JP7155890B2 - Multilayer coated metal plate and manufacturing method of model - Google Patents

Description

TECHNICAL FIELD The present invention relates to a multilayer coated metal plate and a manufacturing method of a model.

Conventionally, a method is known in which a metal plate is coated with a paint containing thermally expandable microcapsules that foam and expand according to the amount of heat absorbed, and then heated to give the metal plate an uneven pattern with excellent texture. (See Patent Document 1, for example).

JP-A-2001-234120

However, it has been difficult to maintain the quality of the metal plate on which the unevenness is formed for a long period of time.

Accordingly, the present invention provides a multi-layer coated metal sheet and a method for manufacturing a model, which can easily form unevenness on the metal sheet and maintain the quality of the metal sheet on which the unevenness is formed for a long period of time. for the purpose.

In order to achieve the above object, a multilayer coated metal plate according to the present invention is provided on one surface of the metal plate and has a first expansion expansion plate formed to expand when heated to a predetermined temperature or higher. a first photothermal conversion layer provided on the first expansion layer for converting absorbed light into heat and emitting heat; a second expansion layer formed after the layers are formed; and a second photothermal conversion layer provided on the second expansion layer, wherein the thickness of the second expansion layer is When the heat emitted from the second photothermal conversion layer has a temperature higher than the expansion start temperature of the first expansion layer, the emitted heat is not transmitted to the first expansion layer. thickness.

Further, a method for manufacturing a model according to the present invention includes the steps of: forming on a metal plate a first expansion layer that expands when heated; and converting light into heat on the first expansion layer. and irradiating the first photothermal conversion layer with light, thereby forming the first photothermal conversion layer corresponding to the region where the first photothermal conversion layer is formed. a step of expanding an expansion layer to form a first intermediate; and after forming the first intermediate, a second expansion layer expanded by heating on the first photothermal conversion layer . forming a second photothermal conversion layer that converts light into heat on the second expansion layer; and irradiating the second photothermal conversion layer with light, forming a second intermediate by expanding the second expansion layer corresponding to the region where the second photothermal conversion layer is formed.

ADVANTAGE OF THE INVENTION According to this invention, although unevenness|corrugation is formed on a metal plate easily, the quality of the metal plate in which this unevenness|corrugation was formed can be maintained for a long period of time.

A multilayer coated metal sheet according to an embodiment of the present invention. FIG. 1B is a cross-sectional view taken along line aa of FIG. 1A; A flow chart of a manufacturing method of a model concerning an embodiment of the present invention. FIG. 4 is an explanatory view of the manufacturing method of the modeled object according to the embodiment of the present invention, and is a cross-sectional view of a state in which the first expansion layer is formed on the metal plate; FIG. 4 is an explanatory view of the manufacturing method of the modeled article according to the embodiment of the present invention, and is a cross-sectional view of a state in which the first expansion layer is formed with the first ink receiving layer. FIG. 4 is a cross-sectional view of a state in which a first light-to-heat conversion layer is formed on a first ink-receiving layer; FIG. FIG. 4 is an explanatory view of the method for manufacturing a modeled article according to the embodiment of the present invention, and is a cross-sectional view of a state in which the first photothermal conversion layer is irradiated with light to form a first intermediate. FIG. 4 is an explanatory view of the manufacturing method of the modeled article according to the embodiment of the present invention, and is a cross-sectional view of a state in which the second expansion layer is formed on the first intermediate. FIG. 4 is an explanatory view of the manufacturing method of the modeled article according to the embodiment of the present invention, and is a cross-sectional view of a state in which the second expansion layer is formed with the second ink receiving layer. FIG. 4 is a cross-sectional view of a state in which a second light-to-heat conversion layer is formed on a second ink-receiving layer; FIG. FIG. 4 is an explanatory view of the method for manufacturing a modeled article according to the embodiment of the present invention, and is a cross-sectional view of a state in which the second photothermal conversion layer is irradiated with light to form a second intermediate.

EMBODIMENT OF THE INVENTION Hereinafter, the form for implementing this invention is demonstrated in detail using drawing.

A configuration of a multilayer coated metal sheet 10 according to an embodiment of the present invention will be described with reference to FIGS. 1A and 1B. FIG. 1A is an external view of a multilayer coated metal plate 10 according to this embodiment, and FIG. 1B is a cross-sectional view taken along line aa. As shown in FIG. 1B, the multilayer coated metal plate 10 according to this embodiment includes a metal plate 20, a first expansion layer 30, a first ink receiving layer 40, a first photothermal conversion layer 50, a second expansion It comprises a layer 60 , a second ink receiving layer 70 , a second photothermal conversion layer 80 and a color layer 90 .

The metal plate 20 may be a steel plate, a non-ferrous metal plate, or a plated metal plate obtained by plating these with a single metal or an alloy. Specific examples include non-ferrous metal sheets such as aluminum, magnesium, and zinc, stainless steel sheets, hot-rolled steel sheets, cold-rolled steel sheets, electrogalvanized steel sheets, hot-dip galvanized steel sheets, Galvalume steel sheets (registered trademark), and the like. It is not particularly limited. The metal plate 20 is preferably subjected in advance to degreasing treatment such as alkaline degreasing or pickling in order to remove dirt on the surface and improve adhesion of the paint. Further, in order to improve corrosion resistance and the like, after the degreasing treatment, chemical conversion film treatment such as chromate treatment, phosphate film treatment, or blackening treatment may be performed.

The first expansion layer 30 is formed on one surface of the metal plate 20 (the upper surface shown in FIG. 1B). The first expansion layer 30 is a layer that foams and expands according to the amount of heat absorbed, and has a plurality of thermally expandable microcapsules dispersed in a resin solution or emulsion used as a binder. As the resin used as the binder, it is preferable to select a thermoplastic resin such as a vinyl acetate-based resin or an acrylic resin so that the thermally expandable microcapsules are thermally softened at the same time when the thermally expandable microcapsules are thermally expanded. Thermally expansive microcapsules are, for example, encapsulating a vaporizable substance with a low boiling point, such as propane, butane, or pentane, in an outer shell made of a thermoplastic resin. The outer shell is formed of a thermoplastic resin selected from, for example, polystyrene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyacrylate, polyacrylonitrile, polybutadiene, or copolymers thereof.

The first ink-receiving layer 40 is a layer formed on the first expansion layer 30 to absorb and receive ink. The first ink-receiving layer 40 receives printing ink used in inkjet printers, printing toner used in laser printers, ink for ballpoint pens and fountain pens, graphite for pencils, and the like, and at least its surface made of material suitable for fixing to As an example, it is possible to use a swelling type that is formed of a water-soluble resin such as polyvinyl alcohol and has a transparent and glossy formed film. Alternatively, it may be of a matte type formed from an inorganic pigment such as porous silica, alumina, or the like, in which the formed film is white. For example, the swelling type should be selected when transparency and glossiness of the formed film are required. In addition, when high water resistance, ink drying speed, and concealability are required on the printed surface, the matte type should be selected. Therefore, even if the metal plate 20 is not plated or chemically coated, it is possible to prevent corrosion of the metal plate 20 . In other words, it can be used as a corrosion prevention layer for preventing corrosion of the metal plate 20 by utilizing its hygroscopicity, and can contribute to a reduction in manufacturing costs.

The first photothermal conversion layer 50 absorbs light in a specific wavelength range, such as near-infrared rays (wavelength 750 nm to 1400 nm), which is formed on the first ink receiving layer 40, converts it into heat, and emits it. layer. For example, it consists of a black (K) ink for printing containing carbon black. When light is irradiated, the heat generation temperature of the photothermal conversion layer changes according to the density of the carbon black, and the first expansion layer 30 expands according to this temperature. Forming intermediate 11 of 1. It should be noted that the higher the concentration of carbon black and the darker the black ink, the higher the heat generation temperature when irradiated with a predetermined amount of light. A convex shape is obtained.

Further, as the first light-to-heat conversion layer 50, for example, cesium tungsten oxide, lanthanum hexaboride (LaB6), etc., which have a high light absorption rate (absorption rate) particularly in the near-infrared region, and in the visible light region A colorless and transparent inorganic material having a low light absorptivity may be used. This may be selected when it is desired to suppress the color tone of the light-to-heat conversion layer and reduce the influence on the color image.

A second expansion layer 60 is formed on the first intermediate 11 . Here, as will be described later, the first intermediate 11 expresses for convenience a modeled object having unevenness formed by the expansion of the first expansion layer 30 on the metal plate 20. .

The second expansion layer 60, like the first expansion layer 30, is a layer that expands according to the amount of heat absorbed, and has thermally expandable microcapsules dispersed in a binder. The thickness of the second expansion layer 60 is preferably such that the heat emitted by the second photothermal conversion layer 80 does not reach the first expansion layer 30 . For example, even if heat higher than the expansion start temperature of the first expansion layer 30 is generated in the second photothermal conversion layer 80, if the heat is not transmitted to the first expansion layer 30, the first expansion layer 30 This is because it is possible to prevent deformation.

Furthermore, the thermally expandable microcapsules used in the second expansion layer 60 preferably have a lower expansion start temperature than the thermally expandable microcapsules used in the first expansion layer 30 . When the second expansion layer 60 is heated and expanded, it is possible to heat it at a temperature lower than the temperature at which the first expansion layer 30 starts to expand. Only the second inflatable layer 60 can be inflated.

A second ink-receiving layer 70 is formed on the second swelling layer 60 . The second ink-receiving layer 70 may use the same material as the first ink-receiving layer 40, or may use a different material. When the same material is used, the raw material can be shared, which can contribute to the reduction of the manufacturing cost. As with the first ink-receiving layer 40, by selecting porous silica as the material for the second ink-receiving layer 70, it can also be used as a corrosion prevention layer. Moreover, when porous silica is used for each of the first ink receiving layer 40 and the second ink receiving layer 70, the hygroscopicity can be further enhanced, and corrosion of the metal plate 20 can be further prevented. .

The second light-to-heat conversion layer 80 is formed on the second ink-receiving layer 70, and may use the same material as the first light-to-heat conversion layer 50, or may use a different material. Moreover, the second photothermal conversion layer 80 may be formed on the region where the first photothermal conversion layer 50 is formed, or may be formed on the region where the first photothermal conversion layer 50 is not formed. , a second photothermal conversion layer 80 may be formed.

A color layer 90 is formed over the second intermediate 12 . Here, as will be described later, the second intermediate 12 expresses for convenience a shaped object having unevenness formed by expanding the second expansion layer 60 on the first intermediate 11. It is.

The color layer 90 is made of, for example, cyan (C), magenta (M), and yellow (Y) color inks for printing. Since the color image may be dull depending on the color of the light-to-heat conversion layer used, the color image may be formed after undercoating with white ink or the like.

Next, a method for manufacturing a model according to this embodiment will be described based on the flowchart shown in FIG. 2 and the cross-sectional views shown in FIGS. 3 to 10. FIG. First, the metal plate 20 and the first expansion ink are prepared, and as shown in FIG. , a blade coater, a die coater, or the like, to form the first expansion layer 30 (step S1). It should be noted that the application is not necessarily limited to the entire surface of the metal plate 20 and may be applied to a part of the metal plate 20 .

Next, a slurry obtained by mixing and dispersing a material selected from porous silica, alumina, polyvinyl alcohol, etc. in a solvent is applied to a bar coater, roller coater, spray coater, flow coater, brush, blade coater, die coater, etc. It is coated on the first expansion layer 30 using a known coating device according to the method. Then, as shown in FIG. 4, the first ink receiving layer 40 is formed (step S2).

Next, as shown in FIG. 5, the first light-to-heat conversion layer 50 is applied to the area of the upper surface of the first ink receiving layer 40 where the first expansion layer 30 is expanded to form desired irregularities. is formed (step S3). The first light-to-heat conversion layer 50 is formed by printing, for example, by an inkjet method, using a black ink containing carbon black as a light-to-heat conversion material having light-to-heat conversion properties.

Subsequently, in order to expand the first expansion layer 30, for example, a light irradiation device such as a halogen lamp is used to irradiate light containing near-infrared rays. Note that the height of expansion differs depending on the concentration of the black ink, and the higher the concentration, the higher the expansion. Then, as shown in FIG. 6, the first expansion layer 30 in the region where the first photothermal conversion layer 50 is formed is expanded to form the first intermediate 11 (step S4).

Next, as shown in FIG. 7, the second expanded ink is applied onto the first intermediate 11, for example, by a known method such as a bar coater, roller coater, spray coater, flow coater, brush, blade coater, die coater, or the like. The second expansion layer 60 is formed by coating using the coating device of (step S5). It should be noted that the application is not necessarily limited to the entire surface of the first intermediate 11 , and may be applied to a part of the first intermediate 11 .

Next, as in the case of forming the first ink-receiving layer 40, for example, a slurry obtained by mixing and dispersing a material selected from porous silica, alumina, polyvinyl alcohol, etc. in a solvent is coated with a bar coater, a roller, or the like. Using a known coating device such as a coater, a spray coater, a flow coater, a brush, a blade coater, and a die coater, the second expansion layer 60 is coated with the second expansion layer 60 as shown in FIG. An ink receiving layer 70 is formed (step S6).

Next, as shown in FIG. 9, a second light-to-heat conversion layer 80 is formed on the upper surface of the second ink-receiving layer 70 in a region where the second expansion layer 60 is expanded to form desired irregularities. is formed (step S7). The second light-to-heat conversion layer 80 is formed by printing, for example, by an inkjet method, using black ink containing carbon black, for example, as a light-to-heat conversion material having light-to-heat conversion properties.

Subsequently, in order to expand the second expansion layer 60, for example, a light irradiation device such as a halogen lamp is used to irradiate light containing near-infrared rays (step S8). The amount of light irradiation and the light irradiation are such that the heat emitted from the second photothermal conversion layer 80 is higher than the expansion start temperature of the second expansion layer 60 and lower than the expansion start temperature of the first expansion layer 30 . Set the time, etc. Then, as shown in FIG. 10 , the second expansion layer 60 in the region where the second photothermal conversion layer 80 is formed is expanded to form the second intermediate 12 .

Subsequently, as shown in FIG. 1B, a desired color image is printed on the second intermediate 12 to form a color layer 90 (step S9), thereby forming a multi-layer coated metal plate 10 having a color image. .

According to the method for manufacturing a multi-layer coated metal sheet and a molded article according to the present embodiment, it is possible to easily form unevenness on the metal sheet and maintain the quality of the metal sheet on which the unevenness is formed for a long period of time. .

In addition, in this embodiment, by using a material having excellent hygroscopicity, such as porous silica, for each of the first ink-receiving layer 40 and the second ink-receiving layer 70, the metal plate 20 can be used as a corrosion prevention layer. Corrosion can be further prevented.

Furthermore, in this embodiment, the number of expansion layers formed on the metal plate 20 may be one or two or more. If it is desired to express unevenness more abundantly, the number of expansion layers should be two or more.

The present invention is not limited to the above embodiments, and modifications can be made without departing from the scope of the present invention.

Moreover, in the above embodiment, as shown in FIG. It is not limited to this. It is also possible to control the unevenness of each expansion layer according to the desired unevenness.

It should be noted that the drawings used in the above embodiments are for explaining the above embodiments. Therefore, the thickness of each layer is not intended to be construed as being limited to the proportions shown in FIG. 1B. For example, although the metal plate 20 is illustrated to be thicker than the first expansion layer 30 in FIG. It does not exclude a thinly formed configuration. The same applies to other layers.

Although preferred embodiments of the present invention have been described, the present invention includes the invention described in the claims and their equivalents. The invention described in the original claims of the present application is appended below.

[Appendix 1]
a corrosion prevention layer provided on one surface of the metal plate for preventing corrosion of the metal plate due to moisture absorption;
a photothermal conversion layer provided on the anti-corrosion layer with an ink material for converting absorbed light into heat;
an expansion layer provided between the metal plate and the corrosion prevention layer and formed to expand with heat converted from light by the photothermal conversion layer;
with
The anti-corrosion layer is formed as an ink-receiving layer that absorbs and receives the ink material.
A multilayer coated metal plate characterized by:
[Appendix 2]
The expansion layer is provided on at least part of one surface of the metal plate,
The multi-layer coated metal sheet according to appendix 1, characterized in that:
[Appendix 3]
The photothermal conversion layer is provided on at least part of the ink receiving layer,
The multi-layer coated metal sheet according to appendix 1, characterized in that:
[Appendix 4]
a first expansion layer provided on one surface of the metal plate and formed to expand when heated to a predetermined temperature or higher;
a first photothermal conversion layer provided on the first expansion layer for converting absorbed light into heat and emitting the heat;
a second expansion layer provided on the first photothermal conversion layer and formed after the formation of the first expansion layer;
a second photothermal conversion layer provided on the second expansion layer;
with
The thickness of the second expansion layer is such that when the heat emitted by the second photothermal conversion layer is at a temperature higher than the expansion start temperature of the first expansion layer, the heat emitted is The thickness is such that it does not spread to the first expansion layer,
A multilayer coated metal plate characterized by:
[Appendix 5]
The second expansion layer has a lower expansion start temperature than the first expansion layer.
The multi-layer coated metal plate according to appendix 4, characterized in that:
[Appendix 6]
forming on the metal plate a first expansion layer that expands when heated;
forming a first photothermal conversion layer for converting light into heat on the first expansion layer;
By irradiating the first photothermal conversion layer with light, the first expansion layer corresponding to the region where the first photothermal conversion layer is formed is expanded to form a first intermediate. and
forming a second expansion layer that expands when heated on the first intermediate;
forming a second photothermal conversion layer that converts light into heat on the second expansion layer;
By irradiating the second photothermal conversion layer with light, the second expansion layer corresponding to the region where the second photothermal conversion layer is formed is expanded to form a second intermediate. and
having
A method for manufacturing a modeled object, characterized by:

10 Multilayer coated metal plate with color image 11 First intermediate 12 Second intermediate 20 Metal plate 30 First expansion layer 40 First ink receiving layer 50 First light-to-heat conversion layer 60 Second expansion layer 70 Second ink receiving layer 80 Second photothermal conversion layer 90 Color layer

Claims (3)

a first expansion layer provided on one surface of the metal plate and formed to expand when heated to a predetermined temperature or higher;
a first photothermal conversion layer provided on the first expansion layer for converting absorbed light into heat and emitting the heat;
a second expansion layer provided on the first photothermal conversion layer and formed after the formation of the first expansion layer;
a second photothermal conversion layer provided on the second expansion layer;
with
The thickness of the second expansion layer is such that when the heat emitted by the second photothermal conversion layer is at a temperature higher than the expansion start temperature of the first expansion layer, the heat emitted is The thickness is such that it does not spread to the first expansion layer,
A multilayer coated metal plate characterized by: The second expansion layer has a lower expansion start temperature than the first expansion layer.
The multi-layer coated metal sheet according to claim 1, characterized in that: forming on the metal plate a first expansion layer that expands when heated;
forming a first photothermal conversion layer for converting light into heat on the first expansion layer;
By irradiating the first photothermal conversion layer with light, the first expansion layer corresponding to the region where the first photothermal conversion layer is formed is expanded to form a first intermediate. and
forming a second expansion layer that expands when heated on the first photothermal conversion layer after forming the first intermediate;
forming a second photothermal conversion layer that converts light into heat on the second expansion layer;
By irradiating the second photothermal conversion layer with light, the second expansion layer corresponding to the region where the second photothermal conversion layer is formed is expanded to form a second intermediate. and
A method of manufacturing a modeled object, characterized by comprising:

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