JPH02279826A - Cover - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention is mainly used for manhole covers in underground pipes installed on sidewalks, such as water and sewer lines, electric wiring, gas piping, telephone lines, etc., or for drainage. The present invention relates to a cover placed on a road surface, such as a cover for a ditch such as a side gutter. In addition, the present invention exhibits high slip resistance due to excellent surface friction even without having an uneven surface, and also exhibits corrosion resistance and
This invention relates to a colored cover that has excellent abrasion resistance and high aesthetics.

(Prior art) Manhole covers for underground pipes such as water supply and sewerage, electrical wiring, gas piping, and telephone lines have conventionally been made of cast iron coated with black tar epoxy resin paint, and concrete. Conventionally, covers made of steel plates and concrete have been commonly used as covers for road drainage ditches, but among these covers, concrete covers These are complicated because they require a concrete hardening process during construction, and so-called iron lids such as cast iron or steel plates are the mainstream for ease of construction. However, although iron lids have excellent properties in terms of ease of construction, strength, and wear resistance as mentioned above, they have the disadvantage that their surfaces are slippery. For this reason, although the surface of the iron lid usually has a textured pattern to prevent it from slipping, it is not sufficiently effective, and many accidents such as passersby falling down occur, especially in rainy weather. This has become a problem.

By the way, in recent years, due to the trend of beautifying and fashioning urban landscapes, techniques for applying color to such covers installed on sidewalks are being considered. For example, there are currently developments in which the surface of the iron lid is patterned with various designs in the form of convexes and convexities, and then painted with colored epoxy resin paint, or those in which the recesses are filled with colored resin and colored. Some of them have been commercialized.

However, resin paint-coated products have low coating film hardness and poor adhesion between the coating film and the iron cover base material, so the coating will wear out or peel off in a short period of time in harsh road environments. Therefore, the aesthetic appearance at the initial stage of construction could not be maintained for a long period of time.
Repainting requires a large amount of maintenance costs, and even resin-filled products are exposed to sunlight for a long time, causing fading due to ultraviolet rays, making it impossible to maintain the initial color for a long time. It had a

Furthermore, with these painted iron lids, the functional requirements such as slipperiness mentioned above are not taken into account at all, and products coated with resin paints in particular have very slippery surfaces that pose a safety risk. It was also problematic from both sides.

From this point of view, the present inventors first formed a corrosion-resistant metal sprayed layer over the entire surface of the iron-based base material on the uneven upper surface, and at least in the convex portions, the corrosion-resistant metal was sprayed. A cover lid was proposed in which a ceramic sprayed layer was formed on top of the sprayed layer, and the entire pores were sealed with a resin-based sealing material (Japanese Patent Application No. 63-548).
No. 46).

This cover has extremely superior slip resistance compared to the above-mentioned painted colored products and resin-filled colored products, and also has high abrasion resistance and corrosion resistance. No matter what color the ceramic sprayed layer is made of and painted, this color or the design expressed by it will remain in its initial state for a long period of time. However, even with this cover having such excellent characteristics, the following problems remain.

In other words, when a design is attached to the upper surface of this cover, the design is formed by introducing the design into the uneven surface shape added to prevent slipping, similar to conventional resin paint-coated products and resin-filled products. However, such designs on the back of the cover are rarely universal, and are generally different for each user (for example, each local government), so the design attached to the back of the cover is different for each user (for example, each local government). It is necessary to make several molds, and the number of cover lids required for each mold is generally very small, ranging from several to several dozen. For this reason, the cost of manufacturing a mold for one cover lid is high, making the price of the cover relatively high.

In addition, when attempting to apply the presence or absence of a ceramic sprayed layer or to change the color in accordance with the uneven pattern formed on the iron-based base material, it is necessary to align the uneven pattern with the pattern of the ceramic sprayed layer. This is difficult, and there is a risk that the product value may be lowered in some cases.

Furthermore, as mentioned above, the color applied to this cover and the design itself are maintained in the initial state of construction for a long period of time, but the concavities on the surface are prone to dirt and dust from the road surface. It easily accumulates, and even if it is painted, if cleaning is neglected, the original color in the recesses will be hidden and the design effect will be diminished.

(Problems to be Solved by the Invention) Therefore, an object of the present invention is to provide a novel cover. Another object of the present invention is to provide a lid of any color that exhibits high slip resistance even without having an uneven surface, has excellent corrosion resistance and abrasion resistance, and is highly aesthetically pleasing. It is something.

Another object of the present invention is to provide a cover that is easy to manufacture and can be manufactured at low cost when various designs are to be formed on the upper surface. A further object of the present invention is to provide a cover that can maintain the initial color tone for a long period of time when it is painted, and does not require special maintenance. A further object of the present invention is to provide a cover that can promote beautification of the urban environment.

(Means for Solving the Problems) - The object of the invention is to provide a covering cover to be placed on a road surface, which has a flat upper surface, and the upper surface of the bracket is made of iron-based base material. A corrosion-resistant metal sprayed layer and a ceramic sprayed layer are successively laminated on the surface of the cover, and a sealing treatment using a resin-based sealing material is further performed thereon.

In addition, the term "flat" used in this specification refers to a state in which there is no macroscopic unevenness such as the unevenness that was conventionally attached to cover lids such as iron lids to prevent slipping. It is something. In this sense, even if the upper surface of the cover lid has microscopic irregularities due to the material itself, or the upper surface of the cover lid is entirely curved with a certain degree of radius, These are also included within the definition of "flat" herein.

(Function) As described above, the cover lid of the present invention has a flat upper surface, and on the upper surface of the bracket, a corrosion-resistant metal sprayed layer and a ceramic sprayed layer are formed on the surface of the iron-based one-stone shrine. are sequentially layered, and then -! Second, the pores are sealed using a resin-based pore sealing material.

BACKGROUND ART Conventionally, a lid made of iron-based metal as a base material usually has an uneven pattern formed on its surface for the purpose of preventing slipping. This is because ferrous metals do not have sufficient wear resistance, and if the surface is made rough, it will easily wear out within a short period of time after use, and the surface will become smooth and extremely slippery. Even if the surface of the base material is covered with a resin-based paint, such a paint film has little effect on improving the slip resistance of the surface, and the paint film easily wears out or peels off. Since the ferrous metal base material is exposed, the formation of an uneven pattern is essential. As is clear from these points, in order to make the surface of a lid made of iron-based metal as a base material flat without any unevenness, it is necessary to
The coating formed on the sliding portion must have excellent slip resistance on its surface and must not disappear over a long period of time due to wear or tlj separation.

Ceramics are highly wear-resistant materials, and as a result of extensive research, the present inventors have found that ceramic sprayed layers generally have a surface roughness of approximately Rmm, 40 to 60 μm; It has been found that this provides slip resistance. Therefore, covering the surface of the ferrous base material with a ceramic sprayed layer is extremely effective in providing the high surface friction resistance required for the cover over a long period of time, but When a layer is formed, the adhesion is weak and defects such as peeling are likely to occur, and since the ceramic sprayed layer has considerable pores, corrosion resistance cannot be expected.

On the other hand, metal sprayed layers generally have very few pores and can densely cover the surface of the base material because the metal has a lower viscosity during spraying than ceramics. The corrosion-resistant metal sprayed layer formed on the surface of the iron-based base material has high adhesion at the bonding interface with the iron-based base material, and is extremely prone to peeling or falling off even when subjected to impact force or vibration. ni (It's something.)

When the above-mentioned ceramic sprayed layer is brought into close contact with the iron-based base material through this corrosion-resistant metal sprayed layer, the ceramic sprayed layer will be held sufficiently firmly to the iron-based CJ material. Furthermore, when such a sprayed ceramic layer is sealed with a resin-based sealing material, the pores existing in the sprayed ceramic layer can be closed without changing the appropriate surface roughness as described above. Combined with the provided dense corrosion-resistant metal spray layer, the surface of the ferrous base material is sufficiently protected, the ferrous base material is not exposed to the external environment, and it has sufficient corrosion resistance. Become.

As described above, in the cover lid of the present invention, by covering the iron-based base material with a covering body having the above-mentioned excellent properties, it is possible to exhibit high slip resistance over a long period of time on a flat surface shape. This is the first time this has been possible.

Furthermore, in the cover lid of the present invention, there is no need to provide an uneven pattern to prevent slipping, so when it is desired to add a design to the cover lid surface, the resin sealing material may be replaced with a transparent one. It is sufficient to simply configure the ceramic sprayed layer with colored ceramics of multiple colors according to the design pattern, eliminating the need to create a new mold of one iron material each time the design changes. A common mold can be used. This reduces manufacturing costs and shortens the manufacturing time required to make the mold. Also, the ceramic spray pattern can be matched to the uneven pattern as in the past. Since this is no longer necessary, there is greater freedom in design, easier thermal spraying, and there is no problem of decreased product value due to misalignment.

Furthermore, in the lid of the present invention, the ceramic sprayed layer that is the outermost layer on the upper surface is sealed with a resin-based pore sealing material as described above, and is substantially non-porous. There is little risk of staining due to the intrusion of rainwater, dust, etc., and as mentioned above, the iron base material is completely covered with a coating and has good corrosion resistance, so there is no risk of red rust from the iron base material. There is no embossment, and both the ceramic and the corrosion-resistant metal are chemically extremely stable, and as mentioned above, the ceramic sprayed layer has excellent wear resistance and is less likely to cause defects such as peeling. In addition, in the cover lid of the present invention, the upper surface is flat and does not have a substantially recessed portion, so that sand and dust accumulate in such a recessed portion as in the conventional cover lid. Problems such as colors being hidden and the design effect fading do not occur essentially, and as mentioned above, the resin-based sealing material is made of a transparent material, and the ceramic sprayed layer is made of colored ceramics of multiple colors. If a colored design is applied to the upper surface of the cover lid depending on the color, it is possible to maintain the original color tone for a long period of time without changing the original color tone even under harsh road conditions without special maintenance.

Hereinafter, the present invention will be explained in more detail based on embodiments.

The covering lid of the present invention is a covering lid placed on a road surface, especially a sidewalk, and is, for example, a covering lid for a manhole in underground pipes such as water supply and sewerage, electric wiring, gas piping, and telephone lines.
It also includes covers placed on road surfaces, such as covers for ditches such as drainage ditches.

FIG. 1 is a cross-sectional view schematically showing the structure of a manhole cover body, which is a one-cusp embodiment of the cover cover of the present invention.

In the manhole cover body of this embodiment, a corrosion-resistant metal sprayed layer 2 is formed over the entire surface of the cast iron base material 1 on its -L two-part surface, and a ceramic sprayed layer is formed on the corrosion-resistant metal sprayed layer 2. 3 is formed over the entire surface, and a resin coating layer 4 made of a transparent resin sealing material is further formed over the entire surface for sealing treatment. However, the second part 5 of the lever is flat because the surface of the cast iron base material 1 is not specially patterned.

In addition, in this manhole cover body, a corrosion-resistant metal sprayed layer 2 is formed on the entire surface of the cast iron base material 1 on the lower surface 6 and the peripheral side surface 7, and a resin-based sealing material is further applied over the entire surface of the cast iron base material 1. resin? t [layer 4 is formed,
Protects the base material surface.

In FIG. 1, the thicknesses of the corrosion-resistant metal sprayed layer 2, the ceramic sprayed layer 3, and the resin coating layer 4 are exaggerated.

In the lid of this embodiment, the ceramic sprayed layer 3
As shown in Figure 2, a plurality of colored ceramics are used, such as light brown ceramics in part A, white ceramics in part 8, green ceramics in part 0, and blue ceramics in part D. In this way, by changing the color of ceramics in a specific pattern, it is said to represent a colorful design. In this embodiment, a transparent resin sealing material is used to constitute the resin coating layer 4, and it is possible to express a design using the ceramic sprayed layer 3 using a plurality of colored ceramics as described above. It is said that

As in the embodiment shown in FIG. 1, the cover of the present invention has an iron-based base material, which satisfies the mechanical strength originally required for the cover and at the same time is economical. is also preferable. In addition, more specific examples of the ferrous base material include cast iron or steel plate. For example, cast iron is used for manhole covers, cast iron or steel plate is used for side gutter covers, etc., depending on the use. selected. Further, the upper surface of this iron-based base material is made flat as described above.

In the cover of the present invention, the upper surface of the iron-based base material is first covered with a corrosion-resistant metal sprayed layer.

The corrosion-resistant metal sprayed layer can be formed on the surface of the ferrous base material using a conventionally known metal spraying method, and if necessary, the surface of the ferrous base material may be pretreated by degreasing, blasting, etc. rear,
It is formed by thermally spraying a corrosion-resistant metal in the form of a wire or powder using a thermal spray gun or the like. Specific examples of the corrosion-resistant metal constituting the corrosion-resistant metal sprayed layer include Ag, Ni, Cr%Zn, and alloys thereof, but from an economical point of view, Al1 to Ag
Alloy, N1-A, 9 alloy, and Nt-Cr alloy are preferred. When constructing a corrosion-resistant metal sprayed layer as an alloy system consisting of multiple metals, it is of course possible to spray a wire or powder that has been made into such an alloy in advance, but it is also possible to spray the wire rod or powder that has been made into such an alloy in advance, but it is not possible to mix the powders of each component metal. An alloy-based thermal spray coating may be formed by thermal spraying at the same time. The thickness of the corrosion-resistant metal sprayed layer is not particularly limited, but is 50 to 30 mm.
It is desired that the thickness be 0 μm, more preferably in the range of 100 to 200 μm. In other words, if the layer thickness is less than 50 μm, there will be a large number of through pores, and there is a risk that a sufficient corrosion prevention effect cannot be obtained. On the other hand, if the layer thickness exceeds 300 μm, there will be a cost disadvantage. This is because there is a high risk that it will become a problem.

On the upper surface of the cover lid of the present invention, a ceramic sprayed layer is formed on the corrosion-resistant metal sprayed layer by, for example, spraying using a conventionally known ceramic spraying method such as a plasma jet spraying method. As in the embodiment shown in Figs. 1 and 2, when forming ceramic sprayed layers of multiple colors, first mask off areas other than the designated areas and spray ceramics of one color, then spray the remaining colors. For the ceramic sprayed layer, repeat this operation one after another to form a ceramic sprayed layer of multiple colors.
). Various types of ceramics can be used to form the ceramic sprayed layer, but when trying to impart a color effect, Ag203, Ti02, C
r203, ZrO2, CooSS i02, Fe2
Oxide-based ceramics containing O3 as the main component and various additives depending on the color are used, such as Af1203, which is white, and AN20, which is black or gray.
Ceramics such as 3-Ti02, Ag203-Coo which exhibits a blue color, and ZrO2Y2O3 which exhibits a light color are preferably used. The thickness of the ceramic sprayed layer is not particularly limited, but is 100 to 300 μm.
m1 is preferably in the range of 150 to 200 μm. In other words, if the layer thickness is less than 100 μm, the wear resistance will not be sufficient, and there is a risk that an appropriate surface roughness cannot be obtained for a long period of time.
This is because if the layer thickness exceeds 300 μm, there is a strong possibility that it will be disadvantageous in terms of cost.

Note that the ceramic sprayed layer can of course be formed of monochromatic ceramics if no design effect is required.

In the lid of the present invention, the above-mentioned ceramic sprayed layer is sealed with a resin-based pore sealing material, and this sealing treatment is performed by brush coating, spray coating, This can be done by applying a resin-based pore sealing material by a method such as dip coating. When such a pore sealing treatment is performed, a film of resin-based pore sealing material is formed on the ceramic sprayed layer as in the embodiment shown in FIG. As long as it is blocked by the sealing material,
The film of the resin-based pore-sealing material is not particularly necessary, and there is no problem even if the film of the pore-sealing material is worn away due to contact with a passing object on the upper surface, for example. Examples of such resin-based pore sealing materials include vinyl chloride resins, acrylic resins, polyester resins, polyurethane resins, melamine resins, epoxy resins, silicone resins, and polymer blends thereof. However, as described above, if the lid is to be colored by the color of the ceramic sprayed layer, it is necessary to use a transparent resin-based sealing material. Furthermore, the resin coating layer formed on the ceramic sprayed layer or the corrosion-resistant metal sprayed layer using such a resin-based pore sealing material in the embodiment shown in FIG. As long as the resin-based pore sealing material is used, it is not particularly required, and the layer thickness is not limited at all, but it should be about 5 to 100 μm, preferably about 30 to 60 μm. is desirable. That is, the layer thickness is 5μ
If the thickness is less than 100 m, there is a risk that the pores in the ceramic sprayed layer cannot be sufficiently closed.
If it exceeds μm, the appropriate surface roughness on the upper surface provided by the ceramic sprayed layer will be buried by the resin coating layer, and in the initial stage of construction,
This is because there is a risk that the cover may become relatively slippery.

(Example) Hereinafter, the present invention will be explained in more detail with reference to Examples.

Example 1 After blasting the surface of a cast iron test piece substrate,
Nickel-aluminum powder was sprayed using a gas plasma gun to form a nickel-aluminum sprayed layer with a layer thickness of 200 μm. Next, gray ceramics (
Gray alumina) was sprayed using a gas plasma gun to form a ceramic sprayed layer with a thickness of 150 μm on the nickel-aluminum sprayed layer. Furthermore, for sealing treatment, a transparent epoxy resin prepolymer was applied and dried and cured to form an epoxy resin pore sealing film layer with a layer thickness of 60 μm. The obtained test pieces were tested for abrasion resistance, slip resistance (BPN), stain resistance, and film adhesion under the conditions shown below. The results are shown in Table 1.

Comparative Example 1 For comparison, a test piece substrate made of cast iron and coated with epoxy resin (film thickness: 60 μm) was prepared. The resulting test piece was examined for abrasion resistance, slip resistance (BPN), stain resistance, and film adhesion in the same manner as in Example 1.

The results are shown in Table 1.

Comparative Example 2 For comparison, the surface of a cast iron test piece substrate was blasted, and then a gray ceramic (gray alumina) was thermally sprayed with a gas plasma gun to form a ceramic sprayed layer with a thickness of 150 μm on the surface of the cast iron substrate. A model was created by directly forming the . Regarding the obtained test piece, abrasion resistance, slip resistance value (BPN), stain resistance, and film adhesion were examined in the same manner as in Example 1. The results are shown in Table 1.

Abrasion Test Using a ball-on-disc device, a steel ball was rotated on each of the obtained test pieces at a pressurizing weight of 3°0 kg and a rotational speed of 7 rpm to measure the average wear depth.

Measurement test for slip resistance value (BPN) After the surface of the test piece was wetted with water in advance, the slip resistance value was measured using a British Portapul skid resistance tester.

Stain test Ink stain: 1 c/cm2 of black ink on the surface of the test piece
The sample was applied at a ratio of 1.c, washed with water after 5 minutes, and the degree of stain remaining on the surface of the test piece was evaluated by visual inspection. The evaluation is ◎ if it is very good with almost no stains, ○ if it is good without stains, △ if there is some noticeable stains.
The evaluation was carried out on a four-level scale, with "×" indicating extremely large amounts of dirt.

Rubber tire slip stain: Rub a piece of rubber tire on the surface of the test piece by applying a load of approximately 10 kg and rubbing it back and forth 10 times, then washing with water using a scrubbing brush, and then visually evaluating the degree of stain remaining on the surface of the test piece. did. Note that the evaluation was performed using the same four-level evaluation as above.

Muddy water stain: Muddy water was poured onto the surface of the test piece, and the degree of stain remaining on the surface of the test piece after washing with water was visually evaluated. Note that the evaluation was performed using the same four-level evaluation as above.

Adhesion Test A tensile test was conducted according to JIS H8666 to examine the adhesion of the film formed on the substrate surface.

Table 1 Average Wear Depth (μm) Adhesion Comparative Example 1 Abrasion exceeded 60 μm in 10 minutes and was discontinued as it reached the cast iron base material 12° Comparative Example 2 Example 2 and Comparative Example 3 No uneven pattern on the surface After blasting the surface of the iron lid, an aluminum sprayed layer with a thickness of 100 μm was formed by arc spraying. Next, according to a predetermined pattern as shown in FIG. 2, ceramics having each color of light brown, white, green, and blue are thermally sprayed with a gas plasma gun while masking in order, and a layer thickness of 150 μm is formed on the aluminum thermal spray layer. A ceramic sprayed layer was formed. Furthermore, for sealing treatment, a transparent vinyl chloride resin clear was applied and dried to form a vinyl chloride resin pore sealing film layer with a layer thickness of 60 μm (Example 2).

On the other hand, for comparison, the pattern shown in Figure 2 is
An aluminum sprayed layer, a ceramic sprayed layer, and a sealing film layer were formed in the same manner as above using an iron lid formed with an uneven pattern (Comparative Example 3).

First, when comparing the two in terms of appearance, it is found that in Example 1, a predetermined pattern as shown in Fig. 2 is neatly formed by a plurality of colored ceramics, and the aesthetic effect is extremely high, whereas in Comparative Example In Example 3, there was a slight discrepancy between the uneven pattern formed on the iron base material and the color pattern formed by the colored ceramic, and its appearance was slightly inferior to that of Example 2. Ta.

In addition, for a short period of time, we placed both of them on a road surface with a certain amount of foot traffic and observed the degree of dirt, etc., and found that neither of them had any noticeable dirt or fading. Although this was not the case, in the case of Comparative Example 3, L dust and the like accumulated in the concave portions, and the design attached to the surface became blurred.

Furthermore, impact force and frictional force were applied to the surfaces of both of them under somewhat excessive conditions, but problems such as cracking or peeling of the coating layer did not occur in either case.

(Effects of the Invention) As described above, the cover lid of the present invention has a flat L part surface, and in these two parts, a corrosion-resistant material is formed on the surface of the iron base material. It is characterized by a thermally sprayed metal layer and a thermally sprayed ceramic layer being sequentially laminated, and a sealing treatment using a resin-based sealing material applied thereon, and the surface does not have an uneven pattern. Nevertheless, due to its high surface friction resistance and good abrasion resistance, it exhibits a high anti-slip effect for a long time when placed on the road surface. This solves manufacturing problems such as problems with molds due to design changes on one side and problems with free design changes, which were caused by the need to attach a cover. It is possible to create a shell without causing problems such as accumulation of dust in the recess.
It is capable of maintaining the color tone at the initial stage of construction for a long period of time, and exhibits excellent effects in terms of functionality, economy, manufacturing, maintenance, and aesthetics.

[Brief explanation of drawings]

FIG. 1 is a sectional view schematically showing an embodiment of the cover lid of the present invention, and FIG. 2 is a drawing schematically showing an example of a coloring pattern used in the embodiment. 1... Cast iron F material, 2. ...Corrosion-resistant metal spray layer, 3
... Ceramic sprayed layer, 4... Resin coating layer, 5...-E section surface, 6... Lower surface, 7... Peripheral side surface.

Claims (2)

[Claims] (1) A cover that is placed on the road surface and has a flat upper surface, and on this upper surface, a corrosion-resistant metal sprayed layer and a ceramic sprayed layer are coated on the surface of the iron base material. A cover lid characterized in that these are sequentially laminated and then sealed with a resin-based pore sealing material. (2) The cover according to claim 1, wherein the ceramic sprayed layer is made of colored ceramics of a plurality of colors, and a transparent resin-based pore sealing material is used as the resin-based pore sealing material.