JP6864710B2 - Manufacturing method of coating film - Google Patents

Description

The present invention relates to a method for producing a coating film.

Conventionally, as described in Patent Document 1, a decorative film for imparting a unique design by being attached to an exterior part of an automobile has been known. In recent years, it has become popular to decorate separated areas such as bonnets, roofs, doors, rear gates, and side mirrors with colors different from other areas. Further, as such a method of decoration, a method of repainting the body and a method of attaching a decoration film are known.

Japanese Unexamined Patent Publication No. 2014-019064

However, the decorative film of Patent Document 1 cannot express a texture similar to that of an automobile body (exterior), and the difference in texture between the decorative film and the body impairs the aesthetic appearance. There's a problem.

An object of the present invention is to provide a method for producing a coating film which has almost the same texture as an adherend (particularly, a painted surface) and can suppress deterioration of an aesthetic appearance when attached to the adherend. There is.

Such an object is achieved by the following invention.

(1) A base layer forming step of forming a base layer containing cyclohexanone on one surface of a film-like base material containing a polyvinyl chloride resin.
A method for producing a coating film, which comprises a colored layer forming step of forming a colored layer composed of a melamine resin paint, an epoxy-modified melamine resin paint or a fluororesin paint by painting on the base layer.

(2) The method for producing a coating film according to (1) above, which comprises a clear layer forming step of forming a clear layer on the colored layer after the colored layer forming step.

According to the method for producing a coating film of the present invention, since a colored layer is formed by painting, it has almost the same texture as an adherend (particularly, a painted surface) and has an aesthetic appearance when attached to the adherend. A coating film capable of suppressing the decrease can be easily produced.

It is sectional drawing which shows the coating film which concerns on a preferable embodiment of this invention. It is a perspective view for demonstrating use of the coating film shown in FIG. It is a perspective view for demonstrating use of the coating film shown in FIG. It is a flowchart which shows the manufacturing process of the coating film shown in FIG. It is sectional drawing for demonstrating the manufacturing method of the coating film shown in FIG. It is sectional drawing for demonstrating the manufacturing method of the coating film shown in FIG. It is sectional drawing for demonstrating the manufacturing method of the coating film shown in FIG. It is sectional drawing for demonstrating the manufacturing method of the coating film shown in FIG.

Hereinafter, the method for producing a coating film of the present invention and the coating film will be described in detail based on the preferred embodiments shown in the accompanying drawings.

FIG. 1 is a cross-sectional view showing a coating film according to a preferred embodiment of the present invention. 2 and 3 are perspective views for explaining the use of the coating film shown in FIG. 1, respectively. FIG. 4 is a flowchart showing a manufacturing process of the coating film shown in FIG. 5 to 8 are cross-sectional views for explaining the manufacturing method of the coating film shown in FIG. 1, respectively. In the following, for convenience of explanation, the upper side in each drawing will be referred to as “upper” and the lower side will be referred to as “lower”.

≪Painting film≫
The coating film 1 shown in FIG. 1 has a structure in which a release sheet 2, an adhesive layer 3, a base material 4, a base layer 5, a colored layer 6 which is a baking coating layer, and a clear layer 7 are laminated in this order. .. That is, in the coating film 1, the base layer 5, the coloring layer 6 and the clear layer 7 are laminated on the upper surface side of the base material 4, and the pressure-sensitive adhesive layer 3 and the release sheet 2 are laminated on the lower surface side of the base material 4. Such a coating film 1 is particularly used by being attached to an automobile body (hereinafter, also simply referred to as an “adhesive body”), and as shown in FIG. 2, a decoration for imparting design to the automobile. It can be used as a film for repairing, or as a repair film for covering scratches on an automobile as shown in FIG. However, the uses and functions of the coating film 1 are not limited to those described above.

-Release sheet-
The release sheet 2 is a sheet used for preventing the evaporation of water from the pressure-sensitive adhesive layer 3 and the adhesion of dust, dust, etc. to the pressure-sensitive adhesive layer 3 and maintaining the adhesiveness of the pressure-sensitive adhesive layer 3. Therefore, the release sheet 2 is peeled off when the coating film 1 is attached to the adherend (immediately before).

The release sheet 2 is not particularly limited, and is, for example, polyethylene terephthalate, high-pressure low-density polyethylene, high-density polyethylene, linear low-density polyethylene, ethylene-vinyl acetate copolymer resin, unstretched polypropylene, stretched polypropylene, and stretched nylon. Silicone-based on the surface (one side) of a base material made of plastic film, high-quality paper, art paper, coated paper, paper material such as glassin paper, non-woven fabric, etc., which is composed of at least one of these as the main material. A release layer composed of a release agent, a fluorine-based release agent, a modified silicone-based release agent, or the like can be used.

-Adhesive layer-
The pressure-sensitive adhesive layer 3 is a layer for attaching the coating film 1 to the adherend. The pressure-sensitive adhesive (tacky composition) constituting the pressure-sensitive adhesive layer 3 is not particularly limited, and may be any of a rubber-based pressure-sensitive adhesive, an acrylic-based pressure-sensitive adhesive, a silicone-based pressure-sensitive adhesive, and the like. Adhesives are particularly preferred. By using an acrylic pressure-sensitive adhesive, a pressure-sensitive adhesive layer 3 having excellent weather resistance can be obtained.

The thickness (dry film thickness) of the pressure-sensitive adhesive layer 3 is not particularly limited, but is preferably about 1 to 500 μm, more preferably about 15 to 50 μm, for example.

− Base material 4-
The base material 4 is a sheet for supporting the base layer 5, the colored layer 6, and the clear layer 7. The constituent material of such a base material 4 is not particularly limited, and for example, a resin material such as a polyethylene resin, a polypropylene resin, a polyvinyl chloride resin, a polyurethane resin, a polyester resin, or a polyacrylic resin. Can be mentioned. Among these, a polyvinyl chloride-based resin is particularly preferable as the constituent material of the base material 4 from the viewpoint of excellent tensile strength and curved surface followability. In particular, the body of an automobile is composed of a complicated curved surface. Therefore, by constructing the base material 4 with a polyvinyl chloride-based resin having excellent tensile strength and curved surface followability, it becomes easier to adhere to the adherend.

The thickness of the base material 4 is not particularly limited, but is preferably about 10 to 100 μm, more preferably about 30 to 70 μm, for example. As a result, the thickness of the base material 4 can be reduced while maintaining the mechanical strength of the base material 4. Therefore, the curved surface followability of the coating film 1 is improved, and the coating film 1 can be easily attached by the adherend.

-Underground layer-
The base layer 5 has a function of improving the adhesion between the base material 4 and the colored layer 6. The constituent material of such an underlayer 5 is not particularly limited, and for example, acetone, isobutyl alcohol, isopropyl alcohol, isopentyl alcohol, ethyl ether, ethylene glycol monoethyl ether, ethylene glycol monoethyl ether acetate, and ethylene glycol monomethyl. Ether, ortho-dichlorobenzene, xylene, cresol, chlorbenzene, isobutyl acetate, isopropyl acetate, isopentyl acetate, ethyl acetate, normal-butyl acetate, normal-propyl acetate, normal-pentyl acetate, methyl acetate, cyclohexanol, cyclohexanol ( Also known as anon), 1,4-dioxane, dichloromethane, N, N-dimethylformamide, styrene, tetrachloroethylene, tetrahydrofuran, 1,1,1-trichloroethane, toluene, normal hexane, 1-butanol, 2-butanol, methanol , Methylisobutylketone, Methylethylketone, Methylcyclohexanol, Methylcyclohexanol and the like. Among these, cyclohexanone and N, N-dimethylformamide (DMF) are particularly preferable, and cyclohexanone is further preferable. As a result, the adhesion between the base material 4 and the colored layer 6 is further improved.

The base layer 5 disappears due to volatilization or the like in the baking step during the manufacturing process, but a part of the base layer 5 may remain. In FIG. 1, for convenience of explanation, the case where it remains is described.

-Colored layer-
The colored layer 6 is a layer for imparting decorativeness to the coating film 1. Such a colored layer 6 is a baking coating layer formed by baking coating, as will be described in the manufacturing method described later. By forming the colored layer 6 by baking coating in this way, the colored layer 6 is excellent in tensile strength and curved surface followability, and further has a high aesthetic appearance and texture.

In particular, baking finish is generally used for body painting of automobiles. Therefore, by forming the colored layer 6 by baking coating, the colored layer 6 can be formed by substantially the same method as the body coating of an automobile. Therefore, the texture of the colored layer 6 can be made to be substantially the same as the texture of the body coating, and it is excellent in harmony with the body when it is attached to the body of an automobile, and a higher aesthetic feeling can be exhibited. Further, for example, it is possible to easily and at a high level express a metallic feeling that cannot be expressed by conventional printing inks.

Further, since the colored layer 6 is formed by substantially the same method as the body coating of an automobile, a paint having substantially the same composition as the paint used for the body coating can be used as the material of the colored layer 6. Therefore, various body colors can be reproduced with higher accuracy. Therefore, for example, when a coating film 1 of the same color is attached to a part of a certain body, the coating film 1 becomes familiar with the surrounding body color and is hardly noticeable. That is, it is hardly known that the coating film 1 is attached. Therefore, according to such a coating film 1, for example, by pasting a coating film 1 of the same color as the body on the scratches to cover the scratches, the scratches can be repaired more inexpensively, easily, and with high accuracy. It becomes possible to do. Here, with the conventional decorative film, it is practically impossible to reproduce the same texture and the same color as the body due to the manufacturing method, and automobile users and repair shops implement such a repair method. It was difficult to do. From this, the coating film 1 can expand the options of the repair method, and in this respect, it has an extremely great merit over the prior art.

The constituent material of such a colored layer 6 is not particularly limited and varies depending on the adherend, but for example, various paints used for painting an automobile can be used. Such paints are not particularly limited, and examples thereof include melamine resin paints, epoxy-modified melamine resin paints, acrylic resin paints, fluororesin paints, and the like. All of the above-mentioned paints are general paints used for baking finish, and by using such paints, the formation of the colored layer 6 becomes easy. In addition, in order to exhibit a predetermined color and function, these paints include pigments (color pigments, metal powder pigments, mica, extender pigments, matte pigments, etc.), solvents, auxiliary agents (plasticizers, desiccants, leveling agents, etc.). , UV absorber, anti-coloring agent, anti-precipitation agent, etc.) are mixed.

The thickness of the colored layer 6 is not particularly limited, but is preferably about 50 to 150 μm, more preferably about 60 to 90 μm, for example. With such a thickness, the function as the colored layer 6 can be sufficiently exhibited, and the colored layer 6 can be sufficiently thinned.

-Clear layer-
The clear layer 7 is a layer for protecting the colored layer 6. The constituent material of such a clear layer 7 is not particularly limited, and for example, a melamine-based resin, an acrylic-based resin, a urethane-based resin, a fluorine-based resin, or the like can be used.

The thickness of the clear layer 7 is not particularly limited, but is preferably about 10 to 100 μm, more preferably about 40 to 60 μm, for example. With such a thickness, the function as the clear layer 7 can be sufficiently exhibited, and the clear layer 7 can be made sufficiently thin.

≪Manufacturing method of coating film≫
Next, the method for producing the coating film 1 described above will be described. As shown in FIG. 4, the method for producing the coating film 1 includes a base layer forming step of forming the base layer 5 on one surface of the film-like base material 4, and a colored layer 6 by painting on the base layer 5. It has a colored layer forming step of forming, a clear layer forming step of forming a clear layer 7 on the colored layer 6, and a baking step of baking the colored layer 6 and the clear layer 7.

-Underground layer forming process-
First, as shown in FIG. 5, a base material 4 cut to a predetermined size is prepared. The pressure-sensitive adhesive layer 3 and the release sheet 2 are laminated in advance on the lower surface (the other surface) of the base material 4. By forming the pressure-sensitive adhesive layer 3 and the release sheet 2 on the base material 4 in advance in this way, for example, the pressure-sensitive adhesive layer 3 and the release sheet 2 are formed on the base material 4 after this step. Compared with the case, the coating film 1 can be easily manufactured.

Next, as shown in FIG. 6, the base layer 5 is formed by applying the above-mentioned various solvents to the upper surface of the base material 4. The method of applying the solvent is not particularly limited, and for example, screen printing (silk printing), spraying, or the like can be used. Further, it may be applied artificially by an operator. Here, the constituent material of the base layer 5 is not particularly limited, but preferably contains cyclohexanone (anone) or N, N-dimethylformamide (DMF), and more preferably contains cyclohexanone. As a result, the adhesion between the base material 4 and the colored layer 6 is further improved.

The thickness of the base layer 5 is not particularly limited, but is preferably about 10 to 100 μm, and more preferably about 40 to 80 μm. As a result, the function as the base layer 5 (improvement of the adhesion between the base material 4 and the colored layer 6) can be surely exhibited, and the base layer 5 can be made sufficiently thin.

-Colored layer forming process-
Next, as shown in FIG. 7, a colored layer 6 is formed on the base layer 5 before the base layer 5 dries. That is, the colored layer 6 is formed on the undried base layer 5. The method for forming the colored layer 6 is not particularly limited, but it is preferable to form the colored layer 6 by spraying (spraying) the paint on the base layer 5, for example. Thereby, a homogeneous and thin colored layer 6 can be easily formed. Further, since the body coating of an automobile is also formed by spraying paint, by forming the colored layer 6 in the same manner as the body coating of an automobile, a coating film 1 having substantially the same texture as the body coating of an automobile can be obtained. Can be manufactured.

The paint used in this step may be any paint that can be used for baking finish, and for example, melamine resin paint, epoxy-modified melamine resin paint, acrylic resin paint, fluororesin paint, and the like can be used.

The thickness of the colored layer 6 is not particularly limited, but is preferably about 50 to 150 μm, and more preferably about 60 to 90 μm. With such a thickness, the colored layer 6 can be sufficiently thinned without impairing the aesthetic appearance.

In the present embodiment, the colored layer 6 is formed of one layer, but the colored layer 6 may be formed of a plurality of layers. For example, it may be formed of two layers, an intermediate coating layer and a base layer. According to such a configuration, for example, the color development of the base layer can be made more excellent.

-Clear layer forming process-
Next, as shown in FIG. 8, a clear layer 7 is formed on the colored layer 6. The method for forming the colored layer 6 is not particularly limited, but it is preferable to form the colored layer 6 by spraying (spraying) the paint on the base layer 5, for example. Thereby, a homogeneous and thin clear layer 7 can be easily formed.

The thickness of the clear layer 7 is not particularly limited, but is preferably about 10 to 100 μm, and more preferably about 40 to 60 μm. With such a thickness, the function as the clear layer 7 can be sufficiently exhibited, and the clear layer 7 can be made sufficiently thin.

-Baking process-
Next, the product obtained in the above steps is heated to bake the colored layer 6. As a result, a polymerization reaction occurs in the coating film, and a dense and high-strength colored layer 6 is obtained. The heating conditions are not particularly limited and vary depending on the type and film thickness of the colored layer 6, but can be, for example, 100 ° C. to 130 ° C. for about 20 minutes to 50 minutes. The base layer 5 disappears due to volatilization or the like in this step, but a part of the base layer 5 may remain.

From the above, the coating film 1 is obtained. According to such a manufacturing method, it is relatively easy and has almost the same texture as the adherend (particularly, the painted surface), and it is possible to suppress deterioration of the aesthetic appearance when the adherend is attached to the adherend. It is possible to manufacture a coating film 1 capable of producing a coating film 1.

Although the method for producing the coating film of the present invention and the coating film have been described above based on the illustrated embodiment, the present invention is not limited to this, and the configuration of each part is an arbitrary configuration having the same function. Can be replaced with one. Further, any other constituents may be added to the present invention.

Further, in the above-described embodiment, the body of the automobile is mentioned as the adherend, but the adherend is not limited to this, and the adherend is, for example, a motorcycle, a bicycle, a ship, a train vehicle, a road sign or various display boards. Examples include various exercise equipment such as helmets, ski boards, snowboards, surfboards, rackets, and golf clubs, mountain climbing equipment, diving equipment, various lighting equipment, various optical equipment, construction machinery, civil engineering machinery, and building structures.

For example, in the above-described embodiment, the method of forming each layer on the base material 4 cut to a predetermined size has been described, but the method for producing a coating film is not limited to this, and for example, the pressure-sensitive adhesive layer 3 Alternatively, the roll-shaped base material 4 on which the release sheet 2 has been formed may be wound up, and the base layer forming step, the colored layer forming step, and the clear layer forming step baking step may be performed in this order in the middle of the winding.

Further, the method of using the coating film 1 is not limited to the method of attaching to the body of an automobile as described above. For example, the coating film 1 is attached to a plate-shaped base material made of various resin materials, and then the base material is molded by various molding methods such as vacuum forming to attach the coating film 1. , A molded product having a predetermined shape can be obtained. Such molded products can be suitably used for, for example, automobile bumpers, side mirrors, and the like.

<< Example 1 >>
First, a base material on which the pressure-sensitive adhesive layer and the release layer were laminated was prepared, and this base material was cut into a size of 10 cm × 30 cm. The thickness of the base material was 50 μm, and the thickness of the pressure-sensitive adhesive layer was 25 μm. Next, cyclohexanone (trade name "Anon": manufactured by Yamaichi Chemical Industry Co., Ltd.) was applied to the upper surface of the base material (the surface opposite to the pressure-sensitive adhesive layer 3) to form a base layer. The thickness of the base layer was 60 μm. Next, before the base layer was dried, the paint was sprayed onto the base layer to form the colored layer 6. The thickness of the colored layer 6 was 80 μm. Next, a clearing agent was sprayed onto the colored layer to form a clear layer. The thickness of the clear layer was 50 μm. Next, the substrate was heated at 110 ° for 40 minutes to bake the colored layer 6. From the above, a coating film was manufactured.

<< Example 2 >>
A coating film was produced in the same manner as in Example 1 described above, except that the material of the base layer was N, N-dimethylformamide (DMF).

≪Exam≫
1. 1. Adhesion The coating films of Examples 1 and 2 were tested for adhesion to the painted surface. In this test, the coating film of each example was attached to the coated surface, and 100 squares of 2 mm × 2 mm grid were formed on the coated film with a cutter, and cellophane tape conforming to JIS Z1522 was attached to the grid. I put it on and peeled off the cellophane tape vigorously. The judgment criteria were "○" when there was no peeling in all 100 squares, and "x" when there was peeling in even one square.

2. Corrosion resistance The coating films of Examples 1 and 2 were tested for corrosion resistance. In this test, the coating film of each example is attached to the painted surface, a scratch mark (cut) that reaches the painted surface is made on the painted film, and the mixture is left for 500 hours in a salt water spray conforming to JIS Z2371. .. Then, after washing with water and leaving it in a standard state for 1 hour, a cellophane tape conforming to JIS Z1522 was attached to the scratch mark portion, and after 30 seconds, the cellophane tape was vigorously peeled off. The judgment criteria were "○" when there was no abnormality such as swelling, cracking, or peeling of the coating film, and "x" when there was an abnormality.

3. 3. Heat resistance The heat resistance of the coating films of Examples 1 and 2 was tested. In this test, the coating film of each example is attached to the coated surface and left at 80 ± 2 ° C. for 168 hours. Then, it was left in the standard state for 24 hours. The judgment criteria were "○" when there was no abnormality (visual), peeling, etc. in the appearance of the coated film, and "x" when there was an abnormality.

4. Water resistance The water resistance of the coating films of Examples 1 and 2 was tested. In this test, the coating film of each example is attached to the coated surface and immersed in water at 23 ± 2 ° C. for 168 hours. Then, after taking it out of the water, it was left in a standard state for 24 hours. The judgment criteria were "○" when there was no abnormality such as swelling, shrinkage, dissolution, discoloration, and peeling of the coating film, and "x" when there was an abnormality.

5. Solvent resistance The solvent resistance of the coating films of Examples 1 and 2 was tested. This test was carried out by attaching the coating film of each example to the coated surface and strongly rubbing the surface with gauze containing MEK (methyl ethyl ketone) (10 reciprocations). The judgment criteria were "○" when there was no abnormality such as swelling, shrinkage, dissolution, discoloration, and peeling of the coating film, and "x" when there was an abnormality.

6. Abrasion resistance The solvent resistance of the coating films of Examples 1 and 2 was tested. In this test, the coating film of each example is attached to the coated surface, and this is set in a friction tester type II conforming to JIS L0849. Then, two sheets of white cotton cloth for friction (cotton (No. 3) of the attached white cloth for the dyeing fastness test of JIS L0803) are attached to the friction surface of the friction element. Then, the friction is repeated under the conditions shown in Table 1 below. The judgment criteria were "○" if the gray scale for pollution was 4 or higher, and "x" if it was 3 or lower.

≪Evaluation≫
The test results of each of the above tests are shown in Table 2 below. As can be seen from Table 2, both Examples 1 and 2 exhibit excellent characteristics in each test. In addition to this, with respect to Examples 1 and 2, wax resistance, fuel oil resistance (gasoline resistance), window washer liquid resistance, and high pressure car wash resistance are particularly considered in consideration of being attached to the body of the automobile. We have conducted tests such as mobility, and have confirmed that high characteristics can be obtained in all of the tests.

1 Coating film 2 Release sheet 3 Adhesive layer 4 Base material 5 Base layer 6 Colored layer 7 Clear layer

Claims (2)

A step of forming a base layer containing cyclohexanone on one surface of a film-like base material containing a polyvinyl chloride resin, and a step of forming a base layer containing cyclohexanone.
A method for producing a coating film, which comprises a colored layer forming step of forming a colored layer composed of a melamine resin paint, an epoxy-modified melamine resin paint or a fluororesin paint by painting on the base layer. The method for producing a coating film according to claim 1, further comprising a clear layer forming step of forming a clear layer on the colored layer after the colored layer forming step .

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