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会員外￥ ７,０００￥１０,０００（税別）

工場塗装ラインにおける塗装・塗料管理ハンドブック（目次）

第１章 塗料概論
１．１ 塗料の種類と原材料 ···························································································································· 1
１．１．１ 塗料の成分構成 ································································································································ 1
１．１．２ 塗料の原材料 ···································································································································· 1
１．１．２．１ 樹脂 ········································································································································· 2
１．１．２．２ 顔料‥‥有機顔料・染料、無機顔料 ·········································································· 3
１．１．２．３ 添加剤‥‥顔料分散剤、揺変剤、消泡剤・レベリング剤、その他 ················ 8
１．１．２．４ 溶剤 ········································································································································· 9

１．２ 塗料の分類 ·············································································································································· 13
１．２．１ 塗料の分類 ······································································································································· 13
１．２．１．１ 樹脂による分類 ················································································································ 13
１．２．１．２ 塗料の乾燥及び硬化機構による分類 ········································································ 15
１．２．２ 各種合成樹脂塗料の基礎知識 ··································································································· 16
１．２．２．１ 天然樹脂を原料とした塗料 ·························································································· 16
１．２．２．２ 油を原料とした塗料（油性塗料） ············································································ 17
１．２．２．３ 繊維素を原料とした塗料（硝化綿ラッカー） ······················································ 18
１．２．２．４ アルキド樹脂塗料（フタル酸樹脂塗料） ······························································· 19
１．２．２．５ フェノール樹脂塗料 ······································································································· 22
１．２．２．６ メラミン樹脂塗料（アミノアルキド樹脂塗料） ·················································· 23
１．２．２．７ アクリル樹脂塗料 ············································································································ 25
１．２．２．８ ポリエステル樹脂塗料 ··································································································· 29
１．２．２．９ 塩化ビニル樹脂塗料 ······································································································· 32
１．２．２．10 塩化ゴム系塗料 ················································································································ 33
１．２．２．11 エポキシ樹脂塗料 ············································································································ 34
１．２．２．12 ポリウレタン樹脂塗料 ··································································································· 38
１．２．２．13 シリコーン樹脂塗料（珪素樹脂塗料） ··································································· 42
１．２．２．14 フッ素樹脂塗料 ················································································································ 45
１．２．２．15 粉体塗料 ······························································································································ 47
１．２．２．16 電着塗料 ······························································································································ 50
１．２．２．17 紫外線（電子線）硬化塗料 ·························································································· 53
１．２．２．18 水性塗料 ······························································································································ 60
１．２．２．19 最近の塗料の動向 ············································································································ 64(1)塗料 (2)塗装プロセス (3)塗膜

１．３ 塗料の製造、調色、貯蔵 ··············································································································· 66
１．３．１ 塗料の製造法 ·································································································································· 66
１．３．１．１ 塗料製造プロセス‥‥(1)液状塗料の製造(2)粉体塗料の製造 ·························· 66
１．３．１．２ 製造設備‥‥(1)液状塗料の主な製造設備(2)粉体塗料の主な製造設備 ········ 68
１．３．１．３ 製造管理‥‥(1)液状塗料の製造管理項目(2)粉体塗料の製造管理項目 ········ 71
１．３．２ 塗料の調色 ······································································································································· 72
１．３．２．１ 調色作業の種類 ················································································································ 72
１．３．２．２ 調色の管理 ························································································································· 72

１．３．３ 塗料の貯蔵安定性 ························································································································· 74
１．３．３．１ 塗料の保管について ······································································································· 74
１．３．３．２ 各種塗料の一般的な貯蔵有効期限 ············································································ 74
１．３．３．３ 貯蔵有効期限を過ぎた時の問題点と対策 ······························································· 75

第２章 塗装概論
２．１ 塗装法の種類と原理及び現場管理のポイント ································································· 79
２．１．１ 吹き付け（霧化）塗装 ················································································································ 79
２．１．１．１ エアスプレー ····················································································································· 79
２．１．１．２ エアレススプレー ············································································································ 83
２．１．１．３ エアエアレススプレー ··································································································· 86
２．１．１．４ 静電吹き付け塗装 ············································································································ 87
２．１．２ 静電粉体吹き付け塗装 ················································································································ 91
２．１．３ 浸漬（ディッピング）塗装及び流し塗り（シャワーコーティング） ······················· 94
２．１．４ 電着塗装 ··········································································································································· 95
２．１．５ 真空塗装 ··········································································································································· 98
２．１．６ ロールコーター及びカーテンフローコーター ··································································· 99
２．１．６．１ ロールコーター ················································································································ 99
２．１．６．２ カーテンフローコーター ···························································································· 101
２．１．７ 各種塗装法の特徴 ······················································································································· 104

２．２ 乾燥・硬化法の種類と原理及び現場管理のポイント ················································ 106
２．２．１ 塗料の乾燥・硬化機構 ·············································································································· 106
２．２．２ 塗料の乾燥・硬化設備と管理 ································································································· 107
２．２．３ 塗装関連装置及び設備 ·············································································································· 112
２．２．３．１ 液状塗料用の塗装ブース ···························································································· 112
２．２．３．２ コンプレッサー ·············································································································· 114
２．２．３．３ 液状塗料の供給機器類 ································································································· 117
２．２．３．４ 自動塗装ガン用の復動装置 ························································································ 118
２．２．３．５ 粉体静電塗装の関連装置類 ························································································ 121
２．２．３．６ 搬送装置（コンベア） ································································································· 126
２．２．４ 副資材‥‥研磨、フィルター ································································································· 134
２．２．４．１ 研磨 ····································································································································· 134
２．２．４．２ フィルター（濾過材） ································································································· 137

第３章 工業塗装ラインの設計と管理に際しての留意点
３．１ 工業塗装ラインの設計 ··················································································································· 139
３．２ 工業塗装における省エネルギー対応技術 ········································································· 144
３．３ 工業塗装ラインの管理 ··················································································································· 145

第４章 金属系被塗物の塗装と塗装管理のポイント
４．１ 素材の種類と表面処理（塗装前処理）及び現場管理のポイント ······················ 147
４．１．１ 素材の種類と特性 ······················································································································· 147
４．１．１．１ 鉄鋼板 ································································································································ 148
４．１．１．２ 亜鉛めっき鋼板 ·············································································································· 148
４．１．１．３ ステンレス鋼板 ·············································································································· 149
４．１．１．４ マグネシウム合金 ·········································································································· 150
４．１．１．５ アルミニウムとその合金 ···························································································· 151
４．１．２ 表面処理（塗装前処理）の種類と特徴 ··············································································· 155
４．１．２．１ 物理的・機械的前処理 ································································································· 156
４．１．２．２ 化学的前処理 ··················································································································· 158

４．２ 被塗物の塗装及び現場管理のポイント ··············································································· 172
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被塗物と塗料 ································································································································ 172
被塗物と塗装方法 ······················································································································· 173
塗装ラインにおける留意点 ····································································································· 177
塗装工程の管理 ···························································································································· 181

４．３ 被塗物各論 ············································································································································ 185
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電気機器①（トランス） ·········································································································· 185
電気機器②（開閉器） ·············································································································· 187
電気機器③（配電盤） ·············································································································· 190
電気機器④（キュービクル） ································································································· 192
屋内金属製品①（鋼製家具、照明機器、暖房機器） ···················································· 195
屋内金属製品②（厨房機器） ································································································· 200
家電製品①（エアコン室外機） ···························································································· 203
家電製品②（自動販売機） ····································································································· 207
金属建材①（プレハブ鉄骨） ································································································· 210
金属建材②（カーテンウォール） ························································································ 213
金属建材③（アルミサッシ） ································································································· 216
金属建材④（鋼製ドア） ·········································································································· 218
ＯＡ機器・通信機器・光学機器①（Ｍｇ合金素材（パソコン、携帯電話）） ····· 222
ＯＡ機器・通信機器・光学機器②（カメラ、顕微鏡、精密機器等） ····················· 228
道路資材①（ガードレール） ································································································· 233
道路資材②（標識柱） ·············································································································· 236
機械①（工作機械） ··················································································································· 239
機械②（産業機械・建設機械（パワーショベル）） ······················································ 243
機械③（農業機械） ··················································································································· 247
金属容器（ＬＰＧガスボンベ） ···························································································· 250
自動車部品（シャフト、ブラケット、鋳鍛造品、薄板等） ······································· 254
鉄道車両 ········································································································································· 259
自動車（車体） ···························································································································· 262

第５章 木材系被塗物の塗装と塗装管理のポイント
５．１ 素材の種類と表面処理（塗装前処理）及び現場管理のポイント ······················ 265
５．１．１ 素材の種類と特性······················································································································· 265

５．１．１．１ 集成材 ································································································································ 265
５．１．１．２ ＭＤＦ ································································································································ 266
５．１．１．３ ＬＶＬ ································································································································ 266
５．１．１．４ 合板 ····································································································································· 267
５．１．２ 表面処理（塗装前処理）の種類と特徴 ··············································································· 268
５．１．２．１ 表面処理に対する要求条件 ························································································ 268
５．１．２．２ 素地調整の種類とその管理 ························································································ 268

５．２ 被塗物の塗装及び現場管理のポイント ··············································································· 270
５．２．１
５．２．２
５．２．３
５．２．４
５．２．５

被塗物と塗料 ································································································································ 270
被塗物と塗装方法 ······················································································································· 270
塗装ラインにおける留意点 ····································································································· 271
塗装工程の管理 ···························································································································· 273
塗膜性能試験方法 ······················································································································· 276

５．３ 被塗物各論 ············································································································································ 278
５．３．１
５．３．２
５．３．３
５．３．４
５．３．５

木工家具①（脚物家具） ·········································································································· 278
木工家具②（箱物家具） ·········································································································· 283
楽器（ピアノ） ···························································································································· 287
木質建材①（木質床材） ·········································································································· 289
木質建材②（木質住宅部材） ································································································· 295

第６章 窯業系被塗物の塗装と塗装管理のポイント
６．１ 素材の種類と表面処理（塗装前処理）及び現場管理のポイント ······················ 303
６．１．１ 素材の種類と特性 ······················································································································· 303
６．１．１．１ 窯業系サイディング ····································································································· 304
６．１．１．２ 窯業系屋根材 ··················································································································· 304
６．１．２ 表面処理（塗装前処理）の種類と特徴 ··············································································· 308

６．２ 被塗物の塗装及び現場管理のポイント ··············································································· 309
６．２．１
６．２．２
６．２．３
６．２．４

被塗物と塗料 ································································································································ 309
被塗物と塗装方法 ······················································································································· 309
塗装ラインにおける留意点 ····································································································· 310
塗装工程の管理 ···························································································································· 313

６．３ 被塗物各論 ············································································································································ 314
６．３．１ 窯業系サイディング ··················································································································· 314
６．３．２ 窯業系屋根材 ································································································································ 317

第７章 プラスチック系被塗物の塗装と塗装管理のポイント
７．１ 素材の種類と表面処理（塗装前処理）及び現場管理のポイント ······················ 321
７．１．１ 素材の種類と特性 ······················································································································· 321
７．１．１．１ 熱可塑性樹脂 ··················································································································· 322(1)汎用熱可塑性プラスチック ·················································································································· 322(2)汎用エンジニアリングプラスチック ································································································ 325(3)スーパーエンジニアリングプラスチック ······················································································· 327(4)その他の熱可塑性プラスチック ········································································································· 329

７．１．１．２ 熱硬化性樹脂 ··················································································································· 331
７．１．２ 表面処理（塗装前処理）の種類と特徴 ··············································································· 335
７．１．３ プラスチックの種類と主な処理方法 ··················································································· 337

７．２ 被塗物の塗装及び現場管理のポイント ··············································································· 338
７．２．１
７．２．２
７．２．３
７．２．４

被塗物と塗料 ································································································································ 338
被塗物と塗装方法 ······················································································································· 338
塗装ラインにおける留意点 ····································································································· 338
塗装工程の管理 ···························································································································· 341

７．３ 被塗物各論 ············································································································································ 344
７．３．１ 家電・製品（テレビ） ·············································································································· 344
７．３．２ 自動車部品（ドアミラー） ····································································································· 347
７．３．３ 携帯電話 ········································································································································· 350

第８章 塗料、塗装管理の計測機器類
８．１ 塗料の管理に関する計測機器 ··································································································· 353
８．１．１ 塗料の粘度管理 ···························································································································· 354
８．１．２ 塗料の密度管理 ···························································································································· 355

８．２ 塗装の管理に関する計測機器 ··································································································· 356
８．２．１
８．２．２
８．２．３
８．２．４
８．２．５
８．２．６

ウェット膜厚の管理 ··················································································································· 358
被塗物表面温度及び炉内温度の管理 ··················································································· 359
被塗物表面や水性塗料のｐＨ管理 ························································································ 360
塗料の電気抵抗値管理 ·············································································································· 360
被塗物の含水率管理 ··················································································································· 361
紫外線照射量の管理 ··················································································································· 362

８．３ 塗膜の外観管理に関する計測機器 ························································································· 363
８．３．１
８．３．２
８．３．３
８．３．４
８．３．５

ドライ膜厚の管理 ······················································································································· 364
塗膜の色管理 ································································································································ 366
塗膜の光沢管理 ···························································································································· 367
塗膜の平滑性（鮮映性）管理 ································································································· 368
塗膜のピンホール管理 ·············································································································· 369

８．４ 塗膜性能に関する試験機器 ········································································································ 370
８．４．１
８．４．２
８．４．３
８．４．４
８．４．５
８．４．６
８．４．７

塗膜の付着性管理 ······················································································································· 371
塗膜の硬度管理 ···························································································································· 373
塗膜の耐冷熱性（耐サーモショック性）管理 ································································· 373
塗膜の耐摩耗性管理 ··················································································································· 374
塗膜の耐湿性管理 ······················································································································· 375
塗膜の耐食性（促進試験）管理 ···························································································· 376
塗膜の耐候性管理 ······················································································································· 377

第９章 塗装において発生するトラブルとその対策
９．１ 塗装における異常・欠陥の種類 ······························································································ 381
９．１．１ 塗装方法と発生し易い塗膜の欠陥························································································ 381

９．１．２ 被塗物別塗膜欠陥と要因 ·········································································································· 382
９．１．２．１ 金属材 ································································································································ 382
９．１．２．２ 木材 ····································································································································· 384
９．１．２．３ 窯業材 ································································································································ 386
９．１．２．４ プラスチック材 ·············································································································· 388

９．２ 塗料・塗装に関するトラブルと対策 ···················································································· 390
９．２．１ 貯蔵中又は開缶時に予想される異常 ··················································································· 390
９．２．２ 塗装中及び乾燥過程中に予想される異常 ·········································································· 391
９．２．３ 塗膜形成後及び経過後に起こる欠陥 ··················································································· 397
各種塗膜欠陥写真例 ··················································································································· 401

９．３ 主な欠陥のチェック項目と対策 ······························································································ 403
９．３．１ シンナーによる欠陥対策 ·········································································································· 403
９．３．２ 塗膜に起こる欠陥対策 ·············································································································· 404

第 10 章 安全と環境問題対策
10．１ 安全・環境に係わる法規制 ········································································································ 411
10．１．１ 労働安全衛生法 ···························································································································· 413
10．１．１．１ 有機溶剤中毒予防規則 ································································································· 413
10．１．１．２ 特定化学物質等障害予防規則 ··················································································· 415
10．１．２ 毒物及び劇物取締法 ··················································································································· 415
10．１．３ 消防法 ·············································································································································· 415
10．１．４ 大気汚染防止法 ···························································································································· 417
10．１．５ 水質汚濁防止法（水質環境基準） ························································································ 418
10．１．６ 悪臭防止法 ····································································································································· 420
10．１．７ シックハウス厚生労働省指針 ································································································· 421
10．１．８ 化学物質の内分泌かく乱作用に関する今後の対応（EXTEND2010） ····················· 421
10．１．９ 化管法（PRTR 制度） ················································································································ 421
10．１．10 ＧＨＳ ·············································································································································· 422
10．１．11 その他の規制・制度 ··················································································································· 423
10．１．11．１ 女性労働基準規則（女性則） ··················································································· 423
10．１．11．２ 廃棄物処理法 ··················································································································· 423
10．１．11．３ バーゼル法 ······················································································································· 423
10．１．11．４ 省エネ法 ···························································································································· 424
10．１．11．５ 資源有効利用促進法 ····································································································· 424
10．１．11．６ 閉鎖海域水質総量削減基準（窒素・りん等の排水規制） ······························ 424
10．１．11．７ ＰＬ法（製造物責任法） ···························································································· 424
10．１．11．８ 公害防止条例・環境基本条例 ··················································································· 424
10．１．11．９ 地球温暖化対策推進法 ································································································· 424
10．１．11．10 ＩＳＯ14000 シリーズ（環境マネジメント、ＬＣＡ） ··································· 425
10．１．11．11 土壌汚染対策法 ·············································································································· 425
10．１．11．12 化審法 ································································································································ 425
10．１．11．13 ＰＣＢ特措法 ··················································································································· 425
10．１．11．14 ＲＥＡＣＨ規制 ·············································································································· 426
10．１．11．15 ＥＬＶ指令 ······················································································································· 426
10．１．11．16 ＲｏＨＳ指令 ··················································································································· 426
10．１．11．17 ロッテルダム条約（ＰＩＣ条約） ·········································································· 426
10．１．11．18 ストックホルム条約（ＰＯＰｓ条約） ································································· 426

10．２ 塗料・塗装を取り巻く環境問題と対応 ··············································································· 427
10．２．１ 環境問題 ········································································································································· 427
10．２．２ 塗料・塗装における環境問題（発生源と因子） ····························································· 428
10．２．３ 塗料・塗装に関する環境問題対応策 ··················································································· 429［付表］塗料一般試験方法 JIS 規格一覧表······································································································· 432

索引 ·················································································································································································· 434
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