JPH0437779B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention mainly involves forming an arbitrary uneven pattern by embossing on a thin metal plate having a decorative coating or a decorative coating made of film, etc., and applying a three-dimensional effect enhancer to this uneven pattern. It is easy to visually add a three-dimensional effect to the mechanical uneven pattern using color.
The present invention relates to a three-dimensional forming device that can easily produce a decorative thin metal plate having a deeper uneven pattern surface. In general, thin metal sheets, particularly organic coated steel sheets, fluorine resin coated steel sheets, stainless steel sheets, aluminum sheets, copper sheets, vinyl chloride steel sheets, etc., are being used for a wide variety of purposes. This is because this type of steel sheet has excellent workability and design, as well as durability. Recently, demand has shifted from the above-mentioned flat steel plates to steel plates with enhanced fashionability by adding a three-dimensional effect or two-tone color to the surface. As a steel plate that can handle this, for example, a steel plate (flat plate) is passed between upper and lower metal rolls with an uneven pattern engraved on the outer circumferential surface, and an uneven pattern is formed by embossing to form an uneven pattern on the steel plate. Steel plates made of aluminum are commercially available. However, when we conducted a salt spray test (JIS-A-2371) on these steel plates, we found that
Rust and peeling of the paint film were observed on the bent parts after ~1000 hours. In addition, when observing the surface of this type of steel plate under 30x magnification, it is possible to see that some of the paint film is visible at the bent parts of the concave and convex parts.
If it peels off, becomes wrinkled, or has scratches,
It was cracked, thinned, and had cracks. This is because the embossing line is not suitable. Furthermore, simply adding two-tone color or the like to the decorative surface has the disadvantage that it lacks the ability to visually enhance the fashionability and three-dimensional effect. In order to eliminate these defects, the present invention softens the decorative film during embossing to exhibit ductility, thereby eliminating peeling, wrinkles, scratches, and cracks in the decorative film, and easily correcting residual distortion during embossing. A three-dimensional effect can be easily created visually by applying a three-dimensional effect enhancer that exerts a shadow function from only one direction on at least the sloped surface (side surface) of the convex pattern of the uneven pattern. This paper proposes an enhanced three-dimensional device for decorative surfaces. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a three-dimensional decoration device (hereinafter simply referred to as a three-dimensional device) for a decorative surface according to the present invention will be described in detail with reference to the drawings. FIG. 1 is a schematic configuration diagram showing an example of the above-mentioned device, and 1 shows a pinch roller 2 and a coil A that guide and feed a thin metal plate A (hereinafter simply referred to as a coil) cut to a regular length in a heater section. The cosmetic coating, essentially the coil A itself, is about 30
From the heater 3, which softens the decorative film by heating it to ~60°C to prevent the decorative film from peeling off from the steel plate, cracking, scratching, or cracking during embossing. It is composed of The heating method is one of a hot air method, an open flame method, and a hot wire method. A pinch roller 4 feeds the coil A to the embossing roll 5 at a predetermined speed, and also functions to feed the coil A and prevent flapping during embossing. Further, the embossing roll 5 has upper and lower rolls 5 having a pattern consisting of male and female uneven parts formed on the outer peripheral surface.
A and 5b are engaged to give the coil A an arbitrary uneven pattern, for example, concave and convex patterns B and C as shown in FIG. 2 a and b, and the upper and lower rolls 5a and 5
The gap b is determined by the height of the uneven pattern and the thickness of the coil A. 6 is for correcting the residual strain existing in the coil A' embossed with a leveler, and upper rollers 6a ₁ , 6a ₂ , 6a ₃ , . . .
...6a _o (shown up to 6a ₃ in Figure 3), lower roller 6
b ₁ , 6b ₂ , 6b ₃ , ... 6b _o (shown up to 6b x ₄ in Fig. 3) in the order of zigzag, and the gap 7 between the upper roller group 6a and the lower roller group 6b is adjusted. It is made to be moisturized. Reference numeral 8 denotes a tensioning pinch roller which rotates faster than the embossing roll 5, and allows the coil A to pass through the steps of the embossing roll 5 and the leveler 6 while being stretched (under tension). 9 is a masking film applicator (hereinafter simply referred to as a film applicator) which uses a roll coater and a brush to coat the top surface of the convex pattern C of the concave and convex patterns B and C of the concave and convex patterns shown in FIG. 2 a and b. A masking film D for masking only is applied, such as a paint or a film. 10 is a three-dimensional effect enhancer applicator (hereinafter simply referred to as a coating machine) that applies a three-dimensional effect enhancer (hereinafter simply referred to as an enhancer) E made of paint, film, etc. from only one direction of the concave and convex patterns B and C. Then, as shown in Fig. 4 a to c, the top surface of the concave pattern B and the convex pattern C and the side surface of the convex pattern C are the surfaces where the application direction α of the promoter E and the traveling direction β of the coil A' collide. In this case, promoter E is only applied. The distribution state of the promoter E on the concave and convex patterns B and C is in the form of a film, dots, lines, stripes, etc. Note that the angle θ ₁ of the coating machine 10 is arbitrarily selected depending on the requirement for a three-dimensional effect. Of course, since the enhancer E is applied to the concave and convex patterns B and C from only one direction, not only the three-dimensional effect is greatly enhanced, but also the concave and convex patterns B and C can be reversed depending on the viewing direction. It can be formed to create an optical illusion. 1
1 wipes off the masking film D and promoter E present on the top surface of the convex pattern C with a wiping machine, and then removes the coil.
It exposes A′ itself or the decorative coating. To explain further, the wiping machine 11 is
A stage or a plurality of stages (not shown) are arranged in parallel, and the masking film D and the promoter E in the above-mentioned areas are gradually wiped off. A specific example thereof includes a wiping roller 11a, a back up roller 11b, a feed roller 11c, and a doctor blade 11d.
The masking film D and promoter E adhering to the surface of 1a are washed away, and a new wiped surface is repeatedly formed. Reference numeral 12 is a drying oven in which the concave and convex patterns B and the top surface of the convex pattern C on the C side are dried, and the promoter E is dried or baked. Next, to explain the operation of the three-dimensionalization device according to the present invention, the coil A cut into 10 shaku pieces is fed one by one to the heater 3 via the pinch roller 2,
The heater 3 heats the cosmetic film to about 30 to 60°C to soften the decorative film and feed it to the pinch roller 4. Next, the coil A sent out from the pinch roller 4 is sent to the embossing roll 5, and the coil A is sent to the embossing roll 5, for example,
As shown in Figures a and b, an embossed pattern consisting of a concave pattern B and a convex pattern C is formed. At this time, the embossing is performed with tension being applied to the coil A. The coil A' sent out from the embossing roll 5 is then corrected by the leveler 6 in the tensioned state between the embossing roll 5 and the tensioning pinch roller 8 to correct the residual strain caused during embossing, and then sent to the film applicator 9. This is what will be sent. Note that the force relationship between the embossing roll 5 and the tensioning pinch roller 8 with respect to the coil A' is such that when the rotation of the embossing roll 5 is taken as a reference, the rotation speed of the embossing roll 5 is slow and the rotation of the tensioning pinch roller 8 is fast. Set in relation to the coil
Embossing, flattening, and removal of residual strain are performed while A′ is in tension. Note that if the speed of the pinch roller 4 is slow between the pinch roller 4 and the embossing roll 5, the coil A will not flap at the entrance of the embossing roll 5. In addition, by setting the speed difference between the tensioning pinch roller 8 and the embossing roll 5, or between the pinch roller 4 and the tensioning pinch roller 8, it is possible to prevent the coil A from shifting during embossing and making the pattern unclear. This will prevent you from getting caught twice. In addition, since leveler 6 is in a state where tension is applied in one direction, concave and convex patterns B and C
It can be easily flattened without deforming it, and residual strain can be easily released. Of course,
The tension within the above region is within a force range that does not change the embossed pattern. Further, in the film applicator 9, a masking film D is applied to the top surface of the convex pattern C.
is applied. Next, the coil A' sent out from the film applicator 9 is coated with a promoter E by the applicator 10, which differs from the decorative film in at least one of density, hue, and saturation, over the entire surface of the concave and convex patterns B and C. , θ ₁
For example, in Figures 4 a to c
Apply to each concave and convex pattern B and C as shown in
It is something that is attached. Of course, in this case, the concave pattern B,
The distribution of the promoter E is uniform in each part of the convex pattern C.
This is a non-uniform distribution, a mixed distribution, or a distribution where the density gradually changes. The coil A′ having such an uneven decorative surface is removed by the wiping machine 11.
The masking film D and promoter E present only on the top surface of the convex pattern C are wiped off, and the drying oven 12
It is then sent to a drying or baking process. Example A colored galvanized iron plate (JIS-G-3312) with a plate thickness of 0.27 mm was used as the coil A, and the temperature of the heater 3 was 10 to 80.
℃, the embossing depth is 0.9 mm, and the ratio of concave pattern B to convex pattern C is 1:1.
The embossing speed was 18 m/min. Further, the speed difference between the pinch roller 4 and the tensioning pinch roller 8 was about 3%. Furthermore, a synthetic resin paint as the masking film D and a black alkyd resin paint as the promoter E are applied with a spray gun, preheated at 90°C for 5 minutes in the drying oven 12, and baked at 200°C for 1 minute. Ta. The paint for coil A is white and uses alkyd resin as a vehicle. Then, when the temperature of the surface of the coil A, the so-called temperature of the decorative film (in this case, the paint film) is changed from 0 to 80°C, peeling of the decorative film, cracking, cracking, shrinkage, etc. , the state of the wound is the fifth
This is shown as a line graph in the figure. Further, the flatness and degree of residual strain (pekotsuki) of the coil A' sent out from the leveler 6 were visually observed. In addition,
The inspection method is (1) the apparent number of Pekotsuki existing per 1 meter of coil A', (2) the distribution state of Pekotsuki, (3) the height difference of Pekotsuki (the bottom surface of the designed uneven part, (difference between the top surface and the actual bottom and top surface), (4)
Observations about the overall appearance are shown. Furthermore, (5)
Coil by visually checking the three-dimensional effect of the concave and convex patterns B and C.
This shows the impression when observed while standing upright in the direction of travel of A' and in the opposite direction. Comparative Example Coil A as described above was passed through a steel plate (flat plate) between upper and lower metal rolls with a concavo-convex pattern engraved on the outer circumferential surface, embossed in the previous process of forming a concave-convex pattern on the steel plate, and then A paint of a color different from that of the coil was applied with a spray gun from directly above the concave and convex patterns B and C of the stopped coil A', and when it dried, it was used as a test piece. [Table] Furthermore, the results of a salt spray test (1500 hours) of the example (coil A when the decorative coating was heated to 50°C) and the coil formed according to the comparative example were as shown in the table below. . [Table] What has been described above is only one embodiment of the three-dimensionalization device according to the present invention, and the number of stages of the rollers of the leveler 6 is concave,
The length of the rollers can be increased or decreased depending on the distribution ratio of the convex patterns B and C, or the length of the rollers can be increased from the entrance to the exit, and the length of the rollers can be arranged in a shape that spreads toward the end.
In addition, the promoter E is added to the coil A' in Fig. 6a~
It is also possible to apply with the applicator 10 from the direction shown in c. In other words, diagram a shows the traveling direction β of coil A′.
On the other hand, the promoter E is applied from the side at angles θ ₂ and θ ₃ or in combination, and angles θ ₂ and θ ₃ are smaller than 90° and 0°, so-called coil
This also includes the case where it is parallel to the decorative surface of A' while maintaining the height G. In addition, in Figure b, the coil A' is formed to have a double width, and is finally divided into two parts and the ends are formed. It can also be applied from directly above coil A' as shown in figure c. In addition, in figures a and c, it is necessary that the sailing speed of the coil A' is 5 to 10 m/min or more, and that the height difference between the concave and convex patterns B and C is 0.5 mm or more.
Furthermore, it is also possible to remove the pinch roller 4 and directly feed the coil A from the heater section 1 to the embossing roll 5, with simple guides provided on both sides along the way. Alternatively, a magnifying glass or a video camera may be installed at the position indicated by the dashed line in FIG. 1 to more clearly monitor the decorative surface after embossing. As described above, according to the three-dimensional device of the present invention, there is no change in the force applied to the coil in the embossing zone, and embossing can be performed under constant tension at all times, so the embossed pattern does not shift during processing and is beautiful. An uneven pattern can be formed. Because the decorative film is heated to make it soft enough for embossing, the decorative film may peel off from the steel plate during embossing, or the decorative film may wrinkle, crack, scratch, or crack. Beautiful makeup film, weather resistance, scratch resistance,
A cosmetic film with excellent chemical resistance can be formed. The distortion caused by embossing can be easily corrected by correcting it under tension.
Residual distortion is sufficiently removed, and a concavo-convex pattern with no unevenness and full of three-dimensional effect can be formed.
The lines are arranged in a straight line, and the process uses a flow that does not apply unreasonable force to the coil, allowing for smooth embossing. Since the coil is heated and embossed, it is not affected by the working environment. The straight line allows for high-speed embossing. The top surface of the convex pattern of the uneven pattern is a highly reflective surface,
At least the sides of the convex pattern are coated with a facilitator that functions like a shadow, so the three-dimensional effect created by the mechanical concave-convex pattern and the visual facilitator can bring out unprecedented three-dimensionality and depth. .
The three-dimensional effect enhancer can be easily applied after the uneven pattern surface is formed. Since the coil is a cut plate, it is possible to create a decorative surface that is smoother and does not twist. It has the following characteristics.

[Brief explanation of drawings]

FIG. 1 is a schematic configuration diagram showing an example of a three-dimensional decorative surface device according to the present invention, FIGS. 2 a and b are explanatory diagrams showing a part of the uneven pattern, and FIG. 3 is one configuration of the device. Perspective view showing an example of a leveler, Figures 4 a to c
5 is an enlarged explanatory diagram showing the process of forming the decorative surface.
The figure is a characteristic diagram showing the temperature of the decorative film and the occurrence of cracks, etc., and Figures 6a to 6c are explanatory diagrams showing other examples. 1 ... Heater part, 5... Emboss roll, 6 ...
...Leveler, 8...Pinch roller for tension, 9...
Masking film applicator, 10... Three-dimensional effect promoter applicator, 11... Wiping machine, 12... Drying oven,
A, A'...Thin metal plate cut to regular length, D...
Masking film, E...stereoscopic effect enhancer.

Claims (1)

[Claims] 1. In an apparatus for three-dimensionalizing the decorative surface of a thin metal plate cut to a regular length, the heater part includes a pinch roller that feeds the thin metal plate and a heater that heats the thin metal plate to 30 to 60°C; an embossing roll for forming an arbitrary uneven pattern on a thin metal sheet fed from a metal sheet; a leveler disposed after the roll; a tensioning pinch roller disposed at the outlet of the leveler; and a top surface of the uneven pattern. a masking film applicator that applies a masking film to the surface of the uneven pattern; a three-dimensional effect enhancer applicator that applies a three-dimensional effect enhancer from only one direction at an acute angle to the uneven pattern surface having the masking film; A device for creating a three-dimensional decorative surface, characterized in that a wiping machine for wiping off a masking film and a three-dimensional effect promoter present on the top surface of a convex pattern of the surface, and a drying oven for drying the three-dimensional effect enhancer are arranged in series.