JP7487461B2 - Method for repairing exterior decorative materials - Google Patents

Description

The present invention relates to a method for repairing a decorative member for exterior use, and more particularly to a method for repairing the surface of a decorative member having a metal substrate and used for housing exterior materials, the surface of which has deteriorated over time.

The application of printing technology to building materials, particularly interior and exterior materials, has become widespread. In the building materials of houses and stores, decorative sheets with designs created using printing technology are now widely used not only for interior materials such as floors, ceilings, walls, and furniture, but also for exterior materials such as exterior walls, replacing those with natural materials on the surface.

When used as exterior components, in addition to design, they are exposed to wind, snow, rain, sunlight, exhaust fumes, flying debris, and other elements of the external environment, so they require properties such as weather resistance, scratch resistance, and stain resistance, and also durability. For this reason, a metal plate such as a steel plate or aluminum plate is used as the base material, and a decorative sheet is laminated on the base material to provide a pattern layer, surface protection layer, etc., but deterioration of the laminated decorative sheet over time has been a major issue for exterior components.

As a measure to prevent deterioration over time of the decorative sheet laminated to the exterior member, acrylic resins are often used as the material for the surface protective layer of the decorative sheet to improve the weather resistance of the decorative sheet itself, and to further improve weather resistance, ultraviolet absorbers and radical scavengers may also be used in the surface protective layer.

For example, Patent Document 1 proposes additive components for improving weather resistance. In order to further improve weather resistance, it is necessary to increase the amount of these additives added. However, depending on the type of additive, there is a risk that the additives may bleed out onto the surface of the decorative sheet, which increases the cost of the decorative sheet, so there are limitations. Furthermore, the surface protective layer itself or the additives themselves often decompose over time, causing the initial performance to be lost.

Deterioration over time can also cause changes in appearance, such as changes in surface gloss and fading, as well as cracks in the surface protective layer and a decrease in additive components for improving weather resistance, resulting in a decline in weather resistance. For this reason, repairs are sometimes carried out by removing the deteriorated parts and installing new parts. For example, Patent Document 2 discloses a repair method in which the surface of a wooden flooring material is cut to form a recess and a repair piece is fitted into the recess. However, with exterior materials that use metal sheets as the base material, it is difficult to perform such partial cutting and fitting.

Patent Document 3 also discloses a method of repairing defective parts of a pattern using an inkjet coating device, but this method requires a highly accurate inkjet coating device, and it is not possible to remove parts of the decorative sheet that have deteriorated over time. In addition, some materials for the surface protection layer have physical properties that make them difficult to apply to the inkjet method. In addition, it is sometimes difficult to remove parts of the exterior material for repair, making it difficult to deal with such cases, and so the use of this method is limited.

In addition, deteriorated designs were sometimes restored by hand-painting, but this was time-consuming and had problems such as large variations in quality.

JP 2008-238444 A JP 2001-159247 A JP 2008-201072 A

To provide a repair method for an exterior decorative member having a metal plate as a base material, which can easily repair the exterior decorative member by removing the deteriorated portion and transferring a pattern when the quality of the decorative sheet attached to the surface of the exterior decorative member has deteriorated over time or due to environmental conditions.

In order to solve the above problem, one aspect of the present invention is
A method for repairing a deteriorated portion of a decorative sheet of an exterior decorative member having a metal plate as a substrate and a decorative sheet having a pattern formed thereon, the method comprising the steps of:
The deteriorated portion is removed by polishing without being impacted by a filler,
A repair material for an exterior decorative member, which is constructed by laminating a base material release layer, a picture ink layer, an adhesive layer, and a release paper in this order, the base material release layer being a polypropylene film or a laminated paper obtained by laminating paper and a polypropylene film, the adhesive layer being an adhesive layer having an acrylic resin as a main chain and urethane cross-linked with an isocyanate, and having an adhesive strength of 10 N/25 mm or more under the following measurement conditions, is characterized in that the release paper is peeled off from the repair material, and the adhesive layer is directly attached to a portion of the decorative sheet where a deteriorated portion has been polished and removed,
By peeling off the substrate release layer, the adhesive layer and the picture ink layer are transferred onto the substrate;
This is a method for repairing an exterior decorative member, which is characterized by applying a weather-resistant paint or laminating a transparent weather-resistant tack film onto the transferred pattern ink layer .
Measurement conditions: A sample piece 25 mm wide and 100 mm long was pressed against a substrate (SUS304 plate) by moving a 2 kg roller back and forth once, and the strength was measured in a 180° direction at a speed of 300 mm/min using a tensile tester.

In the above-mentioned method for repairing an exterior decorative member,
After the adhesive layer and the picture ink layer are transferred onto the substrate, an undercoat coating layer may be provided on the picture ink layer, and a weather-resistant paint may be applied onto the undercoat coating layer, or a transparent weather-resistant tack film may be laminated thereon.

According to the present invention, when the quality of an exterior decorative component having a metal plate such as a steel plate or aluminum plate as a base material and a decorative sheet having a picture ink layer laminated thereon deteriorates due to deterioration over time or the like, a repair method can be provided in which the deteriorated parts can be easily repaired by removing the deteriorated parts from the decorative sheet by polishing, transferring the adhesive layer and the picture ink layer from the repair material, applying a weather-resistant paint as a surface protective layer or laminating a transparent weather-resistant tack film.

1 is a schematic cross-sectional view of one embodiment of a repair material of the present invention. Schematic diagram of a process for removing a deteriorated portion in the repair method of the present invention. 3 is a schematic diagram of a transfer step in one embodiment of the repair method of the present invention. 1 is a schematic cross-sectional view of an example of an exterior decorative member repaired with one embodiment of the repair material of the present invention. 5A to 5C are schematic diagrams illustrating a transfer step in a second embodiment of the repair method of the present invention. 5 is a schematic diagram of a transfer step in a third embodiment of the repair method of the present invention. FIG. 5A to 5C are schematic diagrams illustrating a transfer step in a fourth embodiment of the repair method of the present invention. 13A to 13C are schematic diagrams illustrating a transfer step in a fifth embodiment of the repair method of the present invention.

The following describes in detail an embodiment of the present invention with reference to the drawings. Note that the present invention is not limited to the embodiment described below. In the following, the same reference numerals may be used to designate equivalent parts, and descriptions thereof may be omitted.

Figure 1 is a schematic cross-sectional view of one embodiment of the repair material of the present invention. The repair material 1 is composed of a laminated paper substrate release layer 11 made of polypropylene (PP) film laminated to paper, a pattern ink layer 12, an adhesive layer 13, and a release paper 14 laminated in this order. The release paper 14 is peeled off when the repair material 1 is attached to the exterior decorative member to be repaired, exposing the adhesive layer 13. The substrate release layer 11 is peeled off after the repair material 1 is attached to the exterior decorative member, exposing the pattern ink layer 12. The pattern ink layer 12 side is made of PP film so that it can be easily peeled off from the pattern ink layer 12. In other words, the repair material 1 is in the form of a transfer sticker with release sheets on the front and back. The substrate release layer 11 may be composed of only a film that is not laminated to paper.

The pattern of the pattern ink layer 12 may be appropriately selected to match the pattern of the exterior decorative member to be repaired, and may be applied by a method appropriately selected from gravure printing, inkjet printing, or other known printing and coating methods. The pattern ink layer 12 is not particularly limited, but is preferably made of a urethane-based or vinyl chloride-vinyl acetate-based resin as the binder resin.

The adhesive layer 13 is an adhesive layer having an acrylic resin as the main chain and urethane crosslinked with isocyanate in order to provide sufficient weather resistance and heat resistance when used in an exterior decorative member. The adhesive strength is 10 N/25 mm or more under the following measurement conditions.
Measurement conditions: A sample piece 25 mm wide and 100 mm long was pressed against a substrate (SUS304 plate) by moving a 2 kg roller back and forth once, and the strength was measured in a 180° direction at a speed of 300 mm/min using a tensile tester.

This makes it difficult to peel off when used as an exterior decorative component and provides sufficient weather resistance and heat resistance.

Next, we will explain the repair method using the repair material of the present invention. Figure 2 is a schematic diagram of the process of removing deteriorated parts in the repair method of the present invention. This is the first process of the repair method of the present invention, and is a process that is carried out in common in each embodiment described below. That is, this is a process of polishing and removing deteriorated parts of the decorative sheet 16 formed on the surface of the metal substrate 15 of the exterior decorative member 10 with a polishing tool 17.

The exterior decorative component 10 to be repaired is configured such that at least a decorative sheet 16 is laminated on a metallic substrate 15, such as a steel plate or an aluminum plate. Although not specifically shown, a colored sheet or the like may be laminated between the substrate 15 and the decorative sheet 16 to conceal the metallic luster of the substrate 15, or a protective sheet may be laminated on the surface of the decorative sheet 16.

The abrasive 17 is used to abrade the surface of the decorative sheet 16 by moving it back and forth, and is not particularly limited, but examples include files, abrasive paper, and electric sanders, and a combination of these may be used. When abrading the decorative sheet 16, the amount to be removed by abrading can be set appropriately according to the degree of deterioration of the decorative sheet 16. The decorative sheet 16 may be removed so that a portion of it remains, or may be completely removed so that the substrate 15 is exposed. Also, if the above-mentioned colored sheet or the like is layered between the substrate 15 and the decorative sheet 16, the abrasion may be performed so that the colored sheet remains.

Next, the process after removing the deteriorated decorative sheet 16 will be described. Figure 3 is a schematic diagram of the transfer process of one embodiment of the repair method of the present invention. The repair material of the present invention illustrated in Figure 1, from which the release paper 14 has been peeled off, is attached to the substrate 15 from which the decorative sheet 16 has been removed, with the adhesive layer 13 facing the substrate 15, and the substrate release layer 11 is peeled off to transfer the pattern ink layer 12 onto the substrate 15 (second process). At this time, by setting the adhesive strength of the adhesive layer 13 to 10 N/25 mm or more as described above, the repaired portion is less likely to peel off and has sufficient weather resistance and heat resistance.

Next, a transparent weather-resistant tack film 18 is laminated on the pattern ink layer 12 as a surface protection layer (third step). The transparent weather-resistant tack film 18 is an adhesive film, and by attaching it, the repaired exterior decorative component itself can be made to have sufficient durability and weather resistance. Examples of the transparent weather-resistant tack film 18 include acrylic films and olefin-based films that have been treated with a weather-resistant formula.

Figure 4 is a schematic cross-sectional view of an example of an exterior decorative component repaired in the manner described above. An adhesive layer 13 and a patterned ink layer 12 are laminated on the metal substrate 15 and the polished portion, leaving behind a colored film layer 21 of olefin resin as the colored layer, and a transparent weather-resistant tack film 18 is further laminated as a surface protective layer. Note that the layers are shown in a stepped pattern in the figure for ease of viewing; they are not actually arranged in a stepped pattern, but are arranged to cover all the necessary parts.

As explained above, the repair material and repair method for exterior decorative members according to the present invention can provide a method for easily repairing and restoring an exterior decorative member 10, which is made of a metallic base material 15 with a decorative sheet 16 laminated on its surface, by polishing away deteriorated portions of the decorative sheet 16 that have deteriorated over time since installation or due to environmental conditions, and transferring and attaching the adhesive layer 13 and the patterned ink layer 12 from the repair material 1 instead.

Figure 5 is a schematic diagram of the transfer step of the second embodiment of the repair method of the present invention. After removing the deteriorated portion of the decorative sheet in the first step described above, the repair material from which the release paper 14 has been peeled off is attached so that the adhesive layer 13 faces the substrate 15 as in the previous embodiment, and the substrate release layer 11 is peeled off to transfer the pattern ink layer 12 onto the substrate 15 (second step). Next, an undercoat coating layer 20 is provided on the pattern ink layer 12 (third step). The undercoat coating layer 20 is a coating layer of a penetrating sealer for improving the adhesion between the pattern ink layer 12 and the surface protection layer laminated thereon. The undercoat coating layer 20 is not particularly limited, but can be provided by a coating method such as brush coating, roller coating, or spray coating.

Examples of penetrating sealers include water-based sealers such as SK Clear Sealer, SK Water-Based Elastic Sealer, Miracle Sealer Eco (SK Chemical Co., Ltd.), Super Primer E, K's Water-Based Seal Ace, Penetrating Primer E (Kikusui Chemical Co., Ltd.), Water-Based Transparent/White Sealer, Ultra Sealer III, Water-Based Cationic Sealer (Nippon Paint Co., Ltd.), Emulsion Building Sealer, Cationic Sealer Multi II (Rock Paint Co., Ltd.), and examples of oil-based sealers include One-Component Mild Sealer ES, Mild Sealer EPO, Miracle Sealer ES, Miracle Sealer EPO (SK Chemical Co., Ltd.), Kikusui Primer EPW (Kikusui Chemical Co., Ltd.), One-Component Penetrating Sealer, One-Component Best Sealer, Fine Penetrating Sealer (Nippon Paint Co., Ltd.), Epoxy Sealer Multi, Yume Rock Sealer, and Modified Epoxy Sealer (Rock Paint Co., Ltd.), but are not limited to these and can be appropriately selected depending on the materials of the layers to be coated and the layers to be laminated.

Next, a topcoat coating layer 19 made of weather-resistant paint is applied as a surface protective layer on the undercoat coating layer 20 (fourth step). The topcoat coating layer 19 is a coating layer whose main component is a fluorine-based, acrylic, silicone-based, or urethane-based resin and has a thickness of 5 to 100 μm.

For the topcoat coating layer 19, for example, examples of paint products that can be used include Pureride UV Protect Clear, Pureride UV Protect 4F Clear, Perfect Top, Fine Si, Fine Urethane U100 (Nippon Paint Co., Ltd.), Ares Aqua Gloss, Ares Aqua Retan, Ares Aqua Silicone AC2, Silicone Tex, Vinyl Deluxe, Aqua Yane Fusso, Aqua Yane Silicone, Cera M Retan, Cera M Silicone, Cera M Silicone 2, Muki Fusso, Cosmo Mild Silicone 2, Yane M Silicone, Super Silicone Roof Paint (Kansai Paint Co., Ltd.), Bonflon Water-Based UV Cut Clear, Bonflon Weak Solvent Enamel GT, Bonflon Matte GT-SR Algae Prevention, Bonflon DE Ground Base, and Bonflon Pare Base (AGC Coatec Co., Ltd.). The topcoat coating layer 19 is not particularly limited, but can be suitably provided by applying the coating by brush coating, roller coating, spray coating, or the like, and then drying.

Figure 6 is a schematic diagram of the transfer process of the third embodiment of the repair method of the present invention. In this embodiment, the first three steps are the same as those of the second embodiment described above, and in the fourth step, a transparent weather-resistant tack film 18 similar to that of the first embodiment is laminated. The transparent weather-resistant tack film 18 does not need to be dried after application, making the process more efficient.

Figure 7 is a schematic diagram of the transfer step of the fourth embodiment of the repair method of the present invention. In this embodiment, after removing the deteriorated portion of the decorative sheet in the first step described above, the undercoat coating layer 20 is first provided (second step). Next, the repair material from which the release paper 14 has been peeled is attached so that the adhesive layer 13 faces the substrate 15, and the substrate release layer 11 is peeled off to transfer the adhesive layer 13 and the pattern ink layer 12 onto the undercoat coating layer 20 (third step). In this case, the undercoat coating layer 20 improves the adhesion between the substrate 15 and the adhesive layer. Next, a topcoat coating layer 19 made of weather-resistant paint that serves as a surface protection layer is provided on the transferred pattern ink layer 12 (fourth step).

Figure 8 is a schematic diagram of the transfer process of the fifth embodiment of the repair method of the present invention. In this embodiment, the first three steps are the same as those of the fourth embodiment described above, and in the fourth step, a transparent weather-resistant tack film 18 is laminated, similar to that of the first embodiment.

In this way, the repair material and repair method of the present invention can provide a repair material and repair method that can easily restore or extend the life of an exterior decorative component made of a decorative sheet bonded to a metal base material by polishing off the decorative sheet portions that have deteriorated over time since application or due to environmental conditions, and then repairing the deteriorated surface by applying a transfer sticker-type repair material.

The present invention will be explained in more detail in the following examples.

Example 1
(Preparation of repair materials)
For the repair material in the form of a transfer sticker, a wood grain pattern was printed by gravure printing using a urethane-based ink (Lamistar, manufactured by Toyo Ink Co., Ltd.) on a polypropylene film that had not been subjected to any easy-adhesion processing such as corona treatment, which served as a base material release layer, to form a picture ink layer.
A glassine paper separator (basis weight 70 g/ ^m2 ) with a release treatment (direct silicone coat) applied to one side was used as the release paper, and a 25 g/m2 adhesive layer was applied to the release-treated side using a gravure printing method, with 100 parts of acrylic adhesive (Olivine 5762K, manufactured by Toyo Ink Co., Ltd.) and 1.4 parts of ^{polyisocyanate} curing agent (BXX5627, manufactured by Toyo Ink Co., Ltd.) added. This was then laminated with the above-mentioned picture ink layer to form a repair material.

(Repair method)
The decorative sheet portion of the exterior decorative member, in which the pattern of the decorative sheet had been burned off due to aging, was polished with an electric sander equipped with #80 abrasive paper, and further polished with #1000 abrasive paper, and the polished surface was washed with water. A pattern ink layer was attached and transferred to the polished and washed portion using the above-mentioned repair material, and a transparent clear paint (Pureride UV Protect Clear undercoat/topcoat, manufactured by Nippon Paint Co., Ltd.) was spray-coated as a surface protective layer to finish the surface.

(evaluation)
1) Pattern transfer performance Using the above repair method, the area ratio of the pattern ink layer that was normally transferred from the repair material was determined.
Evaluation: Pass: 70% or more Fail: Less than 70% 2) Weather resistance: The test was carried out under the following conditions using a metal weather tester (manufactured by Daipla Wintes Co., Ltd.).
Light mode: illuminance 65 mW/cm ² , black panel temperature 63° C., humidity 50%, 20 hours Wet mode: black panel temperature 30° C., humidity 98%, 4 hours Before and after the wet mode, take a 30-second shower. The above constitutes one cycle, and 13 cycles were performed.
Judgment: Abnormal appearance (cracks, yellowing, chalking, peeling): Fail Slight whitening on the appearance: △
No abnormalities in appearance: Pass

Example 2
The same repair material as in Example 1 was used, and the repair was performed in the same manner as in Example 1, except that the surface protective layer was an ultra-weather-resistant transparent tack sheet, and the repair was evaluated in the same manner.
Here, the ultra-weather-resistant transparent tack sheet was prepared as follows.
A homopolypropylene with low stereoregularity "TPO" (manufactured by Prime Polymer Co., Ltd., MFR 4.5 g/10 min) was used as a transparent film substrate, to which 0.5% by weight of a triazine-based ultraviolet absorber "TINUVIN 1600" (manufactured by BASF Japan Ltd.) and 0.5% by weight of a hindered amine-based radical scavenger "TINUVINXT850" (manufactured by BASF Japan Ltd.) were added.
- Furthermore, after subjecting the surface of the transparent film substrate to a corona treatment, a surface protective layer is formed by using a base solution having a solid content of 33% by weight, the base solution being composed mainly of an acrylic resin composition consisting of a mixture of 80 parts by weight of methyl methacrylate monomer and 20 parts by weight of cyclohexyl methacrylate, 6 parts by weight of a triazine ultraviolet absorber "Adeka STAB LA-46" (manufactured by ADEKA CORPORATION), 6 parts by weight of "TINUVIN 479" (manufactured by BASF Japan Ltd.), 5 parts by weight of a hindered amine radical scavenger (manufactured by BASF Japan Ltd.), and ethyl acetate solvent added for adjusting the solid content;
A hexamethylene diisocyanate type hardener solution with a solid content of 75% by weight, to which ethyl acetate solvent was added to adjust the solid content,
The base solution and the hardener solution are mixed in a ratio of 10:1.
Further, ethyl acetate was added as a solvent component to adjust the solid content to 20% by weight, and the coating liquid was applied so that the thickness after evaporation of the solvent would be 9 μm.

Example 3
The repair material had the same structure as in Example 1, except that the design ink layer of the repair material was made of vinyl chloride-vinyl acetate ink (VKNT ink, manufactured by Toyo Ink Co., Ltd.), and was evaluated in the same manner.

<Comparative Example 1>
The same procedure was followed as in Example 1, except that the adhesive layer of the repair material was an acrylic adhesive (Cyavine SH-101, manufactured by Toyo Ink Co., Ltd.), and evaluation was carried out in the same manner.

<Comparative Example 2>
After a pattern ink layer was attached and transferred using the same repair material as in Example 1, an exterior decorative member was produced without providing a surface protective layer, and was similarly evaluated.

The results are summarized in Table 1. As is clear from Table 1, the exterior decorative members of each Example had good transferability of the pattern and excellent weather resistance. On the other hand, in the Comparative Examples, sufficient weather resistance was not obtained, or the pattern itself could not be transferred well.

Reference Signs List 1: Repair material 10: Exterior decorative member 11: Substrate release layer 12: Pattern ink layer 13: Adhesive layer 14: Release paper 15: Substrate 16: Decorative sheet 17: Abrasive tool 18: Transparent weather-resistant tack film 19: Topcoat coating layer 20: Undercoat coating layer 21: Colored film layer

Claims (2)

A method for repairing a deteriorated portion of a decorative sheet of an exterior decorative member having a metal plate as a substrate and a decorative sheet having a pattern formed thereon, the method comprising the steps of:
The deteriorated portion is removed by polishing without being impacted by a filler ,
A repair material for an exterior decorative member, which is constructed by laminating a base material release layer, a picture ink layer, an adhesive layer, and a release paper in this order, the base material release layer being a polypropylene film or a laminated paper obtained by laminating paper and a polypropylene film, the adhesive layer being an adhesive layer having an acrylic resin as a main chain and urethane cross-linked with an isocyanate, and having an adhesive strength of 10 N/25 mm or more under the following measurement conditions, is provided by peeling off the release paper from the repair material, and directly attaching the adhesive layer to a portion of the decorative sheet where a deteriorated portion has been polished and removed;
By peeling off the substrate release layer, the adhesive layer and the picture ink layer are transferred onto the substrate;
A method for repairing an exterior decorative member, comprising applying a weather-resistant paint or laminating a transparent weather-resistant tack film onto the transferred pattern ink layer.
Measurement conditions: A sample piece 25 mm wide and 100 mm long was attached to a substrate (SUS304 plate) with 2 kg of
The roller was moved back and forth once to press the material, and the material was then tensioned 300 mm/s in the 180° direction using a tensile tester.
Measured at a speed of min. A method for repairing an exterior decorative member as described in claim 1, characterized in that after the adhesive layer and the pattern ink layer are transferred onto the substrate, a primer coating layer is provided on the pattern ink layer, and the weather-resistant paint is applied or the transparent weather-resistant tack film is laminated on the primer coating layer.