Manufacturing method of special-purpose items

Abstract

To provide a method for manufacturing fittings that have excellent weather resistance and water-sealing properties. [Solution] The present invention provides a method for manufacturing a decorative piece comprising a metal molded plate formed into a predetermined shape and a resin film covering the surface of the metal molded plate, wherein a waterproof treatment is applied to the outer corner or inner corner, and the method is characterized by comprising the steps of: preparing the metal molded plate and a paste containing a resin material and an ultraviolet shielding material; dipping the metal molded plate into the paste while stirring the paste to form a coating film of the paste on the surface of the metal molded plate; and heating the metal molded plate with the coating film to gel the coating film and form the resin film.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a fitting.

Background Art

[0002] In recent years, with the demand for higher durability of buildings, a sheet waterproof structure in which a resin sheet is laid has been adopted in the structures of building rooftops, verandas, and the like.

[0003] In this sheet waterproof structure, for example, at the boundary between the floor part of the rooftop and the wall part provided along the outer edge of the floor part, that is, at the outside corner part or the inside corner part, a seam of the resin sheet occurs. At the seam, in order to suppress the decrease in the water stopping property of the sheet waterproof structure, fittings that are pre-formed according to the shape of the outside corner part or the inside corner part are used.

[0004] Patent Document 1 discloses a method for manufacturing a fitting, in which a steel plate formed into a predetermined shape is dipped in a vinyl chloride resin paste, the vinyl chloride resin paste is coated on the entire surface with a thickness of 1.0 mm, and then the paste is gelled to form a film. Further, in the vinyl chloride resin paste, 70 parts by weight of a plasticizer and 3 parts by weight of titanium oxide are added to 100 parts by weight of the vinyl chloride resin.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, the method described in Patent Document 1 has the problem that titanium dioxide tends to settle in the paste, reducing the concentration of titanium dioxide in the coating. When the concentration of titanium dioxide decreases, there are concerns that the weather resistance of the coating will decrease, as well as the occurrence of cracks and pinholes in the coating, and the resulting decrease in watertightness.

[0007] The object of the present invention is to provide a method for manufacturing fittings that have excellent weather resistance and water-sealing properties. [Means for solving the problem]

[0008] These objectives are achieved by the present invention as described in (1) to (8) below. (1) A method for manufacturing a fitting comprising a metal molded plate formed into a predetermined shape and a resin film covering the surface of the metal molded plate, wherein the outer corner or inner corner is waterproofed, The process of preparing the aforementioned metal molded plate, and a paste containing a resin material and an ultraviolet shielding material, The process involves dipping the metal molded plate into the paste while stirring the paste, thereby forming a coating of the paste on the surface of the metal molded plate. The process involves heating the metal molded plate to which the coating film is applied to cause the coating film to gel and form the resin film, A method for manufacturing a special-purpose item, characterized by having the following features.

[0009] (2) The method for manufacturing the accessory described in (1) above, wherein the ultraviolet shielding material is an inorganic material powder having an average particle size of 0.05 μm or more and 10 μm or less.

[0010] (3) The method for producing the accessory described in (2) above, wherein the inorganic material powder is titanium oxide powder.

[0011] (4) The method for manufacturing a decorative piece according to any one of (1) to (3) above, wherein the amount of the ultraviolet shielding material in the paste is 7 parts by mass or more and 40 parts by mass or less per 100 parts by mass of the resin material.

[0012] (5) The manufacturing method of the article according to any one of (1) to (4) above, wherein the resin material is a vinyl chloride resin.

[0013] (6) The manufacturing method of the article according to any one of (1) to (5) above, wherein the film thickness of the resin film is 200 μm or more and 5000 μm or less.

[0014] (7) The manufacturing method of the article according to any one of (1) to (6) above, wherein the plate thickness of the metal forming plate is 0.1 mm or more and 2.0 mm or less.

[0015] (8) The manufacturing method of the article according to any one of (1) to (7) above, wherein the constituent material of the metal forming plate includes stainless steel.

Effect of the Invention

[0016] According to the present invention, an article excellent in weather resistance and water-stopping property can be manufactured.

Brief Description of the Drawings

[0017] [Figure 1] It is a partial cross-sectional perspective view showing an example of a building where waterproof treatment using an article is applied. [Figure 2] It is a cross-sectional view taken along line A-A of the article shown in FIG. 1. [Figure 3] It is a process diagram for explaining the manufacturing method of the article according to the embodiment.

Mode for Carrying Out the Invention

[0018] Hereinafter, the manufacturing method of the article of the present invention will be described in detail based on the preferred embodiments shown in the accompanying drawings.

[0019] 1. Article First, an example of the article manufactured by the manufacturing method of the article of the present invention will be described.

[0020] FIG. 1 is a partial cross-sectional perspective view showing an example of a building 2 where waterproofing treatment using a fitting 1 has been applied. FIG. 2 is a cross-sectional view taken along line A-A of the fitting 1 shown in FIG. 1.

[0021] As shown in FIG. 1, the fitting 1 is a material for applying waterproofing treatment to the outer corner part 21 and the inner corner part 22. In this specification, the outer corner part 21 refers to a part where two surfaces intersect in a concave shape. Also, in this specification, the inner corner part 22 refers to a part where two surfaces intersect in a convex shape. The outer corner part 21 and the inner corner part 22 have different shapes depending on the building 2. For this reason, the fitting 1 may be formed into a general-purpose shape so as to be applicable to various buildings 2, or may be formed into a shape specific to the different outer corner parts 21 and inner corner parts 22 for each building 2. Further, the fitting 1 is joined to the end of a waterproof sheet (not shown) as necessary. Thereby, continuous waterproofing treatment over a wide range can be performed.

[0022] The part of the building 2 where waterproofing treatment is applied is not particularly limited. In FIG. 1, an example of applying waterproofing treatment to the roof of the building 2 is illustrated. The building 2 shown in FIG. 1 has a floor part 2A and a parapet 2B that constitute the roof. Examples of parts other than the roof include, for example, the roof, veranda, balcony, around the window, the outer wall, etc. Note that the outer corner part 21 and the inner corner part 22 include, for example, the irregularities associated with the drain 23 and the drainage groove 24 shown in FIG. 1.

[0023] As shown in FIG. 2, the fitting 1 includes a metal formed plate 11 formed into a predetermined shape and a resin film 12 covering the surface of the metal formed plate 11.

[0024] The metal formed plate 11 is made of a metal material. Thereby, a fitting 1 having good shape retention and mechanical strength and capable of constructing a waterproofing treatment with excellent durability can be obtained.

[0025] Preferably, the size of the metal molded plate 11 is set to a size that can cover multiple areas where conventional corner patches are attached. Corner patches are sheets attached to the corners of outer corners 21 and inner corners 22, and are molded into a predetermined shape. By using a large metal molded plate 11 for areas where multiple corner patches are attached, waterproofing can be performed at once. This reduces the amount of work required for waterproofing compared to attaching multiple corner patches. In addition, while conventional methods create numerous joints between the corner patches and the waterproofing sheet, the number and area of ​​such joints can be reduced. This makes it possible to apply waterproofing with fewer steps and suppress the occurrence of water leakage due to poor adhesion at the joints.

[0026] The fitting 1 shown in Figure 1 is an example that covers both the outer corner 21 and the inner corner 22. With such a fitting 1, waterproofing treatment can be applied to both the outer corner 21 and the inner corner 22 at the same time. Note that the shape of the fitting 1 may be such that it is applied to only one of the outer corner 21 or the inner corner 22.

[0027] Examples of metal materials include various metal materials such as stainless steel, iron-based alloys such as steel, aluminum alloys, and copper alloys. Of these, iron-based alloys are preferably used, and stainless steel is more preferably used. This further enhances the mechanical strength and durability of the metal formed sheet 11.

[0028] Furthermore, the metal molded plate 11 may be treated with rust prevention treatment as needed. Examples of rust prevention treatments include zinc-aluminum-magnesium plating and zinc plating.

[0029] The thickness of the metal molded plate 11 is not particularly limited, but is preferably 0.1 mm to 2.0 mm, and more preferably 0.3 mm to 1.5 mm. This provides the fitting 1 with sufficient shape retention and mechanical strength. It also suppresses the weight increase of the metal molded plate 11, improving handling.

[0030] The resin film 12 contains a resin material and covers the metal molded plate 11. This enhances the corrosion resistance of the metal molded plate 11 and modifies its surface. As a result, for example, when joining a fitting 1 to a waterproof sheet, the bonding strength between the fitting 1 and the waterproof sheet can be easily increased, and the wind pressure resistance of the waterproof sheet after installation can be improved.

[0031] The thickness of the resin film 12 is not particularly limited, but is preferably between 200 μm and 5000 μm, more preferably between 300 μm and 3000 μm, and even more preferably between 500 μm and 2000 μm. This ensures sufficient coverage of the resin film 12 on the metal molded plate 11, and provides a resin film 12 with fewer pinholes and excellent weather resistance. Furthermore, it suppresses the increase in weight and overall thickness caused by an excessively thick resin film 12.

[0032] Preferably, the resin film 12 covers the entire surface of the metal molded plate 11, but there may be areas that are not covered. Also, the thickness of the resin film 12 may be the same throughout, or it may vary in thickness.

[0033] 2. Manufacturing method of the special item Next, a method for manufacturing the component according to the embodiment will be described. In the following description, the method for manufacturing the component 1 shown in Figure 2 will be used as an example.

[0034] Figure 3 is a process diagram illustrating the manufacturing method of the accessory according to the embodiment. The manufacturing method for the accessory shown in Figure 3 comprises a preparation step S102, a dipping step S104, and a resin film forming step S106.

[0035] 2.1. Preparation process In preparation step S102, a metal molded plate 11 and a paste containing a resin material and an ultraviolet shielding material are prepared. In particular, a solvent may be added to the paste as needed. This allows for the preparation of a paste with excellent viscosity. Alternatively, a plasticizer may be added instead of, or together with, the solvent. Adding a plasticizer improves viscosity, allowing for the omission or reduction of the amount of solvent, and enabling the preparation of a paste with a high proportion of resin material.

[0036] The metal sheet 11 is pre-formed into the desired shape. The metal sheet 11 is formed, for example, by press working, sheet metal processing, or deep drawing. Alternatively, the metal sheet 11 may be manufactured by connecting multiple parts using various joining methods such as welding.

[0037] Examples of resin materials included in the paste include various thermoplastic resins such as polyvinyl chloride (PVC), polyolefin resins, ethylene vinyl acetate copolymers, polyamide resins, and hot melt resins, and one or more of these can be used in combination. Of these, polyvinyl chloride resins are preferred. Polyvinyl chloride resins have excellent solvent weldability, heat weldability, and weather resistance. Therefore, by using polyvinyl chloride resins, a fitting 1 with excellent bonding strength to the waterproof sheet and excellent weather resistance can be obtained.

[0038] The vinyl chloride resin is not particularly limited as long as it is a polymer containing vinyl chloride, i.e., an oligomer, prepolymer, or polymer. Examples include monomeric polymers of vinyl chloride, copolymers of vinyl chloride and other monomers, and mixtures of two or more of these polymers.

[0039] In the case of copolymers, the proportion of vinyl chloride is preferably set to 50% by mass or more, more preferably 70% by mass or more. Examples of monomers copolymerized with vinyl chloride include olefins such as ethylene and propylene; halogenated olefins such as allyl chloride, vinylidene chloride, vinyl fluoride, and trifluoroethylene chloride; vinyl carboxylate esters such as vinyl acetate and vinyl propionate; vinyl ethers such as isobutyl vinyl ether and cetyl vinyl ether; allyl ethers such as allyl-3-chloro-2-oxypropyl ether and allyl glycidyl ether; unsaturated carboxylic acids such as acrylic acid, maleic acid, itaconic acid, 2-hydroxyethyl acrylate, methyl methacrylate, monomethyl maleate, diethyl maleate, and maleic anhydride, their esters, or acid anhydrides; unsaturated nitriles such as acrylonitrile and methacrylonitrile; acrylamides such as acrylamide, N-methylolacrylamide, acrylamide-2-methylpropanesulfonic acid, and (meth)acrylamidopropyltrimethylammonium chloride; and allylamines and their derivatives such as allylamine benzoate and diallyldimethylammonium chloride.

[0040] Examples of polyolefin resins include polyethylene and polypropylene.

[0041] Specific examples of polyethylene include high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and mixtures of two or more of the above types of polyethylene.

[0042] Specific examples of polypropylene include isotactic polypropylene, syndiotactic polypropylene, atactic polypropylene, and mixtures of two or more of the above types of polypropylene.

[0043] As the UV shielding material, for example, an organic material may be used, but an inorganic material is preferred. Since inorganic materials have stable UV shielding ability, they contribute to the realization of a resin film 12 with excellent weather resistance.

[0044] Examples of inorganic materials include metal oxides such as titanium dioxide, zinc oxide, and cerium oxide. These metal oxides shield against ultraviolet rays and electromagnetic waves with shorter wavelengths by absorbing them, and also have excellent weather resistance. For this reason, these metal oxides contribute to suppressing degradation caused by ultraviolet rays in the resin material contained in the resin film 12, and are particularly useful as ultraviolet absorbers.

[0045] The form of the UV-shielding material is not particularly limited, but is preferably an inorganic material powder. The inorganic material powder absorbs ultraviolet rays when dispersed in the resin film 12. This suppresses the degradation of the resin film 12 due to ultraviolet rays. As a result, a resin film 12 with excellent weather resistance is obtained.

[0046] Of these, the inorganic material powder is preferably titanium dioxide powder. Titanium dioxide is relatively inexpensive and readily available. Furthermore, because titanium dioxide has relatively low catalytic activity, it also contributes to improving the chemical stability of the resin material contained in the resin film 12.

[0047] The average particle size of the inorganic material powder is not particularly limited, but is preferably 0.05 μm to 10 μm, more preferably 0.1 μm to 5 μm, and even more preferably 0.2 μm to 1 μm. This improves the dispersibility of the inorganic material powder in the resin film 12. As a result, the inorganic material powder is uniformly dispersed, and a resin film 12 with less variation in UV shielding ability and excellent durability is obtained.

[0048] The average particle size of inorganic material powder refers to particle size D50, where the cumulative frequency from the smallest diameter side accounts for 50% of the volume-based cumulative particle size distribution of the inorganic material powder obtained using a laser diffraction particle size distribution analyzer.

[0049] The amount of UV-shielding material added is not particularly limited, but is preferably 7 to 40 parts by mass per 100 parts by mass of resin material, more preferably 10 to 35 parts by mass, and even more preferably 15 to 30 parts by mass. By setting the amount of UV-shielding material added within the above range, a resin film 12 can be obtained that has sufficient UV-shielding ability, can suppress the deterioration of the resin material, and has sufficient adhesion to the metal molded plate 11. In addition, the probability of contact between UV-shielding materials in the paste can be optimized, and sedimentation due to aggregation of UV-shielding materials can be suppressed.

[0050] Furthermore, if the amount of UV-shielding material added falls below the lower limit, the UV-shielding ability of the resin film 12 may be insufficient. On the other hand, if the amount of UV-shielding material added exceeds the upper limit, the ratio of resin material in the resin film 12 decreases, which may reduce the adhesion of the resin film 12 to the metal molded plate 11. In addition, sedimentation may occur due to aggregation of the UV-shielding materials.

[0051] The resin material is added in powder form. This allows for the preparation of a colloidal paste. The average particle size of the resin material powder is not particularly limited, but is preferably 0.05 μm to 30 μm, more preferably 0.1 μm to 20 μm, and even more preferably 0.2 μm to 10 μm. This allows for the preparation of a paste with excellent viscosity and uniform dispersion of the resin material. As a result, a resin film 12 with sufficient film thickness and excellent coating properties is obtained.

[0052] The average particle size of the powder is defined as particle size D50, where the cumulative frequency from the smallest diameter side accounts for 50% of the cumulative particle size distribution obtained using a laser diffraction particle size distribution analyzer.

[0053] Furthermore, when the resin material is a vinyl chloride resin, the average degree of polymerization of the vinyl chloride resin is preferably 1000 or higher, and more preferably 1500 to 3000. This optimizes the viscosity of the paste, resulting in a resin film 12 with excellent covering and adhesion properties. In addition, a resin film 12 with excellent elongation at break and mechanical strength is obtained.

[0054] The average degree of polymerization is calculated on a standard polystyrene basis using gel permeation chromatography (GPC).

[0055] The paste may contain plasticizers. Examples of plasticizers include phthalate ester plasticizers, phosphate ester plasticizers, adipic acid ester plasticizers, sebatic acid ester plasticizers, etc., and one or more of these are used as a mixture.

[0056] Examples of phthalate ester plasticizers include dimethyl phthalate (DMP), diethyl phthalate (DEP), dibutyl phthalate (DBP), dihexyl phthalate (DHP), di-2-ethylhexyl phthalate (DOP), diisodecyl phthalate (DIDP), butyl benzyl phthalate (BBP), diisononyl phthalate (DINP), and dinonyl phthalate (DNP).

[0057] Examples of phosphate ester plasticizers include tricresyl phosphate (TCP) and trixylylene phosphate (TXP).

[0058] Examples of adipic acid ester plasticizers include dioctyl adipate (DOA) and diisodecyl adipate (DIDA).

[0059] Examples of sebatic acid ester plasticizers include dibutyl sebacate (DBS) and dioctyl sebacate (DOS).

[0060] The amount of plasticizer added to the paste is not particularly limited, but is preferably 150 parts by mass or less per 100 parts by mass of resin material, more preferably 20 parts by mass or more and 100 parts by mass or less, and even more preferably 30 parts by mass or more and 80 parts by mass or less. This results in a resin film 12 with excellent weather resistance and coating properties. As a result, a fitting 1 is obtained in which the occurrence of cracks, pinholes, etc. in the resin film 12 is suppressed.

[0061] Examples of solvents that can be included in the paste include aromatic hydrocarbons such as toluene, xylene, and benzene; aliphatic hydrocarbons such as hexane and isoparaffin; ketones such as acetone and methyl ethyl ketone; and esters such as ethyl acetate, butyl acetate, and dioctyl phthalate. Furthermore, one of these solvents can be used alone or in combination of two or more.

[0062] The amount of solvent added to the paste is preferably 50 parts by mass or less, more preferably 3 parts by mass or more and 40 parts by mass or less, and even more preferably 5 parts by mass or more and 30 parts by mass or less, per 100 parts by mass of resin material. By setting the amount of solvent added within the above range, the dispersibility of the ultraviolet shielding material dispersed in the paste can be improved, and the fluidity of the paste can be optimized.

[0063] The paste may contain any additives in addition to the resin material. Examples of additives include saturated fatty acids, metal soaps, powder flow improvers, colorants, impact resistance improvers, perchlorate compounds, antioxidants, antifungal agents, flame retardants, antistatic agents, fillers, UV absorbers, light stabilizers, and foaming agents.

[0064] Examples of fillers include calcium carbonate, barium sulfate, clay, diatomaceous earth, silica, and talc, and one or more of these are used as a mixture.

[0065] The amount of each additive added to the paste is preferably 100 parts by mass or less, more preferably 50 parts by mass or less, and even more preferably 30 parts by mass or less, per 100 parts by mass of resin material.

[0066] The prepared paste may be stirred before being subjected to the dipping step S104 described later. Examples of stirring methods for this step include a planetary mixer, a three-roll mixer, etc.

[0067] Furthermore, the metal molded plate 11 may be preheated prior to the dipping step S104 described later. Preheating the metal molded plate 11 improves the adhesion of the constituent materials of the resin film 12, regardless of the shape of the metal molded plate 11. As a result, the resin film 12 can be formed uniformly, regardless of the shape of the metal molded plate 11.

[0068] The preheating temperature is preferably between 40°C and 200°C, and more preferably between 50°C and 90°C.

[0069] Furthermore, a primer may be applied to the surface of the metal molded plate 11 as needed. The primer enhances the adhesion between the metal molded plate 11 and the resin film 12. By applying the primer, delamination between the metal molded plate 11 and the resin film 12 is suppressed, and the durability of the metal molded plate 11 and the wind pressure resistance of the waterproof sheet are particularly enhanced.

[0070] The primer is not particularly limited as long as it has the function of improving the adhesion of the resin film 12 to the surface of the metal molded plate 11. The primer is, for example, a liquid composition containing a resin, a curing agent, and a solvent.

[0071] Examples of resins that can be included in the primer include polyester resins, alkyd resins, epoxy resins, acrylic resins, fluororesins, and vinyl chloride resins. The resin included in the primer may also be one or a mixture of two or more of these resins.

[0072] Examples of polyester resins include oil-free polyester resins, urethane-modified polyester resins, epoxy-modified polyester resins, and acrylic-modified polyester resins.

[0073] Alkyd resins are resins obtained by modifying polyester resins with fatty acids. Examples of alkyd resins include phenol-modified alkyd resins, epoxy-modified alkyd resins, and oil-modified alkyd resins.

[0074] Examples of epoxy resins include bisphenol-type epoxy resins and novolac-type epoxy resins. Modified epoxy resins are also produced by reacting the epoxy groups or hydroxyl groups in these epoxy resins with various modifying agents.

[0075] The curing agent is not particularly limited as long as it can react with the above-mentioned resin to cause curing, but examples include amino compounds and blocked polyisocyanate compounds.

[0076] Examples of amino compounds include methylolated amino resins obtained by the reaction of amino components such as melamine, urea, benzoguanamine, acetogranamine, sterognamin, spiloganamine, and dicyandiamide with aldehydes. Examples of aldehydes used in the above reaction include formaldehyde, paraformaldehyde, acetaldehyde, and benzaldehyde. Alternatively, the above methylolated amino resin may be etherified with a suitable alcohol. Examples of alcohols used for etherification include methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, 2-ethylbutanol, and 2-ethylhexanol.

[0077] Blocked polyisocyanate compounds are compounds obtained by blocking the isocyanate group of an isocyanate compound with a blocking agent. Examples of blocked polyisocyanate compounds include aliphatic diisocyanates such as hexamethylene diisocyanate and trimethylhexamethylene diisocyanate; cyclic aliphatic diisocyanates such as hydrogenated xylylene diisocyanate and isophorone diisocyanate; aromatic diisocyanates such as tolylene diisocyanate and 4,4'-diphenylmethane diisocyanate; adducts of these organic diisocyanates with polyhydric alcohols, low molecular weight polyester resins, or water, cyclized polymers of the above organic diisocyanates, and isocyanate biuret compounds.

[0078] Examples of blocking agents include phenol-based blocking agents, alcohol-based blocking agents, oxime-based blocking agents, and activated methylene-based blocking agents.

[0079] The mixing ratio of resin to curing agent in the primer is not particularly limited, but preferably, the resin content is 55 to 95 parts by mass and the curing agent content is 5 to 45 parts by mass. This results in a primer coating film with excellent adhesion to the resin film 12.

[0080] The solvent can be any substance capable of dissolving or dispersing the resin or curing agent, and is not particularly limited, but examples include aliphatic hydrocarbons, aromatic hydrocarbons, alcohols, ethers, esters, and alcohol ethers.

[0081] Specific examples of solvents include xylene, toluene, propylene glycol methyl ether acetate, methanol, isopropyl alcohol, and ethylene glycol monopropyl ether.

[0082] Furthermore, the primer may contain any additives. Examples of additives include coupling agents, curing accelerators, viscosity modifiers, plasticizers, leveling agents, defoaming agents, anti-sedimentation agents, colorants, stabilizers, rust inhibitors, mold inhibitors, fluorescent agents, UV absorbers, antioxidants, and fillers.

[0083] 2.2. Dipping Process In the dipping step S104, the paste is placed in a container equipped with a stirrer. The paste is then stirred using the stirrer. The stirrer is not particularly limited, but for example, a stirrer equipped with stirring blades located at the bottom of the container holding the paste can be used. Specifically, a Henschel mixer can be used. By using such a stirrer, the liquid surface of the paste is opened up during stirring, making it possible to perform the dipping operation of the metal molded plate 11 into the paste while it is being stirred.

[0084] Next, the metal molded plate 11 is dipped into the paste while it is being stirred. This forms a coating film of the paste on the surface of the metal molded plate 11. By dipping the metal molded plate 11 into the paste while it is being stirred, a homogeneous coating film can be formed. A homogeneous coating film refers to a state in which there is little variation in composition throughout the coating film. Furthermore, when dipping multiple metal molded plates 11 one after another, a coating film with little individual variation can be formed. A coating film with little individual variation refers to a state in which there is little variation in the composition of the coating film between the metal molded plates 11.

[0085] Furthermore, variations in composition are particularly problematic when it comes to variations in the concentration of the UV-blocking material. If the concentration of the UV-blocking material decreases, there is a risk of degradation of the resin material due to ultraviolet rays. This may reduce the weather resistance of the resin film 12 and potentially reduce the water-sealing properties of the fitting 1.

[0086] Therefore, in this embodiment, as described above, the metal molded plate 11 is dipped while stirring the paste. This homogenizes the composition of the paste, thereby suppressing variations in the composition of the coating film. As a result, even if the concentration of the UV shielding material in the paste is high, variations in the concentration of the UV shielding material in the coating film can be suppressed, thereby suppressing the deterioration of the resin material due to UV absorption. This makes it possible to efficiently manufacture fittings 1 with excellent weather resistance and watertightness. In addition, it becomes easier to make the resin film 12 thicker, thereby improving the pinhole resistance and coverage of the resin film 12.

[0087] The stirring conditions for the paste can be quantified, for example, by the rotation speed of the stirring blade. The rotation speed of the stirring blade is preferably 200 rpm to 5000 rpm, and more preferably 500 rpm to 3000 rpm. This allows for greater homogenization of the paste composition. As a result, for example, the settling of components such as UV-shielding materials can be suppressed, and a coating film with less variation in composition can be obtained.

[0088] The stirring conditions for the paste can be quantified, for example, by the peripheral speed of the tip of the stirring blade. The peripheral speed of the tip of the stirring blade (blade tip velocity) is preferably 0.5 [m / s] or more and 50.0 [m / s] or less, more preferably 1.0 [m / s] or more and 40.0 [m / s] or less, and even more preferably 2.0 [m / s] or more and 30.0 [m / s] or less. This allows for greater homogenization of the paste composition. As a result, for example, the settling of components such as UV-shielding materials can be suppressed, and a coating film with less variation in composition can be obtained.

[0089] The temperature of the paste during stirring is not particularly limited, but is preferably 30°C to 90°C, and more preferably 35°C to 50°C. This allows for optimizing the viscosity of the paste while suppressing thermal deformation of the resin material in the paste. Furthermore, it is possible to further improve the adhesion of the coating film to the metal molded plate 11.

[0090] 2.3.Resin film formation process In the resin film formation step S106, the metal molded plate 11 with the coating is heated. This causes the coating to gel. As a result, a resin film 12 is obtained. Gelation refers to the solidification of the coating.

[0091] The heating temperature of the coating film (post-heating temperature) is not particularly limited, but is preferably 130°C to 280°C, and more preferably 150°C to 250°C. This allows for good gelation and results in a resin film 12 with suppressed occurrence of cracks and pinholes.

[0092] The heating time (post-heating time) of the coating film is not particularly limited, but is preferably 0.5 minutes to 10 minutes, and more preferably 0.5 minutes to 5 minutes, at the above heating temperature. This allows the coating film to gel efficiently while suppressing overheating.

[0093] After heating the coating film, it may be cooled as needed. The cooling temperature is not particularly limited, but is preferably 60°C or lower, and more preferably 30°C or lower. The cooling method may be air cooling or water cooling.

[0094] 3. Effects achieved by the above embodiment The method for manufacturing a fitting according to the above embodiment is a method for manufacturing a fitting 1 comprising a metal molded plate 11 formed into a predetermined shape and a resin film 12 covering the surface of the metal molded plate 11, and applying a waterproof treatment to the outer corner 21 or inner corner 22, and comprises a preparation step S102, a dipping step S104, and a resin film forming step S106. In the preparation step S102, the metal molded plate 11 and a paste containing a resin material and an ultraviolet shielding material are prepared. In the dipping step S104, the metal molded plate 11 is dipped into the paste while stirring the paste to form a paste coating on the surface of the metal molded plate 11. In the resin film forming step S106, the metal molded plate 11 with the coating is heated to gel the coating and form a resin film 12.

[0095] With this configuration, even with the dipping method, it is possible to form a coating film with suppressed variations in the concentration of the UV-blocking material. As a result, even when the UV-blocking material is contained in the paste at a high concentration, the degradation of the resin material due to UV absorption can be suppressed, making it possible to manufacture fittings 1 with excellent weather resistance and water-sealing properties.

[0096] In the manufacturing method of the accessory according to the above embodiment, the ultraviolet shielding material is an inorganic material powder having an average particle size of 0.05 μm or more and 10 μm or less.

[0097] This configuration utilizes an inorganic material with stable UV shielding capabilities, thus contributing to the realization of a resin film 12 with excellent weather resistance.

[0098] In the method for manufacturing the accessory according to the above embodiment, the inorganic material powder is titanium oxide powder. With this configuration, the fact that titanium dioxide is relatively inexpensive and readily available, and that its catalytic activity is relatively low, can be utilized to improve the chemical stability of the resin material contained in the resin film 12.

[0099] In the manufacturing method of the accessory according to the above embodiment, the amount of ultraviolet shielding material in the paste is 7 parts by mass or more and 40 parts by mass or less per 100 parts by mass of resin material.

[0100] With this configuration, a resin film 12 is obtained that has sufficient UV shielding ability, can suppress the degradation of the resin material, and has sufficient adhesion to the metal molded plate 11. In addition, the probability of contact between UV shielding materials in the paste can be optimized, and sedimentation due to aggregation of UV shielding materials can be suppressed.

[0101] In the method for manufacturing the accessory according to the above embodiment, the resin material is a vinyl chloride resin. With this configuration, the vinyl chloride resin exhibits excellent solvent-weldability, heat-weldability, and weather resistance, resulting in a component 1 with excellent bonding strength and weather resistance to the waterproof sheet.

[0102] In the method for manufacturing the accessory according to the above embodiment, the thickness of the resin film 12 is 200 μm or more and 5000 μm or less.

[0103] With this configuration, sufficient coverage of the resin film 12 on the metal molded plate 11 can be ensured, resulting in a resin film 12 with fewer pinholes and excellent weather resistance. Furthermore, it is possible to suppress the increase in weight and overall thickness caused by the resin film 12 being too thick.

[0104] In the manufacturing method of the accessory according to the above embodiment, the thickness of the metal molded plate 11 is 0.1 mm or more and 2.0 mm or less.

[0105] This configuration allows for sufficient shape retention and mechanical strength to be provided to the component 1. Furthermore, it suppresses the weight increase of the metal molded plate 11, improving handling.

[0106] In the manufacturing method of the accessory according to the above embodiment, the constituent material of the metal molded plate 11 includes stainless steel.

[0107] This configuration allows for greater mechanical strength and durability of the metal molded plate 11.

[0108] The method for manufacturing the special feature of the present invention has been described above, but the present invention is not limited to these.

[0109] For example, the method for manufacturing the special feature of the present invention may be modified from the above embodiment by adding any additional steps for any purpose. [Examples]

[0110] Next, specific embodiments of the present invention will be described. However, the present invention is not limited in any way to these embodiments.

[0111] 4. Production of special effects Each sample No. was manufactured according to the manufacturing conditions shown in Table 1 or Table 2. The shape of the component was as shown in Figure 2.

[0112] Specifically, first, a paste for forming a resin film was prepared (preparation step). Titanium oxide powder was added to the paste along with the resin material, plasticizer, and solvent, as an ultraviolet shielding agent. Next, a metal molded plate was dipped in the paste while stirring to obtain a coating (dipping step). Then, the coating was heated to gel it. This resulted in obtaining a resin film and a special part (resin film formation step).

[0113] The symbols shown in Tables 1 and 2 correspond to the following materials. • SUS: Stainless steel SUS304 SGCC: Hot-dip galvanized steel • PVC: Polyvinyl chloride resin

[0114] Tables 1 and 2 also show the average particle size of the resin material, the content of the plasticizer when the resin material content is 100 parts by mass, the average particle size of the UV shielding material, and the content of the UV shielding material when the resin material content is 100 parts by mass.

[0115] Furthermore, in Tables 1 and 2, a "○" for stirring during film formation indicates that the metal molded plate was dipped while stirring the paste during the dipping process, while a "-" indicates that the metal molded plate was dipped without stirring the paste.

[0116] Tables 1 and 2 show the blade tip speed, paste temperature, and post-heating temperature when stirring the paste during the dipping process.

[0117] In Tables 1 and 2, methods for manufacturing the special features of each sample number that correspond to the present invention are labeled as "Examples," while those that do not correspond to the present invention are labeled as "Comparative Examples."

[0118] 5. Evaluation of the special features The following evaluations were performed on the components of each example and each comparative example.

[0119] 5.1. Concentration distribution of titanium dioxide powder in resin film For each example and comparative example, the resin film was peeled off from the metal molded plate and cut out from five locations on the component to create test specimens. These five locations include both ends of the total length of the component (the maximum length that can be obtained) and are evenly distributed among the five parts.

[0120] Next, the concentration of the UV-blocking material was measured in five test specimens. An EPMA (electron probe microanalyzer) was used to measure the concentration. Quantitative analysis of the surface of the test specimens was performed using EPMA to measure the mass concentration of Ti. The EPMA probe diameter was 100 μm.

[0121] Next, the range of Ti concentrations (the difference between the maximum and minimum values) measured for the five test specimens was calculated. The calculation results were then evaluated against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0122] The variation in AA:Ti concentration is relatively small. A: The variation in Ti concentration is relatively small. B: The variation in Ti concentration is relatively small. The variation in C:Ti concentration is relatively large.

[0123] 5.2. Weather resistance (gloss retention rate under UV irradiation) The 60° reflectance was measured on the surface of the trim pieces of each example and comparative example using a gloss tester. The measurement result is referred to as "pre-test gloss." Next, the trim pieces were subjected to a test at a wavelength of 365 nm and an illuminance of 150 mW / cm². 2 The surface of the component was continuously irradiated with ultraviolet light for 100 hours. Next, the 60° reflectance of the surface of the component after ultraviolet irradiation was measured again using a gloss tester. The measurement result is referred to as "post-test gloss." Next, the gloss retention rate was calculated using the following formula. Gloss retention rate (%) = {(Gloss after test) / (Gloss before test)} × 100

[0124] Next, the weather resistance of the trim pieces was evaluated by comparing the calculated gloss retention rate against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0125] A: Particularly high weather resistance (gloss retention rate of 60% or more) B: Moderately high weather resistance (gloss retention rate of 30% or more but less than 60%) C: Low weather resistance (gloss retention rate less than 30%)

[0126] 5.3. Appearance of resin film after UV irradiation For each example and comparative example, the resin film was observed using an optical microscope after the aforementioned ultraviolet irradiation. The observation results were then evaluated according to the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0127] A: No cracks, pinholes, or other deterioration have occurred in the resin film. B: Slight deterioration such as cracks and pinholes has occurred in the resin film. C: Numerous cracks, pinholes, and other forms of deterioration have occurred in the resin film.

[0128] [Table 1]

[0129] [Table 2]

[0130] Based on the evaluation results shown in Tables 1 and 2, the following can be observed. • In the components of each example, the variation in the concentration of titanium dioxide powder, which is an ultraviolet shielding material, was suppressed compared to each comparative example. • In each example, the gloss retention rate after UV irradiation was higher compared to each comparative example. This is thought to be due to less degradation of the resin film due to UV irradiation. Furthermore, it is believed that suppressing the degradation of the resin film can suppress the decrease in weather resistance and watertightness. • In each example, the deterioration of appearance due to ultraviolet irradiation was suppressed compared to each comparative example.

[0131] From the above, it has been confirmed that the present invention makes it possible to manufacture fittings with excellent weather resistance and water-sealing properties. [Explanation of Symbols]

[0132] 1. Special Features 2 buildings 2A Floor part 2B Parapet 11 Metal forming plate 12 Resin film 21 Corner section 22 Inside corner 23 Drain 24 Drainage S102 Preparation process S104 Dipping process S106 Resin film formation process

Claims

1. A method for manufacturing a fitting comprising a metal molded plate formed into a predetermined shape and a resin film covering the surface of the metal molded plate, wherein waterproof treatment is applied to the outer corner or inner corner, The process of preparing the aforementioned metal molded plate, and a paste containing a resin material and an ultraviolet shielding material, The process involves dipping the metal molded plate into the paste while stirring the paste, thereby forming a coating of the paste on the surface of the metal molded plate. The process involves heating the metal molded plate to which the coating film is applied to cause the coating film to gel and form the resin film, A method for manufacturing a special-purpose item, characterized by having the following features.

2. The method for manufacturing the accessory according to claim 1, wherein the ultraviolet shielding material is an inorganic material powder having an average particle size of 0.05 μm or more and 10 μm or less.

3. The method for producing the accessory according to claim 2, wherein the inorganic material powder is titanium oxide powder.

4. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the content of the ultraviolet shielding material in the paste is 7 parts by mass or more and 40 parts by mass or less per 100 parts by mass of the resin material.

5. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the resin material is a vinyl chloride resin.

6. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the thickness of the resin film is 200 μm or more and 5000 μm or less.

7. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the thickness of the metal molded plate is 0.1 mm or more and 2.0 mm or less.

8. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the constituent material of the metal molded plate is stainless steel.

Images