Method for manufacturing a structure for a paint base and a structure for a paint base

Abstract

To form a coating area for long-term stable formation of a protective coating layer to protect various electrical equipment from external factors such as sunlight. [Solution] A first resin member 10 having an end formed by the intersection of its upper surface and side surface is integrally molded with a second resin member 20 different from the first resin member 10. The second resin member 20 covers the end and forms a wall portion that rises up at the end of the upper surface, thereby forming the boundary of the painted area. A paint film 30 that adheres tightly to the inner wall surface of the wall portion in this painted area is applied to the surface of the paint film 30 and the upper surface of the wall portion, forming a structure for a paint base so that they form a substantially flat plane.

Description

Technical Field

[0001] The present invention relates to a coating base structure and a coating structure for protecting various electrical facilities, buildings, automobiles, personal computers, smartphones and the like from external influences particularly outdoors, such as sunlight, temperature changes, humidity changes, and further falling objects such as rain, snow, frost and hail.

Background Art

[0002] The following technology can be cited as a prior art corresponding to external impacts.

[0003] That is, an on-vehicle safety window is mentioned which is composed of a laminate in which a cured coating film layer, an acrylic resin layer, and a polycarbonate resin layer are sequentially laminated, the thickness of the acrylic resin layer is 0.6 to 2 mm, and the cured coating film layer side of the laminate is located on the vehicle exterior side (Patent Document 1).

[0004] The technique described in Patent Document 1 attempts to solve the problem by the component of the material and the laminated structure itself, for example, by previously laminating a weather-resistant component as a resin sheet or the like.

[0005] In contrast, the present invention aims at long-term stabilization after coating by means of the structure of the coating base itself and the like.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] The problems that this invention aims to solve are to form a painted area for forming a protective coating layer that protects various electrical equipment from external factors such as sunlight in a long-term stable manner, and to enable long-term stable protection of various equipment by a painted structure applied to the painted area. [Means for solving the problem]

[0008] The first invention is a method for manufacturing a paint base structure, characterized in that a first resin member, which is a resin member to be painted and has an end formed by the intersection of its upper surface and side surface, and a second resin member, which is weather-resistant and different from the first resin member, are integrally molded such that the second resin member covers the end of the first resin member and constitutes a wall portion that rises up at the end of the upper surface of the first resin member, thereby forming a region of the upper surface of the first resin member that is exposed from the second resin member as a paint area. The second invention is the method for manufacturing a paint base structure according to the first invention, characterized in that the second resin member is made of a resin material with higher weather resistance than the first resin member. Furthermore, the third invention is a method for manufacturing a paint base structure, comprising a painting step of forming a paint film in the paint area of ​​a paint base structure obtained by the method for manufacturing a paint base structure of the first or second invention, wherein the painting step is characterized in that the paint film is formed so that the paint film is in close contact with the inner wall surface of the wall portion and the surface of the paint film and the upper surface of the wall portion are substantially the same plane. Furthermore, the fourth invention is a paint base structure comprising a first resin member which is a resin member to be painted and has an end formed by the intersection of an upper surface and a side surface, and a second resin member which has weather resistance and is different from the first resin member, wherein the first resin member and the second resin member are integrally molded such that the second resin member covers the end of the first resin member and constitutes a wall portion that rises up at the end of the upper surface of the first resin member, and the inner wall surface of the wall portion of the second resin member constitutes the boundary of the paint area on the upper surface of the first resin member. Furthermore, the fifth invention is a paint base structure of the fourth invention, characterized in that the second resin member is made of a resin material with higher weather resistance than the first resin member. Furthermore, the sixth invention is a paint structure characterized in that the painted area of ​​the paint base structure of the fourth or fifth invention is provided with a paint film that adheres closely to the inner wall surface of the wall, and the surface of the paint film and the upper surface of the wall form substantially the same plane.Furthermore, the seventh invention is a structure for a paint base, comprising: a first resin member which is a resin member to be painted and has an end formed by the intersection of an upper surface and a side surface; and a second resin member which is weather-resistant and different from the first resin member, wherein the first resin member and the second resin member are integrally molded such that the second resin member covers the end of the first resin member and constitutes a wall portion that rises up at the end of the upper surface of the first resin member, and the resin material constituting the first resin member. and , the resin material constituting the aforementioned 2 resin member The combinations are ABS resin and AES resin, ABS resin and ASA resin, PC resin and PMMA resin, or PBT resin and PPS resin. The eighth invention is a structure for paint bases characterized by the following: A structure for a paint base, comprising: a first resin member which is a resin member to be painted and has an end formed by the intersection of its upper surface and side surface; and a second resin member which is weather-resistant and different from the first resin member, wherein the first resin member and the second resin member are integrally molded such that the second resin member covers the end of the first resin member and forms a wall portion that rises up at the end of the upper surface of the first resin member, and the resin material constituting the first resin member is a resin material which has higher adhesion to the paint formed on the upper surface than the resin material constituting the second resin member. The coating formed on the upper surface is characterized by being selected from acrylic, fluorine, polyurethane, silicone, epoxy, and polyolefin-based coatings. paint This is a structure for a base coat. Furthermore, the ninth invention is a painted structure comprising a coating film made of the selected paint on the upper surface of the painted base structure of the eighth invention, characterized in that the surface of the coating film and the upper surface of the wall portion form substantially the same plane. [Effects of the Invention]

[0009] In this invention, a weather-resistant second resin member is integrally molded to form a wall portion that rises up at the end of the first resin member, thereby enabling the formation of a coated area for a long-term stable coating film. Furthermore, in this invention, by using a second resin material with higher weather resistance than the first resin member, the protection of the portion made of the first resin member is enhanced, enabling long-term protection of the protected equipment. In addition, in this invention, the surface of the coating film and the upper surface of the wall portion are substantially flush, resulting in a long-term stable coating film and enabling long-term protection of the protected equipment. Furthermore, in this invention, the resin material constituting the first resin member has higher adhesion to a predetermined paint selected from acrylic, fluorine, polyurethane, silicone, epoxy, and polyolefin types than the resin material constituting the second resin member, enabling the formation of a coated area for a more long-term stable coating film. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic cross-sectional view showing a structure for a paint base according to the present invention. [Figure 2] A schematic cross-sectional view showing a painted structure according to the present invention. [Figure 3] This figure shows an example of an application of the painted structure according to the present invention. [Figure 4] This is a schematic cross-sectional view of a painted structure for comparison. [Figure 5] This is an additional example (schematic cross-sectional view) of a paint base structure according to the present invention. [Modes for carrying out the invention]

[0011] Based on the figures, embodiments for carrying out the present invention will be described. [Examples]

[0012] Figure 1 is a schematic cross-sectional view showing a paint base structure 1 according to the present invention. The paint base structure 1 comprises a first resin member 10 which is a resin member to be painted, and a second resin member 20 made of a highly weather-resistant resin material. These first resin member 10 and second resin member 20 are integrally molded three-dimensionally in a state where they are firmly joined to each other by a molding process such as an injection molding process in which molten resin material is injected into a mold, or a press molding process in which each resin member is press-bonded by heat and pressure.

[0013] In this embodiment, the first resin member 10 is made of a resin material (ABS resin (acrylonitrile butadiene styrene resin)) that has excellent adhesion to paint, and its external shape has a top surface that extends horizontally and a side surface that extends downward from the edge of the top surface. Corners (ends) are formed around the perimeter of the first resin member 10 at the intersection of these top and side surfaces.

[0014] Expressions indicating directions, positions, and spatial relationships, such as "upper surface", "side surface", "above", and "protruding upward" used in the present specification and claims are defined for the convenience of describing the relative positional relationship of each member in a single structure. Therefore, when the structure according to the present invention is incorporated as an actual product, or installed and used, it goes without saying that no matter what direction or posture the structure is arranged in, such as vertical orientation, horizontal orientation, or inverted state, it is included in the technical scope of the present invention as long as the above-described relative structural relationship is satisfied.

[0015] The second resin member 20 is made of a resin material with high weather resistance. Here, "high weather resistance" of the resin material constituting the second resin member 20 means high deterioration resistance against external environmental factors such as ultraviolet rays, moisture, or heat. Resin materials having such weather resistance include all highly durable industrial resin materials that, based on common general technical knowledge, can be suitably used as they are in outdoor environments (or are widely recognized for outdoor exposure applications).

[0016] Specifically, the deterioration resistance includes resistance to occurrence of cracks and fine fractures on the material surface when exposed to the above external environmental factors, resistance to bending, warping, deformation, and strain of the material, as well as resistance to discoloration and chalking. Preferable resin materials with high weather resistance include, for example, AES resin (acrylonitrile-ethylene propylene rubber-styrene resin), PMMA resin (polymethyl methacrylate resin), ASA resin (acrylonitrile-styrene-acrylate resin), PPS resin (polyphenylene sulfide resin), and the like. However, these are merely preferred examples, and the material of the second resin member 20 in the present invention is not limited to these.

[0017] Further, the relative relationship of weather resistance between the first resin member 10 and the second resin member 20 can be selected in a plurality of modes according to required product specifications and usage environments.

[0018] As a first aspect, it is sufficient that the second resin member 20 alone has weather resistance, and an aspect that does not require a clear difference (superiority or inferiority) in weather resistance from the first resin member 10 (for example, a case where both members have equivalent or slightly different deterioration resistance) may be mentioned. Even in this aspect, since the end portion exposed to the outside is covered by the second resin member 20 having weather resistance, it is useful as the structure 1 for a coating base.

[0019] As a second aspect, an aspect in which the resin material constituting the second resin member 20 has higher weather resistance than the resin material constituting the first resin member 10 may be mentioned. In this aspect, it is possible to arrange materials such that higher weather resistance is concentrated on the outer peripheral end portion, while a material specialized in coating adhesion can be freely selected for the inner first resin member 10 that serves as a coating region to be described later.

[0020] In the structure 1 for a coating base, the second resin member 20 is disposed so as to cover the corner portion (end portion) formed around the first resin member 10 from the outside. Further, the second resin member 20 constitutes a substantially L-shaped wall portion that rises vertically or obliquely upward from the upper surface at the edge of the upper surface of the first resin member 10. The inner region exposed to the outside defined by this wall portion has the meaning of a pre-demarcated region for purposes such as protection from external factors and imparting design properties in the design of the structure. Here, the wall structure formed by the second resin member 20 is not limited to a form that continuously surrounds the entire outer periphery (all four corners and all sides) of the upper surface of the first resin member 10, and may be a form that is selectively disposed only on a specific side, a specific corner, or a partial region thereof in the outer periphery.

[0021] Further, the inner wall surface of the wall portion is not limited to a configuration that stands substantially perpendicular to the upper surface of the first resin member 10, and may be configured as a tapered surface that is inclined so that the opening width widens or narrows upward. The inner wall surface of this wall portion functions as a boundary of a coating region that defines the spread of the coating material in the coating step described later on the upper surface of the first resin member 10.

[0022] Figure 2 is a schematic cross-sectional view showing a painted structure according to the present invention. In this painted structure, a coating film having the desired functions, such as weather resistance and cushioning properties to mitigate impact from falling objects, is formed on the painted area of ​​the paint base structure 1, that is, on a predetermined exposed area on the upper surface of the first resin member 10 (a target area intended for protection, decoration, etc.).

[0023] Examples of paints applied to the painted area include acrylic, fluorine, polyurethane, and silicone-based paints. The solvent and form of these paints are not particularly limited and can be any type, such as water-based or solvent-based paints.

[0024] Furthermore, the paint may contain, for example, hollow beads, various fillers, pigments, and additives, for the purpose of imparting or enhancing desired functions to the resulting coating film, such as cushioning, heat insulation, weight reduction, and design. In particular, a configuration containing hollow beads within the coating film 30 allows for the heat insulation effect of the hollow parts to be exerted, and also enhances the cushioning function that effectively dampens and absorbs impact forces when falling objects such as hail or flying debris collide with the coating film during outdoor installation.

[0025] In this embodiment, an anionic acrylic emulsion coating containing acrylic hollow beads was used to achieve thermal insulation and cushioning properties. Other examples of hollow beads include, but are not limited to, polystyrene hollow beads, polycarbonate hollow beads, ceramic hollow beads, and glass hollow beads. By densely dispersing these hollow beads within the coating film 30, the impact resistance and environmental barrier properties of the entire structure are improved.

[0026] In the painting process for forming a coating film, the applied paint spreads along the upper surface of the first resin member 10 and abuts against the inner wall surface of the wall portion of the second resin member 20, and the outer contour of the paint application area is determined to follow the shape of the inner wall surface. At this time, the end face of the paint is in close contact with the inner wall surface of the wall portion of the second resin member 20 without any gaps.

[0027] As shown in Figure 2, the surface of the coating film 30 and the upper surface (top surface) of the wall portion of the second resin member 20 form substantially the same plane. This results in a structure in the finished coated structure in which the end face of the coating film 30 is shielded by the inner wall surface of the wall portion of the second resin member 20.

[0028] With this configuration, the first resin member 10, which constitutes the main parts such as the protective panel, can be protected from external environmental factors and external forces such as ultraviolet rays, moisture, heat, and impacts from falling objects by the coating film 30 formed on its upper surface.

[0029] Figure 3 shows an example of the application of the painted structure 2 according to the present invention. The painted structure 2 is applied as a top plate to protect the top of the outdoor unit of an air conditioner installed outdoors from sunlight, hail, and the like.

[0030] At the same time, durability evaluations were also conducted for painted structures with other structures. Figure 4 is a schematic cross-sectional view of a painted structure used for comparison. In this painted structure used for comparison, the second resin member 20 is integrally molded to cover the side surface of the first resin member 10, but it does not have a wall portion that rises up on the upper surface of the first resin member 10.

[0031] Durability tests were conducted in an outdoor environment for both the painted structure according to this embodiment (the form shown in Figure 2) and the comparative painted structure (the form shown in Figure 4). As a result, it was confirmed that the comparative painted structure tended to develop lifting and peeling from the edges of the coating 30 at an early stage.

[0032] Furthermore, evaluations were repeatedly conducted with the second resin member 20 covering the first resin member 10, not having an L-shaped cross-section, but simply being a rod-shaped second resin member 20 positioned on the side of the first resin member 10, with the upper surface of the second resin member 20 protruding at a higher position than the upper surface of the first resin member 10. Evaluations were also carried out repeatedly with various resin materials and in different locations, such as the rooftop of a building constantly exposed to wind and rain.

[0033] These series of durability tests confirmed that the larger the area of ​​the painted structure exposed to sunlight (for example, when applied to the top panel of an outdoor unit), the more susceptible it is to deformation such as warping and distortion due to thermal contraction and expansion caused by sunlight.

[0034] In this configuration, as in the present invention, where the second resin member 20 has a substantially L-shaped cross-section and encloses and restrains the ends and corners of the first resin member 10 to maintain its shape (as shown in Figure 2), it was observed that the shape stability of the second resin member 20 tends to suppress warping of the first resin member 10.

[0035] Furthermore, it was confirmed that when the edges of the coating 30 are concealed and protected by this L-shaped wall section, the conformability and stability of the coating 30 are maintained even when subjected to thermal stress or deformation, and this leads to an improvement in the overall durability of the painted structure.

[0036] As described above, it was confirmed that the approximately L-shaped wall structure in which the second resin member 20 encloses the corner of the first resin member 10 and protrudes three-dimensionally at the boundary of the painted area is a configuration that improves the overall stability of the painted structure after the paint film is formed.

[0037] Furthermore, it was confirmed that the configuration in which the upper surface of the wall portion of the second resin member 20 and the surface of the coating film 30 form substantially the same plane is effective in maintaining and stabilizing the durability of the coating film 30.

[0038] Furthermore, in the configuration of the present invention, it was confirmed that the adhesion between the coating film 30 and the first resin member 10 has a greater impact on the durability of the coating film 30 than the adhesion between the coating film 30 and the second resin member 20. In other words, with the substantially L-shaped wall structure of the present invention, when selecting and designing the coating agent (paint) for coating film formation, it is basically sufficient to consider only the compatibility (adhesion) with the first resin member 10, which is the main painted area, and there is no need to carefully consider the compatibility with the second resin member 20 that guards the outer perimeter, resulting in a high degree of freedom in paint selection.

[0039] These series of durability tests demonstrated that a specific suitable example of a "resin material / paint" combination with good compatibility between the resin material and paint of the first resin component 10 is, for example, the combination of "ABS resin / anionic acrylic emulsion paint." In this combination, extremely high initial and durable adhesion is achieved due to the chemical affinity of the acrylic emulsion component to the ABS resin surface, and the buffering and heat insulating effect of various hollow beads, such as acrylic hollow beads densely dispersed within the paint film layer, effectively absorbs and attenuates heat input from direct sunlight and impacts from falling objects such as hail, confirming that the paint film does not lift or peel off over a long period of years.

[0040] Furthermore, as the coating agent (paint or primer) for the molded products of the first resin member 10 (e.g., ABS resin) and the second resin member 20 (e.g., AES resin), either solvent-based paints or water-based (emulsion-based / dispersion-based) paints can be suitably used.

[0041] Specifically, solvent-based paints include one-component acrylic paints, one-component vinyl acetate-modified acrylic paints, one-component acrylic urethane paints, two-component acrylic urethane paints made from acrylic polyol and isocyanate, one-component epoxy paints made from epoxy-modified acrylic resin, and chlorinated or polar group-introduced modified polyolefin paints.

[0042] Examples of water-based paints include water-based acrylic paints, water-based urethane dispersion (PUD) paints, water-based one-component epoxy paints, water-based two-component epoxy paints, and water-based modified polyolefin paints. These water-based paints may also be anionic, nonionic, or cationic, each offering the potential for good adhesion to the target resin material (such as ABS and AES).

[0043] Among these, acrylic resins, urethane resins, and epoxy-modified resins are preferred as cationic materials. Anionic materials have the practical advantage of being easy to formulate due to the existence of a wide variety of additives. The structure of this invention can be combined with any of these solvent-based, water-based, and ionic paints selected from the paint groups.

[0044] Here, the substantially L-shaped wall structure made of the second resin member 20 can exert a unique synergistic effect that structurally solves the inherent technical challenges of solvent-based paints and water-based paints in the aforementioned series of paints, enabling their combination.

[0045] Specifically, when solvent-based paints are used, there is a risk of cracking or localized strength reduction at the outer edges where stress tends to concentrate, due to the paint. In contrast, in the present invention, since the edges are enclosed and restrained by the wall portion of the second resin member 20, the occurrence of solvent-induced cracks and structural weakening are suppressed.

[0046] On the other hand, even with water-based paints (including various ionic paints), which do not damage the material but tend to repel at edges and have poor wettability (thinning due to liquid leakage), and which are prone to becoming the starting point for poor adhesion, the structure of the present invention ensures that the paint is reliably filled until it abuts against the inner wall surface of the raised wall portion, and the thickness is controlled so that after drying and hardening it forms a plane substantially flush with the upper surface of the wall portion. As a result, repelling at the edges and insufficient film thickness are structurally eliminated, and gap-free adhesion at the boundary can be ensured.

[0047] Thus, while the various paints described above can be flexibly applied to the first resin member 10 that constitutes the painted area, the adhesion of these various paints to weather-resistant resin materials such as AES resin that constitute the second resin member 20 is relatively lower than that to resin members such as ABS. There is a tendency for adhesion to various paints to decrease relatively as weather resistance increases. However, as described above, in the structure of the present invention, the low adhesion of paints to the second resin member 20 is not a major problem. In other words, regardless of the relationship that adhesion to various paints decreases relatively as weather resistance increases, it is possible to freely select an optimal material specifically for weather resistance as the second resin member 20.

[0048] Specific material combinations of the first resin member 10 and the second resin member 20 that satisfy the relative relationship between weather resistance and adhesion include, for example, "ABS resin / AES resin," "ABS resin / ASA resin," "PC resin (polycarbonate resin) / PMMA resin," and "PBT resin (polybutylene terephthalate resin) / PPS resin." Weather resistance and adhesion are relative and are not limited to these. Furthermore, the main body of the structure (the part corresponding to the first resin member) is not limited to a single-layer structure made of a single resin material, and is not prevented from being configured as a multi-layer structure in which multiple resin materials of the same or different types are laminated, depending on the required mechanical properties and moldability.

[0049] Example 2 illustrates an example of the possible embodiments of the present invention. [Examples]

[0050] The manufacturing method for the paint base structure according to this embodiment first involves preparing a first resin member 10, which is a resin member to be painted and has an end (corner) formed by the intersection of its top surface and side surface, and a second resin member 20, which is weather-resistant and different from the first resin member 10. Then, by a molding process such as injection molding or press molding, these two members are molded together three-dimensionally so that the second resin member 20 covers the end of the first resin member 10 from the outside and forms a wall portion that rises upward at the end of the top surface of the first resin member 10.

[0051] This integral molding process demarcates and forms a painting area for the painting process described later, on the inner portion of the upper surface of the first resin member 10 that is exposed to the outside from the raised wall portion of the second resin member 20. Here, the covering structure (arrangement form) of the end portion by the wall portion of the second resin member 20 is not limited to a configuration that continuously surrounds the entire outer circumference (all four corners and sides) of the upper surface of the first resin member 10, but may be selectively arranged only on specific sides, specific corners, or parts thereof of the outer circumference. Furthermore, it is preferable to select a resin material that has relatively higher weather resistance than the resin material that constitutes the first resin member 10 (for example, AES resin or PMMA resin) as the resin material that constitutes the second resin member 20.

[0052] The method for manufacturing a painted structure includes a painting step of forming a coating film 30 having a predetermined functionality on the painted area (upper surface of the first resin member 10) of the painted base structure 1 obtained by the above method. In this painting step, the thickness and amount of coating film 30 are controlled so that the applied paint spreads until it abuts against the inner wall surface of the wall, so that the formed coating film 30 adheres to the inner wall surface of the wall without any gaps, and after drying and hardening, the surface (upper surface) of the coating film 30 and the upper surface (top surface) of the wall of the second resin member 20 form substantially the same surface.

[0053] The paint base structure 1 of this embodiment, obtained by the above manufacturing method, comprises a first resin member 10 having an end formed by the intersection of its upper surface and side surface, and a second weather-resistant resin member 20, wherein the second resin member 20 is integrally molded to cover the end of the first resin member 10 and form a wall portion that rises up at the end of the upper surface. As a result, the inner wall surface of the wall portion of the second resin member 20 constitutes the boundary of the painted area on the upper surface of the first resin member 10 (a dike function that restricts the spreading of paint). In this structure, it is preferable that the second resin member 20 is made of a resin material that has higher weather resistance than the first resin member 10.

[0054] Furthermore, the painted structure is provided with a coating film 30 that adheres tightly to the inner wall surface of the wall portion without any gaps in the painted area of ​​the painted base structure 1, and is configured such that the surface of the coating film 30 and the upper surface of the wall portion form substantially the same plane.

[0055] Furthermore, the structure for the paint base is based on the premise of an integrally molded structure of the first resin member 10 and the second resin member 20 described above (a structure that covers the ends and forms a wall at the upper end), and a combination of materials has been selected that pays particular attention to the adhesion between the members to the paint.

[0056] Specifically, as the resin material constituting the first resin member 10, a resin material (for example, ABS resin) is selected that has relatively higher adhesion to the acrylic paint, fluorine paint, polyurethane paint, or silicone paint formed on the upper surface than the resin material constituting the second resin member 20.

[0057] A coating structure with high durability is achieved by applying a coating film 30 to the upper surface (coating area) of this coating base structure using a coating selected from acrylic, fluorine, polyurethane, or silicone-based paints (preferably a functional paint containing hollow beads, etc.), and configuring the surface of the coating film 30 and the upper surface of the wall portion of the second resin member 20 to form substantially the same plane.

[0058] Here, if the material is selected and arranged from the perspective of the weather resistance of the second resin member 20, a technical shift (design substitution) becomes possible in terms of design philosophy. In other words, the technical elements that would normally have required considering the properties of the resin material throughout the entire structure can be changed to limited elements that only require the weather resistance of the second resin member 20, or the weather resistance of the second resin member 20 and the effectiveness of the adhesion of the first resin member 10 to the paint. As a result, at least the second resin member 20 is completely freed from the constraints of adhesion, and a design with long-term durability as a whole becomes possible.

[0059] Furthermore, with the roughly L-shaped wall structure of this embodiment, even if the outer edges are protected and the paint film 30 of the inner painted area is damaged due to aging, the original design and protective function of the structure can be restored repeatedly with simple maintenance such as repainting of the painted area, and the main body can be protected permanently.

[0060] This configuration, in which the surface of the first resin member 10 is protected by a coating film 30, offers overall usefulness against external factors such as warping caused by various vibrations and ultraviolet rays, compared to a multilayer structure in which resin members are simply laminated together (for example, a structure in which different types of resin materials are simply firmly bonded together).

[0061] In multilayer structures of resin components, stresses caused by differences in thermal expansion coefficients and external vibrations are directly concentrated at the highly rigid interface, easily leading to significant warping of the entire component and fatal delamination of the joint surface. In contrast, the coating 30 of this invention has flexibility (conformability), so it can absorb and mitigate vibrations applied to the structure and prevent interface failure. In addition, as described above, even when fatigue occurs due to long-term use, the flexible protective layer can be easily regenerated and reset by partial repainting maintenance, thus maintaining a high level of long-term structural stability and durability for the entire structure.

[0062] The coating structure according to the present invention is not limited to its application to the top plate of the outdoor unit of an air conditioner as exemplified in Example 1. The application to the top plate of an air conditioner outdoor unit was also carried out in harsh environments without shielding, such as the rooftops of buildings. A coating structure (a structure for coating substrates) that can withstand such environments can be widely applied to various industrial products that require high durability in outdoor environments and high protective performance against hand sweat, sebum, and impact.

[0063] For example, examples of applications to automotive parts include exterior parts such as roof rails, back door garnishes, cowl top panels, door mirror covers, and front grilles. In these, the structural framework, mounting parts, and main design surfaces are composed of a first resin member 10 with high paint adhesion and a paint film 30 on its upper surface. On the other hand, the outer edges and boundaries that are severely exposed to wind, rain, flying stones, and direct sunlight during driving are fitted with a wall portion of a second resin member 20 that is roughly L-shaped.

[0064] The wall portions of the first resin member 10 and the second resin member 20, and the coating film 30 are integrated, and the surface of the coating film 30 and the upper surface of the wall portion form substantially the same plane. This comprehensive combination structure makes it possible to achieve long-term durability even under the harsh operating conditions of automobiles.

[0065] Furthermore, an example of application to the casings of mobile electronic devices such as smartphones, tablets, and laptops is the boundary structure between the painted area of ​​the rear panel of the casing and the outer frame (side wall) surrounding it. In this configuration, the large central part of the rear is based on a first resin member 10 with high paint adhesion, and various coatings 30 are formed on it. On the other hand, a wall structure made of a second resin member 20 is arranged at the rear edge.

[0066] This comprehensive combination structure, in which the rear panel (first resin component 10 and coating 30) and the outer frame (second resin component 20) interlock tightly, makes it possible to realize an electronic device housing that can be used for a long period of time.

[0067] Furthermore, examples of applications to building materials and housing equipment components (building materials, etc.) include boundary structures and edge structures such as exterior wall panels, soffit panels, and moldings around window frames that are installed outdoors. In these, the main panel surface and design surface, which occupy the majority of the area, are finished with a first resin member 10 having paint adhesion properties and a coating film 30 on its upper surface. On the other hand, a wall structure made of a second resin member 20 is incorporated at the edge and boundary with the sealant.

[0068] This combination structure, in which the main surface coating structure and the end wall structure are tightly bonded at the boundary without any gaps, and their upper surfaces are smoothly continuous, maintains both the appearance and structural protection function throughout the building's long lifecycle, thus enabling a longer lifespan for the building.

[0069] Furthermore, as another structural modification that the present invention can adopt, the second resin member 20 may be integrally molded to wrap around and continuously cover not only the ends and sides of the first resin member 10, but also the entire (or a part of) back side of the first resin member 10, as shown in Figure 5, the paint base structure 1. With this arrangement, the second resin member 20 functions as a reinforcing frame that comprehensively supports the outer shell and back of the structure, thereby improving the overall mechanical strength of the structure. As a result, even when mechanical loads from the outside such as wind pressure and snow accumulation are applied in harsh outdoor environments, or when thermal distortion occurs due to solar radiation or shrinkage of the material due to changes in humidity, deformation behavior such as overall warping, bending, or distortion caused by the first resin member 10 can be restrained by the rigidity of the second resin member 20 that wraps around to the back.

[0070] These are merely specific examples, and the invention can be applied to and modified for various articles and parts without departing from the spirit of the present invention. [Industrial applicability]

[0071] The paint substrate structure and painted structure according to the present invention, as well as the methods for manufacturing them, can be used for components that require weather resistance and environmental shielding in outdoor environments, or for various industrial products, electrical and electronic equipment, building materials, automobile parts, etc. that are exposed to harsh friction and impact in daily use.

[0072] Specifically, it is not limited to the exterior top panels and protective covers of home appliances such as air conditioner outdoor units, but can also be used in the manufacturing and processing of plastic components in industrial fields where painting is applied to the surface, including automotive exterior parts such as roof rails, back door garnishes, door mirror covers, and front grilles, as well as housing panels for mobile electronic devices such as smartphones, tablets, and laptops, and various building materials such as exterior wall panels and decorative moldings. [Explanation of symbols]

[0073] 1. Structure for paint base 10 First resin component 20 Second resin component

Claims

1. A method for manufacturing a structure for a paint base, A method for manufacturing a paint base structure, characterized by integrally molding a first resin member, which is a resin member to be painted and has an end formed by the intersection of its upper surface and side surface, and a second resin member, which is weather-resistant and different from the first resin member, such that the second resin member covers the end of the first resin member and forms a wall portion that rises up at the end of the upper surface of the first resin member, thereby forming a region of the upper surface of the first resin member that is exposed from the second resin member as a paint area.

2. The method for manufacturing a paint base structure according to claim 1, characterized in that the second resin member is made of a resin material with higher weather resistance than the first resin member.

3. The method includes a painting step of forming a coating film on the coating area of ​​a coating base structure obtained by the method for manufacturing a coating base structure according to claim 1 or 2, The painting step is a method for manufacturing a painted structure, characterized in that the painting step is characterized in that the painting film is formed so that it adheres closely to the inner wall surface of the wall portion and the surface of the painting film and the upper surface of the wall portion are substantially the same plane.

4. A structure for use as a base for painting, The material comprises a first resin member, which is a resin member to be painted, having an end formed by the intersection of its top surface and side surface, and a second resin member, which has weather resistance and is different from the first resin member, A paint base structure characterized in that the first resin member and the second resin member are integrally molded such that the second resin member covers the end of the first resin member and forms a wall portion that rises up at the end of the upper surface of the first resin member, and the inner wall surface of the wall portion of the second resin member forms the boundary of the painted area on the upper surface of the first resin member.

5. The paint base structure according to claim 4, characterized in that the second resin member is made of a resin material with higher weather resistance than the first resin member.

6. The painted area of ​​the paint base structure according to claim 4 or 5 is provided with a paint film that adheres closely to the inner wall surface of the wall portion, A painted structure characterized in that the surface of the coating film and the upper surface of the wall portion form substantially the same plane.

7. A structure for use as a base for painting, The material comprises a first resin member, which is a resin member to be painted, having an end formed by the intersection of its top surface and side surface, and a second resin member, which has weather resistance and is different from the first resin member, The first resin member and the second resin member are integrally molded such that the second resin member covers the end portion of the first resin member and forms a wall portion that rises up at the end portion of the upper surface of the first resin member. A paint base structure characterized in that the combination of the resin material constituting the first resin member and the resin material constituting the second resin member is one of the following: ABS resin and AES resin, ABS resin and ASA resin, PC resin and PMMA resin, or PBT resin and PPS resin.

8. A structure for a paint base, The material comprises a first resin member, which is a resin member to be painted, having an end formed by the intersection of its top surface and side surface, and a second resin member, which has weather resistance and is different from the first resin member, The first resin member and the second resin member are integrally molded such that the second resin member covers the end portion of the first resin member and forms a wall portion that rises up at the end portion of the upper surface of the first resin member. The resin material constituting the first resin member is a resin material that has higher adhesion to the paint formed on the upper surface than the resin material constituting the second resin member. A paint base structure characterized in that the paint formed on the upper surface is selected from acrylic, fluorine, polyurethane, silicone, epoxy, and polyolefin types.

9. A painted structure comprising a coating film made of the selected paint on the upper surface of the painted base structure according to claim 8, A painted structure characterized in that the surface of the coating film and the upper surface of the wall portion form substantially the same plane.

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