JPH04143349A - Panel for new unit bath, material thereof, and unit bath and the like constituted therefrom - Google Patents

Abstract

PURPOSE:To improve washing adaptability, workability, and artistic design by forming a panel for a unit bath out of a metal plate of prescribed thickness of which inner face is made of fluororesin containing layer having printing layer. CONSTITUTION:A panel for a unit bath is formed out of an aluminum series metal plate of thickness 0. 1-2mm of which the inner face has fluororesin such as tetrafluoride resin containing film layer of film thickness 10-200mu. Further a printing layer is formed in the fluororesin film. Hereby, the unit bath having excellent washing adaptability, workability, and artistic design can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to novel panels for unit baths, materials for panels, and unit baths that use the panels as constituent elements. Panels and panel materials for unit baths that have a coating layer of resin film on the inner surface, and unit baths that use the same panels as constituent elements.

[Prior Art] Conventionally, unit baths such as unit baths and unit toilets have been made of PVC steel plates, plastic plates, etc., but they have had various problems. For example, in the case of PVC steel sheets, they can be used in a wide range of designs and are inexpensive, but they only have problems in terms of durability and aesthetics, such as rusting due to moisture and mold growing on the PVC film itself. In addition, the waterproof panties and wainscot parts were difficult to clean due to dry water droplets, dirt, flakes, and water stains. On the other hand, although plastic does not rust, it is not strong enough and the design is only similar to stone grain, so it is not sufficient.Also, it does not change color due to detergents or bleach, changes color due to light, and is not durable due to electrolysis or water supply. In the vicinity of the pipe installation, there was a lot of dirt that could not be cleaned, such as a slight amount of rust due to moisture, but it had soaked in and spread over a long period of time, turning it brown.Also, similar to the PVC steel plate, there were problems such as mold and grime. was there.

[Problems to be Solved by the Present Invention] The purpose of the present invention is to solve the above-mentioned problems of the prior art, and to provide a novel unit bath type that has not been known in the past. We provide panels, panel materials, and unit baths used in

Due to its difficult formability, it is extremely difficult to form a complex and highly systematic container, and even if it is formed,
Due to its lack of physical strength, it could hardly be used for pressure-resistant containers or large-capacity containers. Therefore, it is only used sparingly as a small container that requires almost no pressure resistance.

Furthermore, metal plates have been commonly used as a material for containers. It is well known that all of these metal plates have poor corrosion resistance, causing the metal to melt and causing various problems. As a countermeasure to this problem, various fluorine-containing resins are sintered or coated on the surface of the metal plate, but this causes pinholes in the resin, which poses a problem, especially when used in containers for ultra-high purity chemicals. .

[Problems to be Solved by the Invention] The purpose of the present invention is to solve the above-mentioned problems that the prior art had, and to provide a novel unit bath frame panel that was completely unknown in the past. and the materials used for it.

[Means for Solving the Problems] The present invention has been made to solve the above-mentioned problems, and at least the inner layer of the unit bath panel is mainly made of a fluorine-containing resin film, and the outer layer is further made of a fluorine-containing resin film. The present invention provides a novel container characterized by being made of a metal plate. The configuration of the present invention will be explained in more detail below.

The "fluorine-containing resin" used in the present invention is not particularly limited as long as it is a thermoplastic resin containing a fluorine atom in the molecular structure of the resin, but generally, the molecular structure of the resin is Tetrafluoroethylene resins having four fluorine atoms in the formula, trifluoroethylene resins, niftylene resins, -fluoroethylene resins, copolymers of these resins, and mixtures of Among these, tetrafluoroethylene resins and difluoroethylene resins are preferred, and tetrafluoroethylene resins are more preferred. Here, the tetrafluoroethylene resin specifically refers to, for example, tetrafluoroethylene resin (PTFE), tetrafluoroethylene/perfluoroalkoxyethylene copolymer (PFA),
), tetrafluoroethylene/hexafluoropropylene/perfluoroalkoxyethylene copolymer (EPE), tetrafluoroethylene/ethylene copolymer (ETFE), etc. Among them, PFASETFE is preferred, and ETFE is particularly preferred.
is preferred. In addition, the above trifluoroethylene resin is
Specifically, for example, trifluorochloroethylene resin (PC
TFE) and trifluorochloroethylene/ethylene copolymer (ECTFE), among which PCTFE is preferred. Specifically, the difluoroethylene-based and -fluoroethylene-based resins include, for example, vinylidene fluoride resin (
PVDF) and vinyl fluoride resin (PVC).

In addition, it goes without saying that the fluorine-containing resin film used for the inner layer in the present invention must be free from damage such as pinholes, and as long as it completely covers the metal plate that will be the outer layer. The film thickness may be any thickness, but is generally 10 to 1200μ, preferably 20 to 100μ. These fluorine-containing resin films can be produced by conventional methods such as hot melt extrusion and casting, and if necessary, pigments, dyes, glass powder,
Inorganic fillers such as glass peas and glass fibers, aluminum oxide, talc, mica, and erythrium can be blended.

Also, desired designs can be printed on the surface.

Furthermore, the "metal plate" as used in the present invention is not particularly limited, and any metal plate can be used. Generally, for example, iron-based, aluminum-based, copper-based, titanium-based, and nickel-based metal plates are used. Among these, iron-based and aluminum-based metal plates are preferable. The above-mentioned iron-based metal plate may be any metal plate as long as it mainly contains iron in composition, and specifically, for example, cold-rolled steel plate, galvanized steel plate, zinc alloy plated steel plate, etc. There are steel plates, aluminum plated steel plates, copper plated steel plates, stainless steel plates, phosphate treated steel plates, aluminum-zinc steel plates, etc. Among them, galvanized steel plates, zinc alloy plated steel plates, aluminum plated lead steel plates, aluminum-zinc alloy plated steel plates, and stainless steel plates. Steel plate is preferred.

Further, as the aluminum-based metal, any metal plate may be used as long as the metal mainly contains aluminum metal in its composition, but generally, for example,
It is an aluminum plate described in pages 13 to 22 of "Aluminum Handbook (2nd edition)" published by the Light Metals Association, Inc., on March 30th, and specifically, pure aluminum, (Al-Cu
) system, (AI-Mn) system, (A I-S i) system, (A
I-Mg) system, (AI-Mg-S i) system and (A
There is the I-Z n -Mg) system.

Although the thickness of the metal plate in the present invention is not particularly limited, it is generally, for example, 0.102 m/m, preferably 0.2 to 1 m/m.

Next, the fluorine-containing resin film that will be the inner layer and the metal plate that will be the outer layer can be joined by laminating with an adhesive, laminating by heat fusion, etc., but the main method of joining is by heat fusion welding of the film. The method of wearing is preferred.

Films can be bonded by heat fusion welding using conventional methods, but generally, for example,
It can be obtained through processes such as a pretreatment process, a heating process, film lamination, a pressing process, a reheating process, and a cooling process. The above steps will be explained below.

(1) Pretreatment process This process is a process that is carried out as necessary in order to coat the metal plate and the fluorine-containing resin film more strongly.

■ Pre-treatment process for metal plates The purpose of the pre-treatment process for metal plates is to clean and remove oily substances, foreign substances, oxide films, etc. adhering to the surface, and to expose the bare metal to the surface by polishing etc. In addition, surface treatments such as surface plating and acid treatment are performed, and if necessary, roughness is added to the surface.

81 Surface cleaning There are no particular limitations, and cleaning methods conventionally used for specific metals may be used. For example, as a degreasing method,
Degrease and clean using organic solvents, alkaline aqueous solutions, surfactants, etc.

59 Surface Polishing The surface can be polished to expose the bare metal on the surface, for example, by mechanical and chemical polishing methods.

C1 Surface Treatment If necessary, chemical conversion treatments such as plating treatment, coating treatment for installing a metal oxide film layer, and antirust treatment can be performed on the surface covered with the film. For example, specific examples of chemical conversion treatments for iron-based metals include phosphate treatments such as zinc phosphate and calcium phosphate, and chromedol treatments.

60 Surface Roughening The surface can be roughened by physical surface roughening methods such as brushing, sandblasting and shotblasting, or by chemical and electrochemical etching methods and combinations thereof.

■ Film pre-treatment process Removing oily matter, foreign matter, etc. adhering to the film surface, applying an oxide film etc. by corona discharge treatment, straw material treatment, etc., and using various surface treatment agents. For example, treatments such as coating aminosilas vinylsilane, mercaptosilane, etc. can be performed.

(2) Heating process This is a process in which the pretreated metal plate is heat treated in the air or in an atmosphere substantially free of oxygen, and if necessary, the film is also heat treated at the same time.

■Heating atmosphere The above-mentioned “substantially oxygen-free atmosphere” means:
There are no particular restrictions on the atmosphere as long as it can be heated while substantially maintaining the surface condition of the metal plates and films that have undergone the pretreatment process, but specifically, the atmosphere is such that the oxygen content is 1% or less. It has a certain atmosphere. To create this heating atmosphere, it can be filled with an inert gas or heated in a vacuum state. Any type of inert gas may be used, but in general, nitrogen gas, argon gas, neon gas, helium gas, etc. are used, among which nitrogen gas,
Argon gas is preferred.

Further, the vacuum state is 5 TOrr or less.

■ Heating temperature - The optimum heating temperature is determined by the type of fluorine-containing resin film and metal plate to be laminated and coated.
Generally, the softening point temperature (m
p) or higher, preferably (mp+30) Tl: or higher, more preferably (mp+50)"C or higher, and lower than the thermal decomposition temperature. Specifically, fluorine-containing resin film In the case of 4-Si-ethylene-barf-O-roaloxyethylene copolymer, generally 2
80-400℃, ethylene-tetrafluoroethylene copolymer generally 260-370℃, ethylene-tetrafluoroethylene copolymer
For chlorotrifluoroethylene copolymers, the temperature is generally 220-350°C, and for polyvinylidene fluoride, the temperature is 250°C.
~300°C, etc.

■ Heating time - The heating time is not something that should be specified in particular; it needs to be the time required for at least the surface of the metal plate to reach the heating temperature, and is determined as appropriate depending on the type of metal plate, plate thickness, etc. is generally 1 to 20 minutes.

(3) Lamination step This step is a step of covering a heated metal plate with a fluorine-containing resin film by lamination and pressing.

(2) Lamination Atmosphere The lamination atmosphere is not particularly limited, but it is preferable that the atmosphere conforms to the previous step (2).

■ A film laminated and placed on a press-heated metal plate, for example,
This is a process of continuously pressing with a book roll or the like to strongly coat the material. Here, the roll in contact with the film is preferably a roll that does not adhere to the film, such as a rubber roll or a metal roll, and the pressing force is 5 to 30 kg/c, preferably 10 to 20 kg/c.

(4) Reheating process This step is a reheating step that is performed as necessary to further strengthen the fusion force between the metal plate and the film of the film-coated metal plate obtained in the previous step.

■ Heating atmosphere The heating atmosphere is not particularly limited, and is used in the previous process (2
), the atmosphere is similar to that of

■ Heating temperature The optimum heating temperature is determined depending on the type of fluorine-containing resin film and metal plate to be coated, but in general, the softening point temperature (mp) of the fluorine-containing resin film
Above, preferably (mp+20)'C or higher, more preferably (mp+30)'C or higher, and lower than the thermal decomposition temperature, specifically, in the case of a fluorine-containing resin film. , for tetrafluoroethylene/perfluoroalkoxyethylene copolymers, generally 280 to 4
00°C, generally 260 to 360°C for ethylene-tetrafluoroethylene copolymers, and generally 220 to 360°C for ethylene-chlorotrifluoroethylene copolymers.
200-250 at 350℃ and polyvinylidene fluoride
℃ etc.

■ Heating time The heating time is not something that should be specified in particular; it needs to be at least the time it takes for the film to fully adhere to the metal plate, and is determined as appropriate depending on the type and thickness of the metal plate, and is generally 1 to 10 minutes. It is 20 minutes.

(5) Cooling Step This step is a step of cooling the reheated film-laminated metal plate to room temperature, and can be cooled by, for example, an air cooling fan, water, or the like.

If non-uniform cooling is performed here, distortion and deformation will occur in the plate, so uniform cooling is desirable.

The film-laminated metal plate of the present invention obtained through the above process is produced by heating the metal plate and the fluorine-containing resin film to fuse and join them, so that the metal plate and the fluorine-containing resin film are bonded together by strong fusion. It is expected that it will exhibit good adhesion and be usable for a long period of time.

The process of converting the bonded product of the metal and fluorine-containing resin film obtained through the above steps into a panel for a unit bath frame is as follows:
There are conventional processes such as a cutting process, a panel forming process, and, if necessary, a bonding process.

The fluororesin film laminated metal plate was formed into a panel for the frame of a unit bath by cutting it into a desired shape using methods such as shirring and sawing, and then using methods such as bending and drawing.

The panel for unit baths of the present invention thus obtained has excellent cleanability and durability because its inner wall layer is a continuous uniform layer of fluorine-containing resin film with no pinholes. It is easy to wipe off mold rings that adhere to the surface without the above-mentioned strange color caused by various causes, and since it can be printed, it is possible to not only color it but also customize the design to your liking, so it can be used from homes to hotels etc. We can create units, baths, etc. that are wide and suitable for customer service areas.

As the printing layer, it is preferable to provide the printing layer described in Japanese Patent Application No. 1-73899 and Japanese Patent Application No. 1-139155. For example, the printing layer in Japanese Patent Application No. 1-73899 is a fluororesin layer heat-sealed to the metal surface, and the uppermost layer is made of a fluororesin composition with a thixotropic index (TI value) of 2 to 8. The printing layer is formed by printing using the ink of
A preferred embodiment of the printed layer in No. 73899 is a printed layer in which a fluororesin film having a printed layer is heat-sealed to a metal surface with the printed layer inside.

Hereinafter, the present invention will be explained in more detail with reference to examples, but it goes without saying that the present invention should not be limited only to the examples.

Example 1 First, as an aluminum base material, JIS H4000
Using an aluminum plate of A3004P-H34 (thickness 1 mm) specified in
After roughening the surface to 1.8 μm, electrolytic etching was performed in a 4% sodium chloride aqueous solution at a current density of 3.3 A/drd to form a rough surface with an Ra of 35 μm.

This aluminum plate was heated to a temperature of 350°C, and a 50 μm thick ethylenetetrafluoroethylene copolymer film (melt flow index 3) was formed on the rough surface.
0 for 7 seconds) to obtain a fluororesin laminated aluminum plate having the same shape as shown in FIG.

The above-mentioned heat fusion is carried out by applying a pressure of 15 k to the heated metal plate and the above-mentioned film using a silicon roll with a diameter of Ocm.
The test was carried out under the conditions of g/an.

The resin-laminated aluminum plate formed as described above was cut into a predetermined size, then pressed and bent, and fixing studs were welded to create a waterproof pan for a unit bath.

, Example 2 One side of a 40μ transparent film of tetrafluoroethylene/ethylene copolymer was surface-treated using a corona discharge device (Kasuga Denki Membrane) under the treatment conditions of a discharge power of 120W/rd・min. The surface of the film was surface activated to a wettability index of 42 dyne, and the ink described below was used to form an aperture of 270 dynes.
Ethylene-
Printing was performed on the above transparent film made of a tetrafluoroethylene copolymer. This printed material was heat-dried for 10 minutes in a hot air circulation dryer at 120° C. to obtain a printed film in which a 10 μm thick printed layer made of a thin film of the ink was formed in close contact with the fluororesin layer.

On the other hand, J I 5-H-400 with a thickness of 1.0IIIWl
After sandblasting one side of the 1100 series aluminum rolled plate shown in 0 to an average unevenness depth of 10 to 15 microns (surface roughness) and an uneven pitch of 10 to 20 microns, the other side was masked with vinyl chloride resin. Then, the sandblasted surface is electrolytically etched. This electrolytic etching process uses a 3% NaCI aqueous solution and
The test was carried out at a temperature of 0.degree. C., an electrolytic density of 4 amperes/dm, and a current flow rate of 35 clones/crd.

After washing the etched surface with water and drying it, the aluminum plate was preheated to 310°C, the transparent film was placed on the etched surface, and it was pressed with a pressing force of 20 kg/crd.
A fluororesin layer is formed on the aluminum plate by heat treatment at 15° C. for 10 minutes for heat fusion, and the resin-coated metal plate of the present invention is obtained in which the printed layer is laminated on the back side of the fluororesin layer. Ta.

(Production method of ink) A copolymer of tetrafluoroethylene, cyclohexyvinyl ether, ethyl vinyl ether, and hydroxybutyl vinyl ether was obtained by a conventional method. This polymer had a molar ratio of each component of 50:18:22:10 (according to nuclear magnetic resonance method), and was prepared in tetrahydrofuran at 30°C.
The intrinsic viscosity of the copolymer was 0.4 dl/g. 100g of this copolymer was mixed with 80g of carpitol acetate.
, h was dissolved in 20 g of toluene, 50 g of titanium oxide and 6 g of colloidal silica were added thereto, and thoroughly mixed using a three-roll mill to obtain an ink composition. The viscosity of this composition was 270 ps, and the TI value was 5.

A side wall panel for a unit bath was manufactured using the obtained resin corrugated metal plate. In addition, studs were welded on the back side to secure the panel in place.

Example 3 First, an aluminum plate of A3004P-34H (thickness Q, 6 mm) specified in JISH4000 was used as the aluminum base material, and 3.3% of the aluminum plate was used in a 4% sodium chloride aqueous solution.
Ra is 3.5 by electrolytic etching under the condition of A/drrr.
A rough surface with a μ addition was formed.

This surface was printed using the ink described in Example 2.

This aluminum plate was heated to a temperature of 350"C, and a 50 μm thick ethylenetetrafluoroethylene copolymer film (melt flow index 30IX1"/sec) was heat-sealed on the printed surface, and a fluororesin A laminated aluminum plate was obtained.

The above-mentioned thermal fusion bonding is performed by applying a pressure of 15 k to the heated metal plate and the above-mentioned film using a silicone roll with a diameter of 10 cm.
The test was carried out under the conditions of g/cTn.

Using the resin laminated aluminum plate formed as described above, a side wall panel of a unit bath was manufactured in the same manner as in the example.

Example 4 The back side of an Al100P-814 (aluminum) plate specified in JIS A4000 with a plate thickness of 1 and 0 m/n+ was sandpapered with a diameter of 50 m and sandpaper with a roughness of No. 80 was attached.
Using a milling machine to which a circular metal plate of m is fixed, the rotation speed of the milling machine is 1100 rp and the scraping speed is 100 cr.
Scraping was performed under the condition of n/min. The resulting linear scratch pattern had a scratch depth of 1 μm.

After degreasing the back side of the scribed aluminum plate with a 1% caustic soda aqueous solution, the same thickness as in Example 1 was obtained.
A resin laminated metal was obtained by heat-sealing a μ ethylene-tetrafluoroethylene copolymer resin film (volume flow rate: about 20 mm, 27 seconds).

The conditions for the heat fusion are as follows: The aluminum plate and film are preheated and heated to 360°C, and then pressed using a silicone roll with a diameter of 10cm at a pressure of 100kg, and then post-treated at 3400C for 10 minutes. This is what we do.

A side wall panel was manufactured in the same manner as in Example 2 using the obtained resin-coated board.

Example 5 Commercially available phosphate-treated electrical galvanized steel sheet (Nippon Steel:
The surface of a bonded steel plate (EGC, thickness 0.8 m/m) was cleaned with an alkaline degreaser (Fine Cleaner 301, manufactured by Nippon Par Ising Co., Ltd.) at 60°C for 3 minutes, and then washed with water and dried.

This steel plate was placed in a nitrogen-substituted heating furnace with an oxygen concentration of 01% and heat treated at 350°C for 6 minutes, and then a 50μ thick A white ethylenetetrafluoroethylene resin film containing 8 parts by weight of titanium oxide was
Heat fusion was carried out at a pressure of kg/C'm2. Furthermore, this heat-sealed steel plate was reheated at 325°C for 7 minutes in an oxygen atmosphere,
The steel sheet was cooled by being left indoors to obtain an ethylenetetrafluoroethylene resin film-coated steel sheet.

A side wall panel was manufactured in the same manner as in Example 2 using the obtained resin film-coated steel plate.

Performance evaluation was performed using the resin film coated steel sheets and panels obtained in each example. The results are shown in Table 1 below.

(Evaluation method) 1. Cleanability Fluororesin-coated plate obtained in each example (size 50 cm
50cm) was propped up on the wainscot of the bathtub and left unwashed for a month, then I wiped off the dirt with a cloth.

Items that can be easily wiped off with a dry cloth... ○ Items that cannot be wiped off with a dry cloth...x2, film-coated metal plate obtained on each side for weather resistance JISA1415
A 5000-hour accelerated exposure test was conducted using WS type Sunshine Carbon (manufactured by Suga Test Instruments) shown in No. 1977, and its appearance was compared with a preserved test piece. The case where the appearance was almost the same as that of the preserved test piece was marked as ○, and the case where there was a change was marked as ×.

3 Processability A method test piece 100 base holes were cut using the cross-cut method with a width of 1 mm, and then 7
Perform mm drawing process. The test piece after drawing was subjected to a cellophane tape peeling test to determine the number of peeled pieces, and those that did not peel off were marked as ○.

If there was no change in the film of the welded part of the B-method stud, such as discoloration due to melting, and if the stud did not fall off after being bent at about 45 degrees on a bench, it was rated ○.

4. Appearance A rating of O was given when the printed design or scratched pattern was clearly visible.

[Effects of the Present Invention] From Table 1 above, it is clear that the unit bath frame panel having the fluororesin film-covered metal layer according to the present invention has extremely excellent performance and excellent design. It is also obvious that unit baths that use this panel as a component will be extremely superior products.

Claims (1)

[Scope of Claims] 1. A novel panel for unit baths made of metal, characterized in that at least the inner surface mainly consists of a fluororesin-containing film layer. 2. The panel for unit baths according to claim 1, wherein the fluororesin film has a printed layer. 3. The panel for unit baths according to claim 1, wherein the fluororesin is a tetrafluoride resin. 4. The panel for unit baths according to claim 1, wherein the tetrafluorocarbon resin is an ethylene-tetrafluoroethylene copolymer. 5. The panel for unit baths according to claim 1, wherein the fluororesin film has a thickness of 10 to 200 μm. 6. The panel for unit baths according to claim 1, wherein the metal is an aluminum metal. 7. The panel for unit baths according to claim 1, wherein the metal is plate-shaped with a thickness of 0.1 to 2 mm. 8. A material used for a novel unit bath panel made of metal, characterized in that at least the inner surface mainly consists of a fluororesin-containing film layer. 9. Unit baths comprising a novel metal panel characterized in that at least the inner surface mainly consists of a fluororesin-containing film layer.