Resin component

Abstract

This resin member is provided with a photocatalyst coating film on the surface of a resin substrate. Furthermore, the photocatalyst coating film contains anatase-type titanium oxide particles and metal particles, the metal particles are stacked to shield the resin base material, and the anatase-type titanium oxide particles are dispersed among the metal particles. Thus, it is possible to provide a resin member provided with a photocatalyst coating film that has both a high photocatalyst effect and prevention of deterioration of a resin base material.

Description

Technical Field

[0001] This invention relates to resin components, and more specifically, to resin components having self-cleaning properties. Background Technology

[0002] Titanium oxide has the effect of photocatalysis through light energy, which can oxidize and decompose organic matter such as pollutants and odors. In addition, it also exhibits antibacterial / antiviral effects. Therefore, by coating the surface of components, it can impart self-cleaning properties to keep the surface of components clean.

[0003] Regarding the photocatalytic effect of titanium dioxide, the anatase type crystal structure is superior to the rutile type. The anatase type titanium dioxide transforms into the rutile type at temperatures exceeding 700°C, which reduces its photocatalytic effect.

[0004] Patent document 1 discloses the following: by granulation to increase the particle size of titanium oxide, it is possible to suppress the transformation of titanium oxide from anatase to rutile caused by heat during melt spraying, and to increase the residual ratio of anatase titanium oxide.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent No. 3944551 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] However, in the photocatalyst coating material described in Patent Document 1, the transformation of titanium dioxide to rutile is not sufficiently suppressed, resulting in low photocatalyst performance. In addition, the resin substrate deteriorates due to the oxidation of titanium dioxide.

[0010] The present invention was made in view of the problems of the prior art, and its object is to provide a resin component having a photocatalyst coating on the surface with high photocatalyst effect and capable of preventing the degradation of the resin substrate.

[0011] Technical solutions for solving the problem

[0012] To achieve the above objectives, the inventors conducted repeated and in-depth research and found that by using a cold spraying method to blow anatase titanium oxide particles and metal particles onto a resin substrate in a non-molten state, and by using the metal particles to shield the resin substrate, the above objectives can be achieved, and the present invention can be completed.

[0013] That is, the resin component of the present invention has a photocatalyst coating on the surface of the resin substrate.

[0014] Furthermore, the resin component is characterized in that the aforementioned photocatalyst coating comprises anatase titanium dioxide particles and metal particles.

[0015] The aforementioned metal particles are stacked to shield the aforementioned resin substrate, and the aforementioned anatase titanium oxide particles are dispersed between the aforementioned metal particles.

[0016] Furthermore, the present invention provides a method for manufacturing a resin component, wherein the manufacturing of the resin component of the present invention includes a coating step of blowing non-molten raw material particles onto the surface of the resin substrate to form a photocatalyst coating.

[0017] Furthermore, the manufacturing method of this resin component is characterized in that the raw material particles comprise anatase titanium dioxide particles and metal particles.

[0018] The above-mentioned coating process includes a treatment that reduces the temperature of the raw material particles that collide with the above-mentioned resin substrate to 100-150°C.

[0019] Invention Effects

[0020] According to the present invention, since anatase titanium dioxide particles and metal particles are blown onto a resin substrate in a non-molten state and the resin substrate is shielded by the metal particles, a resin component with a photocatalyst coating that can achieve both high photocatalyst effect and prevent degradation of the resin substrate can be provided. Attached Figure Description

[0021] Figure 1 This is a cross-sectional view illustrating an example of the structure of the resin component of the present invention.

[0022] Figure 2 This is a diagram showing an example of raw material particles used in granulation.

[0023] Figure 3 This is a cross-sectional image of the resin component of the present invention. Detailed Implementation

[0024] <Resin Components>

[0025] The resin component of the present invention will be described in detail.

[0026] The resin component of the present invention has a photocatalyst coating on the surface of a resin substrate, the photocatalyst coating being as follows: Figure 1 As shown, metal particles are stacked to shield the resin substrate, and anatase titanium oxide particles are dispersed between the stacked metal particles.

[0027] In this invention, metal particles shielding the resin substrate means that metal particles are present in the light path of light incident on the resin component from all directions, and the titanium oxide of the transmitted light does not connect from the surface to the interface between the photocatalyst coating and the resin substrate, so the light does not reach the resin substrate.

[0028] That is, at a certain depth of the photocatalyst coating, even if there are discontinuous parts of metal particles in the in-plane direction, it is sufficient for metal particles to be present in the out-of-plane direction (at different depths) of that part to block the light. It does not mean that the metal particles are continuous in the in-plane direction at a certain depth until the layer is formed.

[0029] By shielding the resin substrate with metal particles, even if titanium oxide particles are present near the interface between the photocatalyst coating and the resin substrate, the titanium oxide near the interface cannot exhibit an oxidizing effect, thus preventing the degradation of the resin substrate.

[0030] Furthermore, the photocatalyst coating of the resin component of the present invention is formed by stacking metal particles. Therefore, unlike the coating with dispersed titanium oxide, even if peeling occurs, the photocatalyst coating will not form sharp edges. Therefore, even if it is used on a part that is touched by the hand, it will not cause injury.

[0031] The aforementioned photocatalyst coating can be formed by cold spraying.

[0032] The cold spraying method is as follows: in a non-molten state without melting or vaporizing the raw material particles, the solid-state raw material particles collide with the substrate through a supersonic flow of working gas to form a coating.

[0033] According to this cold spraying method, the photocatalyst coating can be formed at low temperature, without the need to heat the anatase titanium oxide particles above their transformation temperature as in other thermal spraying methods. Therefore, it can prevent the titanium oxide particles from transforming from anatase to rutile, resulting in a high photocatalyst effect.

[0034] While the thickness of the aforementioned photocatalyst coating also depends on its thickness, it is preferable that the area % of the metal particles in the cross-section is greater than 50% and less than 95%, more preferably 55-90%, and even more preferably 60-80%.

[0035] By ensuring that the area percentage of the metal particles is within the aforementioned range, it is possible to balance preventing light transmission to the vicinity of the resin substrate with the photocatalytic effect generated by the titanium oxide particles near the surface.

[0036] If the area percentage of metal particles exceeds 95%, the number of titanium oxide particles decreases, and the photocatalytic effect is reduced. Furthermore, if it is below 50%, as described later, the metal particles also act as a binder, thus reducing the coating strength.

[0037] Metal monomers or alloys can be used as the metallic materials that constitute the aforementioned metal particles.

[0038] The aforementioned metallic material possesses ductility and malleability, enabling it to undergo plastic deformation. The metallic particles of this invention not only shield the resin substrate from incident light but also act as an adhesive, retaining the titanium dioxide particles and forming a photocatalyst coating with high bonding strength.

[0039] The Vickers hardness of the above-mentioned metallic material is preferably 700 (Hv) or less, more preferably 500 (Hv) or less, and even more preferably 400 (Hv) or less.

[0040] Metal particles are formed from metallic materials with a Vickers hardness of less than 700 (Hv). Due to the impact during the coating process, the metal particles undergo significant plastic deformation.

[0041] High adhesion / bonding force is obtained through the plastic deformation of the metal particles, which can improve the coating strength and maintain the titanium oxide particles without plastic deformation, thus improving the coating formation efficiency.

[0042] In other words, metal particles blown onto a resin substrate using a cold spray method become embedded in the resin substrate, undergo plastic deformation, and adhere, forming irregular bumps and depressions at the interface with the resin substrate. This bonding effect allows them to adhere to the resin substrate. Furthermore, the metal particles receive and retain subsequently impacted titanium dioxide particles, thus suppressing rebound.

[0043] In this way, according to the film formation method of cold spraying raw material particles containing metal particles, the metal particles are plastically deformed and metallurgically bonded to each other due to collisions. Regardless of the metallurgical bonding such as the formation and diffusion of intermetallic compounds, the titanium oxide particles are mechanically bonded to the metal particles or resin substrate through the anchoring effect.

[0044] There is no particular limitation on the lower limit of the Vickers hardness of the above-mentioned metallic materials, but it has been confirmed that metallic particles with a hardness of up to 350 (Hv) can also form films.

[0045] Examples of the aforementioned metal monomers include copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), iron (Fe), silver (Ag), titanium (Ti), zinc (Zn), and magnesium (Mg).

[0046] In addition, as an example of the aforementioned alloy, an alloy containing 50% by mass or more of a metal selected from copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), iron (Fe), silver (Ag), titanium (Ti), zinc (Zn), and magnesium (Mg) can be cited.

[0047] Among them, because copper or silver has a bactericidal effect, it is preferable to use copper or silver monomers or alloys containing more than 50% by mass.

[0048] Furthermore, from a design perspective, by using monomers of copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), and silver (Ag), a glossy or shiny photocatalyst coating can be applied, while by using monomers of iron (Fe) or titanium (Ti), a matte photocatalyst coating can be formed.

[0049] In addition, by changing the composition ratio of the aforementioned alloys, such as Cu-Zn or Cu-Ni-Zn, it is possible not only to improve the hardness and durability of the photocatalyst coating, but also to change the color of the photocatalyst coating.

[0050] Furthermore, the color of the photocatalyst coating can also be altered by forming a coloring layer on the surface of the metal particles. Examples of such coloring layers include coatings, chemically formed films, and inorganic pigment coatings.

[0051] Examples of such coatings include nickel (Ni), nickel-phosphorus (Ni-P), copper (Cu), and zinc (Zn), which can be formed by electroless plating.

[0052] Examples of such chemically formed films include zinc phosphate films, iron phosphate films, and manganese phosphate films formed by phosphate film treatment; chromium oxide films formed by chromate treatment; and iron oxide films formed by blackening treatment.

[0053] The aforementioned inorganic pigment coating film can be formed by embedding the inorganic pigment into the surface of metal particles through a high-speed airflow impact method or by spray coating using molten glass as a binder. In addition to natural mineral pigments obtained from minerals or soil, synthetic inorganic pigments such as metal oxides can also be used as inorganic pigments.

[0054] The resin component of the present invention can also have a coating on the aforementioned photocatalyst coating, and this coating has defects. Therefore, the color of the resin component surface can be set to a different color than the color of the photocatalyst coating. Furthermore, by exposing the anatase titanium oxide particles from the defects in the photocatalyst coating, the photocatalyst effect can be exhibited.

[0055] The aforementioned defective coating can be fabricated by connecting the photocatalyst coating to a DC power source and forming the coating in a processing solution.

[0056] According to this electroplating method that utilizes DC power, the anatase titanium oxide particles are not conductive. Therefore, no coating is formed on the anatase titanium oxide particles exposed on the surface of the photocatalyst coating. The coating is formed only on the part of the photocatalyst coating formed by metal particles. Thus, the anatase titanium oxide particles can be exposed from the defective parts of the coating.

[0057] As a coating formed on a photocatalyst coating, examples include coatings of electroplatable metals such as copper, nickel, chromium, gold, silver, and zinc.

[0058] Furthermore, the resin component of the present invention can improve the tactile feel by setting the surface roughness (Ra) to 25 μm or less. If the surface roughness (Ra) is in the range of 5 to 25 μm, a high-end feel based on wrinkles can be exhibited, and by setting the surface roughness (Ra) to less than 5 μm, the metallic luster can be improved.

[0059] The average particle size of the aforementioned metal particles is preferably 10–50 μm, more preferably 20–40 μm.

[0060] As a result, the shielding effect is improved, and the kinetic energy of the metal particles during cold spraying is increased, which can improve the coating formation efficiency.

[0061] In addition, when the thickness of the photocatalyst coating is around 100 μm, if the particle size of the metal particles exceeds 50 μm, the metal particles are prone to falling off during grinding. Furthermore, as the metal particles become larger, the uniform dispersion of titanium oxide particles on the surface of the photocatalyst coating will decrease.

[0062] As the aforementioned titanium dioxide particles, anatase-type titanium dioxide particles with an average particle size of 0.01 μm to 2 μm can be used.

[0063] In addition, anatase titanium dioxide particles loaded with copper exhibit photocatalytic effects through visible light rather than ultraviolet light, thus providing self-cleaning properties even in indoor environments with low ultraviolet light, making them a preferred choice.

[0064] Examples of such titanium oxide particles include TKP-103 manufactured by TAYCA.

[0065] Because the resin components of the present invention have self-cleaning properties, they can be used not only for vehicle resin components such as steering wheels and door handles that are prone to the adhesion of sebum and dirt, but also preferably for resin components for conveying equipment, electronic equipment, household appliances, office use, residential use, medical and health use, etc.

[0066] <Manufacturing Method of Resin Components>

[0067] Next, the method for manufacturing the above-mentioned resin component will be described in detail.

[0068] The manufacturing method of the resin component of the present invention includes the following coating process: by cold spraying, raw material particles containing anatase titanium oxide particles and metal particles are blown onto the surface of a resin substrate to form a photocatalyst coating.

[0069] As mentioned above, the above-mentioned cold spraying method is as follows: in a non-molten state without melting or vaporizing the raw material particles, the solid-state raw material particles collide with the substrate through the supersonic flow of working gas to form a coating.

[0070] According to the cold spraying method, a coating is formed by the plastic deformation of metal particles in the raw material particles that collide at supersonic speeds. Therefore, unlike other melt spraying methods, it can minimize the changes in the properties of the raw material particles caused by heat and the oxidation in the coating. Thus, it can prevent the titanium oxide particles from transforming from anatase to rutile.

[0071] In addition, the cold spray method uses a working gas at a temperature of 500-600°C where the raw material particles are not melted.

[0072] In the conventional cold spraying method for forming a coating on a metal substrate, in order to suppress the decrease in temperature and kinetic energy of the raw material particles, the nozzle spraying the raw material particles is brought close to the metal substrate, so that the raw material particles collide with the metal substrate.

[0073] In this invention, because a coating is formed on the resin substrate, the distance between the nozzle that sprays the raw material particles and the resin substrate is increased, thereby reducing the temperature of the working gas to below the heat resistance temperature of the resin substrate.

[0074] Specifically, the working gas, injected at 500–600°C, is reduced to 100–150°C, causing the raw material particles to collide with the resin substrate. This prevents deformation and deterioration of the resin substrate caused by the working gas.

[0075] The working gas expands and cools down as it is ejected from the nozzle. If the distance between the nozzle and the resin substrate is too close, the temperature of the working gas cannot drop sufficiently, and the resin substrate will dissolve. Conversely, if the distance is too far, not only will the working gas be too cold, but the velocity of the raw material particles will also decrease, reducing their adhesion to the resin substrate. Therefore, the distance between the nozzle and the resin substrate is preferably around 150 mm.

[0076] There are no particular restrictions on the resin used to form the above-mentioned resin base material; any of thermoplastic resins or thermosetting resins can be used.

[0077] If the resin substrate is a thermoplastic resin, the kinetic energy of the raw material particles is converted into heat energy due to collision. The thermoplastic resin at the collision site of the raw material particles partially melts and fuses with the colliding raw material particles. Therefore, combined with the bonding based on the above-mentioned anchoring effect, the bonding strength between the resin substrate and the photocatalyst coating can be improved.

[0078] By using cold spraying, raw material particles are embedded into the resin substrate. The speed at which the raw material particles can be bonded through the anchoring effect also depends on the hardness of the resin substrate, but is preferably 200 to 500 m / s.

[0079] The raw material particles can be a mixture of anatase titanium dioxide particles and metal particles, but preferably granulated particles formed by bonding anatase titanium dioxide particles and metal particles to achieve a larger particle size.

[0080] As mentioned above, the titanium dioxide particles are micro powders with an average particle size of 0.01μm to 2μm. Therefore, they are prone to agglomeration, difficult to transport, and easy to cause nozzle clogging.

[0081] By using the aforementioned large-diameter granulated particles as raw material particles, nozzle clogging can be prevented, and the kinetic energy of the raw material particles is increased, thereby improving the film formation efficiency of photocatalyst coating.

[0082] There are no particular restrictions on the method of granulation of the aforementioned particles, such as... Figure 2 As shown, it can be in the form of a metal particle as the core and the above-mentioned anatase titanium oxide particles attached around it, or conversely, in the form of anatase titanium oxide particles as the core and the above-mentioned metal particles attached around it, or in the form of a mixture of anatase titanium oxide particles and metal particles.

[0083] The method for manufacturing the resin component of the present invention includes a step of grinding / polishing the surface of the formed photocatalyst coating after the above-described coating process.

[0084] As mentioned above, titanium oxide particles are smaller than metal particles, so they are easily exposed on the surface of the photocatalyst coating. However, by grinding / sharpening the surface of the photocatalyst coating, anatase titanium oxide is uniformly exposed, thus achieving a homogeneous photocatalyst effect.

[0085] In addition, by grinding / sharpening to adjust the surface roughness of the photocatalyst coating, as mentioned above, it is possible to give it a design that improves tactile feel, gloss, matte finish, wrinkle texture, etc.

[0086] Example

[0087] The present invention will now be described in detail through examples, but the present invention is not limited to the following examples.

[0088] [Example 1]

[0089] A photocatalyst coating is formed by blowing copper particles (Cu-HWQ-350 manufactured by Fukuda Metal Foil Powder Industry) and anatase titanium oxide particles (JA-1 manufactured by TAYCA) at a mass ratio of 6:1 onto the surface of a polypropylene resin substrate using a cold spraying method under the following conditions. The surface is then ground with a brush to produce resin parts.

[0090] Cold spraying conditions

[0091] Device: PCS-1000 (manufactured by Plasma Giken Industrial Co., Ltd.)

[0092] Working gas: N2 gas, injection pressure 3MPa, injection temperature 600℃

[0093] Nozzle-substrate distance: 150mm

[0094] (The temperature of the raw material particles when colliding with the resin substrate is 100℃, and the collision speed of the raw material particles is 300m / s)

[0095] The cross-section of the fabricated resin component was observed using energy-dispersive X-ray spectroscopy (SEM-EDX) to perform elemental analysis of the photocatalyst coating.

[0096] The analysis results are in Figure 3 As shown in the image.

[0097] according to Figure 3 It is known that in areas where there is no titanium (Ti) continuous from the surface to the resin substrate, the resin substrate is shielded by copper (Cu) particles, which can prevent the degradation of the resin substrate caused by titanium oxide.

[0098] Explanation of reference numerals in the attached figures

[0099] 1. Resin components

[0100] 2. Photocatalyst coating

[0101] 21 Anatase titanium dioxide particles

[0102] 22 Metal particles

[0103] 3. Resin substrate

Claims

1. A resin component having a photocatalyst coating on the surface of a resin substrate, characterized in that, The photocatalyst coating comprises anatase titanium dioxide particles and metal particles. The metal particles are stacked to shield the resin substrate, and the anatase titanium oxide particles are dispersed between the metal particles.

2. The resin component according to claim 1, characterized in that, The area of ​​metal particles in the cross-section of the photocatalyst coating exceeds 50% and is less than 95%.

3. The resin component according to claim 1, characterized in that, The Vickers hardness of the metal particles is below 700 (Hv).

4. The resin component according to claim 1, characterized in that, The resin substrate and the photocatalyst coating are bonded at least through an anchoring effect.

5. The resin component according to claim 1, characterized in that, The surface roughness (Ra) is below 25 μm.

6. The resin component according to claim 1, characterized in that, The metal particles have a coloring layer on their surface.

7. The resin component according to claim 6, characterized in that, The coloring layer is a coating selected from nickel (Ni), nickel-phosphorus (Ni-P), copper (Cu), and zinc (Zn).

8. The resin component according to claim 6, characterized in that, The coloring layer is a chemically formed film selected from phosphate film, chromium oxide film and iron oxide film.

9. The resin component according to claim 6, characterized in that, The coloring layer is an inorganic pigment coating film containing inorganic pigments.

10. The resin component according to claim 1, characterized in that, The photocatalyst coating also has a deposit, which has defects. The anatase titanium dioxide particles in the photocatalyst coating are exposed from defects in the coating.

11. The resin component according to any one of claims 1 to 10, characterized in that, The resin component is selected from resin components for vehicles, resin components for conveying equipment, resin components for electronic devices, resin components for home appliances, resin components for office use, resin components for housing, and resin components for medical and health use.

12. A method for manufacturing a resin component, comprising manufacturing the resin component according to any one of claims 1 to 11, characterized in that, The process includes a coating step that involves blowing non-molten raw material particles onto the surface of the resin substrate to form a photocatalyst coating. The raw material particles include anatase titanium dioxide particles and metal particles. The coating process includes a treatment that reduces the temperature of the raw material particles that collide with the resin substrate to 100-150°C.

13. The method for manufacturing a resin component according to claim 12, characterized in that, The coating process includes a treatment that causes the raw material particles to collide with the resin substrate at a speed of 200-500 m / s.

14. The method for manufacturing a resin component according to claim 12, characterized in that, After the coating process, there is a process of grinding and / or polishing the surface.

15. The method for manufacturing a resin component according to claim 12, characterized in that, The raw material particles are granulated particles of anatase titanium dioxide particles and metal particles.

16. The method for manufacturing a resin component according to claim 15, characterized in that, The granulated particles have the metal particles as the core, and the anatase titanium oxide particles are attached around the metal particles.

17. The method for manufacturing a resin component according to claim 15, characterized in that, The granulated particles have the anatase titanium dioxide particles as the core, and the metal particles are attached around the anatase titanium dioxide particles.

18. The method for manufacturing a resin component according to claim 15, characterized in that, The granulated particles are a mixture of anatase titanium dioxide particles and metal particles.

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