JPH057200B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention involves forming an arbitrary uneven pattern by embossing on a thin metal plate having a decorative coating or a decorative film made of film, and applying a three-dimensional effect enhancer to this uneven pattern to create a mechanical uneven pattern. This invention relates to a three-dimensional effect enhancing device that can easily add a visual three-dimensional effect through color, have a deeper uneven patterned surface, and continuously produce decorative metal thin sheets with excellent weather resistance. . In general, thin metal sheets, particularly organic coated steel sheets, fluorine resin coated steel sheets, and vinyl chloride steel sheets, are being used for a wide variety of purposes. This is because this type of steel sheet has excellent workability and design, as well as durability. Recently, the demand has shifted to steel sheets that have enhanced fashionability by adding three-dimensional effects, two-tone colors, etc. to the flat surface of the steel sheet. As a steel plate corresponding to this, for example, a steel plate on which an irregular pattern is formed by embossing is commercially available. However, when a salt spray test (JIS-Z-2371) was conducted on these steel plates,
Rust and peeling of the paint film were observed on the bent parts after 500 to 1000 hours. In addition, when observing the surface of this type of steel sheet under 30x magnification, it can be seen that some of the coating film has peeled off and become wrinkled, scratched, cracked, or thinned at the bent parts of concave and convex parts. or cracks were occurring. This is because the embossing line is not suitable. Furthermore, simply adding two-tone color or the like to the decorative surface has the disadvantage that it lacks the ability to visually enhance the fashionability and three-dimensional effect. In order to eliminate these drawbacks, the present invention softens the decorative coating during embossing to exhibit ductility, thereby eliminating peeling, wrinkles, scratches, and cracks in the coating, and easily correcting residual distortion during embossing. By applying a three-dimensional effect enhancer that exhibits a shadow function from only one direction to at least the sloped surface (side surface) of the convex pattern of the uneven pattern, it is possible to easily create a three-dimensional effect visually. This paper proposes a device for enhancing the three-dimensional effect of a cosmetic surface. DESCRIPTION OF THE PREFERRED EMBODIMENTS A device for enhancing the three-dimensional effect of a decorative surface (hereinafter simply referred to as an enhancement device) according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is a schematic configuration diagram showing an example of the above-mentioned device. 1 is a thin metal plate feeding section (hereinafter simply referred to as the feeding section), which is composed of an uncoiler 2 and a pinch roller 3, and a flat plate wound into a coil shape. This is for attaching a shaped metal thin plate A (having a decorative film such as a decorative paint film or a decorative film) and constantly feeding it to the loop portion 4 without strain. The loop section 4 controls the speed difference and deviation that occur when transferring the thin metal plate A (hereinafter simply referred to as a coil) after the heater section 5 in the next process by loosening the coil A, and also This functions to prevent a large impact from being applied to the coil A being fed. The heater section 5 is composed of a pinch roller 6 that also serves as a guide and a heater 7. The pinch roller 6 pinches the coil A with upper and lower rollers 6a and 6b only at the start of the line, and thereafter acts as a mere guide roller to hold the coil A. It is supplied to the heater 7. In addition, the heater 7 heats the decorative coating of the coil A, which is essentially the coil A itself, at a temperature of about 30 to 60°C.
This prevents the decorative film from peeling off or cracking from the steel plate during embossing.
This prevents scratches and cracks from occurring. The heating method is one of a hot air method, an open flame method, and a hot wire method. 8
The pinch roller feeds the coil A to the embossing roll 9 at a predetermined speed, and also functions as a brake against the movement of the coil A during embossing. The embossing roll 9 has a pattern consisting of male and female uneven parts formed on its outer peripheral surface, and the lower rolls 9a and 9b are engaged to form an arbitrary uneven pattern on the coil A, for example, the uneven pattern shown in FIGS. 2a and 2b. The upper and lower rolls 9a, 9b
The gap is determined by the height of the uneven pattern and the thickness of the coil A. Reference numeral 10 is a leveler for correcting residual strain existing in the embossed coil A', and upper rollers 10a ₁ , 10a ₂ , 10
a ₃ , ... 10a _o (shown up to 10a ₃ in Figure 3), lower rollers 10b ₁ , 10b ₂ , 10b ₃ , ... _10bo (shown up to 10b ₄ in Figure 3) in this order in a zigzag pattern. , and the upper roller group 10a and the lower roller group 10
The gap G between b and b can be adjusted. Reference numeral 11 denotes a tensioning pinch roller which rotates faster than the embossing roll 9 and allows the coil A' to pass through the steps of the embossing roll 9 and leveler 10 while being stretched (under tension). . 12 is a masking film applicator (hereinafter simply referred to as a film applicator) which uses a roll coater and a brush to coat only the top surface of the convex pattern of the concave and convex patterns B and C as shown in Figure 2 a and b. A masking material D, such as paint or film, is applied to mask the area. Reference numeral 13 denotes a three-dimensional effect promoter coating machine (hereinafter simply referred to as a coating machine) that applies the three-dimensional effect enhancer E only from one direction of the uneven pattern, thereby forming a concave pattern surface B and a convex pattern as shown in FIGS. 4a to 4c. The three-dimensional effect enhancer E is applied in the form of a film, dots, or lines only on the top surface of C and the side surface of the convex pattern, where the application direction α of the three-dimensional effect enhancer E collides with the traveling direction β of the coil A′. Shading is formed according to the purpose with one or more types of distribution, and depending on the angle θ of the applicator 13, the shape and depth of the uneven pattern, and the moving speed of the coil A', thereby enhancing the three-dimensional effect. At the same time, it is formed so as to create an illusion that the uneven pattern appears to be reversed depending on the viewing direction. As this type of apparatus, one of a spray gun, a roll coater, and a curtain flow coater is used. Reference numeral 14 is a drying oven in which the top surface of the convex pattern of the concavo-convex pattern surface is dried, and the three-dimensional effect enhancer E is dried or baked. 15 is a device that applies a top coating film F to the top surface of the convex pattern C using a coating machine, and coats the masking material D and the three-dimensional effect promoter E;
For example, it consists of a roll coater. In addition,
The top coating film F may be one that is glossy or one that differs in brightness, saturation, and hue from the three-dimensional effect enhancer E. Reference numeral 16 is a dryer for drying the top coating film F, such as curing or baking. Next, the operation of the device according to the present invention will be explained. First, the flat coil A mounted on the feeding section 1 is fed to the loop section 4 via the pinch roller 3. In addition, at this time, the coil A is connected to the pinch roller 3.
Since the uncoiler 2 is equipped with a braking device (not shown) even when the coil A is pulled by the uncoiler 2, the coil A is fed to the loop section 4 under a certain permissible tension. The coil A is then transferred from the loop section 4 to the heater section 5 by a pinch roller 6 which also serves as a guide.
The cosmetic film is then fed to a heater 7, where it is heated to about 30 to 60°C to soften the decorative film, and then fed to a pinch roller 8. Note that the pinch roller 6 that also serves as a guide functions as a pinch roller until the coil A is stabilized on the pinch roller 8, and thereafter functions as a mere guide roller. Next, pinch roller 8
The coil A sent out from the embossing roll 9 is fed to the embossing roll 9, which continuously forms an embossed pattern consisting of a concave pattern B and a convex pattern C as shown in FIG. 2 a and b, for example, on the coil A. It is. On this occasion,
Embossing is performed with tension applied to coil A. The coil A' sent out from the embossing roll 9 is then sent to the leveler 10.
The residual strain generated during embossing is corrected in the tensioned state between the embossing roll 9 and the tensioning pinch roller 11, and the film is fed to the coating machine 12. The force relationship between the pinch roller 8 and the tensioning pinch roller 11 with respect to the coil A' is as follows:
When the rotation of the embossing roll 9 is used as a reference, the rotation of the pinch roller 8 is set to be slow and the rotation of the tensioning pinch roller 11 is fast.
Embossing, flattening, and removal of residual strain are carried out under tension. As a result, the coil A will no longer form a mountain shape in the above-mentioned area, twist and move, or flap at the entrance of the embossing roll 9, and will not shift during embossing and the pattern will become unclear or double. This will prevent you from getting caught. Further, since the leveler 10 is in a state where tension is applied in one direction, the uneven patterns B and C can be easily flattened without deforming them, and residual strain can be easily released. Of course, the tension within the above range is within the range of force that does not change the embossed pattern. Further, the film applicator 12 applies a masking material D to the top surface of the convex pattern C. Next, the coil A' sent out from the coating machine 12 is coated with the coating machine 1.
According to step 3, the three-dimensional effect enhancer E, which has at least one of density, hue, and saturation different from the decorative film, is applied to the entire surface of the uneven pattern using a spray gun, facing the direction of movement of the coil A' at an angle of θ = 45°. The coating is applied and adhered to each uneven pattern as shown in FIGS. 4a to 4c. Of course, at this time, the distribution of the three-dimensional effect enhancer E in each part of the concave pattern B and the convex pattern C may be uniform, non-uniform, a mixed distribution, or a distribution in which the density gradually changes. The coil A′ having such an uneven decorative surface is dried in the drying oven 14.
The masking material D and the three-dimensional effect promoting material E are dried (baked or hardened) and then fed to the coating machine 15. The coating machine 15 applies the top coating film F to the top surface of the convex pattern surface C to create a difference between it and the concave pattern B, and sends it to the dryer 16 to dry the top coating film F. It is something that is baked on. Example A colored galvanized iron plate (JIS-G-3312) with a plate thickness of 0.27 mm is used as the coil A, and the temperature of the heater 7 is 10 to 10.
The temperature was changed to 80°C, the embossing depth was 0.9 mm, the ratio of concave pattern B to convex pattern C was 1:1, and the embossing speed was 38 m/min. In addition, a pinch roller 8 and a tensioning pinch roller 11 are also provided.
The speed difference between them was about 3%. Furthermore, a synthetic resin paint is used as the masking material D, and a three-dimensional effect enhancer E is used.
For this purpose, paint consisting of black alkyd resin is applied with a spray gun, and heated to 90℃ in a drying oven 14.
The film was preheated at 200°C for 5 minutes and baked at 200°C for 1 minute.
Further, in the applicator 15, a paint made of white alkyd resin is applied to the top surface of the convex pattern surface C using a roll coater, and this is baked in the dryer 16. The paint for coil A is white and uses alkyd resin as a vehicle. Then, when the temperature of the surface of the coil A, the so-called temperature of the decorative film (in this case, the paint film) is changed from 0 to 80°C, peeling of the decorative film, cracking, cracking, shrinkage, etc. ,
The state of the flaws is shown in a line graph in Figure 5. Further, the flatness and degree of residual strain (pekotsuki) of the coil A' sent out from the leveler 10 were visually observed. In addition, the inspection method is (1) coil
The apparent number of Pekotoskis that exist per meter of A′, (2) the distribution state of Pekotsuki, (3) the height difference of Pekotsuki (bottom and top surfaces of the designed irregularities and the actual bottom surface, (4) Observations regarding the overall appearance are shown. Furthermore, (5) the three-dimensional effect of the uneven pattern surface is visually observed when the coil A' is propped up in the advancing direction and in the opposite direction. Comparative example Coil A as described above was embossed in the previous process, and then a paint of a color different from that of the coil was applied using a spray gun from directly above the so-called uneven pattern surface using the usual method. The dried material was used as a test piece.

[Table] Furthermore, the results of a salt spray test (1500 hours) of the example (coil A when the decorative coating was heated to 50°C) and the coil formed according to the comparative example were as shown in the table below. .

[Table] What has been described above is only one embodiment of the reinforcing device according to the present invention, and it is possible to keep the temperature from the heater 7 to the tensioning pinch roller 11 within a temperature range of about 30 to 60°C, and to create uneven patterns B and C. Depending on the distribution ratio, the number of stages of the leveler roller can be increased, the uneven pattern can be arranged so as to spread out from the center, or the uneven pattern can be distributed only over a certain width. moreover,
If the coil is a cut plate, it can be manufactured in the same way from the heater section in a subsequent process, and a curtain flow coater can also be used. In addition, the top surface of the convex pattern can be made into a mirror surface, a matte surface, or a sixth surface.
As shown in the figure, the surface is inclined, or the coating machine 13 is placed in the direction shown in Figure 7 a, b, and the angle 0 from the side surface is 0.
It is also possible to apply the stereoscopic effect enhancer E at ~90°.
Note that the angle of the coating machine 13 is 90° (as shown in Figure 7c)
Therefore, it is necessary that the speed of coil A is 10 m/min or more. Alternatively, a magnifying glass or a video camera may be installed at the position indicated by the dashed line in FIG. 1 to more clearly monitor the decorative surface after embossing. As described above, according to the reinforcing device according to the present invention, there is no change in the force applied to the coil in the embossing zone, and embossing can be performed under constant tension at all times, so the embossed pattern does not shift during processing and creates beautiful unevenness. Can form a shape pattern. Because the decorative film is heated to make it soft enough for embossing, the decorative film may peel off from the steel plate during embossing, or the decorative film may wrinkle, crack, scratch, or crack. Without,
It can form beautiful cosmetic coatings with excellent weather resistance, scratch resistance, and chemical resistance. The residual strain caused by the distortion formed by embossing can be easily and sufficiently removed by correction under tension, and a concavo-convex pattern with no flattening and full of three-dimensional effect can be formed. The lines are arranged in a straight line, and the process uses a flow that does not apply unreasonable force to the coil, allowing for smooth embossing. Embossing is performed by heating the coil, so it is not affected by the work environment even if the line is not kept at a constant temperature. The straight line allows for high-speed embossing. The top surface of the convex pattern of the concave-convex pattern is a highly reflective surface, and at least the sides of the convex pattern are coated with a three-dimensional effect enhancer that functions like a shadow, so the three-dimensional effect of the mechanical concave-convex pattern is improved.
Furthermore, the visual enhancement provided by the three-dimensional effect enhancer makes it possible to exhibit an unprecedented three-dimensional effect and depth. The three-dimensional effect enhancer can be easily applied after the uneven pattern surface is formed. It has the following characteristics.

[Brief explanation of the drawing]

FIG. 1 is a schematic configuration diagram showing an example of a device for enhancing the three-dimensional effect of a cosmetic surface according to the present invention, FIGS. 2a and 2b are explanatory diagrams showing a part of the uneven pattern, and FIG. A perspective view showing an example of a certain leveler, FIG. 4a
~c is an enlarged explanatory diagram showing the process of forming the decorative surface;
FIG. 5 is a characteristic diagram showing the temperature of the decorative film and the occurrence of cracks, etc., and FIGS. 6 and 7 a to 7 c are explanatory diagrams showing other examples. 1 ...Metal thin plate delivery section, 5 ...Heater section, 9...
... Emboss roll, 10 ... Leveler, 11 ... Tension pinch roller, 12 ... Masking film coater, 13 ... Three-dimensional effect promoter coater, 14 ... Drying oven, 15 ... Top coating film coater, A, A'...
sheet metal.

Claims (1)

[Claims] 1. In an apparatus for forming a concavo-convex pattern on a thin metal plate by embossing, there is a thin metal plate feeding unit consisting of an uncoiler and a pinch roller for feeding the thin metal plate, and a thin metal plate fed from the feeding unit to loosen the thin metal plate. a loop part that accommodates the metal sheet in the same state and adjusts the process before and after the process, a heater part that heats the thin metal plate to approximately 30 to 60 degrees Celsius, a pinch roller that also serves as a guide and is placed after the heater part, and a An embossing roll that applies an arbitrary uneven pattern to the thin metal sheet being sent out, a leveler placed after the roll, a pulling pinch roller placed at the outlet of the leveler, and masking on the top surface of the uneven pattern. A masking film applicator that applies a film, a three-dimensional effect promoter applicator that applies a three-dimensional effect enhancer from only one direction to the uneven pattern surface having the masking film, and a three-dimensional effect enhancer applicator that dries the three-dimensional effect enhancer and the masking film. A drying oven for drying, a coating machine for forming a top coating film on the convex-patterned surface of a thin metal plate sent from the drying oven, and a drying machine for drying the top coating film, which are arranged in series. A device that enhances the three-dimensional effect of surfaces.