Decorative steel panel and producing method thereof, decorative steel panel using decorative steel panel and producing method thereof

Abstract

To provide a decorative steel panel having high surface absorption power to a magnet, and improved safety during handling and a producing method thereof, as well as a decorative steel panel using the decorative steel panel and a producing method thereof.SOLUTION: A decorative steel plate 10 disclosed herein has at least a steel plate 1, an adhesive layer A2, and a substrate 3 in this order, and in a plane view from the steel plate side, it has a first area P where the substrate overlaps with the steel plate, and a second area Q arranged outside the first area along at least a part of the outer edge of the first area and not including the steel plate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a steel sheet panel that includes a steel sheet and is used to manufacture a decorative sheet (decorative steel sheet panel) capable of attracting and holding a magnet on its surface. [Background technology]

[0002] Decorative panels, which have a decorative layer on the surface of a non-flammable or wooden base material, have been used for the surface decoration of building interiors and attached furniture, etc. Among them, decorative panels, which have a steel plate between the decorative layer and the base material (referred to as decorative steel plate panels), are particularly useful because they are capable of attracting and holding magnets on their surface.

[0003] Patent Document 1 discloses a decorative magnetic decorative building material that has a facing material (decorative layer), steel foil, and a non-combustible board or wooden board, and is capable of attracting and holding a magnet on the surface of the facing material side. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2017-36650 A Summary of the Invention [Problem to be solved by the invention]

[0005] Decorative steel panels are manufactured by firmly bonding a steel plate to a non-combustible or wooden board substrate with an adhesive, and cutting the resulting composite of the steel plate and the substrate into a desired size for the decorative panel. However, in order for the decorative steel panel to have a high adhesion to a magnet, the thickness of the steel plate needs to be increased. However, when the thickness of the steel plate is increased, burrs are likely to occur on the cut surface, particularly on the cut surface of the steel plate, when the composite is cut to the desired size to form the steel panel. When handling the steel panel, workers are likely to be injured, such as by cutting their hands on the burrs generated on the cut surface or on the corners or edges of the steel plate located at the corners, and there is a problem with safety during handling.

[0006] The present disclosure has been made in view of the above circumstances, and provides a steel sheet panel for decorative boards, which has high surface adhesion to a magnet and improved safety during handling, and a manufacturing method thereof. The present disclosure also provides a decorative steel sheet panel using the above steel sheet panel for decorative boards, and a manufacturing method thereof. [Means for solving the problem]

[0007] The present disclosure includes the following embodiments. [1] A steel sheet panel for decorative panels comprising, at least in this order, a steel sheet, an adhesive layer A, and a substrate, and having, in a planar view from the steel sheet side, a first region where the substrate and the steel sheet overlap, and a second region that does not include the steel sheet and is arranged outside the first region along at least a part of the outer edge of the first region. [2] The steel sheet panel for decorative panels according to the above [1], wherein the thickness of the steel sheet is 0.2 mm to 1.0 mm. [3] The steel sheet panel for decorative panels according to the above [1] or [2], wherein the width of the second region is 3 mm or less. [4] A steel sheet panel for decorative panels according to any one of [1] to [3] above, wherein, when viewed in a plan view from the steel sheet side, the second region is arranged to surround the entire outer edge of the first region. [5] A steel sheet panel for decorative panels according to any one of [1] to [4] above, wherein the adhesive constituting the adhesive layer A is selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive. [6] A manufacturing method for manufacturing a steel sheet panel for decorative board described in any one of [1] to [5] above, comprising at least a preparation step of preparing a steel sheet and a substrate larger than the steel sheet, and a bonding step of bonding the steel sheet and the substrate, wherein the bonding step is a step of applying an adhesive to one side of the steel sheet to form a precursor layer of adhesive layer A, and bonding the precursor layer side of the steel sheet to the surface of the substrate directly or through another layer, or a step of applying an adhesive to one side of the substrate to form a precursor layer of adhesive layer A, and bonding the steel sheet to the precursor layer directly or through another layer. [7] The method for producing a steel sheet panel for decorative board according to the above [6], which does not include a cutting step of cutting a laminate obtained by joining the steel sheet and the substrate via the adhesive layer A after the lamination step. [8] A decorative steel panel comprising a steel plate panel for decorative plates described in any one of [1] to [5] above and a decorative layer provided on the steel plate of the steel plate panel for decorative plates, the decorative steel panel having, when viewed in a plan view from the decorative layer side, a first region where the decorative layer, the steel plate and the substrate overlap, and a second region arranged outside the first region along at least a part of the outer edge of the first region and not including the steel plate. [9] The decorative steel sheet panel according to the above [8], wherein the thickness of the steel sheet is 0.2 mm to 1.0 mm.

[10] The decorative steel panel according to [8] or [9] above, wherein the width of the second region is 3 mm or less.

[11] A decorative steel panel described in any one of [8] to

[10] above, wherein, when viewed in a plan view from the steel plate side, the second region is arranged to surround the entire outer edge of the first region.

[12] A manufacturing method for producing a decorative steel panel described in any of [8] to

[11] above, comprising at least a preparation step of preparing a steel plate and a substrate larger than the steel plate, a bonding step of bonding the steel plate and the substrate, and a decorative layer formation step of providing a decorative layer on the surface of the steel plate, wherein the bonding step is a step of applying an adhesive to one side of the steel plate to form a precursor layer of adhesive layer A, and bonding the precursor layer side of the steel plate to the surface of the substrate directly or via another layer, or a step of applying an adhesive to one side of the substrate to form a precursor layer of adhesive layer A, and bonding the steel plate to the precursor layer directly or via another layer.

[13] A method for manufacturing a decorative steel panel as described in

[12] above, which does not include a cutting step of cutting a laminate formed by joining the steel plate and the substrate via the adhesive layer A after the lamination step. Effect of the Invention

[0008] According to the steel sheet panel for decorative boards of the present disclosure, the second region prevents injuries caused by burrs or corners of the steel sheet during handling, and therefore the panel is highly safe. In addition, the thickness of the steel sheet can be adjusted while ensuring safety, and therefore the panel for decorative boards of the present invention has a high adhesive force for magnets.

[0009] Furthermore, according to the manufacturing method of the steel sheet panel for decorative board of the present disclosure, cutting is not required after joining the steel sheet and the substrate, and the occurrence of burrs can be suppressed. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram showing an example of a decorative steel sheet panel according to the present disclosure. [Diagram 2] FIG. 1 is a schematic diagram showing an example of a decorative steel sheet panel according to the present disclosure. [Diagram 3] FIG. 1 is a schematic diagram showing an example of a decorative steel sheet panel according to the present disclosure. [Figure 4] FIG. 1 is a schematic diagram showing an example of a decorative steel sheet panel according to the present disclosure. [Diagram 5] 1 is a schematic diagram showing an example of a decorative steel sheet panel of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] I. Decorative steel panels The steel plate panel for decorative plates of the present disclosure (hereinafter may be referred to as the steel plate panel of the present disclosure) has at least a steel plate, an adhesive layer A, and a substrate, in that order, and has, when viewed in a plan view from the steel plate side, a first region where the substrate and the steel plate overlap, and a second region that is arranged outside the first region along at least a part of the outer edge of the first region and does not include the steel plate.

[0012] 1(a)-(c) are schematic diagrams showing an example of a steel plate panel of the present disclosure, in which FIG. 1(a) is a schematic top view, FIG. 1(b) is a cross-sectional view along line XX in FIG. 1(a), and FIG. 1(c) is a cross-sectional view along line YY in FIG. 1(a). The steel plate panel 10 of the present disclosure has at least a steel plate 1, an adhesive layer A (reference number 2 in the figure), and a substrate 3 in this order. The steel plate panel 10 has a first region P where the substrate 3 and the steel plate 1 overlap in a plan view from the steel plate 1 side, and a second region Q that is disposed outside the first region P along at least a part of the outer edge of the first region P and does not include the steel plate 1. In the steel plate panel 10 illustrated in FIG. 1(a) and (b), the second region Q is disposed along the entire periphery (four sides constituting the outer edge) of the rectangular first region P, and the surface of the substrate 3 is exposed.

[0013] The steel panel of the present disclosure has the above-mentioned positional relationship between the steel plate and the substrate when viewed from the steel plate side, and can have a first region P where the steel plate and the substrate overlap, and a second region Q located outside the first region P where the steel plate and the substrate do not overlap and there is no steel plate. In other words, the second region Q is a region that includes the substrate but does not include the steel plate. By having these two regions, when a decorative layer is provided on the steel plate to form a decorative steel panel, the first region P composed of a composite material of the steel plate and the substrate can be used as the effective region of the decorative steel panel. The effective region of the decorative steel panel refers to the region used as the usable surface on the decorative layer side of the decorative steel panel.

[0014] The steel plate panel of the present disclosure has a second region that does not include steel plate, and therefore has excellent safety, since injuries to workers caused by burrs on the corners of the steel plate or burrs generated on the steel plate caused by gripping the second region during handling can be suppressed. In addition, the steel plate panel of the present disclosure can have a high adhesive force for magnets because the thickness of the steel plate can be adjusted while ensuring the above-mentioned safety during handling.

[0015] Furthermore, when a decorative steel panel is manufactured by providing a decorative layer on the steel panel of the present disclosure, the first region P of the steel panel can be the effective region of the decorative steel panel. On the other hand, when the decorative steel panel is installed on a wall surface or the like, the second region Q of the panel of the present disclosure can be hidden by arranging an installation member such as a joiner or sealant (hereinafter, sometimes referred to as joiners) on the second region Q, and the step between the first region P and the second region Q can be eliminated by the installation member. This allows the steel panel of the present disclosure and a decorative steel panel using the steel panel to be used without cutting to a desired size.

[0016] In addition, the waste material generated when cutting a steel panel, which is a composite material of a steel plate and a substrate, cannot be recycled as it is because it is a composite material of different materials, and since it is firmly bonded with an adhesive, it is difficult to separate and dismantle the substrate and the steel plate. On the other hand, the steel panel of the present disclosure does not require cutting of the composite material when manufacturing the steel plate panel and the decorative steel plate panel as described above, so the generation of waste material of the composite material can be suppressed. In addition, if the second region Q of the steel plate panel is not required, it can be cut separately. In this case, since there is no steel plate in the second region Q, the cutting workability of the second region is excellent, and furthermore, the waste material disposal of the cut second region Q is easy.

[0017] As a method for omitting the cutting process of the steel plate panel or the composite material of the steel plate and the substrate, it is possible to prepare a steel plate and a substrate having the same planar dimensions and shape in advance and join them with an adhesive. However, since the cutting equipment for the steel plate and the substrate is different, it is difficult to prepare them with exactly the same dimensions and to join a large-sized steel plate and a substrate with high precision so that their outer edges match each other. In contrast, the steel plate panel of the present disclosure can improve the positional accuracy of the steel plate and the substrate by adjusting the steel plate to the planar size of the desired decorative plate and providing the steel plate at a predetermined position on the substrate that is larger than the steel plate, instead of matching the sizes of the steel plate and the substrate.

[0018] The steel sheet panel of the present disclosure has, in a plan view seen from the steel sheet side, a first region where the substrate and the steel sheet overlap, and a second region outside the first region that does not include the steel sheet. The second region being arranged along at least a part of the outer edge of the first region may mean that the second region Q is provided so as to surround the entire periphery of the outer edge of the first region P as shown in FIG. 1, or that the second region Q is arranged along at least a part of the outer edge of the first region P, for example, at least one side constituting the entire periphery of the outer edge, as shown in FIG. 2 and FIG. 3. More specifically, if the first region P is rectangular, the second region Q may be arranged along one side of the rectangle, or along two or more sides of the rectangle. The second region Q shown in FIG. 2(a)-(c) is arranged along one side of the rectangular first region P, and the second region Q shown in FIG. 3(a)-(c) is arranged along two opposing sides of the rectangular first region P. Although not shown, the second region Q may be arranged along two intersecting sides of a rectangle, or along three sides of a rectangle.

[0019] In the steel plate panel of the present disclosure, the size of the first region P in a plan view corresponds to the size of the steel plate in a plan view. Moreover, the size of the first region P is preferably the same as the effective area (exposed area excluding the construction member when constructed on a wall surface) of a decorative board (decorative steel plate panel) using the steel plate panel of the present disclosure.

[0020] In the steel sheet panel of the present disclosure, the second region Q does not have to include a steel sheet, and may include only the substrate, or may include the substrate and one or more layers between the substrate and the steel sheet. In the case where the substrate has another layer, such as a moisture-proof layer, on the surface opposite to the steel sheet, the second region Q may include the substrate and the other layer.

[0021] In the steel plate panel of the present disclosure, the width of the second region Q is preferably more than 0 mm and not more than 3 mm, more preferably more than 0 mm and not more than 2 mm, and even more preferably more than 0 mm and not more than 1 mm. By setting the width of the second region Q in the above range, when a decorative board (decorative steel plate panel) using the steel plate panel of the present disclosure is installed on a wall surface, the second region Q can be hidden with installation members such as joiners and sealants, and the step between the first region P and the second region Q can be eliminated by the installation members. In addition, by setting the width of the second region Q in the above range, commercially available joiners can be used, and the width of the installation members becomes narrower according to the width of the second region Q, so that the installation members become less noticeable and a beautiful interior finish can be achieved. The width of the second region Q refers to the shortest distance between the periphery of the steel plate and the periphery of the substrate, and refers to the length of the symbol w in the figure.

[0022] 1. Steel plate The steel plate in the steel plate panel of the present disclosure is located on the opposite side of the substrate to the adhesive layer A. The above steel plate allows magnets to be strongly attracted and held on the surface of the steel plate panel of the present disclosure and the decorative plate (decorative steel plate panel) in which a decorative layer is provided on the steel plate of the steel plate panel.

[0023] The steel plate may be in direct contact with one surface of the adhesive layer A, or may be in contact with one surface of the adhesive layer A via another layer.

[0024] The steel plate is not particularly limited as long as it can attract a magnet. Examples of such steel plates include steel plates having a magnetic composition, such as stainless steel plates such as ferritic stainless steel and martensitic stainless steel, and carbon steel plates.

[0025] Furthermore, as the steel sheet capable of attracting a magnet, for example, a steel sheet (surface-treated steel sheet) plated with zinc, a zinc alloy, tin, chromium, copper, aluminum, an aluminum alloy, nickel, etc., can be used. As the plating method, an electric plating method, a hot-dip plating method, a vapor deposition plating method, etc. can be applied. After carrying out these platings, a known chemical conversion treatment such as a chromate treatment, a phosphate treatment, a silane coupling agent treatment, or a zirconium treatment may be carried out.

[0026] The thickness of the steel plate is preferably 0.2 mm to 1.0 mm, more preferably 0.2 mm to 0.4 mm, and even more preferably 0.25 mm to 0.35 mm, from the viewpoint of increasing the magnetic attraction force required for the surface of the steel plate panel of the present disclosure and the decorative plate (decorative steel plate panel) using the steel plate panel. The steel plate panel of the present disclosure can be used as a decorative steel plate panel without cutting by providing a decorative layer on the surface on the steel plate side. Therefore, the thickness of the steel plate can be increased to the above range, and the surface of the steel plate panel and the decorative steel plate panel can have a high magnetic attraction and retention force for a magnet.

[0027] 2. Substrate The substrate in the steel plate panel of the present disclosure is disposed on the opposite side of the adhesive layer A from the steel plate. The substrate is joined to the steel plate via the adhesive layer A. The substrate may be in direct contact with the other side of the adhesive layer A, or may be in contact with the other side of the adhesive layer A via another layer.

[0028] The substrate is usually larger than the steel plate in plan view. The substrate may be similar or non-similar to the steel plate in plan view. Examples of substrates larger than the steel plate in plan view include a substrate where the short side length of the substrate is larger than the short side length of the steel plate and the long side length of the substrate is the same as the long side length of the steel plate, a substrate where the short side length of the substrate is the same as the short side length of the steel plate and the long side length of the substrate is larger than the long side length of the steel plate, and a substrate where the short side length and the long side length of the substrate are larger than the short side length and the long side length of the steel plate.

[0029] The thickness of the substrate is not particularly limited, but is preferably 2 mm to 30 mm from the viewpoint of the strength and thickness of the steel sheet panel of the present disclosure.

[0030] The substrate may be an inorganic or organic substrate used in a general-purpose decorative plate. The inorganic substrate may be one with a low resin content and a roughly plate-like shape. In addition to ceramic inorganic substrates, inorganic materials as aggregates or inorganic fibers bound with an organic binder may be used, but the total amount of inorganic materials is preferably 50% by mass or more of the inorganic substrate. The inorganic materials preferably have water of crystallization, such as aluminum hydroxide, magnesium hydroxide, and calcium silicate.

[0031] For the above substrate, it is preferable to use a non-flammable substrate in order to improve non-flammability, and among these, a ceramic-based inorganic substrate is preferable from the viewpoints of heat resistance, non-flammability, and ease of availability. Examples of ceramic inorganic substrates include calcium silicate molded bodies, fiber-reinforced calcium silicate molded bodies, fiber-reinforced cement molded bodies, fiber-reinforced ceramic molded bodies, wood-based cement molded bodies, wood wool cement laminates, volcanic glass laminated bodies, extrusion molded cement boards, slag gypsum boards, lightweight aerated concrete boards (ALC), glass boards, ceramics, tiles, stone materials, and composite boards thereof. Among these, calcium silicate molded bodies, fiber-reinforced calcium silicate molded bodies, fiber-reinforced cement molded bodies, and volcanic glass laminated bodies are preferred.

[0032] The specific gravity of the inorganic substrate is 0.7 g / cm 3 It is preferable that the content is 0.8 g / cm or more. 3 More preferably, the specific gravity of the inorganic substrate is 2.3 g / cm or more. 3 It is preferable that the density is 2.0 g / cm or less. 3 By setting the specific gravity of the inorganic substrate within the above range, it is possible to ensure the mechanical strength of the surface and reduce the burden during construction due to the reduced weight, and it is also easy to obtain a decorative board with high surface hardness.

[0033] Examples of organic substrates include wood substrates and resin substrates. Of these, wood substrates are preferred from the viewpoint of improving economic efficiency and reducing environmental impact. Examples of the wood substrate include fiberboards such as medium density fiberboard (MDF) and hard fiberboard (hardboard), particle boards, and plywood. Of these, the wood substrate is preferably fiberboard or particle board, and more preferably medium density fiberboard (MDF).

[0034] The specific gravity of wood-based boards is 0.5 to 1 g / cm 3 The range is preferably 0.6 to 0.9 g / cm 3 It is more preferable that the range is within this range since the surface hardness of the decorative board can be increased.

[0035] 3.Adhesive layer A The adhesive layer A in the steel sheet panel of the present disclosure is located between the steel sheet and the substrate. The adhesive layer A bonds the steel sheet and the substrate directly or via another layer. Preferably, one surface of the adhesive layer A is in direct contact with the steel sheet, and the other surface of the adhesive layer A is in direct contact with the substrate.

[0036] The adhesive (sometimes referred to as adhesive a) constituting the adhesive layer A may be a known adhesive such as a urethane resin adhesive, a silicone modified resin adhesive, a urea resin adhesive, a vinyl acetate emulsion adhesive, an epoxy resin adhesive, a melamine resin adhesive, a phenolic resin adhesive, an olefin resin adhesive, an acrylic emulsion adhesive, a chloroprene adhesive, a nitrile rubber adhesive, or a styrene-butadiene-rubber cyanoacrylate adhesive. The adhesive a constituting the adhesive layer A may be a hot melt adhesive, a one-component curing adhesive, or a two-component curing adhesive. The adhesive a may be an aqueous adhesive containing water, a solvent-based adhesive containing a solvent, or a solventless adhesive containing neither water nor a solvent.

[0037] The adhesive layer A is preferably composed of a cured product of an adhesive selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive. The precursor layer formed with these adhesives has weak tack and can be secured for a long time until it hardens and becomes the adhesive layer A. Therefore, it is possible to move the precursor layer on the precursor layer when adjusting the lamination position of the two members, the steel plate and the substrate, and it is possible to prevent the surface of the member not having the precursor layer from being contaminated by the adhesive due to repeated re-lamination. This allows sufficient time to align and position the steel plate and the substrate to form the first region P and the second region Q, and allows bonding at a more accurate position.

[0038] The aqueous two-component curing adhesive and the solventless two-component curing adhesive contain a base agent and a curing agent. Among them, the aqueous two-component curing adhesive is preferred because it has a relatively stable viscosity after mixing the two components and because water can be used to clean the adhesive application equipment after work, and therefore has excellent workability in general.

[0039] Examples of the aqueous two-component curing adhesive include emulsions, colloidal dispersions, and aqueous solutions using water as a diluent. Examples of the base material of the aqueous two-component curing adhesive include water-soluble substances such as polyvinyl alcohol, water-soluble ethylene-vinyl acetate copolymers, polyethylene oxide, aqueous acrylic resins, aqueous cellulose derivatives, water-soluble polyesters, and water-soluble epoxy resins; and aqueous emulsions such as polyvinyl chloride emulsions, urethane acrylic emulsions, polyurethane emulsions, silicon acrylic emulsions, polyester emulsions, vinyl acetate acrylic emulsions, ethylene vinyl acetate emulsions, urethane modified ethylene vinyl acetate copolymer emulsions, and vinyl copolymer emulsions. The base material preferably has an acid group and / or a hydroxyl group.

[0040] The curing agent of the aqueous two-component curing adhesive may be a compound capable of forming a crosslinked structure with the base resin. Such a compound may be, for example, a compound having two or more functional groups in the molecule that can react with an acid group and / or a hydroxyl group. Here, examples of the "functional group that can react with an acid group and / or a hydroxyl group" include an epoxy group, an oxazoline group, a melamine group, an aziridine group, a carbodiimide group, an isocyanate group, and the like. Specific examples of such a curing agent include polyisocyanate, a multifunctional epoxy resin, an oxazoline group-containing polymer, a polyamine resin, and an acid anhydride.

[0041] Examples of the solvent-free two-component curing adhesive include a solvent-free two-component curing adhesive that contains a resin selected from urethane resin, acrylic resin, etc. as a main component and a curing agent such as polyisocyanate. The curing agent may be any of the compounds exemplified as the curing agent for the aqueous two-component curing adhesive described above. The solvent-free two-component curing adhesive is substantially free of organic solvent, and the amount of organic solvent in the adhesive is 5% by mass or less, preferably 3% by mass or less, more preferably 1% by mass or less, and particularly preferably does not contain any organic solvent.

[0042] The aqueous two-component curing adhesive and the solventless two-component curing adhesive are preferably isocyanate curing two-component adhesives, more preferably isocyanate curing adhesives containing polyisocyanate. The isocyanate curing agent reacts with the terminal OH group of the base agent to form urethane bonds with excellent water resistance and heat resistance. In addition, the reaction proceeds at room temperature, and is advantageous in that no special heating treatment is required.

[0043] When the aqueous two-component curing adhesive is an isocyanate-curing aqueous two-component adhesive containing polyisocyanate, examples of the main agent of the isocyanate-curing aqueous two-component adhesive include water-soluble substances such as polyvinyl alcohol, water-soluble ethylene-vinyl acetate copolymer, polyethylene oxide, aqueous acrylic resin, aqueous cellulose derivative, water-soluble polyester, water-soluble epoxy resin, etc.; aqueous emulsions such as polyvinyl chloride emulsion, urethane acrylic emulsion, polyurethane emulsion, silicon acrylic emulsion, polyester emulsion, vinyl acetate acrylic emulsion, ethylene vinyl acetate emulsion, urethane modified ethylene vinyl acetate copolymer emulsion, vinyl copolymer emulsion, etc.; etc. The main agent preferably has an acid group and / or a hydroxyl group, and in particular, it is preferable that the main agent has a hydroxyl group (OH group) at the terminal.

[0044] Examples of the polyisocyanate include aromatic isocyanate compounds, aromatic aliphatic isocyanate compounds, aliphatic isocyanate compounds, alicyclic polyisocyanate compounds, and modified products thereof. These polyisocyanates may be used alone or in combination of two or more. More specifically, examples of the polyisocyanate include tolylene diisocyanate (TDI), diphenylmethane isocyanate (MDI), hexamethylene diisocyanate (HDI), xylylene diisocyanate (XDI), isophorone diisocyanate (IPDI), tris(isocyanate phenylmethane), tris(isocyanate phenyl) thiophosphate, and the like. Examples of the NCO modified products include adducts of the above compounds such as trimethylolpropane, HDI biuret, HDI trimer, IPDI trimer, and urethane prepolymers with isocyanate terminals, and the like.

[0045] Furthermore, when the solventless two-component curing adhesive is an isocyanate-curing water-based two-component adhesive containing polyisocyanate, the base resin may be a resin having a hydroxyl group (OH group) selected from urethane resin, acrylic resin, etc., and the isocyanate may be the polyisocyanate described above.

[0046] Examples of the water-based rubber adhesive include those using latex such as natural rubber latex, SBR latex, and chloroprene latex, and nitrile rubber, etc. Specifically, synthetic rubber latex adhesives can be used.

[0047] The adhesive a constituting the adhesive layer A may contain a water-soluble polymer, a plasticizer, a filler, a thickener, a wetting agent, a preservative, an anti-rust agent, an acid absorber, a flame retardant, an anti-aging agent, a colorant, a pH adjuster, an antifoaming agent, and a coupling agent as necessary.

[0048] When the adhesive a is aqueous or solvent-based, the solid content of the adhesive a constituting the adhesive layer A is not particularly limited, but is usually 35% by mass to 60% by mass.

[0049] The coating amount of the adhesive layer A (coating amount of adhesive a) is 20 g / m2 in solid content. 2 ~200g / m 2 It is preferable that the thickness is 30 g / m 2 ~150g / m 2 More preferably, it is 40 g / m 2 ~100g / m 2 By setting the coating amount of the adhesive layer A (adhesive a) within the above range, the steel sheet and the substrate can be firmly bonded together.

[0050] 4. Moisture barrier The steel plate panel of the present disclosure may have at least a steel plate, an adhesive layer A, and a substrate in this order, but may further have a moisture-proof layer. The steel plate and the substrate have different degrees of expansion and contraction due to moisture absorption due to differences in material, so the steel plate panel is prone to warping. In particular, if the thickness of the steel plate is increased to increase the magnet-attaching force of the steel plate panel and the surface of the steel plate panel, the difference between the warping of the steel plate and the warping of the substrate becomes even greater, making the steel plate more likely to peel off. In contrast, the steel plate panel can have a moisture-proof layer at a desired position to reduce moisture permeability and prevent the steel plate and the substrate from warping or peeling off.

[0051] The moisture-proof layer preferably has at least one selected from the group consisting of a moisture-proof resin layer, a metal vapor deposition layer, and a metal foil, and may have two or more.

[0052] An example of a moisture-proof layer having a moisture-proof resin layer is a laminate having a structure in which a paper layer, a moisture-proof resin layer, and a paper layer are laminated in this order. The resin constituting the moisture-proof resin layer is preferably a thermoplastic resin such as an olefin resin, more specifically, a polyethylene resin such as a high-density polyethylene resin (hereinafter referred to as HDPE), a polypropylene resin, etc. As the paper layer, for example, printing paper for building materials, pure white paper impregnated with latex or synthetic resin, thin paper with synthetic resin mixed therein to reinforce the interlayer strength (so-called interlayer reinforced paper), etc. are preferably used.

[0053] As the moisture-proof layer having a metal vapor-deposited layer, a moisture-proof sheet having a vapor-deposited layer formed by vapor-depositing a metal such as aluminum or an inorganic material such as silicon oxide or aluminum oxide on a resin substrate can also be used.

[0054] Examples of moisture-proof layers having a metal foil layer include laminates having a structure in which a metal foil such as aluminum and a paper layer are laminated, and laminates having a structure in which a resin film and a metal foil are laminated. The metal foil and the paper layer or the resin film layer may be bonded via an adhesive or polyethylene resin. The laminate may have a structure in which a paper layer or a resin film layer is laminated only on one side of the metal foil, or a structure in which a paper layer or a resin film layer is laminated on both sides of the metal foil. As the paper layer, for example, printing paper for building materials, pure white paper impregnated with latex or synthetic resin, thin paper in which synthetic resin is mixed to strengthen the interlayer strength (so-called interlayer reinforced paper), etc. are preferably used. As the resin film, for example, a general-purpose resin film such as a PET film can be used.

[0055] The moisture barrier has a water vapor permeability (moisture permeability) of 30g / m 2 - 24 hours or less is preferable, 15g / m 2It is more preferable that the moisture vapor permeability is within the above range, and the moisture vapor permeability is kept low, thereby preventing the steel sheet and substrate from warping, bending, or peeling. The moisture vapor permeability of the moisture barrier layer is measured in an environment with a temperature of 40°C and a humidity of 90% RH in accordance with JIS Z0208 (Moisture Permeability Test Method (Cup Method)).

[0056] The moisture-proof layer may be disposed, for example, directly on the surface of the substrate opposite to the adhesive layer A side or via another layer, or may be disposed between the steel plate and the substrate. The space between the steel plate and the substrate may be between the steel plate and the adhesive layer A, or between the adhesive layer A and the substrate. In particular, it is preferable to have a moisture-proof layer 4 on the surface of the substrate 3 opposite to the adhesive layer A side (reference numeral 2 in FIG. 4) as exemplified in FIG. 4, since this can suppress warping of the steel plate and the substrate and prevent peeling of the steel plate and the substrate. In particular, when the substrate is an organic substrate, it is preferable to have a moisture-proof layer 4 on the surface of the substrate 3 opposite to the adhesive layer A side (reference numeral 2 in FIG. 4).

[0057] When the adhesive layer A is made of a water-based adhesive, it is preferable that the moisture-proof layer is disposed directly or through another layer on the surface of the substrate opposite to the adhesive layer side. If the adhesive layer A is made of a water-based adhesive and the moisture-proof layer is located between the steel plate and the substrate, the moisture in the water-based adhesive is difficult to remove during the manufacturing process of the steel plate panel of the present disclosure, causing problems such as the reaction of the water-based adhesive not proceeding sufficiently to obtain the desired adhesive strength, or the water-based adhesive not curing to form the adhesive layer A.

[0058] When the moisture-proof layer is provided on the surface of the substrate opposite to the adhesive layer A side, it is preferable that the planar dimensions of the moisture-proof layer are the same as those of the substrate, since the entire surface of the substrate can be covered with the moisture-proof layer.

[0059] 5.Adhesive layer B When the steel panel of the present disclosure has a moisture-proof layer, it may have an adhesive layer B between the substrate and the moisture-proof layer. The adhesive layer B bonds the substrate and the moisture-proof layer. The adhesive b constituting the adhesive layer B is not particularly limited, and may be, for example, the adhesive a constituting the adhesive layer A described above or an adhesive exemplified as the adhesive c described below. When the adhesive a constituting the adhesive layer A is an adhesive selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive, it is preferable that the adhesive b constituting the adhesive layer B is different from the adhesive a in order to bond the substrate and the moisture-proof layer in a short time.

[0060] The amount of adhesive layer B applied (the amount of adhesive b applied) is not particularly limited as long as it can firmly bond the substrate and the moisture-proof layer. For example, the amount of adhesive layer B applied is 15 to 50 g / m2 in terms of solid content. 2 is preferable, and 20 to 40 g / m 2 is more preferred.

[0061] 6.Other configurations The steel plate panel of the present disclosure preferably has a number of sheets of paper that can be held when sandwiched between the steel plate side surface of the steel plate panel and a magnet, as measured by the following method, of 6 or more, more preferably 10 or more, even more preferably 12 or more, and even more preferably 13 or more. (Measurement method) Stand the steel panel vertically and place a circular neodymium magnet (Kokuyo super strong color magnet <Neomag> 1030NT) with a magnet diameter of 11 mm) between the steel panel and an A4 size copy paper (68 g / m 2 ) and measured how many sheets of copy paper it could hold.

[0062] 7. Manufacturing method of steel panel The manufacturing method of the steel plate panel of the present disclosure includes at least a preparation step of preparing a steel plate and a substrate larger than the steel plate, and a bonding step of bonding the steel plate and the substrate. In the manufacturing method of the steel plate panel of the present disclosure, the bonding step can be the following first or second mode. That is, the first mode of the bonding step is a step of applying an adhesive to one side of the steel plate to form a precursor layer of the adhesive layer A, and bonding the surface of the steel plate on the precursor layer side to the surface of the substrate directly or through another layer. In addition, the second mode of the bonding step is a step of applying an adhesive to one side of the substrate to form a precursor layer of the adhesive layer A, and bonding the steel plate to the precursor layer directly or through another layer.

[0063] According to the manufacturing method of the steel plate panel disclosed herein, in the bonding process, a steel plate and a substrate larger than the steel plate are bonded via an adhesive layer, thereby forming a first region where the steel plate and the substrate overlap, and a second region that does not include the steel plate.

[0064] (1) Preparation process In the preparation step, a steel plate and a substrate larger than the steel plate are prepared. The substrate may be larger than the steel plate in plan view, and the planar shape of the substrate may be a similar shape or a non-similar shape to the planar shape of the steel plate. The substrate being larger than the steel plate means that when one edge of the substrate and one edge of the steel plate are overlapped, at least one of the other edges of the substrate is located outside the edge of the opposing steel plate, and it is preferable that when one edge of the substrate and one edge of the steel plate are overlapped, there is no region (third region R) that includes the steel plate and does not include the substrate. As an example of the substrate being larger than the steel plate, the size relationship between the substrate and the steel plate shown in Figs. 1 to 3 can be mentioned. For example, if the substrate and the steel plate are rectangular, it is preferable that the longitudinal and lateral lengths of the substrate are larger than the longitudinal and lateral lengths of the steel plate.

[0065] The difference between the longitudinal length of the substrate and the longitudinal length of the steel plate (longitudinal difference) and the difference between the lateral length of the substrate and the lateral length of the steel plate (lateral difference) are each preferably 10 mm or less, more preferably 6 mm or less, and even more preferably 5 mm or less, independently, so that the second region of the desired width can be formed without cutting in the obtained steel plate panel. In addition, the lower limit of at least one of the longitudinal difference and the lateral difference is more than 0 mm, and it is preferable that each is independently more than 0 mm.

[0066] In this process, the steel plate is preferably cut to the size of the decorative plate (decorative steel plate panel) to which the steel plate panel of the present disclosure is applied, more specifically, to the same dimensions and shape as the effective area of ​​the decorative plate (decorative steel plate panel). The effective area of ​​the decorative plate (decorative steel plate panel) refers to the area on the surface of the decorative layer side of the decorative plate that is used as the usable surface.

[0067] (2)Lamination process The bonding step may be the first embodiment or the second embodiment described above. The bonding step of the second embodiment is preferable in that the substrate has the desired strength and thickness, and therefore the adhesive can be easily applied without being limited by the adhesive application method. The bonding step of the first embodiment is also preferable in that contamination by the adhesive attached to the second region Q of the steel plate panel can be suppressed. For example, when the substrate and the steel plate are pressed with a pressing roll as described later, the first embodiment can suppress contamination of the pressing roll by the adhesive attached to the second region Q. Among these, the bonding step of the second embodiment is preferable.

[0068] In each embodiment of the lamination process, an adhesive is applied to a steel plate or a substrate to form a precursor layer of the adhesive layer A. The precursor layer of the adhesive layer A is a layer before the components in the adhesive react (before curing), in other words, a coating of the adhesive. The precursor layer (coating of the adhesive) is cured to become the adhesive layer A.

[0069] Among them, it is preferable that the adhesive for forming the adhesive layer A is an adhesive selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive. By laminating the steel plate and the substrate using these adhesives in the lamination process, it becomes possible to adjust the lamination position of the steel plate and the substrate, re-laminate them, and temporarily fix them until the reaction of the adhesive is completed and a strong adhesive force is developed. This makes it possible to improve the positioning accuracy of the steel plate and the substrate. The type and composition of the adhesive a for forming the precursor layer (adhesive layer A), the amount of adhesive a applied, etc. are the same as the details explained in the above section "3. Adhesive layer A".

[0070] The method for applying the adhesive is not particularly limited, and for example, roll coating, curtain flow coating, wire bar coating, reverse coating, gravure coating, gravure reverse coating, air knife coating, kiss coating, blade coating, smooth coating, comma coating, etc. can be used.

[0071] After laminating the steel plate and the substrate via the precursor layer, the precursor layer may be heated and cured or may be cured at room temperature. In addition, it is preferable to apply a load to the laminate including the steel plate, the precursor layer, and the substrate after laminating the steel plate and the substrate via the precursor layer of the adhesive layer A. By applying a load to the laminate after lamination and leaving it for a desired time, the adhesive solidifies and reacts, the precursor layer hardens, and becomes the adhesive layer A, and the steel plate and the substrate are firmly bonded by the adhesive layer A. The method of applying the load is not particularly limited, but for example, a loading method using a cold press, a loading method using a heated pressure roll, a loading method using a room temperature pressure roll, etc. can be used.

[0072] When the adhesive for forming the adhesive layer A is an adhesive selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive, from the viewpoint of ensuring a curing time that enables positioning and alignment of the lamination position, the above load is preferably a room temperature load or a cooled load, and preferably does not involve heating.

[0073] In the bonding process, the environmental conditions from when an adhesive is applied to form a precursor layer until the precursor layer becomes adhesive layer A can be set appropriately depending on the type of adhesive used to form adhesive layer A.

[0074] In the bonding process, the time until the bonding of the steel plate and the substrate is completed, i.e., the time from applying the adhesive to form a precursor layer, bonding the steel plate and the substrate via the precursor layer, and the time until the precursor layer hardens to become the adhesive layer A (hereinafter, sometimes referred to as the bonding completion time), can be set appropriately depending on the type of adhesive used to form the adhesive layer A.

[0075] In the lamination step, the method for aligning the lamination position of the steel plate and the substrate is not particularly limited, and examples thereof include a method of sliding the steel plate or the substrate laminated on the precursor layer, a method of peeling the steel plate or the substrate from the precursor layer once and placing it again at a desired position on the precursor layer and laminating it, etc. When aligning the lamination position in the lamination step, the time from laminating the steel plate and the substrate to aligning them is not particularly limited, and can be set appropriately depending on the curing time of the adhesive.

[0076] The manufacturing method of the steel sheet panel of the present disclosure includes at least the lamination step, but may include any other steps. For example, the manufacturing method of the steel sheet panel of the present disclosure may include a step of providing a moisture-proof layer (moisture-proof layer forming step). In the moisture-proof layer forming step, the moisture-proof layer is preferably provided on one side of the substrate, and may be performed together with the preparation of the substrate in the preparation step, or may be performed after the lamination step.

[0077] A method for providing a moisture-proof layer on one side of a substrate can be, for example, a method in which an adhesive is applied to one side of the substrate or to the surface of the support layer side of the moisture-proof layer to form an adhesive layer B, and the substrate and the moisture-proof layer are bonded together via the adhesive layer B. The moisture-proof layer and adhesive layer B have been explained above in sections "4. Moisture-proof layer" and "5. Adhesive layer B", and therefore explanation thereof will be omitted here.

[0078] When a moisture-proof layer is provided on one side of the substrate in the lamination step, "one side of the substrate" in the lamination step and the substrate side to be laminated with the precursor layer may be the substrate side on which the moisture-proof layer is formed or the substrate side opposite the substrate side on which the moisture-proof layer is formed. Of these, the substrate side opposite the substrate side on which the moisture-proof layer is formed is preferred because moisture generated during the process in which the precursor layer is converted into the adhesive layer A can be efficiently removed.

[0079] Furthermore, the manufacturing method of the steel sheet panel of the present disclosure may include a step of providing a decorative layer on one side of the steel sheet (decorative layer forming step). The manufacturing of the steel sheet panel and the manufacturing of the decorative steel sheet panel can be carried out in one step. In the decorative layer forming step, the decorative layer is provided on the side of the steel sheet opposite to the side to be bonded to the substrate. The decorative layer forming step may be carried out together with the preparation of the steel sheet in the preparation step, or may be carried out after the bonding step. Details of the decorative layer and the decorative layer forming step will be explained in the section "II. Decorative steel sheet panel" below.

[0080] The manufacturing method of the steel plate panel of the present disclosure can eliminate the need for a cutting step of cutting a laminate formed by bonding the steel plate and the substrate via the adhesive layer A after the lamination step. By not performing the cutting step after the lamination step, the generation of burrs on the side surface of the steel plate can be suppressed.

[0081] II. Decorative steel panels The decorative steel plate panel of the present disclosure comprises a steel plate panel having at least a steel plate, an adhesive layer A, and a substrate, in that order, and a decorative layer provided on the steel plate of the steel plate panel, and has, when viewed in a plan view from the decorative layer side, a first region where the decorative layer, the steel plate, and the substrate overlap, and a second region arranged outside the first region along at least a portion of the outer edge of the first region and which does not include the steel plate.

[0082] 5(a)-(c) are schematic diagrams showing an example of a decorative steel panel of the present disclosure, in which FIG. 5(a) is a schematic top view, FIG. 5(b) is a cross-sectional view taken along line XX in FIG. 5(a), and FIG. 5(c) is a cross-sectional view taken along line YY in FIG. 5(a). The decorative steel panel 20 has a steel panel 10 and a decorative layer 11 provided on a steel plate 1 of the steel panel 10. In FIG. 5, the decorative layer 11 is joined to the steel panel 10 via an adhesive layer C (reference numeral 12 in FIG. 5). The steel panel 10 is the same as the steel panel 10 illustrated in FIG. 1. In a plan view from the decorative layer 11 side, the decorative steel panel 20 has a first region P where the decorative layer 11, the steel plate 1, and the substrate 3 overlap, and a second region Q that is disposed outside the first region P along at least a part of the outer edge of the first region P and does not include the steel plate 1. The second region Q illustrated in FIG. 5 does not include the decorative layer 11, and the surface of the substrate 3 is exposed.

[0083] The decorative steel plate panel of the present disclosure has the above-mentioned positional relationship between the decorative layer, steel plate and substrate when viewed from the decorative layer side, and can have a first region P where the decorative layer, steel plate and substrate overlap, and a second region Q located outside the first region P, where the steel plate and substrate do not overlap and does not include the steel plate.

[0084] The decorative steel panel of the present disclosure has two such regions, which reduces the risk of cutting hands on the corners of the steel plate located at the corners of the first region P. Furthermore, when the decorative steel panel is installed on a wall surface or the like, the second region Q can be hidden by placing an installation member such as a joiner or sealant on the second region Q, and the step between the first region P and the second region Q can be eliminated by the installation member. This eliminates the need to cut the decorative steel panel of the present disclosure to a desired size. Furthermore, if the second region Q is not required, it can be cut separately. In this case, since the second region Q does not contain a steel plate, the second region can be easily cut, and furthermore, the waste disposal of the cut second region Q becomes easier.

[0085] Details of the first region P and the second region Q in the decorative steel panel of the present disclosure are the same as those of the first region P and the second region Q in the steel panel described in the above section "I. Steel Panel for Decorative Plates," so a description thereof will be omitted here. In the decorative steel panel of the present disclosure, the second region Q usually includes a substrate. Also, the second region Q may or may not include a decorative layer.

[0086] 1. Steel panel The steel plate panel in the decorative steel plate panel of the present disclosure has at least a steel plate, an adhesive layer A, and a substrate, in this order. The steel plate panel in the decorative steel plate panel of the present disclosure is the same as that described in the above section "I. Steel plate panel for decorative plate", so the description here is omitted.

[0087] 2. Decorative layer The decorative layer in the decorative steel panel of the present disclosure is disposed on the steel plate of the steel plate panel (i.e., on the side opposite to the substrate side of the steel plate). The decorative layer is a layer that expresses the design of the surface of the decorative steel plate panel by color, pattern, etc. Examples of the decorative layer include a laminated structure having a support layer and a design layer disposed on one side of the support layer, and a laminated structure having a surface protection layer, an adhesive layer, a design layer (ink layer), and a support layer in this order, and the surface on the support layer side is the adhesive surface with the steel plate.

[0088] The decorative layer is preferably disposed over the entire surface (sheet surface) of the steel sheet. The decorative layer needs to cover at least the surface of the first region P of the steel sheet panel (the sheet surface of the steel sheet of the steel sheet panel), but may cover the surface and side of the first region P, or may cover the surface and side of the second region Q. The decorative layer may be wrapped around the end of the substrate of the steel sheet panel to the back surface (back surface of the steel sheet panel) to cover the back surface of the steel sheet panel (the surface opposite to the surface on the steel sheet side).

[0089] The thickness of the decorative layer is not particularly limited, but is preferably 30 μm to 250 μm, more preferably 50 μm to 200 μm, and even more preferably 70 μm to 150 μm. By setting the thickness of the decorative layer within the above range, the desired design can be exhibited and the decrease in the magnetic retention force of the surface of the decorative steel sheet panel of the present disclosure can be suppressed.

[0090] <<Support layer>> The support layer constituting the decorative layer may be made of paper, a resin sheet, a laminated sheet of paper and a resin sheet, etc., as long as it can form a design layer. In particular, from the viewpoint of enabling the decorative steel panel of the present disclosure to exhibit high water resistance, it is preferable that the support layer includes a resin sheet.

[0091] Examples of the paper include plain paper, reinforced paper, impregnated paper, fine paper, linter paper, glassine paper, parchment paper, and kraft paper.

[0092] Examples of the resin sheet include thermoplastic resin sheets. Examples of the thermoplastic resin include polyester resins such as polyethylene terephthalate (PET), polyethylene naphthalate, and polybutylene terephthalate (PBT); polyolefin resins such as polypropylene, polyethylene, polymethylpentene, polybutene, ethylene-propylene copolymer resins, ethylene-propylene-butene copolymer resins, and olefin thermoplastic elastomers; polyurethane resins; polyamide resins; vinyl chloride resins; polycarbonate resins, polystyrene resins, vinyl acetate resins, and vinyl chloride-vinyl acetate copolymer resins. Among these, vinyl chloride resin sheets are the most flame-retardant of all resin sheets, and can enhance the flame-retardant properties of the decorative steel panel of the present disclosure.

[0093] The surface of the support layer may be subjected to a surface treatment such as a corona treatment or a plasma treatment, because this can improve the adhesion between the support layer and the design layer.

[0094] The support layer may be a colored support layer containing a colorant, which exhibits a desired color by incorporating a known colorant such as a pigment or dye in the above-mentioned resin.

[0095] The thickness of the support layer is not particularly limited, but is preferably 30 μm to 250 μm, more preferably 50 μm to 200 μm, and even more preferably 70 μm to 150 μm. By setting the thickness of the support layer within the above range, it is possible to suppress a decrease in the magnetic retention force of the surface of the decorative steel sheet panel of the present disclosure.

[0096] <<Design Layer>> The design layer is a layer disposed on one side of the support layer (the side of the support layer opposite the steel sheet side). The design layer is formed on one side of the support layer by, for example, printing or the like.

[0097] The design layer may be a colored layer (solid colored layer) covering the entire surface of one side of the support layer, a patterned pattern, or a combination of a colored layer and a pattern layer, depending on the design required for the decorative steel panel. When the design layer is a pattern layer, the pattern of the pattern layer can be appropriately selected depending on the design required for the decorative steel panel, and examples of such patterns include wood grain patterns, stone grain patterns, cloth grain patterns, leather grain patterns, geometric patterns, letters, figures, and combinations of these patterns.

[0098] The ink forming the design layer contains at least a resin and a colorant. The resin is not particularly limited, and examples thereof include vinyl chloride acetate-vinyl copolymer resin, acrylic resin, urethane resin, acrylic urethane resin, nitrocellulose, polyvinyl alcohol, polyvinyl acetal, cellulose derivatives, polycarbonate resin, polyamide resin, polyester resin, butyral resin, etc., and one or a mixture of two or more of these resins can be used. These resins can also be made into so-called two-liquid type by using a curing agent. Among them, two-liquid urethane resins are preferred. Examples of two-liquid urethane resins include two-liquid mixtures of polyols such as polyester, acrylic, and acrylic alkyd, and isocyanates, and among them, acrylic urethane resins consisting of acrylic polyols and isocyanate compounds are more preferred.

[0099] Examples of the colorant include pigments and dyes selected from organic pigments and inorganic pigments. Examples of the inorganic pigment include titanium white, carbon black, yellow lead, cadmium yellow, cadmium red, red oxide, ultramarine, and aluminum white. Examples of the organic pigment include quinacridone, lake red, benzidine yellow, isoindolinone, phthalocyanine blue, and Sinclair red. As the colorant, any organic or inorganic pigment can be appropriately used in addition to the above examples depending on the desired color tone.

[0100] The content of colorant in the design layer is preferably 5 parts by mass or more and 90 parts by mass or less, more preferably 15 parts by mass or more and 80 parts by mass or less, and even more preferably 30 parts by mass or more and 70 parts by mass or less, per 100 parts by mass of the resin constituting the design layer.

[0101] The design layer may contain additives such as a matting agent, an ultraviolet absorber, a weathering agent such as a light stabilizer, a plasticizer, a catalyst, and an extender pigment, if necessary.

[0102] The coating amount of the design layer is not particularly limited as long as it can express the desired design, but is preferably 0.1 to 30 g / m in terms of solid content. 2 is preferred.

[0103] The design layer can be formed, for example, by printing on one side of the support layer using ink. The method for printing on the support layer can be, for example, a conventional printing method such as gravure printing, gravure offset printing, inkjet printing, screen printing, rotary screen printing, relief printing, or pad printing.

[0104] <<Surface protective layer>> The decorative layer may have a surface protective layer on the side opposite to the support layer of the decorative layer. By having a surface protective layer on the decorative layer, the surface hardness of the decorative steel panel of the present disclosure can be increased, the surface of the decorative layer can be protected, and the appearance of the decorative layer can be maintained. When the decorative layer has a surface protective layer, the surface protective layer can constitute one of the outermost layers of the decorative steel panel of the present disclosure.

[0105] The surface protective layer is basically transparent. The surface protective layer may be a single layer or may be formed of multiple layers. For example, the surface protective layer may have a multi-layer structure having a protective layer formed of a resin coating agent on a resin film, such as a PET film with a protective layer.

[0106] The surface protective layer can be formed using various commercially available resin coating agents. The surface protective layer is formed of a cured product obtained by curing a composition containing a curable resin such as a thermosetting resin or a radiation curable resin using heat or radiation. Examples of the thermosetting resin include epoxy resin, phenol resin, unsaturated polyester resin, urea resin, melamine resin, silicon resin, vinyl ester resin, polyimide resin, polyurethane resin, and two-liquid curable polyurethane resin. Examples of the radiation curable resin include a mixture of an oligomer component of urethane acrylate, epoxy acrylate, or polyester acrylate, or an acrylate monomer such as 2-hydroxyethyl acrylate, dipropylene glycol diacrylate, or trimethylolpropane triacrylate, and a radical polymerization photoinitiator (e.g., benzoin ethyl ether, benzyl dimethyl ketal, hydroxycyclohexyl phenyl ketone, or 2-hydroxy-2-methyl phenyl ketone).

[0107] If necessary, the surface protective layer may contain weathering agents, plasticizers, stabilizers, fillers, dispersants, colorants such as dyes and pigments, solvents, etc. Furthermore, the surface protective layer may be colored as long as the visibility of the design layer's pattern is ensured.

[0108] The surface protective layer may contain a matting agent. The surface protective layer may have a matte finish, and the gloss of the surface of the decorative steel panel of the present disclosure may be adjusted to a matte finish. The matting agent used in the surface protective layer is preferably of a size within a range that does not impair the magnetic attraction and design of the surface of the decorative steel panel of the present disclosure, and the transparency of the surface protective layer, and the average particle size of the matting agent is preferably 10 μm or less, for example.

[0109] As the matting agent, for example, materials known as matting agents such as silica, resin beads, matting wax, calcium carbonate, feldspar, etc. Among them, silica particles are preferably used.

[0110] The content of the matting agent in the surface protective layer is not particularly limited as long as it is within a range that does not impair the magnetic attraction and design properties of the surface of the decorative steel sheet panel of the present disclosure, and the transparency of the surface protective layer, but it is preferably 1 to 20 mass %, and more preferably 1 to 10 mass %, of the total amount of the composition that forms the surface protective layer.

[0111] The surface protective layer may contain an antibacterial agent and / or an antiviral agent, so that the surface of the decorative steel sheet panel of the present disclosure can have antibacterial and / or antiviral functions in addition to magnetic attraction and design properties.

[0112] The antibacterial and / or antiviral agent may be an inorganic antibacterial and / or antiviral agent, or an organic antibacterial and / or antiviral agent. As the inorganic antibacterial and / or antiviral agent, for example, a metal such as silver, copper, zinc, or a compound thereof, or a mixture thereof supported on an inorganic material is used. Examples of inorganic materials (supports) that support metal ions include ion exchangers such as zeolite, silica gel, clay minerals, zirconium phosphate, calcium phosphate, glass, and metals. Examples of metal oxides include titanium oxide, tin oxide, tungsten oxide, iron oxide, zinc oxide, chromium oxide, and zirconium oxide.

[0113] Examples of the organic antibacterial and / or antiviral agent include alcohols, phenols, aldehydes, carboxylic acids, esters, nitriles, peroxides, halogens such as iodines and chlorines, pyridine-quinolines, triazines, isothiazolones, imidazole-thiazoles, anilides, biguanides, disulfides, thiocarbamates, guanidines, organometallics, terpenes, carbohydrates, tropolones, etc. The antibacterial and / or antiviral agents may be used alone or in combination of two or more.

[0114] The content of the antibacterial and / or antiviral agent in the surface protective layer is not particularly limited as long as it does not impair the magnet adsorptivity and design of the decorative steel panel surface of the present disclosure and the transparency of the surface protective layer, but is preferably in the range of 0.1% by mass to 20% by mass, more preferably in the range of 1% by mass to 10% by mass, based on the total amount of the composition forming the surface protective layer. By containing the antibacterial and / or antiviral agent in the above range, the surface protective layer can achieve both antibacterial and antiviral functions, abrasion resistance, and surface hardness, and the surface of the decorative steel panel of the present disclosure can exhibit these functions of the surface protective layer in addition to the magnet adsorptivity and design.

[0115] The thickness (coating amount) of the above-mentioned surface protective layer is not particularly limited, but for example, it is 0.2 to 25 g / m 2 The thickness can be set to 0.5 to 20 g / m 2 is preferable, and 1 to 15 g / m 2 is more preferable. When the coating amount of the surface protective layer is within the above range, the design of the decorative layer can be visually recognized favorably, and the appearance can be maintained. When the surface protective layer has a multi-layer structure having a protective layer formed by a resin coating agent on a resin film, the thickness (coating amount) of the surface protective layer can be the thickness of the protective layer (coating amount of the resin coating agent).

[0116] The surface protective layer may be in direct contact with the surface of the design layer (ink layer), or may be provided on the design layer (ink layer) via an adhesive layer. The adhesive forming the adhesive layer between the surface protective layer and the design layer (ink layer) is not particularly limited, and any known adhesive (e.g., curing adhesive, hot melt adhesive, etc.) can be used.

[0117] 3.Adhesive layer C The decorative steel sheet panel of the present disclosure may have an adhesive layer C between the decorative layer and the steel sheet panel (steel sheet). The adhesive layer C bonds the decorative layer and the steel sheet panel (steel sheet).

[0118] The adhesive c of the adhesive layer C is not particularly limited as long as it can exhibit good adhesion to the steel plate and the decorative layer, and a general-purpose adhesive can be used. The adhesive c may be a curing adhesive or a hot melt adhesive. Examples of materials for the adhesive c include thermoplastic resins such as polyamide resins, acrylic resins, and vinyl acetate resins, curing resins such as thermosetting urethane resins, two-component curing polyurethane resins or two-component curing polyester resins using isocyanate as a curing agent, reactive urethane hot melt resins, and ethylene vinyl acetate hot melt resins.

[0119] The amount of adhesive layer C applied (amount of adhesive c applied) is not particularly limited as long as it can firmly bond the decorative layer and the steel plate of the steel plate panel. For example, it may be 10 to 70 g / m2 in terms of solid content. 2 is preferable, and 20 to 60 g / m 2 is more preferred.

[0120] 4.Other configurations The decorative steel plate panel of the present disclosure may comprise a steel plate panel having at least a steel plate, an adhesive layer A, and a substrate in that order, and a decorative layer provided on the steel plate of the steel plate panel, but may also comprise other components used in general decorative panels.

[0121] 5. Manufacturing method of decorative steel panel The manufacturing method of the decorative steel plate panel disclosed herein includes a steel plate panel manufacturing process for manufacturing a steel plate panel using the manufacturing method described above in the section "I. Steel plate panel for decorative plate 7. Manufacturing method of steel plate panel," and a decorative layer forming process for providing a decorative layer on the surface of the steel plate.

[0122] In other words, the manufacturing method of the decorative steel panel of the present disclosure includes at least a preparation step of preparing a steel plate and a substrate larger than the steel plate, a bonding step of bonding the steel plate and the substrate, and a decorative layer forming step of providing a decorative layer on the surface of the steel plate. In the manufacturing method of the decorative steel plate panel of the present disclosure, the bonding step can be the following first or second mode. That is, the first mode of the bonding step is a step of applying an adhesive to one side of the steel plate to form a precursor layer of the adhesive layer A, and bonding the surface of the steel plate on the precursor layer side to the surface of the substrate directly or through another layer. Also, the second mode of the bonding step is a step of applying an adhesive to one side of the substrate to form a precursor layer of the adhesive layer A, and bonding the steel plate to the precursor layer directly or through another layer.

[0123] The steel panel manufacturing process in the manufacturing method of the decorative steel panel of the present disclosure includes at least the above-mentioned preparation step and lamination step. The preparation step and lamination step are the same as the preparation step and lamination step described in the above section "I. Steel panel for decorative panel 7. Manufacturing method of steel panel". By the above-mentioned preparation step and lamination step, a steel panel having a steel plate, an adhesive layer A, and a substrate in this order can be manufactured.

[0124] In the manufacturing method of the decorative steel panel of the present disclosure, the decorative layer forming step is a step of providing a decorative layer on the surface of the steel plate. This step may be performed together with the preparation step, or after the lamination step. The decorative layer forming step may be performed together with the preparation step, for example, by providing a decorative layer on one side of a steel plate cut to a desired size and shape, or by providing a decorative layer on one side of the steel plate and then cutting the steel plate to a desired size and shape. In addition, when a decorative layer is provided on one side of the steel plate in the lamination step, the "one side of the steel plate" in the lamination step and the surface of the steel plate to be laminated with the precursor layer refer to the surface of the steel plate opposite to the decorative layer side. In addition, the decorative layer forming step is performed after the preparation step, for example, by providing a decorative layer on the surface of the steel plate of the steel plate panel after the lamination step.

[0125] In the decorative layer forming step, the size (dimensions and shape) of the decorative layer is not particularly limited as long as it can cover at least the surface (plate surface) of the steel plate, and can be appropriately set according to the size (dimensions and shape) of the steel plate, the substrate, and the steel plate panel. The decorative layer is provided so as to cover at least the plate surface of the steel plate of the steel plate panel (i.e., the surface of the first region P), but it may be provided so as to cover the surface and side of the steel plate side of the steel plate panel (i.e., the surface and side of the first region P), or it may be provided so as to cover the surface, side, and surface of the second region Q of the steel plate side of the steel plate panel, and further it may be provided so as to wrap around from the end of the substrate of the steel plate panel to the back surface (back surface of the steel plate panel).

[0126] A method for providing a decorative layer on one side of a steel sheet can be, for example, to prepare a decorative layer having a design layer formed on a support layer, apply an adhesive to one side of the steel sheet or to the surface of the decorative layer on the support layer side to form an adhesive layer C, and then bond the steel sheet and the decorative layer via the adhesive layer C. The decorative layer and adhesive layer C are the same as those explained above in sections "2. Decorative layer" and "3. Adhesive layer C".

[0127] The manufacturing method for decorative steel panel of the present disclosure may include any step other than the preparation step, lamination step (collectively the steel panel manufacturing step), and decorative layer formation step, for example, a step of providing a moisture-proof layer on one side of the substrate. As a method for providing a moisture-proof layer on one side of the substrate, for example, a method can be used in which adhesive b is applied to one side of the substrate or to the surface of the support layer side of the moisture-proof layer to form adhesive layer B, and the substrate and moisture-proof layer are laminated via adhesive layer B. The moisture-proof layer and adhesive layer B were explained in the above sections "4. Moisture-proof layer" and "5. Adhesive layer B" in "I. Steel panel for decorative board", and therefore explanation here is omitted.

[0128] When a moisture-proof layer is provided on one side of the substrate in the bonding step, the one side of the substrate in the bonding step and the side of the substrate to be bonded to the precursor layer may be the side of the substrate on which the moisture-proof layer is formed or the side opposite the moisture-proof layer of the substrate. In particular, the side opposite the moisture-proof layer of the substrate is preferable because moisture generated during the process in which the precursor layer changes into the adhesive layer A can be efficiently removed.

[0129] The manufacturing method for a decorative steel sheet panel of the present disclosure can eliminate the need for a cutting step of cutting a composite material having at least a decorative layer, a steel sheet, an adhesive layer A, and a substrate.

[0130] The present disclosure is not limited to the above-described embodiments. The above-described embodiments are merely examples, and anything that has substantially the same configuration as the technical idea described in the claims of the present disclosure and exhibits similar effects is included in the technical scope of the present disclosure. EXAMPLES

[0131] The present disclosure will be further described below with reference to examples and comparative examples.

[0132] [Example] (Preparation of decorative sheet (decorative layer)) A polybutylene terephthalate (PBT) substrate sheet with a thickness of 80 μm was used, and a colored pattern layer and a protective layer were formed on one side of the substrate sheet by gravure printing to produce a decorative sheet.

[0133] (Preparation of decorative steel sheet) The decorative sheet was laminated on one side of a hot-dip galvanized steel sheet having a thickness of 0.32 mm to obtain a steel sheet with a decorative layer. The steel sheet with a decorative layer was cut into a size of 910 mm x 2420 mm using a shearing machine.

[0134] (Preparation of substrate with moisture-proof layer) A 3 mm thick volcanic glass laminate (product name: Dailite FTL, manufactured by Daiken Kogyo Co., Ltd., with special sheet) was prepared. The volcanic glass laminate had a special sheet laminated on one side as a moisture-proof layer, in which paper, aluminum foil, and paper were laminated in this order, and the other side was a substrate with a moisture-proof layer, which was the base surface of the volcanic glass laminate. The substrate with the moisture-proof layer was cut to 912 mm x 2422 mm using a running saw with a wood chip saw attached.

[0135] (Creating decorative steel panels) A water-based two-component curing vinyl copolymer emulsion adhesive was applied with a roll coater to the surface of the substrate opposite to the surface on which the moisture-proof layer was attached (the bare surface of the substrate). The amount of water-based two-component curing vinyl copolymer emulsion adhesive applied was 150 g / m2 (wet). 2 (Solid content 75g / m 2 The aqueous two-component curing vinyl copolymer emulsion adhesive used was an isocyanate-curing aqueous two-component adhesive, which was made by mixing a vinyl copolymer emulsion resin adhesive (product name: Bond CVC300M, Konishi Corporation) as the base agent and an isocyanate curing agent (product name: Curing Agent NV, Konishi Corporation) as the curing agent in a mass ratio of base agent:curing agent = 100:2.5.

[0136] The steel plate with a decorative layer was placed on the surface of the substrate with a moisture-proof layer coated with an aqueous two-component curing vinyl copolymer emulsion adhesive, with the steel plate side of the steel plate with a decorative layer facing the substrate with a moisture-proof layer, and laminated together. Two minutes after lamination, the steel plate with a decorative layer was slid over the coating of the adhesive so that each of the four sides of the substrate (substrate with a moisture-proof layer) protruded 1 mm from the steel plate (steel plate with a decorative layer), and the lamination position of the steel plate with a decorative layer was fine-tuned. In this state, the composite material consisting of the steel plate with a decorative layer and the substrate with a moisture-proof layer was passed together through a pressure roller to temporarily fix them, and then cold pressed at 2000 N / m for 30 minutes. 2 (0.02kgf / cm 2) was applied to obtain a decorative steel panel. The obtained decorative steel panel had a width of 1 mm in each of the second regions Q located on the periphery of the four sides of the steel plate, and no burrs were observed on the sides. In addition, the second regions Q of the decorative steel panel could be grasped during work, reducing contact between the hands and the steel plate.

[0137] [Comparative Example] A decorative steel panel was obtained in the same manner as in Example 1, except that a decorative steel panel with a decorative layer cut to 920 mm x 2430 mm and a substrate with a moisture-proof layer cut to 930 x 2440 mm were used, the substrate side surface of the substrate with a moisture-proof layer was bonded to the steel plate side surface of the decorative steel panel with a decorative layer via the adhesive, and the four peripheral edges were cut to a size of 910 mm x 2420 mm with a panel saw equipped with a steel plate tipped saw after applying a load by cold pressing. In the decorative steel panel of the comparative example, the width of each second region Q located on the periphery of the four sides of the steel plate was 0 mm, that is, the second region Q was not present, and burrs were generated on the cut surface by the tipped saw. In addition, the contact between the hand and the steel plate increased when the decorative steel panel was held during work. [Industrial Applicability]

[0138] The decorative steel sheet panel of the present disclosure and the decorative steel sheet panel using the same can be used for surface decoration in interiors such as floors, walls, and ceilings of buildings, surface decorative materials for furniture and various cabinets, surface decoration of building fixtures, and surface decoration for vehicle interiors, etc. [Explanation of symbols]

[0139] 1...steel plate, 2...adhesive layer A, 3...substrate, 4...moisture-proof layer, 10...steel plate panel for decorative plate, 11...decorative layer, 20...decorative steel plate panel

Claims

1. The adhesive sheet has at least a steel plate, an adhesive layer A, and a substrate in this order, A steel plate panel for decorative panels, comprising: a first region where the substrate and the steel plate overlap when viewed in a plan view from the steel plate side; and a second region that is arranged outside the first region along at least a portion of the outer edge of the first region and does not include the steel plate.

2. The decorative steel sheet panel according to claim 1, wherein the thickness of the steel sheet is 0.2 mm to 1.0 mm.

3. The steel sheet panel for decorative panels according to claim 1 or 2, wherein the second region has a width of 3 mm or less.

4. The steel sheet panel for decorative board according to claim 1 or 2, wherein the second region is provided so as to surround an entire outer periphery of the first region in a plan view from the steel sheet side.

5. 3. The steel sheet panel for decorative panels according to claim 1 or 2, wherein the adhesive constituting the adhesive layer A is selected from the group consisting of an aqueous two-component curing adhesive, a solventless two-component curing adhesive, and an aqueous rubber adhesive.

6. A manufacturing method for manufacturing the decorative steel sheet panel according to claim 1 or 2, A preparation step of preparing a steel plate and a substrate larger than the steel plate; a bonding step of bonding the steel plate and the substrate; and The lamination step includes: a step of applying an adhesive to one surface of the steel plate to form a precursor layer of the adhesive layer A, and bonding the surface of the steel plate on which the precursor layer is formed to the surface of the substrate directly or via another layer; Or A step of applying an adhesive to one surface of a substrate to form a precursor layer of the adhesive layer A, and bonding the steel sheet to the precursor layer directly or via another layer. The method for manufacturing a steel sheet panel for decorative board is as follows.

7. 7. The method for producing a steel sheet panel for decorative board according to claim 6, which does not include a cutting step of cutting a laminate obtained by bonding the steel sheet and the substrate via the adhesive layer A after the lamination step.

8. A steel plate panel having at least a steel plate, an adhesive layer A, and a substrate in this order; A decorative layer provided on the steel plate of the steel plate panel; having A decorative steel plate panel having, when viewed in a plan view from the decorative layer side, a first region in which the decorative layer, the steel plate and the substrate overlap, and a second region arranged outside the first region along at least a portion of the outer edge of the first region and not including the steel plate.

9. The decorative steel panel according to claim 8, wherein the thickness of the steel plate is 0.2 mm to 1.0 mm.

10. The decorative steel panel according to claim 8 , wherein the second region has a width of 3 mm or less.

11. The decorative steel panel according to claim 8 , wherein the second region is provided so as to surround an entire outer edge of the first region in a plan view from the steel plate side.

12. A manufacturing method for manufacturing the decorative steel sheet panel according to claim 8, A preparation step of preparing a steel plate and a substrate larger than the steel plate; a bonding step of bonding the steel plate and the substrate; a decorative layer forming step of providing a decorative layer on a surface of the steel sheet; and The lamination step includes: a step of applying an adhesive to one surface of the steel plate to form a precursor layer of the adhesive layer A, and bonding the surface of the steel plate on which the precursor layer is formed to the surface of the substrate directly or via another layer; Or A step of applying an adhesive to one surface of the substrate to form a precursor layer of the adhesive layer A, and bonding the steel plate to the precursor layer directly or via another layer. This is a manufacturing method for a decorative steel panel.

13. The method for producing a decorative steel panel according to claim 12, which does not include a cutting step of cutting a laminate formed by joining the steel plate and the substrate via the adhesive layer A after the lamination step.

Images