JP2017179509A - 化成処理金属板 - Google Patents
化成処理金属板 Download PDFInfo
- Publication number
- JP2017179509A JP2017179509A JP2016069931A JP2016069931A JP2017179509A JP 2017179509 A JP2017179509 A JP 2017179509A JP 2016069931 A JP2016069931 A JP 2016069931A JP 2016069931 A JP2016069931 A JP 2016069931A JP 2017179509 A JP2017179509 A JP 2017179509A
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- Prior art keywords
- chemical conversion
- metal plate
- conversion treatment
- resin
- water
- Prior art date
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Abstract
【解決手段】金属基板の少なくとも一方の面に化成処理皮膜が積層された化成処理金属板であって、上記化成処理皮膜が、水溶性樹脂及び潤滑剤を含み、上記化成処理皮膜の膜厚は0.2〜1μmであり、上記潤滑剤は炭素を含み、上記潤滑剤における炭素の1%以上は炭素−酸素結合を有することを特徴とする。
【選択図】なし
Description
本発明で用いられる金属基板としては、特に限定されないが、例えば、非めっき冷延鋼板、溶融亜鉛めっき鋼板(GI)、合金化溶融亜鉛めっき鋼板(GA)、電気亜鉛めっき鋼板(EG)等の鋼板の他、アルミニウム板およびチタン板等を挙げることができる。これらの中でも、溶融亜鉛めっき鋼板(GI)、電気亜鉛めっき鋼板(EG)、アルミニウム板、およびチタン板が好ましく、合金化溶融亜鉛めっき鋼板(GA)がより好ましい。金属基板の厚みは特に限定されないが、最終製品の軽量化のためには、0.3〜3.2mm程度が好ましい。
化成処理皮膜は、化成処理皮膜形成用塗工液を用いて作製することができる。化成処理皮膜は水溶性樹脂を必須的に含有する、すなわち、化成処理皮膜形成用塗工液には、水溶性樹脂が含まれている。
水溶性樹脂を用いることによって、金属基板に化成処理皮膜を備えただけであるにもかかわらず、本発明の化成処理金属板は高い耐食性を実現することができる。水溶性樹脂は水に溶解しているため、金属基板の表面を均一な連続皮膜で覆うことができるからである。なお、本発明でいう水溶性樹脂とは、25℃の水に、1質量%以上溶解するもの、より好ましくは5質量%以上溶解するものを指す。また、pHを5〜9にアルカリ等で調製することで、目視で均一な透明溶液になるようなものも、水溶性樹脂に含まれるものとする。
化成処理皮膜には、さらに、水溶性樹脂とは異なる水性樹脂を含めてもよい。水性樹脂としては、性能の点で水性ウレタン樹脂が好ましく、ウレタン樹脂の水分散体(エマルション)が、上記水溶性樹脂との混合が容易であり好適である。ウレタン樹脂の水分散体としては、第一工業製薬社製の「スーパーフレックス(登録商標)」シリーズが挙げられ、中でも、「スーパーフレックス(登録商標)170」が好ましいものとして挙げられる。ウレタン樹脂の水分散体は水溶性ウレタン樹脂と組み合わせて使用することが好ましい。
本発明の化成処理皮膜には、潤滑剤が含まれている。潤滑剤としては、炭素が含まれていればよく、例えば、ポリエチレン、酸化ポリエチレン、ポリプロピレン等のポリオレフィン系ワックス;パラフィンワックス等が使用可能である。これらの中でも、ポリオレフィン系ワックスが好ましく、炭素原子数2〜20のα−オレフィンの重合体または共重合体からなるポリオレフィン系ワックスがより好ましく、ポリエチレンワックスがさらに好ましい。潤滑剤の量は、化成処理皮膜形成用塗工液の固形分100質量部中、0.5〜10質量部であることが好ましく、1〜5質量部であることがより好ましく、1.5〜3質量部であることがさらに好ましい。
本発明の化成処理皮膜には、コロイダルシリカが含まれることが好ましい。耐食性を高める効果を有するからである。コロイダルシリカとしては、「スノーテックス(登録商標)」シリーズ(日産化学工業社製のコロイダルシリカ)の「XS」、「SS」、「40」、「N」、「UP」等が好適に用いられる。特に、表面積平均粒子径が10〜20nm程度の「スノーテックス(登録商標)40」が好適に用いられる。コロイダルシリカの量は、化成処理皮膜形成用塗工液の固形分100質量部中、30〜60質量部であることが好ましく、35〜55質量部であることがより好ましく、40〜50質量部であることがさらに好ましい。
化成処理皮膜形成用塗工液にはシランカップリング剤を配合しておくことが好ましい。金属基板に対する化成処理皮膜の密着性を向上させることができる。シランカップリング剤としては、具体的には、例えば、γ−アミノプロピルトリメトキシシラン、γ−アミノプロピルトリエトキシシラン、N−(β−アミノエチル)−γ−アミノプロピルトリメトキシシラン、N−(β−アミノエチル)−γ−アミノプロピルメチルジメトキシシランなどのアミノ基含有シランカップリング剤;γ−グリシドキシプロピルトリメトキシシラン、γ−グリシドキシプロピルメチルジメトキシシラン、γ−グリシドキシプロピルトリエトキシシラン、γ−グリシドキシメチルジメトキシシランなどのグリシドキシ基含有シランカップリング剤;ビニルトリメトキシシラン、ビニルトリエトキシシラン、ビニルトリス(β−メトキシエトキシ)シランなどのビニル基含有シランカップリング剤;γ−メタクリロキシプロピルトリメトキシシランなどのメタクリロキシ基含有シランカップリング剤;γ−メルカプトプロピルトリメトキシシラン、γ−メルカプトプロピルメチルジメトキシシランなどのメルカプト基含有シランカップリング剤;γ−クロロプロピルメトキシシラン、γ−クロロプロピルトリメトキシシランなどのハロゲン基含有シランカップリング剤などが挙げられ、中でもアミノ基含有シランカップリング剤であることが好ましい。これらのシランカップリング剤は、単独で用いも良いし、2種以上を併用してもよい。これらの中では、最終的に得られる後述の複合部材における表面処理金属板と樹脂層との接合強度が良好になる点で、アミノ基含有シランカップリング剤やグリシドキシ基含有シランカップリング剤が好ましく、アミノ基含有シランカップリング剤がより好ましい。シランカップリング剤の量は、化成処理皮膜形成用塗工液の固形分100質量部中、1〜20質量部であることが好ましく、3〜15質量部であることがより好ましく、5〜10質量部であることがさらに好ましい。
化成処理皮膜形成時には、塗工液中にその他の公知の添加剤を加えてもよい。金属基板上に化成処理皮膜を形成する方法は特に限定されず、従来公知の塗布方法が採用でき、例えば、化成処理皮膜用塗工液を、ロールコーター法、スプレー法、カーテンフローコーター法等を用いて、金属基板表面の片面もしくは両面に塗布して、加熱乾燥すればよい。加熱乾燥温度は特に限定されるものではないが、化成処理皮膜形成用の塗工液は水性であるため、水が蒸発する100℃前後で数十秒〜数分程度加熱するとよい。
上記化成処理皮膜の上に接着剤層が設けられた表面処理金属板とすることができる。接着剤層は、化成処理皮膜表面の全面に設けてもよいし、化成処理皮膜表面の一部の必要な場所だけに設けてもよく、例えば何本かのライン状や、ドット状に設けてもよい。接着剤層に含まれる接着剤としては、表面処理金属板と複合する後述の樹脂成形品との接着性に優れたものが好ましい。例えば、ナイロンと複合するのなら、ナイロン用の接着剤が好ましく、ポリプロピレン樹脂と複合するのなら、ポリプロピレン用の接着剤が好ましい。具体的には、ホットメルト型ウレタン系接着剤、ホットメルト型ナイロン系接着剤、ウレタン変性ナイロン系接着剤、ウレタン変性オレフィン系接着剤、酸変性ポリプロピレン系接着剤、塩素化ポリプロピレン系接着剤、ポリエステル系接着剤等が好適である。
本発明の表面処理金属板は、樹脂成形品(樹脂層)と複合して用いる、すなわち接着剤層の上に、樹脂層が設けられた複合部材とすることができる。このとき、加工が必要な場合は、化成処理金属板を目的とする形状にプレス成形した後に接着剤層を設けてもよく、化成処理金属板に接着剤層を設けた表面処理金属板を目的とする形状にプレス成形してもよい。そして、表面処理金属板を、射出成形機の金型の中に装入し、型締めして、溶融樹脂を型内に射出し、樹脂が冷却固化すれば、複合部材が得られる。もちろん、本発明の表面処理金属板は、プレス成形法で樹脂と複合してもよいが、射出成形の短時間・高効率というメリットを生かすには、射出成形法を採用することが好ましい。
後述の製造方法で得られる化成処理金属板から試験片を切り出して、切り口(端面)をテープでシールし、JIS Z 2371に準拠した塩水噴霧試験(SST)を500時間行い、白錆発生率を求めた。結果を表1に示した。
動摩擦係数測定機(新東科学社製ヘイドン(登録商標)14D)を用い、下記の条件にて同一サンプルにつき、測定場所の異なる合計5点を測定し、最大値および最小値を除いた合計3点の平均値を動摩擦係数とした。
摺動面 :10mmφ鋼球
摺動速度:100mm/min
摺動距離:50mm
溶接は、ポータブルスポット溶接機(大同興業製UNI−PROD 10 DIGITAL DELUXE)を用いて行った。電極の材質は、陽極、陰極共に、クロム銅合金であり、電極の先端は4mmφの曲面である。溶接は、非塗装金属板と後述の製造方法で得られる化成処理金属板とを部分的に重ねて行った。具体的には、化成処理金属板が上記非塗装金属板の表面の一部と接するように重ねられており、一方の電極に30〜50kgの荷重を加え、上記非塗装金属板を化成処理金属板側へ押し込みながら溶接を行った。溶接時の溶接電流は3kA、通電時間は0.25秒とした。なお、他方の電極には、化成処理金属板から他方の電極が離れない程度の荷重を加えている。評価結果を表1に示した。
後述の製造方法で得られる複合部材において、表面処理金属板の長手方向端部と樹脂層の長手方向端部とを、25℃の雰囲気下で、引張試験機のチャックで掴み、10mm/分の引張速度で引張り、樹脂層が表面処理金属板から剥離した時の引張強度を測定し、その値を接着強度とした。ただし、表面処理金属板の長手方向端部とは、樹脂層で覆われていない方の端部のことであり、樹脂層の長手方向端部とは、表面処理金属板が接着されていない方の端部のことである。
[化成処理金属板]
厚さ1.0mmの合金化溶融亜鉛めっき鋼板の表面に、化成処理皮膜形成用塗工液をバーコーターで乾燥後の膜厚が表1に記載の膜厚となるように塗布し、100℃で1分間加熱し、化成処理皮膜を備えた化成処理金属板を得た。塗工液の組成(添加量は固形分である)を表1に示す。水溶性樹脂として第一工業製薬社製エラストロン(登録商標)MF−25Kを、水性樹脂として第一工業製薬社製スーパーフレックス(登録商標)170を、コロイダルシリカとして日産化学工業社製スノーテックス(登録商標)40(表面積平均粒径10〜20nm)を、シランカップリング剤として信越化学工業社製KBM903(γ−アミノプロピルトリメトキシシラン)を用いた。潤滑剤としては、実施例1〜3及び比較例1・2・5では、後述のプラズマ処理を行ったポリエチレンワックス(三井化学社製ハイワックス(登録商標)800P800PF)を用い、比較例4では、プラズマ処理を行っていないポリエチレンワックス(三井化学社製ハイワックス(登録商標)800PF)を用いた。なお、比較例3では、塗工液に潤滑剤を含んでおらず、比較例5では、塗工液に水溶性樹脂を含んでいない。
潤滑剤のプラズマ処理は、反応性イオンエッチング装置(アネルバ社製DEM−451T)を用いて行った。上記装置内に酸素ガスを導入して13Paの圧力とし、出力200W、13.56MHzの高周波電源を使用して、グロー放電を起こさせ、潤滑剤に対して3分間プラズマ処理を施した処理を行った。次に、上記処理を行った潤滑剤を蒸留水に1時間浸漬させ、その後、乾燥させた。
上記各化成処理金属板の化成処理皮膜上に、酸変性ポリプロピレン系接着剤である三井化学社製ユニストール(登録商標)R−300をバーコーターで膜厚20μmとなるように塗布した後、220℃で2分間加熱し、接着剤層を備えた表面処理金属板を得た。
Claims (8)
- 金属基板の少なくとも一方の面に化成処理皮膜が積層された化成処理金属板であって、
上記化成処理皮膜が、水溶性樹脂及び潤滑剤を含み、
上記化成処理皮膜の膜厚は0.2〜1μmであり、
上記潤滑剤は炭素を含み、上記潤滑剤における炭素の1%以上は炭素−酸素結合を有する
ことを特徴とする化成処理金属板。 - 上記潤滑剤は、ポリオレフィン系ワックスである請求項1に記載の化成処理金属板。
- 上記水溶性樹脂が、水溶性ウレタン樹脂及び水溶性アクリル樹脂の少なくとも一方である請求項1または2に記載の化成処理金属板。
- 上記化成処理皮膜が、さらに上記水溶性樹脂とは異なる水性樹脂を含む請求項1〜3のいずれか1項に記載の化成処理金属板。
- 請求項1〜4のいずれか1項に記載の化成処理金属板における上記化成処理皮膜表面の一部または全面に接着剤層が設けられていることを特徴とする表面処理金属板。
- 請求項5に記載の表面処理金属板における接着剤層の上に、樹脂層が設けられていることを特徴とする複合部材。
- 上記樹脂層がポリプロピレン樹脂を含む請求項6に記載の複合部材。
- 請求項1〜4のいずれか1項に記載の化成処理金属板の製造方法であって、
水溶性樹脂及び潤滑剤を含む化成処理皮膜形成用塗工液を金属基板の少なくとも一方の面に塗布して化成処理皮膜を形成する工程を有する
ことを特徴とする化成処理金属板の製造方法。
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JP2008052875A (ja) * | 2006-08-28 | 2008-03-06 | Tdk Corp | 潤滑膜形成方法、並びに、潤滑膜を備える摺動体、磁気記録媒体、磁気ヘッドスライダ及びハードディスク |
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TW201801911A (zh) | 2018-01-16 |
EP3421640A1 (en) | 2019-01-02 |
EP3421640A4 (en) | 2019-09-11 |
TWI658925B (zh) | 2019-05-11 |
JP6640638B2 (ja) | 2020-02-05 |
WO2017169571A1 (ja) | 2017-10-05 |
KR20180132747A (ko) | 2018-12-12 |
CN109072445A (zh) | 2018-12-21 |
US20190084274A1 (en) | 2019-03-21 |
KR102177892B1 (ko) | 2020-11-12 |
EP3421640B1 (en) | 2023-04-19 |
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