Rust repair methods

Abstract

The objective is to provide a rust repair method that can easily and quickly remove iron rust from a repaired component, restoring the component to its original rust-free condition. [Solution] The rust repair method is characterized by comprising: a surface preparation step of removing rust from the surface of a rusted iron member to be repaired; a cleaning step of removing the rust removed in the surface preparation step from the surface of the member to be repaired; a coating step of applying a primer to the surface of the member to be repaired that has been cleaned in the coating step; a putty application step of waiting for the primer applied in the coating step to dry and then applying an ultraviolet-curing putty to the surface of the member to be repaired that has been coated with primer, so that the surface does not come into contact with air; an irradiation step of irradiating the surface of the putty applied in the putty application step with ultraviolet light to harden the putty; and a coating step of covering the surface of the putty hardened in the irradiation step with a coating material that does not transmit ultraviolet light.

Description

Technical Field

[0001] The present invention relates to a rust repair method for repairing rust on rusted iron products, and in particular to a rust repair method for removing rust and restoring iron products to their original rust-free state.

Background Art

[0002] In Japan, exposed iron products such as external staircases and cubicles are widely used. Such iron products are naturally coated for rust prevention, but the coating will peel off over the years. When the iron material is exposed at the part where the coating has peeled off, rust starts to form there, leading to the progression of corrosion and peeling.

[0003] In particular, when rust occurs on external iron staircases, the strength of the corresponding part decreases. In the worst case, dangerous situations where the structure seems to be maintained at first glance but the strength is insufficient and safety is not guaranteed are commonly observed.

[0004] For this reason, for iron products, it is necessary to regularly check the occurrence status of rust, and when rust is severe, perform work to remove the rust and re-coat. However, it has been pointed out that this work is quite expensive, and during the work, for example, in the case of an external staircase, the staircase cannot be used, which causes inconvenience.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] From the above viewpoint, a method for repairing steel structures shown in Patent Document 1 has been proposed. This repair method is described as a method for repairing steel structures that can suppress the progression of corrosion and peeling even in steel structures where a rust layer remains, and includes: a first step of surface preparation of the rusted surface of a steel material having defects and / or a steel material having a live film to at least three levels of surface preparation; a second step of applying a primer containing a moisture-curing resin to the surface-prepared steel material; a third step of leveling the surface of the steel material to which the primer has been applied with a surface leveling agent containing an epoxy resin; and a fourth step of applying an ultraviolet-curing FRP sheet to the surface-leveled steel material.

[0007] In the rust repair method described in Patent Document 1, the rust is removed from the surface, then the surface is leveled with an epoxy resin-containing surface leveling agent, and a UV-curing FRP sheet is applied to the leveled steel material. However, if, for example, the area where the rust was removed is significantly indented, or if there are missing parts in the steel material due to rust, and a large area requiring repair is created, this repair method cannot restore the original shape or guarantee strength, requiring large-scale and time-consuming work such as replacing the steel material separately. There has been a strong demand for a simpler repair method that requires less work time. Furthermore, it has been pointed out that even if a UV-curing FRP sheet is applied to the leveled steel material, this FRP sheet does not have the function of guaranteeing strength.

[0008] This invention has been made in view of the above circumstances, and its main purpose is to provide a rust repair method that can easily and quickly remove iron rust from a repaired member, thereby restoring the member to its original rust-free state.

[0009] Furthermore, this invention aims to provide a rust repair method that can easily and quickly fill in the missing parts caused by rust on the member to be repaired, thereby restoring the member to its original rust-free state. [Means for solving the problem]

[0010] The rust repair method according to this invention, as described in claim 1, is characterized by comprising: a surface preparation step of removing rust from the surface of a rusted iron member to be repaired; a cleaning step of removing the rust removed in the surface preparation step from the surface of the member to be repaired; a coating step of applying a primer to the surface of the member to be repaired that has been cleaned in the coating step; a putty application step of waiting for the primer applied in the coating step to dry and then applying an ultraviolet-curing putty to the surface of the member to be repaired that has been coated with the primer, so that the surface does not come into contact with air; an irradiation step of irradiating the surface of the putty applied in the putty application step with ultraviolet light to harden the putty; and a coating step of covering the surface of the putty hardened in the irradiation step with a coating material that does not transmit ultraviolet light.

[0011] Thus, by implementing the rust repair method described in claim 1, rust is removed from the member to be repaired, a primer is applied to the repair surface, an ultraviolet-curing putty is applied, the putty is cured by irradiating it with ultraviolet light, and the surface of the cured putty is then covered with a coating material that does not transmit ultraviolet light, thereby blocking further effects of ultraviolet light on the putty and maintaining the performance of the cured putty.

[0012] Furthermore, according to the description in claim 2, the rust repair method of this invention further comprises an adjustment step of smoothing the surface of the putty applied to the repair member in the application step, and the irradiation step is characterized by irradiating the putty that has undergone the adjustment step with ultraviolet light.

[0013] Thus, by implementing the rust repair method described in claim 2, the surface of the putty is smoothed before irradiation with ultraviolet light, so that the appearance of the putty after hardening is maintained in a smooth state, and the surface of the repaired member after rust repair is kept beautiful.

[0014] Furthermore, according to the description in claim 3, the rust repair method of this invention is characterized in that, if there are no missing parts on the surface of the member to be repaired after the surface preparation step, the putty application step is performed by applying a thick layer of putty to a predetermined thickness.

[0015] Thus, by implementing the rust repair method described in claim 3, a primer is applied to the work surface from which rust has been removed through the surface preparation process, and after it has dried, a thicker layer of putty is applied compared to when paint is applied, thereby capturing the rust-free work surface while completely covering it.

[0016] Furthermore, according to claim 4, the rust repair method of this invention is characterized in that, when the rust has penetrated deeply into the surface of the member to be repaired and causes the occurrence of missing parts such as small holes or dents on the surface of the member to be repaired after the surface preparation step, the putty application step includes a first sub-step of applying a thick layer of putty to the surface of a synthetic resin sheet that is non-adherent to putty and is ultraviolet-transmitting; a second sub-step of attaching the synthetic resin sheet to which the putty has been thickly applied, such as a sheet, so that the putty covers the missing parts on the surface of the member to be repaired, thereby covering the surface of the member to be repaired, including the missing parts, with the putty; and a third sub-step of removing the synthetic resin sheet that has covered the surface of the member to be repaired, so that the missing parts are completely covered with the putty. Furthermore, according to claim 5, the rust repair method of this invention comprises a first sub-step of forming an extruded polystyrene insert to match the shape of a large missing portion on the surface of the member to be repaired, and a second sub-step of fitting the insert formed in the first sub-step into the missing portion of the member to be repaired, characterized in that the putty is applied to the entire surface of the member to be repaired, including the surface of the hole-filling material.

[0017] As described above, by implementing the rust repair method described in claim 4, if there are missing parts such as small holes or dents on the surface of the member to be repaired after the surface preparation process, a thick layer of putty is applied to the surface of a synthetic resin sheet that does not adhere to the putty and is ultraviolet-transmitting. The sheet is then lifted and attached to the member to be repaired so as to cover the work surface of the member to be repaired where the rust has been removed and the primer has been applied, thereby transferring the putty applied to the sheet to the work surface of the member to be repaired. In this way, the missing parts such as small holes or dents caused by rust on the surface of the member to be repaired are reliably covered with putty, and thereafter, by irradiating the putty with ultraviolet light to harden it, the missing parts such as small holes or dents caused by rust are reliably hardened and repaired.

[0018] Furthermore, according to claim 5, the rust repair method of this invention comprises a first sub-step of forming an extruded polystyrene insert to match the shape of a large missing portion on the surface of the member to be repaired, and a second sub-step of fitting the insert formed in the first sub-step into the missing portion of the member to be repaired, characterized in that the putty is applied to the entire surface of the member to be repaired, including the surface of the hole-filling material.

[0019] Thus, by implementing the rust repair method described in claim 5, even if there is a large missing portion on the surface of the member to be repaired, the missing portion can be extruded and a polystyrene foam insert can be fitted into it. Furthermore, since putty is applied to the surface of this interlocking component, the strength of the entire interlocking component is increased when the putty is cured by exposure to ultraviolet light. This ensures that the missing parts are completely filled in by rust repair, and the strength is highly guaranteed, restoring it to its original state.

[0020] Furthermore, according to claim 6, the rust repair method of this invention is characterized in that, in the coating step, a paint that does not transmit ultraviolet rays is applied, and the coated layer becomes the coating material.

[0021] Thus, by carrying out the rust repair method according to claim 6, a coating layer impermeable to ultraviolet rays can be formed by the simple operation of applying a paint impermeable to ultraviolet rays.

[0022] Further, according to the rust repair method of the present invention as defined in claim 7, in the coating step, a sheet formed of a synthetic resin material impermeable to ultraviolet rays is attached to serve as the coating material.

[0023] Thus, by carrying out the rust repair method according to claim 7, a coating layer impermeable to ultraviolet rays can be formed by the extremely simple operation of attaching a sheet formed of a synthetic resin material impermeable to ultraviolet rays. Effects of the Invention

[0024] According to the present invention, there is provided a rust repair method capable of easily removing iron rust from a member to be repaired in a short time and restoring the member to be repaired to its original rust-free state.

[0025] Further, according to the present invention, there is provided a rust repair method capable of easily filling missing portions generated by rust in a member to be repaired in a short time, and restoring the member to be repaired to its original rust-free state. Brief Description of the Drawings

[0026] [Figure 1] It is a diagram sequentially illustrating the steps of the first embodiment of the rust repair method according to the present invention from (A) to (E). [Figure 2] It is a diagram sequentially illustrating the steps of the first embodiment of the rust repair method according to the present invention from (A) to (G). [Figure 3] It is a diagram sequentially illustrating the steps of the third embodiment of the rust repair method according to the present invention from (A) to (F). Modes for Carrying Out the Invention

[0027] The configurations of the first to third embodiments of the rust repair method according to this invention will be described sequentially below with reference to the attached drawings. [Examples]

[0028] First, the procedure for the rust repair method of this first embodiment will be described in detail with reference to Figures 1(A) through (E). In this first embodiment of rust repair method, as shown in Figure 1(A), when rust S has occurred on the surface of the iron repair member 10, a surface preparation process is performed to remove the rust from the rusted iron repair member 10 surface. This surface preparation process involves rust removal, and while there are 1 to 4 types of surface preparation specified, in this embodiment, type 3 surface preparation is performed to leave the active film and remove the dead film. Note that within type 3 surface preparation, there are type 3A surface preparation, type 3B surface preparation, and type 3C surface preparation, which are determined by the area where rust has occurred and the area of ​​abnormal paint film, and are selected according to the situation.

[0029] The rust S removed in this surface preparation process is removed from the surface of the repaired member 10 in the subsequent cleaning process, resulting in the state shown in Figure 1(B). In this state shown in Figure 1(B), a primer application process is carried out on the surface of the repaired area 12 of the repaired member 10 that has undergone the cleaning process. Various types of primers exist, but in this embodiment, an epoxy-based primer is used because it is applicable to metal, has high adhesion, and also possesses rust-preventive properties. Specifically, "ESCO EP Primer" (product name) manufactured by Kansai Paint Co., Ltd. is used.

[0030] Furthermore, the primer is not limited to the excise-based type mentioned above; urethane-based primers are also suitable when applied to metal. In short, the primer should be selected to suit the type of putty being used (urethane putty, polyester putty, etc.).

[0031] After waiting for the primer applied in this coating process to dry, a putty application process is carried out in which ultraviolet-curing putty 14 is applied to the surface of the repair area 12 of the repaired member 10 to which the primer has been applied, as shown in Figure 1(C), so as to prevent the surface of the repair area 12 from being exposed to air. As for this ultraviolet-curing putty 14, in this embodiment, in addition to the selection of the primer described above, an epoxy-based putty is used, and in particular, as it has both high adhesion to metal surfaces and sandability, ESCO "UV Putty" (product name) manufactured by Kansai Paint Co., Ltd. is used.

[0032] Furthermore, it goes without saying that the UV-curing putty is not limited in any way to the ESCO "UV Putty" (product name) manufactured by Kansai Paint Co., Ltd. mentioned above; for example, 3M's "Plastic UV Putty 05888" can also be used.

[0033] Next, as shown in Figure 1(D), an irradiation process is performed to harden the putty 14 by irradiating its surface with ultraviolet light from an ultraviolet irradiation device 16. Finally, a coating process is performed to cover the surface of the putty 14 hardened by this irradiation process with a coating material 18 that does not transmit ultraviolet light.

[0034] In this embodiment, the ultraviolet irradiation device 16 used is, for example, the Primelite LED irradiator "ALE / 1C" (product name). The "ALE / 1C" (product name) employs an ultra-high-power LED irradiation system that replaces conventional discharge lamps (mercury lamps), has a maximum output of 50W, can be equipped with up to three LEDs in the range of 365nm to 970nm, has a variable numerical aperture (NA) that depends on the optical system, and employs an internal water-cooling thermal management system. However, it goes without saying that the ultraviolet irradiation device 16 in this embodiment is not limited in any way to such a product, and can be selectively used from various devices as long as they can cure ultraviolet-curable putty 14.

[0035] In this way, by implementing the rust repair method according to the first embodiment, the rust S of the member to be repaired 10 is removed, a UV-curing putty 14 is applied to the surface of the repair area 12 to which a primer has been applied, the putty 14 is cured by irradiating it with UV light from a UV irradiation device 16, and further, a coating step is performed in which the surface of the cured putty 14 is covered with a UV-impermeable coating material 18, thereby blocking further UV light effects on the putty 14 and maintaining the performance of the cured putty.

[0036] Furthermore, in the application process described above, the surface of the putty 14 applied to the repaired member 10 is smoothed using a scraper or the like (not shown) in an adjustment process. In the irradiation process described above, ultraviolet light is irradiated onto the putty 14 that has undergone this adjustment process. As a result, the ultraviolet light is irradiated after the surface of the putty 14 has been smoothed, maintaining a smooth appearance of the putty 14 after hardening, and thus ensuring that the surface of the repaired member 10 remains beautiful after rust repair.

[0037] In the coating process described above, after the surface of the putty 14 is smoothed, ultraviolet light is irradiated to harden the putty 14, and then a paint that does not transmit ultraviolet light is applied to the surface of the putty 14 to form the coating layer 18. In this way, the coating layer 18 that does not transmit ultraviolet light can be formed by a simple process consisting of a coating layer formed by applying a paint that does not transmit ultraviolet light, thereby improving work efficiency.

[0038] In this embodiment, the ultraviolet-blocking paint used is Nippon Paint's Water-Based Thermo Eye Wall Si (product name), a one-component, water-based, reaction-curing, silicone-based heat-shielding paint. However, it goes without saying that the invention is not limited to this product, and any heat-shielding paint that does not transmit ultraviolet rays can be used.

[0039] Furthermore, although this invention has been described as comprising a coating layer as the coating material 18, it goes without saying that this invention is not limited to this configuration, and the coating material 18 can also be made by attaching a sheet made of a synthetic resin material that does not transmit ultraviolet rays. In this way, a coating material 18 that does not transmit ultraviolet rays can be formed by the extremely simple operation of attaching a sheet made of a synthetic resin material that does not transmit ultraviolet rays, thereby improving work efficiency.

[0040] In this embodiment, the sheet formed from a synthetic resin material that does not transmit ultraviolet light, which constitutes the coating material 18, is Seiden Crystal UV (product name) manufactured by Hagitec Co., Ltd. It is an antistatic film with a thickness of 0.3 mm that absorbs ultraviolet light and also has flame retardant properties. However, it goes without saying that it is not limited to this, and any thin film sheet with similar ultraviolet absorption function would be acceptable.

[0041] It goes without saying that this invention is not limited to the procedure of the first embodiment described above, and can be modified in various ways without departing from the spirit of the invention. Below, a second and third embodiment of the rust repair method according to this invention will be described with reference to Figures 2 and 3, respectively.

[0042] First, the putty application process in the first embodiment described above was explained assuming there were no missing parts on the surface of the repair member 10 after the surface preparation process. However, as shown in Figure 2(A), if rust S has penetrated deeply into the surface of the repair member 10, it may cause small holes, dents, or other missing parts on the surface of the repair member 10 after the surface preparation process. In such cases, where simply applying a thick layer of putty is not possible, the procedure for implementing the rust repair method of the second embodiment will be explained with reference to Figures 2(A) to (G).

[0043] Specifically, as shown in Figure 2(A), when rust S has penetrated deeply into the surface of the repaired member 10, and as shown in Figure 2(B), when it causes small holes, dents, or other missing parts on the surface of the repaired member 10 after the surface preparation process, as shown in Figure 2(C), a thick layer of putty 14 is applied to the surface of a sheet 20 made of synthetic resin, such as polyethylene, which does not adhere to the putty 14 and is UV-transparent, and then a thick layer of putty 14 is applied to the surface. The synthetic resin sheet 20 is lifted, and as shown in Figure 2(D), the sheet 20 is attached and transferred so that the putty 14 covers the missing portion (repair area 12) on the surface of the member to be repaired 10, and the surface of the repair area 12 of the member to be repaired 10, including the missing portion, is covered with putty 14. After this, as shown in Figure 2(E), only the synthetic resin sheet 20 covering the surface of the member to be repaired 10 is removed so that the missing portion (repair area 12) is completely covered with putty 14. In the second embodiment, the subsequent irradiation step and coating step are the same as the irradiation step and coating step in the first embodiment described above, as shown in Figures 2(F) and (G), so their explanation is omitted.

[0044] Thus, in the second embodiment, any missing parts such as small holes or dents caused by rust S on the surface of the member to be repaired 10 are reliably covered with putty 14. Subsequently, by irradiating the putty 14 with ultraviolet light to harden it, the missing parts such as small holes or dents caused by rust S are reliably and firmly repaired.

[0045] Furthermore, a third embodiment applicable when there is a large missing portion 22 on the surface of the member to be repaired 10 due to rust SS, as shown in Figure 3(A), will be described with reference to Figures 3(A) to (F). Specifically, in this third embodiment, as shown in Figure 3(B), the rust S on the surface surrounding the missing portion 22 and on the inner surface of the missing portion 22 is removed by scraping, and an extruded polystyrene insert 24 is molded to match the shape of the missing portion 22, and as shown in Figure 3(C), it is fitted into the missing portion 22 of the member to be repaired 10, and then, as shown in Figure 3(D), putty 14 is applied to the entire surface of the member to be repaired 10, including the exposed surface of the insert 24.

[0046] Thus, by carrying out the rust repair method procedure of the third embodiment, even if there is a large missing portion 22 on the surface of the member to be repaired 10 due to rust S, the missing portion 22 is fitted with an extruded polystyrene insert member 24, and putty 14 is applied to the surface of the insert member 24, including the surface of the insert member 24. When the putty 14 is irradiated with ultraviolet light and hardened, the strength of the entire insert member 24 is increased, the missing portion 22 is completely restored by rust repair, and its strength is highly guaranteed, returning it to its original state. In the third embodiment, the subsequent irradiation step and coating step are the same as the irradiation step and coating step in the first embodiment described above, as shown in Figures 2(F) and (G), so their explanation is omitted. [Industrial applicability]

[0047] As described in detail above, by implementing the rust repair method according to this invention, the surface of the repaired material that has rusted can be collected in a short time and at low cost, greatly improving its usability and immeasurable potential for industrial application. [Explanation of Symbols]

[0048] 10. Member to be repaired 12 Repair locations 14 UV-curing putty 16 Ultraviolet irradiation device 18 Covering material 20 sheets 22. Major missing parts 24. Insert material

Claims

1. The rust removal process involves removing rust from the surface of a rusted iron component to be repaired, This cleaning process removes the rust removed in this scraping process from the surface of the repaired member, The cleaning process is followed by a coating step of applying a primer to the surface of the repair area of ​​the repaired member, After waiting for the primer applied in this coating step to dry, a putty application step is performed in which ultraviolet-curing putty is applied to the surface of the repair member to which the primer has been applied, so as not to come into contact with air. This putty application process involves irradiating the surface of the applied putty with ultraviolet light to harden the putty, This irradiation process involves a coating process in which the surface of the hardened putty is covered with a coating material that does not transmit ultraviolet light, A rust repair method characterized by comprising the following:

2. This application process further includes an adjustment step to smooth the surface of the putty applied to the repaired member, The rust repair method according to claim 1, characterized in that the irradiation step involves irradiating the putty that has undergone the adjustment step with ultraviolet light.

3. The rust repair method according to claim 1, characterized in that the putty application step involves applying a thick layer of putty to a predetermined thickness if there are no missing parts on the surface of the member to be repaired after the surface preparation step.

4. The putty application process is performed when rust has penetrated deeply into the surface of the repaired member, and when this process causes small holes, dents, or other defects to appear on the surface of the repaired member after the surface preparation process. A first sub-step involves applying a thick layer of putty to the surface of a synthetic resin sheet that is non-adherent to the putty and has ultraviolet light transmission properties. A second sub-step involves having a synthetic resin sheet to which a thick layer of putty has been applied, attaching the sheet so that the putty covers the missing portion on the surface of the member to be repaired, and covering the surface of the member to be repaired, including the missing portion, with the putty. A third sub-step involves removing the synthetic resin sheet covering the surface of the member to be repaired, so that the missing portion is completely covered with the putty, The rust repair method according to claim 1, characterized by comprising the following:

5. The putty application step is performed if there is a large missing portion on the surface of the member to be repaired. A first sub-step involves forming an extruded polystyrene insert to match the shape of the missing portion, A second sub-step involves fitting the fitting material formed in this first sub-step into the missing portion of the member to be repaired, Equipped with, The rust repair method according to claim 1, characterized in that the putty is applied to the entire surface of the member to be repaired, including the surface of the hole-filling material.

6. The rust repair method according to claim 1, characterized in that in the coating step, a paint that does not transmit ultraviolet rays is applied, and the coated layer is made the coating material.

7. The rust repair method according to claim 1, characterized in that, in the coating step, a sheet formed from a synthetic resin material that does not transmit ultraviolet light is attached to form the coating material.

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