JPH06330344A - Surface-treated material excellent in designability - Google Patents

Abstract

PURPOSE:To produce a surface-treated material having excellent reflectance and glossiness by successively forming a metallic underlayer and an Al coating layer each having a specified thickness on a resin layer formed on the surface of a base material and further forming a transparent resin layer on the top of the Al coating layer. CONSTITUTION:A resin layer 2 for smoothening is formed on the surface of a base material 1 with a resin contg. a dispersed pigment. A metallic underlayer 3 of a metal ensuring lower heat of condensation than Al is formed on the resin layer 2 in >=0.02mum thickness and an Al coating layer 4 is formed on the underlayer 3 in 0.02-2.5mum thickness. A transparent resin layer 5 is further formed as a protective layer on the top of the Al coating layer 4. Thus, the objective surface-treated material capable of secondary working is provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface-treating material capable of forming such as bending and having excellent reflectance and glossiness. The surface-treating material is used for exterior members of home electric appliances and various ornaments, It is useful as a building material.

[0002]

2. Description of the Related Art As a typical method for imparting a reflection characteristic or gloss to an object, there is a method utilizing the high reflection characteristic of a metal, and the specific method is roughly classified into the following two types. That is, one method is to grind on a metal material surface having high reflectance,
It is a method of smoothing by performing rolling, etching, polishing, etc., and obtaining a high glossiness by a smooth surface while making use of the reflection characteristics of the metal material itself. Another method is to finish the surface of the base material to be smooth, It is a method of forming a metal layer having high reflection characteristics on the surface.

The most important technical point for obtaining excellent reflectance and glossiness by the above method is how to smooth the surface. From this point of view, a metal base material is used. It can be said that the latter method, which can obtain a smooth surface by an arbitrary method, is more advantageous than the former method in which the surface itself is processed and smoothed. Further, for example, Al is widely used as a metal material that is inexpensive and has high reflectance, but the upper limit of the reflectance obtained by polishing the surface of the Al material is about 80%, and the former method also improves the reflectance. It costs. Furthermore,
Reflection / gloss is essentially a problem only on the surface, and as is clear from the consideration of Ag, which has better reflection characteristics than Al, it is possible to reflect / gloss itself by subjecting it to processing deformation, surface polishing, etc. Even if the surface is obtained, since the function is only exerted after all, it is not an advantageous method in terms of utilization efficiency and price of Ag.

On the other hand, the latter method is generally used, in which a resin is applied to the surface of a base material, a smooth surface is secured by the smoothing effect of the resin coating film, and then a metal film having excellent reflection characteristics is formed thereon. As a method for forming a metal film, a dry coating method such as vapor deposition, sputtering, or ion plating is adopted. With this method, the purpose can be achieved by an ultrathin metal film, so even if an expensive noble metal such as Ag is used, the economical burden is small, and even if Al is used when the vapor deposition method is adopted. A high reflectance of about 89% can be obtained.

In adopting the latter method, first, a resin layer for enhancing the surface smoothing effect, the adhesion to the base material and the corrosion resistance of the base material is formed, and further smoothing and drying are performed thereon. A resin layer is provided to improve the adhesion to the metal to be coated and to ensure heat resistance during dry coating. In addition, in some cases, in order to further strengthen the adhesion between the base material and the resin layer, the lowermost layer may be subjected to another undercoating, and conversely, smoothing with one resin layer, heat resistance, It may also have various functions such as adhesion and corrosion resistance.

In addition, such a high-reflectivity and high-gloss design surface-treating material maintains its surface condition for a long time and
For example, baking with acrylic clear resin, silicone clear resin, etc. to prevent scratches during transportation, installation, etc., surface oxidation during use, and dirt adhesion during use, UV curing of epoxy / acrylate resin, etc. As a result, a protective film is formed on the uppermost layer. Therefore, the latter method of smoothing the surface with a resin has a multi-layer structure of 3 to 5 layers including the metal layer forming the reflecting surface.

[0007]

By the way, the above-mentioned treatment method is mainly applied to molded parts, and it is not possible to perform the above-mentioned treatment in the state of the molding base material and then to process it into a product shape. Little has been done. However, the processing in the component shape basically has to be an individual processing, so that the processing efficiency is poor and an increase in processing cost cannot be avoided.

One of the reasons why the surface modification treatment is carried out after molding is the heat resistance of the resin used for smoothing. That is, the heat resistance and processability of the resin are difficult to achieve at the same time, and if a resin with insufficient heat resistance is selected with an emphasis on processability, the metal layer forming process to increase the reflectance and the protection of the uppermost layer In the step of baking the clear coating film, the resin layer is softened and deteriorated, which causes quality problems such as a decrease in surface gloss.
Such a tendency is remarkable when Al, which is most widely used at present, is used as the reflective film.

[0009] Therefore, if it is possible to prevent the above-mentioned problems even when forming processing or forming a protective clear coating film after Al coating, continuous treatment to a plate material or the like can be facilitated and a significant cost reduction can be achieved. Becomes When strong processing such as sliding is applied to the surface of the material that requires design, it is not possible to completely eliminate the scratches with any protective layer, but there are also applications that can be handled by mild bending etc. There are many, and development of an Al coating material having high reflectance and glossiness and capable of post-processing such as bending is desired.

The present invention has been made in view of such circumstances, and an object thereof is to provide a surface-treating material having excellent reflectance and glossiness and capable of being post-processed. Is.

[0011]

The structure of the surface-treating material according to the present invention, which has been able to solve the above-mentioned problems, is such that a resin layer containing a pigment is formed on the surface of a substrate, and a resin layer lower than Al is formed on the resin layer. A base metal layer having a thickness of 0.02 μm or more, which is made of a metal having heat of condensation, and Al having a thickness of 0.02 to 2.5 μm on the base metal layer.
The gist is that the coating layer is formed and the transparent resin layer is formed on the outermost surface.

[0012]

Under the above-mentioned problems to be solved, the present inventors have focused on a design improvement technique in which Al is selected as a reflection property-imparting metal and is used in combination with a resin for smoothing. Then, when we first investigated the cause of the above-mentioned defects,
The following facts have become clear.

The resin layer on which the Al coating layer is formed needs to be a hard film having excellent heat resistance in order to prevent deterioration due to heat during Al coating. It causes cracks and loses commercial value. When forming a transparent resin layer for surface protection on the uppermost layer,
Since the protective effect of the room temperature dry type is insufficient, it is necessary to use a bake hardening type or ultraviolet ray hardening type protective film. However, in order to carry out coating baking, it is necessary to heat to above 200 ° C. Therefore, if the resin layer under the Al coating layer has insufficient heat resistance, the Al coating layer (reflection surface ) There are wrinkles or surface alterations that appear visually as cloudiness. Further, when forming a UV-curable protective film, the temperature rise at the time of forming the outermost layer film is avoided, but the equipment and operation including the installation of equipment for exclusive use of the curing become complicated, which increases the processing cost.

Therefore, in order to solve the above problems, it is necessary to improve not only the structure of the resin layer for smoothing but also the entire layer structure. As a result of further research from this point of view, the present invention is schematically shown in FIG. 1 as a requirement for ensuring the heat resistance required at the time of forming an Al coating layer and at the time of forming a protective film and enabling post-processing. As described above, a resin in which a pigment is dispersed is used as the resin layer 2 for smoothing provided on the surface of the base material 1, and the base metal layer 3 made of a metal having a heat of condensation lower than that of Al is further provided on the resin layer. It has been found that it is sufficient to form the Al coating layer 4 for improving the reflectance and then form the transparent resin layer 5 as the protective layer on the uppermost layer.

In the present invention, the reason for dispersing the pigment in the lowermost resin layer 2 is to disperse the pigment.
This is because the heat resistance of the resin layer 2 is increased while ensuring an appropriate moldability by the base resin, and thermal deformation is prevented when the Al coating layer is formed by the dry lamination method or the transparent resin layer 5 is baked. The type of base resin used here is not particularly limited, but typical ones are thermoplastic resins such as polyester resins, polyurethane resins, polyamide resins and the like. There is no particular limitation on the type of pigment, and all known pigments such as TiO ₂ , Al ₂ O ₃ , and ZrO ₂ can be used, and the particle size and content thereof are not particularly limited. However, in order to enhance the smoothing effect of the resin layer 2, it is preferable that the particle size of the pigment is small, and fine particles of about 0.2 μm or less are recommended. In addition, the pigment content in the resin layer 2 is 20 in terms of the total amount of the resin layer 2 in consideration of both heat resistance and moldability of the resin layer 2.
-60% by weight, more preferably 30-50% by weight.

The thickness of the pigment-dispersed resin layer 2 is preferably 5 μm or more, more preferably 10 μm or more in order to effectively exert the smoothing effect, and there is no upper limit of the film thickness, but the film is excessively formed. Even if the thickness is increased, the smoothing effect does not increase further, it is economically wasteful, and in some cases, the formability is adversely affected. Therefore, it is usually suppressed to about 30 μm or less.

The reason why the base metal layer 3 formed on the pigment-dispersed resin layer 2 is a metal having a heat of condensation lower than that of Al is as follows.
The heat energy at the time of forming the underlying metal layer 3 is reduced to reduce the amount of heat applied to the pigment-dispersed resin layer 2 to suppress the deformation / deterioration of the resin layer 2, and the Al coating layer 4 as a reflection film is formed thereon. The heat of condensation applied during formation is relaxed by the underlying metal layer 3, and further the Al coating layer 4 is formed.
The Al coating layer 4 when the transparent film 5 is baked on the
This is because the thermal deformation of the Al is suppressed, and in order to exert such an effect, it is essential to use a metal having a heat of condensation lower than that of Al forming the Al coating layer 4.

Examples of the metal having a low condensation heat that meets these requirements include Ni, Cr, Cu and various alloys containing them. The condensation heat is 2000 cal / although it depends on the thickness of the underlying metal layer. It is preferably g or less.
Further, the film thickness thereof should be at least 0.02 μm or more, preferably about 0.05 μm or more in order to effectively exhibit the above-mentioned functions, and if the film thickness is less than 0.02 μm, the above-mentioned effect as the base metal layer 3 is not achieved. Insufficient to serve the purpose of the invention. Although the upper limit of the film thickness varies depending on the type of metal used, it cannot be set uniformly, but it is preferable to consider about 2 μm in consideration of the condensation heat absorption effect and the economical efficiency when the Al coating layer 4 is formed. It is the following. The method for forming the base metal layer 3 is not limited, but the dry-lamination method or the electroless plating method may be mentioned as an effective method because the pigment-dispersed resin layer 2 on the lower side is insulating. From the viewpoint of speed and workability, the most preferable are dry laminating methods such as vapor deposition, sputtering, and ion plating.

Al coating layer 4 constituting the anti-slope
Is formed by the dry coating method as described above, but its film thickness needs to be 0.02 to 2.5 μm, and more preferably 0.1 to 1 μm, in order to sufficiently exhibit the function of reflection. . If it is less than 0.02 μm, Al
A pinhole is formed in the film, the influence of the underlying layer becomes large, and the reflectance decreases. On the other hand, when the thickness exceeds 2.5 μm, the heat of condensation during formation of the Al coating layer cannot be fully relaxed, and the plating appearance becomes cloudy and the glossiness decreases, and it is economically unnecessarily thick. Doing so is not preferable.

If necessary, an alloy layer of Al and a base metal can be formed between the Al coating layer 4 and the base metal layer 3 to further improve the adhesion between the stacked layers. Does not appear on the surface of the Al coating layer 4, it does not hinder the reflectance and gloss of the final product. Therefore, for example, a continuous vapor deposition method as schematically shown in FIG. 2 (in the figure, a is a material on which a pigment-dispersed resin layer is formed, b is an evaporation tank for a base metal, c is a base metal vapor, and d is A
It is also possible to continuously form the base metal layer and the Al layer by adopting a 1 evaporating tank and e represents Al vapor).

The uppermost transparent resin layer 5 is a transparent resin that transmits light in the visible region with high transmittance, and may be any resin having relatively good workability, such as polyester resin, polyurethane resin, polyamide resin. Resin etc. are illustrated as a typical resin. The film thickness is preferably 1 μm or more from the function of protecting the Al reflection film, and more preferably 2 μm or more.

As the substrate, not only the most common cold-rolled steel sheet but also various iron-based alloys such as stainless steel and non-ferrous metals such as Al and Cu or alloy materials can be applied, but the adhesion to the coating film Considering even the corrosion resistance of the cut end surface, a Zn-plated steel sheet subjected to chemical conversion treatment such as chromate treatment, an Al rolled sheet, and the like are recommended as preferable ones. Further, in order to further improve smoothing and adhesion to the base material, the case where a precoat material or the like having a resin layer formed in advance is used is also exemplified as a modified example of the present invention. Further, in addition to metal, it can be applied to resin plates such as epoxy resin and acrylic resin, glass, or ceramic plates such as alumina and zirconia.

[0023]

EXAMPLES Next, the constitution and effects of the present invention will be described in more detail with reference to examples. However, the present invention is not limited by the following examples, and conforms to the spirit of the preceding and the following. It is also possible to carry out appropriate modification within the scope of obtaining, and all of them are included in the technical scope of the present invention.

Example A 0.4 mm-thick electroplated steel sheet was used as a substrate, and a pigment-containing resin layer, a base metal layer, an Al coating layer and a transparent resin layer were formed under the following conditions. (Pigment-containing resin layer) Base resin: Polyester resin Pigment: TiO ₂ powder or Al ₂ O ₃ powder (average particle size 0.2 μm or less, content of 40% by weight in resin layer) Forming condition: Pretreatment As a coating-type chromate treatment (coating amount: 30 mg / m ² ), the coating is performed so that the dry thickness becomes 10 μm, and baking is performed at 483K for 60 seconds.

(Formation Method of Base Metal Layer and Al Coating Layer) Substrate Pretreatment: Washing and Drying Deposition Conditions: Vacuum Degree 1 × 10 ⁻³ Pa, Substrate Temperature 323K Film Thickness Control: Using a Film Thickness Sensor Using a Crystal Oscillator Evaporated metal: Base metal (Ni, Cr or Cu) + Al (Transparent film forming method) Film material: Polyester clear resin paint Forming condition: After coating to a dry film thickness of 3 μm, 4
Baking for 60 seconds at 83K.

The workability, reflectance, and glossiness of each of the obtained test materials were evaluated according to the following criteria, and the results shown in Table 1 were obtained. (Processability): Visual evaluation of appearance after 1t bending ○: No discoloration, Δ: Some discoloration, ×: Discoloration (Reflectance): Evaluation by total reflectance at a wavelength of 550 nm ○: 85% or more, Δ: 84 to 81 %, × ... 80% or less (glossiness): evaluated by 60 ° specular glossiness ○ ... 400% or more, Δ ... 399 to 201%, x ... 200
%Less than

[0027]

[Table 1]

From Table 1, the following can be considered. No. 1 to 1
No. 0 is an example satisfying all the requirements of the present invention, and excellent results were obtained in terms of workability, reflectance and glossiness. On the other hand, Nos. 11 to 21 are comparative examples lacking any of the specified requirements, and there is a problem in any of the performances as described below.

No. 11: The base metal layer was omitted, and the Al coating layer was formed directly on the pigment-dispersed resin layer. When the transparent film was baked, it was thermally deformed, causing a slight decrease in reflectance and significant gloss. There is a decline. No. 12: The reflectance and gloss are insufficient because the thickness of the underlying metal layer is insufficient. No. 13, 17, 19: Since the thickness of the Al coating layer constituting the reflective film is too thick, the condensation heat at the time of forming the Al coating layer becomes excessive and the pigment-dispersed resin layer is thermally deformed, and the reflectance is increased. The gloss level is significantly low with the shortage. No. 14, 16, 18: On the contrary, it is a comparative example in which the Al coating layer is too thin, and the reflectance and glossiness are insufficient in all cases. No. 15: This is a comparative example in which a pigment is not mixed in the resin layer, and the reflectance and gloss are poor due to insufficient heat resistance of the resin layer. No. 20, 21: Comparative examples in which the film thickness of the pigment-dispersed resin layer is insufficient, and the smoothing effect of the base material is insufficient, so that satisfactory reflectance and glossiness cannot be obtained.

[0030]

The present invention is constituted as described above, and the pigment is dispersed in the resin layer for smoothing, and the Al layer is formed thereon through the underlying metal layer having a heat of condensation lower than that of Al. By forming the pigment-dispersed resin layer, thermal deformation of the pigment-dispersed resin layer can be suppressed, and thus a surface-treated material having excellent reflectance and gloss and capable of secondary processing can be provided.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a laminated structure of a treated material of the present invention.

FIG. 2 is an explanatory view illustrating a method for forming a base metal layer and an Al coating layer used in the present invention.

[Explanation of symbols]

 1 Base Material 2 Pigment Dispersion Resin Layer 3 Base Metal Layer 4 Al Coating Layer 5 Transparent Film

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Atsushi Kato 2222 Ikeda, Ikeda, Onoe-machi, Kakogawa-shi, Hyogo Pref., Kakogawa Research Area, Kobe Steel Co., Ltd. (72) Inventor Atsushi Kihara Onoe-cho, Kakogawa-shi, Hyogo Ikeda character Ikeda Development 2222 Address 1 Kobe Steel Co., Ltd. Kakogawa Research Area within the ward (72) Inventor Kuniyasu Araga Iketa, Onoe Town, Kakogawa City, Hyogo Prefecture 2222 Address Ikeda Development Kakogawa Research Area within Kobe Steel Co., Ltd.

Claims (1)

[Claims] 1. A resin layer containing a pigment is formed on a surface of a base material, and a base metal layer having a thickness of 0.02 μm or more made of a metal having a heat of condensation lower than that of Al is further formed on the resin layer. 0.
A surface-treated material excellent in design, characterized in that an Al coating layer of 02 to 2.5 μm is formed and a transparent resin layer is formed on the outermost surface.