resin component

Abstract

To provide a resin member that has excellent photocatalytic effect, can prevent deterioration in a resin member, and includes a photocatalyst film.SOLUTION: A resin member includes a photocatalyst film at a resin substrate surface. The photocatalyst film includes a shield layer and an active layer in the order from the side of the resin substrate. The active layer has such the structure that an anatase type titanium oxide particles and metal particles are mixed. The shield layer comprises a metallic material, thereby providing a resin member including a photocatalyst film that strikes a balance between excellent photocatalytic effect and prevention of deterioration in the resin substrate.SELECTED DRAWING: Figure 1

Description

Technical Field

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[0001] The present invention relates to a resin member, and more particularly to a resin member having self-cleaning properties.

Background Art

[0002] ​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​​This invention has been made in view of the problems of the prior art, and its objective is to provide a resin member equipped with a photocatalytic coating that has a high photocatalytic effect and can prevent deterioration of the resin substrate. [Means for solving the problem]

[0008] The inventors of this invention conducted extensive research to achieve the above objectives and discovered that these objectives can be achieved by providing a shielding layer made of a metal material on the resin substrate side of the photocatalytic coating, thus completing the present invention.

[0009] In other words, the resin component of the present invention is provided with a photocatalytic coating on the surface of a resin substrate. Furthermore, the photocatalytic coating has, in order from the resin substrate side, a shielding layer and an active layer. The above-mentioned active layer has a structure in which anatase-type titanium oxide particles and metal particles are mixed, and the above-mentioned shielding layer is made of a metal material. the law of nature, The above shielding layer and the above active layer are joined by at least an anchoring effect, The above resin substrate and the above shielding layer are joined by at least an anchoring effect. It is characterized by the following. [Effects of the Invention]

[0010] According to the present invention, by providing a shielding layer made of a metal material on the resin substrate side of the photocatalytic coating, it is possible to provide a resin member equipped with a photocatalytic coating that achieves both a high photocatalytic effect and prevention of deterioration of the resin substrate. [Brief explanation of the drawing]

[0011] [Figure 1] This is a cross-sectional view showing an example of the structure of the resin member of the present invention. [Figure 2] This is a cross-sectional view showing another example of the structure of the resin member of the present invention. [Modes for carrying out the invention]

[0012] The resin component of the present invention will be described in detail. The resin member of the present invention has a photocatalyst film on the surface of a resin substrate. As shown in FIG. 1, this photocatalyst film has, in order from the resin substrate side, a shielding layer made of a metal material and an active layer having a structure in which anatase-type titanium oxide particles and metal particles are mixed.

[0013] The photocatalyst film of the present invention has a shielding layer made of a metal material on the resin substrate side, and titanium oxide particles do not exist at the interface between the photocatalyst film and the resin substrate. In addition, the light incident on the photocatalyst film is shielded by the shielding layer and does not transmit to the resin substrate, so that deterioration of the resin substrate due to the oxidation action of the titanium oxide particles can be prevented.

[0014] Further, the active layer has a structure in which anatase-type titanium oxide particles and metal particles are mixed, and has a high photocatalytic effect.

[0015] <00,00078>The active layer is produced by cold spraying raw material particles containing anatase-type titanium oxide particles and metal particles.

[0016] The cold spraying method is a method of forming a film by colliding raw material particles in a solid phase state with a substrate by a supersonic flow of an operating gas in a non-molten state without melting or gasifying the raw material particles.

[0017] According to this cold spraying method, the active layer can be formed at a low temperature, and it is not necessary to heat anatase-type titanium oxide particles above their transition temperature as in other thermal spraying methods. Therefore, the transition of titanium oxide particles from the anatase type to the rutile type is prevented, and a high photocatalytic effect can be obtained.

[0018] In addition, the metal particles in the active layer serve as a binder for forming the active layer. By containing the metal particles in the active layer, the titanium oxide particles can be held, and an active layer with high adhesion strength can be formed.

[0019] That is, since the above metal particles have ductility and malleability and are plastically deformable, the metal particles sprayed onto the shielding layer by the cold spray method sink into the shielding layer, plastically deform, adhere, form irregular unevenness at the interface with the shielding layer, and are mechanically joined by the anchor effect.

[0020] The metal particles that enter into the unevenness and adhere to the shielding layer not only join with the shielding layer, but also plastically deform by the titanium oxide particles that collide later, receive and hold the titanium oxide particles, so that the rebound can be suppressed.

[0021] In the active layer formed by such a cold spray method, the metal particles themselves and the metal particles and the shielding layer plastically deform due to collision and are joined not only by the anchor effect but also metallurgically. Further, the titanium oxide particles are mechanically joined to the metal particles and the shielding layer substrate by the anchor effect without relying on metallurgical joining such as formation and diffusion of intermetallic compounds, so that the adhesion strength is improved.

[0022] The Vickers hardness of the above metal particles is preferably 700 (Hv) or less, more preferably 500 (Hv) or less, and still more preferably 400 (Hv) or less.

[0023] When the Vickers hardness of the metal particles is 700 (Hv) or less, the metal particles can be greatly plastically deformed by collision and the film strength can be improved.

[0024] Also, the content (area %) of the metal particles in the above active layer is preferably 10% to 50%, and more preferably 10% to 40%.

[0025] When the content of the metal particles in the active layer is 10 area % or more, an active layer with high adhesion strength can be formed, and when it is 50 area % or less, the content of anatase-type titanium oxide particles increases and a high photocatalytic effect can be obtained.

[0026] As the above metal particles, single metal or alloy particles can be used. Examples of elemental metals include copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), iron (Fe), silver (Ag), titanium (Ti), zinc (Zn), and magnesium (Mg).

[0027] Furthermore, examples of the above-mentioned alloys include alloys containing 50% by mass or more of one metal selected from the group consisting of copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), iron (Fe), silver (Ag), titanium (Ti), zinc (Zn), and magnesium (Mg).

[0028] In particular, copper and silver have antibacterial properties, so elemental copper and silver, or alloys containing 50% or more of these by mass, can be preferably used.

[0029] Furthermore, from an aesthetic standpoint, using individual elements of copper (Cu), aluminum (Al), nickel (Ni), chromium (Cr), and silver (Ag) can impart gloss and sheen to the photocatalytic coating, while using individual elements of iron (Fe) or titanium (Ti) can form a matte photocatalytic coating.

[0030] Furthermore, by changing the component ratio of the above alloys, such as Cu-Zn and Cu-Ni-Zn, it is possible to not only improve the hardness and durability of the photocatalytic coating, but also to change the color of the photocatalytic coating.

[0031] In addition, the tactile feel can be improved by reducing the surface roughness (Ra) to 25 μm or less, a textured surface (Ra) in the range of 5 to 25 μm can create a sense of luxury, and a surface roughness (Ra) of less than 5 μm can improve metallic luster.

[0032] The average particle size of the above metal particles is preferably 10 to 50 μm, and more preferably 20 to 40 μm. This improves shielding performance and increases the kinetic energy of the cold spray, thereby improving the efficiency of film formation. Furthermore, when the photocatalytic coating is approximately 100 μm thick, if the particle size of the metal particles exceeds 50 μm, the metal particles tend to fall off during polishing and grinding. In addition, the larger size of the metal particles reduces the uniform dispersion of titanium oxide particles on the surface of the photocatalytic coating.

[0033] As the titanium dioxide particles mentioned above, anatase-type titanium dioxide particles with an average particle size of 0.01 μm to 2 μm can be used.

[0034] Furthermore, anatase-type titanium dioxide particles supporting copper exhibit photocatalytic effects not only with ultraviolet light but also with visible light, making them preferable for use indoors where ultraviolet light is scarce, as they can provide self-cleaning properties.

[0035] Examples of such titanium dioxide particles include TKP-103 manufactured by Teika.

[0036] The above-mentioned shielding layer can be manufactured by cold spraying or electroless plating, and the metal material constituting the shielding layer can be the same as the metal particles of the activated layer, either a single metal or an alloy.

[0037] As shown in Figure 1, the shielding layer produced by the cold spray method forms a particle-layered structure in which multiple metal particles are stacked on top of each other, and adheres to the resin substrate due to the anchoring effect, thereby improving the strength of the coating.

[0038] In the present invention, when forming a shielding layer by the cold spray method, since the shielding layer is formed on the resin substrate, the distance between the nozzle that sprays the raw material particles constituting the shielding layer and the resin substrate is widened to lower the temperature of the working gas to below the heat resistance temperature of the resin substrate.

[0039] Specifically, the working gas, which is injected at 500-600°C, is cooled to 100-150°C before the raw material particles collide with the resin substrate. This prevents deformation and deterioration of the resin substrate caused by the working gas.

[0040] The working gas expands and cools down when it is sprayed from the nozzle. If the distance between the nozzle and the resin substrate is too close, the working gas will not cool down sufficiently and the resin substrate will melt. Conversely, if the distance is too far, the working gas will not only cool down too much, but the velocity of the raw material particles will decrease, reducing their adhesion to the resin substrate. Therefore, the distance between the nozzle and the resin substrate is preferably about 150 mm.

[0041] By forming a shielding layer using the cold spray method, the shielding layer and the active layer can be formed continuously simply by changing the raw material particles, thus enabling the formation of a photocatalytic coating with reduced work steps.

[0042] There are no particular restrictions on the resin that constitutes the above-mentioned resin substrate; both thermoplastic resins and thermosetting resins can be used, but thermoplastic resins are preferred.

[0043] During the formation of the shielding layer, the kinetic energy of the raw material particles constituting the shielding layer is converted into thermal energy through collisions. The thermoplastic resin at the site of the collision melts locally and welds to the colliding raw material particles. Combined with the bonding due to the anchoring effect, this improves the bonding strength between the resin substrate and the photocatalytic coating.

[0044] The electroless plating described above is a plating method that utilizes a chemical reaction centered on a palladium (Pd) catalyst. Because it can form a thin, dense layer over a wide area, it is possible to inexpensively manufacture large resin components with a large surface area for photocatalytic coating.

[0045] Because the resin component of the present invention has self-cleaning properties, it can be preferably used for automotive resin parts such as handles and door handles, which are prone to sebum and other dirt, as well as for resin parts for transportation equipment, electronic equipment, home appliances, office equipment, housing, medical and hygiene equipment, and more. [Examples]

[0046] The present invention will be described in detail below with reference to examples, but the present invention is not limited to the following examples.

[0047] [Example 1] Copper particles (Cu-HWQ-350, manufactured by Fukuda Metal Foil & Powder Industry Co., Ltd.) were sprayed onto the surface of a polypropylene resin substrate using a cold spray method under the following conditions to form a shielding layer. Next, raw material particles, prepared by mixing Cu-Zn particles (Bra-At-350 manufactured by Fukuda Metal Foil & Powder Industry Co., Ltd.) and anatase-type titanium dioxide particles (JA-1 manufactured by Teika Co., Ltd.) in a mass ratio of 4:1, were sprayed onto the surface of the shielding layer under the same conditions to form an active layer. The surface of the photocatalytic coating was then ground with a brush to produce a resin component with the structure shown in Figure 1. Cold spray conditions Equipment: PCS-1000 (manufactured by Plasma Giken Kogyo) Working gas: N2 gas, injection pressure 3 MPa, injection temperature 600°C Distance between nozzle and substrate: 150 mm (The temperature of the raw material particles at the time of impact with the resin substrate is 100°C, and the impact velocity of the raw material particles is 300 m / s.)

[0048] [Example 2] The surface of a polypropylene resin substrate was roughened by etching, and a palladium catalyst was embedded in the surface by catalyst treatment. A photocatalytic coating was formed on this polypropylene resin substrate in the same manner as in Example 1, except for the formation of a shielding layer by electroless plating with copper. The surface was then ground with a brush to produce a resin member with the structure shown in Figure 2.

[0049] Cross-sections of the resin components fabricated in Examples 1 and 2 were observed using energy-dispersive X-ray spectroscopy (SEM-EDX), and elemental analysis of the photocatalytic coating was performed. The results confirmed that the surface of the resin substrate was completely shielded by a shielding layer formed of copper (Cu), thus preventing degradation of the resin substrate by titanium dioxide. [Explanation of symbols]

[0050] 1. Resin component 2 Photocatalytic coating 3 Active layer 31. Anatase-type titanium dioxide particles 32 Metal particles 4 Shielding layer 41 Metal particles 5 Resin base material

Claims

1. A resin component having a photocatalytic coating on the surface of a resin substrate, The above photocatalytic coating has, in order from the resin substrate side, a shielding layer and an active layer. The above-mentioned active layer has a structure in which anatase-type titanium dioxide particles and metal particles are mixed together. The above shielding layer is made of a metal material. The above shielding layer and the above active layer are joined by at least an anchoring effect, A resin member characterized in that the above-mentioned resin substrate and the above-mentioned shielding layer are joined together by at least an anchoring effect.

2. The resin member according to claim 1, characterized in that the anatase-type titanium oxide particles support copper.

3. The resin member according to claim 1, characterized in that the shielding layer has a particle layered structure.

4. The resin member according to Claim 1, characterized in that the surface roughness (Ra) is 25 μm or less.

5. The resin member according to any one of claims 1 to 4, characterized in that it is composed of a resin component selected from the group consisting of resin components for automobiles, resin components for transportation equipment, resin components for electronic equipment, resin components for home appliances, resin components for office use, resin components for housing, and resin components for medical and hygiene use.

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