JP2018140630A - Resin foam composite steel plate panel and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin foam composite steel plate panel exhibiting excellent adhesiveness and rust-proof property, and to provide a manufacturing method thereof.SOLUTION: Provided is a resin foam composite steel plate panel formed with a laminate structure in which two zinc-plated steel plates are laminated with a core material made of a resin foam interposed therebetween. The steel plate and the core material are bonded via an adhesive layer containing one, two, or more kinds selected from a polyester resin, an epoxy resin, an urethane resin, and a melamine resin as a main component.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a resin foam composite steel plate panel suitable for a panel such as an interior board or an exterior board when a building structure is constructed, and a method for producing the same.

  The performance required for the inner and outer panels used as a panel when constructing a building structure is flat, excellent in design properties, good workability, having high rigidity, Furthermore, it is required to be lightweight and have good properties such as heat insulation, vibration control, sound insulation, durability, etc. A laminated structure in which a foam is sandwiched between metal plates is used. As a prior art regarding this point, a composite plate or a composite molded body disclosed in Patent Document 1 is known.

JP 2009-90522 A

  By the way, in the conventional composite plate, the metal plate and the core material are usually simply bonded via an adhesive. However, when the composite plate is processed such as cutting, the metal plate and the core material are separated. It had a defect that peeled off.

  Also, this type of composite plate may cause dew condensation between the metal plate and the core material, and the metal plate and the core material may be peeled off when the corrosion of the metal plate proceeds from there. There was a need for improvement.

  An object of the present invention is to propose a resin foam composite steel plate panel having high adhesion between a steel plate and a core material among metal plates and having excellent rust prevention properties and a method for producing the same.

The present invention is a resin foam composite steel plate panel having a laminated structure in which a core material made of resin foam is sandwiched between two galvanized steel plates and laminated,
The steel sheet and the core material are bonded to each other through an adhesive layer mainly composed of at least one of polyester resin, epoxy resin, urethane resin or melamine resin. It is the resin foam composite steel plate panel characterized.

  The adhesive layer contains 20% by weight or less of a rust preventive pigment, and preferably has a thickness of 1 to 15 μm, and the core material is preferably a polyisocyanurate foam.

  The steel plate may be a galvanized steel plate having a thickness of 0.1 to 0.5 mm. As a method for producing the galvanized steel sheet, a hot dip galvanizing method, an electrogalvanizing method or the like can be used. Furthermore, the total thickness including the steel plate and the core material is desirably 2 to 20 mm.

  Further, the present invention provides a method for producing a resin foam composite steel plate panel having the above-described configuration, in which two galvanized steel plate coils provided with an adhesive layer on a surface in contact with a core material are prepared in advance. Each of the steel sheets is preheated and preheated with respect to the discharged steel sheets, and then the resin is supplied between the steel sheets, and then the steel sheets are kept flat and overlapped to foam the resin. It is the manufacturing method of the resin foam composite steel plate panel characterized by these.

  In the above method, the preheating is preferably performed so that the ultimate plate temperature of the steel plate is 20 to 80 ° C. This is because pre-heating increases the fluidity of the resin and facilitates the spread of the resin between the steel plates. When foaming the resin, it is desirable that the expansion ratio is 5 times or more and 40 times or less.

  According to the present invention, the steel plate and the core material are bonded via an adhesive layer mainly composed of one or more of polyester resin, epoxy resin, urethane resin or melamine resin. The adhesiveness between each other can be improved, and the steel sheet and the core material are not easily peeled off even if the composite plate is processed such as cutting.

  In addition, according to the present invention, since the adhesive layer contains a rust preventive pigment of 20% by weight or less, even if dew condensation occurs between the steel plate and the core material, corrosion of the steel plate is caused. Progress can be suppressed.

  Further, according to the present invention, in the manufacture of the resin foam composite steel plate panel, after supplying the resin forming the core material between the steel plates, the steel plates are held flat and overlapped with each other. Therefore, a core material having a uniform thickness can be formed over the entire surface of the steel sheet.

It is the external appearance perspective view which showed typically embodiment of the resin foam composite steel plate panel according to this invention. It is the figure which expanded and showed the cross section of the principal part of the resin foam composite steel plate panel shown in FIG. It is the figure which showed typically the manufacture point of the resin foam composite steel plate panel according to this invention.

Hereinafter, the present invention will be described more specifically with reference to the drawings.
FIG. 1 is an external perspective view schematically showing an embodiment of a resin foam composite steel panel according to the present invention, and FIG. 2 is an enlarged cross-sectional view of the main part of the resin foam composite steel panel shown in FIG. FIG.

  Reference numerals 1 and 2 in the figure denote steel plates shown in an example having a rectangular planar shape. As the steel plates 1 and 2, galvanized steel plates having a thickness of 0.1 to 0.5 mm are applied. The steel plates 1 and 2 are not limited to the above.

  Reference numeral 3 denotes a core material sandwiched between the steel plates 1 and 2. As the core material 3, a resin foam such as polyisocyanurate or polyurethane can be used. In particular, it is preferable to use a polyisocyanurate foam as a resin foam from the viewpoint of combustion resistance and cost. In this case, the foaming rate is 5 times or more and 40 times or less and the thickness is about 2 to 10 mm. It is preferable, and thereby flexibility can be ensured, and even if the composite plate is bent, it is difficult to break.

  Reference numeral 4 denotes an adhesive layer that bonds the steel plates 1 and 2 and the core material 3 together. As the adhesive layer 4, one having one or more of polyester resin, epoxy resin, urethane resin or melamine resin as a main component (main agent) can be used. Here, the main component means a component occupying 50% by weight or more of the adhesive layer. Such an adhesive layer 4 can be formed as a coating film in the manufacturing stage of the steel plates 1 and 2, and by providing this adhesive layer 4, the adhesion between the steel plates 1 and 2 and the core material 3 is improved. Can be done.

  When the main component of the adhesive layer 4 is composed of two types of polyester resin and melamine resin or epoxy resin and urethane resin, the ratio thereof is polyester resin 60 to 80% + melamine resin 40 to 20% by weight, epoxy It is preferable to use 50 to 80% by weight of resin + 50 to 20% of urethane resin. When the main component of the adhesive layer 4 is composed of three types of polyester resin, epoxy resin, and melamine resin, the polyester resin is 1 to 84% by weight, the epoxy resin is 84 to 1% by weight, and the melamine resin is 15 to 25% by weight. Is preferred. Further, when the main component of the adhesive layer 4 is composed of four types of polyester resin, epoxy resin, melamine resin, and urethane resin, the polyester resin is 1 to 84% by weight, the epoxy resin is 84 to 1% by weight, and the polyester resin + It is preferable that the epoxy resin is 75 to 85% by weight, the melamine resin is 1 to 24% by weight, the urethane resin is 24 to 1% by weight, and the melamine resin + the urethane resin is 15 to 25% by weight. This further increases the adhesion between the steel plates 1 and 2 and the core material 3.

  In order to form the adhesive layer 4 as a coating film in the manufacturing stage of the steel plates 1 and 2, spray coating or roll coater coating is preferable, but not limited thereto. The thickness is adjusted according to the coating amount.

  Further, the adhesive layer 4 can contain a rust preventive pigment in a range of 20% by weight or less, more preferably 5 to 10% by weight with respect to the main component, whereby the steel sheet 1 due to condensation or the like, It is possible to avoid the corrosion of 2 and the accompanying peeling. Here, the lower limit of the content of the anticorrosive pigment is preferably 5% by weight, and the upper limit is preferably 20% by weight, but the reason is that the corrosion resistance is less than 5% by weight of the anticorrosive pigment. On the other hand, if it exceeds 20% by weight, it is feared that the adhesiveness is lowered. The thickness of the adhesive layer 4 is preferably about 1 to 15 μm from the viewpoint of maintaining a rust prevention effect and avoiding cohesive failure of the adhesive layer 4. When the thickness of the adhesive layer 4 is less than 1 μm, the rust prevention effect cannot be expected, and even when the thickness exceeds 15 μm, the rust prevention effect reaches saturation and increases the amount of raw materials used, leading to an increase in cost. Become.

  Specific examples of rust preventive pigments include chromates such as strontium chromate, phosphates such as aluminum phosphate, molybdate such as zinc molybdate, vanadate such as calcium vanadate, calcium silicate, etc. A silicate, magnesium oxide, a metal oxide such as silica, a simple substance such as fluorinated zirconic acid or a combination thereof can be used.

  In addition to the rust preventive pigment, an inorganic compound such as calcium carbonate, barium sulfate, or silica may be mixed to harden the surface of the adhesive layer 4 or roughen the surface thereof. As can be confirmed, a color pigment such as titanium oxide may be mixed, and the addition ratio is preferably in the range of 0.1 to 30% by weight.

  In the present invention, the total thickness of the composite plate is preferably 2 to 20 mm, and more preferably 2 to 10 mm. The reason is that if the thickness is less than 2 mm, the resin foam is difficult to spread uniformly, whereas if the thickness is more than 20 mm, the bending workability is remarkably deteriorated.

  The steel plates 1 and 2 are preferably about 0.1 to 0.5 mm in thickness. This is because when the thickness is less than 0.1 mm, the bending strength and surface flatness of the panel are remarkably lowered, and when the thickness is more than 0.5 mm, the bending workability is remarkably deteriorated.

  The resin foam composite steel sheet panel according to the present invention is not only suitable as an inner / outer panel when a building structure is constructed, but can also be applied to, for example, an inner panel, an outer panel, or a door of an automobile body.

  In order to manufacture a resin foam composite steel sheet panel, as shown in FIG. 3, two steel sheet coils C1 and C2 having an adhesive layer 4 as a coating film 4 'are prepared, and the coating film 4' faces each other. Thus, the steel plates 1 and 2 are discharged and the heated steel plates 1 and 2 are preheated in the heating furnace 5, respectively. Then, the steel plates 1 and 2 are left in a flat state, or at least one of the steel plates 1 and 2 (the steel plate 2 in the illustrated example) is displaced in an upward convex shape (see the plan view of the main part in FIG. 3). After the resin 3 '(polyisocyanurate resin) for forming the core material 3 is supplied by the resin supply device 6 in the vicinity of the center in the width direction (in the illustrated example, the supply is dropped), the steel plates 1 and 2 are flatly stacked. The resin 3 ′ may be foamed by the foaming device 7 while being held in the combined state. After foaming is finished, both ends in the width direction are trimmed by edge trim to remove the resin foam that protrudes from the width edges of the steel sheets 1 and 2 and the resin foam that has not been filled up to the edges of the steel sheets. What is necessary is just to cut | disconnect to predetermined length using the type | formula cutting machine 8, and, thereby, a resin foam composite steel plate panel is obtained.

  In the present invention, when the resin 3 ′ for forming the core material 3 is supplied, the steel plate 2 is displaced in an upwardly convex shape. It is possible to form a resin layer having a uniform thickness over the entire surface, which can flow naturally toward the end in the width direction, and as a result, a core material 3 having a uniform thickness can be obtained. . However, when the resin 3 'is rich in fluidity, a resin supply device 6 having an inverted Y-shaped tip branched in two width directions of the steel plate 2 is used, and the resin 3' is dropped from the resin supply device 6. According to this, it is possible to omit displacing the steel plate 2 in an upwardly convex shape when supplying the resin. When foaming the resin 3 ′, it is important to keep the steel plates 1 and 2 flat.

<Example 1>
A resin foam composite steel plate panel having a laminated structure in which a core material (polyisocyanurate foam having a foaming ratio of 15 times and a thickness of 5 mm) is sandwiched and laminated between two hot dip galvanized steel plates having a thickness of 0.27 mm. A resin foam composite steel plate panel in which an adhesive layer as shown in Table 1 (thickness 10 μm, not containing a rust preventive pigment) is interposed between the steel plate and the core material to be manufactured and bonded to each other. We investigated the effect on the adhesion. In addition, since it is known that it will generally have favorable workability if the adhesiveness is high, in this example, the adhesiveness of the resin foam composite steel sheet panel was investigated.

The adhesion was evaluated based on the maximum tensile stress when a test was performed in accordance with a tensile test on the flatwise surface of the ASTM C297 flat sandwich structure and a tensile force was applied in the thickness direction of the sandwich panel. The thicknesses of the adhesive layers were all 10 μm, and the target value of the maximum tensile stress was set to 20 N / cm ² (the self-adhesion strength of urethane foam to the color steel sheet is generally about 20 N / cm ² , so it is related to adhesion. If the maximum tensile stress is 20 N / cm ² or more, it is considered that the performance is satisfactory).
The results are shown in Table 1.

As is apparent from Table 1, in the resin foam composite steel sheet panel according to the present invention, the adhesiveness indicated by the maximum tensile stress is good at 20 N / cm ² or more, whereas the adhesive layer is polypropylene resin or In Comparative Examples 1 to 3 using a polyethylene resin and a fluororesin, it was confirmed that the adhesion was inferior.

<Example 2>
Next, a steel sheet (same as in Example 1) containing 5% by weight of a rust-preventive pigment composed of strontium chromate and variously changing the thickness as shown in Table 2 (mainly comprising a polyester resin) ) And a core material (same as in Example 1) to produce a resin foam composite steel plate panel (steel plate, core material is the same as in Example 1), and the resulting resin foam composite steel plate panel is rust-proof. On the property and adhesion.

In addition, rust prevention property was evaluated from the JIS Z 2371 salt spray test result about the adhesive layer surface without a crosscut provided with the adhesive layer on the galvanized steel sheet. A visual inspection was performed on the surface of the adhesive layer after 150 hours of spraying, and the presence or absence of a swelling phenomenon of the adhesive layer due to corrosion was examined.
The adhesion was evaluated in the same manner as in Example 1. The results are shown in Table 2.

  As is clear from Table 2, it was confirmed that the resin foam composite steel sheet panels according to the present invention (Compatible Examples 5 and 6) have good rust prevention properties as well as adhesion. On the other hand, when the thickness of the adhesive layer is 0.5 μm (Comparative Example 4), red rust occurs, and when the thickness of the adhesive layer is 20 μm (Comparative Example 5), there is no problem with rust prevention. However, it was confirmed that the adhesiveness was inferior due to cohesive failure of the adhesive layer.

<Example 3>
Resin foam composite steel plate panel (steel plate, core material is bonded with adhesive layer (thickness is 10 μm and the main component is polyester resin) with various contents of rust preventive pigment (same as Example 2) The same as in Example 1 was manufactured, and the adhesiveness of the obtained resin foam composite steel sheet panel was investigated. The adhesion was evaluated in the same manner as in Example 1. The results are shown in Table 3.

  As is apparent from Table 3, in the resin foam composite steel sheet panels (Compatible Examples 7 to 9) according to the present invention, the adhesion was good, whereas the content of the rust preventive pigment is defined by the present invention. It was clarified that the adhesiveness was inferior for those exceeding the range.

  ADVANTAGE OF THE INVENTION According to this invention, the adhesiveness of a steel plate and a core material is high, and the resin foam composite steel plate panel excellent also in rust prevention property and its manufacturing method can be provided.

DESCRIPTION OF SYMBOLS 1 Steel plate 2 Steel plate 3 Core material 3 'Resin 4 Adhesive layer 4' Coating 5 Heating furnace 6 Resin supply device 7 Foaming device 8 Movable cutting machine C1 Steel plate coil C2 Steel plate coil

Claims (8)

A resin foam composite steel plate panel having a laminated structure in which a core material made of resin foam is sandwiched between two galvanized steel plates,
A resin characterized in that the steel sheet and the core material are bonded via an adhesive layer mainly composed of one or more of polyester resin, epoxy resin, urethane resin, or melamine resin. Foam composite steel panel.   2. The resin foam composite steel sheet panel according to claim 1, wherein the adhesive layer contains a rust preventive pigment of 20% by weight or less.   3. The resin foam composite steel sheet panel according to claim 1, wherein the adhesive layer has a thickness of 1 to 15 μm.   4. The resin foam composite steel sheet panel according to claim 1, wherein the steel sheet has a thickness of 0.1 to 0.5 mm.   The total thickness including the said steel plate and the said core material is 2-20 mm, The resin foam composite steel plate panel of any one of Claims 1-4 characterized by the above-mentioned.   The resin foam composite steel sheet panel according to any one of claims 1 to 5, wherein the core material is polyisocyanurate foam.   In producing the resin foam composite steel sheet panel according to any one of claims 1 to 6, two galvanized steel sheet coils provided with an adhesive layer on the surface in contact with the core material are prepared in advance. Each coil is discharged and preheated for the discharged steel sheet, and then the resin is supplied between the steel sheets, and then the steel sheets are held flat and overlapped to foam the resin. A method for producing a resin foam composite steel sheet panel characterized by the above.   The said preheating is performed so that the ultimate plate temperature of the said steel plate may be 20-80 degreeC, and the said foaming is performed by making a foaming ratio into 5 times or more and 40 times or less, It described in Claim 7 characterized by the above-mentioned. Manufacturing method of resin foam composite steel panel.

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