JP2008132446A - Window member repair method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a repairing method of a window member which can be applied to a window member equipped with a hard coat layer on a resin base-material layer, and also in the case where it is applied, does not give a bad influence to the property of the base material and the adhesion property between the base material layer and the hard coat layer. <P>SOLUTION: The repairing method of the window member has the first process of processing a defect 3 generated on the hard coat layer 1 until it reaches the base material layer 2, the second process of packing a defect repairing agent 4, mainly composed of a thermoplastic resin, into the defect 3a after processing, the third process of arranging a shape retention sheet 5 permeating the infrared ray on the hard coat layer 1, and the fourth process of irradiating the infrared-ray laser 7 at the part containing the defect 3a after processing from above the shape retention sheet 5. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a repair method for a window member, and more particularly, to a repair method for a window member provided with a hard coat layer on a surface layer portion of a resin base material layer.

  Transparent resin materials typified by polycarbonate, etc. have low specific gravity, are easy to process, and are more resistant to impact than inorganic glass. They are used as impact-resistant glass for automotive window glass and interior materials. ing. In such a case, since the transparent resin material is often exposed to sunlight for a long period of time, the photodegradation of the base material layer is suppressed by forming a film. Patent Document 1 discloses a covering member including a primer layer made of a resin primer formed on the surface of a resin base material layer, and a top layer (hard coat layer) containing a flexibility imparting agent thereon. Has been.

On the other hand, it is known that glass attached to an automobile is scratched by cracks or the like during traveling, for example, by pebbles that are thrown up by another vehicle. Patent Documents 2 to 6 disclose methods for repairing such glass scratches. Patent Document 7 discloses a technique relating to a method for repairing a scratch generated in a side sill portion of an automobile.
JP 2006-240294 A Japanese Patent Laid-Open No. 2004-210617 JP 11-246242 A JP 11-61099 A JP-A-10-120984 JP 2003-335132 A JP-A-1-306351

  However, the techniques described in Patent Documents 2 to 6 relate to a technique for repairing scratches generated in inorganic glass mainly composed of silicic acid, and are immediately applied to a window member using a resin base material layer. It is not possible. Further, although the technique described in Patent Document 7 relates to the repair of scratches generated on the surface of the resin material, since the resin wound repair agent contains a wax component or a metal salt component, There is a risk of surface cracking in the material layer. Further, the solvent component of the wax may permeate into the interface between the resin base material layer and the hard coat layer, and the adhesive force at the interface may be hindered. Furthermore, when the scratch does not reach the resin base material layer, the scratch repair agent may peel off from the hard coat layer and fall off due to the antifouling property of the hard coat layer.

  Therefore, the present invention is applicable to a window member provided with a hard coat layer on a resin base layer, and when applied, the properties of the base layer and the adhesion between the base layer and the hard coat layer. It is an object of the present invention to provide a repair method that does not adversely affect the work.

In order to solve the above problems, the present invention takes the following means. That is,
The invention according to claim 1 is a method for repairing a scratch generated in a hard coat layer of a window member having a hard coat layer on the surface of a base material layer formed mainly of a light-transmitting resin containing an infrared absorber. Because
A first step of processing the scratches generated in the hard coat layer until the base layer is reached;
A second step of filling the wound after processing with a wound repair agent mainly composed of a thermoplastic resin;
A third step of disposing an infrared transmitting shape-retaining sheet on the hard coat layer;
A fourth step of irradiating an infrared laser to a part containing the scratches after processing from above the shape-retaining sheet;
The above-mentioned problem is to be solved by a method for repairing a window member.

  Here, “light” in the present invention refers to infrared rays having a wavelength of 1 mm or less.

  Further, in the present invention, “mainly comprising” means that the resin contains an additive having a function such as an antioxidant, a weather resistance agent, etc., a filler, etc. It shows that it is more than mass%. Preferably it is 90 mass% or more.

  According to a second aspect of the present invention, in the window member repairing method according to the first aspect, the light-transmitting resin is a polycarbonate resin.

  The invention according to claim 3 provides an automotive window member provided with a hard coat layer on the surface of a base material layer mainly composed of a polycarbonate resin containing an infrared absorber, thereby solving the above-mentioned problem. It is.

  The invention according to claim 4 is characterized in that the window member according to claim 3 is used for a sunroof of an automobile.

  According to the first aspect of the present invention, the infrared absorbent in the base material layer that has been irradiated with the infrared laser light generates heat, and the wound is filled in the inside of the scratch that reaches the depth of the base material layer by processing. The thermoplastic resin of the repair agent and the resin of the base material layer are melted and the two resins are welded and integrated. As a result, a so-called anchor effect occurs, and a firm repair portion is formed. Further, since the hard coat layer is covered with the shape-retaining sheet, the melted wound repair agent is melted and solidified to form a smooth surface integrated with the hard coat layer surface.

  According to the second aspect of the present invention, the base material layer can be formed from a general-purpose resin that has light permeability and is relatively easily available.

  According to the invention described in claim 3 or claim 4, an automobile equipped with such a window member for an automobile has scratches such as cracks on the window member due to pebbles and the like jumped up by another vehicle during traveling. However, the method according to claim 1 or 2 enables easy and reliable and robust repair.

A first aspect of the present invention is a method for repairing a scratch generated in a hard coat layer of a window member comprising a hard coat layer on the surface of a base material layer formed mainly of a light-transmitting resin containing an infrared absorber. Because
A first step of processing the scratches generated in the hard coat layer until the base layer is reached;
A second step of filling the wound after processing with a wound repair agent mainly composed of a thermoplastic resin;
A third step of disposing an infrared transmitting shape-retaining sheet on the hard coat layer;
A fourth step of irradiating an infrared laser to a part containing the scratches after processing from above the shape-retaining sheet;
It is a repair method of the window member characterized by providing.

  Moreover, the other form of this invention is the window member for motor vehicles provided with the hard-coat layer on the surface of the base material layer which has as a main component the polycarbonate resin containing an infrared absorber. The present invention will be specifically described below. First, the structure of the base material layer, the hard coat layer, the flaw repair agent, and the shape maintaining sheet will be described, and then the repair method will be described.

(Base material layer)
In the repair method for a window member or the window member of the present invention, the base material layer is formed mainly of a light-transmitting resin containing an infrared absorber. The light-transmitting resin is preferably one that transmits about 15% to 80% of light in order to achieve a good balance between the light transmittance and the light-shielding rate as a window. In this invention, it has the process of heat-melting resin efficiently with an infrared laser so that it may mention later. Therefore, the light transmissive resin needs to transmit infrared rays. Examples of such a light-transmitting resin include transparent thermoplastic resins such as polycarbonate (PC) resin, polystyrene (PS) resin, polyethylene terephthalate (PET) resin, and polymethacrylate (PMMA) resin. Among these, it is preferable to use a polycarbonate (PC) resin in terms of mechanical properties as a window member, processability, weather resistance, and the like.

  “Main component” means that an additive having a function such as an antioxidant or a weather resistance agent, a filler, or the like is allowed in the resin. The proportion of the resin is 70% by mass or more, preferably 90% by mass or more based on the total amount.

The resin constituting the base material layer contains an infrared absorber. The infrared absorber in the present invention has a function of absorbing heat from the infrared laser and generating heat when irradiated with an infrared laser from the outside during repair. Is not particularly limited in the present invention as long as the infrared absorbing agent having such a function, from the viewpoint of easily absorb infrared radiation, as the inorganic material, zirconium oxide (ZrO _2), indium oxide (In ₂ O ₃ ), Antimony oxide (Sb ₂ O ₅ ), tin oxide (SnO ₂ ), and organic materials include phthalocyanine materials, cyanine materials, dithiol metal complexes, aminium materials, immonium materials, and the like. A preferable content ratio of the light absorbent to the entire base material layer is 0.01% to 2.0% on a mass basis. With this content, the laser light transmittance can be adjusted to about 15% to 95%.

(Hard coat layer)
The hard coat layer in the present invention is not particularly limited as long as it has excellent adhesion to the base material layer and crack resistance. For example, as disclosed in JP-A-2006-240294, a resin primer layer formed on the surface of a resin base material and a top layer containing a flexibility imparting agent formed on the resin primer layer. And the primer layer and the top layer have a layer structure including an ultraviolet absorber. More specifically, the primer layer includes a thermosetting acrylic resin, a thermoplastic acrylic resin, and an ultraviolet absorber, and the top layer includes a silicone-based resin such as polysiloxane, silica sol, and ultraviolet absorber. The thing which added the agent is mentioned.

(Wound repair agent)
The wound repair agent in the repair method for a window member of the present invention is required to have a thermoplastic resin as a main component. This is because when it is irradiated with an infrared laser at the time of repair, it needs to be melted and mixed with the base material layer resin that has been melted and melted at the same time. Examples of such thermoplastic resins include polymethacrylate (PMMA), polycarbonate (PC), polystyrene (PS), and polyethylene terephthalate (PET). Among these, a polymethacrylate (PMMA) resin is preferable in terms of compatibility (adhesion), excellent weather resistance, and scratch resistance. Furthermore, from the viewpoint of making scars inconspicuous, it is preferable that the resin for the wound repair agent is adjusted so that the visible light transmittance is the same as that of the resin used for the base material.

  The wound repair agent is preferably in the form of liquid or powder in order to densely fill the inside of the wound generated in the hard coat layer and the base material layer. Furthermore, it is necessary to match the upper surface of the hard coat layer with the upper surface of the wound after repair. Therefore, it is preferable to fill the hard coat layer with the scratch on the upper surface of the hard coat layer. A powder is preferred. Further, when the wound repair agent is a powder, it is preferably a powder having a particle size distribution corresponding to the size and shape of the scratch. From this viewpoint, the average particle size of the powder is 5 μm to 80 μm. Is preferred. In addition, you may contain the infrared rays absorber similar to what is contained in the said base resin in a wound repair agent.

(Shape retention sheet)
The shape maintaining sheet in the repair method of the window member of the present invention covers the hard coat layer so that the wound repair agent embedded in the scratches of the hard coat layer and the base layer is flush with the hard coat layer surface. Are arranged. It is necessary for the shape-retaining sheet to reach the wound repair agent and the base layer resin disposed below by the infrared laser emitted from the laser light source disposed above the shape-retaining sheet through the shape-retaining sheet. . Therefore, the shape retaining sheet needs to be formed of a material having a property of transmitting infrared rays. Moreover, it is necessary to peel easily from the melt | dissolved wound repair agent after repair. From this point of view, a silicone resin, a transparent fluororesin such as THV, or the like is preferably used as a material for forming the shape maintaining sheet.

(Repair method)
Next, the window member repairing method of the present invention will be described with reference to FIG. FIG. 1A is a diagram schematically showing a cross section of the hard coat layer 1 and the base material layer 2 in the depth direction. FIG. 1A shows a case where a scratch 3 is generated in the hard coat layer 1.

  FIG. 1B is a diagram showing a first step in which a scratch generated in the hard coat layer 1 is processed until it reaches the base material layer 2. The reason why the scratches are processed until they reach the base material layer 2 to produce the artificial scratches 3a is as follows. That is, the hard coat layer 1 may have low adhesion to other materials from the viewpoint of ensuring antifouling properties, and may not be able to be expected to have good adhesion with a wound repair agent. Therefore, both the resins are melted and mixed in order to firmly bond the wound repair agent and the base material layer to obtain a so-called anchor effect. Furthermore, there is also a significance that a new surface is exposed to the base material layer and the hard coat layer by newly processing the scratch at the time of repair, and the adverse effect on the adhesion due to the contaminant attached to the wound surface is removed. If the scratch has already reached the base material layer, the first step may be omitted, but further processing is performed to expose the new surface to the base material layer. It is preferable to achieve reliable joining.

  Next, the artificial wound 3a is filled with a wound repair agent 4 mainly composed of a thermoplastic resin (FIG. 1 (c); second step). The flaw repair agent 4 is adjusted in its filling amount so that its upper surface forms one surface with the upper surface of the hard coat layer 1 after melting and solidifying. Next, the shape-retaining sheet 5 that transmits infrared rays is disposed on the hard coat layer 1 (FIG. 1 (d), third step).

  Further, a laser beam irradiation device 6 is disposed on the shape-retaining sheet 5, and an infrared laser 7 is irradiated to a site including an artificial scratch (scratch after processing) 3a (FIG. 1 (e) fourth step). The laser beam irradiation device 6 is preferably mounted on a robot arm and configured to be variable depending on the scanning speed of the robot. The infrared laser effectively generates heat from the infrared absorber. The scanning speed is preferably 100 cm / min to 1000 cm / min from the viewpoint of obtaining good work efficiency while obtaining strong welding strength. More preferably, it is 300 cm / min to 800 cm / min. From the same viewpoint, the laser output is preferably 50 W to 500 W, and the focal diameter is preferably 1.0 mm to 5.0 mm.

  After the molten base material layer 2 and the wound repair agent 4 are solidified, the shape retaining sheet 5 is removed from the hard coat layer 1 (FIG. 1 (f)), and a repair portion 8 is formed inside the wound. The repair is completed. In addition, you may wash | clean the surface of the hard-coat layer 1 containing the repair part 8 after removing the shape maintenance sheet | seat 5 as needed.

As the window member, a base material layer having the following configuration and a hard coat layer on the surface thereof were prepared.
Base material layer: A polycarbonate resin containing 0.3% by mass of zirconia oxide (ZrO ₂ ) as an infrared absorber.
Hard coat layer: It has a resin primer layer formed on the surface of the base material layer, and a top layer containing a flexibility-imparting agent formed on the resin primer layer. The primer layer contains a thermosetting acrylic resin, a thermoplastic acrylic resin, and an ultraviolet absorber. As a top layer, polysiloxane, silica sol with UV absorber added.

  A scratch (1 mm × 90 mm × 10 μm) generated in the hard coat layer of the window member having the above-described structure was processed into an artificial scratch (3 mm × 100 cm × 100 μm) reaching the base material layer. This processed wound was filled with 20 mg of polymethacrylate (PMMA) resin powder having an average particle size of 20 μm as a repair agent. The PMMA resin was adjusted so that the laser light transmittance was 90%. Next, a silicone resin shape-retaining sheet having a laser light transmittance of 90% was placed on the hard coat layer, and an infrared laser was irradiated from directly above. As the laser output device, a semiconductor (diode) laser manufactured by Roffin was used. Irradiation was performed with a laser output of 100 W, a laser wavelength of 940 nm, a focal diameter of 5.0 mm, a focal length of 150 mm, a focal length of 5 mm, a scanning speed of about 500 cm / min, and an irradiation time of about 1.2 seconds. After irradiation, the shape retention sheet was removed and the hard coat layer surface was washed. By such repair work, a strong scratch repair portion was formed, and the scratch repair portion became inconspicuous visually.

It is a figure which shows roughly each process of a wound repair method in order.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Hard coat layer 2 Base material layer 3 Wound 3a Wound after processing (artificial flaw)
4 wound repairing agent 5 shape retention sheet 6 laser light irradiation device 7 infrared laser 8 repairing part

Claims (4)

A window member comprising a hard coat layer on the surface of a base material layer formed as a main component of a light-transmitting resin containing an infrared light absorber, a repair method for scratches generated in the hard coat layer,
A first step of processing the scratches generated in the hard coat layer until reaching the base material layer;
A second step of filling the wound after processing with a wound repair agent mainly composed of a thermoplastic resin;
A third step of disposing an infrared transmitting shape-retaining sheet on the hard coat layer;
A fourth step of irradiating an infrared laser to a portion containing the scratches after the processing from above the shape-holding sheet;
A method for repairing a window member, comprising: The method for repairing a window member according to claim 1, wherein the light transmissive resin is a polycarbonate resin. An automotive window member comprising a hard coat layer on the surface of a base material layer mainly composed of a polycarbonate resin containing an infrared absorber. The window member according to claim 3, wherein the window member is used for a sunroof of an automobile.

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