WO2016189770A1 - 化粧建築板の製造方法 - Google Patents
化粧建築板の製造方法 Download PDFInfo
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- WO2016189770A1 WO2016189770A1 PCT/JP2015/086520 JP2015086520W WO2016189770A1 WO 2016189770 A1 WO2016189770 A1 WO 2016189770A1 JP 2015086520 W JP2015086520 W JP 2015086520W WO 2016189770 A1 WO2016189770 A1 WO 2016189770A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/0011—Pre-treatment or treatment during printing of the recording material, e.g. heating, irradiating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/08—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by flames
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
- B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/502—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording characterised by structural details, e.g. multilayer materials
- B41M5/508—Supports
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D11/00—Inks
- C09D11/02—Printing inks
- C09D11/10—Printing inks based on artificial resins
- C09D11/101—Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D11/00—Inks
- C09D11/30—Inkjet printing inks
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0871—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having an ornamental or specially shaped visible surface
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2202/00—Metallic substrate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
- B41M3/06—Veined printings; Fluorescent printings; Stereoscopic images; Imitated patterns, e.g. tissues, textiles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5218—Macromolecular coatings characterised by inorganic additives, e.g. pigments, clays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5227—Macromolecular coatings characterised by organic non-macromolecular additives, e.g. UV-absorbers, plasticisers, surfactants
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5254—Macromolecular coatings characterised by the use of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. vinyl polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/50—Recording sheets characterised by the coating used to improve ink, dye or pigment receptivity, e.g. for ink-jet or thermal dye transfer recording
- B41M5/52—Macromolecular coatings
- B41M5/5263—Macromolecular coatings characterised by the use of polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- B41M5/5272—Polyesters; Polycarbonates
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0871—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having an ornamental or specially shaped visible surface
- E04F13/0873—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having an ornamental or specially shaped visible surface the visible surface imitating natural stone, brick work, tiled surface or the like
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
Definitions
- the present invention relates to a method for manufacturing a decorative building board, in which a flame treatment is performed under specific conditions before a pattern is printed on a surface of a metal base material of a metal siding material used in the technical field of building materials by ink jet printing.
- Patent Documents 1 and 2 disclose a metal base material, an ink layer containing polyester, and a coated steel sheet having an ink layer.
- an ink layer is formed by ink-jet printing a solvent-based ink on the surface of the ink receiving layer formed on the metal substrate.
- the organic solvent contained in the solvent-based ink dissolves a part of the surface of the ink receiving layer to roughen the surface, the solvent-based ink can spread and adhere to the ink receiving layer.
- Patent Documents 3 and 4 describe a coated steel sheet used for a building board having a metal base material, an ink receiving layer cured by applying a paint, and an ink layer.
- an ink layer is formed by ink-jet printing a solvent-based or water-based ink on the surface of the ink receiving layer formed on the substrate. At this time, since the ink spreads the groove on the surface of the ink receiving layer due to the capillary phenomenon, the ink can sufficiently spread.
- Patent Document 5 discloses an image forming method using actinic ray curable ink that can stably reproduce high-definition images on various recording materials. And in the cited reference 6, the manufacturing method of a decorative building board which performs inkjet printing using actinic-light curable ink for a metal siding material is disclosed.
- Patent Document 7 discloses a method for producing a decorative building board such as an exterior material. Specifically, a polar group is introduced into the surface of a water-based enamel coating film provided on a base material by flame treatment. Improves the wettability of inkjet ink and aqueous coating film.
- the metal siding material 1 of the present invention has a concavo-convex pattern with a height difference of 0.5 mm or more, and is composed of a metal base material 11, a core material 12, and a back material 13. Further, an ink receiving layer 14 is formed on the metal base 11. In addition, a chemical conversion treatment film or an undercoat coating film may be provided on the metal base material 11, and the ink receiving layer 14 may be formed thereon.
- the ink receiving layer 14 is formed by applying a resin composition containing a resin and a pigment as a paint to a metal base and drying (or curing). Thereafter, the metal base material is subjected to embossing, drawing and the like, and is subjected to uneven processing such as tile tone, brick tone, and wood grain. Furthermore, for the purpose of improving heat insulation and soundproofing properties, a synthetic resin foam or the like is used as the core material 12, and the back surface of the metal base material is covered with a back material 13 such as aluminum laminated kraft paper.
- the present inventors have prevented the uniform wetting and spreading of the actinic ray curable ink from being caused by dirt (foreign matter) when the metal siding material 1 is produced in the ink receiving layer 14. It was found that the cause was adhesion.
- the metal base 11 of the metal siding 1 is molded after the ink receiving layer 14 is applied, and is back-coated with a synthetic resin foam of the core 12 or the like. In these multiple processing steps, the manufacturing equipment and the metal siding material 1 come into contact, and the resin and additive derived from the ink receiving layer and the core material adhere to the manufacturing and processing equipment. It adheres to the layer 14 and stains the ink receiving layer 14.
- the organic solvent contained in the solvent-based ink dissolves part of the surface of the ink receiving layer and roughens it, so there is no effect even if there is some dirt on the ink receiving layer. Few.
- the ink wettability is greatly reduced due to stains because it is impermeable to the ink receiving layer. It can be confirmed that the ink receiving layer is impermeable to ink by observing the cross section of the ink receiving layer and the ink layer with a microscope at a magnification of 100 to 200 times.
- the present inventors realized a uniform wetting and spreading of the actinic ray curable ink by flame-treating the metal siding material 1 under specific conditions and removing the dirt adhering to the ink receiving layer 14 by incineration.
- the present invention includes a metal base material that forms an uneven pattern with a height difference of 0.5 mm or more, a core material, and a back material, and an ink receiving material formed from a resin composition on the base material.
- the metal siding material in which the layers are disposed is irradiated with a flame at an output of 250 kJ / hour to 12000 kJ / hour per 10 mm of the width of the burner, and flame-treated so that the surface temperature of the substrate does not exceed 300 ° C., It is a manufacturing method of a decorative building board including inkjet printing with actinic ray curable ink.
- the surface of the metal siding material is flame-treated before ink jet printing to remove stains, thereby obtaining a uniform wet spread of the actinic ray curable ink and a decorative design board with high design properties. Furthermore, by adjusting the conditions of the flame treatment and setting the temperature at the time of flame treatment of the metal base material of the metal siding material to 300 ° C. or less, peeling due to thermal strain at the interface between the core material and the metal base material is prevented. Can do.
- FIG. 1 illustrates an example of a line-type ink jet recording apparatus used in the practice of the present invention. It is the front schematic of the burner head of the burner used for implementation of this invention. It is the schematic of the adhesive strength measuring method of a metal-type base material and a core material (synthetic resin foam) in an Example.
- the decorative building board produced by the present invention is obtained by subjecting the surface of the metal siding material 1 shown in FIG. 1 to flame treatment under specific conditions and then inkjet printing with actinic ray curable ink.
- the metal siding material 1 includes a metal base material 11, a core material 12, a back material 13, and an ink receiving layer 14.
- a metal plate generally used as a metal siding material can be used.
- the metal plate include a plated steel plate such as a molten Zn-55% Al alloy-plated steel plate, a steel plate such as a normal steel plate and a stainless steel plate, an aluminum plate, and a copper plate. These metal plates are subjected to concavo-convex processing such as tile tone, brick tone, and wood grain tone by performing embossing and drawing forming processing that are widely used in the technical field.
- the metal-based substrate used in the present invention may have a chemical conversion film, an undercoat film, or the like formed on the surface thereof as long as the effects of the invention are not impaired.
- the thickness of the metal base 11 is not particularly limited, but is usually 0.15 to 0.5 mm.
- the metal-type base material 11 of this invention forms an uneven
- the “concave / convex pattern with a height difference of 0.5 mm or more” means that the metal-based substrate 1 forms at least one unevenness with a height difference d of 0.5 mm or more, and the unevenness forms a pattern.
- irregularities with a height difference of less than 0.5 mm may exist, and these irregularities can be combined to form a pattern such as a tile or wood grain on the metal base material.
- the thickness of the ink receiving layer 14 should be taken into consideration, but as described below, the thickness of the ink receiving layer 14 is usually in the range of 3 to 30 ⁇ m, and thus the thickness of the ink receiving layer 14 is. Need not be considered.
- the metal siding material 1 is preferably provided with irregularities having an elevation difference d of 1.0 mm or more, and more preferably 1.5 mm or more.
- the upper limit of the height difference of a metal base material is not prescribed
- corrugation of a metal base material is 7 mm or less, and 5 mm or less is preferable. This is because a pattern having sufficient design properties as a metal siding material can be formed when the height difference of the unevenness of the metal base material is 7 mm at the maximum.
- corrugation of a metal-type base material exceeds 7 mm, a flame cannot be applied to the foreign material which exists in a recessed part, and it may be difficult to remove.
- the pattern can be formed even if the unevenness height difference d is 1.5 mm at the maximum, the maximum value of the height difference d may be 1.5 mm or less.
- Core material 12 is formed of a synthetic resin foam.
- the synthetic resin foam include polyurethane foam, polyisocyanurate foam, phenol resin foam, vinyl chloride resin foam, polyethylene foam, polystyrene foam, urea resin foam, and the like.
- the core material 12 can also utilize inorganic materials, such as rock wool, glass wool, and ceramic wool.
- Back material 13 is aluminum vapor-deposited paper, craft paper, asphalt felt, metal foil (foil of Al, Fe, Pb, Cu, etc.), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber It is also possible to use a laminate of one kind or two or more kinds of cloth, glass fiber nonwoven fabric, etc., or a sheet-like product that has been subjected to a waterproof treatment and a flame retardant treatment.
- the metal siding has a fitting portion for connecting to each other, and is usually created by bending both ends in the width direction of the metal base material so as to form a male-female structure.
- the ink receiving layer 14 used in the present invention may be a coating film formed by curing a resin composition.
- a resin of a high molecular compound generally used as a paint capable of forming a coating film on the substrate can be used.
- polymer compounds such as polyester resin, acrylic resin, polyvinylidene fluoride resin, polyurethane resin, epoxy resin, polyvinyl alcohol resin, phenol resin, and the like can be given.
- a polyester resin and an acrylic resin are preferable because of high weather resistance and excellent adhesion to ink.
- Such a porous ink receiving layer may have a problem in water resistance and weather resistance, and may not be suitable for use as a building material.
- a curing agent can be used in order to adjust its properties and physical properties.
- a melamine curing agent melamine resin curing agent
- examples thereof include methylated melamine (methylol melamine methyl ether), n-butylated melamine (methylol melamine butyl ether), and mixed etherified melamine of methyl and n-butyl.
- the ink receiving layer having a crosslinking density increased by using a curing agent as described above is particularly preferable because non-water-based ink does not penetrate and is excellent in water resistance and weather resistance.
- the ink receiving layer is impermeable to actinic ray curable ink can be confirmed by observing the cross section of the ink receiving layer and the ink layer with a microscope at a magnification of 100 to 200 times.
- the ink receiving layer is non-permeable, the interface between the ink receiving layer and the ink layer can be clearly identified.
- the ink receiving layer is permeable, the interface is unclear and difficult to identify.
- the molecular weight thereof is preferably 2,000 to 8,000 when measured by GPC. If the molecular weight is less than 2,000, the workability may be reduced and cracking of the coating film tends to occur. On the other hand, if the molecular weight is greater than 8,000, the weather resistance may decrease due to a decrease in the crosslinking density.
- the number average molecular weight is particularly preferably from 3,000 to 6,000 from the balance between processability and weather resistance.
- the ink receiving layer 14 of the present invention may contain organic or inorganic solid particles.
- the average particle diameter of the particles is 4 to 80 ⁇ m, preferably 10 to 60 ⁇ m.
- the inorganic particles include silica, barium sulfate, talc, calcium carbonate, mica, glass beads, and glass flakes.
- the organic particles include acrylic resin beads and polyacrylonitrile resin beads. These resin beads may be produced using a known method, or commercially available products may be used.
- acrylic resin beads examples include “Tough Tick AR650S (average particle size 18 ⁇ m)”, “Tough Tick AR650M (average particle size 30 ⁇ m)”, “Tough Tick AR650MX (average particle size 40 ⁇ m)”, “Tough Tick AR650MZ”. (Average particle size 60 ⁇ m) ”,“ Toughtic AR650ML (average particle size 80 ⁇ m) ”,“ Toughtic AR650L (average particle size 100 ⁇ m) ”and“ Toughtic AR650LL (average particle size 150 ⁇ m) ”.
- Examples of commercially available polyacrylonitrile beads include “Toughtic A-20 (average particle size: 24 ⁇ m)”, “Toughtic YK-30 (average particle size: 33 ⁇ m)”, “Toughtic YK-50 (average particle size) manufactured by Toyobo Co., Ltd. And “Toughtic YK-80 (average particle size 80 ⁇ m)”.
- the content of organic and inorganic particles is usually 2 to 40% by mass, preferably 10 to 30% by mass, based on the mass of the coating film.
- the average particle diameter of the solid particles and the color pigment is determined by a Coulter counter method.
- the ink receiving layer 14 may contain a color pigment.
- the average particle diameter of the colored pigment is usually 0.2 to 2.0 ⁇ m.
- coloring pigments include titanium oxide, iron oxide, yellow iron oxide, phthalocyanine blue, carbon black, and cobalt blue.
- it is usually added to the paint so as to be 40 to 60% by mass of the coating film mass.
- the thickness of the ink receiving layer 14 is not particularly limited, but is usually in the range of 3 to 30 ⁇ m.
- a coating film is too thin, there exists a possibility that durability and concealment property of a coating film may become inadequate.
- the coating film is too thick, the manufacturing cost increases, and there is a possibility that a crack is likely to occur during baking.
- the actinic ray curable ink of the present invention uses an ink generally used in the technical field, and includes a radical polymerization type ink and a cationic polymerization type ink, both of which can be used. .
- the actinic ray curable ink usually contains a monomer or oligomer, a photopolymerization initiator, a coloring material, a dispersant, a surfactant, and other additives.
- the material generally used in the said technical field is used.
- the cationic polymerization type ink is particularly preferable because it has a smaller volume shrinkage than the radical polymerization type ink and can provide high adhesion to an impermeable ink-receiving layer having an increased crosslinking density.
- the ink jet recording apparatus used is a line type ink jet recording apparatus M capable of four color ink jet printing of four color inks (yellow, cyan, magenta, black (black)).
- the ink used is an actinic ray curable ink.
- a line type ink jet recording apparatus M in FIG. 3 includes an ink jet recording head 6 (61 to 64), an ink supply tank 7 (71 to 74) connected to the recording head, and a print control system 8. , As well as a conveyor 4. Further, the line type ink jet recording apparatus M is provided with a burner 2 for performing a flame treatment and an actinic ray irradiator 9. The metal siding material 1 is conveyed in the direction of the broken line arrow in FIG.
- the printing surface (ink receiving surface) 1-1 of the metal siding material 1 is the surface opposite to the surface in contact with the transport surface 4-1 of the transport machine 4.
- a desired image can be formed on the ink receiving layer 14 by coloring with actinic ray curable ink discharged from the ink jet recording head.
- the printing surface 1-1 of the metal siding material 1 is flame-treated by a flame discharged from the burner 2 before ink jet printing.
- a specific embodiment of the flame treatment is shown in FIG.
- the burner 2 includes a flame outlet 21 and a burner head 22 through which a flame is discharged.
- the said flame mouth 21 can change the length L in the direction parallel to the conveyance direction (broken-line arrow) in FIG.
- L is 3 to 40 mm.
- L is 3 to 40 mm.
- the burner 2 is set to a position at a distance H from the printing surface 1-1 of the metal siding material 1.
- H means the shortest distance from the printing surface 1-1 of the burner 2. That is, H usually indicates the distance between the burner head 5 and the printing surface 1-1, but the structure in which the flame opening 21 protrudes from the burner head 22 has a distance between the flame opening 21 and the printing surface 1-1. When the distance is shorter than the distance from the printing surface 1-1, H indicates the distance between the flame opening 21 and the printing surface 1-1.
- the distance H is set to be in the range of 10 to 120 mm, preferably 25 to 100 mm, more preferably 30 to 90 mm, and most preferably 40 to 80 mm.
- the metal base material 11 of the metal siding material 1 undergoes a forming process such as an embossing process or a drawing process. For this reason, the metal base material 11 may be warped. If the distance H is less than 10 mm, the burner 2 and the metal siding material 1 may come into contact with each other due to warpage of the metal base material. Since the metal siding material 1 is used as a building board, the length of the metal base 11 may reach several meters (3 to 4 m). At this time, the warp of the metal base 11 is 10 to 20 mm. Can occur. Therefore, the distance H needs to be adjusted according to the length of the metal base 11, that is, the length of the metal siding material 1.
- the distance H exceeds 120 mm, it is necessary to irradiate a high-energy flame in order to achieve the effect of the flame treatment, which is inefficient and undesirable, and 12000 kJ / hour per 10 mm of the width of the flame outlet of the burner. Even with the output of the burner, there may be cases where sufficient foreign matter cannot be removed.
- the output of the burner is 250 kJ / hr to 12000 kJ / hr, preferably 400 kJ / hr to 7500 kJ / hr, more preferably 600 kJ / hr to 5000 kJ / hr, even more preferably 1200 kJ / hr per 10 mm width of the burner
- the output is ⁇ 5000 kJ / hour. If the burner flame outlet is less than 250 kJ / hour per 10 mm width of the burner, the flame is weak, so that the dirt (foreign matter) present on the surface of the metal siding material 1 is not sufficiently incinerated and the removal of the dirt becomes insufficient. .
- the burner flame outlet width exceeds 12000 kJ / hour per 10 mm
- the surface temperature of the metal base material 11 immediately exceeds 300 ° C., so that heat is generated at the interface between the core material 12 and the metal base material 11. Distortion occurs and peeling occurs between the core material 12 and the metal-based substrate 11.
- the heat storage property of the metal-type base material 11 is considered, 250 degrees C or less is preferable.
- the surface temperature of the metal-based substrate 11 is welded to a place where a part of the ink-receiving layer 14 of the metal siding material 1 is removed with a file or the like by welding the thermocouple tip of a thermocouple thermometer (K type). Measurement is performed at an arbitrary place on the printing surface of the material 1.
- FIG. 4 is a front view of the burner 2 of FIG. 2 or FIG.
- the width of the flame outlet 21 of the burner 2 is represented by W.
- This W is selected in consideration of the width of the metal siding material 1, but is usually 40 to 50 cm.
- a ribbon-shaped or round hole-shaped burner can be used.
- Burners having a burner head having such a structure are commercially available, for example, product name F-3000 from Flynn Burner (USA), product name FFP250 from Finecom I & T (Korea), and the like.
- per 10 mm width of the burner flame opening means that W ′ in FIG. 4 is 10 mm.
- the conveying speed of the metal siding material 1 by the conveying machine 4 is not particularly limited as long as the effect of the present invention is exhibited, but is normally 5 to 70 m / min with respect to the fixed burner 2. Preferably, it is 10 to 40 m / min, and more preferably 15 to 30 m / min. If the conveying speed is less than 5 m / min, the surface temperature of the metal-based substrate 1 may exceed 300 ° C. even if the output of the burner is reduced. In addition, if it exceeds 70 m / min, the flame of the burner 2 is affected by the air flow generated by the movement of the metal siding material 1, and the flame can be evenly applied to the printing surface 1-1 of the metal siding material 1. In some cases, dirt (foreign matter) cannot be sufficiently removed.
- LPG liquefied petroleum gas
- LNG liquefied natural gas
- acetylene gas propane gas, or butane, etc.
- Air auxiliary gas
- the flame-treated metal siding material 1 is ink-jet printed by an ink-jet coating machine 5.
- Four inks are used, and yellow, 62 to cyan, 63 to magenta, and 64 to black (black) ink are ejected from the inkjet recording head 61, respectively.
- Ink supply tanks (71 to 74) are connected to these ink jet recording heads, respectively.
- Commercially available actinic ray curable ink can be used as the ink.
- the ink droplets ejected from the ink jet recording heads of the respective colors fly in the vertical direction toward the printing surface 1-1.
- the initial velocity of the ink droplet is generally set to 3 m / sec to 9 m / sec, preferably 4 m / sec to 7 m / sec.
- the initial velocity of the ink droplet is the velocity of the ink droplet when ejected from the recording head.
- the ink droplets ejected from the ink jet recording head are calculated (predetermined distance / time) by a distance of 1 mm in the vertical direction from the ink ejection part and a time required to travel the distance of 1 mm.
- the initial velocity of the ink droplet is less than 3 m / sec, the velocity of the droplet is too slow, and the landing accuracy of the ink droplet may be significantly reduced. On the other hand, if it exceeds 9 m / sec, the landing accuracy is good, but there may be a problem that the image quality deteriorates due to the occurrence of ink satellites.
- the volume of one ink droplet ejected from the nozzle of the ink jet recording head onto the printing surface 1-1 is not particularly limited, but is generally set to less than 60 pl (picoliter), preferably 10 pl or more and less than 45 pl.
- the actinic ray irradiator 9 is installed at a predetermined position on the downstream side in the transport direction with respect to the ink jet coater 5.
- the “active ray” in the present invention includes electron beam, ultraviolet ray, ⁇ ray, ⁇ ray, X ray and the like.
- the actinic ray irradiator 9 includes a lamp for irradiating actinic rays installed toward the conveying surface 4-1 of the conveying device 4, and irradiates the actinic rays in the direction of the conveying surface 4-1.
- the ink droplets landed on the printing surface 1-1 are cured with actinic rays from the actinic ray irradiator 9.
- the transport speed of the transport device 4 and the ink jet are set so that the actinic rays are irradiated after the ink droplet has landed for 1.0 second or longer, preferably 2.0 seconds or longer, more preferably 2.2 seconds or longer.
- the distance from the active coater to the actinic ray irradiator 9 is adjusted.
- water in the air may inhibit the polymerization of the ink, the actinic ray is irradiated within 30 seconds after the ink has landed.
- the control unit 8 controls various processes including patterning by recording an image formed by the ink jet recording apparatus M and temperature adjustment of the ink jet recording head.
- the control unit 8 includes a circuit board on which electronic components are mounted, electrical wiring, and the like. At least a part of the configuration included in the control unit 8 is installed on the upper part of the ink jet recording head as shown in FIG.
- the line type ink jet recording apparatus M includes a predetermined interface (not shown) such as a network interface.
- the ink jet recording apparatus M is communicably connected to an external apparatus such as a personal computer via an interface.
- the external device inputs an image recording command to the printing surface 1-1, data indicating the image to be recorded, and the like to the inkjet recording device M.
- a predetermined process is executed, the above ink is ejected from the ink jet recording head, and a desired image is formed on the printing surface 1-1.
- a manufacturing method is executed.
- a coating type chromate (NRC300NS: manufactured by Nippon Paint Co., Ltd., 50 mg / m 2 as Cr) and a commercially available epoxy resin primer coating (700P manufactured by Nippon Fine Coatings Co., Ltd.) as a primer layer have a dry film thickness of 5 ⁇ m. It was painted with a roll coater. And it baked so that it might become the highest reached
- the composition of the coating material which is a resin composition for forming the ink receiving layer, is as follows.
- a polymer polyester resin manufactured by DIC Corporation
- a melamine resin which is a cross-linking agent
- a methylated melamine resin having 90 mol% of methoxy groups (Cymel 303 manufactured by Mitsui Cytec) was used.
- the blending ratio of the polyester resin and the melamine resin is 70/30.
- titanium oxide having an average particle diameter of 0.28 ⁇ m (JR-603 manufactured by Teika) is 49% by mass and mica having an average particle diameter of 10 ⁇ m (Yamaguchi Mica Co., Ltd.).
- SJ-010) Hydrophobic silica with 13% by mass and an average particle size of 5.5 ⁇ m (Cycilia 456; Fuji Silysia Ltd.) 6% by mass, hydrophobic silica with an average particle size of 12 ⁇ m (Silysia 476 made by Fuji Silysia Chemical Co., Ltd.) 2% by weight was added.
- As the catalyst 1% by mass of dodecylbenzenesulfonic acid was added to the resin solid content.
- dimethylaminoethanol as an amine was added in an amount of 1.25 times as an amine equivalent with respect to an acid equivalent of dodecylbenzenesulfonic acid. After coating with a roll coater so that the dry film thickness of the paint was 18 ⁇ m, it was baked to a maximum plate temperature of 225 ° C.
- the average particle size of the mica, hydrophobic silica and titanium oxide was determined by a Coulter counter method. Specifically, it measured as follows. As a measuring device, a Coulter counter (manufactured by Coulter Electronics, USA) TA-II type was used. About 0.5 g of the sample was placed in a 200 ml beaker, about 150 ml of pure water was added, and the mixture was dispersed for 60 to 90 seconds with ultrasonic waves (ULTRASONIC CLEANER B-220).
- the detailed foaming conditions of the polyisocyanurate raw material are as follows. Line speed 40m / min Flow rate 6kg / min Liquid temperature 30 °C Preheating temperature of metal base material having ink receiving layer 35 ° C Oven cure temperature 50 °C Foaming machine Low pressure agitator mixing foaming machine
- Burner for flame treatment As a burner for flame treatment, FFP200 (Finecom I & T (Korea) Co., Ltd.) was used. LP gas was used as the combustion gas, and LP gas was reduced to 0.1 mm with respect to a width of 10 mm of the burner. After mixing 04 to 2.00 L / min and clean dry air 1 to 50 L / min with a gas mixer, the flame was burned with a burner, and the length of the burner in the direction parallel to the conveying direction at the flame outlet Thicknesses (L in FIG. 1) were 5 mm, 20 mm, 30 mm, and 40 mm. The conveying speed during the flame treatment was 5 to 70 m / min.
- (I) Radical polymerization type ultraviolet curable black ink A radical polymerization type ultraviolet curable black ink was prepared by mixing the following components. The specific composition is as follows.
- Pigment dispersion 1 (Pigment content: 10% by weight) 10 parts by weight Reactive oligomer 2) 25 parts by weight Reactive oligomer 3) 57 parts by weight Photopolymerization initiator 4) 5 parts by weight Photopolymerization initiator 5) 3 parts by weight
- Pigment NIPex 35, manufactured by Carbon Degussa Japan Co., Ltd., dispersion medium: SR9003, PO-modified neopentyl glycol diacrylate manufactured by Sartomer Japan Co., Ltd. 2) CN985B88, bifunctional aliphatic urethane acrylate 88% by mass, 1, Mixture of 12% by mass of 6-hexanediol diacrylate 3) 1,6-hexanediol diacrylate 4) Irgacure 184, hydroxyketones 5) Irgacure 819, acylphos Fin oxides Ciba Japan Co., Ltd.
- the volume of the ink droplet was 42 pl, and dot printing was performed with black ink using an inkjet printing machine (Tritech Co., Ltd., patterning jet).
- the printing conditions at this time are as follows.
- the distance between the dots was set to 500 ⁇ m so that the dots did not overlap each other, and dot printing with black ink was performed on the entire metal siding material.
- the dot diameter was measured using a scanning confocal laser microscope LEXT OLS3000 manufactured by Olympus Corporation. Enlarged to a range where only one dot can be seen (200 times), the dot diameter of eight dots was measured, and the average value was shown.
- the average value of the major axis and the minor axis was taken as the dot diameter.
- the dot diameter of the metal siding before flame treatment varies depending on the degree of dirt adhesion, and the dot diameter of the area where there is much dirt adhesion is about 130 ⁇ m, whereas the area where there is almost no dirt adhesion is about 180 ⁇ m. There was a difference of 50 ⁇ m.
- ultraviolet rays were used as the actinic rays.
- the ink was subjected to ultraviolet curing under the following conditions after inkjet printing. The ultraviolet irradiation was performed 5 seconds after the ink droplet landed.
- Lamp type High-pressure mercury lamp (H bulb manufactured by Fusion UV Systems Japan Co., Ltd.)
- Lamp output 200 W / cm
- Integrated light quantity 600 mJ / cm 2 (measured using an UV light quantity meter UV-351-25 manufactured by Oak Manufacturing)
- the above siding material was flame-treated using the above burner and printed under the above printing conditions.
- the dot diameter of the black ink of this sample and the adhesive strength between the metal-based substrate and the core material were measured. The results of the test are shown below.
- the burner output indicates the output for a 10 mm wide flame opening. For this reason, the energy of the flame radiated from the burner is the same even if the lengths in the traveling direction of the flame mouth are different. For example, in Examples 7 and 8, the burner output is the same, and the length of the flame opening is different, but the energy received by the metal base material of the metal siding material by the flame emitted from the burner is the same.
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Abstract
Description
例えば、特許文献1及び2では、金属系基材、ポリエステルを含むインキ層及びインキ層を有する塗装鋼板が開示されている。これらの塗装鋼板を製造する際には、金属基材上に形成されたインキ受理層の表面に、溶剤系インキをインクジェット印刷することでインキ層を形成する。このとき、溶剤系インキに含まれる有機溶媒がインキ受理層表面の一部を溶解させて粗面化するため、溶剤系インキは、インキ受理層に対して濡れ広がり、かつ密着することができる。
具体的には、本発明は、高低差が0.5mm以上の凹凸模様を形成する金属系基材、芯材および裏面材を含み、該基材上には樹脂組成物で形成されるインキ受理層が配置された金属サイディング材を、バーナーの幅10mmあたり250kJ/時~12000kJ/時の出力で炎を照射して、該基材の表面温度が300℃を超えないように火炎処理した後、活性光線硬化型インキでインクジェット印刷することを含む、化粧建築板の製造方法である。
ここで、図2で示されるとおり、金属サイディング材1は、金属系基材11、芯材12、裏面材13及びインキ受理層14を含む。
なお、本発明で使用する金属系基材は、発明の効果を阻害しない範囲で、その表面に化成処理皮膜や下塗り塗膜などが形成されていてもよい。
また、金属系基材11の厚さは特に限定されないが、通常、0.15~0.5mmである。
なお、高低差dが0.5mm未満の凹凸でのみ模様を形成しても、意匠性の高い模様を形成することが難しい。また、高低差dに関し、インキ受理層14の厚さも考慮されるべきであるが、下記の通り、インキ受理層14の厚みは通常3~30μmの範囲内であるため、インキ受理層14の厚みは考慮しなくてもよい。
また、より意匠性の高い模様を形成するため、金属サイディング材1には高低差dが1.0mm以上の凹凸が形成されることが好ましく、1.5mm以上であることがさらに好ましい。
一方、凹凸の高低差dが最大1.5mmであっても模様を形成することは可能であるので、高低差dの最大値は1.5mm以下であってもよい。
なお、従来の水性インキのインキ受理層として使用されてきた多孔質なインキ受理層を形成するような塗料は使用しないことが好ましい。このような多孔質なインキ受理層は耐水性、耐候性に問題がある場合があり、建築材の使用に適さない場合がある。
上記無機粒子としては、シリカ、硫酸バリウム、タルク、炭酸カルシウム、マイカ、ガラスビーズ、ガラスフレークが挙げられる。また、有機粒子として、アクリル樹脂ビーズ、ポリアクリロ二トリル樹脂ビーズが挙げられる。これらの樹脂ビーズは、公知の方法を用いて製造したものでもよいし、市販品を利用してもよい。市販のアクリル樹脂ビーズの例には、東洋紡株式会社の「タフチック AR650S(平均粒径18μm)」、「タフチック AR650M(平均粒径30μm)」、「タフチック AR650MX(平均粒径40μm)」、「タフチック AR650MZ(平均粒径60μm)」、「タフチック AR650ML(平均粒径80μm)」、「タフチック AR650L(平均粒径100μm)」および「タフチック AR650LL(平均粒径150μm)」が含まれる。また、市販のポリアクリロニトリルビーズの例には、東洋紡株式会社の「タフチック A-20(平均粒径24μm)」、「タフチック YK-30(平均粒径33μm)」、「タフチック YK-50(平均粒径50μm)」および「タフチック YK-80(平均粒径80μm)」が含まれる。
上記固形粒子や着色顔料の平均粒径は、コールターカウンター法により求められる。
活性光線硬化型インキは、通常、モノマーもしくはオリゴマー、光重合開始剤、色材、分散剤、界面活性剤、その他の添加剤を含む。本発明では、当該技術分野で一般的に使用されている材料を用いる。カチオン重合型インキはラジカル重合型インキと比較して体積収縮率が少なく、架橋密度を高めた非浸透性のインキ受理層に対しても高い密着性が得られることから特に好ましい。
当該火炎処理の具体的な態様が図1に示されている。バーナー2は、火炎が吐出される炎口21、バーナーヘッド22を備える。なお、前記炎口21は、図1における搬送方向(破線矢印)に平行な向きにその長さLを変更することが可能である。通常、Lは3~40mmである。なお、金属サイディング材1の搬送速度が大きくなると金属サイディング材1の移動に伴う気流が発生する。Lの値が小さいほどバーナーの火炎3がその気流の影響を受けやすくなるため、火炎3が均一に照射できない場合がある。そのため、最適条件を考慮しながら、Lと搬送速度を調整することが好ましい。
通常、距離Hは10~120mm、好ましくは、25~100mm、さらに好ましくは30~90mm、最も好ましくは40~80mmの範囲になるように設定する。金属サイディング材1の金属系基材11はエンボス加工や絞り成形加工などの成形加工を経る。このため、金属系基材11に反りが生じてしまう場合がある。前記距離Hが10mm未満であると、金属系基材の反りのために、バーナー2と金属サイディング材1が接触してしまう場合がある。なお、金属サイディング材1は建築板として使用するため、金属系基材11の長さが数メートル(3~4m)に及ぶ場合があり、このときに金属系基材11では反りが10~20mm生じ得る。そのため、距離Hは、金属系基材11の長さ、すなわち、金属サイディング材1の長さに応じて距離Hを調整する必要がある。
また、距離Hが120mmを超えると、火炎処理の効果を奏するために高いエネルギーの火炎を照射する必要があり、非効率的であり好ましくなく、また、バーナーの炎口の幅10mmあたり12000kJ/時のバーナーの出力でも、十分な異物の除去ができない場合がある。
このような構造のバーナーヘッドを有するバーナーは市販されており、例えば、Flynn Burner社(米国)の製品名F-3000、Finecom I&T社(韓国)の製品名FFP250などが存在する。
また、前記の「バーナーの炎口の幅10mmあたり」の記載は、図4のW´が10mmであることを意味する。
インキ滴の初速が3m/sec未満では液滴の速度が遅すぎるため、インキ滴の着弾精度が大幅に低下する場合がある。また、9m/secを超える場合は、着弾精度は良いものの、インキのサテライトが発生して画質が低下するという問題が生じる場合がある。
活性光線照射機9は、搬送機4の搬送面4-1に向けて設置された活性光線を照射するランプを備え、搬送面4-1の方向に活性光線を照射する。
印刷面1-1に着弾したインク滴を活性光線照射機9からの活性光線で硬化させる。通常、インク滴が着弾してから1.0秒以上、好ましくは2.0秒以上、さらに好ましくは2.2秒以上経過した後に活性光線を照射するように、搬送機4の搬送速度及びインクジェット式塗装機から活性光線照射機9までの距離を調整する。また、空気中の水分がインキの重合を阻害することがあるため、インキが着弾後30秒以内に活性光線を照射する。
1.金属サイディング材の製造
(1-1)金属系基材の製造
板厚0.27mm、A4サイズの片面当りめっき付着量90g/m2の溶融Zn-55%Al合金めっき鋼板を基材として使用した。このめっき鋼板をアルカリ脱脂した。その後、塗布型クロメート(NRC300NS:日本ペイント株式会社製 Crとして50mg/m2の付着量)、プライマー層として市販のエポキシ樹脂系プライマー塗料(日本ファインコーティングス株式会社製700P)を乾燥膜厚が5μmとなるようにロールコーターで塗装した。そして、最高到達板温215℃となるように焼き付けた。
インキ受理層を形成するための樹脂組成物である塗料の組成は以下の通りである。樹脂としては数平均分子量5,000、ガラス転移温度30℃、水酸基価28mgKOH/gの高分子ポリエステル樹脂(DIC株式会社製)を用いた。架橋剤であるメラミン樹脂としては、メトキシ基90モル%のメチル化メラミン樹脂(三井サイテック製サイメル303)を用いた。ポリエステル樹脂とメラミン樹脂の配合比は70/30であり、着色顔料としては平均粒径0.28μmの酸化チタン(テイカ製 JR-603) 49質量%、平均粒径10μmのマイカ(株式会社ヤマグチマイカ製 SJ-010) 13質量%、平均粒径5.5μmの疎水性シリカ(サイシリア456;富士シリシア株式会社) 6質量%、平均粒径12μmの疎水性シリカ(富士シリシア化学株式会社製 サイリシア476) 2質量%を添加した。触媒はドデシルベンゼンスルフォン酸を、樹脂固形分に対して1質量%加えた。またアミンとしてジメチルアミノエタノールをドデシルベンゼンスルフォン酸の酸当量に対してアミン当量として1.25倍の量を加えた。塗料の乾燥膜厚が18μmとなるようにロールコーターで塗装した後、最高到達板温225℃となるように焼き付けた。
具体的には以下のように測定した。測定装置として、コールターカウンター(米国コールターエレクトロニクス社製)TA-II型を用いた。試料約0.5gを200mlのビーカーに取り、純水約150mlを加え、超音波(ULTRASONIC CLEANER B-220)で60~90秒分散させた。付属の電解液(ISOTON II:0.7%高純度NaCl水溶液)150mlに上記分散液をスポイトで数滴加え入れ、上記装置を用いて粒度分布を求めた。
但し、上記JR-603(酸化チタン)及びサイシリア456(疎水性シリカ)は30μmのアパッチャーチューブを使用した。また、SJ-010(マイカ)は50μmのアパッチャーチューブを使用した。平均粒径は累積粒度分布図の50%径を読み取り求めた。
上記のインキ受理層を有する金属系基材にエンボス加工による表面加工を行った。
アンコイラーに巻かれたインキ受理層を有する金属系基材を連続的に送り出し、ロール式エンボス成形機により、ブリック柄で高さ0.5~1.5mmのエンボス形状に金属系基材を連続して成形し、御影石擬似柄の外観を施した金属系基材を形成した。
形成された金属系基材の裏面に、芯材となるポリイソシアヌレート原料として、ソフランR-HIPとトーヨーソフランR746-19D(いずれも株式会社ソフランウィズ製)とを、発泡機によって質量比10対7で混合しながら混合押出機により吐出した。また、発泡するポリイソシアヌレート原料層上にアルミクラフト紙(裏面材)を送り出した。そして、エンボス加工された金属系基材とアルミクラフト紙との間にポリイソシアヌレート原料層をサンドイッチした状態で加熱、加圧し、発泡成形することにより、インキ受理層を有する金属系基材、芯材およびアルミクラフト紙をこの順で有する金属サイディング材を製造した。なお、芯材の厚みは、17mmとした。芯材の厚みは、上記加熱、加圧時に金属サイディング原板をその積層方向に挟持するダブルコンベア間の距離によって調整した。
ラインスピード 40m/min
流量 6kg/min
液温 30℃
インキ受理層を有する金属系基材のプレヒート温度 35℃
オーブンキュアー温度 50℃
発泡機 低圧型アジテータミキシング発泡機
火炎処理を行うためのバーナーとして、FFP200(Finecom I&T(韓国)社製を使用した。燃焼ガスとしてLPガスを用い、バーナーの炎口の幅10mmに対し、LPガス0.04~2.00L/分、クリーンドライエアー 1~50L/分をガスミキサーで混合した後に、バーナーで燃焼させて火炎処理を行った。また、バーナーの炎口における搬送方向に平行な向きの長さ(図1におけるL)が5mm、20mm、30mm、40mmのものを用いた。
なお、火炎処理時の搬送速度は5~70m/分で行った。
(3-1)
活性光線硬化型インキとして、ラジカル重合型紫外線硬化性黒色インキ及びカチオン重合型紫外線硬化性黒色インキを用いた。各インキの具体的な組成は以下の通りである。
ラジカル重合型紫外線硬化性黒色インキを、以下の成分を混合することにより調製した。具体的なの組成は以下の通りである。
反応性オリゴマー2) 25質量部
反応性オリゴマー3) 57質量部
光重合開始剤4) 5質量部
光重合開始剤5) 3質量部
2)CN985B88、2官能脂肪族ウレタンアクリレート88質量%、1,6-ヘキサンジオールジアクリレート12質量%の混合物 サートマージャパン(株)製
3)1,6-ヘキサンジオールジアクリレート
4)イルガキュア184、ヒドロキシケトン類 チバ・ジャパン(株)製
5)イルガキュア819、アシルフォスフィンオキサイド類 チバ・ジャパン(株)製
高分子分散剤(味の素ファインテクノ社製 PB821) 9質量部とオキセタン化合物(東亜合成社製 OXT211) 71質量部にブラック:Pigment Black 7を20質量部加えて、直径1mmのジルコニアビーズ200gと共にガラス瓶に入れて密栓し、ペイントシェーカーにて4時間分散処理した後、ジルコニアビーズを除去して、ブラックの顔料分散体を調整した。
上記分散体14質量部に、以下の光重合性化合物、塩基性化合物、界面活性剤、相溶化剤、光酸発生剤を混合して、カチオン重合型紫外線硬化性インクジェットインキを作製した。
(a)ノズル径 :35μm
(b)印加電圧 :11.5V
(c)パルス幅 :10.0μs
(d)駆動周波数 :3,483Hz
(e)解像度 :360dpi
(f)インキ液滴の体積 :42pl
(g)ヘッド加熱温度 :45℃
(h)インキ塗布量 :8.4g/m2
(i)ヘッドと記録面の距離 :5.0mm
(j)インキ滴の初速 :5.9m/sec
(a)ノズル径 :35μm
(b)印加電圧 :13.2V
(c)パルス幅 :10.0μs
(d)駆動周波数 :3,483Hz
(e)解像度 :360dpi
(f)インキ液滴の体積 :42pl
(g)ヘッド加熱温度 :45℃
(h)インキ塗布量 :8.4g/m2
(i)ヘッドと記録面の距離 :5.0mm
(j)インキ滴の初速 :6.1m/sec
(1)ランプの種類:高圧水銀ランプ(フュージョンUVシステムズ・ジャパン株式会社製 Hバルブ)
(2)ランプの出力:200W/cm
(3)積算光量:600mJ/cm2(オーク製作所製紫外線光量計UV-351-25を使用して測定)
熱電対温度計(Kタイプ)(日置電機株式会社・温度ロガーLR5021)とセンサー(安立計器株式会社・テープ型多目的温度センサー)を金属サイディング材の金属系基材表面に取り付け測定した。
金属系基材と芯材の接着強度測定方法を図5に示すように行った。まず、裏面材を除去した50mm×50mmの金属サイディング材の表裏をホットメルト接着剤101(商品名:ホットメルトスティック多用途白色 HSW-01K、ヘンケルジャパン株式会社製)で木片102(9mm×65mm×70mm)を貼り付けた。次に、引張用治具103を用いて、上下の矢印方向に引っ張り速度5mm/分で引っ張り、最大剥離強度(kg/cm2)を測定した。サイディングオス側嵌合部、中央部、メス側嵌合部の3箇所の最大剥離強度を平均して金属系基材と合成樹脂発泡体の接着強度とした。接着強度が0.3g/cm2以上であれば合格とした。
2:バーナー、21:炎口、22:バーナーヘッド、3:火炎、d:金属系基材の凹凸の高低差、H:バーナー2と印刷面1-1との間の最短の距離
4:搬送機、1-1:搬送面、5:インクジェット式塗装機、61:インクジェット記録ヘッド(イエロー)、62:インクジェット記録ヘッド(シアン)、63:インクジェット記録ヘッド(マゼンダ)、64:インクジェット記録ヘッド(ブラック)、71:インキ供給タンク(イエロー)、72:インク供給タンク(シアン)、73:インク供給タンク(マゼンダ)、74:インク供給タンク(ブラック)、8:制御部、9:活性光線照射機、1-1:印刷面、M:ライン式インクジェット記録装置
101:ホットメルト接着剤、102:木片、103:引張用治具
Claims (6)
- 高低差が0.5mm以上の凹凸模様を形成する金属系基材、芯材および裏面材を含み、該基材上には樹脂組成物で形成されるインキ受理層が配置された金属サイディング材を、バーナーの炎口の幅10mmあたり250kJ/時~12000kJ/時の出力で火炎を照射して、該基材の表面温度が300℃を超えないように火炎処理した後、活性光線硬化型インキでインクジェット印刷することを含む、化粧建築板の製造方法。
- 前記インキ受理層は活性光線硬化型インキに対して非浸透性である、請求項1に記載の化粧建築板の製造方法。
- 前記活性光線硬化型インキが活性光線硬化型カチオン重合性インキである、請求項1又は2に記載の化粧建築板の製造方法
- 前記凹凸模様の高低差が7.0mm以下である、請求項1~3のいずれかに記載の化粧建築板の製造方法。
- 前記金属サイディング材の搬送速度が5.0m/分~70m/分である、請求項1~4のいずれかに記載の化粧建築板の製造方法。
- 前記芯材はポリイソシアヌレートフォームである、請求項1~5のいずれかに記載の化粧建築板の製造方法。
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CN201580080470.6A CN107708880B (zh) | 2015-05-28 | 2015-12-28 | 装饰建筑板的制造方法 |
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US11466895B2 (en) * | 2017-09-25 | 2022-10-11 | Noritz Corporation | Exterior case for hot water unit |
AU2018232976B2 (en) * | 2017-09-25 | 2023-11-02 | Noritz Corporation | Method of producing exterior case for hot water unit, exterior case for hot water unit and hot water unit |
JP7035562B2 (ja) * | 2018-01-26 | 2022-03-15 | 日本製鉄株式会社 | フレーム処理装置、塗装金属板の製造装置、および塗装金属板の製造方法 |
US11001096B2 (en) * | 2018-08-22 | 2021-05-11 | Ideastream Consumer Products, Llc | Method of applying artwork to a 3D plate |
CN111729824A (zh) * | 2020-07-04 | 2020-10-02 | 上海灿达建材科技有限公司 | 一种水性印花烤瓷铝装饰板的制备工艺 |
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