Manufacturing method for aluminum decorative parts

Abstract

To provide an inexpensive aluminum decorative member capable of reducing occurrence of whitening.SOLUTION: A decorative sheet 7 in which a transparent adhesive layer 3 and two or more transparent thermoplastic resin layers 6 are laminated one upon another in this order is formed on one surface side of a base layer 1 composed of thermoplastic resin. An aluminum member 8 is molded by applying a bending process by roll forming to a planar aluminum plate 11. An aluminum decorative member 9 is formed by attaching the other surface of the decorative sheet 7 to one surface of the aluminum member 8.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an aluminum decorative member. [Background technology]

[0002] As shown in Patent Document 1, there is a highly aesthetic aluminum decorative component, which is an interior / exterior building component, in which a decorative sheet is attached to an aluminum plate. Aluminum decorative components are manufactured by first attaching a decorative sheet to a flat aluminum plate, and then bending the aluminum plate into a predetermined shape. However, when bending an aluminum decorative panel formed by attaching a decorative sheet to an aluminum plate, there is a risk that the surface of the decorative sheet will be damaged by contact with the forming roller. Furthermore, there is a risk of whitening due to the surface of the decorative sheet being stretched at the bent portion, and therefore this method is not applicable to plate thicknesses exceeding 0.8 mm.

[0003] On the other hand, there is a method of attaching a decorative sheet to an extruded aluminum component, but not only does this increase costs, but extrusions generally have a thickness of over 1.2 mm, making this method excessively high quality for use in places where strength is not required.For example, spandrels used as ceiling materials do not require strength, and lightweight construction is required. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6565195 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in view of the above points, and has as its object to provide an inexpensive aluminum decorative member that can suppress the occurrence of whitening. [Means for solving the problem]

[0006] A method for manufacturing an aluminum decorative member, which is one embodiment of the present invention, includes the steps of: creating a decorative sheet in which an adhesive layer and two or more transparent thermoplastic resin layers are laminated in this order on one side of a base layer made of a thermoplastic resin; bending a flat aluminum plate by roll forming to form an aluminum member; and attaching the other side of the decorative sheet to one side of the aluminum member to create the aluminum decorative member. [Effects of the Invention]

[0007] According to the present invention, a flat aluminum plate is first bent by roll forming, and then a decorative sheet is attached, which prevents whitening from occurring at the bent portion. Furthermore, it is possible to manufacture the product more cheaply than by extrusion molding. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 2 is a cross-sectional view of an aluminum decorative member. [Figure 2] 1A to 1C are diagrams illustrating a manufacturing method of an aluminum decorative member. DETAILED DESCRIPTION OF THE INVENTION

[0009] Next, an embodiment of the present invention will be described with reference to the drawings. The drawings are schematic, and the relationship between thickness and planar dimensions, the thickness ratio of each layer, etc., differ from the actual ones. Furthermore, the embodiments shown below are merely examples of configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is not limited to the materials, shapes, structures, etc. of the components described below. The technical idea of the present invention can be modified in various ways within the technical scope defined by the claims.

[0010] (Embodiment) (Configuration of aluminum decorative parts) As shown in Figure 1, the aluminum decorative member 9 of this embodiment has two transparent thermoplastic resin layers 6 laminated on one side of a base layer 1 to create a decorative sheet 7, and the other side of the base layer 1 is bonded to an aluminum member 8 with an adhesive. The decorative sheet 7 of this embodiment is exemplified as having a picture pattern layer 2 between a base material layer 1 and a transparent thermoplastic resin layer 6, with the base material layer 1 provided with the picture pattern layer 2 and the transparent thermoplastic resin layer 6 being bonded together with a transparent adhesive layer 3. Note that the picture pattern layer 2 and the transparent adhesive layer 3 may be omitted.

[0011] (base material layer) The base layer 1 is a sheet-like layer made of a thermoplastic resin. The thermoplastic resin is preferably colored. Examples of thermoplastic resins include polyolefin resins such as polyethylene, polypropylene, polybutene, and polymethylpentene; polyolefin copolymers such as ethylene-vinyl acetate copolymers or saponified products thereof and ethylene-(meth)acrylic acid (ester) copolymers; polyester resins such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyarylate, polycarbonate, and copolymer polyesters (typically 1,4-cyclohexanedimethanol copolymerized polyethylene terephthalate resin, commonly known as PET-G). Examples of suitable thermoplastic resins include thermoplastic resins such as acrylic resins (e.g., polymethyl methacrylate), polyamide resins (e.g., nylon 6, 6,6, nylon 6,10, nylon 12), styrene resins (e.g., polystyrene, AS resin, ABS resin), cellulose derivatives (e.g., cellulose acetate, nitrocellulose), chlorine-based resins (e.g., polyvinyl chloride, polyvinylidene chloride), fluorine-based resins (e.g., polyvinyl fluoride, polyvinylidene fluoride, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer), and copolymers, mixtures, and composites of two or more of these. The substrate layer 1 may be composed of a laminate of such thermoplastic resins.

[0012] In particular, polyolefin resins are more preferred when productivity in a melt extrusion device, environmental compatibility, mechanical strength as a flooring material, durability, price, and the like are taken into consideration. By coloring the base material layer 1, the base material (aluminum member 8) to which the decorative sheet 7 is attached can be concealed, and a hue can be appropriately selected as the base color for the picture pattern layer 2. For example, coloring can be achieved by mixing or kneading in a coloring agent such as a pigment. Alternatively, a colored layer can be provided under the picture pattern layer 2 as a solid ink layer using a coating or printing method before providing the picture pattern layer 2.

[0013] (Pattern layer) The design pattern layer 2 provides a decorative feature as a decorative material. As the design pattern, a desired printed pattern suitable for the area where it is used can be selected, such as wood grain, cork, stone, tile, pottery, or an abstract pattern. The printing ink used for printing is not particularly limited as long as printability and weather resistance are taken into consideration. Examples of pigments used for the design include at least one of isoindolinone, disazo, polyazo, diketopyrrolopyrrole, quinacridone, phthalocyanine, titanium oxide, and carbon black. Combining and blending these pigments can also enhance the expression of the design. Weather resistance can also be improved by adding ultraviolet absorbers, light stabilizers, and the like.

[0014] As for the printing method, known printing methods such as gravure printing, offset printing, silk screen printing, and inkjet printing can be used, and when coloring the entire surface, coating methods and devices may be used in addition to printing methods.

[0015] (Transparent adhesive layer) The transparent adhesive layer 3 of this embodiment can be any transparent adhesive. For example, it may be made of a thermoplastic resin such as polyamide resin, acrylic resin, or vinyl acetate resin, or a curable resin such as thermosetting urethane resin. It may also be a two-component curable urethane resin or polyester resin using isocyanate as a curing agent. In this embodiment, a heat-sealing agent such as an acrylic-polyester-vinyl acetate chloride resin is used as the transparent adhesive.

[0016] (Transparent thermoplastic resin layer) The transparent thermoplastic resin layer 6 includes an outermost layer 5 and an inner layer 4 provided inside the outermost layer 5. Two or more inner layers 4 may be laminated. However, the total thickness of the transparent thermoplastic resin layer 6 is designed to be in the range of 20 μm to 80 μm. It is preferable that the ratio of the thickness of the outermost layer 5 to the total thickness of the inner layers 4 is set within a range of 10:90 to 40:60. In other words, the inner layer 4 side is thicker. The outermost layer 5 is made of polyvinylidene fluoride resin (PVDF), which has a Tg of −39° C. It is excellent in terms of whitening resistance when folded and adhesion to an acrylic resin layer.

[0017] The inner layer 4 is made of a polymethyl methacrylate resin mixture of polymethyl methacrylate resin and polymethyl methacrylate resin-based rubber. The mixture ratio is set to 40% by mass to 70% by mass of polymethyl methacrylate resin and 30% by mass to 60% by mass of polymethyl methacrylate resin-based rubber. The Tg of polymethyl methacrylate resin is approximately -20°C. A known ultraviolet absorber may be added to the polymethyl methacrylate resin.

[0018] "The mixing ratio is 40% by mass or more and 70% by mass or less of polymethyl methacrylate resin and 30% by mass or more and 60% by mass or less of polymethyl methacrylate resin-based rubber" means that the mixing ratio of polymethyl methacrylate resin to polymethyl methacrylate resin-based rubber is 4:6 to 7:3 by mass.

[0019] (aluminum parts) The aluminum member 8 may be an aluminum alloy. The aluminum member 8 is formed by bending a flat aluminum plate using roll forming, and the thickness of the aluminum plate before bending is set to 0.5 mm or more. More preferably, it is set to 1.2 mm or less. This is because aluminum plates provided as rolled materials are 0.5 mm or more and 1.2 mm or less. Although consideration of workability and economic efficiency is required, aluminum plates with a thickness of more than 1.2 mm can also be used as long as they can be bent using roll forming. (Other configurations) A textured pattern may be added to the surface of the decorative sheet 7. The textured pattern may be added by using a known method such as heat embossing.

[0020] (Method of manufacturing aluminum decorative components) FIG. 2 is a diagram showing a method for manufacturing an aluminum decorative member. (a) in the figure shows a flat aluminum plate 11. The aluminum plate 11 has not been subjected to bending processing by roll forming, and no decorative sheet 7 has been attached. It is stored in a stock area in this state.

[0021] (b) in the figure shows an aluminum member 8 formed by bending an aluminum plate 11 using roll forming. Roll forming is a forming method in which a long metal plate is passed through a number of forming stands arranged in series and is bent in stages by rotating rollers, continuously producing products with any cross-sectional shape. In this example, a spandrel used in ceiling material is formed.

[0022] (c) in the figure shows an aluminum decorative member 9 in which a decorative sheet 7 is attached to the design side of an aluminum member 8. Here, the decorative sheet 7 is shown by a dashed line for convenience. The aluminum member 8 and the decorative sheet 7 are bonded together with a two-component curing urethane adhesive (amount applied in a dry state: 24.2±2.2 g / m 2 ) to glue.

[0023] (effect) Next, the main effects of this embodiment will be described. (1) The method includes the steps of: (1) preparing a decorative sheet in which a transparent adhesive layer 3 and two or more transparent thermoplastic resin layers 6 are laminated in this order on one side of a base layer 1 made of a thermoplastic resin; (2) bending a flat aluminum plate 11 by roll forming to form an aluminum member 8; and (3) attaching the other side of a decorative sheet to one side of the aluminum member 8 to prepare an aluminum decorative member 9. In this way, because the flat aluminum plate is first bent by roll forming and then the decorative sheet is attached, the occurrence of whitening at the bent portion can be suppressed. Furthermore, it is possible to manufacture the aluminum decorative member more cheaply than by extrusion molding.

[0024] (2) The aluminum plate 11 has a thickness of 0.5 mm or more and 1.2 mm or less. This allows the use of ordinary aluminum plates provided as rolled material, which is advantageous in terms of cost. Furthermore, the plate can be easily bent while maintaining a predetermined strength. Furthermore, aluminum plates 11 having a thickness of 1.2 mm or less are suitable for building materials that do not require strength and require lightweight construction, such as spandrels used as ceiling materials.

[0025] (3) The aluminum member 8 and the decorative sheet 7 are bonded with a two-component curing urethane adhesive. In this way, the use of a two-component curing urethane adhesive provides excellent peel resistance, impact resistance, vibration absorption, moisture resistance, stress relaxation, etc., and is also inexpensive.

[0026] Next, other effects will be described. First, polyvinylidene fluoride resin is used in the outermost layer 5 of the transparent thermoplastic resin layer 6. By using a fluororesin (polyvinylidene fluoride resin) in the outermost layer 5 in this way, non-flammability can be improved.

[0027] Furthermore, by using polyvinylidene fluoride resin for the outermost layer 5, it has good adhesion to the acrylic resin (polymethyl methacrylate resin) of the inner layer 4, and can improve weather resistance, acid resistance, alkali resistance, solvent resistance, and contamination resistance.

[0028] The inner layer 4 is a mixture of polymethyl methacrylate resin and polymethyl methacrylate resin-based rubber, with the mixing ratio being 40% by mass to 70% by mass of polymethyl methacrylate resin and 30% by mass to 60% by mass of polymethyl methacrylate resin-based rubber. Furthermore, the total thickness of the transparent thermoplastic resin layer 6 is 20 μm to 80 μm. This improves resistance to whitening due to folding.

[0029] In addition, the ratio of the thickness of the outermost layer 5 of the transparent thermoplastic resin layer 6 to its inner layer 4 is set to a range of 10:90 to 40:60. This makes it possible to more reliably achieve excellent non-combustibility. For example, in a heat generation test using a cone calorie combustion tester in accordance with ISO5660-1, (1) the total heat generation amount for 20 minutes after the start of heating is 8 MJ / m 2 (2) The maximum heat generation rate is 200KW / m for 10 seconds or more for 20 minutes after the start of heating. 2 (3) It is possible to reliably meet the non-combustibility requirement of being free of cracks and holes that are harmful to fire prevention for 20 minutes after heating begins. Furthermore, if an uneven pattern is formed on the surface of the decorative sheet 7, the design will be improved.

[0030] Although the present invention has been described above with reference to a limited number of embodiments, the scope of the invention is not limited thereto, and modifications of the embodiments based on the above disclosure will be obvious to those skilled in the art. [Explanation of symbols]

[0031] 1 Base material layer 2. Pattern layer 3 Transparent adhesive layer 4 Inner layer 5 Outermost layer 6 Transparent thermoplastic resin layer 7 Decorative sheets 8 Aluminum components 9. Aluminum decorative parts 11 Aluminum plate

Claims

1. a step of preparing a decorative sheet in which an adhesive layer and two or more transparent thermoplastic resin layers are laminated in this order on one side of a substrate layer made of a thermoplastic resin; A process of continuously forming aluminum members of any cross-sectional shape by performing a bending process using roll forming on a long, flat aluminum plate; and a step of attaching the other side of the decorative sheet to one side of the aluminum member to create an aluminum decorative member.

2. 2. The method for manufacturing an aluminum decorative member according to claim 1, wherein the aluminum plate has a thickness of 0.5 mm or more and 1.2 mm or less.

3. 3. The method for manufacturing an aluminum decorative member according to claim 1, wherein the aluminum member and the decorative sheet are bonded together with a two-component curing urethane adhesive.

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