JPS6156095B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a raised PVC metal plate, and more particularly to a raised PVC metal plate having a so-called suede-like or velvet-like texture.

Conventionally, a resin layer with a cell structure containing air bubbles is provided on cloth, nonwoven fabric, synthetic resin sheet, etc., and the outer surface is brushed to give a suede-like or velvet-like sheet that is used for clothing, furniture, houses, stores, automobiles, etc. It is used as an interior material.

Also used is one in which the above-mentioned napping process is performed by slicing process. However, these base materials are the above-mentioned sheets that are flexible and have poor strength, and cannot be used as strong members themselves, and cannot be subjected to various forming processes such as pressing and bending like mild steel plates or surface-treated steel plates, and cannot be used as needed. It was unable to maintain its shape. On the other hand, it was extremely difficult to firmly adhere the suede-like sheet to the metal plate after molding without wrinkles or unevenness.

The inventors of the present invention have found that the above-mentioned problems can be solved by making the surface of a vinyl chloride metal plate itself, which has excellent workability, corrosion resistance, shape retention, rigidity, etc., suede-like or velvet-like.

The objectives of the present invention are processability, corrosion resistance, shape retention,
To provide a brushed PVC metal plate having excellent rigidity, texture, etc.

According to the present invention, a metal plate is used as a base material, and on one or both sides of the metal plate,
A vinyl chloride metal plate having an adhesive layer and a vinyl chloride resin layer, characterized in that at least the surface layer of the vinyl chloride resin layer has a cell structure containing air bubbles, and the outer surface thereof is brushed. A brushed PVC metal sheet is provided.

The present invention will be explained in detail below using the drawings.

Figures 1 and 2 show a bubble-free PVC resin layer.
FIG. 3 is a cross-sectional view of an embodiment of the present invention in which the adhesive layer and the surface layer of the vinyl chloride resin layer having a foamed cell structure are not present and are present, respectively.

In FIG. 1, a base metal plate 1 is coated with a vinyl chloride resin layer 4 having a foamed cell structure having a large number of air bubbles 5 as a surface layer, with an adhesive layer 2 interposed therebetween. In FIG. 2, a bubble-free vinyl chloride resin layer 3 is adhesively interposed as a lower layer between the adhesive layer 2 and the foamed cell resin layer 4. Here, the PVC resin layer refers to PVC resin polymerized by the so-called suspension method, microsuspension method, emulsion method, etc. with an average degree of polymerization of 500 to 2000, or a combination of PVC resin and vinyl acetate, acrylic acid, methacrylic acid. acid, maleic acid,
A copolymer resin with a carboxyl group-containing resin such as itaconic acid or fumaric acid, or a blend thereof, and a plasticizer that lowers the softening temperature of the PVC resin and imparts flexibility and processability. It consists of a stabilizer to impart heat stability, light stability, and processability to the PVC resin, and a foaming agent to form a cell structure containing bubbles, and further pigments and fillers are added as necessary. refers to the resin layer that has been coated.

The plasticizer includes di-n-octyl phthalate,
Phthalate esters such as di2-ethylhexyl phthalate, dihexyl phthalate, dibutyl phthalate, diisodecyl phthalate, diundecyl phthalate, didodecyl phthalate, fatty acid esters such as dioctyl adipate, dioctyl sepacate, diisodecyl adipate, or tricresyl phosphate, phosphoric acid Phosphate esters such as trioctyl, octyl diphenyl phosphate, and triphenyl phosphate, or trimellitate esters such as trioctyl trimellitate, polyester plasticizers such as polypropylene adipate and polypropylene sebacate, or a type of plasticizer such as chlorinated paraffin. , or a combination of two or more, among which the phthalate esters,
A single fatty acid ester or a mixture of two or more fatty acid esters are preferably used. In addition, the amount of plasticizer added is determined in order to ensure processability and flexibility.
It is effective to add 30 to 200 parts by weight of plasticizer in total per 100 parts by weight.

Stabilizers include lead-based, cadmium-based, barium-based, zinc-based, calcium-based, cadmium-barium-based, barium-zinc-based, calcium-zinc-based,
Metal-free stabilizers such as tin-based various metal salt stabilizers, phosphorous esters as chelators, or epoxy compounds are used. Further, as lead-based stabilizers, tribasic lead sulfate, dibasic lead phosphite, basic lead sulfite, lead stearate, etc. can be used.

In addition, as cadmium-based, barium-based, zinc-based, and calcium-based stabilizers, cadmium-
Barium-based, barium-zinc-based, calcium-zinc-based composite stabilizers and stearates of the metals,
So-called metal soaps of ricinoleate are used. Furthermore, the tin-based stabilizers include organic compounds such as dibutyltin dilaurate, dibutyltin dimethyl maleate, dibutyltin dimaleate, dibutyltin laurate/methyl maleate, dibutyltin dioctyl thioglycolate, dibutyltin diricinolate, and dimethyltin dilauryl mercabutide. Tin-based stabilizers can be applied.

Among the various stabilizers mentioned above, thermal stability, light stability,
Lead-based, barium-based, zinc-based, and calcium-based stabilizers are preferably used from the viewpoint of plate-out resistance and uniformity of foamed cells, and their blending amount is determined from the viewpoint of stability and economic efficiency. For 100 heavy loads
0.5 to 10 parts by weight is preferred.

The foaming agent is an agent that decomposes during heating and melting during the formation of the PVC resin layer to produce a gas mainly composed of _N2 , which causes the PVC resin layer to form a cell structure containing air bubbles. These blowing agents include, for example, azodicarbonamide, azobisbutyronitrile, dinitropentamethylenetetramine, paratoluenesulfonylhydrazide, 4.4'oxybisbenzenesulfonylhydrazide, and the like. Among them, azodicarbonamide and dinitropentamethylenetetramine are particularly preferably used because the decomposition temperature of the blowing agent and the melting temperature of the vinyl chloride resin are relatively close to each other.

Further, the amount of the blowing agent added is an extremely important factor, and the uniformity of the cell structure or the expansion ratio can be delicately controlled by adjusting the amount of the blowing agent added.
In the brushed PVC steel sheet according to the present invention, a PVC resin layer having an expansion ratio of about 2 to 8 times is preferable. In order to ensure the expansion ratio within this range, the amount of the foaming agent added is approximately 1 to 5 parts by weight per 100 parts by weight of the vinyl chloride resin. In this way, a surface layer of the PVC resin layer having a uniform cell structure can be obtained.

As a method for manufacturing the brushed PVC metal plate according to the present invention, the metal plate 1 shown in FIG. An adhesive consisting of a mixture of more than one species is applied by a method such as roll coating, knife coating, dip coating, flow coating, spray coating, brush coating, etc., and then dried and baked to form the adhesive layer 2. Next, plastisol or organosol, which is a stirred mixture of PVC resin, plasticizer, stabilizer, blowing agent, and pigment, filler, and diluent as necessary, is applied by roll coating, knife coating, dip coating, flow coating, spray coating, and brush coating. It is applied by a method such as painting, and then this raised surface layer plastisol or organosol is heated and melted. At this time, as the foaming agent decomposes, bubbles are generated in the PVC resin layer, forming a resin layer 4 having a uniform cell structure, and at the same time completing a strong melt bond with the adhesive layer 2. . Here, in order to form a vinyl chloride resin having a uniform cell structure and to complete strong adhesion, the heating and melting temperature is preferably in the range of about 180 to 230°C. At temperatures below 180°C, the decomposition of the foaming agent is insufficient, making it difficult to obtain a uniform cell structure, and adhesion becomes insufficient, while at temperatures above 230°C, excessive foaming occurs resulting in a coarse cell structure, which is undesirable.

In addition, as a method of forming the foamed cell resin layer 4 on the upper layer with the foamless layer 3 shown in FIG. The base material is a PVC sheet, or a PVC sheet made by coating a metal plate or release paper with plastisol consisting of PVC resin, plasticizer, stabilizer, pigment, and filler and melting it by heating. The above-mentioned raised surface layer plastisol or organosol is applied by roll coating, knife coating, flow coating, dip coating, spray coating, brushing coating, etc., followed by heating, melting, and foaming.

The formed PVC sheet having a bubble-free PVC resin layer 3 as a lower layer and a foamed cell resin layer 4 as an upper layer is a second layer.
A metal plate 1 on which an adhesive layer 2 has been applied in advance as shown in the figure
are laminated by roll crimping or the like. At this time, in order to firmly bond the bubble-free layer 3 and the adhesive layer 2, the metal plate 1 having the adhesive layer 2 should be prepared in advance at a 180°
It is best to heat it to ~230℃.

The foamed cell layer 4 shown in FIGS. 1 and 2 is obtained by polishing the surface layer of the PVC resin layer using a polishing machine such as a belt sander, roll sander, or buffing machine, or by using a splitting machine. By straining, the surface layer of the PVC resin layer is destroyed, the cell structure inside the PVC resin layer is exposed on the surface, and a brushed PVC metal plate having a suede-like or velvet-like surface appearance is obtained. However, even if a conventional PVC steel plate having a PVC film without a cell structure is polished or cut, a suede-like or velvet-like appearance cannot be obtained because the PVC layer does not have a cell structure.

The brushed PVC metal plate has a strong bond between the metal plate and the PVC resin layer via an adhesive, so it is possible to perform sheet metal processing such as bending, pressing, stretching, and shearing. No peeling of the PVC resin layer occurred.

In addition, the surface of the PVC resin layer 3 of the brushed PVC metal plate may be colored with acrylic, urethane, etc., or top coated with a transparent paint, and may also be printed with letterpress, gravure, offset, silk screen, etc., foil stamped, stamped, or embossed. It is also possible to perform surface treatments such as machining. Note that the metal plate serving as the substrate can be a cold-rolled steel plate, various surface-treated steel plates, stainless steel plates, as well as copper plates, aluminum plates, brass plates, and other non-ferrous metals or alloy plates.

By the way, as another method for producing a raised PVC resin-coated metal plate, a PVC sheet produced by foaming and raising according to the method of the present invention is formed into a metal plate by a method such as roll crimping or press crimping. Another method is to stack them.

Regardless of which method is used, it is easy to apply a raised PVC layer to one or both sides of the metal plate if desired.

The present invention will be explained in more detail below using examples.

[Example 1] Plastisol prepared by kneading and defoaming with formulation A was coated with approximately 5 μm of acrylic resin adhesive (16A32 manufactured by Sony Chemical Co., Ltd.) in advance and baked into a 0.6 mm thick electric plate. Coat it on a galvanized steel plate using a knife coater to a thickness of 0.2mm, and heat it at 200℃.
By heating and melting for 60 seconds, a PVC steel plate having a foam layer with a foaming ratio of about 3 times was obtained.

Furthermore, the surface layer of the PVC foam layer of the PVC steel plate was polished using a buffing machine (Kitamura Machinery Co., Ltd.) using #240 abrasive paper.
KIW20B) to obtain a brushed PVC steel plate.
This PVC steel sheet had a suede-like feel and had good workability, with no peeling or ironing of the raised PVC layer observed during roll forming, pressing, and bending.

[Formulation A]

PVC resin (Zeon 43A) 100 parts by weight di-octyl phthalate 70 〃 Dibasic lead phosphite 3 〃 Azodicarbonamide 3 〃 Pigment (TiO ₂ ) 20 〃 CaCO ₃ 10 〃 [Example 2] Example 1 and The surface layer of the PVC foam layer of a PVC steel plate with a foam layer created using the same procedure was split using a splitting machine (KIW-10 manufactured by Kitamura Kikai Co., Ltd.) to create a brushed PVC steel plate with a cell structure on the surface layer. Obtained. This PVC steel plate has a good suede texture,
Even when roll forming and pressing were performed, there was no peeling or ironing of the raised PVC layer, and it had good workability.

[Example 3] Approximately 0.3 mm of plastisol obtained by kneading and defoaming with formulation B was applied to a 0.5 mm thick cold rolled steel plate on which approximately 5 μm of the same acrylic resin adhesive as in Example 1 had been applied and baked. After coating with a knife coater, it was heated and melted at 200°C for 60 seconds to obtain a PVC steel plate having a foamed PVC layer with an expansion ratio of about 3 times.

After the surface layer of the foamed PVC layer of this PVC steel plate was filtered in the same manner as in Example 2, gravure printing was applied to the surface layer of the foamed PVC layer in accordance with a conventional method.

The resulting brushed PVC steel sheet had a suede-like feel and was good, with no peeling of the brushed PVC layer even when processed in the same manner as in Example 1.

[Formulation B]

PVC resin (Zeon 12IL) 100 parts by weight Diundecyl phthalate 80 〃 Azodicarbonamide 3 〃 Stabilizer (KV-83 Ca-Zn system) 3 〃 Pigment (TiO ₂ ) 20 〃 [Example 4] Soft 0.2 mm thick The plastisol obtained by kneading and defoaming with Formulation B was applied onto a PVC sheet (50 parts by weight of plasticizer) using a knife coater to a thickness of 0.5 mm, and this sheet was coated with a 0.5 mm cold rolled steel plate as a support. to
The mixture was heated and melted at 200° C. for 60 seconds to obtain a PVC sheet having a non-foamed layer of soft PVC as a lower layer and a foamed layer as an upper layer. Next, Example 2 shows the foam layer surface layer of this sheet.
Similarly, using a splitting machine, the sheet was split into a sheet having a raised PVC layer, and then an electrogalvanized steel sheet was coated with the same adhesive as in Example 1 so that the thickness after baking was 5 μm. Immediately after baking at 220° C. for 60 seconds, the raised PVC sheet was pressed with a roll and cooled to obtain a raised PVC steel plate.

This brushed PVC steel sheet had a suede-like feel, and had good workability with no peeling or ironing of the brushed PVC layer observed during roll forming, pressing, and bending.

[Comparative example]

The plastisol obtained by kneading and defoaming with the formulation A except for azodicarbonamide was applied to an electrogalvanized steel sheet that had been coated with the same adhesive as in Example 1 and baked, and then heated at 200°C for 60 seconds. , and heated and melted to obtain a PVC steel plate. The PVC layer of this PVC steel plate was polished in the same manner as in Example 1 or in Example 2.
Even after straining in the same manner as above, a brushed PVC steel sheet with a suede-like texture could not be obtained.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of an embodiment of the present invention in which a PVC resin layer with a foam cell structure is coated with an adhesive;
FIG. 2 is a sectional view of another embodiment of the present invention in which a bubble-free PVC resin lower layer is applied. DESCRIPTION OF SYMBOLS 1... Base metal plate, 2... Adhesive layer, 3... Cell-free resin layer, 4... Foamed cell resin layer, 5... Cells.

Claims (1)

[Scope of Claims] 1. A PVC metal plate having a metal plate as a base material and having an adhesive layer and a vinyl chloride resin layer on one or both sides thereof, in which at least the surface layer of the vinyl chloride resin layer contains cells containing air bubbles. A brushed PVC metal plate characterized in that the outer surface thereof is a brushed surface. 2. The raised PVC metal plate according to claim 1, wherein the raised treatment is a polishing treatment using a buffing machine or a belt sander. 3. The raised PVC metal plate according to claim 1, wherein the raised treatment is a straining treatment of the sheet-like vinyl chloride resin. 4. The brushed PVC metal plate according to any one of claims 1 to 3, wherein the metal plate is a steel plate or a steel plate with various surface treatments. 5. Claims 1 to 4, which have a printing layer or a top coat layer on the outer surface after the napping treatment.
The brushed PVC metal plate described in any one of the following items.