JPH04146126A - Resin laminate having welded studs - Google Patents

Abstract

PURPOSE:To prevent the welding of studs from adversely affecting and improve the heat fusion property and heat stability property of a building material for use in interior and external trimming by welding studs to a metal sheet having a thickness of a specific value or more in which at least one face is covered with a resin film having a melting point of a specific temperature or higher. CONSTITUTION:A resin film having a melting point of 150 deg.C or higher, high heat stability and less thermochromism, for example a fluorine-containing resin type film or the like is joined to at least one face of a metal sheet of iron or aluminum type or the like having a thickness of 1mm or more according to a method for melt adhesion under heating and the like. To the so obtained laminate of metal and resin film, studs are welded by the use of a welding gun and machine. The metal sheet having so welded studs is free from dents that would occur on studs at the time of welding thereof, changes of the film incidental to the fusion or discoloration such as burn. Furthermore, the resin film layer is a smooth, continuous homogeneous layer which does not permit the chemical substances to permeate into the metal layers, capable of improving the durability.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention relates to a resin laminated metal plate to which studs are welded, and more specifically to a resin laminated metal plate having one side covered with a resin film having a melting point of 150° C. or higher. The invention relates to a resin laminate with welded studs, characterized by being made of metal plates of 1 mm or more, and specific examples of its use include panels used for the interior and exterior of buildings.

[Prior art]

Conventionally, resin film laminates have no pinholes, have good corrosion resistance, can be easily coated with a printed layer, and are rich in design, so they are used in a variety of fields such as interior and exterior materials for building materials, housings for electrical appliances, desks, and cabinets. It has been done.

When used for the interior and exterior of building materials, studs are often erected to attach reinforcing materials, to attach to structures, or to fix other members to panels, especially when the panels are thin. However, in general, films have problems with their thermal melting properties and thermal stability, and they often melt or burn due to the heat generated when welding studs, so there have been no good ones.

[Problem to be solved by the invention]

The object of the present invention is to solve the above-mentioned problems of the prior art, and to provide a resin laminated metal plate with welded studs, which was completely unknown heretofore.

[Means for solving problems]

The present invention was made to solve the above-mentioned problem, and is characterized in that a stud is welded to a metal plate with a thickness of 1 mm or more and at least one side of which is covered with a resin film having a melting point of 150° C. or more. The present invention provides a resin laminate.

The resin film referred to in the present invention may be any film as long as it has a melting point of 150°C or higher, has high thermal stability, and has little thermal discoloration, such as fluorine-containing resin film, polyester film, polyamide film, polyacrylate film, Examples include polyimide films and polysulfide films, but fluorine-containing resin films are preferred from the viewpoint of weather resistance, corrosion resistance, heat resistance, stain resistance, processability, and the like.

The "fluorine-containing resin" as used in the present invention is not particularly regulated as long as it is a thermoplastic resin that contains 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 them, trifluoroethylene resins, difluoroethylene resins, -fluoroethylene resins, copolymers of these resins, and mixtures, etc. Of these, tetrafluoroethylene resins and -fluoroethylene resins are preferred, and tetrafluoroethylene resins are more preferred. Here, the tetrafluoroethylene resin specifically refers to, for example, tetrafluoroethylene resin (PTFE'), tetrafluoroethylene/perfluoroalkoxyethylene copolymer (PF
A), tetrafluoroethylene/hexafluoropropylene/perfluoroalkoxyethylene copolymer (EPE), tetrafluoroethylene/ethylene copolymer (ETFE), etc. Among them, PFA and ETFE are preferred, and PFA is particularly preferred. preferable. In addition, the above-mentioned trifluoroethylene resin specifically refers to, for example, trifluorochloride ethylene resin (PCTF
E) and trifluorochloroethylene/ethylene copolymer (E
CTFE), among which PCTFE is preferred. Specifically, the difluoroethylene-based and -fluoroethylene-based resins include, for example, vinylidene fluoride resin (P
VDF) and vinyl fluoride resin (PVF).

It goes without saying that the resin film used in the present invention must be free from damage such as pinholes, and if it completely covers one side of the metal plate serving as the substrate, the layer thickness Any one is fine, but in general, 1
It is 0 to 500μ, preferably 20 to 300μ.

These resin-containing films can be produced by conventional methods, such as hot-melt extrusion and casting, and if necessary, pigments and dyes can be added. It is possible to blend and color it, or to improve the strength and the like by blending inorganic fillers such as glass powder, glass beads, and glass fibers, aluminum oxide, talc, mica, and silica. It is also possible to print desired designs.

Furthermore, the "metal plate" as used in the present invention is not particularly limited and can be any metal plate, but generally, for example, it is an iron-based, aluminum-based, copper-based metal plate, etc. Of these, iron-based and aluminum-based metal plates are preferred.

The iron-based metal plate may be any metal plate whose composition mainly contains iron, and specifically,
Examples include cold-rolled steel sheets, galvanized steel sheets, zinc alloy-plated steel sheets, aluminum-plated steel sheets, copper-plated steel sheets, stainless steel sheets, phosphate-treated steel sheets, and aluminum-zinc alloy-plated steel sheets. Among them, galvanized steel sheets, zinc alloy-plated steel sheets, etc. Preferred are steel plates, aluminum plated lead steel plates, aluminum-zinc alloy plated steel plates, and stainless steel plates.

Further, as the aluminum-based metal plate, any metal plate may be used as long as the metal plate 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 of Japan on September 30, 2007, and specifically, pure aluminum, (AI
-Cu) system, (AI-Mn) system, (AI-8t) system,
There are (AI-Mg) type, (AI-Mg-8i) type and (AI-Zn-Mg) type plates, among which pure aluminum type, (Al-Mn) type and (AI-Mg) type plates.
) type board is preferred.

If the thickness of the metal plate in the present invention is too thin, it will deform during welding or the film will break, so generally, the thickness of the metal plate is 1.
．． 0 to 10 m/m, preferably 1.5 to 5 m/m.

Next, the resin film that will become the coating layer and the metal plate that will become the substrate need to be bonded, and there are two methods for joining, such as using an adhesive and heat-fusion bonding. A method of doing so is preferred.

Films can be bonded by heat-melting and bonding using conventional methods, but generally, for example,
It can be obtained through processes such as a pretreatment process, a heating process, film lamination, a pressurizing process, a reheating process, and a cooling process. The lamination process of a fluorine-containing resin film, which is a preferred resin film of the present invention, will be explained below as an example.

(1) Pre-treatment step This step is performed as necessary to more strongly coat the metal plate and the fluorine-containing resin film.

■ Pre-treatment process of metal plates The purpose of pre-treatment of metal plates is to remove oily substances that adhere to the surface.
Cleaning and removing foreign substances, oxide films, etc., exposing bare metal to the surface by polishing, etc., surface plating,
Apply surface treatment such as acid treatment, and if necessary,
Add roughness to the surface, etc.

86 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.

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

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 treatment with zinc phosphate, calcium phosphate, etc., and chromate treatment with reactive chromate, coating type chromate, and the like.

61 Surface Roughening The surface can be roughened by a surface roughening method using physical means such as brushing, sandblasting, and shotblasting, or by a surface roughening method using chemical, electrochemical etching, or a combination 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 aminosilane, 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. In the present invention, the latter is particularly preferable and necessary in the case of iron-based metal plates. In this step, the film is also heat-treated at the same time.

■Heating atmosphere The above-mentioned “substantially oxygen-free atmosphere” means:
There is no particular restriction as long as the atmosphere can heat the metal plates and films that have undergone the pretreatment process while substantially maintaining their surface conditions, but specifically, the atmosphere may have an oxygen content of 1% or less preferable. 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 generally nitrogen gas, argon gas, neon gas, helium gas, etc. are preferred, with nitrogen gas and argon gas being preferred, and nitrogen gas being particularly preferred.

In addition, the vacuum state is 5 Torr or less, preferably I
Torr or less, more preferably 0ITor or less.

■Heating temperature The optimum heating temperature is determined depending on the type of fluororesin film and metal plate to be coated, but in general, the softening point temperature (mp) of the fluororesin film
As mentioned above, it is desirable that the temperature is preferably (mp +30) °C or higher, more preferably (mp +50) °C or higher, and lower than the thermal decomposition temperature. Specifically, in the case of a fluororesin film, tetrafluoroethylene, For perfluoroalkoxyethylene copolymers, generally 280 to 400°C,
For ethylene-tetrafluoroethylene copolymers, the temperature is generally 260 to 370°C, and for ethylene-chlorotrifluoroethylene copolymers, it is generally 220 to 350°C.
°C, and 250 to 300 °C for polyvinylidene fluoride.

■ Heating time Heating time varies depending on the heating method and is not something that should be specified in particular.It must be the time required for at least the surface of the metal plate to reach the heating temperature, and may be adjusted as appropriate depending on the type and thickness of the metal plate. It is determined.

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

■ Lamination atmosphere The lamination atmosphere is not particularly restricted, but in the case of iron-based materials, it must be an atmosphere that is substantially free of oxygen, at least until the film is laminated and placed on the heated metal plate. It is desirable that the atmosphere be similar to that of 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 stick to the film, such as a rubber roll or a metal roll, and the pressing force is 5 to 30 kg/cm.
, preferably 1O to 20 kg/crrI2.

(4) Reheating process This process is a reheating process 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 process.

(2) Heating Atmosphere The heating atmosphere is not particularly limited, and may be in the air, but is preferably an atmosphere similar to that in the previous step (2).

■ Heating temperature The optimum heating temperature is determined as appropriate depending on the type of fluororesin film and metal plate to be coated, but generally it is higher than the softening point temperature (mp) of the fluororesin film, 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 fluororesin film, tetrafluoroethylene/perfluoroalkoxyethylene For copolymers, generally 280 to 400°C, for ethylene-tetrafluoroethylene copolymers, generally 260 to 360°C, and for ethylene-chlorotrifluoroethylene copolymers, generally 220 to 350°C. "C.
and 200 to 250°C for polyvinylidene fluoride.

■ Heating time The heating time does not have to be specified in particular; it must be at least the time it takes for the metal plate to reach a predetermined temperature and for the welding force to be sufficiently developed. The time is determined, but is generally between 1 and 20 minutes.

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

The resin film laminated metal plate of the present invention obtained through the above steps exhibits strong fusion strength between the metal plate and the resin film, and has excellent durability.

To attach studs to the laminate of metal and resin film obtained through the above steps, so-called stud welding may be performed using an existing welding gun and welding device.

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.

The thus obtained metal plate to which the stud of the present invention is welded has no dents caused by the stud, melting changes in the film, or discoloration such as scorching caused by stud welding, and the resin film layer is on top of the metal plate. Since it is a smooth continuous uniform layer made of resin film with no pinholes, it is highly durable as there is no penetration of chemical substances into the metal layer, and it also has an extremely high design quality as it can also have a printed layer. Therefore, it can be used for interior and exterior panels for buildings.

The present invention will be explained in more detail below with reference to Examples, but it goes without saying that the present invention is not limited only to the Examples.

Example 1 First, an aluminum plate of A 3004P-H34 (thickness 2.5 mm) specified in JISH4000 was used as an aluminum base material, and the surface of the aluminum plate was sandblasted (using reduced iron powder 8O mesh, pneumatic pressure). 3 kg/am'') to roughen the Ra (center line average roughness) to 1.8 μm, and then electrolytically etched it in a 4% sodium chloride aqueous solution at a current density of 3.3 A/dd until the Ra was 3.8 μm. A rough surface of 5 μm was formed.

This aluminum plate was heated to a temperature of 350'C, and a 50 μm thick ethylenetetrafluoroethylene copolymer film (melt flow index 30 m''7 seconds) was heat-sealed to the rough surface formed. A fluororesin laminated aluminum plate having the same shape as shown in 1 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 conducted under the condition of g/cm.

The aluminum surface of the resin-laminated aluminum plate formed as described above was coated with an outer diameter of M 8 mm and a length of 10 mm using a stud welding machine Dl-8M type manufactured by Nippon Drive-It.
aluminum stud bolts (JIS A1050 grade) were welded. The conditions at this time were a voltage of 60 volts and a gap of 2.5111 m.

Example 2 The aluminum plate in Example 1 was changed to 3.5 mm, and the fluororesin film was activated to a wetting index of 42 d3 m/an by corona treatment on the surface of the fluorine film in contact with the metal. Next, screen printing is performed on the active surface of the above film using an ink containing polyvinylidene fluoride dissolved in dimethylacetamide and mixed with a pigment to produce a printed film, and then the printed surface of this printed film is brought into contact with the metal. A fluororesin film-coated aluminum plate was prepared in the same manner as in Example 1, and studs were welded under the same conditions as in Example 1.

Example 3 In Example 1, the aluminum plate was replaced with a JISA505P grade thickness of 15mm, and the fluorine film was replaced with a tetrafluoroethylene/perfluoroalkoxyethylene copolymer film with a thickness of 60μ, and the same stud-welded resin laminate was used. Got the board.

Example 4 Commercially available phosphate-treated electrogalvanized steel sheet (Nippon Steel:
Bonded steel plate EGC, thickness 1.5m/m) with an alkaline degreaser (Nihon Baru Ising Co., Ltd., Fine Cleaner 3)
The surface was washed with water for 3 minutes at 60° C. (using 01), and then washed with water and dried. This steel plate was placed in a nitrogen-substituted heating furnace with an oxygen concentration of 0.1% and heat-treated at 350°C for 6 minutes. 50μ ethylenetetrafluoroethylene resin film 7kg/cm”
It was heat fused at a pressure of . Further, this heat-sealed steel sheet was reheated at 325° C. for 7 minutes in a nitrogen atmosphere, and cooled by being left indoors to obtain an ethylenetetrafluoroethylene resin film-coated steel sheet. The outer diameter M of the obtained coated steel plate
8 mm length 108 carbon steel stud bolt for cold heading using stud welding machine manufactured by Nippon Drive Welding D l
Welding was carried out using a -8M type with a voltage of 80 volts and a cap of 25 mm.

Example 5 Commercially available phosphate-treated electrogalvanized steel sheet (Nippon Steel:
bonded steel plate EGC, thickness 1.5m/m) with an alkaline degreaser (Nippon Parkerizing Co., Ltd., Fine Cleaner 3).
The surface was washed with water for 3 minutes at 60° C. (using 01), and then washed with water and dried. An ethylene/tetrafluoroethylene copolymer film (thickness: 60 μm) containing 8 parts by weight of titanium oxide was laminated to this steel plate. The bonding conditions were Sony Pond 5C209 (phenol/nitrile type 5ony
Coating amount: 30 g/n, curing: 150
℃ for 3 minutes. Studs were welded to the metal surface of the obtained resin laminate. The welding conditions were a cold forging carbon steel stud bolt with an outer diameter of M8 mm and a length of 10 mm, with a voltage of 80 V and a gap of 2.5 mm.

As described above, the performance of the resin laminate to which the studs obtained in the examples were welded was evaluated. The evaluation results are shown in Table 1 below.

Table-1 (Evaluation method) 1. Resistance Welding Test A round bar with a diameter of 8 mm and a length of 24 mm is welded to the back of a metal plate using a stud welding machine. At this time, the material of the round bar to be welded is appropriately selected according to the material of the metal plate, and if there is an insulating layer (for example, alumite or service paint) on the back of the metal plate, it is rubbed off with sandpaper.

The back surface to which welding was performed is visually judged as follows.

◎ There is no difference compared to the non-welded part.

○ Slight changes in gloss and smoothness are observed.

△　Irregularities occur and coloring of the resin is observed.

× Resin cracks and carbonization occurs.

2 Welding bending test Bend the welded bolt approximately 45 degrees with pliers to see if the bolt falls off. The case where it did not fall off was rated O.

3 Appearance marks: Those where stud welding was not visible from the film surface were rated O.

Discoloration: A film with no color change or burning on the back side of the stud welded film was rated O.

Film meltability: The film on the back surface of the stud welded film was rated O if it was not melted.

4 Cast: In order to check whether defects such as minute racks or the like were generated in the welded part due to stud welding, a cast test specified in JIS H8681 was conducted, and the evaluation was expressed by visual rating number.

As described above, the resin laminated metal plate to which the studs obtained according to the present invention are welded has no adverse effects due to stud welding, and provides a panel suitable for the interior and exterior of buildings.

Claims (1)

[Claims] 1. A resin laminate to which studs are welded, characterized in that it is made of a metal plate with a thickness of 1 mm or more and at least one side of which is covered with a resin film having a melting point of 150° C. or more. 2. The resin laminate according to claim 1, wherein the resin film is a fluorine-containing resin film. 3. The stud-welded resin laminate according to claim 1, wherein the fluororesin film has a printed layer. 4. The stud-welded resin laminate according to claim 1, wherein the fluororesin is a tetrafluoride resin. 5. The stud-welded resin laminate according to claim 4, wherein the tetrafluoride resin is a tetrafluoroethylene/perfluoroalkoxyethylene copolymer (PFA). 6. The stud-welded resin laminate according to claim 4, wherein the tetrafluoride resin is a tetrafluoroethylene-ethylene copolymer (ETFE). 7. The stud-welded resin laminate according to claim 1, wherein the film has a thickness of 10 to 500 μm. 8. The stud-welded resin laminate according to claim 1, wherein the metal of the metal plate is an aluminum metal plate. 9. The stud-welded resin laminate according to claim 1, wherein the metal of the metal plate is an iron-based metal. 10. A resin laminated metal plate to which a stud according to any one of claims 1, 8, and 9 is welded, wherein the metal plate has a thickness of 1.0 to 10.0 m/m.