Building material component and building material

Abstract

Provided is a building material component which has a surface layer formed on a substrate, wherein the surface layer has a surface arithmetic average roughness Ra of 1.0-8.5 µm and a surface maximum height roughness Rz of 6.0-45.0 µm.

Description

Building parts and materials

[0001] The present disclosure relates to building material components and building materials.

[0002] Conventionally, from the viewpoint of corrosion resistance, a surface layer is formed on a metal substrate.

[0003] Patent Document 1 describes a surface-treated aluminum material having a roughened surface formed on the surface of an aluminum material made of aluminum or an aluminum alloy and a coating layer forming the outermost layer. The surface roughness Rz (Rz: ten-point average roughness according to JIS B 0601-1994), i.e., Rzjis, of the roughened surface has a value corresponding to the hardness of the base material of the surface-treated aluminum material, and the pencil hardness of the coating layer is 6H or more.

[0004] Japanese Patent Application Laid-Open No. 2002-69669

[0005] However, in the surface-treated aluminum material described in Patent Document 1, if the surface of the coating layer is smooth, it will not have a matte finish, and in addition to reducing the designability, the scratch resistance will also be reduced.

[0006] Therefore, the inventors have found an object to provide a component for a building material that can have high designability and scratch resistance.

[0007] The present disclosure relates to a building component having a surface layer formed on a substrate, wherein the surface layer has an arithmetic mean roughness Ra of 1.0 μm or more and 8.5 μm or less, and a maximum height roughness Rz of 6.0 μm or more and 45.0 μm or less.

[0008] 1 is a cross-sectional view showing an example of a laminated structure of a component for a building material according to an embodiment of the present disclosure; 2 is a perspective view showing an example of a building material according to an embodiment of the present disclosure; 3 is a front view showing another example of a building material according to an embodiment of the present disclosure;

[0009] Hereinafter, embodiments of the present disclosure will be described in detail.

[0010] 1, the building component 10 has a surface layer 12 formed on one side of a base material 11. Here, the building component 10 only needs to have the surface layer 12 formed on the base material 11, and for example, the surface layer 12 may be formed on both sides of the base material 11.

[0011] The arithmetic mean roughness Ra of the surface S of the surface layer 12 is 1.0 μm or more and 8.5 μm or less, and preferably 4.0 μm or more and 8.5 μm or less. When the arithmetic mean roughness Ra of the surface S of the surface layer 12 is 1.0 μm or more, the surface of the building material component 10 has a matte finish, and when it is 8.5 μm or less, the surface texture of the building material component 10 becomes uniform. In other words, when the arithmetic mean roughness Ra of the surface S of the surface layer 12 is 1.0 μm or more and 8.5 μm or less, the design of the building material component 10 is improved. Furthermore, when the arithmetic mean roughness Ra of the surface S of the surface layer 12 is 1.0 μm or more, the scratch resistance of the building material component 10 is improved.

[0012] The maximum roughness height Rz of the surface S of the surface layer 12 is 6.0 μm or more and 45.0 μm or less, and preferably 20.0 μm or more and 45.0 μm or less. When the maximum roughness height Rz of the surface S of the surface layer 12 is 6.0 μm or more, the surface of the building material component 10 has a matte finish, and when it is 45.0 μm or less, the surface texture of the building material component 10 is uniform. In other words, when the maximum roughness height Rz of the surface S of the surface layer 12 is 6.0 μm or more and 45.0 μm or less, the design of the building material component 10 is enhanced. Furthermore, when the maximum roughness height Rz of the surface S of the surface layer 12 is 6.0 μm or more, the scratch resistance of the building material component 10 is enhanced.

[0013] In this specification and claims, the arithmetic mean roughness Ra and maximum height roughness Rz of the surface of the surface layer are measured by a measurement method conforming to JIS B0601-2001. Here, it is preferable that the average values ​​of the arithmetic mean roughness Ra and maximum height roughness Rz of the surface S of the surface layer 12 measured in a predetermined direction (e.g., the longitudinal direction) and in a direction perpendicular to the predetermined direction (e.g., the lateral direction) are within the above-mentioned ranges, and it is even more preferable that both the arithmetic mean roughness Ra and maximum height roughness Rz of the surface S of the surface layer 12 measured in each direction are within the above-mentioned ranges.

[0014] The pencil hardness of the surface layer 12 is preferably 2H or more and 6H or less, and more preferably 5H or more and 6H or less. When the pencil hardness of the surface layer 12 is 2H or more and 6H or less, the scratch resistance of the part for building material 10 is increased.

[0015] The glossiness of the surface layer 12 at an incident angle of 60° is preferably less than 10. When the glossiness of the surface layer 12 at an incident angle of 60° is less than 10, scratches on the part for building material 10 become less noticeable.

[0016] The surface layer 12 preferably contains polyolefin wax particles. This allows the arithmetic mean roughness Ra of the surface S of the surface layer 12 to be 1.0 μm or more, and the maximum height roughness Rz of the surface S of the surface layer 12 to be 6.0 μm or more. The content of the polyolefin wax particles in the surface layer 12 is not particularly limited, but is, for example, 0.1 mass% or more and 3.0 mass% or less. The volume-based median diameter D50 of the polyolefin wax particles is not particularly limited, but is, for example, 6.0 μm or more and 9.0 μm or less. The volume-based median diameter D50 is the particle size at 50% of the integrated value of the volume-based particle size distribution measured by laser diffraction / scattering.

[0017] The polyolefin wax particles are not particularly limited, but examples thereof include polyethylene wax particles, polypropylene wax particles, and polytetrafluoroethylene (PTFE) modified polyethylene wax particles.

[0018] The thickness of the surface layer 12 is not particularly limited, but is, for example, 30 μm or more.

[0019] The surface layer 12 is formed, for example, by applying a powder coating containing a curable resin, a color pigment, a curing agent, and polyolefin wax particles to the substrate 11 and then curing the powder coating. The powder coating may further contain a surface conditioner, a plasticizer, a curing accelerator, an ultraviolet absorber, a light stabilizer, an antioxidant, a flowability adjuster, a sagging prevention agent, an antifoaming agent, etc.

[0020] The curable resin is not particularly limited, but examples thereof include hydroxyl group-containing polyesters, epoxy resins, and reactive group-containing fluorine resins, and two or more of these may be used in combination.

[0021] The hydroxyl group-containing polyester may be a known polyester used in curable resins for powder coatings, preferably having a softening point of 100°C or higher and 150°C or lower. Hydroxyl group-containing polyesters can be obtained, for example, by reacting a carboxylic acid component with a polyhydric alcohol component. Examples of the carboxylic acid component include polycarboxylic acids such as phthalic acid, isophthalic acid, terephthalic acid, naphthalenedicarboxylic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, 1,9-nonanedicarboxylic acid, 1,10-decanedicarboxylic acid, 1,12-dodecanedicarboxylic acid, 1,2-octadecanedicarboxylic acid, maleic acid, fumaric acid, cyclohexanedicarboxylic acid, hexahydrophthalic acid, tetrahydrophthalic acid, trimellitic acid, and pyromellitic acid; lower alkyl esters or anhydrides of polycarboxylic acids; and hydroxycarboxylic acids such as malic acid, tartaric acid, 1,2-hydroxystearic acid, and parahydroxybenzoic acid. Examples of polyhydric alcohol components include ethylene glycol, diethylene glycol, triethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,9-nonanediol, 1,10-decanediol, neopentyl glycol, spiroglycol, 1,10-decanediol, 1,4-cyclohexanedimethanol, trimethylolethane, trimethylolpropane, glycerin, and pentaerythritol.

[0022] The epoxy resin may be a known one used as a curable resin for powder coatings, preferably having a softening point of 50°C or higher and 150°C or lower. Examples of epoxy resins include bisphenol A diglycidyl ether resin, bisphenol F diglycidyl ether resin, aminoglycidyl ether resin, bisphenol AD ​​diglycidyl ether resin, bisphenol Z diglycidyl ether resin, o-cresol novolac epoxy resin, phenol novolac epoxy resin, biphenol glycidyl ether resin, cyclopentadiene skeleton epoxy resin, naphthalene skeleton epoxy resin, and GMA acrylic resin. Instead of epoxy resins other than those listed above, resins in which the substituents of the above epoxy resins have been converted to other substituents, such as modified resins modified by CTBN or esterification, may also be used.

[0023] The reactive group-containing fluororesin may be a known one used in curable resins for powder coatings, and has a reactive group that reacts with the curing agent. Examples of reactive groups include hydroxyl, carboxyl, amide, amino, nitrile, glycidyl, and isocyanate groups. Among these, hydroxyl groups are preferred from the viewpoint of stability and control of melt viscosity of the reactive group-containing fluororesin. The reactive group-containing fluororesin is obtained by copolymerizing a reactive group-containing monomer with a fluorine-containing monomer. Examples of fluorine-containing monomers include vinyl fluoride, vinylidene fluoride, trifluoroethylene, tetrafluoroethylene, bromotrifluoroethylene, chlorotrifluoroethylene, pentafluoropropylene, hexafluoropropylene, and (per)fluoroalkyl trifluorovinyl ether (wherein the (per)fluoroalkyl group has 1 to 18 carbon atoms). The reactive group-containing fluororesin may also be obtained by copolymerization with other monomers. Examples of the other monomers include vinyl ethers, olefins, allyl ethers, vinyl esters, allyl esters, (meth)acrylic acid esters, and crotonates.

[0024] The color pigment may be any known color pigment used in powder coatings, including, for example, inorganic pigments such as titanium oxide, yellow iron oxide, titanium yellow, and red iron oxide, and organic pigments such as cyanine blue, cyanine green, permanent yellow FGL, permanent red F5RK, carbazole, quinacridone red, and carbon black, and two or more of these may be used in combination.

[0025] The curing agent may be any known curing agent used in powder coatings. The curing agent is not particularly limited as long as it can react with the curable resin to form crosslinks, and examples thereof include blocked isocyanate curing agents, amine curing agents, and epoxy curing agents, and two or more of these may be used in combination.

[0026] Powder coatings are manufactured by known methods. The manufacturing method of powder coatings includes, for example, a premixing step, a melt-kneading step, a pulverizing step, and a classification step. The premixing step is a step of premixing the raw material composition of the powder coating using a mixer such as a Henschel mixer or a super mixer. The melt-kneading step is a step of melt-kneading the premix using various types of extruders. At this time, it is preferable to use a cooler such as a cooling roll or a cooling conveyor to cool and solidify the molten kneaded material into pellets. The pulverizing step is a step of pulverizing the molten kneaded material using a pulverizer such as a hammer mill or a jet mill. The classification step is a step of classifying the pulverized material using a classifier such as a vibration sieve, an ultrasonic sieve, or a cyclone classifier.

[0027] When applying the powder paint to the substrate 11, for example, the powder paint is applied to one side of the substrate 11, and then dried and heat-cured as necessary. Examples of methods for applying the powder paint include electrostatic coating, electrostatic spraying, atomization, fluidized bed dipping, spraying, spraying, thermal spraying, and plasma thermal spraying. The temperature at which the powder paint is heat-cured is, for example, 110°C or higher and 230°C or lower. Note that, before applying the powder paint, the substrate 11 may be covered with a wrapping sheet, or an electrodeposition coating film or the like may be formed on the substrate 11.

[0028] The material constituting the substrate 11 is not particularly limited, but examples thereof include metals such as aluminum, steel, and stainless steel, resins such as polycarbonate, acrylic resin, and vinyl chloride, fiber reinforced plastics (FRP), and wood. Among these, metals are preferred from the viewpoint of the strength of the substrate 11.

[0029] The building component 10 is not particularly limited, but examples thereof include handrails, roofing materials, shutter slats, door handles, gates, sashes, grilles, terraces, doors, sliding doors, fences, storage frames, etc. Among these, handrails, roofing materials, and shutter slats are preferred because the surface layer 12 functions effectively.

[0030] [Building Material] The building material of the present embodiment is not particularly limited as long as it includes the building component of the present embodiment. Examples of the building material include a roof structure (e.g., a carport or a terrace) including a roofing material and a shutter including shutter slats.

[0031] As shown in Figure 2, the carport 1 includes posts 2, beams 4 connected to the posts 2, and a roofing material 3 connected to the beams 4. The roofing material 3 has a surface layer 12 formed on both the top and bottom surfaces of a base material 11. The surface layer 12 may be formed on the entire carport 1. In other words, the surface layer 12 may also be formed on the base material 11 of the posts 2 and beams 4.

[0032] As shown in Fig. 3, the shutter 5 includes a shutter curtain 6 made up of a plurality of shutter slats 6a, a guide frame (not shown) that guides the shutter curtain 6, and a case 7 that stores the shutter curtain 6 after it is rolled up. The shutter slats 6a have surface layers 12 formed on both the front and rear surfaces of a base material 11. The surface layer 12 may also be formed on the entire shutter 5. In other words, the guide frame and the case 7 may also have the surface layer 12 formed on the base material 11.

[0033] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and the above embodiments may be modified as appropriate within the scope of the spirit of the present disclosure.

[0034] Examples of the present disclosure will be described below, but the present disclosure is not limited to these examples. In these examples, evaluations were performed using test plates instead of building material parts.

[0035] [Examples 1 to 4, Comparative Examples 1 and 2] (Preparation of powder coatings) The raw materials (curable resin, pigment, curing agent, polyolefin (PO) wax particles, and surface conditioner) were blended in the blending amounts [parts by mass] shown in Table 1 and then premixed. Next, the premix was melt-kneaded and then cooled. Next, the melt-kneaded product was pulverized and classified to obtain powder coatings.

[0036]

[0037] Details of the raw materials in Table 1 are as follows: Curable resin: hydroxyl group-containing polyester U-Pica Coat GV570 (manufactured by Japan U-Pica) Pigment: carbon black MA100 (manufactured by Mitsubishi Chemical) Curing agent: ε-caprolactam blocked isocyanate VESTAGON (registered trademark) B1530 (manufactured by Evonik Degussa) PO wax particles: PTFE-modified polyethylene wax particles having a volume-based median diameter D50 of 6 μm Ceraflower 969 (manufactured by BYK) Surface conditioner: Resiflow P67 (manufactured by ESTRON CHEMICAL), IRGAFOS 168 (manufactured by BASF), and benzoin (manufactured by Fujifilm Wako Pure Chemical Industries, Ltd.)

[0038] (Preparation of Test Plate) A 1.5 mm thick anodized aluminum plate was hung vertically and electrostatically coated with a powder paint to a thickness of 70 to 90 μm using a corona-charged electrostatic powder coater at a voltage of −90 kV. Next, the plate was thermally cured in an electric furnace at 180° C. for 30 minutes, and then allowed to cool to room temperature to form a surface layer, thereby obtaining a test plate.

[0039] [Arithmetic mean roughness Ra and maximum height roughness Rz of the surface of the surface layer] The arithmetic mean roughness Ra and maximum height roughness Rz of the surface of the surface layer (10 cm × 15 cm) were measured using a surface roughness measuring instrument, Surfcorder SE500 (manufactured by Kosaka Laboratory). At this time, the arithmetic mean roughness Ra and maximum height roughness Rz were measured in the longitudinal direction (direction 1) and the transverse direction (direction 2) perpendicular to the longitudinal direction.

[0040] [Pencil hardness of surface layer] The pencil hardness of the surface layer was measured in accordance with JIS K 5600. Specifically, a pencil uni (manufactured by Mitsubishi Pencil Co., Ltd.) was set at an angle of 45° to the horizontal and scratched at a constant speed while applying a load of 750 g, and the hardest pencil that did not leave a scratch mark was taken as the pencil hardness of the surface layer.

[0041] [Glossiness of Surface Layer at an Incident Angle of 60°] Using a portable glossmeter GMX-701 (manufactured by Murakami Color Research Laboratory), the glossiness of the surface layer at an incident angle of 60° was measured with the substrate aligned horizontally.

[0042] [Design] The appearance of the surface of the test plate was visually observed, and the design was evaluated according to the following criteria: 2: When the surface is matte and has a uniform texture 1: When the surface is not matte and / or when the surface texture is partially uneven [Abrasion Resistance] Using a reciprocating abrasion tester TRIBOGEAR TYPE: 30S (manufactured by Shinto Scientific), a load of 1000 g was applied and a stainless steel indenter with a diameter of 5 mm was moved back and forth in contact with the surface layer under the following conditions: Travel speed: 6000 mm / min Travel distance: 40 mm (80 mm / reciprocation) Number of reciprocations: 300

[0043] Next, the appearance of the surface layer was visually observed, and the scratch resistance was evaluated according to the following criteria: 3: No scratches reaching the substrate and no scratches on the surface layer 2: Scratches on the surface layer 1: Scratches reaching the substrate

[0044] Table 2 shows the evaluation results of the test panels.

[0045]

[0046] As can be seen from Table 2, the test plates of Examples 1 to 4 have high designability and scratch resistance. In contrast, the test plate of Comparative Example 1 has an Ra of 0.28 μm or less and an Rz of 2.23 μm or less, so the surface is not matte and has low scratch resistance. Furthermore, the test plate of Comparative Example 2 has an Ra of 12.86 μm or more and an Rz of 62.69 or more, so there is partial unevenness in the surface texture.

[0047] 1 Carport, 2 Support, 3 Roofing material, 4 Beam, 5 Shutter, 6a Shutter slat, 6 Shutter curtain, 7 Case, 10 Building material parts, 11 Base material, 12 Surface layer, S Surface

Claims

1. A building component having a surface layer formed on a base material, wherein the surface layer has an arithmetic mean roughness Ra of 1.0 μm or more and 8.5 μm or less, and a maximum height roughness Rz of 6.0 μm or more and 45.0 μm or less.

2. The building component according to claim 1, wherein the surface layer has a pencil hardness of 2H or more and 6H or less.

3. A building component according to claim 1 or 2, wherein the surface layer has a glossiness of less than 10 at an incident angle of 60°.

4. A building component according to any one of claims 1 to 3, wherein the surface layer contains polyolefin wax particles.

5. The building component according to any one of claims 1 to 4, which is a handrail, a roofing material, or a shutter slat.

6. A building material comprising the building material component according to claim 5.

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