Manufacturing method of special-purpose items

Abstract

To provide a method for manufacturing a fitting that comprises a metal molded plate and a resin film of sufficient thickness, and that exhibits excellent mechanical strength, weather resistance, and watertightness. [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 the outer corner or inner corner is waterproofed, comprising the steps of: attaching the metal molded plate coated with a primer to a powder slush molding machine; rotating the metal molded plate with the powder slush molding machine while applying resin to the surface of the metal molded plate to obtain the resin film; and removing the metal molded plate with the resin film from the powder slush molding machine to obtain the decorative piece.

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 high durability of buildings, a sheet waterproof structure in which a resin sheet is laid has been adopted in the structures such as the rooftops and verandas of buildings.

[0003] In this sheet waterproof structure, for example, at the boundary between the floor part on the rooftop and the wall part provided along the outer edge of the floor part, that is, at the external corner part or the internal 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, a fitting that is pre-formed according to the shape of the external corner part or the internal corner part is 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 over the entire surface with a thickness of 1.0 mm, and then the paste is gelled to form a film.

[0005] Patent Document 2 discloses a waterproofing tool used in a region including a joint where a waterproof treatment is performed on a structure of civil engineering and architecture, the waterproofing tool being composed of an integrally formed product of thermoplastic resin sheet pieces formed by a powder slashing method.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] However, the method described in Patent Document 1 cannot form a coating of sufficient thickness. Therefore, there are concerns about the occurrence of cracks and pinholes in the coating, and the resulting decrease in watertightness. In addition, coatings formed using paste contain a large amount of plasticizer, and a decrease in weather resistance due to the aging of the plasticizer is also a problem. On the other hand, the waterproofing device described in Patent Document 2 is composed solely of molded resin sheet pieces, and therefore lacks sufficient mechanical strength and weather resistance.

[0008] The object of the present invention is to provide a method for manufacturing a fitting that comprises a metal molded plate and a resin film of sufficient thickness, and that is excellent in mechanical strength, weather resistance, and watertightness. [Means for solving the problem]

[0009] These objectives are achieved by the present invention as described in (1) to (6) 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, A step of attaching the metal molded plate to a powder slush molding machine, The process involves using the powder slush molding machine to rotate the metal molding plate while depositing raw material powder onto the surface of the metal molding plate to obtain the resin film, The process of removing the metal molded plate on which the resin film has been formed from the powder slush molding machine to obtain a special part, A method for manufacturing a special-purpose item, characterized by having the following features.

[0010] (2) The method for manufacturing the fittings described in (1) above, wherein the step of obtaining the resin film includes a heat treatment of heating the metal molded plate.

[0011] (3) The resin film comprises a vinyl chloride resin, a method for manufacturing the accessory as described in (1) or (2) above.

[0012] (4) The manufacturing method of the article according to any one of (1) to (3) above, wherein the film thickness of the resin film is 100 μm or more and 3000 μm or less.

[0013] (5) The manufacturing method of the article according to any one of (1) to (4) above, wherein the plate thickness of the metal forming plate is 0.1 mm or more and 2.0 mm or less.

[0014] (6) The manufacturing method of the article according to any one of (1) to (5) above, wherein the constituent material of the metal forming plate includes stainless steel.

Advantages of the Invention

[0015] According to the present invention, an article having a metal forming plate and a resin film with a sufficient film thickness can be manufactured, which is excellent in mechanical strength, weather resistance, and water stopping property.

Brief Description of the Drawings

[0016] [Figure 1] FIG. 1 is a partial cross-sectional perspective view showing an example of a building in which waterproof treatment using an article is applied. [Figure 2] FIG. 2 is a cross-sectional view taken along line A-A of the article shown in FIG. 1. [Figure 3] FIG. 3 is a process diagram for explaining the manufacturing method of the article according to the embodiment. [Figure 4] FIG. 4 is a cross-sectional view for explaining the manufacturing method of the article shown in FIG. 3.

Embodiments for Carrying Out the Invention

[0017] 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.

[0018] 1. Article First, an example of the article manufactured by the manufacturing method of the article of the present invention will be described.

[0019] FIG. 1 is a partial cross-sectional perspective view showing an example of a building 2 in which waterproof treatment using an article 1 is applied. FIG. 2 is a cross-sectional view taken along line A-A of the article 1 shown in FIG. 1.

[0020] As shown in FIG. 1, the fitting 1 is a material for waterproofing the outer corner portion 21 and the inner corner portion 22. In this specification, the outer corner portion 21 refers to a portion where two surfaces intersect in a concave shape. Also, in this specification, the inner corner portion 22 refers to a portion where two surfaces intersect in a convex shape. The shapes of the outer corner portion 21 and the inner corner portion 22 vary 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 portions 21 and inner corner portions 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 can be performed over a wide range.

[0021] The portion where waterproofing treatment is performed in the building 2 is not particularly limited. In FIG. 1, an example of performing waterproofing treatment on the roof of the building 2 is illustrated. The building 2 shown in FIG. 1 has a floor portion 2A and a parapet 2B that constitute the roof. Examples of portions other than the roof include a roof, a veranda, a balcony, around a window, an outer wall, etc. Note that the outer corner portion 21 and the inner corner portion 22 include, for example, the irregularities associated with the drain 23 and the drain groove 24 shown in FIG. 1.

[0022] 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.

[0023] 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 waterproof treatment with excellent durability can be obtained.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] The resin film 12 contains a resin material and covers at least one surface of 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 the fitting 1 to the 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. The one surface is the surface facing upwards when the fitting 1 is attached to the building 2. The resin film 12 may cover both the one and the other surface of the metal molded plate 11.

[0030] The thickness of the resin film 12 is not particularly limited, but is preferably about 100 μm to 3000 μm, more preferably about 200 μm to 2000 μm, and even more preferably about 300 μm to 1000 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.

[0031] 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.

[0032] 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.

[0033] Figure 3 is a process diagram illustrating the manufacturing method of the accessory according to the embodiment. Figure 4 is a cross-sectional view illustrating the manufacturing method of the accessory shown in Figure 3.

[0034] The manufacturing method for the accessory shown in Figure 3 includes a preheating step S100, an installation step S102, a resin film formation step S104, and a removal step S106.

[0035] 2.1. Preheating process In the preheating process S100, first, the metal molded sheet 11 is prepared. The metal molded sheet 11 is pre-formed into the desired shape. The metal molded sheet 11 is formed by, for example, press working, sheet metal processing, or deep drawing. Alternatively, the metal molded sheet 11 may be manufactured by connecting multiple parts using various joining methods such as welding or riveting.

[0036] Furthermore, in the preheating step S100, the metal molded plate 11 is preheated. Preheating improves the adhesion of the constituent materials of the resin film 12 when the resin film 12 is formed in the resin film forming step S104, 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. In addition, the film thickness of the resin film 12 can be made sufficiently thick.

[0037] The preheating temperature of the metal molded plate 11 is set appropriately according to the constituent material (resin material) of the resin film 12. Specifically, it is preferable to set the preheating temperature to be above the melting temperature of the resin material. This allows the resin film 12 to be efficiently formed when the preheated metal molded plate 11 is subjected to the resin film formation process S104.

[0038] The preheating temperature is preferably 200°C to 500°C, and more preferably 230°C to 350°C. By subjecting the metal molded plate 11 heated to such a preheating temperature to the resin film forming step S104, the resin film 12 can be formed particularly efficiently.

[0039] If the preheating temperature falls below the lower limit, and a sufficient amount of time is required between the preheating process S100 and the resin film formation process S104, the temperature of the metal molded plate 11 may decrease, potentially resulting in insufficient film thickness of the resin film 12 or uneven film formation of the resin film 12. On the other hand, if the preheating temperature exceeds the upper limit, the metal molded plate 11 may become more susceptible to oxidation, or the resin film 12 may undergo thermal deformation.

[0040] The preheating method is not particularly limited as long as it is a method that can heat the metal molded plate 11, but one example is to apply hot air 55 generated from the hot air generator 54 shown in Figure 4(a) to the metal molded plate 11. Preheating can be done as needed and may be omitted.

[0041] Furthermore, in this process, a primer is applied to the surface of the metal molded plate 11. The primer enhances the adhesion between the metal molded plate 11 and the resin film 12. By applying the primer, a primer coating is obtained. The presence of the primer coating suppresses delamination between the metal molded plate 11 and the resin film 12, thereby particularly improving the durability of the metal molded plate 11 and the wind pressure resistance of the waterproof sheet.

[0042] 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.

[0043] 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.

[0044] Examples of polyester resins include oil-free polyester resins, urethane-modified polyester resins, epoxy-modified polyester resins, and acrylic-modified polyester resins.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] Examples of blocking agents include phenol-based blocking agents, alcohol-based blocking agents, oxime-based blocking agents, and activated methylene-based blocking agents.

[0051] 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.

[0052] 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.

[0053] Specific examples of solvents include xylene, toluene, propylene glycol methyl ether acetate, methanol, isopropyl alcohol, and ethylene glycol monopropyl ether.

[0054] 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.

[0055] 2.2. Installation Process In the mounting process S102, as shown in Figure 4(b), the metal molded plate 11, to which a primer (not shown) has been applied, is mounted to the powder slush molding machine 5.

[0056] The powder slush molding machine 5 comprises a reservoir tank 51, a mold frame 52, and a frame 53.

[0057] The reservoir tank 51 has a stirring chamber 512 and a flow chamber 514. The stirring chamber 512 is a space into which air is introduced into the flow chamber 514. When air is introduced, the powder P of the constituent material of the resin film 12 contained in the flow chamber 514 can be stirred. The flow chamber 514 is a space that contains the powder P.

[0058] The formwork 52 is placed on the reservoir tank 51. The formwork 52 is interposed between the opening of the flow chamber 514 and the metal forming plate 11, preferably connecting the two in an airtight manner. This forms a closed space CS defined by the flow chamber 514, the formwork 52, and the metal forming plate 11.

[0059] The metal molded plate 11 is supported by a frame 53 and placed on a mold 52. The frame 53 supports the metal molded plate 11 in a position where the surface on which the resin film 12 is formed faces the flow chamber 514.

[0060] The metal molded plate 11, supported by the frame 53, is transported and placed on the mold 52. This attaches the metal molded plate 11 to the powder slush molding machine 5.

[0061] Furthermore, the above process sequence is just one example, and other process sequences are also acceptable. For example, the preheating process S100 and the mounting process S102 may be swapped.

[0062] 2.3.Resin film formation process In the resin film formation process S104, a film formation treatment is performed to form a resin film 12 on the surface of the metal molded plate 11 using the powder slush method. This results in the creation of the special part 1.

[0063] The powder slush method is a method of forming a coating by adhering raw material powder P to the surface of an object to be processed and bringing it to a molten or semi-molten state. Specifically, as shown in Figure 4(b), powder P is placed in the flow chamber 514 of the powder slush molding machine 5 beforehand. The powder P contains resin material. Next, a metal molding plate 11 is attached to the powder slush molding machine 5. This creates a closed space CS. Next, a drive unit (not shown) is activated to rotate the reservoir tank 51, mold frame 52, and frame 53 together, as shown in Figure 4(c). This causes the powder P to flow within the closed space CS. As a result, the powder P adheres to the surface of the metal molding plate 11, and a resin film 12 is formed. At this time, air 56 is introduced from the stirring chamber 512 into the flow chamber 514. This stirs the powder P and activates the flow state of the powder P. As a result, a resin film 12 is formed with a more uniform film thickness.

[0064] The powder slush method reduces the amount of powder P wasted, thus lowering the cost of forming the resin film 12. Furthermore, the formed resin film 12 is less prone to residual strain. Therefore, a resin film 12 that is less susceptible to peeling, wrinkling, cracking, etc., can be obtained.

[0065] Examples of resin materials 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.

[0066] 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.

[0067] 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.

[0068] Examples of polyolefin resins include polyethylene and polypropylene.

[0069] 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.

[0070] Specific examples of polypropylene include isotactic polypropylene, syndiotactic polypropylene, atactic polypropylene, and mixtures of two or more of the above types of polypropylene.

[0071] The average particle size of powder P is not particularly limited, but is preferably 10 μm to 300 μm, more preferably 30 μm to 250 μm, and even more preferably 80 μm to 200 μm. This allows for the production of powder P that can flow uniformly within the closed space CS. Furthermore, by using powder P with such particle size, a resin film 12 of sufficient thickness can be formed uniformly in a short time.

[0072] The average particle size of powder P is defined as particle size D50, where the cumulative frequency from the smallest diameter side accounts for 50% of the cumulative particle size distribution of the powder on a volume basis, obtained using a laser diffraction particle size distribution analyzer.

[0073] When the resin material contained in powder P 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 results in powder P with excellent fluidity. Furthermore, a resin film 12 with excellent shape conformability is obtained.

[0074] The average degree of polymerization is calculated on a standard polystyrene basis using gel permeation chromatography (GPC).

[0075] Powder P may contain a plasticizer. 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.

[0076] 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).

[0077] Examples of phosphate ester plasticizers include tricresyl phosphate (TCP) and trixylylene phosphate (TXP).

[0078] Examples of adipic acid ester plasticizers include dioctyl adipate (DOA) and diisodecyl adipate (DIDA).

[0079] Examples of sebatic acid ester plasticizers include dibutyl sebacate (DBS) and dioctyl sebacate (DOS).

[0080] The amount of plasticizer added to powder P is not particularly limited, but is preferably 100 parts by mass or less, more preferably 60 parts by mass or less, and even more preferably 40 parts by mass or less, per 100 parts by mass of resin material. This results in a resin film 12 with excellent weather resistance and coating properties. As a result, a component 1 is obtained in which the occurrence of cracks, pinholes, etc. in the resin film 12 is suppressed.

[0081] Powder P may contain any additives in addition to the resin material. Examples of additives include saturated fatty acids, metal soaps, powder flowability improvers, colorants, impact resistance improvers, perchlorate compounds, antioxidants, antifungal agents, flame retardants, antistatic agents, fillers, ultraviolet absorbers, light stabilizers, and foaming agents.

[0082] The amount of each additive added to powder P is preferably 50 parts by mass or less, and more preferably 30 parts by mass or less, per 100 parts by mass of resin material.

[0083] In the resin film formation process S104, the metal molded plate 11 may be heated during the process of forming the resin film 12. This allows for optimization of the temperature of the metal molded plate 11, making it possible to form a more uniform resin film 12 with sufficient thickness. In other words, by performing a heat treatment, it is possible to suppress the decrease in the temperature of the metal molded plate 11 due to inability to retain heat during preheating, such as when the heat capacity of the metal molded plate 11 is small.

[0084] Examples of heating methods for the metal molded plate 11 include dielectric heating, induction heating, electric heating, resistance heating, and flame heating. Two or more of these methods may also be used in combination.

[0085] Dielectric heating is a heating method that heats an object by irradiating it with electromagnetic waves, causing the molecules within the object to vibrate. Microwaves are used as electromagnetic waves, for example. Dielectric heating using microwaves is usually applied to dielectrics, but it can also be applied to plate-shaped members such as the metal molded plate 11, even if they are made of metallic material. With dielectric heating, the object to be heated can be heated without direct contact with the heat source. Therefore, the metal molded plate 11 can be heated uniformly, and the resin film 12 can be formed evenly across the entire surface of the metal molded plate 11. In addition, since the metal molded plate 11 can be heated without contact using dielectric heating, the resin film 12 can be formed without interruption.

[0086] Alternatively, the metal molded plate 11 may be housed in a container made of dielectric material, and the metal molded plate 11 may be heated by heat transfer or heat radiation from the container.

[0087] Induction heating is a heating method in which an object to be heated is placed in an alternating magnetic field, and eddy currents are generated in the object to be heated to heat it. The alternating magnetic field can be generated, for example, using a solenoid-shaped coil. Alternatively, eddy currents may be generated in the metal molded plate 11 to heat it, or eddy currents may be generated in an object to be heated adjacent to the metal molded plate 11, and the metal molded plate 11 may be heated by heat transfer or heat radiation from the object to be heated. Furthermore, in dielectric heating, the metal molded plate 11 can be heated without contact, so the resin film 12 can be formed without interruption.

[0088] The frequency of the alternating magnetic field in the induction heating method is not particularly limited, but is preferably between 30 Hz and 500 kHz.

[0089] The electric heating method is a heating method that generates heat by passing an electric current through the metal molded plate 11. By attaching electrodes to the metal molded plate 11, the metal molded plate 11 can be heated in a short time, thus shortening the film formation time. Furthermore, since only the metal molded plate 11 can be heated, highly accurate temperature control is possible in a short time. As a result, a resin film 12 of the desired thickness can be efficiently formed.

[0090] Resistance heating methods include a self-heating method in which a resistance heating element is incorporated into the metal molded plate 11 and current is passed through the resistance heating element to heat the metal molded plate 11 itself, and an indirect heating method in which the metal molded plate 11 is heated by thermal radiation and thermal convection from a resistance heating element located away from the metal molded plate 11. In the self-heating method, the metal molded plate 11 is heated directly, so highly accurate temperature control is possible in a short time. This makes it possible to efficiently form a resin film 12 of the desired thickness. In the indirect heating method, the metal molded plate 11 is heated indirectly without contact, so the metal molded plate 11 can be easily heated without incorporating a resistance heating element into the metal molded plate 11 or passing current through it.

[0091] The flame heating method involves applying a flame to the side of the metal molded plate 11 opposite to the side on which the resin film 12 is formed. This allows the metal molded plate 11 to be heated easily.

[0092] By further heating the metal molded plate 11, which has been preheated using the heating method described above, the temperature of the metal molded plate 11 can be optimized even when using a resin material with a relatively high melting point or when the heat capacity of the metal molded plate 11 is small. As a result, the resin film 12 can be formed uniformly and without unevenness in the resin film formation process S104. This suppresses the occurrence of cracks and pinholes in the resin film 12, and enables the efficient manufacture of fittings 1 with excellent watertightness and weather resistance.

[0093] The heating temperature of the metal molded plate 11 in the resin film formation process S104 is set appropriately according to the constituent material (resin material) of the resin film 12. Specifically, it is preferable to set the heating temperature to be above the melting temperature of the resin material. This allows the resin film 12 to be formed with sufficient thickness in the resin film formation process S104. As a result, direct exposure of the metal molded plate 11 is suppressed, and a fitting 1 with excellent weather resistance (corrosion resistance) can be manufactured.

[0094] The heating temperature (film formation temperature) in the resin film formation step S104 is set appropriately according to the melting temperature of the resin material, but as an example, it is preferably 200°C to 500°C, and more preferably 230°C to 350°C. By heating the metal molded plate 11 at such a film formation temperature, the resin film 12 can be formed uniformly with a sufficient film thickness.

[0095] Furthermore, if the film deposition temperature falls below the lower limit, there is a risk that the resin film 12 may not have sufficient thickness. On the other hand, if the film deposition temperature exceeds the upper limit, there is a risk that the metal molded plate 11 may become more susceptible to oxidation, or that the resin film 12 may undergo thermal deformation.

[0096] Furthermore, the film deposition temperature may be lower than the preheating temperature as long as it is within the above temperature range, but it is preferably higher than the preheating temperature, and more preferably at least 5°C higher than the preheating temperature. This allows the film thickness of the resin film 12 to be adjusted based on the film deposition temperature while setting the preheating temperature to a slightly lower level. As a result, it is possible to ensure a sufficient film thickness of the resin film 12 while suppressing thermal deformation of the metal molded plate 11 due to preheating. The temperature difference between the film deposition temperature and the preheating temperature is preferably 100°C or less, and more preferably 50°C or less, taking into account the effect of preheating.

[0097] The time spent heating at the above-mentioned film formation temperature is defined as the film formation time. The film formation time in the resin film formation step S104 is not particularly limited, but is preferably 3 seconds or more and 60 seconds or less, more preferably 5 seconds or more and 30 seconds or less, and even more preferably 5 seconds or more and 20 seconds or less. This allows for the formation of a resin film 12 with sufficient thickness in a short time.

[0098] 2.4. Removal Process In the removal process S106, the metal molded plate 11, which has a resin film 12, is removed from the powder slush molding machine 5. This yields the accessory part 1.

[0099] Furthermore, the metal molded plate 11 on which the resin film 12 is formed may be subjected to post-heat treatment after being removed from the powder slush molding machine 5. This can improve the smoothness of the surface of the resin film 12 and the adhesion of the resin film 12.

[0100] The heating temperature in the post-heat treatment (post-heating temperature) is set appropriately according to the melting temperature of the resin material, but as an example, it is preferably 120°C to 480°C, more preferably 200°C to 350°C, and even more preferably 230°C to 300°C. By setting the post-heating temperature within the above range, the resin film 12 is sufficiently solidified, and a resin film 12 with good adhesion and hardness is obtained.

[0101] After post-heat treatment, the resin film 12 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.

[0102] 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 having waterproof treatment applied to the outer corner 21 or inner corner 22, and comprises an installation step S102, a resin film forming step S104, and a removal step S106. In the installation step S102, the metal molded plate 11 to which the primer has been applied is attached to the powder slush molding machine 5. In the resin film forming step S104, the powder slush molding machine 5 rotates the metal molded plate 11 and deposits raw material powder P onto the surface of the metal molded plate 11 to obtain a resin film 12. In the removal step S106, the metal molded plate 11 to which the resin film 12 has been formed is removed from the powder slush molding machine 5 to obtain the fitting 1.

[0103] With this configuration, a fitting 1 can be manufactured that has excellent mechanical strength, weather resistance, and water-sealing properties, as it includes a metal molded plate 11 and a resin film 12 of sufficient thickness, while also allowing for a reduction in the plasticizer content of the powder.

[0104] In the manufacturing method of the accessory according to the above embodiment, the resin film forming step S104 (step for obtaining the resin film 12) includes a heat treatment for heating the metal molded plate 11.

[0105] With this configuration, the temperature of the metal molded plate 11 can be optimized, making it possible to form a resin film 12 with a more uniform and sufficient thickness.

[0106] In the method for manufacturing the accessory according to the above embodiment, the resin film 12 includes a vinyl chloride resin. With this configuration, a fitting 1 with excellent bonding strength to the waterproof sheet and weather resistance can be obtained.

[0107] In the manufacturing method of the accessory according to the above embodiment, the thickness of the resin film 12 is 100 μm or more and 3000 μm or less.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] In the manufacturing method of the accessory according to the above embodiment, the constituent material of the metal molded plate 11 includes stainless steel.

[0112] This configuration allows for greater mechanical strength and durability of the metal molded plate 11.

[0113] The method for manufacturing the special feature of the present invention has been described above, but the present invention is not limited to these.

[0114] 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]

[0115] Next, specific embodiments of the present invention will be described. However, the present invention is not limited in any way to these embodiments.

[0116] 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.

[0117] The symbols shown in Tables 1 and 2 correspond to the following materials. • SUS: Stainless steel SUS304 (with primer coating) • SGCC: Hot-dip galvanized steel (with primer coating) PVC1: Resin material containing 100 parts by mass of vinyl chloride resin and 30 parts by mass of plasticizer. • PVC2: Resin material containing 100 parts by mass of vinyl chloride resin and 120 parts by mass of plasticizer.

[0118] Furthermore, in Tables 1 and 2, a "○" for the powder slash method indicates that the resin film was formed using the powder slash method, while a "-" indicates that the resin film was formed using a method other than the powder slash method.

[0119] Furthermore, in Tables 1 and 2, a "○" for heating during film formation indicates that heat treatment was performed during the formation of the resin film using the powder slush method, while a "-" indicates that no heat treatment was performed. Flame heating was used for the heat treatment. Tables 1 and 2 show the film deposition temperature and time.

[0120] 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."

[0121] 5. Evaluation of the special features The following evaluations were performed on the components of each example and each comparative example.

[0122] 5.1. Film thickness of the resin film The cross-sections of the components of each example and comparative example were observed, and the thickness of the resin film was measured. The measured film thickness was then evaluated according to the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0123] A: The film thickness is sufficiently thick and has excellent weather resistance (film thickness of 300 μm or more). B: The film thickness is sufficient for practical use (film thickness is 100 μm or more and less than 300 μm) C: Thin film thickness (film thickness less than 100 μm)

[0124] 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

[0125] 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.

[0126] 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%)

[0127] [Table 1]

[0128] [Table 2]

[0129] Based on the evaluation results shown in Tables 1 and 2, the following can be observed. In each example, a resin film with sufficient thickness and good coverage was formed in the fittings compared to the comparative examples. This makes it possible to realize fittings with excellent water-sealing properties. • In each example, the gloss retention rate after UV irradiation was high for the decorative elements. This is thought to be due to the minimal degradation of the resin film upon UV irradiation.

[0130] From the above, it has been confirmed that the present invention makes it possible to manufacture fittings that have excellent mechanical strength, weather resistance, and water-sealing properties, comprising a metal molded plate and a resin film of sufficient thickness. [Explanation of Symbols]

[0131] 1. Special Features 2 buildings 2A Floor part 2B Parapet 5. Powder slush molding machine 11 Metal forming plate 12 Resin film 21 Corner section 22 Inside corner 23 Drain 24 Drainage 51 Reservoir Tank 52 formwork 53 frames 54 Hot air generator 55 Hot air 56 Air 512 Agitation Chamber 514 Fluid chamber CS closed space P powder S100 Preheating process S102 Installation Process S104 Resin film formation process S106 Removal 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, A step of attaching the metal molded plate to a powder slush molding machine, The process involves using the powder slush molding machine to rotate the metal molding plate while depositing raw material powder onto the surface of the metal molding plate to obtain the resin film, The process of removing the metal molded plate on which the resin film has been formed from the powder slush molding machine to obtain a special part, A method for manufacturing a special-purpose item, characterized by having the following features.

2. The method for manufacturing a decorative piece according to claim 1, wherein the step of obtaining the resin film includes a heat treatment of heating the metal molded plate.

3. The method for manufacturing a decorative piece according to claim 1 or 2, wherein the resin film comprises a vinyl chloride resin.

4. The method for manufacturing a decorative piece according to claim 1 or 2, wherein the thickness of the resin film is 100 μm or more and 3000 μm or less.

5. The method for manufacturing a decorative piece according to claim 1 or 2, wherein the thickness of the metal molded plate is 0.1 mm or more and 2.0 mm or less.

6. The method for manufacturing a fitting according to claim 1 or 2, wherein the constituent material of the metal molded plate is stainless steel.

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