied to the surface of a metal plate, dried, and then an overcoat paint containing aluminum powder, pearl mica powder or stainless steel powder is applied onto the undercoat paint, and this overcoat paint is applied. Describes a method of obtaining a metallic coated metal plate having a hammer tone pattern by spraying a solvent on the top coating material while it is in an undried state, followed by drying and baking.

  In addition, there exists a pattern printing metal plate as something similar to a pattern coating metal plate. This is because the ink containing a high concentration of pigment is dried on the entire surface of the metal plate, and then the ink containing the high concentration of pigment is transferred and printed onto the pattern on the top coating. A pattern is developed on the top coat film.

JP 2000-107680 A JP-A-11-19581 Japanese Patent Laid-Open No. 11-19582 JP-A-2005-324122

  In order to prevent the metallic paint metal plate from being conspicuous, three-roll coating or curtain roll coating can be used. However, if three-roll coating is to be performed, it is necessary to newly provide equipment for that purpose. In addition, there is a problem that the cleaning work becomes complicated. In addition, if the curtain flow coating is to be applied, it is not only necessary to newly install equipment for that purpose, but also the paint that can form a stable curtain is limited and the coating is also limited. is there.

  Instead of applying 3-roll coating or curtain flow coating, spray coating is applied on the wet metallic paint as described above to obtain a metallic coated steel sheet having no directivity or a hammer-tone pattern. It has been proposed. However, in order to perform spray coating, it is necessary to newly provide a spray coating facility therefor, and since the coating efficiency of the coating is considerably lower than that of a roll coater, the loss of the coating and solvent is large. In addition, since the size of the paint particles is not constant because of spray coating, there is a problem that the pattern obtained by spray coating is poorly reproducible.

  Next, the pattern-printed metal plate formed by transferring ink containing a high concentration of pigment onto the top coat film forms a pattern with the transferred ink layer scattered in a convex shape on the top coat film. Unlike the pattern obtained by spray painting, the pattern printed on the metal plate has excellent reproducibility. However, since the top coat film cannot be concealed, the color tone of the pattern printed metal plate must be based on the color tone of the top coat film, and the design of the pattern printed metal plate depends greatly on the color tone of the top coat film. Will be. In addition, since the transferred ink layer is scattered in a convex pattern on the dried top coat film, the adhesion to the top coat film is poor, and the ink layer is peeled off from the top coat film. There is a possibility that the pattern portion is missing.

  This invention is made | formed in view of such a problem, and it aims at providing the coating metal plate excellent in the designability with which the adhesiveness of a pattern is good, and a pattern is conspicuous, and its manufacturing method. .

  As a result of various studies on the appearance of a pattern on a painted metal plate, the present inventor has obtained the following findings (i) to (iii).

  (i) A metallic coating metal plate obtained by adding a scaly pigment to a top coating film can exhibit a metallic appearance having no directivity by using three-roll coating or curtain flow coating. Alternatively, after applying the metallic paint, before the metallic paint is dried, a metallic appearance having no directivity can be developed by spraying the upper surface of the metallic paint or spraying a solvent. However, both require new equipment, and there are many difficulties in workability and pattern reproducibility.

  (ii) In contrast, pattern printed metal plates transfer the ink layer containing a high concentration of pigment onto the top coat film after drying the top coat film applied to the entire surface of the metal plate. Since it is for printing, it is excellent in reproducibility unlike the one obtained by spray coating, and workability is also good because it can be transferred by a roll. However, an ink layer containing a high concentration of pigment has a drawback of poor adhesion to the top coat film.

  FIG. 1 is a schematic view of a part of such a pattern-printed metal plate cut out. FIG. 1A is a front (sectional) view, and FIG. 1B is a top view. In this pattern printing metal plate, a top coat film 3 is formed on one surface of a base metal layer 1 via a base treatment layer 2, and an ink layer 4 forms a pattern on the top coat film 3. To be printed. Since the ink is transferred onto the top coat film 3 after drying, the transferred ink layer 4 always has a convex shape, and since the compatibility with the top coat film 3 is small, intense processing was applied. In some cases, the ink layer 4 forming the pattern may peel off and fall off.

  (iii) In order to solve this, instead of forming a pattern comprising an ink layer by transferring an ink containing a high concentration of pigment onto the top coat film, an organic resin compatible with the top coat film It is conceivable to form a pattern layer by transferring the paint. The organic resin paint transferred onto the top coat film becomes a pattern layer with a convex shape, but the adhesion with the top coat film is greater than the convex pattern made of ink containing a high concentration of pigment, so the organic resin Only the pattern layer formed from the paint is less likely to be peeled off from the top coat film.

  In this way, if a pattern layer is formed by transferring an organic resin paint compatible with the top coat onto the top coat, a pattern coated metal plate that is difficult to peel off from the top coat is formed. become. In order to form a pattern layer by transferring an organic resin paint compatible with the top coat onto the top coat, a gravure roll engraved with a gravure cell consisting of a concave pattern on the surface of the roll with a smooth surface. When used as an applicator roll, the organic resin paint is applied only to the recesses, and then the organic resin paint in the recesses is transferred onto the top coat film, so that the convex island pattern layer made of the organic resin paint is applied to the top coat. It will be formed on the coating film. In order to attach the organic resin paint only to the concave portion of the roll, the organic resin paint is once adhered to the entire surface of the roll, and before the roll surface comes into contact with the above-mentioned top coat film, it is applied to the smooth surface of the roll by a blade or the like. What is necessary is just to scrape off the adhering organic resin paint.

  FIG. 2 is a schematic view of a part of such a pattern-coated metal plate cut out. FIG. 2 (a) is a front (sectional) view, and FIG. 2 (b) is a top view. In this pattern-coated metal plate, a flat top coating film 3 is formed on one surface of a base metal layer 1 via a base treatment layer 2, and an island-like shape is formed on the flat top coating film 3. The organic resin paint is transferred. The organic resin paint forming the island-shaped pattern layer 5 is not only highly compatible with the top coat film 3 but also can be transferred onto the top coat film 3 before the top coat film 3 is dried. In this case, the adhesion between the flat top coat film 3 formed on one surface and the island-shaped pattern layer 5 becomes more excellent.

  However, the pattern-coated metal plate obtained by this method is excellent in adhesion between the island-shaped pattern layer 5 and the top coat film 3, but the organic resin paint is applied on the flat top coat film 3. Since the island-like pattern layers 5 are scattered in a convex shape, the top coat film cannot be concealed. Although the hue of the convex island-shaped pattern layer 5 can be changed by adding various pigments, the color tone of the pattern-coated metal plate must be based on the hue of the top coat film. The degree of freedom of the color tone of the pattern-coated metal plate is greatly limited.

  As a result of studying a method for solving these problems all at once, the present inventors have obtained the following findings (a) to (h).

  (a) In order to secure the degree of freedom of the color tone of the pattern-coated metal plate, after the step of forming a flat top coat film, an island-like pattern made of an organic resin paint is transferred onto it to form convex islands. Instead of going through the step of forming a pattern pattern layer, a step of forming a top coat film in which a flat top coat film portion and a convex island pattern layer portion are integrally connected may be adopted.

  That is, when an organic resin paint is applied to one surface of a metal plate that has undergone a base treatment, it may be applied so that a concavo-convex pattern appears on the outer surface of the top coat film formed after the coating. As a method of forming a top coat film having a concavo-convex island pattern on the outer surface, in which a flat top coat film part and a convex island pattern layer part are integrally connected, for example, a ground treatment was applied. When transferring an organic resin paint to one side of a metal plate, an organic resin paint is applied by roll coating using an applicator roll with a smooth surface and a metal pickup roll with a gravure cell partially engraved on the surface. Can be transferred at once. With such a coated metal plate having a top coat film having a concavo-convex pattern on the outer surface, the concavo-convex shape of the outer surface itself expresses the pattern, and the top coat film covers the entire surface of the ground treatment layer. Since the color tone of the coated metal plate is based on the hue of the top coat film, the color tone of the pattern coated metal plate can be freely selected. Therefore, the degree of freedom of the hue of the pattern-coated metal plate is large.

  Also, the organic resin paint is not scattered in a convex shape to form the convex pattern layer, but the pattern appearance is expressed by the uneven shape itself of the top coating film integrally connected with the organic resin paint. Only the concavo-convex shape portion expressing the pattern is not peeled off from the top coat film.

  FIG. 3 is a schematic view of a part of a coated metal plate having a concavo-convex top coat film on the outer surface. FIG. 3A is a front (sectional) view, and FIG. 3B is a top view.

  In this coated metal plate, a top coat film 6 having a convex pattern on the outer surface is formed on a metal plate 1 serving as a substrate via a base treatment layer 2. Since the outer surface of the top coat film 6 has a convex shape, the rugged outer surface of the top coat film 6 itself expresses an island-like pattern appearance. And, in such a coated metal plate having a concavo-convex pattern on the outer surface, the top coat film 6 covers the entire surface of the base treatment layer 2 and conceals the base treatment layer 2. It does not depend on the hue.

  (b) The top coat film is formed by the transferred organic resin paint. In order to further highlight the pattern appearance formed by the uneven shape of the top coat film, the organic resin paint that forms the top coat film is used. Any one of (i) a paint containing a scaly pigment, (ii) a low gloss paint, and (iii) a shrink paint may be used.

  (i) Since the gloss of the top coat film made of paint containing scaly pigments changes depending on the orientation of the scaly pigments in the paint film, it may become blackish or whitish depending on the viewing angle . When a top coat film having a concavo-convex shape in which organic resin paints are continuously connected is formed using a paint containing a flaky pigment, the orientation angle of the scaly pigment is obtained between the flat portion and the inclined portion of the concavo-convex shape. Therefore, the pattern of the contour portion of the convex portion stands out. In addition, as a scaly pigment, aluminum flakes, mica, etc. can be used.

  (ii) The low gloss paint is a fine silica particle or resin bead paint, and the surface of the top coat film is made to protrude upward from the surface of the top coat film of the silica particles or resin beads. A fine convex part is given to the film, and the gloss of the coating film can be lowered. As 60 degree gloss, it is generally 30 or less in the broad sense and 10 or less in the narrow sense. The gloss of such a low gloss paint changes due to the fine irregularities of the silica particles and resin beads on the surface of the top coat film. That is, if the silica particles or resin beads on the surface of the top coat film are large, the gloss becomes low, and if the degree of protrusion is small or does not protrude at all, the gloss becomes high. Therefore, when a top coat film having a concavo-convex shape is formed using a low gloss paint, the convex portions tend to be highly glossy and the concave portions tend to be low gloss. Therefore, when a top coat film with irregularities is formed using a low gloss paint, a pattern-coated metal plate consisting of high-gloss convex portions and low-gloss concave portions is obtained, so that the convex portions stand out. In the case of a coating film made of a dark paint, the high gloss portion looks blackish and the low gloss portion looks whitish.

  (iii) A shrinkage paint is a paint that can form small wrinkles (fine irregular surfaces) on the surface of the paint film by utilizing the difference in curing speed between the paint film surface and the inside of the paint film. The gloss decreases. This gloss reduction method is also affected by the thickness of the coating film. That is, when a top coat film having a concavo-convex shape is formed using a shrink paint, the convex portion tends to form wrinkles, so that the gloss tends to be low gloss, and the concave portion is difficult to form wrinkles, so the gloss tends to become high gloss. Therefore, when a top coat film having a concavo-convex shape is formed using a shrink paint, a pattern-coated metal plate comprising low-gloss convex portions and high-gloss concave portions is obtained, and the concave portions stand out.

  However, the top coat film having a concavo-convex shape on the outer surface is obtained by integrally connecting a single-color organic resin paint, and the island-like pattern appearance is expressed by the concavo-convex pattern of the single-color top coat film. Therefore, the concavo-convex pattern may be buried in the top coat film and become inconspicuous.

  (c) In order to make the concavo-convex pattern conspicuous, after transferring the organic resin paint for the top coat film having a concavo-convex shape, when the top coat film is in an undried state, the top coat film is formed on the top coat film. What is necessary is just to spray paint with a different hue. At this time, a paint having a hue different from that of the top coat is mixed in the top coat, but the concave portion of the top coat has a different hue from the convex portion. The island pattern obtained by the shape can be conspicuous. The reason why the concave part of the top coat film has a different hue from the convex part is that when the top coat film of the outer convex shape is in an undried state, spray coating is performed on the top coat film in an undried state. However, the subsidence rate of the granular paint is different between the concave and convex parts of the top coat film, the subsidence speed is small in the concave part, and the subsidence speed in the convex part. Is big. As a result, when the top coat film after drying is viewed from above, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the apparent area of the granular paint is small in the convex part of the top coat film or This is probably because the granular paint is not visible.

  FIG. 4 shows an example of a pattern-coated metal plate obtained by spraying a paint having a hue different from that of the top coat on the top coat when the top coat having an uneven shape on the outer surface is in an undried state (reference example) ) Is a schematic diagram (partially cut out). FIG. 4A is a front (sectional) view, and FIG. 4B is a top view.

  After forming a top coat film 6 having a concavo-convex pattern on the outer surface via a base treatment layer 2 on a metal plate 1 as a base material, when the top coat film 6 is in an undried state, a top coat is formed thereon. A paint having a hue different from that of the coating film 6 is applied by spraying. Since the spray-coated paint 10 is granular and settles in the film of the top coat film 6, the granular paint 10 is mixed in the film of the top coat film 6. Here, the sinking speed is different between the concave and convex portions of the top coat film, the sinking speed is small at the concave portion, and the sinking speed is high at the convex portion. The granular coating material 10 protrudes from the top coating film 6, whereas the granular coating material 10 is completely buried in the top coating film 6 at the convex portions. As a result, when the top coat film after drying is viewed from above, the apparent area of the granular paint is large in the concave portion, whereas the granular paint cannot be seen in the convex portion. Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat, whereas the hue of the granular paint is not reflected in the convex portion. Therefore, the concave and convex portions of the top coat have different hues. Therefore, the island-shaped concave portions obtained by the concave-convex patterns can be made conspicuous.

  FIG. 5 shows another example of a pattern-coated metal plate obtained by spraying a paint having a hue different from that of the top coat on the top coat when the top coat having an uneven shape on the outer surface is in an undried state. It is a schematic diagram (part cut out) of a reference example). FIG. 5A is a front view (cross section), and FIG. 5B is a top view.

  A top coat film 6 having an uneven pattern on the outer surface is formed on the metal plate 1 serving as the base material via the base treatment layer 2, and in the same manner as the coated metal plate shown in FIG. The paint 10 is mixed in the film of the top coat film 6. However, the sinking speed at the convex portion is different from that of the coated metal plate shown in FIG. 4, and the granular coating 10 protrudes slightly from the top coating 6 after the top coating is dried. As a result, when the top coat film after drying is viewed from above, the apparent area of the granular paint is large in the concave portion, whereas the apparent area of the granular paint is small in the convex portion. Therefore, the concave portion of the top coat film largely reflects the hue of the granular paint, whereas the convex portion only reflects the hue of the granular paint slightly. The convex portions have different hues, so that the island-shaped concave portions obtained by the concave and convex patterns can be made conspicuous.

  (d) Thus, in order to make the uneven pattern of the top coat film conspicuous, after transferring the organic resin paint for the top coat film having the uneven shape, when this top coat film is in an undried state, this top coat A paint having a hue different from that of the top coat film may be spray-coated on the film, and a paint having a hue different from that of the top coat film may be mixed in a granular form in the top coat film.

  However, this can provide a pattern-coated metal plate with conspicuous irregularities in the top coat film, but the hues are only two colors, top coat and spray paint. Therefore, it is not possible to provide a more versatile pattern-coated metal plate.

  (e) In order to obtain a variety of pattern-coated metal plates of three colors or more, after forming an undercoat film on the entire surface of the base treatment layer, an overcoat having an uneven shape so as to cover a part of the undercoat film Transfer the organic resin paint for the film and form a top coat film with an uneven shape on its outer surface. When this top coat film is in an undried state, spray a paint with a hue different from that of the top coat film on it. Just paint. That is, a coated metal plate having an undercoat and an overcoat in order on at least one side of a metal plate that has undergone a base treatment, the overcoat covering a part of the undercoat, and the topcoat If the outer surface of the coating film has a concavo-convex pattern, and the pattern coating metal plate is a mixture of different colors in the top coating film, the pattern coating metal plate is more diverse Can be provided.

  At this time, both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film are in an undried state, and both paint films are different in hue from any paint film. When spray coating is performed, paints having different hues can be mixed in a granular manner not only in the top coat film having an uneven shape on the outer surface but also in the bottom coat film not covered with the top coat film. If the granular paint is embedded in the undercoat, the hue of the undercoat does not change, but if a part of the granular paint protrudes from the undercoat even a little, it is covered with the topcoat. No primer coat reflects the hue of the granular paint. The degree of reflection depends on the apparent area of the granular paint when the undercoat film not covered with the topcoat film is viewed from the top after drying. Can be made.

  On the other hand, when the top coat film having an uneven shape on the outer surface is in an undried state, the undercoat film not covered with the top coat film is in a dry state. If the paints with different coatings are spray-coated, paints with different hues can be mixed in a granular form in the top coat film having an uneven shape on the outer surface, but in the base coat film not covered with the top coat film Cannot mix paints with different hues in granular form. Instead, a pattern coating film having a hue different from that of the undercoat film is present in an island shape on the undercoat film not covered with the topcoat film. Therefore, the spray paint does not sink into the undercoat film in a granular form, but it is present in the form of islands on the undercoat film. Therefore, the spray paint is sprayed on the undercoat film not covered with the overcoat film. The paint is scattered and the color of the spray paint is reflected. The degree of reflection depends on the pattern size of the scattered spray film when the undercoat film not covered with the topcoat film is viewed from the top after drying. The hue of the film can be changed variously.

  FIG. 6 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design according to the present invention. FIG. 6A is a front view (cross section), and FIG. 6B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied when the undercoat film 7 was in an undried state. Then, when both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film are in an undried state, a paint having a hue different from that of the top coat film and the undercoat paint is sprayed thereon. Paint. Since the spray-coated paint 10 settles in the form of the top coat film 6 and the undercoat film 7 not covered with the top coat film, the granular paint 10 is covered with the top coat film 6 and the top coat film. It will be mixed in the film of the undercoat coating 7 which is not broken.

  Here, the sinking speed is different between the concave portion and the convex portion of the top coat film 6, and the concave portion has a low sink rate and the convex portion has a high sink rate. Then, the granular paint 10 protrudes from the top coating film 6 whereas the granular paint 10 is completely buried in the top coating film 6 at the convex portion. The granular paint 10 in the undercoat film 7 not covered with the topcoat film protrudes slightly from the undercoat film 7.

  As a result, when the coated film after drying is viewed from above, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the granular paint is not visible in the convex part of the top coat film. In the undercoat film 7 not covered with the film, the apparent area of the granular paint is small.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat film, whereas the hue of the granular paint is not reflected in the convex portion, and the undercoat film 7 is not covered with the top coat film. In this case, the concave and convex portions of the top coat after drying and the undercoat that is not covered with the top coat have three different hues, and the pattern coating metal has a variety of uneven patterns. A board can be obtained.

  FIG. 7 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design according to the present invention. FIG. 7A is a front (sectional) view, and FIG. 7B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied when the undercoat film 7 was in an undried state. Then, when both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film are in an undried state, a paint having a hue different from that of the top coat film and the undercoat paint is sprayed thereon. Paint. Since the spray-coated paint 10 settles in the form of the top coat film 6 and the undercoat film 7 not covered with the top coat film, the granular paint 10 is covered with the top coat film 6 and the top coat film. It will be mixed in the film of the undercoat coating 7 which is not broken.

  Here, the sinking speed is different between the concave portion and the convex portion of the top coat film 6, and the concave portion has a low sink rate and the convex portion has a high sink rate. Then, the granular paint 10 protrudes from the top coating film 6 whereas the granular paint 10 is completely buried in the top coating film 6 at the convex portion. The granular paint 10 in the undercoat film 7 not covered with the topcoat film is completely buried in the undercoat film 7.

  As a result, when the dried coating film is viewed from the top, the apparent area of the granular paint is large in the concave portion of the top coating film, whereas the granular coating material is not visible in the convex portion of the top coating film. Even in the undercoating film 7 not covered with the coating film, the granular coating material cannot be seen.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat film, whereas the hue of the granular paint is not reflected in the convex portion, and the undercoat film 7 is not covered with the top coat film. However, since the hue of the granular paint is not reflected, the concave and convex portions of the top coat film after drying and the undercoat film not covered with the top coat film have three different hues, thereby creating a variety of uneven patterns. It is possible to obtain a patterned metal sheet having a pattern.

  FIG. 8 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design properties according to the present invention. FIG. 8A is a front (sectional) view, and FIG. 8B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied when the undercoat film 7 was in an undried state. Then, when both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film are in an undried state, a paint having a hue different from that of the top coat film and the undercoat paint is sprayed thereon. Paint. Since the spray-coated paint 10 settles in the form of the top coat film 6 and the undercoat film 7 not covered with the top coat film, the granular paint 10 is covered with the top coat film 6 and the top coat film. It will be mixed in the film of the undercoat coating 7 which is not broken.

  Here, the sinking speed is different between the concave portion and the convex portion of the top coat film 6, and the concave portion has a low sink rate and the convex portion has a high sink rate. Then, the granular paint 10 has its head protruded largely from the top coat film 6, whereas the granular paint 10 has slightly protruded its head from the top coat film 6 at the convex portion. The granular paint 10 in the undercoat film 7 not covered with the topcoat film is completely buried in the undercoat film 7.

  As a result, when the coated film after drying is viewed from the top, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the apparent area of the granular paint is small in the convex part of the top coat film. Even in the undercoat film 7 that is not covered with the topcoat film, the granular paint cannot be seen.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat, whereas the hue of the granular paint is slightly reflected in the convex portion, and the undercoat is not covered with the top coat. 7 does not reflect the hue of the granular paint, so the concave and convex portions of the top coat after drying and the undercoat that is not covered with the top coat have three different hues. It is possible to obtain a pattern-coated metal plate having

  FIG. 9 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design according to the present invention. FIG. 9A is a front (sectional) view, and FIG. 9B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied when the undercoat film 7 was in an undried state. Then, when both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film are in an undried state, a paint having a hue different from that of the top coat film and the undercoat paint is sprayed thereon. Paint. Since the spray-coated paint 10 settles in the form of the top coat film 6 and the undercoat film 7 not covered with the top coat film, the granular paint 10 is covered with the top coat film 6 and the top coat film. It will be mixed in the film of the undercoat coating 7 which is not broken.

  Here, the sinking speed is different between the concave portion and the convex portion of the top coat film 6, and the concave portion has a low sink rate and the convex portion has a high sink rate. Then, the granular paint 10 has its head protruded largely from the top coat film 6, whereas the granular paint 10 has slightly protruded its head from the top coat film 6 at the convex portion. And the granular coating material 10 in the undercoat film 7 not covered with the topcoat film protrudes from the undercoat film 7 greatly.

  As a result, when the coated film after drying is viewed from the top, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the apparent area of the granular paint is small in the convex part of the top coat film. In the undercoat film 7 not covered with the topcoat film, the apparent area of the granular paint is large.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat, whereas the hue of the granular paint is slightly reflected in the convex portion, and the undercoat is not covered with the top coat. Since the hue of the granular paint is considerably reflected in No. 7, the concave and convex portions of the top coat film after drying and the undercoat film not covered with the top coat film have three different hues. A pattern-coated metal plate having an uneven pattern can be obtained.

  FIG. 10 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design according to the present invention. FIG. 10A is a front (sectional) view, and FIG. 10B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied after the undercoat film 7 was dried. And when the top coat film which has an uneven | corrugated shape on an outer surface is an undried state, the paint with a different hue from the top coat film and the undercoat paint is spray-coated on it. Since the spray-coated paint 10 settles in a granular form in the film of the top coat film 6, it is possible to mix paints of different hues in the top coat film 6 having an uneven shape on the outer surface, In the undercoat film 7 not covered with the top coat film, paints having different hues cannot be mixed in a granular form. Instead, a pattern coating film having a hue different from that of the undercoating film 6 exists in an island shape on the undercoating film 7 not covered with the top coating film. Therefore, the spray-coated paint 10 does not sink into the undercoat film 7 in a granular form, but is present in the form of islands on the undercoat film 7 and is therefore covered with the overcoat film. The spray paint is scattered on the undercoat film 7 that is not present, and the hue of the spray paint is reflected.

  Here, the sinking speed of the spray paint is different between the concave portion and the convex portion of the top coat film 6, the sinking speed is small in the concave portion and the sinking speed is high in the convex portion. In the concave portion, the granular coating material 10 protrudes its head from the top coating film 6, whereas in the convex portion, the granular coating material 10 protrudes a little from the top coating film 6. The spray paint on the undercoat film 7 not covered with the topcoat film is scattered on the undercoat film.

  As a result, when the coated film after drying is viewed from the top, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the apparent area of the granular paint is small in the convex part of the top coat film. In the undercoat film 7 not covered with the topcoat film, the spray paint appears to be scattered on the undercoat film.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat, whereas the hue of the granular paint is slightly reflected in the convex portion, and the undercoat is not covered with the top coat. In 7, the scattered spray paint pattern is reflected. Therefore, the concave and convex portions of the top coat film after drying and the undercoat film not covered with the top coat film have three different hues, thereby obtaining a pattern-coated metal plate having various uneven patterns. it can.

  FIG. 11 is a schematic diagram (partially cut out) of an example of a coated metal sheet coated metal sheet excellent in design according to the present invention. FIG. 11A is a front (sectional) view, and FIG. 11B is a top view.

  After covering the entire surface of the base treatment layer 2 on the metal plate 1 serving as a base material, a part of the undercoat film 7 is covered, the hue is different from that of the undercoat film, and the outer surface has an uneven pattern. A top coat film 6 is formed. Here, the top coat film 6 was applied after the undercoat film 7 was dried. And when the top coat film which has an uneven | corrugated shape on an outer surface is an undried state, the paint with a different hue from the top coat film and the undercoat paint is spray-coated on it. Since the spray-coated paint 10 settles in a granular form in the film of the top coat film 6, it is possible to mix paints of different hues in the top coat film 6 having an uneven shape on the outer surface, In the undercoat film 7 not covered with the top coat film, paints having different hues cannot be mixed in a granular form. Instead, a pattern coating film having a hue different from that of the undercoating film 6 exists in an island shape on the undercoating film 7 not covered with the top coating film. Therefore, the spray-coated paint 10 does not sink into the undercoat film 7 in a granular form, but is present in the form of islands on the undercoat film 7 and is therefore covered with the overcoat film. The spray paint is scattered on the undercoat film 7 that is not present, and the hue of the spray paint is reflected.

  Here, the sinking speed of the spray paint is different between the concave portion and the convex portion of the top coat film 6, the sinking speed is small in the concave portion and the sinking speed is high in the convex portion. In the concave portion, the granular paint 10 protrudes from the top coat film 6 greatly, whereas in the convex part, the granular paint 10 is buried in the top coat film 6. The spray paint on the undercoat film 7 not covered with the topcoat film is scattered on the undercoat film.

  As a result, when the dried coating film is viewed from the top, the apparent area of the granular paint is large in the concave portion of the top coating film, whereas the granular coating material is not visible in the convex portion of the top coating film. In the undercoat film 7 not covered with the coating film, the spray paint appears to be scattered on the undercoat film.

  Therefore, the hue of the granular paint is considerably reflected in the concave portion of the top coat film, whereas the hue of the granular paint is not reflected in the convex portion, and the undercoat film 7 is not covered with the top coat film. Then the scattered spray paint pattern is reflected. Therefore, the concave and convex portions of the top coat film after drying and the undercoat film not covered with the top coat film have three different hues, thereby obtaining a pattern-coated metal plate having various uneven patterns. it can.

  (f) In order to obtain a variety of pattern-coated metal plates of three colors or more, after forming an undercoat film on the entire surface of the base treatment layer, an overcoating having an uneven shape so as to cover a part of the undercoat film Transfer the organic resin paint for the film and form a top coat film with an uneven shape on its outer surface. When this top coat film is in an undried state, spray a paint with a hue different from that of the top coat film on it. Just paint. At this time, as described above, the undercoat film not covered with the topcoat film may be in an undried state or in a dry state.

  Even this alone, the concave part of the top coat film has a different hue from the convex part, and the hue of the undercoat film that is not covered with the top coat film can also be changed, so a variety of three or more color-patterned metal plates Can be obtained. At that time, the island pattern obtained by the outer convex shape of the top coat film can be conspicuous, but as an organic resin paint further forming the top coat film, (i) a paint containing a scaly pigment, It goes without saying that the use of either ii) low gloss paint or (iii) shrink paint can further enhance the pattern appearance formed by the uneven shape.

  (g) The undercoat coating film is preferably a coating film having a constant film thickness of about 1 to 30 μm in terms of dry film thickness. The undercoat paint having a certain film thickness can be applied onto a metal plate subjected to the base treatment by using an appropriate coating device such as a roll coater. The coating may be performed not only by application but also by electrostatic coating or electrodeposition coating using a spray coater.

  (h) In order to form a top coat film having a concavo-convex pattern, roll coating may be performed using an applicator roll having a smooth surface and a metal pickup roll having a gravure cell partially engraved on the surface. . That is, a metal gravure roll engraved with a gravure cell having a concave pattern on the surface of a smooth roll is used as a pickup roll, and the organic resin paint adhering to both the concave part and the roll smooth surface of the pickup roll is scraped with a blade or the like. What is necessary is just to transcribe | transfer to an applicator roll, and to transcribe | transfer the organic resin coating material on an applicator roll further to a metal plate, without taking.

  First, roll coating will be described. In roll coating, a paint strip is applied to a steel strip wound around a backup roll using a pickup roll and an applicator roll. When the pickup roll rotates while contacting the paint in the paint pan, the paint is lifted to the pickup roll, and the paint is transferred to the applicator roll while the thickness of the paint is adjusted by the gap between the pickup roll and the applicator roll. Is done. The paint whose thickness is adjusted is unwound from the coil, transferred to a steel strip that is wound around a backup roll so as to be in contact with the applicator roll, and is coated. The steel strip is then heated by suitable means so that the coating is baked and wound on a coil after cooling.

  FIG. 12 shows a schematic view of the 2-roll / reverse roll coating. In the two-roll / reverse method, the rotating direction of the applicator roll 21 is opposite to the conveying direction of the steel strip 20 to be coated. There is also a natural rotation method in which the rotation direction of the applicator roll 21 is the same as the conveying direction of the steel strip 20 to be coated, but the reverse rotation method allows thicker coating and does not generate coating lines. Therefore, the reverse rotation method is more often used in the manufacture of coated steel sheets. In the two-roll type roll coating using the pick-up roll 22 and the applicator roll 21, the coating thickness is controlled by the gap between these two rolls, so that the organic resin coating 25 passes smoothly through the gap. The pick-up roll 22 is normally rotated naturally with respect to the applicator roll 21 so that it can.

  When performing such two-roll / reverse roll coating, an applicator roll having a smooth surface and a metal pickup roll having a gravure cell partially engraved on the surface may be used.

  FIG. 13 is an example of a coating apparatus for transferring a top coat film having an uneven shape on the outer surface. A state in which a gravure cell pattern is transferred to an applicator roll 21 using a pick-up roll 22 having a gravure cell engraved on the surface, and further transferred to a steel strip 20 wound around a backup roll 23 is shown.

  That is, an organic resin paint 25 is picked up using a metal gravure roll engraved with a gravure cell (not shown) having a concave pattern on the surface of a smooth roll as the pickup roll 21, and the concave portion of the pickup roll 21 and the roll smoothness are picked up. The organic resin paint adhering to both surfaces may be transferred to the applicator roll 21 without scraping with a blade or the like, and then the organic resin paint adhering to the applicator roll 21 may be further transferred to a metal plate.

  (i) As the film thickness of the top coat film having a concavo-convex pattern, the film thickness difference between the concavo-convex parts is important, and is preferably 10 μm or more in an undried state (5 μm or more in a dry state). The film thickness of each of the concavo-convex parts is not particularly limited, but the convex part is preferably 80 μm or less in the undried state (40 μm or less in the dry state), and the concave part is 20 μm or more in the undried state. (10 μm or more in the dry state) is preferable.

  (j) When the top coat film having an uneven shape on the outer surface is in an undried state, the paint for spray coating on the top coat film is a paint comprising a resin type different from the resin type used for the paint of the top coat film However, it is preferable to use a paint made of the same resin type. Spray coating may be performed only once, but two or more coatings may be performed simultaneously or sequentially. When performing spray coating a plurality of times, spray coating may be performed using paints made of different resin types, but it is preferable to perform spray coating using paints made of the same resin type. In addition, when performing spray coating a plurality of times, a paint having the same hue may be used, or a paint having a different hue may be used.

  The solvent of the paint used may be either an aqueous or organic solvent, or may be a powder paint that does not use a solvent. When using a solvent, it is preferable to adjust the paint viscosity to about 10 to 60 seconds with Ford Cup # 4 by thinner dilution or the like according to JIS 5400. When the paint viscosity exceeds 60 seconds, it becomes difficult to control the size of the sprayed paint particles.

  This spray paint settles in a granular form in the undried topcoat film. The speed of sedimentation and the size of the particles obtained after sedimentation depend on the amount of air during spray coating and the viscosity of the spray paint. It also depends on the viscosity and film thickness of the coating.

  The paint viscosity is adjusted to 10 to 60 seconds with Ford Cup # 4. The spray coating conditions are: spray air amount is 100 to 200 NL / min, pattern air amount is 100 to 200 NL / min, and metal plate moving speed is 40. Perform at ~ 130 m / min.

  Then, baking is performed for about 40 to 80 seconds so that the maximum temperature of the metal plate is 170 to 250 ° C.

The present invention has been completed based on the above findings (a) to (j), the gist of which is the following (1) to (5) the coated metal plate and the following (6) to ( This is a method for producing a coated metal sheet shown in 8) .

(1) At least one surface of the metal plate that has undergone the base treatment has an undercoating film and an overcoating film in order, the overcoating film covers a part of the undercoating film, and the outer surface of the overcoating film Is a coated metal plate that has a concavo-convex pattern and in which a paint having a hue different from that of the top coat is mixed in the top coat, and the granular paint in the recesses of the top coat is one of them. The part protrudes outward from the coating film of the concave portion, whereas the granular paint in the convex portion of the top coat film is excellent in design characteristics characterized by being embedded in the coating film of the convex portion Painted metal plate.

(2) At least one surface of the metal plate that has undergone the base treatment has an undercoating film and an overcoating film in order, the overcoating film covers a part of the undercoating film, and the outer surface of the overcoating film Is a coated metal plate having a concavo-convex pattern, and in the top coat film, a paint having a different hue from the top coat film is mixed in a granular form, and the granular paint of the top coat film has concave and convex portions. A coated metal plate excellent in design , characterized in that a part thereof protrudes outwardly from the coating film in both, and the protruding amount in the concave portion is larger than the protruding amount in the convex portion.

(3) The coated metal sheet having excellent design properties as described in (1) or (2) above, wherein the top coat film contains a scaly pigment.

(4) The coated metal plate having excellent design properties as described in (1) or (2) above, wherein the top coat film is made of a low gloss paint.

(5) The coated metal plate having excellent design properties according to the above (1) or (2) , wherein the top coat film is formed of a shrink paint.

(6) By roll coating using an applicator roll with a smooth surface on at least one side of the metal plate on which the base treatment and the undercoat coating have been applied, and a metal pickup roll with a gravure cell partially engraved on the surface After forming a top coat film having an uneven shape on the outer surface so as to cover a part of the undercoat film, spray coating a paint having a hue different from that of the top coat film on the undried top coat film, A method for producing a coated metal plate excellent in design, characterized in that a paint having a hue different from that of a top coat is mixed in the top coat.

(7) By spray-coating a paint with a different hue from that of the undercoat on the undried undercoat that is not covered with the overcoat, The method for producing a coated metal plate having excellent design properties as described in (6) above, wherein different paints are mixed in a granular form.

(8) By spray-coating a paint with a different hue from that of the undercoat on the dry undercoat that is not covered with the topcoat, the color of the undercoat is different from that of the undercoat. The method for producing a coated metal sheet having excellent design properties as described in (6) above, wherein different pattern coating films are present in an island shape.

  According to the present invention, it is possible to provide a coated metal plate having excellent design properties having a variety of concavo-convex patterns having good pattern adhesion and making the patterns stand out, and a manufacturing method thereof.

  Below, the coated metal plate excellent in the design property which concerns on this invention, and its manufacturing method are demonstrated.

(A) Metal plate that is the base material of the painted metal plate:
The metal plate that is the base material of the painted metal plate is not particularly limited, and examples thereof include a cold-rolled steel plate, a stainless steel plate, and an aluminum plate.

  In the case of a coated metal plate used for indoor and outdoor building materials and for home appliances, a zinc-based or aluminum-based plated steel plate is preferable in terms of corrosion resistance and economy.

  The plated metal plate may be plated by any method such as hot dipping, electroplating, vapor phase plating, etc., and zinc, tin, aluminum, etc. and alloys thereof are used as the plating metal species. Specifically, a hot-dip galvanized metal plate, a hot-dip Zn—Al alloy-plated metal plate containing 5% Al, a hot-dip aluminum-plated metal plate, a hot-dip Al—Zn alloy-plated metal plate containing 55% Al, and the like can be mentioned. .

(B) About ground treatment:
In order to improve the adhesion between the base metal plate and the coating film, the metal plate serving as the base material of the coated metal plate forms a base treatment layer by applying a base treatment to the surface of the metal plate.

The ground treatment is performed by chemical conversion treatment such as zinc phosphate treatment and chromate treatment. As the chromate treatment, electrolytic or reactive chromate treatment can also be applied, but coating chromate treatment is preferable from the viewpoint of workability. The chromate adhesion amount in terms of metal chromium is preferably in the range of 15 to 80 mg / m ² . If the amount of chromate attached is too small, sufficient adhesion of the coating film cannot be obtained, and if it is excessive, workability will be reduced. One example of a commercially available coating-type chromate treatment solution suitable for use in the present invention is “NRC 300” manufactured by Nippon Paint Co., Ltd. The coating type chromate treatment liquid may be applied by a roll coater or the like according to a conventional method, heated to 50 to 100 ° C. with hot air and dried to carry out the ground treatment.

  If it is not desired to perform chromate treatment using hexavalent chromium due to environmental problems, a chromium-free ground treatment containing silica, resin, zirconium or titanium can also be performed. One example suitable for use in the present invention is “Surfcoat EC2330” manufactured by Nippon Paint Co., Ltd., which is a silica-based surface treatment solution.

(C) About the undercoat film:
After the surface treatment is performed on the surface of the metal plate, one or more undercoat films are formed under the topcoat film.

  For example, epoxy-based, polyester-based, and urethane-based resins can be used as the paint for the undercoat coated on the metal plate serving as the base of the coated metal plate. A resin capable of forming a coating film having excellent adhesion to the metal plate and good workability is preferable. The solvent of the paint used may be either an aqueous or organic solvent, or may be a powder paint that does not use a solvent.

  Various types of epoxy paints are commercially available, and these may be used as appropriate. For example, an epoxy paint containing melamine, amine, or isocyanate as a crosslinking agent may be used. As the epoxy resin type, a bisphenol type epoxy resin is preferable.

  As an example of a polyester-type coating material, what mix | blended melamine and isocyanate as a crosslinking agent with the thermoplastic polyester resin is mentioned. As the polyester, a so-called high molecular weight polyester resin having a molecular weight of about 5,000 to 20,000 is preferable from the viewpoint of processability. As the crosslinking agent, melamine modified with ethyl alcohol or butyl alcohol can be used, and in some cases, paratoluenesulfonic acid, dodecylbenzenesulfonic acid, or the like can be appropriately used as a catalyst.

  Examples of urethane-based paints include those in which a polyester polyol is subjected to a crosslinking reaction with a yellowing polyisocyanate or a non-yellowing polyisocyanate. As examples of the crosslinking agent, isophorone diisocyanate (IPDI), hexamethylene diisocyanate (HMDI) and the like can be used. In this case also, a catalyst such as dibutyltin dilaurate (DBTDL) may be used as appropriate.

  The paint for the undercoat film may contain two or more kinds of resin. The undercoating film may be one layer, but may be two or more layers depending on the application. The undercoat coating film may contain additives such as rust preventive pigments. Examples of the rust preventive pigment include chromium-based rust preventive pigments such as strontium chromate and zinc chromate, and phosphate-based rust preventive pigments.

  The undercoat coating film is preferably a coating film having a constant film thickness of about 1 to 30 μm in terms of dry film thickness. Adhesiveness and corrosion resistance are good when the coating thickness is 1 μm or more. However, when the coating thickness exceeds 30 μm, the corrosion resistance is saturated, but not only the cost increases, but also the workability decreases. In addition, depending on the type of resin, “waxing” occurs.

  The undercoat paint having a certain film thickness can be applied onto a metal plate subjected to the base treatment by using an appropriate coating device such as a roll coater. The coating may be performed not only by application but also by electrostatic coating or electrodeposition coating using a spray coater.

  The viscosity of the paint is adjusted to 30 to 150 seconds with Ford Cup # 4, and after painting, it is heated and baked. The baking can be performed by baking for about 20 to 60 seconds so that the maximum temperature of the metal plate is about 150 to 230 ° C., and a conventional hot air blowing type oven or a heating method such as induction heating or infrared heating can be used. Available.

  The undercoat coating film may be baked at the same time as the coating of the topcoat film or before the coating of the topcoat film is applied.

(D) About top coat film:
The top coat film is for a top coat film having a concavo-convex shape so as to cover a part of the undercoat film after forming a base coat film on the entire surface of the base treatment layer after applying a base treatment to the metal plate. The organic resin paint is transferred to form a top coat film having an uneven shape on the outer surface.

  As the film thickness of the top coat film having an uneven pattern, the film thickness difference between the uneven parts is important. The difference in coating thickness between the convex and concave portions may be appropriately determined in consideration of the particle size of the granular paint formed in the top coat film by spray coating, but is 10 μm or more in the undried state (5 μm or more in the dry state) ) Is preferred. The film thickness of each of the concavo-convex parts is not particularly limited, but the convex part is preferably 80 μm or less in an undried state (40 μm or less in a dry state), and the concave part is 20 μm or more in an undried state (10 μm or more in the dry state) is preferable. If the coating film thickness is thick, the adhesion and corrosion resistance are good, but if it is too thick, the corrosion resistance is saturated, but not only the cost increases, but also the workability decreases. In addition, depending on the type of resin, “waxing” occurs. If the coating film thickness is too thin, the concealability is poor and coloring may be insufficient. In addition, ultraviolet rays are easily transmitted to the undercoat layer, and the weather resistance may be inferior.

  The coating of the top coat film with a concavo-convex pattern is a form that covers a part of the undercoat film of a certain film thickness, using an applicator roll with a smooth surface and a metal pickup roll with a gravure cell engraved on the surface, Painted.

  In addition, when the top coat is applied through the undercoat paint film, the top coat paint may be applied so as to cover a part of the undercoat paint when it is not dried. After drying and curing, the overcoating paint may be applied so as to cover a part thereof.

  It does not specifically limit as an organic resin coating material which forms a top coat film. The paint of the top coat film can be appropriately selected according to the part of the product for which the coated metal plate is used, but it has excellent adhesion with the base treatment layer or the undercoat film. preferable.

  As the resin type used for the top coat, a fluorine-based resin can be used in addition to the resin type described above for the undercoat. When weather resistance and workability are required, polyester-based, urethane-based and fluorine-based resins are preferable. Specific embodiments of the epoxy-type, polyester-type, and urethane-type resin types are the same as those described in the above (C) undercoat film.

  Examples of the fluororesin paint include a mixture of an acrylic resin and PVdF (polyvinylidene fluoride). A mass ratio of 50:50 to 10:90 is preferred. The fluorine-based resin paint is particularly suitable for applications requiring weather resistance.

  The solvent of the paint used may be either an aqueous or organic solvent, or may be a powder paint that does not use a solvent.

  The paint for the top coat film may contain two or more kinds of resin. Moreover, a top coat film can contain a coloring pigment as needed.

  In addition, as the coating material for the top coat film, in particular, when any of the following (i) a coating material containing a scaly pigment, (ii) a low gloss coating material, or (iii) a shrink coating material is used, the unevenness thereof Since the pattern appearance formed by the shape can be further emphasized, it is preferable to use any one of these paints.

  (i) Since the gloss of the top coat film made of paint containing scaly pigments changes depending on the orientation of the scaly pigments in the paint film, it may become blackish or whitish depending on the viewing angle . When a top coat film having a concavo-convex shape in which organic resin paints are continuously connected is formed using a paint containing a flaky pigment, the orientation angle of the scaly pigment is obtained between the flat portion and the inclined portion of the concavo-convex shape. Therefore, the pattern of the contour portion of the convex portion stands out. In addition, as a scaly pigment, aluminum flakes, mica, etc. can be used.

  (ii) The low-gloss paint is contained in fine silica particles or resin bead paint, and the silica particles or resin bead heads are projected upward from the surface of the top coat film, so that the surface of the top coat film is formed. A fine convex part is provided, and the gloss of the coating film can be lowered. As 60 degree gloss, it is generally 30 or less in the broad sense and 10 or less in the narrow sense. The gloss of such a low gloss paint changes due to the fine irregularities of the silica particles and resin beads on the surface of the top coat film. That is, if the silica particles or resin beads on the surface of the top coat film are large, the gloss becomes low, and if the degree of protrusion is small or does not protrude at all, the gloss becomes high. Therefore, when a top coat film having a concavo-convex shape is formed using a low gloss paint, the convex portions tend to be highly glossy and the concave portions tend to be low gloss. Therefore, when a top coat film with irregularities is formed using a low gloss paint, a pattern-coated metal plate consisting of high-gloss convex portions and low-gloss concave portions is obtained, so that the convex portions stand out. In the case of a coating film made of a dark paint, the high gloss portion looks blackish and the low gloss portion looks whitish.

  (iii) A shrink paint is a paint that can form small wrinkles (fine irregular surfaces) on the surface of the paint film by utilizing the difference in curing speed between the paint film surface and the inside of the paint film. Decreases. This gloss reduction method is also affected by the thickness of the coating film. That is, when a top coat film having a concavo-convex shape is formed using a shrink paint, the convex portion tends to form wrinkles, so that the gloss tends to be low gloss, and the concave portion is difficult to form wrinkles, so the gloss tends to become high gloss. Therefore, when a top coat film having a concavo-convex shape is formed using a shrink paint, a pattern-coated metal plate comprising low-gloss convex portions and high-gloss concave portions is obtained, and the concave portions stand out.

(E) About spray paint:
The spray paint is a paint for spray-coating the top coat film in an undried state.

  As a paint for spray coating, spray coating may be performed using a paint made of a resin type different from the resin type used for the top coat and undercoat paint, but a paint made of the same resin type is used. It is preferable to paint. Spray coating may be performed only once, but two or more coatings may be performed simultaneously or sequentially. When performing spray coating a plurality of times, spray coating may be performed using paints made of different resin types, but it is preferable to perform spray coating using paints made of the same resin type. In addition, when performing spray coating a plurality of times, a paint having the same hue may be used, or a paint having a different hue may be used.

  The solvent of the paint used may be either an aqueous or organic solvent, or may be a powder paint that does not use a solvent. When using a solvent, it is preferable to adjust the paint viscosity to about 10 to 60 seconds with Ford Cup # 4 by thinner dilution or the like according to JIS 5400. When the paint viscosity exceeds 60 seconds, it becomes difficult to control the size of the sprayed paint particles.

  This spray paint settles in granular form in an undried topcoat film or in an undried undercoat film not covered with a topcoat film. The size depends on the viscosity of the top coat film or top coat film and the film thickness in addition to the amount of air during spray coating and the viscosity of the spray paint.

  The paint viscosity is adjusted to 10 to 60 seconds with Ford Cup # 4. The spray coating conditions are: spray air amount is 100 to 200 NL / min, pattern air amount is 100 to 200 NL / min, and metal plate moving speed is 40. Perform at ~ 130 m / min.

(F) Baking of top coat or even undercoat and granular paint mixed in these coats:
The baking of the top coating film or the undercoating film and the granular coating mixed in these coating films can be carried out in the same manner as described for the undercoating paint. The viscosity of the paint is adjusted to 30 to 150 seconds with Ford Cup # 4, and after painting, it is heated and baked. The baking can be performed by baking for about 40 to 80 seconds so that the maximum temperature of the metal plate is 180 to 250 ° C.

(G) Other:
In addition, although the coating film according to this invention may be formed only in the single side | surface used as the outer plate | plate of a raw material, you may form in both surfaces of a raw material if desired. In the case of forming only on one side, the unpainted surface may be bare, or may be subjected only to a ground treatment, or may be coated differently from the present invention. When forming on both surfaces, the structure of the pattern coating film may be the same on both surfaces, or may be different.

A molten 55% Al—Zn alloy-plated metal plate (metal plate thickness: 0.35 mm) having a plating composition of Al: 55 mass%, Zn: 44 mass% and Si: 1 mass% is used as a base material. As a treatment, a coating type chromate treatment liquid (NRC 300 [NRC 300] manufactured by Nippon Paint Co., Ltd.) was applied with a bar coater so that the amount of chromium adhered was 30 mg / m ^2, and the maximum temperature reached 100 ° C. The chromate treatment was applied by heating for 2 seconds and drying.

  Next, prepare an epoxy paint (epoxy primer “P667S” manufactured by Nippon Fine Coatings Co., Ltd.) as a paint to be used for the undercoat film, and add thinner to make the paint viscosity 40 seconds in Ford Cup # 4. Adjusted. This metallic paint contains scaly pigments.

  In addition, a polyester resin-based metallic paint (“Polyester paint KP1580 (silver)” manufactured by Kansai Paint Co., Ltd.) is prepared as the paint used for the top coating film, and the paint viscosity is 40 seconds in Ford Cup # 4. Adjusted.

  In addition, a polyester resin-based metallic paint (“polyester paint KP1580 (black)” manufactured by Kansai Paint Co., Ltd.) is prepared as a paint used for spray painting, and the viscosity of the paint is 20 seconds in Ford Cup # 4. It was adjusted.

  Using the above-described chromate-treated Al—Zn alloy-plated metal plate (300 mm × 2000 mm), roll coating of the undercoat and topcoat was performed using a roll coater tester of a two-roll / reverse method. At this time, the top coat film was formed so as to cover a part of the undercoat coat film.

  The roll coater testing machine used was equipped with a pickup roll made of metal roll and an applicator roll lined with urethane rubber. The material can be conveyed at a constant speed in the horizontal direction. The rotation direction of each roll was the same as that shown in FIG. 13, and the paint lifted by the pickup roll was transferred to the applicator roll by natural rotation and then transferred to the substrate by reverse rotation. And the gravure roll which engraved the pattern shown in FIG. 14 was prepared. The shape of each gravure cell was a lattice type with 35 lines / inch and a depth of 170 μm.

The undercoating film was applied using a flat pickup roll so that the above-described undercoating composition composed of the epoxy coating was 5 g / m ² as the coating amount when dried. The undercoat paint was dried by baking for about 60 seconds so that the maximum temperature of the metal plate reached 230 ° C. together with the top coat film and the granular paint mixed in the undercoat film and the top coat film.

  And the top coat film which has an uneven | corrugated shaped pattern was formed with the test coater (width 300mm x length 2000mm) using the paint gravure roll of the top coat film for the pickup roll. As described above, the polyester resin-based metallic paint (“polyester paint KP1580 (silver)” manufactured by Kansai Paint Co., Ltd.) was used as the top coating. The peripheral speeds of the pickup roll, applicator roll, and backup roll were 40 m / min, 96 m / min, and 80 m / min, respectively.

  Both the top coat film having an uneven shape on the outer surface and the undercoat film not covered with the top coat film obtained in this way are in an undried state. The paint with different hues was sprayed using a simple spray coater. The spray conditions were a spray amount of 100 g / min, and spray coating was performed once at a speed of 60 m / min from a height of approximately 40 cm. As described above, a polyester resin-based metallic paint (“polyester paint KP1580 (black)” manufactured by Kansai Paint Co., Ltd.) was used as the spray paint.

  The top coating film, the undercoating film and the granular paint mixed in these films were dried by baking for about 60 seconds so that the maximum temperature reached by the metal plate was 230 ° C. As a result, a coating film having a concavo-convex pattern on the outer surface was formed by including a granular coating material in the top coating film and the undercoating film. However, when the coated film after drying is viewed from the top, the apparent area of the granular paint is large in the concave part of the top coat film, whereas the granular paint is not visible in the convex part of the top coat film. No granular paint was seen even in the undercoat film 7 not covered with the film. In addition, the film thickness of the top coat film after drying was 12 μm on average, of which the film thickness of the concave part was 8 μm on average, and the film thickness of the convex part was average 8 μm. Therefore, the difference in film thickness between the concave and convex portions was 10 μm. The film thickness of the undercoat after drying was 4 μm on average.

  Of the coated metal plate obtained in this way, a portion reflecting the pattern shown on the right side of FIG. 14 is shown in FIG. 15 (unit of scale of display is mm). A dark color part is a recessed part of a top coat film, and a light color part is a convex part of a top coat film. This coated metal plate has not only a pattern appearance on the surface of the top coat film due to the uneven pattern of the top coat film, but also the hue of the undercoat film in addition to the uneven part of the top coat film, A coated metal plate having a variety of concavo-convex patterns in which the pattern is conspicuous and excellent in design was obtained. This coated metal plate had good pattern adhesion, good concealment, and no occurrence of cracks.

A molten 55% Al—Zn alloy-plated metal plate (metal plate thickness: 0.35 mm) having a plating composition of Al: 55 mass%, Zn: 44 mass% and Si: 1 mass% is used as a base material. As a treatment, a coating type chromate treatment liquid (manufactured by Nippon Paint Co., Ltd. [NRC 300]) was applied with a bar coater so that the amount of chromium deposited was 30 mg / m ^2, and the maximum temperature reached 100 ° C. 5 The chromate treatment was applied by heating for 2 seconds and drying.

  Next, prepare an epoxy paint (epoxy primer “P667S” manufactured by Nippon Fine Coatings Co., Ltd.) as a paint to be used for the undercoat film, and add thinner to make the paint viscosity 40 seconds in Ford Cup # 4. Adjusted. This metallic paint contains scaly pigments.

  In addition, a polyester resin-based metallic paint (“Polyester paint KP1580 (silver)” manufactured by Kansai Paint Co., Ltd.) is prepared as the paint used for the top coating film, and the paint viscosity is 40 seconds in Ford Cup # 4. Adjusted.

  In addition, a polyester resin-based metallic paint (“polyester paint KP1580 (black)” manufactured by Kansai Paint Co., Ltd.) is prepared as a paint used for spray painting, and the viscosity of the paint is 20 seconds in Ford Cup # 4. It was adjusted.

  Using the above-described chromate-treated Al—Zn alloy-plated metal plate (300 mm × 2000 mm), roll coating of the undercoat and topcoat was performed using a roll coater tester of a two-roll / reverse method. At this time, the top coat film was formed so as to cover a part of the undercoat coat film.

  The roll coater testing machine used was equipped with a pickup roll made of metal roll and an applicator roll lined with urethane rubber. The material can be conveyed at a constant speed in the horizontal direction. The rotation direction of each roll was the same as that shown in FIG. 13, and the paint lifted by the pickup roll was transferred to the applicator roll by natural rotation and then transferred to the substrate by reverse rotation. And the gravure roll which engraved the pattern shown in FIG. 14 was prepared. The shape of each gravure cell was a lattice type with 35 lines / inch and a depth of 170 μm.

The undercoating film was applied using a flat pickup roll so that the above-described undercoating composition composed of the epoxy coating was 5 g / m ² as the coating amount when dried. And the drying was performed by baking for about 40 seconds so that the highest reached temperature of a metal plate might be 200 degreeC.

  And the top coat film which has an uneven | corrugated shaped pattern was formed with the test coater (width 300mm x length 2000mm) using the paint gravure roll of the top coat film for the pickup roll. As described above, a polyester resin-based metallic paint (“polyester paint KP1580 (silver)” manufactured by Kansai Paint Co., Ltd.) was used as the top coat. The peripheral speeds of the pickup roll, applicator roll, and backup roll were 40 m / min, 96 m / min, and 80 m / min, respectively.

  The top coat film having an uneven shape on the outer surface obtained in this way is in an undried state, and the undercoat film not covered with the top coat film is in a dry state. Spray coating was performed using a simple spray coater with paints that differed in hue from the paint film. The spray conditions were a spray amount of 100 g / min, and spray coating was performed once at a speed of 60 m / min from a height of approximately 40 cm. As described above, a polyester resin-based metallic paint (“polyester paint KP1580 (black)” manufactured by Kansai Paint Co., Ltd.) was used as the spray paint.

  Drying of the top coat film and the granular paint mixed in the film and spray paint sprayed on the undercoat film not covered with the top coat film will result in a maximum metal plate temperature of 230 ° C. For about 60 seconds. As a result, a coating film having an irregular pattern on the outer surface is formed, which includes a granular paint in the top coat film and has an island-like pattern made of spray paint on the base coat film not covered with the top coat film. It was. However, when the dried coating film was viewed from above, the apparent area of the granular coating material was large in the concave portion of the top coating film, whereas the granular coating material was not visible in the convex portion of the top coating film. Further, island-like patterns made of spray paint were scattered on the undercoat film not covered with the topcoat film. In addition, the film thickness of the top coat film after drying was 12 μm on average, of which the film thickness of the concave part was 8 μm on average, and the film thickness of the convex part was average 8 μm. Therefore, the difference in film thickness between the concave and convex portions was 10 μm. The film thickness of the undercoat after drying was 4 μm on average.

  Of the coated metal plate thus obtained, the part reflecting the pattern shown on the right side of FIG. 14 is the same as that of Example 1, and is shown in FIG. 15 (unit of display scale is mm). . As in Example 1, the dark color portion is a concave portion of the top coat film, and the light color portion is a convex portion of the top coat film. This coated metal plate has not only a pattern appearance on the surface of the top coat film due to the uneven pattern of the top coat film, but also the hue of the undercoat film in addition to the uneven part of the top coat film, A coated metal plate having a variety of concavo-convex patterns in which the pattern is conspicuous and excellent in design was obtained. This coated metal plate had good pattern adhesion, good concealment, and no occurrence of cracks.

  According to the present invention, it is possible to provide a coated metal plate having a good pattern adhesion and an excellent design that allows the pattern to stand out, and a method for producing the same.

It is a schematic diagram of an example (conventional example) of a pattern printing metal plate. It is a schematic diagram of an example (conventional example) of a pattern coating metal plate. It is a schematic diagram of an example (reference example) of the pattern coating metal plate which has the top coat film which has an uneven | corrugated shape in an outer surface. It is a schematic diagram of the other example (reference example) of the pattern coating metal plate which has the top coat film which has an uneven | corrugated shape on an outer surface. It is a schematic diagram of the other example (reference example) of the pattern coating metal plate which has the top coat film which has an uneven | corrugated shape on an outer surface. It is a schematic diagram of an example of the coating metal plate coated metal plate excellent in the design property which concerns on this invention. It is a schematic diagram of the other example of the coating metal plate excellent in the designability which concerns on this invention. It is a schematic diagram of the other example of the coating metal plate excellent in the designability which concerns on this invention. It is a schematic diagram of the other example of the coating metal plate excellent in the designability which concerns on this invention. It is a schematic diagram of the other example of the coating metal plate excellent in the designability which concerns on this invention. It is a schematic diagram of the other example of the coating metal plate excellent in the designability which concerns on this invention. A schematic diagram of two-roll / reverse roll coating is shown. It is an example of the coating apparatus for manufacturing the pattern coating metal plate which concerns on this invention. The surface of the gravure roll which engraved the pattern is shown. 2 is an enlarged photograph of the surface of a pattern-coated metal plate obtained in Example 1. FIG. The unit of the display scale is mm.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Metal plate 2 Ground treatment layer 3 Coating film 4 Ink layer 5 Pattern layer 6 Top coat film which has uneven pattern 6-1 Convex part of top coat film 6-2 Concave part of top coat film 7 Undercoat film 10 Granular paint 20 Steel strip 21 Applicator roll 22 Pickup roll 23 Backup roll 25 Organic resin paint

Claims (8)

At least one side of the metal plate that has undergone the base treatment has an undercoat and a topcoat in order, the topcoat covers a part of the undercoat, and the outer surface of the topcoat is uneven. And a coating metal plate in which a paint having a hue different from that of the top coat film is mixed in the top coat film, and a part of the granular paint in the recess of the top coat film is a recess. Painted metal plate with excellent design characteristics, characterized in that the granular paint in the convex part of the top coat film is buried in the convex part of the coating film, whereas it protrudes outward from the coating film of . At least one side of the metal plate that has undergone the base treatment has an undercoat and a topcoat in order, the topcoat covers a part of the undercoat, and the outer surface of the topcoat is uneven. The top coat film is a coated metal plate in which a paint having a hue different from that of the top coat film is mixed in a granular form. A coated metal plate excellent in design , characterized in that a part protrudes outward from the coating film, and the protruding amount in the concave portion is larger than the protruding amount in the convex portion. The coated metal sheet having excellent design properties according to claim 1 or 2 , wherein the top coat film contains a scaly pigment. The coated metal sheet having excellent design properties according to claim 1 or 2 , wherein the top coat film is made of a low gloss paint. 3. The coated metal plate having excellent design properties according to claim 1 or 2 , wherein the top coat film is made of a shrink paint.   Using an applicator roll with a smooth surface on at least one side of a metal plate with a base treatment and an undercoat film, and a metal pick-up roll with a gravure cell partially engraved on the surface, the outer surface is uneven by roll coating. After forming the shape of the top coat film so as to cover a part of the undercoat film, the top coat film is spray-coated on the undried top coat film with a hue different from that of the top coat film. A method for producing a coated metal plate excellent in design, characterized in that a paint having a hue different from that of a top coat film is mixed in a granular form.   By spray-coating a paint with a different hue from that of the undercoat on the undried undercoat that is not covered with the topcoat, a paint with a different hue from that of the undercoat can be formed in the undercoat. The method for producing a coated metal plate having excellent design properties according to claim 6, wherein the method is mixed in a granular form. By spray-coating a paint with a different hue from the undercoat on the dry undercoat that is not covered with the topcoat, a pattern coating with a different hue from the undercoat is applied on the undercoat. The method for producing a coated metal plate having excellent design properties according to claim 6, wherein the film is present in an island shape.

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